M14 Thermal Fluid

Your Preferred Partner
AALBORG
INDUSTRIES
Aalborg industiies BV
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel, +31 (0)181 550 500

Fax +31 (0)181 650 501
Traderegister Rotterdam
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail: rtmw@aalborg-industries.nl
http://www.aalborg-industries.nl
Bankers: Fortis Bank, Rotterdam
Account No. 25.75.69.618
IBAN No. NL85FTSB0257569618
BIC.Code FTSBNL2R
DESCRIPTION AND MAINTENANCE

OF
THERMAL FLUID INSTALLATION
INCLUDING
FINAL DRAWINGS
Jinling Shipyard
Nanjing
P.R. of China
Hull no JLZ04-0411 Projectno.PP5738841 A.OO
Hull no JLZ04-0412 Projectno.PP5738842A.00
JiJ
AALBORG
INDUSTRIES
Aalborg Industries BV
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 550 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91 594.B.01
Account No. 25.75.69.618
BIC Code FTSBNL2R
CONTENTS
PAGE
GENERAL
2.
SPECIFICATION
3.
DESCRIPTION OF THE INSTALLATION
4.
START UP THE INSTALLATION
16-18
5.
CONTROL EQUIPMENT
19-20
6.
SAFETY EQUIPMENT
21-26
7.
BOILING OUT THE SYSTEM
8.
CLEANING
28-29
9.
MAINTENANCE
30-35
10. GENERAL SETPOINTS
4-8
9-15
27
36-38
223
AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohm weg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.8.01
http://www.aalborgHndustries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
^^3
GENERAL
Thermal fluid installation for:
Shipyard
Jinling Shipyard
Nanjing
P.R. of China
Hull no.
JLZ04-0411 (PP5738841-01A.00)
JLZ04-0412 (PP5738842-01A.00)
Classification
Germanischer Lloyd
Delivered by
Aalborg hidustries B.V.

P.O. Box 145
3200 AC SPIJKENISSE
THE NETHERLANDS
Telephone
+31 (0)181-650500
Telefax
+31(0)181-650501
E-mail
rtmw(@aalborg-industries.nl
Project no.
PP5738841-01 A.OO (hull no. JLZ04-0411)

PP5738842-01A.00 (hull no. JLZ04-0412)
Main flow diagram
D53714
Fuel oil diagram
D53715
Electrical diagram
D53716
P\PP\PP2005',PP05 738841 .Aalborg HKG_JLZ04041 l\l 1 Tekmingen PP05,738S41\Jinling PP5738841-01_inanual.doc
page 3
AALBORG
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
Ohrnweg 8
No. 24234179
VAT No. NL0081.91,694.B.01
3208 KE Spijkenisse
The Netherlands
http://www,aa lborg-industries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
SPECIFICATION
Thermal fluid heater

Type
Capacity
800
V4-0-TFO-010
kW
Burner
Make
Type
Weishaupt
RMS7
Temperature controller oil fired heater

Aalborg
93 WOO 701
Make
Type
Temperature sensor
Make
Type
Jumo
PT 100 Ohm
Flue gas thermostat

Make
Type
Range
200 - 500
Jumo
ATHs-7
C
50 - 300
Jumo
ATHs-20
C
Maximum thermal fluid thermostat

Make
Type
Range
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page 4
AALBORG
INDUSTRIES
P-O. Box 145
3200 AC Spijkenisse
Ohmvveg 8
3208 KE Spijkenisse
The Netherlands
Account No. 25,75.69.618
BIC Code FT5BNL2R
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
Leakage device for oil fired heater

Make
Type
Gems
LS-1950/010-242
Flow switch
Make
Type
Range
0 - 0.6
Wika
702.2
bar
Economiser
Make
Type
Capacity
1,000
Wiesloch
EXV660-43-57.0-600
kW
Flue gas thermostat

Make
Type
Range
200 - 500
Jumo
ATH-7
C
200 - 500
Jumo
ATH-7
C
Fire alarm thermostat

Make
Type
Range
Maximum thermal fluid thermostat

Make
Type
Range
50 - 300
Jumo
ATHs-20
C
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pages
AALBORG
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
http://www.aalborg-industries.ni
Account No. 25.75.59.618
BICCode FTSBNL2R
No. 24234179
VAT No. NL0081.91.594.B.01
E ^
Flow switch economiser

Make
Type
Range
O - 0.6
Wika
702.2
bar
Leakage alarm exhaust gas heater

Make
Type
Mobrey
S01DB/T84
Circulating pumps
Make
Type
Capacity
Delivery head
E-motor
Current
Motor make
Allweiler
NTT 50-200
34 m^/h
80 m.l.c.
15 kW
3 X 440 Volt -60 Hz
Siemens
Auto stand-by pressostat

Make
Type
Range
0-8
Danfoss
KPS-35
bar
Dumpcooler
Make
Capacity
Type
1,000
Aalborg
kW
MX20T10
Temperature controller dumpcooler

Make
Type
Aalborg
93W00 700
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page 6
AALBORG
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Tel. +31 (0)181 650 500

Fax +31 (0)181 550 501
Ohmweg 8
No. 24234179
VAT No. NL0081.91.694.B.01
3208 KE Spijkenisse
The Netherlands
http;//www.aalborg-industries.nl
Account No, 25.75.69.618
BICCode FTSBNL2R
Temperature sensor
Make
Type
Jumo
PT 100 Ohm
Threeway control valve for dumpcooler

Make
Type
Bore
DN65
ARI
23.451/PR2.2
PN 16
Pressure controller minimum flow

Make
Type
Range
0-6
Aalborg
93W00 70E
bar
Control valve minimum flow

Make
Type
Bore
DN50
ARI
23.441/PR2.2
PN 16
Pressure transmitter minimum flow

Make
Type
Range
Danfoss
MBS-33
bar
Filling pump
Type
Capacity
Delivery head
E-motor
Current
KF25RF-D15
2.5
40
0,63
3 X 440 Volt
m^li
m.l.c.
kW
-60 Hz
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page?
A a l b o r g Industries BV
Tel. +31 (0)181 650 500
E-mail: r t m w @ a a i b o r g - i n d u s t r i e s . n l
P.O. Box 145
Fax +31 (0)181 550 501
Traderegister R o t t e r d a m
A c c o u n t No. 25.75.69.618
3200 AC Spijkenisse
Ohmweg 8
Bankers: Fortis Bank, R o t t e r d a m
AALBORG
3208 KE Spijkenisse
No.24234179
IBAN No. NL85FT5B0257569618
I N D U S T R I E S
The Netherlands
VAT No. NL0081.91.694.B.01
BIC Code FTSBNL2R
22H
Expansion vessel
Make
Type
Contents
1430
Aalborg
SVE 5950
liter
Level switch expansion vessel

Make
Type
Mobrey
S01DB/F84
Level indicator
Make
Type
Reed contacts
Intra
ITA-3.0-GL
LMS-A
Quick opening valve expansion tank

Make
Type
Bore
Operation
DN65
Econ
100/436 SO
PN 16
Hydraulic
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pages

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AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.8,01
3.
DESCRIPTION OF THE INSTALLATION
3.1.
GENERAL
Account No. 25.75.69.618
BIC Code FTSBNL2R
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In the thermal oil system the following components are installed:

1
Oil fired thermal fluid heater 800 kW with Weishaupt bumer.
Circulating pumps (one pump automatically standby).

Economiser.
Dumpcooler.
De-aerating pipe.
Temperature blocking pipe.
Expansion tank.
Minimum flow control set.
A circulating pump (second pump automatically standby) presses the thermal fluid
hrough the oil fired thermal fluid heater and economiser to the heat consumers.
Returning from the heat consumers, the fluid enters the degassing pipe, which is
connected to the suction side of the circulating pump.
The de-aerating pipe has been constructed in such a way that the velocity of the thermal
fluid is reduced so that gases have the opportunity to escape to the expansion vessel.
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AALBORG
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
Ohmweg 8
No. 24234179
VAT No. NL0081.91.694.B.01
3208 KE Spijkenisse
The Netherlands
Email: rtmw@aalborgHndustries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
^3
3.1.1. Oil fired heater

In the supply pipeline, after the oil-fired heater, a temperature sensor (PT 100 Ohm) is
installed, which is connected to the temperature controller. This takes care of a constant
temperature of the fluid to the heat consumers. The set point can be adjusted at the
temperature controller, installed in the switch panel. The oil-fired heater will be started
automatically if the heat production of the economiser is insufficient by a reduced output
of the main engine.
In the return pipeline to the oil-fired heater a second temperature sensor (PT 100 Ohm) is
installed, which is also connected to the temperature controller. On the controller you can
read out the return temperature of the thermal fluid, by pressing the arrow-up key. While
showing the return temperature, the controller will still maintain the supply temperature at
the set point.
The temperature controller commands the oil burner. The burner is a modulating burner:
1.
2.
Modulating between 30 % and 100 %;

On/off 30%.
In the outlet of the thermal fluid heaters an orifice is installed. An indicating pressure
differential switch (flow switch) measures the differential pressure over the orifice. This
differential pressure is an indication of the flow. This flow switch contains two switches.
With a cold start there will be insufficient flow and the burner cannot start. The electronic
controller will over-ride one contact of the flow switch, and the burner will operate at
partial load (switch 2 of the flow switch). As long as the controller measures a return
temperature below the 80 degrees Celsius, the burner can only operate at partial load.
In any case a flow of approximately 0.05 bar. (switch 1 of the flow switch) must be
available. This is necessary to avoid damage to the thermal fluid and heating coil of the
thermal fluid heater. When after a certain time a temperature of approximately 80 C is
reached (switch 2 of flow switch will be closed), the installation will operate fully
automatic and the burner is able to run on full load.
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A A L B O R G
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail: rtmw@aalborg-indu5tries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
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3.1.2. Economiser
The economiser is built up from concentric coils. The hot exhaust gases of the engine
flow between these coils and transfer their heat to the thermal fluid. The economiser is
installed before the oil-fired heater. The economiser recuperates heat of the exhaust
gasses of the main engine by cooling back these gases.
If the main engine is not running, or is running with a reduced output, the exhaust gas
quantity is reduced and the heat capacity will be reduced as well.
When the heat demand of the heat consumers is more than the heat production of the
economiser, the oil-fired heater will be started automatically at partial- or full load.
The economiser is provided with the following safety devices:
One maximum thermostat, make Jumo, type ATHs-20.
A flue gas thermostat in the exhaust gas pipe after the heater, make Jumo, type
ATHs-7.
A flow safety system consisting of a measuring orifice in combination with an
indicating differential pressure switch, type 702-2.
When activated, these safety devices cause an alarm in the electric panel of the oil-fired
heater and a central alarm in the central switchboard.
When an alarm occurs on the control panel of the economiser, for example:
Max. Temperature thermal fluid;
Max. Temperature exhaust gas;
Thermal fluid flow insufficient.
Low-level expansion tank.
The economiser in combination with the dumpcooler maintains a constant supply

temperature to the heat consumers. The electronic controller is set to a temperature of
200 C for maximum load.
When the heat consumers require more heat than the economiser can produce, the oilfired heater will start automatically in order to replenish the heat shortage.
When the heat consumers require no heat at all the still remaining capacity of the
economiser will be destroyed by the dumpcooler.
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AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 550 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.594.B.01
E-mail; rtmw@aalborg-industries.nl
Account No. 25.75.69.618
BICCode FTSBNL2R
u
223
As with the oil-fired heater, the minimum quantity of thermal fluid flowing through the
heater tubes must be maintained in order to prevent cracking of the thermal fluid and
damaging the heater tubes. During port operation the economiser has to circulate as well.
This is to prevent dew point corrosion.
The economiser is provided with cleaning nozzles, which are installed in the bottom part
and connected to the water system of the ship.
During operation the valves before the nozzles can be opened and the heater will be
cleaned. To keep the heat surface of the economiser clean, it is advisable to open these
valves once a week, during 20 - 30 sec. with intervals of approx. 15 minutes until the
economiser is clean.
The bottom of the thermal fluid heater is provided with a drain connection, which is
connected to a float chamber with a level switch (leakage device). If there is a leakage the
level switch will give an alarm on the control panel of the thermal fluid system.
Furthermore the economiser is provided with extinguish nozzles. These nozzles can be
opened at a safe place and are able to cool the heating surface during 30 minutes.
These nozzles are only to be used in case of a fire.
IMPORTANT:
Use the cleaning nozzles only when the system is on the working temperature of
180C and the Main engine is running on its maximum load.
To avoid sulphur corrosion it is important that the economiser will be kept warm.
Use only fresh water for cleaning and extinguishing.
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AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 550 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail: rtmw@aalborg-industries.ni
Account No. 25.75.69.618
BIC Code FTSBNL2R
^ ^
3.1.3. Dumpcooler
After the oil-fired heater, a dump cooler is installed. It is made of steel so the cooling
water can only be closed fresh water. A dumpcooler is necessary when the heat
production of the economiser is more than the heat demand of the heat consumers.
An electronic temperature controller will activate an electric three-way valve, depending
on the temperature and the (partial) flow will pass through the dumpcooler.
After passing the cooler the thermal fluid is directed to the heat consumers.
IMPORTANT:
Do not close the valves on the waterside.
3.1.4. Minimum flow control set

As mentioned before the oil-fired thermal fluid heater and economiser are equipped with
flow switches. The system must guarantee sufficient flow.
It can happen that a lot of the temperature control valves of the heat consumers will be
closed and in that case the flow over the heaters will be insufficient.
To avoid an alarm due to insufficient flow, a minimum flow control set is installed
between the supply and return line. A pressure controller will open this valve. The pressure will rise in case the flow is reduced and by opening the valve a constant flow is
assured over the oil-fired heater and economiser.
To avoid sulphur / dew point corrosion in the economiser the return temperature may not
come below the 130C. Therefore in the return line of the system a temperature sensor is
installed, this is also connected to the minimum flow controller. When the return
temperature drops below the 130C the minimum flow valve opens and the hot thermal
fluid will warm up the retuming fluid.
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AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No.24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.59.618
BIC Code FTSBNL2R
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3.1.5. De-aeration pipe

The return line of the heat consumers is connected with the de-aerating pipe. The bottom
side of this pipe is connected to the suction side of the circulating pumps. During the
operation of the installation, light fractions or vapours can develop. To give these gases
the opportunity to escape via the expansion tank to the atmosphere, the velocity of the
fluid is reduced in the de-aeration pipe, the top of which is connected with the top of the
expansion tank.
The de-aerating pipe gives the possibility of a continuous de-aeration.
Another pipe is the expansion pipe; it is connected to the bottom of the expansion tank.
This pipeline gives the thermal fluid the opportunity to increase and decrease in volume
caused by temperature differences.
3.1.6. Temperature blocking pipe

The lifetime of thermal fluid can be greatly reduced if the thermal fluid is in contact with
oxygen (air) by high temperature.
Therefore the expansion line of the system to the expansion tank is connected to a
temperature-blocking pipe so that always the coolest fluid will be pressed to the
expansion tank.
3.1.7. Expansion tank
The expansion tank has to be at the highest point of the installation.
By heating, the thermal fluid expands. To give the possibility to expand without
increasing pressure, the de-aeration pipe is connected to the expansion tank.
The tank is provided with a "fixed low low" level switch. If this switch is activated, the
burner and circulating pumps will be stopped. A high level switch is also installed and
when activated it stops only the burner, the circulating pumps will continue to operate.
The expansion line is connected to the expansion tank by way of a cooling pipe. The
cooling pipe is connected in such a way that the coolest fluid is pressed to the expansion
tank. Cooling takes place by ambient air.
The expansion tank is provided with a quick emptying valve. In emergency cases this
valve will be opened and the contents of the expansion tank will be drained in the
drain/collecting tank.
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AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmvveg 8
3208 KE Spijkenisse
Tlie Netherlands
Tel. +31 {0)181 650 500

Fax +31 {0)181 650 501
No. 24234179
VAT No. NL0081,91.694.B.01
http://www.aalborg-industrie5.nl
Account No. 25.75.69.618
IBAN No. NL8SFTSB0257569618
BIC Code FTSBNL2R
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IMPORTANT:
It is very important to keep the expansion tanks as cool as possible because the
quality of the thermal fluid will reduce greatly if the fluid is in contact with oxygen
(air) by high temperature. Therefore be sure that the temperature does not rise
above approximately 70 C. To ensure this a high temperature alarm is installed.
3.1.8. Boiling out pipe
Most lightfi-actionsand vapours will develop by heating the fluid during thefirststart up.
Furthermore it can happen that some water is in the installation, which will evaporate in
the heater. To give the steam and light gases the opportunity to leave the installation as
soon as possible, a boiling out pipe is mounted directly behind the heater on the deaerator. This boiling out pipe is provided with a valve, which is connected to the top of
the expansion tank.
IMPORTANT:
It is only allowed to open the boiling out valve during the first start up period, until
all the gases have escaped to the atmosphere.
3.1.9. Drain/collecting tank
The installation is provided with a drain/storage tank. It is possible to fill the installation
with an electrical filling pump.
The drain valves from the expansion vessel, economiser and the oil-fired heater are also
connected to the drain tank.
The valves of the electrical filling pump are connected in such a way that the following
possibilities can be realised:
To fill the installation from the collecting tank.
To empty the collecting tank outside of the ship.
To empty the installation outside of the ship.
The tank is provided with a second manually activated pump delivered by the yard. This
pump is installed to remove possible condensate from the drain/collecting tank. The
suction line of the manually activated pump is longer than the electrical one.
As soon as you are sure, that no water will be transported by the manual pump and no
water can enter the thermal fluid system. The filling pump can be started.
In any case we advise you to fill the installation over the expansion tank. By fiUing over
the expansion tank possible water will sink to the bottom of the tank and it can be
drained.
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15
AALBORG
I N D U S T R I E S
Aalborg Industries 6V
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.618
BIC Code FTSBNL2R
IN;M/^
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START LP THE INSTALLATION

4.1. GENERAL:
1.
Main switch in position "ON"
2.
Start one of the thermal fluid circulating pumps of the oil fired heater and
economiser.
Check flow over oil fired heaters and economiser.
3.
Start fuel oil supply pumps
4.
Adjust temperature on temperature controller of oil-fired heater.
5.A.
For Weishaupt burner
5.A. 1
Place switch "BURNER ON/OFF" in position "ON".
5.A.2
Press button "RESET"

Burner will start on partial load.
As long as the return temperature is below 70 - 80 C the burner is not able to
bum at full load.
After reaching the 70 - 80 C the burner will run automatically.
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AALBORG
INDUSTRIES
4.2.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
http://wvvw,aalborg-industries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
FUEL OIL OPERATION

General:
The system is able to handle and to bum heavy fiiel oil with a viscosity of 380 cSt at
50 C.
For the first start-up and also if the thermal fluid installation has been out of operation for
a longer period of time, M.D.O. has to be used.
Before starting the burner, be sure that a fuel pump is running. You can start the burner as
described earlier.
If you want to operate on H.F.O., be sure that the fuel oil in the service tank is between
70-80C and that the tracing of the H.F.O.-pipelines for the thermal fluid is in operation.
The H.F.O. will now circulate from the H.F.O. service tank to the gas-air separator over a
pressure rehef valve. The pressure relief valve will adjust at a set point of 2,5 - 3 bar(g),
the pressure can be read out on the pressure gauge, mounted before the relief valve.
During this time the burner is still operating on M.D.O.
CHANGE OVER FROM "M.D.O. " TO "H.F.O. "

4.2.1
WEISHAUPT BURNER
The burner is provided with a fuel oil pre-heater, which will heat up the H.F.O. to the
injection temperature of approx. 130 C (see also instructions of Weishaupt oil burner and
pre-heater). A temperature indicator is situated near the pre-heater.
4.2.2 Then you activate the switch on the electric panel "M.D.O. - H.F.O." in position
"H.F.O.". Now the burner is electrically prepared to run on H.F.O.
4.2.3 Now you can change over the fuel oil side. The two connected change over valves (threeway valves) can slowly be changed over from M.D.O. to H.F.O. These valves are situated
in the suction line of the fuel oil pumps. As soon as the position "H.F.O." is reached, an
electrical switch will be closed and the pre-heater, the nozzle heater inside the burner and
the electrically heated fuel oil strainer will be in operation.
PAPP\PP200y.PP05 738S41 Aalborg HKGJLZ04041 IM I Tekeningcn PP05 73884IUinling PP5738S41-01 manual.doc
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>
iijiiiiii
AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 550 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail: rtmvv@aalborg-industries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
^ ^
It can happen that after the change over procedure the burner stops. Reason for this is that
the heavy fuel oil temperature at the burner is too low. This situation will be shown on the
electric panel. After a few minutes the temperature is sufficient and the burner re-starts
automatically.
Furthermore the fuel pre-heater is provided with a maximum thermostat for fuel oil. If
this thermostat is activated, the burner will be blocked electrically and has to be reset.
CHANGE OVER FROM "H.F.O. " TO "M.D.O. "

When changing back to M.D.O., you manually activate the change over valves slowly
during operation of the burner.
When switching back, activate valve 1.After a few minutes activate valve 2.
This is necessary to avoid that H.F.O. will enter the M.D.O. service tank. Then you
activate the switch "M.D.O. - H.F.O." back in position M.D.O.
P:\PP\PP2005\PP05 738841 Aalborg HKG_JLZ04041 \\\ 1 Tekcningcn PP05 73884njinling PP5738841-01 inanual doc
page 18
ttsii
AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
5.
CONTROL EQUIPMENT
5.1.
OIL FIRED HEATER
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail; rtmwQaalborg-industries.n
Account No. 25.75.69.618
SIC Code FTSBNL2R
^33
Temperature controller
The set point of the temperature controller can be adjusted by pressing the "P" button (see
also instruction book temperature controller). As a temperature sensor a PT 100 Ohm is
connected to the controller.
By pressing the "P" button you can read out this set point. After releasing the press
button, the measured temperature to the heat consumers will be shown on the display.
After adjusting the correct supply temperature, the burner is allowed to start.
The burner will start fully automatic according to the following procedure:
Be sure that one of the fiiel oil transfer pumps is in operation.
Fan and fuel oil pump will be started.
Safety solenoid valves will be opened and fuel oil circulates over the nozzle head
and electric fuel oil pre-heater.
Air flap will be 100 % opened. During approximately 60 seconds (time is fixed in
burner relay) the oil-fired heater will be ventilated.
Air flap goes to start position.
Fuel oil solenoid valves will be opened.
Ignition will take place.
After approximately three seconds, aflamemust have occurred. The bumer starts in
the lowest position. If after these three seconds no flame is registered, the bumer
will give a flame failure, shut off the fiiel oil valves and block the installafion
electrically.
P\PP\PP2005\PP05 738841.Aalborg HKGJLZ040411,11 TekmiiigenPP05 738841UinImgPP573884l.01_iiiiinual.doc
page 19
A A L B O R G
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail: rtmw@aalborgHndustries.nl
Account No. 25.75.69.618
BiC Code FTSBNL2R
"7^."^
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The temperature controller is provided with two switches. When there is a large heat
demand the second switch will be closed and the burner will operate at full load. If the
heat demand is reduced the burner modulates automatically back to partial load.
If the heat production of the economizer is high enough the burner will be switched off
In the return line of the oil fired heater a second PT 100 Ohm sensor is installed, which is
also connected to the temperature controller. By means of a push-button (see the
description of the controller) you are able to read out the inlet temperature of the thermal
fluid into the oil fired heater. While showing the return temperature, the controller will
maintain the supply temperature at the set point.
5.2.
DUMPCOOLER
When there is an overproduction of heat by the economizer, the supply temperature will
be controlled by a temperature controller in combination with a three-way valve. The
three-way valve mixes the un-cooled thermal fluid with the thermal fluid that is cooled by
the Dumpcooler to the required supply temperature.
The three-way valve is controlled by a stop controller with a P + I action.
As temperature sensor for the controller a PT 100 Ohm is used.
5.3
MINIMUM FLOW CONTROL SET

Between supply and return line an electrical pressure control set has been installed. In
case the valves of the heat consumer will be closed (by hand or automatically) the flow
over the oil fired heater and economiser will be reduced and the pressure in the supply
line rises. The minimum flow valve will be opened and in this way a guaranteed flow will
be available for the oil fired heater and economiser.
P.J'P\PP2005\PP05 73S841 Aalborg HKG_JLZ0404H\I1 TckcmiigaiPP05.738841\JinlingPP573S841-01_iTiaiiual.doc
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AALBORG
INDUSTRIES
6.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
http://www.aalborg-indu5tries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
[233
SAFETY EQUIPMENT
IMPORTANT: IT IS NEVER ALLOWED TO OVERRULE THE SAFETY DEVICES!
6.1.
OIL FIRED HEATER
6.1.1. Minimum flow switch

In the outlet of the oil fired heater an orifice is installed. With a pressure differential
switch the flow will be registered. The larger the flow, the larger the pressure drop is at
the pressure differential switch.
The pressure differential switch is provided with two contacts. After starting the
circulating pump the first contact has to be closed and is adjusted at 0.05 bar.
The flow switch will give an indication of approx. 0.4 bar pressure difference through the
installed orifice. During normal circumstances the indication of the pressure differential
switch is 0.4 bar. The second contact is adjusted at approx. 0.25 bar.
If the flow is disturbed a flow-alarm is generated, and the burner will be switched off. The
burner will be blocked electrically.
With a cold start up there will be insufficient flow and the burner cannot start. An
electronic temperature controller is activated and the burner can only operate at partial
load (switch 1 of the flow switch). In any case a flow of approximately 0,05 bar must be
available. This is necessary to avoid damage to the thermal fluid and heating coil of the
thermal fluid heater.
When after a certain time a temperature of 80 C is reached (switch 2 of flow switch will
be closed). The installation will operate fully automatic and the burner is able to run on
fiill load.
PAPP\PP20O5'\PP05-738841 .Aalborg HKG_JLZ0404I IM1 Tekeningen PP05.738841\Jinling PP5738841-OI_mamiaI.doc
page 21
AALBORG
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 550 501
No. 24234179
VAT No. NL0081.91.694.E.01
Account No. 25.75.69,618
BIC Code FTSBNL2R
mmmm
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6.1.2. Maximum temperature of thermal fluid

ha the supply line of the oil-fired heater a maximum fluid thermostat is installed.
The adjusted value will be approx. 20 C (or 10%) above the operation temperature.
Check if this temperature is not above the allowed maximum bulk temperature according
to the instructions of the supplier of the thermal fluid.
If this thermostat is activated, the burner will be stopped and electrically blocked.
6.1.3. Maximum flue gas thermostat
In the flue gas connection of the oil-fired heater a maximum thermostat is installed. This
thermostat has to be adjusted at a set point 10 % higher than the flue gas temperature at
fiill load of the burner, at the temperature of the thermal fluid during operation.
If this temperature is exceeded the burner will switch off and block electrically.
For a good adjustment of the thermostat adjust it above the measured temperature, and
turn it back very slowly with several time intervals. At a certain moment the burner trips,
and then you increase this value of the scale of the thermostat with 10 %.
This thermostat will switch off the burner if the heat exchanger is dirty.
It is possible that after a few weeks this flue gas thermostat will be activated. This does
not mean that the heat exchanger is extremely dirty. The exhaust gas thermostat has to be
adjusted again as mentioned before. In any case inform AALBORG INDUSTRIES BV
about the temperature rise.
Note:
Before resetting this failure on the switch panel, first reset the thermostat itself
(with reset-button).
6.1.4. Leakage device

If there is a leakage in the oil-fired heater, the burner will be switched off and electrically
blocked.
P:\PP>PP2005\PP05 738841 Aalborg HKG_J1-Z0404I l\l 1 Tekeningcu PP05 738841Vlinliiig PP573884I-01^maiiual.doc
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AALBORG
I N D U S T R I E S
6.2.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.618
SIC Code FT5BNL2R
2^3
ECONOMISER
6.2.1. Flow switch

The flow alarm switch will give an indication of approx. 0.4 bar pressure difference over
the installed orifice. If the pressure difference (= flow) is too low, an alarm in the ECR is
generated.
The alarm is adjusted at approx. 0.25 bar.
6.2.2. Maximum temperature of thermal fluid

The economiser is provided with a maximum thermal fluid thermostat (ATH-SE-20). The
set point of the thermostat is approx. 20 "C higher than the maximum operating temperature. If this thermostat is activated, only an alarm in the ECR is generated.
6.2.3. Maximum exhaust gas thermostat

For a good adjustment of the thermostat adjust it above the measured temperature, and
turn it back very slowly with several time intervals. At a certain moment the burner trips
and then you increase this value of the scale of the thermostat with 10 %.
It is possible that after a few weeks this flue gas thermostat will be activated. This does
not mean that the heat exchanger is extremely dirty. The exhaust gas thermostat has to be
adjusted again as mentioned before. In any case inform AALBORG INDUSTRIES BV
about the temperature rise.
Note:
Before resetting the failure on the alarm panel of the ECR, first reset the thermostat itself (with the reset-button).
P.vPP\PP20O5\?P05 738841 Aalborg HKG_JLZ04041 IM 1 Tckmmgen PP05,73S84minJing PP5738841-01_maniial,doc
page 23
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
Tiie Netherlands
AALBORG
I N D U S T R I E S
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.618
BIC Code FTSBNL2R
^ ^
6.2.4. Fire alarm

A second flue gas thermostat is installed and has a higher set point. This thermostat is
activated in case of a fire in the economiser.
If there is afirein the economiser, the valves for the extinguish nozzles have to be opened
and the fire fighting pump has to be started.
The main engine has to be reduced to 50 % of the output.
Note:
Before resetting the failure on the alarm panel of the ECR, first reset the thermostat itself (with the reset-button).
6.2.5. Leakage device

If there is a leakage in the economiser, a floating switch is activated and will stop the
burner. To empty the float chamber the valve under the float chamber should be opened.
On top of the floating chamber of the leakage device a second valve is mounted. Through
this valve you can fill up the floating chamber for testing and via the overflow line you fill
up the siphon.
It is important when starting up the installation that the siphon has been filled up with
thermal oil otherwise the exhaust gases are venting into the engine room.
P\PP.PP2005\PP05 738841,Aalborg HKG_^JLZ04041l\n TckeningeiiPP05.738841\JinlmgPP573S841-01_niaiiual.doc
page 24
AALBORG
I N D U S T R I E S
6.3.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 550 501
No. 24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.618
BIC Code FTSBNL2R
[3233
EXPANSION TANK
On the expansion tank following level switches are mounted:
6.3.1. Low low level

This level switch is mounted on the tank and after energizing the switch the circulating
pumps and burner will be switched off. The level switch will be electrically blocked.
6.3.2. Low level
This level switch (reed contact) is adjustable and mounted on the level indicator.
The adjustable alarm has to be adjusted in such a way that by a normal operation the level
switch is just below the level in the expansion tank.
The alarm has a time delay to avoid alarms due to rolling of the ship.
Alarm can be caused by:
- Too little thermal fluid in the system;
- Cooling down of the installation far below the operating temperature.
6.3.3. High level

The alarm has a time delay to avoid alarms due to rolling of the ship.
Following causes can energize this alarm:
Filling until the level is too high
Leakage in a heat exchanger where the pressure on the secondary side is higher than
on the thermal fluid side.
- Water in the system, which will cause steam generation. The steam, which has a larger
volume than water, presses the thermal fluid in the expansion tank.
P\PP\PP2005\PP05 738841 Aalborg HKG_]LZ040411\11 Tckeningen PP05 73884 lUinling PP5738841-01_manual doc
page 25
AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.618
SIC Code FT5BNL2R
u
^21
6.3.3 Quick emptying valve

Li emergency cases the expansion tank can be emptied quickly by activating the valve.
The contents of the expansion tank will be drained in the drain/collecting tank.
The valve is spring opening and will be activated by means of a pneumatic / hydraulic
actuator which is energized by means of a solenoid valve or a pressurised air cylinder
from the safety station of the ship.
After releasing the solenoid valve the valve is closed and the electrical filling pump can
fill the tank.
6.3.4. General reset

If one of the safety devices is activated, the installation will be switched off and
electrically blocked. The installation has to be reset by pressing the reset button on the
switch panel and the burner can be started again.
If the flue gas thermostat of the economiser is activated, you first have to press the reset
button on the thermostat.
IMPORTANT:
IT IS NEVER ALLOWED TO OVERRULE THE SAFETY DEVICES!
P:\PP\PP3005\PP05 738841 .Aalborg HKG^J1-Z0404H\11 Tckeningen PP05 73884Uinling PP5738841-01_niaiiual doc
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A A L B O R G
INDUSTRIES
7.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694..01
http;//vvww.aalborg-industries.nl
Account No. 25.75.69.518
BIC Code FTSNL2R
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BOILING OUT THE SYSTEM

In spite of our advice to pressure test the installation with nitrogen, it will be necessary to
boil out the installation.
Boiling out is necessary:
1. After the first start-up of the installation.
2.
If the installation is not used during 3 months or more.
3.
After replacement of the thermal fluid.
4.
After entering water or air into the system.
Procedure:
After filling the installation with thermal fluid, the circulating pump has to be started and
air has to be removed by opening air vents.
When the pressure differential indicator shows a constant flow, the burner has to be
started at partial load and the temperature controller has to be adjusted at 90 C.
During the boiling out period the boiling out valve has to be opened to create the
possibility for the vapours to escape to the expansion tank.
The installation has to run at a temperature of 90 "C during approximately 20 minutes.
Then you have to changeover to the secondary pump.
Then increase the temperature on the controller with steps of 2 - 5 C, until a temperature
of 100 C is reached. After each step, the installation has to run at this temperature level
until no fluctuations can be read out of the flow switch and the pressure indicator of the
circulating pump. Continue this until a temperature of 110 C is reached.
After passing the 110 C steps can be increased to 5 -10 C, and the procedure described
above has to be repeated up to the operating temperature.
If no overflow tank is installed, we advise you to install an empty drum into which the
overflow line and vent pipe come out. This will be necessary with regards to possible
overflows.
CAUTION:
FOR EXTENDED DURABILITY OF THE THERMAL FLUID IT IS IMPORTANT

AFTER THE BOILING OUT PROCEDURE TO CLOSE THE BOILING OUT VALVE!
P\PP^J>P2005\PP05.73884I.AalborgHKG_JLZ040411\n TckeningenPPOS 738S4I'Jinling PP573884I-OI_manual doc
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AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
Ohmvveg 8
3208 KE Spijkenisse
The Netherlands
VAT No. NL0081.91.694.B.01
No. 24234179
Account No. 25.75.69.618
SIC Code FTSBNL2R
1^^
CLEANING
CLEANING OF THE HEAT EXCHANGER OF THE OILFIRED HEATER

With an oil-fired heater that bums on MDO, it is hardly ever necessary to clean the heat
exchanger.
If it will happen that the heat exchanger is dirty, you have to clean it with water with an
alkalic additive, steam cleaner or a high-pressure waterjet.
On the outside at the bottom of the heater, two thread connections have to be opened so
that water with removed and dirt can be drained.
The cover can be removed easily without special tools, be aware of the weight of the
cover, for this is provided with refractory lining.
After removing the cover you can clean the radiation and convection part.
When mounting the cover you have to take care of a good condition of the gaskets to
avoid flue gas leakages.
We ask your special attention for a good position of the gasket in the cover for tightening
the flue gasses between radiation part and third pass.
IMPORTANT:
After cleaning it is necessary to fire the burner as soon as possible and run the
installation up to the operating temperature to avoid sulphur corrosion.
P.\PP^PP2005\PP05 73884I.Aalborg HKG_JI-Z04041 HI 1 Tekcningm PP05,738841>Jinling PP5738841-0I_maiiual.doc
page 28
.; i;.
iitiittift
AALBORG
I N D U S T R I E S
8.2.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tei. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B,01
http://wvvw.aalborg-industries.nl
Account No. 25.75.69.518
BIC Code FTSBNL2R
^^3
CLEANING OF THE ECONOMISER

The economiser has a high flue gas speed and smooth pipes. This results in a very good
self-cleaning effect. We know from experience that for some economisers cleaning
programmes are totally unnecessary.
Cleaning the main motor blower with water will result in a speed increase in the
economiser, which will have a cleaning effect.
This economiser is provided with cleaning nozzles. Depending on the capacity of the
economiser one or more nozzles are mounted.
In order to prevent sulphur corrosion, water must not be allowed to come into frequent
contact with the materials.
There must always be a water pressure of 0.8 - 1.5 bar available on the nozzle, otherwise
no spray shower will occur.
As already mentioned, some vessels require no cleaning at all. By measuring the flue gas
temperature with a clean boiler and then making a note of the daily increases a good
indication can be made.
The experience is that cleaning once a week several times with an interval of 5-10
minutes, 15-second water injection is sufficient.
An indication of the pollution of the economiser is the exhaust gases and we advise you
to register these temperatures daily.
IMPORTANT
Once again we point out that, in order to prevent sulphur corrosion, the economiser
should be flushed as little as possible.
Use the cleaning nozzles only when the system is on the working temperature of
180C and the diesel engine is running at maximum load.
P ',PP\PP2005\PP05.738841 Aalborg HKG_JLZ0404 II' 11 Tckeningen PP05.738S41 Uinling PP5738841 -01 jnanual.doc
page 29
AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netlierlands
Tel, +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91,694.B.01
Account No. 25.75.69.618
BIC Code FTSBNL2R
2553
MAINTENANCE
9.1.
EVERYDAY
1.
Oil fired heater:

a.
2.
Thermal fluid:
a.
b.
3.
Outside ofthe burner installation.

Fuel pressure.
Leakage of fuel oil pump, hoses and noise.
Clean strainer.
Level in fuel oil tank.
Hoses
Flue gases, which are leaving the furmel, have to be colourless. If not, the
burner has to be adjusted again.
Control and safety equipment:

a.
b.
c.
5.
Level expansion tank.

The temperature in the expansion tank must never exceed 70 C.
Burner: (see also burner instructions)

a.
b.
c.
d.
e.
f.
g.
4.
Outside.
Temperature adjustment of:

- oil fired heaters
- dumpcooler
Pressure indicators circulating pumps
Flow oil-fired heaters and economiser
Pumps:
a.
b.
Check circulating pumps on leakage.

Check noise.
P',PP\PP2005\PP05 738841 Aalborg HKG_JLZ040411\11 TekenmgcnPP05.738841UinlingPP5738841-Ol_manual.doc
page 30
AALBORG
INDUSTRIES
6.
P.O. Box 145
Tel. +31 (0)181 650 500

Fax +31 (0)181 550 501
http://www.aalborg-indu5tries.nl
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
No, 24234179
VAT No. NL0081.91.694.B.01

Account No. 25.75.59.618
BIC Code FTSBNL2R
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Piping:
Check all:
a.
b.
c.
d.
Flanges and gaskets

Compensators
Valves
Fixed points
of the installation on leakage.

If thermal fluid is absorbed by the insulation, the insulation has to be removed
immediately and replaced.
7.
Strainers:
Check strainers in thermal fluid system (first month after installation; thereafter
every three months).
8.
Switch box:
a.
9.
Lamp test.
Fuel oil system:

a.
b.
c.
Check contents of fuel oil tank.

Check leakage of fuel oil transfer pump.
Check noise.
P:\PP\PP2005\PP05.738841 Aalborg HKGJLZ040411\11 Tekcningen PP05 738841\Jiiiling PP573884l-OI_nianual,doc
sv
pagC 3 1

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iilliiiii
AALBORG
I N D U S T R I E S
9.2.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail: rtmw@aalborg-industries.n
Account No. 25.75.69.618
IBAN No. NL85FTSB0257569ei8
BIC Code FTSBNL2R
^^3
EVERY MONTH
9.2.1. Bumer (See also instructions for burner)

a.
b.
c.
Clean ignition pins.

