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HYUNDAI
MIPO DOCKYARD CO., LTD.
ULSAN KOREA CONSOLII3ATED
58520M001

M-60
FINAL
 Auxiliary Boiler

Customer Hyundai Mipo Dockyard Co., LTD.

Hull No. 0311-6,0442-4
Classification ABS
Work order No. PBC04MP0311~6
PBC04MP0442~4

Specification

* Aux. Boiler Type- PB0301AS10 x 1 set/ship

Capa - 18000kg/h X 7.0 kg/cm2.g

* Oil Burner Type - DDZ/400 x 1 set / ship

OS? No : PB-03-01 -A-S10-01 -01-G-F-V3-B-E-J-K-M-X-W-H-Q b

^u^ufioc?

^ ^ KAWGRIM INDUSTRIES CO.,

40,WOUNGNAM-DONG,CHANGWON CITY,KORE>V-— T^f ~T—T'^l
TEL : 055) 269 - 7700(REP) / 7892(DIR) | F0 R 1' I N; AL j
FAX : 055) 269 - 7795~9(PRODUCTION DIVISION)
E-MAIL: tech1@[Link]
 DOC. NO. PB0301AS10D3

• INDEX

1 . Boiler design Data

2 . Instruction Manual

3 . Drawings of Boiler

4 . Boiler Accessories

5 . Burner Technical Data & Spec.

6 . F.O System with equipments

7 . Forced Draft Fan

8 . Control Panel

9 . Spare parts and Tools

PLAN HISTORY
A
A
A
A
A e>S *>.)-n MoV "iH«) / ^ .^. /^
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
1 . Boiler design Data

^ ^ KANGRIM INDUSTRIES CO.,LTD.

Hull no. Type Customer
0311 -6,0442-4 PB0301 AS 10 Hyundai Mipo Dockyard Co.. LTD.

^ List of boiler design data

NO DRAWING NO TITLE REV. REMARKS

1 - Boiler design data 1

2 MB-TE-01 Safety setting list 1

3 MB-TE-01 Steam pressure setting 0

4 MB-TE-01 Water level setting 0

5 MB-TE-01 Thermal extension of boiler 0

Hull no. Type Customer
0311-6,0442-4 PB0301AS10 Hyundai Mipo Dockyard Co., LTD.

• Boiler design data

General description

The PB type boiler is a cylinderical two drum boiler with membrane water wall panel.
The steam generating section consists of straight tubes with bent pin that provide
a high heat transfer.
Circulation is ensured by placing downcomers outside the membrane walls.
The boiler is insulated and preassembled with boiler mountings for easy installation and
operation.
The boiler is top - fired and equipped with a steam atomizing burner.
As the burner, the control panel and all mountings are mounted on top of the boiler,
this can easily be operaterd. (Refer to Fig.l)

Technical data

Number of boiler / ship 1 set

Steam production 18000 kg/hr
Working pressure 7 kg/cm^ G
Feed water temperature 80 C
Ambient temperature 45 1C
Fuel oil consumption 1315 kg/hr
Air consumption at 45 "C 20773 kg/hr
Draft loss 160 mmAq

Dimension

Diameter excl. of insulation 3050 mm

Height excl. of uptake 6300 mm
^3
Water volume at normal water level 10.2
m
Steam volume at normal water level 4 rr.^
m
Weight of boiler (dry) approx 23 ton
Weight of boiler including of burner and fittings(dry) 26.5 ton

Classification

Hull No.0311-6,0442-4 ABS

Painting color

Boiler body Heat resistance paint

Control panel RAL 7032
HuU no. Type Customer
0311-6,0442^ PB0301AS10 Hyiindai Mipo Dockyard Co., LTD.

PB BOILER LAY-OUT (Fig.l)

Down comer Division wall

Bent pin

FiM TUBE DETAIL

 + +
^^'
FOR E . C . R ^
/
MEAS. NORMAL BURNER
NO. TYPE
ITEM UNIT SET POINT ALARM LIMIT LOACTION
§lllll
DIFF. PRESS. TRANSMITTER
RANf^i<^

-310-
VALUE TRIP
LOW HIGH
s
9n
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1
FOR WATER LEVEL
minHiO +380 4 - 2 0 mA BOILER
3
HIGH WATER LEVEL + 1 6 5 m m H i O , 3.0 mA O
LOW WATER LEVEL -85 m m H i O , 14.8mA o CONTROL
PANEL
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TOO LOW WATER LEVEL - 1 4 5 m m H i O . 16.2mA o o r*-
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2 LEVEL SWITCH
FOR TOO LOW WATER LEVEL
mniHi 0 -145 KD-90C
-SS-F2
o o BOILER a> H
1—1

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PRESS. TRANSMITTER
3 Kg/Cm* 0 - 16 - 8202 4 - 2 0 mA BOILER IK
FOR STEAM DRUM
OQ

4 PRESS. SWITCH
FOR HIGH STEAM PRESS.
Kg/Cm* 1 - 16 8.6 904 o o BOILER tr-
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PRESS. SWITCH
5 Kg/Cm" 1 - 16 6.4/7.6 SDC40a BOILER
FOR BURNER START/STOP

6
THERMOSTAT
ton LOW OIL TEMP.
•c 20- -150 100 ATHs-22 o o BURNER

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7 THERMOSTAT
FOR HIGH OIL TEMP. •c 20- 150 150 ATHs-22 o BURNER
^
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PROJECT 0311~ 6.0442~4 ^^^
TITLE INFORMATION TABLE OF
ELECTRIC INSTRUM SNTS
1^
CLASS Aaa &
I
CUSTOMER HMD o Ul
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K :ANGRIM 3.
INDUSTRIES C0..LT1
R EV. DESCRIPTION DATE NAME [Link].
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FOR E.C.R
MEANS. NORMAL BURNER
NO. ITEM UNIT SET POINT TYPE ALARM LIMIT LOACTION
RANflP' VALVE INPUT SIGr.
LOW HIGH

8
PRESS. SWITCH FOR
LOW OIL PRESS IN RINGLINE
bar 1- -16 6 DSB-15B o o PIPE

9
PRESS. SWITCH OF AUT.
STAND-BY FOR OIL P / P
bar 1- -16 7 904 o PIPE

10 LOW ATOMIZING STEAM PRESS. bar 0.5 - 6 2 DSB-156 o o PIPE

Ul
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11 LOW COMBUSTION AIR PRESS. mbar 0 - 100 (30) DL 50A o o BURNER
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13 POWER FAILURE o I-" r
14
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IN FEED WATER
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16 TEMP. HIGH FOR FLUE GAS •c 0 - BOO 450 - o o PIPE

16

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=5
16 :.|52
TITLE INFORMATION TABLE OF PROJECT 0 3 1 1 ~ 6,0442~4
ELECTRIC INSTRUM ENTS
CLASS Aas M
I
CUSTOMER HMD O
Ty u>
D. ""l
h:J\NGRIM INDUSTRIES CO.,LT] REV. DESCRIPTION DATE NAME [Link].
ai
• NOTE : ( )~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.
 TITLE DATA
SHEET MB-TE-01
NO. :

DESIGN DATA
KANGRIM PAGE : 3 OF 5

PROPOSAL WATER LEVEL

(4 mA)

in
csi

H.W.L (9.0 mA)

in
CD

o
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\7_ N.W (12.8 mA)
in
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LW.L (14.8 mA)

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in
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(20 mA)
 TITLE DATA
SHEET MB-TE-01
NO. :
DESIGN DATA
KANGRIM PAGE 4 OF 5

PROPOSAL SETTING POINT

9.0 SAFETY VALVE OPEN

8.8 HIGH STEAM PRESSURE AU^RM Sc BURNER OFF

8.4 DUMPING VALVE OPEN

7.5 BURNER STOP

7.0 BURNER OPERATION

6.7 BURNER START

5.0 LOW STEAM PRESSURE WARNING

 T I T L E DATA
^KMUbM^ MB—TE—01
NO. :

DESIGN DATA
KANGRIM PAGE : 5 OF 5

THERMAL EXPANSION ON[ BOILER AT WORKING CONDITION

Design Specification

Boiler type : PB-20

Steam production : 1 8000kg/hr
Working pressure (W.P) : 7kg/cm2
Des gn pressure (D.p; : 9kg/cm2
Steam temperature a\ W.P/D. P : 170/18CrC
Ambieni temperature MIN/MAX : 0/45-C

L2=2500
U =-1741

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(At wor king) (A : des gn)

Expansion fo r H1 = 5.5 5.8 mm

1- 2 = 6.2 6.5 mm
H3 = 6.6 7.0 mm
L1 = 3.6 3.9 mm

L2 = 5.2 5.5 mm
2. Instruction Manual

^ ^ KANGRIM INDUSTRIES CO.,LTD.

 DATA
JCANGRIM_ SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE; 1 OF 30
KANGRIM OPERATION AND MAINTENANCE

OPERATION AND MAINTENANCE

A. General description

B. Operating procedure

C. Treatment of feed and boiler water

D. Maintenance
1. Cleaning
2. Water washing and soot blowing
3. Preservation

E. Plugging and replacement of tubes

F. Boiler check list

KANGRIM INDUSTRIES CO., LTD.

 DATA
JCANGRIML SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 2 OF 30
KANGRIM OPERATION AND MAINTENANCE

A. General Description

Introduction

The auxiliary boiler generates steam required for tanker service, the auxiliary boilers,
in some occasion, operated together with the exhaust gas economizer.

When the main engine is out of service, the exhaust gas economizer can not naturally
be used and the steam necessary for tanker service is supplied by the auxiliary boiler
only.

After starting the main engine, the exhaust gas economizer shall be used.
While the load of the main engine is low, the exhaust gas economizer and the
auxiliary boiler shall be used together.

As the engine load increases, the exhaust gas economizer evaporated more steam and
the auxiliary boiler is placed out of service. The exhaust gas economizer thus remains
in service alone.

Such an independent operation of the exhaust gas economizer is generally the case
while at sea. However, in case more steam than generated by the exhaust gas
economizer is required, the auxiliary boiler must be placed in service to supplement
the exhaust gas economizer.

When in port, if the engine load is very low or the engine is at rest, the exhaust gas
economizer is put out of service and the auxiliary boiler is used alone. Therefore,
there are three kinds of boiler operation modes as shown below.

1) Auxiliary boiler alone to be operated. Tanker Service Mode

2) Auxiliary boiler and exhaust gas economizer Eco. Back-up Mode

to be operated together.

3) Exhaust gas economizer alone to be operated. Economizer Mode

KANGRIM INDUSTRIES CO., LTD.

 DATA
SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 3 OF 30
KANQRIM OPERATION AND MAINTENANCE

B. Operating Procedure

1. General notes on boiler operation

(1) Introduction
The following notes on boiler operation are of general nature to be observed by the
boiler operators. Although some basic rules must be strictly followed in operation
and maintenance of the boiler and ancillary equipment, it is up to the operators
familiarize themselves with characteristics of individual equipment.
This can only be accomplished by diligently observing, recording, checking and
comparing data and details. Such attentions and proper measures promptly taken by
the operators often prevent boiler outages and repairs.

(2) Performance

a) The boiler is designed to deliver steam at required pressure and temperature

when supplied with feed water at the specified temperature. Operating
conditions exceeding the design limitations will shorten the life of the boiler and
component parts.

b) The concentration of solids entrained in the steam leaving the steam drum
depends to a great extend upon the quality of the feed water.
Suitable feed water treatment and adequate blow-down should be used to
maintain the boiler water alkalinity and concentration of total solids below a
predetermined point.

c) If each heating surface of the unit is kept clean, the temperature of the gas
leaving the boiler and the draft loss through the boiler will normally be constant
for a given load and excess air ratio.
This illustrates the desirability of keeping records of boiler performance from the
start of operation. If a standard is set up when the boiler is new, the deviation
fi-om it will serve as an indicator that shows the operating condition of the
boiler as well as its own condition.
Then, steps may be taken to determine and correct the cause for the discrepancy
and often avoid the development of difficulties.
It is desirable to keep records of operating data in a form that facilitates
comparison of similar operating conditions.

d) The amount of fiiel oil consumed should be measured.

Fuel oil should also be periodically sampled and analyzed to check calorific
value, chemical composition, etc.

KANGRIM INDUSTRIES CO., LTD.

 DATA
JCAWGRIM SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE 4 OF 30
KANGRIM OPERATION AND MAINTENANCE

e) The temperature and analysis of gases leaving the boiler are invaluable as an
index of complete and economical combustion.
The best percentage of excess air to use depends upon the nature of the fuel,
the design of the fuel burning equipment and other factors. The most desirable
conditions for different rates of evaporation should be established through the
diligent study of the performance of the boiler.

(3) Operation

a) When hot water is used to fill the boiler, care should be exercised to feed
slowly to avoid severe temperature strains on drums, headers, etc. Always see
that each part of the unit is properly vented, and fill it till water level appears
in the level gauge.
The vent valve of the steam drum should be kept open during the filling
operation and should not be closed till all the air is vented from the unit.
The unit vdll have been completely vented by the time when the drum pressure
reaches approximately 2 kg/cm^ g.

b) The time required to bring the boiler up to pressure and temperature depends
upon the pressure and temperature at which it is to operate. During initial start
up of a new boiler, the longer time than the standard must be used for heating
up and pressure raising so as to allow careful inspection of expansion
movements and clearances of various parts. Increase of firing rate should not
exceed a saturation temperature rise of 67 °C (120°F) per hour for a natural
circulation boiler.
Ordinary start-up can be done at faster rate than the above. But, the operating
procedure for starting up the boiler safety should be established through
measurements of metal temperatures of important parts of the boiler, and the
boiler should be started accordingly.

(4) Water level

a) When the boiler is to be filled for operation, slowly feed water till the water
appears 25 to 50mm high in the level gauge. This is a precaution against the
swell that occurs when the boiler water is heated and begins evaporating and
also against the sudden fall of the boiler pressure when feeding comparatively
cold water.
A liberal blow-down will serve to clear the drain valve seat of any foreign
matter that may be present.

KANGRIM INDUSTRIES CO., LTD.

 DATA
JCAWGRIM SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE; 5 OF 30
KANGRIM OPERATION AND MAINTENANCE

When the new boiler is in operation, routine check of the water level gauge
should be made at least once a day. If the action of the water in the gauge is
sluggish when the drain valve is opened or closed, investigation should be made
of the cause and the condition should be corrected immediately.

c) Even through the boiler is equipped with the reliable automatic feed water
regulator and the remote water level indicator, the water level in the level gauge
should be observed periodically during normal operation.
Never shut off the feed water supply completely to the steaming boiler even for
only a short period.

d) Unless otherwise instructed, the water level should be carried near the center of
the gauge glass. Any adjustment of the water level should be gradual. If the
water level is too high, priming may occur, especieilly when the steam demand
is large or rapidly fluctuating.
If priming occurs, blow down the boiler water and changing over the feed
control to manual operation, reduce the water level.
But, the water level should be maintained as such that is just sufficient to take
care of a drop in level that may occur in the subsequent change in steam
demand. Reduce the steaming rate if necessary. Investigate the condition of the
boiler water with regard to concentration of alkalinity and total solids, and
examine the condition of the drum internals when the opportunity is afforded.

e) While the boiler is being brought up to pressure, gradually heat and properly
drain all cold steam piping.

f) During the pressure raising operation, the drum water level often rises higher
than the normal level due to the expansion of water.
If it is desired to keep the water level visible in the level gauge at this time,
boiler water should be blow down.

g) Observe the drum water level at times to confirm the proper functioning of the
automatic feed water regulator.

(5) Others

a) When re-igniting the burner to bring the boiler back into service from the
standby state, the furnace still remains hot, filled with unbumt fuel particles and
unbumt gas, and thus requires internal purging by means of forced draft fan (this
is an exceptional instance in which the furnace, still hot, may be air-purged).

KANGRIM INDUSTRIES CO., LTD.

 DATA
SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 6 OF 30
KANGRIM OPERATION AND MAINTENANCE

b) In case of re-lighting the burner, an igniter must be used. Never attempt to

hght the burner with hot refractory in the furnace.

c) Check chemical contents of the boiler water at least once a day.

Add chemicals or blow down the boiler water as required to maintain proper
concentration of chemicals in the boiler water.

d) Check frequently the smoke indicator to maintaining efficient combustion.

e) Keep burner tips clean as they are adopt to be fouled with dirt and soot.

* Not : Be absolutely sure to use the steam drum surface blow-off valve when
blowing boiler water during boiler operation and to blow boiler water using
the water drum bottom blow-off valve only during boiler outage.

2. Preparations
Prior to starting the boiler, attention should be paid to the following items and through
should be made on them.

Boiler

(1) All foreign materials have been removed from pressure parts.

(2) All gas side heating surface are clean and all refractories are in good condition.

(3) The fiimace bottom and the burner wind box have been cleaned of oil and others.

(4) All personnel are clear.

(5) All manhole covers are securely tightened.

(6) Inspect safety valve and see that gags have been removed and easing levers are in
good condition.

(7) Open root valves for all instruments and controls connected to the boiler.

(8) Open the vent valve of the steam drum.

(9) Open all pressure gauge valves and check and see all valves on the pressure
gauge piping are open.

KANGRIM INDUSTRIES CO., LTD.

 DATA
SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 7 OF 30
KANGRIM OPERATION AND MAINTENANCE

(10) Check and close all blow-off valves and drain valves.

(11) Fill the boiler till water level appears 25 to 50 mm high in the gauge glass.

The boiler shall be filled in the following procedure and the feed water line shall be
inspected simultaneously.

(a) When the boiler was laid up wet (Refer to "Protection of the boiler during
shutdown".), drain the boiler till the water level falls down to the bottom of the
gauge glass, and bring the water level up again to about 25nim high in the
gauge glass feeding through the auxiliary feed water line.

(b) When the boiler was laid up dry, first fill the boiler feeding through the
auxiliary feed water line till the water level just appears at the bottom of the
gauge [Link], raise the water level feeding through the main feed water line
up to about 25 to 50mm higher than the normal water level. This practice
serves to check that both the auxiliary and the main feed water lines are ready
for service. Use distilled water for feed water whenever possible. Boiler
compound shall be added as instructed by the expert of boiler water treatment.

Fuel burning equipment

(1) Make sure that all fuel oil lines including oil filters, etc. are in good condition.

(2) Make sure that no oil residue is in the burner wind box.

(2) Make sure that F.D Fan inlet vane is clean and moves smoothly.

3. Lighting off and pressure raising

(1) Make sure of the drum water level by the water level gauge.
That is, the water level should fall when the drain valve of the water level gauge
is opened, and it should return to the previous level when the valve is closed.
Attention must be paid not to take the empty level gauge for full of water or
stains on the gauge glass for water level.

(2) Start the forced draft fan at low speed

Prior to lighting off, place the forced draft fan with inlet damper fully opened
and purge the furnace for at least one minute.

KANGRIM INDUSTRIES CO., LTD.

 DATA
SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 8 OF 30
KANQRIM OPERATION AND MAINTENANCE

(3) Start the fuel oil burning pump and begin the use of the fuel oil heater, using
heavy fuel oil with normal tip which condition is operated by H.F.O. mode. Start
the fuel oil firing piraip and open the oil re-circulation valve to re-circulate oil
through the oil heater and burner manifold discharging cold heavy oil in the line.

(4) Reduce air pressure at wind box to 10 to 20nunAq. And securely close the oil
re-circulation valve. Check the fuel oil control valve opening by the output signal
to ensure it is ready for service.

(5) Light off the burner and immediately make a necessary adjustment of oil pressure
and air pressure to ensure a stabilized combustion of the fuel.
At this time, care should be taken to obtain such a burning condition that the
fuel oil bums completely vkithout scattering unbumed particles or producing
heavy smoke.
Frequently check the smoke and the flame through the observation holes,
especially after making any change in firing rate or burner inlet air pressure.

(6) When raising the pressure, keep the burner firing five minutes and out of service
15m minutes repeatedly at the lowest oil pressure (2.5 kg/cm^g) for one hour and
then again repeatedly light off and shut down the burner to raise the steam
pressure at the rate indicated in Fig. 2-1 or less.

(7) When the drum pressure has risen to about 2kg/cm^g, close the drum vent valve.

(8) Close the valve of the pressure gauge and remove the gauge.
Then, open the valve a crack and release steam to make sure the tubing for the
gauge is clear.
Reinstall the pressure gauge and see that it works as soon as the valve is opened.
In this case, care should be taken to allow several minutes to cool the line before
opening the valve.

(9) Check the water level gauge to see nothing is the matter with it by opening and
closing its drain valve, and make sure of the drum water level again.

(10) Drain and warm all steam supply lines to the ancillary equipment and devices.
It is very important to discharge drain water from these lines and warm them up
to near the operating temperature before loading the boiler.

KANGRIM INDUSTRIES CO., LTD.

 DATA
JCAWGRIM SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 9 OF 30
KANGRIM OPERATION AND MAINTENANCE

(11) When the drum pressure is raised to about 3 to 4 kg/cm^g below the normal
operating pressure, check the safety valves with the easing gear. Care must be
taken to op)en and close the valve quickly so as to prevent damaging the disc and
the seat of the valve.

Cfl
20

^ 16
S 15
w
Vi

t 10
O
3
00

1.0 2.0 TIME(hr)

Fig. 2-1 RECOMMENDED PRESSURE RISE

4. Cold Start-up

(1) When the boiler is to be started from the cold state in which no steam is
available from the land or the exhaust gas economizer, use the starting diesel oil
for fuel till the steam necessary for the oil heater becomes available.

(2) Fill the boiler with the best water available. For this purpose, prepare distilled
water in the feed tank as much as necessary to start the boiler before shutting
down the boiler.
It is advisable to fill the boiler up to 50 to 80 mm above the normal water level
so that no additional feed water is required till the feed water pump is placed in
service.

(3) Start the diesel generator and light off the burner using diesel oil with the nor tip
which condition is operated by air atomizing F.O. temp. By pass mode and burner
manual mode.
Before lighting off, never fail to purge the furnace adequately.

KANGRIM INDUSTRIES CO., LTD.

 DATA
SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 10 OF 30
KANGRIM OPERATION AND MAINTENANCE

(4) Take necessary measures as described in "PREPARATION".

(5) Close valves of the heavy oil lines from the fuel oil tank to the burner manifold
and open valves of the diesel oil line from the diesel oil tank.

(6) Start the fuel oil pump and open the oil re-circulation valve to discharge heavy
oil remaining in the line, burner manifold and oil inlet pipes to burners
thoroughly.

(7) Set the atomizing air pressure at 6K and fuel oil pressure at 3K.

(8) Rim the forced draft fan at low revolutions and ignite the burner using the pilot
burner.

(9) When the steam pressure has risen to about 2 kg/cm^g, start warming the steam
pipe lines and the feed water pump pipe lines, and turn on steam to the setting
tank.

(10) When the heavy oil in the setting tank has been heated enough to be pumped by
the P.O. pump, turn on steam supply to the oil heater in preparation for
changeover from diesel oil firing to heavy oil firing.

(11) Circulate oil through the oil heater and the oil re-circulation line till the oil of the
proper temperature is available in the burner manifold. Then, switch diesel oil
firing to heavy oil C firing and continue pressure raising.

(12) Start the feed water pump as early as possible so that it can feed water to the
boiler immediately when the drum water level should fall.

5. Shutting down

(1) Shut down the burner.

(2) Continue operation of the forced draft fan for a while after shutting down,
keeping air pressure of about ISOmmAq at burner inlet and purge the fiimace of
combustible gases adequately.

(3) Maintain the drum water level visible about 50 m in the gauge glass.

KANGRIM INDUSTRIES CO., LTD.

 DATA
JCAWGRIM SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE; 11 OF 30
KANGRIM OPERATION AND MAINTENANCE

(4) When keeping the boiler temporarily out of service or in what is called the
"Standby state", be sure to light off the burner from time to time in order to
maintain the steam pressure at the normal working pressure and below.

(5) In order to maintain drum water level visible about 50 mm in the gauge glass
even the boiler in cold, raise the water level 70 to 120 nun above the normal
water level before closing the feed water

(6) When the boiler is to be shut down completely, close the steam stop valve
immediately after the boiler stops steaming.

(7) When the boiler pressure has fallen to the atmospheric pressure, open the drum
vent valve.

(8) It is 4 hours after shut down, the boiler may be cooled with the forced draft fan
operation as the case may require.
But, if possible, such a forced air cooling should be avoided not damage
refractory in the furnace. Do not attempt to cool the boiler by blowing down the
hot boiler water or by refilling the boiler with cold water after blowing down.

6. Emergency operation

Water level low

If the water level falls down to 200 mm or more below the normal water level due to
failure of the feed water supply or neglect of the operator, the alarm lamp on the boiler
control panel goes on and simultaneously the alarm buzzer sovmds. If the level falls
further down to 240 mm or more below the normal water level, the fuel oil emergency
trip valve fully closes cutting of the fuel supply to the boiler automatically. Then, fully
close the feed water valve and the steam stop valve and shut down a burner completely
and stop the forced draft fan.
In this case, never attempt to feed water to the boiler till the boiler has cooled
sufficiently, since, otherwise, there may be a danger of quenching the hot pressure parts
with comparatively cold feed water.

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Flame out

In the event of a flame out, immediately close the oil inlet valves and reduce air pressure
at burner inlet so as to present overcooling the furnace.
Prior to re-lighting burner, purge the furnace adequately following the procedure
mentioned in "Lighting off and pressure raising". A pilot burner must be used for re-
lighting a burner. Never attempt to light a burner by the heat from the hot refractory in
the furnace.

Failure of evaporating tube

(A) In case of a tube failure which results in a loss of water so great that the water
level can not be maintained, use the method outlined below:

(1) Shut off oil supply to burner to extinguish the fire. When the tube failure is
resulted from low water, shut off feed water to the boiler closing the feed water
valve and the steam stop valve.
This is to avoid the damage that may be caused by quenching hot pressure parts
other than the failed tube with comparatively cold feed water. Refer to "Water
level low".

(2) When the failure of the evaporating tube is resulted from the cause other than
low water, maintain the water level, if possible, at the normal level till the boiler
has cooled enough and then close the steam stop valve and open the drum vent
valve

(3) In either case of the above, keep the forced draft fan in operation to maintain
sufficient air flow to carry the escaping steam out through the stack, adjusting the
F.D Fan inlet valve to such an opening so as to avoid damaging refractory by
quick cooling.

(4) Do not blow down the boiler to lower the pressure rapidly unless the failure is so
severe as to endanger the personnel near the boiler.

(5) Dump the boiler water overboard through the bottom blow valve after cooled
enough.

(6) When the furnace has cooled enough to permit a man to enter it, make a
thorough inspection of all pressure parts for any indication of damage. After
necessary repairs have made, apply a hydrostatic test to see whether the unit may
be put back in service or not.

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(B) In case of a leak which does not involve a serious difficulty, the water level
should be maintained and the boiler taken out of service in the normal manner.

(1) Switch the combustion control equipment to manual control and reduce combustion
rate following the normal procedure.

(2) Continue air flow through the unit at reduced rate till all combustible gases,
vapors, etc. Have been removed.

(3) Manually adjust the feed water flow rate to maintain the water at a high level.
Once the boiler evaporation has come to a halt, let the pressure to down by
natural cooling. When the drum pressiu-e has come down to 2 kg/cm^g, open the
drum air vent valve to discharge boiler water.

Fire inside the casing

Shut off oil supply to the burners immediately and close the forced draft fein inlet vane.

Failure of forced draft fan

In case of a failure of the forced draft fan, oil supply to the burners is stopped
automatically with the fuel oil emergency trip valve Close oil inlet valves to the burner.

C. Treatment of feed and boiler water

The below values are, unless special conditions are to be taken into consideration,
to be kept for KangRim Boilers.

1. Control of feed water and boiler-water impurities

With boiler in service, it is recommended that at least once everyday feed water and
boiler water be sampled for analysis and appropriate measures taken for qualitative
control.
When sampling boiler water, care is to be exercised so as to take the sample that truly
represents boiler water, by for example cleaning the sampling vessel twice to three
times with boiler water beforehand.
Feed water and boiler water sampled are to be thoroughly and carefiilly analyzed using
an appropriate analysis equipment, in accordance with instruction given on the use of the
equipment

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Every effort is to be made to control oxygen, p H , salt, dissolved solids, phosphoric

acid, etc. in feed water and boiler water to within the specified limits.
Requirements specified for the ship's boiler as regards the control of feed water and
boiler water impurities follow.

Feed water

(1) Oxygen : The oxygen content of feed water is to be controlled to below [Link]

(2) PH : The recommended pH value is 7.0 to 9.0. For the pH control purpose,
however, it is reconunend that the target be set at 8.5 to 9.0

Boiler water

(1) PH : pH of boiler water requires to be controller to 10.8 to 11.3.

(2) Salt : The salt content of boiler water (as CI") requires to be controlled to
300ppm and as far below as possible , preferably below ISOppm .

(3) Dissolved solids : dissolved solids in boiler water require to be controlled to 2000ppm
and as far below as possible.

(4) Phosphoric acid : phosphoric acid of boiler water (as PO/") requires to be controlled to
20 to 40pp

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2. Limits of chemical concentration

Water boiler water feed water to boiler
Item
PH(at25o C) 10.8-113 7.0-8.0

Phenolphthalein Max. 500

Alkalinity (CaCOj) ppm
Total Max. 600
Alkalinity (CaCO,) ppm
Chloride (CI) ppm Max. 300 -

Total solid ppm Max. 2000 -

Excess 20-40
Phosphate(P04^") ppm
HardnessCCaCOj) ppm - Max. 1.0

Oxygen mg/1 - Max. 500

Hydrazine mg/1 - -

Note : Estimate the pH value from alkalinity tends to give pH readings varying
With silica, Ca, Mg, and other salt contents of boiler water and hence is
not necessarily deemed appropriate : resort to this method only as a means
to obtain a rough guide (alkalinity serves merely as an auxiliary means in
determining the pH level).
Also, be sure to control pH to the target value while, on the other hand,
Keeping alkalinity at the minimum necessary level.
Limiting the P alkalinity to within a certain range would make it possible
to inhibit the alkali corrosion evenifboilerwater concentration should take
place on the heating surface, etc.

3. Boiler blow-down

Blowing down boiler water by operating the blow-down valve and replenishing the amount
of water blown down with fresh water is of vital importance to reducing the
concentration of boiler water to satisfactory level for operation. Also, the boiler blow-down
is just as important to discharging sludge, oily substance, and other impurities
accumulated in the boiler.

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The amount of boiler water to blow down and how often to blow down are to be
decided based on factual data, such as the results of boiler water analysis, turbidity of
sampled boiler water, etc., so that the aforementioned requirements on boiler water
chemistry can be satisfied .

4. Makeup-water and boiler water treatment

The boiler disorders caused by inadequate control of boiler water and feed water may
be broadly defined as follows.

(1) Overheating of heat-transfer surfaces due to accumulation of scale and oil/grease

deposits

(2) Corrosion (and caustic embrittlement)

(3) Turbine and other associated equipment disorders due to carryover some
restrictions, therefore, require to be imposed as follows in order to prevent the
above disorders.

* To cope with (1) above, the hardness and oil/grease content of feed water require
to be controlled to within allowable limits, as does silicic acid contained in boiler
water
* To deal with (2) above, feed water pH and boiler water pH require to be
controlled to allowable levels.
* Salts defy the generalization, some serving to inhibit the corrosion and some
promoting the corrosion. Chlorine (chloride), however, generally promotes the
corrosion when present in a large amount and hence requires to be controlled to
as low a level as is practicable.
* To prevent the problem (3), dissolved solids and oil/grease contained in boiler
water require to be controlled to within allowable limits.

Restriction of individual impurities

(1) Hardness
The formation of scale deposits in the boiler drum and evaporating tube internal
surfaces and accumulation of sludge within the boiler are attributable, principally,
to hardness-constituting elements carried into the boiler by feed water.

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Leaving the feed water supply as it is while obviously high in hardness and
treating it in the boiler has potential of having the impurities adhere to fiat-
absorbing surfaces and also can cause the rise in anti-scale consumption and
quantity dissolved solids.
The best practice dictates, therefore, that the hardness of feed water be restricted to
within an allowable limit and what is left of the hardness removed boiler water
treatment in the boiler.
Specifically, the hardness of feed water for a 16kg/cm^g boiler is to be controlled
to Ippm. With makeup water produced by distilling seawater in a desalination
plant, assuming impurities carried over through evaporation to be same as those in raw
seawater (of total salts, CI- 55%, Ca - 1.2%, andMg - 3.7%), the hardness
brought in per 1 ppm of chlorine ( C ) is 0.34 ppm. Then, even with the
allowable limit of chlorine at 5ppm, the hardness upon evaporation is 1.7 ppm,
which suggests that judging from the rate of makeup feed, restricting the feed
water hardness to within the above mentioned limit is not difficult.
In cases where the distilled water tank is coated with water de-mint (definitely not
encouraged) or where there is leakage in eventually enter the goiler, warranting
due precaution.
In some instances the required hardness is specified for boiler water. The hardness
values suggested for boiler water are prone to error and often turn out to be
unrealistic. For this reason and also since the boiler water hardness should remain
about Ippm as long as excess phospheric acid and pH of boiler water are
controlled to the values given in Table 1, MHI does not make it its practice to
specify the hardness requirement.

(2) pH value (Alkalinity)

The boilers are made almost entirely of steel, and iron, beside being susceptible to
heavy corrosion in acidic environments, dissolves in neutral pure water to produce
iron hydroxide as follows.

Fe + 2 H2O = Fe(0H)2 + H^
Iron water iron hydroxide hydrogen

When iron has dissolved in pure water, pH with Fe(0H)2 at the saturation point is
0.9. The larger the pH value, i.e., the higher the alkalinity, the more sharply the
amount of iron dissolution goes down. It therefore is necessary for the pH value
to be maintained constantly at a high level in order for iron being prevented from
becoming corroded. A word of caution is deemed in order because pH at too high
a level can beck-fire in the form of caustic corrosion or caustic embrittlement or
carryover.

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Also, it is known that boiler water is not uniform in concentration throughout its
body. So, everything considered, the reasonable proposition is that pH of boiler
water be maintained at 10.8 to 11.3.
Alkalinity may be divided into total alkalinity and active alkalinity. Included in the
total alkalinity reading are caustic soda, potassium carbonate, and potassium
bicarbonate, all these being put together. The active alkalinity, on the other had,
called phenolphthalein alkalinity ( or P alkali, in short) represents the
amount of alkali high enough in strength to turn phenolphthalein indicator in color.
It is the active alkalinity that serves as a rough guide to the pH level.
With all the foregoing in consideration, therefore, the phenolphthalein alkalinity as
CaCOj is to be controlled to about 50 to 300 ppm when boiler water is in excess
of 1000 ppm in concentration and to about 30 to 400 ppm when boiler water
concentration is below 1000 ppm.

(3) Dissolved oxygen

The dissolved oxygen constitutes a single greatest factor in causing corrosion,
being responsible for boiler steel corrosion in well more than 50% of time.
In reaction between water and iron, which is defined as Fe + IHjO = Fe(0H)2 + Hj
hydrogen thereby produced is absorbed in metal surface to serve as a negative
factor in the reaction. When oxygen is present, however, it causes hydrogen to
disappear by oxidation, so the reaction progresses toward the right term of the
formula with the dissolution of iron taking place continuously.
In addition, iron hydroxide turns into ferric hydroxide by being oxidized by
oxygen, ferric hydroxide setting down to produce rust, thereby causing the
corrosion of iron to progress intermittently.

2Fe(OH)2 + I/2O2 + H2O = 2Fe(OH)2

iron ferric
hydroxide hydroxide

The pitting corrosion, found concentrated under the drum waterline, is attributable
to the dissolved oxygen. Iron transported form the feed water piping into the drum,
plus iron oxide produced within the drum, accumulates as deposits
or settles down to cause the pitting.
The presence of carbon dioxide gas together with dissolved oxygen in saturated-
steam piping can cause a total corrosion. Carbon dioxide gas is produced by
dissolution of bicarbonate in makeup feed as well as by dissolution of sodium
carbonate within the boiler.

2NaHC02 - Na2C03+ H2O+ CO2

Sodium Sodium Carbon
bicarbonate carbonate dioxide gas
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NaaCOj + H^O 2NaOH + CO2

Sodium Caustic Carbon
carbonate soda dioxide gas

The use of sodium carbonate as boiler anti-scale, therefore, is not recommendable.

Carbon dioxide gas dissolves in water and acts as carbonic acid but does not
cause by itself so heavy corrosion. If there is oxygen together, however, the effect of
the Dissolved carbon dioxide gas becomes pronounced, as if to play a role of some
oxidizing medium as indicated by the following reaction formulas.

Fe + 2H2CO3 = Fe(HC03) + Hj (1)

Carbonic Ferrous
acid bicarbonate

2Fe(HC03)2 + l/20j + 5 HjO = 2Fe(0H)j + 4H2CO3 (2)

Ferric
Hydroxide

The dissolved oxygen in feed water, therefore, requires to be strictly controlled,

preferably to below 0.05 ppm for a 16kg/cm^g boiler even though it is specified to
be 0.5 ppm.
For removal of dissolved oxygen, it is recommended that volatile hydrazine be
continuously added to feed water. Hydrazine reacts as follows .

N2H4 + O2 N2 + 2H2O

(4) Chlorine (Chloride)

Salts, when present in large quantity, raise the electric conductivity of liquid to
promote the corrosion and hence require to be controlled to as low a level in
quantity as is practicable.
Feed water containing too large an amount of magnesium salt can produce the
sediment of magnesium hydroxide upon entering the boiler, and this is said to
raise he corrosiveness of boiler water by bringing down the boiler water pH value.
All the same pH and oxygen remain the greatest factors in causing the corrosion,
and the measurement of chloride is performed more or less to obtain a rough idea
as to the amount of dissolved solids contained.
The relation between the dissolved solids and chlorine ion, though subject to some
variations depending on the water quality or performance of the water-making
device, can be established by measuring these elements in boiler water of each
individual boiler beforehand. Then, it is possible, as well as does no harm for
practical purposes, to estimate t he amount of dissolved solids .

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It is assumed that the concentration of boiler water, as long as it is controlled

of boiler water, as long as yardstick, can not rise to such a level as to greatly promote
the corrosion except in special instances. The feed water committee, therefore, sets
forth no requirements in particular as to the allowable limit of chlorine.

(5) Oil/Grease
Oil / grease coming out of auxiliary machinery, especially those started in
reciprocating motions, enters feed water and then adheres to the boiler heat-
absorbing surfaces to cause the overheating trouble there upon oxidation.
Also, since boiler water is alkaline, both animal and vegetable oils are liable to
be emulsified in it. The results are foaming of boiler water and degradation I n
steam purity.
Although the allowable limit is specified for the amount of oil / grease in boiler
water in some instances, it seems highly likely that such as oil / grease will be
several - hundreds fold greater in concentration at the boiler - water surface than the
mean oil / grease content. As specifying such a limit is deemed to make not so
much of sense, it is only requested that feed water and boiler water be controlled
so that the amount of oil / grease can be kept to zero as far as is practicable.

(6) Silica (Silicic Acid)

The scale that contains silica is the poorest in heat transfer and thus the most
harmful to boiler operation.
Also, what is called the silica carryover takes place, in which silica carried in
steam enters the turbine and deposits itself on the turbine blades as hard scale
encrustation. This is the single most nettlesome phenomenon, which warrants a
serious consideration in connection the care of high - pressure boilers.
For a 16 kg/cm^g boiler, it is recommended that the silica content of boiler
water be controlled to below 50ppm to cope with both the scale formation and
silica carryover.
Silicic acid should be no cause of concern so long as distilled water produced
from seawater is used as makeup feed in nearly all the instances . When water is
obtained from land, however, necessary precautions are to be taken in this
respect.

(7) Dissolved solids

The larger the amount of dissolved solids in boiler water, the bore dampened the
steam becomes, to the point where a large amount of solids are carried in steam
as carryover to the turbine. The tendency of such a carryover varies with the
steam evaporation rate, boiler type, and performance of the steam separator in the
steam drum, as well as with constituents of solids even if the solids are same in
quantity.
Although the relation between these factors still defies quantitative definition, at
least a rough standard can be given for safe and practical operational purposes
from the past experience . In normal operation, the amount of dissolved solids is to
be kept to below 2000ppm.

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6. Boiling out

If the presence of oil is found on the waterside of the boiler, it must be removed by
boiling out. This is necessary after assembly of a new tubes, or if oil has entered the
feed water from some other source.
Boiling out is also a quick and efficient method of removing various types of scale.
The chemicals to be used and the strength of solution required, depends on the
character of the scale. Consult the boiler water chemist.
Boiling out to remove oil requires the use of a fairly strong caustic solution. One
such solution is 2kg of caustic soda and4kg of tri-sodium phosphate, for each 1000
kg of cold water required to fill the boiler. This chemical solution is sufficient to
remove ordinary compounded lubricating oils or the usual protective oil coating applied
to tubes before shipment.
Straight mineral lubricating oils used for high temperature engines requires stronger
solutions . If such oil is present in the boiler used 4 kg tri-sodium phosphate and 4
to 5 kg caustic soda per 1000 kg of water. In addition it is advisable to add detergent
(wetting agent) amounting to about 0 . 5 percent of the boiler water. There are other
chemical solutions that can be used.
There are many satisfactory compounds for boiling out. They are sold under various
trade names by reputable firms. When such compounds are used, follow the
manufacture instructions.

Steaming Method

This is a method in which steam is injected by way of a temporary piping externally

connected to the air - vent valve, for soda boiling. Water is to be discharged by way of
the bottom blow-down valve and through a temporary discharge piping. The discharge
piping is to be connected to the boiler water sampling tank, which is required for
inspection or analysis of boiler water.

(1) Inject chemicals into the water wall tubing as required, using the chemical
injection device . Dissolve the chemicals in clean water, in proportion to the
weight of water required to completely fill respective boiler parts, for injection .
See the " planning particulars " included in this Manual for the weight of water
required to fill each of the boiler parts
Upon finishing the injection of chemical solution, gradually blow in steam in such
a manner as to permit condensed water to collect until the boiler is completely
filled with water to the point where water begins to overflow by way of the air -
vent valve.

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(2) Maintain the boiler pressure at about 3 . 5 kg / cm.g and adjust each air - vent so
that the quantity of overflowing water from each individual air - vent valve and
bottom blow-down valve will be approximately in proportion to the quantity of
water in each corresponding boiler part.
(3) Determine the progress in removal of oil through test of sample water taken from
the discharge piping. Analyze the sample water for alkalinity and then add
chemicals required to maintain the chemical concentration at the specified level :
by so doing, continue the soda boiling until no trace of oil can be seen in the
sampled water.
The oil content can be detected by examining the surface of cooled sample water
for sign of oil. If possible however, analysis by ether method, etc. should be in
order.

Firing Method

If steam and electric power are available and the auxiliaries are ready for service a
boiler can be boiled out using a light fire. When the firing method can be used, it is
much simpler and does not require temporary piping.
The quantity of solution to use should be figures for the weight of cold water required
to fill the boiler to normal steaming level.
(See "Design Data".)

(1) Dissolve the chemicals in water and inject into the boiler with the compovmd
ejector.

(2) Close the boiler and fill to the normal starting level.

(3) In cases where the boiler is of new construction with new refractory in it, avoid
the sharp thermal expansion of the refractory by preheating the fiamace internals by
burning firewood inside the fiimace for 3 to 4 hours or by firing the burner
intermittently.

(4) Ignite and shut down one burner using the smallest- capacity burner tip, repeatedly

(5) until the pressure is gradually raised to the level corresponding to 85 to 88% of
normal operating pressure. Maintain the pressure at that level, for soda boiling. If
necessary to maintain the pressure, intermittently fire the burner.

(6) If the refractory is new, alternate the burner at fifteen minute intervals.

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(7) When the boiler is thoroughly heated, raise the water level slowly to about 75 to
100 mm above normal, operating level, then give a surface blow followed by
several short bottom blows to bring the water level 30 to SOnwn below normal
Refill the boiler slowly, until the water level is reached to about 75 to lOOmm
above normal, and additional chemical based on the approximate amount of water
blown down.

(8) Perform the soda boiling continuously for 6 to 8 hours, blowing down boiler
water through the blow-down valve by 100 to 150 mm on the level gauge each
time.

[Link] and inspect

(1) After boiling out is completed by the firing method, blow down the boiler
through the water drum bottom blow off valve while the boiler is fairly warm.
Discharge the water overboard, to avoid damaging paint in the bilge by the strong
caustic solution.
(2) Open up the boiler and wash it down with a high pressure water playing the
hose into all tubes.
(3) Carefully inspect the boiler, and if any trace or oil remains, repeat the boiling out
process.

n . Maintenance

1. Cleaning

(1) If the feed water is properly treated the possibility of impurities at the water and
steam side of the boiler should be minimal.

(2) Deposits in the tubes are notoriously extremely small owing to the heavy water
circulation. If impurities, which cannot be boiled out, should come inside the
tubes the tubes can be cleaned from the upper drum by scraper. If the oil burner
is functioning correctly and the combustion is complete the soot deposit on the
tubes will be minimal, but in practice it can hardly be avoided that soot deposits
will occur in the course of time, e. g. due to the starting periods of the oil burner.

(3) If the combustion has been had during a long period and the soot deposit has
been so heavy that an ordinary soot blowing is insufficient the tubes can be
brushed outside though the door in the uptake and through the tree doors in the
plate covering round the tube section.

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2. Water washing and soot blowing

Water washing

Water washing is easily carried out from the smoke box outlet with washing hose. And
when washing is carried out the boiler must be out of operation and its temperature
below llOTC.
After washing is completed the furnace bottom refractory must be cleaned with alkaline
water due to the washing water is very corrosive. The boiler must be boiled out
immediately after the water washing has been completed in order to avoid damage on
refractory and heating surface.
The boiler must be lighted-up and pressured as the above described.

Soot blowing

Generally, deposits on the heating surfaces cause to reduce combustion quality. These
deposits will accumulate on the generating tubes if not removed. This boiler is equipped
with soot blowers for cleaning. These are manually operated and arranged for direct
connection to the steam system of the ship. In order to obtain an efficient soot cleaning,
the steam pressure must be at notmal working pressure and boiler load should not be
lower than 50%.
Soot cleaning procedure is as follows.
1) Check the steam pressure.

2) Check that main valve and two manual valves of soot blower are closed.

3) Open the drain valve to drain water from main tube for a few seconds and close it
again.

4) Open the main valve.

5) Open the lower manual valve for approx. 5 sec. and close it again.

6) Open the upper manual valve for approx. 5 sec. and close it again.

7) Repeat above 4) to 6) 3-4 times.

8) Close the main valve.

9) Check that both ball valves are closed.

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Section A-A

3. Preservation

In order to prevent corrosion, if the boiler is to be shut down for a period of 1-30 days,
it should be cleaned from soot deposits and then top filled. If it is to be shut down for
more than one month, the following method can be applied.

Dry preservation

1) The boiler is emptied of water by bottom blowing at 3-5 bar pressure, open and
drain remaining water.

2) If the boiler is cold, drying of the boiler is done by dried air from fan or inserted
silicagel bags.

3) Place a tray with burning charcoal to remove oxygen.

4) Alternatively, a small steam phase inhibitor is to be added to the boiler after cooling
and careful draining, and closed completely.

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Wet preservation

1) Fill with treated boiler water and hydrazine is added until an exec of 100-200 ppm is
obtained.

2) The water should be circulated continuously or at least once per week to avoid
corrosion from any penetrating oxygen. And hydrazine concentration is checked.

* This method can be used for a short period of 1~3 months.

•The pH-value should be 9-10.5.

** This method should not be used to avoid frost damages, if ambient temperature
is below CC.

Wet preservation

1) The boiler has to be drained and dried, sealed

2) Connect to the boiler bottom and open air vent valve in the top of boiler.

3) Connect bottle with nitrogen to the bottom through a reduction valve and purge the
boiler until no oxygen is left.

4) Close air vent valve.

5) Keep approx. 0.2 bar in the boiler.

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PAGE: 27 OF 30
OPERATION AND MAINTENANCE

K. Plugging and replacement of tubes in PB boiler

(1) Remove the manhole in the steam/water drum.

(2) The damaged tube ends should be cleaned before plugging.

(3) The plugged tubes should be cut vertically along the connections with fins
between the tubes in panel wall, Fig. 1.

(4) Weld a number of anchors on the fin and inside the rest of tube.

(4) Refi-actory against it must be carried out in the full height inside the furnace.

Fig. 1

Tube plug

1 1 Detoil A-A

m'/{%W' m
—U-Al\- JJ-LU-L-U~

KANGRIM INDUSTRIES CO., LTD.

 DATA
JCAWGRIM SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE : 28 OF 30
KANGRIM OPERATION AND MAINTENANCE

(6) The insulation around the damaged panel wall tubes should be removed.

(7) The damaged tubes must be cut below and above the tube sheets..

(8) The tubes are removed by cutting out in the fin.

(9) Scraps of metal or welding in the tube holes and the tube plates must be grind
off.

(10) The new furnace panel wall tubes must be welded on as shown in Fig.2

Fig. 2

fl

Weid detail

KANGRJM INDUSTRIES CO., LTD.

 DATA
JCAWGRIM SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE; 29 OF 30
KANGRIM OPERATION AND MAINTENANCE

2. Plugging and replacement of generating tubes

(1) Plugging of the generating tubes are shown in Fig. 3.

** Up to 10% of all generation tubes can be plugged with a conical plug but if more
tubes are damaged, an exchange of tubes are necessary.

(2) For replacement, an opening in the surrounding panel wall must be cut according to
the above procedure.

(3) New pin tubes are build-up one by welding on to the tube plates.

** The tubes are inserted 5-10 mm in the tube plates before welding inside the tube hole.

(4) During assembling the supports are arranged and adjusted.

(5) Finally the opening in the panel wall must be rebuild.

Fig. 3

Tube plug

Steam Drum

KANGRIM INDUSTRIES CO., LTD.

 DATA
_KANGRIM_ SHEET PB-OP-MN-01
INSTRUCTION NO.:
FOR
PAGE: 30 OF 30
KANGRIM OPERATION AND MAINTENANCE

F. Boiler check list

No Item Checking method Frequency

1 Reflex Open and close the drain valve and see Once a day
water level the response of the water level in the
gauge gauge.

2 Boiler water Measure concentration of chemicals in Once a day

boiler water and check water quality.

3 Remote water Lower the drum water level down to Once per
level -100mm by operating the feed water six months
indicator regulator by hand and compare the
indication of the remote water level
indicator with that of the transparent
water level gauge.

4 Burner When the burner only is in service, Once per

flame-eye shut it down and see that the indicator six months
lamp for loss of fire goes on.

5 Water level When the boiler is running under low Once per
alarm load, change the drum water level. two weeks

6 F.O cut-off When the boiler is stopping, change the Once per
condition drum level (low-low), stop the F.D Fan, three
and stop the F.O Pump. months

7 Steam leakage Check the boiler press. Parts, flanges, Once a day
water leakage and valves.

KANGRIM INDUSTRIES CO., LTD.

3. Drawings of Boiler

^ ^ KANGRIM INDUSTRIES CO,LTD.

HuU no. Type Customer
0311-6,0442-^ PB0301AS10 Hyundai Mipo Dockyard Co., LTD.

• List of drawings

NO DRAWING NO TITLE REV. REMARKS

Part list

2 PB0301AS1001 Piping system diagram 2

3 PB0301AS1002 Arrangement of nozzles 1

4 PB0301AS1006 Base & foundation 0

5 PB030IAS 1007 Outside insulation 0

6 PB0301AS1008 Smoke uptake 1

7 PB030IAS 1040 Grating&Handrail detail 1

8 PB0301 AS 1050 Level gauge&Easing gear seat 1

9 MB - LE - A Boiler lifting lug "A" type 0

10 MB-LE-B Boiler lifting lug "B" type 0

HuU no. Type Customer
0311-6,0442^ PB0301AS10 Hyundai Mipo E)ockyard Co., LTD.

Part list of boiler

NO. DESCRIPTION TYPE/SPEC. O'tv. REV REMARK

VI Safety valve with drip pan SV60, PN25 DN65/100 2 0 Mounting

V2 Main steam valve JISF7314,20K250A 1 0 -1
V3 Feed water valve JISF7314,20K65A 2 0
V4 Feed water check valve (SDNR) JISF7473,20K65A 2 0
V5 Scum valve (SDNR) JISF7474,20K40A 1 0 JIS std'
V6 Water level regulation valve JISF7421,20K25A 2 0 dwg is
V7 Low water level switch valve JISF7421,20K25A 2 0 not
V8 Blow down valve JISF7313,20K40A 2 I submitted
V8-1 Blow down valve (SDNR) JIS F7473,20K 40A 2 0
V9 Sampling valve JIS F7388, 20K 6A 0
VIO Pressure gauge valve JIS F7388, 20K 6A 0
VII High steam pressure switch valve JIS F7388, 20K 6A 0
V12 Air vent valve JIS F7388,20K 6A 0
VI3 Water level gauge valve JISF7421,20K20A 4 0
V14 Furnace side drain valve JIS F7363, 5K 50A 0
V15 Circulation inlet valve JISF7313,20K125A 1
V16 Circulation outlet valve JIS F7473, 20K 65A 0
VI7 Heating coil in/outlet valve JISF7421,20K25A 2 0
V21 Atomizing steam valve (SDNR) JISF7410,16K15A 1
V22 By-pjiss steam valve JISF7421,20K25A 0
V25 Soot blower manual valve JISF7313,20K50A 2 0
V26 Soot blower stop valve JISF7313,20K65A 0
V27 Smoke box drain valve JIS F7363, 5K 50A 0
V28 Soot blower drain valve JIS F7388, 20K 6A 1 _
HuU no. Type Customer
0311-6,0442-4 PB0301AS10 Hyundai Mipo Dockyard Co., LTD.

Part list of boiler

NO. DESCRIPTION TYPE/SPEC. O'tv. REV REMARK

Al [Link] STD920/KZ-13 1 0 -1
with three valve manifold
A2 Water level gauge C to C : 690mm 0 Boiler
A3 Low water level switch C to C : 525mm 0 accessary
A9 Soot blower 65A 0 -"
AlO Expansion joint 800A(JIS F7805) 0 Loose part

LI Remote level indicator 144SPDA 0 -I

L2 Steam pressure indicator 0-16kg/cm^ 0
L3 Feed water control valve 16K-50A 1
L4 Sampling cooler 0 part
L5 Dosing unit BT4a 1601PPE 0
L6 Salinometer JK-101 0
L7 Oil detector ODW lAlA 1
L8 Temp, transmitter PT100Q,600t:,PF3/4" 1
L9 Relief valve for heating coil PTl/2"xPT3/4" 1

SI Water test kit SPECTRAPAK310

PI Boiler control panel 0 -I

 PLAN HISTORY -
REV. DATE DESCRIPTION DWN CHK APP'D

A\ I004.10.10 APPROVAL [Link] ~^^~.^

A 1004.12.09 FOR REVISED [Link] ^ ^ ^
A 1005.02.28 FOR REVISED [Link] ^"^~~^
A 1005.10.19 FOR REVISED [Link] ^~~^-^ ^~~~~--^
 P L A N H I S T O R Y

REV. DATE D E S C R I P T I O N OWN CHK APP'D

^ 2004.11.2S REVISED BY YARD [Link]

A 20O5.O2.2i REVISED BY YARD [Link]

A 2005.05.1; REVISED BY YARD [Link]

A 2005.07.14 REVISED BY KANGRIM [Link]

D.P.T Seat SS400

»f^-rtT| Nomeplote seat SS400

43 Transport mounting SS400

A 42 Access door for s m o k e box SS400

Smoke box SS400

She! 0.0 3050
40
4® 39
Inspection door

Inspection door
-B

-A
SS400

SS400
280x440

405x485

38 Access door SS400 405x485

A 37 Lifting lug ( ' B ' t y p e ) SS400 25~60Ton

A 36 Lifting lug ("A'type) SS400 25~35Ton

35

Pet, of nozzle 34 Monhole A516.60 330x430

33 Firehole AS16.60 •431

32 Inspection l)ole

31
30

29 Smoke outlet conn. SS400 JIS F780S BOCA

28 Meosuring boss S20C PF3/8"x»22x30a

27 Smoke box droin volve conn. SS400 5k-50A

26 Soot blower slop volve conn. SF440 20k-65A

25 Soot blower monuol valve conn. SF440

24
23 Heoting coil c o n n . S20C 20fc-400*

Found, detail 22 8 y - p o s s steom volve conn. S20C 20k-25A

A 21 Atomizing s t e a m volve conn. S20C

20 Cir. outlet valve conn. S20C 20k-65A

A 19 Cir. inlet voive conn. S20C 20k-125A

A 18 Heoting coil steam outlet volve conn. S20C

- ^
A 17 Healing coil steam inlet volve conn. S20C 20k-20A

16
15
Furnace drain valve conn, SS400 5k-50A
13 Woter level gouge volve conn. S20C 20k-20A

A 12 Air vent valve conn. S20C •35«M20>1.5ps200l

High s t e a m press, s / w volve conn. S20C M9xM20>I.Spx200L

Seot detoil 10 Press, gouge volve conn. S20C •3S«M20x1.Jpx200l

Sompling valve c o n n . S20C •3SxM20>1.5p>200L

Blow down valve c o n n . S20C 20k-40A

Low woter level s / w valve conn. S20C 20k-25A

Water level reg. valve conn. S20C 20k-25A

5 S c u m valve conn. S20C

A Feed woter valve conn. S20C

Main s t e o m volve conn. S20C 20k-2S0A

Safety volve conn. S20C PN25-DN65/10O

AFT WT.
NO. DESCRIPTION MAT'L QT'Y SIZE (kg) I REMARK
Flonqe detail PROJECT TYPE CUSTOMER CL»SS/RUl£
0311-6,0442-4 PB0301AS10 H.M.D ABS
TITLE
2004.10
SCMJ: PROJECTION

ARRANGEMENT OF BOILER 1/55

W/O NO. PBC04MPOJtl-6

PBC04MP0442-*
owe. NO.
View "A—A" View "B-B" K A N G R I M INDUSTRIES CO., LTD. PBO301AS10-02

2 \
 PLAN H I S T O R Y

REV. DATE D E S C R I P T I O N DWN CHK APP'D

A
A
A

1
1
90"

1/.
6t
orv
m
CM

58

fT)Anchor detoil

25t
View A—A (Ceromic board)
\v\\\\\^vv\
^ ;COSCAST55)s

:^(CqSALITE24)/

(7) Exponsion j o i n t detail

Y
1280

5 Ceromic wool t6x75 %^n

4 Ceramic board - - t25»150
(T) Expansion j o i n t detoi 3 Anchor SUS304 18 15 :
B
2 Relroclory (C0SCAST55) - 1 20S 810 (40ko/a)
1 Refroclory (C0SAUTE24) - 1 18S 453 (25ko/S)
WT.
NO. DESCRIPTION MATERIAL QT'Y SIZE (kg) REMARK
PROJECT TYPE CUSTOMER CLASS/RUIE

0311-6,0442-4 PB0301AS10 H.M.O ABS

DATE
TITLE
2004.10. .
DIM. SCALE PROJECTION

BASE k FOUNDATION mm 1/30 - ^ < ^ A

W/0 NO. PBA04UP03n>S
Pg«MHP044:~4
DWG NO.

<^ PB0301AS10-06
^ K A N G R I M INDUSTRIES CO., LTD.
 c5
P L A N H I S T O R Y
X CHK
REV. DATE D E S C R I P T I O N DWN APP'D

n -n ; — T Tsrtii^=^iL= • II • < II
•B' ^ A
A
f
XT. V.
't W/zz/z/M/A—^\ \ i )
"C" V
'B 13
f
03200
(93050
dX5)
Detail "(D®

c
^

210 ir
\/)//^////y/////y/y//y, -ZZ^
6t
Detail "B"
r^ Detail "(g)' D
c

I 7C
Wf'D' - Note -
The boiler to be insulated with 75mm mine ralwool & rockwool bats,
covered with 0.8mm electroplated plote.
_8t

n SHELL O.D 3 0 5 0
03200
<Membrane>
C

Distance piece SS400 28 t6x25x360 14

Detail " C Flat ring SS400 t6x38x10035 235
Ring support SS400 t6x38 30
Insulation (Rockwool) RW # 8 0 280
Insulation (Cerannic wool)
Electroplated plate tO.8 190
WT.
NO. DESCRIPTION MATERIAL QT'Y SIZE (kg) REMARK
PROJECT TYPE CUSTOMER CLASS/RULE
0311-6,0442-4 PB0301AS10 H.M.D ABS
TITLE DATE
2 Piece ring 0.8mm 2004.04.
electroplated plate. DIM. SCALE PROJECTION
. o
in

75 OUTSIDE INSULATION 1/70

W/O NO. PBA04MP0311~6

ection A—A Section "B —B' Detail "D' DWG. NO.

P8A04MP0442~4

< ^ ^ K A N G R I M INDUSTRIES CO., LTD. PB0301AS10-07

 PLAN H I S T O R Y .
B REV. DATE D E S C R I P T I O N DWN CHK APP'D

< r^«iysr- --ri A 2004.12.05 FOR APPROVAL [Link]

A 2005.02.2: FOR REVISED [Link]

< BliAtadrfhB^^JLadi^^ A 2005.05.0e REVISED BY YARD COMMENT [Link]

VIEW "A-A'

SUPPORT DETAIL
COAMING DETAIL

25A PIPE
CHECKERED PU\TE DETAIL
M10-60L B/N/W / O ,
• 12 Drill hole V^y 13 ANGLE SS400 65x65x6T
12 Stonchion STPG370 25A

|PORT|-a=: r |STBD| Top roil STPG370 25A

' ' in
10 Mid roil SS400 R.B «16
Bolt/Nut SS400 M10x60L
Hondroil socket STPG 32A
30 6T
Cover plate SS400
Support SS400 lOT
^IK CN
Checkered plote (Cooming plote) SS400 6T
— 1 - 1 —
Stud bolt/Nut/Wosher SS400 M20 X 65L

HANDRAIL SOCKET DETAIL M20 KID

BOLT HOLE DIMENSION Support STPG370 20A X SCH80
Checkered plate SS400 6T
Checkered plote SS400 6T
WT.
NO. DESCRIPTION MATERIAL QT'Y SIZE (Kg) REMARK
PROJECT TYPE CLASS/RULE
03n~5,0442~4 PB0301AS10 H.M.D ABS
TITLE DATE
2004.12.
DIM. SCALE
GRATING k HANDRAIL DETAIL
GAUGE BOARD SEAT
mm 1/30
<a-
w/c NO.peco4MP03ii~s
r^Fi CHECKERED PLATE511 £11 COAMING 1 5 !
PBC04MI'0442~4
DWG. NO.
VIEW "B-B' K A N G R I M INDUSTRIES CO., LTD, PB0301AS10-40

T 2 1 1
 PLAN H I S T O R Y ^
REV. DATE D E S C R I P T I O N OWN CHK APP'O

A 2005.03.22 For issued [Link]

A 2005.03.24 For revised [Link]

STBO
A
DRAIN SCUPPER
^ ,jiL
MTTJFS—:1C! ::1tt:!3t FORE • •

!/'-
/
fLEVEL GAUGI
SEAT

fflz-:~E:-:-zffi- A /.;

"i~n- \..>\

^r^! L50x50x6t

i-/ .,.,-. .
, > > r' \ v;"

.....[[pM
/ ,V-' \ I \ > ,.,'// X ^
•' * I ^ *—;// \

\-'K ; > -i ^ ' ^

;:;;rci-i--ft-ir]!i
!!!!R+Hi^!! AFT

llJiiilC^fedii
Ifntrritniinr™ PORT
30
^B
A
Drain pipe
support angle
L65x65x6t
fr4^
ilLULillJJIJiJIiLm
fffjTrpi-u^Jiffl View A—A'

DRAIN PIPE SUPPORT SEAT

riimftil 111 '
l4kffi EASING GEAR")
SEAT
;,, I B 8 400
' ' I , I

ijlLillJllUJJUJL..j
I I I II

iLmJi 75
'
50 50 50 50 50 50 Note:

-3S- s fl , u.
Li i Ai i -J ,
l)Angle Supportb ^lilOIIAI l ^ } ^^%^.
1
1
1
1 2)Level gauge Seat^^S ^A| ^SgOIIA) Sf^^^S.
1 1

OIL COMMING
>
\ANGLE 50x50!(6l
3)0il comming drain lineS S§l ¥ ^ ^ 2 i i ' 5 ! .
^
DRAIN(5K-40A) 4 ) 3 8 Sbll^S Scupper?lx|S iOIEBi sfg^^ 5 .
\ PIPE,15A.;,SPP

LEVEL GAUGE__ SEAT 5)SoQt blower drain line^ Scupper?!xllXI 2 3 i ^ 5 ! .

500
View "B-B" PROJECT CLASS/RULE
0311-6,0442-4 PB0301AS10 H.M.D ABS
TITLE
2005.03
PROJECTION
\SS400.6t LEVEL GAUGE & EASING GEAR SEAT
)<^
EASING GEAR SEAT / DRAIN PIPE& SUPPORT
W / 0 NO. PBAIMUPOJI l~e
PBA04MP0442'-4
DWG. NO.

>KAriaRlM INDUSTRIES CO., LTD. PB0301ASI0-50

 PLAN HISTOR ^
REV. WTE D E S C R I P T I O N OWN CHK APP'O

^^--^
•A
A
^

15 "tl

^''•>'l2'x0.7 f \ ^

\ 7 "1172+1K
"t 172-1 / /FULL

'1172-1 I T S PENETRATION
1 7
•ti72+i^

DETAIL OF LIFTING EYE SECTION " A - A " Allowable Loading Angle

(FOR 75mm INSU.)

NOTES

1. Lifting Ey* P a d ^ Shall PlataSI mms &8I8I7II a | 8 .

TABLE 1
2. S l a a v * t ; S C H . 8 0 ° £ S 8 1 SI8.

Allowoble
SELECT A "C' "tl" "R" "«d" •0- "E" "F" "PI" } Slecvf fi^^ 1 SEE TABLE 1 ("PI") - St WIB 2
Lood [Kg] "t2" "Rl" "P2" "P3"
LiUmq Ey« SS400 SEE TABLE 1
1000
D ?
5000
190 125 20 t22 65 53 260 100 35 14 20 40A 20 6 UHinq Ey« Pod A516-60 SEE TABLE 1

5000 oescRIFTION MATERIAL QT-Y DIMENSIONS

(Ml
D I
15000
300 150 25 t28 70 64 400 150 50 14 30 50A 25 6
PMUCCT ojss/mu
16000
D 25000
400 175 25 130 100 93 500 180 50 14 30 80A 30 8 2001.05.30
OH. SCM£ PMUCCTXM
25000 STANDARD UFTING EYE
• 60000
570 205 35 134 140 118 670 200 50 16 45 lOOA 35 10 FOR 7Sinm INSULATION
(TYPE - "A"]
mm
W/O NO.
1/16 ^ ^
STO-001
[INSU. : 75mm] OOC. MO «V.

< ^ ^ 1 C A N G R I M INDUSTRIES CO., LTD. MB-LE-A

A
 PLAN HISTORY
REV. D*TE D E S C R I P T I O N OWN CHK APP'O

A
A
A
A

i
"t 1 7 2 + I K
•5-
LVir/2-1 /
FULL\'H72-lU- I •I2'.0.7l^<^-
PENETRATION / • ( i y i - l | r
•ir/2+iF

(0
in
<N
0
o> 0

TYP.>py _i7v s
•n
CM

100 t25/TN 40

DETAIL OF LIFTING EYE SECTION "A-A" DETAIL OF REINF. PLATE

(TYPE-"B")

NOTES

1 . Lifting Cya P a d b Shall Pla)«SI JH9i:ai %8i8i:)|| SJS.

TABLE 1 2. SlMv*^ SCH.80°£ S a ! ^ 8 .

Rainl. Plait SS400 125x40x250

Load [Kg] "A" "B" "C" "D" "E" "F" "G" 11 •R- "Rl" "»(l" "H" "j" "K" \" "12" "PI" "P2" "P3" "XX"
Reinf. Plata SS400 125x40x100
1000
/ 460 360 155 65 140 205 15 122 70 65 53 350 120 35 315 14 40A 25 6 30 SIcev*
•STPCTTiT SEE TABU 1 ( > ) • ) SEWIESI
/STB340
5000 SS400 SEE TAaE 1
5000 Lining Eye
600 425 175 65 160 225 25 t25 70 65 64 450 150 50 400 50A 25 6 70 A516-60
10000 Lilting Eye Pod SEE TABLE 1

10000 DESCfllPTION
670 480 190 95 175 270 25 130 100 95 80 520 180 50 470 65A 30 7 115
16000 OASS/IUX
16000
I 700 480 220 100 190 290 25 132 100 100 93 550 200 50 500 80A 30 8 115 OMI 2001.05.30
25000 SCM£
25000 STANOARO U F T * W EYE
750 520 230 105 200 305 35 134 110 105 118 610 220 60 550 100A 35 10 135
J5000 FOR 75--IOO>nm MSULATION 1/16 -^<3
35000 (TYPE - TB") w / 0 MO. sTO-001
840 590 250 140 220 360 35 t40 140 140 118 720 250 80 640 100A 40 10 205
60000 IM>. NO. HE».
ICANQRIM INDUSTRIES CO., LTD. U8-LE'B
A
4. Boiler Accessories

KANQRIM INDUSTRIES CO.,LTD.

Hull no. Type Customer
0311-6,0442-4 PB0301AS10 Hyundai Mipo Dockyard Co., LTD.

List of boiler accessories

POS NO DRAWING NO TITLE O'tv REV REMARK

VI Safety valve with drip pan 2 0 SV60, 65/1OOA Mounting

Al MB-DT-01 [Link] 1 0 STD920& Mounting

with three valve manifold KZ-13

A2 MB-RLG-01 Water level gauge (Reflex type) 2 0 CtoC690 Mounting

A3 MB-LS-01 Low water level switch 0 C to C 525 Mounting

A10 MB-EJ-01 Expansion joint 0 800A Loose

LI MB-RL-01 Remote level indicator 0 144 SPDA Loose

L2 MB-SP-01 Steam pressure indicator 0 0~16kg/ciif Loose

L3 MB-PC-01 Feed water control valve 0 16K-50A Loose

L4 MB-SC-01 Sampling cooler Loose

L5 MB-DU-01 Dosing unit 0 BT4al601PPE Loose

L6 MB-SI-02 Salinometer 0 JK-101 Loose

L7 MB-OD-03 Oil detector 0 ODW lAlA Loose

L8 MB-TT-01 Temp, transmitter 1 PT1002,600i:,PF3/4" LOOSC

L9 JKS-I272002 Relief valve for heating coil 1 PTl/2"xPT3/4" Loose

GIO MB-TS-03 Temperature Switch 1 Set: 450 °C Loose

SI MB-TK-02 Water test kit 0 SPECTRAPAK310 LoOSC

 spir^ TI-S13-27
CH Issue 4

sarco
SV60
Safety Valve
Description 32 31 30
The SV60 is a range of full lift T O V approved flanged safety valves
suitable for use on steam, inert industrial gas and water services.

Applications
The SV60 Is suitable for the protection of steam boilers, pipelines
and pressure vessels, compressors and receivers and for most
general process industry applications.

Available types
Two main variations of the valve are available, the SV607 (body
material SG iron) and SV604, (body material carbon steel). Inlet
sizes range from DN20 to DN150, ead) with an option of easing lever
and open or dosed bonnets. DIN or ANSI flange options availat>le.

Standards and approvals

Approved by the TUV to AD Merkblatt A2 and TRD 421, TRD 721
and Vd TOV 100, 100/4.
Seat tightness to API 527.

Sizes and pipe connections

Inlet sizes include DN20, 25, 32, 40, 50, 65, 80, 100, 125 and 150.
Vah^e type Inlet connection Outlet connection
TvrrnT PN16 (DN65 to 100 only) PN16

SV604 PN40 PN16

SV604 ANSI 300 ANSI 150
Body drain connection Vi" BSP

Materials
No. Part Material SV607 / SV604
1 Body SG iron / steel GGG-40.3 / GSC-25
2 Seat Stainless steel 1.4057
3 Bonnet SG iron / steel GGG-40.3 / GS-C25
4 Cap SG iron GGG-40.3
5 Disc Stainless steel Hardened 1.4021
6 Spring Cartxin steel DIN 17225 50 CrV4
7 Spindle guide SG iron GGG-40.3
8 Sl<irt Stainless steel 1.4031
9 Spindle Stainless steel 1.4034
10 Body bolts DIN-931 5.6 ZN / DIN-933 CK-35
11 Spring plate Steel CK45
12 Bearing ring Steel 1.4034
13 Guide sleeve Steel 1.4031
^. Spring adjustment Steel 1.4034
screw
15 Lock-nut Carbon steel DIN 1651 9S Mn 36 Zp
16 Cap bolt DIN-931 5.6 ZN
17 Collar Zinc plated cari3on steel
18 Lever SG iron GGG 40.3
19 Lever pin Zinc plated carix)n steel
20 Circllp Cartwn steel DIN-471
21 Spindle pin DIN-7343 No. Part Material SV607 / SV604
22 Split ring Steel 1.4034 30 Packing Graphite
23 Spindle ball 1.4034 31 Gland 1.4305
26 Collar pin DIN- 1481 32 Gland nut Cartjon steel
27 Collar circlip Spring steel 32 Gasket (relief only) Klingersil C4324
28 Packed lever spindle 1.4034 34 Gasket Klingersil C4324
29 Cam GGG-40.3 35 Gasket Klingersil

Local regulations may restrict the use of this product to below the conditions quoted.
In the interests of development and improvement of the product, we reserve the right to change the specification. © Copyright 2001
Limiting conditions Dimensions/weights (approximate) in mm and kg
SV604 SV607 Connection
Max. allowable pressure 40 bar 16/25 bar Inlet Outlet A B C Weight
DN20 DN32 85 95 385 10
Max. allowable temperature -10*Cto + 400'C -10'C to + 300*C
PN40/ANSI 300 PN16/PN25 DN2S DN40 100 105 435 12
Inlet flange
DN32 DN50 110 115 450 15
Operating range DN40 DN65 115 140 520 17
DN50 DN80 120 150 535 20
SV604
R N M " DN100 140 170 710 38 1
O 400
DN80 DN125 160 195 790 50
S 300
DN100 DN150 180 220 835 77
3
e 200 DN125 ON200 200 250 1042 115
S. steam
DN150 DN2S0 225 285 1165 180
E 100 saturation
4> curve
t-
-10 10 20 30 40
Pressure bar g
SV607 PN16 inlet
O 300

200
steam
100 saturation
curve
-
12 16
Pressure bar g
SV607 PN25 inlet
O 300 ro ii_n r
ID
3 200
13
steam
100 saturation
curve
-10
0 5 10 15 20 25
Pressure bar g
1 This ptxxJuct must not be used in this region.

Sizing
See TI-S13-28 for steam and air sizing data and TI-S13-32 for
water sizing data.

instaliation
The safety valve should always be fitted with the centre line of the
spring housing vertically above the valve. See full Installation and
Maintenance Instructions.
Open bonnet valves are recommended where the media temperature
exceeds 250*C.
A comprehensive valve refurbishment service is available upon
request.
SV60 safety vaive selection guide:
Model type SV60 |SV60|

Body material 4 = Cast steel

7 = SG iron 1* 1
A = Closed bonnet / easing lever
Configuration B = Closed txjnnet / gas tight cap 1 A 1
1 ** 1
D = Open bonnet / easing lever
Seal material S = Stainless steel 1 s1
Size DN20to150 |DN20|

Inlet PN16(DN65lo100only), PN25, PN40or rpjjjri

connection ANSI 300 I——'

Seiectlon example |sv6o| 4 I A I s ||DN20||PN4O|

How to order example

1 off Spirax Sarco SV604AS, DN20 flanged PN40 safety valve with
the inlet set at 6 bar.

»P"%a, SV60 Safety Valve TI-S13-27 CH Issue 4

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3170050/2 iM-P317-01
^P'-^aiirco CH Issue 2

SV60
Safety Valve
Installation and Maintenance Instructions

7. Safety information

^ 2. Product information 4-
3. Supply

4. Before fitting the valve

5. Installation

6. Damage prevention
A} azD
7. Commissioning

8. Testing during use

9. Guidelines for setting

10. Maintenance
11. Fault finding
Printed in the UK »P*'%airco © Copyright 2002

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— 1. Safety information
Safe operation of the unit can only be guaranteed If it is properly installed, commissioned
and maintained by a qualified person (see Section 1.11 on page 4) in compliance with
the operating instructions. General installation and safety instructions for pipeline and
plant construction, as well as the proper use of tools and safety equipment must also
be compiled with.

1.1 Intended use

Referring to these Installation and Maintenance Instructions, Name-plate and Technical
information Sheet, check that the product Is suitable for the Intended use/application. The
SV60 safety valve range compiles with the requirements of the European Pressure
Equipment Directive 97/23/EC and carry the Ci mark. They fall within Category 4 for Group
2 Gases.
I) The product has been specifically designed for use on steam, air. Inert Industrial
gases and liquids which are in Group 2 of the above mentioned Pressure Equipment
Directive. The product's use on other fluids may be possible but, if this is
contemplated, Spirax Sarco should be contacted to confirm the suitability of the
product for the application being considered.
II) Checi( material suitability, pressure and temperature and their maximum and
minimum values.
Mi) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not Intended to withstand external stresses that may
be included by any system to which they are fitted, it is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise them.
-^- v) Remove protective covers from all connections before Installation. -^-

1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before
attempting to work on the product. Arrange suitable lifting gear if required.

1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work Is required.

1.4 Hazardous iiquids or gases in the pipeline

Consider what Is in the pipeline or what may have been in the pipeline at some previous
time. Consider; flammable materials, substances hazardous to health, extremes of
temperature.

1.5 Hazardous environment around the product

Consider; explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.

1.6 The system

Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical Isolation) put any other part of the
system or any personnel at risk?
Dangers might Include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off In a
gradual way to avoid system shocks.

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1.7 Pressure systems

Ensure that any pressure Is Isolated and safely vented to atmospheric pressure. Do not
assume that the system has depressurlsed even when the pressure gauge Indicates
zero.

1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.

1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables available.
Use only genuine Spirax Sarco replacement parts.

1.10 Protective clothing

Consider whether any protective clothing Is required by yourself and/or others In the
vicinity to protect against the hazards of, for example, chem Icals, high / low temperatu re,
noise, falling objects, and dangers to eyes and face.

1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained In the correct use of the product
according to these Instructions.
Where a formal 'permit to work' system is In force it must be complied with. Where there
is no such system, it Is recommended that a responsible person should know what
work Is going on and, where necessary, arrange to have an assistant whose primary
responsibility Is safety. Post 'warning notices' If necessary.

1.12 Handling - ^
Where the weight of the product exceeds 20 kg It Is recommended that suitable lifting
equipment is used to prevent personal injury.

1.13 Residual hazards

In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of some products
may reach temperatures In excess of 350°C.
Many products are not self-draining. Take due care when dismantling or removing the
product from an Installation (refer to 'Maintenance Instructions').

1.14 Freezing
Provision must be made to protect products which are not self-draining against frost
damage If they are Inoperative In environments where they may be exposed to
temperatures below freezing point.

1.15 Safety information - Product specific

This product should not be dismantled without first releasing the compression on the
adjustment spring.

1.16 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this product
Is recyclable and no ecological hazard Is anticipated with Its disposal providing due
care is taken.

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1.17 Returning products
Customers and stockists are reminded that under UK and EC Health, Safety and
Environment Law, when returning products to Splrax Sarco they must provide
Information on any hazards and the precautions to be taken due to contamination
residues or mechanical damage which may present a health, safety or environmental
risk. This information must be provided in writing Including Health and safety data
sheets relating to any substances Identified as hazardous.

^ ^

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- 2. Product information
To safe area

f
n Safety
Reducing
valve
| ^^X*
V>:^ I i" . /-i^O"
'' •>'"'. ! . - - '

irci^--' ..---^ ^StJ"'' r

A^v- ,!.^-' i
steam <>-: ^>v- -^' • if
supply
Condensate

Fig. 1
Typical installation of safety valve, downstream of a steam pressure reducing valve station

2.1 Description
The SV60 is a range of full lift TUV approved flanged safety valves suitable for use on steam,
inert industrial gas and water services.
The SV60 is suitable for the following applications; protection of steam tx>iiers, pipelines and
pressure vessels, compressors and receivers and for most general process industry
applications.
^ >
2.2 Available types
Two main variations of the valve are available, the SV607 (body material SG iron) and
SV604 (Ijody material cartwn steel). Inlet sizes range from DN20 to DN150, each with an
option of easing lever, and open and closed bonnets.
DIN or ANSI flange options available.

2.3 Standards and approvals

Approved by the TUV to AD Meri<blatt A2, TRD 421, TRD 721 and Vd TUV 100, 100/4.
Seat tightness to API 527.

2.4 Sizes and pipe connections

Inlet sizes include DN20, 25, 32, 40, 50, 65, 80, 100, 125 and 150.
Valve type Inlet connection Outlet connection
PN16 (DN65 to DN150 only) PN16
SV607
_LPN25 PN16
SV604 PN40 PN16
SV604 ANS 1300 ANSI 150
Body drain connection %" BSP

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2.5 Limiting conditions
SV604 SV607
Maximum allowable pressure 40 bar 16/25 bar
Maximum allowable temperature -10'C to +400'C -10*C to +300°C
Inlet flange PN40/ANSI 300 PN16/PN25

2.6 Operating range

SV604 u 400
£ 300
I 200
Steam
I 100 ~ saturation
I-
curve
-10
10 20 30 40
Pressure bar g
SV607 PN16inlet
O 300
£
2 200
Steam
E 100 saturation ~
curve
^ ^
12 16
Pressure bar g
SV607 - PN25 Inlet
O 3001
£
3 200
C Steam
I 100 saturation
ID curve
I-
-10 10 15 20 25
Pressure bar g
I I The product must not be used in this region.

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2.7 Dimensions/weights (approximate) in mm and kg
Connection
Inlet Outlet A B c Weight
DN20 DN32 85 95 385 10
DN2S DN40 100 105 435 12
DN32 DNSO 110 115 450 • 15
ON40 DN65 115 140 520 17
DNSO DNSO 120 150 535 20
|DN65 DN100 140 170 710 38
DNSO DN125 160 195 790 50 1
DN100 DN150 180 220 835 77
DN125 DN200 200 250 1042 115
ON150 DN250 225 285 1 165 180

> A

Fig. 2

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2.8 How to select

Model type SV60

4 = Cast steel
Body material
7 = SG iron

A = Qosed bonnet/easing lever

B = Closed bonnet/gas tight cap
Configuration C = Closed bonnet/packed easing lever
D = Open bonnet/easing lever

Seal material S = Stainless steel

Size DN20to150 DN20

Inlet connection PN16 (DN65 to 100 only), PN25, PN40 or ANSI 300 PN40

^ Selection example | sveo | 4 | A | s 11 DN2O | | PN40

2.9 How to order a new product

Example: 1 off Spirax Sarco S V604AS, DN20 flanged PN40 safety valve with the Inlet set at 6 bar.

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2.9 Materials
No. Part Material SV607 / SV604
1 Body SO iron / steel GGG-40.3 / GSC-25
2 Seat Stainless steel 1.4057
3 Bonnet SG iron / steel GGG-40.3 / GS-C25
4 Cap SG iron GGG-40.3
5 Disc Stainless steel Hardened 1.4021
6 Spring CartxHi steel DIN 17225 50 CrV4
7 Spindle guide SGIron GGG-40.3
8 Skirt Stainless steel 1.4031
9 Spindle Stainless steel 1.4034
10 Body txjits DIN-931 5.6 ZN / DIN-933 CK-35
11 Spring plate Steel CK45
12 Bearing ring Steel 1.4034
13 Guide sleeve Steel 1.4031
14 Spring adjustment screw Steel 1.4034
15 Lock-nut Cariixxi steel DIN16519SMn36Zp
16 Cap tx>lt DIN-931 5.6 ZN
17 Collar Zinc plated cart>on steel
> 18 Lever SGiron GGG 40.3 ^
19 Lever pin Zinc plated cartx>n steel
20 Circlip Cartxin steel DIN-471
21 Spindle pin DIN-7343
22 Split ring Steel 1.4034
23 Spindle ball 1.4034
26 Collar pin DIN- 1481
27 Collar cirdip Spring steel
28 Packed lever spindle 1.4034
29 Cam GGG-40.3
30 Packing Graphite
31 Gland 1.4305
32 Gland nut Carbon steel
32 Gasket (relief only) Klingersll C4324
34 Gasket Klingersil C4324
35 Gasket Klingersil

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32 31 30

«rp

^'

3^-
Gas tight cap

Packed easing lever

- ^
4-

Fig. 3

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3. Supply
Normally, the valve will be supplied set at the required pressure and sealed.
BS 6759, DIN 3320 and local regulations requires ttiat the setting of the valve should only be
canied out by an authorised/competent person, (see Section 1.11).
Spirax Sarco accepts no responsibility for valves which have been reset by unauthorised personnel.

