A. ............................................................. General technical information.........................................................................................................Technical specification
....................................................................................................................................Item list
........................................................................................................................ Spare part list
B. .............................................General danger and safety information
C./D. ................................................................. Start-up/ Commissioning............................................................Start-up for fuel oil supply and booster module
......................................................................Flushing instructions for booster module
E. ................................................................................................. Electricity.........................................................Main control cabinet (Circuit diagram and parts list)
............................................................. Description and allocation of the keypad TD 200
...................................Control cabinet for supply pumps (Circuit diagram and parts list)
.................................Control cabinet for booster pumps (Circuit diagram and parts list)
................................................................Distribution box (Circuit diagram and parts list)
...................................................................Spare part list for supply and booster module
1. .................................................................................... Pumps with drive............Operating instructions screw spindle pumps with magnetic coupling (series K)............................................ Installation and maintenance instructions for electric motors
2. .......................................................................................................... Filter ........... Description and operating instructions for duplex filter 2.04.5 110.260 with DPI.........Description and operating instructions for the back-flushing filter type 6.61 Gr.15
......Description and operating instructions for duplex filter 2.06.5.4.195.250 with DPS
3. ............................................................................................... Flow meter ..................................................................................................................Maintenance VZO
4. ........................................................................................................ Tanks..............................................................................................................................Mixing tank...............................................................................Compensation damping pressure tank
................................................Mounting and operating instructions for float switches SR
..............................................................................................Automatic vent valve EF 8180
9. ........................................................................ Heating medium control............Operating and installation instructions for straight through control valve BR 440
....................................................................Operation instruction for linear actuator CS20
..............................................................Operating and installation instructions for strainer
....................Operating and installation instructions for ball float steam traps CONA SC
10. ..................................................................................................... Valves................................................................................................................Change over valve............................................................................................................................. Ball valves
process engineering • fuel oil modules • liquid systems
02.01.2006 ts17281me_e-mail.doc 4/9
D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
PRESSURIZED FUEL OIL SUPPLY AND BOOSTER MODULE ME TYPE: KAH-22-C60-2D-MC
P & I DIAGRAM no.: KAH-22000-C60-2D-MC-1/A
MAIN COMPONENTS
1. HFO/MDO - CHANGE OVER VAL VE, POS. 10.1
1 pc. manual operated change over valve, with two end position switches for remoteindication of status.
2. PRIM ARY FI LTER, POS. 2.1
1 pc. Duplex strainer BOLL & KIRCH, as pumps protection strainer. Filtration of 320
µm absolute (~50 mesh).
3. SUPPLY PUMPS, POS. 1.1, 1.2
2 pc. Screw pumps with magnetic coupling, complete with full capacity safety valves.
Each pump is equipped with electric driving motor and piped with non-return valveand closing valve.
One screw pump is working while the other screw pump is in stand-by.
4. PRESSURE CONTROL SYSTEM WI TH RADI ATOR COOLER POS. 7.1
1 pc. Directly spring operated control valve for controlling the pressure of the supply
pumps. Pressure range adjustable 0.2 - 0.5 MPa.Piping of r eli ef valve is equipped with fi n coolers.
The relief valve is equipped with bypass and closing valves.
5. AUTOMATIC BACKFLUSH ING FI NE F I LTER, POS. 2.2
1 pc. Automatic fine filter (10 µm absolute), BOLL & KIRCH. The automatic filter is
equipped with an alarm of filter pollution. Complete with electric switch board onthe module. The filter is heated and equipped with closing valves and with
process engineering • fuel oil modules • liquid systems
02.01.2006 ts17281me_e-mail.doc 5/9
D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
6. CONSUMPTION MEASURING SYSTEM , POS. 3.1
1 pc. Flow meter with local totalizer for indicating the total fuel oil consumption of all engines. The flow meter is equipped with closing valves and bypass valve.
Suitable for media temperature up to 130 °C.
7. PRESSURE M IXI NG TANK WITH ACCESSORIES, POS. 4.1
1 pc. Pressure mixing tank with automatic degassing equipment:
with tank heating, insulation and galvanized metal plate covering.
Determined by mixing tank volume of 150 liters changing over is possible at 36 % of
maximum fuel consumption for injection systems with allowed temperature gradient of 2 °C/min at most.
8. BOOSTER PUMPS, POS. 1.3, 1.4
2 pc. Screw pumps with magnetic coupling, complete with full capacity safety valves. Each pump is equipped with electric driving motor and piped with non-return valve
and closing valve.
One screw pump is working while the other screw pump is in stand-by.
process engineering • fuel oil modules • liquid systems
02.01.2006 ts17281me_e-mail.doc 6/9
D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
9. HEATERS, POS. 5.1, 5.2
2 pc. Shell and tube heat exchangers, Aalborg. The heat exchangers are counter flowtype, the heated medium is flowing through the shell and the heating mediumthrough the pipes. The heaters are insulated and equipped with safety valves.
The heaters are equipped with bypass and closing valves.
10. HEATI NG MEDI UM CONTROL VAL VE, POS. 9.1
1 pc. Control valve with built-on positioning drive. The control valve is driven by the
output signal of the viscosity controller and controls the heating medium flow to theheaters.control valve kvs value: 10
The valve is equipped with strainer, bypass and closing valves.
11. VI SCOSITY CONTROL SYSTEM , POS. 6.1, 6.2, 6.3
1 pc. Automatic viscosity and temperature measure and control unit, system VAF - KuWo, complete with:
- sensor (VAF)- temperature sensor PT 100
- controller for viscosity and temperature controlling (including indication)- sensor casing - differential pressure transmitter
- electric driving motor (60 Hz, 230 V)
The sensor, including the differential pressure transmitter is factory calibrated as acommon unit and delivers current output signal, proportional to the measured viscosity (4 - 20 mA).
Viscosity can be set from main control cabinet and from ECR by additional set point device/generator ( loose del ivery ).This additional set point generator is equipped with display for indication of viscosity and temperature.
All scales are: in mm²/s (cSt) for viscosity and °C for temperature.
process engineering • fuel oil modules • liquid systems
02.01.2006 ts17281me_e-mail.doc 7/9
D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
12. INDI CATOR FI LTER, POS. 2.3
1 pc. Duplex filter BOLL & KIRCH, as engine protection strainer. Filtration of 50 µm absolute. The strainer is equipped with a built-on differential pressure indicator for indicating the strainer pollution.
The duplex strainer is heatable and equipped with differential pressure indicator with terminal for remote alarm.
13. COMPENSATION DAMPING PRESSURE TANK, POS. 4.2
1 pc. Compensation damping pressure tank
capacity approx.: 19 litremax. working pressure: 1.6 MPa
test pressure: 2.4 MPamax. working temperature: 160 °C
The compensation damping tank is equipped with 3 ball valves.
The purpose of the compensation damping pressure tank is to avoid the possible pressure peaks and to compensate the quick changes of fuel oil consumption if the fuel oil system is maneuvering and/or when the automatic fine filter is in the back
flushing period.
14. CONTROL AND REGULATI ON OF THE MODULE
The module is controlled automatically with alarms and starters by programable logiccontroller (PLC).
1 pc. Main cabinet with:- automatic change over device for power supply
- main switch
- all required signal lamps- starter viscosity motor - starter viscosity controller - filter controlling
- 3-point-step-controller for viscosity and temperature controlling - ampere-meter for viscosity motor
- alarm outputs on terminal strip (dry contacts):- low level in mixing tank - differential pressure high at automatic filter
- fuel temperature (4-20 mA)- fuel viscosity (4-20 mA)
I nput signals: - fuel viscosity set point (4-20 mA)
All control cabinets contain the necessary components, like transformers, relays, fuses etc. .
All casings of control cabinets meet IP 54.
Power distribution of each pump starter cabinet is done via two distribution boxes
connected to different circuits (MSB, ESB) of sufficient power.
All electrical operated components of the module are completely cabled to the terminal strips in the corresponding cabinets, which are installed on the module.
process engineering • fuel oil modules • liquid systems
02.01.2006 ts17281me_e-mail.doc 9/9
D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
15. PERFORMANCE AND MATERIAL S
Steel construction : The steel construction is a welded construction of profile steel bars for mounting the main components. The base frame is equipped with a metal oil pan for leakageoil.
Piping: All piping components of the module are connected with each other through thenecessary pipes.
Counter f langes: All the ingoing and outgoing piping of the module are flange connectionswith counter flanges type 11 according to DIN EN 1092-1. The ingoing and outgoing piping of the module for compressed air are provided with pipe fittings.
Valves: The fit in valves have a nominal pressure class of at least 1.6 MPa.
Pipes: The material of the piping is steel according to EN ISO 4200.
Insulation: The hot fuel oil pipes (with T > 60 °C) are equipped with hard-top insulationwhich is covered with aluminium foil and wire-gauze.
Trace heating: The HFO pipes of the module are additionally equipped with trace heating.
Trace heating medium: steam (approx. 170 °C). The heating medium pipes are safety protected against contact where necessary.
Spray protection : All flange connections of the fuel oil pipes are equipped with spray protection.
Coating: The module is painted in standard paint color RAL 6019. The control cabinets are
painted in RAL 7038 (customers request) .
Lettering: With name plates (brass engraved) at all main components and on all the inlets
and outlets of the module in English and German language.
Classification: All material and components are according to the rules and regulations of SOLAS and the desired classification society.
Test/Certification: The module will be tested hydrostatical and functional in the workshopwithout heating under surveillance of the classification society’s representative.
Dimensions and component arrangement reservation
The external module dimensions and flange positions as stated herein are referred to therequirements and performance of this technical specification and the so resulting components and control systems.
Supplementary modifications of the module as requested by the customer and namely
changes in capacity, performance and/or functions may lead to revised dimensions and component arrangements.
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 1 of 5
2.1 GENERAL
2.1.1 Introduction
All responsible persons and those who work with KUPKE+WOLF fuel oil supplyand booster modules must read, understand and observe in all points thisinformation.
The complete technical documentation should always be kept in the vicinity
the fuel oil supply and booster module.
This documentation refers to details of particular importance for the deployment of this supply module.
It is very important that all responsible persons acquaint with of the presentdocumentation. Errors on the fuel oil supply and booster module can only beavoided and a trouble-free operation guaranteed by knowledge of thisdocumentation.
We recommend you to read this documentation carefully prior to functioning. Themanufacturer doesn’t take any responsibility for damages or malfunctions resulting
from the non-observance of this documentation!
In case of difficulties, please contact the after sales service and/or spare partsdepartment or one of our representatives. They will be pleased to help you.
For possible changes in illustrations and information included in thisdocumentation, in case of improvement or technical modifications in the fueloil supply and booster module, all rights reserved.
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 2 of 5
2.1.2 Application
Fuel oil supply and booster modules are used among others, for supplying mainengines on board of sea going ships. They are designed as a complete module.
In order to deploy an optimal fuel oil supply and booster module for thecorresponding application, the designs are tuned to the complete system, the fuelsand lubricants as well as the flow rate, temperature and the pressure of themedium.
The fuel oil supply and booster module is only designed for the applicationindicated in the chapter A “General technical information”.
Never use the supply module out of its contractual application (cf. chapter A“General technical information”), without asking the after sales service of KUPKE+WOLF GmbH for advice (the address can be found in the followingchapter). Otherwise the guarantee becomes invalid.
2.1.3 Copyright
The copyright to this documentation remains with KUPKE+WOLF GmbH. Thisdocumentation is intended for the assembly personnel, operators and supervisors.It contains prescriptions and drawings of technical nature that may not be copied,neither completely or in part, nor be distributed or used in an unauthorised manner for competition purposes or be disclosed to third parties.
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 3 of 5
2.2 Safety
2.2.1
2.2.1.1
Symbols and notices
Warning symbol
Hazard to life and limb of persons. Observe these notes andbehave in all cases extreme cautiously.Please forward all notes for the safe system at work to other users as well.Further on, follow the generally applicable safety regulationsand regulations for the prevention of accidents.
2.2.1.2 Important symbol
Special attention! Observe directives, regulations, indications andthe correct sequence of operations to prevent damages anddestruction of the system and/or system components.
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 4 of 5
2.2.2 Notices for the warning symbol
The following notes for work safety are to be observed.
- The fuel oil supply and booster module has been manufactured according tothe actual technical standards and is operationally reliable. However,hazards can emanate from this system if it is used improperly by untrainedpersonnel or not for the intended purpose.
- Each person who is involved in the premises of the user with the assembly,dismantling, disassembly, start-up, operation and servicing (inspection,maintenance, repair) of the fuel oil supply and booster module must haveread and understood the complete documentation and in particular thischapter (2.2). We recommend the user to confirm this in writing form.
- The fuel oil supply and booster module can only be used for the technicalpurpose agreed upon in the contract. Any other use than this one is notconsidered to be normal use. The manufacturer will not be liable for anydamage resulting. It is only risk of the user.
- Normal use also includes observance of the assembly, dismantling anddisassembly, start-up, operating and servicing conditions prescribed by themanufacturer.
- Only authorised, trained and instructed personnel are allowed to operate,maintain and repair the functional module. These personnel must get specialinstruction as regards possible hazards.
- To avoid unnecessary risks, all responsibilities for assembly, dismantlingand disassembly, start-up, operation and servicing must be clearly definedand complied.
- For all work concerning assembly, dismantling and disassembly, start-up,operation, adaptation and servicing, the shut-off procedures have to beobserved.
- Any working method that impairs the safety of the fuel oil supply and booster module is prohibited.
- The operator must ensure that no unauthorised persons work on the system.
- The operator is obliged to report immediately any alterations of the fuel oilsupply and booster module that impair the safety to the responsible safetyengineer.
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 5 of 5
- The user is obliged to operate the fuel oil supply and booster module only inperfect condition.
- The user must ensure cleanness and clarity of the system throughcorresponding instructions and controls.
- Arbitrary rebuild and modifications that influence the safety of the fuel oilsupply and booster module are not allowed.
- Basically, all work on the supply module may be carried out only when thesystem is turned off.
- Prior to performing any work on the functional module, be sure that thesystem is depressurised. Furthermore, its drives and additional equipmentare to be so protected that they cannot be switched on unintentionally.This is possible means a lockable local switch (not in scope of supply).Extreme caution is required when handling components that are stillwarm.
- After servicing and prior to start-up and following repairs, verify that allprotection devices are fitted.
- Remove protection devices only when the system is turned off.
- The lifting capacity of hoisting gears for installation must be sufficiently rated(cf. chapter A “General technical information”).
- Fasten the fuel oil supply and booster module only to the existing liftingeyelets.
- Whenever having carried out an electric installation or repair of the electricequipment, the protective measures installed have to be checked (e.g.earthing resistance).
- The local safety regulations and regulations for the prevention of accidentsapply in each case to the operation of the fuel oil supply and booster module.
2.2.3 Environmental protection and dangerous substances
For handling the fuel oil supply and booster module, it is absolutelynecessary to comply with the provisions regarding environmentalprotection and dangerous substances!
Pumps with magnetic coupling are installed on this module.
Persons with pacemakers must not install, maintain and
operate the pumps.
Make sure that the selective switches S2 and S4 at the control cabinets for
supply pumps and booster pumps are in position “0” before starting pumps. After that switch on the main switches S1 and S3 at the pump control cabinets.
Observe the rotary direction of the supply pumps and booster pumps
by shortly starting the pumps using selective switches S2 and S4 at the
pump control cabinets.
11.1 Start-up supply pump I, pos. 1.1, manually
Set selective switch S2 at the control cabinet for supply pumps in position
“Man.”.
When the ball valve “Shut-off automatic degassing” is open, mixing tank isautomatically degassed.
Close ball valve “By-pass flow meter”, pos. 3.1.3. Observe the pressure gauge
on pressure side of supply pumps. It must indicate 4 bar. If not, adjust the
pressure control valve, pos. 7.1, to 4 bar.
After that check the relief valve of the pump. For this close the ball valve “Inlet
pressure control valve”. Pressure at pressure gauge should be approx. 7 bar.
If not, adjust relief valve of the pump (see separate description in chapter 1
“Pumps with drive” of this documentation). Open the ball valves “Inlet pressure
control valve” and “By-pass flow meter”.
Stop supply pump I.
Take care that both pumps do not run parallel.
11.2 Start-up supply pump II, pos. 1.2, manually
Set selective switch S4 at the control cabinet for supply pumps in position
“Man.”.
Act according to procedure of the two last sections of pos. 11.1.
16.1 Set the selective switches S2 and S4 at the control cabinets for supply pumps
and booster pumps in position “Autom.”.
Indication lamp H6 for automatic operation of supply pumps and indication lamp
H11 for automatic operation of booster pumps light up at the main control cabinet
(panel “Pumps controller”).
16.2 Now it is possible to switch on at first the requested supply pump and after
that - with time delay - the requested booster pump using the selective switchesS7 (for supply pump) and S9 (for booster pump) at main control cabinet (panel
“Pumps controller”). Then the other supply resp. booster pump is in stand-by
operation.
If time delay during switching on the booster pump was not long enough, may
be that pumps change to stand-by operation. The alarm message “stand-by
alarm” lights up on the TD 200-display. This alarm message must be signed
(For this see separate instruction manual for TD 200 in chapter E “Electricity” of
this documentation.).
After that a pump reset is to be done. PushbuttonS8 (for reset stand-by supply
pumps) resp. pushbutton S10 (for reset stand-by booster pumps) must pushed for this at the main control cabinet (panel “Pumps controller”). The alarm
message “stand-by alarm” lights down on the TD 200-display and Indication
lamp, which is integrated in before pushed pushbutton for alarm reset, lights
down also.
17. Operating with heavy fuel oil (HFO)
17.1 Set selective switch S4 “Visco. - temp. control” at main control cabinet into
position “Visco.” and selective switch S5 “Local - remote visco. control” at maincontrol cabinet in position “Local”.
Now “Steam control valve”, pos. 9.1 will be controlled depending on
changes of HFO viscosity.
17.2 Switch on the viscosimeter motor and the viscosity/temperature controller at main
control cabinet17.3 Set viscosity/temperature controller into manual operation.
17.4 Make sure that the “Steam control valve”, pos. 9.1 is completely closed. If not,
switch it off manually via viscosity/temperature controller. (See separate
instruction manual for viscosimeter in chapter 6 “Viscosity measuring system” of
17.5 Open all “Steam inlet” and “Condensate outlet” valves.
17.6 Make sure that the valves “Inlet trace heating”, pos. 9.4.1 and “By-pass
steam control valve”, pos. 9.1.3 are closed.
17.7 Check the viscosity set-point of the viscosity/temperature controller.
17.8 Close the by-pass valve of the manifold valve at the DP-transmitter.
17.9 Set the viscosity/temperature controller into automatic operation.
17.10 Turn 3-way ball valve pos. 10.1 at FO inlet into position “HFO Service”.
Indication lamp H5 for HFO service lights up at the main control cabinet.
Set MDO cooler into by-pass operation.The system will be filled up automatically with HFO depending on consumption of
the engine(s). The viscosity/temperature controller regulates automatically theviscosity to the adjusted set-point (see separate instruction manual for
viscosimeter in chapter 6 “Viscosity measuring system” of this documentation).
17.11 In case of pure HFO service it is also possible to control the steam control valve
in dependency on temperature. Set the selection switch S4 “Visco. - temp.
control” at main control cabinet into position “Temp.” and selective switch S5
“Local - remote visco. control” at main control cabinet in position “Local”. Now
the “Steam control valve” will be controlled in dependency on temperature of
heavy fuel oil.
Open valve “Inlet trace heating” not until the system is completely
filled with HFO or if required.
