Table of contents Plant specification System conceptTechnical data and performance curve............................................................................1General arangement drawings........................................................................................2Steam and water system................................................................................................3Fuel oil system............................................................................................................4Mission OC control panel drawing.................................................................................5Spare part...................................................................................................................6 Instruction MISSION OC boilerDescriptions................................................................................................................7Operation and maintenance...........................................................................................8Feed and boiler water...................................................................................................9Water level gauge......................................................................................................10Safety valves.............................................................................................................11Feed water system......................................................................................................12Regulating feed water valve........................................................................................13Chemical dosing pump...............................................................................................14Oil detection equipment..............................................................................................15Salinity alarm equipment............................................................................................16 Pressure atomising burner KBODescriptions..............................................................................................................17Installation................................................................................................................18Fuel oil pump unit......................................................................................................19Operation and maintenance.........................................................................................20 MISSION OC Control System (Touch)MISSION control system............................................................................................21Operation of the panels...............................................................................................22TABLE OF CONTENTSLanguage UK iCommisioning and service..........................................................................................23Burner sequence diagram............................................................................................24Flame safeguard.........................................................................................................25Menu structure for panels............................................................................................26TABLE OF CONTENTSii Language UKTable of contents Technical data and performance curveDescription Document ID Page.Technical data for boiler plant..................................... .................................. 1-2Technical data for MISSION OC............................. .................................. 1-3Technical data for fuel oil pumps................................. .................................. 1-6Performance curve..................................................... .................................. 1-8TABLE OF CONTENTSLanguage UK 1-1 / 11Technical data for boiler plant1General data Request No./Order No.:...............................................103631-01-2, 103631-02-2 Hull No./Nos.:.................................................................................S1396, S13972General plant data Classification society:..................................................................................RINA Sub-notification (Unattended operation):......................................................UMS Service level:...........................................................................................Essential Flange standard:...............................................................................................EN Plant supply voltage:..............................................................................3 x 440 V Plant control voltage:...................................................................................230 V Pilot voltage:..................................................................................................24 V Frequency:...................................................................................................60 Hz Pressure gauge calibration:...................................Multi-scale(Bar, MPa, kg/cm2) Thermometer calibration:...................................................................................C Language on signs:....................................................................................English Ambient air temperature:..............................................................................45 C3Documentation data Language for manuals:..............................................................................English Set of approval manuals:.................................................................15 sets/project Set of working manuals:..................................................................15 sets/project Set of instruction manuals:.............................................5 sets/1st ship, 4 sets/later Set of CD-rom instruction manuals:......................................................1 sets/shipTECHNICAL DATA FOR BOILER PLANT1-2 / 11 Language UKTechnical data for MISSION OC1General data Request No./Order No.:...............................................103631-01-2, 103631-02-2 Hull No./Nos.:.................................................................................S1396, S13972Dimensions for boiler unit Height to top of smoke outlet box:.........................................................5,390 mm Diameter incl. insulation:.......................................................................2,820 mm Extension length of the water level device:............................See general arr. drw. Weight of boiler unit excl. water:..............................................................18.7 ton Weight of boiler unit incl. water:..............................................................27.7 ton3Water/steam process data Steam output, simultaneous operation:..................................................2,400 kg/h Steam output, oil fired section:..............................................................1,200 kg/h Steam output, exhaust section:..............................................................1,200 kg/h Working pressure:............................................................................7.0 kg/cm(g) Working temperature:..................................................................................170C Max. allowable working pressure:....................................................9.0 kg/cm(g) Feed water operation:..........................................................................Modulating Feed water temperature, layout:.....................................................................80C4Data for pressure part Boiler type:.......................................Vertical, composite smoke/water tube boiler Boiler model:...............................................................................MISSION OC Test pressure:......................................................1.5 x Design pressure kg/cm(g) Protection of boiler body:...........................................................Silver(RAL9006) Insulation thickness:...................................................................................75 mm Cladding type:............................................................................................Trapez Colour of insulation plates:..........................................................Blue(RAL5002)TECHNICAL DATA FOR MISSION OCLanguage UK 1-3 / 115Combustion process data (oil-fired section) Min. calorific value of diesel oil:.......................................................42,200 kJ/kg Min. viscosity of diesel oil:..............................................................3 cSt. at 40C Max. viscosity of diesel oil:............................................................12 cSt. at 15C Density of diesel oil:.................................................................900 kg/m at 15C Min. calorific value of fuel oil:..........................................................40,200 kJ/kg Max. viscosity of fuel oil:.............................................................600 cSt. at 50C Density of fuel oil:....................................................................991 kg/m at 15C Turn down ratio on fuel oil:..............................................................................3:1 Fuel oil temperature before pre-heater:.........................................................60 C Fuel oil viscosity at burner inlet:..............................................................8-10 cSt. Fuel oil temperature at burner inlet:.............................................................145C Air excess No. at 100% load:............................................................................1.2 Flue gas temperature (clean boiler):............................................................329 C Air consumption at 100% load:.............................................................1,378 kg/h Flue gas flow (approx.):........................................................................1,463 kg/h6Combustion process data (exhaust gas sec-tion) Main engine:.......................................................................................................... Engine load, design:...............................................................................90%MCR Design condition:............................................................................................ISO Exhaust gas flow:................................................................................80,900 kg/h Inlet temperature of exhaust gas:.................................................................232 C Outlet temperature of exhaust gas:..............................................................197 C7Data for pressure loss layout Pressure loss across flue gas system, max.:...........................................10 mmWC Pressure loss across boiler (oil-fired section):....................................40.0 mmWC Pressure loss across boiler (exhaust gas section):................................120 mmWC8Data for burner Burner type:.............................................................................Pressure atomisingTECHNICAL DATA FOR MISSION OC1-4 / 11 Language