4. Beforefittingthe valve
4.1 Ensure that the Installation is correct (Rg. 1, page 6).

4.2 ChecK that the details on the safety valve name-plate are compliant with the Installation
and process.
4.3 Blow through the pipework to ensure that it is completely free of any foreign matter that may
otherwise pass to the valve seat and cause damage, leading to seat leakage. Slowdown
must be carried out before installing the safety valve.

4.4 Ensure that valve is set to the con-ect pressure, see Testing during use'. Section 8, page 15.
4.5 Remove protective caps and seal.

, 5^ Installation ^
Note: Before actloning any installation observe the 'Safety information' in Sectioni.

5.1 The valve should always be mounted vertically upwards with its main axis vertical.
5.2 The valve should be fitted to the pipework or vessel by means of the shortest possible
length of pipe or fitting.
5.3 There should be no intervening valve or fitting i.e. it should not be possible to isolate
the safety valve (see Rg. 4).
5.4 The inlet pipe connection should not be smaller than the valve (see Rg. 7 and Fig. 8).
5.5 The outlet pipe size should tie equal or larger than the valve outlet to keep back pressure
below 10% of ttie set pressure.
5.6 Direct the outlet pipework to a safe point of discharge where there is no risk of injury to
persons or damage to property in the event of the valve operating.
5.7 The outlet pipework should be adequately supported such that it does not place undue
stress on the safety va^e.
5.8 Where the outlet pipework is directed upwards a small bore drain should be provided at
the lowest point (Fig. 5). This drain should be taken to a place where any discharge
will not create a hazard or inconvenience.

5.9 Each safety valve should have its own unrestricted discharge pipe.
5.10 Safety valves with open bonnets may release fluid under pressure when discharging.
Ensure this can be done safely.

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5 . 1 1 Safety valve lagging should be limited to the body only.
5.12 Safety valves can operate very suddenly and will be too hot to touch without protection
when Installed on steam systems.

> ^

Discharge to
safe area

Fig. 5

Small bore
drain to
safe area

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6. Damage prevention
Excessive pressure loss at the inlet of a safety valve when it operates will cause extremely
rapid opening and closing of the valve, observed as chattering or hammering.
This may result In reduced capacity as well as damage to seating faces and the otiier parts of the
safety valve.
When nomial pressure is restored it is possible that the safety valve will leal<.

Solution
Pressure loss at inlet should be no more than 3% of pressure differential between set pressure
and superimposed back pressure wfien discharging.
The safety valve should be fitted 8-10 pipe diameters downstream of converging, diverging fittings
or Isends (see Fig. 6).
Inlet tiranches should be as Fig. 7 or Fig. 6.

> i 8 - 1 0 Pipe diameters downstream

of converging "Y" fittings or bends
Fig. 6

Inlet area 'A' approx.

twice that of inlet of
area 'a'.

Radius "r" not less

than inlet diameter

Fig. 7 Fig. 8

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7, Commissioning
7.1 Once the safety valve has been fitted check that there are no leaks from either the inlet or
the outlet connections.

7 . 2 Test the valve by raising the system pressure. Check that the safety valve operates at the
conect set pressure and that the overpressure is limited to 5% of the safety valve setb'ng.

7 . 3 Reduce the system pressure to the normal operating pressure and check that the safety
valve reseats.

8. Testing during use

It is recommended that the safety valve be tested for correct operation at least once every six
months*, as outlined in Section 7, or by manual lifting when the ojserating pressure Is no more
than 85% of the safety valve set pressure.
* Note: Use suitable protection against excess heat and noise when testing safety valves,
period between safety valve tests to be agreed by responsible person or insurance company.
(Check local requirements for frequency of testing).

- ^ - ^

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9. Guidelines for setting
(By Authorised Persons Only)
9.1 Choice of set pressure
A decision must be made regarding the pressure at which the safety valve shouid be set.
The maximum set pressure, in accordance with BS 5500, is the safe worlting pressure of the
plant It protects and the valve must achieve its rated capacity with an overpressure of no more
than 10%.
The SV60 achieves its rated capacity at 5% over pressure. If the valve is set too dose to the
operating pressure of the system the valve may operate prematurely. It will also fail to dose
satisfactorily when nomnal operating pressure is restored.
Fig. 9 outlines the way a safety valve operates.

5% of set pressure
Full lift position

i
Re-seat differential
Set

t pressure I

Fig. 9
x^ \^
(Valve operates)

Time-
Re-seat pressure
(10% of set pressure)

It can be seen that the safety valve does not re-seat when the pressure falls to the safety valve set
pressure.
There must be adequate differential between the maximum system operating pressure and the
safety valve set pressure if the valve is to re-seat
The maximum system operating pressure is most likely to occur during no-load conditions.
A
Fig. 10 shows the range within which the valve must be set.

Maximum allowatrfe Maximum setting of

wori<lng pressure safety valve
or design pressure T / y 7
of vessel Safety valve may
/ be set within
this range /
y Minimum setting of
r safety valve y

/ / ? /
A Re-seat differential
Maximum system
operating pressure
No-load condition
B
Fig. 10 Operating pressure i
Flowrate = Maximum rating of pressure redudng valve
A = 10% of Safety valve set pressure, 0.3 bar minimum
B = Normal system pressure variation
Note: The operating pressure of a system will vary and it is important that the safety valve is set
high enough to accommodate such fluctuations.

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9.2 Setting the valve
A safety valve should only be set by an Authorised Person.
Spjrax Sarco cannot be held responsible for unauthorised alteration of the set pressure.

9.3 Valves supplied unset

Valves supplied unset to approved agents will include a set pressure tag to be stamped with the
appropriate set pressure in bar after setting.
The tag should be permanently attached to the valve when using the locking wire and lead seal.
The bad< of the blue instruction label affixed to each unset valve will indicate the pressure range
ofthe spring fitted.

10. Maintenance-
All safety valves should receive planned maintenance.
Note: Before actioning any maintenance work please read 'Safety Information', Section 1.
It is recommended that the Spirax Sarco SV60 safety valves are returned to Spirax Sarco, or an
approved Spirax Sarco agent, for a thorough overhaul periodically, please read 'Returning
products'. Section 1.17.
The valve will be returned having been overhauled, tested re-set and sealed in accordance with
BS 6759.

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11. Faultfinding
SYWPTOM Valve does not open at set pressure.
CAUSE 1 Incorrect sat pressure. CHECK and
CURE Consult supplier/manufacturer.
CAUSE 2 Test gag fitted.
CHECK and CURE Remove test gag.
CAUSE 3 Protective flange cover not removed.
CHECK and CURE Remove [xotective flange cover.
CAUSE 4 Back pressure too high.
CHECK and CURE Verify the maximum value t>acl< pressure and/or
consult supplier/manufacturer.
SYMPTOM Valve leaking a n d / o r exhibits erratic p o p p i n g action.
CAUSE 5 Line vibrations.
CHECK and CURE Eliminate any vit>rations on tiie valve.
CAUSE 6 Damaged seat
CHECK and CURE Consult supplier/manufacturer.
CAUSE 7 IMIsalignment of parts.
CHECK and CURE Consult supplier/manufacturer.
CAUSE 8 Stress distortions by thermal changes due to fixed discharge.
CHECK and CURE Correct source of distortion by proper support.
SYMPTOM Hang up, will not r e s e a t / b l o w s of continuously.
CAUSE 9 Foreign material In seating or guide area.
CHECK and CURE Consult supplier/manufacturer.
> CAUSE 10 Spring brolcen or relaxed. >
CHECK and CURE Consult supplier/manufacturer.
CAUSE 11 Operating pressure exceeds set pressure.
CHECK and CURE Check valve data and process conditions.
SYMPTOM Excessive b l o w d o w n .
CAUSE 12 High back pressure.
CHECK and CURE Decrease back pressure by increasing outlet pipe discharge area.
SYMPTOM Chatter or short b l o w d o w n .
CAUSE 13 Excessive inlet piping pressure loss.
CHECK and CURE Reduce inlet pressure drop to less than 10% of set pressure.
Change inlet pipe size.
CAUSE 14 Incorrect valve size for application.
CHECK and CURE Review process conditions and valve sizing.
Consult supplier/manufacturer.
CAUSE 15 Gaskets for Inlet/outlet flanges too small.
CHECK and CURE Change the gasket.
CAUSE 16 Back pressure Is variable or exceeds 10% of set pressure.
CHECK and CURE Consult supplier/manufacturer.
SYMPTOM Valve cannot be lifted manually.
CAUSE 17 Operating pressure Is less than 85% of set pressure.
CHECK and CURE Inaease the operating pressure to 85% of set pressure or higher.

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REV. DATE D E S C R I P T I O N OWN CHK APP'O

0A+1O A
^
4

DETAIL A
10 YARD PIPE SC 4 9 12SA

PLATE SS400

BOLT SS400 M10

PACKING 9.5X9.5

FLANGE SS400 5K-25A

DRAIN PIPE SPP 25A

FLANGE SS400 [Link]

•SIZE: SAFETY VALVE DISCHARGE SIZE ELBOW STPGJ70

PIPE STPG370
DRIP PAN FLANGE BOLT W.T
SIZE D DRIP PAN SPP/SS400
A B C E F T S h N d M P (kg) REMARK
WT.
40 216.3 6 0 . 5 48.6 120 140 105 16 140 70 150 4 19 16 150
NO. DESCRIPTION MATERIAL OTY SIZE (kg) REMARK
50 216.3 76.3 60.5 120 155 120 16 140 70 150 4 19 16 150
TITLE
65 216.3 89.1 76.3 120 175 140 18 140 70 150 4 19 16 200
80 216.3 114.3 89.1 140
•100 267,4 139.8 114.3 160
185
220
150
180
18
20
160
180
75
90
180
210
8
8
19
18
16
16
200
250
DRIP PAN FOR DM. SCAU
125 318.5 165.2 139.8 180 250 210 20 200 110 250 8 23 20 250 SAFETY VALVE mm N/S -^<g3-
150 318.5 216.3 165.2 200 280 240 22 220 120 280 8 23 20 300
[WC. NO.

< ^ ^ 1 C A H G R 1 M INDUSTRIES CO., LTD. JKS-I321-001

1
 ITEM NO. Al

T I T L E DATA
SHEET MB-DT-01
NO. :

DIFF. PRESS. TRANSMETTER CODE

KANGRIM PAGE 1 OF 2

Reference Dimension : mm
(inch)

Removal 45.7 59.1 59.1

Without Meter
Clearonce 135
Pl^e
for All Cops
With Meter

Optional
External

Air vent

pressure
(3.35)
Optionol Adapter for ection
1/2 Inch NPT nch NPT
See Detail "A"

Detoil "A"
53.9

High pressure Low pressure

connection connection
1/2 inch NPT 1/2 inch NPT
AUTROL SERIES AUTROL® Operation Manual: M3100-E01B

Model APT3100

Autrol Smart Pressure Transmitter

O p e r a t i n g iVianuai

DUON SYSTEM Co., Ltd.

[Link]

This manual can be change and revised for quality upgrade without an advance notice.
amnisaMPnssmTnMaMttr NwiBii • • • • ! fttttMtm

APT3100 Smart Pressure Transmitter

This manual is made so that general user can help to

install and operate APT3100 Smart Pressure Transmitter
efficiently.
Before handling APT3100 transmitter, all users have to
be fully aware of It.

Information on this manual can be ciianged without an advance notice.

DUON SYSTEM CO., LTD.

60-31, Gasan-dong, Geumchon-gu, SEOUL KOREA
TEL +82-2-860-7900

•UMSystMCtanL
ilFTllNS—thWMWTWWilllf tttnOn UtmU M S N H M

Table of Contents
Qiapter 1 Introduction
1.1 Using This Manual
1.2 Overview of Transmitter
1.3 Software Compatibility
1.4 Transmitter Components

Chapter 2 Handling Cautions

2.1 Unpacking
2.2 Models and Specifications Check
2.3 Storage
2.4 Selecting the Installation Locations
2.5 Calibration on Spot after Installation
2.6 Pressure Connections
2.7 Waterproofing of Cable Conduit Connections
2.8 Restrictions on Use of Radio Transceiver
2.9 Insulation Resistance Test and Dielectric Strength Test
2.10 Installation of Explosion Protected Type Transmitters
2.10.1 KOSHA Certification
2.10.2 KTL Certification
2.10.3 CSA Flameproof Certification
2.11 EMC Conformity Standards

Chapter 3 Transmitter Functions

3.1 Overview
3.2 Safety Messages
3.3 Warning
3.4 Fail Mode Alarm
3.5 EEProm-Write Enable and Disable Mode Jumper
3.6 Configuration of Alarm and Security Jumper Procedures
3.7 Configuration of Zero and Span Procedure
3.8 Configuration of Sensor Zero Trim
3.9 Configuration of Zero Point Adjustment
3.10 Commissioning on the bench with HHT

Chapter 4 Installation
4.1 Overview
4.2 Safety Messages
4.3 Warning
4.4 Commissioning on the bench with Hand-Held Terminal
4.5 General Considerations
4.6 Electrical Considerations
4.7 Wiring
4.8 Mechanical Considerations
4.9 Environmental considerations

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Qiapter 5 On-line Operation

5.1 Overview
5.2 Safety Messages
5.3 Configuration Data Review
5.4 Check Output
5.5 Basic Setup
5.6 Detail Setup
5.7 Information Veiriables Setup
5.8 Diagnostics and Services
5.9 Calibration

Chapter 6 Maintenance
6.1 Overview
6.2 Safety Messages
6.3 Hardware Diagnosis
6.4 Hardware Maintenance

Appendix I
LCD Display Code for APT3100 Smart Pressure Transmitter

Appendix I I
275 Hart Communicator User Guide for APT3100 Smart Pressure Transmitter

Appendix I I I
PDA User Guide for APT3100 Smart Pressure Transmitter

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Chapter 1 Introduction
The APT3100 Smart Pressure Transmitter are correctly calibrated at the factory before shipment. To
ensure correct and efficient use of the instrument, please read this manual thoroughly and fully
understand how to operate the instrument before operating it

0 The contents of this manual are subject to change without prior notice.
(2) All rights reserved. No part of this manual may be reproduced in any fonri without DUON
System's written permission.
(E) If any question arises or errors are found, or if any information is missiong from this manual,
please inform the nearest DUON System sales office.
® The specifications covered by this manual are limited to those for the standard tyfje under
the specified model number break-down and do not cover custom-made instrument.
(5) Please note that changes in the specifications, construction, or component parts of the
instrument may not immediatelty be reflected in this manual at the time of change, provided
that postponement of revisions will not cause difficulty to the user from a functional of
performance standpoint.

1.1 Using Tliis Manual

The Chapters in this operating manual provide information on installing, operating, and maintaining
devices from the AUTROL Model APT3100 Samrt Pressure Transmitter. The Chapters are organized as
follows.
Chapter 2 Handling Cautions

This chapter consists of core information for installing APT3100 on operating place after
buying it. Chapter 2 provides instrvicton on commissioning and operating Model APT-3100 Smart
Pressure Transmitters. Informations on software functions, configuration parameters, and on-line
variables is also included.

Chapter 3 Transmitter Functions

Chapter 3 contains in consideration of handling Model APT3100 Smart Pressure Transmitters.

Chapter 4 Installation

Chapter 4 contains mechanical, environment consideration and electrical installation

instructions on the Model APT3100 Smart Pressure Transmitters.

Chapter 5 On-line Operation

Chapter 5 desaibes the configuration the parameter how to use variety of the Model
APT3100 Smart Pressure Transmitters' software fucntion and configuration. See the following list for
the details.
® Regulations of circuit's InpuVOutput characteristics; Sensor or Output Trim
(2) Changed of output characteristic; Range Configuration, Output Type, Damping,Unit
® Changed of general data; Tag No.,Date,Message etc.

Chapter 6 Maintenance

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Chapter 6 contains hardware diagnostics ,troubleshooting and maintenace task.

1.2 Overview of Transmitter
AutrolD Smart Pressure Transmitter based in a microprocessor is the pressure transmitter, has a
designed capacitance sensor optimized for draft measurement. APT-3100 has a true draft analog
range from 0 to 20mA offering that feature that a pressure range or after convert analog range to
HART (Communication) digital signal transmit for control systems like DCS, PLC. Tliis Model has
explosion protected type (Instrinsically Safety) and high precision, better reliabilty and is available on
digital commuicatlon for the use remotes communication system.
This transmitter is enabled in HART commmunication with Host, HHT (HART Hand-Held Terminal), PC
Configurator, or PDA Configurator. Thus, transmitter various variables in host is enable to be changed,
configured and tested calibrated by users. For the HART Communication between DC Power Supply of
24 Vdc and Transmitter has to terminate 250~ 550 Ohm as loop resistance by series connection. But,
there is no additional loop resistance when transmitter is connected with analog input port or output
port of control system, because b^nsmitter has self resistance 250 Ohm.

1.3 Software Compatibility

AutrolQ Smart Pressure Transmitter's software is implemented and complemented if necssary. Uses of
the transmitter will not be a compatibility software is contained in the host of the HHT(Model 275
HART Communicator). In this case contact us for software DD(Devk:e Descriptor) to be able to use
with the transmitter, you must to use loading in HHT, etc.

There can be deviations on funcitions as to Firmware Revision of transmitter. This manual is based on
Firmware Revision 22. For upgrading Firmware Revision 17 for Revision 22, or Firmware Revision 22
for Revision 23, EEPROM of MCU Board should be changed.

Function deviations as to Firmware Revision are same as under box.

Function Supports
(OK =possible, ^A=impossible)
No Functions
R17 R22 R23

1 Sensor Zero Trim with Zero/Span button NA OK OK

2 Zero Point Adjustment with Zero/Span button NA NA OK

3 Zero Point Adjustment with HART command NA NA OK

[NOTE] Revision 23 will be applied to the goods produced from 1^ [Link],2004

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1.4 Transmitter Components

The components and figure of AutroO Smart Pressure Transmitter is suggested on the next page.
Follow the precedure described on figure 1-1,1-2 and 1-3.

NOTE
1 HOUSING-POLYURETHANE PLANT 16 NAME PU\TE/ CERTI.
2 FRONT COVER 17 SCREW/ GERTIE. PLATE
3 0 - R I N G / GLASS 18 TERMINAL BLOCK
4 GL7\SS-TEMPERED 18-1 BOOT/ T.B
5 GU\SS RING NUT 18-2 SCREW/ TERMINAL
6 0 - R I N G / FRONT COVER 18-3 P I N / T.B
7 REAR COVER 18-1 COMM. TEST P I N / T.B
8 0 - R I N G / REAR COVER 19 SCREW/ TERMINAL BLOCK
9 SCREW/ COVER LOCK 31 ELECTRONICS/ IN-OUT
10 SCREW/ INTERNAL GROUND 32 ELECTRINICS/ MCU
1 1 SCREW/ EXTERNAL GROUND 35 ELECTRONICS/ LCD
12 SCREW/ HOUSING ROTATION SET 34 LCD COVER
13 NAME PLATE/ DATA &c TAG 35 POST/ ELECTRIONICS
14 SCREW/ NAMR PLATE 36 SCREW/ IN-OUT BOARD
15 SERO/ SPAN ADJ. SWITCH 37 SCREW/ ELECTRONICS
15-1 SWITCH/ SPRING 38 SCREW/ LCD METER
15-2 SWITCH/ MAGNET 39 SCREW/ LCD METER
15-3 SWITCH/ BUTTON 74 PLUG, 1/2 NPT
15-4 SWITCH/ COVER

[Figure 1-1 Transmitter HOUSING Exposed View and Components]

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51 SENSOR MODULE 51-1 SENSOR
5 1 - 1 3 RANGE 3, 7.5 KPa 51-2 SENSOR BODY
51-14 RANGE A, 37.3 KPQ 51-3 SENSOR RING
51-15 RANGE 5, 186,5 KPQ 51-4 SENSOR BOARD
51-16 RANGE 6, 690 KPa 51-5 MOLD SOLUTION
51-17 RANGE 7, 2 0 6 8 KPa 52 ELANGE/ PROCESS
5 1 - 1 8 RANGE 8, 6 8 9 5 KPa 53-1 C-RING/ ELANGE
5 1 - 1 9 RANGE 3, 2 0 6 8 0 KPa 53-2 D-RING/ ELANGE
54 BOLT S, NUT / ELANGE
55 ELANGE PLUG
56 BOLT / BRACKET
57 ELANGE ADAPTER
58-1 C-RING/ ELANGE ADAPTER
58-2 0-RING/ ELANGE ADAPTER
59 BOLT / FLANGE ADPATER
60 VENT / DRAIN PLUG
61 C-RING/ SENSOR MODULE

[Figure 1-2 Transmitter SENSOR MODULE - D, G, L Exposed View and Components]

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NOTE :
SENSOR MODULE 51-1 SENSOR
51
(HIGH LINE PRESSURE) 51-2 SENSOR BODY
5 1 - H 4 RANGE 4, 37.3 KPo 51-3 SENSOR RING
5 1 - H 5 RANGE 5, 186.5 KPa 51-4 SENSOR BOARD
5 1 - H 6 RANGE 6, 690 KPa 51-5 MOLD SOLUTION
51 - H 7 RANGE 7, 2068 KPa 52 ELANGE/ PROCESS
53-1 C - R I N G / ELANGE
53-2 0 - R I N G / ELANGE
54 BOLT & NUT / FLANGE
55 ELANGE PLUG
56 BOLT / BRACKET
57 FLANGE ADAPTER
58-1 C - R I N G / FLANGE ADAPTER
58-2 0 - R I N G / FLANGE ADAPTER
59 BOLT / FLANGE ADPATER
60 VENT / DRAIN PLUG
61 C - R I N G / SENSOR MODULE

[Figure 1-3 Transmitter SENSOR I^ODULE - H Exposed View and Components]

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Chapter 2 Handling Cautions

This chapter consists of cautions for transmitter handling and storage, selection of installation
locations, insulation and explosion structure, etc.

[Quick Reference Manual]

step Job Job Details Instrument

1 Unpacking - Unpack transmitter packing

Model and
- Make sure whether the delivered transmitter is same
2 Specifications
as options attached on its nameplate
Check
- Places not exposed to water, non-vibration and non-
impact area
3 Storage
- Ambient temperature 25 deg C and relative humidity
65% RH
-HHT
- Configuration of Range, Zero/Span, Unit, Tag, - Pressure
Calibration on a
4 Damping Time, Transfer Function, DA Trim and other Source
Calibration Room
parameters (requested)
- Galvanometer
- Where ambient temperature is not fluctuated
- Where corrosion happens by chemical materials, etc.
Installation - Where vibration and impact is not severe
5 (Engineering)
Locations - Where non-explosion area is matched on
explosionproof regulations
- Where maintenance is very easy
Mechanic 1 - Where transmitter can be handled easily
6 (Engineering)
Considerations - Be cautious not leaking the pressure.
- Connect 24 Vdc
Electrical (Power Supply is 11.9 Vdc • 45 Vdc)
7 (Engineering)
Considerations - For HART communication, total resistance on
transmitter terminal loop should be 250 n 550 Ohm.
- For mounting transmitter, an appropriate bracket
Mounting and should be used. (Mounting and
8
Installation Installation)
- Transmitter should be fixed well against swing.
- Sensor Zero Trim has to be done after ten seconds,
namely, differential pressure become zero and HHT or
Calibration on
9 stabilized. Zero/Span
Spot
- Make sure that PV value of transmitter is zero and button
current is 4 mA.
- Do not apply the regulated differential and line
pressure.
(Applying
10 Pressure - Close equalizing valve of 3 valve manifold. Then, pressure)
open stop valve on high and low side slowly and
simultaneously.
11 Operation - Make sure whether transmitter operates well or not Eye or HHT

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2.1 Unpacking
When moving the transmitter to the installation site, keep it in its original packaging. Then, unpack
the transmitter there to avoid damage on the way.

2.2 Models and Specifications Cliecic

The model name and specifications are indicated on the nameplate to the case. Please check your
specification and wanted model.

2.3 Storage
The following precautions must be observed when storing the instrument, especially for a long period.

(1) Select a storage area that meets the following conditions:

(a) It is not exposed to rain or water.
(b) It suffers minimum vibration and shock.
(c) If possible, it is preferable at normal temperature and humidity (approx. 25°C, 65% RH).

However, it has an ambient temperature and relative humidity within the following ranges.
• Ambient Temperature: -40 ~ 85°C (without LCD module)
-30~80°C (with LCD module)
* General Use -20 ~ 60°C (CSA Explosionproof)
• Relative Humidity: 5% ~ 98% RH (at 40°C)

(2) When storing the transmitter, repack it as nearly as possible to the way it was packed when
delivered from the (actor/.

(3) If storing a transmitter that has been used, thoroughly clean diaphragm surfaces (the pressure-
detector sections) of the diaphragm seals, so that no measured fluid remains on them. In addition,
make sure before storing that the pressure-detector and transmitter assemblies are securely
mounted.

2.4 Selecting Installation Locations

The transmitter is designed to withstand severe environmental conditions. However, to ensure stable
and accurate operation for many years, the following precautions must be observed when selecting an
installation location.

(1) Ambient Temperature

Avoid locations subject to wide temperature variations or a significant temperature gradient. If the
location is exposed to radiant heat from plant equipment, provide adequate insulation or
ventilation.

(2) Ambient Atmosphere

Avoid installing the transmitter in a corrosive atmosphere. If the transmitter must be installed in a
con-osive atmosphere, there must be adequate ventilation as well as measures to prevent intrusion
or stagnation of rainwater in conduits. Moreover, there should be appropriate ventilation
preventing corrosion by rain gathered on conduit.

11 IIWIiSystMei^lU.
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(3) Shock and Vibration

Select an installation site suffering minimum shock and vibration (although the transmitter is
designed to be relatively resistant to shock and vibratfon)

(4) Installation of Explosion-protected Transmitters

Explosion-protected transmitters can be installed in hazardous areas according to the gas types
for which they are certified.

(5) Select a place that transmitter maintenance is very easy.

2.5 Calibration on Spot after Installation

(1) Sensor Zero Trim should be done after transmitter is installed on spot, because zero point is not
accurate as to mounting status.

(2) For Sensor Zero Trim, make differential pressure of transmitter for zero in advance. Then, make
Sensor Zero Trim after pressure is sufficiently stabilized (after approximately 10 seconds).

(3) There are two ways for making differential pressure for zero. One is to apply zero differential
pressure (making same pressure both high and low side pressure). The other is to close Hign and
Low side of stop valve of 3 valve manifold and to open its equalizing valve.

(4) Sensor Zero Trimming is to use HHT (275 calibrator), PC or PDA configurator, and to use
Zero/Span button. Make sure all details on this manual.

(5) Refer to On-line Operation for configuring another parameters except Sensor Zero Trim

2.6 Pressure Connections

A Warning
Instrument Installed in the process is under presure. Never loosen or tighten the flange bolts as it may
cause dangerous spouting of process fluid.

If the accumulated process fluid may be toxic or otherwise harmful, take approrlate care to avoid contack
with the bodym of inhalation of vapors even after dismounting the instrument from process line for
maintenance.

The following precautions must be observed in order to safely operate the transmitter under pressure.
(1) Never apply a pressure higher than the specified maximum working pressure.
(2) Confirm the option of pressure connection of transmitter. Necessarily use standardized and quality-
approved parts.
(3) In case of being needed by hard circumstances and regulations, there should be seal equipment
for leakage.

2.7 Waterproofing of Cable Conduit Connections

Apply a non-hardening sealant (silicone or tape, etc.) to the threads to waterproof the transmitter
cable conduit connections.

2.8 Restrictions on Use of Radio Transceivers

12 IUONS||[Link].
 A Warning
• Although the transmitter has been designed to resist high frequency electrical noise, if aradiotranseiver is
used near the transmitter of its external wiring, the transmitter may be affected by high frequency noise
pickup. To test for such effects, bring the transceiver in use slowly from a distance of several meters from
the transmitter, and observe the measurement loop for noise effects. Thereafter, always use the
transceiver outside the area affected by noise. _^___

2.9 Insulation Resistance Test and Dielectric Strength Test

Since the transmitter has undergone insulation resistance and dielectric strength tests at the factory
before shipment, normally these tests are not required. However, if required, observe the following
precautions in the test procedures.

(1) Do not perform such tests more frequently than is absolutely necessary. Even test voltages that do
not cause visible damage to the insulation may degrade the insulation and reduce safety margins.

(2) Never apply a voltage exceeding 500 Vdc (100 Vdc with an internal lightening protector) for the
insulation resistance test, nor a voltage exceeding 500V AC (lOOV AC with an internal lighting
protector) for the dielectric strength test.

(3) Before conducting these tests, disconnect all signal lines from the transmitter terminals. Perform
the tests in the following procedure.

(4) Insulation Resistance test

(a) Short-circuit the + and - SUPPLY terminals in the terminal box.
(b) Turn OFF the insulation tester. Then connect the insulation tester plus (+) lead wire to the
shorted SUPPLY terminals and the minus (-) lead wire to the grounding terminal.
(c) Turn ON the insulation tester power and measure the insulation resistance. The voltage
should be applied short as possible to verify that insulation resistance is at least 20MQ.
(d) After completing the test and being very careful not to touch exposed conductors disconnect
the insulation tester and connect a lOOkW resister between the grounding terminal and the
short-circuiting SUPPLY terminals. Leave this resistor connected at least three second to
discharge any static potential. Do not touch the terminal while it is discharging.

(5) Dielectric Strength Test

(a) Short-circuit the + and - SUPPLY terminals in the terminal box.
(b) Turn OFF the dielectric strength tester. Then connect the tester between th shorted SUPPLY
terminal and the grounding terminal. Be sure to connect the grounding lead of the dielectric
strength tester to the ground terminal.
(c) Set the cun-ent limit on the dielectric strength tester to lOmA, then turn ON the power and
gradually increase the tester voltage from '0' to the specified voltage.
(d) When the specified voltage is reached, hold it for one minute.
(e) After completing this test, slowly decrease the voltage to avoid any voltage surges.

2.10 Installation of Explosion Protected Type Transmitters

2.10.1 KOSHA Certification
Caution for KOSHA Flameproof is following type.

[Notel] Model APT3100 diaphragm sealed for potentially explosive atmosphere:

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• Type of Protection and Marking Code: Ex d n C T6

• Temperature Qass: T6
• Ambient Temperature: -20 ~ 60'C
• Process Temperature: Max. 80'C

[Note2] Electrical Data

• Supply Voltage: Maximum 45 Vdc
• Output signal: 4 ~ 20mA, maximum 22mA

[Note3] Installation
• All wiring shall comply with local installation requirement.
• The cable entry devices shall be of a certified flameproof type, suitable for conditions of
use.

[Note4] Operation
• Wait one minute after power -disconnection, before opening the enclosure.
• Take care not to generate mechanical spark when access to the instrument and
peripheral devices in hazardous location.

[NoteS] Maintenance and Repair

• The instrument modification or parts replacement by other than authorized
representative of DUON System is prohibited and will void KOSHA Flameproof.

2.10.2 KTL Certification

Caution for KTL intrinsic safety type is following type.

[Notel] Model APT3200 for potentially explosive atmosphere:

• Type of Protection and Marking Code: Ex ia IT C T5
• Temperature Class: T5
• Ambient Temperature: -20 ~ 60'C
• Process Temperature: Max. 80'C

[Note2] Entity Parameter

• Umax = 40 Vdc
• Imax = 165 mA
• Pmax = 0.9 W
• CI = 1.102 ^F
• Li = 0.94 mH
CAUTIONn Necessarily use an appropriate barrier matched on the above Entity Parameter

[Note3] Installation
• All wiring shall comply with local installation requirement.

[Notes] Maintenance and Repair

• TTie instrument modification or parts replacement by other than authorized
representative of DUON System is prohibited and will void KTL Intrinsic Safety Type.

2.10.3 CSA Certification

Caution for CSA Explosionproof / Flameproof is following type.

14 NMSysMaCl^LDL
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[Notel] Hazardous Area for APT3100 Process Transmitter

• Explosionproof for Class I, Division 1, Group A, B, C and D

• Dust-ignitionprrof for Oass n, Division 1, Group E, F and G ; Qass I I I
• Flameproof for Class I, Zone 1 : Ex d I I C
• Temperature Class T6 T5 T4
• Process Temperature 85 C 100 C 120 C
• Nonsparking Equipment for class I, Zone 2 : Ex nA IIC T4
• Enclosure : Type 4X, IP66
• Ambient Temperature : -20 to 60 C
• Supply Voltage : 42V dc max.
• Output Signal : 4 to 20mA + HART
• Electrical Connection : 1/20 • 14 npt Female
• List of standards that product compiles with, specifically E60079-1 end E60079-15.
• The warning: "WARNING-EXPOISION HAZAIUy-SUBSmVTJON OF
COMPONENTS MAY IMPAIR SUTTABILITY FOR CLASS I, DIVISION 2' or
equivalent

[Note2] Installation
• All wirings have to be installed by the final revision of Canadian Electrical Code.
• Input equipment of cable should be certified by explosionproof and be adjusted to using
conditions.
• Wire connection that is no use has blocked by available plugs.
• All saews of cable tube have to be set the 5 teeth.
• Method of cable connection has to be followed by Class I, Division 1 in spite of its length.
• All cable tubes have to be sealed with 50 cm from housing.
• Installation in Division 2 zone does not need to be sealed.
• In assembly of sensor module and housing, over 7 screws have to be set the teeth and
be fixed in order not to spin.

[Note4] Operation

• Be cautious of the CAUTION attached to transmitter

CAUTION I IN EXPLOSIVE ATMOSHERE DO NOT OPEN WHILE ENERGIZED
• Wait one minute after power-disconnection, before opening the enclosure.
• Take care not to generate mechanical spark when access to the instrument and
peripheral devices in hazardous location.

[NoteS] Maintenance and Repair

• The instrument modification or parts replacement by other than authorized
representative of DUON System is prohibited and will void CSA Explosionprooof /
Flameproof.

2.10 EMC Conformity Standards

EMI (Emission): EN55011
EI^S (Immunity): EN50082-2

DUON System recommends customer to apply the Metal Conduit Wiring or to upset he twisted poir
Shield Cable for signal wiring to conform the requirement of EMC Regulation, when customer installs
AUTROL Series Transmitters to the plant.

15 DDONSyttMM,Ui.
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Chapter 3 Transmitter Functions

3.1 Overview
This Chapter contains information on operating Model APT3100. Tasks that should be perfomied on
the bench priori to installation are explained in this chapter.

3.2 Safety Message

Procedures and instructions in this chapter may require special precautions to ensure the safety of the
personal performing the operations. Information that raises potential safety issues is indicated by
warning symbol(A). Refer to the following safety messages before performing an operation preceded
by this symbol.

3.3 Warning
Warning
Explosion can result in death or serious injury:
# Do not remove the transmitter covers in explosion environments wlien the circuit is alive.
• Transmitter covers must be fully engaged to meet explosionproof requirements.

• Warning
Electrical can result in death serious injury:
• The qualification which is educated only the person v/hom it prepares will be able to establish the
transmitter.

• Warning
Electrical can result in death serious injury:
<#> Avoid contact with the leads and terminals. High voltage that may be present onleads can cause electrical
shock.

3.4 Fail Mode Alarm

AUTROLD Smart Pressure Transmitter automatically and continuously performs self-diagnostic
routines. If the self-diagnostic routines detect a failure, the transmitter drives its output outside of the
normal saturation values. The transmitter will drive its output low(down) or high(up) based on the
position of the failure mode alarm jumper. See Table 3.1 for Output values.

Level 4~20mA Saturation 4~20mA Alarm

Low/Down 3.9mA < 3.75mA
High/Up 20.8mA > 21.75mA
[Tabie 3-1 Standard Alarm and Saturation Value]

Fail Mode Select Jumper Switch has in LCD Module and Main CPU Module and Jumper Switch Line is
connected circuital. In case of Not LCD Module, we can use CPU Module's Fail Mode Select Jumper
Switch and In case of LCD Module we can use LCD Module's Jumper Switch. In this case, CPU Module

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is selected "Down" side. No selected we can select "Down" side.

(Jumper Select Switch is followed in Figure 3-2, 3-3)

Only CPU
Both LCD Module and CPU Module
Select Fall Mode Module
CPU Module LCD Module CPU Module
Fail Down Down D D
Down U
Fail Up U
Up UorD

Fail Mode Select

Jumijer Switch

[Figure 3-2 LCD Module's Fail Mode Select Jumper]

(CPU Module: Fail-Mode Select Jumper Switch

EEP-WRUE JMMl FAIL

DIS 0 0 0 0 UP
0 0 0 0
EN| 0 0 0 0 DOWN
(Select EN) (Select Down)

LCD Modul e: Fail- Mode Select 3umper Switch

U 0 0 0 |0 0|0 D
(Down selected)
° FAILMOC
° )E ° D
(Up selected)

3.5 EEProm-Write Enable and Disable Mode Jumper

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There is the EEPROM (Electrically Erasable Programmable ROI^) restoring various configuration
variables in Transmitter. For protect to change configuration variable data in software, hardware side
there is Write-Protect Mode and Jumper Switch selected it segmented "EEP-Write DIS / EN " in Main
CPU Module. Thus if you connect Jumper to DIS you cant change configuration data in EEPROM,
when you connect Jumper to EN you can change configuration data in EEPROM. No connected Jumper,
it is classified EN. At the factory before shipment, it is configured "EN". (Following figure 3-3)

CPU Module's Jumper

Switch
1) Fail Mode select
2) EEP Write select

[Figure 3-3 CPU Module's Fail-mode, EEP-Write Select Jumper Switch]

There are two security methods in APT3100. Following this.

(1) Security Jumper: protect to writing configuration parameters of transmitter.
(2) Physical removing Zero and Span Magnetic Buttons of Transmitter: you are not able to regulate
Zero and Span in Local.
[Notification] If EEP-Write is not connected, it is classified Security Off state.

3.5.1 Security Jumper (EEPROM Write Protect)

Protect to change Configuration Parameter of transmitter to Write Protect Jumper.

3.5.2 Zero and Span Magnetic Button

To remove Magnetic Button, you can't configure Zero and Span in Local.

3.6 Configuration of Alarm and Security Jumper Procedures

To change Jumper's position, follow this.
(1) If install the transmitter, cutoff power
(2) Open the housing front side covers. In case Power Supply, don't open the covers of
transmitter
(3) After turn off Jumper, turn on at wanted position.
(4) Close the housing covers. You must fully engage to meet explosion proof requirements.

3.7 Configuration of Zero and Span Procedures

There are two method configuring Zero and Span's Range. Follow this.

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(1) Zero/Span Button mounted in Transmitter.

(2) HHT Configurator by HART Communication (following diapter 4)
* * Refer to • 75 Hart Communicator User Guided on Appendix I I for details.

Zero/Span configuration process by Zero/Span Button of transmitter is following this.

(1) Release to both sides bolts of Name Plate in the upper part of transmitter and if push down
right of Name Plate, appear to Zero/Span Button (following figure 3-4)

(2) Zero Configurations

Set the current process value for Lower Range Value (4 mA).
Put purposed pressure for zero over 10 seconds and push Zero Button over 5 seconds. TTien
show uSeroD in LCD window. After checking this message, take off the finger from the button.
Push the button over 3 seconds after 1 second passes. Then show • ZE-Q in LCD window. By
this message, all zero configurations have finished. If the works has failed, show ^^PEr" or
^^EtED in LCD window.

(3) Span Configurations

Set the current process value for Upperr Range Value (20 mA).
Put purposed pressure for zero over 10 seconds and push Span Button over 5 seconds. Then
show '^PAn" in LCD window. After checking this message, take off the finger from the button.
Push the button over 3 seconds after 1 second passes. Then show D SP-0 in LCD window. By
this message, all zero configurations have finished. If the works has failed, show ^"^PErO or
^•^EtED in LCD window.

(4) Zero Trim Configurations.

This work is to trim Primary Value in order to let current process value to know Zero. This work
makes indication value in LCD for zero • ".
Pushing Zero Button and Span Button over 5 seconds simultaneously after zero configurations,
uH-tr" shows in LCD window. After checking this message, take off the finger from both buttons.
Push only zero button over 3 seconds after 1 second passes. Then show "-tr-0 in LCD window.
By this message, all zero trim configurations have finished. If the works has failed, show SitEr"
or ^"^EtED in LCD window. These configurations can be available within Max. 10% of Sensor
Maximum Span.

(5) Close the opened name plate and lock it up.

Zero/Span
Configuratio

[Figure 3-4 Transmitter's Zero/Span configuration Button]

II •••NSystMet,iu.
WTTOI t—iPiMMW JnuaUm HmMm Miwul mUMW

[Error Messages]
When a purposed value passes over Sensor Limit Range, or is smaller than minimum
SPEr
Span
SEtE In case that configured value is not registered in memory
ZtEr In case that configured value is over 10% of Sensor Maximum Span
In case that current worl< would stop during Zero/Span or Zero Trim configurations
bErl
In case that button would be pushed at one time, oir be pushed continuously

3.8 Configuration of Sensor Zero Trim

Sensor Zero Trim means to configure deviations as to transmitter mounting status when transmitter
reads sensor value. When sensor trimming is done, transmitter read its applied pressure for zero
during trimming process. Namely, PV becomes zero. If mounting status would be changed. Sensor
Zero Trim has to be done after process pressure makes zero by draining process pressure. And Sensor
Zero Trim should be needed when transmitter installed on a spot after it is calibrated in calibration
room or shop.

Sensor Zero Trim means that PV (Primary Value, which is displayed in LCD Indicator) is made for zero.
But Zero and Span means that optional PV is indicated to 4 mA and 20 mA output for converting
analog output.

Even though Sensor Zero Trim of general smart transmitters is done with HHT, etc., APT3100 is able to
make Sensor Zero Trim using only Sensor/Zero button.

There are two ways for Sensor Zero Trim of APT3100.

• Using Zero/Span button attached on transmitter
• Using HART communicator, HHT, etc.
For more information and details, please refer to 275 User Guide.

The under guide is a Sensor Zero Trim procedure using Zero/Span button.

(1) Loosen both bolts of Name Plate on upside transmitter and push the right end of Name Plate
back a little bit. (Figure 3-4)
(2) Apply necessary pressure and push Zero and Span button simultaneously over 3 seconds.
Then show "Z-tr" in LCD window (Z-tr means Zero Trim). Remove finger on the buttons after
seeing the message. After one second, push only Zero button over 3 seconds. You can see "-
tr-D By this, all procedures finish. If this procedure is failed, show "ZtErOor "SEtEd
Range for Sensor Zero Trim is within 10% of Sensor Maximum Span. In case that value over
10% is done for Sensor Zero Trim, this has to make Zero Trim after modulating transmitter
horizon status.
(3) Close cover of Name Plate and lock both bolts.

3.9 Configuration of Zero Point Adjustment

Zero Point Adjustment means to configure 1 ^ value which output after Zero Trim. At last. Zero Point
Adjustment is to configure a current PV value for another value, which is not zero, by configuring
Offset value of zero point. This is for configuring a current displayed value for a desiring process value
without making process value zero. Especially, in case of configuring level value is very difficult to
make Sensor Zero Trim, this adjustment is very convenient to configuring a current value for a
desiring value.

21 ••[Link].
MTMIIS—IHMHWTlMS—lt I w i l l w IIIWIll M I U H n i

PV_raw : Value that transmitter calculates signal from sensor

PV : Value that transmitter finishes Sensor Zero Trim or Zero Point Adjustment
Offset : Value calculated when Sensor Zero Trim or Zero Point Adjustment is done

PV = PV raw + Offset
(A) Sensor Zero Trim case :
PV = 0 = PV_raw + Offset^
(In result, Offest = -PV_raw)

(B) Zero Point Adjustment:

PV = PV_raw + Offset,
(Offeet is variable. Therefore, PV value and Zero point can be configured by changing
Offeet value)

There are two ways for Zero Point Adjustment of APT3100.

• Using Zero/Span button attached on transmitter
• Using HART communicator, HHT, etc.
For more information and details, please refer to 275 User Guide.

The under guide is a Zero Point Adjustment procedure using Zero/Span button.

(1) Loosen both bolts of Name Plate on upside transmitter and push the right end of Name Plate
back a little bit. (Figure 3-4)
(2) Apply necessary pressure and push Zero and Span button simultaneously over 3 seconds.
Then show "2-titl in LCD window. And continuously push Zero and Span button over 3
seconds again. Then show u^-AdD in LCD window. After making sure this message, 0.01%
diminishes whenever Zero button is pushed, and 0.01% increases whenever Span button is
pushed. Pushing button continuously makes speed fast or stow. If you push Zero/Span button
over 3 seconds or do not push any button over 10 seconds, "-Zo-D message shows in LCD
window. By this message, all procedures finish.
Range for Zero Point Adjustment is permitted within 100% of Sensor Maximum Span.
(3) Close cover of Name Plate and lock both bolts.

3.10 Shop Commissioning using HHT

Commissioning consists of testing the transmitter, testing the loop, and verif/ing transmitter
configuration data. APT-3100 Pressure Transmitter may be commissioned using HHT of HART
supported either before of after installation.

A If you connect 'TEST" pin, it's not communicated. If it doesn't exposed electronics circuits after
install, you must connect all Jumper of transmitter in the shop commissioning level. Analog output of
transmitter is 4~20 mA, thus it requires Power Supply at 11.9 V ~ 45 Vdc and Ampere meter for
measuring output current. You must connect 250~550 ohm resistor in Power Loop for HART
Communication and HHT or PC Configurator

21 ••MSyttMCtaUL
OTinifimiiftww—HI •HradM Mam Mmura

POWER / SIGNAL CONNECTIONS

Field Control Room

Indicator
Recorder
Controller
Local test or DCS..
Remote Indicotor etc,
2 5 0 ~ 5 5 0 Ohm
(24Vdc)
-^VV Power
Supply

PC Configurator
HART m o d e m "
(HART/RS232)'

1. HHT (HART Cornmunicotor) or PC Configurator moy be connected ot any termination

point in ttie signal loop.
2. HART Communicotion requires o loop resistonce between 250 and 550 ohms(24Vdc).
[Link] operate on 11.9 to 45.0 Vdc transmitter terminal voltage.
[Applied Power]
* 1 1.9 ~ 45.0 Vdr- fnr npn^rol operation
* 17.4 ^ 45.0 Vdt, lui riMFM communication
* 17.4 ^ 42.0 Vdc for CSA approval (Power supply must not exceed 42.0 Vdc)

[Figure 3-5 Connection the transmitter to HHT]

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vmilSMrtPntanTramMttf ivmiiMnMnlllSllura

Chapter 4 Installation
4.1 Overview
The information in this chapter 4 covers installation considerations. Dimensional drawings for Model
APT-3100 variation and mounting configuration are included in this chapter.

4.2 Safety Message

Procedures and instructions in this chapter may require special precautions ensure the safety of the
(personnel performing the operation. Information thatraisespotential safety issues is indicated by a
warning symbol(A). Refer to the following safety messages before performing an operation proceeded
by this symbol.

4.3 Warning
Warning
Explosion can result in death or serious injury :
# Do not remove the transmitter covers In explosion environments when the circuit is alive.
# Both transmitter covers must be fully engaged to meet explosionptxxif requirements

Warning
Electrical can result in death serious injury:
# The qualification which is educated only the person whom It prepares will be able to establish the
transmitter.

Warning
Process leaks can cause death or serious injury:
#> Install and tighten before applying pressure. Ift you don't Hike this, it can cause process leaks.

Warning
Electrical shock can result in death or serious injury. If you install high voltage
environment or false condition, power line and lead will be apprered high voltages.
•#> Avoid contact with the leads and terminals.

4.4 Commissioning on the bench with Hand-Held Terminal

After and before installation, You can handle upon commissioning. However, for correctly handling and
knowing the function, before installation you have to handle upon commissioning on the bench with
Hand-Held Terminal.

23 nONSfftMCl^Ui.
irnmawnPiMi—Tnwmw Mtnuni

Basic Setup
a) Unit Setup
b) Range Setup
c) Damping Setup
d) Transmitter Function Setup

u
Verify
a) Pressure Support

Field Install

a) Jumper/Switch Setup
b) Transmitter take up
c) Transmitter leads
e) Transmitter for Power Supply
f) Process Leak Check

End

[Figure 4-1 Installation Flow Chart]

24 •UONSysuaet,lUL
wmnSMrtPifMnitaMMw •MndMHaniMSltura

4.5 General Considerations

This transmitter uses the capacitive pressure sensor I f it changes the pressure sensor, capacitive
pressure is changed minutely.
I t transfer electrical signal minutely to 4~20mA analog signal. Thus mount the transmitter close t o the
process and use a minimum of piping t o achieve best accuracy. However keep in mind the need for
easy access, safety o f personnel, practical field calibration, and a suitable transmitter environment.
In general, install the transmitter so as to minimize vibration, shock, and temperature fluctuations.

4.6. Electrical Considerations (Power Supply)

The transmitter housing composes o f t w o parts. One side is electronics circuit, and other side is
Terminal Block, Terminal Block side is transmitter's frontside and is indicated " Field Terminal" in
transmitter housing external. Open this side's housing cover, there is Terminal Block in housing inside.
Consider t o this Terminal Block polarity, connect t o Transmitter's Power Supply. Configurator supported
HART connects to "COMM" pin in Power Supply downside. I n the field Indicator connects to "TEST"
pin.

4.6.1 Power Supply

In the transmitter's power supply Input Current Voltage is currently DC voltage between DC 11.9
volt ~ 45 volt and power supply's ripple is not up to 2%. Loop resistance means all resistor sums
in loop.
In case of using Intrinsic Safety Barrier, same includes resistor of barrier.

Max. Loop Resistance [Q} = (E-11.9) [ v d c ] / 0.022 [ m A ]

Here, loop resistance is preferable at 250 ~ 550Q (24 Vdc) for the HART communication.

4.7. Wiring
4.7.1 Caution of Wiring
(1) Install cable in the far from electrical noise resources like capacitive transformer, motors
power supply as soon as possible.
(2) Before wiring put out electrical lead connect cap.
(3) All saew-lined portions paste suture for waterproof. (It promotes the silicon type that is not
hardened.)
(4) Don't lead signal line to power line in same duct for no received noise signal.
(5) The explosion-proof transmitter in order to maintain the explosion-proof quality of the
corresponding transmitter effectively follows in the demand explosion-proof specification that
is provided and must be lead.

4.7.2 Selecting the Wiring Materials

(1) Use over 600V PVC shielded wire or standard lead line of same class or cable. (In order to
ensure proper communication use 24 AWG or lager wire, and do not exceed 1500 meters.)
(2) Use the shielded wire in electrical noise effected area.
(3) At the higher or lower temperature area than ambient temperature it uses the wire or the

25 •[Link]
•miM SaatPmaraTnnaiw MSIM-ira

cable that is suitable like that temperature.

(4) You have to use suitable wire, cable in environment lil<e oil, solvent, toxic gas or liquid.
(5) Terminal process of lead line must use to not soldered tenninal lug. Recommend isolating lead
end terminal using contract tube.

4.7.3 Connections of External Wiring to Transmitter Terminal

Box
Wiring method is following this.
(1) Open the housing cover indicated "nELD TERMINAL". In explosion environment when circuit
is powered on, don't open the covers.
(2) connect the power supply in the terminal indicated "+PWR"(left terminal) and "-" power
supply in the central terminal. Don't connect"+" power supply in "+" terminal of the point
indicated "TEST'. It will be damage to test diode used to connecting TEST terminal.
(3) Seal and close the non-using Conduit Connection Part for severe humidity and explosion on
the terminal box of housing.
(4) Transmitter power is supplied to Signal Wiring. So, don't install near to Signal Wiring with
Power Wiring or near to Power Apparatus. In case of ground signal, ground the signal loop's
one side and other side is not grounded. Promote to ground "-" side of power.
(5) For the better adjustment completely turn Screw terminal.
(6) Again close the transmitter cover. Specially in case of using in explosion area, you must to
satisfy requirement about expfosion.
[Note]
Don't supply high voltage (AC power) in transmitter leads. It can be caused damages to
transmitter.
(7) You have to connect 250~600 W Loop Resistor in Current Loop(between Power Supply and
Transmitter) for HART Communication HART. Following Figure 4-2 about conection of Current
Loop.

250~550 Ohm
(24Vdc)
DCS
+ -AAA^ or
Power
Supply

ti+PWR -TEST+(<

MMM
^ £pu»l~IESlT^

[Figure 4-2 Connection with Terminal Board of Transmitter

21 [Link]
antm SmrtPiwamlMiaMiir MSIIHra

"&r ^ ^
Local Indicator
or
Ampere Meter

4.7A Wiring
Warning
Explosion can result in death or serious injury:
# Do not remove the transmitter covers in explosion environments when the drcuit is alive.
# Both transmitter covers must l3e fully engaged to meet explosion proof requirements

[Link] Loop Configuration

AUTROL Series Transmitters use a two-wire system for power supply, 4~20mA analog signal
transmission and HART digital transmission.
DC Power Supply is required for the transmitter loop. The Transmitter and distributor are
connected as shown below.

(1) Non-Explosionproof / Flameproof Type

Hazardous Location <— -> Nonhazordous Location

Transmitter terminal box

+ - Other Devices
(DCS, Recorder...)

Power Supply

blgf^ :l1.9~45VdC

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UrnHHMUPlMMWTnwKMf

(2) Explosionproof Type

Hazardous Location <— -* Nonhozardous Location

Transmitter terminal box

o t h e r Devices
(DCS, Recorder...)

Power Supply

KOSHA U | g i a » :11.9~45Vdc
CSA U & g / ^ : 42Vdc Max.

(3) Intrinsical Safety Type

Hazardous Location <- -* Nonhczordous Location

Transmitter terminal box

Satety barrier
Other Devices
-o o- + -
(DCS, Recorder..
-=^ o ^ o-

±
Power Supply

ioL
KTL ^[Link],>^ : 360Vdc Max.

[Figure 4-3 Connection between Transmitter and Power Supply]

21 eU0NSytlMie«.Ui.
wniMSMRPmnnTiMSBiw MMmmiHra

[Link] Wiring Installation

(1) General-use Type and intrinsically Safe Type
Mal<e cable wiring using metallic conduit or
Waterproof cable glands.

0. Apply a non-hardening
sealant to the terminal Flexible metal conduit
box connection port
and the threads on the
flexible metal conduit
for the waterproofing. Wiring metal
conduit

Apply a nonhordening
seolant to ttie threods for
waterproofing

[Figure 4-4a Tee •

Typical Wiring using
Flexible Metal Conduit] Drain p l u g -

(2) KOSHA Flameproof Type

Wire cables through a flameproof packing adapter, or using a flameproof metal conduit.

(a) Wiring cable through flameproof packing adapter for KOSHA flameproof type (see
Figure 4-4b)
O Use only flameproof packing adapter by KOSHA.
O Apply a non-hardening sealant to the terminal box connection port and to the
threads on the flameproof packing adapter for waterproofing
O Mounting flameproof packing adapter to the terminal box.

o. Screw the flameproof packing adapter into the terminal box until the 0-ring touches
the terminal box wiring port (at least 5 full turns), and tighten the lock net.

Non—hozordous area

Hazardous orea

Apply a nonhardening
sealant to the threods of
Flomeproof heavy-gauge these fittings for
steel coriduit waterproofing,

•Seal fitting
Drain plug
[Figure 4-4b
Typical Wiring using Flameproof Packing Adapter] After wiring. Impregnote the fitting
with o compound to seal tubing.

21 •NNSvttMCaaii.
unrnuunnMunitrntwrnm MmMni

(b) Rameproof metal cxMiduit wiring (Figure 4-4c)

O A seal fitting must be installed near the terminal box cxxinections port for a sealed
construction.
O Apply a non-hardening sealant to the threads of the
terminal box connection box, flexible metal
conduit and deal fitting for
waterproofing.

Non—hazordous area

Hazardous area

Apply a nonhardening
sealant to the threads of
Flomeproof heavy—gouge these fittings for
steel conduit waterproofing.

Tee -
Seal fitting
Drain plug

[Figure 4-4c After wiring, impregnate the fitting

with a cornpound to seol tubing-
Typical Wiring using Flameproof i^etal Conduit]

4.7.5 Grounding
(a) Grounding should satisfy KS requirements (grounding resistance, 10 Ohm or less). Grounding
is required below 10 Ohm for explosionproof and intrinsic safety.

[Note] In case of with Built-in Lightening Protector, Grounding should satisf/ Special KS
requirements (grounding resistance, 10 Ohm or less)

(b) There are ground terminal on the inside and outside of the terminal box. Either of these
terminals may be used.

(c) Use 600V grade PVC insulated wire for grounding.

31 •nilSystMCt,ldL
armn SMMPnssatnmnMiM' MiiHni

Inteinal External
Ground Termina Ground Terminal

APT3100 S n a r t P r e s s u r e T r a n s n i t t e r
I n t e r n a l and E x t e r n a l Ground Terninal

4.7.5 Power Supply Voltage and Load Resistance

When configuring the loop, mal<e sure that the external load resistance is within the range in the
figure below. Since the voltage of transmitter terminal input is same as follows.
• General Standard : 11.9 to 45 Vdc
• Hart Communication : 17.4 to 45 Vdc
• KOSHA Explosionproof: 11.9 to 45 Vdc
• CSA Explosionproof : 17.4 to 42 Vdc max.

And maximum loop current is 24mA, Load resistance R:

R = (E-11.9) / 0.022 (E = Power Supply Voltage)

[Note] In case of an intrinsically safe transmitter, external load resistance includes safety barrier
resistance.
1500

e
R = (E-11.9)/0.022 /
s:

a:

_ 600
a

1
c
\ \ H A R T CommuntcationAV\
XXAppircable Ronge \\\N

250
^

/
11.9 17.4 25.1 42.0 45.0

Power Supply Voltage E(Vdc)

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vmMSaanPnsnmTnMaltMr

4.8 Mechanical Considerations

Figure 4-3 is transmitter dimensional drawings of APT3100. A mounting example and dimensional
drawings is shown in Rgure 4-4.
126
73 116
43 86
Removal
Clearance
for All Cops

( [ J-"^^* I \_^^
Optional
Adapter
for 1 / 2 - 1 4 NPT

Optional
Digital
Indicator

Standard
Process Connection
1 / 4 - 1 8 NPT

Optional
Side Vent/Drain Valve

Optional
Adapter
for 1 / 2 - 1 4 NPT

Model No. Dimension A

APT3100-D3,4,5 54 m m ( 2 - l / 8 " )
APT3100-D6,7 55.6 m m ( 2 - 3 / 1 6 " )
APT3100-D8 57.1 m m ( 2 - 1 / 4 " )

[Figure 4-3 Transmitter Outline Dimensional Drawings]

12 •NNSntMCt,!!!.
tfTainSMrtPntHraTnnaiiM i N M i N Mawl M t n M n i

Vertical Pipe Mounting

Horizontal Pipe Mounting

Vertical Mounting Type

2" Pipe Mounting Bracket
Model: Angle Type

Vertical Pipe Mounting

Horizontal Pipe Mounting

Horizontal Mounting Type

2" Pipe Mounting Bracket
Model: Flat Type

[Figure 4-4 Typical Bracket Mounting Example]

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uTTimiMrtPiMitTiiwimf mmm mwHi wiw-na

4.8.1 Mounting
To use the cadence carrier from the environment where the vibration is heavy and must install
the transmitter. In the environment where the vibration is heavy you will have to install the
transmitter by using an assistant support. In the case of severe vibration, promote to mount on
pipe using a mounting bracket as option.

4.8.2 Consideration of Transmitter Access

When selecting the establishment location or a place of the transmitter, it treats the transmitter
it probably is a location that is convenient must consider.
(D Rotation of housing: housing can be rotated up to 90°.
(2) Terminal sides of transmitter: location ease us terminal space where be able to pull out
transmitter cover
(H) Circuits side of transmitter: the space where there is a possibility of treating a electronic
circuit / the space where be able to pull out transmitter cover / If LCD meter is installed, it
requires extra space.

4.9 Environmental Considerations

4.9.1 Effect of Ambient Temperature
You have to install at -20t:~60t: (-4~180T), operating ambient temperature range. If predicted
heat seems to exceed or equivalent to ambient temperature range limit, you have to consider
additional method to cutoff the process heat.

• Ambient Temperature: -40 ~ 85°C (without LCD module)

-30 ~ 80°C (with LCD module)
* General Use -20 ~ 60°C (CSA Explosionproof)

4.9.2 Environment of toxic, moisture

Housing of APT-3100 can be protected to moisture or toxic material. Electronic circuit side is
separating from terminal side. When 0-ring Seal cover covers, it is intrinsic safety. But, some drip
could penetrate to the housing of transmitter through conduit pipeline. Therefore, transmitter
should be set up over the position of conduit pipe for preventing drip.

4.9.3 Installation of dangerous place

TtBnsmitter is designed to explosion-proof housing. Installation environment of transmitter must
be confirmed explosion-proof specification.

34 nONSyttMCa^lU.
MTimS—IHMMWTWWMW

Chapter 5 On-line Operation

5.1 Overview
This chapter describes to configure function of APT3100 SMART Pressure Transmitter. Transmitter can
be configured to On-Line or Off-Line mode. In On-Line Configuration Mode, you must connect
configuration sudi as HHT (Hand Held Terminal), etc. Configuration data inputs in Working Register of
HHT and this data is sent to corresponding transmitter.

5.2 Safety Message

Send operation. Do specially notice for safety of operator. In damage and place required specially
safety. We indicate Warning symbol(A). When you operate wori< of Warning symbol, follow Safety
Message.

5.2.1 Warning
Warning
Explosion can result in death or serious injury:
• Do not remove the transmitter covers in explosion environments when the circuit is alive.
• Before connecting HHT in explosion zone, confirm that the configure device has to be installed by intrinsic
safety regulations.
#• Both transmitter covers must be fully engaged to meet explosion-proof requirements

Warning
Electrical sliock can result in deatli or serious injury. If you install high voltage environment
or false condition, power line and lead will be appeared high voltages.
#• Avoid contact with the leads and terminals.

5.2.2 Configuration current to passive mode

In the case of short Current Loop, send or request data to change transmitter output you must
configure Current Loop to passive mode. Don't believe in message indicating HHT, must configure
Current Loop to passive mode with other operation.

5.3 Configuration Data Review

In case of install transmitter in fact site, before operate transmitter reexamine and certify whether
configuration data correspond with fact application environment.

5.4 Cliecic Output

Before other handle transmitter to on-line, you must examine and confirm whether transmitter
currently operate and suitably configure progress variable.

5.4.1 Process Variable

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We use two progress variable in APT-3100 SMART Pressure Transmitter pressure value is Primary
Variable and temperature value of pressure value configure SV(Secondary Variable) with fixed
value.
Moreover this PV value ouputs with 4~20mA analog value.

5.5 Basic Setup

You must configure correlation variable for operating currently transmitter.

5.5.1 Select Sensor Range

Pressure range to measure is depended Range Code of sensor. This value is classified from
pressure sensor module automatically.

5.5.2 Set Output Units

Select from the following engineering units:
Unit: kPa, kg/cm2, bar, psi, mmH20 etc

5.5.3 Rerange
Set the Zero and Span of 4~20mA analog output.

5.6 Detailed Setup

5.6.1 Set Fail Mode
When sensor is wrong or microprocessor of transmitter doesn't operate normally in order to
outputs current value of High or Low.

5.6.2 Set Damping Time

The sensor input value changes the response time of the transmitter to smooth variations in
output readings caused by rapid changes in input. Determine the appropriate damping setting
based on the necessary response time, signal stability, and other requirements of the loop
dynamics of your system. The default damping value is 5.0 seconds, and can be reset to damping
values between 0 and 32 seconds.

5.7 Configuration of Information Variable

5.7.1 Set Tag
Tag variable is better easy method to classify to transmitter in multi transmitter install
environment. Tag Character can be used to 8 word of English/number.

5.7.2 Set Messages

When use several transmitter, user can define for classification each transmitter and use 32 words

U INNSntMCl,lU.
WTSlNSaMPrMamTnnaliw Ummm H m i i MliN4ra

of English/number. This message is saved in EEPROi^ of transmitter.

5.8 Configuration of Breaicdown Diagnostic Function

5.8.1 Loop Test
The Loop Test verifies the output of the transmitter, the integrity of the loop, and the operations
of any recorders or similar devices installed loop. Perform the following procedure for a loop test.

® Connect a reference meter to the transmitter.

(2) Select the Loop Test of HHT and operate the Loop Test.
(3) Select output current ( 4mA/20mA/etc)
d) If the readings match, then the transmitter and the loop are configured and functioning
properly. If the readings do not match, then you may have the current meter attached to the
wrong loop, there maybe a fault in the wiring, the transmitter may require an output trim, or the
electrical current meter may be malfunctioning.

5.9 Calibration
Scaled system implement by calibrating the transmitter. Trim function have several function for the
calibration. Smart transmitters operate differently than analog transmitter. A Smart transmitter uses
a microprocessor that contains information about the sensor's specific characteristics in response to
pressure and temperature inputs for calculating Process Variable. The trim and rerange functions
also differ. Reranging sets the transmitter analog output to the selected upper and lower range
points and can be done with or without an applied pressure. Reranging does not change the factory
characterization curve stored in the miaoprocessor. Sensor trimming requires an accurate pressure
input and adds additional compensation that adjusts the position of the fectory characterization
curve to optimize transmitter performance over a specific pressure range. Rerange functions
provides ability to readjust the 4~20mA points sensor inputs.

5.9.1 Sensor Trim

The Sensor Trim the transmitter sensor input signal convert A/D to lead and how it interprets the
values which it inputs with digital the contents of such interpretation and it is regarding to change
is connected actually in the sensor which in order to correspond.

5.9.2 DA (Digital to Analog) Trim

When the D/A trim convert sensor input signal to 4~20mA output, this ouput value scale
minuteness. Cyclic you recommend to scale analog output for maintain scale.

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Chapter 6 Maintenance
6.1 Overview
This chaprter describes breai<cJown diagnostic and maintenance.

6.2 Safety Message

When operation, it requires specially notice for the safety of operator. Information that raises potential
safety issues is indicated by a warning symbol(A). Refer to the following safety messages before
performing an operation proceeded by this symbol.

6.2.1 Warning
Warning
Explosion can result in death or serious injury:
# Do not remove the transmitter covers in explosion environments when the circuit is alive.
4'Both transmitter covers must be fully engaged to meet explosion-proof requirements

Warning
Electrical shock can result in death or serious injury, if you install high voltage environment or
false condition, power line and lead will be apprered high voltages.
•Avoid contact with the leads and terminals.

A Warning
Electrical can result in death serious injury:
#> The qualification which Is educated only the person whom it prepares will be able to establish the
transmitter

• Warning
Process leal( can result In death serious injury:
#• Before approval pressure install Thermowell or sensor and then close completely. If don't this, it cause
process leak.
#• when operating, don't take out Thermowell.

6.3 Hardware Diagnostics

If you suspect a malfunction despite the absence of any diagnostic messages on the HHT follow Table
6-1 described here to verify that transmitter hardware and process connections are in good working
order.

If you suspect a malfunction despite the absence of any diagnostic messages on the HHT follow Table
6-1 described here to verify that transmitter hardware and process connections are in good working
order.

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•PTUN S M U H W I fmnaiiir

[Table 6-1 Troubleshooting]

Symptom Potential Source Corrective Action

• Check for a minimum of 250 ohms resistance
TtBnsmitter
between the power supply and HHT.
Does not
• Check for adequate voltage to the transmitter.
Communicate Loop Wiring
TTie transmitter always requires 11.9 ~ 45 Vdc.
With HART
• Check for intermittent shorts, open circuits, and
Communicator
multiple grounds.
• Connect HHT and enter the Transmitter test mode
Sensor Input Failure
to isolate a sensor failure.
• Check for dirty or defective terminals,
Loop Wiring
interconnecting pins, or receptacles.
• Check the output voltage of the power supply at
High Output Power Supply the transmitter terminals. It should be 11.9 to 45
Vdc in spite of loop scale.
• Connect HHT and enter the Transmitter test mode
to isolate module failure. Check the sensor limits
Electronics Module
to ensure calibration adjustments are within the
sensor range.
• Check the output voltage of the power supply at
the transmitter terminals. It should be 11.9 to 45
Vdc.
Loop Wiring
• Check for intermittent shorts, open circuits, and
Erratic Output
multiple grounds.
• Check for proper polarity at the signal terminals.
• Connect HHT and enter the Transmitter test mode
Electronics Module
to isolate an electronics mode failure.
• Connect HHT and enter the Transmitter test mode
Sensor Element to isolate a sensor failure.
• Check the PV to see if it is out of range.
• Check for adequate voltage to the transmitter
The transmitter always requires 11.9 ~ 45 Vdc.
Low Output or
Loop Wiring • Check for intermittent shorts, open circuits, and
No Output
multiple grounds.
• Check the loop impedence.
• Connect HHT and check the sensor limits to
Electronics Module ensure calibration adjustments are within the
sensor range.

6.4 Hardware Maintenance

Autrol APT3100 Smart Transmitters have no moving parts and require a minimum of scheduled
maintenance. Both transmitters feature modular design for easy maintenance. If you suspect a
malfunction, check for an external cause before performing the diagnostics as discussed later in this
section. If you must return failed transmitters or parts, send them to DUON System Co., Ltd. for
inspection, repair, or replacement.

6.4.1 Test Terminals

The test terminal, marked as TEST on the terminal block, The test and negative terminals are
connected to the test tenninals; so long as the voltage across the receptacles is kept below the

II lUMSystMCLlll
APmNSamPmsHtnMsainii Miiiura

diode threshold voltage, no current passes through the diode. To ensure that there is no leakage
current through the diode while making a test reading, or while an indkating meter is connected,
the resistance of the test connection or meter should not exceed 10 ohms. A resistance value of
30 ohms will cause an error of approximately 10 percent of reading.

+
Galvanomete

[Figure 6.1 Test Terminals]

6.4.2 Disassembling tlie Electronics Housing

The transmitter is designed with dual-compartment housing; one contains the electronics module,
and the other contains all wiring terminals and the communication receptacles.

[Figure 6.2 Structure of Housing]

•••[Link].
unm SmmUmumtmimUm Maiiura

[Link] Disassembling Electronics Module

Use the following procedure to remove the electronics module.

[Notel]
The electronics are sealed in a moisture-proof plastic enclosure refened to as the electronics
module. The module is a non-repairable unit; if a malfunction occurs the entire unit must be
replaced.

1. Disconnect the power to the transmitter.

2. Remove the cover from the electronics side of the transmitter housing (Figure 6.2). Do not
remove the instrument cover in explosive atmospheres when the circuit is alive. Remove
the LCD meter, if applicable.
3. Remove the two screws that anchor the electronics module to the transmitter housing.
4. Firmly grasp the electronics module and pull it straight out of the housing, taking care not
to damage the interconnecting pins.

[Note2]
The transmitter EEP-Write Jumpers and failure mode are located on the front of the electronics
module. When it will be replaced for a new one, make a same jumper location.

Terminal Board

CPU and
Power Module

[Figure 6.3 Structure of Electronics Module inner Transmitter]

[Link] Fail Mode and Jumper Switch of EEPROM-write

Fall-mode and jumper switch of EEPROM-write is located front of electronics module.

41 [Link].
amniSaaitrmsviTmnanif iviniiHaHnlMSilMlii

6.4.3 Assembling the Electronics Housing

Re-assembling procedure is same as follows.

1. Make sure that Fail-mode and Jumper Switch are set exactly.
2. Insert electronics module in housing.
3. Fix electronics module with 3 screws..
4. Close the cover of housing..

42 INNSyitMei,!!!.
immuunmnanTnmumm

Appendix I
LCS DISPLAY CODE of APT3100

No. CODE Contents

1 e-rd . Read Analog EEPROM for MCU EEPROM
2 -00- . Finish to read Analog EEPROM for MCU EEPROM
3 r-22 . LCD Stat Message (Transmitter Version ul-22D
4 S-FL . Sensor Fail
5 s-op . Sensor Input Over Pressure
6 e-tt . Write MCU EEPROM for Analog EEPROM
7 end . Finish to write MCU EEPROM for Analog EEPROM
8 2ero . Initial message in using Zero button
9 Span . Initial message in using Span button
10 2-tr . Initial message of Sensor Zero Trim in using button
11 -tr- . Good job of Sensor Zero Trim in using button
12 2ter . Over 10% of Sensor Zero Trim limit in using button
13 •2e- . Finish Zero configurations in using Zero button
14 -sp- . Finish Span configurations in using Span button
15 Sete . Fail EEPROM-write in using button
16 Sper . Min/Max span Over in using Zreo/Span Button
17 Beri . Wrong button in using button
18 a-cl . Clear all MCU EEPROM
19 Cp-0 . Verif/ Data Message
20 -cp- . EEPROM SETHNG UP TERMINATION MESSAGE
21 e-fa . MCU data set error
22 — . Clear MCU EEPROM in User area
23 atrl . Finish to clear MCU EEPROM in User area

43 •[Link]
 ITEM NO. 2 5 . 0

T I T L E DATA
SHEET MB-DT-01
NO. :

THREE VALVE MANIFOLD CODE

ICANGRIM PAGE 2 OF 2

Process conn

4 - 7 / 1 6 - 2 0 UNF

219(0pen)
42

1 p <::>•

w
- ( - • • •

— ^' <^^ in
00

1 -r T- 1
1 1
41 .3

Note : The flange adopter combined to the instrument body shall be used.

Model Number Table

No Model No Moteriol Finish Description

1 KZ-13-001 SCS14A - Manifold valve
2 KZ-15-002 SC46 Yellow chrometing Manifold valve

Standard Specifications

• Operating Pressure -1 ~ 140 kgf/cm2

• Operating Temperature -40 ~ +120 X
• Hydraulic Test Pressure 210 kgf/cm2
• Gasket Teflon
• Weight Approx. 2.1 kgf
 llfcM INU. A<:
DATA
T I T L E
SHEET MB-RLG-01
NO. :
WATER LEVEL GAUGE CODE SEE TABLE
ICANGRIM (REFLEX TYPE) PAGE 1 OF 1

VISUAL CAUce WEIGHT

BODY CL>SS CONN REMARK
[Link] SERVICE Q'TY C TO C LENGTH LENGTH (REr. CLASS)
(VL) LENGTH SfZE (Kg)
<OL)
BLR WATER LEVEL 1 525 295 335 320 20A 14 3001036(KR)
BLR WATER LEVEL 1 580 315 380 340 20A 15 3001035
BLR WATER LEVEL 1 630 375 440 400 20A 16 3003431
BLR WATER LEVEL 1 690 430 490 220x2 20A 17.5 3003457
BLR WATER LEVEL 1 780 550 610 280x2 20A 20 3001046
BLR WATER LEVEL 1 800 550 610 280x2 20A 20 3003516
BLR WATER LEVEL - - - - - - -

4-915 holes

T t
+ +
i +
f + 5i
_j
o
f i
f f
+1 1T

SPECIFICATION CLOSE

-GAUGE TYPE : REFLEX

-VALVE TYPE : OFF-SET SCREW DOWN VALVE
-[Link] TEMP. : 20CrC
-[Link] PRESS. : 2 0 K g / c m 2

VALVE DETAIL

NO. DESCRIPTION MATERIAL QT'Y NO. DESCRIPTION MATERIAL QT'Y DESCRIPTION MATERIAL QT'Y

BODY FLANGE(20K-20A) S25C U-BOLT S25C 13 HANDLE FC200

COCK HANDLE S25C GAUGE COVER S25C 14 WIRE ROPE SW

STEM SS400 GLASS BOROSILICATE 15 WIRE CLIP SS41 12

BONNET S25C PACKING ASBESTOS FREE

VALVE BODY S25C GAUGE BODY S25C

BALL DISK SS400 12 DRAIN VALVE 83

h I
L A N H I S T O R Y

DIMENSION TABLE
(UNIT:MM)

I.D [Link] O.D T N-eH AXIAL UTERM. ANGUUm lonc rn. L

SIZE UOfflCNI KTUCnW ROTATIO» RUGATIOf
(mm) (nnm) ( m m ) (mm) (mm) ( m m ) ( m m ) (Deg.) (mm)
2K-250A 269.5 345 385 16 12-«23 ±23 4.0 9.6 6 300
2K-J00A 321 390 430 16 12-e23 ±19 2.3 6.6 300
ZK-350A 358 435 480 16 12-«25 ±19 2.0 6.0 300
2K-400A 409 495 540 16 16-e25 ±19 1.8 5.2 300
2K-450A 460 555 605 16 16-e25 ±27 2.9 6.3 300
2K-500A 511 605 655 16 16-e25 ±27 2.6 5.7 300
• 600A 613 670 710 16 16-e23 ±27 2.2 4.8 300
• 700A 715 775 815 16 16-»23 ±27 1.9 4.1 300
•• 800A 817 875 915 16 20-«23 ±23 1.3 3.2 3 400
• 900A 919 980 1025 18 20-«25 ±23 1.2 2.7 3 400
• 10OOA 1021 1080 1125 18 20-025 ±23 1.1 2.5 3 400
• 11OOA 1122 1180 1225 18 24-«25 ±23 1.1 2.5 3 580

• 1200A 1224 1280 1325 18 24-«25 ±23 1.1 2.5 3 S80

• 1600A 1617 1690 1745 20 28-B27 ±23 1.1 2.5 3 400

1.0 [Link] 0.0 T N-»H AXIAL LATERAL ANCUlAli mw rrR. L

SIZE UMMEM1 ixnicnn ROTATIW RUGATm
(mm) (mm) (mm) (mm) (mm) ( m m ) ( m m ) (Deg.) (mm)

5K-350A 358 435 480 24 12-e25 ±19 2.0 6.0 4 300

5K-400A 409 495 540 24 16-»25 ±19 1.8 5.2 4 300
5K-450A 460 555 605 24 16-e25 ±27 2.9 6.3 4 300
5K-500A 511 605 655 24 20-B25 ±27 2.6 5.7 4 300

MARK FLANGE IS JIS F7805 (GAS PIPE TYPE)

SLEEVE SUS 3 0 4

SETTING BOLT SS 4 0 0

GUIDE PLATE SS 400

BELLOWS SUS 3 0 4 SEE TABLE

m
END PIPE SS 4 0 0

FLANGE SS 4 0 0 SEE TABLE

ME01PGAY
O

EXPANSION JOINT % >

>

<^^1CANGRIH INDUSTRIES CO., LTD. MB-EJ-01

o
-n—r B
 ITEM NO. ALl

T I T L E DATA
SHEET MB-RL-01
NO. :

REMOTE LEVEL INDICATOR CODE 6000739

KANGRIM PAGE 1 OF 1

VERTICAL LEVEL INDICATOR

The I n s t r u m e n t s ore suitable f o r m e a s u r i n g DC c u r r e n t 4 —20mA

SPECIFCATIONS:
Movement : m a g n e t —care PREFAG s y s t e m
moving—coil m o v e m e n t ( 1 4 4 s p ) , with pivot and spring type s t o n e beatings.
I n s t r u m e n t cose : m a d e of steel —plate.
Scale length : 103
P e r m a n e n t overloading : 1.2 —fold c u r r e n t resp v o l t a g e
Class of a c c u r a c y : 1
Mass : a p p r o x . 1.20kg
Fixing elements : two screw —type f a s t e n i n g clips (DIN 4 3 8 3 5 "B")
-INPUT 4-20mA
- I N T . RESIST 2ohms
-Type 144SPDA
-MAKER GANZ

68

V / ®

1
TERMINAL
/
(ill
/~ \ ® 1

170

FRONT SIDE REAR

100 4mA

0 — = 20m»
X
N o n SCALES PANEL CUTTING SIZE
 ITEM NO. AL2

T I T L E DATA
SHEET MB-SP-01
NO. :

STEAM PRESS. INDICATOR CODE SEE TABLE

KANQRIM PAGE 1 OF 1

- ! > -

-3^

5.5

52

Panel cut't size Technical Spec.

1) Flush mounting type

2) Size : 72X72
3) Panel cut : 68X68
4) Input signal
: 4-20mA DC / two wire
5) Accuracy : 1.5 scale

SELECT RANGE (kg/cm» ) REMARK

0~10 3000901
0-16 3001299
F^
0-25 3003587
 ITEM NO. L3

DATA
T I T L E MB-PC-02
SHEET
NO. :
PNEUMATIC CONTROL VALVE CODE
KANGRIM WITH I / P POSITIONER PAGE : 2 OF 4

Model : No, DJD117 (JIS 16K RF-FLANGE)

(DIAPHRAGM SINGLE-ACTION)

P-PDSITIDN SELECT
30

f
rLDW-*[>)<]

f 3
B -SI o
f 3
KK
-rLOv
o
f
D -Kl
[><1 —^Low
o
MODULTING - I N PUT: 4-20nA
DIMENSIONS Air Supply : 2 . 5 - 4 k g f / c n Unit:mm
Weight
slz^-\ d C D L H A
(kg)
15A 2C 70 95 160 600 260 25
20A 23 75 100 160 650 260 26
25A 25 90 125 160 600 260 28
32A 32 100 135 190 680 290 31
40A 40 105 140 190 700 290 34
• 50A 50 120 155 205 720 290 37
65A 65 140 175 220 750 350 41
80A 80 150 200 255 800 350 47
15 Bonnet SS41 1 30 Hanc i Wheel FCD45 1
14 G l a n d Be) l t S T s : 304 2 2 9 Locl- £ N u t STS304 1
13 C l a n d SS41 28 S t e r 1-1 STS304 1
12 Sten-2 S T s : 304 27 F.R Jnit 1 ISW - 2 0 0 0
11 Indecate SS41 26 Posi t i o n e r C I / P 1 SMC - 8 0 0 0
10 Bracket S T s : 304 2 5 Air Tube 2
9 Bonnet Bolt SS41 4 24 Dia b a c k i n g NBR+NYLDN 1
8 Spring S T s : 304 23 S p r i ig.C. SS41 1
7 Gland .P PTFE 22 Main S p r i n g SWP
6 Gasket PTFE 21 Bolt BLDN2E 1
5 D.U Bush SPCE3 20 D-Ri 1 9 NBR 2
4 Bonnet SS41 19 Dia Bot-ton.C SS41 1
3 SeatCPor - t ) 304» Ste" 18 Dia- Bolt SS41 16
2 Seat 3 0 4 * Ste" 17 Dia- " o v e r SS41 1
1 V a l v e B ady SCPH 5/SCS13 16 Dia- Cover SS41 1
ND DESCRI =>TIDN MAT ' L O'T Y REMARK' S ND DE;iCRIPTIDN MAT'L OU^ NTITY REM/! RK'S
 P L A N H I S T O R Y
REV. DATE D E S C R I P T I O N OWN CHK APP'D
COOLING W. INLET
SAMPLING W. INLET /^
A

(PT 3 / 8 " )

riANGE S20C JIS 5 K - I 0 0 A

COIL TUBE SUS 2 0 4 • 12 « [Link]

BODY STPG 3 7 0 ( 1 1 4 . 3 « 4.91

MATHMAL QTY SIZE REMARK

PROJECT TYPE CUSTOMER CLASS/RUlE

TITLE DATE

DIM. SCAU PROJECnON

SAMPLING COOLER mm N/S

(PT 1/2" WITH PLUG) W / 0 NO.

owe. NO. REV.

< ^ ^ I C A N 6 R I M INDUSTRIES CX)., LTD. MB-SC-OI

A
 ITEM NO. AL5
DATA
T I T L E SHEET MB-DU-02
NO. :

Dosing Unit CODE 3001764

KANGRIM PAGE 1 OF 1

1/2"B0S$ VENDOR SCOPE

235 165

HOSE
CHEMICAL TANK 6x4 PVC
CAPACITY : 60 L o
SIZE : »400x560(h)x1t 3
MAT'L ; PE

FOOT

i VALVE
6x4 PP

TANK U^Y-OUT DWG.