Clean flame scanner
Remove flame scanner from the burner during operation.
The burner must then switch off within 4 seconds and on the switch panel the
burner failure must be lit.
9.2.2. Safety equipment

a.
Flow switches
Flow switches of oil fired heater and economiser.
Check flow switches by closing the valve behind every oil-fired heater and every
economiser.
Note: Do not forget to fully open the valve after the testing.
b.
Maximal thermostats
Check the maximal thermal fluid thermostat. To do that, you decrease the set point
of the maximum thermal fluid thermostat during operation. The installation has to
stop and the alarm lamp "maximum thermal fluid" has to light up. Turn the
adjusting knob of thermostat to the original set point value.
c.
Flue gas thermostats:

Check maximum flue gas thermostat. To do that you, decrease the set point of the
maximum flue gas thermostat during operation. The installation has to stop and the
alarm lamp "maximum flue gas" has to light up. Tum the adjusting knob of
thermostat back in the original position. Do not forget to press reset button on
thermometer.
9.2.3. Check leakage device

For checking the leakage device, open the valve just above the leakage device and fill it
up with a small quantity of thermal fluid. The leakage alarm will be generated and the
burner and circulating pump will be switched off. After testing drain the leakage device
by opening the valve behind leakage device.
P:>PP'J>P2005^J>P05.738S41 Aalborg HKG_JLZ040411\11 Tekeningen PP05.738841 Jinling PP5738841-01_manua] doc
page 32
. .
lttttii
AALBORG
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 550 501
No. 24234179
VAT No, NL081.91.694.8.01
http://www.aalborg~industrie5.nl
Account No. 25.75,69.618
BIC Code FTSBNL2R
1\.M,
WWM
BP
; MJ,";'"
9.2.4. Pumps
1.
Thermal fluid circulating pumps:

a.
Lubrication of the circulating pumps (see instruction pump set).
b.
Coupling
c.
Automatic standby function

Check automatic stand-by function of circulating pumps by slowly closing the
valve on the pressure side of the running pump. Second pump must start
automatically.
Note:Do not forget to open valve after testing.
2.
Filling pump:
Start the filling pump and make sure of a good functioning.
3.
Fuel oil transfer pumps: (If installed)

a.
Start second fuel oil transfer pump make sure of a good functioning.
b.
Automatic standby
Check automatic stand-by function of the circulating pumps by closing the
valve on the pressure side of the running pump slowly. The second pump must
start automatically.
Note:Do not forget to open valve after testing.
9.2.5. Remove water from drain collecting tank

Make sure that the installed manual pump only transfers thermal fluid.
9.2.6. Valves
Check good function.
P\PP\PP200yPPO5,738841 Aalborg HKG_JLZ04041 IMI Tckeningen PP05,738841>JiiiIing PP5738841-0l_maiiual,doc
sv
pagC
3 3
AALBORG
I N D U S T R I E S
9.3.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE 5pijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081,91.694.B.01
Account No. 25.75,59.618
BIC Code FTSBNL2R
ISS
EVERY THREE MONTHS

1.
Burner:
a.
Check or let check the flue gasses.

C02
CO
- approx. 9 -12 %
- nihil
Sootnumber in accordance with Bacharach max. 1 - 2.

Do not increase the capacity of your installation, (for capacity see page 4).
Over-firing of your heat exchanger can cause cracking of the thermal fluid and
damage to the coils.
b.
Check if burner is adjusted in the right way.
c.
Clean ignition electrodes.
d.
Clean diffuser and flame head.
e.
Clean flame scanner,
Check refractory lines.
Expansion tank:
3.
a.
Open the self-closing drain valve and be sure that there is no condensation in
the expansion tank any more.
b.
Temperature of expansion tank has to be below 70 "C.
Strainers
Check strainers in thermal fluid system
P:J'P'J'P2005\PP05 738841.Aalborg HKG_JLZ04041 l\l 1 Tekeningen PP05 7.1884IVImling PP5738841-01_manual,doc
page 34
'.ttttt:
iillfflfi
AALBORG
I N D U S T R I E S
9.4.
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 550 501
No.24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.518
BiC Code FTSBNL2R
"lM~,
nri
P
ISS
1 "ns'.';;>
EVERY YEAR
1.
Thermal fluid:
a.
Take a sample of your thermal fluid and have its condition checked by e.g. the
supplier of the fluid.
This sample has to be taken from a part of the installation, which is mostly in
circulation, e.g. the drain valve at the circulating pump.
Burner installation:
a.
b.
c.
d.
e.
f
Clean impeller of blower and combustion air fan.

Replace nozzles.
Replace ignition electrodes.
Replace flame scanner.
Check servomotor air dumper,
Clean air inlet.
P:\PP>J>P20O5\PP05,73884I Aalborg HKG_ILZ040411\I I Tekmingen PP05 738841Uinling PP5738841-01 manual doc
page 35
AALBORG
I N D U S T R I E S
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netlnerlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
E-mail; rtmw@aalborg-industries.nl
Account No. 25.75.69.618
IBAN No. NL85FTSB0257B69618
BIC Code FTSBNL2R
No. 24234179
VAT No. NL0081.91.694.B.01
10.
GENERAL SETPOINTS OF THE CONTROL- AND SAFETY DEVICES
10.1
OIL FIRED HEATER

- Temperature controller
Partial load
Full load
200
195
C
C
- Flow switch
First contact
Second contact
0.05
0.25
bar (g)
bar(g)
- Maximum thermal fluid thermostat

Pre-alarm
High alarm
230
- Inlet minimum thermostat (cold start thermostat) 70
- Max. flue gas thermostat
- Safety valve
10.2
^JJ
280
10
bar(g)
BURNER (H.F.O. OPERATION)

Fuel oil thermostat
Max. fuel oil thermostat
Min. fuel oil thermostat
Oil pressure controller
Min. oil pressostat
C
C
c
bar (g)
bar(g)
P:'J'P\PP2005\PP05.738841.Aalborg HKG_JLZ0404I IM 1 Tekcningcn PP05.738841Umling PP5738841.01_manual doc
page 36
AALBORG
I N D U S T R I E S
10.3
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
No. 24234179
VAT No. NL0081.91.694.B.01
ECONOMISER
- Temperature controller (if present)
Partial load
Full load
200
195
C
C
- Max. thermal fluid thermostat

Pre-alarm
High alarm
230
- Flow switch
0.25
bar
- Flue gas thermostat

Pre-alarm
High alarm (fire-alarm system)
275
320
C
C
- Min. control air pressostat

- Safety valve
10.4
Bankers; Fortis Bank, Rotterdam
Account No. 25.75.69.618
BIC Code FTSBNL2R
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
bar (g)
10
bar (g)
DUMPCOOLER
Safety valve
195
10
C
bar (g)
P:\PP'PP2005\PP05 738841 .Aalborg HKGJLZ04041 IM 1 Tekeningen PP05.738841Uiiilmg PP573884j-01_maniial doc
page 37
AALBORG
I N D U S T R I E S
10.5
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Account No. 25.75.69.618
SIC Code FTSBNL2R
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694,6.01
^ ^
SYSTEM
- Pressure switch for the automatic stand-by
ofthe thermal fluid pumps
3.5
bar
- Minimum flow controller
2.4
bar
Minimum system pressostat (if present)
bar
Temperature controller mixing injection system

(if present)
Max. thermal fluid thermostat
Min. thermal fluid thermostat

Safety valves
10
bar
Note: Final set points will be adjusted during commissioning.

We advice you to have the installation checked by one of our service engineers every
year.
PVPP\PP2005\PP05.738841 Aalborg HKG_JLE0404H\11 Tckenmgcn PP05.738841Uinling PP573884I-01_manual.doc
page 38
THERMAL FLUID
AALBORG
FITTING LIST
HEAT TECHNOLOGY
I N D U S T R I E S
P.O. Box 1 45, 3200 AC; Spijkenisse, The Netherlands

Phone:
Email: rtmw/@aalborg-ir idustries.nl
Fax:
Yardnr.:
JLZ04-041:i&JLZ04-0414 /iterations:
Jinling Sipyard
Yard:
At:
Nanjing - P R of China
Project nr.: PP5738841 & PP5738842
Line no Fitting no
Norn diam
Description / DIN-standard
1
1001
De-airating pipe
2
1002
Temp, blocking pipe
3
141S19
Minimal thermal fluid thermostat inol thermowell
4
141S16
Maximal thermal fluid thermostat inci thermowell
5
6
Circ. pumps
7
1010
Circulating pump with 15kW E-motor
8
1011
100
Globe stop valve with bellow seal / PN16
9
1012
100
Strainer/PN 16
10
1013
15
11
1014
100x1/2"
Mano-vacuum meter glycerine filled
12
1015
1/2"
Manometer valve / PN40
13
1/2"
1016
Manometer syphon / PN40
14
1017
100
Suction bellow with double braiding and flanges
15
1018
80
Delivery bellow with double braiding and flanges
16
1019
80ND
Globe stop valve non return disc with bellow seal / PN16
17
1020
100x1/2"
18
1/2"
1021
19
1/2"
1022
20
15CD
1023
Globe control valve with bellow seal / PN16
21
1024
1/2"
Manometer valve with test connection / PN40
22
1/2"
1025
23
1030
Circulating pump with 15kW E-motor
24
1031
100
25
1032
100
Strainer/PN16
26
1033
15
27
1034
100x1/2"
28
1/2"
1035
29
1036
1/2"
30
1037
100
Suction bellow with double braiding and flanges
31
1038
80
Delivery bellow with double braiding and flanges
32
80ND
1039
33
1040
100x1/2"
34
1041
1/2"
35
1042
1/2"
36
20M10
E-motor 15kW
37
20M14
E-motor 15kW
38
30S12
Auto stand-by pressostat ind. reducer 3/8"x1/2"
39
P:\PP\PP2004\PP04.737230.Aalborg HKG_JinllngM1 Tekeningen PP04.737230\ritl5738841
-31 181650500 Titel of corresponding drawing:

<-31 181650501
Date
THERMAL FLUID DIAGRAM
No. of correspondig dnwg.:
Material
steel
steel
Weight
Remarks
15
78
50 / 300C
0,8
0,8
50 / 300C
GGG40.3
231,5
GGG40.3
28
GGG40.3/Niro 16
GGG40.3
3,7
AISI-304/316
0.9
steel
0,55
steel
0,69
steel
9,1
steel
7,3
GGG40.3
21
AISI-304/316
0.9
steel
0,55
steel
0,69
GGG40.3 / Niro 3,7
steel
1
steel
0,69
GGG40.3
231,5
GGG40.3
28
GGG40.3/Niro 16
GGG40.3
3,7
AISI-304/316
0.9
steel
0,55
steel
0,69
steel
9,1
steel
7,3
GGG40.3
21
AISI-304/316
0.9
steel
0,55
steel
0,69
Fitfing List nr.:
D53714 Thermal fluid diagram

D53715 MDO/HFO diagram
Type / Fig no
Draw no
90427
D50
5950
90429
ATHs-2
951167
ATHs-2
951167
Q=34m3/h H=80mlc NTT 50-200

norm, open
22.046
22.05
drain
22.046
-1+3B
type 213.53.100
S004.16.100
S006.07.110
RFB
RFB
norm, open
22.046ND
0-16B
type 213.53.100
S004.16.100
S006.07.110
keep hot
22.046CD
S004.60.100
S006.07.110
Q=34m3/h H=80mlc NTT 50-200
norm, open
22.046
22.05
drain
22.046
-1+38
type 213.53.100
S004.16.100
S006.07.110
RFB
RFB
norm, open
22.046ND
0-16B
type 213.53.100
S004.16.100
S006.07.110
D53720
22046
22050
22046
62053
941037
941041
90424
90424
22046ND
62053
941037
941041
22046 CD
941037
941041
D53720
22046
22050
22046
62053
941037
941041
90424
90424
22046ND
62053
941037
941041
SP = 3,5 bar
941032
Date 12/4/2006 2:43 PM
KPS35
5738659
Date:
Name:
E-Schema:
16-03-2005
CE
D53716
Maker
Aalborg
Aalborg
Jumo
Jumo
SuppI
Aalborg
Aalborg
Aalborg
Aalborg
System
System
System
System
Allweiler
Albert Richter
Albert Richter
Albert Richter
Wika
Franz Schneider
Franz Schneider
Senior Flexonics
Senior Flexonics
Albert Richter
Wika
Franz Schneider
Franz Schneider
Albert Richter
Franz Schneider
Franz Schneider
Allweiler
Albert Richter
Albert Richter
Albert Richter
Wika
Franz Schneider
Franz Schneider
Senior Flexonics
Senior Flexonics
Albert Richter
Wika
Franz Schneider
Franz Schneider
Siemens
Siemens
Danfoss
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Circ. pumps
Place
page 1 of 5
ttii
THERMAL FLUID
FITTING LIST
HEAT TECHNOLOGY
AALBORG
I N D U S T R I E S
P.O. Box 1 45, 3200 AC) Spijkenisse, The Netherlands

Phone:
Email: rtmw/@aalborg-ir idustries.nl
Fax:
Yardnr.:
JLZ04-041: & JLZ04-0414 Alterations:
Jinling Sipy ard
Yard:
At:
Project nr.: PP5738841 & PP5738842
Line no Fitting no
Nom diam
40
Oil fired heater
41
1100
Oil fired heater
42
1101
80
43
1102
3/4"
Stop valve with welding ends PN 40
44
3/4"
1103
Stop valve with welding ends PN 40
45
1104
10
EO valve for ind. flow control
46
1105
10
EG valve for ind. flow control
47
1106
De-aerator
48
15CD
1107
49
1108
25/40
Safety valve
50
80ND
1109
51
65CD
1110
52
1111
Thermometer with thermowell
53
120M6
Burner
54
141S12
2"
Leakage devoce incl. T-piece
55
141S3
Limit switch burner flange
56
141S6
Maximal thermal fluid thermostat high high
57
141S9
Maximal flue gas thermostat high high
58
142S7
Ind. diff. press, switch with two contacts
59
160B3
Electronic mod. temperature controller
60
160B4
Single PT 100 Ohm sensor incl. thermowell
61
160B6
62
63
Economiser
64
Economiser
1200
80CD
65
1201
66
1202
67
1203
68
1204
10
69
10
1205
70
25
1206
71
1207
15CD
72
1208
25/40
Safety valve
73
80ND
1209
74
65CD
1210
75
1211
76
1212
77
Maximal flue gas thermostat high high
1213
1214
1/2"
78
Ball valve
79
1"
Ball valve
1215
80
Float chamber for leakage device
1216
P:\PP\PP2004\PP04.737230.Aalboig HKG_Jinling\11 Tekeningen PP04.737230\fltl5738841
*3^ 181650500 Titel of corresponding drawing:

t-31 181650501
Date
No. of correspondig drwg.:
Material
Weight
2300
GGG40.3
21
C22.8
2,5
2,5
C22.8
0,4
C22.8
0,4
C22.8
5,8
C22.8
GGG40.3 / Niro 3,7
GGG 40.3
10
21
GGG40.3
GGG40.3 / Niro 11,7
Stainless steel 0.5
0,8
0,8
1,75
0,28
0,28
steel
4500
GGG40.3 / Niro 21
Stainless steel 0.5
Stainless steel 0.5
0,4
C22.8
0,4
022.8
8,8
GGG40.3
GGG40.3 / Niro 3,7
GGG 40.3
10
21
GGG40.3
GGG40.3 / Niro 11,7
Stainless steel 0.5
Stainless steel 0.5
0,8
0,2
0,5
12
GG-20
Remarks
800 kw
norm, open
drain
vent
Boiling Out
s p = 10 bar
norm, open
norm, closed
0-500C
fitted on 120M6
50 / 300C
200 / 500C
0 / 0,6 bar
0-300C
single element
single element
norm, open
0-300C
0-300C
drain
Boiling Out
s p = 10 bar
norm, open
norm, closed
0-500G
0-500C
200 / SOOX
Date 12/4/20O6 2:43 PM
Fitting List nr.:
D53714 Thermal fluid diagra m

Draw no
Type / Fig no
Date:
Name:
E-Schema:
Maker
5738659
16-03-2005
CE
D53716
Place
SuppI
951167
951165
D00776
see doc
901071
901071
Aalborg
Albert Richter
Deinzer & Weilanc
Deinzer & Weilanc
Franz Schneider
Franz Schneider
Aalborg
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Jumo
Weishaupt
Gems
Weishaupt
Jumo
Jumo
Wika
Aalborg
Jumo
Jumo
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
Fired
D53718
22046 CD
951411
951411
951444
951444
22046
22046 CD
25901
22046ND
22046 CD
951411
951411
951165
72859
72859
61670
Aalborg
Albert Richter
Jumo
Jumo
Franz Schneider
Franz Schneider
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Jumo
Jumo
Jumo
Econosto
Econosto
Econosto
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
Economiser
V4-0-TFO-010
22.046
AV11.1 S m S m
AV11.1 SmSm
S338.03.160
S338.03.160
DE 50
22.046CD
25.901
22.046ND
22.046CD
10/1/2002
RMS7
LS-1950/010-242
D53717
22046
951214
951214
951444
951444
90428
22046 CD
25901
22046ND
22046 CD
951411
ATHs-2
ATH-7
Delta Comb 702.2
93W00 701
90.210.F02/dl
90.210.F02/dl
EXV568-41-57.0-600
22.046CD
10/1/2002
10/1/2002
S338.03.160
S338.03.160
22.046
22.046CD
25.901
22.046ND
22.046CD
10/1/2002
10/1/2002
ATH-7
1607N
1607N
fig 802
D11855
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
heater
Heater
page 2 of 5
THERMAL FLUID
AALBORG
FITTING LIST
HEAT TECHNOLOGY
I N D U S T R I E S
P.O. Box 1 45, 3200 AC/ Spijkenisse, The Netherlands

Phone:
Email: rtmv/@aalborg-l idustries.nl
Fax:
JLZ04-041;i & JLZ04-0414 /Mterations;
Yardnr.:
Jinling Sipyard
Yard:
At:
Project nr.: PP5738841 & PP5738842
Line no Fitting no
Norn diam
81
91S2
Ind. diff. press, switch with two contacts
82
91S4
IVIaximal thermal fluid thermostat
83
91S6
IVIaximal flue gas thermostat high
84
91S8
Level switch high
85
86
Expansion tanl(
87
1300
Expansion tank
88
25
Self closing drain valve
1301
89
1302
65
Quick opening globe valve
90
1303
25
91
1304
IVIagnetic level gauge
92
1305
93
1306
50
94
40S11
Level switch low (reedoontact)
95
40S14
Level switch low low
96
40S17
Level switch high high
97
40S8
Limit switch
98
99
IMin. flow control
100
1400
50
Elect, controlled two-way valve with bellow seal
101
1401
65
102
1402
65
103
1403
40CD
104
1404
1/2"
105
1405
1/2"
106
9087
Pressure transmitter
107
9082
Modulating elec. pressure controller
108
90Y5
Electric actuator
109
110
Dumpcooler
111
1450
Dumpcooler
112
1451
65
Electric controlled three-way valve with bellow seal
1452
113
80
114
1453
65CD
115
1454
80
116
1455
50CD
117
Safety valve
1456
25/40
8982
118
Modulating temperature controller
8987
119
120
89Y5
Electric actuator
121
122
Filling pump
123
1510
Filling pump with 0,63 kw E-motor
P:\PP\PP2004\PP04.737230.Aalborg HKG_JinlingM 1 Tekeningen PP04.737230\ritl5738841
f31 181650500 Titel of corresponding drawing:

1-31 181650501
Date
IMaterial
steel
C. steel
GGG40.3
GGG40.3
AISI-304
Stainless steel
GGG40.3
GGG40.3
GGG40.3
GGG40.3
GGG40.3/Niro
steel
steel
Weight
Remarks
1,75
0 / 0,6 bar
0,8
50 /300C
0,8
200 / 500C
3
5,3
21
5,1
15
0.5
11,7
0,2
3
3
0,2
19,5
14,7
14,7
8,8
1
0,69
Norm, closed
norm, closed
norm, closed
0-160C
norm, open
fitted on 1304
norm, open
norm, open
norm, closed
197
35,5
14,7
11,7
14,7
11,7
10
norm, open

Draw no
Type / Fig no
Delta Comb 702.2
D00776
951167
ATHs-2
ATH-7
951165
S01DB/F84
D00734
16-03-2005
CE
D53716
IVIalter
Wika
Jumo
Jumo
Mobrey
SuppI
Aalborg
Aalborg
Aalborg
Aalborg
Place
Economiser
Economiser
Economiser
Economiser
SVE 5950
574
100/432SO
22.046
ITA-3,0-GL
10/1/2002
22.046
LMS-A
S01DB/F84
S01DB/F84
D53719
D00894
90236
22046
D01054
951411
22046
Aalborg
Econosto
Econosto
Albert Richter
Intra
Jumo
Albert Richter
Intra
Mobrey
Mobrey
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
Expansion
23.441/PR2.2
22.046
22.046
22.046CD
3004,60.100
S006.07.110
IVIBS33M (rel)
93W00 70E
PR2.2
73851
22046
22046
22046 CD
941037
941041
951182
see doc
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Franz Schneider
Franz Schneider
Danfoss
Aalborg
Albert Richter
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Min.
Min.
Min.
Min.
Min.
Min.
Min.
Min.
Min.
MX20T10L=1200
23.451/PR2.2
22.046
22.046CD
22.046
22.046CD
25.901
93W00 700
90.210.F02/dl
PR2.2
D53721
72903
22046
22046 CD
22046
22046 CD
25901
see doc
901071
Aalborg
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Aalborg
Jumo
Albert Richter
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Dumpcooler
Dumpcooler
Dumpcooler
Dumpcooler
Dumpcooler
Dumpcooler
Dumpcooler
Dumpcooler
Dumpcooler
Dumpcooler
61943
Kracht
Aalborg
Filling pump
0,28
norm, open
norm, closed
sp=10 bar
0 - 300C
single element
41
Q=2,5m3/h H=4 bar KF25 RF2-D15
Date 12/4/2006 2:43 PM
5738659
Date:
Name:
E-Schema:
D00734
D00734
Fitted on 1302
0-6 bar
0-6 bar
steel
GGG40.3/Niro
GGG40.3
GGG40.3/Niro
GGG40.3
GGG40.3/Niro
GGG40.3
Fitting List nr.:
flow
flow
flow
flow
flow
flow
flow
flow
flow
tank
tank
tank
tank
tank
tank
tank
tank
tank
tank
tank
control
control
control
control
control
control
control
control
control
FITTING LIST
HEAT TECHNOLOGY
AALBORG
I N D U S T R I E S
P.O. Box 1 45, 3200 AC; Spijkenisse, The Netherlands

Phone:
Email: rtm\A/@aalborg-ir idustries.nl
Fax:
Yardnr.:
JLZ04-041:i & JLZ04-0414 /iterations:
Jinling Sipyard
Yard:
At:
Nanjing - PR of China
Project nr.: PP5738841 & PP5738842
Line no Fitting no
Nom diam
124
1511
25
125
1512
25
Strainer/PN16
126
1513
25
127
1514
100x1/2"
Mano-vacuum glycerine filled
128
1515
1/2"
129
1516
1/2"
1517
130
25
131
1518
25
132
1519
25ND
133
1520
100x1/2"
Mano-vacuum glycerine filled
134
1521
1/2"
135
1522
1/2"
136
1523
25
137
1524
25
138
1525
25
139
1526
25
140
20M18
E-motor 0,63 kw
141
Yard
25
Sight glass
142
Yard
Non return valve
25
143
144
IVIDO/HFO system
145
5001
40
Changes over valve set HFO/MDO with limit switch
146
5001
40
Changes over valve set HFO/MDO with limit switch
147
5002
Oil pressure controller
20
148
5003
1/2"
149
5010
MDO/HFO Booster pumpset
150
5100
Burner
151
Fuel oil de-aerator
5101
152
5103
1/2"
153
5104
25
Ball valve set
154
5105
1/2"
Safety valve
155
180S12
Limit switch
156
180S6
Fuel oil pressure switch low low, incl.:adaptor 3/8"x1/2"
3/8"
157
31S12
Auto standby pressostat, incl.:adaptor3/8"x1/2"
3/8"
158
Yard
1/2"
159
100x1/2"
Yard
160
P:\PP\PP2004\PP04.737230.Aalborg HKG_Jinling\11 Takaningen PP04.737230\ffll5738841
+31 181650500 Titel of corresponding drawing:

+31181650501
Date
Material
GGG40.3
GGG40.3/Niro
GGG40.3
AISI-304/316
steel
steel
GGG40.3
GGG40.3
GGG40.3
AISI-304/316
steel
steel
GGG40.3
GGG40.3
GGG40.3
GGG40.3
Weight
5,1
5,5
5,1
0.9
0,55
0,69
5,1
5,1
5,1
0.9
0,55
0,69
5,1
5,1
5,1
5,1
Steel
Steel
25
25
1
1
62
111
6.5
1
1.2
0.7
Steel
Steel
Steel
Steel
AISI-304/316
1
1
0.55
0.9
Remarl(s
norm, closed
norm, closed
-1+3B
norm, closed
norm, closed
norm, closed
0-6B
norm,
norm,
norm,
norm,
closed
closed
closed
closed
672 l/h 2-5 bar

E-Heater 2.6 kW
Setpoint 8 bar
Mounted on 5001
SP = 3,5 bar
SP = 3.5 bar
0-6
Dale 12/4/2006 2:43 PM
Fitting List nr.:

Draw no
Type / Fig no
22.046
22046
22.05
22050
22.046
22046
Type 213.53.100
62053
941037
S004.16.100
941041
S006.07.110
22.046
22046
22.046
22046
22046ND
22.046ND
Type 213.53.100
62053
941037
S004.16.100
941041
8006.07.110
22.046
22046
22.046
22046
22.046
22046
22.046
22046
25
25
FDR 20
S004.60.100
ZAS 550
RMS 7
Size 2
S004.60.100
1515
KPS35
KPS35
S004.16.100
Type 213.53.100
D01026
D01026
D00800
D00749
D00840
D00799
D00749
D00839
D11428
D01026
61727
61727
941037
62053
5738659
Date:
Name:
E-Schema:
16-03-2005
CE
D53716
Maker
Albert Richter
Albert Richter
Albert Richter
Wika
Franz Schneider
Franz Schneider
Albert Richter
Albert Richter
Albert Richter
Wika
Franz Schneider
Franz Schneider
Albert Richter
Albert Richter
Albert Richter
Albert Richter
Kracht
Suppi
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
/Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Yard
Yard
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Filling
Aalborg
Aalborg
H.Paulsen
Franz Schneider
Allweiler
Weishaupt
Weishaupt
Franz Schneider
Aalborg
Econosto
Aalborg
Danfoss
Danfoss
Franz Schneider
Wika
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
MDO/HFO
Place
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
pump
system
system
system
system
system
system
system
system
system
system
system
system
system
system
system
page 4 of 5
""'
FITTING LIST
HEAT TECHNOLOGY
AALBORG
I N D U S T R I E S
P 0 . Box 1 45, 3200 AC; Spijkenisse, The Netherlands

Email: rtmvi/@aalborg-ir idustries.nl
JLZ04-041:i & JLZ04-0414 Alterations:
Yardnr.:
Jinling Sipyard
Yard:
At:
Nanjing - PR of China
Project nr; PP5738841 & PP5738842
Line no Fitting no
Nom diam
161
Spare parts
162
9001
IVIodulating Nozzle
1 pc
163
9002
1 pc
Ignition electrode left
164
9003
1 pc
Ignition electrode right
165
9004
Flame sensor RAR7
1 pc
166
9005
Rubber cross coupling
2 PC
167
9006
2pc
Ignition cables complete
168
9007
Coupling for burner pump
1 pc
169
170
9100
1 pc
Joint 400.1
171
9101
1 pc
Joint 400.3
172
9102
2 PC
Gland seal packing 461.01
173
9103
Joint 411.06/07
2pc
174
9104
1 pc
IVIechanical seal 433.01 (IVI3N4/32-SBVGG)
175
9105
2pc
Distance washer 551.4/5
176
9106
Circlip 932.02/04
2pc
177
9107
Washer 932.01
1 pc
178
Seegerring 936.01
9108
1 pc
179
Ball bearings for Pump
9109
2pc
180
9110
Ball bearing for E-motor
2pc
181
182
9200
PT 100 ohm sensor
1 pc
183
9201
1 pc
Max. thermal fluid thermostat type ATH-SE-20
184
9202
1 pc
Max. flue gas thermostat type ATH-SE-20
185
186
9300
Aux relais
1 pc
187
9301
1 pc
Aux relais
188
9302
Aux relais
1 pc
189
9303
1 pc
Signal lamp glass green
9304
190
1 pc
Signal lamp glass red
191
9305
1 pc
Signal lamp glass yellow
192
9306
Signal lamp glass blue
1 pc
193
9307
1 pc
Signal lamp glass white
194
9308
1 pc
Lampholder complete
195
9309
Lampbulbs
10 PC
P;\PP\PP2004\PP04.737230.Aalborg HKG_JinlingM 1 Tekeningen PP04.737230Mitl5738841
Phone: +31 181650500 Titel of corresponding drawing:

Fax:
+31181650501
Date
No. of correspondig drvig.:
Material
Weight
Remarks

Draw no
Type / Fig no
Date:
Name:
E-Schema:
Maker
5738659
16-03-2005
CE
D53716
SuppI
Place
Monarch
Monarch
Monarch
Monarch
Monarch
Monarch
Monarch
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Spares for
Spares for
Spares for
Spares for
Spares for
Spares for
Spares for
ALR049680
ALXA 551
ALXA 932
ALXA932
ALXA936
ALR0112062
6309-2Z
Allweiler
Allweiler
Allweiler
All Weiler
Allweiler
Allweiler
Allweiler
Allweiler
Allweiler
Allweiler
Allweiler
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Spares for circ.

Spares for circ.
Spares for circ.
Spares for circ.
Spares for circ.
Spares for circ.
Spares for circ.
Spares for circ.
Spares for circ.
Spares for circ.
Spares for circ.
90.21-F02/dl
ATH-SE-20
ATH-SE-20
Jumo
Jumo
Jumo
Aalborg
Aalborg
Aalborg
Spares for Safeties

Spares for Safeties
Spares for Safeties
CAD32P7
CAD32P7
CAD50P7
ZB-V03
ZB-V04
ZB-V05
ZB-V06
ZB-V07
Telemecanique
Telemecanique
Telemecanique
Telemecanique
Telemecanique
Telemecanique
Telemecanique
Telemecanique
Telemecanique
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Aalborg
Spares for
Spares for
Spares for
Spares for
Spares for
Spares for
Spares for
Spares for
Spares for
Spares for
212
212
111
111
163
163
964
151
1020/7
1021/7
1201/2
0901/2
111 782 0901/2

ALXA402
ALXA403
ALR 060782
Date 12/4/2006 2:43 PM
Fitting List nr.:
Burner
Burner
Burner
Burner
Burner
Burner
Burner
Pump
Pump
Pump
Pump
Pump
Pump
Pump
Pump
Pump
Pump
Pump
Control
Control
Control
Control
Control
Control
Control
Control
Control
Control
page 5 of 5
Box
Box
Box
Box
Box
Box
Box
Box
Box
Box
JUL
WTESnWP
06-12-04
10
11
12"
'*
^^~T
17
16
1'8
J9
20
U:13J2
PO Box 145, 3200 AC Spijkenisse The Netherlands

+31 181 650500
+31 181650501
rtmw @ aalborg-industries.nl
/ S S S S f t THERMAL FLUID
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Nanjing
Country
Classification
P.R. of China
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Burner type
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Yard number chonQd

Added ygrj number
Dots
05-08-29
06-04-20
Noma
RP
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05-04-25 RP
Project
Project
Project
Project
Project
Project
Project
Project
Project
1
PP5738659A.00 Yard nunnber
2 PP5738660A.00 Yard nunnber
3 PP5738661A.0O Yard number
4 PP5738862A.00 Yard number
5 PP5738841A.00 Yard number
6 ; PP5738842A.00 Yard number
7 PP5739698A,00 Yard number
8 ; PP06.052352-01 Yard number
9 : PP06.052352-02 Yard number
Noma
OILFIREDHEAT
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THERMAL FLUID
HEAT TECHNOLOGY F :+3\ ISISaOSOl
Front page
1
2
3
4
5
6
7
8
9
; JLZ04-0409
; JLZ04-0410
: JLZ04-0413
; JLZ04-0414
; JLZ04-0411
JLZ04-0412
JLZ04-0416
: JLZ04-0415
JLZ04-0417
Job Number
PP5738659A.0CI
Drowing number
D53716
Revision
A3
Page 10
Next 11
DMESTMIP
06-12-04
14:13:17
Installation
OILFIREDHEAT
Pcqe
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
i
i
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
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OILFIREDHEAT
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OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
OILFIREDHEAT
Rflvlaion Daacription
Dote
Noma
Front page
Date
04.10.29
Index
04.10.29
Index
04.10.29
General information
04.10.29
Controlbox dimensions
04.10.29
04.10.29
Description
10
11
12
14
15
16
20
21
24
25
29
30
31
40
89
90
91
95
101
102
120
141
142
150
151
160
170
180
185
Front
Data
layout
Main current
04.10.29
Main current
04.10.29
Control current
04.10.29
Stand still heating
04.10.29
Reset
04.10.29
Themal fluid pumps
04.10.29
Fuel oil pumps
04.10.29
Expansion tank
Dumpcooler
04.10.29
Minimum flow control
04.10.29
Economiser
04.10.29
Potential free contacts
04.10.29
Pilot lamps
04.10.29
Pilot lamps
04.10.29
Main current
04.10.29
Burner safeties
04.10.29
Burner safeties
04.10.29
Burner safety circuit
04.10.29
Burner control
04.10.29
Burner control
04.10.29
Burner air valve and nozzles
04.10.29
Burner safeties
04.10.29
H.F.O. Pre-heoter
04.10.29
04.10.29
Nama
35-04-25 RP
Name
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
RP
Job Number
OIUHREDHEAT
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THERMAL FLUID
HEAT TECHNOLOGY E-<HJ: rtnwa adbaiu liitirtilMjii
Page index
PP5738659A.0a
Revision
A3
Drawing number
Poge 11
D53716
Next 12
MIESTMIP
06-12-04
14:13:12
Installation
OILFIREDHEAT
Paqe
200
201
OILFIREDHEAT
Date
04.10.29
Description
Name
RP
04.10.29 RP
Pilot lamps
Pilot lamps
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Pote
Norne
Dote
Norne
D5-04-25 RP
Job Number
OimREDHEAT
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THERMAL FLUID
HEAT TECHNOLOGY F M
:-f31 181100601
E-mal: rtnw o^wu tHtwIilMiJ
Page index
PP5738659A.0q
Revision
A3
browing nunnber
Page 12
D53716
Next 14
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12
^13
14
15
16
17
18
^F
^W
20
.^4V/102.3
L24V/24.a
13
30K4\
/ 3 0 . 4 1 14
13
30K8\
/ 3 0 . 8 ^ 14
43
30K10\
/ 3 0 . 1 0 ^ 44
13
30K18\
/ 3 0 . i a 1 14
13
31K4\
/ 3 1 - 4 ^ 14
13
31K8\
/31-8
14
43
31K10\
/31.10 > 44
u
o:
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13
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z
a: C
< "
<
.
^
O 0^
^
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101D3
13
14
15
16
17
18
19
20
21
22
10
23
Q
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O
r>
o
f- o:
11
12
o: o
i2
lamptest
3
25S16-\
4
/25.16
XI
XI
lOIHS^^""
101H5(5^'"
|X2
jX2
N24V/24.8
T.F. PUMP 1
T.F. PUMP 2
IN OPERATION
XI
101H6(5^"'
]X2
XI
101H9 ( X ) "
1X2
STAND-BY PUMP
IN OPERATION
ACIUATH)
XI
XI
*" 101H14 *" 101H15 0
"*
|X2
TX2
J[X2
XI
101H12 0
nUJNG PUMP
IN OPERATION
FUa OIL PUMP 1