UK Burner regulation:...............................................................................Modulating Model:............................................................................................KBO-E-R13M Primary fuel:...................................................................................Heavy fuel oil Secondary fuel:.......................................................................................Diesel oil Burner capacity on diesel oil, min.:............................................................32 kg/h Burner capacity on diesel oil, max.:...........................................................88 kg/h Burner capacity on fuel oil, min.:...............................................................32 kg/h Burner capacity on fuel oil, max.:..............................................................85 kg/h Nozzle:.............................................................................................12-W2-70-60 Flame tube:................................................................................................OD200 Diffuser disc:.............................................................................................152x50 Colour of burner unit:...........................................................................RAL 30029Data for control system Insulation class:...................................................................................................F Degree of protection:......................................................................................IP54 Colour of boiler control panel:................................................Munsell(7.5BG7/2)10Operational data for boiler plant Operation:......................................................................................24h unattended Automatic mode:.............................................................................................Yes Manual mode:..................................................................................................Yes Emergency mode:............................................................................................YesTECHNICAL DATA FOR MISSION OCLanguage UK 1-5 / 11Technical data for fuel oil pumps1General data Project No.:.................................................................103631-01-2, 103631-02-2 Hull No./Project name:....................................................................S1396, S1397 Classification society/Local authority:.........................................................RINA Pressure gauge calibration:.............................................................................MPa Thermometer calibration:..................................................................................C Language for signs:..........................................................................................UK Colour of fuel oil pump unit:...................................................Munsell 7.5BG 7/22Data for fuel oil pumps Pump:................................................................................................Screw pump Pump type:............................................................................SPZ10R28G8.3FW8 Delivery head:..........................................................................................3.3 Mpa Relief valve set point (factory set):...........................................................3.6 Mpa Oil temperature, maximum:........................................................................150 C Pump capacity at 3 cSt:...............................................................................344 l/h Pump capacity at 380 cSt:...........................................................................702 l/h NPSH at 3 cSt. (including filter):...................................................................2.6m NPSH at 380 cSt. (including filter):..............................................................4,0 m Weight of fuel oil pump unit:.......................................................................106kg3Data for pump motor Motor make:...................................................................................Branded motor Motor type:..........................................................................................90S/M3AA Power supply:...............................................................................3 x 440V, 60Hz Rated output for motor:.............................................................................1.75kW Revolutions:.........................................................................................3420r.p.m. Ambient air temperature:...............................................................................45C Starting method:..........................................................................................Direct Starting current:..............................................................................................20A Operating current (full load):.........................................................................3.4ATECHNICAL DATA FOR FUEL OIL PUMPS1-6 / 11 Language UK Power consumption at 3 cSt:.....................................................................0.93kW Power consumption at 380 cSt:.................................................................1.36kW Numbers of cable gland size:.................................................................M20 x 1.5 Heating element(stand still):.......................................................................NONE Thermostat protection:................................................................................NONE Insulation class:...................................................................................................F Degree of protection:.............................................................................Min. IP44TECHNICAL DATA FOR FUEL OIL PUMPSLanguage UK 1-7 / 11Performance curvePERFORMANCE CURVE A.11-8 / 11 Language UK Fuel type Calorific value Working pressure Feed water temperature : : : : Heavy Fuel Oil 40200 7.0 80 kJ/kg bar g deg. C Version no.: Page 1 of 42.0 Date: User Initials: Project Name: Project no: Performance Calculation MISSION OC Standard Size: 1250 kg/h 09/12/2009 mva STX Shipbuilding Co Ltd103631 PERFORMANCE CURVE A.1Language UK 1-9 / 11 Date: User Initials: Project Name: Project no: Performance Calculation MISSION OC Standard Size: 1250 kg/h 09/12/2009 mva STX Shipbuilding Co Ltd103631 Version no.: Page 2 of 42.0 Fuel type Calorific value Working pressure Feed water temperature : : : : Heavy Fuel Oil 40200 7.0 80 kJ/kg bar g deg. C PERFORMANCE CURVE A.11-10 / 11 Language UK Date: User Initials: Project Name: Project no: Performance Calculation MISSION OC Standard Size: 1250 kg/h 09/12/2009 mva STX Shipbuilding Co Ltd103631 Version no.: Page 3 of 42.0 Fuel type Calorific value Working pressure Feed water temperature : : : : Heavy Fuel Oil 40200 7.0 80 kJ/kg bar g deg. C PERFORMANCE CURVE A.1Language UK 1-11 / 11 Date: User Initials: Project Name: Project no: Performance Calculation MISSION OC Standard Size: 1250 kg/h 09/12/2009 mva STX Shipbuilding Co Ltd103631 Version no.: Page 4 of 42.0 Fuel type Calorific value Working pressure Feed water temperature : : : : Heavy Fuel Oil 40200 7.0 80 kJ/kg bar g deg. C General arangement drawingsDescription Document ID Page.General arrangement for OC....................................... 04Y_056884............... 2-3Gauge board drawing................................................. 61Z_054988............... 2-5Water level control, Gestra, DN 100............................ 62Z_057339............... 2-7Language UK 2-1 / 8General arrangement for OCGENERAL ARRANGEMENT FOR OC 04Y_056884#A.2Language UK 1-3 / 8Gauge board drawingGAUGE BOARD DRAWING 61Z_054988#A.1Language UK 1-5 / 8Water level control, Gestra, DN 100WATER LEVEL CONTROL, GESTRA, DN 100 62Z_057339#A.2Language UK 1-7 / 8Table of contents Steam and water systemTag Number Description Document ID Page.................................... Steam and water P&ID diagram.................................. X01_701406............... 3-3................................... List of parts - steam/water........................................... X01_701406............... 3-5C1, C301..................... Safety valve, DN 32/50, PN 40/16............................... 6040000006................ 3-7C184, C484.................. Expansion joint, DN 50.............................................. 85Y_013421............... 3-9C186, C486.................. Remote pull for safety valve....................................... K03_032121............... 3-11C2............................... Stop valve, angle, DN 100, PN 25................................ 2511094..................... 3-13C3, C303, C6, C7, C307................................... Stop valve, straight, DN 25, PN 25.............................. 2501088..................... 3-14C4, C304..................... Stop valve, straight, non return, DN 25, PN 25.............. 2641088..................... 3-15C9, C10, C11............... Stop valve, straight, DN 8, PN 160.............................. 6220000002................ 3-16C16, C198................... Stop valve, gate straight, DN 50, PN 10........................ 2531005..................... 3-17C17.............................Waterlevelgaugewithilluminator,left,model26,DN25, PN 40................................................................. 7010000436................ 3-18C18.............................Water level gauge with illuminator, right, model 26, DN25, PN 40................................................................. 7010000435................ 3-20C187, C487.................. Remote pull for water level gauge................................ K03_032122............... 3-23C331, C431.................. Needle valve, straight, " x ", PN 400....................... 2541002..................... 3-25C33............................. Pressure gauge, 100................................................. 6632973..................... 3-26C35............................. Pressure switch RT30AW 1-10 Bar............................. 6310310..................... 3-27C43............................. Pressure transmitter 0 - 10 barg................................... 8010000012................ 3-29K8, K9........................ Temperature gauge.................................................... 8080000029................ 3-30C162........................... U-tube manometer, 400 mm........................................ 8050000052................ 3-31W1..............................Pneumatic control valve, DN 15, PN 25, with DP actuatorand I/P positioner....................................................... 6050000001................ 3-32W3.............................. Filter regulator with automatic drain............................ 2915101..................... 3-33K5, K305..................... Temperature switch AHTs-20/a................................... 6320110..................... 3-343M23.......................... Chemical dosing unit................................................. 9296006004................ 3-35H2, W32...................... LED indicator / limit switch........................................ 