In case of back-flushing of automatic filter will released because differential
pressure increased, indication lamp H16 “Back-flushing release by differential
pressure” lights up at the main control cabinet and is lighting as long as a reset is
done. A corresponding alarm message will be indicated also on the
TD 200-display. The alarm message has to be signed at this display using key
F2 (= reset for indication lamp H16 also).The reason for back-flushing release has to be investigated. Insufficient HFO
quality can be a reason for this. In this case change time setting for “flushing cycle
time” to a lower value at TD 200-display using key F3.
The default value of time setting for “flushing cycle time” (see pos. 15 of this
start-up) has to be adjusted as soon as HFO of better quality has been
(BLZ 290 700 50) Kto. 1 007 004Deutsche Bank Holm(BLZ 200 700 00) Kto. 5 924 824VR Bank eG, Schwerin
(BLZ 140 914 64) Kto. 170976
Geschäftsführer
Paul Kupke, Jürgen Wolf
AmtsgerichtPinneberg HRB 1380
Ust.-ID-Nr. DE 116735004
APPENDIX / DEVIATION CONTRACT
->at ten t ion fo r Sh ipyard : F lush ing ins t ruc t i ons fo r boo s te r mo du le =======================================================================================================
All diesel engine manufacturers require a flushing procedure of the fuel oil systembefore the diesel engine is started up (see engine guide -> general flushing
procedures).Your fuel oil system includes a supply and booster module made by kupke+wolf gmbh.
The internal tubes of our modules are sandblasted, cleaned and each module iscarefully flushed with diesel oil on the test bench.To save the guarantee of this module (and its main components) the shipyard has
to pay attention to some additional requirements regarding flushing of the fuel oilsystem including the booster module.
Our instructions:- Flushing of the module must be effected with Marine Diesel Oil (MDO) with
minimal viscosity of 4 mPas (resp. 4.6 cSt).- Make sure that the internal piping is cleaned and pre-flushed.- Open the drain of mixing tank and compensating pressure tank to flush out the
rests of the conservation oil remained after flushing on the test bench.- Flushing of the booster module has to be done from flange A or B (fuel inlet) to
flange C (outlet to engine) using the internal automatic fine filter on the module.- The return stroke from the engine to the mixing tank has to be flushed as well.- In order to ensure that dirt from the external pipe lines (especially from the return
pipe line of the shipyard does not get into the booster module the additionalfilters should be installed before flange A or B (fuel inlet) and before flange D
(return stroke from engine = return inlet to the mixing tank). These filters shouldhave purity rate of min. 25 µm absolute. The filters should have a check bag or
any other possibility to control the cleanness.- Flushing should be provided in two steps: - Step one: Flow meter, heater, viscosimeter and compensating pressure tank have
to be closed and flushing has to be done through the bypass lines of thesecomponents. After four hours of continuous flushing the shipyard representativehas to check the additional filters. Flushing has to continue until the filters are
clean. When the filters are clean proceed to step two.
- Step two: The bypass lines are to be closed and flushing has to be done throughthe flow meter, heater, viscosimeter and compensating pressure tank. After four hour of continuous flushing the shipyard representative has to check the additionalfilters. Flushing has to continue until the filters are clean.
- As experience shows the whole flushing process should continue min. 24 hours.
If you have any further questions regarding these instructions, please don’t hesitate to
The pumps and automatic filter are controlled by a SPS, located in the
main-cabinet.With the key pad TD 200 it is possible to change some necessary adjustments.
The buttons allocation is fixed as follows:
F1 Automatic filter manually flush
Press button F1 to release the flushing
F2 Reset of the lamp - ”backflushing release by differential pressure”
Press button F2 to reset displayed message
F3 Changing the time settings of the filter
Press button F3 to indicate the adjusted flushing time. After pressing the ENTER-button the displayed value starts to flash.With the arrow keys it is now possible to increase or decrease the value.Confirm with ENTER-button to proceed to the next step.*
Afterwards the filling up time (blocking time) is indicated in the display.
By pressing the ENTER-button the value starts to flash and can also bechanged in the same way as described above.Confirm with ENTER-button to proceed.*
At last the display switches to the adjusted flushing cycle time (automaticflushing release) This value can also be changed in the same way as described
above.
F4 Changing the delay time for pumps st.-by start
1. Approach of the st.- by pumps after pressure-drop or breakdown
of operation pump. Range: 3 - 30 sec.Press button F4 to indicate the adjusted delay time.
After pressing the ENTER-button the displayed value starts to flash.With the arrow key this value can be increaded or decreased.
Confirm with ENTER-button.*
*
To prevent that the TD 200 left off in change-mode, all changes of adjustmentshave to be done within 50 sec.Afterward the TD 200 returns to display-mode automatically.
The service life of the pump is heavily dependent on the pump operating conditions. If the
operational limits are adhered to, see "Operating data", page 4, the pump will last for many years.Symptoms of advanced wear in individual pump components can be detected in accordance with
the following table.
Tab. 1 Chart for testing the maintenance requirement
1. Check the pump regularly every four weeks, both by looking at it and by listening to it.
2. Check for symptoms of premature wear in accordance with the above chart and eliminate the
cause.
Findings Cause Remedy
Running noise increases Onset of bearing damage Replace bearing
Increased leakage Onset of seal damage Replace shaft seal
Abrasive components at the
seal
Non-volatile media Clean seal
Increased shaft coupling play Advanced wear in the
Check if any damage has occured duringtransportation.üCheck nameplate data.üRemove shaft locking device (if any) beforeoperating the motor.üTurn the shaft with the hand to make sure it
is turning freely.
HANDLING AND TRANSPORTATION1 - General
MOTORS MUST NOT BE LIFTED BY
THE SHAFT, BUT BY THE EYEBOLTS
Lifting devices, when supplied, aredesigned only to support the motor. If the motorhas two lifting devices then a double chain mustbe used to lift it.
Lifting and lowering must be done gentlywithout any shocks, otherwise the bearings canget damaged.
DURING TRANSPORTATION,
MOTORS FITTED WITH ROLLER OR
ANGULAR CONTACT BEARINGS
ARE PROTECTED AGAINST
BEARING DAMAGES WITH A
SHAFT LOCKING DEVICE.
THIS LOCKING DEVICE MUST BE
USED ON ANY FURTHER MOTOR
TRANSPORTATION, EVEN WHEN THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE.
STORAGE
If motors are not immediately installed,they must be stored in dry places, free ofdust, vibrations, gases, corrosive smokes,
under constant temperature and in normalposition free from other objects.
Motor storage temperature must remainbetween 5ºC to 60ºC, with relative humidity notexceeding 50%.
In case the motors are stored for more thantwo years, the bearings must be replaced or thelubrication grease must be totally removed aftercleaning.
Single phase motors when kept in stockfor 2 years or more must have their capacitorsreplaced (if any).
We recommend to turn the shaft (by hands)at least once a month, and to measure theinsulation resistance before installing it, in casesof motors stored for more than 6 months or whensubject to high humidity areas.
If motor is fitted with space heaters, theseshould be switched on.
Insulation Resistance Check
Measure the insulation resistance beforeoperating the motor and/or when there is anysign of humidity in the winding.
The resistance measured at 25ºC must be:
Ri ≥ (20 x U) / (1000 + 2P) [MΩ](measured with a MEGGER at 500 V d.c.)where U = voltage (V); P = power (kW).
If the insulation resistance is less than 2megaohms, the winding must be driedaccording to the following:
Warm it up inside an oven at a minimumtemperature of 80ºC increasing 5ºC every houruntil 105ºC, remaining under this temperaturefor at least one hour.
Check if the stator insulation resistanceremains constant within the accepted values. Ifnot, stator must be reimpregnated.
INSTALLATION
1 - Safety
All personnel involved with electricalinstallations, either handling, li fting, operationor maintenance must be well informed and
updated concerning safety standards andprinciples that govern the work and carefullyfollow them.
We strongly recommend that these jobsare carried out by qualified personnel.
Motors must be protected against acci-dental starts.
When performing any maintenanceservice, disconnect the motor from the powersupply. Make sure all accessories have beenswitched off and disconnected.
In order to prevent from penetrating dustand/or water into the terminal box, cable glandsor threaded pipe in the lead holes must beinstalled.
Do not change the regulation of theprotecting devices to avoid damaging.
2 - Operating Conditions
Electric motors, in general, are designedfor operation at an altitude of 1000m above sealevel for an ambient temperature between 0ºCand 40ºC. Any variation is stated on thenameplate.
COMPARE THE CURRENT, VOLTAGE,
FREQUENCY, SPEED, OUTPUT AND
OTHER VALUES DEMANDED BY THE
APPLICATION WITH THE DATA GIVEN
ON THE NAMEPLATE.
Motors supplied for hazardous locations
must be installed in areas that comply with thatspecified on the motor nameplate.
KEEP AIR INLET AND OUTLET FREE
AND CLEAN. THE AIR BLOWN OUT
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE
INLET OPENING DIAMETER.
3 - Foundation
Motors provided with feet must be installedon solid foundations to avoid excessivevibrations.
The purchaser is fully responsible for the
foundation.Metal parts must be painted to avoid
corrosion.The foundation must be uniform and suf-
ficiently tough to support any schock. It must be
TH E MOTORS ARE DYNAMICALLY
BALANCED WITH HALF KEY, AT NO
LOAD AND UNCOUPLED.
Transmission elements such as pulleys,couplings, etc must be dynamically balanced
with half key before installation.Use always appropriate tools for installation andremoval.
6 - Alignment
ALIGN THE SHAFT ENDS AND
USE FLEXIBLE COUPLING,
WHENEVER POSSIBLE.
Ensure that the motor mounting devices
do not allow modifications on the alignment andfurther damages to the bearings.
When assembling a half-coupling, be sureto use suitable equipment and tools to protectthe bearings.
Suitable assembly of half-coupling:Check that clearance Y is less than
0.05 mm and that the difference X1 to X2 is lessthan 0.05 mm, as well.
Note: Dimension X1 and X2 must be3mm minimum
Figure and alignment tolerances
designed in such a way to stop any vibrationoriginated from resonance.
4 - Drain Holes
Make sure the drains are placed in thelower part of the motor when the mounting
configuration differs from that specified on themotor purchase order.
5 - Balancing
7 - Belt Drive
When using pulley or belt coupling, thefollowing must be observed:
Belts must be tighten just enough to avoidslippage when running, according to the
WARN I NG : WARN I NG : WARN I NG : WARN I NG : WARN I NG :
Excessive tension on the pulleys willdamage the bearings and lead to a
probable shaft rupture.
8 - Connection
WARNING:
Voltage may be connected at standstillinside the terminal box for heating elements ordirect winding heating.
WARNING:
The capacitor on single-phase motorscan retain a charge which appears across themotor terminals, even when the motor hasreached standstill.
A WRONG CONNECTION CAN
BURN THE MOTOR.
Voltage and connection are indicated on
the nameplate. The acceptable voltagevariation is ± 10%; the acceptable frequency
variation is ± 5% and the total acceptablevariation is ± 10%.
9 - Starting Methods
The motor is rather started through directstarting. In case this is not possible, usecompatible methods to the motor load andvoltage.
The rotation direction is clockwise if themotor is viewed from DE side and if the
phases are connected according to thesequence L1, L2, L3.
To change the rotation direction, inter-change two of the connecting leads.
Make sure to use the correct cabledimension, based on the rated current stampedon the motor nameplate.
BEFORE ENERGIZING THE
TERMINALS, CHECK IF THE
GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIALAGAINST ACCIDENT RISKS.
When the motor is supplied withprotective or monitor temperature device suchas thermostats, thermistors, termal protector, etc,connect their terminals to the correspondingdevices on the control panel.
10 - Start-Up
THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE
MOTOR.
a) The motor must start and operatesmoothly. In case this does not occur, turn it offand check the connections and the mountingbefore starting it again.
b) If there is excessive vibration, check ifthe fastening screws are correctly fastened.Check also if the vibration comes from a
neighbour machine. Periodical vibration checksmust be done.
c) Run the motor under rated load for ashort period of time and compare if the runningcurrent is equal to that stamped on thenameplate.
1 - General Inspection
üCheck the motor periodically.üKeep the motor clean and assure free air flow.üCheck the seals or V Ring and replace them, ifrequired.üCheck the connections as well as supportingscrews.üCheck the bearings and observe: Any excessive
noise, vibration, bearing temperature and greasecondition.üWhen a change, under normal conditions, isdetected, check the motor and replace therequired parts.
WARNING:
SAFETY CHECK LIST
MAINTENANCE
E N G L I S H
specifications stated on the belt supplierrecommendation.
THE CONNECTION TO THE POWER
SUPPLY MUST BE DONE BY
QUALIFIED PERSONNEL AND WITH
FULL ATTENTION TO ASSURE A SAFE
AND PERMANENT CONNECTION.
AFTER CONNECTING THE MOTOR,CHECK FOR ANY STRANGE BODY
Motors up to frame 200 are normally fittedwithout grease nipples. In these cases theregreasing shall be done at the preventivemaintenance job observing the followingaspects:
üDisassemble carefully the motors.üTake all the grease out.üWash the bearing with querosene or diesel.üRegrease the bearing immediately.
LUBRICATION
2 - Machines Fitted with Grease Nipples
It is strongly recommended to grease themachine while running. This allows the greaserenewal in the bearing housing. When this isnot possible due to turning parts by the greasedevice (pulleys, bushing, etc) that offer somerisk to the physical integrity of the operator,
proceed as follows:üClean the area near the grease nipple.üPut approximately half of the total grease andrun the motor for 1 minute at full speed.Then turn off the motor and insert the rest of thegrease.üThe injection of all the grease with the motor instandstill can make the grease penetrate into themotor, through the inner seal of the bearinghousing.
RELUBRICATION INTERVALS
The frequency of the inspections dependson the motor type and on the applicationconditions.
When ordering spare parts, please specifythe full type designation and product code asstated on the motor nameplate. Please alsoinform the motor serial number stated on thenameplate.
MOTORS FOR HAZARDOUSLOCATIONS
Besides the recommendations givenpreviously, these ones must be also followed:
THE SPECIFICATION OF THE MOTOR
INSTALLATION PLACE IS FOR
CUSTOMER’S RESPONSIBIL ITY,
WHO WILL ALSO DETERMINE THE
ENVIRONMENT CHARACTERISTICS.
Motors for hazardous locations aremanufactured according to specific standardsfor such environments and they are certified byworldwide certifying entities.
1 - Installation
The complete installation must followprocedures given by the local legislation in effect.
THE INSTALLATION OF HAZARDOUS
LOCATION MOTORS MUST BE
CARRIED OUT BY SKILLED PEOPLE,
AND THE THERMAL PROTECTION
MUST BE ALWAYS INSTALLED,
EITHER INSIDE OR OUTSIDE THE
MOTOR, OPERATING AT THE RATED
CURRENT.
2 - Maintenance
Maintenance must be carried out by repair
shops authorized by KUWO.Repair shops and people without KUWO’sauthorization who will perform any service onhazardous location motors wil l be ful lyresponsible for such service as well as for anyconsequential damage.
E N G L I S H
N o te :N o te :N o te :N o te :N o te :üThe ZZ bearings from 6201 to 6307 do notrequire relubrication as its life time is about20,000 hours.üTables 1 and 2 are intended for the lubricationperiod under bearing temperature of 70°C (forbearings up to 6312 and NU 312) andtemperature of 85°C (for bearings 6314 and NU314 and larger).
üFor each 15°C of temperature r ise, therelubrication period is reduced by half.üThe relubrication periods given above arefor those cases applying Polyrex ® EM grease.üWhen motors are used on the verticalposition, their relubrication interval is reducedby half if compared to horizontal positionmotors.
N o te s :N o te s :N o te s :N o te s :No tes :üAlthough Polyrex ® EM is compatible with typesof grease given above, we do not recommendedto mix it with any other greases.ü If you intend to use a type of grease differentthan those recommended above , first contact
KUWO.üOn applications (with high or low temperatures,speed variation, etc), the type of grease andrelubrification interval are given on an additionalnameplate attached to the motor.
THE USE OF STANDARD MOTORS
IN SPECIFIC AREAS OR SPECIAL
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE
MANUFACTURER OR KUWO
Compat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rex ® ® ® ® ® EM greaseEM greaseEM greaseEM greaseEM grease
wi th other types of grease:wi th other types of grease:wi th other types of grease:wi th other types of grease:wi th other types of grease:
Containing polyurea thickener and mineral
oil, the Polyrex ® EM grease is compatible withother types of grease that contain:üLithium base or complex of lithium or polyureaand highly refined mineral oil.üInhibitor additive against corrosion, rust andanti-oxidant additive.
WARNING:
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING
RESULTING IN COMPLETE
DAMARGE.
WE RECOMENDED TO USE BALL
BEARINGS FOR MOTORS DIRECTLY
COUPLED TO THE LOAD.
Disassembly and assembly must be doneby qualified personnel using only suitable toolsand appropriated methods.
DISASSEMBLY AND ASSEMBLY
The stator grips must be applied over theside face of the inner ring to be disassembled orover an adjacent part.
It is essential that bearings assembly bedone under cleanning conditions to ensuregood operation and to avoid damages. Newbearings shall only be taken out from their caseswhen assembling them.
Before installing a new bearing it is
required to check the shaft fitting for any sharpedge or strike signals.For bearing assembly warm their inner
parts withsuitable equipment - inductive pocess- or use suitable tools.
When performing maintenance,installation or relubrication, follow theseinstructions:
üCheck if all components are free of edges,knocks or dirt.üMake sure all parts are in perfect conditions.üLubricate the surfaces of the endshield fittingswith protective oil to make the assembly easier.üUse only rubber hammer to fit the parts.üCheck for correct bolts tightening.üUse clearance calibrator for correct T-box fitting(smaller than 0.05mm).
DO NOT REUSE DAMAGED OR
WORN PARTS. REPLACE THEM BY
NEW ONES SUPPLIED BY THE
FACTORY.
MOTORS DRIVEN BY VFDApplications using VFD´s without filter
can affect motor performance as follows:
IF SUCH RECOMMENDATIONS ARE
NOT FOLLOWED ACCORDINGLY,
MOTOR WARRANTY WILL BE VOID.
2- Inverter Duty Motors:
üCheck power supply voltage of the forcedcooling set.üFilters are not required.
üLower efficiency.üHigher vibration.üHigher noise level.üHigher rated current.üHigher temperature rise.üReduced motor insulation.üReduced bearing life.
1- Standard Motors
üVoltages lower than 440V do not require filter.üVoltages equal or higher than 440V or lowerthan 575V require filter for motor power supplycables longer than 20 meters.üVoltages equal or higher than 575V requirefilter for any size of power supply cables.
WARRANTY TERMSWe warrant our products against defects inworkmanship and materials for twelve (12)
months from the invoice date issued by thefactory, authorized distributor or agent limitedto eighteen (18) months from manufacturing dateindependent of installation date as long as thefollowing items are fulfilled accordingly:
- Proper transportation, handling and storage;- Correct installation based on the specified
ambient conditions and free of corrosivegases;
- Operation under motor capacity limits;- Observation of the periodical maintenance
services;- Repair and/or replacement effected only by
personnel duly authorized in writing by KUWO;- The failed product be available to the supplier
and/or repair shop for a required period todetect the cause of the failure andcorresponding repair;
- Immediate notice by the purchaser aboutfailures accured and that these are acceptedby KUWO as manufacturing defects.
This warranty does not include disassemblyservices at the purchaser facilities,
transportation costs with product, tickets,accomodation and meals for technical personnelwhen requested by the customer.The warranty service will be only carried out atKUWO Authorized Repair Shops or at ourfacilities.
Components whose useful life, under normaluse, is shorter than the warranty period are notcovered by these warranty terms.