IN OPERATION
FUa OIL PUMP 2

IN OPERATION
F.O. PUMP
STANO-BT
IN OPERATION
Revislon Description
Dots
Norne
Date
Dnnm
Norne
05-04-25 RP
Job Number
OllflREDHEAT
iiiiit;
- Z I I U I I L THERMAL FLUID
POBi>i]200AC4iqMkaiiMiMiMi<i
If. :t2 12S2?
Pilot lamps
PP5738659A.0C
Revision
A3
Drawing number
Poge 101
D53716
Next 102
MIE STAMP
J ^
0S-12-M
^B
^ ^
14:1132
1 ^
10
11
12
l ^ i
14
15
17
18
L24V/101.19*
20
L24V/200.3
40K11
/40.11
40K14
/40.14
22
40K19
'40.19
22
K3
32
40K16
'40.16
40K8
/40.8
91K2 7
/91.2 '22
?1K4
91 KB
/91-6
/91.4 22
t / 7
1K8
91.8
22
40K10
'40.10
22
22
22
a
z
'S V
102D3
13
14
15
16
17
18
19
20
21
22
10
23
Q.
O Q
o: uj
1- C
m Si
o:
^ go
o:
11
C/101.19
.1
12
200.18
O UJ
< "
l _
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i
XI
102H3 ^
N24V/101.19'
1fVEL
yx2
EXP.TANK
LOW
XI
XL
102H5 6 ^h "
1X2
102H6
.XI
102H9 6 ^
TX2
LEVa EXP.TANK
LOW LOW
LEVEL EXP.TANK
HIGH HIGH
yx2
QUIK EMPTYING VALVE
OPEN
XI
102H12 ( X?)
102H14
|X2
T.F.aOW ECON.
LOW LOW
XI
6h
102H15
yX2
T.F.TEMP. ECON.
HIGH HIGH
XI
60
xf/101.19
102H16 6
yX2
EXHAUSTGASTEMP.
ECON. HIGH HIGH
p<2
^24V/200.3
LEAKAGE
ECONOMISER
Revision }escription
Dot
Noma
Data
Dmm
Chm
tod
Nome
D5-04-25 RP
Job Number
OIlflREDHEAT
jtHHii;
A U Z M A THERMAL FLUID
poBoiHi32oosn*n
I * = * " 1??!?!??
ul
Pilot lamps
PP5738659A.0C
Drawing number
D53716
Revision
A3
Paqe102
Next 120
DMESTW
"I
06-12-04
g T
I ' r
12
14
15
16
17
18
J9
20
14:11:47
LI I
L2I
L3I
BURNER MOTOR
. \
3 ^
,33 ,43
1 3 5
PRE-HEATER
^
m^-N-
120Q10 h - g
6lth-7.3A
17-23A ! _ "
7>^
2 4 6
' i
&5
|33 |43
-J
3)l2.aniin2
1=1
o:
o
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/150,13 12 1416
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185K18 \ - \
/185.18 121416
o.
O a
in >o
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111 a
P o:
a:
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t fmiM M Mnfnwwo
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S""
o z
120M6
5 9
BURNER MOTOR
PRE-HEATER
440 Volts
440 Volts
3.7 KW
13,2 KW
7,3A
20 A
Reviaion Daaeriptlon
Pote
Name
120E10
Dote
"^
Name
OllilRmEAT
D5-04-25RP
- ^
PO B M I ^ 3200 AC yfiMilMI
T4 :-tJI laiSBQSOO
THERMAL FLUID
te i-f laiHoaoi
HEAT TECHNOLOGY E-iml! rim *IQ lidurt<ri
Main current
Job Number
PP5738659A.0a
Revision
A3
Drawing number
Poge 120
D53716
Next 141
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06-12-04
12
14
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n2
18
17
16
20
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L/151,2
L/142.19 I
X150(^
SPARE BURNER RELAY TO BE INSTALLED

|03
180K5 \
/180.5 \
150W6 I
C H r - y 150S2
103
180K9 \
.9 04
PRESS.
1S0B8
Supply
Zsro
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uj S
Q.
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141K9 \
/141.9 ]^^
142K10 \
/142.10 V 4
03
141K3 \
/141.3 ^04
53
30K4\
/30.4 ^ 5 4
53
30K8\
/ 3 0 . 8 ^54
150K11
.11
^ F l a n e s e n s o r cable MUST
be a s e p a r o t e c a b l e )
. 57
150K18V#
^ |03
142K9 '
/142,9
^ lo3
141K5 '
/141,5
04
03
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/141.14
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SAFETf CIRCUrr
Cl
'^-JJ^
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53 t 54
SAFETY CIRCUIT
'^JJ^
''-J^'
03
2j5X,_a
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KP^ /200.8
M
I 04
43
, 44
/200.9
/151.17
Data
D5-04-25 RP
03 I 04
'J-^
/120.6
3
* /120.6
5
/120.6
13', 14
:j5.
' i X - i ' /160.15
2l3Xj2
314^
j44
/151.17
66
f 54
61513
Noma
Name
Job Number
OIUnREDHEAT
PO 801146^3200 AC
THERMAL FLUID
fl l ^ S S T
HEATTECHNOLOGY E-mai; r t w a iidhBfQ hdwMwjil
N/151.2
BURNER MOTOR
BURNER TROUBLE
/160.18
/95.3
150K18
A2
N/142,19 I
30sec. JAI
3sec. I A I
150K13
Al
iV\Q^
Data
33
120Q6 34
/120.6
141K12
/141.12
141K8
/141.8
Ravlsion Oascription
Rama aanaor
22
21
141K11 \
/141.11 V 4
40K16 \
/Arne
\ 04
/40,16
03
Bumar
motor
Rasat
7160,14
53
I 23
185K16 \
180K14 \
/185.16 l s / 1 8 0 , 1 4 ^ 24
180K6 \
/180.6 \
0 3 LOW m v
-^ ui
S""
W^'
|03
40K14 \
/40.14
'""''
104
!2 o:
fe
a: o
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/180.8
Bumr
trouble
180K3 \
/180.3 ^
Burner safety circuit
PP5738659A.0q
Revision
/151.3
.13
A3
Drawing number
Poge 150
D53716
Next 151
li
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15
17
16
20
18
SOMMOPQR
dOSE/OPEN
14:11:22
L/iso.a
L/151,19 I
/150.8
160B3
Xk4-40.4
XkS-142.3
Controllar typa : 9 3 W 0 1
Ronga : 0-4S5o C
2728
20
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ar
o
21
|03
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t - ^
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''"^"^ (22/142.3 ^ g^BURNER
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r
u.
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O
CH
Q.
160B4
P-tlOO
14
13
150K13
170K4 \ /150,13
/170.4 >
14
160B6
P-tlOO
2 1 "
O -
On/off control
bumar
Air pranura
chak
Ralaaaa load
control
4 5 6
1 2 3
150B8
Burner relay LAL2.25
701
12
'/170.3
13
/150,6
14
Autonollo
PtrtU
looil
OTF
160S8
E/170.2
F/170.2
Q
tiJ
O
BURNER
160S8 h v
>1
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o: o
o UJ
z o
u z
o
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N/151,19
N/170.2
i
m
I
Ravision
Dascripfaon
Date
Norne
Data
D5-04-25 RP
Noma
Job Number
OimREDHEAT
itm^fi
poaKi4&]20OM:
U :+31 in
THERMAL FLUID
:43i innoaoi
HEAT TECHNOLOGY Fa
E-mal: rtiw diiwu
Bumer control
iiiliirtiliaj^
PP5738659A.O0
Revision
A3
Drawing rnumber
Page 1 6 0
D537116
Next 170
'2
""8
10
11
12 ~ r
14
15
I "W
17
"*
1^^
06-12-04
14:11:17
/160.14 /
Burner relay LAL2.25

150B8
Bumer in
operation
Servomotor
opan
Feedback
Ignal
19
Servomotor Servomotor
cloae
cloae
11
10
Nozzle*
Ignition
traneformer
18
16
F/160.16 I
143
170K2 \
.2
i3
i
i
170K4
.4
\AA
03
'32
170K4 \ 04
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170K4
,4
E/160,16 I
li.
H/151.5
M/151.19
76
87
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88
X170 U X170
170W5
27
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128
129
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114
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L_J
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V I I = LIMIT
SWITCH
SWITCH
SWITCH
SWITCH
16
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t
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PEN
CLOSED
IGNITION POSITION
PARTIAL LOAD
> ^
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3
N/180.2
BURNER IN
OPERATION
'iJ^"
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/200.6
M
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2151122 g
^J^M^ is
43 |_J4 4
M
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liTjE
BI^TM
n _ ' 74
Revieion Descfiption
Date
Norne
Date
Nome
D5-04-25 RP
OllflREDHEAT
iitiiitii
THERMAL FLUID " : ^ S S S f

HEAT TECHNOLOGY c l ^ j ^ ^ r * "
Burner air valve and nozzles
Job Number
PP5738659A.0CI
Drawing number
D53716
Revision
A3
Poge 170
Next 180
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10
11
12
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06-12-04
14
15
16
17
18
20
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L24V/102.19
03
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03
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50.11 ^ 0 4
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142K9
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142.10
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14
15
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17
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201.18
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1-
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5 Q
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XI
200H3 ( X )
JX2
N24V/102.19>
BURNER IN FORCED
PARTIAL LOAD
XI
200H6 ( X )
]X2
X1
200H8 ( X )
]X2
XI
200H9 ( X )
1X2
BURNER IN
OPERATION
BURNER CONDdlONS
CORREa
XI
200H11 ( X )
1X2
XI
200H12 ( X )
1X2
BURNER
TROUBII
LEAKAGE
(XL RRED HEATER
XI
200H14 ( X )
1X2
I
XI
200H15 ( X )
1X2
I
FLUEGAS TEMP. THERMAL FLUID FLOW

HIGH HIGH
LOW LOW
T.F. TEMP.
HIGH HIGH
A^ rd
200H17 ( X J
TX2
g24V/201.3
*
BURNER FIANGE
OPEN
en
Ravialon Description
Data
Noma
Data
Oman
OMCIXI
Noma
D5-04-25 RP
OllflREDHEAT
jtiHiti;
y^JJJJpJL THFRMAI Flllin
poaaii4&aooc4i|MiiMiiMiMiiirin4i
i laieeoMo
e-iMl: rbma odbara-MMtrlMiri
Pilot lamps
Job Number
PP5738659A.0C
Drawing number
D53716
Revision
A3
Page 200
Next 201
VKN
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tO-Jl-90
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To a SAFE place
/ " N in the atmosphere
PRESSURE INDICATOR
PRESSURE ALARM
25
MANUAL VALVE
IMI
MANUAL VALVE N.C.
I^<1| MANUAL VALVE

" ^ ' WITH LOOSE DISC
PRESSURE CONTROLLER
IMI
FLAME ARESTOR
1^1
ELECTRIC TWOWAY VALVE
MANUAL VALVE N.C.

WITH WELDING ENDS
r/\
STRAINER
TEMPERATURE ALARM
1^1
TEMPERATURE CONTROLLER
<<>i MANUAL VALVE

^ ' ^ WITH REGULATION DISC
AND WELDING ENDS
FLOW INDICATING ALARM

PRESSURE DIFFERENTIAL SWITCH
INCL. VALVES AND ORIFICE
BLOCKING VALVE
SELF CLOSING
k.
|j<^| MANUAL VALVE

WITH REGULATION DISC
TEMP. INDICATOR CONTROLLER
.
.^*
MANUAL VALVE
WITH WELDING ENDS
TEMPERATURE INDICATOR
TEMPERATURE TRANSMITTER
SELFCLOSING
SOUNDING PIPE VALVE
f^
PRESSURE TRANSMITTER
PRESSURE INDICATING CONTROLLER
J _ ^
MANUAL VALVE N.C.

^
' ^
MANUAL VALVE N.C.

AND WELDING ENDS
v<i
MANUAL VALVE
WITH LOOSE DISC
AND WELDING ENDS
11^
I m )
MANUAL DRIVEN PUMP
_^3\_
ELECTRIC DRIVEN PUMP
!<]
NON RETURN VALVE
"Z
ilREDUCER
l y
BELLOW
FILTER AIRREDUCER
SAFETY VALVE
2 - W A Y SOLENOID VALVE
LEVEL INDICATOR
3 - W A Y SOLENOID VALVE
LEVEL ALARM
LEVEL CONTROLLER
P<i\
PNEUMATIC CONTROLED VALVE
1^1
ELECTRIC 3 - W A Y VALVE
6^
TEMPERATURE TRANSMITTER
WITH DOUBLE ELEMENT
m\
ELECTRIC 2 -
CALORIMAT
') ^ _
WAY VALVE
IIXII
IIXII
" " " " CAPILLARY TUBE
THERMAL FLUID
00 00
AIR-TUBE
STEAM
ELECTRIC LINES
WATER
MECHANICAL CONTROL VALVE
L.C. = Loose Cone
PIPE SIZING TABLE

ACQ. TO ISO
OUTSIDE DIAMETER
DN15
21.3
DN20
26.9
DN25
33.7
DN32
42.4
DN40
48.3
DN50
60.3
DN65
76.1
DN80
88.9
DN100
114.3
DN125
139.7
DN150
168.3
DN200
219.1
DN250
273.0
DN300
323.9
TO
HEAT CONSUMERS
200*0
DN80
Min flow control

TYPE: Electrical
acc. dwg 62050
150C
^
FROM
HEAT CONSUMERS
YARD
: Jinling Shipyard
At
: Nonjlng - P.R. of China
CLASS
: Germanischer Lloyd + MCE,AUT(SBG)
Newbuilding
Aolborg Project
PP5758659A.00
JLZ04-0409
A
PP5738660A.00
JLZ04-0410
A
PP5758661A.00
JLZ04-0413
A
PP5758662A.00
JLZ04-0414
A
PP5738841A.00
JLZ04-0411
A
PP5758842A.00
JLZ04-0412
A
052352-1
JLZ04-0415
A
PP5739698A.00
JLZ04-0416
A
052352-2
JLZ04-0417
A
REMARK: A Type EXV568-41-57.0-600 is used dwgnr. D53718
REMARK: A Type EXV660-43-57.0-600 is used dwgnr. 054051
( 20M7 ) For electrical diagram see DWG D53716

lTl
For item number see fittinglist FITL5738659

Yard Delivery
add new Fitno.

Hull numbers added
DESCRIPTION
04-05-2006
13-02-2006
NAME
PROJECTION
For MDO/HFO diagram see DWG D53715
DATE
Thermal Fluid Diagram
DRAWN: CE
DRAWING No:
SCALE: n o n e
DATI: 16-03-2005
D53714
REVISION SHEET
1
0F1
PO Box 145,3200 AC Spijtenisse The Netheriands THIS DRAWING AND DESIGN SHOWN
AALBORG THERMAL FLUID I d :+31 181650500

HEAT TECHNOLOGY'"" '*'" '^'^'
I N D U S T R I E S
II1_M1
ll_VylinVJI_UUI
E-mail: rtmwe aalborg-industries.nl
HERDN IS THE PROPERTY OF AALBORG

INDUSTRIES AND MUST NOT BE USED
BY OR REPRODUCED FOR THRD PARTY
AI
in
DAILY
SERVICE
TANK
MDO
PART OF MAIN
FUEL SYSTEM
115V
rHTl-ff^
Setpoint 8 Bar
o<
BURNER WEISHAUPT
Type RMS 7-ZMD
E-motor: 2.6 [kW]
E-heater: 13.2 [kW]
0-6
DISTANCE FROM DE-AERATORS TO BURNER
AS SHORT AS POSSIBLE
]jiMn
^
DN 25
Oil Pressure
Controller
Type: FDR 20
Ace dwg.:D00800
ISSD
FUEL OIL DE-AERATOR

Size 2
Ace. dwg D00799
YARD
: J'mlbq Shipyard
At
: Nanjing - P.R. of China
CIASS
: Germanischer Uoyd + MCE,AUT(SBG)
Newbuilding
Aalborg Project
PP5738659A.00
1204-0409
PP5738660A.00
JLZ04-0410
PP5738661A.00
JI204-0413
PP5738662A.00
1104-0414
PP5738841A.00
1.Z04-0411
PP5738842A.00
1204-0412
052352-1
JLZ04-0415
PP5739698A.00
1204-0416
052352-2
1.Z04-0417
DN 25
Change Over Valves

Type: PHD 40
Ace dwg. D42950
H.F.O. Circulating Pumps

Type: ZAS 550
Cap.: 672 L/hr
H.:
2 - 5 Bar(g)
E-Motor: 0,37 kW
Current: 3x440V - 60Hz
Aec. Dwg. D00840
QOMTJ For electrical diagram see DWG D53716

150031
Hull Numbers added

For item number see fittinglist FITL5738659 REV.
DESCRIPTION
ER|
Yard Delivery
PJ
iiliiiU
DATE
NAME
PROECIKIN
For System diagram see DWG D53714
13-02-2006
MDO / HFO Diagram

Modulating Burner
DRAWN: CE
DRAWING No:
SCALE none
DATE: 1 6 - 0 3 - 2 0 0 5
THERMAL FLUID
l^'^l^'STA'"'"'^'
AALBORG HEAT TECHNOLOGY ^ - ^ . ^ . ^

INDUSTRIES
D53715
REVISION SHEET
1
0F1
D B MUWK AW DESm SHOW

WREn rS 1HE PROFERIY OF A t i r a
MUSnss MB HSr NOT S USED
Bv 01 tEmonxa FOR D M I PARTY
A2
ALUVEILER
Operating and Maintenance Instructions
VM No.:
460.0008 GB
Edition:
07.01
Ident No.
Volute-Casing Centrifugal Pumps
550 102
Retain
for future
use!
Series NTT and CTT

Order No.:
Pump Ident. No.:
Machine No.:
Pump Type:
Operating data, dimensions and other additional information can be found in the order-specific part of the
documentation.
These Operating and Maintenance

Instructions contain information from
the pump manufacturer. They may need
to be supplemented by instructions of
the operator company for its personnel.
These instructions do not take account
of specific information relating to operation and maintenance of the process
plant into which the pump is integrated.
Such information can only be given by
the persons responsible for construction and planning of the plant (plant
manufacturer).
Such specific instructions relating to
operation and maintenance of the
process plant into which the pump is
integrated have priority over the
instructions of the pump manufacturer. The plant manufacturer must
on principle observe the limits of
use!
Refer to the operating instructions of
the plant manufacturer!
Contents
1. General
2. Safety
3. Transportation and Intermediate
Storage
4. Description
5. Installation/Mounting
6. Start-up/Shutdown
7. Maintenance/Repair
8. Operating Faults, Causes and
Remedial Action
9. Associated Documentation
Important note:
This operating manual is to be supplemented
by the order-related informations.
NTT/CTT
1
General
1.1
Pump designation
The exact designation can be found In the order-specific documents (see data sheet).
1.2
Properuse
Information on proper use of the pumps is provided in
the technical data sheet.
The pumped liquid must not contain any abrasive constituents nor corrode the pump materials.
1.3
Performance data
The exact performance data can be taken from the order data sheet and/or acceptance test report.
1.4
Warranty
Our warranty for shortcomings in the supply is laid
down in our delivery conditions. No liability will be undertaken for damages caused by non-compliance with
the operating instructions and service conditions.
If at any later date the operating conditions change (e.g.
different fluid conveyed, speed, viscosity, temperature
or supply conditions), it must be checked by us from
case to case and confinned, if necessary, that the pump
is suited for those purposes. Where no special agreements were made, pumps supplied by us may, during
the wan-anty period, only be opened or varied by us or
our authorized contract service wori<shops; otherwise
our liability for any defects will cease.
1.5
Testing
Prior to leaving our factory, all pumps are subjected to
a leak test. Additional tests will only be peribmied on request.
1.6
Availability
As a matter of principle, we recommend stocking
replacement pumps and withdrawable units (hydraulic
action system) where the supplied pumps are a
decisive factor in maintaining a production or delivery
process. In this way downtimes can be avoided, or
reduced to a minimum.
1.7
Pressure limit
The sum of inlet pressure and maximum delivery pressure must not be greater than the permissible internal
pump pressure (see data sheet).
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
ALLWEILER
ALIWEILER
NTT/CTT
2
Safety
These operating instructions contain basic safety
instnjctions
for
installation,
operation
and
maintenance. It is therefore essential that they are read
by fitters and all specialist staff and customer personnel
prior to installation and start-up. They must always be
kept at hand at the place of installation.
2.3
The special safety instructions contained in the other

chapters must be observed in addition to the general
safety instructions in this chapter.
2.1
Identification of safety instructions in the

operating manual
The safety instmctions contained in these operating
instmctions which represent a danger to personnel if
not complied with are specially marked by the general
danger symbol:
Dangers in the event of non-compliance with

safety instructions
Failure to comply with the safety instructions may result
in danger to persons, and place the environment and
the machine at risk. Non-compliance with the safety
instructions will lead to the loss of any claims for
damages.
Non-compliance may result in the following dangers:
Failure of important functions of the plant
Failure of specified methods for maintenance and

servicing
Danger to persons resulting from electrical,

mechanical and chemical effects
2.4
Responsible working practices

The safety instructions contained in these operating
instmctions, current national accident prevention
regulations, as well as intemal working, operating and
safety rules of the customer, must be observed.
2.5
Safety instructions for the user/operator
Warning symbol
as per DIN 4844-W9
Waming of danger from electric voltage is indicated as
follows:
A
Waming symbol
as per DIN 4844-W8.
Instructions which are essential to avoid endangering
the machine and its operation are marked by the word
ATTENTION
Instructions affixed directly to the machine such as
Directional markers
Signs for flukl connections
must always be observed and maintained in fully

legible condition at all times.
Hot or cold machine parts representing a danger

must be protected against accidental contact on
site.
Personnel qualification and training

The operating, maintenance, inspection and mounting
personnel must be appropriately qualified for the duties
assigned to them. The scope of their responsibilities,
competency and supervisory duties must be closely
controlled by the customer. If the personnel do not have
the required knowledge, they must be trained and
instmcted. If required, this may be provided by the
manufacturer/supplier on behalf of the customer. The
customer must additionally ensure that personnel fully
understand the content of the operating instructions.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
Protection against accidental contact for moving

parts (such as the coupling) must not be removed
while the machine is in operation.
When operating pump aggregates in a dust-laden

environment (e.g. milling, chipboard manufacture,
bakeries), the surfaces of the pumps and motors
must be cleaned at regular intervals, depending on
local conditions, in order to maintain the cooling
effect and eliminate the possibility of spontaneous
combustion. Please also see explosion protection
regulations (ZH 1/10).
Leakage (e.g. from the shaft seal) of hazardous
substances being handled, such as explosive, toxic
or hot materials, must be discharged in such a way
that no danger to persons or the environment is
aeated. Legal regulations must be observed.
2.2
Danger to the environment resulting fi-om leakage of

hazardous substances
Dangers from electrical energy must be eliminated.

For details in this regard, please refer to VDE and
local power company regulations.
ALLWEILER
NTT/CTT
2.6
2.7
2.8
Safety instructions for maintenance, inspection

and installation
The operating company must ensure that all
maintenance, inspection and installation tasks are
performed by authorized and qualified specialist
personnel who have thoroughly studied the operating
Instructions.
Wort< on the machine Is only to be carried out when the
machine Is at a standstill. The procedure for shutting
down the machine described In the operating
Instructions must always be followed.
Pumps or aggregates handling fluids which are
detrimental to health must be decontaminated. All
safety and protective devices must Immediately be
refitted and made operational on completion of the
work.
The Instnjctlons under Section 6.1, "Preparation for
start-up", must be observed before restarting.
Unauthorized conversion and production of
replacement parts
Conversion or modification of the machines Is only
permissible after consultation with the manufacturer.
Original replacement parts and accessories approved
by the manufacturer are intrinsic to safe operation. If
other parts are used the manufacturer cannot be held
liable for the consequences.
Unacceptable modes of operation
The operational safety of the machine supplied Is only
ensured when it Is used In accordance with Section 1 of
the operating instructions. The limit values given on the
data sheet must not be exceeded under any
circumstances.
Transportation and Intermediate Storage

3.1
Packaging
Attention must be paid to the figurative markings on the
packaging.
The suctk)n and pressure side and all auxiliary connections must always be closed during transportation and
storage.
The coverings must only be removed imATTENTION mediately before connecting the pipeline.
3.2
Transportation
The pump or pump aggregate Is to be safely transported to the place of Installation, if required by means
of lifting gear.
A
A
The regulations for lifting loads in accordance with

VBG 9a must be observed. Crane and sling equipment must be adequately dimensioned. Sling
equipment must not be secured to the lifting eyes
of the motor, except as additional protection
against overturning in the event of nose-heaviness.
Transportation to and at the Installation site
Make sure that the unit Is transported safely and In a
stable position. Overtuming due to nose-heaviness
must be prevented.
Transport damage
Check the pump for damage on receipt.
ATTENTION Any damage detected must be notified Immediately.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
ALIWEILER
NTT/CTT
3.3
Preservation / Storage of centrifugal pumps
3.3.1
Preservation
In the case of storage or prolonged standstill, the
pumps must be protected against corrosion. In those
cases, an outside and inside preservation is to be provided. The durability of the protection against corrosion, which is limited in time, depends on the composition of the preservative to be applied and the storage
conditions.
Under normal circumstances the pumps
ATTENTION have no special preservative.
At an additional charge we can, however, supply
pumps and replacement parts ex factory with a preservative adequate to the planned storage period.
3.3.1.4 Depreservation
Prior to setting the pump in motion, the inside preservation must be removed.
Environmentally compatible disposal must be ensured.
Preservatives can be removed with wax solvents, petroleum ether, diesel, petroleum or alkaline cleaners.
However, the simplest method is to use a steam cleaner.
Recommendation for Tectyl 506 EH: Allow petroleum ether to act for 10 minutes before any further action.
3.3.1.1 Outside preservation

The outside preservative should be applied by painting
or spraying with a spray gun.
Points of preservation:
All bright and unvamished parts (e.g. shaft ends, couplings, flange facings, valve and manometer connections).
3.3.1.2 Inside preservation

(Not required for pumps made of stainless materials.)
Intemal preservation is applied by painting, spraying
using spray guns, filling/dipping and subsequent draining. Finally, the suction and outlet branches as well as
all other supply and discharge branches must be
sealed with dummy flanges or dummy plugs (plastic
caps).
All bright parts inside the pump (e.g. pump casing inside, bearing bracket, shafts, impellers and diffusers).
Note: The preservatives listed are to be regarded as a

recommendation. Altematively, technically equivalent
products from other manufacturers can be used.
When handling preservatives, the safety hints contained in the relevant DIN safety data sheets and those
of the manufacturer must be complied with.
Pumps that are used in the food or drinking water sector

must be dismantled and thoroughly cleaned prior to depreservatk)n.
A suitable solvent that is compatible with the liqukj to be
pumped (drinking water/food) can be used as the
cleaning agent, e.g. Spiritus, Ritzol 155 or suds with a
high alkaline content. Steam cleaning is ideal.
After a prolonged storage period (more
ATTENTION than 6 months), all elastomers (O-rings,
shaft seals) must be checked for elasticity of shape.

Embrittled elastomers must be replaced. EP rubber
elastomers (EPDM) must be replaced on principle.
3.3.2
Storage
During storage of the pump, the suction and outlet
branches and all other supply and discharge branches
must always be closed with dummy flanges or dummy
plugs.
Storage should be in a dry, dust-free room. During storage, the pump should be cranked at least once a
month. During this process, parts such as the shaft and
bearings should change their position.
3.3.3
Monitoring of preservation
The preservatrn must be checked at regular intervals.
The preserved areas must be inspected every 6
months and re-treated, if necessary.
We cannot accept any liability for defects
ATTENTION that arise due to incorrect preservation
treatment.
3.3.1.3 Storage times

Depending on the required storage period and the surroundings, we recommend the use of preservatives
from Valvoline GmbH, Hamburg.
storage in a closed, dry and dust-free room
Storage time
up to 6 months
up to 12 months
over 12 months 0)
Intemal presenvation
Tectyl 511 M
Tectyl 511 M
Tectyl 506 EH
External preservation
Tectyl 511 M
Tectyl 511 M
Tectyl 506 EH
Storage in the open-air, central European climate

Storage time
up to 6 months
up to 12 months
Intemal preservation
Tectyl 542
Tectyl 542
over 12 monttis
Tectyl 506 EH
Extemal preservation
Tectyl 542
Tectyl 506 EH
Tectyl 506 EH
Storage in the open-air, tropical climate, aggressive Industrial air or

proximity to the sea
storage time
up to 6 months
up to 12 months
over 12 months (S
Intermal preservation
Tectyl 542
Tectyl 542
Tectyl 506 EH
Extemal preservation
Tectyl 506 EH
Tectyl 506 EH
Tectyl 506 EH
Internal and extemal preservation must t renewedafter 48 months at the latest.

External preservation must be renewed after 18 months at the latest.
Internal presen/ation must t renewed after 48 months at the latest
Extemal preservation must be renewed after 12 months at the latest.
Internal presenration must t renewed after 46 months at the latest
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
ALLWEILER
NTT/CTT
4
Description / Principle design of the pump

The pictorial presentation may not correspond with the pump supplied.
The actual design will be stated in the specific order documents.
Volute casing
Bearing bracket
Impeller
Safety stuffing box
A
r,
i\
Contact protection to EN 809

by coupling guard
Earthing connection to EN 809

at the base plate
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
Shaft
Shaft seal
ALIWEILER
NTT/CTT
Installation/Mounting
5.1
Installation
For installation methods and locations, please see installation drawing.
A
A
Other methods of installation are not permissible

without prior consultation with the manufacturer.
5.2.3
Characteristics of a floor/concrete foundation

The foundation must be horizontal, flat and clean, and
be capable of bearing the full load upon it.
Note: Concrete foundations must be executed with
standard concrete of strengfli dass B 25 as a minimum.
5.3
Alignment of the pump aggregate

The pump aggregate must be aligned to its pre-set
height and system dimensions. This is done using suitable steel shims, an-anged direcfly adjacent to each f i xing bolt.
The overall height of the steel shims is determined by
the established system dimensions of the plant. The
steel shims and the base plate must be positioned
evenly and securely.
If the fixing holes are more than 750 mm apart, we r e commend fitting additional steel shims in the middle of
the base plate.
The safety regulations and tests in accordance

with DIN 4754 and VDI 3033 must be observed
where pumps are installed in heat-transfer plants.
When installing the pump, please ensure
AHENTION that the cooling air from the motor fan can
flow unimpeded over the bearing bracket to the casing

cover.
5.1.1
Place of Installation
Temperature:
min. -20
max. +40
C
C
Baseplate
relative air humidity:

permanent
max.
85 %
temporary
max. 100 %
Installation height:
max. 1000 m above NN
For data differing from this, please consult the manufacturer.

Intensive vibrations in the vicinity of the
ATTENTION pump unit can lead to bearing damage and
must therefore be avoided.
5.1.2
Protective devices
In order to prevent injuries due to bums, at pumping
liquid temperatures higher than 60'C protective devices in accordance with EN 809 must be provided on
site.
Foundation
5.2.1
General
The foundation may be a floor/concrete base or a loadbearing steel foundation frame.
The foundations must be constructed in
ATTENTION such a way that they can take the weight of
the pump unit and all operating forces that occur.
5.2.2
Characteristics of a steel foundation frame

A steel foundatkxi frame must be constructed in such a
way that pump feet or base plate are supported evenly
and can be secured with screw fixings.
If the base plate is only supported at four
AHENTION points the pump aggregate will hang down
in the middle. This will affect the alignment of the coupling and may also lead to severe noise being generated.
VM 460.00O8 GB/07.01 - Ident-Nr. 550 102
T.
V
Fig. 1: Alignment with steel shims

Horizontal alignment of the aggregate is produced by
way of flat-machined surfaces on the pump using a
machine spirit level. Measurements are taken in longitudinal and transverse directions of the pump aggregate.
Permissible deviation: max. 1 mm per 1 m length.
5.3.1
Heat insulation
Only the volute housing may be insulated
ATTENTION with heat insulating material. In order to
enable optimum heat dissipation no other pump components may be insulated.
5.2
7L
Fixing the pump aggregate

In order to prevent deformation of the base plate/pump,
this must first of all be screwed tighfly at three points.
Before tightening the rest of the screws, spacers
should again be positioned around the SCTew, in order
to balance out the unevenness of flie seating.
The prescribed tightening torque (Section
ATTENTION 7.2.3) must be observed.
Precise details on the shape and dimension of the flxing
are provided in the installation drawing.
5.3.2
Checking the alignment

After aligning and tightening the screws, it must be
possible to tum the pump and drive by hand, without
any strain.
Note: The pump unit should not be welded to the base
for technical installation reasons.
ALLWEILER
NTT/CTT
5.4
Checking the coupling alignment
5.4.1
Adjusting the support foot

Before aligning the coupling, all screws on the support
foot (183...) must be loosened, so that the insert unit is
stress-free. After aligning the coupling, screw the support foot (183...) down to the base plate. The fixing
screw (901...) on the bearing bracket should still be
loose. Check that the bearing bracket Is not twisted during tightening. For this purpose, the fixing screw (901...)
must SCTew freely into the bearing bracket. If this is not
possible, the seat of the support foot on the base plate
must be corrected (e.g. by placing spacer plates underneath). Then tighten the fixing saew (901...).
5.4.2
Figure 5.3: Alignment of the coupling with dial gauges

Note: The permissible axial and radial deviation,
measured on the front face of the coupling and the
coupling circumference respectively, may be max.
0.1 mm, but as far as possible should be kept below
0.05 mm.
Checking the coupling alignment in case of horizontal setup on base plate

A complete delivered pump aggregate has t)een carefully assembled at the factory. After proper Installation,
and prior to start-up of the pump aggregate, the alignment of the coupling must be checked.
The check can be made with a straight-edge and a
feeler gauge, or with other suitable equipment (such as
a laser alignment device).
If a height, lateral or angle offset is detected between

the two coupling halves, the drive motor should be r e aligned such that the coupling halves are flush with
each other (level out with flat packing shims as necessary).
The measurements are taken in two planes, each offset

by 90, on the circumference of the coupling.
Whe the fixing bolts have been aligned and tightened

the pump/drive motor unit must be able to be spun by
hand without pressure points.
Out-of-flush errors on the coupling may
ATTENTION lead to heavier wear of the coupling, the
anti-friction t)earing and the shaft seal, and even cause
the shaft end to be tom off.
The gap between the two coupling halves must be the

same all round the circumference of the coupling. The
specified gap is shown In the installation diagram.
The spacing between the straight-edge laid over both
coupling halves and the respective shaft must be the
same all round the circumference.
5.4.3
Coupling alignment of special designed couplings

(if present)
Refer to the operating instructions of the coupling
manufacturer.
5.5
Assembly of pump and drive motor

If the aggregate is only assembled at the place of use,
the following wori< is to be performed:
I \
II
V straight-edge
II
II
1 /
1. Coat the pump and motor shaft ends with a fine film
of molybdenum disulfide (e.g. Molykote) and insert
keys.
-Fef sler gauge

Figure 5.2: Alignment of the coupling with
straight-edge and fee-ler gauge
For couplings with a distance piece (removable couplings) the alignment of the coupling can be checked
with dial gauges.
Push on the coupling halves on the pump and motor

side with the aid of a pusher device until the shaft
end is flush to the coupling hub.
If no puller Is available, heating the coupling halves
to approx. 10O'C (without mbber buffer) facilitates
pushing.
The possibility of shock and stress on
ATTENTION the pump and drive motor components
must be eliminated.
3. Tighten the grub screw on both coupling hubs.
4. When assembling the pump and motor, make sure
the specified gap between the coupling halves is
maintained (see our Installatbn drawings).
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
ALIjyVEILER
NTT/CTT
Shorter pipelines on the suction side are
5. In the case of horizontally mounted pump

aggregates fixed on a base plate or directly on the
foundation, the coupling must be aligned as
described in Section 5.4.
the hydraulic performance data. Shorter pipelines on

the discharge side are possible, but may lead to increased noise development.
6. Mount the contact protection.

According to accident prevention regulations, the
pump must only be operated with a protection
against accidental contact.
Note: When installing pumps with symmetrical feet
which are supplied without base plate, make sure that
the guide bolt at the volute casing is seated In a guide
hole. The hole diameter must be provided according to
the representation below. The 5 mm distance must be
observed.
Fig. 5.4:
5.6
ATTENTION possible, but may lead to a deterioration of
Compensators must not generate any un-
ATTENTION acceptable additional forces on the pump

connection branches. Special care is needed in cases
where compensators are used, whose pressurised diameter is greater than the nominal width of the pump
connection branches.
5.7.2
Changes in cross-section and direction

Sudden changes in cross-section and direction, as
well as bends with a bend radius less than 1.5 times the
interior pipe width, must be avoided.
5.7.3
Supports and flange connections

All pipelines must be connected to the
ATTENTION pump stress-free in accordance with
VDMA standard sheet 24277.
The permissible pipeline forces must not
ATTENTION be exceeded in any operating status.
We therefore recommend on principle that a calculation
of the pipeline forces is performed, which takes into
consideration all operating status (e.g. cold/warm,
empty/full, depressurised/pressurised, etc.).
Pipeline supports must always be free sIkJing and must
not rust in (check regulariy).
Volute casing with guide bolt in the base plate
Space required for maintenance and repair

The pump must be accessible from all
AHEMTION sides in order to be able to cany out
necessary visual inspections.
Adequate space must be provided for maintenance
and repair work. It must also be ensured that all
pipelines can be attached and removed without
hindrance.
5.7
Laying the pipelines
5.7.1
Nominal widths
The nominal diameters of the pipelines need not
necessarily correspond to those of the inlet and outlet
branch, however, they must not be smaller. Different
nominal diameters of suction branches and suction
pipelines are to be compensated by centric transition
pieces. Formation of air bags is to be avoided.
min. 5xDNs
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
The flanges must lie plane-parallel.
5.7.4
Cleaning pipelines prior to attachment

Prior to assembly, all pipeline parts and valves must be
thoroughly cleaned.
No impurities must reach the pump fi-om
ATTENTION the pipeline system (e.g. welding beads.
residues from preservatives, etc.).
Flange gaskets must not protrude inwards. Blanking
flanges, plugs, protective film and/or protective paint on
flanges and seals must be removed completely.
Filters on suction side must be cleaned
ATTENTION regulariy. We recommend monitoring with
differential manometer and/or contact manometer.
5.7.5
NPSH observation
The NPSH conditions of the system must be adapted to
the respective pump requirement (NPSHêq.)An essential condition is fulfilled if the system NPSH value (NPSHavaii.) is at least 0,5 m at>ove the pump
NPSH value (NPSHêq.). The NPSHreq, can be taken
from the characteristic curves of the relevant pumps.
In these areas, pipe fittings such as gate

valves, bends, compensators etc. should
be avoided wherever possible.
Disconnect the pipeline from the pump at the connecting flanges.
After disconnecting the connecting flanges, the

pipeline must be freely movable In all directions in
the area of expected expansion.
Note: up to 0 150 mm by hand
from
0 150 mm with small lever
Figure DN 1
Recommendation for straight pipeline
lengtti before and after the pump
nJLm
How to assess a pipeline connection

To conduct an assessment, the pipeline must be depressurised, completely drained and cooled. The
pumping liquid must be disposed of with respect for the
environment.
ALLWEILER
NTT/CTT
5.9
The applicable NPSH values in the char-
ATTENTION acteristic curves are for water with 20 C.
For other media and/or temperatures, the NPSH value

may deviate from the characteristic curves.
Uncertainties in the determination of
ATTENTION NPSH conditions, particularly for media
other than water and/or other temperatures, must be
compensated for by increased safety factors (please
consult the manufacturer).
5.7.6
Inlet pipeline
In order to avoid the formation of air bags, the inlet
pipeline must be laid rising to the pump.
The pump must not run dry, not even for
ATTENTION checking the sense of rotation.
5.7.6.1 Stop valve (inlet mode)

A stop valve is to be installed in the inlet pipeline. It must
be fully open during operation (see figure DN 1).
5.7.7
Pressure pipeline
5.7.7.2 Non-return valve in the pressure pipeline

The pump must not njn liackwards. It is recommended
that a non-retum valve is fitted between the pressure
branch and the stop valve.
5.7.7.3 Bleeding
In the pressure pipeline, bleeding facilities should be
provided at the highest point and in front of the norv-retum valve.
Auxiliary connections
The positions of the auxiliary connections on the pump
are shown in the installation drawing. All auxiliary
pipelines must be connected in accordance with the
installation drawing, stress-free and sealed.
5.8
Safety and control devices
5.8.1
Manometers
We recommend to provide suitable pressure gauges in
the inlet and pressure pipelines, and in the pressurized
auxiliary pipelines.
5.8.2
Thermometers
Thermometers must be provided to monitor the temperature of the delivery fluid.
5.8.3
Safety devices in the inlet, delivery and auxiliary

pipelines
Safety devices in the form of stop valves must be
Installed in the pipelines, if not already provided, to
allow the pipelines to be shut ofF and disconnected
during maintenance and repair work.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
Refer
6.1...
5.10
Checking the pressure of the system with built-in

pump
If the whole system with built-in pump is to be subjected to a final pressure test, the test pressure must
not be more than the maximum permissible internal
pressure of the pump (see data sheet).
5.7.7.1 Stop valve in the pressure pipeline

A stop valve should be installed in the pressure pipeline.
5.7.8
Electrical connections
The power supply cables of the drive motor must be
connected by a trained electrician, according to the
motor manufacturer's circuit diagram. The valid VDE
regulations, the regulations of the local electricity board
and the operating manual for the motor must be
complied with.
Danger due to electrical power must be excluded and
an EMERGENCY STOP switch in accordance with EN
809 must be provided.
10
Control of drive motor sense of rotation
ALLWEILER
NTT/CTT
6
Start-up/Shutdown
When starting up and shutting down the pump(s),

general and special safety requirements for heat
conducting equipment (e.g. from DIN 4754, VDI
3033, etc.) must be observed as well as the applicable accident prevention regulations (e.g. U W /
VBG 64).
Plant manufacturers and operators are responsible for informing personnel of safety requirements, as well as for the implementation and continued observation of the same.
6.1
Preparations for (initial) start-up
6.1.1
Filling and bleeding the pump in the plant

Prior to starting up, the pump must lê bled In the plant.
For this, the plant and the pump must l3e filled with delivery fluid (see plant manufacturer's operating Instructions).
During filling with delivery fluid, we recommend slowly
rotating the pump shaft by hand to allow air pockets to
escape into the piping system.
If the pump fails to build up pressure when started up
(see manometer), bleeding must be repeated.
6.1.2
'|\
*
Control of drive motor sense of rotation

The sense of rotation of the motor must match the
sense of rotation arrow on the pump. To check the
sense of rotation, the motor can be switched on briefly
when the pump is full.
The pump must not run dry, not even for
ATTENTION checking the sense of rotation.
In the case of pumps with a mechanical seal that is dependent on the sense of rotation, the motor must always be disconnected in order to check the sense of
rotation.
if the sense of rotation is Inconêct, the sense of rotation
of the three phase motor can be reversed by switching
any two phases.
6.2
Start-up
6.2.1
General
Before starting, all filling and venting openings must be
completely closed.
A
6.2.2

Prior to starting and after the first mn-up of the pump to
operating temperature, the coupling alignment and the
fixing of the supporting foot Is to be checked. Readjust,
if necessary (please refer to Section 5.4 above). The
pump shaft must be capable of being cranked by hand
and without any pressure points.
6.2.3
Starting
To avoid overioading the drive motor, the pump should
be run up only against a closed pressure stop valve during starting.
The stop valve in the inlet pipeline must be fully open.
6.2.4
Drive
Switch on the motor.
Refer to the operating instructions of the drive motor
manufacturer
6.2.5
IMinimum rate of flow

Immediately after reaching the operating speed, the
pressure-side stop valve must be opened and the
pump operated up to at least the minimum rate of flow
(see data sheet).
Filling and bleeding the bearing bracket

Due to the sealing effect of the safety stuffing box, the
bearing bracket must be separately filled with heat
transfer oil.
For bleeding and filling, the screw plugs of connections

V and FF are removed and at connectrn FF, clean heat
transfer oil of the same quality as the liquid pumped Is
filled in until same emerges at connection V. In order to
achieve a good flow it may be required to heat up the
heat transfer oil prior to filling.
A
A
6.1.3
The connections must be resealed imperviously after

filling and bleeding.
During bleeding of the pump and the plant, hazardous
or environmentally harmful fluid and gas emerging
must t>e safely collected and discharged.
Note for pumps in high temperature plant:

First, heat the plant to 100 - 130C with the pump mnning. For these purposes, the stop valve on the supply
side must be completely opened. Run the pump and
plant at this temperature until uniformly warmed
through and fully de-aerated. Then heat up to operating temperature slowly.
The plant manufacturers' instructions con-
ATTENTION cerning heating-up of the plant have priority over the above general recommendations.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
ALLWEILER
NTT/CTT
6.2.6
6.2.7
6.4
Setting the pump power output values

The pressure-side stop valve must be opened until the
required pump power output values are obtained (see
data sheet).
Until the operating temperature has been
ATTENTION reached, it may be necessary to run the
pump at a reduced capacity. This will compensate for
the increased power consumption due to high viscosity.
Pumped liquid
May solidify
+
has a preservative effect <3>
+
Temperature
In order to prevent injuries due to bums, at pumping
liquid temperatures higher than 60C protective devices In accordance with EN 809 must be provided on
site.
Spare pump
A spare pump belonging to the plant must always be
kept ready for operation. For these purposes, the stop
valve on the supply side must be completely open. The
stop valve on the outlet side must be opened to such a
degree that the pump, filled and Weeded, has operating
temperature.
In plants in which impermissible tempera-
ing pump, a standby pump of sufficient output must be

provided.
Two independent energy sources must be provided for
the operating and standby pumps.
Shutdown
Pressure pipeline
If a non-return valve is installed in the pressure pipeline, the stop valve can remain open. Without n o n retum valve, the stop valve must be closed.
Drive
Switch off the motor. Make sure the pump runs down
smoothly and evenly.
Inlet line
Close stop valve in inlet line.
It must be ensured that the pump does not run backwards after switching off. Othenwise, the pump may
reach unacceptably high speeds, and shaft seals dependent on the direction of rotation will be severely damaged.
VM 460.0008 GB/07.01 - Idetit-Nr. 550 102
Measures in the event of

prolonged standstill
Hear or drain pump
Drain pump
12
Hear or drain pump
Drain and preserve pump
Does not solidi^

+
has a preservative effect
Does not solidify

+
does not have a presen/ative effect
Drain arxj preserve pump
See section 3.3
ATTENTION ture may arise due to failure of the operat-
6.3
Measures in ttie event of

brief standstill
May solidify
does not have a preservative effect
It must be ensured that the pump housing

AHENTION is evenly heated. Differences in temperature between the top and bottom of the pump, as well as
sudden temperature changes, should be avoided.
Temperature changes in the material of more than
SO'C per minute are not permissible.
6.2.8
Measures in the event of standstills
ALLWEILER
NTT/CTT
7
Maintenance/Repair
7.1
Maintenance
The pump side medium-lubricated rolling bearing is

maintenance-free.
The instructions in Section 2, Safety, must be

observed in maintenance and repair work.
The drive-side rolling bearing is lubricated with special

grease and is filled with grease at the factory.
Regular monitoring and maintenance of the pump

and the drive motor are essential for optimum service life and safety.
7.1.1
General monitoring
Bearing bracket size 360 and 470:

Sealed rolling bearing with guard discs, provided
with a lifetime grease filling at the factory.
Bearing bracket size 530 and 650:

Open rolling bearing with Nilos rings and grease
filled at the factory. These bearings must be regulariy relubricated.
For the relubrication periods, please refer to the following listing.
1. The pump must not run dry.