8001000002................ 3-37M25............................ Sample cooler........................................................... 8750005..................... 3-39M145.1........................ Control unit for oil detection equipment....................... 8210000025................ 3-41M145.2........................ Ultrasonic sensor for oil detection equipment................ 8310000005................ 3-42M146.1........................ Conductive electrode, type SL 700 E........................... 8620000082................ 3-43M146.2........................ Control device, salinometer, type SL 700...................... 8210000032................ 3-44M146.3........................ T-piece for salinity alarm equipment............................ 8500000115................ 3-45C191........................... Water washing hose with nozzle.................................. 2941001..................... 3-46S-C-9.......................... Spare parts box.......................................................... 6499402..................... 3-47................................... Counter flange........................................................... K16_004096............... 3-49TABLE OF CONTENTSLanguage UK 3-1 / 49Steam and water P&ID diagramSTEAM AND WATER P&ID DIAGRAM X01_701406#A.3Language UK 3-3 / 49List of parts - steam/waterBoiler plant:...................................................................................................................1 x MISSION OCRequest number:................................................................................................................................103631Configuration number:.................................................................................................................................1Hull number(s):........................................................................................................................S1396, S1397Project number(s):................................................................................................103631-01-2, 103631-02-2P&I diagram drawing number:...................................................................................................X01:701406P&I diagram revision:....................................................................................................................................Readingguide: List of Parts reflects parts delivered by Aalborg Industries.Tag Numbers are given without the index used on the P&I diagram. E.g. C2" is found on the P&I Diagramas "1C2" and "2C2" for boiler 1 and 2 respectively.Tag no. Qty. Dim (DN) Application Type Datasheet or draw-ingComposite boiler (Qty. gives the number of parts per boiler)C 1 N/A MISSION OC - 04Y:056884C1 (a) 1 32/50 Safety valve Safety 6040 000006C301 (a) 1 32/50 Safety valve Safety 6040 000006C184 1 50 Expansion joint for safety valve - 85Y_013421C484 1 50 Expansion joint for safety valve - 85Y_013421C186 1 N/A Remote pull for safety valve - K03_032121C486 1 N/A Remote pull for safety valve - K03_032121C2 1 100 Main steam valve Stop 2511094C3 1 25 Feed water valve Stop 2501088C303 1 25 Feed water valve Stop 2501088C4 1 25 Feed water valve Stop SDNR 264 1088C304 1 25 Feed water valve Stop SDNR 264 1088C6 1 25 Scum valve Stop 2501088C7 1 25 Blow down valve Stop 2501088C307 1 25 Blow down valve Stop 2501088C9 1 1/2" Sample valve Stop 6220000002C10 1 1/2" Air escape valve Stop 6220000002C11 1 1/2" Gauge board valve Stop 6220000002C16 1 50 Furnace drain valve Gate 2531005C17 1 25/length 700 Water level gauge left Illuminated 7010000436C18 1 25/length 700 Water level gauge right Illuminated 7010000435C187 1 N/A Remote pull for water level gauge - K03_032122C487 1 N/A Remote pull for water level gauge - K03_032122C198 1 50 Drain valve for exhaust gas part Gate 2531005W33 1 100 Water level meas. electrode - 8125000010 Feed water regulation valve (Qty. gives the number of parts per boiler)LIST OF PARTS - STEAM/WATERLanguage UK 3-5 / 49W1 1 15 Feed Water Control Valve with pneumaticactuatorControl 6050000001W3 1 1/4" Filter regulator with automatic drain 0-10 bar(g) 2915101Chemicald osingu nits-MISSIONOC(Qty. gives the number of partsper composite boiler )3M23 1 N/A Chemical dosing - 9296 006004 Smoke outlet - MISSION OC (Qty. gives the number of parts per boiler)C179 1 - Smoke outlet - -K5 (a) 1 1/2" Temperature switch, smoke outlet ATHs-20/a 6320110Exhaust in/-outlet boxes - MISSION OC (Qty. gives the number of parts per boiler)K305 (a) 1 1/2" Temp. switch (high), exhaust outlet ATHs-20/a 6320110 Remote indication - Steam pressure and Water level - MISSION OC (Qty. gives the number of parts per boiler)H2 1 N/A Remote indication of Steam pressure Digital 8001 000002W32 1 N/A Remote indication of Water level Digital 8001 000002 Sample coolers - MISSION OC (Qty. gives the number of parts per boiler)M25 1 N/A Sample cooler SCS20 8750005 Gauge Board - MISSION OC (Qty. gives the number of parts per boiler)C30 1 N/A Gauge board - 61Z:050512C331 1 1/2'' Instrument stop valve - 254 1002C431 2 1/2'' Instrument stop valve - 254 1002C33 1 0-16 bar Pressure gauge - 663 2973C35 1 0-10 Pressure switch, max. steam - 6310310C43 1 0-10 Pressure transmitter - 8010 000012K81 N/ATemperature gauge Exhaust gasinlet8080 000029K91 N/ATemperature gauge Exhaust gasoutlet8080 000029C162 1 N/A U-tube manometer - 8050 000052 Control system - MISSION OC3L2 1 - Local control panel - -Tag no. Qty. Dim (DN) Application Type Datasheet or draw-ingHot well - oil detectionM145.1 1Control unit - 8210000025M145.2 1Sensor- 6 m cable - 8310000005Salinity controlM146.1 1 N/AConductive electrode SL 700 E 8620000082M146.2 1 N/AControl device SL 700 8210000032M146.3 1 25T-piece - 8500000115Water hose and spray gunC191 1 N/A Water hose and spray gun (not shown on the di-agram)-294 1001Spare part boxS-C-9 1 N/A Spare part box (not shown on the diagram) - 6499402Counter flanges(c.fl.) 1 - Set of counter flanges (not shown on the P&I di-agram)- K16:004096LIST OF PARTS - STEAM/WATER3-6 / 49 Language UKType:Safety valve, full lift25.901Size:Nominal diameter: DN 32/50Application:To blow off saturated steam, air or waterMaterial:Body: GGG 40.3DIN-Material No.: 0.7043Seat: X6 Cr Ni Mo Ti 17122DIN-Material No.: 1.4571Disc: X35 Cr 17DIN-Material No.: 1.4122.05Technical data:Nominal pressure: PN 40/16Weight: 14 kgFlanges according to DINInlet: DN 32, PN40Outlet: DN 50, PN16DATA SHEETTag No(s): C1, C301Type No.: 6040Version: A.2Safety valve, DN 32/50, PN 40/16 6040000006Language UK 3-7 / 49Expansion joint, DN 501--- NO TITLE ---EXPANSION JOINT, DN 50 85Y_013421#A.3Language UK 3-9 / 49Tag No(s): C184, C484Remote pull for safety valve1 REMOTE PULL FOR SAFETY VALVE K03_032121#B.1Language UK 3-11 / 49Tag No(s): C186, C486Type:Stop globe valve, angleSize:Nominal diameter: DN 100Application:For steam and/or water flowMaterial:Body: GP240GH+NDIN-materiale No: 1.0619+NSeat: G19 9 Nb SiDIN-materiale No: 1.4551Disc: X20Cr13+QTDIN-materiale No: 1.4021+QTTechnical data:Nominal pressure: PN25Weight: 34 kgFlanges according to DIN225 100175DiscSeatBody 23517536300 190 / 8 x 22DATA SHEETTag No(s): C2Type No.: 6010Version: B.2Stop valve, angle, DN 100, PN 25 2511094Language UK 3-13 / 49Type:Stop globe valve, straightSize:Nominal diameter: DN 25Application:For steam and/or water flowMaterial:Body: EN-GJS-400-18U-LTDIN-materiale No: EN-JS1049Seat: X20Cr13+QTDIN-materiale No: 1.4021+QTDisc: X20Cr13+QTDIN-materiale No: 1.4021+QTTechnical data:Nominal pressure: PN 25Weight: 5.4 kgFlanges according to DIN 14013190 85 / 4 x 14 25 115160BodyDiscSeatDATA SHEETTag No(s): C3, C303, C6, C7, C307Type No.: 6010Version: B.1Stop valve, straight, DN 25, PN 25 25010883-14 / 49 Language UKType:Stop check globe valve, screw down nonreturn, straightSize:Nominal diameter: DN 25Application:For steam and/or water flowMaterial:Body: EN-GJS-400-18U-LTDIN-materiale No: EN-JS1049Seat: X20Cr13+QTDIN-materiale No: 1.4021+QTDisc: X20Cr13+QTDIN-materiale No: 1.4021+QTTechnical data:Nominal pressure: PN 25Weight: 5.4 kgFlanges according to DIN 14013190 85 / 4 x 14 25160 115DiscSeatBodyDATA SHEETTag No(s): C4, C304Type No.: 6030Version: B.1Stop valve, straight, non return, DN 25, PN 25 2641088Language UK 3-15 / 49Type:Instrument stop cone valve, straight, withsecurity plateSize:G " x 12Nominal diameter: DN 8Application:For steam, water and/or airMaterial:Body: C 22.8DIN- Material No. 1.0460Seat: X20 Cr13DIN- Material No. 1.4021Needle tip: X35 CrMo17DIN- Material No. 1.4122Technical data:Nominal pressure: PN 160Inlet: G " male DIN 19207, form ROutlet: For steel tube 12Weight: 0.8 kg 751/2 BSP221290Security plate115DATA SHEETTag No(s): C9, C10, C11Type No.: 6220Version: A.2Stop valve, straight, DN 8, PN 160 62200000023-16 / 49 Language UKType:Stop valve, gate straightSize:Nominal diameter: DN 50Application:Sea water, fresh water, oil, steam etc.Material:Body: GG 25Technical data:Nominal pressure: PN 10Max. temperature: 150 CWeight: 11.5 kgDATA SHEETTag No(s): C16, C198Type No.: 6010Version: A.2Stop valve, gate straight, DN 50, PN 10 2531005Language UK 3-17 / 49Type:Transparent water level gauge with illu-minator.Orientation: leftModel size:269030Size:Connection, nominal: DN 25Connection, drain: 10Pressure rating:Pressure of unit, nominal: PN 40Pressure of connection valves, nominal:PN 40Pressure of drain valve, nominal:PN 40Connection type:Connectiontype:FlangesaccordingtoDINApplication:For boiler water level indicatorMaterial:Body: Carbon steel 45#Connection valve body: WCBDrain valve body: WCBTechnical dataConnection valves type: PXWeight:27.9 kgElectrical specifications:Power supply:230 V 50/60HzBulb type: Clear glassBulb size: 100WSocket type: ESocket size: E 27DATA SHEETTag No(s): C17Type No.: 7010Version: A.2Water level gauge with illuminator, left, model 26,DN 25, PN 4070100004363-18 / 49 Language UKDimension:H:700H1: 530H2:493H3:250H4:160H5:115H6: 350L:84.5L1: 130L2: 100L3: 230W:125W1: 105W2: 290D: 10d: 3/4L3L2 L1LWW2A AA AH3H6H5H4H H1Drain connection DElectrical connection dVisible length H2W1DATA SHEETTag No(s): C17Type No.: 7010Version: A.2Water level gauge with illuminator, left, model 26,DN 25, PN 407010000436Language UK 3-19 / 49Type:Transparent water level gauge with illu-minator.Orientation: rightModel size:269030Size:Connection, nominal: DN 25Connection, drain: 10Pressure rating:Pressure of unit, nominal: PN 40Pressure of connection valves, nominal:PN 40Pressure of drain valve, nominal:PN 40Connection type:Connectiontype:FlangesaccordingtoDINApplication:For boiler water level indicatorMaterial:Body: Carbon steel 45#Connection valve body: WCBDrain valve body: WCBTechnical dataConnection valves type: PXWeight:27.9 kgElectrical specifications:Power supply:230 V 50/60 HzBulb type: Clear glassBulb size: 100WSocket type: ESocket size: E 27DATA SHEETTag No(s): C18Type No.: 7010Version: A.2Water level gauge with illuminator, right, model26, DN 25, PN 4070100004353-20 / 49 Language UKDimension:H:700H1:530H2:493H3:250H4:160H5:115H6:350L:84.5L1: 130L2: 100L3: 230W:125W1: 105W2: 290D: 10d: 3/4L3L1 L2LW2WH3H6H4HH1Visible length H2Drain connection DA AH5Electrical connection dA