The repair and/or replacement of parts orcomponents, when effected by KUWO and/or anyKUWO Authorized Repair Shop, will not givewarranty extension.
This constitutes KUWO’s only warranty inconnection with this sale and the company willhave no obligation or liability whatsoever topeople, third parties, other equipment orinstallations, including without limitation, any
The segment valve (18) is operated by the lever (21). The lever moves through an
angle of 144ø. The travel stops of the lever are located inside the change-over housing. A cam, which is cast integral with the neck of the segment valve extension, moves over the valve position indicator plate (25) to indicate to the operator the position of thesegment valve (see Picture 2).
1. Changing over filter chambers:1.1 Slacken the air vent plug (4) of the cleaned filter chamber.1.2 Turn the lever (21) to move the position indicator cam from position "1" to position "2"
(see Picture 2). In this position the segment valve opens a port to allow liquid to flow inand fill the cleaned chamber. As soon as the liquid flows free of air bubbles from the ventplugt (4), close the vent plug.
2. Preparing the Filter for Operation2.1 Position the lever (21) in the middle position - both filter chambers in operation.2.2 Open both filter chamber vent plugs.2.3 Start and slowly run the plant or equipment.2.4 As soon as liquid flows from the vent plugs free of air bubbles, close the vent plugs.2.5 Operate the lever to close one of the filter chambers; whilst the other filter chamber
takes over filtration of the liquid, the other (closed) filter chamber remains in reserveuntil, due to contamination, the maximum preset differential pressure is reached. At adifferential pressure of 1,2 bar allowed for starform elements or 0,8 bar allowed for basket-type elements, the reserve or cleaned filter chamber is to be put into operationas follows:
2.6 Momentarily open the vent plug (4) of the reserve chamber and check to make sure thatthis chamber is full.
2.7 Change over the filters as described under paragraph 1.2.8 Open the vent plug (4) of the closed filter chamber to relieve any pressure in this
chamber. It will now be possible to check whether the segment valve (18) has in factclosed the inlet port to this chamber.Note that a complete sealing of a segment type valve is not possible. By opening thesludge discharge plug (2), any liquid that has leaked passed the segment valve duringcleaning can be drained off.
2.9 Remove the filter cover (11) from the closed (shutoff) filter chamber.2.10 Open the sludge discharge plug (2) and drain down the liquid until the liquid level is
below the seat of the element. Remove the filter element from the filter housing.
2.11 Clean the filter element (see the Operating Instructions for cleaning the element).2.12 Replace the cleaned element into the filter housing. Make sure the seal of the element
2.13 Replace the filter cover (11). The vent plug isto be left open at this stage. Make sure that thecover seal (12) and its seat are clean and in agood condition, if necessary, renew the seal (12).
2.14 Move the lever (21) from position "1" to position "2" - the cleaned filter chamber will now be refilled and vented of air.
2.15 Close the vent plug - the filter chamber is now in an operational-ready condition.
3. MaintenanceMaintenance of the duplex filter extends to an inspection and eventual replacement of the sealing elements and screens. If the filter assembly shows signs of corrosion, then itshould be reconditioned or renewed as necessary.The filtering of cooling water and other certain types of operating mediums can lead toformation of harmful deposits on the surfaces of the components in the change-over housing, it is therefore advisable to operate the change-over mechanism at regular inter vals to avoid seizure of the segment valve.
Removing and Replacing the Segment valve (18)3.1 Open both filter chamber vent plugs (4) to depressurize the filter chambers.
3.2 Drain both filter chambers.3.3 Using circlip pliers (DIN 5256C - Securing Borings), remove the circlip (20) from the
groove.3.4 By rotating and at the same time lifting the segment valve (18), remove the valve
from the change-over housing.3.5 Detach the O-rings (19).3.6 Thoroughly clean the segment valve and examine the valve for damage. Remove any
traces of scoring by polishing the valve with a suitable, fine carborumdum paste.Examine the valve bore in the change-over housing and if necessary treat in thesame manner.
3.7 Lightly oil the O-rings (19) and then refit them in the grooves of the segment valve. It isrecommended to renew these O-rings as, due to hardening and compression they
loose a certain amount of elasticity.3.8 Carefully insert the segment valve (18) into the top of the change-over housing and, by
pressing down and rotating the valve at the same time, push the valve into the housing.
3.9 Position the indicator cam to point to the centre position on the valve position indica tor plate (see Picture 2).
3.10 Now push the segment valve further down into the bore until the groove for the circlip (20)becomes visible.
3.11 Refit the circlip (29) in the groove.3.12 Check the segment valve for ease of operation.3.13 Prepare the filter assembly for operation as described in paragraph 2.
It is recommended to wet the recess for the O-ring (12) in the Filter housing withVaseline to make it more difficult for theO-ring to move..
1. Maintenance and Cleaning1.1 Take the filter out of operation. See the
operating instructions for simplex and
duplex filters.
1.2 The filter chamber taken out of operation isdrained, using the discharge screw, until thelevel of the liquid is below the elementsupport. The basket element is thenremoved from the housing. The coarsestdirt particles can now be shaken off. Theelement should then be placed in a suitablecleaning agent, e.g. BOLL CLEAN 2000,and compressed air should carefully be
blown through the element from the outsideto the inside. For obstinate dirt, use of a softbrush which will not damage the mesh isrecommended.
If media containing ferritec particles are tobe filtered out, the basket element is fittedwith a bar magnet (225).
1.3 Structure of the Basket ElementThe basket element is a compoundstructure, consisting of a bottom plate (11),top ring (1), handle (124), support mantle(80) and tie rod (222).
All the elements are held together on the tie rod (222). The thread on the tie rod(222) is glued to the handle (124) so that the element can only be dismantled byundoing the hexagonal nut (221).The wire gauze (100) is welded from inside on to the support mantle (8).The flow is always from the inside to the outside.
1.4 Basket elementThe element is to be inspected and cleaned at regular intervals. The length of theintervals depends on the amount of contamination expected. It is recommended,however, that the initial cleaning should take place immediately after a newsystem is flushed trough.In general, however, the pressure drop across the filter is a good indicator of thecontamination on the filter element. This pressure drop should not exceed 0,8 bar,since otherwise there is a danger of the element fracturing.(Dedicated differential-pressure monitors are available from the our
RATING : MAX. PRESSURE 100 BARMAX. TEMPERATURE 150°C
RANGES OF PRESSURE DIFFERENTIAL DELTA P = 0 - 0.5 BAR0 - 0.8 BAR0 - 1.2 BAR TO BE SPECIDIED WHEN ORDERING0 - 2.0 BAR0 - 3.0 BAR
DESCRIPTION:
THE PURPOSE OF THE DEVICE IS TO MEASURE AND GIVE A VISUAL INDICATION OF A VARIABLEPRESSURE DIFFERENCE.
METHOD OF OPERATION:
A PISTON WITH DIAPHRAGM SEAL DIVIDES THE SPACE UNDER PRESSURE INTO TWO CHAMBERS.THROUGH THE ACTION OF A SPRING UNDER TENSION THE PISTON IS KEPT IN THE ZERO POSITION WHENDELTA P = 0.
AS THE PRESSURE DIFFERENCE INCREASES (DELTA P > 0), THE PISTON MOVES AGAINST THE SPRING. ATTHE SAME TIME AN INDICATOR DISC IS ROTATED BY MAGNETIC MEANS, THAT IS VIRTUALLY WITHOUTFRICTION. AS A RESULT OF THE MOVEMENT OF THE PISTON, THE RED SEGMENT OF THE DISC BECOMESVISIBLE IN THE REGION EXTENDING FROM APROX 50% TO 100% OF THE DIFFERENTIAL PRESSURERANGE.
2.06.5. = Doppelfilter aus GG25 duplex filter made of GG25 Filtre double en GG25 G . = Gehäusedurchmesser cabin diameter diamètre du corpsQ . = Filtereinsatzlänge length of the filter element longueur du panier DN .= Anschlußflansche connection flanges brides désirées
retaining ringanneau de protection 2200002 1 2200002 1 2200001 1
18Druckausgleichkükencock for equalizuation of pressurerobinet d'equilibroge de pression
Z35775 1 Z35775 1 Z35775 1
19O-Ring (Viton)O-RingO-Ring (Perbunan)
3034796
30400942
3034796
30400942
3034796
30400942
20Schraubescrewvis
2007497 2 2007497 2 2007497 2
21
Federring
springressort
2209799 2 2209799 2 2209799 2
23Hahnschlüsselreversing handleclé
WN 48.3SW 27 1
WN 48.3SW 27 1
WN 48.3SW 27 1
24Differenzdruckanzeiger differ. press. indicator indi. de diff. de pressure
TypDruck
TypePressure
TypePression
30Verschlußschraubescrew plugvis
2002885 2 2002885 2 2002885 2
31 Dichtunggasket joint
3270002 4 3270002 4 3270002 4
32Verschlußschraubescrew plugvis
2002885 2 2002885 2 2002885 2
39Mutter Nutecrou
2100003 1 2100003 1 2100003 1
47Dichtunggasket joint
3380041 2 3380041 2 3380040 2
48Dichtunggasket joint
4-18109 1 4-18109 1 4-18109 1
49Stiftschraubestud boldvis
2000001 4 2000001 4 2000001 4
50Mutter Nutecrou
2100004 4 2100004 4 2100004 4
*) Bei Mantelsieb (1) und Kerzeneinsatz (2) zusätzlich.These items are supplementary by multimantle- (1) and filtercandle-element (2)En supplément avec panier á manteaux (1) et cartouches (2) filtrantes.
Duplex filters which can be changed over consist of two filter housings operated inparallel by a two-stage change-over device. The filter housings are designed tomeet the current regulations for a particular pressure range, the filter elements areprovided with an appropriate safety factor for the differential pressures indicated onthe filter nameplates. The maximum differential pressure for filter meshes is 0.8 bar,for micro-cartridges 2 bar.Duplex filters are used in cases where the contaminated filter elements have to beregenerated without interrupting the filtration process.
The change-over devices, i.e. cylindrical plugs, ball valves or double-stage change-
over valves, permit change-over without pressure shocks. Owing to the design of the change-over device it is not possible for both filter chambers to be switched off at the same time.
2. Installation
When the filter is attached to its foundation, the filter housing must be free fromstrain. The same applies to the connected piping. The connections for the inlet andoutlet depend on the strainer element used (see works standard WN 211). Payattention to the arrow marked on the housing.
Heated filters with shut-off devices:- Special equipment needed for heatable filters -
Heating of the filter serves to offset the heating loss at the filter during the filtration process
or before start-up of the plant to heat the liquid in the filter.
According to the AD Information Sheets, the filter housingsare only rated for internal overpressure. Additional externalforces and moments at the connection flanges of the filter are to be avoided (possibly support feed lines).
a) Steam-heated filters:
Safety valves for the filter chamber set to operate at therelief pressure which is 10 % above the max. admissibleoperating pressure of the filter housing.
b) Electrically heated filters:Thermostats which cut off the power supply to theheating element at a max. admissible temperature of 150 °C in the filter chamber and one safety valve per filter pot.
3.1 Pressure filters (> 0.1 bar pressure in the filter)Set the change-over device to the mid-position, both chambers in service, pressureequalising cock open.Open air vents of both chambers (with venting screws only about 1 turn).Start plant up slowly.Close air vents when the air has escaped and the liquid has started to emerge.Isolate one filter chamber by operating the change-over device, leave the pressureequalising cock open; while one of the filter chambers is being used for filtering, theisolated chamber is on stand-by until the admissible differential pressure has built upas a result of clogging. At a differential pressure of 0.8 bar in filter meshes or 2 bar in micro-cartridge filterschange over to the clean filter chamber as follows:
Cleaning
• Check that the pressure equalising cock is open and whether the stand-bychamber is full by briefly opening the air vents.
• Change over.
• Close pressure equalising cock.• Open the air vent on the isolated filter; this releases the liquid pressure and it isthen possible to check whether the change-over device has cut off the flow to thefilter chamber.In contrast to the change-over and ball valve devices, complete sealing is notpossible with the plug-type system; by opening the sludge outlet, liquid leakingduring the cleaning process can be drained off.
• Remove the housing cover from the isolated filter chamber.• Drain liquid down to the strainer base in the case of basket strainers; drain filter
housing completely in the case of mantle strainers, cartridge strainers and micro-cartridges.
• Remove the filter element vertically upwards.
It is imperative for the pressure equalising cock to onlyremain closed in the cleaning phase so that there is noinadmissible pressure build-up through the thermalexpansion of the medium in the isolated chamber.
In smaller duplex filters without pressure compensation theheat expansion of the medium is so low that there is norisk to the components.
• Clean filter element (see operating instructions "Strainer cleaning"); renewdisposable elements and install them in the filter.
• Before mounting the cover, check that the seal is in perfect condition and seatedproperly.It is imperative to renew seals which have become hardened and deformed.
Screw cover on, the air vent remains open.Open pressure equalising cock or, if not installed, set change-over device to midposition until the air has been vented.
• Close air vent. This filter is now on stand-by.
3.2 Suction filters (< 0.1 bar pressure in filter)
Recommended container filling for suction filters
drain
filling line
• Fill and vent both filter halves.• Isolate one of the filters with the change-over device, close pressure equalising
cock.• Start up the plant. While one filter chamber is being used for filtration, the isolated
chamber is on stand-by. When the differential pressure across the filter reachesthe maximum allowed by the pump suction head, a change-over to the other filter
half must be made.• Open pressure equalising cock.• Change over.• Close pressure equalising cock.• Open air vent on the isolated filter half.
• Dismantle the housing cover from the isolated filter half.• Drain liquid down to the strainer base.• Remove filter element vertically upwards.• Clean filter element (see operating instructions "Strainer cleaning"). Renew
disposable elements and install in the filter.• Fill filter housing (see Fig.).• Before mounting the cover, check that the seal is in perfect condition and seated
properly.It is imperative to renew seals which have become hardened and deformed.Close air vent.
• The cleaned filter half is ready on stand-by. This procedure is to be repeated fromsection as and when required.
4. Servicing:Servicing of the duplex filter comprises checking and, if necessary, renew theseals and filter elements. If the filter is provided with rust-inhibiting paint, touch up or repaint as and when required.When filtering cooling water or media which may cause sedimentation on thechange-over device, it is advisable to activate the change-over device as often aspossible and at regular intervals in order to prevent clogging.
It is not permitted to fill the filter against theindicated flow direction of the filter elements.
OPERATING INSTRUCTIONSFOR SEGMENTAL COCK CHANGE-OVER VALVE FOR DUPLEX FILTER TYPE 2.06.5 AND 2.06.7
1. GeneralThe segmental cock valve is used as a change-over element in duplex filters.The flow diagram, Fig. 1, shows the change-over arrangement and the filter chamber in use.
The special design and the limited change-over movement of the segmental cock (2) preventpressure surges and interruptions to the flow.
Ease of movement and pressure-tightness of the
segmental cock (2) are achieved by means of exact fits and small friction surfaces.
2. Operation
Change-over The segmental cock (2) is moved through 120°by turning the valve lever (6) to the left or right.The pin "A" in Fig. 1 points towards the ap-propriate symbol indicating which chamber themedium is flowing through.The pressure equalisation knob (3) is closed byturning the knurled screw (5) clockwise until
screwed in full. This covers a bore located atright angles to the cock axis.The relevant filter chamber is filled through thisopen transverse bore.The isolated filter chamber is pressure-relievedby loosening the venting screw and can then becleaned (see Operating Instructions for DuplexFilters and Operating Instructions for Strainer Cleaning).
In the operating mode the pressureequalisation knob must always be open,i.e. both filter chambers are under operating pressure.
When the filter chambers are operated in parallel, the pin „A“ in Fig. 1 isin the central position pointing towards the relevant symbol.In this position both filter chambers are in operation.The illustration in Fig. 2 shows the parallel-operation position of thesegmental cock.
1. The multi-mantle filters consist of up to 6 nested filter elements.Fields of application are filter meshes < 200 µm.In order to prevent flow short-circuits, the joins of the individual components are sealed with O-rings.
2. The admissible differential pressures depend on the multi-mantle filter diameter:
supplied as accessories: • magnetic primary filter (19)• magnetic secondary filter (20)
4. Maintenance
4.1 Clean and inspect multi-mantle filter elements at regular intervals. The length of these intervalsdepends on the amount of dirt that has accumulated.
4.2 Carry out the first cleaning operation immediately after the installation has been flushed. A risingpressure loss is a sign of increasing dirt accumulation.The differential pressure is not to exceed 0.8 or 1.2 bar (suitable monitoring appliances are availablefrom BOLL & KIRCH).
5. Cleaning
5.1 Shut off single filter or change over duplex filter. Release pressure from the filter housing by undoingthe venting screw and remove the housing cover. Open the drain screw in the filter base and draincontents completely. Slacken the self-locking nut (4) on the central tie rod (5) and lift out the inner filter with the lifting eye (18). Lift the remaining filter elements out individually by gripping the inside of the filter ring.
5.2 Place the individual filter elements into containers with cleaning agent and brush off with not too harda brush (e.g. nylon brush).
5.3 Now blow compressed air at about 4 bar through the filter element cleaned in the above manner from the clean side. To this end insert the cleaning gun type 5.02 (22) into the openings located inthe upper filter ring and blow through the filter surface from the inside with up and down motions.
5.4 In the case of persistent dirt or paint encrustation, place the filter into a container (e.g. as shown indrawing No. 3-23700) with cleaning agent (to sheet KV 349) and allow to soak for up to 4 hours.Make sure that the filter is not completely immersed but that the upper ring remains free. Thisprevents dirt from reaching the clean side.
5.5 Remove filter and continue to treat as described under points 5.2 and 5.3.5.6 If necessary, repeat points 5.4 and 5.5.5.7 For final cleaning, rinse the filter in clean cleaning fluid (e.g. petroleum ether, paraffin, hot water or
similar) and blow through again. Then check fabric for cleanness and damage. Assess cleaningeffect by holding the filter element against the light. Use a torch for finer fabrics. If the light
penetrates evenly, the fabric has been cleaned well.5.8 Check all seals including cover seals. Seals which have become hard and deformed must berenewed without fail.
Before you open the filter chambers, observe the operating instructions for
DIFFERENTIAL PRESSURE CONTACT INDICATOR TYPE 4.36.2
DESCRIPTION:THE PURPOSE OF THIS DEVICE IS THE MEASUREMENT, AND VISUAL INDICATION OF THE DIFFERENCE INPRESSURE BETWEEN TWO POINTS, AND THE ESTABLISHMENT OF AN ELECTRICAL CONTACT WHEN THEPRESSURE DIFFERENTIAL ATTAINS A SPECIFIED FIGURE.
METHOD OF OPERATION:A PLUNGER SEALED BY A DIAPHRAGM SEPARATES THE SPACE UNDER PRESSURE INTO TWO CHAMBERS.A PRE-LOADED SPRING CAUSES THE PLUNGER TO TAKE UP ITS ZERO POSITION WHEN THE PRESSUREDIFFERENCE DELTA P IS ZERO. AS THE PRESSURE DIFFERENCE INCREASES (DELTA P > 0), THE PLUNGERIS FORCED TO MOVE AGAINST THE SPRING. AT THE SAME TIME, AN INDICATOR DISC IS MOVEDMAGNETICALLY, AND THEREFORE VIRTUALLY WITHOUT FRICTION, AND THE TWO REED CONTACTS AREACTUATED.
THE RED SEGMENT OF THE INDICATOR DISC IS VISIBLE OVER A PRESSURE RANGE EQUAL TOAPROX.50-100% DELTA P . THE FIRST REED CONTACT IS ACTUATED AT 75% DELTA P1, AND THE SECONDAT 100% DELTA P2.