400

TYPE : BT4a 1601 PRE GOOAAOGG

METERING PUMP DEMENSION DWG
CAPACITY : 1.1 L/HR
BACK PRESSURE ; MAX. 16 BAR
POWER : 220V, 10, 60Hz, 17W
Operating Instructions Manual
Solenoid Dosing Pump
BT4a and BT5a

PIMW read the Op*rat<ng Inslnictlona manual through complataly bafora commlaaioning thia aquipment
Do not dlacard! Any part which haa bam aubjaet to mlauaa la axcludad from tha warranty!
BA BE 002 10/98 GB • Part No. 987871
Illustrtted views of beta

D -
a a
.

w 1

wmW •'-' t ^ i i ^

^f
^^^^K
11 llJ^H
^ ^ ^ ^ ^ L «
l@s g^^J^^iXiSB
SE^

^^^9SI
'M^H^^unB
Sl3^^£ccE?u^

a ^ P w j i P pl^^^
ia^^^M^M ^Kfc
IIII^H^^fi^3^ «|HV|,J,^UJ.'-,!i W^i.
^P

s^ i ^ % .
liFi
SK T B U S T " TT^

ftfu.r ^'* Hi
^rs
' 1

Fig. 01

Page1
 i<gw A
Major Components

Malor Components

1 Control unit
1a Stroke length adjustment knob
1 b Red LED display, fault Indtealor
1c Yelkw LED display, warning Indkiator >
Id Green LED display, operating status
1e MultifunctkMi switch
If Mains connector
1g External operating temiinal
1h Float switch connector
2 Poiwrend
2a Relay insertton point
2b Optional relay
3 Liquid end
3.1 LIqukJ end without bleed valye, withAvlthout valve spring
3.2 Liquid end without bleed valve, with/without valve spring
3.3 Liquid end with bleed valve, with/without valve spring (PP-version)
3.4 Liqukl end with bleed valve, with/Without valve spring (NP-verslon)
3-5 Self-degassing liquid end
: 3a UquM end back plate
jdb Lkfuklend
: 3c Suctton connection
3d Discharge connectkm
3e Bleed valve connection (self degassing liquid ends)
3f Bleeding/fine biQiadlngvalve
3g Bypass tublngnozzle

General User Inforniation:

This opererting instnjctions manual contains the product descijptions in the main text.
• main points
> Instructions
and safety Irdpnnatlon are indicated by pictograms:

A Dangerl
Ignoring safety Information can endanger life or reatStin serious injuryl
CautlonI
A Ignoring safety Information can result in Injury to persons or damage to machinery or other
materialsl
WamlngI
Ignoring safety information can result in damage to machinery or other materialsl
/\ Noticel
Special Guidelines.
Important!
® Woridng guidelines.

Page 2
 Table of Contents

GENERAL USER INFORMATION

2.1 Safety Guidelines

2.2 Directives and Standards
2.3 Testing and Permits
2A EC Declaration of Confonnity

4.1 Identity Code 8

4.2 Sizes and Weights 9
4.3 Capacity Data 15
4.4 Reproducibility 17
4.5 Viscosity 17
4.6 Materials Information 17
4.7 Electrical Data 17
4.8 Environmental Conditions 18
m^im^^^^^^M^B

6.1 AssemtHing Metering Pump 19

6.2 Connecting Tubing 20
6.3 Electrical Installation 22
^^M£
afcS^^^Ssraffi
7.1 Operating Elements 23
7.2 beta Relay Retrofit Kit 25
7.3 Commissioning 26
7.4 Feed Rate Settings Graphs 27

Record Data 43
Guarantee Form 44
Safety Declaration 46

Page 3
 Application

The pumps in the ProMinent*beta series am microprocessor controlled solenoid rnelMnftiHlilli;

Liquid media They offer highly accurate reprodudlHe metering in the dosing of liquid chemicals in preMuitilid
pipe systems and into open and dosed containers.
CompatMlty Specified components/accessories in the t>ata pump series are compatlbie with those In the
CONCEPT, gamma-CtassIc and gamma series ag follows:
Signal cable: gamma/Vailo tvyo core, and fouricore for 'extemaT function
Two stage float switch (gamrfia/Varlo)
gamma dischaigs line
Standard gamma connector set
gamma wan mounting k>racl<et
Feed container and fixing plates
Total height (distance between suction luiddlscha^e line connectors)
Distance between the connectors and mounting ho^s on the pump
Identical accessories used, e.g. t>ack pressiiris valves, multifunction valves, flow monitors and
flushing apparatus.

A WamlngI
• The pump Is not designedforu^e vrilhidtait^JSii^l^lib or suspended solids.
• Take care when using agf^essl^'&iluimitS^pi^-ttHf^mWriai^u^ In the pump are resistant
to those chemicaJs.
• The pump Is not designedforuse m0>ifibi^ifMiaif^^
• The punf}p may only t)e used for aiX^^siMBMlf^^SiQW^il^^
spedncaHons descrttied In the operating in^raetipris manual.''

Safety

2.1 Safety Guidelines

A Dangerl
• In emergencies the pump should lie switched off immedieftelyl Disconnect the power catle
from Ow power sufi^.
• Do not dispatch pumps which are designedforuse with radioactive chemlcalsl
• When using pumps with flammat>le chemicals, observe (/7S relevant regulations concerning the
transport and storage of flammal)ie fluids (Ex, Vo, Vt> F)l
• When Installing outside Germany, always obisen/e relevant national regulations!
• CoirMning PnMttnehfmeteirihg pomps ynith parts not approved and tested by Proh4lnent is
not permissible. It can cause injury or damage to persons or materials for which we cannot
accept liatJliltyI

A CautionI
• Pumps must be accessible at all times for both (grating and sen/icing. Access must not be
obstructed In any way!
• The pumps and peripherals must be serviced and repaired by qualified and authorised
persons only!
• Always de-pressurise the liquid end prior to working on a pumpi
• Empty and rinse the liquki end before working on a pump which has been used with
hazardous or unknown chemlcalsl
• Always read chemk^l safety data!
• Always wear protective clothing when handling hazardous or unknown chemtoalsl

Page 4
 Sataty

2.2 Directives and Standards

EU Directives The pump range conforms to the following EU QuideHnes:

EU Machine duectives 89/392/EWG, 91/368yEWG, 93/44/EWG
EU Low Voltage directives (73/23/EWG)
EU EMV directives (8a/336/EWG) 1. d. F. 92/31/EWG
Harmonised EN Standards EN 291-1,-2 Safety of MacMnes
PREN 809 Pumps and pump systems for use with Hqulds
EN 60335-1 A6 Safety of Electrical Apparatus for Domestic Use (only for 115 V AC, 230 V AC)
EN 60335-2-41 Safety of Electrical Apparatus, special pumps
EN 50061-1,-2 pi8turt)ance Signal Emissions (domestic-industrial)
EN 50082-1,-2 DisturtMince Resistance (domestic-industrial)
EN 61000-3-2 EMV Umit Values for High Voltage Cunents
EN 61000-3-3 EMV Limit Values for Voltage Ructuation and FKckot
EN 60950 The safety of information technology equipment including electrical (rffice
equipment
(universal version 90-253 V AC)
EN 550014 Radio Interference of electrical products
DIN VDE 0700 T 500
Related National and identical to above EU standards:
International Nonns
• lEC 1000-3-2 EMV Limit Values for High Voltage Cun^ents
• lEC 1000-3-3 EMV Limit Values for Voltage Ructuation and Flicker
Include for paclcaging, delivery and transport:
• DIN EN lEC 60068 'Environmental Testing'
• DIN EN 22248 'Drop Testing*
• 'Notes for the testing of packaging for postal deliveiy
For manufacture and delivery in the USA and Canada include:
• CSA Standard C 22.2 No. 0-M91 'General Requirements*
• CSA Standard C 22.2 No. 108-M89 'Uquid Pumps*
• UL 778 "Operated Water Pumps*
• UL 950, lEC 950, CSA 1950. Corresponds to EN 60950

2.3 Testing and Permits

Certification and The system canles thie following authorisation:

authorisation of system CSA, UL, TUV-GS
System meets all requirements of CE symbol.
Certification and authorise- The components used In the system carry the same authortsatkin as the whole system
tlon of Integral components described above.

Pages
satety
•fwwai^anxi

2.4 EC Declaration of (k>nformity

EC Declaration of Conformity

V\fe

hereby declare that, on the tjasis of its functional concept and desfgn and In the version brought into
circulation by us, the product specified in the following complies witii the relevant, fundamental safety
and helth stipulations laid down by EC regulations.
Any nfKxJification to the product not approved by us will invalidate this declaration.

Produkt description: Metering pump, Series Beta/ja

Product type: BT4a...... 075a..

Serial number see type Identification plateoverieaf and on device

Relevant EC declarations: EC - machine regulation {89/392/EEC)

subsequently 93I44IEEC
EG - low voltage regulation (73/23/EEC)
EG ' EMV - regulation 89/33S/EEC
suttsequently 92/31/EEC

Angewandte harmonisierte Normen EN 292-1, EN 292-2, EN 809

insbesondere: EN 60335-f A6, EN 60335^-41
ENSOOei-1/2, ENS00B2-1I2, ENSS014

National standards and other DIN VDE 0700 T1

technical specifications used, DIN VDE 0700 T41
in particular DIN VDE 0700 T500
CSA Standard C 22.2 No. 0-M91 (115V + Universal)
CSA Standard C22.2No.108-M89(115V+ Universal)

07.04.1998
{{Ay^—
Date/manufacturer's signature:

The undersigned: Dr.-lng. Rainer Dulger, Managing Director

Page 6
 Design and Function

3 Design and Function

Main components Operating panel

Power end
Uquidend
Operating Prindple Chemical feed occurs as a result of pulsed deflexions of the dosing diaphragm within the liquid
end, which causes pressure differentiation twtween the suction side, the liquid end cavity and the
disc^iarge side. The pressure differentiation causes the suction and discharge self-acting valves
to open and close, resulting in chemical feed.
The dosing diaphragm is driven by an electromagnet, which is stimulated and controiled kty a
microprocessor.
Pump Capacity The feed rate is detemiined by the strolte length and stroldng rate.
TTie strol<e length Is adjustable between 0 % and 100 % using the stroke length adjustment knob.
However reproducibiiity is only technically practicable in the adjustment range of between 30 %
and 100%.
Stroking rate is adjustable in 10 % steps between 0 % and 100 % using the multifunction switch.
This ^ e s a higher rate of reprodudbie metering accuracy.
Operating Modes Operating nnxles are selected using the multifunction switch.
Three L£D displays Indicate operating and fault status.
Intsmal operating mode: "Manual":
Stroking rate is manually adjustable in 10 % steps via the multifunction switch.
"External" opera ting mode:
Alk)ws adjustrrtent of Individuai strokes via the external operating mode temiinal by means of
contact or semi-conductor devices.
"Auxiliary Frequency" operating mode:
Enat>les activation of optionally selectable and programmable stroking rate, controlled via the
external operating mode terminal. This stroking rate ovenldes 'Manual" and 'ExteniaT operating -
modes.
In the standard version the "Auxiliary Frequency* function is programmed to 100 % stroking rate.
"Pause" function:
The external operating terminal can be used to operate a remote pump stop function.
"Stop" function:
This function allows the pump to be deactivated without disconnecting from the power supply.
"Test" function:
This function checks ttie priming function of the pump. The switch setting "Tesr on the
multifunctton switch is self-locking.
Self-degassing Self-degassing metering pumps are used in closed discharge lines to create suction and to direct
trapped air to bypass lines, and/or remove gas emitted by gaseous chemicals during operation,
independentiy of existing back pressure.
installing a back pressure valve ensures precise chemical feed can be achieved, even when
operating under atmospheric pressure.
Options The float switch connector can be used to connect a two stage float switch.
There is also optionally available a relay terminal for an alarm indicating relay, and a switch output
which is synchronised to each stroke.

Page?
 •MMa^iliirttaBii^

Technical Dsbi.

4 Technical Data

4,1 Identity Code

The device label attached to the title page is Identicai to that on the pump to facilitate matching the correct operating InBtru^ions
to the pump. , • . ., •
Please enter the Identity code on the device label into the grey tx>x below.

BT4A 1000, 1601. 1602,1005, 0708, 0413, 0220 D Custom version

BT5A 1605, 1008, 0713, 0420, 0232

PP Polypropylene Q Custom version

PC PVC
NP Plexiglas/PVC
TT PTFE with carbon
SS stainless steel

standard with EPDM seals • Custom version

standard with FPM (Viton) seals
standard with PTFEflatseals

no bleed valve, no vaJve spiinj;^.., n Custom VBCsHxi

no bleed valVe, with valve eprlrigs
with bleed valve, no valve sprtngfrter*Rfrt<l^aQd NRfdn^-.;^
with bleed valve, with v a t y e ^ n f t f t M , ) ^ jE?0 AiHljNyPonly;
self-degassing for PP and Nr

200-230 V, ±10% • Custom version

100-115 V, ±10%
100-230 V, ±10%

'm^mMi;Bm^^mmm:^^^i
2 m European D Custom version
2 m Swiss
2 m Australian
2 m USA

no relay
fault indicating relay (N/C)
fault indicating relay (N/0)
as 1 + pacing relay
as 3 + pacing relay
n Custom version

no accessories
with foot and delivery valve, 2 m PVC tubing,
5 m RE tubing
n Custom version

no options
no options
no options
n
n
0 I no options n D.

Kj...,KU^,r-^->^''.
BT4A ij^^'Miii^^^[Link]-fcifi" >>;-'
Rg.02

Pages
 Tvchnlcal Data

4.2 Sizes and Weights

Materials option: PP

if *^
~ 3 ""
<
^
5 •'
I
en

Tni
I I II LJJ

8Cl/BC
, 92-'102

Jtmenstons beta/ 4 / beta/ 5

Page 9
 Technical Data

4.3 Capacity Data

beta/4 PA 180 Strokes/minute and 100% stroke length

^^BU^SB^^^^S^^W^^^
W^^^KSm^^^^M
^^Sl
mmm^ mmm^ M-j'^H^^a
^i^Wi b0.m^!^
1000 10 0.7 0.064 5 0.7 0.07 6x4 6 1.8 8 2.9/3.6
0700 7 0.9 0.083 3.5 0.9 0.083 6x4 6 1.8 e 2.9/3.6
0400 4 0.9 0.084 2 1.1 0.10 6x4 6 1.8 8 2.9/3.6
1601 16 1.1 0.1 6 1.4 0.14 6x4 6 2.0 8 2.9 / 3.6
1001 10 1.3 0.12 5 1.5 0.14 6x4 6 2.0 8 2.9 / 3.6
0701 7 1.4 0.13 3.5 1.5 0.14 6x4 6 2.0 6 2.9/3.6
0401 4 1.5 0.14 2 2.0 0.18 6x4 6 2.0 8 2.9/3.6
1602 16 2.2 0.2 8 2.7 0.25 6x4 6 2.5 5.5 2.9 / 3.6
1002 10 2.5 0.23 5 2.8 0.26 6x4 6 2.5 5.5 2.9 / 3.6
0702 7 2.6 0.24 3.5 3.1 0.29 6x4 6 2.5 5.5 2.9 / 3.6
0402 4 3.0 0.28 2 3,9 0.36 6x4 6 2.5 5.5 2.9 / 3.6
1005 10 5.0 0.46 5 5.5 0.51 8x5 5 3.0 3 3.1/4.5
0705 7 5.8 0.54 3.5 7.0 0.65 8x5 5 3.0 3 3.1 / 4.5
0405 4 6.7 0.62 2 8.5 0.79 8x5 5 3.0 3 3.1/4.5
0708 7 7.7 0.71 3.5 9.9 0.92 8x5 4 2.0 2 3.1/4.5
0408 4 11.0 1.0 2 14.0 1.30 8x5 4 2.0 2 3.1/4.5
0413 4 13.0 1.2 2 16.4 1.52 8x5 3 2.5 1.5 3,1/4.5
0220 2 20.4 1,89 1 22.0 2.04 12x9 2 2.0 1 3.1/4.5

twta/ 4**' - self-degassing types i^t 180 strokes/minute and 100% stroke length
•> Max. Pump cftbft^slp;'^^' \^fMa«?ptifS^'ca^ deity j p f f i i a ^ viEW^h - "••mt^^K
\i- y^C:'- •
p:l^\jrnp atmaxirriLffti -,; , •• at medium ,"• size-?--'- ••.lift''' • • - • - I t f t " "••"?
^ - - . '• • . ••
^Hi
ttype ij^ck pn^m •i^:,k • ,,'i^t backpfessure-'••••.'.^-^ ^ ^ f f ^ ' " '••- ' " - " - " ' • • • • • • - • " : . "r^^i^ST:.;::^
••iji
NP
, 3 - • • " . ' • •

^^t:i>;^
" '>^P^ Ite-..;.itVi';! ?^KPK S'.- •

'^S-*i*^&iiM '^fm^^^.i^llt'ltreifii ^^^^*^ tliM^I^ W t ^ ^ J^l^l?^^ w^m^^W^^- .l???W|S'Sfi i^P(8^:kg

1601 16 0.59 0.06 8 0.79 0.07 6x4 - 1.8 0.5 2.9
1001 10 0.59 0,06 5 0.79 0.07 6x4 - 1.8 0.5 2.9
0701 7 0,59 0.06 3.5 0.79 0.07 6x4 - 1.8 0.5 2.9
0401 4 0.59 0.06 2 0.79 0.07 6x4 - 1.8 0.5 2.9
1602 16 1.35 0.13 e 1,8 0.17 6x4 _ 2.1 0.5 2.9
1002 10 1.35 0.13 5 1.8 0.17 6x4 - 2.1 0.5 2.9
0702 7 1.35 0.13 3,5 1.8 0,17 6x4 - 2,1 0.5 2,9
0402 4 1.35 0.13 2 1.8 0,17 6x4 - 2.1 0.5 2.9
1005 10 4.4 0,40 5 4.2 0.43 8x5 - 2.7 0.5 3.1
0705 7 4,4 0.40 3.5 4.2 0.43 8x5 - 2.7 0.5 3.1
0405 4 4,4 0.40 2 4.2 0.43 8x5 - 2.7 0,5 3.1
0708 7 6.9 0.64 3,5 8.3 0.77 8x5 - 2.0 0.5 3.1
0408 4 6.9 0.64 2 8,3 0,77 8x5 - 2,0 0.5 3,1
0413 4 10.8 1,00 2 13.4 1.24 8x5 - 2,5 0.5 3.1
0220 2 16,0 1.48 1 17,4 1.61 12x9 - 2.0 0.5 3.1

* Suction lift when suction line and liquid end are full
** Priming lift when valves are clean and have been wetted
•"The feed rates are minimum feed rates and relat to water

Page 15
 Itehnlcal Data

4.4. Reproducibility

Reprodudbla
metering accuracy - 5 % to +10 % at max. stroke length and max. back pres&ure for versions in all materlais.
Reproducibility ±2 % under constant conditions and at minimum 30 % stroke length.
As the setf-t}leeding pump is used with outgassing media and in application with gas-t}ubbles, the
metering accuracy and reproducibility cannot be Indicated.
The recommended min. stroke length for selfbteeding dosimh pumps is 50 %.

4.5 Viscosity
The metering pumps are Intended for use with liquids with a viscosity of up to:
• max. 200 mPas for standard liquid end
• max. 500 mPas for spring valves
• max. 50 mPas for self-degassing metering pumps.

4.6 Materials information

M
TiUg ^Hi
Polypropylene Polypropylen EPDM ceramic
Polypropylene Polypropylen FPM (Viton) ceramic
Hjj^^^if^aM
^^ PVC PVC EPDM ceramic
PVC PVC FPM (Viton) ceramic
^^^B
Plexiglas PVC EPDM ceramic
Plexiglas PVC FPM (Vilon) ceramic
i'^M^^^^^Sj
rwa ^^^^^^
^KSiWilS^S^i^ PTFE with carbon PTFE with carbon PTFE ceramic
^EaajwWiijwg
sg ^^^^&il
^ ^^^H stainless steel No. 1.4571 stainiess steel No. 1.4571 PTFE ceramic
Fig. 05

4.7 Eiectrlcal Data

• Version: 200-230 V ±10%, 50/60 Hz

mw^

Page 17
Taobnloal GMa

Version: 100-115 V ±10 %. 50/60fHt'

• " ' 1 7 W ^ ••• •"' •22W

[Link] 2.0 A
.', - - I S A - • • - • : • 15A
"^ i):8AT 0.8 AT

Version: 100-230 V ± 10 %, 50/60 Hz

17W 22W
2.0 A 2.0 A
15A 15A
0.8 AT 0.8 AT

Note Only use fuses carrying VDE, UL and CSA authorisallon, e.g; type 19195 from Fa. Wickmann
as given in lEC publication 127 - 2/3.

4;8 Envtronmental Conditions

Temperatures StotBge and transport temperature: -1 O^C ... +50°C

Ambient temperature wtien in operation: -^p.°C ... +45''C
Permissible feed chemical temperature: -10°C ... +35°C
Temperature resistance of different liquid end material types

Rg. 07
Climate Permissible relative humidity; 92 % non-Gondenetng
Corresponding to humidity
and fluctuations in climate: FW 24 according to DIN 50016
Enclosure rating Contact and humidity enclosure; IP 65 according to (EC 529, EN 60529, DIN VDE 0470 part 1
Noise level Noise level: < 70 dB(A) w/lthln 1 m distance according to EN 23741
or EN 23742
Electrical safety requirements Safety class 1 - mains connector with earth lead

Page 18
 R«movtl?offlM)fcioiii#

Removal of HackagMig

Removal (^pada^ng > BeWahren Sie die Umveipackung auf, urn die Dosierpumpe bei RlBparatur- und Garantlefailen
. wfaiJfM'zurOdoef^^
> Refedh'the packa^riigi. It can be used to return the pump In csase of repair ortor guarantee
purposes.
: • Compare dellve<^'note wHticoments of p a c k t ^ ^
> CiMwk th«rt the c(etslla glvi9a on the metef1r)[Link])p <fevice lat)el correspond with your ordering
"•'.,.(tefaibr. :•• '"^ •
>• Shofild you ejq^jwleiice any probl^n^iix^^ branch or suppllerl
i^ Give the Ideht^ OodejarVd serial Hurii^rl'vi^idhyQav^l!^^ on the device label, In the event of
goods returns' or when orderir^ replac^[Link]|BVl1ii8 yi^ ensure correct Identification of the
puinp type and ijcajbsrialyersioh^^^^^
Included In Delhwy • Metering pump with malne cable
• OpersMng instructions manual with conformity declaration, with accessories if applicable

A 6 Assiiriibly «mlJnsUillat(on^

Danger!
• The metering pun^Jn We beUi feiies must be i ^
InstnKtlons sfiwm in the opkiaWig InsHiictlons m^ni^^
• His notpamiltted tp assemt>[Link] with non-proMlnentcomponents, unless
tested arKlapptxiiiid by PmMlhenil\,
• When using beta pumps with dangerous or imiaiown liquids, It Is Imperativefftatall relevant
accident prevention regulaOons are observedl
• Before working on the metering punv>, always de-pressurlse Vie dlsc^rge line, empty the
liquid end and rinee doti
• Never allow the metering pump to operate when the stop valve on the discharge line la dosed,
as this can result in the rupture of the discharge Ural
• Wiren using ctwmlcals wtiich afiould not come Into contact with water, ensure liquid end Is
absolutely dryl
• DIscormect from mains power prior to screwlrig down the cap (e.g. when changing the fuse)l
• Obsen/e all national regulations when installing qu^ide Gerrnanyl

6.1 Assembling Dosing Pump

® ImportantI
Make sure that the pump is fastened into place firmly, and will not vibrate when In usei
• Ensure V\at the pump Is accessible at all times for operating and meJntenance purposesi
• Suctton and discharge valves (bleed valves for self-degassing llquki ends) must be In a vertkial
pmiltton.
Mounting metering pump >/ The metering pump must be mounted with the pump foot resting on a firm horizontal base.

Page 19
AsMmUy^widifistaHrtlon

6.2 Connecting TUbIng

(D Importanti
•
- ,. ' .
When instalBng suction discharge and by^^ss SH&s, ensure they are free from all me<^nical
stress/
• Arrange ffie lines so that ft Is posslble.^tf rjecessary. topull Vie liquid end andtf?epump apart
sideways!
• When using extremely aggresslveof dangerous chemicals, a bleed valve and return line in the
chemical feed container and a stop valve on the discharge and suction sides is recommended.
•To ensure long term effacnvehess Of cemnefctions, use only those clamping rings and tubing
nozzles with the correct dl^m4ter't6r mSTOblngi
• Use original tubing oniy TO guaranwe. asfract diameter and wall s^ngthl
' Do not exceed maximum pehnlSSSH^^'Mdfttl^lon pressurel
• Ensure that the max. pennia9ibt9:0p9mting pressure for the metering pump and the tubing Is
maintalnedl

Fitting tubing onto > Ensure tubing length ends are cut straight across.
plastic valves > Insert tubing through uniori nul and clamping ring.
(PP. PC. NP. TT >• Push tubing ends up to the J^lof) on-tfie tube nozzle.
materials options) Widen tf necessary.
>- Place tubing and nozzle onto vatve.
>• Clamp tubing:
Tighten union nut, pushing tubing dowr\ at the same time.
>• Rnaldamp: / .
Pull briefly on the tubing'attacKed to the liquid end and then
retighten the union nut.

1 Tubing Fig. OS
Union nul
Clamping ring
Nozzle
0-ring
6 VaWe
Assembling stainless steel >- Push pipe through union hut and
pipe connectors clamping ring approx. 10 mm.
(SS option) > Push pipe into the valve as far as the stop.
>- Tighten the union nut.

Mounting PE or PTFE tubing > Insert additional stainless steel support insert into the tubing.
onto stainless steel valve

Pipe R(J.09
Union nut
Rrst ctamp(ng ring
Second clamping ring
Valve

Page 20
 Assembly and Installation

Installation of suction line

® The auction Hne should be as short as possR)le.

• The sucdonUieshoukilie laid on an asoencKt^ Incline, to avoid air bubbles coHeOlngl
• Do not use 90'joints to negotiate bends In p^>ework. Swept bend Joints are pennlsslble.
• Calculate cross secd(»i and ler^ to ensure that the negative pressure In ^ suction line
does n(A reach the vapour pressure for the feed chemlcall
• To much negMve pressure on the suction side Is demonstrated In extreme cases as a break in
tfie fluid column, or by Incon^ete return strokesi
• Do not exceed the maxmtum permissible pressure on the suokm skie.
• Please note that the suction Hft x chemteal density ^ max. suction lift In mWC
Mounting foot valve > The free end of the suction Une should lie cut to length so that the foot valve ends just atxive
the t>ase of the chemical tank, or slightly higher, for chemicals containing contaminants or
sediment.
installing Discharge Une

A WamingI
• Discharge line dimensions must tie cakxjiated so that the peak pressure does not exceed the
maxtnuttn pem^ssible operating pressure during the return stroke.
To protect the discharge line against excess pressure, it Is advisable to instaJI a overtiow valve,
e.g. ProMinent multifunction valve with return line In the chemksal feed tank.
• Check lengtit and cross sectioni
installing Self-Degassing Metering Pump

A Wamlngi
• Obsenv all Installation and safety guidelines as for standard pumpi
• Do not exceed values given for pipe aoss sections, priming lifts, admisskm pressure and
viscosity of cfiemtealsl
A return line should be attached to the upper side of the liquid end in addition to the suction and
discharge line.
The discharge line connector is on the front side of the liquid end.
Installation of Bypass Bleed Line
In the event of positive pressure on the suction side, at least the same pressure should exist in
the t>ypas8 line. It is possible to operate with positive pressure In the bypass line and at
atmospheric pressure in the suction line.
> Push tubing onto bypass nozzle. In case of seK degassing liquid ends connect bypass tybing
at the bleed valve connection (3e). We recommend 6 x 4 flexible PVC.
> if using PE tubing, secure with a rapid cable adhesive to prevent slippage.
>• Feed the free end of the tubing into the chemical feed container.
> Cut the bypass line short enough to prevent its being immersed in the feed chemical.

Bleed connector for return feed to

chemical tanl<, 6/4 mm

Pressure connector to injector

6/4 -12/9 mm

Suction connector, 6/4-12/9 mm

Page 21
AtMitiMy Hid Inttatlttlon

6.3 Electrical Installation

^ Dangttrl
• Observe the relevant natlonat regulations when installing the pump outside Germanyl
• Do not connect power supply to external tenninalsl
• Make sure that the power supply conesponds to the details on the de\^ce tabell
When connecting In parallel wiffi inductive consumers a ^parate switch contact, e.g. relay or
earth should be attedl
Mains connee^on The pump is connected via the fixed mains cable to the correct power supply.
ON/Off ^Witching The pump should only be able to be disconnected from the power by
• renrovlng the plug from the socltet
• via the "stop" setting on the multifunction switch
• remote stop via an external cable (see 7.1)
Connecting in parallel If the pump is connected to ttie power In parallel with inductive consumers, e.g. {solenoid valve,
motor), they must be electrically Isolated from these items to prevent damage from induction
voltages when switching off.
> Fit separate contacts, power supply via contacter relay or relay
If this is not possible, then:
>• Parallel connection via varistor (order number 710912) or an RC circuit
(0.22 ^F/220 a order number 710802).
Power Unit
(in pump base)

Fig. 10
1 Fuse
2 Optional retay connector
3 Mains connector
4 Solenoid earth lead
5 Sotenoid connector

Option fault indicating relay Contact VDE-cable CSA-cable

NO white white
NO green red
C brown biaclt
Option fault indicating NO (fault indicating relay) yellow
and pacing relay C (fault indicating relay) brown
NO (pacing relay) white
C (pacing relay) green

Page 22
 Operation and Settings

Operation and Settings

/ 7.1 Operating Components and Functions

Stmk0 length adjustment knob The stroke length is. continuously adjustable between 0 % and 100 % via the stroke length
adjustment knot}. Reproducibility is only technlc^ly practicable in the adjustment range of
between 30 % and 100 % however.
Multifunction switch The multifunction switch {1 e) is used to select \he operating mode and to set the stroking rate.
The following operating modes are selected using the multifunction switch:
• Stop
• External ,.
• Manual (to set stroking rate in10 % steps)
• Test (priming suction function)
External operating terminal The "tennlnal for external operating" is a five channel connector. It is compatible with two and four
channel signal cables used previously. The "auxiliary frequency' function can be used only with
the Ave channel cable, however.
Pump configuratkMi
Electrical Interface:
^m f^'rmWM. • Open (Contact voltage:approx. +5 V
^^w
fM^^ ^/wP' • Input resistance;
• ContnjI:
10 k£}
volt free contact {0.5 mA at+5 V).
or: sem1 conductor switch (residual voltage < 0.7 V)
^fp(5iEjj^^-C • minimum contact duration: S20ms
=^^H
[Link]

Plug configuration
Function 2channel cable 4channel cable Schannel cabte
pin 1 pause bridge to pin 4 brown brown
pin 2 external brown white while
pin 3 not configured - blue blue
pin 4 reference potential white black black
(earth)
pin 5 auxiliary frequency - — grey
Fig. 12

"Pause" Function
The pump runs when
• There is no cable connected (e.g. pin 1 free)
" The cable is connected and the contact is earthed (pins 1 and 4 connected).
The pump does not run when
• The cable is connected and the contact is open (pins 1 and 4 not connected).
"External" Operating Mods
A dosing stroke Is triggered when a contact is made for a minimum of 20 ms with pin 2 (external)
and pin 4 (earth), and the "pause" input Is at pin 4 (earth).
Operating Characteristic Variations: Changing from "Extsmal" to "Manual"
The operation of the beta pump when changing from "extemal" to "manual" options
(when extemal cable is connected) takes three forms:
Identity code: "safety lock".
• 0: no lock
"External" and "manual" operating modes can be activated at any time. All pump functions
correspond to the texts on the multifunction switch and the pre set operating mode. The pump
operates in "manual" mode even when extemal cabte Is connected. This is the standard
version.
• 1: with lock
The "external" operating mode Is only available when external cable is connected.
The "manual" function Is only available when the cable is removed,

Page 23
operation and 8«mno«

Altering External Frequwicy Function (AuxlHaiy Fraquency)

This function switches the pump over to a pre-programmed frequency, as long as the con-ect input
Is connected to pin 4 (reference potential) and the pump is not In "pause" or 'stop" modes.
The 'auxiliary frequency" function ovenidee a rn&nually set operating frequency and also
'external" operating mode.
If the 'auxiliary frequency' function and the 'F»U8e" function are bo^ active Vhe pump stops, in the
standard version this function is prograirimedto 100 % stroking rate.
Connecting float swiU^ It is possible to fH a two stage float switch to activate early warning and limit switch functions.
Pi .
Electrical Interface:
• Open contact voltage: approx. +5 V
• Input resistance: 10 kO
• Control: volt free contact (0.5 mA at+5 V).
on semi conductor switch (resklual voltage < 0.7 V)

Rg.13
Plug configuration
Function 3chanrwl cable
reference potential (earth) black
minimum waming indication blue
minimum fault (switches off) brown

Fig. 14

Function and fault indicatorsA signal is sent to the pump (minimum waming or minimum fault) when the liquid level in the
chemioal feed tank drops below speclfk: levels.
Three LED displays act as the function and fault indicators.
Green LED Indicator, operating display
Tliis LED illuminates briefly when a discharge stroke is activated.
Yellow l-ED indicator, warning Indicator
This LED lights up when the liquid level drops below the first fk>at switch triggering level.
Red LED Indicator, fault Indicator
This LED lights up when liquid levels reach the fault Indicating level (20 mm remaining in chemicai
feed tank)
It also flashes to indicate undefined operating statijs.
Relay
Relay output, fault indicating An optional fault indicating relay is available to order.
It is used to relay processor fault and 'level faulf signals.
The selection of NC/NO relay status is indicated by the identity code. The basic setting is as NC.
The basic version can be retrofitted, and is ready to operate after plugging In relays.
The connector cable Is plugged In.
Electrical interface: Contact load: 250 V/2 A 50/60 Hz
Operating life: > 200.000 switch functions
Fault signal output Two semi conductor switches are available to order as signal output and pacing relay.
and pacing signal output These outputs are electrically Isolated by optical couplers.
The pulse output of the pump drives an open collector transistor Interfaced to the input device.
This option may be retrofitted, the connector cable is plugged In.
Electrical interface: For 8eml<onductor switch For relay output
• Residual voltage: < 0.4 Volt at Ip = 1 mA • Contact load:
• Maximum current: < 100 mA 24 V/100 mA 50/60 Hz
• r^ax. voltage: 24 V DC • Operating life:
• Pacing relay pulse length approx. 100 ms > 200.000 switch functions

Page 24
 Operation WHI SotiiRf^

7.2 beta Relay Retrofit Kit

Part No. 1002526 - Mann relay beta

Part No. 1002528 - Alarm and pacing relay beta

FIrat, please check the scope of delivery:

1 complete relay board with 2 fastening screws
2 additionalfesteningscrews
1 complete relay cable with socket
1 seal
• Before starting the work, disconnect the power supply to the pump andflushthe lk]uki end.
• Place ttM pump on a firm base with the relay aperture tadng upward.
• Fit 0 8 - 1 5 mm punch on drift for relay aperture and knock through with a hammer.
if necessary, clean edge of opening.
• Remove punched-out sectkm from pump.
• Fit relay board through the opening until contact Is made with the control board.
• Screw cover on housing.
• Fit seal in frame arxi screw ori relay cable.
• The pump Is programmed ex factory to'alarm relay drop-out actkMi* and, if fitted,
"pacing relay pick-up actton*. The pump cari be reprogrammed at the Hektoiberg plant
if any other switching functkm Is required.

Page 25
o^mtmi§mb*mm§i

7.3 Commisslontng

ds Dangvrl
• When hanOlngclanganHismedkiWherspmteeeve goggles and clotNngl
• The nqdUmd may sm contain water fnm the kt-house pump test
When handUng nrnSa which must not come Into contact with water, make sure liquid end is
absoMefydryl

® Imporlantl
• AdHustments should always t>ecanied out when punp Is mnnlngi
• The priming Utt when the liquid end Is empty Is prOfklrtlonal to stroke volume:
The pump shoukl admit when the stroke length = 100 %. Ax^iM the priming lift to make the
putnp en:y}ty and t)eglnrerprimlng a a k}wer setting wlttma altering ttw
• The prtniUng capacity Isllmltedwhenoperating under pre^rel
• It is notpossltlle to guarantee absolutely reliable rwferi^ wfwn the pump has l)een klle fw
time. Regular checks are nacessaryl
Prior to Commisstoning > Check pump connections and sealsl
Removal of water When using with chemicals which should not come into contact with water
from the Ikpjid end >• IRotate pump through 180°
> Empty liquid end
>r Flush the ^suction connector with an appropriate flushing agent.
Filling the Ikiuki end For liquid ends without bleed valve:
> Connect the suction line, but not the discharge line at this point, to the liquid end,
>• Switch pump on and mn at max. stroldng rate and length, until the liquid end has completely
filled, and contains no air bubbles,
> Switch off pump,
>• Connect discharge line to liquid end.
The pump is ready to operate.
Filling the Ikfuid end For liquid ends with bleed valve and bypass:
> Connect the suction line and discharge line to the liquid end,
>• Connect bypass line,
>- Open the bleed valve by rotating the stem anticlockwise. This frees the outlet for coarse
extraction bleed via the bypass valve, "
> Switch pump on and run at max. stroking rate and length, until the liquM end has completely
filled, and contains no air bubbles (when the chemk»l becomes vislfclle in the bleed/discharge
line),
> Ctoae the bleed valve,
> Switch off pump.
The pump Is ready to operate.
Important!

® • Part of the feed ftow is constantly fed back intotfiechemlcatfeed container. This quantity
should be approx. 20 % of the feed quantity.
• The Chemkiais shouM be non-viscous and free from suspended soMs.
• If the return line ends betow Vie llquki level, the fine bleed valve operates as a vacuum breaker
and prevents the feed tank from being entirely eniptied, shoukl a vacuum occur In the
discharge line.
• After 24 operating hours, retlghten the screws in the Ikfuid endl
Fining the liquid end For self degassing dosing pumps:
>- Connect the suction line and the discharge line to the liquid end,
>- Connect the bypass line at the bleed valve connection (3e),
>• Switch pump on and mn at max, stroking rate and length, until the liquid end has completely
filled,
> Switch off pump.
The pump Is ready to operate.

Page 26
 Opflvating w ^ l 8«tHn0t

7.4 Feed Rate Settings Graphs

General
• Turn to the correct page of your pump type.
• Firstly determine the correction factor. Read off the back pressure for your current application
and inark on the gre^jh "Correction faciiiff' in relaflon to pressure".
• Trace a line from this value yerttealiy upward to the curve, and then horizontally lefL Readoff
the correctton factor.
• OivfcJe the draired feed rate by the correctkm factor obtained above. Mark this value (I/h) on the
axis "Vni' in the graph "Feed rate in relation to stroke length and stroke rate'.
• Trace a line from this point horizontally to the lefL At the point where this line intersects the
straight line for the adjustable strokefrequencies,trace a line vertk»ily downwards to the
"^stroke length" axis.
• Set the pump to the stroke frequency and stroke length given.
M2ZE:
It Is good practice to draw a line as near to fwrlzontal as possible through the next largest stroke
lengtti with a whole numerical value.
For highly viscous or gaseous liquids select a larger strolce length and a lower stroke rate.
To ensure good mixing, select a kfw stroke length andtowfrequency.
For precise dosing ensure stroke lenght is above 30%.
Achieving preciw doMges:
• Determine the actual feed rate on the suction skJe of the dosing pump using a measuring
glass or by weighing.
• Conect pump settings if necessary.
The measurements for the analysis of the feed rate for the foliowing nonrngraph were canted out
using water. The correctton factor was detemiined at a stroke length of 70%. The distributton of
the feed rate across ail material-types was -5%...+15%.

Page 27
 Optrating antf SMHngi

Capad^ stroke frequency

BT4a 1601 at nwdium back praaaura
ml l * - 100

90
1,2- n— ISOstrodEea/min /

— 162 strollEea/rnin
— 1448tro*Ees/min 60
— 126stro»les/min
_— loestrotns/tnin
— 90 strokeis/min 70
• — 72 stroke»/mln
— 54 stroke>8/rnbi
— 36 stroke>s/tnin 60
0,0 • •
— 18 stroke>s/mln

•
SO

40
- y/
-..

30
U,4 -

•
20

U,^

10
•

0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
stroke length

0 MTecUonfactor
1,4-
\,C '
1 "
0,0 *

0,4 -
[Link] 1

1 2 4 5 3 11 13 16
Back pressur»

Page 29
 8 Maintenance

Maintenance imefvals Every quarter when in normal use (apptox. 30 % of continuous operation)
Shorter intervals under heavier use (e.g. continuous operation)
Maintenance tasks Chedt wear on dosing diaphragm
Chedc liqidd end screws
Cheol( discharge iine connections
Chedf dtecharge and suction vaive connections
Chedc the entire iiquid end for ieaiuge
Chedt feed rale: mn the pump for a short period In prirrring mode
Checi( electrical connections for damage
Self-degasaing pimp Makitain as for standard pump
Chedc liypass connections
Examine discharge and t>ypa8s Hnes for kinits
Chedt bleed valve function

9 Repair

A Dangerl
The MIowIng repair measures must be canied out t>y authorised persmnel on site, or In the
factory:
• Replace damaged mains connection oal>le
• Exchange fuses and electrical controllers
• Refit to dhange capacity, material or contmiler type.
Contsua your PmMinent branch orsuppilerl
Send the pump to te repaired only once it has been deaned, and after the Hqukl end has been
rinsedi
Danger!
Do not dispatch pumps which are designed for use with radioactive chemlcalsl

® ImportantI
AH commercial undertakings are subject to the legal requirements for woridng safety which require
that employees are protected from harmful infects resulting from handling dangerous 8ul)stances.
inspecOon or repair can therefore take place only on production of a safety declaration which has
been correctly and fully filled out by authorisedand qualified pump operating personnel.
If, despite careful emptying and cleaning of the pump, there are still possible safety hazards, the
relevant Infonnatlon must be entered in the safety dedaraUonl
The safety declaration Is part of the inspection/repair contract.
A form Is provided in the appendix of this operating instnjcOons manual.
Exchanging bleed valve > Rernove bypass line
(self degassing liquid ends) > Unscrew bleed valve from liquid end
> Remove seal from liquid end using a small screwdriver
> Insert new seal
>• Screw In new bleed valve up to the stop
>• Refit bypass line
>• Reset metering pump
Exchanging discharge valve > Remove discharge line
> Unscrew discharge valve from the liquid end
> Remove the 0-ring from the liquid end
> Screw In new discharge valve with 0-ring up to the stop
> Refit discharge line

Page 40
 Repair

® Importontl
Especial care must be taken to avoid the pump running with a ruptured dosing diaphragm. Wear Is
heavily dependant upon the operating conditions and regular monitoring should be carried out by
the operator.
Exchanging diaphragm The diaphragm seal is checked y/\a the leak bore hole in the back plate. If moisture is found here,
the diaphragm should be replaced.
> De-preesurise the system
>- Empty the liqukJ end (flush thoroughly after use with hazardous chemicaisi)
> Set stroke length to 0 % when pump is running, then switch off pump
> Unscrew hydraulk: connectors from the discharge and suction side, observing all relevant
safety measures
> Unscrew liquid end (2)
> Replace diaphragm (3)
> The diaphragm should be attached fimily by hand, and the stroke length set to 1 DO %. On
pump type beta/ 4 (capacity type 0220) the diaphragm has fixing holes. The fixing screws are
inserted through the liquid end, through the fixing holes on the diaphragm and through the
t)ack plate so that once the diaphragm is tightened up, the drain plug of the back plate and the
suction connector project vertically downwards. This procedure is carried out while pump is in
operatkHi, and at 100 % discharge stroke. The pump is then stopped.

J-^j

-*v:
1 Screws Fig. 22
2 LIqukI end
3 Diaphragm
4 Head plate
5 Pump housing

Page 41
DroublMhooting

10 Troubleshooting

A Wamlnal
• Wear pm^cthregogglaaanicMhktg when working wHhhazardcHJachemkxIsI
• Please obsen/e the safety Infomtation sheets for dosing medial
• Always de-pressurise the HqiM end prior to working on a pumpi
Pump Is not priming t v M at full •trek*tongth,and opm blasd valve.
Reason Crystalline deposits on the ball seat because valve has dried out
Remedy > Detach suction tubing from chemlcai feed container and rinse liquid end thoroughly.
> if this fails, dismantle valves and dean.
Qreen LED display (operating dtspla^ not lit
Reason Power supply not connected, or inconrect power supply.
Remedy > Connect to correct power supply according to the details on the device label.
Reason Fuse is defective.
Remedy > Contact your ProMinent branch or supplier!
Yellow LED display (warning Indicator) la IH
Reason Liquid level in the feed tank has reached the first float-switch trigger level.
Remedy > Reflll chemicat tanic
Red LED display (fault Indicator) is lit
Fleason Liquid level in the feed tank has reached ttie fault fioat-swttch trigger level (20 mm from empty).
Rerttedy > Refill chemical tanit.
Red LEO display (fault Indicator) Is flashing
Reason Pump operating mode is undefined.
Remedy > Select the required operatir^ mode.
LlquM Is lealdng from bade plate
Reason There is a faulty seal between the liquid end and the diaphragm.
Remedy > Tighten screws in the liquid end.
> If this fails, replace diaphragm..

11 Decommissioning, Dismantling and Disposal

L% Notlcel
• When dismantling a pump, clean thoroughly, paying particular attentton to the liquid end In
order to remove all traces of chemicals and dirt.
* When disposing of a pump It must be broken down Into separate material types. All parts must
be sent for recycling or for correct disposal according to current legal waste disposal
requirements.
Cleaned, chemical-free pumps may be returned to your ProMinenI branch for disposal.

Page 42
 ITEM NO. AL6
DATA
1' I T L E
SHEET MB-SI-02
ri^woRi^^ NO. :

Salinity Indicator
KANGRIM PAGE : 1 OF 4

1. S P E C I F I C A T I O N

SALINITY INDICATOR
INSTRUMENT SHIPYA?D H.M.D
TYPE : JK - 101

USE Boiler teed water SHIP NO.

SECIFICATION

1 SERI/^L NO.

2 MEASURING RANGE 0 - 2 0 0 PPM

3 ACCURACY

1) INDICATION + 2.5% OF SCALE

2 ) ALARM DIFFERENCE + 2 PPM

4 WATE R TEMP. COMPENSATION RANGE 0 °(: - 100 °C

5 CELL OPERATING PRESSURE 10 < g / C m 2

6 ALAR M POINT 10 1='PM FULL SCALE VARIABLE

7 ALAF M & CONTROL SIGNAL

1) SALINITY HIGH SIGNAL 1 NC - NO - C

2) SOLENOID VALVE SIGNAL 0 OPTIONAL

8 ROWER SOURCE AC 220V 60Hz 10

9 POWER CONSUMPTION 3 W

10 MOUNTING WALL

11 GLANID 20Cx3

COMPONENTS

NO. NAI^E OF PART TYPE Q'TY REMAR K

1 Mai n Unit JK-1C 1 1 Wall

2 Sal" nity Cell & cable TPNP- 0.75 1 2.0 m

3 Gat 3 Valve BS 1 10 K g / ( :m^

5 Spare Parts (Fuse) 0.2 A 1

 ITEM NO. AL6
T I T L E DATA
^'^KJinQft^ SHEET MB-SI-02
NO. :

Salinity Indicator
KANQRIM PAGE 2 OF 4

2. INSTALUTION & MAINTENANCE

/
1) INSTALL ON FEED WATER TANK

TANK

• MMM '
L_ __ fPWE^f
BOSS
!
ALARM SIGNAL

2) INSTALL ON PIPE LINE

Coble

////////////////////////////

3) MAINTENANCE
CLEANING OF ELECTRODE(CELL)

TO KEEP THE INDICATOR OPERRATING ACCURATELY ALL THE TIME, DETACH

THE ELECTRODE(CELL) AND CLEAN THE SENSOR AT LEAST ONCE A MONTH.
IN CLEANING THE ELECTRODE, CAREFULLY WIPE OFF DUST AND SCALE FROM
ITS SURFACE WITH SOFT CLOTH. DO NOT USE SANDPAPER, A FILE OR
OTHER MATERIAL WHICH MAY HURT THE SURFACE.
 ITEM NO. AL6

T I T L E DATA
SHEET MB-SI-02
^^MiaK^
NO. :

Salinity Indicator
KANGRIM PAGE 3 OF 4

3. M A I N U N I T

160
o
148 92

m.
e m
®

SALINITY INDICATOR

® POP
dod
PPM
(•c)
••

®
o
ID
@a@s CD

CM
® ® © CNJ

-^ [Ol foi foi (D MJUV

inv.

(D [O' foi [O] ® AUM

•en

®
HODEL : JK - 101
PUSAH GENERAL ELECTRIC
LD
tn

12 ^
4-05
Maker sensor cable
20C X 3ea
* Weight : 6.0Kg

NO. Description
1 INDICATOR 6 OFF BUTTON
2 ALARM ADJUST 7 TEMP. VIEW BUTTON
3 POWER LAMP 8 A U R M ACK. BUTTON

4 ALARM LAMP 9 TEST SW. BUTTON

5 ON BUTTON 10 ALARM CUT BUTTON

 ITEM N O . A L 6

T I T L E DATA
SHEET MB-SI-02
.^^^^
NO. :

Salinity Indicator 4 OF 4
KANGRIM PAGE :

4. G A T E V A L V E WITH CELL

* WEIGHT : 3.0Kg

NO. NAME MATERIAL Q'TY REMARKS

8 BOSS 1 YARD SUPPLY

7 CALBE GLAND 1
6 CABLE TPNP-0.75 2m
5 ELECTRODE 1
4 GATE VALVE BS 1
3 ORING 1
2 NUT BS 1
1 NIPPLE JOINT BS 1 PT 1 1 / 4
 INSTRUCTION MANUAL
MODEL: JK-101
DIGITAL SALINITY INDICATOR
21 :
SALSMtn subtaaon

ei
B M-ltt
rmw GtMiM. lucnic
3>
ET
fll ^ j
O S EES
a
ABLE OF CONTENTS
NOTES ON SAFTY INDICATIONS 2

NOTES FOR SAFTY OPERATIONS 3

INTRODUCTION 4

SYSTEM OVERVIEW 5

COMPONENT DESCRIPTIONS 6

OPERATIONS AND FUNCTIONS 8

DESCRIPTIONS OF WIRING AND CONNECTION 10

MAINTENANCE 12

SPECIFICATIONS 13

TROUBLESHOOTING GUIDE 14

CONNECTION DIAGRAM 15

OUTER DIMENSIONS 16

APPLICATION DIAGRAM 18

ACCESSARIES 20

MODEL & SUFFIX CODE SELECTION 23

NOTES ON SAFTY INDICATIONS

The user is requested to read these instructions and the attached documents carefully
before the installations, operation and inspections or maintenance of the Salinity
Indicator so that it will be used properly.

Please be sure to get accustomed thoroughly to the knowledge of, and the safety
information and motes about, the indicator prior to use it.

[Safety notes in this Instruction Manual will be indicated by any one of the following
three levels:]

Indicates a case where an erroneous operation of

the machine would produce a dangerous situation
which could result in death or serious injury and the
A DANGER level of emergency is high when such a situation
occurs. This note will appear limitedly for very
dangerous cases.

Denotes a case where an erroneous operation of

the machine would produce a dangerous situation
A WARNING which could result in death or serious injury.

Represents a case where an erroneous operation of

the machine would produce a dangerous situation
A CAUTION which could result in slight injury or material damage.

Please note, however, that a

A CAUTION case could result in more serious
consequences than assumed above by the synergy of different conditions, So, it is
important to live up to the instructions herein to forestall any factor which would inhibit
safety operation.

NOTES FOR SAFETY OPERATION

These Operating instructions must be read through carefully for the proper and safe
use of this product.
Any erroneous operation could cause a breakdown and/or a disaster resulting in injury
and/or material damage..

A CAUTION

1. Turn off the power source prior to wiring or inspecting the inside of the indicator;
otherwise the worker could suffer an electric shock. The main source must be
turned off at both ends.

2. Prior consultation with the manufacturer is necessary if the indicator is intended for
uses where its breakdown or erroneous operation could endanger a human life or
lives or cause hazards to people
3. No excessive load, vibration or impact must be given to the body or the cell.

4. The indicator must be used within the specified temperature range.

5. In case detaching the cell, stop the pump and lower residual pressure by closing
the pipeline valve(s) beforehand.

6. Do not adopt the indicator to add a new function to it or for any other purposes. For
repairs, call the manufacturer.

7. To wire the indicator, strictly follow instructions in the "Wiring and connection" part
of this brochure.

8. Prior to use, make sure that the correct voltage has t»een chosen on the voltage
selector.

INTRODUCTION
The JK-101 Salinity Indicator continuously measures the saline concentration of high-
purity water, such as distilling plant water, drain water and feed water for boilers, and
indicates the outcome therefrom in PPM. In case the saline content level goes higher
than a preset value, the indicator will light up an alarm lamp and send out en-or signals
(no-voltage and voltage signals).
Some types of the measuring unit would automatically activate a solenoid valve to
discharge high salty water outside the system.
The alarni is automatically canceled when the saline concentration is back to a level
below the preset value.

SYSTEM OVERVIEW
The operation flow for the JK-101 system is shown in Figure 1.
FIGURE 1 : JK-101 BLOCK DIAGRAM

PPM display
EEPROM
O O O (Non-volatile memory)

h^"H
-^
U U U
Key Pad CPU temperature^
_ ^ 1 Flectrorie
O OO O A/D ^ 1 1 II ^
O OO O salinity ^ 1 1 II h=
AmpI fier
fcl^
^P Q 4-20mA

///7
1 ^
J "^o Power fail alarm
^

^
]< Horr1

^
]< Sole noid or alarm
COMPONENT DESCRIPTION
I
fii

&

r»rinnti csFHVMni Kit^'cmi-rr

4-
17
afaa
16

18

Components Description

1. Display (unit: PPM).

2. SET Pushbutton for alarm adjustment.
3. ENTER Pushbutton for alarm adjustment.
4. INC Pushbutton for increasing alarm set value.
5. DEC Pushbutton for decreasing alarm set value.
6. Power LED (green).
7. Alarm LED (red).
8. Power on pushbutton switch.
9. Power off pushbutton switch.
10. Test switch.
11. External alarm cut.
12. Display of automatic temperature compensation.
13. Alarm acknowledges.
14. Screw for front panel.
15. Mounting bracket.
16. Cable gland.
17. Cell (Electrode).
18. Fuse holder (0.2A)
19. Terminal block.
OPERATIONS AND FUNCTIONS

The indicating section

Dispiav

Indicates measured values, a preset alarm value and test values (5 PPM) in PPIM, and
also temperature in "C. If measurement exceeds maximum range (0-200 PPM), the
display value of indicator will be flickered with alami lamp synchronously.

POWER (Power iamp)

Green LED on: Power has been tumed on

Green LED off: Power has been tumed off

AI-ARM (Alarm lamp)

Red LED flicker: measurement exceeds alami value without alarm

acknowledges
Red LED on: measurement exceeds alarm value after alarm acknowledges
Red LED off: measurement remains below alann value

The switching section

POWER (Power switch)

Operations:
1) On pushbutton
: Press when salinity indicator turned off - Indicator on, power LED on, value
displayed.

2) Off pushbutton
: Press when indicator turned on - Indicator off, power LED off and display dead.

TEST SW (Test switch)

Operations:
Press the test switch and 5 PPM is displayed.
This switch is used to test the checking of function of the JK-101 Salinity Indicator
except its measuring cell.

ALARM VALUE (Alarm value switch)

Operations:
Press the SET switch - preset alarm value displayed.
To revise a set value, see ALARM ADJUST (Alarm value adjustment) item below.

ALARM CUT

Initial start

Press the alarm cut switch when the alarm occur until the salinity is stabilized after the
distilling plant starts to operate (because salinity in the distilled water remains unstable)
After the salinity is stabilized, the alarm is automatically canceled when the saline
concentration is back to a level below the preset value.
Normal operation

When the alarm occur, (D Press the ALARM CUT switch and then the alarm contact for
external horn alann will be released © Press the ALARM ACK. Switch and then the
alarm LED will be changed to steady condition from the flickering condition. The alarm
is automatically canceled when the saline concentration is back to a level below the
preset value.

ALARM ADJUST fAlarm value adjustment)

To revise a preset alarm value, press the set switch (SET), and press the increase
switch (INC) or the decrease switch (DEC) until a desired value is displayed. And also,
to change the digit of a desired value, press the enter switch (ENTER) and a selected
digit will be flickered.
Then press the set switch (SET) again and now the new value has been set.

Cell (Electrode)

Dipped in distilled or fresh water to measure saline content in it.

DESCRIPTIONS OF WIRING AND CONNECTION

Break the power source during wiring work and the linking of connectors

The source power with voltage selection taps

COM 110V 220V

18 19 20^1 Terminal Block number

0 00
• • * 1 -

* 1 Choose the voltage to be used for this salinity indicator from the voltage selection
taps on the terminal block.
Connect the COM tap and the desired voltage tap.

Optional parts

+ - + -
rPl
COM NC NO
4 5 6 7 8 9 10

0000000
DC24V 4-20mA POWER FAIL
ALARM
Alarm and solenoid contacts

rTI rTl
COM NC NO COM NC NO

11 12 13 14 15 16

0HH0HH
ALARM or
HORN SOLENOID
VALVE
In standard equipment, the alarm contact is a no-voltage contact (free contact).
Make sure that the electrode (cell) is connected with the con-ect cables in accordance
with the numbers shown below.

Sensor i Electrode or C e l l )
SAL TEMP COM
NOTE:
SAL: Salinity value ( 0-200 PPM)
TEMP: Temperature value( 0-100 'C )

ELECTRODE

MAINTENANCE
Cleaning of Electrode I C e l l )

To keep the indicator operating accurately all the time, detach the electrode
(cell) and clean the sensor at least once a month.
In cleaning the electrode, carefully wipe off dust and scale from its surface with
soft cloth. Do not use sandpaper, A file or other material which may hurt the
surface.

SPECIFICATIONS
Measurable range: 0 ~ 200 PPM
Measuring accuracy: ± 2.5%
Temperature compensation: 0 ~ 100 "C (1 1%)
LED lamps: Power-GREEN 5 0
Alarm - RED 5 0
Power source: 110/220VAC
Power consumption: 5W (MAX)
Finishing color: RAL 7035
Pressure durability of cell: 5 kg/cm«
Cell mounting screw: M30x2.
TROUBLESHOOTING GUIDE

Trouble Cause Troubleshooting

Powered but fails to No power source of Check the power cable

operate; Power LED FUSE (0.2A) blown by or replace FUSE (0.2A)
dead. abnormal current flow in with a spare.
the circuit.
The set alamri value is Check the set alarm
Alarm LED fail to light. inadequate. value. See "ALARM
ADJUST item on the
page 9 in this brochure
for changing set values.
Broken relay or error in Replace the I/O PCB
the alarm circuit. with a new one because
the relay and the alarm
circuit is directly bonded
on the printed circuit
board.
Display value unusually Foreign matter deposited Clean the electrode
low. on sensor surface (cell).
working as insulator.
Broken wire in the Replacement of new
sensor. one.
Display value unusually Foreign matter deposited Clean the electrode
high. on sensor surface (cell).
increases conductivity.
A short circuit of Call the manufacturer.
measuring part or
malfunction.
Alarm LED remains lit. The set alarm value is Check the set alarm
inadequate. value. See "ALARM
ADJUST item on the
page 9 in this brochure
for changing set values.
Broken relay or error in Replace the I/O PCB
the alarm circuit. with a new one because
the relay and the alarm
circuit is directly bonded
on the printed circuit
board.
CONNECTION DIAGRAM
SAL
SENSOR
TEMP
^E o
a
HORN FOR ALARM
(OPTION)
COM
'DII
«E
'IE
C
n 24VDC /0.5A (OPTION)
ALARM or SOLENOID
VALVE

C D
4-20mA (OPTION)
FRAME GROUND

E
9
C ?I POWER FAIL ALARM
(OPTION)
220VAC

10 E
 DATA
T I T L E SHEET MB-OD-04
NO.

KANGRIM Oil d e t e c t o r PAGE 1 OF 3

TECHNICAL SPECIFICATIONS

• Model OIL DETECTWISE 0DW-1A1A

• Power supply AC 20 ~ 250V
• Output 1 X SPOT relay contact
• Cable gland ^J-J^^^<^i^^^
• Conn, size JIS 5K 50A)FF steel flange ^
• Electrode Length tobespecifled by stiipyard ( 500 mm)
• Housing plastic PBT(VALOX)
• Mounting boss steel 1-1/2" PF
• Adaptor flange steel JIS 10K 50A FF flange
• Insulator PTFE
• Electrode Fully insulated electrode
• Diameter of electrode 20mm
• Max. working temp. 100'c
• Protection IP 66
• Mounting top mounting
•Q'ty 0NE(1) set
• Service OIL DETECTION IN BOILER FEED WATER FILTER TANKl

• OIL DETECTING PRINCIPAL

Boiler feed filter tank tiave a inspection chamber or devide area
In tank to accumulate oil whien oil contamination in boiler water.

When incoming oil contaminated water in inspection chamber

the feed water only go out to feed filter tank and oil with be
accumulate In inspection chamber until drain oil.
When the normal conditions,
The end part of electrode will be in water level always.

But the water contaminate oil than the oil is accumulate top
level in Inspection chamber the electrode will be in oil level
Instead of water level the oil detector will activate alarm.

After drain oil in Inspection chamber the oil detector return to

normal condition.
 DATA
TITLE SHEET MB-OD-04
jAWGRia NO.

KANGRIM Oil detector PAGE 2 OF 3

CAPACITANCE LEVEL SWITCH

MODEL OIL DETECTWISE • TECHNICAL DATA
0DW-1A1A
Housing
• Housing meternol : plastic PBT (polyester)
• Protection : IP 66
• Coble entry : PG 13.5
• Terminals : for max. 1.5mm'cross-section
DIMENSION Thread
• Thread : PF 1 - 1 / 2
80x110 ^gppr. 30 • Adaptor flonge : JIS lOK 50A FF x PF 1-1/2

Electrode
• Boss maternol ; steel
•Electrode : steel ond PFTT fully insulated
• Weight : obout 3kg

Pq13.5 Ambient conditons

JIS 5K 50A ^ "Ambient temp, on housing : - 4 0 ' c + 70'c

•Product temp. : -50"c ~ +100'c
•Storage temp. : -40*c ~ +80'c
• Operating press. : 10 BAR
Oscillators
• Frequency : 400 KHz
• Sensitivity 1 / 2 / 3 ; 0 ~ 2 0 / 8 0 / 4 5 0 PF
• Switch histerisis : opprox. 2% of capacitance value
• Output : relay output
•Power supply : AC 20 ~ 250V 50/60Hz free
020 : DC 20 ~ 72V
•Power consumption : Max. 1.5W

:=ld
ELECTRIC WIRING

-l-
LI N J^ \.

01 0 0 QA5 0 ^ 5
2 \ 5 3
J
e
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R RELAY
c30WE Y C)UTPL T
5UPPL
 o
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n
O

FEED WATER INLET

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3 D CO
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z —
r
ELECTRODE
OIL DETECTOR -5
JIS 10K 50A o ^
n z
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Y//^///^Jfff//':rr ^) / / JJ f / f i7-rT7 -n -^
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z
OUTLET FEED WATER
TO FEED FILTER TANK
INSPECTION CHAMBER U
OF BOILER FEED WATER FILTER TANK " V T

TJ " 1-1
>
O P3 '
r / / j / / / / ^ / / / j / j / / y / / / / / / / / ^ ^ / j j ^ i / ^ / f / f f f / f
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O O
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CO o
 DATA
T I T L E SHEET MB-TT-01
JCAHORIM; NO.

TEMPERATURE TRANSMITTER
KANGRIM PAGE 1 OF 1

HEAD

TETMINAL

•WELDED POCKET • ELEMENT

R B B
R RED •NOTE
B BUCK
1. MATERIAL :

F=1n oc)n A1r 0•c CONNECTION HEAD : AL-DIECAST

OTHER : SUS 304

2. IP GLADE : IP 54

3. ELEMENT ; PT100 DIN 3 WIRE

4. WORKING LIMIT TEMP. : MAX. 600'C

J 00, 150, 170, 200
P2
300. 400. 6 0 0 ( m m ) 5. NP (lettering) :
PF 3 / 4 or M27x2P
15c
 P L A N H I S T O R Y

REV. DATE D E S C R I P T I O N OWN CHK APP'O

•04.03.10 FOR APPROVAL [Link]

/^
A

16 SEAL Pt> 2 - -
15 SET SCREW GASKET PTFE - -
M CAP GASKET PTFE - -
Droln fay yord
13 BODY GASKH PTFE - -
12 S n SCREW C 3604 - -
11 LOCK NUT C 3604 - -
10 ADJUST SCREW C 3604 - -
9 SPRING SEAT(UP) C 3604 - -
1. BODY MAT'L 8 SPRING SEAT(LOW) C 3604 - -
SCS 13 15A-25A 7 SPRING SWOCS - -
SUS 304 40A-50A 6 VALVE STEM SUS 304 - -
5 ADJUST RING & GUIDE SCS 13 - -
4 DISC SUS 304 STELLITED - -
3 CAP C 3771 - -
2 BONNET BC 6 - -
DIMENSIONS UNIT : mi 1 BODY SEE TABLE STEaiTEO - -
vn.
SIZE HI PTd PTdl W.T(kg) Q'TY(set) NO OESCRIFTION MATERIAL QT'Y SIZE (kal REMARK

PROJECT TYPE 1 CUSTOMER CLASS/RULE

: = ^ 15A 13.0 42.0 62.0 178.0 1/2" 3/4" 1.4 - -
20A 13.0 42.0 64.0 180.0 3/4" 3/4" 1.5
TITLE DATE
-
SAFETY VALVE DIM. SCALE PHOJtCTWN
HIGH LIFT TYPE
25A 18.0 44.0 70.0 198.0 1.9
(MODEL NO : BSR-HP)
N/S 4t$y -^-J
40A 25.0 57.0 88.0 259.0 1 1/2" 1 1/2" 2.3 W / 0 NO
-
50A 32.0 65.0 108.0 299.0 2" 5.8 REV.
DWG. NO
.
<Sj^ I C A N I G R I M INDUSTRIES CO.. LTD. JKS- •1272002
A
 ITEM NO. GIO

T I T L E DATA
SHEET MB-TS-03
NO. :

TEMPERATURE SWITCH CODE 5004214

KANGRIM PAGE 1 OF 1

J33- J3L

I r--

Csi =(13_:PF1/2

CD

"^Z
O
120

NOTE
MODEL :
RANGE : 0 600 C

L(LENGTH) 400

SETTING 450 C°
 ITEM NO. SI

T I T L E DATA
SHEET MB-TK-02
NO. :
TEST KIT CODE 3001343
KANGRIM (SPECTRAPAK 310) PAGE 1 OF 4

230

' ^

o
CN

75

BOILER WATER TEST KIT

CI <& ALCALINITY No. 310

NO. DESCRIPTION (kg)

MATERIAL Q'TY SIZE REMARK
WT.
1 PLASTIC BOX - 1 - - -
2 CHLORIDE 250 TABLETS - 1 - - -
3 P ALKALINITY, 250 TABLETS - 4 - - -
4 PLASTIC STIRRING ROD - 1 - - -
5 SAMPLE BOTTLE, 200ML - 1 - - -
6 INSTRUCTION FOR USE - 1 - - -
7 FOAM RUBBER - 1 - - -
 ITEM NO. SI
DATA
T I T L E
SHEET MB-TK-02
NO. :
TEST KIT CODE : 3001343
KANGRIM (SPECTRAPAK 310) PAGE 2 OF 4

UNITOR TEST KIT SPECTRAPAK 310

(LOW PRESS. BOILER WATER TEST KIT)

P-ALKALINITY TEST

LToke o 200ml [Link] o n e p—olkalinlty [Link] p—oikalinit/ is [Link] tablet oddition

water sample in the tablet, ond shoke present the sample until the yellow color
stoppered bottle the stoppered bottle will turn blue chonges to p e r m o n e n t
provided provided yellow

< > ( 1

CALCULATION
[Link].(os ppm C o C 0 3 ) - ( N u m b e r of tablets usedx20)-10 ( -1 f 1

(Exomple) I >

If A tablets ore used

P Alkolinity=(8x20)=150ppm t ) ffTO < ) ( >
< 1 ( 1
( >
[Link] the results on t h e
log sheet [Link]
the dote ot which thetest
wos token

CHLORIDE TEST

1 .Toke o SOmI sample [Link] o n e chloride [Link] will turn [Link] toblet oddition
in the stoppered toblet ond shoke yellow if chlorides until the yellow color
bottle provided to disintegrote ore present changes to p e r m o n e n t
orongo/brown

' ' ' I C

CALCULATION (SOmI SAMPLE) I > I 1 |g

ChlorideCos p p m C r ) « « ( n u m b e r of toblets usedx20)-20 I 1 I 7

(For exomple):
If A Toblets ore used then Chloride p p m ( 1 S I S C

= (4x20)-2O-60ppm
<—) (—I c

[Link] the results on t h e

log sheet [Link]
the dote ot which the test
wos token
 ITEM NO. SI

T I T L E DATA
SHEET MB-TK-02
NO. :
TEST KIT CODE : 3001343
KANGRIM (SPECTRAPAK 310) 3 OF 4
PAGE :

Product Dosoge and Control Limits

• Initiol d o s a g e for on untreated s y s t e m is 3 0 0 grms COMBITREAT/1000 litres of make up wotor. This will b r i n g the
treatment up to o m i n i m u m level of lOOppm [Link].
• The dosage chart given below is f o r c o v e n i e n c e in c o l c u l o t i n g the amount of COMBITREAT r e q u i r e d to bring the
level t o the point between the minimum ond maximun — (mid point: — 200 ppm. [Link].)
After a short period of use the operotor will be a b l e to eosily d e t e r m i n e the level of treotment required.

P ALKALINITY p p m CoCQj 0 50 100 150 (^ 225 300 350 400

DOSAGE OF COMBITREAT KG/100L 0.4 0.3 0.2 0.1 0 0 0 1 — Slowdown

Slowdown is d e p e n d e n t on c h l o r i d e levels, e n d blowdown nnust be increased with rise in chlorides.

In g e n e r a l the ronges ore:

P Alkalinity : 100-300 ppm CoCOj

Chlorides 200 ppnn CI max.

T h e s e o r e r e c o m m e n d e d volues b a s e d o n experience, and ore in no way intended to reploce the boiler monfocturers
s p e c i f i c o t i o n s , or c o m p o n y r e g u l o t i o n s .

SAFETY AND HANDLING PRODUCT PROPERTIES

HAZARDS Irritoting t o e y e s . r e s p i r a t o r y s y s t e m a n d skin.

Repeoted exposure moy cause chronic eye APPEARANCE: Ton powder
i r r i t a t i o n , d e f o t t i n g , drying a n d c r o c k i n g of
skin. pH(0.3 wt%): 10
W e a r s u i t a b l e p r o t e c i t i v e c l o t h i n g , gloves a n d
PROTECTIVE
e y e / f a c e p r o t e c t i o n . Do not b r e a t h e d u s t .
MEASURES COMPATIBILITY:
Provide a d e q u a t e g e n e r a l a n d locol e x h a u s t
ventilation. Metol Avoid o l u m i n i u m , zinc, tin and
their olloys.
SPILLAGE C l e a n up p e r s o n n e l should use r e s p i r a t o r y
Rubber : No k n o w n e f f e c t
protection a n d other suitable protective
c l o t h i n g . S h o v e l spltl into dry c o n t a i n e r s .
Cover and m o v e container.

FIRE May portly b u r n . Extinguishing m e d i a

g o v e r n e d by o t h e r m a t e r i a l s involved.

FIRST AID EYES P r o m p t l y w a s h e y e s with tots of w o t e r while

lifting eye lids. C o n t i n u e to rinse for a t leost
1 5 minutes ond get medicol ottention.

SKIN R e m o v e v i c t i m f r o m s o u r c e of c o n t o m t n o t l o n .
Dust off p r o m p t l y a n d flush c o n t a m i n a t e d
skin with w a t e r for at least 15 m i n u t e s
o n d seek m e d i c o l a t t e n t i o n .

INHALATION Move e x p o s e d p e r s o n to f r e s h olr a t o n c e .

P e r f o r m ortlflciol r e s p i r a t i o n if b r e o t h i n g hos
stopped. Keep the affected person w a r m
o n d ot r e s t . Get p r o m p t m e d i c a l o t t e n t i o n .

IF SWALLOWED Do not i n d u c e v o m i t i n g . Get p r o m p t m e d i c a l

a t t e n t i o n . P r o m p t l y let v i c t i m drink lots of
woter to dilute the swollowed c h e m i c a l .
NEVER MAKE AN UNCONSCIOUS P E R S O N
VOMIT OR DRINK FLUIDS.

HANDING K e e p c o n t a i n e r tightly c l o s e d . K e e p in c o o l ,
STORAGE dry. v e n t i l a t e d s t o r a g e .
K e e p owoy f r o m ocids.

TRANSPORT IMOG Class / poge - Not listed

UN N u m b e r - Not listed
ADR - Not listed

PACKAGING N o n - r e t u r n a b l e contoiners. Approx. 2 5 0 g .

D e p e n d i n g o n location a n d ovoilobtllty.

Unitor or ony o s s o c l o t e d or subsldiory c o m p a n y ' s w a r r a n t i e s of fitness a n d m e r c h o n t o b l l l t y . If any, os well a s

ony e x p r e s s w o r r o n t l e s r e g o r d i n g this p r o d u c t shoH not be e f f e c t i v e or a c t t o n o b l e unless the g o o d s o r e u s e d
a s d i r e c t e d herein a n d In no o t h e r m o n n e r due t o p o t e n t i a l h a z o r d s f r o m i m p r o p e r use of the g o o d s
d e s c r i b e d h e r e i n . P r o d u c t s m a y wary slightly d e p e n d i n g o n c o u n t r y of origin.
 ITEM NO. S I

T I T L E DATA
SHEET MB-TK-02
NO. :
TEST KIT CODE 3001343
KANGRIM (SPECTRAPAK 310) 4 OF 4
PAGE

Product Dosoge and Control Limits

• Initiol d o s a g e for an untreoted system is 2 . 0 litres of LIQUITREAT/1000 litres of untreated distilled feed water. This
will b r i n g the treotment up to o minimum level of 100 ppm [Link].
• The dosoge chort given below is f o r covenience in c a l c u l a t i n g the amount required to bring the level t o the mid
point between the minimum and moximun — (mid point: — 200 ppm. [Link].)
After a short period of use the operotor will be o b l e to eosily d e t e r m i n e the level of treatment required.
• LIOUITREAT should be diluted with condensate or g o o d quolity distilled water in o d o s a g e tonk to be fed to the
boiler feed woter, preferably by metering pump, where the required quontity is d o s e d to bring the treotment up to
the level r e q u i r e d . Continuous dosage is p r e f e r e d , but slug dosage moy be sotisfoctory if specified values are
mainloined.

P ALKALINITY p p m CaCOj 0 50 100 150 ^ ^ 225 300 350 400

DOSAGE OF LIQUITREAT Ltrs/1000L 2.4 1.0 1..2 0.6 0 0 0 1 — Slowdown

B l o w d o w n is d e p e n d e n t o n c h l o r i d e levels, o n d blowdown must be increosed with rise in chlorides.

In g e n e r o l t h e r a n g e s o r e :

P Alkotinity : 100-300 ppm CaC03

Chlorides 200 ppm CI mox,

T h e s e are r e c o m m e n d e d v o l u e s b a s e d o n e x p e r i e n c e , ond o r e in n o woy i n t e n d e d to reploce the boiler monfacturers

s p e c i f i c o t i o n s . or c o m p a n y r e g u l a t i o n s .

SAFETY AND HANDLING PRODUCT PROPERTIES

HAZARDS Irritoting t o e y e s a n d s k i n . C o n t o c t with a c i d s

l i b e r o t e s very t o x i c g o s . R e p e a t e d e x p o s u r e APPEARANCE: Pole liquid
moy cause chronic eye irritotion, defotting,
drying o n d c r o c k i n g of s k i n . DENSlTY/in g/ml ol 15'C: 1.2
PROTECTIVE Wear suitable protecitive clothing, gloves ond
e y e / f o c e protection.
MEASURES

pH(0.2 Vol%): 10
SPILLAGE P r o v i d e v e n t i l o t i o n a n d c o n f i n e spills. Do not
run off t o s e w e r . Collect with
non —combustible obsorbent moteriol. COMPATIBILITY:
Metol Avoid a l u m f n i u m ,
FIRE W o t e r b o s e d . H o s e d r u m s to k e e p c o o l . galvanised steel.
(Toxic s u l p h u r dioxide m a y b e e v o l v e d . ) Rubber : N o known e f f e c t .

FIRST AID EYES P r o m p t l y w a s h e y e s with tots of w a t e r while

lifting e y e lids. C o n t i n u e to r i n s e for ot leost
1 5 minutes and get medicol a t t e n t i o n .

SKIN R e m o v e victinn f r o m s o u r c e of c o n t o m i n o t i o n .
p r o m p t l y wosh c o n t o m i n o t e d skin with s o o p
ond woter. Promptly r e m o v e contominoted
c l o t h i n g o n d c o n t i n u e to wosh for a t least
1 5 m i n u t e s . Get m e d i c o l o t t e n t i o n .

INHALATION Move e x p o s e d p e r s o n t o f r e s h olr a t o n c e .

P e r f o r m ortificiol r e s p i r o l i o n if b r e o t h i n g h o s
stopped. Keep the a f f e c t e d person worm
a n d a t r e s t . Get p r o m p t m e d i c a l a t t e n t i o n .

IF SWALLOWED Do not i n d u c e v o m i t i n g . Get p r o m p t m e d i c a l

o t t e n t i o n . P r o m p t l y let v i c t i m drink lots of
w a t e r t o d i l u t e t h e swollowed c h e m i c a l .
NEVER MAKE AN U N C O N S C I O U S P E R S O N
VOMIT OR DRINK FLUIDS.

HANDING K e e p in c o o l , d r y , v e n t i l a t e d s t o r o g e a n d
STORAGE c l o s e d c o n t o i n e r s . K e e p owoy f r o m oxidisers,
h e o t ond f l a m e . K e e p owoy frorn a c i d s .

TRANSPORT IMOG Class / page - 8/8214

UN Number - 1814
AOR - 8.42(b)

PACKAGING Non —returnoble contoiners. opproximotely

2 5 litres D e p e n d i n g o n l o c o t i o n a n d
ovailobility.

U n i t o r or ony a s s o c i a t e d or s u b s l d i o r y c o m p o n y ' s w o r r o n t i e s of f i t n e s s o n d m e r c h o n t o b i l i t y . if a n y . a s well os

any e x p r e s s w a r r a n t i e s r e g a r d i n g this p r o d u c t sholl not be e f f e c t i v e or a c t i o n a b l e unless t h e g o o d s a r e u s e d
OS d i r e c t e d h e r e i n o n d in n o o t h e r m o n n e r d u e t o p o t e n t i o l h o z o r d s f r o m I m p r o p e r u s e of t h e g o o d s
d e s c r i b e d h e r e i n . P r o d u c t s m a y vory slightly d e p e n d i n g on c o u n t r y of origin.
5. Burner Technical Data & Spec.

KANGRIM INDUSTRIES CO.,LTD.

Hull no. Type Customer
0311-6,0442-4 PB0301AS10 Hyundai Mipo Dockyard Co., LTD.

Burner technical data & spec. (Page 1 of 2)

Specification:

Number of boiler / ship 1 set

Burner type ( Steam atomizing type) DDZIO
Number of burner each boiler 1 set

Fuel data:

* Heavy fuel oil (H.F.O)

Viscosity (at 50 o C) 700 Cst
Specific gravity 990 kg/m^
Low calorific value 9700 Kcal/kg

* Diesel oil (D.O) - for starting up and pilot burner

Viscosity (at 40 o C) 6 Cst
Specific gravity 820 kg/m^
Low calorific value 10200 Kcal/kg

Burner data

D.O consumption - max. 1250 kg/h

H.F.O consumption - min. of flow control 133 kg/h
H.F.O consumption - max. 1315 kg/h
H.F.O viscosity at burner inlet 12 Cst
H.F.O temperature at burner 150 o C

Atomizing steam pressure at burner 7 kg/cm

Atomizing steam consumption - max. 54 kg/h

Atomizing air pressure 7 kg/cm

Atomizing air consumption 1.1 m^/h
Excess air ratio at MCR 1.15
Air register draft loss (MCR) 300 mmAq
Turn down range approx. 1:10
Hull no. Type Customer
0311-6,0442-4 PB0301AS10 Hyundai Mipo Dockyard Co., LTD.

(Page 2 of 2)
F.Q Equipments

* F.O Heater(1 sets/ship)

Type Shell & tube
Heavy fuel oil capacity (inlet 71 o C-outlet 150o C) 1853 kg/h
Steam consumption at 7kg/ciif 135 kg/h

* F.O Pimip (2sets/ship)

Type DCS 7/1800
Pump capacity at 15 bar 1950 1/h
Operating pressure 15 bar

* Ignition pump ( 1 set/ship )

Type PZHDS 30
Pump capacity 3 5 - 4 7 1/h
Operating pressure 7 - 1 4 kg/cm^

General data

Boiler feedwater temperature (heat balance only) 80 . C

Combustion air temperature 45 . C
Ambient air temperature 45 . C
Temperature calibration o C

Electric power source AC 440 X 3ph

Electric control source AC 220 X 1ph
Frequency 60 Hz

Insulation class F or B
Protection class IP 44

Classification ABS
 Duoblock Burner DDZ

•
•mmmm
Data and
DInwnsion Shaat
for the combustion of fuel oil

Combustion air *

L = Rame scanner
* Connection dimensions on page 2
S L = Peephole/flame scanner
Z = Igniter * * 1^,2 - P'ant-specific

Dimensions in mm
Burner type Dl Dmi Dm2 tflil A B c E F MF
300 331 417
OOZ 8 315 346 432 160 980 700 1050 550 560 2000
335 366 452
355 386 472
37R dOA Kin
DOZ10 1 400 431 538 200 1160 800 1250 700 776 2000
•ViXi
450 481 588
476 506 640
DDZ 12 500 531 665 250 1450 1000 1300 900 1016 3000
530 561 695
560 591 725
600 631 792
DDZ 14 630 661 822 300 1900 1400 1750 1100 1170 3750
670 701 862
710 741 902
750 781 969
DDZ 16 800 831 1019 350 2500 1800 2250 1350 1285 4500
850 881 1069
900 931 1119

Technical Documentation
SAACKE GmbH 4 Co. KG SAACKE GmbH & Co. KG Tel. 0421/6495-0
Siidweststra3e 13 P.O.B. 210261 Fax 0421/64 95 224 (SAACKE)
28237 Bremen 28222 Bremen E-Mail: info@[Link]
Germany Germany lntsmet:htlp://[Link]<[Link] 1-1301-1269a/02
2003-10-30 Page 1/2
•
Data and
Dimension Sheet

—r
FZri>~, -^^.4>—-ms-^A~ x s f -
.
1- "^
1*
i Steel sheet thickness P i ^
X
i
>
1
J ._L-
\ N
H

.kt
0
1 ••—-—' 1

L - ^ — c ^ — <|>^^'^ -,^-
P^^l," :; •

1
t*
^w —^

11

>Vr inlet elbow

Dimensions in mm

type 0 P S T U V W X Y Z

DDZ 8 t1.5 B 600 350 700 660 6X95 450 410 3x110

DD2U ^^.5 » SM 450 900 860 7X110 550 510 4x105

bE)2i2 11.5 8 1000 600 1100 1060 10x95 700 660 6x95
DD214 11.5 8 1200 750 1300 1260 11 X105 850 810 8x90
DDZ 16 14.0 10 1500 1000 1600 1560 14X105 1100 1060 10x95

Technical Documentation

(SAACKE^
1-1301-12693/02
Page 2/2 2003-10-30
 Structural and Duoblock Burners DDZ
Operational iSescriptlon
for the combustion of fuel oil

Oil gun swirled main air

Nozzle

Fuel oil

^^SH Steam
1 Core air

I Air guiding unit

Steam Fuel oil Swirl unit

Fig.: Functional diagram of the duoblock txjrner DDZ

1 General description
The SAACKE duobioclc burner DDZ is usedforthe combus- Depending on the scope of order, thefollowingcomponents
tion of fuel oil as defined in DIN 51603. are fitted at the burner or arranged near to the burner:
The burner operates with the steam-assisted pressure jet
principle. • ignition system
As a construction kit, the burner is composed of several • flame scanner
structural assemblies. • oil compound regulator with sen/o-
Thanks to the specific partition of the combustion air as main motor or
air and core air: • control elements for changing the steam, oil
• a wide control range and and air quantities by means of an electronic
• optimum combustion with compound control system
• low emission values • safety shut-off valves for the release of fuel oil
are realized in every load position. to the burner
• fuel oil preheater when firing heavy fuel oil
• fuel oil supply system
• steam valves and fittings
• combustion air fan.
These components are described in separate leaflets.
The fuel oil and steam valves and fittings inclusive of the fuel
oil preheater can be delivered mounted as one structural
unit on a base frame that - at the same time - serves as an
oil tray.