AW1DATA SHEETTag No(s): C18Type No.: 7010Version: A.2Water level gauge with illuminator, right, model26, DN 25, PN 407010000435Language UK 3-21 / 49Remote pull for water level gauge1 REMOTE PULL FOR WATER LEVEL GAUGE K03_032122#C.1Language UK 3-23 / 49Tag No(s): C187, C487Type:Pressure gauge valve needle straight.Size:1/2 x 1/2Application:For instrument connectionsMaterial:Body: C22.8DIN-material No. 1.0460Technical data:Nominal pressure: PN 400Test connection: M20 x 1.5 mm threadedmaleWeight: 0.4 kgDATA SHEETTag No(s): C331, C431Type No.: 6210Version: C.1Needle valve, straight, " x ", PN 400 2541002Language UK 3-25 / 49Type:Pressure gaugeSize: 100Application:For all gaseous and liquid mediaMaterial:Case: Stainless steelSocket: Cu-alloyLiquid filling: GlycerineTechnical data:Measuring unit: bar Mpa - kg/cmMeasuringrange:016/1.6/16withmechanical stopConnection: BSP 1/2-mOperating temperature:Ambient: -20to + 60CMedium, max.: + 60CProtection: IP 65 107 1003081.58BSP 1/2-mbarMPa=bar x 0.1kg/cm001616DATA SHEETTag No(s): C33Type No.: 8050Version: C.1Pressure gauge, 100 66329733-26 / 49 Language UKDATA SHEETTag No(s): C35Version: B.2Pressure switch RT30AW 1-10 Bar 6310310Language UK 3-27 / 49Tag No(s): C35DATA SHEETTag No(s): C35Version: B.2Pressure switch RT30AW 1-10 Bar 63103103-28 / 49 Language UKType:Pressure transmitterRange:0 10 bargApplication:Thepressuretransmitterconvertspres-suretoanelectricsignal.Theunitsaresupplied as two wire transmitters with anoutputsignalof4-20mA.Theoutputcurrent is linearly proportional to the in-put pressure.Material:Housing:Stainlesssteelwithceramicmeasuringcellandelectronicsmodule.Thetemperature-compensatedceramicmeasuringcellhasathin-filmstraingauge which is mounted on a ceramic di-aphragm.Process connection: Stainless steelGasket: VitonTechnical data:Electrical specification:Current output signal: 4 to 20 mAVoltageoutputsignal(onlymeasuringrange > 1 bar: 0.10 VDCPowersupplyterminalvoltageforcur-rent output: 10.36VDCAccuracy:Response time T99: < 0.1 sInfluence of ambient temperature at startof scale: 0.25%/10K (0.25%/10K) of fullscale valueInfluence of ambient temperature at fullscale value: 0.25%/10K (0.25%/10K) offull scale valueMechanical: Process temperature: 30C to +120C Ambient temperature: 25C to +85CDegree of protection to EN 60529: IP65Weight: 0.25 kgConnection diagram:12720G 1/2-m 27SW 2750PG 111+I Output currentU Power supplyRLoadConnections:1 (+U )2 (-U )0 B LBB+UBRLIo2-DATA SHEETTag No(s): C43Type No.: 8012Version: A.2Pressure transmitter 0 - 10 barg 8010000012Language UK 3-29 / 49Type:Temperature gaugeSize: 100Application:For marine applicationsMaterial:Case: AISI 304 naturalProbe: AISI 316Window: AcrylicLiquid filling: SiliconeTechnical dataMeasuring range: 0 to 400CCapillary tube: 10 mConnection: None (smooth sensor), con-nector supplied separatelyAmbient temperature: -40 to +100C45048 10851C0100200300400116 133 x 6, PCD 116DATA SHEETTag No(s): K8, K9Type No.: 8080Version: A.2Temperature gauge 80800000293-30 / 49 Language UKType:U-tube manometer, 400 mm1221 M-400-W/MApplication:For determining velocity and static pres-sure, leakage, fan and blower efficiency,filter resistance and differential gas pres-sures.Material:U-tube: Shatter proof clear butyrate tub-ingBase plate: AluminiumTechnical data:Range: 200-0-200 mm H2OAccessories:One ounce bottle of fluorescein greendye concentrate gauge fluid3519.542517121.57528 23.5Cutting ring 12 AA - AA700728 7 72001002001000DATA SHEETTag No(s): C162Type No.: 8050Version: A.2U-tube manometer, 400 mm 8050000052Language UK 3-31 / 49Type:Control globe valve, straight with pneu-matic actuator and I/P positioner23.470, DP 32Size:Nominal diameter: DN 15Application:For control of air, gas, water, steam, andoil flowMaterial valve:Body: GGG 40.3DIN -Material No. 0.7043Seat: X20 Cr13DIN Material No. 1.4021.05Plug: X20 Cr13DIN Material No. 1.4021.05Stuffing box: PTFE V-ring unit(-10C to+ 220C)Technical data, valve:Nominal pressure: PN 25Positioning ratio: 50:1Flow characteristic: Equal percentageKvs value:1.6 m/hStroke:20 mmPlug type: Parabolic shaft guidedFlanges according to DINTechnical data, actuator:Control signal: 0.4 1.2barMax. permissible closing pressure:40 barDiaphragm area: 250 cmMax. air supply pressure: 6 barAction:Spring closes on air failureTechnical data, I/P positioner:Air connection inlet: G Inlet air supply: 1.4 to 7 bar, instrumentairAir inlet consumption in stable state:0.036 Nm/hCable inlet: M20 x 1.5Input signal: 4-20 mAAmbient temperature: -30C to +80CProtection: IP65Technical data unit:Weight: 18 kgInstallation:Only as shown in the picture 225 250270 1565/4x 14 95470BodyPlugSeatStuffing box130I/P PositionerActuatorStroke indicatorHand wheelDATA SHEETTag No(s): W1Type No.: 6050Version: B.1Pneumatic control valve, DN 15, PN 25, with DPactuator and I/P positioner60500000013-32 / 49 Language UKType:Filter regulator with automatic drainSize:Connections ports 1/4 BSPGauge ports 1/8 BSPApplication:Instrument air for regulating pressureTechnical data:Medium: instrument air onlyMax. inlet pressure: 17 barOperating temp.: 20 C to + 65 C Filter element: 5 mRecommendpressureregulatingrange:0.14-7.0 barPressure gauge: 0 10 barWeight: 0.4 kgMaterial:Body: SteelBin: SteelHandle: AcetalFlow characteristicsOutlet pressure [bar]Air flow [ dm /s] 3123456781 2 3 4 5 6 7 8 9 10Inlet pressure7barConnectionsportsDismantel length 138SW193841997 143028Max. 6661862382.54431R19Gauge portsBinBodyHandleFitting7.5DATA SHEETTag No(s): W3Type No.: 8000Version: B.1Filter regulator with automatic drain 2915101Language UK 3-33 / 49Type:Temperature switchATHs-20/aApplication:For exhaust gasMaterial:SteelTechnical data:Measuring range: + 20 - +500 CProtection: IP54Cable entry: PG 13.5G 1/2300678566894DATA SHEETTag No(s): K5, K305Type No.: 8070Version: A.2Temperature switch AHTs-20/a 63201103-34 / 49 Language UKType:DosingpumpCNPA-1601PPE2withchemical tank.Application:Forchemicaldosing,modulatingfeedwater regulation.For boiler with Max. design pressure: 12barMaterial:PumpLiquid end: PolypropyleneValves: PolypropyleneSeals: EPDMBalls: CeramicChemical tank: Polyethylene 159590 410Feed line to boilerRelief valve, item 6000 000088 6/ 4 x 5000 mm PE HoseAir escape valveDosing pump, item 5540 000313incl. air escape valve, hoses, dosing valve andnon return valveManual stirrer, item 8500 00071660 l chemical tank, item 8500 000715Dosing valve, spring loadedNon return valveCooling neck 200 - 300 mmYard supplyTechnical data:Max. outlet pressure: 16 barMax. inlet pressure: 8 barCapacity at 16 bar: 1.0 l/hStroke at 16 bar: 0.10 mlCapacity at 8 bar: 1.4 l/hStroke at 8 bar: 0.13 mlMax. frequency: 180 stroke/minSuction lift: 6 m WCMax.ambienttemperatureatatmax.counter pressure: 45CWattage: 10 WPeak current: 0.5 AFuse(placedbehindthecontrolpan-el): 0.16 ATEnclosure rating: IP 65Insulation class: FMotor: 1 phase ACControl supply: 230 V 50/60 HzWeight: 8 kgPover connection9618Customer connection 1/2Dosing valve 3035DATA SHEETTag No(s): 3M23Type No.: 9296Version: B.1Chemical dosing unit 9296006004Language UK 3-35 / 491,61,41,210,80,60,40,20% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%0I/h180 strokes/min135strokes/min90strokes/min45 strokes/minStroke lengthCNPa 1601 at medium back pressure21,510,501 2 3 4 8 11 13 16Back pressureCorrecti on factorDATA SHEETTag No(s): 3M23Type No.: 9296Version: B.1Chemical dosing unit 92960060043-36 / 49 Language UKTypeLED indicator/limit switch5714BApplication:1248965714OK120The 5714 with 2 relay outputs is designedfor digital readout of current / voltage ortemperature signals.Relay outputs:Are selected as either a make or a breakfunction. The relays can be used as a tripamplifier.Two yellow front LEDs indicate the re-lay status. The relays can be set up witheither delayed on or off. Active relay canbe selected for either an increasing or de-creasingsignal.Thearrowkeyscanbeused for fast change of the set point.Technical data:Panel cut out: 44.5 x 91.5 mmWeight: 230 gElectrical specifications:Common specifications:Supply voltage:Max. voltage: 24230 VA C, 10%5060Hz24250 VDC 20%Internal consumption: 2.7WMax. consumption: 3.0 WAuxiliary voltages:2-wire supply: 2516 VDC / 020 mAEMCimmunityinfluence: 20 S/cm- Measuring range 375 mm to 675 mm: switch "J" position 4, water > 20 S/cm- Measuring range 775 mm to 1375 mm: switch "J" position 5, water > 20 S/cm- Measuring range 1475 mm to 1975 mm: switch "J" position 6, water > 20 S/cm4CommissioningWiring check:StepA: Check that the system has been wired according to the wiring diagram (seeFigure 3 and the electrical drawings).StepB: Check that the mains supply corresponds to the value shown on the label ofthe equipment.WATER LEVEL CONTROL SYSTEM OM8210_13#A.212-12 / 14 Language UKApplication of mains voltage:StepA: Unscrew the screws "G" and remove the housing cover "I".StepB: Apply mains voltage. The LED "L" will light up (see the position in Fig-ure 2).Adjustment of the lower measuring point:StepA: Fill the boiler with water until the lower measuring point is reached.StepB: Starttheboileraccordingtotheseparateinstructionsforstart/stopoftheboiler.StepC: Raise the boiler pressure till normal working pressure.StepD: Turn the potentiometer "K" to the left. The red LED "L" lights up.StepE: Turn the potentiometer "K" to the right until only the green LED "M" lightsup.The lower measuring point is now adjusted.Adjustment of the upper measuring point:StepA: Fill the boiler with water until the upper measuring point is reached.StepB: Operatetheburneruntiltheboilerpressurehasreachednormalworkingpressure.StepC: Turn the potentiometer "O" to the right until only the red LED "N" lightsup.StepD: Turn the potentiometer "O" to the left until the green LED "M" lights up.StepE: Turnthepotentiometer"O"totherightuntilthegreenLED"M"extin-guishes.StepF: Mount the housing cover "I" and screw in the screws "G".The upper meas-uring point is now adjusted.Note: When adjusting the measuring points of the electrode in a cold boiler, themeasuring points will shift with rising temperature as a result of the lon-gitudinal expansion of the electrode rod. The adjustment must be correctedproportionally.WATER LEVEL CONTROL SYSTEM OM8210_13#A.2Language UK 12-13 / 145Fault findingFault finding chartFault RemedyThe equipment does not workMains voltage has not been applied. Apply mains voltage. Wire the equipment according to the wir-ing diagram.The thermal fuse has failed. In the case of a defective thermal fuse, the mains voltage has notbeen connected to terminal "Q". Replace the defective thermalfuse.The ambient temperature must not exceed 70C.The electrode housing does not have earth connection to theboiler.Clean the seating surfaces and insert the metal joint ring (ofstainless steel) 27 x 32 to DIN 7605.Do not insulate the compact system with hemp or PTFE tape.The electronic board is defective. Replace the board.The equipment does not work accuratelyThe electrode has been installed without the protection tube. Theprotection tube serves as reference electrode.Install the protection tube.The vent hole in the protection tube does not exist, is obstructed,or flooded.Check the protection tube and, if necessary, provide a vent hole.The desired zero point does not lie within the measuring rangeof the electrode. The electrode is too short.Replace the compact system. Choose an adequate electrodelength.The adjustment of the measuring range is wrong. Adjust switch "J" correctly (see the instructions).Dirt deposits have been accumulated on the electrode rod. Remove the compact system and clean the electrode rod with awet cloth.The gasket of the electrode rod is damaged. Measure the currentat terminal 1 and 2 (>20 mA).Replace the compact system.Table 2WATER LEVEL CONTROL SYSTEM OM8210_13#A.212-14 / 14 Language UKTable of contents Regulating feed water valveDescription Document ID Page.Control valves, type 470/471....................................... OM6010_02.............. 