SPECIFICATION:PROTECTION CLASS: IP 65
ELECTR. DATA: SWITCHING VOLTAGE V= MAX.= 250 220
FREQUENCY HZ MAX.= 0-60 0-60SWITCHING CURRENT A MAX.= 1 0.8MAKING AND/OR BREAKING CAPACITY
Beim Austausch einer einteiligen Messkammer (DN 15, 25, 40 oder 50) gegen eine neue, zweiteiligewerden zusätzlich Pos. 11 (Flansch) und Pos. 12 (Schrauben) benötigt. Siehe Hinweis auf Seite 7.
Lorsqu'une chambre de mesure monopièce (DN 15, 25, 40 ou 50) doit être remplacée par une neuve,comportant 2 pièces, il faut, en plus, pos. 11 (bride de la chambre de mesure) et pos. 12 (vis). Voir remarque page 7.
If a measuring chamber in DN 15, 25, 40 or 50, consisting of one part, has to be replaced by a new one(consisting of two parts), pos. 11 and 12 (flange and screws) are needed additionally. See remark onpage 7.
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
11 Messkammmerflansch PN 16 1 12874Bride de la chambre de mesure PN 25/40 12877Flange of measuring chamber PN 16...40 1 -- -- 12978 19547 19508
12 Schraube M 6 x 16 PN 16 4 12958Vis M 6 x 16 PN 25/40 6 12958Screw M 6 x 12 PN 16 4 19035
M 6 x 16 PN 25/40 6 12958M 8 x 25 6 13101M 12 x 40 8 19548M 16 x 50 10 19549
VZE / VZEA Zähler mit elektronischem Zählwerk / Compteur avec totalisateur électronique /
Meter with electronic register Zur Bedienung des elektron. Zählwerkes sicher stellen, dass Gebrauchsanleitung des Zählers, Art. Nr. 11601,vorhanden ist. Umbausätze VZO in VZE oder komplette Aufbaugruppen auf Seite 11.
Le totalisateur électronique doit être adapté au compteur; la marche à suivre figure dans le mode d'emploi ducompteur, document no. 11601. Veuillez vous assurer que ce document est à disposition. Kit de conversion VZO enVZE ou dispositifs complémentaires voir page 11.
In order to operate the electronic register assure that the manual of the flow meter, PN 11601, is at hand.Conversion kits VZO to VZE or complete modules see page 11.
Beim Umbau eines Ölzählers VZOzu einem VZE muss die ganze
Aufbaugruppe ersetzt werden. Dieneuen Teile werden mit der Kalibrierung zum Defaultwert undZählerständen NULL ausgeliefert.
Die ausführende Stelle ist für dieZähleridentifikation nach demUmbau verantwortlich. Wir empfehlen, das Typenschild mit denZählerdaten zu ergänzen.
Lors de la modification d’un VZO enVZE, l’ensemble du dispositif complémentaire doit être changé.Les pièces de remplacement seront livrées avec des valeurs decalibration standard, et le nouveau
compteur sera mis à zéro.
Pour celui ou celle qui entreprend lamodification, celle-ci reste sous sonentière responsabilité. Nour recommandons de complèter la plaque d'identification avec laspécification du compteur.
During the modification from theVZO into a VZE, the completeancillaries related to the VZO mustbe dismantled. The exchanged itemswill be delivered with standardcalibration values, and the counter will be set to zero.
The modification remains under theresponsibility of the party who makesthat modification. We recommend tocomplete the name plate with themeter data.
Fotos/Conversion.tif
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
Umbausatz VZE .... 70°C 19776 19777 19778 19779 --Kit de transformation VZE .... 70 °C Conversion kit VZE .... 70°C
Umbausatz VZE .... 70°C - INA 19785 19786 19787 19788 --Kit de transformation VZE .... 70 °C - INAConversion kit VZE .... 70°C - INA
This is a measuring instrument to be handled with care.
Note on safety
· When removing from pipe, observe safety instructions in the operating manual.· When using inflammable cleaning substances, inflammable objects and liquids are to be removed from the
working area. Room to be well ventilated.· Prior to disassembly, the measuring instrument must be free from residues that could represent a danger to
persons or test equipment. Flush thoroughly with care.
Repair instructions for measuring sensors
Replacement of filter
When removing the filter, small splinters can be formed, and these must not be allowed to enter the measuring unit.It is therefore recommended to separate the housing from the measuring unit.
1. Remove measuring chamber screws (Item 12).
2. Remove housing (Item 1).3. Extract filter (Item 2) with screwdriver and replace.4. Remove deposits from housing surface and seating using fine emery-cloth (Fig. 1).5. Clean housing connections with a cloth.6. Fit new filter (Item 2) in housing connection. Press the metal ring into position using a round bar.
è Do not press on the filter bottom!7. Wash housing and remove any splinters with cloth.8. Locate the inlet and outlet space of the housing (Item 1) opposite the openings in the cover of the measuring
chamber (Fig. 6) and place housing on measuring chamber (Item 3).9. Insert measuring chamber screws (Item 12) and tighten. Correct torque see page 2.
1. Remove measuring chamber screws (Item 12).2. Remove housing (Item 1).3. Remove cover of measuring chamber (Item 3).4. Remove driver (Item 6), rotary piston (Item 7), separating plate (Item 8), and guide roller (Item 9).5. Replace worn parts and clean all remaining parts.
è For cleaning purposes it is recommended to use non-fraying cloths and kerosene or solvents.6. Remove deposits from housing surface and seating using fine emery-cloth (Fig. 1).
7. Replace guide roller (Item 9) on pin at bottom of measuring chamber (Item 10).8. Insert separating plate (Item 8).9. Insert rotary piston (Item 7) with guide pin facing downwards.
è The guide pin has a larger diameter than the driver pin and is located at the center of the rotarypiston.
10. The rotary piston (Item 7) has very little clearance but can easily be rotated.11. Rotate the rotary piston (Item 7) to the starting position (Fig. 2).
è The driver pin of the rotary piston lies on the axis of the separating plate.12. Place the driver (Item 6) on the pin of the cover of measuring chamber (Item 3).
è Locate the long, deep, groove of the driver opposite the groove for the separating plate (fig. 3).13. Place cover of measuring chamber (Item 3) with driver (Item 6) on the measuring chamber and press down
firmly avoiding tilting (Fig. 4).è The cover of the measuring chamber and the measuring chamber now form a continuous surface.
When the measuring chamber is shaked in a circle, the rotary piston can move freely.14. Treat new gaskets (Items 4 and 5) with lubricant (silicon grease) and mount on cover of measuring chamber (Item 3) (Fig. 5).
15. Locate the inlet and outlet space of the housing (Item 1) opposite the openings in the cover of the measuringchamber (Fig. 6) and join.
16. Align boring mark or cast mark on the measuring chamber base (Item 10) in a right angle to the housing axle.17. Insert measuring chamber screws (Item 12) and tighten. Correct torque see page 2.
Flow meters with rotary pistons in metal must only be tested and operated using fluids having a
lubricating effect!
Repair instructions for modules
è The individual modules are not screwed together. Be careful to ensure that these do not fall apart whenremoving from meter housing.
1. Note the position of the cover opening and the pulser connection in relation to the housing axle.2. Remove Allen screws (Item 20).3. Remove head ring (Item 18) with cover (Item 22).4. Remove counter with clamping ring.5. Replace worn or damaged modules.6. Reassemble in reverse order.
Fault finding
Fault Identification Possible cause Procedure 1)
· Meter not working· No reading on counter · No or very little flow· Quantity shown is too small
· Flow rate below Qmin or aboveQmax of meter
· Check flow rate· If flow rate too high, reduce flow
or fit larger meter · If flow rate too low, increase flow
or fit smaller meter · Dirt trap filter heavily soiled · Clean dirt trap or replace filter · Safety filter in meter inlet clogged · Fit correct filter mesh in dirt trap
· Replace safety filter in meter · Measuring unit jammed · Remove and clean measurement
· Quantity shown is too large · Gas or air bubbles atmeasurement position
· Meter positioned at highest pointof plant
· Check operating conditions andmeter positioning
· Thoroughly and carefully de-aerate pipes
· Pointers of roller counter do notrotate regularly
· This is normal at high flow ratesand has no effect on accuracy of measurement
· No action necessary
· High pressure drop at meter exit · Dirt trap filter heavily soiled · Clean dirt trap or replace filter · Meter runs backwards · Meter mounted in wrong direction · Mount meter with arrow in
direction of flow· No pulse output signal · No flow · Check flow using counter
Purpose of the mixing tank is to mix the warm return-flow fuel from the engine with the coldfuel flow as provided from the daily tank. In this way the injection pumps are protected againstquick temperature shocks by switching from HFO operation to MDO operation.The mentioned switching should not be performed during higher engine load situation (pleasesee engine’s operation manual). The mixing tank is equipped with a level monitoring device(float switch, pos. 1).
The purpose of the compensation damping pressure tank is to avoid possible pressurepeaks and to compensate the quick changes of fuel oil consumption if the fuel oil systemis manoeuvering and / or when the automatic filter is in the back flushing period.
Technical data:
Capacity: 19 litres
Maximum working pressure: 1.6 MPaTest pressure: 2.4 MPaMaximum working temperature: 160 °C
Equipped with:
1. Inlet valve2. Outlet valve3. Aerating valve
Maintenance:
To ensure perfect operation it is recommended to let out the fuel in intervals of about14 days so that the air cushion can be build up again to 100 per cent.
This measure can be carried on during operation.
In order to do so take the following steps:
1.) Close the fuel inlet valve of the compensation tank.
2.) Slowly open the outlet and the aerating valve.
When no more fuel is running out close the outlet and the aerating valve. Afterwardsopen fuel inlet slowly.
Instruction Manualfor VESTATM MXTable of contents for instruction manual
1.
General Description........................................................................................ 12. Installation Space Requirements .................................................................... 2
7. Conservation during shut down periods ......................................................... 4
8. Maintenance and Cleaning ............................................................................. 4
9.
Dismantling and reassembling of the tube section ......................................... 510. Spare Parts...................................................................................................... 5
Appendix:
- Spare Parts Drawing
1. General DescriptionVesta MX heat exchangers are of the shell and tube type with u-tubes.
The Vesta MX heaters range from 0,5 m² to 60 m² heating surface with design pressures 16 or 30 BAR.
Other capacities may be manufactured at request.
All heaters may be delivered as immersion or outflow heaters for insertion intanks.
Vesta MX heat exchangers are primarily used as fuel oil, lubrication oil, or water heaters (JCW).
The heating media used is either steam, hot water or thermal oil.
Safety valve, thermometer, and pressure gauge may be mounted on a standard
outlet tube (optional).
Regulating equipment for either oil, steam or water is optional.
All heaters have been hydrostatic pressure tested before delivery.
Vesta MX heat exchangers have been type approved by all major classificationsocieties.
2. Installation Space Requirements
2.1. Space allowance
When mounting the heater sufficient space must be allowed for withdrawal of
the tube insert for cleaning, inspection, or replacement purposes.
Please refer to dimensional drawing for withdrawal space requirements.
2.2. Installation surface
The heater must be placed on a level and stable surface.
3. Storage
3.1. Damp and humidity
Store the heater only in a dry storage room before installation. If the room isdamp the heater must be isolated with bags of silica gel. To avoid damage it isrecommended the heater be stored in the original packaging.
3.2. Hydrostatic testing
All heat exchangers have undergone hydrostatic pressuretesting before delivery. The testing fluid used contains a certain amount of corro-sion protection (Castrol Rustilo Aqua 2); hence no further actions regarding stor-age are required before installation.
3.3. Extended storage
When heat exchangers are to be kept in storage for an extended period of timewe recommend Castrol Rustilo Aqua 2 be used as protection against corrosion.
4. Mounting and InstallationThe heat exchanger is designed for vertical or horizontal installations.
In case of horizontal installation, the inlet pipe and media outlet pipe must faceupwards.
If the heater is placed vertically the inlet and outlet tubes as well as the mediainlet must be at the bottom and the heater must be equipped with an air escape
The steam regulator (optional) must always be placed horizontally.
The steam trap (optional) should be mounted as close to the condensate outlet as
possible and somewhat lower. The steam trap is always to be placed horizon-
tally.
Place the heater on the surface and drill the holes for the foundation bolts. Placethe bolts into the holes and tighten up.
5. Connecting the Heat Exchanger
5.1. Preparation and pipe connection of the heat exchanger
Remove all plugs and cover flanges before connecting the heater. Make suresand and other impurities are removed from all connections. Set up the pipe con-nections and make sure that no forces are transferred to the heat exchanger.
6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securelytightened.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.
6.2. Initial adjustments
The safety valve must be adjusted to maximum design pressure or lower.
6.3. Initial start-up
IMPORTANT: Fluid flow through the heat exchanger must be established be-fore the heating medium is applied.
Tighten all main flange bolts according to below schedule. Operate the heater for one hour, stop, and retighten all bolts according to schedule.
Both sides of the heater must be carefully vented and the circuits carefully in-spected for leakage during the whole start-up period.
6.4. OutputThe output of the heater is subject to the supply of heating media at the inletsteam valve. The steam pressure/heating media temperature applied, is to be ac-cording to heater size calculation.
The output is furthermore subject to correct type of steam trap being used. Cor-rect layout of the condensate system avoids negative effect of counter pressure.
7. Conservation during shut down periodsCorrosion occurrences in shut down periods are mainly caused by oxygen. Thecorrosion occurs if non-distilled or alkaline water remains in the heat exchanger.
However, even when fully emptied, heaters are exposed to corrosion caused bywater residues or condensation. Hence, heaters out of service should be protectedagainst corrosion.
If the heater is out of service for an extended period of time – in particular duringwinter seasons with frost – it must be carefully emptied. Open the air escapevalve and check for clogging.
8. Maintenance and Cleaning
8.1. Regular cleaning periods
The heater should be cleaned regularly every six months by removing the tubeinsert or at any time there is a decrease in output not related to other causes.
Note: The heat exchanger must be emptied before removing the tube section.
Check if any deposits have collected on the tubes.
8.2. Cleaning of tubes
Cleaning of the tube system from the outside is carried out after removing thetube insert using a sharp liquid jet (citric acid or water).
Cleaning of the tube system from the inside is carried out after removing the
cover by flushing the tubes with e.g. citric acid.
8.3. Heavy contamination
If the heater is heavily contaminated with carbon deposits Aalborg Industriesrecommends the heater chemically cleaned with a carbon remover.
After cleaning has been completed the heater must be flushed carefully withfresh water and allowed to dry afterwards.
8.4. Checking the safety valves
Once every year the safety valve must be checked for correct set point.
9. Dismantling and reassembling of the tubesectionThe tube section is inserted into the heater and fastened tightly between the shellflange and the end flange. The back end of the tube section is not fixed.
The primary connection for heating media must be dismantled before disman-tling the tube section for inspection, cleaning, etc. The tube flange has threadedholes for dismantling screws and for mounting eyebolts for lifting devices.
Gasket surfaces are to be cleaned and protected against damage. New gaskets areto be fitted every time the flange connection has been dismantled.
IMPORTANT: Fluid flow through the heat exchanger must be established be-fore the heating medium is applied.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.
3.2 Change over from Diesel oil operation to heavy fuel oil (HFO)
operation
1. The system has been started up with Diesel oil already. Supply pumps and
booster pumps are running.
2. The shut-off valves (D and E, see fig. 5) at valve manifold of the transmitter
have to be opened; the counterbalance valve (F) has to be closed.
3. Check adjusted viscosity set point at controller and set the controller inautomatic operation.
4. a) with electrically operated heat exchangers (automatic operation)
Set selective switch on heater control cabinet „Man. – 0 – Auto“ in position
„Auto“. Be sure that all heating steps are turned off. If not, switch off theheating steps using the keypad of the viscosity controller. Switch “on” the main
switch at heater control cabinet.b) with electrically operated heat exchangers (manual operation)
Set selective switch on heater control cabinet „Man. – 0 – Auto“ in position„Man.“. Switch on the needed heating steps by using the toggle switches for
heating steps.
c) with steam operated resp. thermal oil operated heat exchangers
Be sure, that the heating medium control valve is completely closed. If not,switch it off manually via viscosity controller.
5. Change over the plant from Diesel oil operation to heavy fuel oil operation.
6. The system will be filled up automatically with HFO depending on
consumption of engine. Now the viscosity controller regulates automaticallythe viscosity to the adjusted set point.
3.3 Change over from heavy fuel oil operation to Diesel oil
operation
1. Switch over the plant to Diesel oil operation.
2. The inflow of Diesel oil leads to dropping of viscosity. In consequence of the
nominal value default the controller switches off all heating steps automatically(with electrically operated heat exchangers) resp. closes the heating medium
control valve (with steam operated resp. thermal oil operated heat
exchangers).
3. When the system is completely filled with Diesel oil, you should stop
viscosimeter and set controller to manual operation in order to avoid
1. Change over the plant from heavy fuel oil operation to Diesel oil operation.
2. Turn off trace heating. The system will be filled up slowly with Diesel oil,that brings about a dropping of viscosity. In consequence of the nominal
value default the controller switches off all heating steps automatically (with
electrically operated heat exchangers) resp. closes the heating medium
control valve (with steam operated resp. thermal oil operated heat
exchangers). This brings about a dropping of temperature.3. When the system is filled with Diesel oil, viscosimeter motor shall be
turned off.
4. Open counterbalance valve (F) at valve manifold.
5. Set controller to manual operation.
6. Close steam inlet resp. thermal oil inlet before control valve (only withsteam operated resp. thermal oil operated heat exchangers).
4. Maintenance
4.1 Maintenance plan „A“
Following checks should be carried out by capable personnel:
Time slice Check
Monthly Zero adjustment of the differential
pressure transmitter
4.2 Maintenance plan „B“
Following checks/maintenance procedures should carried out every 2 years:
Denomination of the part Check/Maintenance procedure
Differential pressure transmitter Zero adjust
Complete system Commissioning for checking the fullefficiency of the system
Note:
Checks according to maintenance plan „B“ as well as fault repairs, inspections and
part exchange of the viscosity sensor and associated parts must be carried out only
by a service engineer from Kupke + Wolf GmbH. Kupke + Wolf GmbH will give neither
liability nor guarantee for damages which result from the third party.
A complete overhauling of the system is advisable every 4 - 6 years. This overhauling
shall be carried out by a service engineer from Kupke + Wolf GmbH or by other qualifiedservice personnel provided that required spare parts are originals from
Kupke + Wolf GmbH.
Kupke + Wolf GmbH will give no liability for maintenance work carried out by the thirdparty.
Checks according to maintenance plan “C” are:
- checks which be considered accordingly maintenance plan “A” and “B”
- complete inspection and cleaning of all instruments- substitution of worn and faulty parts- fresh factory calibration of the viscosity sensor - reassembly of the overhauled equipment and test run accomplishment
If possible the maintenance work will be carried out on the spot. But calibration of
viscosity sensor must be effected on the calibration stand in our factory. If repair on the
spot is not possible, the corresponding part and/or other system components must be
overhauled in the factory or nearest service representative.
For service work aboard a ship the service engineer must be provided with allnecessary labour, equipment, tools, and appliances (fuel, oil, current, air pressure etc.).
Guarantee terms of Kupke + Wolf GmbH apply for maintenance work which is carried
out by our authorized service engineer.
4.4 Maintenance of the differential pressure transmitter
The differential pressure transmitter requires minimum of maintenance under normaloperating conditions.
Zero check is to be carried out monthly as follows:
Note: It is possible only to carry out this check only when the viscosimeter system is
in operation and voltage supply is switched “on”.