2. The pump must not run in cavitation.
3. The minimum delivery rate must always be maintained (see Section 6.2..).
Speed
Bearing bracket size
5. The bearing temperature of rolling bearings must

not exceed 120*C.
mirr''
Lubrication period in operating hours
1450
11.400
10.500
6. The shaft seal must have no inadmissible leakage.
1750
10.100
9.300
4. The drive motor must not be overloaded.
530
Notes:
7. The pump unit must not experience or generate any

undue vibrations (e.g. as a result of incorrect alignment). Intemational standard ISO 10816 must be referred to for assessment.
1. At a maximum ambient temperature of 35*0 and

maximum admissible operating temperature, the
temperature at the drive-side rolling bearing is approx. 70'C. Higher ambient temperatures or bad
ventilatton may cause higher temperatures.
8. Changes to the normal operating data may indicate

faults. The causes must be established.
2. In case of temperatures over 70*C, the lubrication

period for 15*0 each temperature rise must be reduced to one half!
9. Installed standby pumps must be started up once a

week.
Note: In addition, the instructions for erection, operation and servicing of heat transfer plants according to
DIN 4754 and VDI 3033 are to be observed.
7.1.2
3. Unfavourable operating and ambient conditions

such as dust, high air humidity, aggressive atmosphere etc. may require even shorter lubrication
periods.
Maintenance of components
Fill with grease
7.1.2.1 Bearing
The nominal service life of the liearing is designed for a
minimum of 2 years continuous operation, in accordance with DIN ISO 281. The actual usable life may be
lower, due to intermittent operation, high temperature,
low viscosity, vibrations or the like.
The running noises and the temperature in the bearing
area must be checked at regular intervals. We recommend monitoring bearings by means of shock pulse
measurements. If damage to a bearing is detected, the
bearing must be replaced.
The bearing area can become very hot
Risk of burning If touched!
Fill hollow spaces between the rolling bodies up to

approx. 40% with grease.
Bearing
bracket size
530
650
Rolling bearing
Abbreviation
6410 J C4
6413 J C4
Grease quantity
in grams
ca. 35
ca. 65
Scrape off excess grease (most suitably with your

fingers; do not use metal objects).
As a precautionary measure, we recommend that

the ball bearings are replaced every 2 years.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
650
13
ALLWEILER
NTT/CTT
Rolling bearing greases:
For the lubrication of the drive-side t)earing, the belov\flisted rolling bearing grease or an equivalent special
grease with the following characteristics must be used.
Quality:
The rolling bearing grease must be free from resin and
acid and anti-con-osive.
Characteristics:
Worked penetration
Dropping point
Range of temperature
application:
250-280 mm/10
>250 ' C
Brand
Klber
ASONIC GHY 72
(3) Manufacturer KLBER LUBRICATION MNCHEN KG

Gelsenhausenerstr. 7
81379 Mnchen
Germany
General
The system operator is responsible for ensuring that instruction in safety is provided. The personnel must be
made aware of all hazards that can arise in connection
with the pumped liquid or the plant.
7.1.2.2 Shaft seal

The built-in mechanical seal is maintenance-free.
A maximum dripping rate of 10 g/h may occur during
operation and is nonnal. If the dripping is heavier, the
shaft seal must be replaced.
Repair
-40 bis 180 ' C
Manufacturer
7.2
A defective shaft seal can cause uncontrolled discharge of pumping liquid.

This constitutes a hazard to people (possibility of
spraying liquid) and to the environment!
At the site, it must be assured by the operator that the
seepages drained through seepage drain LO are safely
and completely collected in a closed tank.
Mounting and repair work

Trained Service fitters are available on request to carry
out mounting and repair wori<.
For all repairs, it must be ensured that the pump is depressurised, completely drained and cool. The motor
must be protected against unintended switching on.
We must refuse acceptance of repair wori< on pumps
filled with fluid, for the protection of our staff and for
environmental reasons. The expenditures for disposal
with respect to the environment are to be cany by the
customer/operating company.
Hazardous substances
Where repairs are to be earned out on pumps which"
have been operated with hazardous substances
and/or
environmentally
harmful
media,
the
customer/operator must inform its own personnel on
site, or our personnel where repairs are retumed to our
factory or a service wori<shop, without being
specifically requested to do so.
Together wrtti the request for a Service fitter a
verification of delivery material, for example in the form
of a DIN safety data sheet, must be submitted to us.
Altematively, you can request a certificate of safety
(form no. 448/191) from our Service department, filling
it out trulhfijily, correctly and in full. Send the completed
form to the center commissioned with carrying out the
repair, or hand it to our Service fitter.
3) Hazardous substances are:
7.1.2.3 Coupling
Following initial start-up, after first heating of the pump
to operating temperature and at regular intervals, the
alignment of the coupling and the condition of the flexible elements in the coupling Is to be checked (please
refer to Section 5.4 above).
Note: Wom flexible elements are to be replaced.
7.1.2.4 Drive
Refer to the operating instructions of the motor
manufacturer.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
14
Toxic substances
Health-endangering substances
Corrosive substances
In'itants
Explosive substances
Fire-inducing substances
Highly flammable, easily flammable and normally
flammable substances
Carcinogenic substances
Substances impairing fertility
Genetically distorting substances
Substances in other ways hazardous to humans
Pumps or units which pump hazardous substances or

substances that are dangerous to Vne environment
must be completely decontaminated.
ALIWEILER
NTT/CTT
7.2.1
Dismounting the centrifugal pump

Before dismounting, the following work must be carried
out:
Electrical danger must be eliminated! The motor

must be secured against being switched on. If
necessary, the power supply cable must be
disconnected from the motor by an authorized
electrician.
Close all stop devices in the inlet and delivery pipeline, and in the auxiliary pipelines.
7.2.2
Mounting the centrifugal pump

Before remounting check all parts for wear
ATTENTION and aging and, as necessary, replace with
original replacement parts.
Clean all parts before mounting. Always fit new
gaskets.
The pump must be mounted by a qualified technician using the pertaining drawings. The prescribed
tightening torque must be observed.
To prevent damage, it is especially important to ensure
that the components are mounted concentrically and
that they are not tilted.
Allow the pump housing to cool to ambient

temperature.
Mounting instructions:
Drain the fluid in flowable condition from the pump.

Note: Use a collecting tank.
The pump must be depressurized and drained.
Hazardous substances and/or environmentally

harmful media must be drained off and collected
such that no danger to life and limb is created.
Environmentally compatible disposal must be
ensured.
The mari<ings applied when dismounting must be

observed. The components must be put back in their
original fitting position.
When assembling, screws and nuts must be painted

with a suitable high-temperature screw paste (e.g.
Molykote P37).
After fitting the insert unit, the pump shaft must lie
exactly flush with the motor shaft.
Remove auxiliary pipelines, if fitted.
After tightening the screws, it must be possible to

turn the pump and drive manually without straining
points.
Dismount manometer lines, manometers and holding devices.

Dismount protection against accidental contact.
7.2.3
The pump must be dismounted by a qualified

technician using the pertaining drawings.
To prevent damage, it is especially important to ensure
that the components are dismounted concentrically
and that they are not tilted.
Note: With poor and lightly greased surfaces, the values must be increased by 10-15%, in order to reach
the required perfonnance.
Part no.
Dismounting instructions:
The pumps are produced as standard in process design. This means that the insert unit can be dismounted without the need to remove the volute
housing and the pipes.
If a coupling with a distance piece is used, the motor
can remain on the base plate during this process.
The fitting position of all components must be accurately marked before dismounting.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
Tightening torque
15
Thread
Quality
Tightening
torque
[Nm]
902.1
920.1
901.01
902.01
920.01
MIO
M12
M16
8.8
GA-T2
35
60
146
901.02
902.02
M12
M16
8.8
GA-T2
60
146
901.03
901.14
M10
8.8
35
901.13
M12
M16
8.8
31
146
903.1
903.2
903.02
903.06
903.07
903.18
903.19
G V4
G 3/8
GV2
St
10
15
30
914.4
914.08
M6
M8
MIO
8.8
9
22
35
922.2
922.01
M20x1,5
M24x1,5
M30x1,5
M 36x1,5
1.7139
112
188
340
700
ALLWEILER
NTT/CTT
Following the mounting the centrifugal pump, the
following operations are to be performed.
7.3
Replacement parts
The application guidelines in accordance with DIN 24
296 can be taken as a basis for spare parts stock holding (see Section 7.3.2).
Align coupling (please refer to Section 5.4 above).

Attach protection against accidental contact and
supporting foot, if any.
However, for reasons of operational safety, we recommend the stocking of complete insert units or spare
pumps.
Advantage: In the event of damage, a defective unit
can be replaced by a spare unit without great expenditure and in a very short space of time.
Attach manometer pipelines, manometer and holding devices to the pump.

Electrical danger must be eliminatedl Power supply
cables must only be connected by qualified
electricians. Pay attention to sense of rotation.
7.3.1
Start up pump as per instructions in Section 6.
Ordering spare/replacement parts

The following details are required for handling orders
for replacement and spare parts:
Pump abbreviation
ffi
Pump n u m b e r
Year of construction
Part n u m b e r
Denomination
Quantity
refer to name plate
7.3.2
Replacement parts for two-year continuous operation as per DIN 24 296
Part No.
Part denomination
Number of identical pumps (including standby pumps)

2
6 und 7
8 und 9
10 und mehr
30%
30%
Set/Replacement parts quantity

171.1/01
Diffuser
(all two-stage pump sizes)
210...
Shaft witti distan washer

distance washer
impeller nut
circiip
circlip
spring
ring
spring washer
key
l<ey
551.1/551.04
551.3/551.05
922.2 / 922.01
932.2 / 932.02
932.7 / 932.07
930.1 / 936.01
930.2 / 934.01
940.1/940.01
940.2/940.02
(
1
30%
30%
Groove ball bearing

Groove ball bearing
1
1
1
1
2
2
2
2
3
3
4
4
50%
50%
Cartridge-unit pump, consisting of:

Bearing bracket, casing cover, shaft,
groove ball bearing etc.
433.1/01
Mechanical seal, complete
90%
461.1/01
Stuffing box packing (set)
40%
Gaskets for pump casing (set)

Other gaskets (set)
12
150%
230.1/01
Impeller
230.2/02
230.3/03
514.1/01
904.5 / 05
Impeller first stage and

Impeller second stage with
Threaded ring and
Hexagon socket with cup point
321.1/01
321.2/02
diverse
(all single-stage pump sizes)
Can be purchased as assembly group/sale group.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
16
ALLWEILER
NTT/CTT
8
Operating Faults, Causes and Remedial Action
8.1
Faults with reference number for cause and remedial action

The table below is intended as a guide to identifying faults and their possible causes.
If faults occur which are not listed here, or which cannot be traced back to the listed causes, we recommend consulting the
factory, or one of our branch offices or sales offices.
The pump must be depressurized and drained when faults are being rectified.
Centrifugal pump faults
Reference numbers for cause and remedial action
Delivery rate too low
1,2,3,4,5,6,7,8,9,21,22
Delivery head too low
2,3,4,5,6,7,8,9,21,22
Power consumption of pump too high
9,11,12,16,17,21,22,25
Delivery pressure too high
9,12
Bearing temperature increased
16,17,18,20,25
Pump housing leaky
23
Heavy leakage of shaft seal
10,13,16,17,27
Pump not operating smoothly
1,2, 3, 4, 5, 6, 8, 11, 16, 17, 24, 25, 26
Pump gets hot
2, 5, 26
8.2
Causes and remedial action
Ref. no.:
Cause
Remedial action
Delivery head higher than nominal delivery head 1. Open stop valve in pressure pipeline until operating point is
of pump.
reached.
2. Install impeller with larger diameter.
3. Increase rotation speed (turtaine, frequenzy control,...).
Pump or pipelines not properly bled or filled.
Bleed and top up pump or pipelines.
Inlet pipeline or impeller blocked.
Clean pipelines and impeller
Air pockets forming in pipeline.
Perhaps install a vent valve, or lay pipeline differently.
NPSHpiant (inlet) too low.
1.
2.
3.
4.
5.
Wrong direction of rotation of pump.
Reverse polarity of any two phases on motor.
Rotation speed too low.
Increase rotation speed (turbine, frequenzy control,...).
Excessive wear on inner pump parts.
Replace worn parts.
Density or viscosity of delivery medium does not Consult the factory in the event of faults due to non-compliance
comply with pump design data.
with design data.
Check fluid level in inlet tank.

Open stop valve in inlet pipeline fiilly.
Lay inlet pipeline differently if friction losses are too high.
Check filter in inlet pipeline, if fitted.
Check inlet flow conditions of pump.
d)
10
Shaft sleeve damaged.
Mount new shaft sleeve.
11
Delivery head lower than nominal delivery head 1. Regulate operating point with stop valve in pressure pipeline.
of pump.
2. Tum off impeller in event of continuous overtoad.
12
Rotation speed too high.
Reduce rotation speed (turbine, frequenzy control,...).
13
Shaft seal damaged.
Check shaft seal parts for wear and replace if necessary.
14
15
16
Pump aggregate wrongly aligned.
Re-align pump as described.
17
Pump twisted.
Check pipelines for twists in connectkins.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
17
(B
ALLWEILER
NTT/CTT
18
Clean relief bore holes in impeller.
Excessive axial thrust.
19
20
Specified coupling half gap not complied with.
Set coupling half gap as per Installation diagram.
21
l\4otor voltage incon-ect.
Use motor with correct voltage.
22
Motor runs only to two phases.
1. Check cable connection.

2. Replace fuses.
23
Screws not tight.
1. Tighten screws.
2. Replace gaskets.
24
Impeller out-of-true.
1. Clean impeller.
2. Re-balance impeller.
25
Groove ball bearing defective.
Replace groove ball bearing.
26
Delivery rate below minimum.
Increase delivery rate to minimum.
27
Pumped liquid corroding mechanical seal mate- Check pumped liquid (e.g.: incon-ect temperature, concentration, dosing of additives, etc.)
rial.
Consult factory
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
18
ALLWEILER
NTT/CTT
Associated Documentation
Sectional drawing NTT
Sizes at bearing bracket size 360 und 470
FF
565.01
903.06 903.07
330.01 321.02 932flt

9W.02
360.02
901.B
901.01 901.03
183fl1 710.01
LO
ViewX
FF Smna
rtw
S^-!
ES.3602
565.02
934.01
902.01
92Q01
901.01 bei Lgtr. 530
52S02
97201
55001
Shaft seal:
Uncooled, unbalanced mechanical seal with safety stuffing box
Abbreviation: USA
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
19
914.08
.01 00.02 509.01 901.02 901J01

Design with intermediate ring
ALlMfEILER
NTT/CTT

Two-stage sizes at bearing bracket size 360
171.01
940.03
210.02
230.02
90405
514.01 230.03
108.01 400.01 161.02
901.01
Shaft seal:
Uncooled, unbalanced mechanical seal with safety stuffing box
Abbreviation: U5A
Oenomination
Volute casing
Stage casing
Casing cover
Casing cover
Diffuser
Supporting foot
Shaft
Shaft
Impeller
Impeller first stage
Impeller second stage
Groove ball bearing
Groove ball bearing
Bearing bracket
Bearing cover
Gasket
Gasket
Gasket
Joint ring
Joint ring
Joint ring
Joint ring
Mechanical seal
Stuffing box packing
Intermediate ring
Threaded ring
Spacer sleeve
Claming sleeve
Washer
Part No.
102.01
108.01
161.01
161.02
171.01
183.01
210.01
210.02
230.01
230.02
230.03
321.01
321.02
330.01
360.02
400.01
400.02
400.03
411.02
411.06
411.07
411.09
433.01
461.01
509.01
514.01
525.02
531.01
550.01
i/M 460.0008 GB/07.01 --Ident-Nr. 550102
Part No.
Denomination
Distance washer
Distance washer
Distance washer
Rivet
Rivet
Pipe
Hexagon screw
Hexagon screw
Hexagon screw
Hexagon screw
Stud bolt
Screw plug
Screw plug
Screw plug
Screw plug
Grub screw
Socket-head cap screw
Nut
Impeller nut
Circlip
CIrclip
Circlip
Spring washer
Spring ring
Key
Key
Key
Name plate
Information plate
20
551.01
551.04
551.05
565.01
565.02
710.01
901.01
901.02
901.03
901.13
902.01
903.02
903.06
903.07
903.09
904.05
914.08
920.01
922.01
932.01
932.02
932.04
934.01
936.01
940.01
940.02
940.03
971.01
972.01
Connections
FD
FF
LO
V
Draining
Filling
Leakage outlet
Bleeding
ALLWEILER
NTT/CTT
Sectional drawing CTT
FF
565.1
903.18
903.19 330.1
321.2
932.2
551.1 I 9W).2
902.1
932.7
321.1
901.13
183.1
730.1
551.3
360.2
LO
Shaft seal:
Uncooled, balanced mechanical seal with safety stuffing box
Abbreviation: U5.1A
ViewX
ViewY
symmetrical feet
930.2
Shaft seal:
Uncooled, balanced mechanical seal

with safety stuffing box
Abbreviation: U5.1A
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
21
ALIWEILER
NTT/CTT

Two-stage sizes at bearing bracket size 360
90^^.5
230.3
171.1
230.2
Shaft seal:
Uncooled, balanced mechanical seal with safety stuffing box
Abbreviation: U5.1A
Denomination
Part No.
Denomination
Part No.
Connections
Volute casing
Stage casing
Casing cover
Diffuser
Supporting foot
Shaft
Impeller
Impeller first stage
Impeller second stage
Groove ball bearing
Groove ball bearing
Bearing bracket
Bearing cover
Gasket
Gasket
Joint ring
Joint ring
Joint ring
Joint ring
Mechanical seal
Stuffing box packing
Threaded ring
Washer
Distance washer
Distance washer
102.1
108.1
161.1
171.1
183.1
210.1
230.1
230.2
230.3
321.1
321.2
330.1
360.2
400.1
400.13
411.1
411.2
411.18
411.19
433.1
461.1
514.1
550.6
551.1
551.3
Distance washer
Spring dowel
Rivet
Rivet
Pipe union
Hexagon screw
Hexagon screw
Stud bolt
Screw plug
Screw plug
Screw plug
Screw plug
Grub screw
Hexagon nut
Impeller nut
Spring ring
Spring washer
Girclip
Circlip
Girclip
Key
Key
Name plate
Information plate
551.4
560.2
565.1
565.2
730.4
901.13
901.14
902.1
903.1
903.2
903.18
903.19
904.5
914.4
920.1
922.2
930.1
930.2
932.2
932.6
932.7
940.1
940.2
970.1
970.2
FD
FF
LO
PM2
V
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
22
Draining
Filling
Leakage outlet
Pressure measurement
Bleeding
ALIWEILER
NTT/CTT
Order-specific Documentation
These operating instructions are supplemented by the following documents:

Acceptance of order
No.
Data sheet
No.
Installation drawing
No.
Sectional drawing
No.
Part list
No.
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
23
ALLWEILER ^
NTT/CTT
Subject to technical alterations.
ALUVEILER
A Member of the
COLFAX PUMP GROUP
ALLWEILER AG Werk Radolfzell
Postfach 1140 78301 RadoHzell
Allweilerstralle 1 78315 Radolell
Germany
Tel. +49 (0)7732 86.0
Fax +49 (0)7732 86-436
E-mail: service@allweiler.de
Internet: http://wvvw.atlweiler.com
VM 460.0008 GB/07.01 - Ident-Nr. 550 102
24
ALLWEILER
Operating and Maintenance Instructions
VM no.:
626.0011 GB
Edition:
12.98
Ident no.:
Screw Pumps
Retain
for future
use!
Series ZAS, ZASV

Order no.:
Pump ident. no.:
Machine no.:
Pump type:
Operating data of pump as per order data sheet

Dimensions as per technical specification VIM 533/..
Contents
1. General
2. Safety
3. Transportation and
Intermediate Storage
4. Description
5. Installation/Mounting
6. Start-up/Shutdown
These Operating and Maintenance

Instructions contain information from
tiie pump manufacturer. Ttiey may need
to be supplemented by instructions of
the operator company for its personnel.
These instructions do not take account
of specific information relating to operation and maintenance of the process
plant into which the pump is integrated.
Such information can only be given by
the persons responsible for construction and planning of the plant (plant
manufacturer).
Such specific instructions relating to
operation and maintenance of the
process plant into which the pump is
integrated have priority over the
instructions of the pump manufacturer.
Refer to the operating instructions of
the plant manufacturer!
7. Maintenance/Repair
8. Operating Faults, Causes and Remedial Action
9. Associated Documentation
550 213
ZAS, ZASV
ALLWEILER
General
1.1
Abbreviation
The abbreviation of the screw pump is set up according
to the following schema, and is engraved on the type
plate.
1.3
Performance data
The exact performance data applicable to the pump
can be taken from the order data sheet and/or
acceptance test report, and are engraved on the name
plate.
The pressure data indicated there apply only to
approximated static pressure load. In the case of
dynamic alternating pressure load, consult the
manufacturer.
1.4
Warranty
Our wananty for shortcomings in the supply is laid
down in our delivery conditions. No liability will be
undertaken for damages caused by non-compliance
with the operating instructions and service conditions.
If at any later date the operating conditions change (e.g.
different fluid conveyed, speed, viscosity, temperature
or supply conditions), it must be checked by us from
case to case and confinned, if necessary, that the pump
is suited for those purposes. Where no special
agreements were made, pumps supplied by us may,
during the warranty period, only be opened or varied by
us or our authorized contract service workshops;
othenA/ise our liability for any defects will cease.
1.5
Testing
Prior to leaving our factory, all pumps are subjected to a
thorough test run and performance test on the test
stand. Only properly operating pumps, achieving the
performance assured by us, leave the factory.
Thus, compliance with the following operating
instructions ensures fault-free operation and full
delivery.
The pump aggregates were subjected to a type
testing according to DIN 4736 and provided with a
registered DIN test mark.
1.6
Availability
As a matter of principle, we recommend stocking
replacement pumps and withdrawable units (hydraulic
action system) where the supplied pumps are a
decisive factor in maintaining a production or delivery
process. In this way downtimes can be avoided, or
reduced to a minimum.
Example:
Series
Z A S 3150 G 8.3 F E - W 2 0
Twin Aggregate
ZAS = horizontal installation
ZASV = vertical Installation
Size
= Delivery (approx.) in [l/h] at
p = 4 bar, v = 12 mm^/s and
f = 50Hz
Special design feature
G = Internal slide bearing
U = Rolling bearing inside.
Shaft seal uncooled/unheated
Shaft seal
8.3 = Mechanical seal
Design with filter
Design with electric
filter-heating
Material code
1.2
Application and installation

The screw pump twin aggregates of series ZAS and
ZASV consist of two three-screw rotating displacement pumps, in flange construction, for lubricating
fluids.
The fluids must contain no abrasive components and
must not chemically attack the materials of the twin
aggregate.
VM 626.0011 GB/12.98- Ident-Nr. 550 213
ZAS, ZASV
2
ALLWEILER
Safety
These operating instructions contain basic safety
instructions
for
installation,
operation
and
maintenance. It Is therefore essential that they are read
by fitters and all specialist staff and customer personnel
prior to installation and start-up. They must always be
kept at hand at the place of installation.
2.3
The special safety instructions contained in the other

chapters must be observed in addition to the general
safety instructions in this chapter.
2.1
Marking of instructions in the operating

instructions
instructions which represent a danger to personnel if
not complied with are specially marked by the general
danger symbol:
A
Warning symbol
Warning of danger
from
electric
voltage is given as
as per
DIN
4844-W9
follows:
A
Warning symbol
as per DIN 4844-W8.
Instructions which are essential to avoid endangering
the machine and its functioning are marked by the word
Dangers in the event of non-compliance with

safety instructions
Failure to comply with the safety instructions may result
in danger to persons, and place the environment and
the machine at risk. Non-compliance with the safety
instructions may lead to the loss of any claims for
damages.
Non-compliance may relate to the following dangers:
Failure of important functions of the plant
Failure of specified methods for maintenance and

servicing
Danger to persons resulting from

mechanical and chemical effects
Danger to the environment resulting from leakage of

hazardous substances
electrical,
2.4
Responsible working practices

instructions, current national accident prevention
regulations, as well as intemal working, operating and
safety rules of the customer, must be observed.
2.5
Safety instructions for the user/operator
Hot or cold parts representing a danger must be

protected against accidental contact on site.
Protection against accidental contact for moving

parts (such as the coupling) must not be removed
while the machine is in operation.
When operating pump aggregates in a dust-laden

environment (e.g. milling, chipboard manufacture,
bakeries), the surfaces of the pumps and motors
must be cleaned at regular intervals, depending on
local conditions, in order to maintain the cooling
effect and eliminate the possibility of spontaneous
combustion. Refer also to explosion protection
regulations (ZH 1/10).
Leakage (e.g. from the shaft seal) of hazardous

substances being handled, such as explosive, toxic
or hot materials, must be discharged such that no
danger to persons or the environment is created.
Legal regulations must be observed.
Dangers from electrical energy must be eliminated.

For details in this regard, refer to VDE and local
power company regulations.
ATTENTION
Instructions affixed directly to the machine such as
Directional markers
Signs for fluid connections
must always be observed and maintained in fully
legible condition at all times.
2.2
Personnel qualification and training

The operating, maintenance, inspection and mounting
personnel must be appropriately qualified for the duties
assigned to them. The scope of their responsibilities,
competency and supervisory duties must be closely
controlled by the customer. If the personnel do not have
the required knowledge, they must be trained and
instructed. If required, this may be provided by the
manufacturer/supplier on behalf of the customer. The
customer must additionally ensure that personnel fully
understand the content of the operating instructions.
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
ZAS, ZASV
2.6
2.7
2.8
Safety instructions for maintenance, inspection

and mounting work
The operator company shall ensure that all
maintenance, inspection and mounting work is
performed by authorized and qualified specialist
personnel who have thoroughly studied the operating
Instructions.
Work on the machine is only to be earned out when the
machine is at a standstill. The means of shutdown of
the machine described in the operating instructions
must always be followed.
Pumps or aggregates handling fluids which are
detrimental to health must be decontaminated. All
safety and protective devices must immediately be
refitted and made operational on completion of the
work.
The instnjctions under Section 6.1, "Preparation for
start-up", must be observed before restarting.
Unauthorized conversion and production of
replacement parts
Conversion or modification of the machines is only
permissible after consultation with the manufacturer.
Original replacement parts and accessories approved
by the manufacturer serve safety purposes. If other
parts are used the manufacturer cannot be held liable
for the consequences.
Impennissible modes of operation
The operating safety of the machine supplied is only
ensured when it is used in accordance with Section 1 of
the operating instructions. The limit values given on the
data sheet must under no circumstances be exceeded.
VM 626.0011 GB/12.98- ident-Nr. 550 213
ALLWEILER
Transportation
Storage
and
Intermediate
3.1
Packaging
Attention must be paid to the markings on the
packaging.
The suction and pressure sides and all auxiliary
connections must always be closed during
transportation and storage. The closing plugs must be
removed when the pump aggregate is installed.
3.2
Transportation
The pump or pump aggregate is to be safely
transported to the place of installation, if required by
means of lifting gear.
The generally applicable safety regulations for

lifting loads must be observed. The crane device
and cables must be adequately dimensioned. The
cables must not be attached to the attachment eyes
of the motor.
During transportation ensure that the
aggregate is secured against toppling
over. The attachment eyes of the motor can be used to
secure it.
AHENTION
Transport damage
Check the pump for damage on receipt.
AHENTION Any damage detected must be notified immediately.
ZAS, ZASV
3.3
Preservation and storage of the screw pumps
3.3.1
Preservation
In the case of storage or prolonged standstill, the
pumps must be protected against corrosion. In those
cases, an outside and inside preservation is to be
provided. The durability of the protection against
corrosion, which is limited In time, depends on the
composition of the preservative to be applied and the
storage conditions.
Under normal circumstances the pumps
AHENTION have no special preservative.
At an additional charge we can, however, supply
pumps and replacement parts ex factory with a preservative adequate to the planned storage period.
ALLWEILER
3.3.1.4 Depreservation
Prior to setting the pump in motion, the preservative
^ \
applied must be removed.
ensured.
The preservative applied for inside preservation can
normally be removed by flushing the pump with the fluid
to be conveyed.
Alternative, suitable solvents may be applied for
removing the inside and outside preservation.
Appropriate solvents are for example: petroleum,
benzene, Diesel fuel, spirit, alkalis (industrial cleaners)
or any other wax solvents. Steam jet cleaning devices
with appropriate admixtures can also be used (allow
wax solvent to act beforehand).
We will be pleased to specify suitable preservatives for

you on request.
Prior to start-up after prolonged storage,
AHENTION all elastomers (0-rings, shaft seals) must
3.3.1.1 Outside preservation

The outside preservative should be applied by painting
or spraying with a spray gun.
be checked for their elasticity of shape. Embrittled

elastomers must be exchanged. Elastomers of
ethylene-propylene aibber (EPDM) must always be
replaced. The pump must be filled with fiuid to prevent
seizing of the components. A pressure-relief valve
attached or fitted in the pipeline must be checked for
passage.
Note: If on the plant side, the pipelines, (oil) tanks or
other parts are wetted with paraffin-containing
preservative, the entire plant must be depreserved as
paraffin is detrimental to the air separating capability of
oil. This may result in unsteady operation of the pump
and loud noise.
All bright and unvamished parts (e.g. shaft ends, couplings, flange facings, valve and manometer connections).
3.3.1.2 Inside preservation
The presen/ative Is to be applied by filling the pump. For
these purposes, the suction side of the pump must first
be closed with a dummy flange. During filling, the
pressure flange must be on a higher level than the
suction flange. During the filling process, the shaft must
be slowly cranked against the direction of rotation.
Filling must be continued until the preservative reaches
the sealing strip of the delivery flange, bubble-free.
Then the outiet side is to be closed with a dummy
flange.
Note: Not required for pumps made of stainless materials.
All bright parts inside the pump (e.g. pump casing inside, screw spindles, ball bearings, pressure-relief
valves).
3.3.1.3 Monitoring of preservation
In Vne event of prolonged storage, the preservation of
the pump must be checked by the customer at regular
intervals.
Every six months the pump level must be checked; if
necessary, preservative must be topped up to the
sealing strip on the pressure flange.
At the same time, the packing must be checked for
destnjction, and repaired if necessary.
Note: Liability for damages caused by improper
preservation cannot be assumed by us.
VM 626.0011 GB/12.98- Ident-Nr. 550 213
3.3.2
Storage
During storage of the pump, the suction and outiet
branches and all other supply and discharge branches
must always be closed with dummy fianges or dummy
plugs.
Storage should be in a dry, dust-ft-ee room. During
storage, Vne pump should be cranked at least once a
month. During this process, parts such as the shaft and
bearings should change their position.
ZAS, ZASV
ALLWEILER
Description
4.1
Structural design of the pumps

Three-screw pumps in flange design form, with a
double-threaded
driving
spindle
and
two
double-threaded idler spindles, enclosed in a housing
insert with narrow running clearance.
The delivery elements are installed in a pump housing
which is closed off on the drive side and the end side by
pump caps.
4.1.1
Bearing and lubrication

Sizes 150 to 3150:
By an intemal medium-lubricated slide bearing.
Mode of operation of the screw pumps

Through the suction connection and the suction
chamber in the reversing valve casing, the fluid is
conveyed into the suction chamber of the pump. From
there the fluid flows into the spindle chambers, which
are constantly formed by the rotary motion at the
spindle end on the suction side. By the translatory
rotary motion, the chambers filled with the fluid move
from the suction side to the outlet side. During this
process the closed chamber volume does not change.
At the spindle end on the outlet side the chamber opens
towards the delivery chamber. The fluid is steadily
pushed out into the delivery chamber from where it is
transported, through the delivery chamber of the
reversing valve casing and the pressure connection,
into the pressure pipeline.
The axial thrust acting on the faces of the profile flanks
on the ouflet side is hydraulically balanced by an
appropriate dimensioning of the compensating piston
of the driving spindle. Thus the bearing is relieved of
the hydraulic axial thrust. The axial thrust of the two
idler spindles is hydrodynamically absorbed by the
pump cover, non-drive side or by the filter casing.
The idler spindles are hydraulically driven by means of
appropriate dimensioning of the spindles. Only the
torque resulting from the fluid friction is transmitted via
the profile flanks. They are therefore practically
stress-ft-ee, and not subject to any wear.
As a result of the constant chamber volume the medium
inside the pump is transported, almost entirely free of
turbulence and squeezing, from the suction side to the
outlet side.
The compartment for the shaft seal is connected to the
pump suction chamber
The structural design and mode of operation of the
screw pump ensure a very low noise level and an
almost pulsation-free delivery.
4.3
Structural design of the twin aggregate

Twin aggregate of the compact type of construction,
with two screw pumps connected with one another by
means of a reversing valve casing.
4.3.1
Drive
A specific driving motor (serial standard motor) is firmly
assigned to each pump size.
Normally surface-cooled three-phase squirrel cage
induction motors are used as driving motors, type IIVl
V1, class of protection IP 54 to IEC standard, class B
insulation, outputs and speeds to DIN 42 677.
By an intemal medium-lubricated groove ball bearing to

DIN 625.
Sizes 3600 to 6450:
4.1.2
4.2
Shaft seal, design 8.3

Uncooled, maintenance-free mechanical seal of the
unbalanced type.
Materials of the mechanical seal:
Rotating seal ring: Tungsten carbide
Stationary seal ring: Tungsten carbide
Auxiliary gaskets:
Viton
Spring:
CrNIMo steel
Metal parts:
CrNilVIo steel
4.1.3
Flanges/connections
Flanges
Suction and outlet side with flange connections.
Counter flanges PN16, DIN 2633 with screws and
gasl<ets are included in the scope of supply.
Connections
ZAS without filter
M1, M2 Manometer
ZAS with filter:

B7
Draining filter casing
E7
Venting filter casing
M 1 , M2, M3 Manometer
ZASV without Filter:

B8
Venting
M1,M2 Manometer
ZASV with Filter

B8
Venting
E7
Draining filter casing
M 1 , M2, M3 Manometer
4.1.4
Pressure-relief valve
As an overload protection, a pressure relief-valve is installed in each pump which is serially set to a response
pressure of 7 bar
4.1.5
Filter
To protect against coarse dirt contamination, the
pumps can be fitted with a built-on star-shaped
strainer filter, mesh width 0.4 mm.
A mano-vacuummeter supplied with the filter indicates
the pressure downstream of the filter. This gives an indication of the pressure loss in the filter, and so prevents possible dirt contamination.
4.1.6
The exact motor data are to be found in the technical

specification VM 564/... or in the order data sheet.
4.3.2
Electric heating
In design versions with filters, heating shells can be
used for filter heating.
A
VM 626.0011 GB/12.98- Ident-Nr. 550 213
Shaft coupling and contact protection