Technical Documentation
SAACKE GmbH & Co. KG SAACKE GmbH & Co. KG Tel. 0421/6495-0
SiJdweststraSe 13 P.O.B. 210261 Fax 0421/64 95 224 (SAACKE^
28237 Bremen 28222 Bremen E-Mail: inf6@[Link]
Germany Gennany lnternet:[Link] 1-1301-3177b/02
2004-12-08 Page 1/2
 Structural and
Operational Description

2 Dosing the volume flows

2.1 Fuel oil 3.2 Combustion air
The fuel oil volume flow is dosed by a control element. A separately an-anged combustion air ^ supplies the main
2.2 Combustion air comtHJStion air via the deunper frame into the windt)ox.
The combustion air volume flow is modified by the air dam- The core air is taken from the combustion air flow in the
pers of the damper frame before entering the windbox. reach of the damper frame. The required amount of core air
is set by a separate damper.
2.3 Electronic compound control system These two air portions are guided separately up to the fur-
As an alternative, an electronic compound control system nace in parallel with the oil gun. Built-in swirlringsgive every
with separate servodrives and control elements for fuel oil air portfon an additfonal swiri.
and combustion air can t>e delivered. Where several bumers are equipped with one common
3 Guiding and releasing the volume flows windbox, one sepeu'ate drum-type slide valve with pneuma-
tic drive is required for each burner.
3.1 Fuel oil For the supervision of the combustion air fan, a pressure
The separately arranged supply system feeds the fuel oil to monitor is arranged upstream of the windlsox. Proper ope-
the oil gun with the atomizing nozzle. ration of this pressure monitor can be checked by means of
The oil gun consists of two pipes nested one into the other. a manually activated shut-off valve.
The steam is guided to the nozzle through the inner pipe The position of the inlet eltx>wof the windbox can be chosen
and the fuel oil through the outer pipe. (22.5* around the burner axis) depending on tiie fan arran-
The oil gun is positioned in a pipe that is equipped with a gement or the combustion air supply.
swirl ring for the core air and a swing-check valve. 4 Igniting the burner
The swing-checl< valve obturates the protective tulse ope- The bumer is ignited either by a fuel gas- or a fuel-oil opera-
ning to the furnace when the oil gun is dismantled. ted igniter. In some igniter types, the ignition flame is moni-
Dunng the commissioning works, the position of the swirl
tored by an ionisation electrode. A separate comtxtstion air
ring and the nozzle can be modified.
Fuel oil and steam are mixed in the nozzle immediately be- supply equipment is requiredforthe igniter. The air quantity
fore leaving the nozzle. The atomized fuel oil-steam mixture can be adjusted manually by means of a throtUing valve.
then leaves the nozzle and enters the fumace in a certain 5 Flame monitoring
nozzle angle. The burner can be equipped with either an infrared or an UV
Depending on the oil grade and the marginal conditions, the flame monitoring system. The flame scanner is cooled with -
steam consumption is abt. 5% - 8% of the fuel oil throughput. cooling-Zsealing air.
The steam temperature should t>e 50 K above the saturated
steam temperature. 6 Blowing-out
The fuel oil preheater brings the heavy fuel oil to a viscosity Eachtimewhen the oil operation is shut-down, the oil piping
of 11 cSt. between the shut-off valves and the shaft, the shaft itself and
Each time when the oil operation is shut-down, the oil piping the atomizer nozzle must be blown-out with steam.
between the shut-off vetlves and the shaft, the shaft itself and In case of so-called upwardfiringbumers, however, we re-
the atomizer nozzle must be blown-out with steam. commend to suck off the fuel oil.
7 Hints
In order to ensure constent operational readiness and relia-
bility, the burner and its control and monitoring systems
should be checked once a year.
See also:
• DIN 4755 Part 1, Section 6
• TRD411,Section10
An appropriate free mounting space has to be considered
for mounting/dismounting the oil gun. See 'Date and Di-
mension Sheet'.

Technical Docutiwnlation

(SAACKE)
1-1301-3177b/02
Page 2/2 2004-12-08
 Steam-assisted pressure jet burner DDZ 8...1
Instructions for
initial Operation for the combustion of fuel c

Ctye air gats vafve

Oil gun *\
ynewirled main Swirled main
jdr ' ftT

Air guiding
system
S t e ^ Fuel oil

Swiri unit

Operetional diagram of a steam-assisted pressure jet burner DDZ 8...10

1 Introduction
The initial start-up must be carried out by competent and skilled The staff carrying out the initial oparation must be familiar t
personnel, comply with the local regulations on personal safety, environm
if anything in the text is not clear, the burner should or no account tal protection and accident prevention.
be put into operation "by trial and error'. Replacing SAACKE parts and accessories by other makes or
in case of doubts, please consult our service department for ad- ture installation or addition of units is subject to our prior writ
vice. consent.
The use of the burner Is reserved to the contractually stipulated ap- The plant will be handed over to the user ready for operation t
plications. together with an acceptance protocol comprising a taUe of m
SAACKE may not be held responsible for damages due to failure sured data.
to comply with the Instnjctions for Initial Operation or with the con- Should the operational circumstances change later (e.g. by UE
tractual application. an other fuel), the settings have to be checked and, where
quired, up-dated.

SAACKE GmbH & Co. KG Tel. 0421/6495-0 Technical Documentation

Sudwest5tra6a13 Fax 0421/64 95 224
Postfach 21 0261
W-2eoo Bremen 21
Telex 24 42 30
Telegramm: ^aockebrenner CSAACKE)
1-2201-4155/02
 IrMtnjctiotntor
InWalOpwatipn

2 Genaral
2.1 For your piirtlcularattantlonl 7. In case of ring mains, adjust the pre«sui«oonlioHer so tfiat
When hwriing-up thefiringpkuit for [Link] instrucdons the oil pressure upstream ofttieoil gun is icept constant fi
of the manufacturer of Ibe fiesi generjedor have to be sMdltjf 6b- a vedue «f mux. lb...14 bar.
*aiv»d.
8. Settiieheatirigsy^em of the tank, of tile fuel diiheatir,And
Vyh9n starting or stopping the butndr jOn afightor extra-Jight fuel
that of tiie f u ^ oil supply systwn $o that a AOMtantviisoP-
oil (miBix. Jdnenx viscpsiity « 17 rT»n2/sec.)make surefiiattA heat-
sify of 11 c$t is maintained. The tennperatureshould be up-
ing systems shown on ttie termlrwd vubing diagram orttteelecttie
proDic. 160*C.
drcutt diagrams ate definfolysvyflohed off. A/Vhenfiie fuel oil sup-
ply system has been charigBd ^nvertoheavy fuel oil supply, the *) tea rule, providjad or necessary only for heavy fuel ojii opera-
bumsr may only be started if the heavy fuel ciil i$ ctvaBabla up- tion. MIertiielnifialapersfloli oftiieburner but prior to the fin*^
stream of the burner wHhftie required ternperatureand the admis- tsrnpeiatur^ edlusbnept attfiefuel oil heater andttietank hen
sible pressure. er, the heatbig tracere which (^uinot he oontrpiled (e.g, steam-
or hotilvaterHOperated heating tracere) have to ha sviriltehed off.
Z 2 Prlgrtotties)ait4ipof1uel«lloperatign,
ptattse verify that 2.4 Steam preparaUon
1. The hstaUaUon of th0 oil supply pipes is in accordance vnth The sl9Qfn shouM be superheated at a vabJS df at least SO K above
ttie corresponds^ technical informslion on tfw fuel oil the saturated sle<am temperatMre. This 1$ especial^ requteed'when
supply s^^em. firing light oil. The j^eiBm upstream of the gun tjhmM fiov* a max.
2. The electrical connections are in compliance wi0i the rele- pressure of 3...1<2 bar.
vant electric circuit diagram .or temiinal wiring diagram of
fiieburrier. za igniter
3. Tiie plant is ready for operation, i.e. Ignition gas pressure, ignition gas volumeflow,ignition eHr pres-
sure, ionisation electrode and ignition electrode have to be set in
• tanl<filledwith fuel oil;
accordance witiitfiedata given In Sheet 2—3308-3127.
• nOnnal water leysi in heat generator;
• flue gas damper open;
• shut-off and control valves and fittings
in operating positions:
• control and safety systems of the plant set at
porrect control or shut-down ppirrt.
4. All manual shut-off valves .andfittingsintinefuel oil supply
system are open, except the safety shut-off valves up-
stream of the burner.

2.3 preparing the fuel oil supply system

In order to assure satisfactory burner operatioh, proceed carefully
OS follows:
1. Start tiw tdnk heating ^stem *).
2. Switdh ontiieheating tracer*) of the fuel oil supply piping.
3. Start the fuel oil heater*) upstream of the burner.
4. Wait until the fuel oil in tiie storage tani( has reached the
required temperature*).
5. Switch on the fuel oil supply system.
6. Vent the entire fuel oil supply system thoroughly.

1-2201-4155/02
 Steam-assi9ted pressure j6t burner DDZ 8...1
for the combustion of fuel c

3 Comm>ssionln9 of DDZ 8...16

C<WQ air gede valve
3.1 Core air gate vahreadluatmsnt
The partition d the cwmbu^on air as main air and core air is ef-
fected by the core ^ r g^e valve. The gate valve should be set to
the 20 mm position. Position 0 Is preset In the factory. This mea-
sure detemnines tfie distance between the threaded pin and the
nut. At closed core air gate valve, the threaded rod is flush with the
looknuL

Operating principle of the core air gate valve

Core air Control element

max. min. Core air

Core air gate valve adjustment

Technical Documentation

(SAACKE)
1-2201-4155/02
 ln8trucllon.8 for
Initial Op0ratloh

1 Min. swift

2 Max, swirl Control element

(position 0} Swiri unit
•»- CM

1I

Swiri unit adjustmert

3.2 Swirl unit adjustment
The swirl unit situated In the main air annglus can be axially dis-
placed. A maximum swirl Is reached at position 0. When the swrl
Swirled main air unit Is movad fonvard, a part of the air is directed past the unit in
unswirled condition. This enables to modulate the degree of swirl.
A heavy avwrl results in a good mixture of ttw combustion compo-
nents thus supporting the stability of the flame. The flame is then
large and short

Air guiding system

Unswirled
air Swirl unit

Operating principle of the swirl unit

1-2201-4155/02
 steam-assisted pressure jet burner DDZ 8...1
f<^ the combustion of fuel c
;3.3 Oilgunadlustmertt
Ths oil 0UI1 CQiisists of tMo pipes nested one into the Pther. The 30or4Oniit)
sleean .flpw is dimcted ihrough the inner pipe whw^ea the tuei oil
flows through tiie outaf pipe. Thie means that the rear connection
is to be fitied to the steam piping (witti the pipe elbonAi) and «»front
onetothedipipibi0.
The gun ie Jocaisd in a gun protecting tiiie which, ait the same 1
tune, si^jporte the {gnitidn screen/etatiilizBr.
The gun eswell as the ignition screen can be di^>laosd in both di- 115 rasp. 20 mm, ^
ractJom.
, ^ • ^ *

Gun positions:

J
DDZ 8 + 1 0 : +aO...-aonwn
ODZ13 + 14 + 16: + 4 0 . . . - 4 0 mm
The oil gun Js pre-setin our faotorylo position +2Q tesp. +30, i.e.
the gun is e i t ^ nwp. 30 mm in front of the air guiding s^tom.
The tgnWon screen is $et in our factory with a 15 mm (POZ 8 and
1(9 tesp. 20 mm PDZ12,14 + 16) protrusion to the air guiding
system.
/
Ignition screen Nozzle

Air guiding system

linn ei/fsfrom B

Operating principle of the oil gun

Oil gun
30 or 40 mm

Steam Fuel oil

L
on gun adjustmefi

Technical DofeumenMlon

(SAACKE)
1-2201-4155/02
 InstnieHonsiar
iniflai Oporatfon

wwmiiiM^^
314 COBIIPI Of ftiei oil volume flow
The Hiei bH volumeflpvyIs mdered out by a control module such
OS the SAACKE oompourid isgulator.

3^8 Control of oombuetioo air woluine flow

The ditfnpers (uranged In the windbox df the 5te9m-a$slsted
preeeure jet atomizer meter out the oombusGon air volume flow to
tie added. These dampeis tan, for example, opntcolled by the
SAAQKE compourKU regulator via a linkage.

3.8 [Link] regulajtor

The SAACKE compound regidBtor enables a perfect coordination
of luel oil and combustion air quantities jsy adding a vrall propor-
fioned combustion air flow to the Individutd fuel volume flow ttius
assurfrxg optimum combustion.
For furtiwr InfonnatiQnj please lefer to the Instructions fpr Initial
Operation of Compound Regulatpis 1-3509-4109.

1-2201-4155/02
 Steam-dsslsted pressure }et burner DD2 8...1
liistniptioimfor
Dismounting for firing fuel o

swiridr
air guiding unit

swirl urilt

tjumer plate with

gun protection
tube

fuel oil

steam

Operational diagmm of a stsam-assl^ed prsssuro jet burner DDZ8... 16

8AACKE GmbH & Co. KG Tel. 0421/5495-0 1bchnl<»l DocumentaUon

StidweststiaBe 13 Fax 0421/6495 224
Post^h210261
VI-2B222 Bremen
Telex 24 42 30
Telegrsmm; Saackebrenner C SAACKE)
1-1301-4190/02
 fcistmctkNisfbr
DbmouniHng

ollqun
. ^ v 0.,.30mm
ixxTugated
flexible steel
tift>e K / ? m r r ^

n wa.
I M12 nut

steam fuel oil

© Qoupling nut

n
DismminSng the oil gun resp. Vte iK^e/nOzzle shaft
1.1 Dismounting the oil gun
O-ring

nozzle mount
\
PQZzle shaft
no22l<

a. Loosen the flexible supply -tube (conugated flexible steel

tube) 1
DN12/15, wrench opening: 27 (32) (DD2 8 + 10)
PN15/20, wrench opening: 32 Im (O0Z1Z)
PN 80/2S, wrench opening: 36 (41) (PP214 4-16)
b. Loosen the two M 12 nuts, wrench opening: 19
C. Pull out the gun and put it aside
d. Loosen the coupling nut,
weftdn openings (w.o.) for
PDZ 8+10 W.o, 36 + 32
PPZ12 w.o.50 + 41
PPZ14+16 [Link]+46
e. Reniove the nozzle
f. Re-a%emb:ly in revetse XMtier
AttentiQn: Assure proper seating of the O-ring seal

n**^^ n 0^X3
 Steam-assisted pressure ]et burner DOZ 8*. J
for firing fm^ o

d) ^wilier

(V) Welding admixture material 1.497(

Bxchianging the swirlsr

tut Exchanging the ftwirter

a. Dismount the d i igun (see i .1)
b. Loosen the hexagon nuts M12, w,o. 19
C. Pull out the burner plate with the gun protection tube and
theswirler
id, Separate (by sawing) the swirier at the weld seam
e. Re^adiust the swirier and weld it back
Attention: welding admixture material: 1.4370
f. Re-assembly in reverse order

Technical Documentation

CSAACKE)
 In9truetlon«for
Dismounting

Dismounting the front plate

1.3 Dismounting the front plate

9. DisrnounttheoJlguh(&ee1.1)
b. Loosen the M 24 screws on the air guiding unit, w.o,: 36
C. Loosen the Screws M 16, w.o.: 24
d . Full the front plate fonwards out [Link] Windbox
e. Re-assembly In reverse order
 steam-assisted pres^re Jet burner DDZ 8...1
for firing fuel o

Exchanging theswirt unit

1.4 Dismounting the SWIFI unit

a. Dismount th0 oil gun (see 1 i1)
b. Dismount tiie front plate (see 1.3)
c. iLoosenthiefestenens for tfie tie rods
d. Shove the swirl unit forwards ahd remove it
0. Re-{Bsembly in reverse Order

Technical Ppctun^ntiition

c 3
 histnictlomfor
DtompuntiiHi

Eicheuiglng the air guiding unit

1 3 DJsmountlqg the air nuldlng unit (alf register)

a. Dismount the oil gun (see 1.1)
b. Dismount the front plate (see 1.3)
c. Loosen the hexagon nuts :M 12 at the windbox, w.o.: 19
d . Pull the air giiidlng unit out of the windbox
e. He-araembly in reverse order
f. Cheol< thieeedling of the air annulus against the refraptOry
lining and replace it, wfiere necessary

—. #> *< «> rtr* f\r9 rt-»

 Steam-assisted pressure Jet burner DD^ DDZG 8...16
Instructions for
Dismounting to be unscrewed in two parts

1.1 Dismounting the oil gun

a. Loosen the supply hose, f. Loosen the two nuts Ml 2 or the connection to the
corrugated steel hose pneumatic cylinder.
DN 12/15, size: 27(32) (DDZ 8 + 10) g. Lower the gun until the union becomes visible.
DN 15/20, size: 32(36) (DDZ 12) h. Loosen the union.
DN 20/25, size: 36(41) (DDZ 14 + 16)
I. Mounting in reverse order. When doing so, all unions
b. Loosen the union nut, should be treated with a temperature-resistant pa-
wrench sizes for
DDZ8 + 10 size 36+ 32 ste.
DDZ 12 size 50+ 41 (SAACKE-article no. 8-6620-528561)
DDZ 14+ 16 size 60+ 46
c. Pull out the steam guiding tube (inner tube) until the Attention: IMake sure that the O-ring seal and the
union becomes visible. seallngs are properly seated.
d. Loosen the union.
e. Remove the steam tube.

SAACKE GmbH & Co. KG SAACKE GmbH & Co. KG Tel. (04 21)64 95 0 Technical documetatlon
SiidweststraBe 13 Postfach 210261 Fax (04 21)64 95 22 4
28237 Bremen 28222 Bremen E-Mail info@[Link] C SAACKE)
Germany Germany Internet [Link] 1-1315-4203/02
2000-10-19 Page1
6. F.O System with equipments

KANGRIM INDUSTRIES CO.,LTD.

 PART LIST FOR DDZ /PB0301AS10
Doc. No.: MB-PL-02
Rev.: 0
(Page 1 of 4 )

#> Part list for burner Dwgno:PB0301AS10-60 >

No Title Type Q'ty Remarks

(/burner
1 Duoblock burner system - comprising : Turndown 10: 1
1.01 Steam press, jet atomizer DDZ 10 1315/131 kg/h
1.03 Burner air register incl. combustion air DDIO
section swirl & gun protecting tube
1.04 Steam atomizing gun ZIO
1.04.01 Nozzle shaft Mounted on 1.04
1.04.02 Nozzle Mounted on 1.04
1.04.03 Two corrugated steel hoses - oil / steam 1 set DN20
1.05 Windbox LKDIO
1.05.01 Damper
1.05.02 Pipework windbox
1.05.03 Wiring windbox
1.07 Primary air accessories -
1.07.02 Core air damper system Mounted on 1.01
1.07.03 Air pressure gauge for core air 612.20.100
1.09 Press, monitor with 3-way control plug v/v DL50U 30-150mbar
1.09.01 Shut-off valve DIN 16270 Mounted on 1.09
1.11 Air press, gauge KP 100, 1/2" Mounted on 1.09
1.15 Light oil igniter with transformer ZLE 52C/95
1.15.01 Air throttle w. double nipple 1/2"
1.15.02 Flexible tube unit air
1.17 Ignition oil v/v comprising:
1.17.01 Ignition transformer ZM /ZE (2x7.5kw)
1.17.02 Manual rapid shut-off v/v 3400 (DN4) R 1/8"
1.17.03 Electromagnetic v/v 9500295.3205.230.50 Gl/4"
1.17.09 Second electromagnetic v/v 9500295.3205.230.50 Gl/4"
1.17.11 Electromagnetic v/v 122K8363 2 Gl/4"
1.17.15 Pressure gauge for ignition

1.25 Fine mesh strainer SF335 Rl/2"

1.27 Ignition oil pump PZHDS 30
1.27.01 Ignition pump motor 440V 3ph 60Hz 0.22 kw
1.28 Expansion vessel PTl/2"
 PART LIST FOR DDZ /PB0301AS10
Doc. No.: MB-PL-02
Rev.: 0
(Page 2 of 4 )

No Title Type Q'ty Remarks

2 Fuel v/v and fittings DN25, PN16
V/v and fittings mounted within windbox :
2.01 Mounting material
2.01.01 Compound regulator VRKM14e
[Link] Servomotor HD60D2
2.01.03 Bracket imit -
[Link] Linkage between VRKM-air damper
[Link] Clamping level unit
2.01.13 Liquid feed unit,consisting of
[Link] Oil pressure gauge
[Link] Shut-off valve DIN 16270
[Link] Oil thermometer
[Link] Doble Two-Point temp. monitor(Oil alarm) ATHS-22
[Link] Oil pressure monitor DWR 6-203
[Link] Test valve ECONOSTO
[Link] Coilpipe 2
2.01.15 F. 0 press, controller - spring regulating V 22 D28 1 set max.3900 l/h,13bar
2.02.05 Electro pneumatic v/v with pneumatic actuator K514466 PT150/RDB40 2 control air : 6 bar
2.02.06 Non-return v/v RK44 DN25, PN16
2.02.07 Pressure gauge 111.10.63 0~16bar
2.02.08 shut-off valve DIN 16270
2.02.09 Dirt trap SF335 DN32
2.02.11 Manual rapid shut-off v/v FIG.1619 DN20
2.02.17 Oil flowmeter with pulser In VZO25,0.11iter/pulser DN25,PN16
2.02.20 Four-way plug v/v for by-pass line DN32
[Link] Bracket unit DN32
2.02.25 Oil pressure monitor DWR 6-203
2.03 Flexible control cable Type5,Type70
2.03.01 Strap
2.03.05 Electropneu. v/v w. cont. v/v & limit sw "normally open" 20 bar, max.350°C
2.03.08 Shut-off valve Fig.40/1 R 1/2"
2.03.09 Pressure gauge 111.10.63 0~16bar
2.03.10 Shut-off v/v DIN16270 DN15
2.03.11 Coil pipe
2.03.12 Two point steam press, monitor DSB 158-FOOl 0.5 ~ 6 bar
2.03.13 3-way ball Test v/v Fig.l635L
2.03.14 Coil pipe
2.03.22 Dirt trap 12.050(DN20) DN20,PN16
 PART LIST FOR DDZ /PB0301AS10
Doc. No.: MB-PL-02
Rev.: 0
( Page 3 of 4)

No Title Type Q'ty Remarks

2.03.24 Atomizing steam pressure controller unit AFP/VFGS2 D03 DN15

[Link] Pressure control valve
[Link] Distributor
[Link] Manual rapid shut-off v/v FIG.1619 2 DNIO
[Link] Manual rapid shut-off v/v FIG.1619 DN15
2.04.05 Electropneu. v/v w. cont. v/v & limit sw K514466PT150 20 bar, max. 1601;
2.04.06 Non-return v/v RK84 PN16,DN15
2.04.08 Shut-off valve EVN(DN15) Rl/2"

3.01 F.D Fan with silencer BSTF-7

3.01.01 F.D Fan motor 1770 rpm, 440V 63kw, "F", IP44

4 Pump with srainer group coprising: DCS 7/1800 1950 1/h at 15 bar
4.07 3-way ball v/v with limit sw. 10K-50A
4.08 Double screw pump
4.08.01 Two drive motor 440V, 3400rpm 2 2.2 kw
4.08.03 Double strainer 2
4.08.04 Check v/v 2
4.08.05 Safety v/v
4.08.06 Pressure gauge
4.08.07 Compound gauge 2
4.08.08 Thermometer
4.08.09 Oil tray
4.09 Press, sw for auto change-over pump 904 l~16bar
4.09.01 3-way test cock 3/8"
^/bumei •)
(/ ship ]
5 F.O heater unit comprising :
5.01 F.O heater
5.01.1 Relief v/v 1/2"
5.01.2 Thermometer "L"type
5.01.3 Air vent v/v 30K-6A, \m
5.01.4 Steam drain v/v 30K-6A, 10$
5.01.5 F.O drain v/v 30K-6A, lOO
5.02 Temp, control v/v 20H2F, V4.05
5.02.1 Y-strainer 20A
5.03 Steam trap Ball float type
1
 PART LIST FOR DDZ /PB0301AS10
Doc. No.: MB-PL-02
Rev.: 0
(Page 4 of 4 )

No Title Type Q'ty Remarks

8.01 Steam seperator unit Iset JISIO

8.01.01 Steam seperator S20 1 PN16,DN15
8.01.02 Steam strainer Fig 37 1 PN16,DN15
8.01.03 Steam trap FT14 1 PN16,DN15

6.01 Automatic sequence control system F-OSA 1

6.03 Flame detector with flame scanner(normal) FLUS06/FLS09 1
6.17 Emergency operation system NB02 1
6.17.01 Control unit for Emergency operation 1
6.17.03 Flame detector with flame scanner(emergency FLUS06/FLS09 1
6.21 Flame trouble indicator CMFSOl 1

9.05 Electric heating tracer KH12 1 0.55 kw .

9.07 Clamp-on thermostat for heating tracer RAK82.4/3729T 1 80-180 'C

10.0 Temp, transmitter PTIOO 1 0-200 °C

11.0 Press. Transmitter 8202 1 0~16kg/cm2
11.1 3-way test cock valve PF3/8 1
 8
P L A N H I S T O R Y •
REV. DATE D E S C R I P T I O N OWN CHK APP'O

A "02.10.10 rOR ISUUED [Link]

A '04.11.20 FOR REVISED [Link] H

A "05.10.20 REVISED BY MAKER [Link]

CAUCE BOARD

r n
-OD- rCJ3 C ^
Took D.O
Light 0;i

MS)-

Flue 9 0 s

D
L_U 6K Compressed oir

1>
Combustion oir

o sc •• NOTE ••

— Fuel—oir/piping

_ Linkage
^
_ Trocing
(LS) (LS)^fl*I QoaoBy
-^ Supplied by moker

xh HX- I I jDNSO I 1
H.F.O
B Settling Tank
4:07—^ ^
I I Supplied by moker B
I [Link].c
I I

L-JX-
PROJECT TYPE CLASS/RULE
031l~6,0442~4 PB0301AS10 H.M.D ABS

TITLE O*'^ 2004.10

DIM. SCALE

F.O P & l DIAGRAM mm N/S ^ ^

w/0 NO. PBC04MP0311~6
PBC04MP0442~4
DWG. NO.
K A N G R I M INDUSTRIES CO., LTD. PB0J01AS10-60
A
 I ? 3 I i \ T \ » I 10 1 II I 12 I 13

y///////////////.

CoiT^ustion air

OH comminq drain hoper

5K-tOA

Air tnleF FUngc

(CombusMon air)
_S5S_
••finitKtMwna irrMtl nvcri M t n t / V I
_5J!L HarMntmt%y9^%ra M • 1 1 * / l 1 t « t M n I t
_15!L [XXX I
[Link]

» <\
Burner connection platt •1V5
(not Saacke supply)

26.10.2004 Preifer

A: Oil inlef (Flange DN25)

B: Oil refurn (Flange DN15) e^ IM21U
AbwaMltufif fiMT l M « r » l r * M -

OBvUIMn r«r • • • • r biWK M l : 10

MMM/OMMiM* 0 * Q C
C: Steam inlef valve (JIS 7410,16K-15A) Ptranfid L*|a _ _ _ (titflnf
Ftra • M P M W I M B H Q K G l S N N I t V H
••MTkUlf/lltMrk

D: Compressed air inlet (Flange DN15) Burner DDZ-10 for top firing boiler

• miwiunf/O* •crip li«n

-t 1:
E: Condensate outlet (Flange DN15) Feuerungsanlage Kang Rim
Firing plant HHDCH-0442 Series

To oil comming dram hopper 010 copper pipe

Sailt-NrVArtMl* Itfrawin^l No

F: Diesel oil inlet(08 sus pipe end) 0-0133-33851.3 81.1

/I
Dtaf t lM<htr»r"**** ISO t i n s y i j 1^0.) f(kAACKi) MAMNl •YOTIIW ]
Sorf M l »rn»*l> •»/
ISO 1101 V

nJ SAACKC-rarNMM' • • • m - » ) ] ] T t . m i - t l S<nuti*«r«i«rti OW H M M h t a n y e i v a * * r i r t r ra p r « i « t M n narKt » m DM H .

rr I 3 I t I 7 I ~r 12 I I IS T

Q : To oil comming drain hopper

010 copper pipe

1 : Manometer und Druckschalter mussen durch eine

zusatzliche Halterung auf Grund von Schiffsvibrationen A: Oil inlet (Flange DN25)
montiert werden.
B: Oil return (Flange DN15)
(SAACKE Lieferumfang)
C: Steam inlet valve (JIS 7410,16K-15A)
1: Pressure gauges and pressure switches have to be D: Compressed air inlet (Flange DN15)
mounted with an additional support due to ship vibration E: Condensate outlet (Flange DN15)
(SAACKE supply) -> To oil comming drain hopper

nt6

•(•nntWIwiyiif arlatf) Mch M t n ( / t 1

Narklnf Ki*T«M« ( • M >rt»/*1 taitlwi I t
n » l l lutr ita>M|iMMiwn( f^rgl
tM«« f WHiBn I ***1

^}0
WwaiihiiAf fuar Li
lUITU
OavUlten r*r I M * M l : 10

Baaarhimt/MM'*
Burner DOZ-10 (or top firing boiler
To oil comming drain
••«t«nnunf/D<Krip lt*n
010 copper pipe
Feuerungsanlage Kang Rim

D Firing plant HMOCH-04A2 Series

Sxh-Nr /ArrrtIV Itfrswingl Na

0-0133-338543 612
/I
Ob«rtlaKMn«|r"MI« iso t l T » l * j Lp j
S«rfK* tyinMft M / i_r . i _ _ lAACKM^ M A M N I SYSTIRM
ISO i i a i V

t tAACKC-F«rMMl*r • - t m - t » m , IM>-tt
3 I T S I » I SfhwKvamwrti OM 14 M M M i n . / » i a « M r t f i r la prmaf rt«n iwlka «« M OW H .
 «U*OCMI-0\«

POSNO. 1.17 <Ja Oet-eintritt

OH-ln(ct
SRV •
SRV 8

43 23 <750 IQ) 62,63 24 30 81 y4-n Oei-fcistrtt't SRV 8

NJJJ (M-auttct SRV 8'

yj-m CnttastunQsleltung SiV 8

<j3]eigC RelleF piping SRV 8

Kerienstecker
^ Spsrfc plug connector

45,41 yjjb-jl K«ri*fWt«*er

N r ^ SpM* plug connector
^dr-n Kobetversdirauliung ft 9
^ f - " CoUc connector Pg 9

jAr^i Kobeiverschraufcung Pg 11
^r-^ Can* connector Pg U
54,55,60
40,41
$RV • Oonplng ring coupUngs
25,34,38
25 <30 lQ>
40,41

3E
GeroeteonscMuss / Appliance connection - T l
ZuenGltransfonwtor / Ignition tronsfomer

OnschoCtdauer / P e r c e n t a g e d u t y cycle 80 X / 3 nin

Prinoer-Anschluss / Prinory connection 1 8 7 ^ 4 2 V / 60 Hz
Lttetungswifnohne / P O M T Input S5 VA
SekundteronschUiss / Secundtry connection 2 x 7S80 Vi30 nA
IP 40j a.60*C

1 55,57,58 ao,22
Geroetcwischluss / Appliance connection - T l •ra
DektronagnctventX / Dectronagnetlc valve
^
^
Anschlusssponnung / Operating voltage -Vi-Hz s-Tobellc
Lcistungsaufnahne / Po««r Input nox. 22 VA Anzug / Pkk up
IS VA I M t e / Holdhg
Ekischoltdouer / Percentage duty cydc UM t
IP 6S| *SSMSS*C Sponnung 4-10 -ISZ
Zugelassen noch BIN 3272S Fuer Heteoele nach DIN S1603

65 70 52,53 56 31 52,53
GeroetconscNuss / Appliance connection - T 3
QAktrwogM'tvcntl ( dKctronagnetlc valve

AnscMussspannung / Operating voltage slehe TabeUe

Lebtungsaufnohne / Paver Input nax. 32 VA Anzug / Pick up
US VA / 8V Halte / Holding
Qnschaltdouer / Percentage duty cyde MO X
Stronlos offen / Open vhen deenerglce
^ ^ 62,63,64

2-a32«-93M» MHz
X-332«-9M1U

[Link] 30.10^12 UchUnbTg

2 17 15 3 3 17.04.01 IJditanbwa 1T.t4J1 Uchtenbara
o*.[Link] 0«.04J01 UdiUnbafg
twkk

01.t4.01 _UcMMb«|_ 0tO4,O1 Uchlenberj

a*niifvO««M%

CSMCKE) t ll
d> katnaSv
*' • M « | M k f M bMMM ««»>•
CwilB .^ V * <wiwiii« w r r<»,t h »

ZQndarmaturen
r Ignition valves and fittings

— B4> (4> N i c h t l e s b a r e Angaben u n d oUg. r e r t l g u n g s o n w e l s u n g e n slehe SN 0 8 7 6

2-3328-530192
fa
lUefllble d o t t t a n d g e n e r a l n a n u f o c t t i r l n a r c q u l r e n e n t s s e e SN 0 6 7 6
^ m ^ M B i M • I r •••! • • « _ . . H ^ ^ p B ~ J b ^ > ~ > i ^ ^ ••
9*M »>|
M^—^11 • w n ^ ^ ^ ^ B ^ i H . ^ | M | M B
»a »fc'Vt'TTBI
I " JL J | '
U > W' K ">< a Mtl
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fel I « t
Wwrwtt^dnnn torn/ Mw*«t ««* rw«« ^ "^
..a ^«« «ac ,.i«o .^w ^loflo ^oool -4000
• C I A l l t MVMMatorxinn C M M l <»»™i U M r M M O n t r K U • « « « « * * » L £ i i i i i i i * * • * * " .•STilS'S'[Link]!
y^ 1 >*<*
32
JHLOUSUZeL •""•»'" M4 k * J * t j BCT** ecstsrte;*^
jir
SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION!0190/ZN

P A R T S L I S T
ARTICLE NO.
DESCRIPTION: IGNITION VALVES + FITTINGS 2-3328-530192
(0IL)3 VALVES 220 V^ 60 HZ
SHOWN IN DRAWING NO : 2-3328-530192/1 SHEET: 1

ITEM QUANTITY ME DESCRIPTION ARTICLE

# -SPARE PART REMARK

•-WEARING PART

I M P O R T A N T H I N T S

1. IN YOUR PARTS ORDERS PLEASE STATE

- ORIGINAL CONTRACT NO. (SEE ABOVE),

- DESCRIPTION, AND
- ARTICLE NO. OF PART

2. ALL RIGHTS RESERVED ACCORDING TO DIN 34 !

•••CONTINUATION SHEET EXISTS**

SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:0190/ZN

P A R T S L I S T
ARTICLE NO.
DESCRIPTION: IGNITION VALVES + FITTINGS 2-3328-530192
(OIL)3 VALVES 220 V, 60 HZ
SHOWN IN DRAWING NO : 2-3328-530192/1 SHEET: 2

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART
1 # 1 OFF IGNITION TRANSFORMER 7-5615-500270
TYPE EBI NO. 052F0030
2 2 OFF RAPID SHUT-OFF VALVE 7-0583-013250
8X8-CONNECTION FOR PIPE
3 # 2 OFF ELECTROMAGNETIC VALVE 7-0800-528024
9500295.3205.230.50 50/60 HZ
NORGREN HERION
11 1 OFF ELECTROMAGNETIC VALVE 7-0800-509001
122K8321-8760.23-483824-T1
15 1 OFF PRESSURE GAUGE 7-7370-012178
FORM E,D=63,R1/4,KLASSE 1,6
20 # 1 OFF PRIMARY CABLE WITH PLUG 7-8774-502165
F. IGNITION TRANSF.EBI052F0030
21 # 2 OFF IGNITION LEAD 4-8480-282644
[Link] TRANSF. EBI052F0030
22 2 OFF BUSH 7-4784-501585
[Link] TRANSF.EBI052F0030
23 1 OFF FLEXIBLE TUBING 6-4300-529730
DN 6,PN400/700 LONG,MARINE
24 1 OFF BOX TYPE CASING 7-5846-006184
CM 06/318
25 2 OFF PIECE OF PIPING 5-3111-220718
26 1 OFF PIECE OF PIPING 5-3111-220718
30 1 OFF TRESTLE 5-6537-220729
31 1 OFF STRAP 5-4523-240539
34 1 OFF ADJUSTABLE ANGLE UNION 6-4845-511164
EMB VBDKO 8-L A3L
35 2 OFF SEALING RING 6-3030-000679
A 14X18 CU
36 2 OFF STRAIGHT SCREW-IN UNION 6-4590-001759
WALTERSCHEIDT K-GEV 8 LR
38 2 OFF ADJUSTABLE L-TYPE UNION 6-4665-014767
WALTERSCHEID P-ELV 8 L
40 3 OFF STRAIGHT SCREW-IN UNION 6-4590-530491
41 4 OFF SEALING RING 6-3030-000677
A 10X13,5 CU
43 1 OFF STRAIGHT UNION 6-4610-014752
WALTERSCHEID P-GV 6 L
44 1 OFF [Link]. GAUGE CONNECTION 6-4630-014766
WALTERSCHEID EMAS 8 LR +DKR
45 1 OFF STRAIGHT SCREW-IN UNION 6-4590-001756
WALTERSCHEID P-GEV 6 LR
52 2 OFF [Link] SCREW >ISO 4762 6-0110-000135
M 8X 30 > 8.8-A3F
53 2 OFF HEXAGON NUT >ISO 4032 6-1080-000427
M 8 >8-A3F

•••CONTINUATION SHEET EXISTS**

SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:©190/ZN

P A R T S L IS T
ARTICLE NO.
DESCRIPTION: IGNITION VALVES + FITTINGS 2-3328-530192
(OIL)3 VALVES 220 V, 60 HZ
SHOWN IN DRAWING NO : 2-3328-530192/1 SHEET: 3

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART

54 2 OFF [Link] SCREW >ISO 4762 6-0110-000109

M 4X 16 > 8.8-A3F
55 4 OFF [Link] WASHER>DIN 6798 6-1850-000522
A 4,3 >FST-A3F
56 2 OFF [Link] SCREW >ISO 4762 6-0110-001444
M 4X 12 > 8.8-A3F
57 2 OFF [Link] SCREW >ISO 4762 6-0110-530353
M 4X 45 > 8,8-A3F
58 2 OFF HEXAGON NUT >ISO 4032 6-1080-000424
M 4 >8-A3F
60 6-1590-014805
2 OFF DISTANCE ROLLER
62 [Link].=8MM,[Link].=4.3MM 7-4793-526239
3 OFF NUT PG 9
POLYAMID, DIN 46320/03
63 JACOB 7-4793-526222
4 OFF UNION, PG 9, 2 - 6 MM
POLYAMID, BLACK, IP 68
64 JACOB 7-4791-006456
1 OFF REDUCTION
65 H PG 11-PG 9; DIN 46320/02 7-4793-526223
1 OFF UNION-PG 11, 3...7 MM
POLYAMID, BLACK, IP 68
70 JACOB 6-4990-013975
2 OFF UNIVERSAL PROTECTIVE PLUG
GPN 610-U 1

*** END OF THE LIST ***

0 3 I H I 9 MARINE SYSTEMS Doku-Nr.: SMS 3-0003-0026//2

Issued on: 13.04.2004

DATA SHEET Issued by: 1100/Fre

IGNITION TRANSFORMER - 2 x 7.5 kV

Technical data:

Application: Included in set of ignition valves for marine SKV / SKVJ / DDZ
burners with ZLE type pilot burner.

Material, casing: Special plastic

Ambient temperature, max.: +60'C

Supply voltage: 187...242V. 50...60HZ

Ignition voltage: 2 X 7.5 kV
Degree of protection: IP 40

Article number: 500270

This document consists of 1 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse13, 28237 Bremen, GERMANY

Tel.;+49 421 6495 138, Fax.:+49 421 6495 363, email: marine@[Link]
r-fiTiTH A ^ MARINE SYSTEMS Doku-Nr.: SMS 3-0003-0017//2

Issued on: 13.04.2004

DATA SHEET Issued by: 1100/Fre

IGNITION OIL VALVE - Type 9500295.3205.230.50

Technical data:

Application: Ignition oil quick-dosing valve. Mounted on ignition vaives set

on SAACKE marine burners

Material: housing: brass

spindle and seat: 1.4104
Medium pressure, max,: 50 bar
Ambient / Medium temperature, max. +80/+180 "C
Connection thread: BSP y*". female
Mounting: preferably with magnet on top
Operation: by direct acting soienold
Voltage: 230 V. 40...60 Hz
Degree of protection: IP65
Electrical connection: by plug, DIN 43650 Fonii A

Article number: 528024

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERIVIANY

Tel.:+49 421 6495 138. Fax.;+49 421 6495 363, email: marine@saacl<[Link]
CSAACKE: MARINE SYSTEMS Doku-Nr.: SMS 3-0003-0p17//2

Issued on: 13.04.2004

DATASHEET Issued by: 1100/Fre

Dimensions:

Valve body:

rMo •"Tl
f 1
1 1
i SW19 1
, a
•Tr 1 J "T"
1 \
1
H 1
1
I.I
K-I-f-1
K i 1
1
1
f I
Stg .i : .
l-i-Z rK
I
T^ •r-

,
3S
'1
674
i
.26.

Magnet:

81,5

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363. email: marine@[Link]
t - ^ i T i I H A4 MARINE SYSTEMS Doku-Nr: SMS 3-0003-0018//2

Issued on: 13.04.2004

DATA SHEET Issued by: 1100/Fre

PRESSURE RELIEF VALVE - Type 122 K

Technical data:

Application: Pressure relief valve. Mounted between ignition oil valves and
between main oil valves. Opens when ignition oil or main oil
valves pair closes to prevent pressure from building up between
the ignition oil or main oil valves.

Material: housing: brass

spindle and seat: stainless steel
Medium pressure, max.: 30 bar
Ambient / Medium temperature, max. +60/+160°C
Connection thread: BSP %", female
Mounting: preferably with magnet on top
Operation: by direct acting solenoid
Voltage: 230 V, 50...60 Hz
Degree of protection: IP44
Electrical connection: direct viflred

Article number: 509001

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERMANY

Tel,:H9 421 6495 138. Fax.:+49 421 6495 363. email: marine@[Link]
(SAACKE: MARINE SYSTEMS Doku-Nr.: SMS 3-0003-a018//2

Issued on: 13.04.2004

DATASHEET Issued by: 1100/Fre

Dimensions:

44 22 87
« p^

_»-
.•
>
" xt;^ £!_
f' l,:!,!.,
*
=. rtftl ^.^ • ' '
zx.
(A K
m « '
iC f r- M^.
ev
T-
• 1
}r^ lb ^
u r^ •wAlMlfc

' 5
.> ?::: -1—
G
4 19
• - ' -»»*•
<».—
a/
•« «>^i

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363. email: marine@[Link]
CSAACKE] MARINE SYSTEMS Doku-Nr.: SMS 3-0003-O015//2
Issued on: 08.04.2004
DATASHEET Issued by: 1100/Fre

IGNITION OIL PRESSURE GAUGE -Type 111.16

Dimensions:

D1: 68.0 mm e: 5.0 mm

D2: 63.0 mm
b1: 30.0 mm G: BSP %"
b2: 47.5 mm SW: SW14

Technical data:

Application: Ignitior1 oil pressure indi

on SKV and DDZ bumers.

Scale range: 0...16 bar

Medium pressure, max.: 16 bar
Ambient / Medium temperature, max.: +60''C
Material, casing: Special plastic
Material, measuring tube: copper alloy
Accuracy dass: 1,6
Connection: BSP 1/4"

Article number: 012178

Tills document consists of 1 page(s) 1

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363, email: mar1ne@[Link]
 POS NO. 1.25

' DN K H d €*
c a SW
Rp 3/8-1/2 65 4B 1? 16 28,5 11 27
Rp 3/4 75 56 22 21 34 12 32
Rp 1 90 64 27 26 41 14 41
Rp 1 1/«. 110 ?6 52 31 51 16 50
Rp 1 1/2 120 84 38,5 37,5 61 18 5S
Rp 2 150 102 4 8 5 47,5 74 20 70

Ciah ^^scticnweite Q5nini

4 1 -J'cD oraht * - 0.4flni Screen 1.4401/1.4571
3 1 Dichfung DIN 7603 Sealing , Cu
2 1 Stopfen Plug P CuZn40Pb2 vernickelt
1 1 Gehduse Body P CuZn40Pb2 vernickelt
Pos. Stuck Benennung DesignaHon Material

sf 6?a Oritan itaArajii-Mr.;

Mkf HMyH^ PRiiDftiCH KROMBACH
A»ifWiWr. onUH [Link]' MfiMirantibrtk
_2ijiai JS^L^ KRONBtftCM 0H$7»SKnHxW - PovtfMh 1130
AWMTUkEN
Maltih/tt cHDHNffif f "JT* .'
Schmutzfanger mft MuffenanschlufB SF335

/o
Strainer with socket connection type SF335 S4-584-
DN 3/8" - 2" PN 40
 POSNO. 1.27

CSAACKE: MARINE SYSTEMS Doku-Nr.: SMS3-000»-0007//2

Issued on: 21.0B.2003

Issued by. HOQ/Fre

IGNITION OIL PUMP PZHDS 30

WMMffitlQ

Technical Data:

Pump: Motor

- Discharge pressure: 7...14 bar Voltage: 230 V

- Inlet pressure, max.: 2 bar Frequency: 50/60 Hz
- Return pressure, max.: 2 bar Speed: 2800/33001/min
- Viscosity range: 2...75 cSt Power consumption: 0,18/0,22 kW
- Oil temperature, max.: 60 °C Protection: IP 54
- Installation: as shown
Inlet connection: Clamping ring coupling for piping 0 6 x 1.5
Outlet connection: Clamping ring coupling for piping 0 1 0 x 2

Return connection: to be plugged up

Weight of complete pump aggregate: ~8kg

It is to be ensured that the pump is always filled with oil. For this purpose, a check valve has to
be installed in the suction pipe in case of tank level below pump level.

A protective strainer with max. mesh size of 0.25 mm has to be installed in the suction piping.

Under the above mentioned conditions, the pump is maintenance free, only the bearings of the
drive motor have to be cleaned and re-greased every 5000 operating hours.

Dieses Dokument besteht £UJS 1 Seite(n) 1

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERMANY
Tel.:+4g 421 6495 138, Fax.:+49 421 6495 363, email: marlne@[Link]
SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:0190/ZN

PARTS LIST
ARTICLE NO.
DESCRIPTION: PUMP SET PZHDS 30 1-3851-279060
SHOWN IN DRAWING NO : 1-3851-1272 SHEET: 1

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART

I M P O R T A N T HINTS

1. IN YOUR PARTS ORDERS PLEASE STATE :

- ORIGINAL CONTRACT NO. (SEE ABOVE),

- DESCRIPTION, AND
- ARTICLE NO. OF PART

2. ALL RIGHTS RESERVED ACCORDING TO DIN 34 !

•••CONTINUATION SHEET EXISTS**

SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:0190/ZN

PARTS LIST
ARTICLE NO.
DESCRIPTION: PUMP SET PZHDS 30 1-3851-279060

SHOWN IN DRAWING NO : 1-3851-1272 SHEET: 2

ITEM QUANTITY ME DESCRIPTION ARTICLE

# "SPRRB PART REMARK

*=WEARING PART

1 1 OFF YOKE 5-6559-109096

DIAM. 115
2 1 OFF SERVOMAX COUPLING 7-1900-601782
SHORE 64 D, MODELL EK2 060/B
3 1 OFF RATING PLATE 5-8116-999038
9 6-2360-000590
2 OFF GROOVED PIN >ISO 8746
10 2X 6 >ST-A3F 6-0630-000327
2 OFF STUD BOLT
12 M8X25 M 8.8 ZN 8 6-1080-000427
2 OFF HEXAGON NUT >ISO 4032
14 M 8 >8-A3F 6-4590-501561
2 OFF STRAIGHT SCREW-IN UNION
15 WALTERSCHEID P-GEV 10 LR-WD 6-4845-501563
2 OFF ADJUSTABLE ANGLE UNION
16 WALTERSCHEID P-EWVD 10 L
2 OFF WELDING CONE BUSHING W/O-RING 6-4782-001265
17 SN 10X1,5- 028784
1 OFF STRAIGHT SCREW-IN UNION 6-4590-501562
18 WALTERSCHEID P-GEV 6 LR-WD
1 OFF WELDING CONE BUSHING W/O-RING 6-4782-013571
19 SN 6X1,5- 028782 6-0110-000134
4 OFF [Link] SCREW >ISO 4762
20 M 8X 25 > 8.8-A3F 6-1510-000477
6 OFF PLAIN WASHER >ISO 7090
21 6-1080-000428
8 >200 HV-A3F
22 4 OFF HEXAGON NUT >ISO 4032 6-0110-000145
MIO >8-A3F
23 4 OFF [Link] SCREW >ISO 4762 6-1510-000478
MlOX 30 > 8.8-A3F
31 4 OFF PLAIN WASHER >ISO 7090 7-7370-006001
10 >200 HV-A3F
33 1 OFF PRESSURE GAUGE 0-25 BAR
FORM AS D= 50 Rl/8 CLASS 1.6
35
1 OFF PARALLEL KEY >DIN 6885-1 6-2810-001968
A 2X 2X 20 >C45+C
1 OFF GEAR PUMP 7-2425-501531
AN 47 D 7219 - 3 P: 54 FLANGE
SUNTEC

*** END OF THE LIST ***

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LSSTUNG BB O A M i R B ^ T R ^ (SI) / Output at SI dui^

UM6EBUNCSTEMPERATURBiS40*C / Eo\^rpWnentaltemperature)p 40*0

PflP Mifiiii^ TCMt* Htnii* llwin* [Link] W M u i i i g » AataMf* Aiilwr. Nftp. H„„n 9iivlcd)t

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4 > P O U 0 . SYHCHROriDREHZAHt 1S0O U M N .

4 - P 0 | £ . SYMCajRQNOUS SPEED laOQipnnr

7AA6iiMe4K 0.06 13Q5 0v4? 030 0J8 663 23 13 AO 030027 A

7AA5eMQ4 e.P8 1300' Q.64 039 . KTT 56.0 3.3 2;» 2.1 3.00027 3
7AA8aMp4K mM 1315
m 0,^ 9.77 ^P %Q J3 13 Wippao 33

TMBm9* D.W 1315 13 J038 0.78 593 U 2,0 2.0 030040 4.1 -
7M71M.(MK 035 1325 13 031 Q,n 613 33 13 13 0.00060 43
7AA7tMD4 037 1375 23 1.05 0.77 663 V 2.0 2.0 0.00060: 6

7AAa0M.04K A.55 1986 37 1.42 0.79 713 4.7 23 2.4 030160 6

7AMKIII404 0,76 1396 5.1 1.66 0,7a 743 63 2i5 2.6 0.O018Q' M
7AA909fl4 •.1 1415 73 &55 031 773 43 23 2.4 030260^ 123
7AA9QL04 13 1«^ 10 3.40 031 793 63 2.4 23 moBo 15^6

fi-jPOUO, SYNeHRQMDAEHZAHL tOQQ UiMW.

6 - P Q I f . SYNCHRONOtiS SPfgO IOOO. ipm

7M63liil0iSK 0.06 ] 830 ,0.7 0.34 3.66 393 2*0 13 "13 03PQ9Q' 33
7AAl^MD6 0.09 ' iso 1.1 Q.4«t 0.66 413 : 2 3 / 13 13 0,00040 4.1
7AAriMgeK 0.1* 83p 23 01S» 0.71 633 43 13 - 1,9 030060 63
7AA71»ilQ6 0J!5 - 826 23 033 0.74 59.0 33 23 2.0 O.Q0D80 63
7AA«i(l4i)QK 037 810 33 1.M 0.72 62.0 23 13 2.0 Q3IM50 73
7AA8QM051 0.66 900 • 6 3 •• 1,67 Q,r3 653 3.2 23 2,1 Q.OQ180 0.4
7AA90a06 ai75 fiCUt
CRra 83 2.10 0.T7 673 33 23 23 0.00260: 123
7AA90L06 1,1 .900 12 3.00 076 71.0, 4.1 2,4 2.4 030350 15.7

a • P O U O . SYNCHRQNDBEH7AHL 7S9|1iinN.
8 T FCLE, SYNCHRONOUS SPEED 750 ipm

7AA71M^0eK
m. 630 1.4 ,0,36 036 663 2,4 1.7 i.r 01.QQ090 6.3
7M71M.06 0.12 655 1,8 0,66 0.5? 513 .2,2 1.7 i.r Q.00090i ,. 6 j 3
7AAeQM:00K 0,16 675, ^8 0,73 036 513 2,4 1.7 13 O.Q015P 73
7AA8QM0B 0,26 670 53 , 1,12 0.6? 523 23 1.7 1,7 0.00180 9.4
7AA9ffiSQe 037 ^ 665, i 53 . 1.16 0.76 813 2,8 1.4 1,7 0.00^ 10.5
7AAeQI.06 0.65 esQ ' 73 132. 0,76 65,0 2,9 13 1.7 0,00350 13,2
7AA9a.06 0.75 655 It 2,7 ; 0,87 603 23 : 1.7 13 0.0«|5P. 13.6

Sond^rleistungen a u f A n f t a g e / Special output upon nBquest A n d e r u i ^ e n vQrtwhaltap / Subiect to possible charKie

ELEKmOMOTORiN
General biformatton

PnisfcSapi^i: IP 55

InslatlDntlass: F (nvx^temperalMrBlroittsrC^

Tempwalure Increase; lnli«]QrM88s(<8QK)

BnvlPcnmenM tampeFatuTK f ^ 8tanda(dseniigutrih)0lk]m'2D'^

SpdCiatoonSguraSons: QpfBtpiest ailso oSvriXQleK^ ^ipee, «tan(i8Wlie!aler.^9cpinlig!arafipn,

IveloiaiM l>e9rlrp,JttMrinQ-«e^^ spedai siiafl& andflanges,special paNng,
S P J i m^fiwing riipffe. iQiaBinalaxftialsins, sp^cJsA peifonaBtm

PfQtecQon roof on ihd cooling Ian l»Qi;( AMoRsinyilMaiBon

StmitaRl* M d flagubiHom:

DiNeiaQ 034-^1 Genral f^itbtions, Rotating B « $ 4 r k » I N b ^ ^

DIN42«7a A|laciiii»nlDlfneniriQn»aixlAEK<gniTi^ .

OiN42W Machnient Dknen^QDs and As^gnmant of PierlannaKie for t^

13INEN60034>::^12 ai«ilng Chai;acterl4tl(se>, I % Q U ^

CMNVDEO^TOl-ft Qonnecfion Qe^graAms and RotaSonaTDIrectlQn, Bcita^aaietrical Ma(it»s

W EM 8 ) 0 3 4 - 7 QesHgnafion? for OonsiniGtion Forma and Positions

DIN 4202$ Uad-in totheTanninal ^

DIN£NSQQ34-^ ilmiltog Noise V^iues^J^QtattigElaqlrica^

t}|NIEC6Q038 lEC-^tendardAAHiag^

DIMeN«K»4-fi T)fpes<ilQo9i[!g, fU«te(ling Et0(4riGal]li^^^

1

£HNEN«0Q34-14 Atechaidcal Vjbratjiqns, Rotating Elediicai Machines

OINENfip034-5 ProtiBetiQQ typ^, Rotating Electrical Macjiines

DIN 7 4 8 - 3 CyiMiical Shall Ends, Electrical Machines

H o u ^ Colouration

7AA56-132 AhimlnlMim alloy

ZJB^-IOO Abntinium alloy
7JE^-100 Ali«n|n1uma1l(^
7BA16a Grey cast iron
C180-20a Grqfc^DtH)
16BA220'-2Q3 GrE^G^iron
315-355 Grey cast iron

Bearing End Plate Configuration Grey cast Iron lor all construction tks$ and standard configurations
BAUFORMEM NACH DIN JEC 34 TEIL 7
CONSTRUCTION FQRKfIS ACCORDING IX) DIN lEC 34. PAFCT 7

GB3&iOaEFsmmn&o^ mxiasenomi FOR Pie CoDipaifBon pfttw dwrt des|gnaiionstarthe,oon(iguiaaoRB

gAW^ORM^ MACH OIN lEC 34 TEH. rjU^Q PB« <bmis 9i»>reln9toPIN jeQ 34, Rsvt 7 and • ! » Ql(f DIN 4 3 « 9 0 .
>^TEN&IN4a95P

DM IPC 34 tmAgfBSQ
TWT alt
Codati CMe2

MP3 MIQOI aa
]MV5 iflOll vs •«B3 MB<S ««B7 mBA Mvs ftf^re
iMvei Ad'Hiail V9
IMW JMIcei Be

IM1B7 041064 B7
JMB8, JW1071 B8

iMfiae 142001 93/B5

IMB34 1M21Q1 ^/B14 ^ " &
•(IBS lUVI MYS MBA MV«
IMB5 1M30&1 B§ MVD
WVI IM^qii VI
iMV3 iMseai va

#»Bt4 (M^l ei4

o
IMV19 iM^eii V18

WV19 M3«31 via

niBio ayi4(nt B$e
mrnn vw IMBt4 WVJfl IMVtS
IWVIO MB3S IMe34
MV14 W4031 V14
IMyi« M4131 vie ANMERNI^Ne: Note:
BEfMERIBAI^VQNMOTOREN IN AUS- f=[Link]!e4f (he (notpiv of tti»
9»Bai MfilOt 69 FOiflWNG E E x ^ UNO EEXid IN^ENKRECH- Eix<e and EE«<l conRiUwIiooB.
IMVS Mtiii VB TER ANORDNUNG IjST ZUpftTZUOH EtN . i n 4 i 9 v«illc4 priBofi, a n addittDna(
iMVa IM9131 m S C H U m i A C H V0RZU9EHB1I pMBcOoct toqf IstoIw piMded-

WKjhanv^WMl BabtototfrnvchrmiMi
Bldwriifitt Btmf
AOe AiM<Mi^>twlW( a M nur Im 4>ar«iiJng8tiM8n aisland AR Q9nnadloi> wodc Istobe (Mffarmad in a vgttage^aa
:M8zul9hr*n-Qa« AnscWaBen iat von efcwr PacMoalt, dto ^ opndMc^. The cenneoiHisi i ttolia made ) ^ a a p w M M Unt
yb&Sliiberhan^tiQaMnmitiaw ywtiaut J ^ v i x t u n e ^ ^ Is t M l l h r will the V t ^ [Link] m a m i A i ^ ^
H«ii«te9er Iwfiet |iMi|4ur S d i a d « . dto auTtiniMw^ la jwt liBblator dalnege. causad by impcopiar InetalMionw
Inatalfrtkin bzw. BMyitainozviOolQSUiQhien sind.
b i M l ^ l t o n und jMiMrilunB naaainant aqd bnWliAon
Die AuMiiund und Mqiilt^ doa Mob^tngB dnr auCdeih. Tliaplapainaat^^inaunllngaf (tie nwlqrmu^oivregxind
[Link])$nan, Baufann 0ntspi9Ch«n. AehlanSIa to. the (xinstwIlQPtormglbaii^liie nxiloriiaiTieFikte. 1 ^
|ii«ri^ dBQMr, d a f t ^ H u f t In mganithaaOor MenuBjungatAndert jcai»thatfiQoan0jBlri)anflQM(iin([Link]
9wt(ta!ian1«nn.J^ FUrwihmelQnn [Link]<Bi4)-F|ani>ph!Mi:M <[Link]«oi»wHfafTpi4)llaq0ea, O^a
(ta nia)[Link]«Nai>gederM«dagcMnrt B H f ^ iiia)dmMm,acraMhbilang9ic!ftheinqi)nlln0Mtsl8fli^^
Bolzandutichnwssarbegrensrt (um'm vemwlden, daB dl« MeMna Z $ timea I M btilt diamaiar (to i««vant the Mrimlngftticn
l)e«d«M0$wM). b f l ^ damaged).
BaMria^NrArwcMHB BiatMcsat OamasMoa
>AirAiwNuBda>MatoraMdlavodiapdec»Birt1eb5spah|^ Qa(oi» ocwfiaBling theroalonttiaaviallable a p a m i ^ vpKaga
darBpaonunsMweabaai^ demUlB|tAicia«^ Motor* a t Mto..baocniparad w ^ Ihe iWjtaQa (fivari An Iha pailomiaooe
VBigM^ben-ghdaMf dto SchaNiunQ dar Motofen zu Bchiaa<«ieha namaplato or the motor andtoed f a t t y af the mator latobe
B«lwllM(0.|HaQBMvainerQbBrt»lastangdesKM^ . obsanoKl (tea Gftodt^ilaaramioJ^ I l i a 4 a i ^ of m a r l ^
oUa thannschia Sidiaiung w bagrsnzan. FOr dan AqacitM von toe motoriato be Hmlledtay a lhaniMiAtkjaa. f<irtoa
PtC-T>MI(iiii8toran.(Wb ymjhwidan)tetd|s. VbmaAdung elna« GonneolKHi of f ^ Ihennialem ipn «aaaavailable], thfrqae of
spazialla^ TharniMMrrtMB nolwendig. a apaoial thacmlripr lalw fa flaqaaaaiy.
Die Italoran i!0nnen Ar iialda l^afairtchtijpoen panuM v i « ^ tliajmotonoarkN^iaadfcrbolh^BOllanaofia^
]Q9i&ttGhaiinaM9|lprenaljiaen dch rnejatens rwrfi^ ftgisa motcMi aFB eaualy aulattia 6>r only ^ a dlnactlqn of
DrehrtidMungl («)aha^Or«hiMtfiingspM0, tatoUen (aaatototloDalfaction aoow).
WwtMiiAKpNnaifi <}«(ianri Mialnlai^i^iea
Unbare [Link] auB«r da^i was IroAbsehnIti Thamakita raqiAa n a a ^ e ! ^ maMananoewMi ^
'SchNacuntT anasaaagtlat, lolfterbaQondaianVVMunti. DI9 axoapHoi; ofthatfillban Intoea^aclfcin TMbdoation*. Tlia
GeWuaaioljarilMw und dlaiuflalnJtfWaMif^ aoHIMtJedoah stols iioiw!^ s i e t ^ a n d l b a ak'lnlelo(>ariin(|a ahoitfd atymysba
aau|)ersahailan iwalan,^fcKiri!tdia VVainiMbgatte n i ^ leapt cHran, hcwwar. st^lhal • « taat dtnlpaSon Js not
StaMtv und 5chmutzab)aciarunoan baahiR^chfigt v«iid. degraded by dust and dUt dapoattft.
LagarbaHiuAi;
MotoranntOnanlrqcken «IIK1 aohwingungsMg^agortwerden. Motora mustbeatoiad in diyand vibreOoo-liae locaHons.
OffhungjanlDr KafealelnPHvnsan undduir^sehanda Openingatotcabtotoad^[Link]
BafatUQupQtilOcher In f t (B14>-Flan8cliiBn q)0ssi»i vgrHberoeherid attai^imant In H<Bi4}[Link].
abgedlchlat wmden. Warm dlaMottxan Hngms ZJsM aMltar Betiiel) VVhan the mcrtoia tmva b a w oMt of apaaVon tbr a (ongtBT
gaw{esefl alod, einpa^ft as, sk^, vor dam ^scbaltan dan tima, Ibe ipeasi^ig oftbatostilatlon^ntaMani^Is
Isolatlqnswlderaland m masaen. Bai strmm Wlattonsiwkiantand Facommaodad b a f ^ awMchlng on. For an InsiitaUon
voq vtenipar ais 0,& M-OhW (gamassan bel cthiar Bpannun^ von 600 realatonoa of leM that 9.6 ftf-Qhra (measured with 600 vdts),
VEitt) lat as noilMiendig, zuerat die MatpiwIcMung trecknan TPU lassan. It Is ftat iwcessaiytoalkw the pK>l» wlMhigtodry.
datanfla Guaranlaa
QarantleansRcOcha warden gamAB wiserer 'Allgemelnen Ouarantee claims will be pradtaBadaGeordlng toaur
tletanmga- iind Zahlungsbedingupgen'ftiderzuni Zeitpunlct der IGenen) Delivery and Payment Conditions^ in dthe veis jon
LMiarMn^ gOWgan Fasiung beaiteltet vatldatthe timeof the dellveiy.
Tedmlsche ErISuteruiigen / TecNitcal fnfomiafiQn

MiQQizuortNtung / Selecflon a bearings

BsiqUPBe PoiiMM _ AS-Ugwr BS -Uig«r | • •

iMkDk'illMMi-'
FFainesiZ9 NQ.«|poie!9 Drivd-end N9iKlriu!e |
,<«?*9,.„ wAbwaJma Me»
56 0|IQ /.BH 62012^03 62Q12ZC3 M3
63 ale/«il 6201^01 i£2012ZC3 M4
7i a^tsU 6^]@2ZC3 62022203 MS
80 $ite/air fi2D42ZC3 6204 2ZCa M6
90S.I. nH^/aii ^52203 62052ZC3 M«
iOQL did/all 62062ZC3 62062Z03 M10
t12M a«B/al| 6306 22C3 6306 2ZC3 W10
432S,M aOe/aft 6^08 2ZC3 ^30855203 M12
46QM,L $4e/aB ^92ZC3 6^)9 aZC3 M16
t80M.L 8ffle/4ll 6310G3 631003 M16
200L 91(0/all 6312 C3 )^12C3 Mifi
225S,M stfle/aN J6313C3 631303 ^20
25DM afle/att 631503 ^1503 M20
26QS.M 2 6316 C3 631603 M26
280S.M 4bis6 6317 C3 631703 M20
fiau§r5fte 3l5iKid355 aiifAnfrage AfKilaTungen vorbehai^ /sutiiQctta poMUpctwige
Frame $ize 3t5,and. 35$ pn rsqu^

Die nomkiHIe taawlebiMwiauer iBr MoMiM in w m g a i e c ^

40.000 h,urMw Auwwlaina d^^ itiMiTitil zuiaiBS^
OtolJagerder Motoran bis BaiigrBe«'16D L habwiDqawMMiieiuv-^BatigiQfto ]Bp*|i)«t.«lw tteobsGhiiKtwMnrlchtung voctahdm.
Von BaiifflWe Vnim 160LMj«ln(>NaehM»miienJns(n«9|k^ B n t q y ^ ^
n9chqMO)ni<«rtWinl«[Link]!nH;dle noiin|i)c|Hs4jeb|i!nG4au6rtpr«icl«tw«r(l«[Link].
Dl!«ang«gab,iNt^FM|Babi|iM<iM<»i9r.g!lt bcrl nonl«!arl/«[Link], M Laoaiwoflre(tifit)NQuai1s8ne4iirAnlia^

Am WolDnn hahen t^!Wllager auf der Vgnttatornotti.

Media.n(sdlet Laiiftviha.
Atel4u^sindiii!lidngai«storMb8rta<4sderdyi)W^ DIN ENW034
-14 J ! a ^ deisScMn9<n^VQ<tnNw vpn MoMilnm/HMn M (n A ^

Bearings
T»i4 iKmNd bearing wtvk« Nfi»(br'niohinil^
loads b. at least 40,OOQhOui8, with utisaWoi) of tie niaxlrnum aVow^bla leadings, atJeast 90,Q0Ohou(e\i«hen|he mbjtorJs operated wMi
50Hz.
Ttie twaclngeof the motofsiupto IheconstruolloaelSa IBQltieiMpflFmanerit lubdcatiofi. StaiDng with the constnicthm sim IBQM. re-
lu^ikvQng faoRIUes aiapmsant. Fonn cOn^bW^llo^Kln 1<)^
B^jimdii^ onttjft ^eivlqa Nl^ e(the gieaee, the beerjngs nwstli^ii^lUbrlQated (egulfKiy «o Ihat the nominal eeiytoa life ca tw achieved,
The B<«ylce life of the gpeaeetfvenapplleafornomniiieaifno ponfiguceiionB; fbr bea(b%is wHh [Link] {ctnces, on request.
All ino(0(8 have solM hearings pnttwcooHnsfaa end.

MechanM ftunidng Smoothness

AH Fotprs srs dyranioel^ btaianced wffh insacted hattfisattwrlwys In accordance with the. vihratiDn ampKliide slepM (nonnal). The
vttxation chaFaqleri4ioeof rhechkioi aieraguletadhypiN EN 60034 -14. Herein Is the iMjencIngtype'hatf-wedge balancing'
IKesalbed baeed on DJN190 6S21.
BE-mUEBSSCHAP'UflO VON 0REHSTROMiyiOTOREN

VlflddMiOB- WMbaapm- MRKf^igUMiar

qustOhiuid nur^lny vncMungs9t«Rlliaing 230 VMOO VY
IDrdrektM fPrV/A dkektsq @nsctitf(en )>^BBtilabsq|p#ranin(|
b0l6(MH2 Bnsctalton ,Anlplff Y-^Antetrf
hel B^Webespanpung
220O8IOY 220 220 A 22ft
2«IV 400 V 53BV
380 *0Y •r
kl
DIefindeQclBr
23(V40QY 230 230A 23Q aiWddundafitrlinpei

J^
SplwNting
400 4P0Y ' dor .gehonzMtn
WiCUUt|08r y-Sctienar
380Y 380 380¥ '
400Y 400 400Y -
dciialtung m w
SOOY QOO JSf»Y ^ MP
i|u»iHii>i
SOOA 900 500 A

aaoA
aoiQ
360
Kferametv
brett
4J|w| - 3J
>gr „ ^ —
w;
3B0A<eeOY3B0
660
JU 13 U. "—T—1-*=f
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4(»A/BgOY400 40QA 4(» YA^Chqlkind
690 660Y '
«eaY 660 fieoY -
fiWY <B90 «!0Y .
iMwung idlgmi^tn
ln(MrStandaniau8|Qhnjn03rtpddteM<riQranmltC34«t^^
auagerl^toL FQr l^figoreo, M dQiten die l ^ t i ^ MiElnsni 1 ^ ^
Wl0^eKbsm h(4>sn TbtppeinMuren Buege^^
^leasiallettgndfoder^wKWlafiarwfMsndetweR^
UlfftUBJB
Die ^tatore^ sindtoyiMaifieHaate F ausgelQIiit dto Au«ni4^ Ij^Bjefvetinfiferuna
8|3rictt WannelduiaQ B. Soil dle^ AufemdzuM
niiuK t>^ ^tNink^hendAn Bedbigufigan <fi$ a^iwtigelLeiBluna i^dtepre' <fle1i«cilprooderBeuy.S6-. 160 tMB*jB*w;rtOM»^ienUiga»n
Qherid den tncdHtehenden IRiMlei^bMtlinnt wwdeA> aMSge^Lelljsl uqd hSrven eomlt oWit napi^geiK^ndprtjmirdeii.
Oatiarraptsaendfeae ijoer n«A AUftuf dfr
BinMo^ialebeqadauer Oder fiaUiebiBindaiwr AiqetBMsqtt
AidWeHungs- mtMim^VBfaSatlD'Q W!e»riaiv(iMeheTa!b!Qla)[8lamiBrdcnSIU|awe^
tlQbeilNrNNJniii <30 aCMO 45 SO 1 68 60 [Link] mK^slfieniSchiiii^npiUtfl ^ e i n s r
l^efecetfiziarnpQQijUr vpa$S>C9eliefert, Auoh m l Hfir^ilick mi
loop 1^7 1.«> 0,98 0,S2 ^ iQ.87 0^2 widereFal^tiiiw, ebiva Var«<tnwtiw<iatif>d Srfwiilaing yon
ojar W 0.84 0i79 UMmttilll0iBlt,i»Mi^MUiMtitb
15D0
2D00
t,04
.„J.<» 0^ 0,?0
w
0,86! 0,8? 0,77 Jaitnzuameuem.
2500 ,0(86 QJO 0,68 a^ 0,78 6^74
NiachiKlinikMiiMiQde
3000 Pr^ Q.86 Q.80 0.79 0.7S 0,70 Die Nadwcbmtaperiode Mngtim sfarkan MaBA ytm d^r
39>0 0^ 042 0,7» 0,75. 0.71 0,67 Dretealil, dar UgertiaftBtuna, C^i^gebunBBMtortKi utid defr
4QD0 0;82 [Link] <?.74 ,0.71 0,67 0*83. Au^rtellars d n Motarefibi Bcipci Nai;*!^^
Efflpii^npan des l.:KRr- Mnd FatttMar^tedeis 2u beachten. Q^
Moforan iiK einer ver^alen AMMslung muA die
Nadischinleiperlode! h a l l ^ vvteitten. §B| Uigertemperaturen,
)iKe.li9b0F Re^e^ale dto Iteieiui'u^mpeiatur dee benuteten
PettBB, m n l ^ ^ Nac(KCibmieitBiiQde jewKispre 16C£rti^ihung
liaibieiiwerdBn. Bei njadiimran Lagertecnpeialiwan [Link])e
Hbigew Nac^iedvii^enjeriade, die jediM^
FetttabcinsclaiKtrln Stundfen M g^schloAsendn DoRpeilto dest anigegdMinen vvertis sein 8pll(e.

btnnh NaciischrniijBnseit in Stun^eti |>et offsnen Lagem. Fultaorta

Uneem Moioreii, die mit ofl<anen. tiisefn auegerOstet sind.
WQFdeQ etaivlaid'^DAiMg Mt Kthiuniveieeiflen F e ^ ale
Artder SaMgrOAe : RoNzata) Fet^i^bnaMdSis- bzsKNaob- Schniii^nnittel getefertFOrdle NeciMC^WTiletung 1(8^
Sc^vniening dau0r schmlerll'^ f=)MlsQiton mif MVilHnweiliBnbatfe tnftelneni mtneraliKiien
IwtKTZB'C Qaeis5| twiMtzt yranjen.
mm^'o
Oeuer- bis 160 2 lOOQQrt 2QQa0h Offipina Ugar mtt SchmuMMkamnaiir
SchiDiecung 4i)|a6 20.Q0Qh «)!0Q0h Bel den MptOPtn d ^ BlNiigr. tSO - 355 w^rdiSia olfene I4ger
benutzt, die tnit einern Ki^aBBifett auf d«r <3ivndlage vDp
Nach- 180bfsZ2S 2 70qQli t4000li Utbiumseif^niit einemflilnerfiwdieno i ge«chn[i^
SdtnfilAnjng 4 bis 8 11000(1 220001) Uger l^nnen melwnalsnaciiGieacbQiiettiwBi^^ wctietdas
attD Fett Jn der Sphmutzfettlcammer dee iagetdeclnis
250 2 ssooh IIOQDh auta^omrn^ winl. Diese Lagec mOasen bei laufMidem. Motor
4bl»8 10 soph 21QQ0h nadnBOBctiniiait werdenv 9ei der«nten HaohecslimienJAg istzu
berClokslciitigen, da^ der vom PetlQ^I Air Uasiericainindr
280 bis 315 2 200Qh 4Q00h varlaiiiwdB FetNnai noeii gate leer l9t. Jsiach meljnniBiiigem
4biBft 4Q00h 8Q00h jNadwchmieten muHdfe SctimuMettkaaimerjieFeinigt und die
Lqgereventued (Nj^etausdUwenien. E£x-e-Motoren rjiit
35$, 2und4 200Qh 4 OQO It olienen l^erhtnjd BdimutzfotScammer wetdan ohhe
8 undo 8000 h Sotifnienw^ gtdleliari
4.000 h
Andeiungen vorbehaHen.
OPERATING CONNECTIONS FOR THR£E-PMA$E MOTORS

WkuSngn Qp^^ating WRlhjKiutaoel -

loonflguralion volag9 iJBBget fCfiar f w Vyin(Hna«)nl9unafloti^30,VAAIQQVY
drect PQTY/A
at SO Hz swlici^on jMwUhg [Link]|)!Bi|rtin|)volte«^ Y^QiartlrHiat
opaistli^ voltage of
230y 400V
zmm^ 220 22»A ^ ^ V
3ffi> 380Y ^
The. end|i qfttwfhrse
aSQMQOY 230 230A 230 QoftnacHon viMinglegtt
4qa 40QY - oTttw. ^toaYewflt^
wincllnii
awY 38t> 380 y - leas \fl 12.
\» w
400Y 400 400 Y >-
CpnwcUqn
5D0Y 600 BQIOY •^ onit» ma^Hjyz \K0i|.U2oi
SODA 600 fiO^A 600 twdjual
biotwri^
380A/!aB0Y

400A^eOY
38(>
fl«^

40Q
380 A
68Qy

4DaA
380
-

40Q
11 U iS
^^^^^ff "^W^iwn ¥«- ^Y£jk
A t a tDpqhiKI6r|
U
wecl
12 U
Vi^rCpnmplfctn
690 fiOQY •1"

660 Y 66Q eooY -

690 Y 690 «aQY '

Oeoeiral Beorlng Information
In 4ie standard nnt^MFailotiij the molors are q(4pp4d, with.C3
jMaring..For ntolorB.«fli0aat)[Link] aiJ|;K«M to axtraiwiy
lowjor extrBitiely{)i|h.tnnp6ratur^. speeial grease andfor
Ratt9d o u t p u t i^woiai iiMdngs-iw^ ba usad..
The niQtoiB 9rB manuCactiWBjJ In Glass F, utWzaljOf) cones^
Class B. 1 ^ aiqfdeyialiQiw. torti ttww c d n d W ^
Beating Mibffeation
ou^tshoi4d tteacyustadaoooraipg totwfbllcwkg tables. Cioaad P<wilim>
Theinblorsqf1^cansti!U6tiQtigniiip€6to IfiOaliBeqtilppad
wM) Glosadl)aadm and tt^raliciis cannot be r a J t M ^ a i ^
tl^isBaon,iheseMailiis}s must lie laplaoad after the .feflgue
fmt^ifiSL) CgqlaiittanDpeirahifai coto'C servtoe He ororaasa s e i y i ^ Mb eiiplise (MetaKIa).
Abcmsfalawanlnin oa 30-40 45 SJ 56 60 tn the lilandaBttiimIHgmiiioau currnotamans d e O ^ ^
tMailngt^ilWi a ioMem*. wRhafsC^canosleHipemlurectf 85 *C.
1000 VW t,«o ^•» o.n •,87 0,8? Also, viih regard to ottiarfttctorssut^ as ooKbvAtna^ and 0ia
1SQ0 1.04 0,07 0,8? 0.89 0,84 0,79
lafl^was of humldite Die ranawal of 2Z.4eadngs is rscoiQinendad
• at (Mst everyfouryeais.y
2000 1.00 0.94 OM &86 a82 0,77
2500 D.96 OrW ojea 0.83 0.78 0,74 Re^bricatfon Intervals
3000 0,92 0 ^ ofii a79 0.75 0,70 l i w RaHubrtcallon IrAarvata dapandio a l a i ^ depee on tha
3S0b OM 0,82 0.7$ 0,75 0,71 0,67
speed, Iha Itaadng loading,ttieanvlnncnatialfaclboiB^ndthe
rnounQng ctf tha .tnoler-1^ rs4ydifteating> Oja jiaGOcrnnaodaions
*OQQ 9fiZ 0.77 0,74 0,71 0,67 0,63 of iha .hearing and grsase mani^adupsts an; to i)a obsatvad.
ForniotgAwdlh vertical itiQisilltia,.lhei»dMbirt!ta^
mgat be twlved, Forbeaffng iBRiperatwasttiatars h l ( ^ r than
tharafB!tenc9tenipaiature^t|«{lFQaseiMsM><hara-lubiicaik)n
tnieryal mustba balva4 for aacih 15 *C of 4eimpara(4i9 Jncrsasa-
For lownrbaaiing tainpacBtuKi, a tengar i»[Link]«rlo4 Is
ad<K|Malak hOMtevar, should nattslqngar than douMa ttia value
GF99^S9 ^eryi^ Iffe in hctui* for dosatf biaarlnQs or l^v^.
r9-lubi1cating times In iiours for open bearings.
lypea of Grease
Our molora that ara ec|iipp«4 with Qpan .beaiings are dellvared
In the [Link] ihlunj sapomlad grease as
Type of Frantesize No, QraaselMs andtor th&iiubilpant ^or ca:RjlHlQEitlng, grsaae typos pf a WhlMm soap
lubiteatkMi tiass vi#i a jdkwtal titea oil can bs used.
Off poles re)u|>jlGatiqn Icitaival
i!tCT40*C alCT25*C
Open BearinfP vi#i Contaminated Grease
Pt9- toieo 2 lOOOfiih 20000 h Cannier
Mnft^atecl 4tQ8 20QCi0h 40 000 h Formotorsof thecon^bwUon group 180 to 3§5,of>an bearings
ana usedthatare lubripatadwilh baH bearing graase onihe
Regresabia 180to225 2 7,000 h UOQDh t>asls af1ltblun)[Link] oil, Thesa bearings csan be
4lp8 tiJPOOh 22 000 h ra^ilbiricaled savaral llnies y^ieraby the old gitraise Js taken up
In the oontanilna^ greeise chamlier of the bearing cover.
250 Z 5600 ti I t MO h Thes$ bearings must iM te-iubricated whUa the nwlor Is
4ID8 10 500 IT ZiQOOh running. For the iiiBt rsTJuhricatton, it must!». taken jntp account
that tha gcaasa canal njnrijng. trnri tfia grewie (tippja IQ tha
2S0.to31S 2 2000h 4000h t)aaring chamber is styi completely ampfy. After siaveraj ra-
4 to 8 4PQ0h 6QQ0h lubricaUons. ihacontairUnated gr^na tihsmbar must bia
oleanad and the bearing possibly raplaced. £&(<« motord with
open baarings and contamated graasa phambar are deHvared
355 2to4 2qQ0h AQOOh VvHhout graase rilpples..
6ioB 4 000ti 8000h
Subject lo possible change.
* ' 1 ^
Drehstrommotoren
Thrqe-Phas6 Motors L A M M ER S
Moteurs triphas^s E L f K T R O M A S C H I N E N f A B R J K

Motores trifdsicos JCJ- Uimmers GmbH & Co. KG • Etetdromaschlnenfabfj

<:7
Motori trifasi
Trefasmotocer
A
I...
Betriebsanleitung / Operating Instructions Ausgabe / Edition: 1.98
V

Baijgri5lien(BG)/Franie sizes (BG}/D6signationde,cartasse(BG)/Tamafios<Mnstmctivos(BG)/Grande^

BG56...gOL-IM@3 BG100L-IMB3 BG112M...132M-1MB3 BG160M...315L-fMB3

Bauformen /Types of constfuction / Formes de cxinstructlcm /Formas constructivas / Forme costruttive / Monterir^ssatt

o$Jer Oder Oder

or or or
ou
IMV5 IMV6 ou ou IMV1S
o ^ o
oppure ; oppure oppure
elisr 7 [[ ® B f ® 1MB 5 ener 1MV1 IMV3 IM B 14 eller 1MB 35
IMS 34
Fig.1 IMB6 tMB7 1MB 8 IM V 19

ENGLISH

NOTE: Fig. 2-6:[Link] on page3,4

Description

Application
The motors have degree of protection IP 54/55 and tropicalized insulation, and can therefore be operated in dusty or dar
environments. If the motors are properly stored or Installed outdoors, there Is generally no need to take any special weatherproof!!
measures.
Unless otherwise specified, the rated powers specified apply to continuous operation at cpolant temperatures of between -20 and +•
"Caridataltitudesofupto 1000 m above sea-level.

Construction and mode of operation

The motors are self-ventilated (with fans). The cooling air must be able to flow in and out of the motors unhindered. The feet of fOi
mounted motors are cast integrally with the frame or screwed with it.

Operation

Before starting any work on the motor, be sure to isolate it from the powrer supply

Installation
If the motors are stored following delivery for more than four years under favourable condKlons (kept In a dry place free from dust a
vibrations) or for more than two years under adverse conditions prior to being put Into sen/ice, the bearings should be repl aced.
Special protective measures should be taken (e.g. the provision of protective roofing) in the case of motors with shaft extensio
pointing upwards or downwards, or motors exposed to direct solar Irradiation.
In the case of terminal boards with six temiinals, the terminal box covercan be turned through 4 x 90 degrees.

(El Van/loffnUlniinn iinH VPrhroltiinn - n i i o h niicJiincivfiko _ niir mit cr'h^lHIi^hor ft^onohminnni-i

Balancing rotorsiHtd the tidismission elements connected tothem
The rotors are dynamically balanced with a fuHfeathedteyfitted in the stiafl end.
Mai(e sure the transm^ion elements are bislanced in the same way a$ the rotor.
t^[Link] [Link] componente as shown in Fig.^.

EiectijcalconnecUons
Check to see that the system voltage and fre<quency ag^ee with the data on theratingplate. Connect the terminal links as shown in thi
diagram inside the terminal txnc.
Connectthe P.E conductorto the tenninai marked {!)
The recommended torque fortightenlng ngtsetcontheterminal board are listed in Fig. 2.
Use benteyes [Link])(eiugs to connectthe pfhase conductors.