1. Switch over the system to manual operation.2. Open counterbalance valve (F, see fig. 5 on page 8) at valve manifold of the
differential pressure transmitter and turn off viscosimeter motor.
3. When output signal of the differential pressure transmitter is correct (4 mA),the controller display indicates „0.0“. If not, adjust zero at differential pressure
transmitter.4. Turn on viscosimeter motor and close counterbalance valve (F) at valve
manifold.
5. Set viscosity controller to automatic operation.
The reduction gear is already filled with gear oil at manufacturer’s side. The gear
requires no maintenance under normal operating conditions apart from exchanging thegear oil after 10,000 hours of operation resp. 2 years of operation.
Clean reduction gear as follows:
1. Dismantle reduction gear and electric motor from viscosity sensor.
2. Disassemble electric motor from gear.
3. Remove side cover of gear after dismantling the four socket head screws.4. Clean gear with a solvent and dry with clean air pressure.
5. Assemble electric motor on gear.
6. Fill gear with 200 ml gear oil (Shell Tivela, Shell Omala 220 or similar).
7. Mount side cover and reattach gear motor at measuring flange of theviscosimeter.
5. Troubleshooting
5.1 Viscosity signal is too low
Possible cause Corrective action
Sensing lines between viscosimeter
and transmitter (plus side) leaking.
Tighten couplings.
Repair leaks.
Air entrapped in sensing lines
between viscosimeter and transmitter. Vent sensing lines.
If an abnormality occurred in the process or transmitter, action should be taken with reference to the
table below.
If remedy is impossible, contact Fuji Electric’s service department.
(1) The manifold valve doesnot open/close normally.
(2) Pressure leak is occurring.(3) Process piping is improper.(4) Process pipe is clogged.(5) Power supply voltage
and/or load resistance isimproper.
(6) Voltage between the
external connectionterminals of transmissionunit is wrong.
(7) Zero and span are notadjusted.
(8) Electronics unit is faulty.
(1) Same as (1) to (4) above(2) Power supply polarity is
wrong.(3) Power supply voltage and/
or load resistance isimproper.
(4) Voltage between theexternal connectionterminals is wrong.
(5) Electronics unit is faulty.
(1) Process piping is improper.(2) Gas or solution is mixed in.(3) Liquid density changes.(4) Ambient temperature
changes widely.
(5) Zero or span has deviated.(6) Electronics unit is faulty.
Repair the valve so that it opens/closes normally.
Repair a leak.Make correct piping.Eliminate the cause of clogging.Make arrangement to obtain proper values.(For power supply voltage and load resistance,refer to “7.2” (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Check for faulty cable, insulation, etc. and repair
as needed.(For power supply voltage and load resistance,refer to “7.2” (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Readjust according to sections 4 (page 9).
Replace the electronics unit according to 5.3 (page32).
Correct wiring (according to 7.1 (page 48)).
Make arrangement to obtain proper values.(For power supply voltage and load resistance,refer to “7.2” (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Check for faulty cable, insulation, etc. and repairas needed.(For power supply voltage and load resistance,refer to "7.2" (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Replace the electronics unit according to 5.3 (page32).
Correct the piping.Vent or drain the transmitter.Perform density compensation.Minimize the temperature change.
Readjust zero or span.Replace the electronics unit according to 5.3 (page32).
If the transmitter requires a replacement part, drain process fluid from the transmitter,
disconnect it from the process and carry out replacement in an instrument room.
Replace the transmission unit with a spare one in order to determine whether it is the
detecting unit or transmission unit which is faulty.
When the faulty unit is identified, it should be replaced with a new one.
Indicator
Connection at rear of electronics unit
Electronics unit
Replacing procedure
(1) Turn off the power supply.
(2) Remove the indicator.
(3) Remove the electronics unit.
Unplug each connector.
(4) Remove the stud bolts which fastens
the indicator.
(5) Replace the electronics unit with a
new one and assemble it by
reversing the above procedure from
(4) to (1).
When installing the electronics unit, make sure that thezero adjust screw and the volume control are posi-
tioned as shown the right.
Important
Zero/spanadjustment screw
Volume control
DANGER
When removing an explosion-proof transmitter, turn OFF the main power, then dis-connect the piping and wiring. Do not remove it when the power is ON to prevent
serious accident such as explosion, fire, etc.
To identify faulty part
Replacement of electronics unit
Important The electronics unit should be removed carefully so as not to damage the internal
wiring.
(6) After completion of replacement, perform zero and span adjustments.
Industry controller type Kuwo 93KU10 B 93KU10 E Operating instructions - page 1 -
data subjects to alteration 93KU10e1.doc / 0110809
cSt
°CK4
K3
K2
K1
Viscosity Alarm
Controloutput
Temp. Alarm
3
1
2
4 5
6
1 Digital display actual value 1 (viscosity)2 Digital display actual value 2 (temperature)3 LED-display relay function4 Key for setpoint and parameter mode
5 Setpoint adjustment
6 Parameter mode lock switch (back face)
Brief description:
The 93KU10 industrial controller is a two-channel, three-point step controller for viscosity andtemperature control. Each control channel has a dedicated measurement input, a dedicatedactual value indicator as well as separate control parameters available to it.
The switch state of a binary input determines whether the viscosity or the temperature controlcircuit is switched through to the output relays K1 and K2. The corresponding green LED’s showthe switch state.
Each control circuit has one accessory alarm contact assigned to it (K3 and K4). When theallowable deviation from the actual value is exceeded, the corresponding relay opens and thecorresponding red LED lights.
The viscosity can be displayed either in mPas, as well as in cSt after entering the density.Sheets with appropriate inscriptions are enclosed with the device.
A signal output makes actual value 1 (viscosity) available at the terminals for further processing.
Before installation inspect the controller for any visible signs of damage caused during transportCheck power supply acc. to name plate.Push the housing from the front into the DIN- panel cut-out and secure from behind with thefastening devices supplied.
Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following thewiring diagram; wire cross section max. 1,5 mm2
- To avoid cross interference all low voltage measuring lines and pilot wires must be encasedin a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally to protect the output relays. - Phase wire and neutral wire must not be transposed.
Putting into operation:
Switch on power supply. Digital display and control lamps will light up according tothe setpoint after some seconds. If nothing happens check the fine-wire fuse on the back panelof the controller and the electrical wiring. Adjust set value and check other adjustments.
Maintenance: All electronic controllers in the Kuwo range are virtually maintenance-free. Provided that thecontroller is correctly installed and put into operation and is protected against mechanicaldamage and inadmissible operating conditions, it should give years of trouble-free service.In case of faults repair work by the customer should be restricted to the externally accessible
leads and connections and components the customer is expressly permitted to deal with himself(bridge circuits, fuses).
All further work, especially on internal components will terminate warranty, makes subsequent inspection and fault repair more difficult and can cause considerable damage to the circuitry.
For repair remittance remove plug board with connected leads on the rear side,loosen fastening devices and remove controller from the panel.
In case of remittance please give precise details of the fault to reduce time and cost of repair.
Error messages:
Err 1...6 Fault on measuring input nr. ...check measuring lines for short circuit or breakage
check measuring input by connecting a RTDErr 55 Fault on loading the parameter;
press any key, the controller starts in emergency operation mode,configuration of the parameters has to be checked
Err 50 Hardware error in program sectionErr 52 Hardware error in data section
no further operation possible, remit controller for repair
Error messages during self adaptation:
Err 202 Ambient conditions are not suitable for self adaptation;adjust parameter manually
Err 205 routine exceeded the setpointraise setpoint or lower actual value and start adaptation again
Err 206 Fault on measuring input during adaptation;check the wiring and start adaptation again
Industry controller type Kuwo 9...Installation and connection
Industry controller type Kuwo 93KU10 B 9... EOperation - page 3 -
data subjects to alteration 93KU10e3.doc / 0110809
Operating status:
The upper display shows the actual value of measuring input 1 (viscosity)
The lower display shows the actual value of measuring input 2 (temperature)
Setpoint value setting:
press - key shortly (do not hold down) each
The upper display shows the abbreviation ofthe activated setpoint adjustment mode,the lower display shows the adjusted value.
The indicated value can now be changed by the (lower) and (higher) -keys.
Each variation of the set value is immediately active, without any more operating steps. The arrow keys have a built-in accelerator mode:longer pressing causes faster alterations.
1SP viscosity set point
2SP temperature set point
d15 density at 15°C
Return to operating level:
Press - key shortly
(or automatically after 30 seconds without any key-action)
Manual operation: (optional)
Hold down - key and press - key, then release both keys.
The lower diplay shows "H *" and - if activated - the output position.The upper display still shows the actual value. The automatic control is interrupted.
Manual control is now possible using the ... - keys.
Return to operating level only by pressing the - key (if present: the - key) .
SA3 switching interval (absolut value) for following (additional) contact no.3 2,5 ___Sd3 switching difference for additional contact no.3 0,1 ___
SA4 switching interval (absolut value) for following (additional) contact no.4 10,0 ___Sd4 switching difference for additional contact no.4 1,0 ___
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
Level 2: Invoke: Hold down - key and press - key,hold down both keys for more than 5 sec. until display changes.
Unit switch-over of the display unit (cSt/cP (cP=mPas)) cSt ___1bLo/1bHI start / end of display range for voltage- / current -input (only) 0/50 ___1SLo/1SHI start / end of range for signal output (only), referring to signal 0/50 ___
1/2nSt modification of decimal point characters (0 / 1 / 2) 1/0 ___1Lo / 1HI start / end of viscosity setpoint range 0/50 ___2Lo / 2HI start / end of temperature setpoint range 0/200 ___dSPL select display function for lower display (AUS / IST2) ISt2 ___
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
Industry controller type Kuwo 9.. B 9... EOptimization - page 5 –
data subjects to alteration 9_E5.DOC / 0110813
1. manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to balance
an appearing deviation as quickly, non-oscillating and exactly as possible,
according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replacedby this brief information.The following informations are for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):lower value= shorter impulse gaps, faster balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):increases the controller reaction in case of fast actual value or setpoint alterations(adjust only if necessary). Higher values cause higher increase.
2. Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjuststhe optimum control parameters Xp, Tn and Tv.
Operation, if contained in supply schedule: (Parameter-safety-switch on the rear panel of the controller has to be unlocked: position "u")
Check starting assumptions:Actual value at least 20% below the adjusted set value,(e.g.:heating phase), otherwise first:Lower actual value adequately by manual operation (position of final control element) (quick circuits)or increase setpoint adequately, if admissible. (faster procedure for slower circuits)
Call manual operation level: Press - key plus - key (optional: seperate key).Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down - key for more than 5 sec. on manual operation level.During operation the lower display shows: "-Ad-",the upper display still shows permanently the actual value.
Information about computer operation: First the self-adaptation program waits for stabilizationof the actual value according to the given controller output (actual value alteration < 0,1% / min),then it increases the output signal about 10% or, in case of three- point- step controller operation,it triggers an output impulse with about 10% of the adjusted regulating time.The optimum parameters are computed according to the unit- step response.
Cancel: Press - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
Industry controller type Kuwo 93KU10 B 93.. EConfiguration - page 6 -
data subjects to alteration 93KU10E6.DOC / 0110809
Access from the operating level.Unlock the access first: Turn the switch on the rear panel of the controller to position "U"
(= unlocked). It is not possible to configure the controller with locked switch.
(Lock access after the adjustments: Switch position to "L"= locked)
Hold down the - key and press the - key,hold down both keys for more than 5 sec. until the display changes
Enter the code number (password) ... (1...9999), factory setting: 1move on to next input: briefly press - key
Alternatively: Hold down key after entering code for more than 10 sec.Possibility to modify code number (optional)
Select control function (type dependent): the displayed ID number for the configuredcontrol function can be changed by pressing the - key.(Example Type 930K31: choose (92..) 200, 201, 700, 701)
Return to operating level: briefly press the - key
ormove on to following adjustments: hold down - key for more than 5 sec.Note: when switching is continued after a function has been changed, the display will first flash for several seconds, only then will the controller return to the selected level.
Configurations are displayed in succession (type and design dependent)and can be changed: ...
(move on to next input: press - key shortly)
factory setting Ist1/2 correction value to change the controller display (+ / -) 0.0/0.0 Ain1 type of DC signal for input No.*:rtd/ 0/4-20mA/ 0/2...10V 4...20 mA
(observe different terminal connection I/U)Y' ' travel time of the actuator "6...600" (sec.) 60 sec. 1out adjusting output characteristics direct/inverted "di/in" CH1 di 2out adjusting output characteristics direct/inverted "di/in" CH2 in Sout adjusting type of information signal "0..20/4..20(mA)/0..10/2..10(V)" 4...20 mA
1Y_S behaviour of the output in case of measuring line fault CH1:
relay position:"rel1 / rel2 / AUS" ( AUS = relays off) rel2 2Y_S behaviour of the output in case of measuring line fault CH2:
relay position:"rel1 / rel2 / AUS" ( AUS = relays off) rel2 reL3 function selection for add. switching contact K3 : LCA
select the corresponding measuring input ISt1 select the corresponding control circuit 1SP relay condition in case of measuring line fault: "SiE/SiA"(on/off) Si A
reL4 function selection for add. switching contact K4 : LCA
select the corresponding measuring input Ist2 select the corresponding control circuit 2SP
Adr bus adress (adress no.) (for interface equipment only) 5
relay condition in case of measuring line fault: "SiE/SiA"(on/off) Si A
Return to operating level: briefly press the - key again
Industry controller type Kuwo 93KU10 B 93.. ETechnical data - page 8 -
data subjects to alteration 93KU10e8.doc / 0110809
Characteristics:Adjustment on parameter level, with lock switch,pre adjusted on customer´s demand.(parameters depending on sub type:)Proportional band Xp: 0,1...999,9 %
Integral action time Tn: 0,0...999,9 minRate time Tv: 0,0...99,9 minSensitivity of response Xsh: 0,1...1,0 %Travel time of the actuator Tm: 6...600 secFunction characteristics: direct / invertedSwitching interval SA (add. contacts): 0..100,0 KSwitching difference Sd: 0,1...100,0 K
Installation dimensions:
three- point- step- controller (inverted)
on
off actual value
Additional contact functions:
As switching interval above and below setpoint orindependent adjustable with own setpoint andmeasuring input, switching function adjustable(ref. to chapter additional switching contacts)
Other data:
Housing for panel mounting, 96 x 96 mm (type 92..,93..) or 72 x 144 mm (type 94)
Power supply: 230VAC +/- 10 %, 48...62Hzalternative 115 VAC, 48 VAC, 24 VAC, 24 VDCPower consumption: approx. 14 VAProtective system DIN 40050: IP54 (terminals IP20)Permissible ambient temperature: 0...60°CNominal temperature: 20°CClimatic category: KUF to DIN 40050Relative humidity <= 75 % yearly average,no condensationEMC: refer to EN 50081-2 and EN 50082-2
Wiring diagram: (Example, depending on sub type some details can be missedvalid for each delivered controller is the wiring diagram on its casing only)
L
B +0,8
H +0,8
For m 96 x9 6: L= 150 mm , B = 9 2m m H= 92m mForm 72x144: L= 170mm, B=168mm H=139mm
This function expansion makes it possible to switch over control units of series 92/93/94/95 from the internalequipment set point value to an externally specified set point value, as desired.
The analog input for processing the external set point value signal is identified on the connection terminalswith the designation SPE, as well as the optional connection type of voltage (U) or direct current (I).
The voltage or current range may be configured to 0 or 2...10 V or 0 or 4...20 mA. Furthermore, the set pointrange allocated to the signal range is freely adjustable. The function of the value is selectable by menu asabsolute (abs) adding (add) or subtracting (sub).
Depending on type, switch-over from the internal to the external set point value takes place through a binarycontrol input (potential free normally open contact), alternative: voltage 5V...24V (type extension ..u") or is toselect by menu adjustment in the set point level (F-SP: choice SP = intern or SPE = extern setpoint. (typeextension "..u")
In the operating level, the incoming external set point value signal is displayed under the designation “SPE”after the set point value “SP”, once the P key is actuated again. In addition, it can be recognized whether thisis currently effective, depending on the switch setting: The respective active value SP or SPE appears in the
normal display, the inactive value only flashing.
Providing the set point value in the operating level is displayed in the bottom display, this displayautomatically switches over to the external set point value, i.e. as soon as it has been activated it displays thecurrent effective set point value.
Types List No.
Control input for potential free normally open contact 99bwaControl input 0V / 5...24V 99bwauto activate with menu function 99bwam
Order text: Accessory equipment:Function expansion for external set point valuewith additional analog input 0/4...20mA o. 0/2...10Vcontrol input.. / to activate.. List No.....
Additional connection terminals:
* Terminal No. depending on the number of available or required inputs:
1. binary input: terminal 19 (+Us) / 20 (^)
2. binary input: terminal 21 (+Us) / 22 (^)
1513 14
I U T
SPE
*
internal setpoint is active*
external setpoint is active*(*=only 99bwa)
*
Us = 0V : internal setpoint is active
Us = 5...24V : external setpoint is active
UsT
Li.No. 99bwa + 99bwamPotential free normally open contact
The units in 96 x 96 panel mounting format are based on the Kuwo 92 industrial control unit series and allowexternal setting of one to three setpoints or continuous control outputs and up to 4 three-level signals. Upper
and lower limits can be assigned to the setting ranges.
The unit has a dual display. In operating mode, the target value or control output is displayed in the lowerrow. The upper row can optionally be used for the remote display of the actual value.
Accessories from the Kuwo 92 product range are available as an option.
Types: Type
Setpoint generator 9293.Setpoint generator with actual value remote display (Pt100 / standardised signal) 9293.0 / e
Controllers of series 9.. may be equipped with up to 4 analog inputs per unit in addition to the measuringinputs available as standard. They may be used to display additional measuring values or as reference
value for installed additional contacts.
The display is continuously switched over to additional inputs by actuating the key. In addition, thebottom display shows the brief designation of the attendant measuring input. The display automatically
switches back to the standard operating condition 5 seconds after the last key was pressed.Furthermore, input 2 may be configured as a second display in addition to the controller actual value.
For temperature sensor inputs, °C or °F may be selected as display unit, for standard signal inputs, a
scaling between -999 and +4000 may be infinitely set..
Measuring input: List-No.: Measuring/display range
The safety instructions contained in these operating instructions are identified by thefollowing attention symbol:
If these instructions are not observed, danger to personnel and equipment can result.
General Safety Instructions
The operating safety of the equipment supplied is only guaranteed under theprescribed conditions of use (see „Description of Equipment“). The stated limitingvalues (see also „Technical Data“) must not be exceeded under any circumstances.
Personnel who are responsible for the installation, operation and the repair of the
pressure limiting valve, must possess an appropriate qualification; this can have beenobtained through training or relevant instruction. Such personnel must be acquaintedwith the contents of this instruction.
During all work, the prevailing national regulations relating to accident prevention andsafety in the work place and, where appropriate, internal regulations of the operator,must be adhered to, even where these are not named in this introduction.
During all work and prior to installation, the connecting pipelines must be de-pressurised!
The operator must ensure that these operating instructions are accessible to thepersonnel concerned at all times.
The DocumentationThese operating instructions describe the adjustment and venting of the SPVF pressurelimiting valve. The valve is manufactured in various versions.The designated version of a particular valve is given on the type reference plate.
Description of Operation
The directly controlled pressure limiting valves are used to protect low pressure circuits, upto a maximum pressure of 20 bar (SPVF 10, p max 30 bar).In a cast hydraulic housing 10, a valve spool 30 seals the pressure chamber P from thereservoir connection T, when acted on by the the pressure spring 70. When the set pressureis reached, the valve spool 30 opens to create a connection between P and T. As thepressure in P falls below the set pressure value, the valve closes.