Power transmission is effected via a flexible coupling.
Additional radial forces must not act on the driving
spindle.
Drive by means of belt or gear wheel is not
ATTENTION admissible.
The pump lanterns serve as contact protection as per
OIN 24 295.
According to accident prevention regulations, the
pump must only be operated with a protection
against accidental contact as per DIN 24 295.
ZAS, ZASV
If no contact protection is provided, it must be attached
by the operator
4.3.3
Pump brackets
The flange pumps are joined to the drive motor by pump
brackets (lanterns) as standard.
4.3.4
Non-return valves/stop valves

For each pump, a non-return valve and a stop valve are
provided in the reversing valve casing. The non-return
valves operate automatically and are lockable by hand.
4.3.5
Operating control device
ALLWEILER
Switching diagram
Series ZAS/ZASV without filter
Manometers:
ZAS/ZASV without filter
Outlet side: one manometer (Included In the scope
of supply). If a mano-vaccummeter is
requested on the suction side, same
must be provided at the site. Bore hole of
the screw plug (227) is provided for connection.
ZAS/ZASV with filter
Suction side: two mano-vakuummeters
Outlet side: one manometer
(each included In the scope of supply).
Reversing unit:
If a reversing unit was supplied for operation control, its
circuitry is such that in case of failure of the operating
pump, the spare pump is automatically switched on.
Signal lamps denote the respective operating conditions.
1
2
3
5
7
Operating and spare pump

Three-phase motor (901)
Stop valve (355)
Lockable non-retum valve (356)
Manometer with ball valve (360) and (363)
Switching diagram
Series ZAS/ZASV with filter
Reversing unit UZ1: For motor performance up to 3kW

(380V) across-the-line starting.
For the scope of supply of the reversing unit, refer to our
Brochure VM 564/...
4.3.6
Oil drip pan

ZAS: with loose oil drip pan.
ZASV: with finnly attached oil drip pan.
4.4
Mode of operation of the screw pump twin aggregate

Both screw pumps are jointly attached to the reversing
valve casing (301). While one pump Is in operation, the
spare pump is at standstill.
The pumps can be actuated alternately by hand or
automatically by means of a reversing unit (UZ1). By
means of two separate connecting chambers in the reversing valve casing (301), the respective two suction
flanges and the two pressure flanges of the two pumps
are connected with one another. Uninterrupted delivery
during the reversing process is thus ensured.
During operation, the two lockable non-retum valves
(356) and the two stop valves (355) must be opened so
that reversal is optionally possible from one pump to the
other. The respective connected pump draws the fluid
through the suction chamber of the reversing valve
casing (301).
The operating pressure built up In the delivery chamber
of the pump opens the non-retum valve (356) of the operating pump and, through the pressure In the delivery
chamber of the reversing valve casing (301), closes the
non-retum valve (356) of the non-operating pump.
This prevents the spare pump from mnning in reverse
motion.
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
1 Operating and spare pump

2 Three-phase motor (901)
3 Stop valve (355)
4 Filter (481)
5 Lockable non-retum valve (356)
6 Mano-vacuummeter with ball valve (361) and (362)
7 Manometer with ball valve (360) and (363)
ZAS, ZASV
ALLWEILER
Installation/Mounting
5.1
Installation
ZAS aggregates can be installed horizontally or vertically.
ZASV aggregates must be Installed vertically.
For safety reasons the "downward-facing motor"

arrangement is not permitted.
5.2
Mode of fastening
The mode of fastening Is dependent on the local
Installation conditions.
2J^S aggregates are fastened by means of foot angles
at the place of installation.
For ZASV aggregates, the firmly fixed oil drip pan
serves as fastening base.
Push on the coupling halves on the pump and motor

side with the aid of a pusher device until the shaft
end is flush to the coupling hub.
The possibility of axial shock stress on
ATTENTION the pump and drive motor components
during assembly of the coupling must be eliminated.
3. The coupling does not need to be re-allgned.
4. Flange the pumps and motors onto the lantems.
5.6
Space required for maintenance and repair

The pump aggregate must be accessible
AHENTION from all sides In order to be able to carry out
necessary visual inspections.
Adequate space must be provided for maintenance
and repair work, in particular for removal of the drive
motors or of the complete pump aggregate. It must also
be ensured that all pipelines can be attached and
removed without hindrance.
5.7
Laying the pipelines
5.7.1
Nominal widths
If possible, the nominal widths of the suction and
pressure pipelines should be rated so that the rate of
flow does not exceed a maximum of 1 m/s In the suction
pipeline and 3 m/s In the pressure pipeline.
Note: The nominal width of the inlet and delivery pipeline should be the same or greater than the nominal
pump width. On the suction side, the nominal width
must never be less than the nominal pump width, as
otherwise difficulties will be encountered during suction.
5.7.2
Change of cross-sections and directions

Sudden changes of cross-sections and directions, as
well as hairpin bends, are to be avoided.
5.7.3
Supports and flange connections

The pipelines must be connected to the pump,
stress-free. They must be supported close to the pump
and must allow easy screwing-on to avoid twisting.
When the connections are loosened the pipeline must
neither be slanted nor springing, nor must it be under
pressure.
Any thermal stresses occumng on the pipelines must
be kept away from the pump by suitable means, e.g.
Installing compensators.
5.7.4
Cleaning pipelines prior to attachment

Prior to assembly, all pipeline parts and valves must be
thoroughly cleaned; especially in the case of welded
pipelines, burrs and welding beads must be removed.
Flange gaskets must not protrude Inwards. Blanking
flanges, plugs, protective film and/or protective paint on
flanges and seals must be removed completely.
Water residues, still In the pipeline network from
pressing-out or steeping for example, must be
removed.
Delivery of water destroys the pump. The pump relies
on the fluid being conveyed for Its lubrication.
Precise details on form and dimensions are given in the

Installation diagram.
5.3
Foundation
5.3.1
Design
The foundation may be concrete or a load-bearing
foundation frame, of steel for example.
The condition for all foundation designs is:
The foundation must be designed so that it can take the
weight of the pump aggregate across Its entire area.
5.3.2
Characteristics of a steel foundation frame

A steel foundation frame must be designed so that the
foot angle or the oil drip pan can be bolted or welded on.
5.3.3
Characteristics of a concrete foundation

The set concrete foundation must be horizontal, flat
and clean. Smears on the foundation must be removed.
The cut-out anchoring holes for the foundation bolts
must be cleaned and blown out with air
5.4
5.5

In the case of pumps with flanged drive motor, the pump
and motor are precisely centered in the lantern.
Alignment or re-alignment of the coupling is not
required.
Note: Improper handling, e.g. during transportation,
may impair the alignment between the pump and the
motor In this case the motor must be removed from the
lantern. The true mnnlng accuracy and axial run-out of
the shaft ends to the center diameters and end faces of
the lantern must be determined by means of a dial
gauge with retaining bracket and clamp. If a value of
more than 0.05 mm is recorded, the pump and/or the
motor must be returned to the factory for checking.
Assembly of pump and drive motor
If the aggregate is only assembled at the place of use,
the coupling Is assembled as follows:
1. Coat the pump and motor shaft ends with a fine film
of molybdenum disulfide (e.g. Molykote) and Insert
keys.
VM 626.0011 GB/12.98- Ident-Nr. 550 213
ZAS, ZASV
5.7.5
ALLWEILER
Non-return valves/stop valves

In the reversing valve casing, a non-return valve and a
stop valve are provided for each pump.
Note: When the non-return valve and stop valve of the
stopped pump are closed the associated filter can be
cleaned, even If the pump Is under Inlet pressure.
5.7.6
Pressure-relief valve
See Section 4.1 ...
5.9.1
5.7.7
Bleeding
The pumps can be bled on the suction side by means of
the screw plugs (227) on the pump casing (1). In addition, a vent valve must be provided at the highest point
in the pressure pipeline.
Note: In the case of horizontal pump installation and
where the connecting flanges are turned to the side, the
filling and vent holes and the connections for the pressure gauges must point upwards.
5.7.8
Filtering
To protect the pump against coarse dirt contamination,
we recommend as a matter of principle installing a filter
in the suction pipeline, mesh width 0.4 mm.
Note: The service life of the pump is decisively
influenced by the degree of dirt contamination of the
fluid being conveyed, that is, by the number, size and
hardness of the abrasive components.
Note: A filter to DIN 4736 must be Installed in oil supply
systems for oil bumers.
5.8
Safety and control devices
5.8.1
Manometers
Dependent on the plant-side operating states, appropriate suction and delivery side pressure gauges
must be provided. There are connection facilities in the
suction and delivery flange of the pump casing. See
brochure VM 564/...
Standard delivery:
Design without filter: One manometer on the delivery
side, measuring point l\/12.
Note: If, in the version without filter, a mano-vacuummeter is required on the suction side, it must be provided by the customer. Measuring point M1 is provided
for connection.
Design with filter: One manometer on the delivery side,
measuring point M2. Two mano-vacuummeters on the
suction side on the filter, measuring point M3, for measurement of the pressure downstream of the filter. This
can be used to prevent filter contamination.
Note: Ball cocks in front of measuring instruments may
only be opened to monitor pressure.
5.8.2
Control, safety and display devices

A pressure-relief valve is installed in each pump (see
Section 4.1...).
Other control, safety and display devices,
AHENTION as required for oil supply systems in accordance with DIN 4736, are not supplied with the pump
aggregate as standard. They can be acquired from us
as accessories, but must in all cases be installed by the
operator.
VM 626.0011 GB/12.98 - Ident-Nr 550 213
5.9
Electrical connections
The power cables of the coupled drive motors, any
fitted filter heating and/or switchgear must be connected by a qualified electrician. The applicable VDE
specifications and the regulations of the local power
supply company must be observed.
Avoid all danger from electrical energy
Motor connection
Standard three-phase motors can be used for the following circuit configurations:
Terminal connection diagram:
^v2 (^"*
(^'"
^b ^b v i ( ^ ^
LI
LZ
-Û2
-0U1 -Avi
.^va
.Awi
L3
A-circult
5.9.2
^ w i
Y-clrcult
Electric filter heating

The heating shells of the electric filter heating system
should be connected to a voltage of 220 V according to
the following diagram.
Connection diagram
r'
L.
"~]
IK
J SL
220V~
R
Mp
Degree of protection IP 44
ZAS, ZASV
ALLWEILER
Sta rt-u p/s h utdo wn

6.1
Preparation for start-up
6.1.1
Filling the pumps with fluid

Prior to initial operation, the two pumps
AHENTION must be filled with fluid and bled. This at the
same time provides the spindles with the sealing required for suction.
The pump must not run dry.
Before filling, the operator must ensure
AHENTION careful and thorough rinsing of the pump if
the fluid to be conveyed is not chemically compatible
with the test medium (see performance test report).
The fluid should be Introduced via the delivery pipeline
or the connections on the pump or filter casing, until it
emerges free of air bubbles.
During bleeding of the pump and the plant, hazardous

or environmentally harmful fluid and gas emerging
must be safely collected and discharged.
6.1.2
Heating the delivery fluid

When conveying heavy heating oils or other delivery
media which solidify when cooled, heating must be provided in the plant (e.g. pipe steam trace).
The delivery fluid must be flowable and pumpable when
the pump is started up, in order to prevent damage to
the pump.
Heavy heating oil, for example, must be heated to at
least 10C above the solidification point before starting
the pump.
The pumps can be fitted with built-on filters. Heating
shells are used for filter heating (on customer request).
The heating power of the shells is rated such that, at an
initial temperature of 20C a minimum heat-up time of
120 minutes is necessary. A correspondingly longer
heat-up time should be expected at lower temperatures (below 0C). The heating system is not suitable
for attaining a significant temperature increase of the
delivery medium during operation. The heating shells
should be connected to 220 V (parallel circuit, no in-series connection).
6.1.3
Control of drive motor direction of rotation

The direction of rotation of the motor must match the
direction of rotation arrow on the pump. The motor can
be briefly switched on with the suction and pressure
valves open to check the direction of rotation. If the
direction of rotation is wrong there is no pump suction.
This damages the pump. The direction of rotation of the
three-phase motor can be reversed by swapping any
two phases.
If the direction of rotation is to be checked
AnENTION before the pump is filled with fluid, the drive
motor must be disconnected from the pump. The pump
must not run dry.
6.2
Start-up
6.2.1
Starting
The opening pressure can be changed within narrow limits using an adjusting screw. The pressurerelief valve must not be used to regulate the flow.
3. During starting, a vent valve Installed on the outlet
side of the plant must be opened until the air has escaped from the suction side of the pump. As soon as
fluid emerges the vent valve can be closed. The
pump is self-priming and is automatically vented
without counter-pressure.
Drive
Switch on the motor.
Pay attention to product-specific characteristics. Refer
to the operating Instructions of the drive motor
manufacturer
6.2.3
Checking the delivery values

When the motor has reached its operating speed, the
Inlet pressure and ouflet pressure of the pump must be
checked using manometers.
The motor must not be overioaded. The current consumption can be checked with an ammeter. In this connection, the temperature and viscosity of the fluid must
also be checked. The readings must be checked
against the layout or acceptance test report.
Note: Pressure gauges are normally equipped with
stop valves. The stop valves may be openend only during start-up for pressure control purposes. During permanent operation, same must be kept closed.
If there should be an inadmissible Increase
AHENTION In pressure, intemal pressure-relief
valves may shift the media from the discharge to the intake side (recirculation).
Recirculation leads to heating up of the medium. An inadmissible pressure and temperature inaease can be
indicated by a pressure gauge and a thennometer. Detennine the cause immediately and eliminate it in order
to avoid damage to the pump as the result of excessive
heating up and the related drop In viscosity.
6.3
Shutdown
6.3.1
Stopping and interrupting operation

1. Switch off the motor of the operating pump. Make
sure the pump runs down smoothly and evenly
2. The non-retum valves and stop valves in the reversing valve casing remain open.
6.3.2
1. Prior to starting the operating pump, the two stop

valves on the suction side and the two lockable nonretum valves on the outlet side of the revereslng
valve casing, and gate valves, If any, must be
opened In the plant.
2. The pumps are fitted with a pressure-relief valve,

which is set as standard to a response pressure of 7
bar.
VM 626.0011 GB/12.98- Ident-Nr. 550 213
6.2.2
10
Measures in case of prolonged interruption

If a prolonged interruption is intended, the pump must
be drained thoroughly via the connections on the pump
or filter casing.
If the adjusting screw (333) of the built-in
AHENTION pressure-relief valve is to be used to drain
the pump, the reach of the screw should be recorded
beforehand using a depth gauge. The screw must be
screwed back in precisely to this depth, so that the response pressure of the pressure-relief valve is not
changed.
Safe draining and environmentally compatible disposal
of the fluid must be ensured.
Preservative should then be applied to the pump (see
Section 3.3).
ZAS, ZASV
ALLWEILER
Maintenance/Repair
7.1
Maintenance
The instructions in Section 2, Safety, must be
observed in maintenance and repair work.
Regular monitoring and maintenance of the pump

and drive motor increases their service life.
The following instructions are generally applicable.

7.1.1
General monitoring
1. The pumps must not run dry.
2. The drive motors must not be overloaded.
3. The suction and pressure pipelines must be
checked for leaks. Air must be prevented from
entering the delivery system.
4. There must be no serious leakage from the
mechanical seals.
5. Pressure and temperature monitors must be
observed.
7.1.2
IMaintenance of components
7.1.2.1 Bearing and lubrication

Sizes 150 to 3150
In the case of sizes 150 to 3150, the bearing of the driving spindle is provided by a maintenance-free medium-lubricated slide bearing.
The sen/ice life of the slide bearing is designed to
match the service life of the pump under normal operating conditions, and is dependent on the degree of dirt
contamination of the delivery medium.
7.1.2.3 Pressure-relief valve

Pressure-relief valves must be checked from time to
time, in particular after prolonged downtimes, for
passage and functioning. Leaking pressure-relief
valves may cause damage to the pump. Damaged
parts should be replaced or repaired as necessary.
The pressure-relief valves are set as standard ex
works to an opening pressure of 7 bar. If the opening
pressure is to be changed, the screw plug (222) in the
end-side pump cover (4) or in the filter casing (9) must
first be removed. The adjusting screw (333) is then accessible.
Turning the screw clockwise increases the opening
pressure, turning anti-clockwise reduces it. Any adjustment must be made only with an intact pressure
gauge.
7.1.2.4 Filter
The filters fitted to screw pumps must be cleaned at
regular intervals.
The filter casings (9) are fitted with a mano-vacuummeter (361) which indicates the pressure downstream
of the filter (481). The pressure loss gives an indication
of the degree of dirt contamination of the filters. For precise recording of the differential pressure, we recommend installing a pressure gauge upstream of the filter
on the suction flange of the pumps, or in the suction
pipeline. In the event of a detectable differential pressure, the filter (481) must be cleaned, or replaced as
necessary.
Filter cleaning
Filter cleaning involves removing the filter (481) from
the filter casing (9), cleaning it and rinsing out the dirt
particles encrusted on the filter casing bottom.
Stop the operating pump and switch to the standby
pump.
Sizes 3600 to 6450

In the case of sizes 3600 to 6450, the bearing of the
driving spindle is provided by a maintenance-free medium-lubricated groove ball bearing.
The groove ball bearing of the screw pumps is designed for a service life of approx. 24,000 hours under
normal operating conditions.
The actual service life may be reduced due to
intermittent operation, high temperature, low viscosity,
pooriy lubricating fluids and the like. We therefore
recommend checking the ainning noises and
temperature in the bearing area at regular intervals,
if scraping or rattling noises are heard compared to the
normal humming, or if excessive temperature rises are
detected, this indicates impending bearing damage,
and the groove ball bearing should be replaced as soon
as possible.
7.1.2.2 Shaft seal, design 8.3
The built-in shaft seal is maintenance-free. Minimal
dripping of non-volatile media, such as oils, resulting
from the functioning of the components is to be
expected. In the event of heavy leakage due to wear,
the mechanical seal should be replaced.
Since the mechanical seal must not be
ATTENTION allowed to run dry, the pump must only be
started up when charged and bled.
VM 626.0011 GB/12.98- ident-Nr. 550 213
Close the non-return valve and stop valve of the

stopped pump.
Allow the pump and delivery fluid to cool to ambient
temperature.
After loosening the hexagon screws (207), remove
the (filter) casing cover (7) and take the filter (481)
from the filter casing (9).
Drain the filter casing (9) by way of the screw plug

(235).

hannful media must be drained off and collected
such that no danger to life and limb is created. Environmentally compatible disposal must be ensured.
Place the filter in a vessel containing cleaning fluid to

clean it and remove encrusted matter
Health-endangering cleaning agents must only be
used in compliance with DIN safety data sheets.
Note: The filter must only be immersed in the fluid up
to the rim, as otherwise the loosened dirt will attach
to the clean side.
ZAS, ZASV
ALLWEILER
7.2
After allowing the filter to drip off from the clean side
to the dirty side (from the inner to the outer, not vice
versa!), blow it out with compressed air.
Note: Suitable cleaning agents are benzene, spirit,
diesel fuel or a solvent-free cold cleaning agent.
The use of other special cleaning agents Is possible.
The concentration depends on the nature and severity of the dirt.
A soft brush can be used to clean the filter. Sharp implements must not be used.
In the case of excessive dirt contamination we recommend replacing the filter (481).
After cleaning, the filter (481) is loosely slotted onto

the pipe (30) in the filter casing bottom. The filter
cover (7) is re-attached to the filter casing (9).
Note: The O-ring (119) must be in its groove and
must not be damaged. Replace it as necessary. The
(filter) casing cover (7) must close air-tight, to prevent the pump from taking in air.
Re-open the non-return valve and stop vatve of the

stopped pump. Fill and bleed the pump as per Section 6.
Note: When retrofitting a filter to a pump, it is essential

that the pipe (29) is installed first.
7.1.2.5 Coupling
The condition of the flexible elements in the coupling
should be checked after initial start-up and at regular
intervals.
Note: Worn flexible elements must be replaced.
Repair (Dismounting and IVIounting Instructions)

General
Trained Service fitters are available on request to cany
out mounting and repair work.
Where repairs are carried out by the operator's own
personnel or by specialist fitters, it must be ensured that
the pump is fully drained and cleaned.
This particulariy applies to pumps which are sent for
repair to our factory or one of our service workshops.
We must refuse acceptance of repair work on pumps
filled with fluid, for the protection of our staff and for
environmental reasons. Otherwise we must invoice the
customer/operator for the costs of environmentally
compatible disposal.
Where repairs are to be carried out on pumps which
have been operated with hazardous substances (D
and/or
environmentally
harmful
media,
the
customer/operator must inform its own personnel on
site, or our personnel where repairs are retumed to our
factory or a service workshop, without being
specifically requested to do so.
In such cases a verification of delivery material, for
example in the form of a DIN safety data sheet, must be
submitted to us together with the request for a Service
fitter.
Altematively, you can request a certificate of safety
(form no. 448/191) from our Service department, filling
it out truthfully, correctly and in full. Send the completed
forni to the center commissioned with carrying out the
repair, or hand it to our Service fitter.
Hazardous substances are:
7.1.2.6 Drive
Toxic substances
Health-endangering substances
Corrosive substances
In-itants
Explosive substances
Fire-inducing substances
Highly flammable, easily flammable and normally
flammable substances
Carcinogenic substances
Substances impairing fertility
Genetically distorting substances
Substances in other ways hazardous to humans
Refer to the operating instructions of the motor

manufacturer.
For all wori< on site, the operator's own personnel

and/or our fitters must be advised of the possible
dangers involved in the repair work.
The most important dismounting and mounting
operations are described in these instructions. The
mounting steps described in the individual sections
must be consistently observed.
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
12
ZAS, ZASV
7.2.1
ALLWEILER
Dismounting the screw pump

Before dismounting, the following work must be carried
out:
Switch on the standby pump and stop the operating
pump. Close the non-retum valve and stop valve of
the pump to be dismounted. Service is maintained
by the standby pump.
Mal<e sure the power cable is disconnected from the

pump motor by a qualified electrician. Electrical
danger must be eliminated! The motor must be secured against being switched on.
Use an implement to dismount mechanical seal

counter-ring (186) and O-ring from pump cover (3).
Note: Special care should be taken to ensure that
the mechanical seal counter-ring is pushed out concentrically over the shaft and not canted, to avoid
damaging the counter-ring.
Remove rotating part of mechanical seal (186) over

driving spindle (12).
Remove support washer (263) from driving spindle

(12).
7.2.1.3 Dismounting the spindle set, slide bearing and

casing insert from sizes 150 to 3150
Drain the fluid In flowable condition from the pump.

After removing shaft seal, detach spindle set with

bush (10) from casing insert (2).
Dismount idler spindles (13) from driving spindle

(12).
Remove bush (10) from driving spindle (12).
Unscrew socket-head cap screws (201) from endside pump cover (4) or filter casing (9).
Remove end-side pump cover (4) or filter cover (9)

from pump casing (1).
Remove gasket (100) and cleaning sealing faces.
Unscrew socket-head cap screw (24) from side of

pump casing (1).
Note: This socket-head cap screw fixes the casing
insert (2) in position.
Mark positions of casing insert (2) and pump casing

(1) to each other.
Detach pump from centering ring of lantern (460)

and remove from reversing valve casing (301).
Press casing insert (2) out of pump casing (1) from

pump-end side using a suitable tool. In case of
pumps with filter, first remove pipe (29) from pump
casing (1).
Remove gasket (125) and (126) and clean sealing

faces.
7.2.1.4 Dismounting the mechanical seal and spindle set

from sizes 3600 to 6450
7.2.1.2 Dismounting the mechanical seal from sizes 150 to

3150
Detach pump-side coupling half from shaft end (12).

Use puller device!
,.
*\

harmful media must be drained off and collected
such that no danger to life and limb is created.
ensured.
The pump must be depressurized and drained.
Allow the pump and motor to cool to ambient
temperature.
Remove the manometer cables, manometers and
retaining brackets.
7.2.1.1 Dismounting a screw pump from the twin

aggregate
Unscrew socket-head cap screws (215) from lantem (460).
Unscrew hexagon nuts (236) and (238) from suction
and delivery flange. Remove socket-head cap
screws (206) and (208).
Detach pump-side coupling half from shaft end (12).

Use puller device!
Remove key (290) from driving spindle (12).
Remove key (290) from driving spindle (12).
Unscrew socket-head cap screws (200) from driveside pump cover (3).
Unscrew socket-head cap screws (200) from driveside pump cover (3).
Remove O-rings (120) and (122) and clean sealing

faces.
Remove drive-side pump cover (3) with mechanical

seal counter-ring from pump casing (1) over driving
spindle (12).
Remove drive-side pump cover (3) with spindle set,

mechanical seal (186) and groove ball bearing from
pump casing (1).
Remove O-rings (120) and (122) and clean sealing

faces.
Dismount idler spindles (13) from driving spindle

(12).
Remove circlip (250) from drive-side pump cover

(3).
Remove circlip (250) from drive-side pump cover

(3).
VM 626.0011 GB/12.98-ldent-Nr. 550 213
13
ZAS, ZASV
ALLWEILER
7.2.2
Press driving spindle (12) with groove ball bearing

(292), support washer (263), spacer bush (20) and
mechanical seal (186) out of drive-side pump cover
(3) using a suitable tool.
Remove mechanical seal (186) from driving spindle
(12).
Mounting the screw pump

Before remounting check all parts for wear
ATTENTION and, as necessary, replace with original
replacement parts.
Clean all parts before mounting. Always fit new
gaskets.
7.2.2.1 Mounting the casing insert, slide bearing and

spindle set to sizes 150 to 3150
Unscrew socl<et-head cap screws (201) from e n d side pump cover (4) or filter casing (9).
Lightly oil the fitting faces on the casing insert (2).

Press casing insert (2) into pump casing (1) from
drive side using a suitable tool.
Note: Pay attention to marking made prior to dismounting !
Drill together pump casing (1) with casing insert (2)

by way of bore hole on side for socket-head cap
screw (24).
Bore diameter: 4 mm
Bore depth: 6 mm
Screw socket-head cap screw (24) with sealing

washer (151) Into side of pump casing (1) and tighten.
Push bush (10) over driving spindle (12) up to collar.
Lightly oil driving spindle (12) and press into pump

casing (1) from drive side together with bush (10).
Note: This guides the driving spindle concentrically
through the bush in the pump casing.
After removing shaft seal and spindle set, dismount

spacer bush (20) and circllp (251) from driving
spindle (12).
Screw Idler spindles (13) into casing insert (2) from

pump-end side.
In case of pumps with filter, push pipe (29) over casing insert (2).
Place new gasket (100) on cleaned sealing face of

pump casing (1).
Remove end-side pump cover (4) or filter cover (9)

from pump casing (1).
Remove gasket (100) and cleaning sealing faces.
Unscrew socket-head cap screw (24) from side of
pump casing (1).
Note: This socket-head cap screw fixes the casing
Insert (2) in position.
Mark positions of casing insert (2) and pump casing
(1)to each other.
Press casing insert (2) out of pump casing (1) from

pump-end side using a suitable tool. In case of
pumps with filter, first remove pipe (29) from pump
casing (1).
7.2.1.5 Dismounting the groove ball bearing from sizes

3600 to 6450
Detach groove ball bearing (292) fi-om driving

spindle (12). Use puller device!
Clean bearing seats.
Attach end-side pump cover (4) or filter casing (9) to

pump casing (1) with socket-head cap screws^
(201).
7.2.2.2 Mounting the mechanical seal to sizes 150 to 3150
Mechanical seals are high-grade precision parts.
Careful handling and extreme cleanliness during installation are essential to ensure proper functioning. A suitable lubricant can be used to aid mounting (e.g. oil, not
grease).
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
14
Push support washer (263) over driving spindle

(12).
Push rotating part of mechanical seal (186) over

driving spindle (12) up to support washer (263).
Push mechanical seal counter-ring (186) with new

0-rlng concentrically into cleaned pump cover (3).
Use a suitable implement.
the mechanical seal counter-ring is pressed concentrically into the pump cover and not canted, to
avoid damaging the counter-ring.
Insert new 0-ring (122) into pump casing (1) In froni

of return bore hole
ZAS, ZASV
ALLWEILER
Attach pump cover (3) with new O-ring (120) and

built-in mechanical seal counter-ring (186) to pump
casing (1) with socket-head cap screws (200).
centrically into the pump cover and not canted, to

avoid damaging the counter-ring.
Mount circlip (250) in front of mechanical seal counter-ring (186) in drive-side pump cover (3).
Insert key (290) into driving spindle (12).
Insert new 0-ring (122) into pump casing (1) in front

of return bore hole.
Push pump-side coupling half onto driving spindle

(12).
Push pump cover (3) with new 0-ring (120),

pressed-in driving spindle (12) and built-in mechanical seal counter-ring (186) into pump casing
(1) and attach with socket-head cap screws (200).
As necessary, carefully clean groove ball bearing

(292) with diesel fuel. If the mnning surfaces are
bright and undamaged, the groove ball bearing
(292) can be re-used. If not, the bearing must be replaced.
Screw idler spindles (13) into casing insert (2) from

pump-end side.
In case of pumps with filter, push pipe (29) over casing insert (2).
Lightly oil bearing seat on driving spindle (12).
Place new gasket (100) on cleaned sealing face of

pump casing (1).
Insert circlip (250) into drive-side pump cover (3).
7.2.2.3 Mounting the groove ball bearing to sizes 3600 to

6450
By light tapping on the inner ring, push the groove

ball bearing (292) onto the driving spindle (12) up to
the shaft shoulder using a suitably sized tube.
Attach end-side pump cover (4) or filter casing (9) to

pump casing (1) with socket-head cap screws
(201).
Mount circlip (251) in shaft groove provided in front

of groove ball bearing (292).
Lightly oil driving spindle (12) and press into pump
cover (3) together with groove ball bearing (292).
Insert key (290) into driving spindle (12).
Push pump-side coupling half onto driving spindle

(12).
7.2.2.4 Mounting the casing insert, spindle set and mechanical seal to sizes 3600 to 6450
7.2.2.5 Mounting a screw pump onto the twin aggregate
Lightly oil the fitting faces on the casing insert (2).
Press casing insert (2) into pump casing (1) from
drive side using a suitable tool.
Note: Pay attention to marking made prior to dismounting!
Place gasket (125) on delivery flange and gasket

(126) on suction flange.
Note: To facilitate mounting we recommend coating
the gasket with a suitable adhesive.
Drill together pump casing (1) with casing insert (2)

by way of bore hole on side for socket-head cap
screw (24).
Bore diameter: 4 mm
Bore depth: 6 mm
Push pump into centering ring of lantern (460).
Attach pump to reversing valve casing (301) with

socket-head cap screws (206) and (208) and hexagon nuts (236) and (238).
Screw socket-head cap screw (24) with sealing

washer (151) into side of pump casing (1) and tighten.
Attach pump to lantern (460) with socket-head cap

screws (215).
Note: Mechanical seals are high-grade precision

parts. Careful handling and extreme cleanliness during
Installation are essential to ensure proper functioning.
A suitable lubricant can be used to aid mounting (e.g.
oil, not grease).
When the screw pump has been mounted the

following work must be carried out:
Push rotating part of mechanical seal (186) over

driving spindle (12) in front of circlip (251).
Push spacer bush (20) over driving spindle (12) into

cleaned pump cover (3).
The power supply cable must be connected to the

motor by an auttiorized electrician. Electrical danger
must be eliminated! Pay attention to direction of
rotation.
Fill pump with fluid.
Push mechanical seal counter-ring (186) with new

0-ring concentrically into cleaned pump cover (3).
Use a suitable implement.
the mechanical seal counter-ring is pressed con-
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
Attach manometer lines, manometers and brackets

to pump.
Start up pump as per instructions in Section 6.
15
ZAS, ZASV
7.3
ALLWEILER
Replacement parts/spare parts

The parts marked with footnote in the parts list can be
provided as replacement/spare parts.
The casing insert (2) with spindles (12) and (13) are
available only as a complete spare part set.
However, for operational safety reasons, we recommend you always stock a complete cartridge-unit or
standby pump.
The advantage Is that in the event of a fault or damage
the standby unit can replace the non-functioning unit
quickly and without great effort.
When ordering spare and replacement parts, besides
the part number, denomination and quantity, the following should also be quoted:
Pump abbreviation,
Pump number,
Year of construction.
This information is engraved on the rating plate of the
pump.
VM 626.0011 GB/12.98- Ident-Nr. 550 213
16
ZAS, ZASV
ALLWEILER
Operating Faults, Causes and Remedial Action
8.1
Faults with reference number for cause and remedial action

The table below is intended as a guide to identilying faults and their possible causes. Faults relating to the pressure-relief
valve are listed separately.
If faults occur which are not listed here, or which cannot be traced back to the listed causes, we recommend consulting the
factory, or one of our branch offices or sales offices.
'iX
The pump must be depressurlzed and drained when faults are being rectified.
Screw pump faults
No pump suction and no delivery
1,2,3,4,5,11
Delivery too low
2,6,7,8,9,10,11
Pump operates noisily
4 , 5 , 6 , 7 , 8 , 1 0 , 1 1 , 12,13
Irregular delivery
6,7,10
Pump gets too warm
6,7,11,14,16
Pump is seized
14, 15, 16
Motor overload
6,13, 14,15,16
Pressure-relief valve faults
Delivery pressure drops
17
Pressure-relief valve does not open
18
Pressure-relief valve does not close
19
Pressure-relief valve knocks
20
8.2
Causes and remedial action
Ref. no.:
Cause
Remedial action
Pump not filled with fluid before initial operation. Fill pump with fluid.
Stop valves/sliders not open or only partially Fully open stop valves/sliders during operation.
open.
Motor direction of rotation wrong.
The direction of rotation of the motor must match the direction

of rotation arrow on the pump. The direction of rotation can be
reversed by swapping any two phases.
Suction pipeline or shaft seal leaky.
Retighten flange screw connections. Check shaft seal.
Air in suction and pressure system.
Open vent valve on pump pressure side until air has escaped.
Close valve again.
Wrong fluid viscosity.
Check that viscosity matches entries in acceptance test report.

In case of zero-pressure delivery of low-viscosity fluids, apply
1 to 2 bar to pump.
Pressure-relief valve leaking.
Check pressure-relief valve for passage. If necessary, regrind

valve seat and/or exchange valve cone.
Geodetic suction head too high.
Check underpressure on suction side using connected

pressure/vacuum gauge. Increase fluid level in tank, lower
pump.
Motor speed too low.
Check speed and current consumption of motor. Check voltage

and frequency against motor rating plate.
10
Air separating time in operating tank too short.
Provide better air separation in operating tank. Retum lines

must emerge below oil level of tank.
11
Fluid level in tank too low.
Fill tank to necessary fluid level.
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
17
ZAS, ZASV
ALLWEILER
12
Flow rate in suction and pressure pipelines too Flow rate in suction pipeline must not exceed max. 1 m/s, and
high.
in pressure pipeline max. 3 m/s.
13
Motor speed too high.
Check speed and current consumption. Check voltage and

frequency against motor rating plate.
14
Delivery pressure too high.
Set specified delivery pressure via pressure-relief valve. Pump

outlet pressure must not be exceeded.
15
Foreign bodies in pump.
Dismantle pump, remove foreign bodies and smooth damaged

points with oilstone.
Check suction filter and strainer.
16
Damaged ball bearing.
Replace ball bearing.
17
Pressure spring fatigued.
Install new pressure spring.
Valve seat leaking.
Install new valve cone.
Pressure spring heavily pre-tensioned.
Release pressure spring using adjusting screw, and reset to

required pressure.
18
Valve cone stuck in valve housing.
a) Due to foreign body or

Dismantle pressure-relief valve. Clean internal parts.
b) Operating temperature of plant substantially
Consult factory.
higher than quoted on order.
19
20
Pressure spring not pre-tensioned,

insufficiently pre-tensioned.
or Tum adjusting screw to right until required operating pressure

is reached.
Valve seat leaking.
Rework or replace valve cone and valve housing.
Pressure-relief valve knocking.
Check overpressure with pressure valve closed. Reset valve.