13-2Pneumatic actuator, type dp........................................ OM5520_01.............. 13-7Positioner, SIPART PS2 6DR5000.............................. OM5510_05.............. 13-14TABLE OF CONTENTSLanguage UK 13-1 / 30Control valves, type 470/4711GeneralThis type of control valve is suited to regulate fluids, gases and steams. The valve plugis normally a parabolic plug, but can also be supplied in a perforated design. Both typesof plugs can have either linear or equal percentage flow characteristic.The flow direction for parabolic plugs is always against the closing direction. However,with perforated plugs for steam and gases, it is in the closing direction. If a valve witha perforated plug is operated by means of a pneumatic actuator with the flow in theclosing direction, the pneumatic actuator should have a stronger thrust force. This isnecessary to prevent thumping near to the closing position.All control valves can be fitted alternately with manual-, pneumatic-, electric- or hy-draulic operation devices.Illustration of control valves type 470 and 471Figure 1 om6010_02_val47xx0056570en..wmfCONTROL VALVES, TYPE 470/471 OM6010_02#A.213-2 / 30 Language UKTable of position numbers in Figure 1Part Designation Part Designation Part Designation1 Body 7 Gland flange 15.1 Studs2 Seat ring 7.1 Screw joint 17 Hexagon nuts3 Mounting bonnet 8 Spindle guiding 17.1 Hexagon nuts3.1 Mounting bonnet 10 Stuffing box 19 Spring-type straight pin4 Guiding bush 10.1 Stuffing-box packing 21 Set-pin5 Plug 14 Gasket 25 Bellow housing6 Spindle 14.1 Gasket 26 Bellow unit6.1 Spindle 15 StudsTable 12Operation2.1Fitting instructionsThe valve should be inserted so that the spindle has a vertical position together withtheactuator.Thevalvecanalsobetiltedtoamaximumhorizontalpositioniftheinstallation point does not allow any better condition.Toguaranteeadisturbancefreefunctionofthecontrolvalve,theinletandoutletstretchesofthepipingshouldbeofstraightpipinglength(min.twotimesthepipediameter by inlet and six times by outlet). The piping should be rinsed to clear out anypollution, welding beads, rust, etc. before inserting the control valves. A strainer shouldbe fitted in front of the control valve to catch the remaining particles. Bolts should betightened after taking into operation.The flow direction is signalled by an arrow on the valve body. The valves should beinsulated against high temperatures to guard the actuator.2.2Actuator assemblyThe control valves are normally delivered with actuators already fitted. For alternationsor maintenance of actuator, the assembly should occur in accordance with the operationinstructions for the actuator.2.3Setting into operationWhen the piping system is filled, the spindle sealing should be checked for leakageand, if necessary, tightened. A PTFE-V-ring unit does not require any tightening asthe spring tension maintains the necessary force.The bolts must be tightened gradually in steps, diametrically in pairs, but not tighterthan it is necessary for the sealing. Flange connection bolts should never be loosenedor tightened when the valve is under temperature or pressure even if a leakage mayarise.CONTROL VALVES, TYPE 470/471 OM6010_02#A.2Language UK 13-3 / 30For actuators please see to the appropriate actuator operation instructions.3MaintenanceBefore any maintenance of the control valve is carried out, the piping system must beshut off and pressure free.3.1Exchange of the stuffing-box packingA leak stuffing-box packing should initially be carefully tightened to stop the leakage.If this does not help, a new layer should be inserted, or the complete packing shouldbe replaced.3.1.1Additional packing layerStepA: Open the valve fully and unscrew the hexagon nuts (17).StepB: Lift the gland flange (7) and the spindle guiding (8) upwards.StepC: Insert adequate quantity of packing rings (split ring-displacement, splittingat 180 to avoid overlapping).StepD: Fix the hexagon nuts (17) properly.3.1.2ExchangeStepA: Drive the actuator into middle position and dismantle the actuator.StepB: Unscrew the hexagon nuts (17) from the studs (15).StepC: Remove the gland flange (7), the spindle guiding (8) and the old stuffingbox (10) and clean the packing compartment.StepD: Clean the valve spindle and check for damage and if necessary replace. Ifthe damaged spindle is not replaced, the new packing will leak after a shortperiod.StepE: Insertthenewpackingrings(splitring-displacement,splittingat180toavoid overlapping).StepF: Fix the hexagon nuts (17) properly.Note: Strenuous tightening will prevent leakage, but will also have a brake effecton the spindle which aggravates the movement of the spindle.3.2Exchange of a PTFE-V-ring sealing unitA PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good sealeven by low operation pressures. It is replaced as mentioned above.The PTFE-V-ring sealing unit should be lubricated before it is inserted. The sealinglips must face against the pressure direction.Note: Special care should be given to the spindle surface. Rough surfaces wearthe sealing lips enormously and can be due to failure of the packing unit.CONTROL VALVES, TYPE 470/471 OM6010_02#A.213-4 / 30 Language UK3.3Exchange of the bellow unitStepA: Drive the actuator into middle position and dismantle the actuator.StepB: Unscrew the screw joint (7.1).StepC: Unscrew the hexagon nuts (17) and remove the bellow housing (25). Dis-mantle the plug as described in the next section.StepD: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1).StepE: The bellow unit (26) is removed from the bellow housing (25).StepF: Replace the two gaskets (14.1) and the gasket (14).StepG: When the bellow unit (26) is replaced, the proper position of the anti-twistingdevice must be observed.StepH: The set pins (21) have to drive within the slots of the anti-twisting device.Check for friction-free movement.StepI: Replacemountingbonnet(3.1)andscrewdownthehexagonnuts(17.1)crosswise.3.4Exchange of the plug-spindle unitStepA: Drive the actuator into middle position and dismantle the actuator.StepB: Unscrew the gland flange (7).3.4.1Control valve type 470StepA: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).StepB: Pull out the plug with the spindle and exchange this unit.StepC: Remove the spring-type straight pin (19) and unscrew the spindle (6).StepD: Replace the old parts and assemble it.StepE: Drill a hole through the plug shaft and insert a new pin.StepF: Replace the gasket (14) and assemble the mounting bonnet (3).StepG: Tighten the nuts (17) evenly, crosswise.3.4.2Control valve type 471StepA: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) withplug (5).StepB: Drive the spindle in the bottom position and remove the spring-type straightpin (19).StepC: Unscrew the plug.StepD: Screw a new plug at the spindle and drill through the shaft. Drive the spring-type straight pin (19) into the hole.StepE: Replace the gasket (14).StepF: Assemble the bellow housing (25) with plug (5) together with the body (1)and fix it by screwing the hexagon nuts (17) crosswise.The spindle can onlybe completely replaced together with the bellow.3.5Changing the seat ringThe seat ring is screwed into the valve body. The seat ring can be obtained after re-moving the bonnet and can then be refinished or replaced as required.CONTROL VALVES, TYPE 470/471 OM6010_02#A.2Language UK 13-5 / 30StepA: Clean and lubricate the thread and conical sealing surface before insertion.CONTROL VALVES, TYPE 470/471 OM6010_02#A.213-6 / 30 Language UKPneumatic actuator, type dp1GeneralThe pneumatic linear actuator is designed to be mounted directly on a control valve.The pneumatic actuator converts positioning command signals into stem thrust forces.The required back setting force is produced by the spring arrangement inside the ac-tuator. The rolling-diaphragm produces linear spindle movements over the completestroke.The preferred mounting position is with the actuator and valve spindle in vertical po-sition.The mode of operation for the actuator depends on how the springs are inserted whenthe actuator is assembled. Even when the actuator is fitted in a piping system, the modeof operation can be changed.The pneumatic actuator can be operated as:Spring opens valve/air closes valve operation modeAir opens valve/spring closes valve operation modePNEUMATIC ACTUATOR, TYPE DP OM5520_01#A.2Language UK 13-7 / 30Illustration of a pneumatic actuatorFigure 1 om5520_01_dpactux0053610en.wmfTable 1 below shows a list of the position numbers in Figure 1 and Figure 2.Table of position numbers in Figure 1Part Denomination Part Denomination1 Rolling diaphragm 15 Stroke indicator2 Diaphragm housing 16 Hexagon nut3 Diaphragm lid 17 Mounting rod4 Diaphragm plate 18 Bellow5 Spindle 19 Collar nut7 Spring 21 O-ring (spindle)10 Coupling flange 22 O-ring (bushing)11 Guide flange 26 Slotted guide bearing12 Rotation guard 27 Spindle guide13 Socket screw 30 Hexagon nut14 Threaded bushing 31 Hexagon nutTable 11.1Pneumatic connectionThe air supply should be dry and at a low service temperature. A heat-guard should beinstalled to prevent high service temperature.PNEUMATIC ACTUATOR, TYPE DP OM5520_01#A.213-8 / 30 Language UKThe pneumatic supply tube must be connected to the diaphragm housing (2) by oper-ation mode spring closes" and to the diaphragm lid (3) by operation mode springopens.By air failure the stem automatically returns into the original position caused by theinserted springs.Warning: The actuator diaphragm may only be pressure loaded on the side op-posite of the springs. The vent hole in the other connection must remainopen.1.2Assembly of the actuator on the valveThe assembling of the actuator on the valve is shown in Figure 2. For both springclosesandspringopensoperationmodesthefollowingassemblingprocedureshould be followed:StepA: If the actuator and the valve are separated, press the plug and spindle unit(5) into the closed position for operation mode spring closes or into theopen position for operation mode spring opens.Warning: Make sure that the plug does not turn while pressing on the seat duringassembly.StepB: Loosen the socket screws (13), remove the rotation guard (12) and the guideflange (11). The threaded bushing (14) is now free.StepC: Turn the locking hexagon nut (30) onto the valve spindle. Place the rotationguard (12) and the guide flange (11) over the valve spindle and then turn thethreaded bushing (14) onto the valve spindle.StepD: Check the actuator for proper operation mode and connect the pneumaticsupply to the connection piece in the diaphragm housing (2) for operationmode spring closes or in the diaphragm lid (3) for operation mode springopens.StepE: Drive the actuator into approximately mid-stroke position over the air supplyand mount it onto the valve (read the value from the pressure gauge - middleof the spring range).StepF: Tighten the hexagon nuts (31).PNEUMATIC ACTUATOR, TYPE DP OM5520_01#A.2Language UK 13-9 / 30Assembly of the actuator on the valveFigure 2 om5520_01_dpactsx0053600en.wmf1.3Adjustment of the starting pressure signalStepA: Drive the actuator to the required spring-starting point over the air supply.StepB: Turn the threaded bushing (14) up against the coupling flange (l0) so thatthe collar enters into the flange and presses against it. Make sure that theplug is lying on the valve seat.Attention: Note that sufficient thread of the valve spindle is inside the threadedbushing (14). If not, turn the coupling flange (10) downwards fromthe actuator spindle and pull the threaded bushing (14) against it.StepC: For operation mode: spring closes:- Attach the guide flange (11) and the rotation guard (12) with the socketscrews (13) to the coupling flange (10).