Installation of the Pressure Limiting ValveThe valve should preferably be installed in a vertical attitude, with the adjustment screwunderneath.Before installing the pressure limiting valve, the pipe work system must be cleaned to
eliminate dirt, scale, sand, swarf, etc. Welded tube, in particular, must be scoured orscavenged. Cotton rags must not be used in the cleaning operation. The pipelines must beconnected to the valve in an absolutely stress-free condition.The pipes and connections used must be those appropriate for the operating pressurerange. The pipe manufacturers specifications should be consulted!On installation, care should be taken that no sealing material finds its way into the pipeline.Sealing materials such as hemp and mastic are not permissible, since they can lead tosoiling and hence impair the function of the valve.
The pressure limiting valve is set to the pressure required by the customer. It may benecessary to carry out a check on the pressure setting during commissioning, since differentflow rates, oil viscosities and pipe lengths can affect the response value. In such cases a
manometer should be connected directly to the valve oil pressure connection. Theircharacteristics are such, that each of the four pressure springs available is only suitable for alimited range of setting pressures.These pressure ranges are specified in the Spare Parts List 58 601/4.The pressure setting adjustment is made by removing the protecting cap 50 and looseningthe hexagonal headed nut 90 on the threaded rod 80, by means of an internal hexagon ringspanner.Rotation to the right increases the pressure setting, rotation to the left decreases thepressure. On achieving the desired pressure setting, the hexagon headed nut 90 must betightened and the cap 50
Venting
Pressure limiting valves only operate correctly when all the voids within the valve are filledwith hydraulic fluid. If the installed attitude is incorrect, air may collect in the spring chambersand lead to hydraulic shock. In these circumstances the valve must be ventilated (bled). Thisis achieved by unscrewing the vent screw 100 through one turn. Venting should occur at lowpressure and is complete when oil is discharged free of air bubbles. After venting, the ventscrew is tightened again.
.
Servicing and adjustments to the pressure limiting valve which require it to be dismantled,are only to be carried out by trained and appropriately qualified personnel.When dismantling the pressure limiting valve, the components must be directly protectedfrom damage and soiling.Fluids emerging from the valve must be collected and disposed of in such a way that there is
no danger to personnel or to the environment. The currently applicable regulations must beobserved.
Fühler: BalgMessbereich: -0.9...1.5 bis 0...100 bar Ausgang: potentialfreier Umschaltkontakt Schaltdifferenz: nicht einstellbar Reproduzierbarbeit: ± 1.0 % d.S. typ.Skalengenauigkeit: ± 2.0 % d.S. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Capteur: soufflet Plage de mesure: -0.9...1.5 à 0...100 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableReproductibilité: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Sensor: bellowsMeasuring range: -0.9...1.5 to 0...100 bar Output: floating change-over contact Switching differential: not adjustableRepeatability: ± 1.0 % FS typ.Scale accuracy: ± 2.0 % FS typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
VORTEILE AVANTAGES PRINCIPAUX MAIN FEATURES
HAUPTMERKMALE CARACTÈRES DISTINCTIFS MAIN CHARACTERISTICS
Motorenbau Constr. de moteurs Engine manufacturingSchienenfahrzeuge Véhicules sur rail RailwaysMaschinenbau Machines-outils Machine toolsHydraulik Hydraulique HydraulicsHLK CVC HVACKältetechnik Réfrigération RefrigerationProzess Techn. Techn. de procédés Process technology
Wasseraufbereitung Traitement de l'eaux Water treatment Autoindustrie Industrie automobile Automotive industry Prüfstände Banc d'essai à frein Test benches
Ex Ex Ex Lebensmittelindustrie Industrie alimentaire Food Industry Autoklaven Autoclavage Autoclaves
Rugged aluminium housingProtection IP 65 Any mounting position possible
Robustes Alu-GehäuseSchutzart IP 65Beliebige Einbaulage
Boîtier robuste en aluminiumProtection IP 65Montage toutes positions
Andere Varianten auf Anfrage/ Autres variantes sur demande/ Other variations on request
BESTELLINFORMATION / INFORMATION POUR LA COMMANDE / ORDERING INFORMATION
900/904/912PRESSOSTAT P/PS
Dämpfungselemente und Snubber/ Eléments d'amortissement et Snubber/ Damping elements and Snubber:siehe Datenblatt/ voir spécification /see specification sheet H72258
(((((siehe Katalog/ voir catalogue/ see catalogue: „Standard Products“
Varianten Code/ Codification de variantes/ Custom build code XXX.XXXX.XXX.XX.XX...
Mit Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 900 With display; with adjusting screw Ohne Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 904
Without display; with adjusting screw Mit Anzeige; mit Verstell-Knopf/ Avec affichage; réglage par mollette/ 912
With display; with adjusting knob
Mikroschalter1) Grosse Schaltdifferenz/ Interrupteur à grand différentiel/ Big switching differential 06Microrupteur Kleine Schaltdifferenz/ Interrupteur à petit différentiel/ Small switching differential 10Microswitch Mittlere Schaltdifferenz/ Interrupteur à moyen différentiel/ Average switching differential 11
Erhöhte Vibrationsbeständigkeit/ Résistance de vibration élevée/ Improved vibration resistance 23Hohe Vibrationsfestigkeit/ Résistance de vibration forte/ High vibration resistance 26Mit vergoldeten Kontakten/ Avec contacts dorés/ With gold plated contacts 21
1) Schaltdifferenz/ Différentiel de l'interrupteur/ Switching differential: nicht einstellbar/ non ajustable/ Not adjustable
Befestigung Direkt am Fühler oder Gehäuse/ Directement à capteur ou boîtier/ Direct on sensor or housing 00Fixation Mit Montagebügel/ Avec platine murale/ By mounting bracket 31Mounting
Zubehör Plombierung (Schutz vor Manipulation)/ Plombage (protection contre manipulations/ 16 Accessoires Lead seal (mani-pulation protection) Accessories Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland PG 16 32
Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland M 24 x 1.5 (DIN8280) 27Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland M 18 x 1.5 (DIN8280) 40Ohne Kabelverschraubung/ Sans passe-câble à vis/ Without screwed cable gland 33Bahnsichere Ausführung / Exécution pour ferroviaire/ Railway-safety execution 28
Sensor: bellow Measuring range: -0.9...1.5 to 10...100 bar Output: floating change-over contact Switching differential: not adjustableEN60730-1/ EN60730-2-9: Typ 2.B.H
Anziehdrehmoment: max. 25 NmEinbaulage: beliebigGewicht: ~ 710 g
SPÉCIFICATIONS
CARACTÈRES DISTINCTIFS
Capteur: soufflet Plage de mesure: -0.9...1.5 à 10...100 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableEN60730-1/ EN60730-2-9: Typ 2.B.H
PRÉCISION (@ 20°C)
Reproductibilité capteur: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.Différentiel de l'interrupteur: voir tableau
MICRORUPTEUR Pouvoir de coupure: voir tableauRésistive d'isolation: > 2 MΩRigidité diélectrique: 1.25 kV contre la masseDurée de vie (mécanique)
ELEKTRISCHE DATEN SCHALTER / SPÉCIFICATIONS ÉLECTRIQUES DE L'INTERRUPTEUR / ELECTRICAL DATA SWITCH
2...25
4...400.51.02.06.040
1...10
1...160.20.40.82.424
0...4
0...60.080.20.31.212
Bereich/ Plage/ Range [bar]
Mikroschalter/ Microrupteur/ Microswitch
BalgfühlerCapteur soufflet Bellows sensor
1011/21/23
2606
-0.9...1.5
0.2...1.60.2...2.50.030.10.1
0.3510
6...60
10...1001.53.05.018
100Schaltdifferenz [bar]: fester Wert, nicht einstellbar Différentiel de l’interrupteur [bar]: valeur fixe, non ajustableSwitching differential [bar]: fixed value, not adjustable
Type Caractéristiques Pouvoir de coupureType Features Rating
AC DC
06 Grosse Schaltdifferenz 380 V 20 (4) A 220 V 0.6 (0.4) A Interrupteur à grand différentiel 110 V 0.7 (0.5) A large switching differential 24 V 20 (15) A
12 V 20 (15) A
10 Kleine Schaltdifferenz 125 V 10 (1.5) A 250 V 0.2 (0.02) A Interrupteur à petit différentiel 250 V 10 (1.25) A 125 V 0.4 (0.03) A
Small switching differential 30 V 2 (1) A 14 V 15 (2.5) A
11 Mittlere SchaltdifferenzInterrupteur à moyen différentiel
Average switching differential
23 Erhöhte Vibrationsfestigkeit; mittlere Schaltdifferenz 125 V 15 (1.5) A 250 V0.25(0.03) A Résistance de vibration élevée; interrupteur à moyen différentiel 250 V 15 (1.5) A 125 V 0.5(0.05) A Improved vibration resistance; average switching differential 500 V 10 (1.5) A 30 V 6 (1.5) A
26 Hohe Vibrationsfest igkeit; mitt lere Schaltdifferenz 14 V 15 (2.5) A
Résistance de vibration forte; interrupteur à moyen différentielHigh vibration resistance; average switching differential
21 Mit Goldkontakten, geeignet für eigensichere Schaltkreise 24 V 0.01(0.01)A 24 V0.01(0.01)A Avec contacts dorés, approprié aux circuits de côntrole à sécurité intrinsèque 12 V 1 (1.0) A 12 V 1.0 (1.0) A Gold plated contacts, suitable for intrinsically safe control circuits 5 V 2 (2.0) A 5 V 2.0 (2.0) A
Fühler: BalgMessbereich: -1...6 bis -1...18 bar Druckdifferenz: -0.6...3.4 bis 1...16 bar Ausgang: potentialfreier Umschaltkontakt Schaltdifferenz: nicht einstellbar Reproduzierbarbeit: ± 1.0 % d.S. typ.Skalengenauigkeit: ± 2.0 % d.S. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Capteur: soufflet Plage de mesure: -1...6 à -1...18 bar Press. différentielle: -0.6...3.4 à 1...16 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableReproductibilité: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Sensor: bellowsMeasuring range: -1...6 à -1...18 bar Differential pressure: -0.6...3.4 to1...16 bar Output: floating change-over contact Switching differential: not adjustableRepeatability: ± 1.0 % FS typ.Scale accuracy: ± 2.0 % FS typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
VORTEILE AVANTAGES PRINCIPAUX MAIN FEATURES
HAUPTMERKMALE CARACTÈRES DISTINCTIFS MAIN CHARACTERISTICS
Motorenbau Constr. de moteurs Engine manufacturingSchienenfahrzeuge Véhicules sur rail RailwaysMaschinenbau Machines-outils Machine toolsHydraulik Hydraulique HydraulicsHLK CVC HVACKältetechnik Réfrigération RefrigerationProzess Techn. Techn. de procédés Process technology
Wasseraufbereitung Traitement de l'eaux Water treatment Autoindustrie Industrie automobile Automotive industry Prüfstände Banc d'essai à frein Test benches
Ex Ex Ex Lebensmittelindustrie Industrie alimentaire Food Industry Autoklaven Autoclavage Autoclaves
Rugged aluminium housingProtection IP 65 Any mounting position possible
Robustes Alu-GehäuseSchutzart IP 65Beliebige Einbaulage
Boîtier robuste en aluminiumProtection IP 65Montage toutes positions
Andere Varianten auf Anfrage/ Autres variantes sur demande/ Other variations on request
Dämpfungselemente und Snubber/ Eléments d'amortissement et Snubber/ Damping elements and Snubber:siehe Datenblatt/ voir spécification /see specification sheet H72258
BESTELLINFORMATION / INFORMATION POUR LA COMMANDE / ORDERING INFORMATION
(((((siehe Katalog/ voir catalogue/ see catalogue: „Standard Products“
Varianten Code/ Codification de variantes/ Custom build code XXX.XXXX.XXX.XX.XX...
Mit Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 920 With display; with adjusting screw Ohne Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 924
Without display; with adjusting screw Mit Anzeige; mit Verstell-Knopf/ Avec affichage; réglage par mollette/ 932
With display; with adjusting knob
Mikroschalter1)
Microrupteur Kleine Schaltdifferenz/ Interrupteur à petit différentiel/ Small switching differential 10Microswitch Mittlere Schaltdifferenz/ Interrupteur à moyen différentiel/ Average switching differential 11
Erhöhte Vibrationsbeständigkeit/ Résistance de vibration élevée/ Improved vibration resistance 23Hohe Vibrationsfestigkeit/ Résistance de vibration forte/ High vibration resistance 26Mit vergoldeten Kontakten/ Avec contacts dorés/ With gold plated contacts 21
1) Schaltdifferenz/ Différentiel de l'interrupteur/ Switching differential: nicht einstellbar/ non ajustable/ Not adjustable
Befestigung Direkt am Fühler oder Gehäuse/ Directement à capteur ou boîtier/ Direct on sensor or housing 00Fixation Mit Montagebügel/ Avec platine murale/ By mounting bracket 31Mounting
Zubehör Plombierung (Schutz vor Manipulation)/ Plombage (protection contre manipulations / Lead seal (mani- 16 Accessoires pulation protection) Accessories Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland PG 16 32
Kabelverschraubung/ Passe-câble à vis / Screwed cable gland M 24 x 1.5 (DIN8280) 27Kabelverschraubung/ Passe-câble à vis / Screwed cable gland M 18 x 1.5 (DIN8280) 40
Sensor: bellow Measuring range: -1...6 to -1...18 bar Differential pressure: -0.6...3.4 to1...16 bar Output: floating change-over contact Switching differential: not adjustableEN60730-1/ EN60730-2-9: Typ 2.B.H
Anziehdrehmoment: max. 25 NmEinbaulage: beliebigGewicht: ~ 610 g
SPÉCIFICATIONS
CARACTÈRES DISTINCTIFS
Capteur: soufflet Plage de mesure: -1...6 à -1...18 bar Press. différentielle: -0.6...3.4 à 1...16 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableEN60730-1/ EN60730-2-9: Typ 2.B.H
PRÉCISION (@ 20°C)
Reproductibilité capteur: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.Différentiel de l'interrupteur: voir tableau
MICRORUPTEUR
Pouvoir de coupure: voir tableauRésistive d'isolation: > 2 MΩRigidité diélectrique: 1.25 kV contre la masseDurée de vie (mécanique)
ELEKTRISCHE DATEN SCHALTER / SPÉCIFICATIONS ÉLECTRIQUES DE L'INTERRUPTEUR / ELECTRICAL DATA SWITCH
920/924/932DIFFERENTIAL PRESSURE PRESSOSTAT PD
-1...12
-1...18
0.20.40.524
Bereich/ Plage/ Range [bar]
Mikroschalter/ Microrupteur/ Microswitch
BalgfühlerCapteur soufflet
Bellows sensor
1011/21/23
26
-1...6
-1...8
0.080.160.2512
Schaltdifferenz [bar]: fester Wert, nicht einstellbar Différentiel de l’interrupteur [bar]: valeur fixe, non ajustableSwitching differential [bar]: fixed value, not adjustable
Type Caractéristiques Pouvoir de coupureType Features Rating
AC DC
10 Kleine Schaltdifferenz 125 V 10 (1.5) A 250 V 0.2 (0.02) A Interrupteur à petit différentiel 250 V 10 (1.25) A 125 V 0.4 (0.03) A Small switching differential 30 V 2 (1) A
14 V 15 (2.5) A
11 Mittlere SchaltdifferenzInterrupteur à moyen différentiel
Average switching differential
23 Erhöhte Vibrationsfestigkeit; mittlere Schaltdifferenz 125 V 15 (1.5) A 250 V0.25(0.03) A Résistance de vibration élevée; interrupteur à moyen différentiel 250 V 15 (1.5) A 125 V 0.5(0.05) A
Improved vibration resistance; average switching differential 500 V 10 (1.5) A 30 V 6 (1.5) A 26 Hohe Vibrationsfest igkeit; mitt lere Schaltdifferenz 14 V 15 (2.5) A
Résistance de vibration forte; interrupteur à moyen différentielHigh vibration resistance; average switching differential
21 Mit Goldkontakten, geeignet für eigensichere Schaltkreise 24 V 0.01(0.01)A 24 V0.01(0.01)A Avec contacts dorés, approprié aux circuits de côntrole à sécurité intrinsèque 12 V 1 (1.0) A 12 V 1.0 (1.0) A Gold plated contacts, suitable for intrinsically safe control circuits 5 V 2 (2.0) A 5 V 2.0 (2.0) A
5.1 General notes on installation...................................7
5.2 Requirements at the place of installation ................85.3 Installation instructions concerning actuators .........8
6.0 Putting the valve into operation.................... 9
7.0 Care and maintenance................................... 9
7.1 Replacement of stem sealings ............................... 97.1.1 PTFE V-ring unit design..................................... 97.1.2 Stuffing box packing design ............................. 107.1.3 Bellows seal design .......................................... 11
7.2 Replacement of internal parts .............................. 127.2.1 Replacement of plug and stem ....................... 127.2.2 Replacement of seals of
pressure balanced plugs................................. 137.2.3 Replacement of the seat ring ........................... 13
7.3 Tightening torques................................................ 147.3.1 Tightening torques for .................................... 147.3.2 Tightening torques for seat rings ................... 14
Str. thr. control valves - STEVI ® 440 / 441, 445 / 446
1.0 General information on operating instructions
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.Information marked with the above symbol and “ ATTENTION ! ” describe practices, afailure to comply with which can result in serious injury or danger of death for users or thirdparties or in material damage to the system or the environment. It is vital to comply withthese practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damageto property.
3.0 Storage and transport
- At -20°C to +65°C.- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
ATTENTION !
. . . Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See catalog sheet for weights.
Str. thr. control valves - STEVI ® 440 / 441, 445 / 446
4.0 Description
4.1 Scope of applicationsValves are used for „controlling the flow of liquids, gases and vapours in chemical and other processing plants and for plant engineering“.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
ARI control valves are especially suitable for actuation by pneumatic or electrical actuators.
Four plug types are available to suit the various applications:parabolic plug (standard)
perforated plugV-port plugpressure balanced plug
The flow through control valves is always against the closing direction.
In the case of control valves with perforated plugs, gases and vapours flow against theclosing directions, but liquids flow through in the closing direction. If a pneumatic actuator isto be used on a straight-way valve with a perforated plug with the fluid moving in the closingdirection, a higher closing force will be needed. This is to prevent vibration as the plugapproaches the closed position.
If the forces generated by the actuators are too low, arrangements should be made to
relieve the pressure as far as this is compatible with service conditions.
ATTENTION ! - Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from grey cast iron are not authorised for use in systems subject to TRD 110.
Str. thr. control valves - STEVI ® 440 / 441, 445 / 446
5.0 Installation
5.1 General notes on installation
The following items should be taken into account besides the general principles governinginstallation work:
Planners / construction companies or operators are responsible for positioning and
installing products.
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces areavoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.Refer to data sheet for weights.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Strainers or filters should be installed before the valves.
Str. thr. control valves - STEVI ® 440 / 441, 445 / 446
5.2 Requirements at the place of installation
The place of installation should be easily accessible and provide ample space for maintenance and removing the actuator. Stop valves should be installed before and after the control valve to enable maintenance working without draining the piping system. Thevalve should preferably installed vertically with the actuator at the top. Inclined or horizontal
installation without supports is permissible only with light actuators.For this installation position, the two distance columns (or joke) have to be above eachother in the vertical plane.
Permissible actuator weights for valves with unsupported horizontal stems:
20 kg for DN 15 - 3225 kg for DN 40 - 6535 kg for DN 80-100
The pipes must be lagged to protect the actuators from excessive heat. Sufficient spacemust be left for the maintenance of the stem packing.