Opening pressure 10 % above operating pressure.
VM 626.0011 GB/12.98- Ident-Nr. 550 213
ZAS, ZASV
ALLWEILER
Sectional drawing
Series ZAS without filter
Section A - B
441 124 355
Section E-F
227
123 440 204 356 108 206 125 236 900 290 216 231
156 107
301 126
/ / / / / /
g^r.r,-ntr7r,/irilf4U^-H|F238 100 222 142 333 340 331 330 120 200 263
217 231 901 910
Section C-D
Sizes 3600 to 6450
Sizes 150 to 3150
Part No.
1
2
i
4
1U
12
13
20
24
1UU
107
108
120
122
123
124
125
126
(1)
0)
CD
0)
(1)
CD
(D
0)
S>
0
475 24 976 280 215 3
Denomination
Pump casing
Pump casing insert
Pump cover
drive side
norv-drive side
Bush
Driving spindle
Idler spindle
Spacer busti
Gasket
Joint ring
Joint ring
0-ring
O-ring
Gasket
Gasket
Gasket
Gasket
Part No.
142
145
151
153
156
158
160
186
200
201
204
205
206
208
215
216
217
222
227
a)
<D
VM 626.0011 GB/12.98- Ident-Nr. 550 213
153 450 363 158 360
Denomination
Joint ring
Gasket
Sealing washer
Joint ring
Joint ring
Gasket
Joint plug
Mechanical seal
Socket-head cap
Socket-head cap
Hexagon screw
Hexagon screw
Socket-tiead cap
Socket-head cap
Socket-head cap
Hexagon screw
Hexagon screw
Screw plug
Screw plug
Part No.
231
236
238
250
251
263
280
290
292
301
330
331
333
340
355
screw
screw
screw
screw
screw
356
360
363
19
d)
CB
Denomination
Hexagon nut
Hexagon screw
Hexagon nut
Circlip
Circlip
Supporting washer
Rivet
Key
Groove bail t>earing
Reversing valve casing
Valve cone
Valve spring plate
Adjusting screw
Valve spring
Stop valve
Lockable n o n return valve
Pressure gauge
Ball valve
Part No.
440
441
460
471
475
900
901
910
976
Denomination
Welding neck flange
Welding neck flange
Lantem
Foot angle
Oil drip pan
Coupling half
pump side
drive side
Driving motor
Name plate
d) Spare i arts/replacement parts
ALLWEILER
ZAS, ZASV
Sectional drawing
Series ZAS with filter
Section E-F
Section A-B
7
227
362 146 143 207 238 208 441 301 206 124 204 356 108 440 123 206 125 236 216 360
I /
1 i
119 235 159 962 431
30
100 142 333 340 331 330
151
13 201
156
355 107 126
152
361 364 157
M i l '
1
120 200 263 250 900 217
10
160 122 186
Section C-D
9
29
12
901 290
Sizes 3600 to 6450
S i z e s 150 to 3150
Part No
1
2
3
7
9
10
12
13
20
24
29
30
100
107
108
119
120
122
123
124
125
126
142
223 475 24 976 280 215 3
Denomination
(D
m
fn
m
3)
<B
s
fl)
Ci)
(f)
<D
3)
O)
CO
Pump casing
Pump casing insert
Pump cover
drive side
Casing cover
Filter casing
Busti
Driving spindle
Idler spindle
Spacer busti
Soci<et-tiead cap screw
Pipe
Pipe
Gasket
Joint ring
Joint ring
0-ring
0-ring
0-ring
Gasket
Gasket
Gasket
Gasket
Joint ring
m
a
3)
3)
m
(i)
m
S)
CD
(T)
CD
VIVI 626.0011 GB/12.98 - Ident-Nr. 550 213
Joint ring
Gasket
Gasket
Sealing washer
Joint ring
Joint ring
Joint ring
Gasket
Gasket
Joint ring
Joint plug
Mectianlcal seal
Socket-tiead cap
Socket-tiead cap
Hexagon screw
Hexagon screw
Socket-head cap
Hexagon screv^
Socket-head cdp
Socket-head cap
Hexagon screw
Hexagon screw
Screw plug
Venting screw
Denomination
Part No
Denomination
Part No
143
145
146
151
152
153
156
157
158
159
160
186
200
201
204
205
206
207
208
215
216
217
222
223
153 460 363 158 231 910
227
231
235
236
238
250
251
263
280
290
292
301
330
331
333
340
355
screw
screw
screw
356
360
361
382
363
365
screw
screw
20
CC
cf.
(1)
tt>
IS
Screw plug
Hexagon nut
Screw plug
Hexagon screw
Hexagon nut
Cirdip
Circllp
Supporting washer
Rivet
Key
Groove ball bearing
Valve cone
Valve spring plate
Adjusting screw
Valve spring
Stop valve
Lockabie n o n return valve
Pressure gauge
Pressure gauge
Ball valve
Ball valve
Connector
Denomination
Part No.
440
441
460
471
475
481
900
901
962
910
976
CD
CD
Welding neck flange

Welding neck flange
Lantern
Foot angle
Oil drip pan
Filter
Coupling half
pump side
drive side
Ring heater
Driving motor
Name plate
Spare parts/replacement parts

Ring heaters supplied on
request only (surcharge).
ZAS, ZASV
ALLWEILER
Sectional drawing
Series ZASV without filter
Section A-B
Section E-F
Section C-D
rx^
Sizes 150 to 3150
Part No.
1
3
4
1U
12
13
2U
24
1UU
10/
10
12U
122
123
124
125
126
0)
0)
0)
(1)
w
(])
0)
0)
CD
(D
Denomination
Pump casing
Pump casing insert
Pump cover
drive side
non-drive side
Busti
Driving spindle
Idler spindle
Spacer busti
Gasket
Joint ring
Joint ring
0-ring
O-ring
Gasket
Gasket
Gasket
Gasket
Sizes 3600 to 6450
Part No.
142
145
151
153
156
158
160
186
200
201
204
205
206
208
215
216
222
227
231
VM 626.0011 GB/12.98- Ident-Nr. 550 213
Denomination
Part No.
Denomination
Joint ring
Gasket
Sealing wastier
Joint ring
Joint ring
Gasket
Joint plug
Mechanical seal
Socket-head cap
Socket-head cap
Hexagon screw
Hexagon screw
Socket-head cap
Socket-head cap
Socket-head cap
Hexagon screw
Screw plug
Screw plug
Hexagon nut
236
237
238
250
251
253
280
290
292
301
330
331
333
340
355
Hexagon screw
Hexagon nut
Hexagon nut
Circlip
Circlip
Supporting washer
Rivet
Key
Groove ball Ijearing
Valve cone
Valve spring plate
Adjusting screw
Valve spring
Stop valve
Lockable n o n return valve
Pressure gauge
Bail valve
screw
screw
screw
screw
screw
356
360
363
21
Part No.
365
440
441
460
475
900
901
910
976
Denomination
Connector
Welding neck flange
Welding neck flange
Lantem
Oil drip pan
Coupling half
pump side
drive side
Driving motor
Name plate
Spare t arts/reDlacement parts
ZAS, ZASV
ALLWEILER
Sectional drawing
Series ZASV with filter
Section A-B
Section C-D
Section E-F
235 ! 481 i 208 ^ 7

30
962
9
Sizes 150 to 3150
PartNc
1
2
3
7
9
10
12
13
20
24
29
30
100
107
108
119
120
122
123
124
125
126
142
143
.
a)
a)
a)
<s>
4)
C!)
Denomination
Pump casing
Pump casing insert
Pump cover
drive side
Casing cover
Filter casing
Bush
Driving spindle
Idler spindle
Spacer bush
Pipe
Pipe
Gasket
Joint ring
Joint ring
O-ring
0-ring
O-ring
Gasket
Gasket
Gasket
Gasket
Joint ring
Joint ring
207 i 143 D
119
152
Sizes 3600 to 6450
PartNc
145
146
151
152
153
156
157
158
159
160
186
20O
201
204
205
206
207
208
215
216
222
223
227
231
235
PartNc
Denomination
CD
m
a>
<s>
m
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
Gasket
Gasket
Sealing washer
Joint ring
Joint ring
Joint ring
Gasket
Gasket
Joint ring
Joint plug
Mechank:al seal
Socket-head cap
Socket-head cap
Hexagon screw
Hexagon screw
Socket-head cap
Hexagon screw
Socket-head cap
Socket-head cap
Hexagon screw
Screw plug
Venting screw
Screw plug
Hexagon nut
Screw plug
236
237
238
250
251
263
280
290
292
301
330
331
333
340
355
screw
screw
screw
356
360
361
352
363
364
365
440
441
screw
screw
22
Denomination
o;
<D
(fi
a)
Hexagon screw
Hexagon nut
Hexagon nut
Circlip
Circiip
Supporting washer
Rivet
Key
Groove ball bearing
Valve cone
Valve spring plate
Adjusting screw
Valve spring
Stop valve
Lockabie n o n return valve
Pressure gauge
Pressure gauge
Ball vaive
Ball valve
Connector
Connector
Welding neck flange
Welding neck flange
Denomination
Part No.
460
475
481
900
901
962
910
976
Lantern
Oil drip pan
Filter
Coupling half
pump side
drive side
Ring heater
Driving motor
Name plate
Spare parts/replacement parts

Ring heaters supplied on
ZAS, ZASV
ALLWELER AQ
Werk Rodollzell
Posifochmo 0-7760 Rodolfzell
VM 626.0011 GB/12.98 - Ident-Nr. 550 213
Circuit diagram for

switchgear UZ-1
23
ALLWEILER
Drawing no.
69C 0005 659
Ell s i EI ll
UUI il
\ \ \ \
in
nl9llzl >p
Date: 28.03.90 Wei.

Bjaj jopeiuoo
JOpeiUOO J9M0cl
joioBjuoo jaMOd El I s IEI ll
zviim
diuei iinej
10
.2 c
in E
o a)
"I
C o
. >.
E E
o (0
E fe
CO
< n
ZAS, ZASV
ALLWEILER
Subject to technical changes.
ALLWEILER AG
Werk Radoifzell
Postfach 1140
D-78301 Radollzell
Allweilerstrafte 1
D-78315 Radoifzell
Germany
^
(++ 49) 7732 86 0
Fax
(++ 49) 7732 86 436
E-mail: service@allweiler.de
Intemet: http://www.allweiler.de
VM 626.0011 GB/12.98- Ident-Nr. 550 213
24
ARMATUREN
Betriebs- und Montageanleitung

Durchgangs-Stellventile - STEVl 440 / 441, 445 / 446
BR 440, 445
BR 4 4 1 , 446
Inhaltsverzeichnis
1.0 Allgemeines zur Betriebsanleitung
2.0 Gefahrenhinweise
2.1 Bedeutung der Symbole
2.2 Erluterungen zu sicherheitsrelevanten Hinweisen
3.0 Lagerung und Transport
4.0 Beschreibung
4.1 Anwendungsbereich
4.2 Arbeitsweise
4.3 Schaubilder
4.3.1 Kegelausfhrungen
4.4 Technische Daten
4.5 Kennzeichnung
5.0 Montage
5.1 Allgemeine Montageangaben
5.2 IVIontageangaben zum Einbauort
5.3 IVIontageangaben zum Antriebsaufbau und -abbau
6.0 Inbetriebnahme
7.0 Pflege und Wartung
7.1 Austausch der Spindel-Abdichtungen

9
7.1.1 Ausfhrung mit Dachmanschetten
9
7.1.2 Ausfhrung mit Stopfbuchspackung
10
7.1.3 Ausfhrung mit Faltenbalg
11
7.2 Austausch der Innengarnitur
12
7.2.1 Austausch von Kegel und Spindel
12
7.2.2 Dichtungsaustausch beim
Druckentlastungskegel
13
7.2.3 Austausch des Sitzringes
13
7.3 Anzugsdrehmomente
14
7.3.1 Anzugsdrehmomente der Sechskantmuttern .. 14
7.3.2 Anzugsdrehmomente der Sitzringe
14
8.0 Ursache und Abhilfe bei
Betriebsstrungen
14
9.0 Fehlersuchplan
15
10.0 Demontage der Armatur bzw.

des Oberteiles
16
11.0 Garantie / Gewhrleistung
16
12.0 Konformitts- / Herstellererklrung
17
Operating a n d Installation instructions.

Rev. 0 0 4 0 3 0 1 0 0 0 3504 d e u t s c h / englisch

DG-Stellventile - STEVI 440 / 441, 445 / 446
:^lTfe> A R M A T U R E N

Diese Betriebsanleitung gilt als Anweisung, die Armaturen sicher zu montieren und zu
warten. Bei Schwierigkeiten, die nicht mit Hilfe der Betriebsanleitung gelst werden
knnen, nehmen Sie Kontakt mit dem Lieferant oder Hersteller auf.
Sie ist verbindlich fr den Transport, Lagerung, IVIontage, Inbetriebnahme, Betrieb,
Wartung, Reparatur
Die Hinweise und Warnungen sind zu beachten und einzuhalten.
- Handling und alle anderen Arbeiten sind von sachkundigem Personal durchzufhren bzw.
alle Ttigkeiten sind zu beaufsichtigen und zu prfen.
Die Festlegung des Verantwortungsbereiches, des Zustndigkeitsbereiches und der
berwachung des Personals obliegt dem Betreiber.
- Bei Auerbetriebsetzung, Wartung bzw. Reparatur sind zustzlich die aktuellen
regionalen Sicherheitsanforderungen heranzuziehen und zu beachten.
Der Hersteller behlt sich das Recht von technischen nderungen und Verbesserungen
jederzeit vor.
Diese Betriebsanleitung entspricht den Anforderungen der EU-Richtlinien.
A
V
ACHTUNG!
Warnung vor einer allgemeinen Gefahr

Bei dieser Betriebs- und Montageanleitung wird auf Gefhrdungen, Risiken und
sicherheitsrelevante Informationen durch eine hervorgehobene Darstellung besonders
aufmerksam gemacht.
Hinweise, die mit dem oben aufgefhrten Symbol und ACHTUNG!" gekennzeichnet sind,
beschreiben Verhaltensmanahmen, deren Nichtbeachtung zu schweren Verletzungen
oder Lebensgefahr fr Anwender oder Dritte bzw. zu Sachschden fr die Anlage oder die
Umwelt fhren knnen, Sie sind unbedingt zu befolgen, respektive die Einhaltung zu
kontrollieren.
Die Beachtung der nicht besonders hervorgehobenen anderen Transport-, Montage-,
Betriebs-und Wartungshinweise sowie technische Daten (in den Betriebsanleitungen, den
Produktdokumentationen und am Gert selbst) ist jedoch gleichermaen unerlsslich, um
Strungen zu vermeiden, die ihrerseits mittelbar oder unmittelbar Personen- oder
Sachschden bewirken knnen.
ACHTUNG !
- Gegen uere Gewalt (wie Sto, Schlag, Vibration usw.) schtzen.
-Armaturaufbauten wie Antriebe, Handrder, Hauben drfen nicht zur Aufnahme
van ueren Krften wie z.B. fr Aufstiegshilfen, Anblndungspunkte fr
Hebezeuge, etc. zweckentfremdet werden.
- Es mssen geeignete Transport- und Hebemittel verwendet werden.
Gewichte siehe Katalogblatt.
- Bei -20C bis +65C.

- Die Lackierung ist eine Grundfarbe die beim Transport und am Lager vor Korrosion
schtzen soll. Farbschutz nicht beschdigen.
Seite 2
Rev. 0040301000 3504
gQ*> ARMATUREN

4.0 Beschreibung
Armaturen werden zum Regeln von flssigen, gasfrmigen und dampffrmigen Medien in
der Verfahrens- und Prozesstechnii^ sowie im Anlagenbau" eingesetzt.
ACHTUNG!
- Einsatzgebiete, Einsatzgrenzen und -mgliclikeiten sind dem Kataiogblatt zu
entnehmen.
- Bestimmte Medien setzen spezieile Werkstoffe voraus oder schiieen sie aus.
- Die Armaturen sind ausgelegt fr normale Einsatzbedingungen. Gehen die
Bedingungen ber diese Anforderungen hinaus, wie z.B. aggressive oder abrasive l\Aedien, hat der Betreiber die hheren Anforderungen bei der Bestellung
anzugeben.
- Armaturen aus Grauguss sind fr den Einsatz in Anlagen nach TRD 110 nicht
freigegeben.
Die Angaben sind konform mit der Druckgerterichtlinie 97/23/EG.

Die Einhaltung unterliegt der Verantwortung des Anlagenplaners.
Besondere Kennzeichnungen der Armatur sind zu beachten.
Die Werkstoffe der Standard-Ausfhrungen sind dem Katalogblatt zu entnehmen.
Bei Fragen ist Rcksprache mit dem Lieferanten oder Hersteller zu fhren.
4.2 Arbeitsweise
ARI-Stellventile sind insbesondere fr die Bettigung durch pneumatische oder elektrische
Ventilantriebe vorgesehen.
Als Drosselkrper sind je nach Einsatzfall vier verschiedene Ausfhrungen mglich:
Parabolkegel (Standardausfhrung)
Lochkegel
Laternenkegel
Druckentlastungskegel
Stellventile werden grundstzlich gegen die Schlierichtung angestrmt.
Beim Einsatz mit Lochkegel wird das Stellventil bei Gasen und Dmpfen gegen die
Schlierichtung und bei Flssigkeiten in Schlierichtung angestrmt. Soll ein
Durchgangsventil mit in Schlierichtung angestrmten Lochkegel mit einem
pneumatischen Stellantrieb bettigt werden, so muss mit hheren Antriebskrften
gerechnet werden. Das ist erforderlich um ein Schwingen nahe der Schliestellung zu
vermeiden.
Sind die Antriebsstellkrfte zu gering, sollte unter Bercksichtigung der
Betriebsbedingungen eine Druckentlastung vorgesehen werden.
Rev. 0040301000 3504
Seite 3

ARMATUREN
4.3 Schaubilder
Bild 1:BR440DN15-100
Bild 2: BR 441 DN15-100
Bild3:BR440DN125-150
Seite 4
Rev. 0040301000 3504

KJy> A R M A T U R E N
Bild 4: BR 445 DN 15-100 (nur Edelstahl)
Bild 5: BR446 DN15-100 (nur Edelstahl)
4.3.1 Kegelausfhrungen
Bild 6: Ausfhrung mit Lochkegel
Bild 7: Ausfhrung mit Laternenkegel
(Druckentlastungskegel siehe Bild 16)
Rev. 0040301000 3504
Seite 5
ARMATUREN


wie z.B.
- Hauptabmessungen,
- Druck-Temperatur-Zuordnungen, usw.
sind dem Katalogblatt zu entnehmen.
4.5 Kennzeichnung
Typen-Nummer
Nennweite
Hersteller
CE-Kennzeichnung
Benannte Stelle
Kvs-Wert
Kegelausfhrung
Werkstoff der
Innengarnitur
kundenspezifische
Angaben
Baujahr unverschlsselt
(1. und 2. Stelle)
Spindelabdichtung
Bilds
Anschrift des Herstellers: siehe Pkt 11.0 Garantie / Gewhrleistung
Entsprechend der Druckgerterichtlinie Diagramm 6, Anhang II drfen Armaturen ohne
Sicherheitsfunktion erst ab DN32 CE-gekennzeichnet werden.
Armaturen mit Sicherheitsfunktion sind:
Typ 440 DP-G / 441 DP-G und
Typ 440 / 440-D mit FR2.1 und -Zeichen
Seite 6
Rev. 0040301000 3504
ARMATUREN

5.0 Montage
Neben den allgemeingltigen Montagerichtlinien sind folgende Punkte zu beachten;
ACHTUNG!
- Flanschabdeckungen, falls vorhanden, entfernen.
- Der Innenraum von Armatur und Rohrleitung muss frei von Fremdpartikeln sein.
- Einbaulage in Bezug auf Durchstrmung beachten, siehe Kennzeichnung auf
der Armatur
- Dampfieitungssysteme sind so auszulegen, dass Wasseransammlungen
vermieden werden.
- Die Rohrleitungen so verlegen, dass schdliche Schub-, Biege- und
Torsionskrfte ferngehalten werden.
- Bei Bauarbeiten Armaturen vor Verschmutzung schtzen.
- Anschlussflansche mssen bereinstimmen.
-Armaturaufbauten wie Antriebe, Handrder, Hauben drfen nicht zur Aufnahme
von ueren Krften wie z.B. Aufstiegshilfen, Anbindungspunkte fr
Hebezeuge etc. zweckentfremdet werden.
- Fr Montagearbeiten mssen geeignete Transport- und Hebemittel verwendet
werden.
- Spindelgewinde und Spindelschaft mssen farbfrei bleiben.
- Dichtungen zwischen den Flanschen zentrleren.
- Vor der Armatur Schmutzfnger / Filter vorsehen.
Fr die Positionierung und Einbau der Produkte sind Planer / Baufirmen bzw. Betreiber
verantwortlich.
Rev. 0040301000 3504
Seite 7
ARMATUREN


Die Einbaustelle soll gut zugnglich sein und gengend Freiraum zur Wartung und zum
Abnehmen der Stellantriebe aufweisen. Vor und hinter dem Stellventil sind
Handabsperrventile vorzusehen, die Wartungs- und Reparaturarbeiten am Stellventil
ermglichen, ohne die Anlage zu entleeren. Das Stellventil soll vorzugsweise senkrecht mit
obenliegendem Antrieb eingebaut werden. Schrge bis waagerechte Einbaulage ist ohne
AbSttzung nur bei Antrieben mit geringem Eigengewicht zulssig.
Der Antrieb muss jedoch so montiert sein, dass die beiden Distanzsulen bzw. das Joch in
senkrechter Ebene bereinander liegen:
Bild 9: Rohrleitung senkrecht
Bild 10: Rohrleitung waagerecht
Zulssige Antriebsgewichte bei waagerechter Einbaulage in Bezug auf die Spindel, ohne
bauseitige Absttzung, sind:
20 kg fr DN 15-32
25 kg fr DN 40 - 65
35 kg fr DN 80-100
Um die Stellantriebe vor zu hoher Wrme zu schtzen, sind die Rohrleitungen zu isolieren.
Hierbei ist gengend Platz zur Wartung der Spindelabdichtung vorzusehen.
Zur einwandfreien Funktion des Stellventils sollte die Rohrleitung vor dem Stellventil auf
einer Lnge von min. 2 x DN und hinter dem Stellventil min. 6 x DN gerade ausgefhrt sein.
5.3 Montageangaben zum Antriebsaufbau und -abbau

Im Normalfall wird das Stellventil komplett mit aufgebautem Stellantrieb geliefert.
Fr bereits im Betrieb befindliche Armaturen, unter Betriebsdruck und Temperatur, ist der
Auf- und Abbau von Antrieben nicht zulssig. Bei Umbau oder Wartung ist die Montage der
Antriebe gem den Betriebsanleitungen fr Antriebe vorzunehmen.
Bei Montagearbeiten darf der Kegel nicht unter Anpredruck auf dem Sitz gedreht werden.
ACHTUNG!
Bei Faltenbalgventilen ist darauf zu achten, dass beim Aufbau, bzw. Abbau des
Antriebes die Spindeleinheit nicht verdreht wird, damit der Faltenbalg nicht
beschdigt wird.
(An der Schlsselflche der Spindel gegen Verdrehen sichern!)
Bei nachtrglichem Aufbau von Stellantrieben mssen die, fr die Bettigung maximal
zulssigen Stellkrfte beachtet werden:
BR 440 / 445
12kNfrDN 15-50
29kN fr DN 65-100
Seite 8
BR 441 / 446
ISkNfrDN 15-100
Rev. 0040301000 3504
ARMATUREN

DG-Steilventile - STEVI 440 / 441, 445 / 446
6.0 Inbetriebnahme
ACHTUNG!
- Vorder Inbetriebnahme sind die Angaben zu Werkstoff, Druck, Temperatur und
Strmungsrichtung zu berprfen.
- Grundstzlich sind die regionalen Sicherheitsanweisungen einzuhalten.
- Rckstnde in Rohrleitungen und Armaturen (wie Schmutz, Schweiperlen,
usw.) fhren zu Undichtigkeiten bzw. Beschdigungen.
- Beim Betrieb mit hohen (> 50 "C) oder tiefen (<0C) Medientemperaturen
besteht Verletzungsgefahr bei Berhren der Armatur.
Ggf Warnhinweise oder Isolierschutz anbringen!
Vor Jeder Inbetriebnahme einer Neuanlage bzw. Wiederinbetriebnahme einer
Anlage nach Reparaturen oder Umbauten ist sicherzustellen:
- Der ordnungsgeme Abschluss aller Arbeiten!
- Die richtige Funktionsstellung der Armatur
- Schutzvorrichtungen sind angebracht.

Die Wartung und Wartungsintervalle sind entsprechend den Anforderungen vom Betreiber
festzulegen.

PTFE-Dachmanschetten (Pos. 12) bestehend aus:
1 Grundring
4 Dichtringe
1 Deckring
Durch die eingebaute Druckfeder (Pos. 15) ist diese
Spindelabdichtung selbstnachsteliend.
Bei Undichtigkeiten an der Spindel ist der Dichtsatz
verschlissen und muss ausgetauscht werden.
Austausch der PTFE-Dachmanschetten:
ACHTUNG!
Vor Demontage der Armatur Punkt 10.0 und
11.0 beachten.
- Antrieb abbauen. (Siehe Betriebsanleitung des

Stellantriebs!)
- Bei Austausch der Dachmanschetten (Pos. 12) auf
richtige Reihenfolge und Einbaulage der Einzelteile
achten
(siehe Bild 11).
- Dichtung (Pos. 17) muss erneuert werden.
Beschdigte Kegel-Spindeleinheiten mssen ebenfalls
ausgetauscht werden (Beschreibung siehe Punkt 7.2), da
ein neuer Dichtsatz bei beschdigter Spindel innerhalb
kurzer Zeit wieder undicht wird.
Rev. 0040301000 3504
Bild 11;
Seite 9
ARMATUREN

DG-Steilventile - STEVI 440 / 441, 445 / 446

Die Stopfbuchspackung (Pos. 23) ist nicht wartungsfrei.
Bei auftretenden Undichtigkeiten sofort stufenweise die Verschraubung (Pos. 25) bis zur
Dichtheit der Packung (Pos. 23) anziehen.
Durch regelmige Kontrolle auf Dichtheit wird die Lebensdauer der Stopfbuchspackung
(Pos. 23) erhht.
Ist ein Abdichten durch Nachziehen nicht mehr mglich, muss mit einem neuen
Packungsring (Pos. 23) nachgepackt werden.
Nachpacken der Stopfbuchspackung:
ACHTUNG!
Vor Demontage der Armatur Punkt 10.0 und 11.0 beachten.
Antrieb abbauen, (siehe Betriebsanleitung des Stellantriebs!)

Neuen Packungsring einlegen, Einbau gem Darstellung Bild 11 - Bild 13.
Bild 12: Stopfbuchspackung
Wird ein geteilter Packungsring verwendet, ist

beim Zuschneiden auf einen schrgen
Schnittverlauf gem Darstellung Bild 13 zu
achten.
Bild 13: geteilter Packungsring
Beschdigte Spindeln mssen ebenfalls ausgetauscht werden (Beschreibung siehe
Punkt 7.2), da ein neuer Dichtsatz bei beschdigter Spindel innerhalb kurzer Zeit wieder
undicht wird.
Seite 10
Rev. 0040301000 3504
ARMATUREN


Bei Undichtigkeiten an der Spindel liegt ein Defekt des eingebauten Faltenbalges
(Pos. 20.3) vor. Zunchst kann durch leichtes Anziehen der Verschraubung (Pos. 20.17)
eine ausreichende Dichtheit erzielt werden.
Bei einem Austausch knnen Spindel und Faltenbalg (Pos. 20.3) nur gemeinsam
ausgetauscht werden.
Austausch der Faltenbalgelnheit:
20,17
ACHTUNG!
Vor Demontage der Armatur Punkt 10.0
und 11.0 beachten.
- Antrieb abbauen.
(Siehe Betriebsanleitung des Stellantriebs!)
- Muttern (Pos. 11) lsen.
- Faltenbalgaufsatz (Pos. 20) abnehmen.
20.2
20.8
-Verschraubung (Pos. 20.17) um ca. eine

Umdrehung lsen.
20.6
- Spindel-ZFaltenbalgeinheit (Pos. 20.3) in der unteren

Stellung gedrckt halten.
- Spannhlse (Pos. 4) mit einem Dorn heraustreiben.
20.3
- Kegel (Pos. 3) abschrauben.

- Muttern (Pos. 20.8) lsen.
- Traversendeckel (Pos. 20.2) abnehmen.
- Spindel-ZFaltenbalgeinheit (Pos. 20.3) aus dem
Faltenbalggehuse (Pos. 20.1) herausnehmen.
- Neue Teile verschrauben und bohren.
- 2 Flachdichtungen (Pos. 20.6) und
1 Flachdichtung (Pos. 9) erneuern.
- Zusammenbau in umgekehrter Reihenfolge.
- Mit Muttern (Pos. 11 u. 20.8) befestigen und
kreuzweise anziehen. (Anzugsdrehmomente siehe
Punkt 7.3.1)
- Verschraubung (Pos. 20.17) bis zur Dichtheit der
Stopfbuchspackung (Pos. 20.10) anziehen.
Bild 14:BR441 /446
Rev. 0040301000 3504
Seite 11
ARMATUREN

DG-Stellventile - STEVi 440 / 441, 445 / 446

7.2.1 Austausch von Kegel und Spindel
ACHTUNG!
Vor Demontage der Armatur Punkt 10.0
und 11.0 beachten.
- Antrieb abbauen.
BR 440 / 445:
- Traversendeckel (Pos. 7) abnehmen.
- Verschraubung (Pos. 19 bzw. Pos. 25) um ca. 1
Umdrehung lsen.
- DN15-100: Kegel-ZSpindeleinheit (Pos. 3) herausziehen.
- DN125-150: Kegel (Pos. 3) mit Spindel (Pos. 5)
herausziehen.
- DN125-150: Stift (Pos. 4) mit einem Dorn heraustreiben.
- DN125-150: Kegel (Pos. 3) abschrauben.
- DN125-150: Neue Teile verschrauben, bohren und
verstiften.
Bild 15: BR 440/445

DN15-100
- Flachdichtung (Pos. 9) erneuern.

- Zusammenbau in umgekehrter Reihenfolge
- Mit IVluttern (Pos. 11) befestigen und kreuzweise anziehen.
(Anzugsdrehmomente siehe Punkt 7.3.1)
BR 441/446:
Der Austausch von Kegel und Spindel bei Armaturen mit Faltenbalg (BR441/446) ist unter
Punkt 7.1.3 beschrieben.
Seite 12
Rev. 0040301000 3504
<^3>> ARMATUREN

DG-Steliventile - STEVI 440 / 441, 445 / 446
7.2.2 Dichtungsaustausch beim Druckentlastungskegel
ACHTUNG!
Antrieb abbauen.
Kegel ausbauen wie unter Punkt 7.2.1
beschrieben.
Verschlissene Kolbendichtung (Pos. 32) mit
geeignetem Werkzeug (z.B. Schraubendreher)
aus der Nut im Kegel heraushebeln.
- Neue Kolbendichtung (Pos. 32) einsetzen, dabei
aufrichtige Einbaulage achten (siehe Bild 16).
Fhrungsband (Pos. 31) austauschen.
- Laufflche der Fhrungsbuchse (Pos. 30)
subern;
ggf. mit feinem Schleifmittel gltten.
- 2 Flachdichtungen (Pos. 9) erneuern.
Mit Muttern (Pos. 11) befestigen und kreuzweise
anziehen.
(Anzugsdrehmomente siehe Punkt 7.3.1)
Bild 16: Druckentlastungskegel
7.2.3 Austausch des Sitzringes

Der Sitzring ist nur bei Stellventilen BR 445 / 446 eingeschraubt.
ACHTUNG!
Antrieb abbauen.
Muttern (Pos. 11) lsen.
Ventil-Oberteil abnehmen.
Sitzring (Pos. 2) mit Spezialschlssel (kann vom Hersteller bezogen werden)
herausschrauben.
Gewinde und Dichtkonus im Gehuse (Pos. 1) subern und mit geeignetem Schmiermittel
bestreichen.
- Sitzring (Pos. 2) austauschen bzw. nacharbeiten.
Sitzring (Pos. 2) einschrauben. (Anzugsdrehmomente siehe Punkt 7.3.2.)
Flachdichtung (Pos. 9) erneuern.
- Ventil-Oberteil aufsetzen.
Mit Muttern (Pos. 11) befestigen und kreuzweise anziehen.
(Anzugsdrehmomente siehe Punkt 7.3.1.)
Rev. 0040301000 3504
Seite 13

ARMATUREN
7.3 Anzugsdrehimomente
7.3.1 Anzugsdrehmomente der Sechskantmuttern
M10
M 12
M 16
=
15-30Nm
= 3 5 - 5 0 Nm
=
80-120Nm

DN 15/20
DN 25/ 32
DN 40/ 50
DN65
DN80
DN100
=
=
=
=
=
=
100 Nm
150 Nm
350 Nm
480 Nm
660 Nm
980 Nm
/ Antriebsaufbau siehe
fr betreffenden
Betriebsanleitung
Antrieb!
8.0 Ursache und Abhilfe bei Betriebsstrungen

Bei Strungen der Funktion bzw. des Betriebsverhaltens ist zu prfen, ob die Montage- und
Einstellarbeiten gem dieser Betriebsanleitung durchgefhrt und abgeschlossen wurden.
ACHTUNG !
- Bei der Fehlersuche sind die Sicherheitsvorschriften zu befolgen.
Bei Strungen die anhand der nachfolgenden Tabelle siehe Pkt. 9.0 Fehlersuchplan"
nicht behoben werden knnen, ist der Lieferant oder Hersteller zu befragen.
Seite 14
Rev. 0040301000 3504
CSIS^ AHMATUHEIM

9.0 Fehlersuchplan
ACHTUNG!
- vor Montage- und Reparaturarbeiten Punkte 10.0 und 11.0 beachten!
- vor Wiederinbetriebnahme Punkt 6.0 beachten
Strung
Mgliche Ursachen
Abhilfe
Kein Durchfluss
Armatur geschlossen
Armatur ffnen (mittels Antrieb)
Flanschabdeckungen wurden nicht

entfernt
Flanschabdeckungen entfernen
Armatur nicht ausreichend geffnet
verunreinigter Schmutzfnger
Sieb reinigen / austauschen
Geringer Durchfluss
Ventilspindel bewegt sich

nur ruckweise
Ventilspindel bzw. Kegel

sitzt fest
Verstopfung im Rohrleitungssystem
Rohrleitungssystem berprfen
Ventil bzw. Kvs-Wert falsch gewhlt
Ventil mit grerem Kvs-Wert

einsetzen
Zu fest angezogene Stopfbuchsabdich- Geringes Lsen der Verschraubung

tung (bei Ventilen mit Graphit-Packung) (Pos. 25/20.17)
Dichtheit muss gewhrleistet bleiben.
Ventilkegel hat aufgrund von FestSchmutzpartikeln leicht gefressen
Innenteile subern,
beschdigte Stellen gltten
Sitz und Kegel stark mit Schmutz verklebt, insbesondere bei Schlitz- und
Lochkegeln
Sitz und Kegel mit geeignetem

Lsungsmittel reinigen
Sitz und Kegel austauschen;

Ventilkegel hat aufgrund von Ablagerungen oder Feststoffen im Medium, im ggf. Ersatzteile aus anderen
Werkstoffen vorsehen.
Sitz oder in der Fhrung gefressen.
An der Spindel undicht
Dachmanschetten-Dichtsatz beschdigt Dichtsatz (Pos. 12) austauschen;

oder verschlissen
siehe Punkt 7.1.1
Bei Ausfhrung mit Stopfbuchspackung Verschraubung (Pos. 25) nachziehen
ist die Stopfbuchsbrillenspannung zu
ggf. nachpacken; siehe Punkt 7.1.2
gering
Bei geschlossenem Ventil

ist die Leckrate zu hoch
Faltenbalg defekt bei Ventil in Faltenbalgausfhrung
Austausch der Faltenbalgeinheit;

siehe Punkt 7.1.3
Diohtflchen am Kegel ausgewaschen

oder verschlissen
Kegel austauschen;
siehe Punkt 7.2.1
Dichtkante am Sitz beschdigt oder

verschlissen
Sitz austauschen (nur bei BR445/446);

siehe Punkt 7.2.3,
evtl. Schmutzfnger montieren
Kolbendichtring bei druckentlastetem

Ventil verschlissen
Dichtring austauschen;
siehe Punkt 7.2.2
Verschmutzung von Sitz und/oder

Kegel
Ventil-Innenteile subern;
evtl. Schmutzfnger montieren.
Pneum. Antrieb nicht vollstndig entlf- Luftkammer des Antriebs ganz

tet. Federkraft wird nicht voll wirksam. entlften
Antrieb zu schwach
Rev. 0040301000 3504
Strkeren Antrieb einsetzen,

Betriebsdaten berprfen
Seite 15
ARMATUREN

10.0 Demontage der Armatur bzw. des Oberteiles
ACHTUNG!
Insbesondere sind folgende Punkte zu beachten:
- Druckloses Rohrleitungssystem.
- Abgekhltes Medium.
- Entleerte Anlage.
- Bei tzenden, brennbaren, aggressiven oder toxischen Medien Rohrleitungssystem belften.

Umfang und Zeitraum der Gewhrleistung ist in der zum Zeitpunl<t der Lieferung gltigen
Ausgabe der "Allgemeinen Geschftsbedingungen der Albert Richter GmbH & Co. KG"
oder abweichend davon im Kaufvertrag selbst angegeben.
Wir leisten Gewhr fr eine dem jeweiligen Stand der Technik und dem besttigten Verwendungszweck entsprechenden Fehlerfreiheit.
Fr Schden, die durch unsachgeme Behandlung oder Nichtbeachtung der Betriebsund Montageanleitung, des Katalogblattes und der einschlgigen Regelwerken entstehen,
knnen keine Gewhrleistungsansprche geltend gemacht werden.
Schden die whrend des Betriebes, durch vom Datenblatt oder anderen Vereinbarungen
abweichenden Einsatzbedingungen entstehen, unterliegen ebenso nicht der Gewhrleistung.
Berechtigte Beanstandungen werden durch Nacharbeit von uns oder durch von uns beauftragte Fachbetriebe beseitigt.
ber die Gewhrleistung hinausgehende Ansprche sind ausgeschlossen. Anspruch auf
Ersatzlieferung besteht nicht.
Wartungsarbeiten, Einbau von Fremdteilen, nderung der Konstruktion, sowie natrlicher
Verschlei sind von der Gewhrleistung ausgeschlossen.
Etwaige Transportschden sind nicht uns, sondern unverzglich Ihrer zustndigen Gterabfertigung, der Bahn oder dem Spediteur zu melden, da sonst Ersatzansprche an diese
Unternehmen verloren gehen.
ARMATUREN
Technik mit Zultunft.

DEUTSCHE QUALITTSARMATUREN
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schlo Holte-Stukenbrock
Telefon +49 (0)5207 / 994-0 Telefax +49 (0)5207 / 994-297 oder 298
Internet: http://www.ari-armaturen.de E-mail: info.vertrieb@ari-armaturen.de
Seite 16
Rev. 0040301000 3504
<K> A R M A T U R E N

DG-Steliventile - STEVI 440 / 441, 445 / 446
12.0 Konformitts-/ Herstellererklrung

ARl-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, 33756 Schlo Holte-Stukenbrock
EG-Konformittserklrung
im Sinne der
EG-Druckgerterichtlinie97/23/EG
Hiermit erklren wir,
dass gem der oben genannten Druckgerterichtlinie, die unten aufgelisteten Produkte ausgefhrt
sind und nach Diagramm 6, Anhang II Modul H bzw. Modul Hl (mit Sicherheitsfunktion; zustzlich
EG-Baumusterprfung gem Modul B+D) von LLOYD'S REGISTER QUALITY ASSURANCE
(BS-Nr. 0525), Mnckebergstr. 27, 20095 Hamburg, geprft wurden.
Modul H, Zertifikat-Nr; 50003/1
Absperr- u. Stellventil in Durchgangsform
Typ 405, 460, 440, 441, 445, 446, 470, 471, 422, 462, 425, 426, 480
Angewendete Normen;
DIN EN 60534 Teil 1
VDIA/DE 3844 Blatt 1
DIN 3840
AD 2000 Merkblatt A4
- Gusseisen mit Kugelgraphit
- Stahlguss
- Schmiedestahl
Modul H l , Zertifikat-Nr; 50003/2
Stellventil in Durchgangsform mit Sicherheitsfunktion
Typ 440, 441
Angewendete Normen;
DIN EN 60534 Teil 1
VDIA/DE 3844 Blatt 1
DIN 3840
- Stahlguss
- Schmiedestahl
Herstellererklrung
im Sinne der
EG-Maschinenrichtlinie 98/37/EG
dass die aufgefhrten Produkte, in der gelieferten Ausfhrung zum Einbau in eine Maschine oder
Anlage bestimmt sind und dass die Inbetriebnahme der Maschine / Anlage solange untersagt ist,
bis festgestellt wurde, dass die Maschine / Anlage den Bestimmungen der EG-Maschinenrichtlinie
98/37/EG entspricht.
Schlo Holte-Stukenbrock, den 26.11.2002
(Brechmann, Geschftsfhrer)
Rev. 0040301000 3504
Seite 17
ARMATUREN
Seite 18
Betriebs- und Montageanieitung

DG-Stellventiie - STEVI 440 / 441, 445 / 446
Rev. 0040301000 3504
ARMATUREN
Operating and installation instructions

straight through control valves - STEVI 440 / 441, 445 / 446
S ?^"^^^^'o
-^^
Series 441,446
Series 4 4 0 , 4 4 5
Contents
1.0 General information on operating
instructions
20
2.0 Notes on possible dangers

2.1 Significance of symbols
2.2 Explanatory notes on safety information
3.0 Storage and transport
20
20
20
20
4.0 Description
4.1 Scope of applications
4.2 Operating principles
4.3 Diagram
4.3.1 Plug design
4.4 Technical data
4.5 Marking
5.0 Installation
5.1 General notes on installation
5.2 Requirements at the place of installation
5.3 Installation instructions concerning actuators
6.0 Putting the valve into operation
21
21
21
22
23
24
24
25
25
26
26
27
7.0 Care and maintenance

7.1 Replacement of stem sealings
7.1.1 PTFE V-ring unit design
7.1.2 Stuffing box packing design
7.1.3 Bellows seal design
7.2 Replacement of internal parts
7.2.1 Replacement of plug and stem
7.2.2 Replacement of seals of
pressure balanced plugs
7.2.3 Replacement of the seat ring
7.3 Tightening torques
7.3.1 Tightening torques for nuts
7.3.2 Tightening torques for seat rings
8.0 Troubleshooting
27
27
27
28
29
30
30
9.0 Troubleshooting table

10.0 Dismantling the valve or the top part
33
34
11.0 Warranty / Guarantee
34
12.0 EC declaration of conformity /

Manufacturers declaration
35
Rev. 0 0 4 0 3 0 1 0 0 0 3 5 0 4 englisch
31
31
32
32
32
32
p a g e 19
ARMATUREN

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 be
solved 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 be
supervised and checked.
It is the owner's responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking 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.