- Check that the plug lifts off the seat at the required spring starting point.StepD: For operation mode: spring opens:- Check that the plug leaves the end position at the required spring startingpoint, and finishes the valve stroke at the spring-range end value.- The plug must then also press on the valve seat.StepE: After the test operation set the stroke indicators (15) into the end positions.StepF: Lock the hexagon nuts (16 + 30) at the valve mid-stroke.StepG: Do not turn the plug on the seat when it is under force.PNEUMATIC ACTUATOR, TYPE DP OM5520_01#A.213-10 / 30 Language UK2Reversal of the actuator actionThe actuator action can be reversed even when the valve is installed in a piping system.The position numbers mentioned in this section refer to Figure 1 and Figure 2.StepA: Drive the actuator into approximately mid-stroke position with the air sup-ply.StepB: Loosen and remove the socket screws (13) from the coupling flange (10)and drop the rotation guard (12) over the valve spindle.StepC: Remove the hexagon nuts (31) from the actuator and lift off the valve.StepD: Reduce the air supply until the chamber is pressure free.StepE: Loosen and remove the diaphragm lid screws.StepF: Remove the diaphragm lid (3).Warning: The actuators DP 32 and DP 33 have two longer screws when fittedwithstrongerspringranges.TheactuatorDP34hasfour.Thesescrews should be the last screws to be loosened, and must be loosenedevenly to reduce the high spring tension.StepG: For reversal from spring closes into spring opens:- Remove the springs (7) and the diaphragm plate (4) with the diaphragm(1) and the spindle (5).- Loosen and remove the seal lock nut (19) and remove the spindle (5).Turn over the diaphragm plate (4) with the diaphragm (1) and the dia-phragm clamping flange, and place it over the spindle (5).- Tighten with the seal lock nut (19). Make sure that the spindle surfaceis not damaged.- Grease the spindle surface and the 0-ring.- Place the diaphragm plate (4) with the diaphragm (1) into the diaphragmlid (3).- Arrange the springs (7) onto the moulds pressed into the diaphragm plate(4).- Place the diaphragm housing with the spindle sealing unit over the spin-dle, and screw it together. Make sure that the springs stay properly ar-ranged.- Turn the hexagon nut (16) and the coupling flange (10) onto the spindle(5).- Mount the actuator as described previously, and connect the air supplytube to the diaphragm lid (3).PNEUMATIC ACTUATOR, TYPE DP OM5520_01#A.2Language UK 13-11 / 30StepH: For reversal from spring opens into spring closes:- Remove the diaphragm (1) and the diaphragm plate (4) with the spindle(5) and the springs (7).- Loosen and remove the seal lock nut (19) from the spindle (5). Turn overthediaphragmplate(4)withthediaphragm(1)andthediaphragmclamping flange, and place it on the spindle (5).- Tighten with the seal lock nut (19). Make sure that the spindle surfaceis not damaged.- Grease the spindle surface and the 0-ring.- Stick the diaphragm plate (4) with the diaphragm (1) and the spindle (5)into the diaphragm housing (2).- Arrange the springs (7) onto the moulds pressed into the diaphragm plate(4).Place the diaphragm lid (3) on the top, and screw it together. Makesure that the springs (7) stay properly arranged.- Turn the hexagon nut (16) and the coupling flange (10) onto the spindle(5).- Mount the actuator as described previously, and connect the air supplytube to the diaphragm housing (2).3Manual operation deviceSome actuators are fitted with a manual operation device. The device is connected tothe actuator by means of a new diaphragm lid, a spindle extension with a USIT-ringand a spindle sealing unit.The manual operation device is equipped with stroke indicators. The stroke indicatorsof both the actuator and the manual operation device must be in the same end positionswhen the actuator is pressure free.Themanualoperationdevicemustbesetintoneutralpositionwhentheactuatorisrunning automatically.The locking device of the manual operation device must be unlocked before operating.The locking device prevents an unwanted disarrangement of the setting during oper-ation, e.g. due to vibration, etc.4MaintenanceThe pneumatic actuator is maintenance free. To maintain a disturbance free operation,the air should be supplied by an air-supply station.The diaphragm, spindle sealing unit and springs are wear parts and should be replacedwhen necessary.PNEUMATIC ACTUATOR, TYPE DP OM5520_01#A.213-12 / 30 Language UK4.1Exchange of spindle sealingWhen the spindle sealing is changed, the slotted PTFE-guide bearing and the 0-ringshouldbereplaced.Thespindlesurfacemustbecleanandundamaged.Beforetheactuator is assembled, the spindle unit and the spindle must be greased.PNEUMATIC ACTUATOR, TYPE DP OM5520_01#A.2Language UK 13-13 / 30Positioner, SIPART PS2 6DR50001GeneralThe following instruction is a general description of SIPART positioners and coversthe complete range in the PS2 6DR5000 series.The electronic pneumatic positioner is used as the final control element of a pneumaticlinear actuator or a part-turn actuator (rotary movements). The positioner converts acurrent output signal (4 to 20 mA) from a process controller or control system to a setpoint value and into a corresponding movement. The positioner changes the pressurein a pneumatic actuator chamber or cylinder until the position corresponds to the setpoint value.Thepositionercanbesetupeitherasasingle-actionpositioneroradouble-actionpositioner. The single-action positioner is mainly used together with a control valve.Theoppositemovementforthecontrolvalveissuppliedbymeansofsprings.Thedouble-action positioner is mainly used to control an air damper via a pneumatic cyl-inder (actuator). All movements of the pneumatic cylinder are supplied by the posi-tioner. An illustration of the function diagram for the positioner is shown in Figure 1.The function diagram is shown with option modules.1.1Mode of operationComparison of the set point and the actual value takes place electronically in a microcontroller. If the micro controller detects a deviation, it uses a 5-way switch procedureto control the piezoelectric valves, which in turn regulate the flow of air into the ac-tuating chambers. When connected in a two-wire system, the SIPART PS2 draws itspower exclusively from the 4 to 20 mA set point signal.The piezoelectric valve converts the command into a pneumatic positional increment.The positioner outputs a continuous signal in the area where there is a large controldeviation (high-speed zone). In areas of moderate control deviation (slow-speed zone)it outputs a sequence of pulses. No positioning signals are output in the case of a smallcontrol deviation (adaptive or variable dead zone).Commissioning (initialisation) is carried out automatically to a large extend. Duringinitialisation, the micro controller automatically determines the zero, full-scale value,direction of action, and positioning speed of the actuator. It uses these to determine theminimum pulse time and dead zone, thus optimising the control.The positioner can also be operated manually by the pushbuttons and the LCD of theSIPART PS2.POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.213-14 / 30 Language UKThe installation of the positioner must be carried out in the following order:Mechanic connectionElectric connectionPneumatic connectionCommissioningIllustration of a function diagramFigure 1 om5510_05_sips2_x0053470en.wmf2Mechanic connection of the positionerNormally the positioner is pre-mounted on the actuator or cylinder. If not, follow theinstallation guide lines below.2.1Mechanic connection to an actuatorFigure 2 shows the mechanic connection of the positioner to an actuator for a controlvalve.POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.2Language UK 13-15 / 30StepA: Mount clamping assembly (3) with hexagon socket cap screws (17) and lockwashers (16) on the actuator spindle.StepB: Insert the pick-up bracket (2) into the recesses of the clamping assembly.Set the necessary length and tighten the screws so that the pick-up bracketcan still be shifted.StepC: Push the roll (5), spring (13), and guide washer (22) onto the pin (4).StepD: Insert the pin in the lever (6) and assemble with nut (18), spring washer (14),and U-washer (12).StepE: The value of the stroke range specified on the actuator should be set or ifthis does not exist as a scaling value, the next greatest scaling value shouldbe set. The centre of the pin must be in line with the scaling value. The samevalue can be set later under parameter 3.YWAY in commissioning to dis-play the way in [mm] after initialisation.StepF: Assemble the hexagon socket cap screw (17), spring washer (16), washer(12), and square nut (19) on the lever.StepG: Push the pre-mounted lever onto the positioner axis up to the stop and fixwith the hexagon socket cap screw (17).StepH: Fit the mounting bracket (1) with two hexagon head screws (9), lock washer(10), and flat washer (11) on the rear of the positioner.StepI: Selection of the row of holes depends on the width of the actuator yoke. Theroll (5) should engage in the pick-up bracket (2) as close as possible to thespindle but may not touch the clamping assembly.StepJ: Hold the positioner with the mounting bracket on the actuator so that the pin(4) is guided within the pick-up bracket (2).StepK: Tighten the pick-up bracket.StepL: Position the mounting parts according to the type of actuator.- Actuator with ledge: hexagon head screw (8), flat washer (11), and lockwasher (10).- Actuator with plane surface: four hexagon head screws (8), flat washer(11), and lock washer (10).