To ensure that the control valves function correctly, the pipe run should be straight for atleast 2 x n.d. upstream and 6 x n.d. downstream of the valve.
Normally, control valves are supplied complete with actuator fitted.It is not permitted to mantle / dismantle actuators with valves operating and serviceconditions (temperature and pressure). The actuators must be assemble as describe in theoperating instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seating at closing pressure.
When retrofitting actuators, the maximum permissible force for valve actuation must betaken into account:
Str. thr. control valves - STEVI ® 440 / 441, 445 / 446
6.0 Putting the valve into operation
7.0 Care and maintenance
Maintenance and maintenance intervals have to be defined by the operator according tothe service conditions.
7.1 Replacement of stem sealings
7.1.1 PTFE V-ring unit design
PTFE V-ring unit (pos. 12) consisting of:1 backing ring4 sealing rings1 cover ring
Owing to the installed compression spring (pos. 15), thisstem packing is self-adjusting. If the stem starts leaking,the ring pack is worn out and must be replaced.
Replacement of PTFE V-ring units:
- Remove actuator.(Refer to operating instructions for actuator!)
- When replacing PTFE V-ring unit (pos. 12), make surethat the parts are installed in the correct order andpositions (refer to Fig. 11).
- Gasket (pos. 17) must be replaced.
Damaged stems must also be replaced (refer to item 7.2for instructions) since a new ring pack will soon startleaking again if the stem is damaged.
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
ATTENTION !
Refer to item 10.0 and 11.0 beforedismantling the valve.
Str. thr. control valves - STEVI ® 440 / 441, 445 / 446
7.3 Tightening torques
7.3.1 Tightening torques for
7.3.2 Tightening torques for seat rings
! Refer to operating instructions for actuator concerned for
installing actuators !
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
Str. thr. control valves - STEVI ® 440 / 441, 445 / 446
10.0 Dismantling the valve or the top part
11.0 Warranty / Guarantee
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.The warranty shall not cover maintenance work, installation of external parts, designmodifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ ATTENTION !” describe practices, a failureto comply with which can result in serious injury or danger of death for users or third partiesor in material damage to the system or the environment. It is vital to comply with thesepractices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damageto property.
3.0 Storage and transport
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Donot damage paint protection.
ATTENTION !
. . . Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See catalog sheet for weights.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
The medium flows through the strainer screen in the direction shown on the strainer and isthereby cleaned.
ATTENTION ! - Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD110.
The following points should be taken into account besides the general principles governinginstallation work:
- Planners / construction companies or operators are responsible for positioning andinstalling products.
5.2 Installing valves with butt weld ends
Please note that only qualified persons using appropriate equipment and working inaccordance with technical rules are allowed to install fittings by welding.The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces areavoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See data sheet for weights.
- Leave sufficient space to remove the screen basket during installation in pipelines.
- Make sure that the trap is installed to suit the direction of flow.
- Installation position:
a) The screen basket should never be at the top, otherwise the dirt will fall back into the pipe.
b) If water hammer is possible due to condensation in steam lines,never install the trap with the screen basket at the bottom, but install it so that it is horizontal.
- Centre gaskets between the flanges.
- Install compensators to compensate for thermal expansion of the piping.
Maintenance and maintenance-intervals have to be defined by the operator according tothe requirements.
- If necessary, the strainer can be fitted with an additional start-up filter (e.g. filter withsupporting cage) to start up the system.Depending on the degree of dirt accumulation in the system, the filter must be cleanedafter a system-specific number of service hours.
- Flush the plant thoroughly before starting it.
- The strainer requires little maintenance.
- Strainers must be cleaned when clogging becomes apparent.General rules concerning cleaning intervals cannot be given because plants varyconsiderably in their characteristics.
- Before reassembling the unit, remember that the bearing surface must be cleaned and anew gasket (6) must be inserted.
- Set the strainer cover in place.
- Tighten the cover bolts evenly crosswise.
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
9.0 Troubleshooting table
DNhexagon nuts /
boltsTorque(Nm)
15- 32 M 10 20-35
40 M 12 20-35
50- 65 M 12 60-80
80-150 M 16 100-125
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
-
ATTENTION !
It is essential that the safety regulations are observed when identifying faults.
ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work! - read point 6.0 before restarting the plant !
Fault Possible cause Corrective measures
No flow Flange covers have not been removed
(7, Fig. 3, page 4)
Remove flange covers
(7, Fig. 3, page 4)
Flow too low strainer clogged. Clean/replace screen.
Piping clogged. Check piping system.
Flange broken between
unit and pipingBolts tightened unevenly.Mating flanges not properly aligned.
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.The warranty shall not cover maintenance work, installation of external parts, designmodifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these operating and installation instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ ATTENTION ! ” describe practices, afailure to comply with which can result in serious injury or danger of death for users or thirdparties or in material damage to the system or the environment. It is vital to comply withthese practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damageto property.
3.0 Storage and transport
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage.Do not damage paint protection.
ATTENTION !
. . . Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valves must not be used to take external forces, e.g. they are not designed for use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See catalog sheet for weights.
Series 634: Float-type steam traps with level- and thermal control are used for the drainageof steam facilities.
Series 636: Float-type steam traps with level control are used for the drainage of systems f
with compressed air or aqueous gases.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
(refer to Fig. 4 page 9)
The steam trap is controlled by a swivel-mounted ball float (Pos. 24.16).If condensate is flowing towards the steam trap, the ball float (Pos. 24.16) rises and opensthe discharge valve using the lever mechanism.
In series 634 only (version with diaphragm capsule): An intercoupled diaphragm capsule (Pos. 24.17) ensures automatic start-up air ventingwhen cold.
If the amount of condensate decreases or if there is no condensate, the float ball(Pos. 24.16) falls and shuts the discharge valve.
The compact float ball (Pos. 24.16) exerts level-dependent control on the valve ball
(Pos. 24.4) by means of a lever mechanism. As the level of condensate rises, the valve ball(Pos. 24.4) is rolled off the valve bore by the lever mechanism, thus opening the valve. Thecondensate can now drain away.If the amount of inflowing condensate is less than the possible valve output or if there is nocondensate flow, the ball float (Pos. 24.16) falls and the valve ball (Pos. 24.4) rolls backonto the valve bore. The valve is now closed.
If the steam trap is only acted upon by gas, the float ball (Pos. 24.16) remains in equilibrium,the valve stays shut.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD110.
- Valves with different types of connection , etc.refer to datasheet.
4.5 Marking
5.0 Installation5.1 General notes on installation
The following points should be taken into account besides the general principles governinginstallation work:
- Planners / construction companies or operators are responsible for positioning andinstalling products.
Manufacturer
Typ Type
Bj. Year of manufacture
According to the Pressure Equipment Directive appendix 2 diagram 7 valves acc. to article1 paragraph 2.1.2 (pipes) only show the CE-marking from DN40 onwards.
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- The ball float steam trap may be installed for vertical or horizontal flow. Noteinstallation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valves must not be used to take external forces, e.g. they are not designed for use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See data sheet for weights.
- Centre gaskets between the flanges.- Precautions against freezing should be taken as a matter of course in any facilities susceptible to frost. If a system not in operation is in a positionsusceptible to freezing, we recommend that the drain plug (Pos. 50) on theunpressurised steam trap be unscrewed, the residual condensate drained off,the seal faces cleaned and the plug screwed down again.The sealing ring (Pos. 49) should be replaced if necessary.(see Fig. 2 page 4 and item 7.3).
Please note that only qualified persons using appropriate equipment and working inaccordance with technical rules are allowed to install fittings by welding.The responsibility for this lies with the system owner.
Please refer to the catalogue sheet for information on type and instructions relating towelding socket weld ends/butt weld ends.
When welding products to the pipeline system they should be adequately cooled to preventany adverse effect on the complete controller assembly (Pos. 24) or the flat gasket(Pos. 17). The heat-affected zone should be restricted to the immediate weld seam area!Note pre- and post-welding heat treatment in accordance with Material Fact SheetDIN EN 10222.
If there are plans to acid clean the facility before putting it into operation, the controllers(Pos. 24) should be dismantled completely, replaced by acid cleaning inserts, and reassembledafter
acid cleaning (refer to 7.1). In such an event please contact the manufacturer.
5.3 Controller adjustment
The controller is manufactured in 3 pressure stages and is not adjustable.
5.4 Steam trap testing through ultrasonic measurement
Testing the operation of the steam trap in the installed state is straightforward with the“SONACON” function tester.
Refer to data sheet „CONA further components / accessories “.
5.5 Installation position
(refer to Fig. 3 page 7 and Fig. 4 - Fig. 5 page 9)
The float steam trap can be installed for vertical or horizontal flow. This should be statedwhen ordering.If the installation position is not stated it will be supplied for vertical flow (L->R).
It is possible to change the installation position at a later stage (see 7.2).
However, the controller (Pos. 24) must always be installed so that the ball float (Pos. 24.16)operates in a vertical plane.
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
Horizontal installation:
Horizontal installation:Vertical installation (standard):Inlet from the top
- Remove dirt from body (Pos. 1) and hood (Pos. 16); tiny dirt particles can be removed byflushing out the ducts and rinsing the body (Pos. 1).
- If necessary dismantle the float controller (Pos. 24) and clean separately or change floatcontroller.
- Unscrew the hollow-core screw (Pos. 24.10) of the float controller (Pos. 24) from the body(Pos. 1).
- Pull complete float controller (Pos. 24) out to remove, taking care with the sealing ring(Pos. 11).
- Check lifting force of ball float (Pos. 24.16) by immersing the whole controller (Pos. 24) ina water bath. When immersed in the water bath the ball float (Pos. 24.16) must float to the
top. If the ball float (Pos. 24.16) sinks (i.e. goes under) the complete controller (Pos 24)should be replaced!
Series 634 version with diaphragm capsule only:
- Pull spring clip (Pos. 24.18) off radially and remove diaphragm capsule (Pos. 24.17) fromseat (Pos. 24.19).
- Clean and inspect diaphragm capsule (Pos. 24.17) (see 7.4).
- Form-fit diaphragm capsule (Pos. 24.17) to seat (Pos. 24.19) and push the spring clip(Pos. 24.18) radially into slot of seat (Pos. 24.19), at the same time pushing the twoangled ends of the spring clip legs (Pos. 24.18) onto the diaphragm capsule (Pos. 24.17).
- Replace the sealing rings (Pos. 17 and Pos. 11).
- Assemble in reverse order (see 7.5).
ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work! - refer to item 6.0 before restarting the plant!
Prior to installation, threads and seal faces should be coated with temperature-stable lubricant (e.g. “OKS Anti-Seize Paste” white/metal-free for PN16-40 or “Rivolta” lubricant and parting agent silver for PN63 onwards).
With a dry, cold diaphragm capsule the diaphragm surface with the circular bead must restagainst the top part of the wall (with 3 knobs), capsule is open (see Fig. 7).
If it rests against the bottom part of the wall, this is a sign that it is defective and must bereplaced with a new diaphragm capsule (see Fig. 8).It should also be replaced if there are visible deformations on the surface.
ATTENTION !
Escape of hot medium under pressure!
Observe item 2.2!
Accumulated inert gases can be discharged to theenvironment with the manual air vent valve (Pos. 51) byopening the pressure screw (Pos 51.1).
It is possible to return the accumulating gases to the system byconnecting a pressure compensation line to the union(Pos. 52).
In Series 634 the residual condensate can be drained by wayof the drain plug (Pos. 50) (see 5.1) (standard in Series 636).
Accumulated dirt and condensate can also be removed fromthe hood (Pos. 16) using a ball valve (Pos. 56).
During operation it is imperative to observe general workingsafety conditions and possibly fit devices to guard againstscalding/injury.
Note section 7.5 when installing and operating the option.
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
Pos. CONA SC PN16-25Torque (Nm)
DN15-25
24 Controller 6027 Cheese head screw M10 15
47 Plug 50
50 Plug 50
51 Manual ari vent valve 50
51.1 Pressure screw 30
52 Union for pressur compension line 50
56 Ball valve for blow down valve 50
-
ATTENTION !
It is essential that the safety regulations are observed when identifying faults.
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacementdelivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
Compact designProtection class IP 65Mounting measurements according toDIN EN 50047Hinged snap lid
l Compact switches for safety or controlapplications in protection class IP 65
l 3 different contact configurationsavailable as slow-action or snap-actiondevices
l Positive break pl Two channel safety monitoring possiblel Galvanically isolated terminals, type Zbl Approvals UL, CSA, BGl Cable entries M 16 x 1.5l 4 screw terminals M3.5 with self-lifting
- Ball valves must always be stored either completely opened or completely closed. We
advise storing them completely opened to prevent damage to the ball surface.
- Valves that are not needed immediately should be fitted with a protective cap and stored in a
well-aired, dry room.
5. Functioning:
- Ball valves serve as shut-off devices in plants, where they are screwed or welded into the
pipe system.
- Ball valves are OPEN/CLOSE devices which are generally opened and closed by rotation
through 90°. The closing direction according to DIN standards is achieved by rotating thehandle clockwise. They are not intended for throttling or regulating the flow of medium,
and intermediate positions are therefore not permissible.
6. Installation:
- The piplines must be cleaned or flushed before installation, so that any residues and foreign
bodies do not get into the ball valves.
- Should the valves be dirty or contaminated, then set the ball previously to 45° and blow the
interior clean with oil-free com pressed air. Then clean the housing.
- Lead the piplines free of stress up to valve to be installed.
- Ensure that the ball valves are in their open position.- Place the fitting between the pipes using a crane or elevator if necessary. Tighten the flange
screws in opposite directions with the appropriate torque.
- Protect the interior parts of the valve before carrying out any welding (observe maximum
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenanceand repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safetyinformation are highlighted to attract special attention.
Information marked with the above symbol and “ ATTENTION !” describe practices, a failureto comply with which can result in serious injury or danger of death for users or third partiesor in material damage to the system or the environment. It is vital to comply with thesepractices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
3.0 Storage and transport
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Donot damage paint protection.
ATTENTION !
. . .
Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
4.1 Scope of applicationsValves are used for „shut-off and/or throttling of media“.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
The valve is closed by turning the hand wheel clockwise (valve plug/seating function).
The valve spindle is sealed by a bellow and an outer safety stuffing box.Tighten the stuffing box if required.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD110.
ATTENTION !
Do not use tools to increase the torque on the hand wheel.
- Planners / construction companies or operators are responsible for positioning andinstalling products.
5.2 Installing valves with butt weld ends
Please note that only qualified persons using appropriate equipment and working inaccordance with technical rules are allowed to install fittings by welding.The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
- Lockable stop valves must be installed in such a way that the spindle is vertical and the flow agent enters under the taper. If the valves are installed in pipelinesin positions other than specified, they must be fitted with a closing spring.
- Design with loose plug A plug damper should be used in critical applications, immediately downstream
of pumps, compressors, etc., where severe turbulence and pulsating pressuresurges may occur.Through the damper function of the loose plug, the negative influence of pressure shocks and high turbulences, are not transferred onto the valve.
Valves with pressure balancing plugs have to be installed with medium flowing over theplug (3) as indicated by flow direction arrow on valve body.Working principles:When the valve is closed, anticlockwise rotation of the hand wheel lifts the pilot plug (3.1)off the larger balancing plug (3). This allows the medium to pass through the plug andequalizes the pressure of the medium under the plug (3). After the pressures have beenequalized within the values stated in the table below, the valve can be opened by turningthe valve further.
- Pressure balancing plugs are fully effective only in closed line section.
- The pressures of the medium on either side of the plug cannot be equalized if the mediumis discharged into “open air”.
- If adequate pressure equalisation cannot be achieved using a pressure balancing plug,other design solutions must be used instead (e.g. a bypass line).
5.4 Installing valves with limit switchesThe valves with limit switches must be connected up as shown in the plans of the plant onthe basis of their working principles.
ATTENTION !
ARI stop valves must be equipped with pressure balancing plugs if thedifferential pressures listed in the table below are exceeded in the closed state.
Valves with pressure balancing plugs should be installed so that the pressure of the medium acts on the plug ( 3).
fig. 5
Balancing plug DN 125 150 200 250 300 350 400 500
Pressure difference ∆P 25 bar 21 bar 14 bar 9 bar 6 bar 4,5 bar 3,5 bar 1,5 bar
Maintanance and maintenance-intervals have to be defined by the operator according tothe requirements.
- Observe safety instructions!
- Keep the spindle well greased!
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Lubricant: e.g. Klüberpaste HEL 46-450 (at valves for oxygen: Oxigenoex FF 250)to order at: Klüber Lubrication München KG, Postfach 701047, D-81310 München
or a lubricant wich is suitable for the application.
- If the valve spindle (4) leaks, gradually tighten the stuffing box seal (6) evenly inincrements by means of the hex. nuts (19) until leaking stops.
- Replace stuffing box packings only after the system has cooled down and the pressure inthe plant has been relieved.In the case of corrosive or aggressive mediums, drain and ventilate the valve beforereplacing the packing.
- Valve service life can be improved by leakage checks.
Mounting of the bonnet:
- Before reassembling the unit, remember that the bearing surface must be cleaned and 2new gaskets (9) must be inserted.
- Set the cover in place
- Tighten the hexagon nuts (hexagon screws for valves of cast iron) evenly crosswise.
- Tightening torque‘s for hexagon nuts / screws:
ATTENTION !
Pay attention, that the lubricant is suitable for the media.
ATTENTION !
- Retighten the stuffing box packing if required and re-pack it in good time.
- For safety reasons we recommend that valves only be repacked whendepressurised.
- Refer to point 10.0 and 11.0 before dismantling the valve.
fig. 7: Split packing ring
- When cutting the new packing from the roll,make sure that the ends are cut with a slant
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
-
ATTENTION ! It is essential that the safety regulations are observed when identifying faults.
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.The warranty shall not cover maintenance work, installation of external parts, designmodifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
This instruction manual contains important safety instructions. Please read carefully before installation and initialoperation. It is hardly recommended to keep this manual within the operation area.
SR32.40 32-100 6-40 A1 HSR30.160 32-100 63-160 A1 ZRK1 125-600 10-40 H ZRL1 125-600 10-40 H
SR40.40 32-100 6-40 A1 SR50.40 32-100 6-40 A1 ZRK1S 125-600 10-40 H ZRL1S 125-600 10-40 H
SR20.40 125-200 6-40 H SR30.40 125-200 6-40 H ZRK2 125-600 10-40 H ZRL2 125-600 10-40 H
SR20.40ST 125-200 6-40 H SR34.40 125-200 6-40 H ZRK3 125-600 10-40 H ZRL3 125-600 10-40 H
SR22.40 125-200 6-40 H SR35.40 125-200 6-40 H ZRK4 350-600 6-16 H ZRL4 350-600 6-16 H
SR25.40St 250-350 6-40 H SR55.40 125-200 6-40 H ZRK5 125-600 10-40 H ZRL5 125-600 10-40 H
All valves in size DN £25 comply with article 3, paragraph 3 and are not permitted to be markedneither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH HamburgMönckebergstrasse 27
20095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
No harmonized standards available at present
Other Applied Standards and Technical Rules
AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
ZRD G/K3 350 - 600 6 - 16 H ZRD G/API594 12" - 24" Class125, 150 H
ZRD G4/K3 350 - 600 6 - 16 H ZRD G4/API594 12" - 24" Class125, 150 H
ZRD 4/K3 350 - 600 6 - 16 H ZRD 4/API594 12" - 24" Class125, 150 H
ZRD 6/K3 350 - 600 6 - 16 H ZRD 6/API594 12" - 24" Class125, 150 H
ZRD 1/K3 125 - 600 6 - 40 H ZRD 1/API594 5" - 24" Class150, 300 H
ZRD 2/K3 125 - 600 6 - 40 H ZRD 2/API594 5" - 24" Class150, 300 H
ZRD 3/K3 125 - 600 6 - 40 H ZRD 3/API594 5" - 24" Class150, 300 H
All valves in size DN £25 comply with article 3, paragraph 3 and are not permitted to be markedneither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH Hamburg
Mönckebergstrasse 2720095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
No harmonized standards available at present
Other Applied Standards and Technical Rules
AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
22.01.2002 Herfried Schrader Date Authorized Subscriber
This instruction manual applies to the above mentioned valves which are subject tothe Quality Management System Standard acc. to DIN/ISO9001 in both the manner of manufacturing as well as testing and which do meet the basic safety requirementsof Annex I of the Pressure Equipment Directive 97/23/EC. This instruction manual isintended to support the user of above mentioned valves in installation, operation and
maintenance.