Insulation test
Before putting the motor into $ervk:e for the first time, and after prolonged periods of storage or standstill, measure ttie insulatk>i
resistanceofthewindingstothefrarnewithaPCvoltage.
Wtien measuring the insulation resisUmcs and immediately iafterwards, some of the terminals may cany dangerou:
voitagjBsandmustnotbetouched
Whisn taking [Link] stop until thefinat resistance value is reached. The measuring voltage, as well asthi
limiting values for the minimum insulation r^stance and tlie critk»i insulation resistance (for measurements at a wip'«ci(
temperature of 25 °C), are listed in Fig. 5.
During the service life of the motor, the insulationresistance offliewindings may decrease as a result of environmental conditlDn
and other influences. The criScal value of the insulatk>n resistance at a winding temperature of 25 *C is calculated by inultiplyhiglhi
rated voltage (kV) with the specific critical resistance value (Mohms/kV) (see Fig. 5); e.g. critteal resissiance for a rated voibgi
(Urated)o^690V:

0.69 kVxO.5 Mohms/KV-0.345Mohms

if the measured insulation resistance assumes values above the calculated crib'cal insulatkjn resistance during file service life of th<
motor, the motor can be kept In service, .^hould the value measured reach or drop below the critical insuiaSon resistance, th
windings must be dried, or the n3tor removed and the windings thoroughly cleaned and drNi. If the value measured approaches th<
critk^l value, thelnsulation reslstanceshouldthenbechecked atappropiiately short Intervals, orthe windirigcleaned.

Maintenance

Before starting any work on the motor, be sure tolsolate it from the power supply

Lubrication
Under normal operating condittons, the grease filling in the bearings should lastforseveral years. Operating conditions permitling
the journals of motors with rotational speeds of up to 3,600 rev/min should be cleaned and the bearings replaced after 20,000 servid
hours or, at the latest, every three years.

The bearings cannot l>e relubrlcatedl

Thegrease in the newbearings must have the properties and quality specified inPig. 3.
The standard motors have prelubricated deep-groove ball bearings (to DIN 625) with two cover plates 2Z and end play C3 (see Fl£
4). The space between the cover plates Is packed 30 to 40% withgrease.
Always use a suitable jig to fit and remove the rolling-contact bearings (Fig.4).
Heat the rolling-contact bearings unifomnly to a temperature of about 80 to 100 "C before fitting them. Avoid any hard blows (e.g. wif
a hammer or othertools).
Adjacent grease chambers are packed with grease (e.g. in the bearing ehdshlelds for sealing off the shaftfoore-hole,generally 2/
full). Use the same type of grease forthis as forthebearings. Do npt mbt different types of grease.
NOTE: When replacing the ktearings, it is advisable to also replace any sealing elements subject to wear (e.g. radial shaft sealim
rings).
Replace any damaged parts.
Standard parts are obtainable from commercial sources (stating dimensions, material and surface finish).
Spare parts areavailable on application.

© Vervlelfaltlgung und Verbrelfung - auch auszugswelse - nur mit schriftlicher Genehmlgung

CI, Lafnmers GmbH & Co. KG; Stdtforst 3 - 0-48432 Rhelne; Postfach 17 38 - D-48407 Rhelne
Tel. 0 59 71 / 7 92-0; Fax 0 59 71 / 7 92-33; e-mail; lnfo@[Link]; Internel; [Link]
ANHANG /APPENDIX/APPENDICE / ANEXO / APPENDICE/BILAGA ..^____
AnziehdrohmDinentefar8chraMbenveifaiii|iuiH|ea(ittrel9kMsdienAnsehlQsse-Klemnwnbr«tUnsch
11gIiteningt9r!qM*sfor*craW9dBl9ctricali»nn9^Qns-t«rminal)>a!aniRonnectioqs(oxc^
Couples de«erfaQ«k.d9sborfi!B8d« l a p b q u e ]iilK>niw<n« c o n c w m p a s les h«>mleni)
Pares d« apriste para unian(»s atomilladas da las conaidofies elfatriias en la placa da i^omas (exceptuando las regletas d a i>onfias).
Copple dl carragglo par la vtti di atlacco di collegamanti alattrlci /deiportamorsafU (aaduaeinorsettlaFa)
AtdragnlngsnK>ment(erdaalaKti1sJ(aarrelutningarnasaiaiJvf9rt>afid{iitcMnpA)conj^^

(j«witKie+ /Tnmad-+
-•iJufiMage / -fde EanMKa
DIametrodelfneilo/Qangdkneter. M4 MS M6 ;M8 M10 M12 Ml 6
Andehdrehmoment
llghlaning torque mjn 0,8 1,8 2.7 6.5 9 14 27
Coupledeserrage ,^m
Panto apilelB "^
Coppiadisemagglo |„g^ 2.5 4 20
Atcbagning^fflocn^nt
1.2 8 13 40

Die oblgen Anziehdrehmoinento gelton 6umXMk\e anderen Werte angegeban sindl

[Link]^
[Link] deserrage JndiquiscUessus spmvalabtas pourautant qt/aMCunevaleur'Sp^lh)tiene soit donn6^^
Estospares daapriato i^enmiantras nose lodlquenolras.
Laoopplaidlseiiagglo indicatequi disopra sonovalde aepon sonoincficatl altrlvahxi.
Fig.2 OvainittondeAtdragningstnonient g9lleroni ajandra ySidenangiyilBl

Schmieffett/tulMrlcant/Graisse de lubrifi(»tioii/Grasa/Grasso<li Itibrific^aionaiSmdrlmedel

Motor biWanneklas9enachVPE053P MotorkONtamperaiur FeUsortederl^agerschmierung

Motor insulation plass in accordanoa WNti WDE0530 Motor coolant temperature Grease typefortaaririglubrication
Classe disolatibo du moteuraelon VDE 0S30 Tempdratun du1luidei^lrig6rantdu moteur Graisse pour roulements
Clase de material aislante deiimtors. VDEJQSSO empelefiira del medio reMgerente del motor T^dagra$a paraiubifficarios rodainlentos
Ctas^deltnateriatB:ls6lanteseaVDE0630
Quality del grasso perla lutxificazione deloiscinetti
MDtoriisolennalaiiaNa«» [Link]

F -20.„+6q*C DIN $1825-K3N

zuni Beispfel / lor example / example / por c^smplo / ad as. / T, ex, UHIREX N3* < E 3 $ 0 )
Lout hler;teleitngcibe;UiufpfQllirigBrK]ctiDlNS1806 tseiderPiCftempeK^
lk4cinufoK:tu(e('sspeclllcqllon:l)urriirfstestBtoDlNSl806pcissedsucicessluty
IncJcqIlons du fotxlcnnt: sollstcWd ressol en ITV3K:^ B s e ^
5egi^irKJ(xcl6n del fobiiccrite; se ha supeioclotopiuebo cleniachg BsegOn t^^
'Sec(xido Infonrnozlonl avute clal loinlloie. la p(OM] dl riKircIa B.«ec. DIN 5)iB06 ^ sl^
TII\«[kafBns wppjEilft: K6itestB enl. (>N 61 BQb IdorcA vid prdvningslernpef^

Fig.3
LagergrdBen / Bearing sizes/Tallla des rpulements/Taiiiano de Ips rodaihlejrtos / DimenalonI dei cusclnetti / Lagerstorlekar

BG 56 «3 71 SO 90 100 112 132 160 160 200 225 250 260

AS 6200 ZZ 6201 ZZ 6202 ZZ 6204 ZZ 620SZZ 6206 ZZ 6306 ZZ B3DB ZZ 6306 ZZ 6310 '6312 6313 . NU.315 NU3U
BSj " • • *
» • • :• a * • a •m
6313 631!

PQ.315 mm: ibr question.

BG!° BaugrSOen / Frame sizes

PteignatlondecarcaBse /Tamaiios constructiyQs
Grandezze / LWiirlngsstoriekar
AS=Lager-Ablriebsselte /Drive-end bearing Zwlschensclieibe.(Schutz derZentrlenjng Im Wellenende)
[Link] /Rodamlentoejesallda SpacerWasher (to protect centring bore In shaft end]
Latodelcuscinetto /Lagerpidrivsidan Rondelle (protection du p6ntr;age en boutd'arbre)
BS=.LagerrBeliUftungsseite / Non-drive-end bearing Plscolntermedlo (protegeel centrado en el extremo del eje)
Paller,cat6 yentilateur/Rodamlento ventHador Spessore (pmtezlbne della Centisturanull'estremitSid'albero)
Latoventilazlonedelcusclnetto/ljagerpaickedrivandBsldan DIstansbrido (skydd av centreringeni axqltappen)

Fig.4

© Vefvlelfditlgung und Verbreltung - auch auszugsvvelse - nurmit schriftllcher (5enehmigung

CI. Lammers GmbH & Co. KG; Stdtforst 3 - P-48432 Rhelne; Postfach 17 38 - D-48407 [Link]
Tel. 0 59 71 / 7 92-D; Fax 0 59 7 1 / 7 92-33; e-mail: lnfo@[Link]; Internet; ,[Link]
Isolatfonsprufung / Insulatiantest/Cbnb'dled'teolement IPtutbi del aisia miento/ Prova d'Jsolamentb 7 Isolatlonskontrpll

&wizvim1eMBMliessungkspaniHmg.U|j| /UmWngvaluMofthanrlMlyoHag*U,alg,|/SwnpoiirtM»ionauignteU|( Valort^ U» < 1 KV

limn* a latenslinaslgnada tiff / Vatori [Link] tenslone d1 taratun Uf^i^gg /Giiiisvanien y U [Link]|j

Me&spannung (6lelchspannimg)/Mea8uring voltage (DC) 500 V DC

Tendon de meSnte (tenaipn contlnue)/TeivliJn{te m e i ^ (lensi^ «ont|nua)
Tensione dimisiifa (tenskxw conlinaa)/ Uppmatl spSrirfngOikspfinoing)

MindesUsolatlonswijJeffiland beineuen, geraJnjgtenoderinsUaKlgesettlon Wickhjiigen

lOMOhm
Minknunn insulation resistance gf new, cleaned andserviced wiocHngil
Resistance minimaiedlsoiemsntd'enroulements nauft. natti^iteoti temisen^t
ResJstincia minima del aislantiento de devanados nuevos, Hmpiados.o rsparados
Reslstenza mininia d'tsotamanto con awoiginienti nuovi, pMlifi o ripaiall
Minsta isolalionsniotstSnd I nya,rengjordaallsrrepareradeHndnliigar

[Link] nachiangeisrBetrfelMZdt
$pepillp critical [Link] period of servipe
O^MOhm/kV
Resistance dlsoietnentaWquis sptelfique apite une longue durte d^ioitatibn
Reststenda crftica y especifica del aisiamlanto, despuels de prakingados perlodosde servido
ResistenTa disoiamentospedlicacrlfica dopowi periodo dtatUvIld pnlungato
Spedlikt,1irHlsl(a isolaUonsmotst^d efteren ifingre tids drill

Fig.5
Auf-find AbzieheA yon Abtriebs»leraeDten / Pressing on and pulling off drlve«lemeiits
Emmanchementet9xtractiond*organesdetransmission/ Caladoyextracei6ndee1ein«ntosd«acclonaniiento
Calettanientoedestrazioned«gli«ienientldiasldnamento / [Link]

Zwischensdielbe (Schutz der Zenlrienmg 1m WeHenende)

Spacerwaaher (toprolecicentringboFeinshalleod)
Boocislletpiotection ducentrage snlxKit d'aitKe)
— CfMOPflrtenilMM (protegee! [Link];diefnpde1eje)
itpimfw* tptaH izlone deHacentratura nutfestremitad'alben))
CWBWfcrfclMi^i l(ydd avcentceringen laxeiteippen)

"^iLJ---J- • • • 1 1 - ,

f^J-T^J

Zum AuHzletien von Atrtiiebselenienten (Kupplung, Zaiinrad, Riemensciielbe usw.), Gewlnde im Wellenende iienulzen und - sofem mSglich - Alitrletiseiemente nach 8e(
erwdnnen. Zum Abzlehen geelgnete Von'IcMung verwenden. Es durlen belm Auf- und Abziehen keine SdiiSge (z;B. mit i^ammeroder ghnllchem) Oder grdfiere als die I
Kataiog zulSssigen radlalen oder axlaten KrSfte Oberdas Wellenende auf die MotoriagerOberttagen werden.

Use ttis tapped hole provided in the end of the shaft forfittingdrive components sgch as couplings, gearwheels, belt pulleys, etc. and, If possible, heat the qomponsnts
necessary. Usee suitable puller tool fpr removing the components. i3o not strllte the cornponents, e.g. with a hammer or similar tool, when fitting or reirKWing them and
not exert more than the maximum value ofradiaior axial force - according to the catalog - transmitted to the motor bearings through the shaft e)densh^
Pour monter ies organes de transmission (accouplements, roues denties, pouiies k coumole, etc.), utlllser is taraudage du twut d'arbre. Au besoin et lorsque ceia
possible, chauffer'les organes de transmission. Pour ie ddmontage, utliiser un disposttif approprii. Aucun coup (par ex. marteauj-supdrieur aux efforts axiaux et radii
admis8lt)lee mentionnds au catalogue ne doit ttns transmis par farisre awreulemehtsen cours de montage ou de ddmontSge.

Para calar IQS elementos de acoplamiento (acpplsmlentos, meda dentada, poiea, etc.) utilizar la rosea en el extrsmo del eje y - siempre que sea posible -caier
conveniebtemente dichos elementos. Utiilzarel dispositive adecuado para la extraccl6n. Durante las operacloiies de calado o extraccl6n rw golpear (p. ej, con martill
similar) nl ejencer sobre los cojinetes del motora trav6s del extreme deleje fuerzas axlales o radiales superlores a las admlsibles segUn cat^logo.
Per calettare gii elementi di azlonamerrto (giunti, rgote dentate, pulegge, ecc), utlUzZare H foro fllettato nell'estremita d'elbero e, se posslblle, riscaldare gll elemenl
azionamento. Per restrazione vanno adoperati attrezzi adatti. 3ono da evitare cplpl o martellate, e forze radiali o asslall tresmesse dairastremitd d'albero ai Cpsdnettl i
siano maggloridi quelle consentlte tea H catalogo.
Anvdnd axeltappensg^inga vid [Link] drivdon (l(oppling, kugghjui, remsidva etc) och vfirm om mojllgt upp drivdonen omsd behSvs, AnvSnd ISmpliga verktyg
avdragningen. MSgraslag([Link].)fdraidrig fflrekommavkl pS-ochavdragnlng, Dch radlellaoch axieila kraftersomSratorrean despm angesil(!>*Hlp|
^rintefiverfSras till motoriagren via axeitappen. >

Fig.6 ^
Anderungen vorbehalten / Subject to change without prior notice /SousT^iserve de modifications
Sujeto a modlflcaclones;/ Con riserva di eventual! modlflche/ Fdrbehdllf5rSndrlngar
© Vfetvlelfditlgung und Vefbreltung - ouch auszugswelse - nur mit schriftllcher Genehmlgung
 POSNO. 1.28

CSAACKE: MARINE SYSTEMS Doku-Nr.: SMS 3-0003-0005//2

Issued on: 02.03.2004

DATASHEET Issued by: 1100/Fre

EXPANSION VESSEL FOR IGNITION OIL LINE

1.) Shell
2.) Diaphragm
3.) Plug
4.) Screw plug

Type: HY/AD 0,35

Volume: 0.351
Pressure, max: 160 bar
Weight: 1.3 kg
Connection: G1/2"

Accessories: Welding stud G 1/2"

Sealing ring
Mounting clamp

Article number: 307324

This document consists of 2 page(s) 1

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363, email: marine@[Link]
CSAACKE: MARINE SYSTEMS Doku-Nr.: SMS 3-0003-0005//2

Issued on: 02.03.2004

DATASHEET Issued b/: 1100/Fre

Dimensions:

Membrane vessel: Mounting damp:

ti

^ m ^^SN
a

r" ~1
1
«

s
d = 92

h = 114

Weight:
iso Bitmf^

mm

mm
*

1.30 kg
m>

S A = 135
8 = 96
C = 150
0 = 110-120
E = 50
H = 64-69
L=10
M = M8
mm
mm
mm
mm
mm
mm
mm

Weight: 0.35 kg

Connection Form A:
Welding stud:

SW,
SWi
r—r /
1 '"IT —f—1
•f- L._-<>...
L. g ^ ^M
"Tf1
'; 3 1 2
-—/,
-"5

d1 = R1/2"
Sealing ring: 11 14 Tim
d7 = =^3/4"
Nomi: DIN 7603, Form A 11 37 •nm
Material: Cu n5 = 32.5 •nm
Dimensions: 2 6 x 2 1 X 1.5 mm SW 1 32 •nm
SW2 27 nm

DN 0 Tim

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363, email: mar1ne@[Link]
 Oil Compound Regulatbr
with two cam strips
Data and Type:VRK/VRKM8e+14e

Dimensions in mm

1.10 1-14 1.2.31

1.1 Casing unit with locking lever a) Fuel oil outlet DN 16

1.2 Control disk unit b) Fuel oil inlet and return DN 16
1.2.11 Adjustable cam strips 1) c) Connection for linkage of control element
(air damper)
1.2.31 Adjusting screw for cam strip d) Connection M 10 for additional linkage
1.3 Rotary valve e) Connection M 5 for flexible control cable
2. Microswitch unit
(positively disconnecting microswitches -S1. .-S2)
*) Electric servodrive (motor)
1.8 Lever unit
1.9 Setting unit
1.10 lx)w fire spindle
1.14 Bearing bracket body
1.15 Handle
Fig. 1

SAACKE GmbH & Co. KG SAACKE GmbH & Co. KG Tel. (0421)64 95 0 Technical Documentation
SQdweststraBe 13 Postfach 210261 Fax (0421) 64 95 22 4
26237 Bremen 28222 Bremen E-Mail infb@[Link] ( SAACKC)
Germany Germany Internet [Link] 1-3500-11833/02
2002-08-21 Page 1 /3
 • Data and Dimension Slieet

Hints for mounting: Technical data:

The angle a (see Page 3) of the control levers (item 1.9) can Maximum fuel oil throughput
be chosen at will. The control levers can be mounted on the -VRK/VRKM 8e :400kg/h
left-hand orright-handside, in front or in the rear. - VRK/VRKM 14e : 200 kg/h bei 3 bar
Free movability of the linkages must be guaranteed. Working range : 2.4...5 bar

**) Any possible shaft projection can be removed after the Electric servomotor
final arrangement oif the control levers. - Torque : 20 Nm
- Type of current, frequency,
Article nos. for objects with *-marl<lng are specified in the supply voltage : 1 -50/60 Hz 230V
plant parts list. - Power input : 6.6 W (50Hz)
7.35W(60Hz)
- Enclosure type : IP 54
Microswitch unit, 2 microswitches (positively disconnec-
ting) ; data for each microsv^tch:
- Cx>nstant current : 10 A
- Switching capacity : 250 VAC/1 OA
24VAC/6A
- Enclosure type : IP 40
Weight
-VRK : 23.0 kg
-VRKM : 26.5 kg

Fig. 2: Fastening dimensions and throughput

Electric servomotor -Y1 Microswitch unit

S3 34 85 86
M'W
-SI -S2 -S3

normally closed contacts 1 -2

positively disconnecting
DODDQDnaniDCKDQIDQLlClIDIDElEI]

s
H aufl ClUI I clockwise rotation *)
II counterclocKwise rotation
*) upon request only

Fig. 3: Circuit diagrams

Technical Documentation

(SAACKE)
1-3500-11838/02

2002-08-21 Page 2 / 3
 Oil Compound Regulator
with two cam strips
Type: VRK/VRKI\4^+ 14e

left- or right-hand
in front

66 150
390 200

Fig 4: Control lever arrangement

VR K M 8 e

L - status of design

= compound regulator size

= with electric servodrive
= two cam strips

= compound regulator

Fig. 5: Type explanation

Technical Documentation

(SAACKE)
1-3500-11838/02

2002-08-21 Page 3 / 3
 BcplOcidnnslchnung
^,_G(ptod«dyiew
.QHyU9«e«tte CSAACKE
Vista estaOada

6l-Verbundregler VR/VRM/VRK/VRKM 8e und 14©

Oil Compound Regulator / R6gulateur Compound h mazout / Regulador para fuel -oil
Banannungen / BeMM<nn. ( ° SKh-Nm.) dar QtgenMinda i M i a SiaMUa. .OBpylBB«'tW»«iociwi«[Link]>lao»'*te»nd •wuM/groonanvHoaltoivoitteoon'
EiorKisd08Cffpllonk./.oniirnof. (*MiDl9iMMt)of AcKMMMVPAifii'iBt tenteMrao(i!n^)it)iddMiMttibvlte4nM#tittMMtt|(.OHBijdtniMl|ditetoA^pi^fiMntoi
dMMgo^ M ilsM'aw'oao*vBdtothetftf^nlol Vivyranl of 9 pateift'of Jto MdMniion of J
Pou'l«iricim«ncliCuw«/Htw><teeoiiwiin<l»(*ni».<«iBc|e)dei.o>j«tt voir fate B» udl^piofW'Ordwv'.
T M ^ OQntt^ailcifton ou npfodui^9on cto 00 dpeumon^ l i M t aMlolHfen ou ootanMrtGi^
DMarnkwcipna* / rms. d« paeido ( s not. d» anicyo) de I n ol^gios nonibrado* <nte1 ^ fion da abn o^ntenu aort kiteidite% aajf MteilaMten jiNMaiaii IbUI inalMiuMMil A calk
^Aj^.aatffdteatfRpoaoaonajutewMivMMyiMAoacfcjilHiHyasalMMl^lbup'npailnkk
DwUehnmlangtamn von im [Link]. wmjJWwfcpeur tecaa da [Link]* (ftai bww<ttii«[Link]>wiiaiil dlw

Vm wppo of Mppiy-iniif wyimn twt npiOMiMBU hiiulii. OlhtiuaafiaiKpiiBaa teilbi!iarliVi/niiald<luMii|i>iaiteiiiwitoMPhiilrt>teHwnwliyTjftniBttl

[Link] toumllufw poutdMnr dA !• fspiteonMliin. oparapl da aato docMnanlo^ aal^binQau uaohidobido ji/0;auaidiblcioijoopmunlaBlon
&paaU*qM« te fMteniita dil (wnkMrp M dMVto (tell npaaeniacWn. •[Link] loa M M o i w S0 jtedgM al poffw^Ofidtonte tvatecMante da daftaajrfnriul*
cloa. 8e laaarM Mteateadarathoa pan [Link]«o.d«1«'oanoeii6n daiMtento da-taviincHn
fidiutcnRne* nwh DM [Link] M n g h i m daUodakiMuaMal.

SQdweststraBe 13 Tel. (0421) 6495-0

S A A C K E Postfach 2102 61
Fax 64 95 224 1-3500-7041/31
GmbH A Co. KG n - pn^sp Rwmon n - oooo-r D-
SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:0190/ZN

P A R T S L I S T
ARTICLE NO.
DESCRIPTION: OIL COMPOUND REGULATOR UNIT 2-3595-284876
FOR VRK 14,IND.E,2X200/66
SHOWN IN DRAWING NO : 1-3500-7041/31 SHEET: 1

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART

I M P O R T A N T HINTS

1. IN YOUR PARTS ORDERS PLEASE STATE :

- ORIGINAL CONTRACT NO. (SEE ABOVE),

- DESCRIPTION, AND
- ARTICLE NO. OF PART

2. ALL RIGHTS RESERVED ACCORDING TO DIN 34 !

•••CONTINUATION SHEET EXISTS**

SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:0190/ZN

P A R T S L I S T
ARTICLE NO.
DESCRIPTION: OIL COMPOUND REGULATOR UNIT 2-3595-284876
FOR VRK 14,IND.E,2X200/66
SHOWN IN DRAWING NO : 1-3500-7041/31 SHEET: 2

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART
A S S E M B L Y
1 OFF CASING UNIT 2-3501-220706
CASING: GAL 228
CONSISTING OF :
1. 3 1 OFF CASING 5-6783-220701
1. 4 1 OFF PIN 5-2330-220711
1. 5 1 OFF SPINDLE 5-2366-065582
1. 6 1 OFF BUSHING 5-2744-054096
1. 7 2 OFF DISK 5-0041-054573
1. 9 3 OFF GASKET 6-3064-001481

1. 10
14X8X1,5 -PTFE 6-1040-000422
1 OFF HEXAGON THIN NUT >ISO 4035
1.,11
MIO >05-A3F 6-4750-001037
3 OFF UNION
D20-ST
1.,12 EMB 6-3030-602722
4 OFF SEALING RING
1.,13 A 26X32-ST,SIM. TO DIN 7603 6-0830-000317
1 OFF SCREW PLUG >DIN 910
1.,14 G 3/4A >ST -A3F 6-5010-001690
1 OFF COMPRESSION SPRING
1,.15 D1.5,DA11.5,LO41,IG13.5,1.1200 6-6180-000777
1 OFF BALL END HANDLE, STRAIGHT
1,.17 K 80-D2=16-D4=8 H7-ST,GALV. 6-2510-000598
1 OFF SPRING-TYPE PIN >ISO 8752
1 .18 3X16 >ST 6-0110-000110
2 OFF [Link] SCREW >ISO 4762
1 .19
M 4X 20 > 8.8-A3F 6-2530-001315
2 OFF THREADED INSERT
1 .20
M 8-302 080.16 6-0110-530069
2 OFF [Link] SCREW >ISO 4762
1 .21 6-1040-001302
M 4X 8 > 8.8-A3F
2 OFF HEXAGON THIN NUT >ISO 4035
1 .22 6-0120-000203
M 6 >05-A3F
1 .23 2 OFF [Link] SCREW >DIN 7984 6-7370-014762
M 6X 16 > 8.8-A3F
1 .30 # 4 OFF BUSHING 7-1802-007683
MB 2515 DU
1 .31 1 OFF LOCKING DISK 7-0004-007388
DESIGN 2, PA 6
1 OFF NAME/RATING PLATE
41X100X1,5-AL

•••CONTINUATION SHEET EXISTS**

SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTIONS0190/ZN

P A R T S L I S T
ARTICLE NO.
DESCRIPTION: OIL COMPOUND REGULATOR UNIT 2-3595-284876
FOR VRK 14,IND.E,2X200/66
SHOWN IN DRAWING NO ; 1-3500-7041/31 SHEET: 3

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART

A S S E M B L Y
1 OFF CONTROL DISK UNIT 2-3547-284874
2 CAMS: 2 + 3 GT [Link],GA2,GA3
CONSISTING OF :
2.3 1 OFF CONTROL DISK 5-7450- 220696
2.7 4 OFF CAM STRIP BLOCK 6-7900- 014863
TYPE 4
2.9 1 OFF SECTOR 5-3092-•107524
2.11 4 OFF CAM STRIP 5-4426- •235363
2.20 5 OFF [Link] SCREW >ISO 4762 6-0110- •001444
M 4X 12 > 8.8-A3F
2.21 8 OFF COUNTERSUNK SCREW >ISO 10642 6-0225- •525938
M 4X 10 > 8.8-A3F
2.22 8 OFF HEXAGON NUT >ISO 4032 6-1080- •000424
M 4 >8-A3F
2.23 11 OFF WAVE SPRING WASHER>DIN 137 6-1740- •000513
B 4 >FST-A3F
2.24 2 OFF BUSHING 6-7370- •014778
MB 4020 DU
2.27 24 OFF SPRING-TYPE PIN >1S0 8752 6-2510- -000594
2X10 >ST-A3F
2.28 4 OFF PARALLEL PIN >ISO 8734 6-2220- -000549
5X 16-A >ST
2.29 24 OFF HEXAGON NUT >ISO 4032 6-1080- -000426
M 6 >8-A3F
2.30 20 OFF CAM STRIP BLOCK 6-7900- -001429
TYPE 1 1.1191
2.31 24 OFF [Link] SCREW >ISO 4762 6-0110- -014900
M 6X 90* > 8.8-A3F
2.32 48 OFF PLAIN WASHER >ISO 7092 6-1530- -000489
6 >CUZN
- 2.34 1 OFF GRADUATED SCALE, TYPE 3 7-0038--007989
1...10-3.2151-SEGM.R1;2=51;69
2.35 1 OFF SECTOR 7-0386--011381
RI= 68,5-PA 6
2.36 1 OFF SECTOR 5-3092--201679

A S S E M B L Y
# 1 OFF ROTARY VALVE 2-3532-235227
CONSISTING OF :
3.1 1 OFF BUSHING 5-1506-103506
3.2 1 OFF SPACER 5-0051-054654
3.3 1 OFF GATE VALVE 5-7350-103474
3.4 1 OFF SET SCREW 5-1562-054650
3.7 1 OFF HEXAGON NUT >ISO 4032 6-1080-000428
MIO >8-A3F

•••CONTINUATION SHEET EXISTS^^

SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:0190/ZN

P A R T S L I S T
ARTICLE NO.
DESCRIPTION: OIL COMPOUND REGULATOR UNIT 2-3595-284876
FOR VRK 14,IND.E,2X200/66
SHOWN IN DRAWING NO 1-3500-7041/31 SHEET: 4

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART
3.8 1 OFF PLAIN WASHER >ISO 7090 6-1510-000478
10 >200 HV-A3F
3.9 1 OFF PARALLEL KEY >DIN 6885-1 6-2810-000711
A 6X 6X 12 >C45+C
3.10 # 2 OFF SQUARE SEALING; RING 6-3310-000803
12,37X17,61X2,62-514 AD(VITON)
3.11 # 1 OFF SQUARE SEALING; RING 6-3310-000806
23,40X30,46X3,53-514 AD(VITON)

A S S E M B L Y
8 2 OFF LEVER UNIT 2-3560-220700
CONSISTING OF .
8.3 1 OFF LEVER 5-7101-220695
8.4 1 OFF ROTARY SEAT 5-0221-054662
8.5 1 OFF RING 5-0112-054686
8.6 2 OFF BUSHING 5-3302-054663
8.10 2 OFF CAM FOLLOWER 6-7340-001453
110-4970
8.11 2 OFF LATERAL PANE 6-1650-001461
-SNSH8X18X2
8.12 4 OFF [Link] SCREW >ISO 4762 6-0110-000113
M 5X 10 > 8.8-A3F
8.13 1 OFF BALL TYPE LUBRICATOR 6-3710-000943
AM 6
8.15 2 OFF HEXAGON THIN NUT >ISO 4035 6-1040-000421
M 8 >05-A3F
A S S E M B L Y
2 OFF LEVER UNIT 2-3560-236236
CONSISTING OF :
9.1 1 OFF LEVER 5-7126-236252
9.4 1 OFF [Link] SCREW >ISO 4762 6-0110-000834
MlOX 45 > 8.8-A3F
9.5 2 OFF WAVE SPRING WASHER>DIN 137 6-1740-000517
BIO >FST-A3F 6-2220-000558
9.6
1 OFF PARALLEL PIN >ISO 8734
9.7 6X 50-A >ST 6-1080-000428
1 OFF HEXAGON NUT >ISO 4032
MIO >8-A3F
11 1 OFF DISK 5-2903-103498
12 2 OFF PIECE OF PIPING 5-1654-237786
13 2 OFF PIN 5-2005-237785
14 1 OFF BEARING BRACKET BODY 4-6275-235261
15 1 OFF HANDLE 5-6410-236306

•••CONTINUATION SHEET EXISTS*•

SN 0423/508*62 ORDER NO. PASSWORD CONTRACT NO.
DATE OF ISSUE
17.05.05 SECTION:0190/ZN

P A R T S L I S T
ARTICLE NO.
DESCRIPTION: OIL COMPOUND REGULATOR UNIT 2-3595-284876
FOR VRK 14,IND.E,2X200/66
SHOWN IN DRAWING NO : 1-3500-7041/31 SHEET: 5

ITEM QUANTITY ME DESCRIPTION ARTICLE

# =SPARE PART REMARK

*=WEARING PART

16 2 OFF SHAFT 5-0020 -235265

OUTPUT SHAFT VR 8/14
18 1 OFF LEVER 5-7114 -236331
FOR VRM8/14 NEW
19 1 OFF FLANGE 5-0301--054649
20 1 OFF RATING PLATE, TYPE 1 5-8113--999011
28 2 OFF SPRING LOCK WASHER>DIN 128 6-1710--000503
A 6 >FST-A3F
29 6-0110--000121
2 OFF [Link] SCREW >ISO 4762
30 M 6X 12 > 8.8-A3F 6-2220--000557
6 OFF PARALLEL PIN >ISO 8734
32 6X 40-A >ST 6-1130--014864
4 OFF HEXAGON CAP NUT >DIN 917
33 M16X 1,5-SW24 >6-A3F 6-1510--001362
4 OFF PLAIN WASHER >ISO 7090
35 16 >200 HV-A3F 6-1450- 014894
4 OFF ADJUSTING RING >DIN 705
36 A25 >ST-A3F 6-4991- 524889
1 OFF HEXAGON PROTECTIVE CAP
37 6-0560- 000404
GPN 1000-MlO-INTERNAL SW16
38 1 OFF SET SCREW >DIN 913
M 8X 30 >45H -A3F 6-6010- 001997
39 1 OFF BALL KNOB, BLACK 6-0110- 530400
E40-M 8-FS/CUZN DIN 319
40 2 OFF [Link] SCREW >ISO 4762 6-0110- •000126
M 6X 50 > 8.8-A3F
41 1 OFF [Link] SCREW >ISO 4762 6-0110- •000121
45 M 6X 30 > 8.8-A3F
6-2360- •000592
2 OFF [Link] SCREW >ISO 4762
M 6X 12 > 8.8-A3F
4 OFF GROOVED PIN >ISO 8746
3X 6 >ST

*** END OF THE LIST ***

 Oil Compound Regulator
with one or two cam strips
Instructions for Initial Operation VR / VRM 8e + 14e , VRK/VRKM 8e + 14e

General remarks:

For the initial commissioning, the linkage between the

electric servomotor and the Compound Regulator must Seniomotor
— pfc ,
be dismantled and the locking iever must point to the op- 1 1
erator's side. In this locking lever limit position, a notch •i-
is. r^
ttr~* 1
holds the Compound Regulator in the positions 1,2,3... L
10 and the positions in between and makes sure that the
positions can be adjusted manually. Locking Lev«r
f-e
If a flexible control cable is to be mounted between a
-pj
driven lever of the Compound Regulator and a damper Turning Slider
yig
intended for metering the primary air or fuel gas volume Buatil ___^|^~*"
flow (in dual fuel plants) etc., it ought to be mounted in
accordance with Sheet 7-1831 -1152.
Smal Load ^ n
^^zi^^4 ,

ftrinfitlt- jj
Factory setting: T A V ^ V J

- Rotary valve Max. opening cross section

Greasing MpplB Ml JJL* \
3?7^ <JJf Dflvelever
- Low-fire spindle Min. opening cross section
- Cam strips Max. stroke for the driven levers Wj J mj
\\ Dnv»l«v«l Screws Xi to Cam
Slot in bushing T for raguMs Cam
Adjustment
the rotary valve on
the back of the Com-
pound Regulator :vertical - must not be changedn Illustration 1

For the Initial commissioning of

A Compound Regulator/burner, the

instructions for commissioning the
heat generator have to be considered!

Set tlie fuel oil flow

for the minimum burner output

The Compound Regulator must be in position 1. Setting

is made with closed rotary valve (slot of bushing I - verti-
cal) by means of the low-fire spindle.

- Loosen the hexagon nut I I (SW16).

Tuming the spindle m (SW 6)

- clockwise = less flow
counter-clockwise = more flow.

- Tighten the hexagon nut II; when doing so, hold the
spindle III with a suitable key.
Illustration 2

SAACKE GmbH & Co. KG SAACKE GmbH & Co, KG Tel. (0421)64 95 0 Technical Documentation
SudweststraBe 13 Postfach 210261 Fax (0421)64 95 22 4
28237 Bremen 28222 Bremen E-Mail info@[Link] ( SAACKE)
Germany Germany Internet [Link] 1-3500-41093/02
2002-08-21 Page 1 /3
Set the combustion air volume flow
for the minimum burner output
The Compound Regulator must be in position 1.

The slot in the air damper axle indicates:

- if situated in direction of flow = damper fully open

- if situated crosswise to flow direction = damper closed

The coarse adjustment is made on lever IV of the air

damper
loC-ti
- Loosen the hexagon nut of the pivot head on lever IV

- If the distance between linkage A and damper axle is

reduced = more volume flow,
reduced = more volume flow

- Tighten the hexagon nut.

The final adjustment has to be made by changing the Damper for combustion air
cam strip position. The direction of rotation of the screws
XI for changing the cam strip position has to be deter-
mined according to the air damper movement for more or Illustration 3: Example of arrangement
less combustion air - see example in Illustration 3.

Set the fuel oil flow

for the rated burner output
The Compound Regulator must be in position 10.

Setting is made by means of screw VII of the rotary valve.

- Dismount the hexagon protective cap Vni and loosen

the hexagon nut IX (SW16).

- Turning the screw VII (SW 6)

clockwise = more flow;
counter-clockwise = less flow.

- Tighten the hexagon nut IX; when doing so, hold the
screw VII with a suitable key.

- Re-mount the hexagon protective cap VIII.

From Compound Regulator position 1 to position 10, the

rotary valve proportions the fuel oil flow approx. linearly,
Illustration 4

Technical Documentation

(SAACKE)
1-3500-4109a/02

2002-08-21 Page 2 /3
 Oil Compound Regulator
with one or two cam strips
VR/VRI\/18e + 14e , VRK/VRKM 8e + 14e

Set the combustion air volume flow

for the rated burner output and the Compound Regulator
positions 2... 9

The Compound Regulator must be in Position 10.

Setting is made by changing the cam strip position. The

direction of rotation of ttie screws XI for changing tiie
cam strip position has to be detennined according to the
air damper movement such as made for the final adjust-
ment of the combustion air for the minimum bumer
output.

The cam strip has then to be set so to assure that the air
volume flow allowing optimum combustion is added to
the fuel in each Compound Regulator position.

Set the second cam strip (If provided)

for the adjustment of a control element witii damper for
metering the fuel gas or primary air etc.
The procedure of cam strip adjustment is the same as for
the first cam strip. Particular attention must be paid to tiie
direction of rotation of the metering damper - see exam-
ple given in Illustration 3.

Metering the volume flow of

- fuel gas (in dual fuel plants): in relation to the

combustion air volume flow already set for fuel oil,
and the combustion values,

- primary air; so as to produce and maintain a steady

flame and a good fuel/air ratio especially in the low fire
range.

Maintenance:
Grease the bearing point (ball type lubricators XII) witii a
good grade of heat-resistant ball bearing grease at least
threetimesa year. At tiie sametime,also clean and re-
grease the cam strips. The ball bearing greases intended
for the ball bearings of the burner or burner motors can
be used as lubricant.

Technical Documentalon

(SAACKE)
1-3500-41093/02

2002-08-21 Page 3/3

J^-fiTiTHLlit MARINE SYSTEMS Doku-Nr.: SMS 34003-0019//2

Issued on: 13.04.2004

DATA SHEET Issued by: 110a/Fre

ELECTRIC ACTUATOR FOR COMPOUND REGULATOR - Type HP 60 D2

Technical data:

Application: Compound regulator VR 8 / 1 4 and compound control unit on

marine SKV 15... 100 / SKVJ 10.. .25 / DDZ 10 burners

Nominal torque: 20 Nm
Ambient temperature, max.: +60 "C
Operating angle / time; 120° / 88 s
Mounting: screw on console with 4 x M6, any direction except upside down
Operation mode: S4 - 30% ED - 1200 cycles / hour
Voltage: single phase 230 V. 50,..60 Hz
Degree of protection: IP54
Accessories; 6 limit switches
feedback potentiometer, 130 Ohm

Article number: 502577

This document consists of 2 page(s) 1

SAACKE MARINE SYSTEMS Suedweststrasse13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49421 6495 363, email: marine@[Link]
CSAACKE: MARINE SYSTEMS Doku-Nr: SMS 3-00034)0ig//2

Issued on: 13.04.2004

DATASHEET Issued by: 1100/Fre

Dimensions:

-150-

-32-H
-4(>--i

Electrical connection diagram:

r %) R^ R2 S3 34 S5 S6 R3

n r n\ f] "\ r
-I '••••):•

A * I

S1^ JS2

23456789 0i11|12j13|14|15 6171819 20 212223 24-J

MP
Y"
R
right turn
left turn D2

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse 13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363, email: marine@[Link]
 Instructions fxiv planning and mountlnjg^ Type:

(SAACK6)
^^m^mtmmmmmmmmmmi^^mm^^
Flexible Control Coble
Subject t o chaise
mmmmmi'^r'lmmtmt^mi^rmitmi^

Figure 1
Xhese i n s t r u c t i o n s include the h i n t s tor
noMntin;^ to be observed for the following
f l e ] ( i b l e control c a b l e s : •[]• € ^
- J)esijgn 1, mike Vofafles; - Type 5
-^ Design 2, nake Flexball r- Type 70

D e s i g n I <Figure 1)
:This f l e x i b l e control cable i s used for the
transmission of pressure and t e n s i l e f o r c e s .
The cabl6 core ( 1 ) c o n s i s t s of a s p e c i a l l y
stranded and s t i f r « i i e d cdble and i s sheathed
Mith o i l - n o d i f i e d p l a s t i c n a t e r i a l . The i n -
s i d e of the fleji:ible tube (2) a c t l o g aca
force transmitter 1$ l i n e d with an acetal
tube. This Ideal a a t e r i a l combirtation of the
external cable core and the internal l i n i n g Figure 2
of th« f l e x i b l e tube as well ^s of the end
f i t t i n g s i s the guarantee for optimal s l i -
ding q u a l i t i e s , a long s e r y i c e l l f « , exempr-
t i o n from maintenance a« well as r e s i s t a n c e
to cold.
- Type marking i d e n t i f i e d on the Jacket;
- Lift = 50 mm;
- Bending radius % .80 mm
" Three-dimeosional i n s t a l l a t i o n i s a l s o ' Balf-rfwnd b«rs
possible. ' Bxilp
• Ball' ctga •(braps (with ths balli, Unas fuids Utt
• w l n ^ central 'lamella)
- Hpvliie central lamilU which tMnaait* tiiia alter-
nate notUin and i s aqutppeil with the neceaaary
canoectlons far final amably tor the dipfeasnt
appllcattona.
• Flerible ateel tube
- FVC ^pthins l^or the protectipn acainBt a l l
Meathera, aplaah Vfat^ or other contminstions^
D e s i g n 2 { F i g u r e s 2 through 8)
This f l o x i b l e control cable i s used for the
transmission of pressure and t e n s i l e forces^ Figure
For i t s structure, s e e Figure 2.
- Type marking i d e n t i f i e d on the Jecket;
- Lift • 70 mmj
- Bending radiUs S 90 mm;
- Three-dimensional installation is also
possiblef

~ Attach the fastening clips On the flexible

part with distances of ait least 500 mm,
in order to avoid any strangling of the Spontaneous bending:
Control cable, only the clips supplied by
SAACKB should be used. Operating end is falling
The angular deflection caused by the bend free without resistance*
height "ra" of the lever travel must have
free motion. The first fastening clip
has, therefore, to be mounted In suffl-^
cient distance behind the flexible tube
holder (see Figure 5).. Figure 4

When installing the control cable, this

should never be forced into a certain posi-
tion; however, It should be exaihinfed in
what direction the control cable is bending
spontaneously. This can be done by a
siinple manual try with the stretched con-
trol cable ( see Figures 3 and 4)-

No spontaneous bending
Operating end bends upwards.
Internal resistance can dis-
tinctly be felt and seen.

Vi Continued on Page 2

Issue: 5/2/8S telefon (0421)6495-1 Sadweslstraae 13 7 - 1 8 3 2

6<«.. Gb/Pich. I
Telagr. SAACKEBRENNER
Telex 24 42 30
SAACKE PQSIfach 210261
2800 Bremen 21 7-1831-1152/02
Page 7-1831-1152/02

This -cotttro:! cabl^ tran6mi.t:s t e n s i l e and

pressure forces but no t o r s i o n a l forces.
I t should, therefore', be i n s t a l l e d i n a
way t o exclude the eiffect of t o r s i o n a l
f o r c e s pn the s l i d i n g or end b o l t s and
guide s l e s v e s . In order t o avoid such top-r^
s i o n a l f o r c e s , the wrench f a c e s of the said
parts have t o be used wheti mounting the
c o n t r o l cable ( s e e Figure S) •
The guide s l e e v e iias to be supported so Slidine bolt
t h a t i t i s siibnated c « n t r l c a l l y t o the
point of appliCstion of t h e s l i d i n g b o l t .
( The s l i d i n g b o l t must operate without
mechanic s i s t r e s s e s . ) Qall joint

As t o the b a l l J o i n t , i t s d e f l e c t i o n has t o Suide >!••»•

centrical to the
be considered, i . e . the d e f l e c t i o n has t o point of application
be the sSm'e t o both s i d e s and should not
exceed - 8 .. In order t o g e t a small de-
f l e c t i o n angl6, the dimension ".Ic" must be Strap (fixed point)
choseq as large as p o s s i b l e i n accordance
with the 4 v a i l a b l e thread length {see f i -
gure 5 ) .
^he control c a b l e i s , on the transmission
and riBcelving ends, to be d i r e c t e d so that
t h e c e n t r s l l a m e l l a absorbs the angular
d e f l e c t i o n with i t s f l a t end s i d e ( see
Figure 6).
Care must be taken that t h e f l e x i b l e part
w i l l not be buckled downstream of the
guide s l e e v e and w i l l be i n s t a l l e d
s t r a i g h t on a length of at l e a s t 50 m Figure 6
< s e e Figure 5 ) -
When the Control .cable i s mounted, i t Central lamella
should, at fir^st, b^ connected only pro-
v i s i o n a l l y and put in t h e s u i t a b l e form.
The easy-ruiining, the b a l l j o i n t d e f l e c -
t i o n and the l i f t shouXd then be examined
and p o s s i b l e corrections be carried out.
In case that the control c a b l e operates
s a t i s f a c t o r i l y , the connecting points and
f a s t e n i n g c l i p s must be duly f i x e d . Mien
doing s o , the wrench faces should be used
as described above^
Figure 8
When i n s t a l l i n g the f l e x i b l e control cable
t o the third l e v e l , the f o l l o w i n g should
be observed t
After determining the spontaneous bending • i
as described i n Figure 3^ t h e free end i s
bepded i n S-form (Figure 7') and then
turned i n t o th0 third l e v e l (figure 8 ) .

Remark
The flexible control cable should not be
dismantled.
 POS NO. 2.02.25

032333 MARINE SYSTEMS Doku-Nr: SMS 3-0003-0010//2

Issued on: 21.0S.2003

Issued by: 1100/Fre

PRESSURE S W r C H DWR 6-203

Technical data:

Function: When the pressure exceeds the selected setpoint, the microswitch Is operated through a
mechanism and the circuit is opened or closed. When the pressure falls below the setpoint
(by the adjustable switching difference), the microswitch returns to its inital position.

Approval: T O V . D W F S 00-281

Set point range: 0,5...6,0 bar

Medium pressure, max.: 16 bar
Medium temperature, max.: +70°C
Ambient temperature, max.: +70''C

Material, casing: GDAISi12

Protection: IP 54 nach DIN 40 050
Connection: G 1/2" Manometer connection

Switching element: Microswitch with diange-over contact

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse13. 28237 Bremen, GERMANY

Te].:+49 421 6495 138, Fax.:+49 421 6495 363, email: marine@[Link]
(SAACKE: MARINE SYSTEMS Doku-Nr.: SMS 3-0003-0010//2

Issued on: 21.08.2003

Issued by: 1100/Fre

Connection diagram:

•7l
12 3©

Dimensions:

III li^fcii i«l>Tkii^

n in I 111
Ifi it!
ST-

M ei« _

Article number: 532290

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse13, 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363, email: marine@[Link]
 POS NO. 2.01.15

Pressure relief controller

V22 D28

For heavy oil and high-viscosity media

Instructions for Mounting, Start-up and Maintenance

SIBC [Link].11.02
Contents

1. General data Page

1.1 Correct application

1.2 Incorrect operation
1.3 Storage, transport and paddng
1.4 Warranty
1.5 Nameplate
1.6 Design 2
1.7 Technical data 2

2. Mounting

2.1 Safety notes 3

2.2 Safety precautions on the site 3
2.3 Mounting 3
2.4 Application examples 3
2.5 Mounting dimensions 4

3 Start-up procedure

3.1 Principle of operation 5

3.2 Special notes 5
3.3 Start-up 5

4. Maintenance and repairs

4.1 Troubleshooting 6
4.2 Repair instructions 6
4.3 Maintenance notes 6
4.4 Solutions 6
4.5 Spare parts list 6
 General Data

Pressure relief controller is designed for modulating control of the pressure in 1.1 Correct application
technical devices operating with heavy oil and other high-viscosity media with
temperature of up to 140°C.

Pressure relief controller may only operate in the required mounting position 1.2 incorrect
and with the medium stated above. Operation In conditions which differ from application
the technical requirements is not allowed. Ensure that the ranges stated in
Technical data are strictly observed.

Check if the shipment Is complete. In case the goods are damaged during 1.3 Storage,
transport, immediately inform trsinsport agent and manufacturer. If the goods transport and packing
are transhipped during the transport, the original packing must be used.
Storage location must be clean and dry.
Storage and transport temperature:

Warranty is applied according to the delivery conditions valid in thetimeof 1.4 Warranty
delivery. Warranty becomes void if mounting and start-up is not performed
according to Instructions for Mounting, start-up and Maintenance. Mounting,
start-up and maintenance may only be performed by authorized personnel.

Actuator 1.5 Nameplate

Valve

o d
Typ
S.-Nr
kvs mVl:
tmax "C
Ap bai
iiiiiiHiiiiigiiiiiD
Q 0000 0J0 00 0 Q

Fig. 1: Nameplate
Design

1.6 Design V22 Valve

1 Valve body
2 Seat
3 Valve cone
4 Plug stem

D28 Control element

5 Coupling nut
6 Actuator stem
7 Diaphragm plate
8 Diaphragm
9 Larger Diaphragm plate
10 Diaphragm housing
11 Set-up spring
12 Pressure element with spheres
13 Set point adjustment

1.7 Technical data Table 1: Technical data valve V22

Nominal size DN 15 20 25 32 40 50 65
kvs (m'/h) 3,6 6,6 9,3 13,5 23,5 35 55
Differential pressure l^Pnn (bar) 16 16 16 16 16 16 16
Nominal flow (m'/h) 1.5 3 4,5 7 11 18 27
Weight (kg) 5,5 6 9 12 15 19 30
Max. operating temperature 140 "C
Body material GGG-^10.3
Nomin al press urePN 16(Dir J 2401)
Max. operating pressure
do not exceed Apmn

Table 2: Technical data actuator 028

Control element D28 Size (cm^) 32 80

silver (bar) 3-11 1-5
Set point ace. to the yellow (bar) - 0,5-2,5
black (bar) 10-16 -
Weight approx. (kg) 8,0 7.5
Nominal pressure 25
body Steel, mat. No. 1 .0338, chromated
Material
diaphragm FKM
 Mounting

Please read carefully and observe the instructions for Mounting Start-up and 2.1 Safety notes
Maintenance prior to starting any worl< on tiie device. Also observe tiie Operating
Conditions and Guidelines of the Proffesionai Association "SOddeutsche Edel-
und Unedelmetailberufsgenoschenschaff, Stuttgart, Hausmanstreisse 6, as well
as valid DIN guidelines.

Mal<e sure that the pipes which are connected to the device are depressurized 2.2 Safety precautions
and enough time is allowed for the pipes to cool down. Shut-off valves in the on the sHe
relevant sectiwi of the pipeline must be secured against accidental opening.
Before starting welding procedures, necessary fire-preventing measures must be
tai<en.

Flush the pipe system before mounting the flow regulator. Pressure test must be 2.3 Mechanical mounting
performed before mounting tai<es place or test pressure must not exceed max.
differential pressure across the flow regulator.
Controller must be installed In horizontal pipeline with the actuator in pointing
upwards. This mounting position enatHes the transfer of media temperature to
the actuator. The medium must flow through the valve in the direction indicated
by the arrow on the valve body. Installation of strainer Is strongly recommended
as well as the installation of shut-off valves and pressure gauges upstream and
downstream of the pressure relief controller. Avoid mechanical stress of the valve
body during installation of pipes. The operation of pressure relief controller does
not require any control lines.
In case valve and actuator are delivered separately, both parts must be joined.
Firstly put the actuator on valve necl< and then screw (clockwise) the actuator
stem into the valve stem until it stops. Unscrew the joint for one turn (counter
clockwise) to prevent any additional tension between actuator and valve. Fasten
the actuator onto the valve neck with the R 1 V*" coupling nut.

Recommended layout
Shut-off Shut-off
valve Strainer valve
2.4 Application examples
-^i^ 0 ^ ^ ^D^h^-{>kl-

Fig. 3: Recommended layout

Pressure reduction in heavy-oil igniting devices

*»-. I [—1«—Ja—I

Fig 4: Application example

Mounting

2.5 Dimensions Table 3: Dimensions of valve V22

Nominal size DN 15 20 25 32 40 50 65
L (mm) 130 150 160 180 200 230 290
B (mm) 100 105 115 125 135 140 150

Table 4: Dimensions of actuator D28

Control element D2B Size (cm^ 32 80

0 A (mm) 172 172
H (mm) 480 465

Fig. 5: Dimensions i. II 11 ^

T
CD D
F^^

lb: c
C
::

''
B
r C = ^
1 ^.u.

irn
H
ITJ
..,-' "**

"•—0A *•
 start-up procedure

After opening shut-off valves the medium flows through the valve and acts with its 3.1 Principle of
pressure on the control diaphragm of the actuator through the internal channels. operation
After the system or end user is fiiled-up and the pressure reaches the pre-set value,
the cross-section of flow in the valve changes proportional to the difference of the
set point. The required equilibrium between pressure in the diaphragm chamber
and setting force holds the valve stem and thus the valve cone in the position which
gives the required flow.

Make sure that the operating values for temperature and pressure, stated in 3.2 Special notes
technical data are not exceeded. Pipeline system must be equipped with elements
which compensate excessive stretch- or torsion forces. Avoid sudden pressure
drops, which means that quick shut-off valves can be used as an emergency valves
only.

Caution!
Sealing of the upper and lower valve parts is perfomied when the valve is installed
on the actuator. Therefore system must be depressurized before dismounting the
actuator from the valve.

Pressurize the system by turning on the circulation pump while shut-off valve in 3.3 Start-up
front of the regulator remains closed. Slowly "open the shut-off valves and check the
pressure relief controller connection for leaking. Adjust the required pressure by
turning the set-up nut while watching the pressure gauge at the same time (Rg. 2,
pos. 13). Turn the nut counter clockwise to Increase the pressure and clockwise to
reduce the pressure. The adjustment range can be obtained from the nameplate.
After short operating time check all connections and ventilating plugs for leaking.
Maintenance

4.1 Maintenance Pressure relief controller V22 D28 is maintenance free under normal operating
conditions.

4.2 Repair instructions Prior to working on the regulator depressurizre and cool down the device. Perform
repairs according to section 2.3. Follow the instructions in section 3.3 to perform
start-up procedure.

4.3 Troubleshooting The pressure exceeds or does not reach the set point. Possible reasons:

- valve does not close

- actuator is out of order

4.4 Solution Replace the valve

In case the valve leaks, the possible cause may be impurities in the valve or valve
cone and seat being warn out. Replace or repair the valve.

Replace the actuator

In case actuator is not working the diaphragm chamber may be blocked by the
deposits or the diaphragm is defective. Replace the actuator.

4.5 Spare parts Should you order spare pars please submit the data about control valve type,
nominal size, actuator size and set point range. Please send your order to the
address stated in 4.7 or to the manufacturer.
Spare part
-ValveV22DN...PN16
- Actuator D28, operating surface ... set point...
 POS. NO. 4.07
DATA
TITLE SHEET MB-BV-01
NO. :
3-Way ball valve with
KANGRIM Limit Switch PAGE 1 OF 1

21 STOP RING SUP6

20 PACKING TEFLON
19 GASKET TEFLON
18 STEM SEAT RING TEFLON

ememf^ 17
16
15
BONNET GASKET
LEVER
GLAND BOLT
ASBESTOS FREE
FCD
SUS304
L. TYPE -E4AZE--=24&=-
14 HEXAGON BOLT BS
r^Tni \r^Tn: 13 CONTROL RING BC6
T. TYPE
12 ADAPTER 8SBFD2
BUSHING BSBFD2
10 STOPPER SUS304
PLATE SS4L
NOTE LIMIT SWITCH CA2,15B
PACKING GLAND 6C6
1. HYDROSTATIC TEST PRESSURE
PACKING TEFLON
BODY : 12 K g / C m ' STEM SUS304
SEAT : 10 Kg/Cm^ SEAT RING TEFLON
BALL SUS304
2. MAX. WORKING TEMP. : 160 "C
BODY CAP 8C6
BODY BC6
NO. NAME OF PART MATERIAL O'TY REMARK
 POS NO. 2.02.17

(SAACKE M A R I N E SYSTEMS Poku-Nr.: SMS 3-0003-0013//2

Issued oit 30.04J2O03

DATA SHEET issued by: 1100/Fre

OIL FLOW METER V Z 0 25

Type; VZOZS
Nominal bore: ON 25
Nominal pressure; PN16
Connection: BSP 1 1/4"
Flow rate; m3X.2OO0l/h
• S''"-' min. 75 l/h
Casing material: Red brass
Operating temperature: max. 130-0

Pulse transmitter optionally available

Article numbers:

VZO 25 with roller counter only: 250794

VZO 25 with additional pulse transmitter 0,1 500970

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse 13.. 28237 Bremen, GERMANY

Tel.:+49 421 6495 138.. Fax.:+49 421 6495 363, email: marine@[Link]
033333 MARINE SYSTEMS DokM-Nr.: SMS 3-0003-0013//2

(ssued on: 30.04.2003

DATASHEET Issued by: 1100/Pre

Basic element dimensions:

s
L n
/ — ^
1—n T
I

i 1 ~ T [4— "TT--
Bi "1
• ,

—^_j _ fc.
T*
' ,r X3 ^
tr u

I i V

Ui^—= —-i^
B -*———
* - —• a ^—•

L - igonrni Dimension h2resultsfrom lieight of tlie

B ^ 130 mm selected counter equipment. Dimensions
a = 305 mm of counter equipment please see below.
0F « 115 mm
b = 77 mm
hi = 101 mm
P * BSP1 1/4*
r = BSP1*

Counter dimensions:

Roller counter Roller coynter witfi pulse transmitter IN 0,1:

10 y v^ n
o
e ^ TT*
f 1 I.

0105 -.8 10
0
0
OJ

00
r u

0105
4 157 - — •

This document consists of 2 page(s)

SAACKE MARINE SYSTEMS Suedweststrasse 13. 28237 Bremen, GERMANY

Tel.:+49 421 6495 138, Fax.:+49 421 6495 363. email: marine@[Link]
 aqua
m

Technical information

CONTOIL X T
fuel oil meters

• Flow measurement for mineral oils and heating of propellanl fuels |

• In burners, on board ships, land vehicles and fixed-position motorst?..! ^ |
• "GermanischerUoyd'apfffoval for use on board ships (option) "-"^iL

.-. ^T^

X
.O

-li^
CONTOIL'' f u e l oil meters -
t h e right product for every application...
VZ£15i^>^:50 range (StantlaFd)! Hrttti miilti-^iictlpn display and remptei tnmsnil^iiHi - .

Electronic display of
• total volume
• resettable volume
• flow rate in l/h in digitals and as bar diagram in %
other operating data in ttie service level

Simple to operate

Normal commercial long-life battery, simple to ctiange, data security

Opton: Inductive INA pulser for control purposes

Housing witti threaded or flanged connection

Main diaracterlstic data:

• f l o w range 1 0 . . . 30,000 l/n
• temperature 70,130 and 180*C
• nominal pressure PN16 and PN 25 bar

Informations In chapter 1 Pages

^p;4i...50«nfl»i(Classlc)- \ ^ : ^ . . . . total volume display and remcrte transmission

Total volume display on roller register

Option: Reed pulser RE or RV for remote totalisation

Option: Inductive IN pulser for control purposes

Housing wltb threaded or flanged connection

Main ctiaracteristic data:

• flow range 0.5... 30,000 i/ti
• temperature 60,130 and 180° C
• nominal pressure PN 16, PN 25 and PN 40 bar

Informations in cftapter 2 Pages

Tecfmlcal informations CONTOIL*

 ...COIMTOIL* product groups and selection criteria
VZEA/VZQA15.,.50range Optimal#Glifidn for similal appllcatipns i ^ t o :

• differential measurement
• custody transfer / iegal verification
• testing fadiities

VZEA
Bectronic display of
• total volume
• resettable volume
• flow rate in l/h in digitals and as bar diagram in %
other operating data in the service level

VZOA
• Volume display on roller register

Option: Inductive pulser, INA or IN, for control purposes

Option: RV Reed pulser Jor remote totalisation,

integrated into the roller register (VZOyy

Housing with threaded or flanged connection

Main c^aracte^istic data:

• flow range 10... 30,000 l/h
• temperature 130 and 180° C
• nominal pressure PN16 and PN 25 bar

with special pairing for minimum measurement variance,

Infoimations in chapter 3 Page 15

Accessories Chapter 4 Page 21

Meter data (Appendix) Chapter 5 Page 22
Selection matrix for the optimal meter Chapter 6 Page 29
Fluid fuel oil Chapter 7 Page 30
How to obtain an optimal measurement Chapters Page 31
Application examples Chapters PageX

' flowmeters are needed for hazardous areas, please contact next sales office.

Technical Information CONTOIL*

CONTOIL* the world's most f r e q u e n t l y
used oil consumption meter
Leading manufacturers of oil burners and operators of fieating systems, ships or diesel engines rely on CONTOIL* fuel oil meters -
and with good reasons.

The advantages of CONTOIL* fuel oil meters - your benefits

You can decide which of these many benefits are the most important for you:
• the optimal solution for every application
• simple burner setting with flow rate display Qypes VZQ
• simple consumption monitoring or manual dosing feature, with the resettable counter ( ^ e s VZE)
• can be mounted on the pressure or suction side
• space-saving installation, because no straight inlet/outlet sections are needed
• the meter can be mounted flexibly in a horizontal, vertical or inclined position
• accurate measurement result, smce the reading is independent of the temperature and viscosity of the fluid
• minimum failure costs due to simple function monitoring, rapid fault analysis and the possibility of simple repairs on site

Areas of use
• to measure heating fuel consun^on by oil burners (for example, in heating boilers, industrial furnaces, tar processing plants)
• to measure propeliant fuel consumption by motors and engines (such as diesel locomotives, construction machinery and ships,
or in standby power groups, combined heating and power stations)
• consumption monitoring
• flow measuremwt for mineral oils, option with remote transmission
• manual dosing/filling
• flow measurement for machine and motor/engine oils
• engine testbenches

Medium
• heating fuel extra light / light, medium, heavy
• naphtha
• diesel
• petrol
• and other media which can be used for lubrication purposes

Technical Infomiations CONTOIL*

1. VZE 15 . 50 (Standard)
Technical data"
• with electronic display oftotalvoiume, reseltable volume and flow
rate, units: litres or US gailons ^
• fuel oii meter witti threaded or flanged connection
• for mounting in a horizontai, vertical or inciined position

Option: witti inductive IMA pulser

Versions available on request:

• different flange driiiings. such as ANSI, JIS

i m \ :••:.• VZE 15 VZE 20 : VEE 25 -VZB40 VZE 50

Nominal di^neter DN mm 15 20 25 40 50
Inch Vs 3/4 1 Vh 2
installation length mm 165 165 190 300 350
Nominal pressure with threaded ends PN bar 16
with flanges PN bar 25
Maximum temperature "C 70,130,180
Maximum flow rate O.,.' l/h 600 1500 3000 9000 30000
Nominal flow rate 0,3) l/h 400 1000 2000 6000 20000
Minimal flow rate Qmin l/h 10 30 75 225 750
Approx. starlinq flow rate l/h 4 12 30 90 300
Max. permissable error ±1%of actual value
Repeatability ±0,2%
Smallest readable amount;
Total volume 1 No decimals
Resettable volume 1 3 decimal places with floating decimal point
Digital flow rate display l/h 1 decimal place
Registration capacity approx. 1 100000000
Registration at Qn before returntozero h 250000 100000 50000 16660 5000
Safety filter mesh width mm 0.400 0,400 0,400 0,800 0,800
Dirt trap mesh width mm 0,250 0,400 0,400 0,600 0,600
Volume of the measuring chamber approx. cm' 12 36 100 330 1200
Housing finish enamelled red RAL3013
Weight with threaded ends '^ approx. kg 2,2 2.5 4.2 17,3 -
with flanges PN 25 approx. kq 3,8 4,5 7,5 20,3 41,0
Pulse values of pulsers: approx.
IMA inductive according to DIN 19234 W 1/pulse 0.0006 0.00185 0,005 0.017 0.060
Pulse freguency INA atOmu Hz 277,778 225,225 166,667 147,059 138.889
a t Qniln Hz 4,630 4,505 4,167 3,676 3,472
1) Manubnuief's spedncatnn, velld !cir Ihs rste^ence condillDn aa tc«cffleil undn imtti A l i pmite^,
2) 1 UStatacarreawnferol/BSIItrES.
3) [Link]«E«l»nadb'pannar«ntnw.F(xhlonetriKOsrty,^
nnge must BIM t» considered: set Chapters Sand 8.
4) Weight HtltnuIcounlinsG
i) T>iap[acfseputEevalu«cenhBIB]imliorlinerneKt;iMsontrknaymaner|h9(slln([Link]

Technical information CONTOIL*

Electronic display
Display values: • total volume, resettable volume, flow rate
• In the swvice level, service hours and ottier information can be
read out
Display: • S-characta' LCD with identification of the parameter, height of
numbers: 8 mm, flow rate (meter load) using bar diagram
Temperature: • ambient temperature-10 ... +70° C,
storage temperature -20° ,.. +80° C
Safety: • CE, vibration and shodt test to DIN EC 68
Supply: • usualcommerdallithiumbattery,typeCR1/2AAorCR2
Data reception: • by non-volatile memory (EEPROM)
Change of battery: • after 5 years, based on a battery lifetime of 6 years with a
maximum of 10 hours' digital display of the flow rate
Pn)tection; • IP54 (lEC 144) against splash vrater and dust

Pressure drop curves

in chapter 5

Dimensions In mm

Mew : Lengtti : Width Height of meters VZE

V2E...7a°C VZE... 130° C and 180° C : ;
-s
J
I
1 s1 VZE15
L--.:
165
W
105
H

106
^ • "H^-T--
147
:.:-H.::^±-

185
••.;:-• •:.H::.'

185
1— ' i VZE20 165 105 115 156 194 194
VZE25 190 130 142 183 221 221
VZE40 300 210 194 235 273 273
VZE50 350 280 250 291 329 329
OgEslol (HmenMral drminQS in cii«t> 5

INA pulsers
High-resolution pulsers for industrial applications.
Plug-in proximity switch.

Switching element: inductive slot initiator according to DIN 19234

Switching voltage: 5.,.15VDC
Residual ripple: max, 5%
Switching current: >3mAat8VDC/lkOhm
Static current: < l m A a t 8 V D C n kOhm
ON-time: 50% ±10%
Ambient temperature: -10...+70-0
Type of protection; IP 65 (lEC 144) against water jets and dust
Connection: Pulser supplied with special plug, Required cable min.
2 X 0.35 mm^ and 4. ..6 mm external diameter or optional
pn 80019 with mounted cable.
Option; Cable mounted, 2 x 0.5 mm^, PVC black, length 3 m (pn 80019)

Type designation key

\/ZE25FL130/25-INA

Pulser
Nominal pressure bar
Temperature "C
Connection
Dimension mm
Type

Technical informations CDNTOIL'

 Ordering specifications
Threaded ends -ilyiK#..a.;:---. 0rdehN8;;Mi: V -•v:1ype . ••.-«:;-;::;.L;.^i-;;;;::: ,iOifderNci; n;;

VZE15 RC 70/16 92206 VZE 25 RC 70/16 92224

VZE15RC70/16-INA" 92207 VZE25RC70/16-II\1A" 92225
^ ... 92226
^ VZE 15 RC 130/16 92208 VZE 25 RC 130/16
f \ VZE15RC130/16-lNA'i 92209 VZE25RC130/16-INA1' 92227
VZE 20 RC 70/16 92214 VZE 40 RC 70/16 92234
n - — ZZT-
.1
1 1 VZE20RC70/16-INA" 92215 VZE40RC70/16-INA" 92235
1...-. -.1 ' VZE 20 RC 130/16 92216 VZE 40 RC 130/16 92236
VZE20RC130/16-INA" 92217 VZE40RC130/16-INA'> 92237

Bar ges VZE15FL130/25 92212 VZE40FL130/25 92240

130•c/PNas VZE15FL130/25-INA'> 92213 VZE40FL130/25-INA" 92241

92220 VZE 50 FL 130/25 92246

V—T VZE20FL130/25
VZE20FL130/25-INA'> 92221 VZE50FL130/25-INA" 92247

1
1
1 1' i VZE 25 FL130/25 92230
VZE25FL130/25-INA" 92231
1
Flariges VZE 20 a 180/25 92222 VZE 40 FL 180/25 92242
18C°C/PN25 VZE20FL180/25-INA" 92223 VZE40FL180/25-INA" 92243

/ u VZE 25 FL 180/25 92232 VZE 50 FL 180/25 92248

T -+-\- VZE25FL180/25-INA'i 92233 VZE50FL180/25-INA" 92249
1
i
DNtS mins am not uRaUeft)riMsv)tudmi. tfiia ia an)y possMe it ipedat precautions we takea

OptIon/Accessory^)

Cat)le Mounted cable IN/INA 80019

Technical informations CONTOIL*

2. VZO 4 ... 5 0 (Classic)
2.1

VZ04and8

Technical data"
• oil meter with insidetfireadconnections located on the bottom plate
• with mectianicai roiier counter, volume dispiay in litres
• meters in US-Gallons 2
• lor mounting in horizontal, vertical an inclined positions

Option: Reed puiser 48 V

TjrtJe • ;;i r-•:;•:•'/;••"•.•/;-J:, ' • • ' ' - • • • • '-'• • • " ,,,,^,,. WO 4 VZ04 \^0 8
;Qmii.o,5 •
Nominal diameter mm 4 4 8
incti '/B VB Vfl
Connectiontfireadsof meter incti '/B VB 74
Nominal pressure bar 25
Temperature 'C 60
Maximumflowfrate Q™,^ l/h 40 80 200
Nominal flow rate Qn" l/h 25 50 135
Minimal Row rate Q^^i l/h 0,5 1 4
Approx, starting flow rate l/h 0,3 0,4 16
Max. permissabte en'or ± 1 % of actual value *^
Repeatabiiitv ±0,2%
Smallest readable amount 1 0,001 0,001 0,01
Registration capacity nf 100 100 1000
Registration at Qr. before retum to zero h 4000 2000 7400
Safety filter mesh width mm 0,125 0,125 0,150
Dirttrap mesh width mm 0,080 0,080 0,100
Volume of the measurirq chamber approx. cm^ 5 5 12,5
Weight without couplings approx. kfl 0,65 0,65 0,75
Reed puisers RE1 1/pulse - - 1
RE 0,1 - 0,1 0,1
RE 0,01 - 0,01 -
RE 0.00125 - 0,00125 -
RE 0,00311 - - 0,00311
Pulse frequency for RE 0,00125 s* atQmu Hz - 17,777 -
atQrTUn Hz - 0,222 -
Pulse frequency for RE 0,00311*' at Qinax Hz - - 17,864
at Qfflii Hz - - 0,357
t) ManuiacTursr'isito'i'^t^n,w^KivITierctEiinccco;i[JIMnasK«cinsdunOsfineteiAsia lannei).
2) I US[|allDnt;Drrss{itind9ti)3.7S5IIIr(3
3) Fci Curncfs and ergliKis or mMrs, U'B ireler rmjst basically be is'etitO lor pernufienl Dow. For higlwt viscosity, n il t)i« nuMr le IrntallBdon V« luctian tide, UIG preuura diai ind any [eduction In the mea5ulr)|]
langa must also be con90ereil;Gee Cheplers i and B.
4) Maxpernilss8ble8(ror:VZO4Q-0.5:0.5lfli...2I* = + lH/-2«.VZO4:1Wl...?Wi- + 1%/-21l.
5) BrieMniervelswrvn switched Mbavs ID McoruUeied

Pressure drop curves

in chapter 5

Technical informations CONTOIL*

 Dimensions in mm Dial
VZ04 VZ08

height = 79
width = 6 5
depth = 65

"l 111! l l

Detailed dimensional drawings in chapter 5

Mounting KitforVZO 8 Order No. 81130: some possible mounting positions

n a.
R W
D = ^ ^
1^ •r

w E n kX
m " ^

REPulsers
Switching element: • Reed switch with dry contact (inert gas)
Svyitching voltage: •Max. 48 VAC/DC
Switching cun^nt: • Max. 50 mA
Static cun'ent: • Open Contact
Switching power: • Max.3VA
ON-time: • VZO 4-RE 0,00125: 65, ,90%
- +/- • VZO 4-RE 0,01: 10 ,30%
iismA
• VZO 4-RE 1: 30 ,70%
• VZO 8-RE 0.00311: 65 ,90%
• VZ08-RE0.1: 10...30%
•VZO 8-RE 1: 30...70 %
Temperature: • Ambient-10...+60''C
Protection: Meters without pulser:
• IP 65 (lEC 144) against water-jets and dust
Meters with pulser RE:
• IP 50 (lEC 144) against dust deposits
Connection: • On plug supplied with product for cable, 2 x 0,35 mm^

Ordering specifications

•me:Vi''' • ; GrderNQ!;;:;:;; ;^;:IVDe-:;.-:;;.:•;•;-••,. Order No,: ^

VZO 4 92680 VZO 8 92630
VZO 4 RE 0,00125 89763 VZO 8 RE 0,00311 89733
VZO 4 RE 0,01 89760 VZO 8 RE 0,1 89730
VZO 4 RE 0,1 89761 VZO 8 RE 1 89731
VZO 4 Qmio 0,5 92678

Special versions witli gasicets FiVIP floor elastomer

Type • : . • , ., Order No.

VZ04V 92487
VZ0 4V-REO,01 92488
VZ04V-RE0,1 92489

Teclinlcal informations CQNTOIL*

 2.2

VZ04and80EM

Technical data"
fuel oil meters for OEM's (original equipment manufacturers),
to be mounted under the burner cover
meters with internal threaded connection, positioned laterally
with 230V Reed pulser to display measurement values on remote
totaliser or on burner control unit
for mourting in horizontal, vertical or inclined positions

Type " - . • ' • " • ' - • • ^ - •?••••• VZ0 4 VZ08

OEM ... . OEM
Nominal diameter mm 4 B
inch Vs V4
Connecton threads of meter inch Vs V4
Nominal pressure bar 32 25
Temperahjre "C 60 60
Maximum flow rate 0™ ^ l/h 80 200
Nominal flow rate . & ^ l/h 50 135
Minimal flow rate Q™ ^ l/h 1 4
Approx. starting flow rate l/h 0,4 1,6
Max. pemiissable error ± 1 % of actual value ^'
Repeatability ±0,2%
Safety filter mesh width mm 0,125 0,150
Dirt trap mesh width mm 0,080 0,100
Volume of the measuring chamber approx, cm' 5 12,5
Weight approx, kg 0.65 0,75
Reed pulsers RE 1/pulse 0,005 0,0125
Pulse frequency at Omw Hz 4,444 4,444
atQmr Hz 0,056 0,089
1| Manuteclwif's Bpeellicaacr, ysW (m Uia rrtotence ooraHlui u ipecifled unflei msUr OaB (annwl-
Z) Fo^bu[TWsarldeng'^esar[TulOl^.[^«FTIalmml«lba!h:a[lyl»EelKtcdlWP«lnancntnclW.l^niOlw wscM^^
range must also b« ccrMtnd, xe Ouptcrs 5 and 9-
31 Ma«.perfn(ssti«eeiTorWO«0£M-lWi...2Wi = + 1%/-.?V

Pressure drop curves

in chapter 5

10 Technical Informations CONTOIL*

 Dimensions [n mm
VZ04 0EM VZ08 0EM

f
—:*l
• ^ ». itrr [
-K\i=^ ^

1 \T
'L
n -
-1 —1— t
a
J 1

-1 - -^ 10

en

RE Pulsers
Switching element: • Reed switcti with dry contact {inert gas)
Switching voltage: • max. 230VAC/DC
Switching cun'ent; • max. 50 mA
Static current: • Open Contact
Switching power: • max. 3 VA
ON-time: • 40 . . . 5 5 %
Temperature: • Ambient-10 ... +60°C
Protection: • IP 65 (lEC 144} against water-jets and dust
Connection: • Cable cross section 2 x 0,5 mm^ length 480 mm

Remote totaliser for VZO 4 OEM

Power supply: • 230 V, 50/60 Hz
Pulse value (input): • 0,0051
Smallest readable
amount: • 0,005 I
Registration capacity: • 100001
Registration: • at Qn before return to zero 200 h
Panel cut-out: • 2 7 x 1 4 , 4 - 0 / + 0 . 2 mm
Installation depth: • 56 mm

Ordering specifications

Description Order No.

Jm.
VZO 4 OEM-RE 0,005 Version for OEM's 89765
Remote tolaliser for VZQ 4 OEM 93349
VZO 8 OEM-RE 0,0125 Version for OEM's 89771

Teclinical information COIfTOIL* 11

 • Volume display on roller register, in litres
• fuel oil meter with threaded or flanged ends
• for horizontal, vertia^ or inclined mounting

Option: Reed puiser or RV / IN pulser

Versions available on request:

• differentflangedrillings, such as ANSI, JIS
• meters in US Gallons ^ (option)

type :VZ015 VZ0 20 VZ025/ VZ040 VZ050

Nominal diameter DN mm 15 20 25 40 50
inch V2 V. 1 Vh 2
Installation length mm 165 165 190 300 350
Nominal pressure with threaded ends PN bar 16
with flanges PN bar 25,40
Maximum temperature °C 130,180
Maximum flow rate Q™- ^ l/h 600 1500 3000 9000 30000
Nominal flow rate Qn" l/h 400 1000 2000 6000 20000
Minimal flow rate OT™ l/h 10 30 75 225 750
Approx. starting flow rate t/h 4 12 30 90 300
Max. permissable emir ± 1 % of actual value
Repeatatjility ±0,2%
Smallest readalJle amount 1 0,01 0,1 0,1 0,1 1
Registration capacity m3 1000 10D00 10000 10000 100000
Registration at On before rehirn to zero h 2500 10000 5000 1667 5000
Safety filter mesti width mm 0,400 0,400 0,400 0,800 0,800
Dirt trap mesfi width mm 0,250 0,400 0,400 0,600 0,600
Volume of the measuring chamber [Link]^ 12 36 100 330 1200
Housing finish enamelled red RAL3013
Vi/eight with threaded ends *'' [Link] 2,2 2,5 4,2 17,3 -
with flanges PN 25 [Link] 3,8 4,5 7,5 20,3 41,0
with flanges PN 40 [Link] 4,4 5,5 7.8 20,5 42,0
Pulse vaiues of pulsers:
IN inductive according to DIN 19234 1/pulse 0,01 0,01 0,1 0,1 1
RV Reed 1/pulse 0,1 1 1 1 10
RVReed 1/pulse 1 - - 10 100
Pulse frequency IN atOma Hz 16,667 41,667 8,333 25,000 8,333
at Qnin Hz 0,278 0,833 0,208 0,625 0,208
t) UanilKhi'm's uecincaLltfi. valid lor Hie relargncs conditon u speOHii undar maler tm (annen).
2) t [Link]
3) Fa turrets BUS engines a imtors, Iha rneigt musi Diiically De scfecMd lor pemDnenI ItoMi. Fgr hlffiti ttectielly, nr II the metti Is litstaDed on Vn tucam eldi, Ihe pressure dicQ and any reduction In Ihe melivrlno
large miz\ liso Co cursideredi see CIUJHSCE imit,
41 WelotU wHDoul nuiillngs.

Pressure drop curves

in chapter 5

12 Technical Informations CONTOIL'

 Dimensions hi mm

Meter Length Width Height of meters VZO

"
VZO.„130'C
-RV ^ -«i
m.-wc-RV -IN
j ^ L W H H H' -H H H
VZ015 165 105 106 130 185 147 171 225
VZ020 165 105 115 139 194 156 180 234
VZ025 190 130 142 166 221 183 207 261
VZ040 300 210 235 259 273 235 259 313
VZ050 350 280 291 315 329 291 315 369
( M i M ttoMniloal dramlniis in ctapler 9

RVPuisers
This pulser is Integrated into the roller counter and Is thus especially appropriate for remote
totalisation. For other applications the use of the inductive pulser IN Is preferable.

Switching element: • Reed switch with dry contact (jnert gas)

Switching voltage: • max. 48 V AC/DC
Switching cun-ent: • max. 50 mA (Ri = 47 Ohm/0,5 W)
Static cun-ent ' O p e n Contact
Switching power: • max. 2 W
ON-time: • 5 0 % ±10%
Temperature: • Ambient - 1 0 . . . +70° C
Protection: • IP 65 (lEC 144) against water-jets and dust
Connection: • Cast-In cable, length 3 m
Cable cross section: • 2 x 0,14 mm'

IN Pulsars
Pulser i(x industrial applications. Supplied with plug-in pulser sensor.

Switching element: Slot initiator according to DIN 19234

Sv\ntchlng voltage: 5.,.15VDC
Residual ripple: max. 5%
Switching cun^ent: >3mAbel8VDC/1kOhm
Static cun'ent: <1mAbei8VDC/1l<0hm
ON-time: 50% ±10%
Temperature: Ambient-10...+70° C
Protection: IP 65 (lEC 144) against water-jets and dust
Connection: ' Pulser supplied with special plug. Required cable min.
2 X 0.35 mm' and 4...6 mm external diameter or optional
pn 80019 wrtth mounted cable.
Option: ' Cable mounted, 2 x 0.5 mm', PVC blacK length 3 m (pn 80019)

Type designation liey

VZ0 25FL130/25-IN..,

L_ Pulser
Nominal pressure bar
Temperature °C
Connection
Dimension mm
Type

Technical information CONTOIL* 13

 Ordering specifications

Threaded ends OpajcNb. jptdtfiNO;

VZ01 SRC 130/16 92041 VZO 25 RC 130/16 92057
VZ015RC130/16-RV0,1 92042 VZ025RC130/16-RV1 92058
^ VZ015RC130/16-RV1 92043 VZO25RC130/16-IN0,1"
I V 91913
VZ015RC130/16-INO,01" 91900
VZO 20 RC130/16 92047 VZO 40 RC 130/16 92004
VZ0 20RC130/16-RV1 92048 VZO40RC130/16-RV1 92018
VZ020RC130/16-IN0,01" 91902 VZ040RC130/16-INO,1" 91906
Ranges VZ015FL130/25 92044 VZ040FL130/25 92005
130°C/PN25 VZ015FL130/25-RV0,1 92045 VZ0 40FL130/25-RV1 92020
VZ015FL130/25-RV1 92046 VZ0 40FL130/25-INO,1" 91907
VZ015ai30/25-IN0.01" 91910

3 VZO 20 FL130/25
VZ020FL130/25-RV1
VZ020FL130/25-INO,ffl'i
VZO 25 Fi 130/25
92049
92050
91903
92059
VZ050FL130/25
VZ050FL130/25-RV10
VZ050ai30/25-IN1"
92007
92024
91909

VZ025FL130/25-RV1 92060
VZO25FL130/25-IN0,r' 91914

Flanges VZ015 FL 180/25 92250 VZO 40 FL 180/25 92274

180''C/PN25 VZO15FL180/25-RVO.1 92251 VZ0 40FL180/25-RV1 92275
VZ015FL180/25-RV1 92252 VZO4Oai80/25-IN0,1" 92276
1/ VZO15FL180/25-IN0.m'»
VZO 20 a 180/25
92253
92258 VZO 50 FL 180/25 92280
VZ020FL180/25-RV1 92259 VZ0 50FL180/25-RV10 92281
VZO20FL160/25-IN0,01" 92260 VZO50FL180/25-IN1'> 92282
VZO 25 FL 180/25 92264
VZ025FL180/25-RV1 92265
VZ025FL180/25-IN0.1" 92266
Flanges VZ015 FL 180/40 92254 VZO 40 a 180/40 92277
180°C/PN40 VZO15FL180/40-RV0,1 92255 VZ0 40FL180/40-RV1 92278
VZ015FL180/40-RV1 92256 VZ0 40ai80/40-INO,1" 92279
VZ015FL180/40-INO,01 " 92257

u ^
VZO 20 FL 180/40
VZ020FL180/40-RV1
VZ020FL180/40-INO,01'>
92261
92262
92263
VZO 50 FL 180/40
VZ0 50FL180/40-RV10
VZ0 50FL180/40-IN1"
92283
92284
92285
VZO 25 FL 180/40 92267
VZ0 25FL180/40-RV1 92268
VZO25FL180/40-IN0,1" 92269
ON 15 metars are rK>( suitable ror heavy M oK; this Is onty possible tr special precaUtons are IsKen.