- Actuator with columns: two U-bolts (7), four hexagon nuts (21) withflat washer (11), and lock washer (10).StepM: Secure the positioner onto the yoke using the previously positioned mount-ing parts.Note: Settheheightofthepositionersothatthehorizontalleverpositionisreached as close to the stroke centre as possible. The lever scale can be usedas orientation. It must be guaranteed that the horizontal lever position ispassed through within the stroke range.POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.213-16 / 30 Language UKMechanic connection of the positioner (linear actuator)Figure 2 om5510_05_sips2_x0053480en.wmfPOSITIONER, SIPART PS2 6DR5000 OM5510_05#A.2Language UK 13-17 / 302.2Mechanic connection to a pneumatic cylinderThe positioner is connected to a pneumatic cylinder by means of fixing bracket, leverarm with Allen screw, extension arm, and roller.The pneumatic piston is connected to a guide rail with an oblique angle via a linkage.The guide rail moves together with the piston, and the roller/lever connection sensesthe position of the piston. By operating both sides of the pneumatic cylinder, the setpoint is reached. A spring inserted between the fixing bracket and the lever arm securesthat the roller is pressed down against the guide rail.2.3Mechanic connection to a rotary actuatorFigure 3 shows the mechanic connection of the positioner to a rotary actuator.StepA: Attach the mounting console (9, actuator specific) onto the rear of the po-sitioner and secure using the hexagon head screws (14) and lock washers(15).StepB: Adhere pointer (4.2) onto the mounting console in the centre of the centringhole.StepC: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mmand tighten the hexagon socket head screw (18) with the Allen key provided.StepD: Place the carrier (3) onto the end of the actuator and secure using Fillisterhead screw (16) and washer (17).StepE: Carefully place the positioner with mounting console onto the actuator suchthat the pin of the coupling wheel engages in the driver.StepF: Align the positioner/mounting console assembly in the centre of the actuatorand screw tight (screws are not included in the delivery, they are part of theactuator mounting console).StepG: Follow the start-up sequence as described later. Drive the actuator to the endposition and adhere the scale (4.1) onto the coupling wheel (2) according tothe direction of rotation and rotaryactuator. The scale is self-adhesive.POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.213-18 / 30 Language UKMechanic connection of the positioner (rotary actuator)Figure 3 om5510_05_sips2_x0053490en.wmfPOSITIONER, SIPART PS2 6DR5000 OM5510_05#A.2Language UK 13-19 / 303Electric connection of the positionerWhen the positioner is connected in a two-wire system, the positioner draws its powerexclusively from the 4 to 20 mA set point signal. Figure 4 indicates the input circuitsfor the positioner.View of the controls and connectionsFigure 4 om5510_05_sips2_x0053500en.wmf4Pneumatic connectionEnsure that the air quality is suitable. Grease-free instrumental air with a solid content P88.4duIUOr adjustslidingclutchupto displayThen onlyContinue usingthe down keyP6.4d0IUUp tol erancebandvi olatedP19.8U-d 5 sec.Remaining st epsare carried outaut omatically2.)1.)Direction ofaction is determinedP 32.4RUN13.)P 92.4RUN24.)P 82.4RUN35.)P 32.4RUN46.)P 52.4RUN57.) 32.4FINSH8.)Checking of t ravel and adjustment ofzero andst roke (from stopto st op)Determina tion anddisplayofpositioning timedown (dxx. x),up (uxx.x). St op with the down keyDetermina tion ofminimumincre mentlengthOptimisati onoftransient respon seInit ialisation terminated successfully(travel in mm f or linear actuat ors)(angle of r ot ation forpart-turn act uators)Continueu singhandsymbol ke yPressing t he up key init iates leakage measurementFigure 7 om5510_05_sips2_x0053530en.wmf5.3ParametersTable 2 shows the parameter list for the positioner. The parameter name is written inplain text in the menu line column. The function of the parameter is described brieflyin the Function column. In addition, the possible parameter values, the physical unitand the factory setting of the parameters are shown.After the initialisation process, the positioner can be configured to meet the require-ments of a specified task. The factory settings correspond to the requirements for atypical application. This means that normally only a few parameters will need to bechanged.The positioner can be installed and configured to fit linear and part-turn actuators withreverse action. E.g. linear actuators with the set point in the falling direction or part-POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.2Language UK 13-25 / 30turn actuators for counter clockwise operation direction. In this case the parameters7.SDIR and 38.YDIR should be set to FALL.Parameter listMenu line Function Parameter values UnitFactory set-tingCustomersetting1.YFCT Type of actuatorturn (part-turn actua-tor)WAY (linear actuator)LWAY (linear actuatorwithout sine correc-tion)ncSt (part-turn actuatorwith NCS)-ncSt (part-turn actua-tor with NCS, inverted)WAY2.YAGL1)Rated angle of rotation for feedback(must correspond to gear ratio)9033Degrees 333.YWAY2)Stroke range (optional setting)When used, the value must correspondwith the set of the leverage ratio on the ac-tuatorDriver pin must be set to the value of theactuator travel or, if this value is notscaled, to the next lager scale valueOFFmm OFF5 , 10 , 15 , 20(short lever 33)25 , 30 , 35(short lever 90)40 , 50 , 60 , 70 ,90 , 110 , 130(long lever 90)4.INITA Initialisation (automatically) noini / no / ###.# / Strt no5.INITM Initialisation (manually) noini / ###.# / Strt no6.SCUR Current range of set point0 to 20 mA 0 MA4 MA4 MA4 to 20 mA7.SDIR Set point directionrising riSEFALLriSEfalling8.SPRA Set point for start of split range 0.0 to 100.0 % 0.09.SPRE Set point for end of split range 0.0 to 100.0 % 0.010.TSUP Set point ramp upAuto0 to 400s 011.TSDO Set point ramp down 0 to 400 s 012.SFCTSet point functionLinearEqual-percentage 1:25, 1:33, 1:50Inverse equal-percentage 1:25, 1:33, 1:50Freely adjustableLin125 , 133 , 150n125 , n133 , n150FrEELin13.SL03)14.SL1to32.SL1933.SL20Set point turning point at 0% 5% to 95% 100%0.0 to 100.0 %0.05.0to95.0100.0 34.DEBA Dead zone of controllerAuto0.1 to 10.0% Auto35.YA Start of manipulated variable limiting 0.0 to 100.0 % 0.0POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.213-26 / 30 Language UKParameter list36.YE End of manipulated variable limiting 0.0 to 100.0 % 100.037.YNRMStandardisation ofmanipulated variableTo mech. travelTo flowMPOSFLOWMPOS38.YDIRDirection of manipulatedvariable for displayRisingFallingriSEFALLriSE39.YCLSTight closing withmanipulated variableWithoutTop onlyBottom onlyTop and bottomnouPdouPdonoTable 1POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.2Language UK 13-27 / 30Parameter list continuedMenu line Function Parameter values UnitFactory set-tingCustomersetting40.YCDO Value for tight closing, bottom 0.0 to 100.0 % 0.541.YCUP Value for tight closing, top 0.0 to 100.0 % 99.542.BIN14)Function of BI 1:NoneOnly message (NO/NC contact)Block configuring (NO contact)Block configuring and manual (NO con-tact)Drive valve to pos. up (NO/NC contact)Drive valve to pos. down (NO/NC contact)Block movement (NO/NC contact)OFFon / -onbLoc1bLoc2uP / -uPdoWn / -doWnStoP / - StoPOFF 43.BIN24)Function of BI 2:NoneOnly message (NO/NC contact)Drive valve to pos. up (NO/NC contact)Drive valve to pos. down (NO/NC contact)Block movement (NO/NC contact)OFFon / -onuP / -uPdoWn / -doWnStoP / -StoPOFF44.AFCT5)Alarm functionWithoutA1=min. A2=max.A1=min. A2=min.A1=max. A2=max.oFFN , NAN , NNA , NAOFF45.A1 Response threshold of alarm 1 0.0 to 100.0 % 10.046.A2 Response threshold of alarm 2 0.0 to 100.0 % 90.047.FCT6 )Function of alarm outputOn faultFault + not automaticFault + not automatic + BI(+ means logical OR operation)nAnAb48.TIMMonitoring time for fault messagecontrol deviationAuto0 to 100s Auto49.LIMResponse threshold for fault messagecontrol deviationAuto0.0 to 100.0% Auto50.STRKLimit for stroke integralOFF1 to 1.00E9OFF51.DCHGLimit for direction changeOFF1 to 1.00E9OFF52.ZEROLimit for end stop monitoring, bottomOFF0.0 to 100.0% OFF53.OPENLimit for end stop monitoring, topOFF0.0 to 100.0% OFF54.DE-BALimit for dead zone monitoringOFF0.0 to 100.0% OFF55.PRSTPreset (factory setting)no nothing activatedStrt start of factory setting after pressingkey for 5 sec.oCAY display following successful fac-tory settingnoStrtoCAY POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.213-28 / 30 Language UKParameter list continuedCAUTION: preset results in NO INIT1) If turn is selected it is not possible to set 33.2) Parameter does not appear if 1.YFCT = turn has been selected.3) Turning points only appear with selection 12.SFCT = FrEE.4) Alternatively no if initialisation has not yet been carried out.5) NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level.6)Normal means: high level without fault. Inverted means: low level without fault.Table 26DiagnosisIn the diagnostic mode the current operating data (such as number of strokes, numberofchangesindirection,numberoffaultmessages,etc.)canbedisplayed.Fromtheautomaticormanualmodesthediagnosticmodecanbereachedbysimultaneouslypressing all three keys for at least 2 seconds.Table3showsanoverviewofthedisplayablevalues.Thediagnosticdisplayhasasimilar structure as the parameter menu displays. The respective next diagnostic valuecan be selected with the hand symbol key. Certain values can be set to zero by pressingthe key for at least 5 seconds. These are menu item line 1, 2, 3, and 4. Somediagnostic values may be greater than 99999. In this case the display switches to ex-ponential display.Diagnostic listNo.: Abbreviation Meaning DisplayablevalueUnit1 STRKS Number of strokes 0 to 4.29E9 -2 CHDIR Changes of direction 0 to 4.29E9 -3 CNT Fault counter 0 to 4.29E9 -4 A1CNT Alarm counter 1 0 to 4.29E9 -5 A2CNT Alarm counter 2 0 to 4.29E96 HOURS Operating hours 0 to 4.29E9 Hours7 WAY Determined actuating path 0 to 130 mm or 8 TUP Travel time up 0 to 1000 s9 TDOWN Travel time down 0 to 1000 s10 LEAK Leakage 0.0 to 100.0 %11 P0 Potentiometer value below stop (0%) 0.0 to 100.0 %12 P100 Potentiometer value bottom stop (100%) 0.0 to 100.0 %13 IMPUP Impulse length up 2 to 100 ms14 IMPDN Impulse length down 2 to 100 ms15 DBOP Dead zone up 0.1 to 100.0 %16 DBDN Dead zone down 0.1 to 100.0 %17 SSUP Short step zone up 0.1 to 100.0 %18 SSDN Short step zone down 0.1 to 100.0 %POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.2Language UK 13-29 / 30Diagnostic list19 TEMP Current temperature -45 to 85 C20 TMIN Minimum temperature -45 to 85 C21 TMAX Maximum temperature -45 to 85 C22 T1 Number of operating hours in Temperature range 1 0 to 4.29E9 Hours23 T2 Number of operating hours in Temperature range 2 0 to 4.29E9 Hours24 T3 Number of operating hours in Temperature range 3 0 to 4.29E9 Hours25 T4 Number of operating hours in Temperature range 4 0 to 4.29E9 Hours26 T5 Number of operating hours in Temperature range 5 0 to 4.29E9 Hours27 T6 Number of operating hours in Temperature range 6 0 to 4.29E9 Hours28 T7 Number of operating hours in Temperature range 7 0 to 4.29E9 Hours29 T8 Number of operating hours in Temperature range 8 0 to 4.29E9 Hours30 T9 Number of operating hours in Temperature range 9 0 to 4.29E9 Hours31 VENT1 Number of cycles pre-control valve 1 0 to 4.29E9 -32 VENT2 Number of cycles pre-control valve 2 0 to 4.29E9 -33 STOREStore current values as last maintenancePress the up key for at least 5 seconds (store)- -Table 37Service and maintenanceThe positioner is largely maintenance-free. The positioner is fitted with filters in thepneumatic connection as protection against coarse particles of dirt. If the pneumaticenergy supply contains particles of dirt, the filters may be clog and impair the functionof the positioner. In this case the filters can be cleaned as follows:StepA: Switch off the pneumatic power supply and remove the pipes.StepB: Unscrew the cover.StepC: Remove the three screws from the pneumatic connector strip.StepD: Remove the filters and O-rings behind the connector strip.StepE: Clean the filters (e.g. with compressed air).StepF: After cleaning first insert the filters in the recesses in the housing and thenplace the O-rings on the filters.StepG: Align the pneumatic connector strip on the two lugs and screw tight withthe three self-tapping screws.Note: Make sure that the same thread is used. To do this, turn the screws anti-clockwiseuntiltheysnapintothethreadaudibly.Onlythenshouldthescrews be tightened.POSITIONER, SIPART PS2 6DR5000 OM5510_05#A.213-30 / 30 Language UKTable of contents Chemical dosing pumpDescription Document ID Page.Chemical dosing pump............................................... OM5540_07.............. 