Attention
Disregarding the following caution advices could evokedangerous situations which entail an inefficacy of the manufacturers’warranty.For any questions, please contact the manufacturer and also seechapter 11.
3. Intended Use
Wafer type check valves are solely destined for installation within a pipeline systemin consideration of the admitted pressure and temperature limits to avoid a backflowof the media.It is the operators’ responsibility to examine the chemical resistance in relation to thespecified operation data. All valid operation data are indicated in chapter 8 respectively in the technical datasheets of the relevant types.
4. Safety Instructions
4.1 General Safety Instructions
Those safety regulations applying to the pipeline system apply to the valves itself accordingly, i. e. any national or international rules for accident prevention as well aspossibly existing operators’ working-, production- and safety regulations have to beconsidered. This instruction manual only points to those safety instructions whichhave to be considered additionally.
4.2 Qualification of Personnel
Only qualified staff is permitted to install and maintain the valves. The operator isobliged to coordinate the competencies, the responsibilities and the surveillance of his staff. Should the staff not have the necessary knowledge, the operator mustprovide adequate additional training. The operator has to ensure that the content of this instruction manual is comprehended in all its particulars.
4.3 Safety Instructions for the Operator
Due to the fact that the following points are not in the responsibility of the valvemanufacturer the operator has to ensure when using the valves that
· the valves are solely used in the way described in chapter 3
· the pipeline system is installed in a professional manner. The wall thickness of the valve body is designed in a way that tensions which do exist within thepipeline system are considered in a usual order of magnitude.
· the valves are properly installed between the flanges.
· an usual flow rate within the pipeline system is not exceeded during acontinuous operation. For abnormal service conditions, e. g. oscillation, water shock, cavitation or a medium that contains larger solid particles, pleasecontact RITAG for clarification.
· the valves are protected against touch when working at a temperature<0°C respectively >40°C.
Danger
Prevention from misusing the valves:It has to be particularly ensured that the selected body materials andinner parts of the valve are suited for the medium that is used. Themanufacturer assumes no liability for any damages caused byaggressive media.Disregarding this precaution may evoke dangerous situations for the operating personnel or cause damages to the pipeline system.
4.4 Special Dangers
Danger toLife
Before disassembling the valve the pipeline has to be depressurized,the pipe has to be totally drained and released. Afterwards the flangescrew connections can be unscrewed and the valve can bedismantled.Misusing this precaution means danger to the life of theoperating personnel.
5. Transport and Storage
The valves are provided ready for installation. They need to be treated, conveyed
and stored carefully.· Those valves that are delivered with a protecting packing need to be storedwithin this packing up to the moment of installation.
· In case of a direct storage at the installation location the valve has to be storedin a closed room and has to be protected against any damaging impacts.
· It is recommended to use up any stock items first in order to achieve shortstorage periods.
· Those valves that are equipped with a soft sealing need to be protectedagainst sunlight that might hit this soft sealing or any other UV-radiation inorder to avoid ageing.
· Lifting tools for transport are only to be fastened on the valve body. Inner parts
The sectional drawings shown in this chapter do exemplary illustrate the basic designof the valves. Detailed information can be found in the technical data sheet of thespecific valve type.
7.1 Marking
All valves are marked in acc. to PED 97/23/EC, TRB 801 No. 45 or EN19.
General Marking
Manufacturer RITAGValve type ...Nominal diameter DN...Nominal pressure PN..Material ...Batch no. (retraceability of the material) ...
Year of manufacture (month, year, e.g. 5.02) ... Arrow of flow direction - CE-marking (starting from category I, see chapter 1 u. 6) CECode of the Notified Body (Module A1 und H) 0525 Stamp of inspector ...
Further special markings, e. g. plant identification code or project name could beadditionally affixed on request.
Wafer type non-return valves are valves which are controlled by the backflow of themedium. The obturator (disc, cone, plate) is first lifted and then opened by the flow.In the event of an incipient backflow (e. g. failure of a pump) the obturator closes self-controlled by its dead weight. This closing process can optionally be supported by
using a spring.
8 Installation
8.1 General Information
Positioning within the isometry of the pipeline as well as a proper installation of thevalves is basically the responsibility of the engineer or the operator. Any faults inengineering or installation could cause misfunction of the valves and constitute asignificant danger.For the installation of the valves the same safety regulations are to be considered as
for connecting pipelines and its components.
Attention
Pipelines have to be laid in such a manner that shearing strain andbending stress are not able to affect the valve body. The flangefacings have to be in a parallel position to each other. The facingsneed to be clean and undamaged.
Danger
Valve bodies in material cast iron EN-JL1040, EN-JS1030 must notbe treated by sudden pressure (e. g. hammer blow) becausecomponents may be destroyed.Valves working at temperatures <0°C respectively >40°C need to beprotected against touch.
8.2 Operational Characteristics
Wafer Type Lift Check Valves Type SR/HSROperating data for SR - valves
permissible working temperature (°C) 20 100 150 200 250 300 350 400 450 500
Type Material P/T group EN1092-1, -2 PN permiss ible working pressure (bar)
Lowest working temperature: ZRD G, ZRD G4, ZRD1, ZRD3, ZRD4, ZRD6 minus 10°C; ZRD2 minus 200°C
8.3 Range of Applications
Industrial plants, heating systems, fluids, gases and vapour (see also fluid groups intable of article 6), hot water heating systems DIN4751 / DIN4752, heat transmissionplants DIN4754, steam boiler plants TRD110, pressure vessel plants TRB801No. 45. Potential restrictions by any technical body of legislation are to beconsidered. The materials of the valves have to be applicative for the medium.
The arrow indicating the flow direction and the flow direction itself need to run in thesame direction.For the valve to open a minimum dynamic pressure is required. Valves without springcan only be installed in vertical lines with upward flow.
Wafer type non-return valves are designed for installation betweentwo pipeline flanges including appropriate flange sealings. The outer diameter of the valve centres itself by the flange bolts. The fastenersrequire a technical applicability in accordance to the serviceconditions. They have to comply with the regulations and have to betightened with the permissible torque. Screws, nuts or flange sealingsare not covered by the valve manufacturers’ scope of supply.
9 Initial Operation, Shut-down, Maintenance
9.1 Initial Operation
General information
Materials and service conditions have to be compared with the pipeline system databefore pressure test and initial operation in order to check resistance and load.For new plants or repairs the pipeline system has to be thoroughly rinsed in order to
clean it from potential welding residues or any other damaging solid particles.
Pressure tests of pipeline sections
Since non-return valves are always in a closed position within a filled pipeline sectiona testing overpressure value of 1,1 x PS must not be exceeded (PS = NP = max.permissible working pressure).
Throughout the pressure test process the valve and the flange connections have tobe examined regarding any leaks. Leakages have to be immediately sealed byretightening all fasteners.
9.2 Shut-down
If the system is out of operation for a lasting period all media which might change itscondition (i. e. polymerisation, crystallisation, solidification) have to be drained off thepiping system. Rinse the system if necessary.
9.3 Maintenance
The valves are maintenance-free. For safety reasons and in order to avoid
unnecessary periods of interruption the operator is advised to examine functionalityand reliability of the valves within reasonable and regular intervals (periods to bedefined by the operator).Safety instructions in chapter 4 are to be considered.
High leakage rate · Contaminated seat facings ð Clean the seat facings, regrindif necessary
· Deformation of disc/cone/plate by hammer blow
ð Replace disc/cone/plate
· Damaged seat ring ð Replace seat ring
· Disc/cone/plate does notclose, cone is hanging, highactivity rate causes a seizingdue to friction
ð Recheck operating data,reengineer all parts
Inappropriate noises Insufficient flow rate,turbulent flow, deceleratedstarting of the pump
ð Select reduced sizesð Recheck the distance betweenpipe bend and pump (5-7xDN)ð Use lighter plates or springswith reduced opening pressureð Extend the period of running upthe pump
wrong wayð Arrow of flow direction has torun in the same direction as theflow itself.
Leaks of flange sealings Connection flanges are notwired
ð Retighten fasteners
10 Spare Parts
Attention
For repair work any valve parts must only be replaced by spare parts
from the original supplier. Unauthorised conversion as well as spareparts production cause an expiry of the declaration of conformity andmay also invalidate any warranty claims.
Any springs or o-rings (relevant for valves equipped with a soft sealing) can beordered as spare parts. The full marking of the valve body has to be specified in thepurchase order.
8.0 Care and maintenance.............................................9
8.1 Setting instructions .....................................................108.1.1 Removing the cap ................................................................ 118.1.2 Changing the set pressure “without” spring change ............ 118.1.3 Changing the set pressure “with” spring change ................. 11
These operating instructions contain information necessary to install and operate the valve both safelyand effectively.If problems arise which cannot be solved with the aid of these operating instructions, please contact thesupplier/manufacturer for further information. These operating instructions comply with applicable EN
safety standards as well as regulations and codes of practice applicable in the Federal Republic of Germany. If the valve is used outside the Federal Republic of Germany, the operator or the personresponsible for the system design must ensure that valid national codes of practice are complied with.The manufacturer reserves all rights to implement technical modifications and improvements at anytime.The use of these operating instructions assumes the user is qualified as described under Section 2.3"Qualified Personnel".The operating personnel must be instructed in accordance with the operating instructions.
2.0 Notes on possible dangers
2.1 Significance of symbols
Warning of general danger
Non-compliance with operating instructions is dangerous!Read the operating instructions before installation, operation, maintenance ordisassembly and adhere to them strictly.
2.2 Safety-related definitions
The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / orconsiderable damage to property can occur.
WARNING means that if the relevant information is disregarded, there is a danger of serious injury and / or damage to property can occur.
CAUTION means that if the relevant information is disregarded, there is a danger of injury and / ordamage to property can occur.
NOTE means that particular attention must be paid to certain technical aspects.
All other information not specifically emphasised such as transport, installation, operating andmaintenance instructions as well as technical data (in the operating instructions, product documentationand on the device itself) must also be complied with to the fullest extent in order to avoid faults which inturn can cause serious injury to persons or damage to property.
2.3 Qualified personnel
The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-up and operation of the product and have the qualifications corresponding to their responsibilities suchas:Instruction and obligation to comply with all operational, regional and in-company regulations andrequirements;Training or instruction in accordance with safety technology standards with regard to the upkeep and useof appropriate safety and work protection equipment;First aid training, etc.
- Storage temperature -20˚ to +65˚C dry, free of dirt
- The painting is only a primer, intending to guard against rust during stock or transportation. Don‘tdamage the paintwork.
- A desiccant or heating to prevent condensation is necessary in damp rooms.
3.2 Transport
- Transport temperature -20˚ to +65˚C.
- Protect against external force (impact, vibration etc.).
- Don‘t damage the paintwork.
3.3 Handling before installation
- If flange covers are fitted, remove shortly before installation!
- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.
4.0 Specification
4.1 Applications
Safety valves are safety devices designed to prevent the pressure in any pressurised system fromexceeding the maximum permissible pressure by more than the permissible tolerance of, usually +10%.The engineer planning a plant is responsible for selecting the correct valve for a given application.The special features of the valve concerned must be taken into account.
- Valves for oxygen application (O2) have a fixed plate.
- Valves for Ammonia (NH 3) acc. to TRD 451-452 must be free from nonferrous metalswith flanges DIN 2512 form N.
- ARI-Valves of GG-25 are not allowed in systems acc. to TRD 110.
- Valves for inflammable, aggressive or toxic media, must be off tensile material.
- With applications for media that demand special criteria, please consult.
- -marking for applications acc. to Pressure Equipment Directive on request.
4.2 Technical specification
Terms as defined in DIN 3320 T1, TRD 421, TRD 721, AD-A2, *ASME Code Section VIII-Devision 1
Direct loaded safety valve
A direct loaded safety valve is a valve, in which the opening force underneath the valve disc is opposedby a closing force such as a spring or a weight.
*Standard safety valve
A standard safety valve is a valve which, following opening, reaches the degree of lift necessary for themass flow to be discharged within a pressure rise of not more than 10%. No further requirements aremade for the opening characteristics.
Full lift safety valve
A full lift safety valve is a valve which, after commencement of lift, opens rapidly within a 5% pressure
rise up to the full lift as limited by the design. The amount of lift up to the rapid opening (proportionalrange) shall not be more than 20% of the total lift.
Series with thread connections are marked on the body.
5.0 Installation
The following points should be taken into account besides the general principles governing
installation work:
- See appropriate TRD 421, AD-A2, DIN, ASME Code rules for piping and installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before installation.
- Safety valves shall be installed with vertical spindle.
- Safety valves shall be installed with upright spindle, not series 950 when marked, „Installation onlyhorizontal“, then they must be installed horizontally.
- No static, dynamic or thermal loads shall be transferred to the valve.
- Flange gaskets shall be fitted concentrically and not restrict the flow cross section.
- Dirt and foreign bodies shall not be permitted to enter the safety valve.
- Blow-off lines shall be laid with gradient.
Safety valve (TÜV)
Safety valve (ASME)
d0 αd CE-marking
Set pressure
Set pressureCapacity
NB-stamp UV-stamp CE-markingSize (inch)
Units: SCFM = airLB/HR = steamGAL/MIN = water
MechanicNo.Year
ARI Set pressure (bar / psig)
Serial-No. BA/BQ
disc
E = EPDM up to +150°CV = Viton up to +180°CN = Neoprene up to +125°C
- Water shall be drained from the safety valve and blow-off line via the blow-off line (drainage pointsalways at the lowest point).
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- All drainage systems shall be laid with gradient to a visible discharge.
- The arrangements shall permit the discharge of condensate without danger at all times
fig. 5
- The blow-off line shall be sufficiently large to ensure that the internal back-pressure while blowing-off does not exceed 15% of the set pressure.(Exception: safety valves with metallic bellow for back-pressure compensation).
- The safety valve shall be equipped with a metallic bellow for back-pressure compensation if the back-pressure exceeds 15% of the set pressure.
- The ratio pao/po shall be taken into account when dimensioning the system.
- The inspection connection on the bonnet of safety valves with metallic bellow is for checking the state
of the bellow as damage to the bellow leads to failure of the safety valve (in this case the bellow wouldhave no back-pressure compensating effect and the safety valve would not function as required).
- The state of the bellow is checked by connecting a pressure gauge to the inspection connection so thatthe back-pressure can be seen in the event of damage.
- Caution: No piping or screws shall project through the inspection connection into the bonnet!Danger of jamming !
- Safety valves shall be equipped with support tongues to absorb high reaction forces.
- Pressure losses in the line to the safety valve shall not exceed 3%.
- Any blocking screws shall be removed.
5.1 Safety noteFailure to observe the instructions in point 5 may endanger personnel, the plant and other
objects.
6.0 Notes on dangers during installation, operation and maintenance
DANGER !
Operation can be completely safe only if the valve is properly installed, put into operation andmaintained by trained personnel (cf. point 2.3 “Qualified personnel”) paying full attention to thewarnings in these operating instructions. In addition, the general installation and safety rules for pipingand plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict
attention must be paid to the operating instructions during all work on the valve and when handling it.Injury or damage can be caused by ignoring them.
- Check that the data of the valve are correct for the plant (see Typ test plate).
- Remove protective caps and lever lock before putting the valve into service.
- Clean and flush the plant before it is put into operation as dirty media can cause leaks in safety valves.(See point 5 “Installation”.)
DANGER !
Before putting a new plant into operation or restarting a plant after repairs or modification, always makesure that:- all installation and assembly work has been completed!- only trained personnel (see point 2.3) are employed to start the plant!- existing guards have been attached and in good order.
7.1 Potential hazards
- Always make sure that the safety valve cannot freeze or become clogged or blocked(see point 5 “Installation”.)
- The surface temperature of the casing can become very high during operations with high mediatemperatures. Danger of burns!
- If no blow-off line is provided, medium may suddenly emerge from the valve outlet. Danger of scalding, explosion or injury!
- Loud noises may be generated when blowing off.
- Hot media may emerge from the inspection opening of the spring bonnet.
- with open bonnet hot media may escape.
8.0 Care and maintenance
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due to particlesbetween the seat and disc.
- If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been damaged.This can only be rectified at our works or by an authorised contractor.
- The safety valve must be lifted from time to time in line with current regulations to ensure that thevalve works correctly.(The intervals at which this must be done depends on various factors so that no generally applicableinterval can be specified).Note: Too frequent lifting for test purposes can increase wear of the sealing surfaces.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be returned to theoriginal position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- Our setting instructions (point 8.1) must be strictly adhered to when changing the set pressure orchanging the set pressure and the spring.It is best to have these operations done at our works (Schloss Holte- Stukenbrock).
- The manufacturer accepts guarantee liabilities only if tampering by third parties is prevented.
Caution:
Safety valves acc. to ASME Code Section VIII Division 1 are only allowed to be required, altered andreset by ARI!
- Extract spindle (14) with disc (12/12a), guide plate (4/4a) and bottom spring-plate (26).
- Clean seat (2) and disc (12/12a).
- Insert spindle (14) with disc (12/12a), guide plate (4/4a), spring-plate (26) and different spring (37).
- Fit bonnet (11/42) and reset the set pressure; make sure spring setting range is appropriate.
- Secure spring setting by means of lock nut (21).
- Assemble lifting device.
- If necessary, replace both spring plates (26) and use longer studs (3) when fitting a spring for a higherset pressure.
- Further information obtainable from the manufacturer.
Only for the 900 series.When changing the set pressure and fitting a new spring, note that safety valves with set pressuresbetween 0.2 and 1.5 bar have a greater lift.Therefore:
Caution:Safety valves acc. to ASME Code Section VIII Division 1 are not allowed to be delivered with a liftlimitation!
Only for the 950 series
Caution:
Safety valves for horizontal application, must also to be set in a horizontal position.
9.0 Troubleshooting
In the event of failures or malfunctions, check that the valve was assembled and installed as described inthese instructions.
Compare the DN, opening pressure, blowing-off power, back pressure, operating pressure andtemperature with the information given in the plans of the piping system. Check also that the serviceconditions correspond to VDTÜV, AD, TRD, ASME Code and the data given on the Type test plate andthe technical data.
Danger!
It is essential that the safety regulations are observed when identifying faults!
If malfunctions cannot be eliminate with the help of the following „ troubleshooting table“, the supplieror manufacturer should be consulted.
Set pressure in the range Spring change only inthe range
Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screwabove cap, Figure 990).
Spring corroded by medium and broken. Replace safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
In the case of vapour, select open cap orbonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. liquids)emerging from valve.
Replace safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
Select design with closed bonnet and cap.Install a guard if necessary.
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or radiusin connection socket. Select larger line if necessary.Relieve pressure first!
Observe points 7.0 and 11.0!
Poor welding (root pass), gaskets at inlet andoutlet flanges too small or not concentric. Change conditions.Relieve pressure first!