Option/Accessory^}

Cable Mounted cable IN/INA 80019

14 Technical informations CONTOIL*

3. V Z E A / V Z O A 1 5 . . . 5 0 products for special
requirements / applications
For applications requiring an increased accuracy of ± 0,5 % or better, as i.e.:
• Measurement of heating fuel EL or diesei in testing faciiities
• Differential measurement
• Custody transfer witti legal verification
Ttiese products require strainers witti smaller mesh size.

Products for the differential measurement

For a differential measurement, the flow is measured in the supply and return pipes. The difference between the two measurements
is regarded as the consumption.

To obtain optimal measurement results, you should only use VZEA or VZOA COMTOIL* fuel oil meters calibrated in pairs, which are
co-ordinated precisely to the plant/system operating conditions. The flow rate occumng in each meter, the permissible pressure drop
and the viscosity of the fluid must al be considered during the design phase. The load on the meter is obtained as follows: flow in
supply section less consumption = flow in return section.

When the order is placed, the following infomiatlon is required:

• application e.g. differential measurement for diesei engines in a
standby power group
• fluid e.g. diesei fuel
• temperature e.g. 1 5 . . . 40° C
• operating pressure e.g. 4 bar
• flow rate in supply section e.g. fixed pumping rate 200 i/h
• flow rate in return section e.g. 1 2 0 . . . 1901^ (for a consumpflon of10... 80 I/h)

The meters are marked "supply" and "return" during calibration and final testing in the factory. They must then be installed in the
conect pipes.

For further information on the subject of differential measurement, please see Chapter 8, System Ranning and Chapter 9,
Application Examples.

3.2- V. -^-^ :••>;.• •- --••-:•:::'-;:;{:;:-: ^ - - ^ - i ' W ^

Products for custody transfer / legal verification

Plants which are ready to work and are used for custody transfer, usually have to be tested and calibrated by the local authorities.
These plants require a "pre-calibrated version", that means a meter with legal certification or a seal. The local regulations apply for
the measuring devices.

The products VZOA meet the approval conditions as well as the requirements of OIML117. This standard demands a max, permissa-
ble enror of ± 0.3 %. As a result, limited ranges for flow and viscosity are applicable. Please ask for availability and technical data.

Technical information CONTOIL* 15

 Technical data "
• Product versions for optimal results from differential measurement
Of for custody transfer (option)
• VZEA witti electronic display of total volume, resettable volume.
and flow rate, units: litres or US gallons ^
• VZOA witn display of total volume on roller register, units: litres.
Optional versions wit^ display in US gallons
• VISA option: witti inductive IMA pulser
• VZOA option: witti reed or inductive pulser, RV or IN
• with threaded or flanged connection
• for mounting in horizontal, vertical or inclined positions

Versions available on request;

• differerrt flange drillings, sucti as ANSI, JIS

Type .. ,. VZEA/ VZEA/ VZEA/ VZEA/ \7£N:

; :V20A. • VZOA VZOA VZOA ""• VZOA:
:.IS- 20 25 : 40 50 :
Nominal diameter DN mm IS 20 25 40 50
inch W VA 1 V/2 2
Installation lengtti mm 165 165 190 300 350
Nominal pressure with threaded ends PN bar 16
with flanges PN bar 25
Maximum temperature "C 130,180
Maximum flow rate CW ^' l/h 600 1500 3000 9000 30000
Nominal flow rate (k ^ l/ti 400 1000 2000 6000 20000
Minimal flow rate Qmm \/h 10 30 75 225 750
Approx. startinq flow rate l/ti 4 12 30 90 300
Max. permissabie error < 0,5% of actual value
Repeatability ±0,1%
VZEA
Smaller readable amount:
Total volume 1 No decimals
Resettable volume 1 3 decimal places with floating decimal point
Digital flow rate display l/ti 1 decimal place
Registration capacity approx. 1 100 000 000
Registration at Qr. before return to zero h 250000 100000 50000 16660 5000
VZOA
Smallest readable amount 1 0,01 0,1 0,1 0,1 1
Registration capacity m^ 1000 10000 10000 10000 100000
Registration at Qn before return to zero h 2500 10000 5000 1667 5000
Safety filter mesh widtti mm 0,400 0,400 0,400 0,800 0,800
Dirttrap mesh width mm 0.10O 0.10O 0,250 0,250 0,250
Volume of the measuring ctiamber approx, cm^ 12 36 100 330 1200
Housing finish enamel led red RAL3013
Weight with threaded ends *' apprax. kg 2,2 2,5 4,2 17,3 -
with flanges PN 25 approx. kq 3,8 4,5 7.5 20,3 41,0
Pulse values of pulsers on VZOA:
IN inductive according to DIN 19234 1/pulse 0,01 0,01 0,1 0,1 1
RV Reed 1/pulse 0,1 1 1 1 10
RV Reed 1/pulse 1 - - 10 100
Pulse values of pulsers on VZEA: approx.
INA inductive according to DIN 19234 s) I/pulse 0,0006 0,00185 0,005 0,017 0,060
Pulse frequency IN at 0 ™ Hz 16.667 41,667 8,333 25,000 8,333
at Qmiti Hz 0,278 0,833 0,208 0,625 0,208
Pulse freguency INA atOtna Hz 277,778 225,225 166,667 147,059 138,889
at Qmifi Hz 4,630 4,505 4,167 3,676 3,472
1) Mt/iulacIuiei'B speclllcatiwi, vtild tor \!\t tclerenre mnaibon as specHied under mcier data \[Link][.
3) l ^ b u I l 1 W G a ^ ( l a n Q l ^ » a m o t o l E , I ^ B [ l l B l a m L l c t I m l a f y l M S 9 l B d s d t a ^ p B f m ^ n G n l l 1 ( w . [Link]
tar^gs muil also becaiELdeied; sao D^aplet 5 and 6
4) WflHili|i*llhoutnwplln(j).
5} The p r e O u p u i M value c^Qelal>£n tram lh«niet«r; Ills only known i l t e r i n e u l i b W o i . T h B next d e v i u n i L i a h s v c i j i a d ^

16 Technical informations COffTOIL*

 Electronic display
Display values: • total volume, resettable volume, flow rate
• In the service level, service hours and ottier information can be
readout
Display: • 8-ctiaracter LCD with Identification of the parameter, height of
numbers: 8 mm, flow rate (meter load) using bar diagram
Temperature: • ambient temperature-10... +70''C,
storage temperature-20.., +80''C
Safety: • CE, vibration and shock test to DIN lEC 68
Supply: • usual commercial lithium battery, type CR1 /2AA or CR2
Data reception: • by non-volatile memory (EEPROM)
Change of battery: • after 5 years, based on a battery lifetime of 6 years with a
maximum of 10 hours' digital display of tfie Now rate
Protection: • IP54 (lEC 144) against splash water and dust

Pressure drop curves

in chapter 5

Dimensions VZEA in mm
,:-:;:;•;.

Meter Length ,Widtti ^ ;i-":%-'": Helphf Of meters VZEA

rvzEA, .130'Gandl80°C
-tNA :

r
' . ^ ^ • . : - : : - - •

^ L • W . H . H^-
\ 1 VZEA 15 165 105 185 185
\ , ~l "•HB^l^ 165 105 194 194
1 \fZ^25 190
VZEA 40 300
130
210
221
273
221
273
VZEA 50 350 280 329 329

Dimensions VZOA In mm

Meter Length Width • Height of meters VZOA

VZOA... 130" e •' VZOA... l e O ' C -
-RV -IN
B
f L W H H H H H H
VZOA 15 165 105 147 171 185 147 171 225
"1 165 105 156 180 194 156 180 234
t VZOA 20
VZOA 25 190 130 183 207 221 183 207 261
VZOA 40 300 210 235 259 273 235 259 313
VZOA 50 350 280 291 315 329 291 315 369
DalallUcliniGnilanal diwlnys in chapler 5

Technical information CONTOIL' 17

 RVPuisers
This pulser is integrated into the roiier counter and is thus especially appropriate for remote
totalisation. For other applications the use of the inductive pulser IN Is preferable.

Switching element: • Reed switch with dry contact (inert gas)

Switching voltage: • max. 48 V AC/DC
Switching current: • max. 50 mA (Ri = 47 Ohni/0,5 W)
Static cun'ent: • Open Contact
W470hni t- Switching power: • max. 2 W
ON-time: • 5 0 % ±10%
Temperature: • Ambiait - 1 0 . . . +70° C
Protection: • IP 65 (lEC 144) against water-jets and dust
Connection: • Cast-in cable, length 3 m
Cable cross section: • 2 x 0,14 mm''

IN/INAPulsers
Pulser for industrial applications. Supplied with plug-in pulser sensor.

Switching element- Slot initiator according to DIN 19234

Switching voltage: 5...15VDC
Residual ripple: max. 5%
Switching cun'ent: >3mAbei8VDC/1l<0hm
Static cun-ent: <1mAbei8VDC/1k0hm
ON-time: 50% ±10%
Temperature: Ambient-10...+70° C
Protection: IP 65 (lEC 144) against water-jets and dust
Connection: Pulser supplied with special plug. Required cable min.
2 X 0.35 mm2 and 4...6 mm extemal diameter or optionai
pn 80019 with mounted cable.
Option: Cable mounted, 2 x 0.5 mm2, PVC black, length 3 m (pn 80019)

Type designation key

VZOA25FL130/25-IN

Pulser
Nominal pressure bar
Temperature °C
Connection
Dimension mm
Type

18 Technical informations CONTOIL*

 Informationrequiredto process orders
When the order is placed, information is required on the plant operating conditions (as stated atttiebeginning of this chapter). Rea-
se note that for custody transfer (commercial transactions) VZOA type meters have to tie used.

Example for differential measurement

Application: differential measurement Diesel, supply 2001^,
return 120.... 190 l/h
2 Pieces Order No. 92290 CONTOIL*fuel oil meter, type VZOA 20 RC130/16
2 Pieces Order No. 96112 Modification for differential measurement

Example for custody transfen

Application: Custody transfer in Germany, heating fuel extra light
flow rate 200...400 l/h, temperature approximately 2 0 '
1 Piece Order No. 92290 COMTOL. fuel oil meter, type VZOA 20 RC 130/16
1 Piece Order No. 96026 Modification for legal verification Gennany

Example for meter without modification:

Application: Measurement of Diesel fuel on testing facility,
flow rate 200...400 l/h, temperature 20...50 °C
1 Piece Order No. 92333 CO^fTOIL, fuel oil meter, type VZEA 20 RC 130/16

Ordering specifications VZEA (witli electronic display)

Threaded ends Type Order No. Tvpe- OrderNd:-;

VZEA 15 RC 130/16 92331 VZEA 25 RC 130/16 92335
/t s^^
VZEA15RC130/16-1NA'' 92332 VZEA25RC130/16-INA'> 92336
f \
VZEA 20 RC 130/16 92333 VZEA 40 RC 130/16 92337
\ 1 VZEA20RC130/16-INA" 92334 VZEA40RC130/16-INA'i 92338
i
Flanges VZEA 15 FL130/25 92339 VZEA 40 FL 130/25 92353
130°C/PN25 VZEA15FL130/25-INA" 92340 VZEA40FL130/25-INA11 92354
r~ "!» VZEA 20 FL 130/25 92343 VZEA 50 FL 130/25 92361
VZEA20FL130/25-INA" 92344 VZEA50FL130/25-INA" 92362

-M-
h-^ \
VZEA25FL130/25
VZEA25FL130/25-INA"
92347
92350

Flanges VZEA 15 FL 180/25 92341 VZEA 40 FL 180/25 92355

180°C/PN25 VZEA15FL180/25-INA" 92342 VZEA40FL180/25-INA'> 92360
T < ^ VZEA 20 FL 180/25 92345 VZEA 50 FL 180/25 92363
f ' V t t f l c\i rL lOU/tO-IIMA ' 92346 VttA OU rL loU/cO-iiMM ' 92365
.1.. VZEA 25 FL 180/25 92351
^ t-
VZEA25ai80/25-INA" 92352
^\ 1 ^1

Modification and Option/Accessory *>

Modification For differential measurement (for VZEA or VZOA) 96112

Option/Accessory" Mounted cable IN/INA 80019

Teclinical information CONTOIL* 19

 Ordering specifications VZOA (Vdume display onrollerregister)

Threaded ends JffiL QcdarNo. ;Gtde)f:N6.;

VZOA 15 RC130/16 92286
Jm.
VZOA25RC130/16 92293
VZOA15RC130/16-RVO,1 92287 VZOA25RC130/I6-RV1 92294
J ^ VZOA15RC130/16-FIV1 92288 VZOA25RC130/16-IN0.r' 92295
7—r VZ0A15RC130/16-IN0,01" 92289
VZOA 20 RC130/16 92290 VZOA 40 RC 130/16 92296
VZOA20RC130/16-RV1 92291 VZOA40RC130/16-RV1 92297
VZOA 20 RC130/16-IN 0 , 0 1 " 92292 VZOA40RC130/16-IN0.1" 92298
Ranges VZOA15ai30/25 92299 VZOA40FL130/25 92309
130'C/PN25 VZOA15FL130/25-RV0,1 92300 VZOA40FL130/25-RV1 92310
VZ0A15FL130/25-RV1 92301 VZOA40FL130/25-IN0,1'' 92311
VZ0A15FL130/25-IN0,01" 92302

c VZOA20FL130/25
VZOA20FL130/25-RV1
VZOA 20FL130/25-IN0.01"
VZOA 25 FL130/25
92303
92304
92305
92306
VZOA 50 FL 130/25
VZOA50ai30/25-RV10
VZOA50FL130/25-IN1'i
92312
92313
92314

VZOA25FL130/25-RV1 92307
VZOA 25 FL 130/25-1<0,1 " 92308
Flanges VZOA 15 FL 180/25 92315 VZOA 40 FL 180/25 92325
180"C/PN25 VZOA15FL180/25-RV0,l 92316 VZOA40FL180/25-RV1 92326
VZOA15FL180/25-RV1 92317 VZOA 40 FL 180/25-IN 0 , 1 " 92327
1 f ^ r VZOA 15 FL 180/25-IN 0,01 " 9<:31B
V -^( VZOA20FL180/25
VZ0A20FL180/25-RV1
92319
92320
VZOA 50 FL 180/25
VZOA50FL180/25-RV10
92328
92329
•1 h VZOA 20 FL 180/25-IN 0,01" 92321 VZOA 50 FL 180/25-IN 1 " 92330
VZOA 25 FL 180/25 92322
i VZ0A25FL180/25-RV1 92323
VZOA 25 FL 180/25-IN 0 , 1 " 92324

Modification and Option / Accessory "

Modification For differential measurement (for VZEA or VZOA) 96112

For type approval GL German. Lloyd (forVZO/^ 96295
For custody transfer/legal verification (for VZOA in Germany) 96026
Option/Accessory" It/lounted cable IN/INA 80019

20 Technical informations CONTOIL*

4. Ancillaries
Ordering specifications for andilaries

Type Description Order No.

Threaded connections VSRVa" forDN15 81160
VSRWxVa" forDN20 81163
VSR'A" forDN20 81166
1 B BD VSR1" forDN25 81169
VSRI'/j" forDN40 81181
Threaded connections kit PS-Kit VZO 4 V8"-8 81583

n
©^ D©
T-n—"
Mounting kit PS-Kit VZO 8 Mounting Kit 81130
VSRW Threaded connections to suit PS-Kit VZO 8 81156

D = ^ h
Order specifications for supplementary equipment

Type Description Order No.

Remote totaliser Pulse counter Pulse counter, with or without zeroing, 93374
adjustable
S^M
immti
«
Separafing relays Separating relays Ex with relay output, max. 10 Hz 81705
HtHHH Separating relays Ex with electronic output, max. 5 kHz 80013

fHHHH j

Order specifications for supplementary equipment witli mounting Icits

Type Description Order No.

Transducers Flow calculator freely programmable, with analogue output 92439
1 «
4...20 mA, Indication of flow rate, limit values
Differential flow calculator freely programmable, with analogue output 92440

.O 0 O. Both Inputs can be read out individually.

Frequency cunrent converter freely programmable. 92439
Mou nting kit Kit for wall mounting or on rail DIN 35 mm on request

Teclinlcal information CONTOIL* 21

5. M e t e r data (annexe)
Function
CONTOIL* flow meters work on the volumetric principle of rotary piston meters (positive displacement meters).

The main features of ttiis measuring principle are large measuring ranges, higii accuracy, suitat)ility for fiigti viscosity's and indepen-
dence from power supply; flow disturtiances do not influence proper operation.

Constnidion
Rotary piston, guide roller and driver are ttie only moving parts in contact vvith ttie liquid. As ttie tiydraulic part is completely separat-
ed from ttie roller counter, ttie movement of tfie rotary piston Is transmitted by a magnetic coupling through the sealing plate.

VZ04anilVZ08 VZE/VZO/VZEA and VZ0A15 ... 50

Inlet and outlet connections are to be made These meters are equipped with counters,
perpendicular to the bottom plale of the meter. which are rotatable through almost 360° for easy reading
OEM versions with connections located at the sides. (exception: versions with Reed pulser RV).

Accuracy Limits: Reference Conditions

Accuracy limits according to technical data of meter in % of actual value for the whole measuring range.

Reference conditions
Liquid; Calibration oil similar to heating fuel extra light, density at 20° C = 814 kg/m^
Viscosity = 5,0 m m % selon DIN 51757 / ISO 3104 (con-esponds to 4,1 mPa.s)
Temperature: 1 8 . . , 2 5 ° C
Horizontal mounting, readings on register,
CONTOIL* Oil meters are never to be tested with water, otherwise they would get damaged.

lOmln 10
Flnvrati

22 Teclinical informations CONTOtL*

 Pressure drop curves
Viscostty Information
Kinematic viscosity Stokes. Centi-Stokes, mm*/s St cSt, mmVs
Dynamic viscosity Pascal seconds, miillpascal seconds Pas, mPa.s
Poise, Centipolse (outmoded) P,cP

Conversion cSt X density = mPa.s

Engier degrees °E to mPa.s: only using comparative tat)ie
Saytioid units to mPa.s: only using comparative table
Redwood units to mPa.s: only using comparative table

Ruleofttiumb 1 cSt - + 1 mmVs - • 1 mPa.s

VZO 4 and 8 / VZO 4 OEM and VZO 8 OEM

VZ04 VZO 8
ZZ^^ = = = =S ^ = : ^ z: z I :: \ ^ = .— ~ z ~ ::::
1
TIT
1 ^
tooo .
= ^ il
= = E Tff == E EE :•
_ rf
j = 5 a zrr n z: : : : : :
4-1+ " • : ' * ' ;

1 ^ ^^'
I*'
^' >^
no.
^= — z :
' ^ ^
^= Wn^^ = ^5 =M i y ~~ = = = E!E
y£ — j^
1 —-Ef u^^—'•
"Til ^^
;' < —
"P ~t
s
t 10 .
t' ^ y' iJj'O — •^ (f f^
^S — i - - W"^ ^ = i : • : \rrr'L. = = = = :::|
'' 1
J J!-'
'^-'*'- iTT~7n — / - -
1 r 2 --
'' ^, -^2..
*' m / THZ = = =
^"^^= = | ! Tn^^ :: I •
= = = ^ :::;
7^
TH' —
,* 1/
^,'_
'= = = | : T f f = ^il ^ = z : \\ ; = ^_ _,_._..-.
—/-- TTT
^ y

0.01
Row rata hi lAi 1 1000 Fkwralelnl/li 1
*^ III _._...

! I I I
f Q-ii/n I a-eoi/ti I Q.4n> ) D.200l/h

Viscosity curves: A = 5mPa.s C=100mPa.s E = 500 mPa.s

B = 50 mPa.s D=200mPa.s

For a pressure drop of more ttian 1 bar, you are advised to use the next higher nominal meter width.
Maximum permissible pressure drop = 3 bar

Technical information COMTOIL* 23

 VZE / VZO / VZEA / VZOA15... 50
VZE/VZO/VZEA/VZOA20
10000

r ' 1
1000 1000

.'Vl

^——— — "";'
I ,^^
'.''
I — f i n - = zzta £ : : : : .c

i ^IIMHi: I
ii Li . . .''-'
^^^-iilV: ^ :;lr
= j!:
^^EEEiii!
::^ .^ ,/
,/
~_^
=fe = = [Link]
i
T' ji.
1 T - •
t ^
/ !
0,01
FkHratthMi 1
^r^""-- 1000
0.01
Rwotglnl/li 10
10 no 1000 10000

I I 1
t a»ioi/ii I (Uooovh a>30Ml i a_isooifii

VZE/VZ0/VZEA/VZ0A25 VZE/VZ0/VZEA/VZ0A40
nooo

?^ :::

' v; /

""TT

.!'' — ^
-?• —
EJ t'- - r r

.''' . ' - • ' \\

= = = = r:::
^— — ? -

?'•
_^'
~ " TIT =z—'--i:::

A i
/
0,01 y
Row rale in l/T) 10 00 1000 10
10000 Rowfatelnl/n 100

i
OwTSI/h 1 a_30oov)i i ON. 90001/11

Viscosity curves: A = SmPa.s C= 50mPa.s E = 200 mPa.s

B = 25 mPa.s D=100niPa.s F = 500 mPa.s

For a pressure drop of more than 1 bar, you are advised to use ttie next higher nominal meter width.
Maximum permissibie pressure drop = 3 bar

24 Technical informations CONTOIL*

 VZE/VZ0/VZEA/VZ0A50
== = ==S

1
1000 .
= = = = = : Ij
!
1 _y^
^ ^ = = =z
' — "- —
, I
I
.fi ^ ^' ^ •
ix^=i
^• ^ = / '

~*rf'
y-
Z--
• 1 » , .'
.' i /
,'' _,^-7
= ^ g = - - Z
Ji ^
—J
:^
_: 1,1
, r
/ -I. —
= ^ —p "
1
'\ ' 1
/ 1
Hownlelal/h 100 1000 10000

t I
t a-750Vh i a»30oxi/ti

Materials Meter Size DN

Part Material 4 8 15 20 25 40 50
Housing / Measuring unit Brass • •
Housing with threaded ends Cast brass • • •
Spheroidal graphite iron GGG •
Housing with flanges Spheroidal graphite iron GGG
Measuring chamber
-PN16/25 Cast brass • • • •
Red brass •
-PN40 Stainless steel
Seals NBR Butadiene-Acrylnitril •
P M Fluor-Elastomer S
Rotary piston Aluminium anodized
Anciliaries Plastic
Cover of meter Plastic • •

S = Special versions

Technical information CONTOIL* 25

 Dimensions In mm
VZ04and8
VZ04 VZ08

"pw ^..

without pulser without pulser

• 1

-—T—n t
, -r-i
' ! *l '.111 1 L
R e
: i
—r^—
s

i R E e
f \^
1
; i
, _ j — ,
a

^^iZaV— 1 j ^ujy" L
]^J^^ V

i » • 1 •t i

with pulser with pulser

^-i
I i-y I
\ 8

JL
'. i
1 i 1 1
^IC^XdB • y\Lai-i4J°
i i

26 Teclinical Informations CONTOIL*

 Dimensions in mm
VZE / VZO / VZEA / VZOA iyieasuring units
DN15,20,25: with threaded ends DN 40: with threaded ends

T 1
T 4
M
•F 1 Xt[ 4—"f'- ^
•• 4

T
,
1L 1 1
£
. , . ,
- ^ ^ ^ T rl
9 G62l3a L— t J

DN 15,20,25: withflangesP N 2501/SN 21843) DN 40,50: with flanges piN 2501/SN 21843)

nhCT _m ^ = ^ ,
LJ Ul LI LJ

m
Ndirilnal width L B a 0F b hi P r
DN15 165 105 260 95 45 65 GW GV2"
DN20 165 105 260 105 54 74 Gl" GW
DN25 190 130 305 115 77 101 G 1'A" Gl"
DN40 300 210 440 150 116 153 G2" GlVa"
DN50 350 280 - 165 166 209 - -

VZE/VZEA AnclUaries
Electronic display Electronic display Electronic display Bectronic display
andlNApulser and INA pulser

.
/. . /
8 JB S
JDB ' •

0105 . 0W5 . 5CMI5C

0105 MHISk

Tmax.70°C Tmax.130''Cresp.180°C

Technical information CONTOIL* 27

 Dimensions in mm
VZO/VZOAAncillaries
VZ015,20,25 Roller register Roller register
wIthRVpulser

Tmax.130''C
/ = ^ ^
4—glW ,[mmA SI
VZ040,50 Roller register Roller register Roller register
VZ0A15...50 witti RV pulser and IN pulser

S
/ "s -1 / V
~ o
r r •18 .
^4".
CM

^ •

, 0"» . IMIUt 0105 , 0105

. 15'
Tmax.130'C

VZ015...50 Roller register Roller register Rolla' register

VZ0A15...50 with RV pulser and IN pulser

f >
/ ^
/ V, i
Jl
m
,„
- s
r i
, «"» .
ni 1_.
0105 1
Tmax.180°C >| IIMIIU4
157

Electronic display/dial
VZE/VZEA VZ0/VZ0A15 \/ZO/\/ZOA20,25,40 VZO/VZOA50

28 Technical Informations CONTOIL*

6. Selection of the optimal meter
Type VZE vzo VZO VZEA/ VZOA
/-<ti,>,A5rSQ-- ^:vm • 15-50 15-50 15-50 :
Application
Direct consumption measurement • • • • •
Differential measurement - o - • •
Custody transfer/ legal verification ^> - — - - •
Most frequent areas of use
Domestic / industrial burners • • • • •
Diesel engines • • • • •
Petrol engines 0 • o o O
Medium
Heating fuel light • • • • •
Heating fuel medium • • • • •
Heating fuel heavy' • - • o o
Diesel • • • • •
Petrol o • o o o
Display of flow data
Total volume • • • • •
Resettable vobme • - - • -
Actual flow rate • - - • -
Method of display
Electronic display LCD • - - • -
Total volume display on rolier register - • • - •
Accuracy limit
± 1 % of actual value • • • - -
±0,5% of actual value or smaller - - - • •
In accordance with cal. laws / appr. conditions '> - o - - •
Pulser (Option)
Inductive, with high resolution • - - • -
Inductive, with decadic pulse value - - • - •
Reed pulse for remote totalisation - • • - •
lirtilnjMimi^ litehaptsr V / • : • ; . : : ; :ii- •: .•:V::;.V2.:>:;.^
..,.-y.-:i-2;-' 3 •. , - . 3 : : . ;•

Fluids and suitable meter sizes DN4 DNS DN15 ;.:; .mm^, DN25 . DN40 DN50
Heating fuel light • • • • • • •
Heating fuel medium • • • m • • •
Heating fuel heavy - - 1) • • • •
Diesel • • • • • • •
Petrol 31 • • O o O O O

1) Venkms with legilvwffication on request

2) ONISmelenaremtsUlalilefofheavyhjelolktillslsailypossiblell<peGlalprecwli(XB»laken|irulleintifmeshe4^
31 Conitlora of usetobe chedwiKtIhmeiiufBctunf (other measurement datal)

• appncal*
O HmltBdappllcaljItity
- notaniltaito

Application note
For viscosity's higher than 5mPa.s or for installations on the suction side, consider pressure drop and possible limitation of flow
range (see chapter 5 and 8),

Technical information CONTOIL* 29

7. Fluid fuel oil
Characteristics of different fuels

m:/:c-'i^i^>r^'^:-'--ry::y.:-^^^ i;l6«itra:|ight:: ':^mv^ariWfeiiftJHi •;•:•; ;ioi3^..^:,•. I Bunker C -

Density at 1 5 * 0 m\n. kg/dm' 0,82 0,82 0,82 0,82 0,90
max. kg/dm* 0.86 0,95 0,96 0.99 1.01
Volume at average density
Viscosity at 20° C
m
mPa.s
1,19
8
1.12
14
1,12
50
1.11
420
1.08
4200
40''C mPa.s 3 5 16 60 380
100" C mPa.s - - 3 10 35
Energy value kWh/kg 11,8 10,6 11.4 11,2 11,0

Data for Iximer and engine power

Burner

Burner Fuel oil meter

Power Flow rale tieating fuel EL Fknwrate . Dimension
uptokW Mh W) Qmin...Qn l/ti ON
500 42 50 1.. 50 4
1300 113 135 4.. 135 8
4000 336 400 10.. . 400 15
10000 840 1000 30. . 1000 20
20000 1680 2000 75. . 2000 25
60000 5040 6000 225. . 6000 40
200 000 16800 20000 750. .20000 50
Formula for consumption in litres/hour: Example:

Bimer power in kW 600 kW

= 62IAi
Energy value of fuel in kWtVkg x density in kg/dm' 11,8 kWti/kgx 0,82 kg/dm'

Engines

Engine Fuel oil meter"'

Power up to.,. Diesel fuel consumption Flow rate Dimension
approx, HP approx. kW l/h Qmin.„Qn l/h DN
250 184 50 1... 50 4
680 500 135 4... 135 8
2 000 1470 400 10... 400 15
5000 3 680 1000 30... 1000 20
10000 7 360 2 000 75... 2000 25
30000 22 000 6 000 225... 6000 40
100000 73 600 20 000 750... 20 000 50
1) For dJtlBfential imasurement ttw flaw meter hastobe selected according to Ihe pump (low rate and Hie (low in the return pipe. Consider chapter 9t

Formula: 1 HP = 0,736 kW 1 kg Diesel at 0,84 kg/dm3 = 1,191

1kW = 1,36HP

Rule of thumb: approx. 190 g/kWh con-espond to 0,226 lAWh

approx. 140 g/HP and hour correspond to 0,167 l/HP/h

30 Teclinical informations CONTOIL*

8. How to obtain an optimal measurement
8^
Planning
Row meters are precision measuring instruments. They achieve optimai results If
• a few important niies are observed during plant design,
• mounting and commissioning are earned out with care,
• the meters are usedfortheir defined purpose only.

Layout of Pipework
• The quantities consumed t}y all the users must be registered tv the meter.
• Rotary piston meters can bs mounted without straight stabilisation pipes (after bends, T-pieces or fittings) in horizontal, vertical or
inclined position. Do not mount the meter with the head pointing downwards.
• The layout of piping must ensure that the meter is at all times filled with liquid and that no inclusion of air or gas may occur.
• Easy access for reading the meter and controlling the ancillary equipment is essential.

Selection of the Meter and Ancillaiies

To be considered when selecting the meter:
• Operating temperature
• Viscosity of the medium
• Operating pressure
• Row rate
• Resistance of the material against liquid to be metered and working conditions

The technical data are valid for the following reference condition: EL heating fuel / diesel at 20° C. For higher viscosity's or if the
meter is mounted on the suction side, it Is necessary to determine the pressure drop and the flow rate that can still be attained by
using the pressure loss curves {Chapter 5). If the pressure drop is more than 1 bar, you are advised to use the next higher nominal
meter width. Maximum permissible pressure drop = 3 bar,

Tectinical information CONTOIL* 31

 Example 1: Medium Mineral oil, Viscosity 450 mPa.s
Mounting VZE 25 on pressure side
= ==
1. Viscosity line
E = 200 mPa.s
/ F = 500 mPa.s
= ==
—y • ^
2. Supposition for max. pennissalile pressure drop = 1 t)ar
y ^ S --
= = E
/ . ?^ 3. From the intersection of line F and pressure drop 1 bar
downwards, the possible flow rate of 2000 l/h is obtained.
f
•- ' ' Tl
I • '
* rit
=3^
e -^-- ;2p
~ E 7 '~ y
' ,'i|
'' = 5E|
7^

yy
0.1 'n1
= ==
2
h /
am
1
Flow rate in l/h 10 100 1DOO 10000

1
1 Q-rsi^ i 0 - 3000 Vh

Example 2: Medium Heating fuel extra iigtit

Mounting VZO 8 on suction side
= ^ = —\—
1. Viscosity line
I A = 5 mPa.s
i B = 25 mPa.s
= = == C = 50 mPa.s
t

2. Supposition for max. pemiissable pressure drop = 40 mbar

i
= ^ A-- 3. From the intersection of line A and pressure drop 40 mbar
downwards, the possible flow rate of 100 i/h Is obtained.
y
^=^ ^
' 1.'
?-'-'' ^-r
'
=^
' - . . • zz:z — L i -

f^
1
[ y rrr:
-s :: : -^ZZZZL zz-zzzz:

/ T
/
Q.0I
flow rate In l/h
. . — i
1
Q..4l/h 0.200 l/h

32 Technical informations CONTOIL*

 Mounting on pressure side (burners)
Flowmeter
Tank Supply RIter Burner Bumernozzle

Magnetic valve

3ZI£E: SK>96S>4M

•Mounting on Suction side (burners)

Tank Supply RIter Row meter Riter Burner Magnetk: valve Burner nozzle

=3ZK2:
d•r Return

impurities in plant or iiquid

Should impurities occur in the plant or in ttie liquid, a strainer (dirt trap) has to be installed before the meter. The filter mounted in the
meter inlet is only a safety filter and is too small to act as a strainer.

Maximum mesh width for strainers/dirt traps Meter size Meter type
VZE VZO VZEA/VZOA:
DN 4 - 0,080 mm 0,080 mm
DN 8 - 0,100 mm 0,100 mm

£Z 13 DN15
DN20
0 250 mm
0,400 mm
0,250 mm
0,400 mm
0,100 mm
0,100 mm
0,400 mm 0,250 mm
1 DN25
DN40
0,400 mm
0,600 mm 0,600 mm 0,250 mm
DN50 0,600 mm 0,600 mm 0,250 mm

Teciinicai information CONTOIL* 33

 Shut-Off Devices
In order to avoid backflows and drainings, shut-off devices iiave to tie mounted after ttie meter. Backflows and dralnings cause
measuring errors and can damage the meter.
t

Filling/Dosing
F a filling and dosing the valve has to be mounted between meter an discharge. The shorter the pipe section between meter and
discharge, the higher the accuracy. Fast opening and shutting of the valve should be avoided (pressure hammerQ.

-©-
V^.
Remote Processing/Ancillaries
Any baci<flow must be avoided on meters equipped with pulsers for remote processing. If this cannot be achieved by appropriate
plant design, a non-return valve should be fitted.

Electrical lines and Installat'ons

Electrical lines and installations are subject to statutory regulations which must be tal<en into account when planning the system.
For installations in zones subject to explosion hazards, please consult an expert

The following factors should be taken Into account during plant design:
• ancillaries connected after the meter
• environmental disturbances
• maximum cable lengths with or without amplifier
• connection boxes, cable guides

34 Technical informations CONTOIL*

 92
Pulsers
Power supply
Our range of products Includes passive pulsers for the remote processing of flow data. The pulser generates one pulse unit of
volume and is to be supplied with power from the pulse processing device.

-crj:]

Power supply 5 . . . 48 V AC/DC Power supply 5 . . . 15 V DC

Selection of the appropriate pulsar

The selection of the most appropriate pulser and pulse value depends on the application. As a rule, remotetotalisationdemands
rather large pulse values, whereas analogue signals, dosing control or Indication of actual flow tendtoneed small values. Battay
supplied devices can only be used together with Reed pulsers.

Selection of ttie processing device

The pulse length depends on the flow rate. Continuous contact may occur at zero flow. The device connected must therefore Ire able
to accept continuous load; otherwise, protective measures have to be taken, fat remotetotalisation,you are recommended to use an
electronic pulse counter with a low power consumption and bounce filter.

Correct puise processing

inten'upted flow may cause hydraulic oscillation of the liquid in certain plants (hydraulic vibration with minimal flow backward/fonward).
The pulses which can occur in such cases may be interpreted as fonward flow by the connected device. Such faulty pulses do not
affect the indication of the actual value since they can only occur at almost zero flow. However, if the pulser controls a counting
device, hydraulic vibration must be avoided by an appropriate modification or layout of the plant.

Puise values
Pulse values depend on type and nominal diameter of the meter. They are listed in the technical information of the meter concerned.

Pulse period

, Swidi ON-tme Swilcll OfF-Umi,

Pulse peHod

Pulse period as well as on- and off-times can be calculated with the following fonnula:

pulse value In litres x 3600

Pulse period in s
flow Q in l/h

pulse period in s x on-time in % of pulse period

On-time
100
Off-time = pulse period in s minus on-time

We recommend that this calculation is carried out for the min. and max. expected flow rates,

Teciinical Information CONTOIL* 35

9. Application examples
Diesel engine
Direct consumiition measurement
In place of ttie fuel feedback, an intermediate container with a heat exchanger is Installed in Itie tank on the system side. The flow
measurement Is taken In the supply pipe to the intermediate tank. The load on the meter and the measuring result consspond
precisely to the consumption.

ConoMMr
([Link]'[Link]
nmp Row meter

Differential measurement
For a differential measurement, the pipe routing is kept unchanged, with circulation t)ack into the tank. A flowmeter Is installed in
t)oth the pipes. The consumption is detemiined as the difference between the amount In the supply section and the amount in the
return section. The meter loads therefore correspond to the supply and return flow rates.

Cotwimcr
Flown («.[Link],englM|

-O—1"

Reason to use meters with special pairing

Standard meters feature a large measuring range and a max. pennlssable error of ±1 %. This makes them unsuitable for differential
measurements, as the following example shows:

Full load Supply 4001^ Error ±1% = nominal ±4,01

Return 1501/h Error ± 1 % = nominal ±1,51
Consumed 250 l/h Measuring error nominal ±5,51
Maximum measuring eaor
Consumed = 5,5x100; 250 = ±2,2%

Min. load Supply 4001^ EnDr±1% = nominal ±4,01

Return 360 l/h Error ±1% = nominal ±3,61

Consumed 40 l/h Measuring error nominal ±7,61

Maximum measuring error
Consumed = 7,6 x100:40 = ±19%

For an optimal result, special meters are therefore used for differential measurements. These are precisely co-ordinated to the
operating conditions and are calibrated in pairs. This means that the measurement variance can be significantly reduced
(for example: supply, at constant flow, to ±0.1%; return, with slightly variable flow, to ±0.3%).

36 Technical Informations CONTOIL*

 Loads on meters
Example: Engine power 500 hp, vehicle with electric pump

in
SupplircaastanllMUi I

CominpHanfutiaoUi

IMlini1(ia..174Hl

I
174

Effective loads on meters Supply constant 180 l/li

Return 100...174l/ti

Example: Engine power 500 lip, vehicle with RPM dependent pump 1:4

C<l|lM4S ...1801/11

CofnnnptoiMWIMi

-,'lllctMl
lldijni3S...100Ui

Effective loads on meters Supply 45...180l/h

Return 39...100l/h

Technical information CONTOiL* 37

 Consumption measurement on lioani ships
On board ships, care is usuaiiy tal<en to ensure that the engine can s t i l ! » operated at fuii power even if the fiitsr is heavily
contaminated or if the meter is damaged. When switching over to the tiypass, attention may be drawn to the necessary maintenance
via an alarm output, and the engine can be teniporarily operated without measuring the consumption.

Conlad manoitMlar or dilfafwtial

p m u n cwWi Aypxt valwl

Magnctcvatn

The magnetic vaive opens as soon as the pressure drops below a defined level.

Contact manomeler or ififferaitial

pnsoufe w i c h (bypass ntve)

Flow motor
ntor (wHhorwItmitlMltor)

^ ^

Magnetic vaive
Engine

Float or valve control in service tank required, i^miation of gas Is to be avoided. The magnetic valve opens as soon as the pressure
drops below a defined level. For measuring the consumption of more than one engine, each will require a separate Installation similar
to the one above.

38 Tedinical informations CONTOIL*

AQUAMETRDAG AQUAMETROSA AQUAMETRO AQUAMETRO AQUAMETRO s.r.D. I Dlilrlbiitlon I §
MESSTECHNIK GmbH BELGIUM SPRl i
RIngslrasse 75 RueduJuralO Zum Panrepel 24 Bd. LambermonI t31 PnisBckd76 S
CH-4106Tlieiwll CH-1B0OV«v«y D-28307 Bremer B-1030Bruxelle5 CZ-190 00Praha9 8
Phone 06172511 22 Phone 021 923 51 30 Phone 0421 / 871 64-0 Phone 02 / 241 62 01 Phone 02 / 66 86 77 78 g
Fax 0G17261696 Fax 0219225844 Fax 0421/87164-19 Fax 02/2162263 Fax 0 2 / 8 6 8 8 9 5 5 9 j.
info@[Link] inlo@[Link] [Link]@[Link] [Link]@[Link] [Link]@[Link]
[Link]
 Anwendungstechnlk VD 4-412 DE 02.96

ApplicaUatt Notes

CONTOILVZO

Zahlereinbau auf der Saugsalte

Meter MoaatiRg on Suction Sltte

Differenzmessung
Differential Measurement

./•""v.

m)
Tedinische Infoimation Twdinical Information

1. ZShlereinbau auf der Saugseite 1. Meter Mounting on Suction Side

1.1 1.1
Verhfiltnisse am Zfihier CondHtons at the Meter

Der Druckvehust In der Antage entsteht einerseits in der Leltung und an Pressure loss is caused by pipes and valves on the one hand, and by the
den Ventilen, andererseits am Zahler selbst wie auch am Filter, tm Laufe meter itself and by tiie filter on the other. In addition to these, impurities
derZeit l<onnen Verunreinigungen am Filter den Druck zusatzlich schwa- collected by the filter can gradually decrease the pressure. Pressure loss
chen. Der Druckverlust am Zahler ist abhangig vom Typ, von der depends on the flow rate and on the viscosity of ttie liquid tieing
DurctitlLJSsleistijng und der Viskosltat des Messstoffes. Die genauen measured. Precise figures for the meters can be taken from the pressure
Werte kortnen fiir jedes Zahlermodell in den Druckveriustkurven abge- loss curves for each type.
lesen werden.

1.2 1:2

EInbau auf der Druckseite Mounting on Pressure Side

In der Regel stetit von der Pumpe ein Vortiruck von mehreren bar nir In general, pumps generate pressures of several bars. Only a fraction of
Verfiigung. Bel maxtmalem Durchfluss wird am Zahler ein Bruchteil this will be lost at maximum flow, and an increasing pressure loss due
davon als Druckverlust verbraucht. Auch am Filter kann ein Ansteigen to impurities can be easily tolerated. That is why this type of mounting
des Druckverlustes infolge Verunreinigung ohne Probleme verkraftet Is always safe and problemfree.
werden. Deshalb ist diese Losung immer slcher und unproblematisch.

Zlliln/ Rmimtar
Bminr/ Atnwr ennnerdOM/ BumornaOt

tvA/nnt

libgngMiin / Mcwlfc nhv

I ^ „-Jff imMmtlMam

1.3 1.3

Gnbau auf der Saugseite Mounting on Suction Side

Beim Einbau auf der Saugseite ist dem Druckverlust jeder Anlage- Mounting the meter on the suction side demands careful consideration
komponente ganz besondere Aufmerksamksit zu schenken. Per Druck- of each component of ttia plant with regard to pressure loss. The
verlust in der Aniage ist gegeben. Beim Filter muss ein Sicherheitsfaktor pressure toss In the plant Is defined. A safety factor must be planned in
fOr das Ansteigen des Druckverlustes infolge Filterverschmutzung ein- case of an increase in pressure loss due to the Impurities collected in the
geplant werden. Unter Umstanden muss oer Filter h^ufiger gerelnlgt filter. Under certain circumstances, the filter will have to be cleaned
werden als bei einem ZShlerelnbau auf der Druckseite. Der Rest des more often. The remaining negative pressure has to tie large enough so
Unterdmckes muss am Zahler ausreichen, um die gewunschte Ourch- as to actiieve the desired flow rate; minimum and maximum flow rates
flusslelstung noch zu erretchen. Dies kann aus den Druckverlustkurven can be determined from the pressure loss curves of the meter con-
des Zahlers wie tolgt ermlttelt werden: cerned:

BnnuK I BuiJier DnnnmlSsi/ Burner aoaa

Voriaul / Si^ly
nnk/ hnir

Mapngtvf ndl / Uagnellc valvt

TTriRteW«ut/*(wii
AbspgtnentI / S!mt-ofl nhv

W^hlen Ste die Viskosltatsiinle, die dem verwendeten Messstoff Select the viscosity line corresponding to the liquid to be measured
entsprlcht (z. B. bel iielzol extra lelcht / Dieselol 4,5 mPa.s). (e.g. 4.5 mPa.s for heating fuel).
WShlen Sie auf der vertlkalen Achss den noch zulSsslgen Druckvertust Select the maximum permissible pressure loss on the vertical axis.
des Zahlers.

VD4-412DE Aquametro AG
Technlsche Information Tectinical Information

Auf der horizontalen Achse kann dann unter dem Schnittpunkt der • Ttie intsrsection of these two values will indicate the max. flow rate
beiden obigen Werte der noch mogliciie Durchfiuss abgelesen wer- on the horizontal axis. Should the necessary flow rate not be achieved,
den. Falls die erforderliche DurchflussleisUing nicht mehr etreicht select the next size of meter and repeat this check until all cgnditions
werden kann, ist der nachstgrossere Zahler vorzusehen und die afe fulfilled. However, the flow rate must lie within the measuring
Uberprufung zu wiedeitiolen, bis alie Bedingungen erfiJIit sind. Dabei range specified on the meter's data sheet.
sollte der Durchfiuss imrner noch innerltalb des auf dem Zahler-
Datenblatt speziflzierten Messbereiches liegen.

iA
Beispiel: VZO 8 fOr HelzSI extralaicht / Example ofVZOB for Heating Fuel (Extra UgMf

DNS
VIskositaten / VfscoslOes
A = 4.5mPa.s
B s 50 mPa.s
C = 100 mPa.s
D s= 200 mPa.8
E = 500 mPa.s

Viskositit / Viscosity A = 4.5 mPa.s

Deflnierter Druckvehust / Defined pressure loss 40 mbar

w-Beschrankung der Durchflusslelstung auf ca. 100 l/h.

Flow rate limited to approx. 100 lAi.

•Qmananvh

ON 8
Viskositaten / Viscosities
A = 4.5mPa.s
B = 50mPa.s ijxn •iiiiinRtiiiiiir
C = 100 mPa.s
D = 200mPa.s >M2niiiiii33K'.4J^:]i<i?-xmBBiiii!
E = 500 mPa.s nii)!IIPS«!;il!'!;i!^'llllill
too
Viskosftat / Viscosity A = 4.5 mPa.s
Deflnierter Druckvertust / Peflned pressure loss. 300 mbar vs»tiiy'.\:.mm?K-\\mMH\\\
^Keine Etnschrjinkung der Ourchfiussleistung; Qmax des ZShlers kann [Link]

voll ausgenutzt werden. dlHSiiliiS^^afl^illlHI 11111111

No limitation of tlie flow rate, full use of Qmax possible.

ijs 1J

SchwerkraftfSrderung Gravity Fed Supply

Bei derSchwerkraftforderung. wie diese auf Schtffen zwischen Tages- The same points as mentioned in "Mounting on Suction Side" have to be
tank jnd DIeselmotor vorkommt, sInd die gleichen Parameter zu beriJck- considered with gravity fed supplies, which are generally used in ships
sichtigen wie belm Zdhlereinbau auf der Saugseite. between service tank and diesel engine.

Aquametro AG VD4-412DE
TBChnlBche InfonraUon / Technical labiraaUott

2. Differenzmessung / DmerenOal Measurement

%
2.1

Aufgabenstellung / Type ofPiMem

1
1M/IM

™j-,,_^_^_ Vtitnudw/Comiimrf
mmifmmiw (iBBnwm Motor/•.fti«nn»r,Mjffl»)
Punpo/nrnp __

—0—-a-^
-a-
2.2 2.2

Messtechnik Measuring Technique

Die Auslegung der StandardzShler hat zum Ziel, einen grossen Mess-
bereich innerhalb einer max. Messfehlergrenze von ± 1 % (in gewissen
Fallen ± 0,5 %) abzudecken. Dadurch wird die nominate Abweichung
zwischen gemessenem Durclifluss und dem effektlven Wert be< alien
in standard use, a meter is required to cover as large a measuring range
as possible within the accuracy limits of max. ± 1 K (in some cases ±
0.5 %). The nominal difference between the flow measured and the
effecthre value will be very small.
o
Betriebsbedingungen sehr Mein sein.
Bei der Differenzmessung bestettt eine vfillig andere Zieisetzung, die Differential measurements have, however, completely different objec-
auch andere LSsungen veilangt Anhand eines Beispiels soil aufgezeigt tives that require different considerations. Hie following example illus-
werden, welciies Ergebnto mit den Standardgertten berauskommen tiates what could happen if bivo standard meters are used for this
i(dnnte. Die Messfehler der beidsn Gerate itSnnten sich im Extremfall purpose. In the worst case, the measuring errors of the two meters
ungunstig ioimulieren. vrouid accumulate.

Voilast Vorlauf 100 l/h lUessfehter ± 1 % = nominal ± 1,01 Full load Supply 100 i/h ErTor±1% = nominal ± 1.01
Rucl^iauf 10 i/h Messfehler ± 1 % = nominal ± 0,11 Return 10 l/h Error±1% = nominal ± 0.11

Verbrauch 90 l/h Messfehler : nominal ± 1 , 1 1 Consumed 90 l/h Measuring error = nominal ± 1 . 1 1

Der Messfehler i^ann im theoretischen Extremfail Tbeoreticaliy, the maximum measuring error can amount to
1,1 X 1 0 0 : 9 0 = ± 1,22 % ausmachen. ± 1.1% X 1 0 0 : 90 = ± 1 . 2 2 % .

Minimailast vorlauf 100 l/h Messfehler ± 1 % = nominal ± 1 , 0 1 Min. load Supply 100 l/h Error ± 1 % = nominal ± 1.01
Rucidauf 90 l/h Messfehler ± 1 % = nominal ± 0,9 i RebJm 90 i/h Error ± 1 % = nominal ± 0.9 i

Verbrauch 10 l/h Messfehler = nominal ± 1,91 Consumed 10 i/h Measuring error = nominal ± 1.91 ^
Der Messfehier Vam im theoretischen Extremfail Theoreticaiiy, the maximum measuring error can amount to
1,9 X 1 0 0 : 1 0 = ± 19 % ausmachen. ± 1.9 % x 1 0 0 : 1 0 = ± 1 9 % .

2.3 2.3

Giite Ldsungen Appropriate Solutions

Der Messfehler verhalt sich umgeltehrt proportional zum Verbrauch. It will be seen that the measuring error is inversely proportional to the
Also miissen bei der Differenzmessung andere Ldsungen gewShit wer- consumption. Therefore, other methods for differential measurements
den. Die nachstehenden drel Mdglichl<eiten bieten sich an: should be chosen. The following three possibilities can be considered:

TM(/BA»

Zwltchtnonk/ Swfc* tai*

VnbnudMr / Comwmr
TMtt I Flmmtur (LBBnfn«,M«lor/o.f. lainar, englm)
Pumpa/Amp
H

VD 4-412 OE Aquametro AG
Tadmiscbe Infonnation Technical Information

Aniagekonzeption Plant Design

Anstelle einer Differenzmessung immerzuerstnach einer anlagstBchnisch It is always best to look first for an alternative soiutfcm to the differentiai
besseren Losung suchen wie z.B. measuring technique when designing the plant, as for example:

Differenzniessung Differential Measurements

Wenn die Aniagekonzeption nicirt angepasst werden lann, sind die if the plant design cannot be modified and measuring differentially is the
Zihier spezielt fik die Oifferenzmessung auszuiegen. Dazu geliSrt auch only solutwn, then the metens must be selected to meet the specific
die Ai)stlmmung aitf die spezlfischen Betriel>sbedingungen in der Anla- operating conditions of the plant.
ge.
Geben Sie uns deslialbzurAuslegung derMessgerSte mSgliclistgenaue In order to make an appropriate selection we would need to know as
Daten an: precise as possible the following data:

• Effeldiwr Durclifluss von ... bis ... i/li im Vorlauf. Bei Venivendung • Effective flow rate (from... to... i/h) on the supply (inlet) side. This may
einer Pumpe dOrfte dies ein recttt i(onstanter Wert sein. be a quite constant when using a pump.
• [Link]- • The minimum and maximum amounts consumed by the burner, plant
beiastung wird dann im Work berechnet etc.. The load on the meter can then be detennined in our vrorks.
• Angestrebte Differenzfehiergrenze. Je nach IMessstoff und Durch- • Accuracy limits aimed a t There are several technical possibilities
flussbereicli ergeben steti mehrere tectmisctie MSgiicbkelten. ilohe according to the lk]uid to be measuredand the flow range. As a rule,
Anfbrderungen veriangen in der Regei grSsseren Aufwand. the more stringent the requirements are, thehlgher Hie expense.

Der Auftraggeberistdafiirbesorgt,dassjeder Zihier am vorbestimmten The customer is responsible for mounting the meters In the places
Ort eingebaut wird. Unter Umstanden ist in der Aniage noch eine provided for them. Under certain circumstances, the user may have to
Feinkaiibrierung durcli den Abnehmer erforderlich (z.B. bei PrQfstinden carry out a precise calibration (e.g. on test benches for engines). Meters
fur Itotoren). Produkte in den Nennweiten 15...S0 verfOgen Qber eine of nominal diameters 15...50 have a simple regulating gear. Some
einfaclie EinstellmSglidikeit Durch einige Vergleichsmessungen kann comparative measurements will determine the residual error, which can
der Restfehier ermlttelt und durch die EInsteiiung weiter reduziert then be reduced by adjustment. The possibliities for reducing the paired
werden. Bei den Produkten VZO 4 und VZO 8 ist die Reduktton des errors on VZO 4 and VZO 8 meters are restricted (selection from the
Paariauffetilers nur in besctiranktem Umfang mdglich (Seiektion aus der producikin Une).
SerienprodukUon).

Elnsteliung dor Messfehlofkurve (NachkallbrioFung) Adjustment of the Measuring Error (Precise Calibration)
Das MessgerSt wurde Im Werk auf Pritfstinden kalibriert und die The meters are calibrated and sealed in our works. The seal may only be
Einstellung piombiert. Die Werksplombe darf nur entfemt werden, wenn removed when a readjustment or a precise calibration becomes neces-
es sich bei der Messung ntoht urn Abrechnungsverkehr mit Dritt- sary, and if the meter is not used for transactions with third parties:
personen liandelt und wenn eine Nach- bezw. Feinkaiibrierung in der
Aniage erfordertich wird. Die Einsteiiung srfolgtam Reguliergetriebe wie 1. Remove the seal from the reguiathig gear screw (synthetic cap
folgt: covering the screw hole). Other seals are not to be touched.
2. Determine the resMuai error In per cent.
1. Entfemung der Werksplombe am Reguliergetriebe (Kunststoffdeckel [Link]>n of a minus error (indicated value is smaller than the
in der Bohrung der Reguiierschraube). Die Obrigen Piomben sind zu effective flow rate): Turn the adjusting screw clockwise. The adjust-
ment works progressively; the correction per turn lies between 0.1
2. ErniitUung des Restfehlers In Prozent and 0.6 %. Therefore, start slowly.
3. Korrektur eines Minusfehlers (wenn die Anzelge Kleiner ist ais die 4. Correction of a plus mor. turn the adjusting screw anticlockwise.
effektive Durchflussmenge): Versteiispindei Im Uhrzeigersinn in Rich- 5. Repeat this procedure from point 2 on until the desired result is
tung und Markierung drehen. Die Versteilung wirkt progressiv, die achieved.
Korrektur pro Umdrehung liegt Im Bereich von 0.1...0.6%. Beglnnen
Sie deshalb iangsam.
4. Korrektur eines Plusfehiers erfolgt umgekehrt von Punkt 3.
5. Wiederholung des Vorgehens ab Punkt 2, bis das gewQnschte Ergeb-
nls errelcht ist.

VentoUaplniM. iriKWHkiplonibe
Rtgaltllntltin
KfiMnnt senw ultliBal

Funktionswelse des Reguliergetriebes: Operation of the regulation gear:

Das Reguliergetriebe Istals Pianeten-Dlfferentlalgetriebe mit Leistungs- The regulation gear is constructed as a planetary differential gear with
verzweigung konstruiert. Etwa 10% des Drehmomentes werden iiber torque splitting. Approx. 10% of the torque is transmitted by the
die Regullermechanik mit einem Einsteilbereich von ca. ± 3% gefiihrt. regulating mechanism with an adjustment range of approx. ± 3%. This

m
Dadurch wird eine stufeniose Korrektur der Anzelge und des Impuls- allows an almost infinitely variable correction to be made withing this
wertes erreicht. range.

Aquametro AG VD 4-412 DE
Technische biformatioii Technical Information

2A 2.4

AustogungsbetepMo Examples w
Fahneuge mH Hektropumpen Vehicles with Electric Pumps
Die angegebenen Werte sind Richtwerte, sie konnen je nach Fahrzeug Thefigurespresented here are only indicative; they may vary according
und Motorenhersteller abweichen. to the type of vehicle and to the engine manufacturer.

Motorenleistung von 500 PS / Engine power 500 hp

in
vbitaurkoMtnt/jimiiyciMttiiinnui I
t--
I VMnuchvoatsI / GniHi»|i('a> M totf 80 Mi

Miit/afwsom
/Mttm
RlMlaiil / flsllni 100-.174 Vh

I
174

Effel(thre Z§hlert>elastungen Effective loads on meters

-Vortauf 180 i/h -Supply 180 i/h
- RQcldauf 100...174 i/h -Return 100...174i/h

Motorenleistung von 100 PS / Engine power 100 hp

100
w
_4.
I
—t V«trauclivontt/Cn»wqKA»/M(/iHif20Vh
- J MM/OAvlOMi
I I
^ sutvtiiativtt

Effelttive Zahlerbelastungen Effective toads on meters

- Vorlauf 100 l/h - Supply 100 i/h
- RQckiauf 80... 98 i/h - Return 80... 98 i/h

Messbereich VZ08 und Belastungsbereiche bei LKWs mit 100...500 PS / l/ZDS measuring range and load ranges for trucks with 100. ..500 hp

ZUIn/M>r<r4...200l/h

200
VorlMi(/$tw(f10a..iaOHl

Racl(luil/fl)(iim100..1tOni
ISO
r>

Fahrzeuge mIt Membranpumpen Vehicles with Diaphragm Pumps

Die angegebenen Werte sind Richtwerte, sie konnen je nach Fahrzeug The figures presented here are oniy indicative, they may vary according
und iMotorenhersteiler abweichen. to the type of vehicle and to the engine manufacturer.

Motorenieistung von 500 PS / Engine power 500 hp

45 110
Varlaul/Sl«>M'45...l80l/h
-r
I Veitnucti vodut / CominvUim full lout M l/h

-|Slanilaas"iC'6Vli
ftOcU«if/fl>lwn3l...1(10l/ti

39 100

Effektive Z^hterbelastungen Effective loads on meters

-Vorlauf 45...180i/h (drehzahlabhangigePumpe1:4) -Supply 45...180l/h (RPM dependent pump 1:4)
-Ruckiauf 39...100i/h - Return 39...100 I/h

VD 4-412 DE Aquametro AG
 Technisetie Information / TechiUcal InfomuUou

Motorenleistung von 100 PS / Engine power 100 hp

VaUm/IISirpIr 25 100

Vntftudi vo(W / CDRtmiiUwi Aiff iMtf 20 H I

SlaidgK/MbtHi
mMMtiHeim
23.M»
•23

EffekUve Zahlerbelastungen Effective loads on meters

-Vorlauf 25...100l/h - Supply 25...100 l/h
- Riksklauf 23... 80 l/h - Return 23... 80 l/h

Messbereich VZ08 und Belastungsbereiche be! LKW's mit 100...500 PS / VZOB measuring range and load ranges for trucks with 100...500 hp

-k
ZMiler/«fctef*-200Mi
-I--
200
VWIau)/aiwi(yi8l.1»0l/h

± ROcUiiit/nirini 23.-100 Ml
'IW

100

3. Anwendungsbeispiele / Typical Applications

Kraftstoffverbrauchsmessung auf Schiffen oder Fahrzeugen Measuring Diesel Consumption in Ships or Vehicles

3.1

r Mit Vergasermotor ohne ROcklauf I^Carlmrettor Engine without Return

MinooieUr mil KoiilaMaiilnahim

oikr DmBienzdnicKEthBltar (bypos-VtnM)
Caiua mummfnrtlKfmiilUI
pntsan nifteli fiypiss alve)
Dunlillussnutur
(imt ixM' ohni Imputtotber)
Flown»ltrfii4lh
nitef/flWer orwIUmniHilser)

Mfen Motor/fng/m

_j
Magmtventn / Uttiallc nhn

1^) Das Umgehungsventil (IMagnetventil) offnet, wenn der Drucl< den einge- The magnetic valve opens as soon as the pressure drops below a defined
stellten Wert unterschreitet (z.B. bei verstopftem Filter oder blockiertem level (e.g. caused by blocked fitter).
Zahler).

Aquametro AG VD 4-412 DE
Technisciw Infonnatlon / Ttdmleal lutmmaffon

3-2 I

MIt Bnspritz- Oder Vergasermotor, mit RDcklauf / litfeethm or Carbunttor Engine wlOi Return
te

edn DMmmtactadoiK (mwMHI)

Onbcf nuanMuarttltntiatl
pmtimntKcilbiifiuvilit) IMrvU

X.
Vbitauf/Awtr

tbgaaMiH/MpnXfc nhe IMor/fiwAw

MMuHimtmi

Schwimmer- Oder Ventilsteuerung im Zwischentank erforderlich. Gas-

bildung ist zu vermelden. Das Umgehungsventil (Magnetventll) Sffnet,
Float or valve control in servtee tank required. Formation of gas is to be
avoided. The magnetic valve opens as soon as the pressure drops below
U
wenn der Druck den eingesteltten Wert unteischreiteL Bel mehr als a defined level. For measuring the consumption of more than one
einem Motor ist pro Motor eine komplette Aniage gemSss obigem engine, each will require a separate installation similar to the one above.
Schema erforderlich.

•qua
m etro
Durchfluss- und Energie-
Messsysteme
Flow and Energy Measuring
Systems
lui [MTEGRA Company
 POS NO. 4.08

BETRIEBSANLEITUNG OID 01 A
Ausgabe 01/01
OPERATING INSTRUCTIONS Edition 01/01

Schraubenspindelpumpen
Screw Spindle Pumps
Doppelstationen DL / DS / DCL / DCS
Fijr Heizol leicht und schwer
Double Stations DL I DS I DCL I DCS
For light and heavy fuel oil

/• "N

+•
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^ 1
^

*^l M1
^i k1
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i
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Krautler Gesellschaft m.b.H. & Co Pumpen-Volumeter, A-6893 Lustenau/Austria, Postfach 304/[Link] 304, Tel. Int. +43 5577/86644-0, Fax Int. +43 5577/88433
1. ALLGEMEINE INFORMATION 1. GENERAL INFORMATION

Betriebsanleitung ist griindlich durchzulesen und vom The staff concerned with the unit should read the ope-
beteiligten Personal verbindlich zu befolgen. rating instructions and follow it.

Die Verantwortung fur die Einhaltung der Instruktio- The user is responsible for taking any precautions
nen ubemimmt der Betreiber. outlined in this manual.

Alle Pumpen werden einem Probelauf und einer Lei- The capacity of all pumps has been tested during a
stungsprufung unterzogen. Unser Werl< verlassen nur test run. We supply only pumps which guarantee a
einwandfrei funktionlerende Pumpen. trouble free operation.

Maximale Werte der Einsatzbedingungen siehe Lei- Maximum operation values are given on the perfor-
stungsschild. Abweichungen davon bedurfen unserer mance plate. Any differences require our confinna-
Zustimmung. Offene Fragen bitte mit unserem Werk tion. Contact us for any special information.
abj^laren.

Das Fordermedium muB ausreichende Schmierfahig- The medium must be lubricant. Mechanically abrasive
keiten aufweisen. Mechanisch abrasive und chemisch and chemically aggressive parts In the medium redu-
aggressive Bestandteile im Medium reduzieren die ce the life span of the pump. No guarantee can be gi-
Lebensdauer der Pumpe. FiJr Schaden die durch ven if the instructions in the manual have not been
Nichtbeachtung entstehen, ubernehmen wir keine observed. The user must maintain the unit periodical-
Garantie. VerschleilJ rechtzeitig wahmehmen und ly and replace the wearing parts.
entsprechende Wartung vornehmen.

Aniagen, bei denen der Ausfall oder das Versagen zu Installations which could lead to personal Injury and/
Personen- oder Sachschaden fiihren kann, sind mit or material failure should be equipped with an alarm
Alarmeinrichtungen und/oder Reserveaggregaten system and/or reserve aggregate. This system should
auszustatten, und deren Funktionstuchtigkeit in regel- be checked periodically.
maUigen Abstanden zu uberpriifen.

FiJr die Einhaltung der allgemeinen Unfallverhutungs-, The user is responsible for following the general pre-
Sicherhelts- und Betriebsvorschriften ist der Betreiber ventation of accidents and the local safety and/or
verantwortlich. operating directions.

Wichtlge Hinweise: Important Remark:

Bei Ruckfragen oder Ersatzteilbesteliungen ist stets For questions regarding the pump and for spare parts
die Type und Pumpen Nr. anzugeben. orders please always mention type and pump num-
ber.
Kann eine Storung nicht selbst behoben werden, so If any problems occur which need our help, return the
ist uns die Pumpe moglichst in ungeoffnetem Zustand complete pump (for a correct damage report) and
und kostengunstigst zuriJckzusenden (bessere Scha- choose the transportation with the lowest price. It is
densklarung). Bitte darauf achten, dali Zubehorteile important that all the assembling parts like screws,
wie Verschraubungen, Kupplungen und dergleichen coupling a.s.o. are being dismantled as no guarantee
demontiert werden, da fiJr die Rucksendung keine is given for the return shipment.
Gewahr ubernommen werden kann.

2. ANLIEFERUNG 2. DELIVERY

Lieferung auf Vollstandigkeit uberprijfen, Reklamatio- Inspect the received goods for any shortages. Report
nen sofort weitergeben (Spedition / Werk). any mistakes immediately (to the forwarding agent or
the factory).

GEWAHRLEISTUNG WARRANTY

Gewahrleistungsumfang gemali unseren Lieferbedin- Warranty according to our terms of delivery. Repairs
gungen. Instandsetzungsarbeiten wahrend der Gar- during the guarantee period must be carried out only
antiezeit darf durch unsere ausdruckliche Zustim- by the user or any other person authorized by us and
mung und Anweisung nur der Betreiber selbst, oder in accordance with our agreement and instructions.
ein von uns Beauftragter, durchfiihren.
4. AUSFUHRUNGSBESCHREIBUNG 4. DESCRIPTION
4.1 Aufbau und Konstruktion, DurchfluRrichtungs- und 4.1 Design Construction, flow directions and the direc-
Drehrichtungsanzeige der Pumpe >- Bild 1 tion of rotation of the pump >• sclieme 1

Ruckschlagventil
non return valve
Lateme
lantern
Kupplung Sichertieltsventil
coupling safety valve

Druckraum
pressure chamber

Schraubenspindelpumpe Umschalthebel
screw spinde pump switch over level
Dreiwegkugeihahn
Saugraum three way ball valve
suction chamber
Olwanne Mano-Vakuummeter
oil pan mano-vacuummeter

4.2 Hydraulisches Schaltschema >- Bild 2 4.2 Hydraulic Scliematic >-scheme 2

Baureihe/series DL2 Baureihe/serles DL3, Baurelhe/series DL7.

DL4. DS1.DS3. DS4 DS7. DCLZIDCSTI
3 ^ 5 (B) @ (6)
(M) ®

/1-^
®^ r® ^
9 6 7 9 6 7 1 2 4 5 6 7
1) Thermometer thermometer 6) Slcherheitsventl! safety valve
2) Dreiwegkuken jeweils A/B + C/D three-way-cock A/B + C/D connected 7) Ruckschlagventil non return valve
3) abspen-bare Mano- und Vakuummeter lockable mano- and vacummeters 8) absperrbares Manometer lockable manometer
4) Korbfilter ( DL2 - Schutzsieb ) basket filter ( DL2 - strainer) 9) Dreiwegkugeihahn three vi/ay ball valve
5) Pumpenaggregat pump aggregate

4.3 Einsatzgrenzen / Leistungsdaten 4.3 R a n g e of A p p l i c a t o n / R a n g e of C a p a c i t y

>> Bild 3 >- scheme 3
Die angegebenen Werte beziehen sich auf gut The mentioned values refer to good lubricating medi-
schmierende Fordermedien. um.
Leichtol / light fuel oil Schwerol / heavy fuel oil
Blockaggregate DL2 DL2 DL3 DL4 DL7 DCL7 DS1 DS3 DS4 DS7 DCS 7 Block Aggregates
150 bis/up
240 1300
a Druck bar 6 6 6 6 6 40 6 6 6 6 40 pressure stage, bar
b Temperatur °C min. 10 10 10 10 10 10 50 50 50 50 50 temperature °C min.
Temperatur °C max. 50 50 50 50 50 50 130 130 130 130 150* temperature °C max.
c Min. Temperatur fiJr Doppel- min.-temperature for material
max. -10°C max. -10°C
station-Werkstoffe of double stations
d Viskositat mm^/s min. 4 4 4 4 4 4 10 10 10 10 10 viskosity mm2/s min.
Viskosltat mm^/s max. 37 37 37 37 37 37 700 700 700 700 700 viskosity mm2/s max.
e Drehzahl / Viskositat: RPMWiscosity
2900 1/min - max. mm^/s 80 80 80 80 80 80 152 152 152 152 152 29001/min - max. mm2/s
1450 1/mln - mm^/s 700 700 700 700 700 1450 1/min-mm2/s
Saugh6he siehe beiNPS H-Ken ilinien !,ee NPS>H - characteris ic lines suction head
f Zulaufdruck: inlet pressure:
- mit Radialdichtung 0.5 bar - with radial shaft seal
- mit Gleitringdichtung 5 bar - with mechanical seal
. ab 130°C bis 150°C ist eine AuBenlagerung und . from 130°C to 150°C a outside bearing and
eine SiC-Gleitringdichtung erforderlich a mechanical seal (SiC) is necessary
Andere Werte auf Anfrage Other values upon request
4.4 Erforderliche NPSH-Werte (m WS) >• Bild 5 4.4 NPSH Required m WC >- scheme 5
Die NPSH-Werte beriicksichtigen nicht, ob das For- The NPSH values do not take into account whether
dermedium bei geringerem Unterdmck schon entgast the medium degases at lower pressure (e. g. light fuel
(z.B.: bei Heizol EL und Dieselol max. 4 m WS). sxoil or diesel oil max. 4 m WC).

Einbaupumpe Viskositat mm^/s Viscosity tnm^/s

6* 37 152 380
insert pump Drehzahl 1/min RPM 1/min
1450 1750 2900 3500 1450 1750 2900 3500 1450 1750 2900 3500 1450 1750 2900 3500
NPSH erfbrderlich (m WS) NPSHrequired(m WC)
FE 5 / N E 5 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3,1
NE7,5 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3,3 3,5
NE10 3 3 3 3 3 3 3 3 3 3 3 3,3 3 3,1 3,6 4
NE13 3 3 3 3,3 3 3 3 3,3 3 3 3,6 4,1 3,2 3,4 4,4 5,1
NE15 3 3 3 3 3 3 3 3 3 3 3 3,2 3 3 3,6 3,9
NE20 3 3 3 3,1 3 3 3 3,1 3 3 3,4 3,8 3,1 3,3 4,1 4,7
NE26 3 3 3,2 3,7 3 3 3,2 3,7 3 3 3,9 4,5 3,3 3,6 4,9 5,8
NE32 3 3 3 3 3 3 3 3 3 3 3,3 3,7 3 3,2 4 4,5
NE42 3 3 3,2 3,7 3 3 3,2 3,7 3 3 3,9 4,5 3,3 3,6 4,9 5,8
NE54 3 3 3,5 4,2 3 3 4 4,9 3,1 3,4 5 6,2 3,8 4,2 6,4 —
OLD 55 3 3 3 3,3 3 3 3 3,3 3 3 3,6 4,1 3,2 3,4 4,9 5,6
CLD74 3 3 3,5 4,1 3 3 3,5 4,1 3 3,1 4,3 — 3,5 3,8 5,9 —
OLD 85 3 3 3,8 4,5 3 3 3,8 4,5 3 3,3 4,7 — 3,6 4 6,5 —
OLD 118 3 3 — — 3 3 — — 3,2 3,5 — — 3,9 4,3 — —
* Bei Heizol EL empfetilen wir eine max. Saughohe For fuel oil we recommend a max. suctton head of 4 m WC,
von max. 4 m WS am Stations-Saugflansch gemessen. measured at suction flange of the station.

Zuordnung: Einbaupumpen - Stationen Allocation: insert pumps - stations

FES DL2/150 NE20 DL3/2300 DS3/1100 CLD55 DL7/6000 DS7/2800 DCS7/3000
DL2/240 DL7/1100 DS3/2300 DCL7/6500 DS7/6000 6500
DL7/2300 DS7/1100
NE5 DS1/150 CLD74 DL7/8500 DS7/3500 DCS7/4100
DS1/240 NE26 DL3/2900 DS3/1500 DCL7/7500 DS7/8500 7500
DL3/1500 DS3/2900
NE7,5 DL2/400 DS1/ 400 CLD85 DL7/9000 DS7/3800 DCS7/4500
DL3/2900 DS7/1500
DL2/ 750 DS1/ 750 DCL7/9000 DS7/9000 9000
DS7/2900
NE10 DL2/ 320 DS1/ 320 CLD118 DS7/7000
NE32 DL4/3200 DS4/1600
DL2/ 500 DS1/ 500
DL7/3200 DS4/3200
DL2/1000 DS1/1000
DS7/1600
NE13 DL2/1300 DS1/1300 DS7/3200
NE42 DL4/4000 DS4/2000
NE15 DL3/1800 DS3/ 900
DL7/4000 DS4/4000
DL7/ 900 DS3/1800
DS7/2000
DL7/1800 DS7/ 900
DS7/4000
NE54 DL4/6000 DS4/6000

4.5 Zulaufdruck / Saugverhalten >- Bild 7 4.5 Inlet Pressure/Suction Behaviour >• scheme 7
Das im Heizol "Schwer" enthaltene Wasser verdampft The water contained in the heavy fuel oil is evapora-
bei zu hohen Temperaturen und zu geringem Zulauf- ting because of high temperatures and less inlet pres-
druck. Das Diagramm zeigt den IVIindest-Zulaufdruck sure. The diagramm shows the minimum inlet pres-
am Saugstutzen der Pumpe. Diese Werte sind einzu- sure on the suction side of the pump. These values
halten, um einen einwandfreien Betrieb zu gewahrlei- must be observed to guarantee perfect operating con-
sten (Temperatur max. 150°C). ditions (temperature max. 150° C).

70 80 90 100 110 120 130 140 150

Verdampfungsdrucl< Wasser / vapour pressure water

empfohlener Zulaufdrucl< / recommended inlet pressure
4.6 Sicherheitsventil 4.6 Safety Valve
4.6.1 Das Sicherheitsventil dient zum Schutz der Pumpe 4.6.1 The built-in safety valve protects the pump from beco-
vor Oberdrucit und darf nicht als Steuer- oder Regel- ming overpressured and should not be used as a con-
ventil verwendet werden. trol valve.
4.6.2 Der Offnungsdrucl< ist ca. 10% iJber dem Betriebs- 4.6.2 The opening pressure is adjusted 10 % above the
drucl< werkseitig eingestellt (jedoch nicht unter 3 bar). operating pressure (but not less than 3 bar).
4.6.3 Kontrolle des eingestellten Kurzschluftdruckes 4.6.3 Checking the Adjusted Opening Pressure.
Druckseitiges Abspenventil langsam schliellen. Das Close the stop valve at the pressure side of the pump.
Manometer zeigt den Kurzschlulldruck an. Achtunq: The manometer shows the opening pressure.
Ein zu langer Umlauf des Mediums innerhalb der Attention: When the medium is circulating too long in
Pumpe kann zu Erhitzung und in der Folge zu mecha- this way, the pump will warm up and as a result this
nischen Schaden fuhren. can cause mechanical damage.
4.6.4 Ventilverstellung >> Bild 8 4.6.4 Adjusting the Valve >- scheme 8
Drehen nach rechts (Uhrzeigersinn) erhoht den Off- Turning the adjusting screw clockwise increases the
nungsdruck, drehen nach links vermindert den Off- opening pressure, turning it anticlockwise decreases
nungsdruck. Beachtung: Bel DL7/DS7/DCL7/DCS7 ist it. Attention: Before adjusting the valve please remove
vor der Ventilverstellung die Fixierschraube zu losen. the cover screw for DL7/DS7/DCL7/DCS7.

DL2 DL3, DL4, DS1,DS3, DS4 DL7, DS7, DCL7JDCS7

4.7 Heizung 4.7 Heating

4.7.1 Bei hochviskosen Medien ist eine Pumpenheizung er- 4.7.1 It is necessary to install a heating if the fluid is of high
forderlich. Kaltstarts sind zu vermeiden (Aufheizzeiten viscosity. To avoid cavitation and damage of seals,
beachten). Kavitation und Weliendichtungsschaden don't start up the pump with cold fluid. (Pay attention
konnen die Folge sein. Beim Aufheizvorqanq sind we- to heating up period). When heating UP. all valves
cen der Warmeausdehnuno samtliche Ventile zu off- must be opened because of expansion due to heat.
nen.
4.7.2 Elektro-Heizungen >- Bild 9 4.7.2 Electrical Heating >- scheme 9.
E-Heizungen sind durch eine begrenzte Heizleistung Electrical heatings are dimensioned for a limited hea-
so dimensioniert, daU eine Uberhitzung nicht moglich ting capacity and can therefore not overheat.
ist.
a) Spannung 220 Volt a) voltage 220 Volt
b) Frequenz 50 Hz/60 Hz b) frequency 50 Hz / 60 Hz
c) Leiterquerschnitt 2 X 1 mm2 c) wire cross section 2 x 1 mm2
Andere Werte auf Anfraqe Other values upon request
DS1 OS 3, DS 4 DS 7, DCS / L 7
Heizleistung / heating capacity Heizleistung / heating capacity Heizleistung / heating capacity
180 Watt 250 Watt 400 Watt

4.7.3 Medium-Heizung >> Bild 10 4.7.3 IVIedium Heating >- scheme 10

Beachten der Aufheiztemperaturen im Pumpen - und Pay attention to heating up temperature in fpump/-
Dichtungsraum. and seal casing.
a) bei Radialdichtungen max. 80°C a) for radial shaft seals max. 80° 0
b) bei Gleitringdichtungen max. 100°C b) for mechanical seals max. 100°C
Dampfheizung Steam Heating
a) Temperatur max. 180°C a) temperature max. 180°C
b) Druck max. 18 bar DS1 b) pressure max. 18 bar DS1
max. 6 bar DS3, DS4 max. 6 bar DS3 DS4
Bei der Dampfheizung muU dafur gesorgt werden, With steam heating it is important to avoid higher hea-
da(i die Aufheiztemperatur von max. 100° C nicht ting up temperatures than max. 100° C, measured in
ijberschritten wird. the station casing.
 a) b) a) c) 0
B
Elektrisch t (min) Dampf P t Dampfmenge t (min)
Aufheizzeiten/ Eiectrical ao-c 50°C Steam (bar) (°C) Steam Capacity 20°C SOX
Heating Up Period DS1 (180W) 60 180 DS1 15 180 5kg/h 30 100
DS4 (250W) 120 -240 DS4 15 180 5kg/h 40 120
DS7 (400W) 180 420 DS7 5 150 5kg/h 60 240

DS1 DS3, DS4 DS7,lDCS7

Standardausfiihrung mit eingebauter Mediumheizung
Standard design wim built in medium heating
\
i -t.
i

to
/
.t\ /
i 30 'i

elektr. Heizung / electr. heating :

I
^
^ ^ ^
Z ^
/ J I > > I I I r4-A

Mediumheizung / medium heating >> Bild 10 / scheme 10

6ei nachtraglichem Einbau wird die Heizung seitlich

eingeschraubt. Die Elnfull-ZEntluftungsschraube off-
nen und mit Theimool auffullen, bis ca. 65 mm von
Oberkante-Einfulldffnung bis zum Olspiegel (ent-
spricht ca. 1,41 Ol).
When the heating device is Installed later, it must be
screwed In laterally. Open the feed-/vent screw and
fill with thermo oil approx. 65 mm below the upper ed-
ge (approx. 1,41 oil).

070,1 AbscliluBdeckel *730,2 Fiachdichtung 070,1 end cover *730,2 flat gasket
161 Wamieleitpiatte •730,5 Fiactidichtung 161 head conductor plate *730,5 flat gasket
242 Heizbiock 908,2 Verscliluiischraube 242 heating block 908,2 screvtr plug
*481 Heizpatrone 908,3 Verscliiulisctiraube •481 heating cartridge 908,3 screvi^ plug
484 Klemmieiste 914,1 Zylinderscliraube 484 porcelain terminal 914,1 socket screws
493 Verschraubung 915,4 Zylinderschraube 4.849?.r
4 .849^reslfi{^tJlSJfl^'9B s c h e t r ^ ^ ^ . socket screw
*empfohlene Ersatzteiie Stop viff^i^'Sf'ffliflaPWfidP^uummeters are always
4.8 Drucl(anzeige >- Biid 11 closed. Open only for the purpose of checking!
Absperrhahne bei Mano- und Vakuummeter sind
grundsatzlich gesclilossen. Nur zu Kontrollzwecken
offnen!