ATTENTION!
Warning of general danger.

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 I" describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and 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 fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
ATTENTION!
- Protect against external force (like impact, vibration, etc.).
- Valve mountings sucti as actuators, handwheels, hoods 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.
- At -20X to +65C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
Page 20
Rev. 0040301000 3504
i:aV'
ARMATUREN

4.0 Description
Valves are used for controlling the flow of liquids, gases and vapours in chemical and other
processing plants and for plant engineering".
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.
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.

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 plug
V-port plug
pressure 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 the
closing directions, but liquids flow through in the closing direction. If a pneumatic actuator is
to be used on a straight-way valve with a perforated plug with the fluid moving in the closing
direction, a higher closing force will be needed. This is to prevent vibration as the plug
approaches 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.
Rev. 0040301000 3504
Page 21
ARMATUREN

4.3 Diagram
Fig. 1: Series 440 DN15-100
Fig. 3: Series 440 DN125-150

Page 22
Rev. 0040301000 3504
ARMATUREN

Str. thr. control valves - STEVI 440 / 441, 445 / 446

(only stainless steel)

(only stainless steel)
4.3.1 Plug design
Fig. 6: Design witli perforated plug
Fig. 7: Design with V-port plug
(Design with pressure balanced plug refer to Fig. 16)
Rev. 0040301000 3504
Page 23
ARMATUREN

4.4 Technical data

for
- Principal dimensions
- Pressure-temperature-ratings, etc. refer to data sheet.
4.5 Marking
_
., ,
Type-Number
Nominal diameter
Manufacturer
Nominal pressure
Flow
characteristic
Kvs-value
PN
Pack.
DN
Plug
design
4E^ TKV^
laMat.
Notified body
^>C <^
SN
^
Serial-No,
IVIaterial of
internal parts
CE-marking
Customer-specific
information
Stem sealing
Year of manufacture clear speech

(Land2. position)
Fig. 8
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
According to the Pressure Equipment Directive table 6, annex II, valves without safety
function are only allowed to bear the CE-marking DN32 onwards.
Valves with safety function are:
Type 440 DP-G / 441 DP-G and
Type 440 / 440-D with FR2.1 and Ll-sign
Page 24
Rev. 0040301000 3504
ARMATUREN

Str. thr. control valves STEVi 440 / 441,445 / 446
5.0 Installation
The following items should be taken into account besides the general principles governing
installation work:
ATTENTION!
- Remove flange covers if present.
- Ttie 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 are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valve mountings such as actuators, handwheels, hoods must not be used to
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.
Planners / construction companies or operators are responsible for positioning and

installing products.
Rev. 0040301000 3504
Page 25
ARMATUREN


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. The
valve 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 each
other in the vertical plane.
Fig. 9: Pipeline vertically
Fig. 10: Pipeline horizontally
Permissible actuator weights for valves with unsupported horizontal stems:

20 kg for DN 1 5 - 3 2
25 kg for DN 40 - 65
35 kg for DN 80-100
The pipes must be lagged to protect the actuators from excessive heat. Sufficient space
must be left for the maintenance of the stem packing.
To ensure that the control valves function correctly, the pipe run should be straight for at
least 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 service
conditions (temperature and pressure). The actuators must be assemble as describe in the
operating instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seating at closing pressure.
ATTENTION!
Care must be taken with the bellow type valves when actuators are mounted or
removed. (Hold the valve-stem against turning with an open-end wrench!)
When retrofitting actuators, the maximum permissible force for valve actuation must be
taken into account:
Series 440 / 445
Series 441 / 446
12kNforDN 15-50
I S k N f o r D N 15-100
29kN for DN 65-100
Page 26
Rev. 0040301000 3504
ARMATUREN

Str. thr. control valves STEVI 440 / 441,445 / 446
ATTENTION!
- Before putting the valve into operation, check material, pressure, temperature
and 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) media
temperatures 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.

Maintenance and maintenance intervals have to be defined by the operator according to
the service conditions.

PTFE V-ring unit (pos. 12) consisting of:
1 baclîng ring
4 sealing rings
1 cover ring
Owing to the installed compression spring (pos. 15), this
stem 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:
ATTENTION!
Refer to item 10.0 and 11.0 before
dismantling the valve.
- Remove actuator.
(Refer to operating instructions for actuator!)
- When replacing PTFE V-ring unit (pos. 12), make sure
that the parts are installed in the correct order and
positions (refer to Fig. 11).
- Gasket (pos. 17) must be replaced.
Damaged stems must also be replaced (refer to item 7.2
for instructions) since a new ring pack will soon start
leaking again if the stem is damaged.
Rev. 0040301000 3504
Fig. 11
Page 27
g!3fe> A R M A T U R E N


- The stuffing box packing (pos. 23) requires maintenance.
- If leaks develop, immediately tighten the screw joint (pos. 25) gradually until the packing
(pos. 23) stops leaking.
- The service life of stuffing box packings (pos. 23) can be increased by checking regularly
leakage.
- If leaks can no longer be stopped by tightening the screw joint (pos. 25), a new packing
ring (pos. 23) must be inserted into the gland.
Replacement of stuffing box packings:
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
Remove actuator. (Refer to operating instructions for actuator!)

Insert new packing ring as shown in Fig. 12 - Fig. 13.
Fig. 12: Stuffing box packing
If a split packing ring is used, cut with a chamfer

as shown in Fig. 13.
Fig. 13: Split packing ring

Damaged stems must also be replaced (refer to item 7.2 for instructions) since a new ring
pack will soon start leaking again if the stem is damaged.
Page 28
Rev. 0040301000 3504
ARMATUREN
Operating and Installation instructions

Str. thr. control valves STEVI 440 / 441,445 / 446

If the stem leaks, the bellows seal (pos. 20.3) is defective. The leak can initially be stopped
by tightening the screw joint (pos. 20.17).
Stem and bellows (pos. 20.3) can only be replaced together.
Replacement of bellows seals:
20,17
ATTENTION!
- Remove actuator.
- Loose nuts (pos. 11).
20,2
20,8
- Detach bellows assembly (pos. 20).

- Slacken screw joint (pos. 20.17) by about one turn.
- Press stem/bellows unit (pos. 20.3) down.
20,6
- Drive pin (pos. 4) out with a drift.

- Unscrew plug (pos. 3).
20,3
- Loose nuts (pos. 20.8).

- Detach mounting bonnet (pes. 20.2).
- Extract stem/bellows unit (pos. 20.3) from the
bellows housing (pos. 20.1).
- Bolt new parts together and drill them.
- Replace 2 gaskets (pos. 20.6) and 1 gasket (pos. 9).
- Assemble in reverse order.
- Secure with nuts (pos. 10 u. 20.8) and tighten them
crosswise.
(For tightening torques refer to item 7.3.1)
- Tighten screw joint (pos, 20.17) gradually up to
tightness of the stuffing box packing (pos. 20.10).
Fig. 14: Series 441/446
Rev. 0040301000 3504
Page 29
ARMATUREN

Str. thr. control valves - STEVI 440 / 441, 445 / 446

7.2.1 Replacement of plug and stem
ATTENTION!
- Remove actuator.
Series 440/445:
- Detach mounting bonnet (pos. 7),
- Slacken screw joint (pos. 19 or 25) by about 1 turn.
- DN 15-100: Extract plug/stem assembly (pos. 3).
- DN 125-150: Extract plug (pos. 3) and stem (pos. 5).
- DN125-150: Drive pin (pos. 4) out with a drift.
- DN125-150: Unscrew plug (pos. 3).
- DN125-150: Bolt new parts together, drill and pin them.
Fig. 15: Series 440 / 445
DN15-100
- Replace gasket (pos. 9).

- Secure with nuts (pos. 11) and tighten them crosswise.
(For tightening torques refer to Item 7.3.1.)
Series 441/446:
For replacement of plug and stem with bellows sealing (Series 441/446) refer to item 7.1.3.
Page 30
Rev. 0040301000 3504
g J i ^ ARMATUREN

Str. tlir. control valves - STEVI 440 / 441,445 / 446
7.2.2 Replacement of seals of pressure balanced plugs
ATTENTION!
Refer to item 10.0 and 11.0 before dismantling tfie valve.
- Remove actuator.
- Remove plug as described in item 7.2.
- Prise worn piston seal (pos. 32) out of groove in
plug with suitable tool (e.g. screwdriver).
- Insert new piston seal (pos. 32), taking care that
it is in the correct position (refer to Fig. 16).
- Replace guide ring (pos. 31).
- Clean sliding surface of guide bush (pos. 30);
smooth with fine abrasive if necessary.
- Replace 2 gaskets (pos. 9).
- Secure with nuts (pos. 11) and tighten them
crosswise.
(For tightening torques refer to item 7.3.1.)
Fig. 16: Pressure balanced
7.2.3 Replacement of the seat ring

Only with control valves series 445 / 446 the seat ring is screwed in.
ATTENTION I
Remove actuator. (Refer to operating instruction for actuator!)

Loose nuts (pos. 11).
Detach valve top part.
Unscrew seat ring (pos. 2) with a special wrench (can be obtained from the manufacturer).
Clean thread and sealing taper in body (pos. 1) and apply with suitable lubricant.
Replace respectively recondition seat ring (pos. 2).
Install seat ring (pos. 2). (For tightening torques refer to item 7.3.2.)
Replace gasket (pos. 9).
Assemble valve top part.
Secure with nuts (pos. 11) and tighten them crosswise.
Rev. 0040301000 3504
Page 31

ARMATUREN

7.3.1 Tightening torques for
M10
M12
M 16
=
=
=
15-30Nm
35-50Nm
80-120Nm

DN 15/20
DN 25/ 32
DN 40/ 50
DN65
DN80
DN100
=
=
=
=
=
=
100 Nm
150 Nm
350 Nm
480 Nm
660 Nm
980 Nm
/ Refer to operating instructions for actuator concerned

installing actuators I
for
8.0 Troubleshooting
In the event of malfunction or faulty operating performance checl< that the installation and
adjustment wori< has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
- It Is essential that the safety regulations are observed when identifying faults.
If malfunctions cannot be eliminate with the help of the following table

"9.0 Troubleshooting table", the supplier or manufacturer should be consulted.
Page 32
Rev. 0040301000 3504
ARMATUREN

ATTENTION!
- read item 10.0 and 11.0 prior to dismantling and repair work!
- read item 6.0 before restarting the plant!
Fault
Possible cause
Corrective measures
No flow
Valve closed.
Open valve (using actuator).
Flange covers not removed.
Remove flange covers.
Valve not sufficiently open.
Open valve (using actuator).
Little flow
Valve stem moves in jerks.
Dirt sieve clogged.
Clean / replace sieve.
Piping system clogged.
Check piping system.
Kvs value of valve unsuitable.
Fit valve with higher Kvs value.
Stuffing box sealing too tight

(for valves with graphite packings).
Slacken screw joint (pos. 25/20.17)

slightly Valve must nor start leaking!
Valve plug slightly seized owing to

solid dirt particles.
Clean internals, smooth rough spots.
Valve stem or plug cannot be Seating and plug clogged with dirt;
moved.
especially with V-port and perforated
plugs.
Valve stem leaking.
Clean seating and plug with suitable

solvent.
Valve plug seized in seating or guide

owing to deposits or dirt in medium.
Replace plug and seating; use parts

made from different material if necessary.
PTFE V-ring unit damaged or worn.
Replace ring pack (pos. 12);

refer to item 7.1.1
Stuffing box gland too slack in valves

with stuffing box packings.
Tighten screw joint (pos. 25);

refer to item 7.1.2.
Bellows defective in valves with bellow Replace bellows unit;

seal.
refer to item 7.1.3
Leakage too tiigti wtien
valve is closed.
Sealing surfaces of plug eroded or

worn.
Replace plug;
refer to item 7.2.1.
Sealing edge of seating damages or

worn.
Replace seating
(only at Series 445/446); refer to item
7.2.3, fit strainer if necessary.
Piston sealing ring worn (pressurerelieved valves).
Replace sealing ring;

refer to item 7.2.2
Seating and/or plug dirty.
Clean internals of valve;

fit dirt sieve if necessary.
Vent actuator air chamber completely.

Pneumatic actuator not completely
vented; spring force not fully effective.
Actuator not powerful enough.
Rev. 0040301000 3504
Install more powerful actuator.

Check service data.
Page 33
ARMATUREN

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.

The extent and period of warranty cover are specified in the "Standard Terms and
Conditions 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 the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or 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 specialist
appointed 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, design
modifications or natural wear
Any damage incurred during transport should not be reported to us but rathertothe
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be Invalidated.
ARMATUREN
Technology for the Future.

GERMAN QUALITY VALVES
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com
Page 34
Rev. 0040301000 3504
ARMATUREN

12.0 EC declaration of conformity / Manufacturers declaration

ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, D-33756 Schlo Holte-Stukenbrock
EC declaration of conformity
as defined by
the Pressure Equipment Directive 97/23/EC
Herewith we declare,
that according to the above mentioned Pressure Equipment Directive (PED) the below listed products comply and have been approved according to table 6, annex II module H or module H1 (with
safety function: also EC type test according to module B+D) through LLOYD'S REGISTER QUALITY ASSURANCE (NB-No. 0525), Mnckebergstr, 27, D-20095 Hamburg.
Module H, Certificate-No: 50003/1
Straight through stop and control valves
Type 405, 460, 440, 441, 445, 446, 470, 471, 422, 462, 425, 426, 480
Applied standard:
DIN EN 60534 part 1
VDIA/DE 3844 sheet 1
DIN 3840
AD 2000 leaflet A4
- Cast iron with spheroidal graphite
- Cast steel
- Forged steel
Module H1, Certificate-No: 50003/2
Straight through control valves with safety function
Type 440, 441
Applied standard:
DIN EN 60534 part 1
DIN 3840
AD 2000 leaflet A4
- Cast steel
- Forged steel
as defined by
the Machinery Directive 98/37/EC
Herewith we declare.
If the supplied model is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by this directive and must be put into service until the machinery into which it is be incorporated has been declared in conformity with the provisions of the ECMachinery Directive as amended by 98/37/EC.
Schlo Holte-Stukenbrock, 26.11.2002
, Managing director)
Rev. 0040301000 3504
Page 35
ARMATUREN
Page 36

Rev. 0040301000 3504
ARMATUREN

3-Wege-Stellventile - STEVI 450 / 451
^M
ia
BR450
BR451
Inhaltsverzeichnis
2
2
2.2 Erluterungen zu sicherheltsrelevanten Hinwelsen 2
4.0 Beschreibung
4.2 Arbeitsweise
4.3 Schaubilder
4.3.1 Ausfhrung mit Mischkegel
4.3.2 Ausfhrung mit Verteilkegel
4.5 Kennzeichnung

8
9
10
7.1.3.1 Faltenbalg und Mischkegel
10
7.1.3.2 Faltenbalg und Verteilkegel
12
14
14
16
17
7.3.1 Anzugsdrehmomente der Sechskantmuttern ..17
17
8.0 Ursache und Abhilfe bei
Betriebsstrungen
17
2
3
3
3
4
4
5
6
6 9.0 Fehlersuchplan
5.0 Montage
6 10.0 Demontage der Armatur bzw.
6
des Oberteiles
5.2 Montageangaben zum Einbauort
7 11.0 Garantie / Gewhrleistung
5.3 Montageangaben zum Antriebsaufbau und -abbau 7 12.0 Konformitts- / Herstellererklrung
6.0 Inbetriebnahme
8
8
8 Operating and installation Instructions.
Rev. 0 0 4 0 3 0 6 0 0 0 3 5 0 4 d e u t s c h / englisch
18
19
19
20

3-Wege-Steilventiie - STEVI 450 / 451
ARMATUREN

Diese Betriebsanleitung gilt als Anweisung, die Armaturen sicher zu montieren und zu
warten. Bei Schwierigkeiten, die nicht mit Hilfe der Betriebsanleitung gelst werden
knnen, nehmen Sie Kontakt mit dem Lieferant oder Hersteller auf.
Sie ist verbindlich fr den Transport, Lagerung, Montage, Inbetriebnahme, Betrieb,
Wartung, Reparatur.
Die Hinweise und Warnungen sind zu beachten und einzuhalten.
- Handling und alle anderen Arbeiten sind von sachkundigem Personal durchzufhren bzw.
alle Ttigkeiten sind zu beaufsichtigen und zu prfen.
Die Festlegung des Verantwortungsbereiches, des Zustndigkeitsbereiches und der
benwachung des Personals obliegt dem Betreiber.
- Bei Auerbetriebsetzung, Wartung bzw. Reparatur sind zustzlich die aktuellen
regionalen Sicherheitsanforderungen heranzuziehen und zu beachten.
Der Hersteller behlt sich das Recht von technischen nderungen und Verbesserungen
jederzeit vor.
Diese Betriebsanleitung entspricht den Anforderungen der EU-Richtlinien.
2.1 Bedeutung der Symboie
ACHTUNG!
Warnung vor einer allgemeinen Gefahr.

Bei dieser Betriebs- und Montageanleitung wird auf Gefhrdungen, Risiken und
sicherheitsrelevante Informationen durch eine hervorgehobene Darstellung besonders
aufmerksam gemacht.
Hinweise, die mit dem oben aufgefhrten Symbol und ACHTUNG!" gekennzeichnet sind,
beschreiben Verhaltensmanahmen, deren Nichtbeachtung zu schweren Verletzungen
oder Lebensgefahr fr Anwender oder Dritte bzw. zu Sachschden fr die Anlage oder die
Umwelt fhren knnen. Sie sind unbedingt zu befolgen, respektive die Einhaltung zu
kontrollieren.
Die Beachtung der nicht besonders hervorgehobenen anderen Transport-, Montage-,
Betriebs-und Wartungshinweise sowie technische Daten (in den Betriebsanleitungen, den
Produktdokumentationen und am Gert selbst) ist jedoch gleichermaen unerlsslich, um
Strungen zu vermeiden, die ihrerseits mittelbar oder unmittelbar Personen- oder
Sachschden bewirken knnen.
ACHTUNG!
- Gegen uere Gewalt (wie Sto, Sctilag, Vibration usw.) sctitzen.
-Armaturaufbauten wie Antriebe, l-iandrder, Hauben drfen nicfit zur Aufnafime
von ueren Krften wie z.B. fr Aufstiegstiilfen, Anbindungspunl<te fr
l-lebezeuge, etc. zwecl<entfremdet werden.
- Es mssen geeignete Transport- und Hebemittel verwendet werden.
Gewichte siefie Katalogblatt.
- Bei -20C bis +65C.

- Die Lackierung ist eine Grundfarbe die beim Transport und am Lager vor Korrosion
schtzen soll. Farbschutz nicht beschdigen.
Seite 2
Rev. 0040306000 3504
=^3TK> ARMATUREN

4.0 Beschreibung
Armaturen werden zum Regeln von flssigen, gasfrmigen und dampffrmigen Medien in
der Verfahrens- und Prozesstechnik sowie im Anlagenbau" eingesetzt.
ACHTUNG!
- Einsatzgebiete, Einsatzgrenzen und -mglichil<eiten sind dem Katalogblatt zu
entnehmen.
- Bestimmte Medien setzen spezielle Werkstoffe voraus oder sctilieen sie aus.
- Die Armaturen sind ausgelegt fr normale Einsatzbedingungen. Gehen die
Bedingungen ber diese Anforderungen hinaus, wie z.B. aggressive oder abrasive Medien, hat der Betreiber die hheren Anforderungen bei der Bestellung
anzugeben.
- Armaturen aus Grauguss sind fr den Einsatz in Anlagen nach TRD 110 nicht
freigegeben.
Die Angaben sind konform mit der Druckgerterichtlinie 97/23/EG.

Die Einhaltung unterliegt der Verantwortung des Anlagenplaners.
Besondere Kennzeichnungen der Armatur sind zu beachten.
Die Werkstoffe der Standard-Ausfhrungen sind dem Katalogblatt zu entnehmen.
Bei Fragen ist Rcksprache mit dem Lieferanten oder Hersteller zu fhren.
4.2 Arbeitsweise
ARI-Stellventile sind insbesondere fr die Bettigung durch pneumatische oder elektrische
Antriebe vorgesehen.
Je nach Einsatzfall sind zwei verschiedene Ausfhrungen mglich;
1. Ausfhrung mit Mischkegel
2. Ausfhrung mit Verteilkegel
Die Ausfhrung mit Mischkegel ist die Standardausfhrung.
Sie wird gewhlt wenn die Armatur als Mischer (2 Eingnge, 1 Ausgang) eingesetzt wird.
In Ausnahmefllen wird die Ausfhrung mit Mischkegel auch als Verteiler (1 Eingang, 2
Ausgnge) eingesetzt. Voraussetzung sind jedoch geringe Differenzdrcke und ein stabiler
Antrieb.
Die Ausfhrung mit Verteilkegel wird nur bei Verteilbetrieb eingesetzt.
Zur Erklrung:
Mischbetrieb
Verteilbetrieb
AB H ^ ^ B ^ A
AB
Rev. 0040306000 3504
Seite 3
Betriebs- und iVIontageanleitung

ARMATUREN
4.3 Schaubilder
Seite 4
Bild 1:BR450DN15-150
Bild 2: ER 451 DN15-150
Bild3:BR450DN125v-150v
Bild4:BR451DN125v-150v
Rev. 0040306000 3504

3-Wege-Stellventiie - STEVI 450 / 451
ARMATUREN
4.3.2 Ausfhrung mit Verteillêgei
Bild 5: BR 450 DN15-150
Bild 6: BR 451 DN15-150
Bild 7: BR 450 DN125v-150v
Bild 8: BR451 DN125v-150v
Rev. 0040306000 3504
Seite 5

3-Wege-Steliventile - STEVf 450 / 451
ARMATUREN
4.4 Techinisclie Daten

wie z.B.
- Hauptabmessungen,
- Druck-Temperatur-Zuordnungen, usw.
sind dem Katalogblatt zu entnehmen.
4.5 Kennzeichinung
Typen-Nummer
Nennweite
Hersteller
CE-Kennzeichnung
Nenndrucl<
, Benannte Stelle
Kennlinie
Kvs-Wert
Kegeiausfhrung
Werkstoff der
Innengarnitur
kundenspezifsche
Angaben
Baujahr unverschlsselt
( l u n d 2. Stelle)
Spindelabdichtung
Bild 9
Anschrift des Herstellers: siehe Punkt 11.0 Garantie / Gewhrleistung
Entsprechend der Druckgerterichtllnle Diagramm 6, Anhang II, drfen Armaturen ohne
Sicherheitsfunktion erst ab DN32 CE-gekennzelchnet werden.
5.0 Montage
5.1 Aligemeine IVIontageangaben
Neben den allgemeingltigen Montagerichtlinien sind folgende Punkte zu beachten:
ACHTUNG!
- Flanschabdeckungen, falls vorhanden, entfernen.
- Der Innenraum von Armatur und Rohrleitung muss frei von Fremdpartikeln sein.
- Einbaulage in Bezug auf Durchstrmung beachten, siehe Kennzeichnung auf
der Armatur
- Dampfleitungssysteme sind so auszulegen, dass Wasseransammlungen
vermieden werden.
- Die Rohrleitungen so verlegen, dass schdliche Schub-, Biege- und
Torsionskrfte ferngehalten werden.
- Bei Bauarbeiten Armaturen vor Verschmutzung schtzen.
- Anschlussflansche mssen bereinstimmen.
- Armaturaufbauten wie Antriebe, Handrder, Hauben drfen nicht zur Aufnahme
von ueren Krften wie z.B. Aufstiegshilfen, Anbindungspunkte fr
Hebezeuge etc. zweckentfremdet werden.
- Fr Montagearbeiten mssen geeignete Transport- und Hebemittel venwendet
werden.
- Spindelgewinde und Spindelschaft mssen farbfrei bleiben.
- Dichtungen zwischen den Flanschen zentrieren.
- Vor der Armatur Schmutzfnger / Filter vorsehen.
Fr die Positionierung und Einbau der Produkte sind Planer / Baufirmen bzw. Betreiber
verantwortlich.
Seite 6
Rev. 0040306000 3504
M K > ARMATUREN


Die Einbaustelle soll gut zugnglich sein und gengend Freiraum zur Wartung und zum
Abnehmen der Stellantriebe aufweisen. Vor und hinter dem Stellventil sind
Handabsperrventile vorzusehen, die Wartungs- und Reparaturarbeiten am Stellventil
ermglichen, ohne die Anlage zu entleeren. Das Stellventil soll vorzugsweise senkrecht mit
obenliegendem Antrieb eingebaut werden. Schrge bis waagerechte Einbaulage ist ohne
AbSttzung nur bei Antrieben mit geringem Eigengewicht zulssig.
Der Antrieb muss jedoch so montiert sein, dass die beiden Distanzsulen bzw. das Joch in
senkrechter Ebene bereinander liegen:
Bild 11: Rohrleitung waagerecht

Bild 10; Rohrleitung senkrecht
Zulssige Antriebsgewichte bei waagerechter Einbaulage in Bezug auf die Spindel, ohne
bauseitige Absttzung, sind:
20 kg fr DN 15-32
25 kg fr DN 40 - 65
35 kg fr DN 80-100
40 kg fr DN 125-150
55kgfrDN125v-150v
Um die Stellantriebe vor zu hoher Wrme zu schtzen, sind die Rohrleitungen zu isolieren.
Hierbei ist gengend Platz zur Wartung der Spindelabdichtung vorzusehen.
Zur einwandfreien Funktion sollte die Rohrleitung vor dem Stellventil auf einer Lnge von
min. 2 X DN und hinter dem Stellventil min. 6 x DN gerade ausgefhrt sein.
5.3 IVIontageangaben zum Antriebsaufbau und -abbau

Im Normalfall wird das Stellventil komplett mit aufgebautem Stellantrieb geliefert.
Fr bereits im Betrieb befindliche Armaturen, unter Betriebsdruck und Temperatur, ist der
Auf- und Abbau von Antrieben nicht zulssig. Bei Umbau oder Wartung ist die Montage der
Antriebe gem den Betriebsanleitungen fr Antriebe vorzunehmen.
Bei Montagearbeiten darf der Kegel nicht unter Anpressdruck auf dem Sitz gedreht werden.
ACHTUNG!
Bei Faltenbalgventilen ist darauf zu achten, dass beim Aufbau, bzw. Abbau des
Antriebes die Spindeleinheit nicht verdreht wird, damit der Faltenbaig nicht
beschdigt wird.
(An der Schlsselfiche der Spindel gegen Verdrehen sichern!)
Bei nachtrglichem Aufbau von Stellantrieben mssen die, fr die Bettigung maximal
zulssigen Stellkrfte beachtet werden:
BR450
BR451
18 kN fr DN 15-100
12kNfrDN 15-50
37 kN fr DN 125-150 / 125v-150v
29 kN fr DN 65-100
40kNfrDN 125-150
59kNfrDN125v-150v
Rev. 0040306000 3504
Seite 7
ARMATUREN

3-Wege-Steliventile - STEVI 450 / 451
6.0 Inbetriebnahme
ACHTUNG!
- Vor der Inbetriebnahme sind die Angaben zu Werkstoff, Druck, Temperatur und
Strmungsrichtung zu berprfen.
- Grundstzlich sind die regionalen Sicherheitsanweisungen einzuhalten.
- Rckstnde in Rohrleitungen und Armaturen (wie Schmutz, Schweiperlen,
usw.) fhren zu Undichtigkeiten bzw. Beschdigungen.
- Beim Betrieb mit hohen (> 50 C) oder tiefen (<0C) Medientemperaturen
besteht Verletzungsgefahr bei Berhren der Armatur
Ggf Warnhinweise oder Isoiierschutz anbringen!
Vor jeder Inbetriebnahme einer Neuanlage bzw. Wiederinbetriebnahme einer
Anlage nach Reparaturen oder Umbauten ist sicherzustellen:
- Der ordnungsgeme Abschluss aller Arbeiten!
- Die richtige Funktionssteliung der Armatur
- Schutzvorrichtungen sind angebracht.

Die Wartung und Wartungsintervalle sind entsprechend den Anforderungen vom Betreiber
festzulegen
7.1 Austausch der Spindel-Abdichitungen

PTFE-Dachmanschetten (Pos. 12) bestehend aus:
1 Grundring
4 Dichtringe
1 Deckring
Durch die eingebaute Druckfeder (Pos. 14) ist diese
Spindelabdichtung selbstnachstellend. Bei
Undichtigkeiten an der Spindel ist der Dichtsatz
verschlissen und muss ausgetauscht werden.
Austausch von PTFE-Dachmanschetten:
ACHTUNG!
Vor Demontage der Armatur Punkt 10.0 und
11.0 beachten.
Antrieb abbauen.
(Siehe Betriebsanleitung des Stellantriebs!).
Bei Austausch der Dachmanschetten (Pos. 12) auf
richtige Reihenfolge und Einbaulage der Einzelteile
achten (siehe Bild 12).
Bild 12: Dachmanschetten
- Dichtung (Pos. 17) muss erneuert werden.
DN15-150
Beschdigte Spindeln mssen ebenfalls ausgetauscht
werden (Beschreibung siehe Punkt 7.2), da ein neuer
Dichtsatz bei beschdigter Spindel innerhalb kurzer Zeit wieder undicht wird
Seite 8
Rev. 0040306000 3504

ARMATUREN

Die Stopfbuchspackung (Pos. 13) ist nicht wartungsfrei.
Bei auftretenden Undichtigkeiten sofort die Verschraubung (Pos. 42) bzw. stufenweise die
Sechskantmuttern (Pos. 24) gleichmig, bis zur Dichtheit der Packung (Pos. 13)
anziehen.
Durch regelmige Kontrolle auf Dichtheit wird die Lebensdauer der Stopfbuchspackung
(Pos. 13) erhht.
Ist ein Abdichten durch Nachziehen nicht mehr mglich, muss mit einem neuen
Packungsring (Pos. 13) nachgepackt werden.
Nachpacken der Stopfbuchspackung:
ACHTUNG!
Antrieb abbauen. (Siehe Betriebsanleitung des Stellantriebs!)

Neuen Packungsring (Pos. 13) einlegen, Einbau gem Darstellung Bild 13 bzw. Bild 14.
Bild 13: Stopfbuchspackung DN15-150
Bild 14: Stopfbuchspackung DN125v-150v
Wird ein geteilter Packungsring verwendet, ist

beim Zuschneiden auf einen schrgen
Schnittverlauf gem Darstellung Bild 15 zu
achten.
Bild 15: geteilter Packungsring
Beschdigte Spindeln mssen ebenfalls ausgetauscht werden (Beschreibung siehe
Punkt 7.2), da ein neuer Dichtsatz bei beschdigter Spindel innerhalb kurzer Zeit wieder
undicht wird.
Rev. 0040306O00 3504
Seite 9
ARMATUREN


Bei Undichtigkeiten an der Spindel liegt ein Defekt des eingebauten Faltenbalges
(Pos. 20.3) vor Zunchst kann durch leichtes Anziehen der Verschraubung (Pos. 20.17)
bzw. der berwurfmutter (Pos. 20.16) eine ausreichende Dichtheit erzielt werden.
Bei einem Austausch knnen Spindel und Faltenbalg (Pos. 20.3) nur gemeinsam
ausgetauscht werden.
Austausch der Faltenbalgeinheit:
ACHTUNG!
- Antrieb abbauen. (Siehe Betriebsanleitung des Stellantriebs!)

- Verschraubung (Pos. 20.17) bzw.benwurfmutter (Pos. 20.16) um ca. eine Umdrehung
lsen.
- Unteren Sitzring (Pos. 2) herausschrauben (Punkt 7.2 beachten) bei Verteilkegelausfhrung (Bild 18, Bild 19) nicht ntig.
- Mutter (Pos. 4) abschrauben und dabei an der Schlsselflche (Spindel oben)
gegenhalten.
- Kegel (Pos. 3 bzw. 31) ausbauen.
7.1.3.1 Faltenbalg und Mischkegel
PNI 5-150
- Demontage gem Punkt 7.1.3.
Faltenbalggehuse (Pos. 20.1) herausnehmen.
- Adapter (Pos. 37) abschrauben.
Hinweis:
Adapter (Pos. 37) und Spannhlse (Pos. 6) sind bei DN4050 nicht vorhanden.
- Neue Teile verschrauben, bohren und verstiften.
- 2 Flachdichtungen (Pos. 20.6) und
1 Flachdichtung (Pos. 9) erneuern.
ACHTUNG bei DN125-150!
- Beim Einsetzen der neuen Spindel-ZFaitenbalgeinheit auf rictitige Steliung der
Verdreiisiciierung actiten. Den Passkerbstift
(Pos. 20.9) in die Nut der Verdreiisiciierung
einfiiren. Auf reibungsfreien Lauf actiten!
Mit Muttern (Pos. 11 und 20.8) befestigen und kreuzweise
anziehen. (Anzugsdrehmomente siehe Punkt 7.3.1)
Verschraubung (Pos. 20.17) bis zur Dichtheit der
Bild 16:BR451 DN 15-150
mit Mischkegel
Seite 10
Rev. 0040306000 3504

ARMATUREN
DN125V-150V
20 16

- Muttem (Pos. 20.8) lsen.
- Stopfbuchsgehuse (Pos. 20.13) abnehmen.
Faltenbalggehuse (Pos. 20.1)
herausnehmen.
- Spannhlse (Pos. 6) mit einem Dorn
heraustreiben.
- Neue Teile verschrauben, bohren und
verstiften.
- 2 Flachdichtungen (Pos. 20.6) und 1
Flachdichtung (Pos. 27) erneuern.
ACHTUNG!
- Beim Einsetzen der neuen Spindei-/
Faltenbalgeinlieit aufriclitige Steliung
der Verdretisiclierung achten. Den
Passkertistift (Pos. 20.9) in die Nut
der Verdrehsictierung einfliren.
Auf reibungsfreien
Laufacfiten!
Mit Muttern (Pos. 29 und 20.8) befestigen und

kreuzweise anziehen.
benwurfmutter (Pos. 20.16) bis zur Dichtheit
der Stopfbuchspackung (Pos. 20.10) anziehen.
Bild 17:
BR451 DN125v-150v mit Mischkegel
Rev. 0040306000 3504
Seite 11
ARMATUREN

7.1.3.2 Faltenbalg und Verteilkegel

DN40-150
- Distanzhlse (Pos. 32) von dem Adapter (Pos. 38)
ziehen.
Hinweis:
Distanzhlse (Pos. 32) ist bei DN125-150 nicht
vorhanden.
- IVluttern (Pos. 11) lsen.
- DN15-100: Kegel (Pos. 40) von dem Adapter
(Pos.38) ziehen.
- DN125-150: Spannhlse (Pos. 33) mit einem Dorn
heraustreiben. Kegel (Pos.40) von dem Adapter
(Pos. 38) schrauben.
- IVluttern (Pos. 20.8) lsen.
Faltenbalggehuse herausnehmen.
Hinweis:
Adapter (Pos. 38) und Spannhlse (Pos. 6) sind bei
DN40-50 nicht vorhanden.
- 2 Flachdichtungen (Pos. 20.6) und 1 Flachdichtung
(Pos. 9) erneuern.
ACHTUNG bei DN125-150!
- Beim Einsetzen der neuen Spindel-/
Faltenbalgeinheit auf richtige Stellung der
Verdrehsicherung achten. Den
Passkerbstift (Pos. 20.9) in die Nut der
Bild 18:
Verdrehsicherung einfhren.
BR 451 DN15-150 mit Verteilkegel
Auf reibungsfreien Lauf achten!
kreuzweise anziehen. (Anzugsdrehmomente siehe Punkt 7.3.1.)
Verschraubung (Pos. 20.17) bis zur Dichtheit der Stopfbuchspackung (Pos. 20.10)
anziehen.
Seite 12
Rev. 0040306000 3504

ARMATUREN
DN125V-150V
20,16
20,8
- Demontage gem Punl<t 7.1.3.