14-2Relief valve.............................................................. OM6000_01.............. 14-14TABLE OF CONTENTSLanguage UK 14-1 / 16Chemical dosing pump1GeneralThe chemical dosing pump is a microprocessor controlled solenoid metering pump.The pump offers highly accurate reproducible metering in the dosing of liquid chem-icals in pressurised pipe systems, and into open and closed containers. The main com-ponents of the chemical dosing pump are the operating panel, power end, and liquidend Figure 1 illustrates the chemical dosing pump.The working principle of the pump is that chemical feed occurs as a result of pulseddeflections of the dosing diaphragm within the liquid end, which causes pressure dif-ferentiation between the suction side, liquid end cavity, and discharge side. The pres-suredifferentiationcausesthesuctionanddischargeself-actingvalvestoopenandclose, resulting in chemical feed. The dosing diaphragm is driven by an electromagnet,which is stimulated and controlled by a microprocessor.Regulation of the required dose is variable via the stroke length in the range of10-100% in steps of 10% or can be set at 1 of the 4 settings via the stroke frequency. Thisgives an adjustment ratio of 1:40. Optimum dosing reproducibility is achieved by set-ting the stroke length between 30% and 100%. For external actuation a retrofit kit isneeded in addition.Illustration of the chemical dosing pumpFigure 1 om5540_07_chem_0x0200520en.wmfCHEMICAL DOSING PUMP OM5540_07#A.214-2 / 16 Language UK2SafetyThe following guidelines describe correct use of the equipment and how to avoid po-tentially dangerous situations and must always be observed during installation, com-missioning, operation, maintenance, and repair.The pump may be used only for metering liquid media!All other uses or modifications are prohibited!The pump is not suitable for metering gaseous media or solids!Thepumpmustbeoperatedbyappropriatelytrainedandauthorisedpersonnel!The personnel must be familiar with metering pumps and their operation!The pump may start to operate as soon as it connected to the mains power supply!Ensure that no hazardous metering chemical can leak out! If you have not done so,set the multifunction switch to STOP or disconnect the pump from the mains im-mediately.The pump cannot be switched off! In the case of an electrical failure, disconnectthe mains cable from the power supply.Disconnect the power cable from the mains before working on the pump.Riskof electric shock - This pump is supplied with a grounding conductor andgrounding-type attachment plug. To reduce the risk of electric shock, be certainthat it is connected only to a properly grounding-type receptacle.Always depressurise liquid end before working on the pump.Always empty and rinse the liquid end before working on the pump if used withhazardous or unknown feed chemicals.Wear safety equipment appropriate to the metering chemical when working on theliquid end.Never let the pump work against a significantly increased operating pressure or aclosed stop tap on the discharge-side. This can cause lines to burst.Avoid overfeed due to positive pressure difference between intake and dischargesides. E.g. use a ball check valve with at least 1.5 bar opening pressure with anatmospheric pressure outlet.Assembly and installation of this metering pump with non original parts, whichhave not been checked and recommended by supplier is not allowed and can leadto harm to persons or property for which no liability can be accepted.Note all national directives which apply to the installation.CHEMICAL DOSING PUMP OM5540_07#A.2Language UK 14-3 / 163InstallationThe chemical dosing pump is normally pre-mounted on a chemical tank. However, incase that the pump must be mounted elsewhere or replaced please observe the followinggeneral installation notes:The chemical dosing pump must be located in an environment with ambient tem-perature between -10C to +45C and a maximum permissible relative humidityof 92% non-condensing.The pump must be mounted with the pump foot resting on a firm horizontal base.Ensure that it is fastened into place firmly, and will not vibrate in operation.The maximum permissible priming and operating pressures must not be exceeded.For this type of pump the maximum priming lift is 2 mm WC and the maximumoperating pressure is 16 barg. In case that the operating pressure is exceeded, e.g.due to the position of the chemical feed into the feed water system, the dischargesidemustbeprovidedwithareliefvalve.Thesurpluschemicalsshouldbeledback to the chemical tank.Suction and discharge valves must be installed in a vertical position.The tubing should be attached in such a way that it allows lateral detachment ofthe pump and liquid end, if necessary. The tubing must be free from stress andbends when fitted. Only original hoses with the correct dimensions should be used.The suction tubing should be as short as possible and rising in order to prevent airbubbles forming.The foot valve should be installed so that it hangs just above the bottom of thechemical tank. For chemicals with impurities or sedimentation at the bottom, thefoot valve should be positioned well above this layer.The check valve, which connects the discharge line to the feed water system, mustbe tightened properly.3.1Assembling of the tubing to plastic valves3.1.1Assembling of the tubing to plastic valvesWhen assembling the suction and discharge tubing to the plastic valves of the liquidend carry out the following work procedures (see figure 2).StepA: Cut the hose ends straight across.StepB: Push the union nut and clamping ring onto the hose.StepC: Push the hose end over the grommet to the stop (widen if necessary).StepD: Ensure that the O-ring is sitting correctly onto the intake connector.StepE: Clamp the connector hose by tightening the union nut while pressing in thehose.StepF: Retighten the hose connector by pulling the hose connected to the liquid endbriefly and then retighten the union nut.CHEMICAL DOSING PUMP OM5540_07#A.214-4 / 16 Language UKAssembling of the tubing to plastic valves(Section)HoseClampingringGrommetIntakeconnectorO-RingUnion nutFigure 2 om5540_07_chemicx0053980en.wmf3.2Electrical installationThe pump is connected to the mains power supply by using the mains lead. If the pumpis connected to the mains in parallel with inductive power consumers (e.g. solenoidvalves, motors) it must be electrically isolated. This prevents damage caused by in-duction and voltage surges when switching off.4CommissioningStepA: Check that the connections for the pump are completed properly.StepB: Open the bleed valve by rotating the knob anticlockwise (see Figure 3)StepC: Switch on the pump and allow it to run at maximum stroke length and rateuntil the liquid end is full and free from air bubbles (the feed chemical isvisible at the bleed valve). The stroke length should only be set while thepump is running (see Figure 3).Note: Thepumpshouldprimeat100%strokelengthasthesuctionliftisde-pendent upon the lift volume when the liquid end is empty. If the pump isrequired to prime at less than 100% stroke length, and fails to do so, thenselect a correspondingly smaller suction lift.StepD: Close the bleed valve (turn clockwise).StepE: Switch off the pump.StepF: The pump is ready to operate. Retighten screws in the liquid end after 24hours operation time. Tightening torque for liquid end screws: 4.5 to 5 Nm.CHEMICAL DOSING PUMP OM5540_07#A.2Language UK 14-5 / 16Illustration of liquid endLiquid endSuctionvalveDischargevalveBleedvalveFigure 3 om5540_07_chem_px0053970en.wmf4.1Determining the feed capacityWhen the necessary chemical dosing feed is known, e.g. by means of feed and boilerwater analysis, the feed capacity of the pump can be set. Figure 4 shows the feed ratesetting diagram for the pump. The measurements for determining the feed rate fromthe diagram were carried out using water as medium. In order to find the feed capacitythe correction factor must be found and subsequently the stroke rate and stroke lengthshould be set. For determination of the feed capacity carry out the following proce-dures:StepA: Mark the operating pressure for the chemical dosing pump in the lower di-agram.Theoperatingpressureisequaltothepressureinthefeedwatersystem at the point of dosing.StepB: Trace a line from this value vertically up to the curve and then horizontallyleft. Read off the correction factor.StepC: Divide the required feed rate by the determined correction. Mark this value(l/h) on the "l/h" axis in the upper diagram.StepD: Trace a horizontally line from this value to the left. Trace a line from theintersection with the straight line for the adjustable stroke frequencies ver-tically downwards the "stroke length" axis.StepE: Set the pump to one of the stroke frequencies determined in this way, andthe corresponding stroke length.CHEMICAL DOSING PUMP OM5540_07#A.214-6 / 16 Language UKFeed rate setting diagram1,61,41,210,80,60,40,20% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%0I/h180 strokes/min135strokes/min90strokes/min45 strokes/minStroke lengthCNPa 1601 at medium back pressure21,510,501 2 3 4 8 11 13 16Back pressure`Correction factorFigure 4 om5540_07_chem_gx0053960en.wmf5OperationThe operation panel of the chemical dosing pump is equipped with operation knobs/switches, connection terminals, and indicators, which support the operation and settingof the pump. Figure 5illustrates the operation panel of the chemical dosing pump.CHEMICAL DOSING PUMP OM5540_07#A.2Language UK 14-7 / 16The pump can be operated through manual control or external control. If the pump isintended only to operate in manual mode it will not be provided with the optional socketconnection for "external control. When the pump is intended to operate via "externalcontrol" and/or "float switch", a external connection retrofit kit and/or float switchretrofit kit must be provided.The "Float switch