Stellung offen Stellung geschlossen

position open position closed

5. A^TEMBLING
5. MONTAGE 5.1 instaliation
5.1.1 To identify the best installation position consider the
5.1 Aufstellung max. application limits and NPSH values.>-scheme 5
5.1.1 Bei der Standortwahl sind die Einsatzgrenzen und 5.1.2 Consider the environmental conditions.
NPSH-Werte zu beachten. >- Biid 5 Influence of temperature, moisture and explosive at-
5.1.2 Es sind die Umgebungsbedingungen zu beachten. mosphere can affect function, security and life time of
Funktion, Sicherheit und Lebensdauer diirfen nicht the pump.
durch Feuchtigkeit, Temperatureinflusse oder explo- 5.1.3 When locating the unit ensure that it can be worked
sionsfahige Athmospharen beeintrachtlgt werden. on easily as you will need to maintain it.
5.1.3 Beim Aufstellen ist darauf zu achten, dali alle Teile
der Pumpe gut zuganglich sind, und eine Wartung
leicht moqiich Ist.
5.1.4 Einbaulage / Durchfluftrichtungen >- Bild 12 5.1.4 Assembling Position/Flow Direction: >-scheme 12

DL2 DL3, DL4, DS1, DS3, DS4 DL7, DS7, DCLTIDCST]

* Motorschaltschema
motor circuit schematic
fur/for 01^150 , Dl^240
EIN/ON
AUS/OFF

J:

5.2 RohrleitungsanschluR 5.2 Pipework Connection

Rohrspannungen vermeiden. Grundsatzlich durfen Avoid stress of pipes. The pumos should not serve as
die Pumpen nicht als FixDunkt der anaeschlossenen a fixed reference point for the Installed pipe line. Such
Rohrleitunqen dienen. Eventuell auftretende Krafte wgurencg? shouM be avoide'J. if possible, e. g. bra-
und Momente (z.B.: Verspannunaen. Ausdehnunaen cing. the expansion of pipe due to variations in tem-
der Rohrieitung durch Temperatureinfliisse. Reak- perature and unit stress. We recommend to install a
tlonskrafte^ sind zu vermeiden. Bei moglichen War- compensator In case of heat expansions of the pipes.
meausdehnungen der Rohrieltungen ist der Einbau The dimensions of the suction pipe must allow a liquid
von Kompensatoren zu empfehlen. Die Saugleitung velocity of 0,5 up to max. 1,3 m/sec and the pressure
Ist so zu bemessen, daft die Flieftgeschwindigkeit pipe must allow a liquid velocity of 2 - 3 m/sec. The
zwischen 0,5 bis max. 1,3 m/sec. und die Drucklei- suction pipework must be installed with a gradual rise
tung zwischen 2 bis 3 m/sec. liegt. Die Saugleitung and air-tight. The pipework and the pump must be
muft vakuumdicht und stelgend verlegt werden. Rohr- free of Impurity (e.g. flushing). When the pipework in-
system und Pumpe miissen frel von Verunreinigun- stallation is being tested for leaks pay attention to the
gen sein (z.B.: Spulung). WIrd das Rohrsystem auf max. admissible inlet pressure of shaft seal. Attention:
Dichtheit gepruft, Ist der max. zulassige Zulaufdruck don't use water cause of rust formation. When drai-
der Wellendlchtung zu beachten. Achtuna: weaen ning the system It is important that pipe and pump are
Rostbllduna kein Wasser verwenden. Belm Entleeren free from dirt (e. g. welding beads, pieces of steal
der Flussigkeit ist darauf zu achten, daft die Rohrlei- etc). Carry out preservation (see Preservation). Oxv-
tung und die Pumpe frei von Verunreinigungen sind dation and impurity can cause a breakdown.
(z.B.: Schweiftschlacke, Zunder). Konservierung vor-
nehmen (siehe Konservierung). Oxvdation und Ver-
unreiniounaen konnen zu einem PumoenausfaJI fijh-
ren.
5.5 Foot Valve
5.5 Fullventil With the suction operation it is necessary to install a
Bel Saugbetrieb Ist ein FuRventil mit Saugkorb elnzu- foot valve with strainer. This process prevents the in-
bauen. Der Ansaugvorgang wIrd erieichtert, grobe duction of Impurity and draining of the suction pipe.
Verschmutzungen ferngehalten, und eIn Entleeren
der Saugleitung verhlndert.
5.6 Electrical Installation
5.6 Etektrischer AnscliluK All electrical connections should be made overload
Motor Ist entsprechend den ortllchen Vorschriften und protected in accordance with any local regulations
dem Motorlelstungsschlld iiberlastgeschiitzt anzu- and with the motor labels. Check motor labels for cor-
schlieften. Vorhandene Netzspannung mIt Motorlei- rect voltage and current ratings. Pay attention to the
stungsschild vergleichen. Schaltbild Im Motorklemm- wiring schematic in the motor terminal box.
kasten beachten.
6. INBETRIEBNAHME 6. START UP
6.1 Trockenlaufschutz 6.1 Dry Running Protection
Pumpen durfen nie trocken laufen, da es zur Zersto- Ttie pumps must never be allowed to run dry, as this
rung von Pumpenteilen kommen kann. Leichtgangig- will cause severe damage to all the pump parts.
keit handisch priifen. Empfehluna: Pumpe sowie Sau- Check by hand if the pump runs easy. We recom-
gleitung mit Medium fijllen und entluften (A - Aufful- mend: to fill the pump and suction pipe with the medi-
len, B - Entluften) >- Bild 16 um and vent. (A - to fill, B - to vent) >• scheme 16
Type DL2 Type DL3, DL4, DL7. DS1, DS3,
DS4. DS7, DCL7, DCS7
908.2

074-^
f"
w4^, H
FiJIIvorgang: How to 1
^
\
, _. ^-k**) j
c:^ 1 — ! -7

VerschluBschraube 908,2 entfemen - remove screw plug 908,2 - Beide Filterdeckel 074 entfemen Remove Ijoth filter covers 074
Hebel nach links - dl einfOllen - turn lever to the left - fill with oil und Station mit Ol auffiillen. and fill station with oil.
Hebel nach rechts - Ol einfQIIen - turn lever to the right - fill with oil

Pumpe handisch laut Drehrichtunaspfeil durchdrehen Rotate the pump bv hand in the direction of the arrow
und auf Leichtqanqiqkeit prtifen. and check if the oumo mns easv.
6.2 Drehrichtungsl(ontrolle 6.2 Checlcing the Direction of Rotation
Die Drehrichtung des Motors muli mit dem Drehrich- The direction of rotation of the motor should corre-
tungspfeil der Pumpe ijbereinstimmen. Zur Drehrich- spond with the arrow shown on the pump. To check
tungskontrolle kann der Motor, bei geoffneten Saug- the direction of rotation it is allowed to start the motor
und Druckventilen, kurzzeitig eingeschaltet warden. for a short time, when the suction and pressure val-
Bei falscher Drehrichtung saugt die Pumpe nicht an ves are open. In case of wrong sense of rotation
und fiJhrt zu Schaden an der Pumpe. Langer dauern- pump does not prime and as a result this can cause
de Drehrichtungskontrolle ist ohne Pumpe durchzu- damage of the pump. If checking the direction of ro-
fiihren. tation longer than recommended this process should
be continued without the pump.
6.3 Start 6.3 Startup
Vor dem Anfahren saug- und dnjckseitige Ventile off- Prior to start up open valves on suction and pressure
nen. Wahrend des Anfahrvorganges ist die Pumpe / side. Vent pump/station during start up. Extreme tem-
Station zu entluften. Extreme Temperaturschocks perature shock may destroy the pump/station. Pay at-
konnen die Pumpe / Station zerstoren. Hebelstellung tention to the lever position at block aggregates and
bei Blockaggregaten und Stellung der Absperrventile to the position of the stop valve at single and double
bei den Einzel- und Doppelstationen beachten. stations.
>• Bild 17 >-scheme 17

Type DL2

I
i] i,
Type DL3,
DL4,

Hebel rechts: nur rechte Pum- Hebel links: nur linke Pumpe 'Hebel MIttelstellung: beide
pe ist betriebsbereit ist betriebsbereit Pumpen sind betriebsbereit
Lever right: only right pump is Lever left: only left pump is re- Lever position middle: both
ready for operation ady for operation pumps are ready for operation

Type DL7,DS7, O^n Bom w^M O©®)

DCL7, DCS7
©0®
linke Pumpe und linker Fil-
ter betriebsbereit
rechte Pumpe und rechter
Filter betriebsbereit
linke Pumpe und rechter
Filter betriebsbereit
W^M
reohte Pumpe und linker
Filter betriebsbereit
left pump and left filter rea- right pump and right filter left pump and right filter re- right pump and left filter re-
dy for operation ready for operation ady for operation ady for operation

(Ji^irip Piimnon nnri linkpr Filtftr hfttriphRhfiroit @ . lh nnmnc; anrl loft filtpr« rpftrlw fnr nnoratinn
^ ^ i r i p Piimnfin linH rprhtpr Filtpr hptriphshfirpit h niimns anrl rinht fittfir*; rAariu fnr rtnpratinn
 BEDIENUNG, WARTUNG 7. MAINTENANCE
7.1 Wartung und Kontrolle 7.1 Maintenance and Inspection
Sicht- und Gerauschkontrolle sowie Dichtheitsiiber- We recommend that the unit is given a visual and noi-
wachung sollten taglich durchgefuhrt werden. se check every day, as well as checking the function
of gaskets.
7.3 Filterreinigung 7.3 Cleaning the Filter
Die Filterreinigung ist abiiangig vom Verschmut- The frequency of cleaning the filter is dependent on
zungsgrad des Fordermediums. Die angebauten Va- the contamination of the medium. The degree of con-
kuummeter dienen zur Verschmutzungsanzeige. tamination is visible on the vacuummeter built on.
Hochstzulassiges Vakuum bei IHeizdl EL max. 0,5bar admissible vacuum at: light fuel oil max. 0,5 bar
Heizol S max. 0,7bar heavy fuel oil max. 0,7 bar
Bei zu stark verschmutzten Filtem tritt Kavitation A high contamination of the filter will cause cavitation
(starke Gerausche) auf. Die Filterreinigung darf niclit (noise). Cleaning the filter is not allowed when lever is
bei Mittelstellung des Umschalthebels erfolgen. in the middle position. Tum the lever first to the spare
Zuerst auf die Reservepumpe schalten und dann den pump, then turn lever to the running pump (see 6.3
Umschalthebel zur laufenden Pumpe drehen (siehe start / position of lever) >- scheme 17
6.3 Start / Hebelstellung) >• Bild 17
7.4 Pumpenausbau 7.4 Dismantling the Pump
Zu beachten ist elektrische Abschaltung, Umschalthe- Pay attention to the electrical switch off, close lever or
bel Oder Saug- und Druckventile schlielJen, Pumpen suction- and pressure valve, drain pump (drain plug),
entleeren (Entleerungsschraube), beim Wiedereinbau when installing the pump again check if flat gaskets/o-
Flachdichtungen und 0-Ring auf evt. Schaden prijfen. rings are damaged. The insert pump can be removed
Der Ausbau einer Einbaupumpe kann ohne Betriebs- without interruption of operation. Tum the lever as
unterbrechung durchgefuhrt werden. Der Umschalt- described under point 7.3 "Cleaning the Filter". Dis-
vorgang ist wie bei der Filterreinigung 7.3 auszufuh- mantle the motor and lantern. Loosen insert pump by
ren. Motor und Laterne ausbauen. Einbaupumpe mit using 2 screw drivers. Check whether non return val-
2 Schraubendreher vorsichtig losen und kontrollieren ves are leaky and oil is penetrating. If not remove the
ob eventuell durch undichte Ruckschlagventile Ol insert pump. Before installing the insert pump, make
austritt. Bei Gutbefund Einbaupumpe herausheben. sure that the level of oil in the station casing is max.
Vor dem Einbau darauf achten, dali im Stationsge- 50 mm. Otherwise it may prove difficult to install due
hause der Olspiegel max. 5 cm hoch steht. Anson- to oil displacement Check the O-rings of the insert
sten erschwerter Einbau der Einbaupumpe durch 01- pump whether they are damaged or not and grease
verdrangung. 0-Ringe der Einbaupumpe auf Scha- them slightly. Push the insert pump under light pres-
den uberprufen und leicht einfetten. Einbaupumpe mit sure inside the station casing. Mount lantern and mo-
leichtem Druck ins Stationsgehause einschieben, La- tor and turn the lever to the middle position.
terne und Motor aufbauen und Umschalthebel in Mit-
telstellung bringen.
7.5 Konservierung, Einlagerung 7.5 Preservation and Storage
Durch den Pruflauf ist die Pumpe mit Prijfol benetzt The pumps have been wetted and preserved with hy-
und dadurch konserviert. Die vom Werk nicht konser- draulic oil ISO VG 46, during testing. The user has
vierten Telle sind nach den ortlichen Gegebenheiten got to preserve all other parts, which are not preser-
vom Betreiber durchzufuhren. Bei langerem Stillstand ved in the factory, in accordance with the local condi-
Oder Nichtinbetriebnahme ist vom Betreiber ein Korro- tions. If the pump is not in operation for any period of
sionsschutz anzubringen. Empfehlunq: Pumpenin- time or stored the user has to preserve it with an anti
nenbereich - Saure und harzfreies 01. Pumpenaulien- rust lubricant. We recommend: The inside surface of
bereich - Castrol Rustilo DWX 33 oder nach Wahl des the pump - acid and resin free oil. Pump outside - Ca-
Betreibers, ortsbezogen. strol Rustilo DWX 33 or others, selected by the user
regarding the local conditions.
7.6 Mogliche Schaden 7.6 Preventation of Damage Caused by Leakage
Mogliche Schaden durch evt. auftretende Undichthei- The user must install an alarm device to prevent da-
ten an der Pumpe sind verbraucherseits durch Einbau mage caused by leakage.
von Warngeraten zu verhindern.
7.7 Kontrolle der Reservepumpe 7.7 Checking of Spare Pump
Die Kontrolle der Reservepumpe sollte wochentlich It is necessary to check the function of the spare
einmal durchgefuhrt werden. Die Kontrolle des Um- pump weekly. It is recommended to operate the lever
schalthebels auf Leichtgangigkeit ist empfehlenswert. weekly to guarantee that it doesn't become stuck.
Die Ruckschlagventile konnen durch Verschmutzun- Contamination of the non return valves can cause le-
gen undicht werden. Durch mehrmaliges Umschalten akage. Contamination can be removed by switching
der Pumpe 1 auf Pumpe 2, sowie gemeinsamen over from pump 1 to pump 2 or when both pumps are
Pumpenbetrieb konnen evt. Verschmutzungen gelost operating together for a short period of time. If either
werden. FiJhrt dies nicht zum Erfolg, ist Rucksprache of these solutions fail it is necessary to discuss it with
mit dem Werk erforderlich. the factory.

• 9 -
8. STORUNGEN / BEHEBUNG 8. FAILURES/REMEDIES

Betriebsstorung Mogliclie Ursache / Behebungsvorschiag Failures

Possible Reasons, Remedies
- Pumpe saugt nicht an 1,2,3,4,5,12 - pump does not prime
- Pumpe bringt nicht die voile Leistung 3,4,5,8,9,10,11,17,18 - pump does not produce full capacity
- Pumpe arbeitet laut 3.4,5,6,7,10,11,13,17 - pump is noisy
- Motor wird zu wami 9,10, 13 - motor heats up
- ungleichmalJIge Forderung 3,5,8,10,11,18 - irregular flow
- Wellendichtung ist undicht 7,10,14,15,16,18 - leaking shaft seal

Nr. BEHEBUNGSVORSCHLAG
1 PUMPE IST TROCKEN
Pumpe mit Medium fullen No. REMEDIES
2 DREHRICHTUNG DER PUMPE IST FALSCH 1 PUMP IS DRY
Drehrichtung entsprechend dem Pfeil einstellen fill pump with liquid
3 SAUGFILTER,-VENTILODER-LEITUNG 2 INCORRECT DIRECTION OF ROTATION
VERSTOPFT adjust rotation according to arrow on pump
Telle uberprufen und reinigen 3 CLOGGED SUCTION STRAINER. VALVE OR PIPE
4 SAUGLEITUNG ODER WELLENDICHTUNG check parts and clean
UNDICHT
Saugleitung (Verbindungsstellen, Ventile) bzw. 4 SUCTION PIPE LOOSE, SHAFT SEAL LEAKS
Wellendichtung uberprufen check suction pipe (connections, valves) resp. shaft
5 SAUGHOHE ZU GROSS seal
Ansaughohe (Niveauunterschied) verringern,
Leitungslange verringern, Leitungsquerschnitt vergro- 5 SUCTION HEAD TOO HIGH
Bern, Viskositat des Mediums verringem (en«armen) reduce static suction head or length of suction pipe,
groliere Saugfilter einbauen. increase suction pipe dia. or decrease viscosity of li-
6 ACHSFEHLER Pumpe - Kupplung - Motor quid (heat up), use larger suction filter.
Wellenende genauerausrichten, Kupplung
auswuchten 6 PUMP-COUPLING-MOTOR NOT CORRECTLY
7 SCHWINGUNGEN UND PULSATION IN DER ALIGNED
ANLAGE correct alignment, balance coupling
Aggregat elastisch lagern, Anschliisse mit 7 PIPEWORK "HAMMER"
Schlauchen ausfiihren support elastic, connect suction and discharge to sta-
8 UBERDRUCKVENTIL VERKLEMMT BZW. ZU tion with flexible hoses
NIEDRIG EINGESTELLT
Ventil uberprufen bzw. neu einstellen 8 SAFETY VALVE JAMS, OR IS SET TOO LOW
9 FALSCHE SPANNUNG ODER FREQUENZ check valve or change pressure setting
Drehzahl und Stromaufnahme des Motors kontrollie-
ren, Spannung und Frequenz mit Typenschild 9 INCORRECT VOLTAGE OR FREQUENCY
vergleichen check speed and current of motor and compare
10 MEDIUM D I C K F L O S S I G voltage and frequency with the data shown on the
Mediumtemperatur erhohen, kleinere Drehzahl name plate of the motor
11 L U F T E I N S C H L O S S E BZW. GASBILDUNG IM 10 LIQUID OF HIGH VISCOSITY
MEDIUM increase temperature of liquid, select lower speed
Lufteintrittsstellen beseitigen, Saughohe verringern 11 AIR OR GAS IN LIQUID
bzw. Zulaufdruck erhohen check if suction is airtight, reduce suction head, resp.
12 PUMPE E N T L U F T E T S I C H N I C H T increase inlet pressure
Druckleitung an der hochsten Stelle entluften
13 MOTORLAGER BESCHADIGT 12 PUMP DOES NOT VENT
Motor neu lagern vent at highest point of discharge pipe
14 WELLENDICHTUNG BESCHADIGT 13 MOTOR BEARING DAMAGED
Wellendichtung auswechseln replace motor bearing
15 ZULAUFDRUCK ZU GROSS ODER ZU KLEIN 14 SHAFT SEAL DAMAGED
Zulaufdruck aniagenseltig verringern, druckseitig replace shaft seal
Ruckschlagventil einbauen 15 SUCTION PRESSURE TOO HIGH OR TOO LOW
16 KALTSTART BEI F O R D E R U N G VON SCHWER-OL reduce suction pressure, Install a non-return valve on
Pumpenheizung einbauen discharge side
17 SICHERHEITSVENTIL FLATTERT 16 START WITH COLD LIQUID (Heavy fuel oil)
Offnunasdruck hbher einstellen. durch Drehen der install a oumo heatina device
9. ERSATZTEILE / DEMONTAGE 9. DISMANTLING OF SPARE PARTS
9.1 Assembling Instructions
9.1 Montagehinweise
Remove coupling with removal device and remove
Abziehen der Kupplung mit Hilfe einer Abziehvor key also.
richtung und PalJfeder entfemen.
Mark installation position of each part.
Einbaulage und Stellung der einzelnen Telle markie- Attention: Spindle set must be reassembled In the ori-
ren. Wichtia: Splndelsatz muB in urspriingiicher Stel- ginal position.
lung wieder eingebaut werden.
Check flat gaskets and o-rings whether they are da-
• Flachdichtung und O-Rlnge auf Schadhaftigkeit kon- maged. If necessary replace them.
trollieren und evt. ersetzten.
Clean and polish the running surface of the main
Laufflache der Hauptspindel Im Bereich der 0-Ringe spindle In the range of the o-rings and seal lips.
und Dichtlippen reinigen und glatten.
The coupling end should be covered with an installa-
Zum Schutz der O-Ringe und Dichtlippen rnuR der tion sleeve to protect the o-rings and the seal lips. For
Kupplungszapfen mit einer Montagehulse Oder ahnli- an easy installation it is useful to grease the surface
chem abgedeckt werden. Flachen zur Montageer- slightly.
leichterung leicht einfetten.
Install new radial shaft seals with spacer according to
Neue Radialdichtringe mit Stutzring entsprechend the section drawing and fill the space between with
dem Schnittbild einbauen und Zwisclienraume mit grease. We recommend Molybdenum Disulphlde gre-
Fett fijllen. Wir empfehlen eine Molybdan-Dlsulfid Pa- ase.
ste.
Mechanical Seal:
Gleitringdichtung: Zur Erieichterung der Demontage To dismantle the mechanical seal, remove the slide
Gleitring und Feder durch Drehen im Uhrzeigersinn ring and the spring from the main spindle by twisting it
von der Hauptspindel abziehen. Gegenring mit einer clockwise. Press counter ring with a plastic sleeve out
Kunststoffhulse Oder ahnlichem aus dem Gehause of the casing. When reassembling, make sure that the
drucken. Beim Einbau darauf achten, da(J der Gegen- counter ring is closed to the o-ring.
ring satt auf dem O-Ring liegt.
Be careful about the flat surfaces of the new mechani-
Die Dichtfiachen der neuen Gleitringdichtung aulierst cal seal. Clean it with petroleum ether and grease it
vorsichtig behandeln. Mit Waschbenzin reinigen und with a few drops of resin free oil. When Installing try to
mit einigen Tropfen harzfrelem Schmlerol versehen. avoid touching the part and try to avoid getting It dirty
Beim Zusammenbau moglichst nicht beruhren und je- also. Slide on the spring by turning it clockwise.
den Schmutz fernhalten. Aufschleben der Feder
durch Drehen im Uhrzeigersinn.
When reassembling make sure also, that the overflow
Beim Zusammenbau darauf achten, dali die Uberlauf- bypasses from casing and seal correspond.
bohrungen vom Gehause und der DIchtung iiberein-
stimmen.
After Installation it is necessary to check if the pump
Nach der Montage durch handlsches Drehen Leicht- rotates easy when turning clockwise by hand.
ganglgkelt prufen.
9.2. Explosionszeichnungen >- Bild 20 9.2 Cut View of Pump >-scheme 20

Einbaupumpe FE 5
Insert Pump FE 5
Einbaupumpe
insert pump
NE5-13
NEG5-13

Einbaupumpe
insert pump
NE15-57
NEG15-57
NEGA15-57
Einbaupumpe
insert pump
CLDR 15 bis/to CLDR 42
CLDG 15 bis/to CLDG 42

- ^ ^ ^ ^

AuKenlagerung
outside bearing
1)CLDGA15-26
2) CLDGA 32 - 42
Einbaupumpe
insert pump
CLDR55-118
CLDG55-118

•fS^

AuKenlagerung
outside bearing
CLDGA55-118
Nachtraglicher Umbau der Stationen DCL und DCS auf Subsequent rebuilding of the station DCL and DCS with
AuKenlagerung outside bearing

1. Motoren demontieren 1. dismantle motor

2. Muttern (HVM 09) heraus- 2. remove hexagon nut (HVM 09)
drehen
3. remove old lantern
3. bestehende Lateme ab-
4. remove pump
nehmen
5. remove bolt screw
4. Pumpe herausnehmen
6. cut again thread of bolt screws
5. Stiftschrauben herausdrehen
and clean it with nitro thinner
6. Gewinde fiir Stiftschrauben
nachschneiden und mit
7. glue the long bolt screws in
Nitroverdunnung reinigen
place e.g. with Loctite 270
7. lange Stiftschrauben mit z. B.
8. clean the seal surface and re
Loctlte 270 einkleben
move dents
8. Dichtflache saubem und etwai
9. insert sealing (HPD...)
ge Schlage legalisieren
10. install new lantern
9. Dichtung (HPD...) einlegen
11. install new pump
10. neue Laterne aufsetzen
12. tighten hexagon nut (HVM 09)
11. neue Pumpe einschieben
crosswise
12. IVIuttern (HVM 09) kreuzweise
13. install motor
anziehen
13. Motor montieren Necessary new parts:
coupling
Folgende Neuteile sind hierzu insert pump with o-ring
notwendig: lantern
Kupplung
CS gasket (HPD)
Einschubpumpe mit 0-Ring
Laterne
CS long stud screws

Dichtung (HPD)
lange Stiftschrauben
9. ERSATZTEILE-DEMONTAGE 9. DISMANTLING OF SPARE PARTS
9.3 Schnittbild und Teileliste 9.3 Section Drawing with Part List
Station DL2/150-240

915.1

Station DL2/320-1300

908.2 739.2
730.2
704.1
739.1
870.1 915.2
885
915.3
730.1
908.1 704.2
166 739.3
300
859

if
001 Einbaupumpe 735,1 Kupferdichtung 001 insert pump 735,1 Cu seal ring
040 HiJIse 739,1 O-Ring 040 spacer 739,1 0-ring
052 Kupplung 739,2 O-Ring 052 coupling 739,2 0-ring
055,1 Dichtring 739,3 O-Ring 055,1 seal ring
060 Scheibe 060 disc 739,3 0-ring
119 DruckgehSuse 751,1 Druckfeder 119 casing 751,1 spnng
137 Ventilgehause 809,1 Kugel 137 valve casing 809,1 ball
155,1 Rohr 859 SpannhUise 155,1 pipe 859 clamping sleeve
166 Verstellschraube 870,1 Wellensicherungsring 166 adjusting screw 870,1 circlip
180 Laterne 885 Gewindestift 180 lantern 885 set screw
222,1 Dichtung 894,1 Sechskantmutter 222,1 gasket 894,1 hexagon nut
222,2 Dichtung 894,2 Sechskantmutter 222,2 gasket
241 Olwanne 241 oil pan 894,2 hexagon nut
300 Ventilgriff 900,1 Sechskantschraube 300 lever 900,1 hexagon screw
304 SteuerkOken 900,2 Sectiskantsctiraube 304 control lever spindle 900,2 hexagon screw
501 Druckfeder 900,3 Sechskantschraube 501 spnng 900,3 hexagon screw
529 Motor 900,4 Sechskantschraube 529 motor 900,4 hexagon screw
606,1 absperrbares Manometer 901 Stiftschraube 606,1 lockable manometer 901 locking screw
606,2 absperrbares Manometer 908,1 Venschiullschraube 606,2 lockable manometer 908,1 screw plug
704,1 Flansch 908,2 704,1 flange
704,2 Flansch VerschlulSschraube 908,2 screw plug
704,2 flange
730,1 Flachdichtung 915,1 Zyiinderschraube 730,1 gasket 915,1 socket screw
730,2 Flachdichtung 915,2 Zyiinderschraube 730,2 gasket 915,2 socket screw
730,3 Flachdichtung 915,3 Zyiinderschraube 730,3 gasket 915,3 socket screw
•empfohlene Ersatzteile * recommended spare parts

17-
 001 Einbaupumpe •730,1 Rachdk:htung 001 insert pump 730,1 flat gasket
018 Siebkorb •735,1 Kupferdichtung •018 filter basket 735,1 Cu seal ring
052 Kupplung •739,1 O-Ring 052 coupling 739,1 0-ring
055,1 Dichtring 739,2 O-Ring •055,1 gasket 739,2 0-ring
074 RIterdeckel 893 Hutmutler 074 filter cover 893 cap nut
116,1 Aggregatgehause links 894,1 Sechskantmutter 116,1 left casing 894,1 hexagon nut
116,2 AggregatgehSuse rechts 894,2 Sechskantmutter 116,2 right casing 894,2 hexagon nut
155,1 Rohr 900,1 Sechskantschraube 155,1 pipe 900,1 hexagon screw
160 Winkel 900,2 Sechskantschraube 160 angle 900,2 hexagon screw
180 Flanschlateme 900,3 Sechskantschraube 180 flange lantern 900,3 hexagon screw
222 Flachdk:htung 901,1 Stiftschraube •222 flat gasket 901,1 locking screw
241 Olwanne 901,2 Stiftschraube 241 oil pan 901,2 locking screw
423 Entluftungsventil 901,3 Stiftschraube 423 vent valve 901,3 locking screw
501 Kegel-Druckfeder 904,1 Scheibe 501 conical spring 904,1 disc
529 Motor 904,2 Scheibe 529 motor 904,2 disc
606,1 absperrbares 908,1 VerschluBschraube •606,1 lockable 908,1 screw plug
Vakuummeter vacuummeter

' empfohlene Ersatzteile • recommended spare parts

Steuerblock *Pos. 675 Control device *pos. 675

•055,1 Dichtring •055,1 seal ring
137 Ventilgehause 137 valve casing
165,1 Verschlu8schraube 165,1 screw plug
165,2 VerschluBschraube 165,2 screw plug
165,3 VerschluBschraube 165,3 screw plug
166 Verstellschraube 166 adjusting screw
298 Ventileinsatz 298 valve insert
299 Ventileinsatz 299 valve insert
300 Ventilgriff 300 lever
•304,1 Ventilkegel •304,1 valve cone
•304,2 Ventilkegel •304,2 valve cone
312 Verstellspindel 312 valve spindle
407 Steuerkugel 407 valve ball
•456 Formdichtung •456 form gasket
"606,2 absperrbares Manometer •606,2 lockable manometer
704 Flansch 704 flange
730,1 Flachdichtung 730,1 flat gasket
730,2 Flachdichtung 730,2 flat gasket
•739,3 O-Ring • 739,3 O-ring
•739,4 O-Ring •739,4 O-ring
•739,5 O-Ring •739,5 O-ring
739,8 O-Ring 739,8 O-ring
•751,1 Druckfeder •751,1 spring
•751,2 Druckfeder •751,2 spring
•751,3 Druckfeder •751,3 spring
•765 Tellerfeder •765 plate spring
•809,1 Kugel •809,1 ball
868 StiJtzring 868 supporting plate
•869,1 Wellensicherungsring •869,1 circllp
886 Gewlndestift 886 set screw
915,1 Zylinderschraube 915,1 socket screw
915,4 Zylinderschraube 915,4 socket screw

-18-
station DL3, DIA, DS3, DS4

894.2

001 Einbaupumpe •735,1 Kupferdkshtung 001 insert pump •735,1 Cu seal ring
018 Siebkorb •739,1 0-Ring •018 filter gasket •739,1 O-ring
052 Kupplung 739,2 0-Ring 052 coupling 739,2 O-ring
055,1 Dichtring 893 Hutmutter •055,1 seal ring 893 cap nut
074 Filterdeckel 894,1 Sechskantmutter 074 filter cover 894,1 hexagon nut
116,1 AggregatgehSuse links 894,2 Sechskantmutter 116,1 left casing 894,2 hexagon nut
116,2 AggregatgehSuse rechts 900,1 Sechskantschraube 116,2 right casing 900,1 hexagon screw
155,1 Rohr 900,2 Sechskantschraube 155,1 pipe 900,2 hexagon screw
160 Winkel 900,3 Sechskantschraube 160 angle 900,3 hexagon screw
180 Flanschlateme 901,1 Stiftschraube 180 flange lantern 901,1 locking screw
241 Olwanne 901,2 Stiftschraube 241 oil pan 901,2 kicking screw
423 Errtiaftungsventil 901,3 Stiftschraube 423 vent valve 901,3 locking screw
501 Kegel-Druckfeder 904,1 Scheibe 501 conical spring 904,1 disc
529 Motor 904,2 Scheibe 529 motor 904,2 disc
606,1 absperrbares 908,1 Verschlulischraube •606,1 lockable 908,1 screw plug
Vakuummeter vacuummeter
730,1 Flachdichtung •730,1 flat gasket

Steuer block *Pos. 675 Control device *pos. 675

•055,1 Dichtring 055,1 seal ring
•055,2 Dichtring 055,2 seal ring
111,1 VorschweiRflansch 111,1 flange
111,2 VorschweiRflansch 111,2 flange
137 Ventilgehause 137 valve casing
166 Verstellschraube 166 adjusting screw
•222 Flachdichtung 222 flat gasket
298 Ventileinsatz 298 vaive insert
299 Ventiieinsatz 299 vaive insert
300 Ventilgriff 300 iever
•304,1 Ventilkegel 304,1 valve cone
•304,2 Ventilkegei 304,2 valve cone
312 Verstellspindel 312 valve spindle
407 Steuerkugel 407 valve ball
•456 Fonndichtung 456 form gasket
•606,2 abspenbares Manometer 606,2 lockable manometer
729,1 Flachdichtung 729,1 flat gasket
729,2 Fiachdichtung 729,2 flat gasket
•739,3 O-RIng 739,3 O-ring
•739,4 O-RIng 739,4 O-ring
•739,5 0-Ring 739,5 O-ring
•751,1 Druckfeder 751,1 spring
•751,2 Druckfeder 751,2 spring
•751,3 Druckfeder 751,3 spring
•765 Teilerfeder 765 plate spring
•809,1 Kugei 809,1 ball
868 Stiitzring 868 supporting plate
•869,1 Wellensicherungring 869,1 circlip
886 Gewindestift 886 set screw
900,4 Sechskantschraube 900,4 hexagon screw
908,2 Verschlulischraube 908,2 screw plug

* empfohiene * recommended
Ersatzteiie spare parts

-19-
station DL7, DS7, DCL7JDCS7

870.2
Detail: Z

•Pos. 304.2 •Pos.611

529 870.1

884.2

606.2 164.1 739.7

809.1
751.2
900.2 304.3 870.3

301
751.1

306 137
854

001 Einbaupumpe •730,2 Flachdichtung 001 Insert pump •730,2 flat gasket
018 Siebkorb * 730,3 Flachdichtung •018 filter basket •730,3 flat gasket
052 Kupplung •730,4 Flachdichtung 052 coupling •730,4 flat gasket
057 Gewindering •739,1 O-RIng 057 ring nut •739,1 0-ring
066 Oichtscheibe •739,2 O-RIng 066 seal disc •739,2 0-ring
074 Filterdeckel •739,3 O-Ring 074 filter cover •739,3 0-ring
111,1 VorschweiRflansch •739,4 O-Ring 111,1 flange •739,4 0-ring
111,2 Vorschweiliflansch •739,5 O-Ring 111,2 flange •739,5 O-ring
116 Aggregatgehause •739,6 O-Ring 116 casing •739,6 O-ring
121 FiltergehSuse •739,7 O-Ring 121 filter casing •739,7 O-ring
137 Ventilgehause •751,1 Druckfeder 137 valve casing •751,1 spring
164,1 Verstellschraube •751,2 Dnjckfeder 164,1 adjusting screw •751,2 spring
164,2 Verstellschraube •809,1 Kugel 164,2 adjusting screw •809,1 bail
180 Flanschlateme •870,1 Wellensicherungsring 180 flange lantern •870,1 circllp
222 Flachdichtung •870,2 Wellensicherungsring •222 flat gasket •870,2 circlip
241 Olwanne •870,3 Wellensichenjngsring 241 oil pan •870,3 circlip
300 Aufsteckringschlijssel 854 Splint 300 lever 854 split pin
301 Tellerfeder 859 Spannhulse 301 spring plate 859 clamping sleeve
304,1 Steuerkuken 884,1 Gewlndestift 304,1 control lever spindle 884,1 set screw
Saug 884,2 Gewindestift suction set screw
304,2 Steuerkuken 893 Hutm utter 304,2 control lever spindle 884,2 cap nut
Druck 894,1 Sechskantmutter pressure 893 hexagon nut
304,3 Ventilkegel 894,2 Sechskantmutter •304,3 valve cone 894,1 hexagon nut
306 Verstellmutter 894,3 Sechskantmutter •306 valve nut 894,2 hexagon nut
312 Verstellspindel 900,1 Sechskantschraube 312 valve spindle 894,3 hexagon screw
423 Entluftungsventil 900,2 Sechskantschraube 423 vent valve 900,1 hexagon screw
501,1 Kegel-Druckfeder 900,3 Sechskantschraube 501,1 cone spring 900,2 hexagon screw
501,2 Druckfeder 901,1 Stiftschraube •501,2 spring 900,3 locking screw
529 Motor 901,2 Stiftschraube 529 motor 901,1 locking screw
606,1 absperrbares 908,1 VerschiuBschraube 606,1 lockable 901,2 screw plug
Vakuummeter 908,2 Verschiullschraube vacuummeter 908,1 screw plug
606,2 absperrbares 915,1 Zylinderschraube 606,2 lockable 908,2 socket screw
Manometer 915,2 Zylinderschraube manometer 915,1 socket screw
611 RiJckschlagventil •611 non return valve 915,2
717 Thermometer •717 thermometer
730,1 Flachdichtung * empfohlene •730,1 flat gasket • recommended
Ersatzteile spare parts
Einbaupumpe Insert pump

Type FE 5 Type NE 5-13 Type NEG 5-13

739.3

91S.2

Type NE 15-57 Type NEG 15-57 Type NEGA15-57

062

870

739.2

039 DIstanzhulse •669 Spindelsatz 039 distance sleeve 669 spindle set
042 Ausgleichshulse •735 Kupferdichtung •042 distance sleeve 735 Cu seal ring
052 Kupplung •739,1 0-Ring 052 coupling 739,1 0-ring
056 Distanzring * 739,2 0-Ring 056 spacer 739,2 0-ring
058 Aufnahmering •739,3 O-Ring 058 mounting ring 739,3 0-ring
059 Aufnahmering •745 Radialdichtring 059 mounting ring 745 radial shaft seal
062 Distanzscheibe 751 Daickfeder 062 spacer 751 spring
063 Stiitzring 809 Kugel 063 support plate 809 ball
070 Abschlulideckel •817 Kugellager 070 end cover 817 ball bearing
074 Flanschdeckel 861 Zylinderkerbstift 074 flange cover 861 pin
080 Lagerdeckel 866 PalJfeder 080 bearing cover 866 key
127 Lagergehause •869 Wellensicherungsring 127 bearing housing 869 circlip
131 Gehause •870 Wellensicherungsring •131 casing 870 cirolip
155 Rohr 879 Zylinderstift 155 pipe 879 straight pin
417 Zylindersieb 915,1 Zylinderschraube •417 strainer 915,1 socket screws
457 Gleitrlngdichtung 915,2 Zylinderschraube •457 mechanical seal 915,2 socket screw

"empfohlene Ersatzleile • recommended spare parts

Einbaupumpe Insert pump

CLDR15-42 CLDG 15-20 CLDR 55-118 CLDG 26-118

CLDGA 15-26 CLDGA 32-118

074.1 761 809

134 464 074.2 661.1

041 Distanzhiilse 457 Gleitringdichtung 041 distance sleeve 457 mechanical seal
*042 Ausgleichszylinder 464 Nilos-RIng * 042 balance sleeve 464 Nilos-ring
056 Distanzring ab Gr.: CL55 661 Splndelsatz 056 spacer from size; CL55 661 spindle set
057 Gewindering 661,1 Splndelsatz 057 ring nut 661,1 spindle set
062,1 Distanzscheibe * 739,1 0-Rlng 062,1 spacer •739,1 0-ring
063 Stutzring * 739,2 O-RIng 063 support plate •739,2 0-ring
074 Flanschdeckel * 745 Radialdlchtung 074 flange cover •745 radial shaft seal
074.1 Flanschdeckel 751 Druckfeder 074.1 flange cover 751 spring
074.2 Flanschdeckel 809 Kugel 074.2 flange cover 809 ball
127 Lagergehause *817 Kugellager 127 bearing housing *817 ballbearing
*131 Gehause 866 PaRfeder *131 casing 866 key
134 Dichtungsgehause 868 Stutzring 134 sealing housing 868 supporting plate
•222,1 DIchtung *872 Runddrahtsprengring •222,1 gasket • 872 cirdlp
•222,2 DIchtung 884,1 Gewindestlft •222,2 gasket 884,1 set screw
412 Schmiernippel 915,1 Zylinderschraube 412 lubricating nipple 915.1 socket screw
454 Dichtkantring 915,2 Zyllnderschraube 454 edge seal 915.2 socket screw
915,3 Zyllnderschraube 915.3 socket screw
1037 Lagerbiichsenset 1037 bearing shell set

•empfohlene Ersatztelle
* recommended spare parts

-22-
 POS NO. 4.09
DATA
TITLE SHEET MB-PS-01
JCAHGRIM
NO.
PRESSURE SWITCH
KANGRIM (TPE 904) PAGE 1 OF 1

'Dimensions

106 lb 6 40

91

i^^- *

oo
O)
to \\- N P --*i 2!

4- . 1"^
—I
PG 13.f
X

1X
23

'Single stage Controller 'Microswitch ratings

^ Robust a l u m i n i u m die cast housing, epoxy Switch type No. 10

coated AC 250V~10(2)A
DC 2 2 0 V - 0 . 2 ( 0 . 0 1 )A 110V-0.4(0.02)A
^ A c c u r a c y ±2% of full scale
24V-2.0(1.0)A 12V-15(7)A
• Repeatability < ±0.5% of full scale
Switch type No. 1 1 , 23 and 26
^ Protection IP 65 AC 380V~15(3)A
^ Any mounting position possible DC 2 2 0 V - 0 . 2 ( 0 . 0 2 ) A 110V-0.4(0.03)A
24V-6(2)A 12V-15(8)A
^ Electrical connection to three point terminal
Switch type No. 06
inside housing AC 380V~20(4)A
^ Calibrated f o r increase pressure(decreasing DC 220V-0.6(0.4)A 110V-0.7(0.5)A
20V-20(15)A 12V-20(15)A
pressure on request)
Switch type No. 21
AC/DC 24V 0.01(0.01)A
AC/DC 12V 1.0(1.0)A
'Specifications AC/DC 5V 2.0(2.0)A

Pressure rang Max. working Max. short time Switch type Switching Ambient Media
in bar pressure over pressure # number differential temp. temp.
in bar in bar in bar
-0 9 1 5 10 ca. 0.03
0.2 .. 1.6 10 13 11,21,23 CO. 0.06
26 ca. 0.08
0.2 .. 2.5 06 ca. 0.35
0 ... 4 10 ca. 0.08
11,21,23 ca. 0.2
12 26 26 ca. 0.25
0 ... 6
06 CO. 1.2 CJ o
10 ca. 0.2 o o
1 ... 10 11,21,23 ca. 0.4 r^
24 36 26 ca. 0.5 +
"t^-1 ... 16 06 ca. 2.4 d d
CSI •'»•
10 ca. 0.5
2 ... 25 11,21,23 CO. 1.0
4 ... 40 40 75 26 ca. 1.2
06 ca. 6.0
6 ... 60 10 ca. 1.5
11,21,23 ca. 3.0
100 160 26 ca. 4.0
10 ... 100 06 ca. 18
# without damage, but may result in decalibration !
 POS NO. 4.09.01/11.1

T I T L E DATA
SHEET BNR-NV-Ol
NO. :

NEEDLE VALVE CODE 2000015

KANQRIM PAGE 1 OF 1

Pressure Gauge

Needle Valve with Test Flange

Dimensions Resistance Seat Approx.

SELECT
SIZE d d4 F G H L R Z kg
r^ 10 3/8" 3/8" 3 15 75 54 55 180 3.5 0.41
15 1/2" 1/2" 5 20 75 64 55 800 3.5 0.52
 POS NO. 5.02.1
DATA
T I T L E SHEET BNR-SN-01
NO.
STRAINER
KANGRIM ("Y" TYPE FLANGED) PAGE 1 OF 1

fl M
\^*?-\>^/
\ x't^TLL
• (/(®—A FST-F 15A~50A
SST 15A~40A

|XH Si MATERIALS FUUIO SYMBOL

AIR
—.,____^ MODEL Steam
NO. FST-F SST
NAME " ~-^_ Water
1 Body CAST IRON CAST CARBON STEEL Noncortosive FKid
2 Cap • CAST IRON CAST CARBON STEEL
3 Screen STAINLESS STEEL STAINLESS STEEL
4 Gasket ASBESTOS ASBESTOS
B Plug MALLEABLE IRON CARBON STEEL
6 Bolt CARBON STEEL CARBON STEEL
1. W ORKING PRESSURE Max lOkgf/cnr Max 20kg(/air
2. W OflKING TEMP Max 2 2 0 t Max 300X:
3. W ORKING FLUID A. S. W. NF A. S. W. NF
4. C()NN£CWON lOK FF Flanqe 20K RF Flange

1*1 DIMENSIONS
Uivi:ia
\SIZE
MODEL 1&A 20A 25A 32A 40A 50A 65A 8aA 100A 125 A 150 A 2O0A 260A 300A 350A
PART\
L 125 140 165 178 195 220 262 290 342 400 475 570 650 800 900
H 65 75 85 96 110 126 180 210 230 300 320 420 470 560 600
FST-F ds 21 26 31 38 46 59 75 89 109 141 167 219 264 324 365
Cs 31 46.5 54,5 63 65 87.5 115 138 158 258 272 351 365 425 465
.'i, - - - y.' X' K' X' J^" r 1" 1" IK 2" 2" 2"

L 145 ibU 170 195 212 243 256 295 340 410 480 580 660 800 900
H 75 85 105 115 125 160 155 190 215 290 300 400 _440 545 600
SST ds 24 31 39 44 44 52 75 89 109 141 161 219 264 324 359
(s 53 67 80 95 102 134 115 133 158 258 265 351 355 415 455
d, - - - - - M3axi.5 M24X2 M24X2 M30X2 M30X2 M30X2 M30X2 M3«X2 M36X2 M36X2
 POS NO. 5.02

T I T L E DATA
SHEET BNR-TC-02
NO. :
T e m p e r a t u r e Control Valve CODE 2004735
KANGRIM with Sensor PAGE 1 OF 3

Specifications

Flonge Opening Kvs—value Rated Weight

Type connection ON travel
(mm) (mm) (m3/h) (mm) (kg)
15/4H1F 15 4 0.20 6 3.3
15/6H1F 15 6 0.45 6 3.3
15/9H1F 15 9 0.95 6 3.4
15/12H1F 15 12 1.7 6 3.4
15H1F 15 15 2.75 6 3.4
20H1F 20 20 5 6.5 4.6
25H1F 25 25 7.5 7 6.1
32H1F 32 32 12.5 8 9.0
40H1F 40 40 20 9 10.8
20 20 5 6 5 5.0

Dimensions Dimension sketch

L HI H2 b D k d
Type (mm) (mm) ( m m dio.)
(mm) (mm) (mm) (mm) dia. dio. (number)
r
15/4H1F 130 80 60 16 95 65 14 X (4)
l]A nto
15/6H1F 130 80 60 16 95 65 14 X (4) 1 ajD
4J
-L 1 - X

4.'4
15/9H1F 130 80 60 16 95 65 14 X (4)
15/12H1F 130 80 60 16 95 65 14 X (4)
o JC
15H1F 130 80 60 16 95 65 14 X (4)
20H1F 150 85 65 18 105 75 14 X (4) tN
- -o
25H1F 160 95 70 18 115 85 14 X (4) -
-1
32H1F ISO 105 75 18 140 100 18 X (4) H—'
40H1F 200
150
110
85
85
70 18
18 150
105
110
75
18 X (4)

*^ X \^^}
1 L

Temperature limits

Temperature of valve medium :

30X 170"C 250X 350-C )

JP
IDI==0=

ij
Mounted upwards or downwards
Without cooling unit
uMounted only downwards
y
With cooling unit K S - 4 ') | With cooling unit KS - 5 ')

Temperature of sensor
-30"C 1 40X 160'C 280X )

Glycerin filled
I l)See accessories on the
back of this leaflet.
Poraffine filled
Sensor of copper 2) 2)Max.l60X -incl.40"C

Sensor of stainless steel over-temperoture.

 POS NO. 5.02

T I T L E DATA
SHEET BNR-TC-02
NO. :
T e m p e r a t u r e Control Valve CODE 2004735
KANQRIM with Sensor PAGE 2 OF 3

Thermostat types Copillory tubes

Thermostat tvoes Choice of capillary tube, length and

Technical doto V\ materiel, is determined according
V.2.05 V.4.03 \.4.05 V.4.10 V.8.09 V.8.18 to the table below, independont of
Mox. closing force (N) 200 400 400 400 800 800 the choice of the thermostat type.

Setting ronge for 0-60 0-16&« ^ 0 - 1 2 0 0-60 0-120 0-60 Length Copper PVC-coate<J Stainless
(m) copper steel
stondord thermostats > CC) 30-90 40-160 30-90 40-160 30-90
3.0 0 O O
60-120 60-120 60-120 4.5 O
6.0 O O O
Neutral zone CO 2.5 2.0 2.0 2.0 1.5 1.5
7.5 O
For volves with •oted 10 12 12 31 9.0 O O O
(mm) 21 21
travel up to : 10.5 O
2) 12.0 O O O
Trovel in nnm/'C - 3 0 ~ 160X 0.5 0.3 0.5 1.0 0.9 1.8 O
13.5
(amplification) 3! 15.0 O O O
in range: 140~ 280X 0.7 0.33 0.7 1.33 1.2 2.4 16.5 O
l)Setting ronges from - 3 0 t 0 280*C an reques t. -Exces s temp, sofety range:40"C. 18.0 0 0 0
19.5
2)Glycerine 3)pa 'affine 21.0 0 O

Sensor types

1. Sensors with BSP 2. Sensors with oir 3. Sensors with steel 4. Sensors without
threoded connection duct flonge flange connection

A A

t\
I
¥
11 11 ' ' 11 11

Time coefficient for sensors

The time coefficients for rod and spirol sensor

are measured in woter flowing at o velocity of
I m / s . , for air duct spiral sensors in air at a
velocity of 4 m / s .

In the tovle the time log To ond time coefficient T sec

T are indicated in sec.

Copper Acid-resistant stoinless steel Copper with sensor pocket

Spiral sensor Liquid in

Type Rod sensor Spiral sensor Rod sensor Spirol sensor Rod sensor
for air duct sensor pocket

To To
V.2.05 10 85 20 360 10 85 20 20 210 Hot oil

V.4.03 120 20 360 90 20 20 250 Hot oil

• V.4.05 130 20 360 100 20 20 200 Hot oil
V.4.10 165 20 360 150 25 25 300 Hot oil
V.8.09 165 30 600 220 30 25 450 Hot oil
V.8.18 280 10 65
 POS NO. 5.02

T I T L E DATA
SHEET BNR-TC-02
NO. :
T e m p e r a t u r e Control Valve CODE 2004735
KANGRIM with Sensor PAGE 3 OF 3

Dimensions and weights

The m e o s u r e m e n t s G and H ore • . 6 Thermostat/ Sensor m a t e r i e l

Vv
are nnm. Weight : net
Type V . 2 . 0 5 Type V . 4 . 0 3 Type V . 4 . 0 5 Type JA.^O Type V . 8 . 0 9 Type V,8.18
C = c o p p e r sensor
S = o c i d - -resistant stoinless steel sensor. C S C S C S C S C S C S

Adjusting cylinde
TTJ
r p
A 305 305 385 385 385 385 385 385 560 560 560

E
< itt B 405 405 525 525 525 525 525 525 740 740 740

E
CQ
i
Weights
see below 773rr
1
Sensor with BSP thre odec C 210 190 210 190 390 380 490 515 710 745 800
connection D 235 170 235 170 235 250 325 325 425 435 810
_ . • 50 E F E 22 22 22 22 22 22 28 25 28 25 34
h —1

A -4 r F 49 49 49 49 49 49 49 49 49 49 49

1 G 3/4- 3/4- 1" 1" 1" r r 1" 2" 2" 2"

1 1
1 H 2" 2" 2" 2" 2" 2" 2" 2" 2" 2" 2'
o o ;

1 ir G •• H
i ET"
ffi fi i
Weig
1
inclusiv
e
1
of G - c o r nection kg 1.8 1.8 2.4 2.4 2.6 2.6 3.3 3.3 6.3 6.3 7.3
Weig ht
ht Inclusiv e of H - c o r inection kg 2.3 2.3 2.9 2.9 3.1 3.1 3.8 3.8 6.3 6.3 7.3

Dimensionol sketch Accessories

1 rtl n Manual adjusting device Cooling unit K S - 4 Cooling unit K S - 5

-1

1 /
"i—Tl" ^M i B i i i i i i i a i i l ///
•iiiiliiiilliiAf/',
U, J
mm
c <
1^F1 G I
With stuffing box. For
tightening ond monuol
operoion of the valves,
Cooling unit protecting
the stuffing box of the
Cooling unit with built-in
bellows gland.
E
!1 nt h
T1 when an actuator has
motor/thermostat.
To be opplied at volve
Replaces stuffing box of
thermostat.
not been fitted, eg. during temperatures between Must be applied by valve
i ^^ periods of construction. 170'C and 250X temperatures between 250"C
and 350'C and in cose of
hot oil systems.

For R
Dimensions i T millimeters
thermostat product
S ao L h S BSP
/— R type number

// X V2.05 3290069 1"

rv\ 215
/ . II V4.03 3290182
25
9 36
1 ,/4"
f 1 1

II o — V4.05 3290077 25 390 10 46 1 '/••"

^ II V4.10 3290085 34 512 10 46 1 1/4"

i 1 II V8.09 3290093 34 740 12 80 21/2"

V8.18 3290204 38 805 12 80 21/2"

h L
1 t/V
V4.03 3290239 25 195 29 50
conicol
 PERFORMANCE

HULL NO. TYPE CUSTOMER DATE

0311-6,0442-4 KRSHM01 HYUNDAI MlPO DOCKYARD CP.,LTD 05-10-24

SHELL SIDE TUBE SIDE

Capacity 49.098 kcal/hr

Fluid STEAM H.F.O.

Inlet Temperature 169.6 84.46 1C

Outlet Temperature 169.6 150 X)

Flow Rate 100 kg/hr 1.95 m^/hr

Operating Pressure 7 15 kg/cm^

Design Pressure 7.7 16.5 kg/cm^

Test Pressure 11.6 24.8 kg/cm^

Pressure Drop 0.4 0.2 kg/cm^

Velocity 25 0.4 m/sec

Inlet Nozzle Size 10K-25A 20K-40A

Outlet Nozzle Size 10K-15A 20K-40A

Number of Pass 1 2 pass

LMTD(Tm) 44.6 °C

Heat Transfer Coefficient 114.46 kcal/m^hrTC

^2
Surface(Calculated) 9.62
m
Foul ing Factor 15 %

Surface Margin 14 %

Surface(Actual) 11
 1 S T O H r

ocseiii»iiON
TUBE REmVia SPUE
1200

NOTC
1. INSUUTION METHOD : ROCK WOOL SOt k HEX STEEL n R E NET
+ CAL'V TIN PLATE 0 . 5 t
2. INSTALLED LEAD PIPE AT AIR VENT, RELIEF VALVE AND DRAIN VALVE
EXTEND TO LEG SIDE

CONNECTION FLANGE
PART NAME tfTY REMARK
AK VENT VALVE 20K-eA, [Link] TUBE
DRAIN VALVE 20K-6A. [Link] TUBE
THERMOMETER 0~200'C. "L" TYPE. 120L
REUEF VALVE SETHNG PRESS. 16.5 KC/CM^
NAME PUTE BRASS
PRESSURE GAUGE WTTH ROOT VALVE ( 6 0 ' B '

CONNECnON FLANGE
FLANGE SIZE
NO. PART NAME BORE SCH.
RATE O.D. £ca BOLT
H.F.O. IN/OUTLET FLANGE 40A 180 20K 140 105 4-M16
STEAM INLET FLANGE 25A t60 lOK 129 90 4-M16
DRAIN OUTLET FLANGE 15A 1 4 0 . lOK 95 70 4-M12

UFHNG LUG SS400

PASS PARTITION SS400

PRESS. GAUGE BOSS SS400 PF3/6'

GASKET ASa FREE 3.0t
HEXBOLT k NUT S45C 32SET MMxllOL
AIR VENT BOSS SS400 PF3/6'
»331 DRAIN BOSS SS40O PF3/6"
REUEF VALVE BOSS SS400 PTl/2'
OUTSIDE FINAL COATING HEAT RESISTANCE SILVER
THERMOMETER BOSS SS40O Pn/2'
INSIDE COATING OF COVER RUST PREVENTIVE OIL
SUPPORT SADDLE SS40O 121
NAME PLATE BRACKET SS40O
DESIGN TEST CONDITION
SURFACE AREA 11.0 U^
FLUID
SHELL SIDE
STEAK
TUBE SIDE
F.O.
TUBE
OUTLET CONWECnON
A179
:K
STPG370. SS400
X W9.05 2.11 t

INLET CONNECTION STPG370. SS400

FLUID flUANTmr 100 KG/Hr 1.95 iP/Hr
REVERSING COVER STPG370
INLET TEMPERATURE 169.6 •c 64.46 •C
ISO CHANNEL COVER STPG370
OUTLET TEMPERATURE 169.6 •c r CHANNEL FLANGE saoc or 3r440 40r
NO. OF PASS 1 2
VELOCITY 0.02 M/S 0.04 M/S S H E a FLANGE S20C or SF440 42T
PRESSURE DROP 0.03 KG/CM* 0.12 KC/CM^ SHELL STPG370 350A 140
OPERATING PRESSURE 7.0 KG/CM2 15 KC/CM^
TUBE PITCH DESIGN PRESSURE 7.7 KG/CMZ 16.5 KC/CM2 0J1I~».0442~«
HYDHO'C TEST PRESSURE 11.6 KG/CMZ 24.8 KG/CMZ
CLEANUNESS FACTOR 85%
JOINT EFFICIENCY 60X F.O STEAM HEATER N/ fii\i—1
TUBE ARRANGEMENT WEIGHT EMPTY FULL
wM MO.
(KG) 550 650 PBCQ4MP0311 - 6 . 0 * * 2 ' - 4

KRSHMOI-01
< ^ ^ I C A N 6 R I M INDUSTRIES CO.. LID.
1 e I •—
 P L A N H I S T O R Y

REV. DATE D E S C R I P T I O N DWN CHK APP'O

A "01.11.20 FOR MANUFACTURE

DIMENSION UNIT : mm FLANGE SF 440A

FUNGE j i s e 2210 W'T Q'TY NAME PUTE SUS 2 0 4

RATING SIZE d L H2 H
D C 9 T f N-H (kg) (Set) PLUG SUS 3 0 4

15A 15 110 30 59 89 80 60 - 9 - 4-12 SCREEN SUS 3 0 4

5K FF 20A 20 120 30 59 89 85 65 - 10 - 4-12 INSULATION CAP SUS 3 0 4

DISC SUS 4 2 0 J 2
25A 25 125 35 64 99 95 75 - 10 - 4-12
CAP SCS 13
15A 15 120 30 59 89 95 70 - 14 - 4-15
BODY SCS 2
10K.16K,20K FF 20A 20 130 30 59 89 100 75 - 16 - 4-15 WT.
OESCMIIPTION MATERIAL QT'Y (ko) f^EMARK
25A 25 135 35 64 99 125 90 - 16 - 4-19
CLASS/RULE
LISA 15 120 30 59 89 95 70 51 14 4-15
DATE
10K,16K,20K RF 20A 20 130 30 59 89 100 75 56 16 4-15 TITLE

DIM. SCALE
25A 25 135 35 64 99 125 90 67 16 4-19
DISC STEAM TRAP
mm N/S •^<3
ISA IS 140 30 59 89 lis 80 55 20 4-19 (JKD-41F)
W / 0 NO.
30K,40K RF 20A 20 140 30 59 89 120 8S 60 20 4-19 B
DWG. NO. REV.
2SA 25 150 35 64 99 130 95 70 22 4-19
ICANGRIM INDUSTRIES CO., LTD. MB-ST-02
A S
 ft $' spira^c TI-P081-01
ST Issue 8

Figsarco
\ ^ ^ j / v UKAS
QUUmr
^ • ^ ^ ^ ^
kUNMXMEN*
001

Cert. No. LRQ 0963008 37

I ISO 9001 I
SG Iron
Strainer
Description
The Fig 37 is an SG Iron integrally flanged Y-type strainer. The
standard stainless steel screen in the DN15 to DN80 size range is
0.8 mm perforations, in the DN100 to DN200ftIs 1.6 mm perforations.
As options other perforations and mesh sizes are available as
well as monel screens. The strainer cap can be drilled and tapped
for blowdown and drain valves if required.
Optional extras
For optional extras see overleaf.
Standards
This product fully complies with the requirements of the European
Pressure Equipment Directive 97/23/EC.
Certification
The product is available with material certification to EN 10204 2.2
for the body and cap as standard and EN 10204 3.1.B to special
order at extra cost.
Note: All certification/inspection requirements must be stated at
the time of order placement.

Sizes and pipe connections

DN15 to DN150 standard flange EN 1092 PN40 and ANSI 150.
DN200 standard flange EN 1092 PN25 and ANSI 150.
JIS/KS10K and 20Kflangesare available on request for the following
sizes: DN15, DN20 and DN32 to DN200.

Pressure/temperature iimits
A
350 • v hv^
B •* \ Nv
o 300 c
§ 200 ^ ^—— - ^
3
2
o 100
\ ^ \
Q. Sleain
E saturation
.<•> 0
-10H c IB E D A
10 20 30 40
Pressure bar g
This product must not be used In this region.
A Flanged EN 1092 PN40.
B Ranged ANSI 150.
C Flanged JIS/KS 10K.
A Flanged JIS/KS 20K.
A Flanged EN 1092 PN25.

DN15-DN150 PN40
Body design conditions
DN200 PN25
Maximum allowable DN15 - DN150 40 bar g @120°C
PMA
pressure DN200 25barg@120°C
TMA Maximum allowable temperature 350-0
Minimum allowable temperature -10°C
pi^Q Maximum operating DN15-DN150 40 bar g @120''C IVIaterials
pressure DN200 25 bar g @120°C No. Part Material
DN15-DN150 350°C@ 28.5 bar g
Maximum operating 1 Body SGIron DIN 1693GGG40
TMO temperature
DN200 350°C@ 17.5 bar g DN15toDN50 SG iron DIN 1693 GGG 40
2 Cap
Minimum operating temperature -ICC DN15toDN100 Carbon steel DIN 17245 C22.8
3.1.B
PN25 38 bar g DN125 to DN200 Carbon steel DIN 17245 GS C25N
PN40 60 bar g 3 Cap gasket Reinforced exfoliated graphite
Designed for a
maximum cold hydraulic ANSI 150 30 bar g 4 Strainer screen Stainless steel ASTM A240 316L
test pressure of:
JIS/KS 20K 49 bar g Cap stud DN65 to DN200 Carbon steel BS 4439 Gr. 8.8
JIS/KS 10K 28 bar g| Cap nut DN65toDN200 Carbon steel BS 3692 Gr. 8

Local regulations may restrict the use of this product to tielow the conditions quoted.
In the interests of development and improvement of the product, we reserve the right to change the specification. © Copyright 2004
Kv values For conversion: Cv (UK) = Kv X 0.963 Cv (US) = KvX 1.156
Size DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN125 DN150 DN200
Perforations 0.8,1.6 and 3 mm 5 8 13 22 29 46 72 103 155 237 340 588
iMesh40and 100 5 8 13 22 29 46 72 103 155 237 340 588
Mesh 200 4 6 10 17 23 37 58 83 124 186 268 464

Dimensions /weights [approximate) in mm and l^g Spare parts

The spare parts available are shown in solid outline. Parts drawn
ANSI
in broken line are not supplied as spares.
PN40 PN25 150 Screening
Size A A A B C area cm' Weight Available spares
DN15 130 122 70 110 25 1.85 Strainer screen 4
DN20 150 142 80 130 42 2.80 (state material, size of perforation or mesh and size of strainer)
DN25 160 156 95 150 71 3.50 Cap gasket (packet of 3) 3
DN32 180 176 135 225 135 6.20 How to order spares
DN40 200 200 145 240 161 7.40 Always order spares by using the description given in the column
headed 'Available spares' and state the size and type of strainer and
DN50 230 230 175 300 251 11.20
perforation or mesh required.
DN65 290 291 200 335 352 20.00 Example: 1 off Stainless steel strainer screen having 0.8 m m
DN80 310 311 210 340 360 24.00 perforations for a DN50 Spirax Sarco Fig 37 strainer having
EN 1092 PN25 connections.
ON100 350 350 255 415 540 36.00
DN125 400 398 300 510 840 60.00
DN150 480 482 345 575 1 115 83.00 DN15 to ON50
DN200 - 600 600 435 730 1 905 148.00

C Withdrawal
distance

DN15 to DN50 shown

Safety information, instaiiation and maintenance

For full details see the Installation and Maintenance Instructions
(IM-S60-18) supplied with the product.
Warning:
The strainer cap gasket contains a thin stainless steel support ring,
which may cause physical injury If not handled and disposed of
carefully.
Disposal
The product Is recyclable. No ecological hazard Is anticipated with
disposal of this product, providing due care is taken. \/-^40 y
Optionai extras
strainer screens
1 R mm (DN15toDN80)
Perforations ——
stainless steel screen 3.0 mm (DN15toDN200)
Ivlesh 40, 100 and 200
0 8 mm (DN15toDN80)
Perforations ——
Monei screen 3.0 mm (DN15toDN200) —^'T\
v.>5
l^esh 100

Biowdown or drain valve connections

Recommended tig itening torques
or H
The cap can be drilled to the following sizes to enable a biowdown
or drain valve to be fitted at extra cost. Item Qty Size r^ Nm
mm g
strainer size Biowdown valve Drain valve
DN15 22 IV128 50-55
DN15 y." V." DN20 27 M32 60-66
DN20 and DN25 %•• %" 2 DN25 27 M42 100-110
DN32, DN40 and DN50 1" 'A" DN32 46 Iu156 250 - 275
DN40 50 M60 250 - 275
DN65 to DN125 VA" %••
DN50 60 1^72 310-340
DN150 and DN200 2" %" 8 DN65 19 IVl12x35 20-24
8 DN80 19 M12x35 30-35
How to order 8 DN100 24 1^116x45 50-55
Example: 1 off Splrax Sarco DN80 Fig 37 strainer having flanged 5 8 DN125 30 M20 X 50 80-88
EN 1092 PN40 connections with a stainless steel screen having 8 DN150 30 M20 X 55 100-110
0.8 mm perforations. 12 DN200 36 M24 X 65 90 -100

»P"%aiirco Fig 37 S G Iron Strainer T I - P 0 8 1 - 0 1 ST Issue 8

 / # ^
(bl W\. I f )
^
L X
V sjfirax TI-S02-26
ST Issue 5

sarco
V^^JL^^ UKAS
QUUITV
^^^^^ MlAMaMeXT

om
Cert. No. IRQ 0963008
I ISO 9001 I
FT14
Ball Float Steam Trap
Description
(Flanged)
The FT14 is an SG Iron ball float steam trap with integral automatic
air venting facility and flanged connections.
Available options
FT14 (R-L) Horizontal connections with flow from right to left.
FT14 (L-R) Horizontal connections with flow from left to right.
FT14V Vertical connections with flow downwards.
Optional extras
An optional steam lock release (SLR) valve
(designated 'C on the nomenclature) can be fitted
FT14C to the trap to prevent steam locking of the system,
this feature is available in addition to the air vent.
FT14X Optional integral strainer screen.
Standards
The product fully complies with the requirements of the European
Pressure Equipment Directive 97/23/EC.
Certification
This product is available with material certification to EN 10204 2.2.
Note: All certification/inspection requirements must be stated at
the time of order placement.
Sizes and pipe connections
DN15, DN20andDN25
Flanged EN 1092 PN16, ANSI 150 and JIS/KS 10.
Pressure/temperature limits (iso 6552)
250
" 200
2
3 150
i 100
Q. sdtur 3tion
E 50 curve

0 2
— 1 41 6 8 10 12 14 16
Pressure bar g
The product must not be used in this region

Body design conditions PN16

PMA Maximum allowable pressure @ 120*0 16 bar g
TMA Maximum allowable temperature 250'C
Minimum allowable temperature O'C
PMO Maximum operating pressure 14 bar g
for saturated steam service
TMO Maximum operating temperature @ 12 bar g 250'>C
Minimum operating temperature FT14C (R-L)
FT14-4.5
o-c
4.5 bar
Maximum
APMX differential FT14-10 10 bar No. Part
pressure Material
FT14-14 14 bar
7 Main valve assembly screws Stainless steel BS6105CIA2-70
Designed for a maximum cold hydraulic test pressure of 24 bar g
8 Ball float and lever Stainless steel BS 1449 304 316
9 Air vent assembly Stainless steel
Materials
10 Pivot frame Stainless steel BS 1449 304 S16
No. Part IVIaterial
11 Pivot pin Stainless steel
* 1 Body SG iron DIN 1693 GGG 40
12 SLR assembly Stainless steel BS 970 303 S21
2 Cover bolts Steel BS 3692 Gr. 8.8
Reinforced exfoliated graphite 13 SLR gasket Stainless steel BS 1449 304 S16
3 Cover gasket
4 Cover SG iron DIN 1693 GGG 40 14 SLR seal Graphite
5 Main valve seat Stainless steel BS 970 431 S29 15 Erosion deflector (DN25 only) Stainless steel BS 970 431 S29
Main valve/air vent 16 Valve spring (DN25 only) Stainless steel BS 2056 302 S26
Stainless steel BS 1449 409 S19
seat gasket • Note: Item 15 is pressed into item 1 (DN25 only).

Local regulations may restrict the use of this product to below the conditions quoted.
In the Interests of development and improvement of the product, we reserve the right to change the specification. © Copyright 2004
Dimensions/weights (approximate) mmm and kg
A G
S'** PN/ANSI JIS/KS B C D E F Withdrawal distance Weight
DN15 150 1 150 107 - 101 51 47 26.5 115 4.5 1
DN20 150 150 107 101 55 47 26.5 115 5.0
DN2S 160 170 117 70 100 10 21.0 120 6.5

n DN15andDN20 ON25

G-^ FT14-C

Capacities Safety infonnation, instaiiation and maintenance

Note. Capacities shown are based on discharge at steam saturation For full details see the Installation and Maintenance Instructions
temperature. When discharging sub-cooled condensate the air vent (iM-S02-13) supplied with the product.
provides extra capacity. Under start-up conditions the thermostatic Instaiiation note:
air vent will be open, and will provide additional condensate capacity The FT14 must be installed with the direction of flow as indicated on
to the main valve assembly. On 4.5 bar units this will provide a the body, and with the float ann in a horizontal plain so that it rises
minimum of 50% increased capacity alx)ve the hot condensate figures and falls vertically. If required the flow orientation can be changed
shown. On 10 and 14 bar units this will be a minimum increase of on site.
100% on the published capacity. For full details see TI-S02-28. Disposal
This product is recyclable. No ecological hazard is anticipated with
1500 —1 the disposal of this product providing due care is talcen.

1000 How to order

AO Example: 1 off Spirax Sarco DN25 FT14-4.5 (R-L) bail float steam
trap with flanged PN16 connections and integral air vent.
'^^- - . A ^
500 •^A§l- -
Spare parts
x: 400 . »\96, \^' The spare parts available are shown in solid outline. Parts drawn
O)
300
^ ^ ,^^^ '•'-''. Ji. In broken line are not supplied as spares.
(1)
(S Available spares
200
c 3, 5, 6, 7 (2 ofO,
<1> ^ Main valve assembly with float g 10, 11 16(DN25only)
TJ
c
^
o 100 Air vent assembly 3,6.9
O -- Steam lock release and air vent assembly 3, 6, 9,12, 13
^ -^
^^^_^^^
• ^
Cover gasket (packet of 3) 3
50 Maintenance kit 3, 5, 6, 7 (2 off), 8, 9, 10 11 16(DN25only)
40 ^,^-^
How to order spares
30 Always order spares by using the description given in the
20 -H
0.1 0.2 0.3 0:5
.1— —
1 2 3 4 5 10 14
column headed 'Available spares' and state tlie size, type of trap
and pressure range.
Example: 1 - Main valve assembly for a Spirax Sarco DN25
Differential pressure bar (x 100 = l<Pa) FT14-10 ball float steam trap.

Steam lock Air vent assembly Recommended tightening torques

release assembly
,
112 + 14
1
iJ Item F1 *"' ^3
Nm
^<Z^ mm
2 17A/F M10x30 47-50
5 17A/F 50-55
7 Pozidrive M4x6 2.5 - 3.0
9 17A/F 50-55
12 and 14 19A/F 50-55

Main valve assembly

Note: Item 16 Is required for DN25 size only

«P"^Aaiirco FT14 Ball Float Steam Trap (Flanged) T I - S 0 2 - 2 6 ST Issue 5

 POS NO. 10.0

T I T L E DATA
SHEET MB-TT-01
NO.

TEMPERATURE TRANSMITTER
KANGRIM PAGE 1 OF 1

HEAD

TETMINAL

•WELDED POCKET o ELEMENT

R E E

R RED • NOTE
B BUKCK
1. MATERIAL :

=T IOC) r Alr OX CONNECTION HEAD AL-DIECAST

OTHER : SUS 304

2. IP GL/iDE : IP 54

3. ELEMENT : PTIOO DIN 3 WIRE

4. WORKING LIMIT TEMP. : MAX. 2 0 0 X
100. 150, 170, 200
P2
300, 400, 600(mm) 5. NP (lettering) :
PF 3 / 4 or M27x2P
15c
 POS NO. 11.0

T I T L E DATA
SHEET MB-PT-02
NO. :

PRESSURE TRANSMITTER CODE 3003506

KANGRIM PAGE 1 OF 2

^ Constant current device

Connections
^ Rigid cost aluminium epoxide coated housing
• Stainless steel s e n s o r ( 1 7 - 4 , 1.4542)with sputtered thin
580.8 I
Type 8 9 1 0 film strain gauges
Emometer H
o ^
^
Excellent long t e r m stobility and temperature
Customized ranges possible
drift

12.0 ^ Protection IP 65
^ Insensitive to pressure peaks and dynamic pressure changes

9i:::iffl
Sn-Triffl
U.-/-
u.
I10/J20 V Approvals (relative pressure)
I2...M V in preparation

BV, DNV. RINA, GL. PRS, ABS LRS

91
Di m e ns lor I S

- — 1 — 1

(1^ 4 — I If 1
\®
oO^II '.*!
a
c
^_^
c c • * O)
\
01 o> U9
V)
3 V ^ = ZJ
(
CM
t- i^^-^^ ?i e
b.
o -" T

V/—I
cS)
in
(III)
H 313.5 Type 8202
J - 1
w
rn'
HF-inference: The instrument is protected against
HF-interference
s 1 06
AA Short circuit

Noise:
current: <32mA

typ. 0.15 % FS
Zero adjustment: adjustable - 2 . 5 % . . . + 3 0 % FS

Specifications 8202 Span (range) adjustment: odjustable ±535 FS

Response time: < 5 ms for 90% of nominal pressure

input
Environmental
Meosuring ronges in bar, based on relotive or absolute pressure.
Operoting temp, ronge: 0...70-C
Electrical data
Nominal [Link]: 0...70'c, compensated
power supply
Medio t e m p , range: - 2 5 . . . + 125-C
Supply voltage: 10...36V DC, nominol 24 V DC
Storage t e m p , ronge: -40...+85"c
Permissible ripple: U» ^ 2 . 5 V ( 1 0 $ U . < 3 6 V)
Humidity 55'c ond 98% relotive humidity
Insulation: > 2 5 0 V DC to ground. (According to GL ond Lloyds Reg.)
Vibration: 6g (1...2000Hz)
Output
Shock: 50g/1ms
Output signol; 4...20 mA
Resolution: infinite Physical doto
Accurocy (NLH) $ ± 0 . 5 % F S p $ 16bar Sensor materiot: Stoinless steet 1 7 - 4 (1.4542)
BSL through zero $± 0.3%FS p > 2 5 b a r
Housing materiol: Cost Aluminium, coated with e p o -
Repeotability ± 0.05% FS xyde powder opplied by means of
on electrostatic procedure.
Long ternn stability (Grey to VSM 37021)
(in operation) <0.2% FS / 12 mounths
Pressure connection: G 1 / 4 : , female
Thermal zero shift: $ ± 0,02% FS / K
Resonance frequency: 10...70 KHz, depending on pressure
Thermal sensitivity ^ ± 0.02% FS / K ronge
shift (Range)

Load mox. ( u . - 10V) . s o n Mounting torque: 25 Nm, [Link]—in depth 1 2 m m

Impedonce: >1 Mn
Influence of chonging electrical connection: for 0.5...2.5 m m ' wires
± 0 . 0 1 % FS/V, between 10...34 V
supply voltage:
Weight: Approx.520g
Misconnection: Protected
Instollolion: Woll/ponel mounting with or
Voltoge tronsients: Moximum power absorption 1 Ws without bracket
 FOS NO. 11.0
DATA
T I T L E SHEET MB-PT-02
NO. :

PRESSURE TRANSMITTER CODE 3003506

KANQRIM PAGE 2 OF 2

Standardtypes (see also standard catalogue)

with connection R 1 / 4 " internal thread
Ronge in bar Order number Type Range in bar Order number Type

0...1.0 N 1.0 8202.71.2210 0... 16 N 16 8202.79.2210

0...2.5 N 2.5 8202.75.2210 0... 25 N 25 8202.80.2210
0..A.0 N 4.0 8202.76.2210 0... 4 0 N 40 8202.81.2210
0...6.0 N 6.0 8202.77.2210 0...100 N 100 8202.83.2210
0...10 N 10 8202.78.2210

Order number XXXX . XX . XXXX . XX . XX . XX . XX . XX . XX . XX.

Type Range !n bar mox. overpressure Burst pressure

ond 0...0.4 3 100 8202.69
Range 0 - 0 - 6 3 100 8202.70
^ 0...1.0 3 100 8202.71
0...1.6 6 100 8202.73
0...2.5 6 100 8202.75
0...4.0 15 100 8202.76
0...6.0 15 100 8202.77
0...10 32 200 8202.78
• / — • - 0...16 32 200 8202.79
—5Z5S— 66 366 6262.36
80 300 8202.81
0...40
200 500 8202.82
0...60
0...100 200 500 8202.83
0...160 500 1000 8202.85
0...250 500 1000 8202.74
0...400 1000 2000 8202.84
0...600 1000 2000 8202.86

Customized special ranges for exomple:

- 1 . . . + 1 bar, 0.2...1 bor, 0...12 bar [Link]

Sensor Relative pressure G 1/4" femole 2210

Relative pressure G 1/2" male 2211
Absolute pressure G 1/4" female 2610
Absolute pressure G 1/2" mole 2611

Fixing Woll mounting brocket 31

Accessories (to be added in random order)

Connection with Marine coble gland M 24X1.5 27
M 18X1.5 40

Adoptor R 1/4"-M12 x 1.5 internal stainless steel( 1.4435) PI

Adaptor R l/4"-R 1 / 2 " external brass A2

Adaptor R 1/4"-R 3 / 8 " external brass Al

Adaptor R 1/4"-Ml2 x 1.5 internol brass LI

Pressure peak damping elements

R 1/4"-R 1/4" internal woter stoinless steel( 1.4435) K5 brass F5

R 1/4"-R 1/4" internal light oil stainless steel( 1.4435) K4 brass F4

R 1/4"-R 1/4" internal heavy oil stainless steel( 1.4435) K3 brass F3

R 1/4"-R 1/2" externol water stainless steel(l .4435) KB brass F8

R 1/4"-R 1 / 2 " external light oil stainless steel( 1.4435) K7 brass F7

R l/4"-R 1 / 2 " externol heavy oil stainless steel( 1.4435) K5 brass F6

Out to policy of continoufl dtvclopmwit w* r v M r v t th« right to omend tht sptcificotion without notilitolioo.
7. Forced Draft Fan

KANQRIM INDUSTRIES CO.,LTD.

 F.D FAN SPEC, /PB0301AS10
DocNo. :PB0301AS10
Rev.: 0
(Page 1 of 1)

# F.D Fan specification

F. D Fan data ;

Type TURBO
Actual outlet position
Revolutions 1770 rpm
Static pressure 615 mmWs
Power consumption (at 45 o C) 61.0 kw

Fan motor data :

Type TEFC
Speed 1770 rpm
Effect (nor./max.) 63 kw
Voltage 3 ph X 440 V
Frequency 60 Hz
Standstill heating element 60 W
II p II
Insulation class
Protection IP 55
Ambient temp, for motor 45 "C
Starting method Star-Delta
Operating current Refer to motor data
Starting current (direct) Refer to motor data
Noise level fan db(A) with silencer max. 105 dB
Final color MUNSELL NO 7.5BG 7/2
Weight fan incl. motor 1300 kg
 SAM WON TECH
1 _ REV.BS001002-001
FAN DATA SHEE T PAGE. 1
DATE. 0 0 . 1 0 . 0 2
[Link] AUXILIARY BOILER
[Link] FORCED DRAFT
[Link] TYPE & NO. TURBO
[Link] NO. BSTF - 8
[Link] 1 SET
[Link]
iSPECIFICATIOm (DESIGN CONDITIONS)
[Link] RATE 352 mVmin [Link]
[Link] STATIC PRESS(Psl) -15 mmAq o TYPE TURBO
9.0UTLETSTATICPRESS(Ps2) 600 mmAq o DIA. 0 1200
[Link] 45 r [Link] GD''(AT MOTOR SHAFT)136.8 k g • M^
[Link] AIR [Link] SPEED 2124 RPM
[Link] WEIGHT 1.109 kg/nf ( 45 V) [Link]
[Link] HUMIDITY 65 96 o TYPE NA
[Link] PRESS. DIFF. ( P s 2 - P s l ) o LUBRICANT NA
615 mmAq o LUB. METHOD NA
[Link] VELOCITY PRESS.(Pv 1) o COOLING METHOD NA
NA mmAq [Link]
16.0UTLET VELOCITY PRESS.(Pv2) o INLET TYPE NA
NA mmAq TORQUE kg-M
^[Link] STATIC PRESS.(Ps2-Ps]l - P v l ) o OUTLET TYPE NA
NA mmAq TORQUE NA kg•M
[Link].(Ps2+Pv2) ( P s l + P v l ) 39 .POWER TRANSMISSION
615 mmAq DCOUPLING HMOTOR DIRECT DPULLEY
(OPERATING CONDITIONS) ( WEIGHT)
[Link] SPEED 1770 RPM 40 .ROTOR 190 kg
20 .BRAKE HORSE POWER KW ( 45 TC) [Link] 280 kg
[Link] TOTAL EFFICIENCY 75 96 [Link] 450 kg
22.N0ISE LEVEL 105 dB(A) [Link] 120 kg
(.MATERIAL) [Link] 245 kg
[Link] 45 .TOTAL 1285 kg
O MAIN PLATE SS400 46 .HEAVIEST MAIN LIFT NA kg
O SIE PLATE SS400 (REMARKS)
O VANE SS400 [Link] WATER Q'TY : NA TON/HrEA
[Link] SS400 [Link] TC NA
[Link] SS400
[Link] GC20 [Link] TEST
[Link] HOUSING NA OVIBRATION 75 /m
[Link] BASE SS400 OBALANCING GRADE G 6.3
(MOTOR) [Link] PRESS . IS CONVERTED TO 20 t
29 .TYPE TEFC
30 .POWER 63 KW 4 P
[Link] SOURCE 440 V 60 Hz 3 0
[Link] F CLASS
'^[Link] 40 t:
£Y DESCRIPTION PREPARED BY CHECKED BY APPROVED BY
J.S.J K . K .H Y.S.M
 REV: 01 1
n
SMA ffUlN i t l H EibllMAllLU rtiKfUKMAlNU tUKVlLb Uf BLUWtK DOCUMENT NO.
B S 0 0 0 9 2 2 -- (301
SERIAL NO. B F O O - TF ITEM NO DATE

TYPE TURBO CUSTOMER KANGUM IND, CO PREPARED J.S.J

MODEL B :5 T F 8 PROJECT [Link] [Link] CHECKED Y.S.M

CAPAC ITY nVmir1 352 TYPE n ELECTRIC MOTORD

S D
P R
STATIC PRESS rTimAq 615 OUTPUT 63 kw VOLTAGE 440 V
E 1
C •= V
1 TEMPERATURf 45 E POLE 4 p PHASE 3 0
r h
1 SPEE[ ) rpm 1770 SPEEC) 1770 rpm FREQ. 60 Hz
cA SHAFT POWER (W 6 TRANSMISSION •DIRECT MOTOR DCOUPLING DV- BELT
T
1
0
EFFICIENCY(nt) % 75 TYPE DROLLING DSLIDING
Rf
N DLnrMiNO
SPEC. WEIGHT \^g/ m^ 1.10S LUBE DGREASE DOIL

(%) (Kw) (mmAq)

900 -

100 800

90 — 700
'\
SI \\\ r -•w-S s x
80 - s v^
—
600
"s
7n v^ N ,s
/U IS
\ , \ ,A
500 \
60 -
•^
N, ' \
z! \, \,
y rr " f l :iE MP Y \ v
/ LI 1 1 1 'WJ 1. s, \
400 /' \, I I
50 "" / \, T :
/ \
90 - / ^
40 300
~t- t
/
/
,^0 - 60 - t
200 / -^WAh 1 \-'() WFIV
/
20 - /
/
30 - /
m 100 -i
ID / 1— f-^

/ 1) fN/ \\l (, HK E S S ^
0 0 /
0 f 1
E P P ic 0 2C0 300 4(30 5(30 6 00
F 0 R
F W E
E S C;AP AC TY (n ^1min)
R S
R ST^ RTING ME:THO : : 5TAR- DELJA
E
M
A
R
K
S
 REV: 0 page: 3
SAM ffON TECH ESTIMATED DAMPER TORQUE CURVE DOCUMENT NO.
BS000922 - 001
SERIAL NO. BFOO-TF ITEM NO. DATE

TYPE TURBO FAN CUSTOMER KANGRIM INO,CO PREPARED J.S.J

MODEL B S T F-8 PROJECT [Link] [Link] CHECKED Y.S.M

GD^ (refered to motor shaft) 136.8 kg-m' MOTOR 75Kw X 1770 RPM

21
20
19
18
17
^\
16 N,
\
\,
15 s
\ ,V
14
en 13
\,
\
12 \,
\
11 N,
\
10
9 \

8 \,
O \
on 7
o
6
5
4
3
2
1 \,
\
0
10 20 30 40 50 60 70 80 90 100

REVOLUTION, %

NOTE: IF the inlet temperature is lower than that in the design point,
the torque will rise in proportion to the density.
 MFG N O . :
PAINTING
SAM WON TECH
SPECIFICATION Page 4

FAN NAME SPECIFICATION REMARKS

SURFACE
Sa 2
PREPARATION

TYPE OF PAINT RP 140

PRIMER DRY FILM THICK 60 micron

[Link]
(0009/10) ALUMINUM
COLOR
LIGHT

THPE OF PAINT RT 546

FINISH DRY FILM THICK 30 micron

COLOR 7.5 BG 7/2

NOTE
1. THE AB(3VE PRODUCTS ARE FROM " K 0 5lEA CHEMICAL (zo.:
2. UNLESS OTHERWISE SP ECIFIED PARTIC;ULARLY STAINI . E S S S T E E L .
NON FEl^ R O U S ] M E T A L , ] PLASTIC SURFA CES ARE NOT T(3 BE P A I N T E D .
3. WHERE THE FAN CASIN G IS TO BE INS ULATED 1^FTER ERECTION.
THE FIN ISHING COAT W ILL NOT BE RE QUIRED.
 MFG N o . :
Q A1
oAivi w WIN lEjKjn
cr«r\T>ii.
bUUrrj wr o u r r i j i Page 5

TOTAL
NO. NAME OF PARTS MATERIAL REMARKS
Q'TY
1 CASING 1 SS400

2 INLET CONE 1 SS400

3 AIR SEAL 1 SET [Link]-ASBESTOS

4 MAIN PLATE 1 SS400

5 IMPELLER SIDE PLATE 1 SS400

6 VANE 12 SS400

7 IMPELLER BO SS 1 GC20

8 INLET VANE I)AMF 'ER NA SS400

9 INLET SILENC!ER 1 SS400

10 OUTLET FLEX IBLE J O I N T 1 SET SS400.STS304

11 MANHOLE 1 SET SS400

12 OUTLET COMI'ANION FLANGE 1 EA SS400

13 COMMON BEE 1 SS400

14 SETTING BOL T, NUT 1 LOT SS400

15 MOTOR 1 SET SS400 63KWx4Px30xlP55

 wax
30 ^161x5=805, 30

r-^-i-"""'
^ - — I — u i
I 8 - » 1 9 HOLES
'W*»

Detail of OUTLET FUNGE

View of Y

_a5a. _a32_

ISO
Section of A - A
NOTE
1. DIMENSIONS OF * MARK ARE CHANGEABLE IN ACCORDANCE
\m~ WITH MOTOR DIMENSIONS

-G ACCESSORIES
ISOUTOR PAD RUBBER
SOTING B / N & T/W, S / W
EXP JOINT SS400
INLET SILENCER
SEALING SS400
OUTLCT EXP' JOINT SILENCER SS400
COMPANION FLANGE MOTOR SPE"
CASING SS400 4.5t
VIEW 'A'
No. DESCRIPTION MAT"L OTY DIMENSION REMARKS
S P E C I F I C A T I O N
APPROVED TITLE
FAN TYPE TURBO CHECKED
AUXIUARY BOILER F.D FA^
CAPACITY 3S2 H'/MIN REVOLUTION DESIGN CUSTOMER SCALE DATE SET
XANCRIM [Link]..LTD
SUCTION PRESS -15 mmAq TEMPERATURE 45 DRAWING N/S 05.02.2;
( 031l/»/V«/»/«.04««/>/4)
DISCHT10N PRESS 600 rnmAq TOTAL PRESS 615 mmAq DWG No.
MOTOR 63 KW 440 V 6 0 Hj
^ SAM WON [Link] KR0311-n
 ik li li
Technical Data Sheet ABB ref. no. Undefined
•Customer: Date: 2003-08-14
Handled by: Undefined
'reject name: Item Name:
Customer ref. Undefined Case: Undefined
Location: Revision: A
TIo Definition PaiayUnU I Remarlts
1 Product ^action motor
TEFC, 3-phase, squirrel cage Inat
2 Product code 3GQA 252 301-ADA
3 Type/Frame M2QA 250 M4A 4
4 Mounting IM1001, B3(foot)
5 Rated output PN 63 kW
6 Rated output 84 HP
7 Service factor 1
8 Type of duty SI(IEC)
9 Rated voltage UN 440 VD ±5%(IEC60034-1)
10 Rated frequency fw 60 Hz ±2%(IEC60034-1)
11 Rated speed n^ 1776 r/min
12 Rated current IN 101.8 A
13 No-load current 29 A
14 Starting cun'ent y\^ 6.7
15 Nominal torque TN 339 Nm
16 Locked rotor torque TJTn 2.4
17 Maximum torque T^ax^N 2.4
18 Minimum torque Tmin/TN 1.1
19 Speed at minimum torque 306 r/mIn
20 DOL
Maximum starting time from hot DOL 13 s
21 Maximum starting time from cold 23 s Ace. to lEC 60034- 2
22 Efficiency - full load 100% 92.3 %
23
Efficiency - 75% 92 %
24
Efficiency - 50% 91 %
25
Power factor - full load 100% 0.88
26
Power factor - 75% 0.86
27
28 Power factor - 50% 0.8
29 Power factor at start 0.42
30 Insulation class / Temperature class F F
31 Ambient temperature 40 "C
32 Altitude 1000 m.a.s.l.
33 Enclosure IP55
34 Cooling system IC411 self ventilated
35 Bearing DE/NDE 6314 C3 - 6314 C3
Lubrication / lubricant 84 dB{A) +3dB(A)
36
Sound pressure level (Lp dB(A) 1m) 0.78 kg-m^
37
38 Moment of inertia J = Vi GD^
39 Balancing
40 Vibration class
41 Terminal box arrangement
42 Terminal box entries; no, dimens.
CWorCCW
43 Number of power terminals
450 kg
44 Direction of rotation
45 Weight
46 piniension drawing no.
Ex-motors Additional infonmation
Type of protection
47 Certification No.
48 tE time
Option49Variant Codes / Definition

Remarks:
Data based on catalogue values 01-4-12
Guaranteed values on request
iFile Name: [Link] Page: 1.1

LV Motors
 D-connection

W2 U2 V2
r\ r^

01 02
ui VI W1

LI L2 L3 PE

360

=^ 40

: ^

39
a E I
140.°, 168 349
455
930

Cable size/Cable glandMS6X2<cable diameter:32-Mfnm>X1+M27X1.5(cab e diamefer:11-15mm)X1

Space heater:<H/E :220V 60W: D CONNECTION Start method iimt:
Voltage Frequency Output Pole r.p.m Ins. Temp rise K Cos 0 Effic.%
UO V 60 Hz 63 KW /t 1776 90 0.88 92.3
Mount Rating D-end ND-end Weight Explosion Current A IP
B3 S1 6314 C3 6314 C3 450 kg 101.^ _S1
ABB Totally Enclosed Fan Cooled Cage Induction Motor Date:
MOTORS TYPE: M2QA250M4A [Link]:

CUSTOMER: ABB MOTORS

PROJECT: INDEX:
MANUAL FOR
BLOWER

ENVIRONMENT KEEPER

A SAM W O N TECH. CO., LTD.

TEL. 082-55-327-0150-2
FAX. 082-55-327-0153
 CONTENTS

1. SUMMARY 3
2. DELIVERY 3
2.1 CHECK 3
2.2 UNLOADING 3
2.3 STORAGE 3
2.4 ASSEMBLY MARK 4
2.4.1 CASING ASSEMBLY MARK 4
2.4.2 CASING INTAKE 4
2.4.3 DAMPER 4
2.4.4 BEARING HOUSING 4
3. INSTALLATION 4
3.1 PREPARATION 4
3.1.1 CHECK FOUNDATION DIMENSIONS 4
3.1.2 FOUNDATION ADJUSTMENT 4
3.2 SITE ASSEMBLY AND INSTALLATION 5
3.2.1 ENVELOPE TYPE 5
3.2.2 BOTH SUPPORT TYPE 6
3.2.3 INSTALLATION OF HOT AIR BLOWER ••• 7
3.2.4 BEARING ADJUSTMENT AND SETTING OF BEARING HOUSING
LOCATION 8
3.2.5 ASSEMBLY AND ADJUSTMENT OF CASING 9
3.2.6 FOUNDATION BOLT FIX AND READJUSTMENT 10
3.3 DUCT CONNECTION AND CASING INSULATION 11
4. OPERATION 11
4.1 CHECK BEFORE TRIAL OPERATION 11
4.2 CHECK OPERATION 12
4.3 CHECK ITEMS DURING OPERATION 13
4.4 SHUTDOWN 14
5. REPAIR 14
5.1 IMPELLER • 14
5.2 ROLLING BEARING 15
5.2.1 SOLID TYPE BEARING HOUSING 15
5.2.2 DIVIDED TYPE BEARING HOUSING 16
5.3 METAL BEARING 17
5.3.1 DISASSEMBLY 17
5.3.2 GAP CHECK 17
5.3.3 ASSEMBLY 18
5.4 TRANSMISSION GEAR BOX 18
5.5 LUBRICANTS 18
5.5.1 OIL 18
5.5.2 GREASE 19
5.6 DAMPER 19

ANNEXATION I . CENTERING PRINCIPLE AND STANDARDS

APPENDIX 1. JUDGEMENT STANDARD OF VIBRATION
2. TROUBLESHOOTING
1. SUMMARY
Blower is usually classlfiecl by its type, applications, and use conditions. It
is composed of casing, impeller, shaft, bearing, coupling(or V-pulley)l bed,
and air flow control equipment. Before installation of the delivered blower,
please be well aware of its capacity, type, component, materials, arrangement
of bearing, and lubricant by referring to the assembly drawings(or a cross
sectional view). This manual describes in general how to install, assemble,
operate and repair our blowers. Pleas use this manual for your efficient
operation of blower.

2. DELIVERY
2.1 Check
Please check a delivered blower with a statement of delivery, When you
inquire about this blower, use the manufacturing number in the name plate
of blower.
2.2 Unloading
(1) Do not make dents on the shaft when you lift up impeller with rope.
The rope shall not directly touch the bearing and other parts to be ass-
embled.
(2) Do not put impeller on the ground but on the wooden support when
unloading.
(3) Be aware of balancing the weight when lifting up casing with ropes.
2.3 Storage
(1) Do not unpack the package in order to protect the blower form dam-
age or corrosion after inspection.
(2) Store the rotating parts indoor. They should be water proved when
they are stored outdoor.
(3) Electric equipment should be stored indoor.
 2.4 Assembly mark
Large blower is delivered as a disassembled condition. Please nnatch tine
assennbly mark when assembling blower. When blower is delivered in an
assembled condition, be care when disassembling it(for maintenance) as
there are no assembly marks.
2.4.1 Casing Assembly Mark
When casing is delivered in a disassembled condition, there are marks
such as "Up", "Down", "No.1", and "No2" in each part. If there is a su-
ction box, there are marks near the shaft perforation part such as "M"
and "F" for "motor side" and "opposite to motor side" respectively.
2.4.2 Casing Intake
In order to identify the vertical position fo intake, mark "UP" or hook
is on the upper part of intake.
2.4.3 Damper
Connect damper flange to the casing flange at the corresponding
color.
2.4.4 Bearing Housing
If it is delivered after it is assembled to the bearing housing shaft of
fixed to the bed, it is easy to identify the installation location. If it is
delivered in a disassembled condition, "M" and "F" are marked on bear-
ing housing and bearing housing bed to indicate "motor side" and "op-
posite to motor side". In case of metal bearing, "M" and "F" are marked
on the bearing partition face.

3. INSTALLATION
3.1 Preparation
3.1.1 Check Foundation Dimensions
Check foundation dimensions, foundation bolt location and arrange-
ment of parts with assembly outline drawings.
3.1.2 Foundation adjustment
 (1) Foundation is generally Installed on the backer plates which are on
both sides of foundation bolt. This should be considered as an allo-
wance for the height of foundation. Backer Plate should be levelled
before it is firmly fixed by mortar grouting.
(2) Put taper liner(1/10~1/15) or shin liner on the backer plate to adj-
ust during installation. Weld backer plate and liner after levelling to
protect centering error from fan vibration during operation.
Observe the above procedures if it is installed on the shaped steel.

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^ h j m liriPr

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= ^
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1

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1
1
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Morlar

<fig. 1>
3.2 Site Assembly and Installation
Before assembly, remove foreign materials from the casing and bearing
house. Wash it with kerosene if necessary. If foreign materials are in the
bearing, it will cause an accident.
3.2.1 Envelope Type(BearinQ is on one side of Impeller)
(1) Installation of Casing
Put casing on the foundation if it is delivered with the bearing and
motor assembled to the bed. If casing is delivered in a disassembled
condition, put lower casing on the foundation liner. Do not fasten
tightly the foundation bolt until casing centering is completed.
(2) Installation of Bed and Bearing Housing
(a) If bearing housing is divided into upper and lower bearing hous-
ings, install bed and lower casing in a designated place and bolt
them. Put level on the dividing surface of bearing housing and
adjust the level. And then put the bearing assembled shaft on it.
 (b) If bearing housing is a solid type, put bed on ttie designated
place and put shaft in which bearing and bearing housing are ass-
embled and then bolt them. Put level on the shaft between bearin-
gs and adjust the level.
(Note) The above level adjustment can be done by adjusting founda-
tion liner under bed or insert copper plate below bearing housing.
3.2.2 Both Support Type(Bearing are on both sides of impeller)
(1) Bed Installation
Install temporarily bearing housing bed and motor bed on the desig-
nated place and measure and adjust bed height with transit and the
distance between bearings with tape measure.
(a) Bearing Housing is A Solid Type
Put level on the bearing housing bed and measure and adjust
the level in longitudinal, transverse and diagonal directions and
fasten lightly the foundation bolt on the bearing housing bed.

•yiz^Bq^ ^ ^ , , „ ^
Lev*!. -Jll

•^—kiu^Zirv^— tn
iJ« I "^".'Li
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<Fig. 2>

(b) Bearing Housing is A Divided Type

Bolt lower bearing housing to the designated place, Put level on
the bearing housing dividing surface and adjust the level in the
same way as (a) and then fasten the foundation bolts lightly.
 3tanRif '•Ji'sc

<Fig. 3>
(2) Installation of Lower Casing
Install lower casing on tine foundation liner and do not fasten tiglitly
the foundation bolt until centering is completed. If casing is delivered
after it was assembled with bearing and motor on the bed, install bed
on the designated place and adjust the level in the same way as (a)
and (b) and fix lower casing to the bed.
(3) Installation and Adjustment of Shaft
Set impeller assembled shaft as shown in <Fig. 2> or <Fig. 3> and
put level on the shaft both motor side and its opposite side and adj-
ust level by liner under the bed.
The following should be observed.
- The difference of level slope on right and left shall be less than
0.05mm.
- The gap between bearing shaft perforation parts and shaft shall be
less than 0.2mm.
3.2.3 Installation of Hot Air Blower
The installation procedure is the same as 3.2.1 and 3.2.2 But sole
plate shall be supplied if the expected expansion of casing is big dur-
ing operation. Be aware of the followings.
(1) Insert sole palte between casing support and foundation surface.
 (2) Sole plate Is fixed on the foundation surface with foundation bolt
and casing support is designed to slide on the sole plate.
(refer to assembly outline drawing)
(3) Casing si subject to thermal expansion radiately at a datum as sh-
own In <Flg. 4>. Therefore there are round hole at heat expansion
datum In the casing support and rectangular holes In the other place
the withstand heat expansion.
(4) The setting bolt which locks sole plate and casing support shall be
slanted a little bit as shown oh the right in <Flg. 4>.
Anchor holr. r^ul ..ijififf 5!flt:i!ig Iwjt
Spri;nij x h

Muicr B-.L
•n-ii-^*

<Fig. 4>
3.2.4 Bearing adjustment and setting of bearing housing location
(1) Remove bearing cover from the bearing housing for solid type but
remove upper bearing housing from the bearing housing for divided
type. And confirm and adjust the bearing lie down conditions. The
allowance of bearing lie down is 0.05mm.
(2) Setting of bearing housing location by considering shaft expansion
allowance.
Blower shaft expands In axis direction due to the heat of compres-
sor or gas temperature, therefore it is designed that one bearing is
fixed at a bearing housing but the other bearing moves freely.
In <Fig. 5>, dimension "L" is the expansion allowance of a shaft. In
case of rolling bearing, the dimension "L" is the same on the right
and left as shown in <Fig. 5a> and <Fig. 5b>.
 free side K cf^^
:*i I.

ta-wo

m
fixed side

tL_i_t:
<Fig. 5a>
• t t . ^Q$c <Fig. 5c>
<Fig. 5b>
If dimension is indicated in tiie drawing, please observe the dimen-
sions. Please refer to the repair procedure for detailed assembly of
rolling bearing and metal bearing.
3.2.5 Assembly and adjustment of casing
When installation of lower casing, adjustment of bearing, and setting
of location of shaft and bearing housing are completed, attach upper
casing and intake.
(1) If casing intake and impeller are overlapped as shown in <Fig. 6>
set upper casing first and attach intake.
il

\ ic
vX.1 i' -i- ^-^
>^ -Xi/"^
^ -

-iti r ^HV-ji
--tf
<Fig. 6a> <Fig. 6b>
 (2) Be care not to hit the impeller when putting upper casing on. Use
adjust bar to fix correctly the bolt hole.
(3) If damper is attached on the upper casing, assemble it with the
damper vane closed.
(4) After attaching intake, measure the gaps between impeller and int-
ake and shaft and casing shaft perforation in 90° intervals and adjust
so that the values are almost the same, Assemble the hot air blower
in dimensions shown in outline drawings or cross sectional drawings.
(5) Attach seal packing on the shaft perforation part as shown in <Fig.
7>. High temperature seal packing has a structure to slid up and
down to absorb casing expansion.
Packing push should not touch the shaft. If it touches shaft, acc-
idents may occur.
(6) After the above adjustments, bolt all flange and foundation bolt.

.-<n;r;tnK

<Fig. 7>
3.2.6 Fix of foundation bolt and readjustment
(1) When air blower is completely installed, fill mortar into each found-
ation bolt hole and fasten the nut when mortar becomes hard.
(2) After fastening the nuts tightly, check again the change of dimen-
sions and centering and readjust if required.
(3) After installation is completed, weld backer plate and liner and car-
ry out mortar grouting.
Note, - Refer to appendix 1 "CENTERING PRINCIPLES AND STANDARDS" for
centering work.
- Record and store the air blower installation dimensions and
centering data.
 3.3 Duct connection and casing insulation
(1) If damper is supplied, check damper operation condition and damper
vane rotation direction before connecting to duct.
(2) When connecting duct, be care not the duct load applied to the air
supplier If possible. If a big load Is applied to the air blower, casing
deformation or air blow control equipment malfunction may cause acci-
dents.
(3) When Insulating casing for thermal insulation or soundproofing, the
principles are written on the outline drawings or other special drawings.
Be sure that manhole and inspection equipment are openable when in-
sulating. Do not insulate moving parts of damper.

4. OPERATION
4.1 Check before trial operation
Check and adjust the followlngs before trial operation.
(1) Check foreign materials in the casing.
(2) Check Impeller by rotating It with hand.
(3) Check if there Is interference between bearing
(4) Check fastening conditions of each bolt. Specially check fastening
conditions of bearing house bolt by tapping it with hammer.
(5) Check opening and closing conditions of damper and close damper
vane.
(6) Check bearing is full of lubricant.
(a) For grease lubricant
Confirm the grease In the bearing as we delivered after filling grea-
se for the factory test.
(b) For oil lubricant
Bearing housing is delivered after applying grease or rust preventing
oil. Remove and wash out the oils with kerosene and fill specified
oils up to the center of oil level gauge.
(7) It happens sometimes for metal bearing that oil film breaks at the in-
itial stage of operation. Therefore supply oil with hands to the oil inlet
of the bearing housing or rotate motor slowly so that oil film forms on
the metal bearing.
 (8) If bearing is water cooling type, then check cooling water flow.
(9) Check coupling is filled with grease.
(10) Consult with the personnels in the operation and installation depart-
ments and fix the operation tinne and establish emergency system for
shut down in emergency.

4.2 Check after operation

Check the following items.
(1) Check rotation direction for three minutes and start operation.
(2) Stop blower and check parts if abnormal vibration and noise or ab-
rupt rise of bearing temperature happen.
(3) If abnormal vibration occurs, check seal packing of shaft perforation
part whether it presses down the shaft.
(4) Check the followings if bearing temperature rises very rapidly.
(a) If felts is used in shaft perforation part, check if it presses down
the shaft and check the gap is uniform between shaft and shaft pre-
foration parts.
(b) Check oil is over filled or oil quantity is optimum.
(c) If bearing housing is a solid type, check if bearing housing cover
on free side presses down the bearing outer rim.
(d) Check cooling water is supplied to the water cooking bearing.
(e) For rolling bearing, check any dent on the outer and inner rims of
bearing, ball or roller.
(f) For metal bearing, check oil ring rotation is normal and the contact
between metal and shaft is normal. If oil ring stops or does not ro-
tate, it is possible that oil ring is deformed.
(g) For belt driving, check if belt is over strained or non-uniformly st-
rained.
(5) For checking bearing rotation noise, use the sound detector like as
shown in <Fig. 8>.

- 12
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aboai 3 -it^ SfjU i " -^.

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10 lint Lifjirrg ;ast:

<Fig. 8>
(6) Open damper slowly by looking at amnneter if there is no abnormality
after operation. For high temp, air blower, raise gas temperature slowly
so that there Is no temperature gradient in the rotating parts.
4.3 Check During Operation
The following items shall be regularly checked, measured, and recorded
when air blower becomes normal operation conditions. This also applies
to the trial operation.
(1) Bearing temperature
Bearing temperature shall not be higher than the ambient temperature
bearing temperature by 40°C bur there is no problems if the temperature
difference between bearing temperature and ambient temperature is not
more than 70 °C
(2) Bearing vibration
Vibration of bearing housing should be measured in vertical, horizon-
tal, and axial directions. The judgement for vibration is shown in appen-
dix 1. It is advisable to maintain the bearing "excellent" conditions.
When recording amplitude, classify if it is single or double amplitude.
In our test certificate, double amplitude is recorded.
(3) If oil is used for bearing lubricant, check oil leakage. If oil leaks,
check the followings.
(a) Check oil is over filled.
(b) Check bearing housing and air vent are clogged.
(c) Check the location of oil films between bearing housing and shaft
is normal.
(d) check liquid packing is sprayed on the bearing housing dividing
surface.
 (4) For metal bearing, check oil ring operation is nornnal.

4.4 Shutdown
Please observe the followings when air blower is shutdown.
(1) Close dannper.
(2) If the water in the bearing housing is suspicious to be iced, rennove
water from the bearing housing or let the water flow during shutdown.
(3) Shut down the air blower when the casing internal temperature is
loot.
(4) If shutdown time is long, then rotate impeller by hands or motor for a
few minutes in every 4 or 5 days.
(5) Check overheating and contamination of bearing lubricants during
shutdown.

5. REPAIR
5.1 Impeller
(1) Check impeller and casing regularly as they may cause abnormal vi-
bration if they were corroded, abraded and dust collected.
(2) If vibration is caused by the adhesion of foreign materials, remove
foreign materials. But replace or repair impeller if the vibration is caus-
ed by corrosion or abrasion.
(3) Be care of cracking when welding balance weight to the impeller du-
ring balancing at site.
(4) When impeller was removed form the shaft, the assembly order is the
same as follows.
(a) Heat inside of impeller boss with burner and insert boss into the
flange until it stops. Take care of key and key way. There should be
no gap between boss and flange.
(b) Insert lock nut and lock washer.
(c) Fasten lock nut again when boss is cool.
(d) Insert washer and into the nut way and fix it firmly, If the washer
has no end, then fold it on the flat area of the nut.
5.2 Rolling Bearing
Bearing shall be replaced in the following sequence after removing
coupling(or V-Pulley).
(1) Wash and clean bearing and parts to be assembled.
(2) Check rust or any dent on the bearing race way and balKor roller).
(3) Be care when washing roller bearing as roller may come out during
washing.
5.2.1 Solid Type Bearing Housing

mllm^ nrinn*;" / •m^ a^iLn-ii '.?*•: :o''C-

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w.
<Fig. 9a>
w <Fig. 9b>
^r
(1) Before mounting bearing onto the shaft, push oily felt ring into the
bearing case cover and insert cover into the shaft as shown in <Fig.
9b>. Please note that the dimensions "H" of fixed and free side c o -
ver are not the same.
(2) Put bearing into the oil container and heat it up to 70°C. Mount the
bearing on the shaft before it cools. Do not tap outer and inner tri-
ms of bearing with hammer but use a jig if necessary.
(3) Insert bearing and push it to the end of flange at right angle and
stick bearing fast to the shaft so that there is no gap.
(4) Insert lock washer and nut and fasten them.
(5) Fasten nut again after bearing is cool.
(6) Insert washer one end into the nut way and fix it.
(7) Push carefully bearing housing.
(8) Grease bearing fully.
(9) Insert both covers with felt ring mounted by taking care of free
side to match with fixed side.
 (10) After removing cover again, clieck if fixed side cover presses
down bearing and free side cover does not touch witii tfie bearing.
(11) After fixing both covers, adjust the gap between shaft perforation
parts and shaft to be less then 0.2nnm.
(12) After adjustment, install bearing housing which is assembled to the
shaft on the bed and remove cover again and measure and adjust
bearing lie down with dial gauge as shown in <Fig. 10>. The toler-
ance of scale is 0.05mm.

[Link] sao|J(^

<Fig. 10

5.2.2 Divided Type of Bearing Housing

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• <Fig. 11> ^ "^
(1) Heat up bearing in the oil container and fix bearing with lock
washer and nut in the same way as that of (2) ~ (6) in 5.2.1
(2) For oil lubricants, insert slinger into the shaft and push it to the
predestined location.
 (3) Assemble the assembled shaft of bearing Into the lower bearing
housing on the bed.
(4) Adjust the bearing lie down within 0.05mm as shown if <Fig. 10>.
(5) Spray liquid packing on the dividing surface and fix it to the upper
bearing housing and adjust the gap between shaft and shaft perfor-
ation parts to be within 0.2mm.

5.3 Metal Bearing

5.3.1 Disassembly
(1) Remove piping for cooling bearing.
(2) Remove upper bearing housing and then disconnect upper bearing
metal. Be care not to damage flange surface as both metal sides of
fixed side contacts with shaft flange.
(3) Move oil ring to both sides.
(4) Remove lower bearing metals from the shaft by floating up the s h -
aft a little bit and tapping wooden block with a hammer as shown in
<Fig. 12>.
5.3.2 Gap Check
_^CK> flikil
Insert lead wire and fasten upper and V^he iihail

lower bearings as shown in <Fig. 13>

and measure and record the gap bet-
ween shaft and bearing by using the
following equation.

Gap=
(a+b) <Fig. 12>

where a, b and c are the measured lead wire thickness. The gap
Lead vires, of bearing is shown in the assembly
'v'pfgr "Sranng
_ rnataL
drawings. If the measured gap is
twice as big the specification, replace
bearing.
[£woMTeiirinjj
mcLaT

<Fig. 13>
 5.3.3 Assembly
(1) Install lower bearing housing and insert
lower bearing nnetal after cleaning up the
inside of bearing housing.
(2) Put shaft on and set oil ring at the
prescribed position.
(3) Assemble upper bearing metal being
careful on fixed side. Be careful not to <Fig. 14>
deform bearing being jammed under metal or shocked.
(4) If deformed oil ring is used, oil ring shall collide with bearing, or
rotation becomes abnormal, or stops, causing accidents. The defor-
mation allowance of bearing(the difference between maximum and
minimum diameters) is about 3mm. If the deformation is more than
3mm, replace it with a new one.
(5) It can be safely assembled if oil ring is hold with string and lower-
ed down with metal bearing as shown in <Fig. 14>.
(6) Connect cooling water piping.
(7) Lubricate liquid packing on the bearing housing dividing surface
and attach upper bearing. But do not spray liquid packing on the
bearing metal dividing surface. If liquid packing penetrates between
shaft and bearing metal, bearing shall be damaged.

5.4 Transmission Gear Box

It is a power transmission gear which connects between motor shaft
and air blower shaft. There are steel flexible coupling(grid coupling), gear
coupling, flange coupling, diaphragm, no oil supply coupling, fluid coup-
ling, and V-Belt. Please refer to the catalogue or description attached.

5.5 Lubricants
5.5.1 Oil
(1) Oil shall be changed after the first three months of use and then
every year. Take samples regularly and check oil burnt, oxidation,etc.
 between the change cycles.
(2) Remove air vent in the upper bearing housing and supply oil throu-
gh the air vent hole. Rennove oil plug to drain out oil from the bear-
ing housing.
(3) Please refer to the lubricant list for oil type and oil quantity to use.
0 * ^ i | 'J H

5.5.2 Grease
(1) Remove bearing housing cover and change grease every year.
(2) Please refer to the lubricant list when supplementing grease inter-
mediately. <Table 1> shows grease supplementary time and quantity.
(3) When changing grease, remove plug under the bearing housing and
inject grease through grease nipple with grease gun. Drain out all old
grease by unplugging.
(4) If too much grease is injected, temperature shall rise due to the
heat by agitation. In general the optimum quantity of oil injection is
about a half of bearing housing volume. Do not full more than 2/3 of
bearing housing volume.

5.6 Damper
(1) Bearing for damper does not require oil supply. Even rolling bearing
is used, it is designed without oil supply.
(2) Vane control damper does not need adjustment if it is not deformed.
Disassembly and adjustment can be done in reference to <Fig. 15> if
opening and closing movement is not smootii and periodical inspection
is required.
(3) Inject grease periodically into the control ring of vane control damper
to maintain smooth operation.
Note. Damper vane opens in impeller rotation direction. Please remem-
ber this when assembling after disassembly.

.Wi
, : | l i i » i - n l . 3 V « l l ml'. f ? = ^ l C

•'-'^M.r- • " twtKVK 'i klOK'--

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. ^ • • ^

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mil vana u i t liAi«n T rCHvr .8
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•-. .. .'y rtTiiKM n o J cmti^l ^ins

<Fig. 15>
ANNEXATION I . CENTERING PRINCIPLE AND STANDARDS
1. Centering of Coupling

CenUitaiK ifailmn 'x\^ _\

<Fig. 1> <Fig. 2>

(1) Measure and adjust centering of flange coupling by attaching dial gauge
on the periphery of coupling as shown in <Fig. 1>. For grid or gear cou-
pling, put dial gauge on the centering internal datum surface by the aid of
holding metal as the datum surface is too narrow <Fig. 2>.
(2) If the dial gauge is put under the coupling, there may be an error in an
indicator. Therefore put the dial gauge on and under the coupling and
measure the difference of indicator and adjust the measurements. The
error, particularly, shall be great if it is measured in the way as shown on
the right in <Fig. 1>. The shorter the arm is, the batter it is. If arm is very
long, then it will bend and make an error.
(3) The distance between coupling faces should be set by taper or thick-
ness gauges at the same values indicated in the outline drawing.
(4) As shown in <Fig. 1 & 2>, put mark A, B, C and D on both datum
faces at an interval of 90°.
(5) Rotate both datum faces at the same timed.e. rotate motor and air blo-
wer shafts at the same time) and record and amend the nonconformance
of shaft centering at A, B, C and D and the gap between two faces.
(6) If both datum faces can not be rotated at the same time, amend the
errors in the following sequence.
(a) Put dial gauge on the blower side and set the dial gauge scale "0" at
A and stop motor shaft and rotate blower shaft in 90°C interval and
mark four points.
 (b) Move dial gauge and rotate motor shaft and measure as the same
way as before.
(c) The arithmetic means of measured values in a and b are the center-
ing values.

2. Centering standard
The centering allov\/ance is as follows.

RPM OF BLOWER ECCENTRICITY GAP ALLOWANCE BETWEEN TWO FACES

< 1,800 rpm < 0.05mm within 0.1 mm
> 1,800 rpm < 0.025mm within 0.05mm

3. Centering Precautions
(1) Measure two or three times and adjust with liner under motor.
(2) Confirm again the centering even if motor and bearing are delivered
after they are installed on the common bed.
(3) Before connecting coupling, operate motor and check and confirm its
rotation direction and abnormality.
(4) The motor centering height shall be increased due to the increased tem-
perature during operation. When centering, install motor shaft center at s l -
ightly lower position by considering this phenomenon, the value is about
iC^times of motor centering height.

4. Adjustment of V-Belt and V-Pulley

For V-Belt driving, adjust as follows.
(1) Check the level of V-Pulley.
(2) Adjust the level by moving motor itself on the slide base or liner under
the slide base.
(3) If blower and motor shafts are not parallel as shown in <Fig. 3>, the
abrasion of V-Belt and bearing shall be accelerated and severe vibration
shall occur.

- 22 -
(4) Be care not to pull the belt too much and whirling

WVl fVAA/ MWI

' t -

IAAAJ A/vJ InA/xi

JWrvi

(o^ Cx) (x>

APPENDIX 1. JUDGEMENT STANDARD OF VIBRATION
KS B 6311-1982
8.6 Operation Conditions
Operation conditions siiall be tested in accordance with 5.2.7.
(1) Tlie bearing temp, shall not be higher than ambient temp, by 40t;.
(2) Vibration should not be significant and operation should be smooth. The
allowance of vibration is shown in <Fig. 23> for reference.

(a4 m mRim BOX)

'T
i_x .
th w i l
\
?tWj T- — -T-

N[<:v,
; I .M
\
I -:--p^>i^ j V j
t *••> t—
45,..H.!--Xr"-
:. 1 !
7ft 4 - -
i » JH :
. .^ .1
; i , .%.. .
K^n-llrnll ' \ '•\

<!•

I .. _ . _ _ ! .
/ I ' • '
lilll ''•II I "I*

<Fig. 23>
Remarks. Care should be taken on coupling as the vibration from motor
may affect the blower.

Reference. The relations between amplitude a{fJ^) and vibration speed

p(mm/s) is as follows.
(a co) (a Q) n)
2 6 X 10 ^ '
where (D(acceleration)=(2Eii)/60 (rad/s)

APPENDIX 2. TROUBLESHOOTING
 BEARING LOAD
OVER REDU DETER
VIBRAT TEMP IS ABNO OVER
LOAD LOAD CTION lORAT
ION IS INCREAS RMAL AT DURI DURIN ED
REMARKS
^~"-~~-........_^^ NCREA ED NOIS STAR NG G
PERFO
SED ABNORM E OPER RMAN
TING ATION OPER
ALLY ATION CE
DRIVE COPPER PIPE INTO THE
WEAK FOUNDATION O GROUND
FOUN BAD FOUNDATION o
DEFORMATION DUE TO CONCRETE
HARDENING o
INSTAL BAD INSTALLATION o o O UNBALANCED BOLT TIGHTENING
UTION BAD CONNECTION o o
LARGE CAP o o
SMALL GAP o
CONTAMINATED LUB. o
IMPROPER LUB. o
SHORT OF LUB. o
SHAFT POOR BOLT FASTENING o o
COUP BROKEN WASHER o o
LING FOREIGN MATERIALS o o
SHORT OF COOLING WATER o
POOR OIL RING ROTATION o
FAULTY MATERIALS o
BAD CONTACT o
POOR OIL WAY o
ABRASION OR CORROSION o o O
FOREIGN MATERIALS o o o o O
IMPELL CONTACT o o o o O
ER DEFORMATION o O
UNBALANCING o o o
WRONG CONNECTION o O NO REVERSE LOAD AT START
BEARING DENTS o
SCRATCH o o
BAD FITTING o o
SEAL BRAKING AND VANE
CONTACT o o o o CONTROL CONTACT
SHAFT BAD BOSS DETENT o o
BAD SHAFT COUPLING DETENT o o o
FAULTY KEY o o
CRITICAL VELOCITY OPERATION o o o
UNBALANCING o
COUPLI RUBBER RING ABRASION AND o
NG & BOLT DEFORMATION
V-PULL BELT LOOSENESS o o o
EY BEAT ABRASION o o o
NONUNIFORM BELT o o o
FOREIGN MATERIALS o o
CASING ABRASION o o
DEFORMATION CAN HAPPEN
DEFORMATION o o o DURING OPERATION
BED DEFORMATION o o
HIGH RPM o o o o o
LOW RPM o o
REVERSE ROTATION o o
RISE OF INHALING TEMP CHANGE o o o
DROP OF INHEALING TEMP CHANGE o o
MALFUNCTION OF AIR CONTROL o o o o
GENER EQUIP.
AL TROUBLE OF AIR CONTROL EQUIP. o o o o
BALANCE CLOGGING o
SURGING OPERATION o o o o
INCREASED CHANGE OF FACILITY o
RESISTANCE o
DECREASED CHANGE OF FACILITY o o
RESISTANCE
8. Control Panel

KANGRIM INDUSTRIES CO.,LTD.

 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 lo 17

BOILER CONTROL PANEL

R

ORDER NUMBER : PBC04MP0311~6,0441-4

C

CUSTOMER : HYUNDAI MlPO DOCKYARD CO., LTD.

D
NEWBUILDING : 0311~6. 0 4 4 2 - 4

E OIL BURNER : DDZ-10

COMBUSTION OF : DIESEL OIL OR HEAVY FUEL OIL

F

TOTAL POWER CONSUMPTION : 70KW

G

H
POWER SUPPLY : 440 VOLTS, 60 C/s

1 CONTROL VOLTAGE : 220 VOLTS, 60 C/s

CLASSIFICATION : A B S \
J

TIM: PROJECT 1
3311-6,0442-4 C0570MW H„o
r^rwjCD
OUVLK CLiircT
oHLLI ct>ss ^ B s
^[Link] ^"'^ 2004.11
L 0 FOR FINAL DWG. 2005.10 [Link] '^"•^.cj.T^ w/o NO. PBC04MP0311 ~6,0442~4
< ^ ^ K A N Q R I M INDUSTRIES CO., LTD.
REV. DESCRIPTION DATE NAME ""^[Link]} [Link]. KB-EL-910 ^'^ 1
 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1o 17
CONTENTS REVISIONS
A SHEET NO. NAME SHEET NO. INDEX DATE NAME
1 COVER SHEET
2 UST OF CONTENTS
3,4 CONTROL PANEL LAY OUT
5 NAME PLATES
B 10, 1 WIRING DIAGRAM POWER QRCUIT

12,13,14,15,16,17,18,19.20,21,22.23.24,[Link].29,30.31 WRING DIAGRAMS

40.41,42,43,44,50

60,61,62,63.64,65.66 CONNECTION DIAGRAM

D

70,7 1 UST OF PARTS

E
INTERPRETATION GUIDE :
RELAYS :
l ( . l \ M I I N M l . l^UI'^MCV^ IIUI'< \jn t\tLMI, V^UIL
F TERMINAL STRIPS ! CO-OUR CODE SIGNAL LAMH-b :
r CONTACT FROM RELAY 18K11
I -• -' -* M *

-• (Q\ f9
n rs- K 11
18K11
«
09 K^ \^ \^ €)
iI i^ GREEN RED BL IF WHITf YELLOW
v_X . Cai LOCATED ON SHEET 18, CURRENT PATH 11
\ ' COIL LOCATED ON SHEET 18 Ol 4». v l 00 (0
TERMINAI S
RELAY NAME

H a - ) <1 • NO TERMINALS IN CONTROL PANtL

b TERMINAL CONNECTION ON RELAY, CONTACTS -X2 • NO TERMINALS IN .JUNCTION BOX ON BURNER
a TERMINAL NO. - X 3 • NO
11, 6 a TFRUINIAI STR P wn
1 , ,
SHEET NO. - X 5 • NO
CONTACT SET a TO BE FOUNu UN bHtti n , CUKKtNI PAIH b - X 6 • NO TERMINALS IN JUNCTION BOX ON BOILER GAUGE BOARD
CONTAOI b t l a TO BE FOUND ON SHEET 11
- X 7 • NO
J
Wll <\W - > 8 • NO
INTERNAL WIRING, SCREENED WIRING
INTERNAL WIRING, NORMAL WIRING
K EXTERNAL WIRING

T1TI£ PROJECT 1 CUSTOMER

3311~6,0442'-4 HMD
COVER SHEET APP CLASS
[Link] °*^ 2004.11 A B S
L 0 W / O NO.
Sii^) k FOR Fl NAL DWG. 2005.10 [Link] °"'*' [Link] PBC04MP0311 ' ' 6 . 0 4 4 2 - > 4
( ^
' iL A M O R i M INDUSTRIES CO., LTD. REV. DESCRIF Tl(DN DATE NAME °*°' 1.S.W00
DWO. NO
KB- EL-910
SHEET 2
 10 11 12 13 14 15 lb 17

I BOITR CONTROL P A N g |

lOAQ

K l H 6 | |41H12| KlHUl |42H7| |43H7| |43Hfl| Mwij

(X) (X) (D <^ (X (2) <X>
PIHg kJHil |43H3| |43H5| |41H10| |43Hl1 |44H11| |44H13| |4aH1l| |4(IH13| PROTECTION : IP 4 4
(X> (D <r <x> <X> (Z> ® <8> ® ® COLOUR : RAL 7 0 3 2

|44Ha| | M H 7 | K3H13I |41H4) |42H3| |41H2| |14S4| |l4Sa|

(Z> (Z> (X> (S) <X) (X> d D

|42Hli |40H7| l^w^ 1 ^ ^ 1 h4Sa| 114591
(S> ® (S" ® ®
|44H1| |44HS| 1 ^ ^ i l*4H3| h2S3a| R o H ^ |40H3|
(X) (gl €» ® <2l <t
b4S14| |18S10| |22S13| |30S5| |2SS5| |l2Sa|

[®] [S d
|30Se| |30S7| |40S2|

® ® <S)

INSTRUCTION
LASa

TITLE: PROJECT CUSTOMER

0311~6,0442~4 HMD
LAY OUT APP.
[Link] 2004.11 A B S
W/O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~6.0442~4
K A M Q f t i M INDUSTRIES CO., LTD REV. DESCRIPTION DATE NAME owo. [Link]
owo. NO.
KB-EL-910
IHECT
 10 11 12 13 14 15 1o 17

1400 PAINTING COLOR : RAL 7032

260 1350 016
I PROTECTION : IP 44
^ ,
'25 fTSl
T •|i
._y WEIGHT : APP. 250Kg
, -r- "T
0 0
^
r-
^
FAN AIR OUTLET AIR DUTLET

o
o
o» 0 0

o o
I10Q2

0
AIR [ vILL T TERMINAL BLOCK AIR INLET 016
—1 1 1

L
r 1 TERMINAL BLOCK 1

0 0
1 T/B

<ANGRIM
1
J
o

° 30 380 580 380 30

240 1400
^
TITLE 0311~6.0442~4 CU'TOMW H M D
LAY - OUT
[Link] 2004,11 A BS
FOR FINAL DWG. 2005.10 [Link] [Link] w/o NO. PBC04MP0311~6,0442~4
k A M Q f t i M INDUSTRIES CO., LTD, REV. DESCRIPTION DATE NAME [Link]
DWO. N O .
KB-EL-910
 1 2 3 4 5 6 7 8 ^ 10 11 12 13 14 15 1o 17 1
POS TEXT TO BE ENGRAVED TYPE/COLOR POS TEXT TO BE ENGRAVED FYPE/COLOR
1002 MAIN POWER SUPPLY OFF - ON 40H15 AUTO ST-BY OIL TRANSFER PUMP STARTED RED
A

10Q5 COMBUSTION AIR FAN MOTOR MAX. 150A 40S2 LAMP TKT PUSH BUTTON

tf 10QU IGNITION OIL PUMP MOTOR MAX. 0.63A

41H2 UPTAKE GAS TEMP HIGH RED
10A6 AMMETER FOR COMBUSTION AIR FAN 41H4 RRE IN WINDBOX HIGH TEMPERATURE RED
41H6 HIGH WATER l£VEL RED
C 1106 OIL TRANSFER PUMP 1 MAX. 6.3A 41H8 LOW WATER LEVEL RED
1109 OIL TRANSFER PUMP 2 MAX. 6.3A 41H10 TOO LOW WATER LEVEL RED
11F13 PILOT LAMPS MAX. 4A 41 HI 2 LOW OIL PRESSURE ON BURNER RED
11FU TRANSFORMER SUPPLY MAX. IDA 41H14 HIGH STEAM PRESSURE RED
11F15 CONTROL VOLTAGE MAX. 6A
D
12S3a EMERGENCY STOP 42H3 LOW STEAM PRESSURE RED
12S8 CONTROL VOLTAGE OFF/ON/RESET 42H5 HEATING TRACER GREEN
42H7 HIGt-1 SAUNITY IN FEED WATER RED
L 42H9 SPACE HEATER ON YELLOW
42H11 OPERATION WHITE
14S4 OIL TRANSFER PUMP 1 [Link] 42H13 FLAME ONfOIL VALVE OPEN) GREEN
US5 OIL TRANSFER PUMP 1 OFF/ON 42H15 IGNITION WHITE
14S8 OIL TRANSFER PUMP 2 [Link]
h 14S9 OIL TRANSFER PUMP 2 OFF/ON
43H1 LOW OIL THJP. RED
43H3 HIGH OIL TEMP. RED
43H5 COMBUSTION AJR FAN OVERLOAD RED
15A2 WATER LEVEL CONTROLLER 43H7 OVERLOAD IGNITION PUf|IP RED
G 43H9 LOW COMBUSTION AIR PRESSURE RED
18S10 HEATING TRACER OFF/ON 43H11 LOW ATOMIZING STEAM PRESSURE RED
43H13 HIGH OIL CONTENT IN FEED WATER RED

25S5 BURNER OFF/ON

H 22S13 SPACE HEATER OFF/ON 44H1 RED
EMERGENCY OPERATION
24S14 BURNER OPERATION [Link]/AUTO 44H3 CONTROL POINT YELLOW
44H5 FLAME FAILURE RED
44H7 TROUBLE fFLAME SCANNER FAILURE) RED
1 30S5 BURNER MODULATION MAN - AUTO 44H9 COMBUSTION AIR FAN RUN GREEN
30S6 MANUAI DECREASE BURNER LOAD PUSH BUnON 44H11 FEED WATER PUMP 1 QN GREEN
30S7 MANUAL INCREASE BURNER LOAD PUSH BUnON 44H13 FEED WATER PUMP 2 ON GREEN
30A10 STEAM PRESSURE CONTROLLER

J
40H2 SUPPLY ON WHITE
40H3 EMERGENCY STOP RED
40H7 DIESEL OIL OPERATION BLUE
40H9 HEAVY FUEL OIL OPERATION BLUE
K 40H11 OIL TRANSFER PUMP 1 ON GREEN
40H13 a L TRANSFER PUMP 2 ON GREEN
TIM: PROJECT Q3^ ^ ~ 6 , 0 4 4 2 ~ 4 CUSTOMER
HMD
NAME PLATES APP DATE 2004.11 CLASS
[Link]
A B S
L
0 FOR FINAL DW("V 2 005.10 [Link] ° " ' * - [Link] w/o NO. PBC04MP0311 ~ 6 , 0 4 4 2 - 4
^ ^ ^ ^
K A M Q f t i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME °**'- [Link] owe. NO. KB-EL-910 SHEET 5
 1
1 I 3 4 6 7 8 J 10 11 12 13 14 15 1o 17

^ ^ ^11 1"!
A
^ ^ M1 11
T _ / 4 4 W\

y"

Jl

C •o -Q5 L)-QU
150A p 7 0.63A
? ? ? ? ? ^

D
b <
\
"7
' \ ' k
•"7 '• - J - Q 2
II (A)-A6
1
p c
r 1P 1• ) / 1 7 5 A f-—f—^27K14
c 5
?-N 38 ° 38 •
E <b u 0
2.0"
o

( On ( Jfl Oo On On On On

F
G Y B
Hh J22KQ
G Y B
<
a
22 • 22 ° 1

U
G
-XI' R ' S T

?.l l i r
- X I •U2 • V2 .W2
1
1 - X V U1 ' VI
1
W1 -X.I
H 1 1 1
— - 1 iY1

1
N/
<sf J T
K
{ ~
^ ^
/^
1 ^ \ - M5
<
1
J
P 63 KW v^
1 In 101.8A (Y-£^
?Q)\ /VER SUPP LY 1 1 -M14
Z%A I-40V. 60H Z 1 1st 682A (3 . 0.22 KW

,1 7nt <W COMBUSTION 1n : 0.58 A

AIR FAN St : 1.9 A
TEF; M I N / I^L CC)DE ( 5 8 W*"*
R(L0 : GREEN 1GNITION OIL
SfV rELLC)W f'UMP
K 0 : BROV\IH
TITLE: PROJECT CUSTOMER H^^o
0311 ~ 6 , 0 4 4 2 ~ 4
LiA IM
MA llN
^;iRC1UlNT
I 1 DIAGRAM APP DATE CLASS ^ B s
2004.11
[Link]
L c FOR FINAL DWG
W/O NO.
PBC04MP0311 - 6 . 0 4 4 2 - 4
^gmnBjS 2005.10 [Link] °"'*' [Link]
) Uk >lki
' imWk\u M INDUSTRIES CO., LTE • R E V. DESCRIPTION DATE NAME '"*^' [Link]
OWO. NO.
KB-EL-910 **^" 10
 1 1 2 3 4 5 6 7 8 d 10 11 12 13 14 15 1o 17

(^n^^^ ^ "
A
(1017) ^ ^

(1017) i^ ^
B
< <
(y
V^ivQ3
(^ cy 6.3A <
ki^ivoe -F14
10A
D^ <y <p 6.3A
C (i H ' >G
440V

-T13
( (
•1 1.5KVA

Lir^^
r[ ' rri
D yi4K3

J
24V
:"
zo° zo° ^-F15
> - *) \ —
9' 9'
J 6A
L
4A 1 A ^ ^1-1 1^

F
1 B

^
-

*
(12. 1)

( 4 0 . 1)
G Y B G Y B D ^ Ho 1^

G
- X I ' U3 ' V3 . W3 -XI i U 4 • V4 . W4

TRANSFORMER
CONTTROL VOLTAGE
H

K
v^?^
\ ^ 1 \
i 1
1

-M 6 -M 9
13 • 2.2K w 2.2K W
3
1n : 4.2 A n : 4.2 A
J
1 St : 32 / 1 St : 32 /
TERMINAL CODE
R ( U ) : GREEN
)IL Tf ^ANS FER
^ C)IL TFM N S FER
S ( V ) : YELLOW ^ UMP 1 F'UMP 2
K T(W) : BROWN

TITLE; PROJECT CUSTOMER H^^D

0311 ~ 6 . 0 4 4 2 ~ 4
MAIN LIKOUII UIA GRA M APP
°*"^ 2004.11 CLAW ^ g s
[Link]
L 0 FOR FINAL DWG. 2005.10 [Link] '*^'*' [Link] w / o NO. PBC04MP0311 ~ 6 . 0 4 4 2 ~ 4
<^^KiUiQRiMI INDUSTR]ES CO, LTD. REV. DESCRIPTION DATE NAME °'^' [Link] owo. NO. KB-EL-910 '""^ 11
 10 11 12 13 14 15 lb 17
(11,16)- (13, 1)

-F13
2A
-K3 -K6

-XI

U r n
I-S3
29!f'^ OFF\ ON/RESET
/
\ /
- S\ 8/
CONTROL VOLTAGE
-XI t 6

-S3a
9'
-K6
4? h

(11.16)-
2SEC
K2;

0 [-K6

-K5
-K8
©
(13. 1)

40, 1 a ,4 a . 7 a , 5 a 16, 4 a 26.16 a

50, 3 b 40. 3 b b 50, 2 b 16. 6 a 19.10 a
50, 3 a b b b 50, 8 b 16. 8 a 19,12 a
b 50. 1 a a a , 6 a 14,13 a 19,14 a
OFF DELAY a a a a 19, 7 a 26.15 a
SUPPLY ON [Link] STOP 50.15 b b 17. 3 a 20, 4 a
50,15 b b 17. 5 a 20, 7 a
59,17 b b 17. 7 a 18, 5 a
- S 3 • REMOTE LOCKABLE EM'CY STOP 50,17 b b 17, 9 a 18. 7 a
(NOT KANG-RIM SUPPLY)
-S3a: LOCAL LOCKABLE EM'CY STOP RESET VENTILATION FAN
CONTROL VOLTAGE
TITLE: 0311-6.04X2-4 CUSTOMER HMD
CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] S.W.JE0NG PBC04MP0311 ~ 6 . 0 4 4 2 ~ 4
K A M Q R i M INDUSTRIES CO., LTD, REV. DESCRIPTION DATE NAME owo. [Link]
DWO. NO.
KB-EL-910
SHCET
12
 1 I ~ 10 11 12 13 U 15 17
1 1
(12.17)
(14. 1)

-XI t 7 -XI \ 9
1 1

4^= • ^
S7

I I
- X I +8 -XI+10

(12.17)
K5

0 (14. 1)
- S 5 / S 7 : LMITS SWITCHES ON 21, 6 a 18, 4 a
FUEL SELECT VALVE 21. 4 b 40. 7 b
-S5 : CLOSED IN 0.0 POS 40. 9 b b
-S7 : CLOSED IN H.F.O POS a 18.10 a
40.10 a 40. 8 a
18. 2 a 21, 4 a
b 21. 6 b
D.O H.F.O
OPERATION OPERATION

TITLE: CUSTOMER
0311~6.0*42~4 HMD
CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ' - 6 , 0 4 4 2 ~ 4
k A M Q R i M INDUSTRIES CO., LTD, REV. DESCRIPTION DATE NAME
DWO.
[Link]
Dvra. NO.
KB-EL-910
SHEET
13
 10 11 12 13 14 15 1u 17

(15. 1)

(13.17) (15. 1)
, 6 a 11. 3 a .10 a 11. 6 a .12 a a
.16 b 11, 3 a .17 b 11. 6 a . 3 b .12 b -A3+A7:
, 9 b 11. 3 a ,5 b 11. 6 a . 7 REMOTE START/STOP
b
SWITCH LOCATED AT
40,12 a a 40.14 a Q 50,14 a OIL TRANSFER PUMPS
Q b a b 40.16 a MODE : A
40.11 b 40.13 b a SET : 5 Sec
a a 40.15 b
OIL TRANSFER PUMP 1 OIL TRANSFER PUMP 2 a
a
AUTO S T - B Y
OIL TRANSFER PUMP
STARTED
TITLE: CUSTOMER
0311~6,0442~4 HMD
CONTROL CIRCUIT DIAGRAM CLASS
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~6,0442~4
K A M Q f t i M INDUSTRIES CO., LTD REV. DESCRIPTION DATE NAME owo. [Link]
DWO. NO.
KB-EL-910 14
 1 [ 10 11 12 13 14 15 1o 17
1
—
(14.17) (16. 1)

•6 •8 *1 *2 SDC40A5G

'l EV2 EV3

+
I
"7 t9 •17 •18 f3 f11 T12

230

28

- X I +30
X1+32 -X1*33 *S1

I [D--fl-L8 ;
-A13

- X I j 31 - X I • 171 +170 "

l/P

r;^;3
REMOTE WATER LEVEL
SIGNAL TO ECR
10 ( 4 ~ 2 0 mA)
10 Sec 10 Sec
(14.17) -A1 : WATER LEVEL TRANSMITTER (16. 1)
16. 3 a 16, 5 a a -EV1 : - HIGH WATER LEVEL
b b a -EV2 : - LOW WATER LEVEL
a -EV3 : - TOO LOW WATER LEVEL
a -L8 : WATER LEVEL SWITCH - TOO LOW WATER LEVEL
HIGH LOW a TOO LOW -A2 : WATER LEVEL CONTROLLER
WATER LEVEL WATER LEVEL WATER LEVEL -A13 : l/P CONVERTER ON FEED WATER VALVE
16. 7 a -A15 : POWER SUPPLY UNIT
MODE : D MODE : D OFF DELAY
SET : 5 Sec SET : 5 Sec a SET : 5 Sec

TlllI: CUSTOMER
0311->'6,0442-«'4 HMD
CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 '<'6.0442~4
K A M Q f t i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME owe. [Link] OWO. NO.
KB-EL-9tO
SHEET
15
 1 I ~2 10 11 12 13 U 15 17

(15.17) (17. 1)

-K5 12K8 t-K7 12K8

9 '

15K8

(15,17) (17. 1)
. 3 a . 5 a , 7 a
41. 6 b 41. 8 b 41,10 b
17,13 b 17.14 b b
41. 7 a 41. 9 a 41,11 a
50, 1 a 50. 1 a 21, 8 a
a a
b b

HIGH LOW TOO LOW

WATER LEVEL WATER LEVEL WATER LEVEL

HUE: 0311~6.0442~4 ~»-~wo< HMD

CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
FOR FINAL DWG. 2005.10 [Link] [Link] W/O NO. PBC04MP0311 - 6 . 0 4 4 2 - 4
K A M Q R A M INDUSTRIES CO., LTD REV. DESCRIPTION NAME [Link]
DVVO. NO.
KB-EL-910 16
DATE
 10 11 12 13 14 15 It) 17

(16,17) (18. 1)

6 I O I I ^1 ^1
-K2 12K8 -K4 |l2K8 -K6 12K8 -K8 12K8
' 9' 9 ' 9 ' 0 '

-XI f75 - X I t 44 -X1 90 - X I t 33

I I I
-X2f207 -X6|3 -X2i216
I

[P]-|]-P2 [a-Hr-P4 [l}-^-T6 m--^ -T8

I
-X2»208 -xeK I
-X2I217
I I
I
-XI +76 -XI 45 -XI+91 - X 1 \ 34

-K4

(16.17) (18. 1)
. 2 a . 4 a . 6 a . 8 a 50, 3 a 50, 4 a 50, 5 a
41.12 b 41,14 b 41. 4 b 41. 2 b b b b
b b b b
41.13 a 41.15 a 41, 5 a 41. 3 a IMPULSE IMPULSE IMPULSE
TIMER TIMER TIMER
21. 8 a 21.10 a 21,10 a 21,10 a

LOW OIL PRESS. HIGH STEAM FIRE IN WINDBOX UPTAKE GAS MODE : L
SET : 2 Sec
ON BURNER PRESSURE HIGH TEMP TEMP HIGH

TITLE: PROJECT CUSTOMER

0311~6.0442~4 HMD
CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 • v 6 , 0 4 4 2 ~ 4
l U N Q f t i M INDUSTRIES CO., LTD, REV. DESCRIPTION DATE NAME I.S.W00
DWO. NO.
KB-EL-910
SHCCT
17
 10 11 12 13 14 15 K 17

(17.17) (19. 1)

13K5 -K4 12K9 -K6 12K9

OFF

-Xlf67 -X1f69
I I -S10
-X2+210 -X2+213 HEATING
-A3 TRACER

-F1 -F2

ny-/ El--/.
LOW 2 HIGH 2 4
CONTROL
THERMOSTAT

-X2f211 -X2f214
I I
- X I + 68 -XI • 70

(17.17)
0 -K6

(19. 1)
43. 2 a 43. 3 a 42. 6 a
43. 1 b 43. 4 b 42. 5 b
b b b
21. 4 a . 6 0 a
. 4 a 50,16 a a
HEATING TRACER

LOW OIL TEMP. HIGH OIL TEMP.

-A3: OIL SAFETY TEMPERATURE

TITUJ PROJECT 0311~6.0442--4 ^'-TO^ER HMO

CONTROL CIRCUIT DIAGRAM
[Link] o-^^ 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 G.J. ANN S.W.JE0NG PBC04MP0311 ~ 6 , 0 4 4 2 ~ 4
k A M Q R i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME owo. I.S.W00
owe NO.
KB-EL-910 18
 10 11 12 13 14 15 I0 17

(18.17) (20. 1)

I ^1
;:iOF7 ::iOQi4 -K6 i2Ka -K9 12K9
01 Q I

- X I '' 77 -X1 t79

I
I
-X2I2OI
22K7 '28K12
[a-(t-p9
-X2t205 -X2t202
I
I I
- X I \ 78 - X I \ 80

e 0
K4

(18.17) (20, 1)
22, 9 a 27,12 a , 6 a . 9 a
43, 5 b 42. 7 b 43, 9 b 43.11 b
b b b b
43, 6 a 42, 8 a 21,10 a 43,12 a
24, 4 a 24, 2 a 43.10 a 21, 8 a

OVERLOAD OVERLOAD LOW LOW

COMBUSTION IGN. PUMP COMBUSTION ATOMIZING STEAM
AIR FAN AIR PRESSURE PRESSURE

•miE: 0311-6,0442-4 <=«»•«>""' HMD

CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 - 6 . 0 4 4 2 - 4
K A M Q f t i M INDUSTRIES CO., LTD REV. DESCRIPTION DATE NAME owo. [Link] owo. NO. KB-EL-910
SHCCT
19
 10 11 12 13 14 15 Iv. 17
1
(19.17) (21. 1)

I I
-K3 12K9 -K6 12K9
0' o I o I

-XI *^ -XI "54 -XI iA -XI f56

I
-F16
> - ) 4A
3' O'
SA OD

-XI TB -X1 +55 -XI tB -XI +57

-XI iDI D2
DOSING P U M P
SOURCE
-K6 AC220V

(19,17) (21. 1)
, 3 a ,6 a
«• 7 b 43,13 b
45. 9 b 45.11 b
42, 8 a 43.13 a
50,14 a 50.16 a
a a
b b

HIGH SALINITY IN HIGH OIL CONTENT IN

FEED WATER FEED WATER

TITLE: 0311~6,0442-4 ="S™MER ^^^^p

CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A BS
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0511 ~6,0442~4
K A N Q R J M INDUSTRIES CO., LTD REV. DESCRIPTION DATE
DWG. NO.
KB-EL-910
SHBCT
20
NAME [Link]
 10 11 12 13 14 15 17

(20.17) (22, 1)
a
b
b
a
a

OFF 22. 9 a
DELAY b

TITIE; 0311-6.0442-4 cusTOMW HMD

CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A BS
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 - 6 . 0 4 4 2 - 4
K A M Q f t i M INDUSTRIES CO., LTD, REV. DESCRIPTION DATE NAME [Link]
OWO. NO.
KB-EL-910 21
 10 11 12 13 14 15 lb 17

(21,17) (24. 1)

OFF ON

19K2 -SI 3

<J21K12 <j 29T2

o I o I -F16
301 »/ a' 4A

>-K3 K3
> - ^ — - f K 1 3

-K7 -K5
-XI SHI SH2

SPACE HEATER

0
-K5 -K7

15 Sec 1 min
(21.17) (23. 1)
a 10. 9 a 10. 7 a 10. 5 a 42,10 a .13 0
50,10 h 10, 9 0 10. 7 a 10. 5 a 42. 9 b b
b 10, 9 a 10. 7 a 10. 5 a b
a . 7 a . 5 0 28.16 0 .16 a
a b b 44. 9 b ,17 a MODE : A
1 MIN
. 7 a 30. 1 a 44.10 a
ON
DELAY , 5 b a .14 b
b COMBUSTION AIR FAN
LAD-S26
a SPACE HEATER
COMB. AIR FAN

TITIE: COSTOMCR
0311 " 6 . 0 4 4 2 - 4 HMD
CONTROL CIRCUIT DIAGRAM c^TE 2004.11
[Link] A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~ 6 , 0 4 4 2 ' o 4
k A N Q R l M INDUSTRIES CO.. LTD REV. DESCRIPTION DATE NAME
OWG.
[Link]
OWO. NO.
KB-EL-910
SHEET
22
 10 11 12 13 U 15 lb 17

293 320 320

-(24. 1)
8t 81
83 83 317,
-(27. 1)

-K8

310.
-(28. 1)
-K8 -A6 h-t 24K14

SAACKE FLUS OS

Oi OI N3 318 .318^ (27. 1)

24K15
27K3
f-
- X I A99 +100 +101 +102 +103 +104
- X I 181 |82 -XI |83 +84 i r"' 1 1 1 1~^ 27K2
I I I I { ^1 1 1 1 H
- X 2 ' 196 • 195 - X 2 '•197 '198 86
27K3
-X2 +506 +501 +502 +503 +504 +505
-A1 -H4 -XI+86 - X I + 8 8 -XI+131

p
-S2 -S3 BK BU RD GN WH YE I I I
-A12 -X2t17 -X2420 - X 2 t 1 4
-O &—H 0 0
-Y15 -Y16 -Y17

- X 2 ' 199
-KS FLS 09 ra
- X 2 iI 18
cH czH
- X 2 II 21 - X 2 I 15
-XI 185 - X I * • 87 --X
X1I | 8 9 - X U 1 3 2

(22,17) (24. 1)
, 4 a
b
-A1 : EMERGENCY OPERATION BOX b -A6 FLAME DETECTOR FLUS 06 Y15 : OIL VALVE 1
-S2 : IGNITION SWITCH FOR EM'CY OPERATION Y16 : OIL VALVE 2
-S3 : OIL VALVE SWITCH
.15 a
A12 : FLAME SCANNER FLS 09 Y17 . OIL REUEF VALVE
-H4 : FLAME ON a FOR EM'CY OPERATION

EM'CY FLAM ON

CUSTOM CR
TITLE: 0311~6.0442-4 HMD
CONTROL CIRCUIT DIAGRAM DATE
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~ 6 , 0 4 4 2 ~ 4
K A N Q f t i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME
DWO.
[Link]
owe. NO. KB-EL-910
SHCCT
23
 10 11 I 12 \ 13 14 15 1o 17

,J —L_^
(22,17) (25. 1)

320
(23. 3)

16,

2 / - ^ ^ ^
EM"CY AUTO

322 -S14
V
EMERGENCY OPERATION
19K4 19K2

- - % • ] -

-J-K8
oJ
321 325 326

e
-K6 -K14 -K15 -K16

(23.17) (25. 1)
25, 2 a 25. 2 a 23.16 a 21. 9 a 28. 4 a
29,15 b 29,15 b 23.16 b 21. 8 b b
b b SAFETY INTERLOCKS EMERGENCY 28. 2 b 30. 6 b b
28, 5 a 28,12 a CIRCUIT OPERATION 28.15 a 23. 1 a a
28.12 a 50. 7 a H 2 a 23. 2 a a
,8 A * ,8 A 30. 3 b 23. 2 b
,6 B * .6 B 44. 1 b 30. 7 a
25. 5 b 30. 8 a

TITLE: 0311-6.0442-4 ^J'TO^^" HMD

CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A BS
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 - 6 , 0 4 4 2 - 4
k A M Q R i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME owo. 1.S.W00
DWC3. NO.
KB-EL-910
SHEET
24
 1 I 10 11 12 13 14 15 lb 17
1
(24.17) (26. 1)

280 24KU OFF ON

(26.10)
(21,17)
•si
1 Ay
V
-S5
334 •(26.10)

BURNER
SAACKE-AUTOMATIC SEQUENCE CONTROL - F-OSA
-A2

X3: X4: X3: X4: X3: X3: X3: X3: X3:

16 35 17 37 20 14 19 18 21

-A8
SAACKE FLUS 06
31K13
M

4K6

f<
I
-X1 i l 0 5 +106 |107 +108 |109 +110
|24K8 I r'—I 1—I—1"^

1
{ *^l 1 1 1 1-'
-X2 +512 +507 | 5 0 8 +509 |510 +511

BK BU RD GN WH YE
-A12

FLS 09

(24,17) (26. 1)

-A8 : FLAME DETECTOR FLUS 06

FOR AUTOMATIC OPERATION
-A12 : FLAME SCANNER FLS 09
FOR AUTOMATIC OPERATION

CUSTOM CR
TITLE: 0311 '«'6,0442->'4 HMD
CONTROL CIRCUIT DIAGRAM DATE CLASS
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~ 6 , 0 4 4 2 ~ 4
K A N Q R i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME
DWO.
[Link]
OWO. NO.
KB-EL-910 sHorr 25
 10 11 12 13 U 15 K 17

^ 1 1 >
(25.17) (27. 1)

SAACKE-AUTOMATIC SEQUENCE CONTROL - F-OSA

X4: XI: X4: X3: X4: X4: XI: X3: X4:

24 3 31 15 30 40 5 23 39

28K7

-A12

-K16
o I
- X l t 113 - X I t 114 -XI 111 - X I t 112 12K9
I I I I
I I I I
-X2J228 -X2 ^ 2 9 -X2 "231 - X 2 4232 ?.
334
(25.17)
-S2o- -S5o—
/ (25. 3) - K - ^ 5 0 _ 12K9

-K13 K16

(25.17) (27. 1)
44. 6 a . 9 a
-S2: UMIT SWITCHES - AIR DAMPER MAX. 44. 5 b , 8 b
PURGE POSITION
b b
-S5: UMIT SWITCHES - AIR DAMPER MIN.
IGNITION POSITION a a
-A12: TROUBLE INDICATOR CMFS01 a a
FLAME FAILURE RESET

TITLE: CUSTOMER
0311~6,0442~4 HMD
CONTROL CIRCUIT DIAGRAM
[Link] t*-^^ 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~6,0442'«-4
k A M Q f t i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME
owe. [Link] KB-EL-910
SHCCT
26
 10 11 12 13 14 15 lb 17

^ 1 1 >
(26.17) (28. 1)
SAACKE-AUTOMATIC SEQUENCE CONTROL - F-OSA

X4: X3:
36 22

360
-(28,1)

> -K15 19K4 -K15

(23.17)

(23.17)

- X I . 116 -XH20 -x4l22 -Xljil 33

I I
-X2| 2 -X2t 5 -X2f 8 -X2'11

-TIC -Y15|±}X-Y16l±fX-Y17M

-X2i 3 -X2i6 -X» 9 -X2412

0 0
I
,-K2 -K3 I
1
I I
,1
25SEC
.1
Xlt 117 -X1f121 -X1t123 - X I .134

3 SEC 2
(26,17) (28, 1)
23,16 a 23.16 0 10.14 a a
29,15 b 30. 8 b b
-T10 : IGNITION TRANSFORMER 10,14 a
28,14 a b 10.14 a .15 a
24,10 50.12 -Y15,-Y16 : ELECTROMAGNETIC
a a 42,16 a a
IGNITION VALVE 1+2
a 29. 2 a 42,15 b a
OFF -Y17 : RELEIF VALVE
DELAY 29.15 a 4Z14 a
.10 a IGNITION
42.13 b IGNITION P / P
OIL VALVES a OPERATION a ON DELAY
TIM: CUSTOMER
0311-6.0442«-4 HMO
CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] S.W.JE0NG PBC04MP0311 -6.0442-4
KiUHQftiM INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME I.S.W00
OWO. NO.
KB-EL-910 27
 10 11 12 13 14 15 I I0 17

, 1 1
(27.17) (29, 1)
\ 310
( 2 3 . 3) 361 361
24K6

SAACKE-AUTOMATIC SEQUENCE CONTROL - F-OSA

X4: X4: X4: X4: X4: X4: | 224K14

4K14 *|
H29K15
24K8
34 26 28 27 32 29

361
24K14

-K10 27K2
401

24K16

<j-K3 |-K3
24K6 -K12

» - X 1 | 124
I
I
-X2J32
360 360
(27.17) (29.12) O X -YH

0 0 0 0
K31 -K4 -K9 -X2i33
I
I
lOsec lOsec - X l i 125

(27.17) ATOMIZING (29, 1)

, 2 a 30, 1 a H 7 a 30, 1 a a ,12 a ,14 a
50, 7 b STEAM VALVE
b 30. 3 b 30, 3 b 42,11 b a b
b a b b b a b
a a 44, 8 a 30. 6 a 42.12 a a a
a a 17,15 a 30, 9 a a a a
OFF ON
DELAY , 1a a DELAY
CONTROL
IGNITION TIME b PRE-PURGE TROUBLE RELEASE OPERATION END OF PURGE 19.10 b
TlTlf: PROJECT 0311~6.0442~4 CUS™"ER ^,^JJ
CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A 8 S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link]:ONG PBC04MP0311 ~6.0442'>'4
K A M G R i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME I.S.W00 KB-EL-910 28
 10 11 12 13 14 15 lb 17

-J ^
(28,17) (30. 1)
I

27K3 «j-T11 ^27K2

9 '

27K2

24K6

24K8

- X I i 126
-K15

-X2|35

-Y16 \ ± \ ^
A1 • 360
6 (28. 5) (-KI5) -X2i36
T2> (^ry 2 A2
- X l f 127
10 10
40 Sec. 40 Sec. 15 Sec.
(28.17) (30, 1)
. 9 a .13 a
22.10 a 9_a . 7 a
b b BURNER
b ~ b .10 a
30. 3 b b PURGE STEAM VALVE
30. 9 a a
a a
MODE : D MODE : D MODE : A
SET : 40 Sec SET : 40 Sec SET : 15 Sec 28.16 a OFF DELAY
b SET : 15 Sec

TITlt 0311~6,0442~4 "J*f«"» HMD

CONTROL CIRCUIT DIAGRAM CLASS
A B S
[Link] 2004.11
FOR FINAL DWG. 2005.10 [Link] [Link] w/o NO. PBC04MP0311 ~ 6 . 0 4 4 2 ~ 4
K A M Q R I M INDUSTRIES CO., LTD REV. DESCRIPTION owo. [Link] KB-EL-910
SHCCT
29
DATE NAME
 _L_J L 10 11 12 13 14 15 17

30A10

0
(29,17)
30A10 : STEAM PRESSURE CONTROOER
Z5. 6 a
K 3b
b
H. 4 a
a

CONTROL POINT
BURNER START/STOP

TITLL PROJCCT
0 3 1 ' 1->6,0442~4 [c"»TOM»w HMD
CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~ 6 . 0 4 4 2 ~ 4
K A M Q R i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME [Link]
OWO. NO.
KB-EL-910
aHCCT
31
 10 11 12 13 14 15 "lb I 17

(11.16) •LT
(41. 1)

(41. 1)

12K2 I—S2

-43K7
3 3K5
1
O I
4K2 .-|l4K6 -44K11

12K6
Ol
s. 8
S' vl"-

(ji
9"-

h S2 12K3

§.-

,..,,t- t (S)
1
-H3 -H7 -H9 -H11 -H13 -HIS

(11 ^
(41, 1)
(/) m •D >
c
-0
"D
m
::D
I >
^ ^
> >
C C
f5
WW
^ z z
o
-< m
w I/) 5!r
(/)
O
-o
m O
[—
s::o
Tl
::D
•0
X) W
Fl^
•D
;D
> c cz OQ
- S 2 : BUZZER/LAMP TEST
=j
o o Tl 13 —
r
•0
3J >
> z
=1 to
o

TITIE: CUSTOMED
0311~6,0442~4 HMD
CONTROL CIRCUIT DIAGRAM CLASS
A B S
[Link] 2004.11
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~ 6 , 0 4 4 2 ~ 4
K A N Q R I M INDUSTRIES CO., LTD. REV. DESCRIPTION NAME owo. [Link] KB-EL-910 40
DATE
 1 1 2 3 4 5 e 7 8 s( 10 11 12 I 13 14 15 T i o - 17

(An iy\ ^ ^ (a.'f 1^

A
(AHM^ ^ ^ I'lii 1^
r- 1 - 1- (- ~* ^ t4Z, 1J
m —t m - 1 m r- m 1- m -1 m -t r\ Q
-4 -4

—^ . 41
1 O 1 1 " 1 t " 1 1 61 p > 1 ' ii
_J17K'« -IITICK -JlCtl-T IlCI/C Jni/o JlTl^il

C o1
' 9
r ?'"
1 ( 1 1

f r'""'
1
' ? 1 1 •

2 2 (J «J o> Ul SS
M M u •• Ul o> •J

G 0 ^-H2
<2 1
^-H4
0t -H6
<:
^-H8
c h-H10
c ^-H12
C ^-H14

H
(10 1 7 ) ^
c
T
—n

>
X
<D
X
-n
;o
m
« X
> o
^ X
:£ 1—
> o
^ «
s
>
r
Fl
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TITLE: PROJECT CUSTOMCR

0311-6,0442-4 HMD
CONTROL CIRCUIT DIAGRAM
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W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~6.0442~4
K A N Q R i M INDUSTRIES CO., LTD, REV. DESCRIPTION DATE NAME
DWO.
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IN FEED WATER IN FEED WATER
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14K11 12K5 18K6 12K5
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2ND FAULT ALARM FUNCTION (OIL VALVE OPEN)
- POWER FAILURE
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- LOW WATER LEVEL
- LOW STEAM PRESSURE

TIM: 0311~6,0442~4 CUSTOMER ^^^

CONTROL CIRCUIT DIAGRAM
[Link] 2004.11 A B S
W/O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~6.0442-«'4
K A M Q R I M INDUSTRIES CO., LTD, REV. DESCRIPTION DATE NAME
DWO.
[Link] KB-EL-910 50
 10 11 12 13 14 15 1o 17

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POWER CONSUMPTION
ABOUT 70KW 3.01.01 1.27.01 4.08.01 4.08.01 L5

NOTE : * MARK WILL BE PRE-WIRED BY KANGRIM

•niLE: CUSTOMER
0311~6,0442~4 HMD
EXTERNAL CONNECTION DIA. DATE
A B S
[Link] 2004.11
W / O NO.
FOR FINAL DWG. 2005.10 [Link] S.W.JE0NG PBC04MP0311 " 6 ^ 0 4 4 2 ^ 4
K A M Q R I M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE owo. [Link]
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[Link] 2004.11
W/O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 --6,0442-4
K A M Q f t i M INDUSTRIES CO., LTD REV. DESCRIPTION DATE NAME owo. [Link] owo. KO. KB-EL-910
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PROJECT CUSTOMER
TIM: 0311~6,0442~4 HMD
EXTERNAL CONNECTION DIA.
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ~6.0442~4
K A M G R I M INDUSTRIES CO., LTD REV. DESCRIPTION DATE NAME
DWO.
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T1U£: PROJECT CUSTOMER
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EXTERNAL CONNECTION DIA.
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 - 6 , 0 4 4 2 - 4
k A M Q f t l M INDUSTRIES CO.. LTD. REV. DESCRIPTION DATE NAME [Link]
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TITLE: PROJECT CUSTOMER
0311~6,0442~4 HMD
EXTERNAL CONNECTION DIA. APP. DATE
[Link] 2004.11 A B S
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311 ^ 6 , 0 4 4 2 ^ - 4
K A N Q R J M INDUSTRIES CO., LTD REV. DESCRIPTION DATE NAME owe. [Link] KB-EL-910
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TIM: PROJECT CUSTOMER
0311-6,0442-4 HMD
EXTERNAL CONNECTION DIA. OATC
[Link] 2004.11 A BS
W / O NO.
FOR FINAL DWG. 2005.10 [Link] [Link] PBC04MP0311-6,0442~4
K A M Q R i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME
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EXTERNAL CONNECTION DIA.
[Link] 2004.11 A B S
W / O NO.
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K A M Q f t i M INDUSTRIES CO., LTD. REV. DESCRIPTION DATE NAME I.S.W0O
D«W. NO.
KB-EL-910 sneer 66
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<o TRANSFOMER 440/0,24,0,220,1.5KVA 11T13

LOAD COTROLLER SDC40A2G YAMATAKE 30A10

LEVEL CONTROLLER SDC40A5G YAMATAKE 15A2 >

in O Ul
ONE SHOP SIGNAL UNIT OSSU a:

BELL 220VAC
g
—3

C3
•* FLAME DETECTOR FLUS 06 SAACKE 23A6,25AB

TROUBLE INDICATOR CMFS1 26A12

to AUTOMATIC SEQUENCE F-OSA 25A2 \_ 5

AIR TIMER LAD-T026 ON DELAY 27K15,28K12
(

CV|
LAD-R026 OFF DELAY 12K2.15K8,27K2,28K3,29K15 (n
LAD-R046 OFF DELAY (K
21K12 t
c1 .
LAD-S26 ON DELAY 22K3
AMMETER

(ijk9
150/5 KA60 300% 10A6

C/T

1
150/5 10A6
^
< m o 1 o u 11. O X — -3 i^: 1 _i
9. Spare parts and Tools

KANQRIM INDUSTRIES CO.,LTD.

Hull no. Type Customer
0311-6.0442-4 PB0301AS10 Hyundai Mipo Dockyard Co., LTD.

Spare part list

''Spare part for boiler

NO DRAWING NO TITLE TYPE O'tv REMARK

1 MB-PL-01 Spring«feDisc of safety valve SV607 2 DN 65/100

2 - Glass ofwater lever gauge Borosilicate 1 C to C 690
3 - Gasket ofwater lever gauge Non-asb 1 C to C 690
4 - Gasket of manhole Non-asb 1
5 - Pressure gauge 1 O150
6 - Tube plug for boiler tube 15 $63.5
7 - Tube plug for boiler tube 20 048
8 - Steel box 1 600x400x300
9 - Steel box 1 400x400x300
10 - Fuse(Glass) 1 0.2A
11 - Water washing hose 1 M42xl0m

^Spare part for burner

NO DRAWING NO TITLE TYPE O'tv REMARK

1 MB-PL-02 Steam Atomizer nozzle

2 - Peephole glass
3 - Swirler
4 - Flexible tube For steam side
5 - Flexible tube For H.F.O side
6 - Nozzle for igniter
7 - Flame scanner
8 - Nozzle shaft with 0-rin
9 - Gasket For ignition oil p/p
Hull no. Type Customer
0311-6,0442-PB0301 AS 10 Hyundai Mipo Dockyard Co., LTD.

*Spare part for F.O pump

IQ DRAWING NO TITLE TYPE O'ty REMARK

1 MB-PL-03 Filter basket BAS22 1

2 - 0-Ring DD085 1 Viton
3 - Mechanical Seal BDG33 1 Sic-sic
4 - Ball bearing DLR04 1 6304

^Spare part for F.D. FAN

NO DRAWING NO TITLE TYPE mx REMARK

1 MB-PL-04 Ball bearing 2

2 Impeller tools 1

^Spare part for contro panel

NO DRAWING NO TITLE TYPE 0 tv PART No.

1 MB-PL-05 Main contactor LC1-D6511 ] 6002175

LC1-D096 ] 6003451
LC1-D126 1 6003452
LC1-D8011 ] 6002323
2 THERMAL RELAY LR2-D3363 ] 6001970
3 TIMER H3BA-11 ] 6001605
4 AUX. CONTACTOR CAD326 1 6008877
CAD506 1 6008876
5 FUSE lOA :> 6000666
6 CONTROL MODULE TIME CARD I 6002815
RELAY CARD I 6002814
BULBS B24V
Hull no. Type Customer
0311-6,0442-PB0301 AS 10 Hyundai Mipo Dockyard Co., LTD.

*Spare part for Steam Heater

NO DRAWING NO TITLE TYPE Q'ty REMARK

1 Gasket Non-ASB 2
2 Relief Valve Spring SWO-B 1
3 Tube 4)I9.05xl200L 5
4 Plug Wood 10
5 Nylon Brush 1400L 1
6 Tools Box 1
 DATA
TITLE SHEET MB-PL-01
JCNtBRm NO.

SPARE OF BOILER
KANGRIM PAGE 1 OF 2

SUPPLY
SPEC/MATERIAL REMARK
PER SHIP
NO. DESCRIPTION SKETCH
YARD WEIGHT(KG)
CODE NO. SPARE
WORK'G

65A X 100A
SAFETY VALVE
SPRING / SUP9

2007850

C to C
BOROSILICATE
GL^VSS = 690
( 220 )

3003592

NON- C to C
GASKET (C = 690
ASBESTOS
( 220 )

3003592

3txOD480xOD330 FOR
r^\ o MANHOLE
GASKET / NON-ASBESTOS
%
480
t=3
2001518

0~25 kg/cm^
PRESS.
B15O0, PF3/8"
GAUGE

3000755

FOR
TUBE PLUG- CARBON-STEEL 15
063.5
BOILER TUBE

4000387

FOR
TUBE P L U G - CARBON-STEEL 10
048
BOILER TUBE

WITH KEY
SPARE BOX AND LOCKER

5004026
 T I T L E DATA
SHEET MB-PL-01
JCWIQfo^ NO.

KANGRIM SPARE OF BOILER PAGE 2 OF 2

SUPPLY
SPEC./MATERIAL REMARK
PER SHIP
NO. DESCRIPTION
CODE NO. YARD SPARE WEIGHT(KG)
WORK'G

/^"^QQ^ WITH KEY

1

9 SPARE BOX
—T^ o AND LOCKER

^ ^
—KJZ 5003724

•N
rt
FOR
0,2A
10 FUSE ~ SALINITY
(GLASS)
20
3001723

M42 X P2 BALL V / V
1 — m t n f&^
1 1 WATER ynDc^J WMOi a HOSE L—10m 10K-25A
)
WASHING HOSE y

- GBoni— = 1 1 a
4000397
 DATA
TITLE SHEET MB-PL-04
^^iWOR^ NO.
SPARE OF F.D. FAN
KANGRIM PAGE 1 OF 1

SUPPLY
SPEC./MATERIAL REMARK
PER SHIP
NO. DESCRIPTION SKETCH
CODE NO. YARD SPARE WEIGHT(KG)
WORK'G

BEARING

IMPELLER
1 XIIL.

TOOLS
 DATA
JCANGRIM. PUMP SPARE PART SHEET MB-PL-02
NO.:

DCS7/1800 PAGE: 1 OF 1
KANGRIM
Drawing
Supply per
No. Name Sketch Material Remark
ship No. Part
No.

r.
FILTER
BAS22
BASKET

90x3.5
0-RING FOR 70 SHORE
VITON
FILTER COVER
DD0 85

MECH. SEAL SIC-SIC EDO 33

BALL BEARING
6304 DLR04
FOR PUMP
 F.O. HEATER PAGE

«
3PARE PART ANE) COMMON TOOL LIST SHIP NO.

TOTAL TOOLS DRAWING BOX

NAME SKETCH MATERIAL REMARK
NO. PER SHIP NO. NO.

/ ^
ASBESTOS
1 GASKET -ZL/_^^i\_ 1 KRSHMOl SPARE
FREE a c t
V^/
2 GASKET
^^i ASBESTOS
1 SPARE
^ FREE a c t

RELIEF ( ^

3 VALVE SWO-B 1 SPARE

SPRING »21.5 1
p^ 1
_

4 TUBE t A179 5 SPARE

1200 ^

i
•H-^

5 PLUG s.
:g)BE 35
-i WOOD 10 TOOL

NYLON mm il NYLON k
6 1 TOOL
BRUSH 1400L i SS400
-1

// /07 /1
TOOLS BOX PLASTIC TOOL
7 / 1
/