- Faltenbalgaufsatz (Pos. 20) incl.
Stopfbuchsgehuse (Pos. 39) abnehmen.
heraustreiben.
- Kegel (Pos. 40) von dem Adapter (Pos. 38)
abschrauben.
- Stopfbuchsgehuse (Pos. 20.13) abnehmen.
Faltenbalggehuse herausnehmen.
heraustreiben.
- 2 Flachdichtungen (Pos. 20.6) und je 1
Flachdichtung (Pos. 27, Pos. 9) erneuern.
ACHTUNG!
' \
- Beim Einsetzen der neuen Spindel-/
Faltenbalgeinheit aufrichtige Stellung
der Verdrehsicherung achten.
Den Passkerbstift (Pos. 20.9) in die
Nut der Verdrehsicherung einfhren.
Auf reibungsfreien Lauf achten!

benwurfmutter (Pos. 20.16) bis zur Dichtheit der
Bild 19:
BR451 DN125v-150v mit Verteilkegel
Rev. 0040306000 3504
Seile 13

ARMATUREN
7.2 Austauscli der Innengarnitur
ACHTUNG!
- Antrieb abbauen.
Zum Herausschrauben des Sitzrings (Pos. 2) ist ein Spezialschlssel erforderlich, der vom
Hersteller bezogen werden kann.
Vor dem Einbau eines neuen bzw. berarbeiteten Sitzes, Gewinde und Dichtkonus im
Gehuse subern und mit geeignetem Schmiermittel bestreichen.
Der Austausch von Kegel und Spindel bei Armaturen mit Faltenbalg (BR451) ist unter
Punkt 7.1.3 beschrieben.
DN15-150
- Sitzring (Pos. 2 unten) herausschrauben und
erneuern oder berarbeiten.
Umdrehung lsen.
- Kegel (Pos. 3) mit Spindel (Pos. 5) herausziehen und
entsprechend austauschen.
Hinwels:
DN125-150 Neue Teile verschrauben, bohren und
verstiften.
(Anzugsdrehmomente der Sitzringe siehe Punkt 7.3.2)
Austausch des oberen Sitzrings Ist nur mglich bei:
DN125-150 mit Standard Kvs-Werten
DN 15-150 mit mehrfach reduzierten Kvs-Werten
- Demontage von Sitzring, Kegel und Spindel wie vor
beschrieben.
- Muttern (Pos.11) lsen.
- Traversendeckel (Pos.7) abnehmen.
- Sitzring (Pos.2 oben) herausschrauben und erneuern
oder berarbeiten. (Anzugsdrehmomente der Sitzringe
siehe Punkt 7.3.2.)
- Flachdichtung (Pos.9) erneuern.
- Mit Muttern (Pos.11) befestigen und kreuzweise anziehen
Seite 14
Rev. 0040306000 3504
Bild20:BR450DN15-150
mit Mischkegel
gMfe> A R M A T U R E N

DN125v-150v
- Sitzring (Pos. 2 unten) herausschrauben und
- Muttern (Pos. 24) um ca. 2-3 Umdrehungen
lsen.
- Kegel (Pos. 3) mit Spindel (Pos. 5) herausziehen
und entsprechend austauschen.
- Zusammenbau in umgel<ehrter Reihenfolge.
(Anzugsdrehmomente der Sitzringe siehe
Punkt 7.3.2.)
Austausch des oberen Sitzrings:
- Demontage von Sitzring, Kegel und Spindel wie
vor beschrieben.
- Stopfbuchsgehuse (Pos. 39) abnehmen.
- Sitzring (Pos. 2 oben) herausschrauben und
Punl<t 7.3.2.)
- Zusammenbau in umgel<ehrter Reihenfolge.
- Mit Muttern (Pos.11) befestigen und l<reuzweise
anziehen. (Anzugsdrehmomente siehe
Punkt 7.3.1)
2(oben)
2 (unten)
Bild 21:
BR450 DN125v-150v mit Mischkegei
Rev. 0040306000 3504
Seiteis
= K Q * > ARMATUREN


DN40-150
Umdrehung lsen.
- Traversendeckel (Pos.7) abheben.
- Mutter (Pos. 4) lsen.
- Kegel (Pos. 31) mit Distanzhlse (Pos. 32) nach
unten herausziehen.
Hinweis:
Distanzhlse (Pos. 32) entfllt bei DN125-150.
- Kegel (Pos. 40) mit Spindel (Pos. 41) nach oben
herausziehen und entsprechend austauschen.
Hinweis:
DN125-150: Neue Teile verschrauben, bohren und
verstiften.
- Sitzringe (Pos. 2 unten und oben)
herausschrauben und erneuern oder
berarbeiten. (Anzugsdrehmomente der Sitzringe
siehe Punkt 7.3.2.)
- Mit Muttern (Pos.11) befestigen und kreuzweise
anziehen.
DN125V-150V
- Stopfbuchsgehuse (Pos. 39) abheben.
- Mutter (Pos. 4) lsen.
- Kegel (Pos. 31) nach unten herausziehen.
- Kegel (Pos. 40) mit Spindel (Pos. 41) nach
oben herausziehen und entsprechend
austauschen.
- Neue Teile verschrauben, bohren und
verstiften.
- Sitzringe (Pos. 2 unten und oben)
herausschrauben und erneuern oder
berarbeiten.
Punkt 7.3.2)
- Mit Muttern (Pos.11) befestigen und
2 (unten)
Bild 22:
BR450 DN40-150 mit Verteilkegel
(oben)
2 (unten)
Bild 23:
BR450 DN125v-150v mit Verteilkegel
Seite 16
Rev. 0040306000 3504

ARMATUREN
7.3.1 Anzugsdrehmomente der Sechskantmuttern
M10
M 12
M16
M20
=
=
=
=
15-30Nm
35-50Nm
80-120Nm
150-200 Nm

DN 15/20
DN 25/ 32
DN 40/ 50
DN65
DN80
DN100
DN125/125V
DN150/150V
=
=
=
=
=
=
=
=
100 Nm
150 Nm
350 Nm
480 Nm
660 Nm
980 Nm
1450 Nm
2000 Nm
/ Antriebsaufbau siehe Betriebsanleitung fr betreffenden

Antrieb!
8.0 Ursache und Abhilfe bei Betriebsstrungen
Bei Strungen der Funktion bzw. des Betriebsverhaltens ist zu prfen, ob die Montage- und
Einstellarbeiten gem dieser Betriebsanleitung durchgefhrt und abgeschlossen wurden.
ACHTUNG!
- Bei der Fehlersuche sind die Sicherheitsvorschriften zu befolgen.
Bei Strungen die anhand der nachfolgenden Tabelle siehe Pkt. 9.0 Fehlersuchplan"
nicht behoben werden knnen, ist der Lieferant oder Hersteller zu befragen.
Rev. 0040306000 3504
Seite 17

i > ARMATUREN
9.0 Fehlersuchplan
ACHTUNG!
- vor Montage- und Reparaturarbeiten Punkte 10.0 und 11.0 beachten !
- vor Wiederinbetriebnahme Punkt 6.0 beachten
Strung
Mgfiche Ursachen
Abhilfe
Kein Durchfluss
Armatur gesctilossen
Flansctiabdeckungen wurden nicht ent- Flanschabdeckungen entfernen

fernt
Geringer Durclifluss
Spindel bewegt sicti nur

rucl<weise
Armatur nicht ausreichend geffnet
Verunreinigter Schmutzfnger
Sieb reinigen / austauschen
Verstopfung im Rohrleitungssystem
Rohrieitungssystem berprfen
Armatur bzw. Kvs-Wert falsch gewhlt
Armatur mit grerem Kvs-Wert einsetzen
Zu fest angezogene Stopfbuchsabdich- Geringes Lsen der Verschraubung

tung (bei Armaturen mit Graphit(Pos. 42/20.17) bzw. der IMuttern
Packung)
(Pos. 24) Jedoch muss Dichtheit
gewhrleistet bleiben
Kegel hat aufgrund von Fest-, Schmutz- Innenteile subern, beschdigte Stellen
partikeln leicht gefressen
gltten
Spindel bzw. Kegel sitzt

fest
Sitz und Kegel stark mit Schmutz verklebt, insbesondere bei Schlitz- und
Lochkegeln
Sitz und Kegel mit geeignetem

Lsungsmittel reinigen
Kegel hat sich, aufgrund von Ablagerun- Sitz und Kegel austauschen; ggf.
gen oder Feststoffen im IVIedium, im Sitz Ersatzteile aus anderen Werkstoffen
oder in der Fhrung festgefressen
vorsehen
An der Spindel undictit
Dachmanschetten-Dichtsatz beschdigt oder verschlissen
Dichtsatz austauschen;
siehe Punkt 7.2
Bei Ausfhrung mit Stopfbuchspackung Verschraubung (Pos. 42) bzw. Schrauist die Verschraubung (Pos.42) bzw. die ben (Pos. 24) nachziehen; ggf. nachpaSchrauben (Pos. 24) nicht stark genug cken; siehe Punkt 7.1.2
angezogen
Faltenbalg defekt bei Armatur in Falten- Austausch der Faltenbalgeinheit;
balgausfhrung
siehe Punkt 7.1.3
Bei gesctilossener Arma- Dichtflchen am Kegel ausgewaschen
tur ist die Lecl<rate zu hocti oder verschlissen
Kegel austauschen;
siehe Punkt 7.2
Dichtkante am Sitz beschdigt oder ver- Sitz austauschen;

schlissen
siehe Punkt 7.2
Verschmutzung von Sitz oder Kegel
Innenteile subern
Pneum. Antrieb nicht vollstndig entlf- Luftkammer des Antriebs ganz

tet, Federkraft wird nicht voll wirksam
entlften.
Spindel schlgt"
Seite 18
Antrieb zu schwach
Strkeren Antrieb einsetzen
Durchstrmen in Schlierichtung
Kegelausfhrung (Misch- oder Verteilkegel) mit Einsatz vergleichen und

gegebenenfalls Garnitur austauschen
oder Antriebskrfte erhhen
Rev 0040306000 3504
ARMATUREN

10.0 Demontage der Armatur bzw. des Oberteiles
ACHTUNG!
Insbesondere sind folgende Punkte zu beachten:
- Druckloses Rohrleitungssystem.
- Abgekhltes Medium.
- Entleerte Anlage.
- Bei tzenden, brennbaren, aggressiven oder toxischen Medien Rohrleitungssystem belften.

Umfang und Zeitraum der Gewhrleistung ist in der zum Zeitpunkt der Lieferung gltigen
Ausgabe der "Allgemeinen Geschftsbedingungen der Albert Richter GmbH & Co. KG"
oder abweichend davon im Kaufvertrag selbst angegeben.
Wir leisten Gewhr fr eine dem jeweiligen Stand der Technik und dem besttigten Verwendungszweck entsprechenden Fehlerfreiheit.
Fr Schden, die durch unsachgeme Behandlung oder Nichtbeachtung der Betriebsund Montageanleitung, des Katalogblattes und der einschlgigen Regelwerken entstehen,
knnen keine Gewhrleistungsansprche geltend gemacht werden.
Schden die whrend des Betriebes, durch vom Datenblatt oder anderen Vereinbarungen
abweichenden Einsatzbedingungen entstehen, unterliegen ebenso nicht der Gewhrleistung.
Berechtigte Beanstandungen werden durch Nacharbeit von uns oder durch von uns beauftragte Fachbetriebe beseitigt.
ber die Gewhrleistung hinausgehende Ansprche sind ausgeschlossen. Anspruch auf
Ersatzlieferung besteht nicht.
Wartungsarbeiten, Einbau von Fremdteilen, nderung der Konstruktion, sowie natrlicher
Verschlei sind von der Gewhrleistung ausgeschlossen.
Etwaige Transportschden sind nicht uns, sondern unverzglich Ihrer zustndigen Gterabfertigung, der Bahn oder dem Spediteur zu melden, da sonst Ersatzansprche an diese
Unternehmen vedoren gehen.
ARMATUREN
Technik mit Zukunft.

DEUTSCHE QUALITTSARMATUREN
Telefon +49 (0)5207 / 994-0 Telefax +49 (0)5207 / 994-297 oder 298
Internet: http://www.ari-armaturen.de E-mail: info.vertrieb@ari-armaturen.de
Rev. 0040306000 3504
Seite 19

12.0 Konformitts-/ Herstellererklrung
Mergelhejde 56-60, 33756 Schlo Holte-Stukenbrock
EG-Konformittserklrung
im Sinne der
EG-Druckgerterichtlinie 97/23/EG
dass gem der oben genannten Druckgerterichtlinie, die unten aufgelisteten Produkte ausgefhrt
sind und nach Diagramm 6, Anhang II, Modul H von LLOYD'S REGISTER QUALITY ASSURANCE
(BS-Nr. 0525), Mnckebergstr. 27, 20095 Hamburg, geprft wurden.
Zertifikat-Nr: 50003/1
Stellventil in Dreiwegeform
Typ 450, 451, 423, 463, 483
Angewendete Normen:
DIN EN 60534 Teil 1
VDI/VDE 3844 Blatt 1
DIN 3840
- Stahlguss
- Schmiedestahl
Herstellererklrung
im Sinne der
EG-Maschinenrichtlinie 98/37/EG
dass die aufgefhrten Produkte, in der gelieferten Ausfhrung zum Einbau in eine Maschine oder
Anlage bestimmt sind und dass die Inbetriebnahme der Maschine / Anlage solange untersagt ist,
bis festgestellt wurde, dass die Maschine / Anlage den Bestimmungen der EG-Maschinenrichtlinie
98/37/EG entspricht.
Schlo Holte-Stukenbrock, den 12.09.2002
(Brechrirann, Geschftsfhrer)
Seite 20
Rev. 0040306000 3504
g3iS> A R M A T U R E N

3-way control valves - STEVI 450 / 451
CTZD
Series 450
Series 4 5 1
Contents
1.0 General information on operating

instructions
4.0 Description
4.3 Diagram
4.3.1 Mixing plug design
4.3.2 Diverting plug design
4.4 Technical data
4.5Marl<ing
5.0 Installation
22
22
22
22
22
23
23
23
24
24
25
26
26
26
26
27
27
28

7.1.3.1 Bellows seal and mixing plug
7.1.3.2 Bellows seal and diverting plug
7.2.1 IVlixing plug design
7.3.1 Tightening torques for hexagon nuts
8.0 Troubleshooting
12.0 EC declaration of conformity /
Rev. 0040306000 3504
28
28
28
29
30
30
32
34
34
36
37
37
37
37
38
39
39
40
page 21

ARMATUREN

and repair.
These Operating Instructions comply with the requirements of ED Directives.

ATTENTION !

in these Operating and Installation Instructions dangers, risks and items of safety
Information marked with the above symbol and "ATTENTION I" describe practices, a
to property.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
See catalog sheet for weights.
- At -20C to +65C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
Page 22
Rev. 0040306000 3504
ARMATUREN

4.0 Description
Valves are used for controlling the flow of liquids, gases and vapours in chemical and other
processing plants and for plant engineering".
ATTENTION !
- Refer to the data sheet for applications, iimits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed forstandard 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.
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.

ARI control valves are especially suitable for actuation by pneumatic or electrical actuators.
Depending on the mode of operation, two different execution methods are possible:
1. Execution with mixing plug
2. Execution with diverting plug
The execution with the mixing plug is the standard execution method.
This execution method is to be chosen when the valve is also employed as a mixer
(2 entrances, 1 exit).
In exceptional cases, the execution with the mixing plug can also be employed as a
diverting plug (1 entrance, 2 exits). This requires, however, low differential pressures and
stable propulsion.
The execution method with the diverting plug is only to be employed with the operation of
diverting.
Explanation:
Mixing operation
AB ^ B ^ ^ ^ A
Diverting operation
AB
Rev. 0040306000 3504
Page 23

g>> A R M A T U R E N
4.3 Diagram
1 iSeries 450 DN15-150
Fig. 3: Series 450 DN125v-150v

Page 24
Rev. 0040306000 3504

i : ^ i > ARMATUREN
Series 450 DN15-150
Series 450 DN125V-150V
Rev. 0040306000 3504
Page 25

< S 3 ^ ARMATUREN
4.4 Technical data

for
- Principal dimensions
- Pressure-temperature-ratings, etc. refer to datasheet.
4.5 Marking
Type-Number
Nominal diameter
Manufacturer
CE-marking
Notified body
Kvs-value
Customer-specific
information
Stem sealing
IVIaterial of
internal parts
Year of manufacture clear speech

(1. and 2. position)
Fig. 9
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
According to the Pressure Equipment Directive table 6, annex II, valves without safety
function are only allowed to bear the CE-marking DN32 onwards.
5.0 Installation
The following items should be taken into account besides the general principles governing
installation work;
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 are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
connecting points for lifting gear.
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.
Planners / construction companies or operators are responsible for positioning and

installing products.
Page 26
Rev. 0040306000 3504

=:K(IK> ARMATUREN

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 behind
the control valve to enable maintenance working without draining the piping system. The
valve 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 each
other in the vertical plane.
XU,
a
Fig. 10: Pipeline vertically
Fig. 11: Pipeline horizontally
Safe actuator weights for a horizontal installation position with reference to the stem,
without structural support, are as follows:
20 kg for DN 1 5 - 3 2
25 kg for DN 40 - 65
35 kg for DN 80-100
40 kg for DN 125-150
55kgforDN125v-150v
The pipes must be lagged to protect the actuators from excessive heat. Sufficient space
must be left for the maintenance of the stem packing.
To ensure that the control valves function correctly, the pipe run should be straight for at
least 2 X DN upstream and 6 x DN downstream of the valve.

Normally, control valves are supplied complete with actuator fitted.
It is not permitted to mantle / dismantle actuators with valves operating at service conditions
(temperature and pressure) the actuators must be assembled as describe in the operating
instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seatring at closing pressure.
ATTENTION!
Care must be taken with the bellow type valves when actuators are mounted or
removed. (Hold the valve-stem against turning with an open-end wrench!)
When retrofitting actuators, the maximum permissible force for valve actuation must be
taken into account:
Series 450
Series 451
12 kN for DN 15-50
18 kN for DN 15-100
29 kN for DN 65-100
37 kN for DN 125-150 / 125v-150v
4 0 k N f o r D N 125-150
59kNforDN125v-150v
Rev. 0040306000 3504
Page 27

ARMATUREN
ATTENTION!
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leal<age.
- Touching the valve when it is operating at high (> 50 C) or low (< 0 C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.

IVIaintenance and maintenance intervals have to be defined by the operator according to
the service conditions.

PTFE V-ring unit (pos. 12) consisting of: 1 backing ring
4 sealing rings
1 cover ring
Owing to the installed compression spring (pos. 14), this
stem packing is self-adjusting. If the stem starts leaking, the
ring pack is worn out and must be replaced.
Replacement PTFE V-ring unit:
ATTENION I
Refer to point 10.0 and 11.0 before
- Remove actuator,
- When replacing V-ring unit (pos. 12), make sure that the
parts are installed in the correct order and positions
(refer to Fig. 12).
- Gasket (pos. 17) must be replaced.
Damaged stems must also be replaced (refer to point 7.2
for instructions) since a new sealing will soon start leaking
again if the stem is damaged.
Page 28
Rev. 0040306000 3504
Fig. 12:
Installation V-ring unit
DN15-150

The stuffing box packing requires maintenance.
If leaks develop, immediately tighten the screw joint (pos. 42) respectively the hexagon nuts
(pos. 24) gradually until the packing ring (pos. 13) stops leaking.
The service life of stuffing box packings (pos. 13) can be Increased by checking regularly
leakage.
If leaks can no longer be stopped by tightening the screw joint (pos. 42) respectively the
nuts (pos. 24), a new packing ring (pos. 13) must be Inserted Into the gland.
Replacement of stuffing box packings:
ATTENION!
Refer to point 10.0 and 11.0 before dismantling the valve.
Remove actuator. (Refer to operating Instructions for actuator!)

Insert new packing ring as shown in the Fig. 13 and Fig. 14.
Fig. 13: Stuffing box packing DN15-150
Fig. 14: Stuffing box packing DN125v-150v
If a split packing ring Is used, cut with a chamfer

as shown in Fig. 15.
Fig. 15: Split packing ring

Damaged stems must also be replaced (refer to point 7.2 for instructions), since a new
sealing will soon start leaking again if the stem Is damaged.
Rev. 0040306000 3504
Page 29

3-way control valves - STEVr .450 / 451
ARMATUREN
If the stem leaks the bellows seal (pos. 20.3) is defective. The leak can initially be stopped
by tightening the screw joint (pos. 20.17) respectively the sleeve nut (pos. 20.16).
Stem and bellows (pos. 20.3) can only be replaced together.
Replacement of bellows seal:
ATTENION !
Refer to point 10.0 and 11.0 before dismantling the valve.
- Remove actuator. (Refer to operating instructions for actuator!)

- Slacken screw joint (pos. 20.17) respectively sleeve nut (pos, 20.16) by about one turn.
- Unscrew the bottom seat ring (pos. 2) (refer to point 7.2) with diverting plug version (Fig. 18, Fig. 19) not necessary.
- Unscrew hexagon nut (pos. 4), (holding against spanner face).
- Remove plug (pos. 3 or 31).
7.1.3.1 Bellows seal and mixing plug
P N I 5-150
20,17
- Dismantle as point 7.1.3.

- Detach mounting bonnet (pos. 20.2).
- Extract stem-/bellows unit (pos. 20.3) from the bellows
housing (pos. 20.1).
- Unscrew stem adapter (pos. 37).
Note:
Adapter (pos. 37) and straight pin (pos. 6) are not existing at
DN40-50.
- Bolt new parts together, drill and pin them.
- Replace 2 gaskets (pos. 20.6) and 1 gasket (pos. 9).
ATTENTION at DN125-150!
'\
- Ensure that the torsion lock is correctly
positioned when inserting new stem/bellows
unit. Introduce the grooved pin (pos. 20.9) into
the torsion lock groove.
Make sure it runs smoothly!
Secure with nuts (pos. 11 and 20.8) and tighten them

crosswise. (For tightening torques refer to point 7.3.1.)
- Tighten screw joint (pos. 20.17) gradually up to tightness of
the stuffing box packing (pos. 20.10).
Page 30
Rev. 0040306000 3504
Fig. 16:
Series 451 DN 15-150
with mixing plug

< Q X > ARMATUREN
DN125v-150v
- Dismantle as point 7.1.3.
- Detach stuffing box housing (pos. 20.13).
- Extract stem-/bellows unit (pos. 20.3) from the
- Replace 2 gaskets (pos. 20.6) and 1 gasket
(pos. 27).
ATTENTION !
- Ensure that the torsion lock is
correctly positioned when inserting
new stem/beliows unit Introduce the
grooved pin (pos. 20.9) into the
torsion lock: groove.
Secure with nuts (pos. 29 and 20.8) and tighten

them crosswise.
(For tightening torques refer to point 7.3.1.)
Tighten sleeve nut (pos. 20.16) gradually up to
tightness of the stuffing box packing
(pos. 20.10).
Fig. 17:
Series 451 DN125v-150v
with mixing plug
Rev. 0040306000 3504
Page 31

ARMATUREN
7.1.3.2 Bellows seal and diverting plug
DN40-150
20,17
- Dismantle as item 7.1.3.

- Pull distance bush (pos. 32) from adapter (pos. 38).
Note:
There is no distance bush (pos. 32) on DN 125-150.
- DN 15-100: Pull plug (pos. 40) from adapter
(pos. 38).
- DN 125-150: Drive straight pin (pos. 33) out with a
drift. Screw plug (pos. 40) from adapter (pos. 38).
- Detach mounting bonnet (pos. 20.2).
- Extract stem-/bellows unit (pos. 20.3) from the
Note:
Adapter (pos. 38) and straight pin (pos. 6) are not
existing at DN40-50.
- Replace 2 gaskets (pos. 20.6) and 1 gasket
(pos. 9).
ATTENTION at DN125-150!
- Ensure that the torsion lock is correctly
positioned when inserting new stem/
bellows unit Introduce the straight pin
(pos. 20.9) into the torsion lock groove.
Secure with nuts (pos. 11 and 20.8) and tighten

them crosswise.
Fig. 18:
Series 451 DN15-150
with diverting plug
Tighten screw joint (pos. 20.17) gradually up to tightness of the stuffing box packing
(pos. 20.10).
Page 32
Rev. 0040306000 3504

ARMATUREN
DN125v-150v
- Dismantle as item 7.1.3.
- Detach bellows assembly (pos. 20) ind.
stuffing box housing (pos. 39).
- Unscrew plug (pos. 40) from adapter (pos. 38).

- Detach stuffing box housing (pos. 20.13).
- Extract stem/bellows unit (pos. 20.3) from the
- Replace 2 gaskets (pes. 20.6) and each
1 gasket (pos. 27, 9).
ATTENTION!
- Ensure that the torsion lock is
correctly positioned when inserting
new stem/bellows unit. Introduce the
straight pin (pos. 20.9) into the
torsion lock groove.
Secure with nuts (pos. 29 and 20.8) and

tighten them crosswise.
Tighten sleeve nut (pos. 20.16) gradually up to
tightness of the stuffing box packing
(pos. 20.10).
Fig. 19:
with diverting plug
Rev. 0040306000 3504
Page 33
g> ARMATUREN

ATTENION!
- Remove actuator. (Refer to operating instructions for actuator!)

A special wrench is needed to remove the seatring (pos. 2). It can be obtained from the
manufacturer.
When fitting a new or reconditioned seatring, clean thread and sealing taper in body and
apply suitable lubricant.
Item 7.1.3 describes how to change the plug and stem in valves with a bellow seal
(series 451).
P N I 5-150
- Unscrew seat ring (pos. 2 bottom) and renew or
recondition.
- Slacken screw joint (pos. 19 or 42) by about 1 turn.
- Extract and replace plug (pos. 3) and stem (pos. 5).
Note:
DN 125-150: Bolt new parts together, drill and pin them.
The top seat ring can only be replaced in:
DN 125-150 with standard Kvs values
DN 15-150 with multiple reduced Kvs values
- Dismantle seat ring, plug and stem as described above.
- Detach mounting bonnet (pos. 7).
- Unscrew seat ring (pos. 2 top) and renew or recondition.
2 (bottom)

- Secure with nuts (pos. 11) and tighten them crosswise.
Page 34
Rev. 0040306000 3504
Fig, 20:
Series 450 D M 5-150
with mixing plug

ARMATUREN
DN125v-150v
- Unscrew seat ring (pos. 2 bottom) and renew or

recondition.
- Slacken nuts (pos. 24) by about 2-3 turns.
- Extract and replace plug (pos. 3) and stem
(pos. 5).
2 (top)

Changing the top seat ring:
- Dismantle seat ring, plug and stem as described
above.
- Detach stuffing box housing (pes. 39).
- Unscrew seat ring (pes. 2 top) and renew or
recondition. (For tightening torques refer to
item 7.3.2.)
- Assemble in reverse order
crosswise.
2 (bottom)
Fig. 2 1 :
with mixing plug
Rev. 0040306000 3504
Page 35

ARMATUREN

DN40-150
- Slacken screw joint (pos. 19 and 24) by about 1
turn.
- Detach mounting bonnet (pos. 7).
- Loose nut (pos. 4) and pull plug (pos. 31) with
distance bush (pos. 32) down.
Note:
There is no distance bush (pos. 32) in DN125-150.
- Pull plug (pos. 40) with stem (pos. 41) up and
replace.
Note:
DN 125-150: Bolt new parts together, drill and pin
them.
2 (bottom;
- Unscrew seat rings (pos. 2 bottom and top) and

renew or recondition.
crosswise.
Fig. 22:
Series 450 DN40-150 with diverting
plug Verteilkegel
DN125v-150v
- Detach stuffing box housing (pos. 39).
- Loose nut (pos. 4).
- Pull plug (pos. 31) down.
- Pull plug (pos. 40) with stem (pos. 41) up and
replace.
- Unscrew seat rings (pos. 2 bottom and top) and
renew or recondition
2 (top)
2 (bot.)

crosswise.
Fig. 23:
Series 450 DN125v-150v with div. plug
Page 36
Rev. 0040306000 3504

ARMATUREN

7.3.1 Tightening torques for hexagon nuts
M10
M12
M 16
M20
=
=
=
=
15-30Nm
35-50Nm
80-120Nm
150-200 Nm

DN 15/20
DN 25/ 32
DN 40/ 50
DN65
DN80
DN100
DN125/125V
DN150/150V
=
=
=
=
=
=
=
=
100 Nm
150 Nm
350 Nm
480 Nm
660 Nm
980 Nm
1450 Nm
2000 Nm
Refer to operating and installation instructions for actuator

concerned for installing actuators!
8.0 Troubleshooting
In the event of malfunction or faulty operating performance checht that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
A
'\
ATTENTION I
-It is essential that the safety regulations are observed when identifying faults.

"9.0 Troubleshooting table", the supplier or manufacturer should be consulted.
Rev. 0040306000 3504
Page 37

ARMATUREN
ATTENTION!
- read item 10.0 and 11.0 prior to dismantling and repair work!
- read item 6.0 before restarting the plant!
Fault
Possible cause
Corrective measures
No flow
Valve closed
Open valve (using actuator)
Little flow
Stem moves in jerks.
Flange covers not removed
Remove flange covers
Valve not sufficiently open
Open valve (using actuator)
Dirt sieve clogged
Clean / replace sieve
Piping system clogged
Check piping system
Kvs value of valve unsuitable
Fit valve with higher Kvs value
Stuffing box sealing too tight

(for valves with graphite pacl<ings)
Slacken screw joint (pos. 42/20.17) or

hexagon nuts (pos. 24) slightly;
valve must not start leaking!
Valve plug slightly seized owing to solid Clean internals, smooth rough spots.
dirt particles
Stem or plug cannot be
moved.
Stem leal<ing.
Seatring and plug clogged with dirt;

especially with V-port and perforated
plugs
Clean seatring and plug with suitable

solvent
Valve plug seized in seatring or guide

owing to deposits or dirt in medium
Replace plug and seatring; use parts

made from different material if necessary
PTFE V-ring unit damaged or worn
Replace ring pack; refer to item 7.2
In valves with packed stuffing boxes

tighten screw Joint (pos. 42)
Tighten screw joint (pos. 42) or hex.

nuts (pos. 24); replace packing if necessary; refer to item 7.1.2
Bellows defective in valves with bellow Replace bellows unit; refer to item
seal
7.1.3
Leal<age too higti when
valve is closed.
Stem "hammers".
Page 38
Sealing surfaces of plug eroded or worn Replace plug; refer to item 7.2
Sealing edge of seatring damages or
worn
Replace seatring; refer to item 7.2
Seatring and/or plug dirty.
Clean internal parts of the valve
Pneumatic actuator not completely

vented; spring force not fully effective
Vent actuator air chamber completely
Actuator not powerful enough
Install more powerful actuator;

check service data
flow in the closing direction
Compare the plug operation (mixing- or

diverting plug) with the application and
if necessary exchange the fittings or
increase actuator force
Rev. 0040306000 3504

ARMATUREN
10.0 Dismantling tlie valve or the top part
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.

We guarantee freedom of faults in compliance with state-of-the-art technology and the
or disregard of operating and installation instructions, datasheets and relavant regulations.
appointed by us.
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rathertothe
else claims for replacements from these companies will be invalidated.
ARMATUREN

Rev. 0040306000 3504
Page 39

ARMATUREN
12.0 EC declaration of conformity / iVIanufacturers declaration

Mergelheide 56-60, D-33756 Schlo Holte-Stukenbrock
declaration of conformity EC
as defined by
the Pressure Equipment Directive 97/23/EC
that according to the above mentioned Pressure Equipment Directive (PED) the below listed products comply and have been approved according to table 6, annex II, module H through LLOYD'S
REGISTER QUALITY ASSURANCE (NB-No. 0525), Mnckebergstr. 27, D-20095 Hamburg.
Certificate-No: 50003/1
3-way control valves
Type 450, 451, 423, 463, 483
Applied standard:
DIN EN 60534 part 1
DIN 3840
AD 2000 leaflet A4
- Cast steel
- Forged steel
as defined by
Herewith we declare.
If the supplied model is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by this directive and must be put into service until the machinery into which it is be incorporated has been declared in conformity with the provisions of the ECMachinery Directive as amended by 98/37/EC.
(Brechrpiann, Managing director)
Page 40
Rev. 0040306000 3504
ARMATUREN
Operating and Installation Instructions

Thrust Actuator ARI-PREMIO
Contents
4.0 Description
4.1 Field of application
4.2 Method of functioning
4.3 Diagram
4.3.1 ARI-PREMIO 2,2 - 5 kN
4.3.2 ARI-PREMIO 12-15 kN
4.3.3 Parts list
4.4 Technical data
4.5 Dimensions
5.0 Installation
5.1 General installation data
5.2 Manual operation
5.2.1 ARI-PREMIO 2.2 - 5 kN
5.2.2 ARI-PREMIO 12-15 kN
3
3
3
4
4
5
5
5
6
6
7
8
9
11
12
12
14
14
15
Rev. 0040501000 2403 englisch
5.3 Installation instructions for mounting to valves

5.3.1 Mounting for valve-lift up to 30 mm (yoke version)
5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version)
16
16
17
5.4 Electrical connection

5.4.1 Wiring diagram ARI-PREMIO 2.2 - 5 kN
5.4.2 Wiring diagram ARI-PREMIO 12 - 1 5 kN
5.4.2.1 ARI-PREMIO 12 -15 kN 1 Ph~ / 3 Ph~ without reversing contactor
5.4.2.2 ARI-PREMIO 12 -15 kN 1 Ph~ / 3 Ph~ with reversing contactor
5.4.3 Connection
19
19
20
20
21
22
5.5 Settings
:
5.5.1 Torque and travel switches - standard feature
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN)
5.5.3 Travel switch
5.5.3.1 Installation of additional travel switches
5.5.3.2 Setting of standard travel switch (S3)
5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25)
5.5.4 Potentiometers
5.5.4.1 Installing the potentiometer
5.5.4.2 Setting the potentiometer
5.5.5 Heating
5.5.5.1 Installation of heating
5.5.6 Electronic position indicator Ri21
5.5.7 Electronic position controller ES11
5.5.8 Electronic position indicator (RI21) and position controller (ES11) together in the actuator
5.5.9 Integrated temperature controller dTRON 16.1
5.5.9.1 Installation of the dTRON 16.1
5.5.10 Integrated reversing contactor
5.5.10.1 Installing the reversing contactor
-.
5.5.10.2 Electrical connection with ES11 or dTRON 16.1
5.5.11 Phase control relay
5.5.11.1 Installing the phase control relay
23
23
23
24
24
26
27
28
28
30
30
30
32
32
33
34
34
35
35
35
36
36
6.0 Putting the actuator into operation
37
37
8.0 Troubleshooting
37
38
10.0 Dismantlement of thrust actuator
39
11.0 Warranty/ Guarantee
39
12.0 EC declaration of conformity
40

Thrust actuator ARI-PREMIO
ARMATUREN
1.0 General infornnation on operating instructions

and repair.
These Operating Instructions comply with the requirements of EU Directives.

ATTENTION !
Warning of dangerous voltage.
Exposed to injury!
Don't touch the turning handwheel when the motor is running.
A
AQ
Exposed to injury!
Don't put your hand into the up or downwards moving
appliance.
Danger when not observing the operating and installation
instructions!
Before installing, operating, maintenance or dismantling read
and observe the instructions.
Danger though voltage!
Before dismantling the hood, switch of the electrical source
and secure against turning on again.
0040501000 2403
Page 3
ARMATUREN


In these Operating and Installation Instructions dangers, risks and items of safety
Information marked with the above symbol and "ATTENTION!" describe practices, a
to property.
ATTENTION!
- Valve mountings such as drives, handwheels, iioods must not be used to tai<e
external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
See "4.4 Technical data" for weights.
At -20 to +70C dry, free from dirt.

Do not unpack thrust drive or setting equipment assembly prior to installation.
Protect against external force (impact, vibration etc.).
Do not soil or damage type identification plate and wiring diagram on the controller.
Page 4
0040501000 2403
ARMATUREN

4.0 Description
4.1 Field of application
ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves
requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN.
The thrust actuators are set to the thrust forces specified in the technical data. If supplied
with the valve, the lift of the thrust actuator will be set to the stroke distance of the valve.
Selection of the proper actuator version in alignment with the corresponding fitting as well
as use of the thrust actuator in accordance with the specified technical data is the
responsibility of the systems engineer.
See data sheet for areas of application, application limits and potential.
Any use of the thrust actuator beyond the specified technical data or improper use of the
actuator is deemed to be not for the intended purpose.
The ambient conditions have to be conform to the actual electromagnetic compatibility
directives. Additional the compatibility to this directives has to be maintained in case of
expansion or other changing of the ambient conditions.
4.2 Method of functioning

The thrust actuator, fitted with a yoke or columns, is mounted to the valve.
Transfer offeree is effected via a coupling safeguarded against torsion.
The torsion safeguarding feature also serves as a lift indicator.
The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear
clamps mounted to the column.
The electrical components are accommodated separately from the gearbox underneath a
sealed hood, thus being protected against operating and environmental effects.
Following removal of the hood, easy access is provided to the switchgear and indicating
feature.
The rotary motion of the motor is transmitted to the spindle nut by means of spur gear.
The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut
and thus performs a pull or push motion depending on the sense of rotation.
In the final positions of the valve, the spindle nut is pressed against a set of springs so as to
produce closing force.
The motor is switched off by means of two load-dependent switches and one strokedependent switch. The load-dependent switches will also switch off the motor if foreign
bodies have lodged themselves between the valve seat and cone.
The load-dependent switches serve to protect the valve and thrust actuator against
damage.
0040501000 2403
Page 5
ARMATUREN

Thrust actuator ARl-PREIVIIO
4.3 Diagram
4.3.1 ARl-PREMIO 2,2 - 5 kN
Column Version
Yoke Version
50.25
Fig. 1
Page 6
0040501000 2403
ARMATUREN

Thrust actuator ARI-PREIVIIO
4.3.2 ARI-PREMIO 12 -15 kN
50,119
Fig. 2
0040501000 2403
Page 7

ARMATUREN
4.3.3 Parts list

Designation
Designation
50.1
Gearbox
50.34
Bellow
50.1.1
Gearbox cover plate
50.35
Grub screw DIN ISO 4766 - M6
50.36
Set collar
50.2
Cable conduit fitting

2.2-5l<N: 2xPG11
12-15kN: 2XPG13.5/1 x PG9
50.37
Grub screw DIN 913-M3x5
50.38
Guide spindle
50.3
Blanking plate
50.39
Hexagon nut DIN EN ISO 4034 - M5
50.4
Sealing plug 1 x PG11
50.40
Synchronous motor, complete
50.5
Gasket
50.40.3 Motor capacitor
50.6
Hood
50.41
Head cap screw

DIN EN IS0 4762-M4-18
50.7
Hood seal
50.42
Board support
50.8
Counter-sunk screw DIN 7991M5x20
50.43
Standard board
50.9
Sealing washer DIN EN ISO 7089
50.43.1 Directional switch (valve - up) S3
50.10
Column
50.43.2 Torque switch
50.11
Conical spring washer
50.45
Shift lever
50.12
Handwheel
50.46
Washer
50.12.1 Turning handle of handwheel
50.47
Wiring diagram sticker, standard
50.14
Yoke
50.48
Connector, 3-pole (standard)
50.15
Flange
50.50
Trip slide
50.16
Spring washer DIN 128-A10
50.51
Setting spindle for switch S3
50.17
Hexagon head screw

DIN EN ISO 4 0 1 7 - M l 0x30
50.52
50.18
Hexagon head screw

DIN EN 24017-M 10x45
50.53
50.19
T-head bolt DIN 261-Ml2x40
50.54
Trip cam
50.20
Washer DIN EN ISO 7089
50.56
Spring PREMIO for trip slide
50.21
Spring washer DIN 128-A12
50.57
Head cap screw

DIN EN ISO 4762-M4x10
50.22
Hexagon nut DIN EN ISO 4032 - M12
50.58
Protective conductor terminal
50.23
Lift dial
50.59
Head cap screw

DIN EN ISO 4762 - M4x6
50.24
Distance column
50.87
Threaded bush
50.25
Hexagon nut DIN 980-V-M16
50.96
0-ring DIN 3 7 7 1 - 4 x 1 . 8
50.26
2-ear clamp (stroke indicator)
50.101 Connector, 8-pole
50.27
Coupling
50.110 Geared butterfly valve
50.30
Driving spindle
50.115 0-ring DIN 3771 - 52x2.5
50.31
Spindle safety feature
50.119 Fan wheel
50.32
Torsion safety feature
Pages
0040501000 2403

ARMATUREN
4.4 Technical data

Type
Thrust force
Strol<e distance max.
ARI-PREMIO
l<N
Motor voltage
Power consumptionW
mm
Duty classification in accordance

with DIN VDE 0530
Control speed
2,2
mm/sec.
5,0
12,0
15,0
50
80
S1 -100 % duty cycle; S4 - 80% duty cycle

1200 c/h
SI -100% ED;
S4-50% ED 1200 c/h
0.25
'
0.38
0.38
1,0
11.7
0.38
230V - 50Hz
230V - 50Hz / 60Hz *

10.3
0.79
25.3
52.9
109
96
Torque switch
2 only, permanently wired,

switching capacity 10A, 250V~
2 pes., permanently
wired
switching capacity
16A, 250V~
Travel switch
1 only, permanently wired,

switching capacity 10A, 250V~
1 pes.,
permanently wired
switching capacity
16A, 250V-
Enclosure IEC 60529
IP 65
Max. permissible ambient

temperature
Handwheel
Mounting position
Gear lubricant
Weight kg
-20 C ... +70 C

Yes (rotating during operation)
Yes (engageable)
Any. Exception: motor must not be suspended downwards

Klber/ Isoflex Topas NB152
5.4
50/50-mix
Klber Isoflex NBU15
Ultra and
Klber Nontrop KR291
6.5
10.5
* Control speed and power consumption are 20% higher at frequency of 60 Hz
0040501000 2403
Page 9

ARMATUREN
Accessories
Type
Thrust force
ARI-PREMIO
kN
I Additional travel switches

Additional travel switches for
low-voltage / electronic system
5,0
2,2
12,0
15,0
2 additional travel switches, zero potential.

Switching capacity 10A, 250V ~
2 additional travel switches, zero potential, with gold contacts,
for low breaking capacity and in an aggressive atmosphere,
switching capacity max. 0.1 A, 4-30V
Potentiometer
max. 2 only Ohmage optional: 100, 200, 500, 1000, 1000 Ohm; 1,5 Watt
Electronic position indicator

RI21
0(2)... 10V . 0(4) ...20mA, Only 1 potentiometer possible

Using the temperature controller, installation is only possible in the control
cabinet
Electronic position controller

ES 11
0(2)... 10V . 0(4) ...20mA, Only 1 potentiometer possible

Not compatible for use with the temperature controller.
Heating resistor
Additional voltages / frequencies
Standard-voltage connection
board, PA
Low-voltage connection board
(electronic system), NA
Integrated temperature-controller
dTRON 16.1
(with automatic switching)

230V-50HZ, 115V-50HZ, 24V-50Hz, 15 Watt
24V - 50 / 60Hz
115V-50/60HZ'
24V-50HZ
24V - 60Hz*
115V-50Hz
115V-60HZ*
230V-60Hz*
2 torque switches and 1 travel switch, zero

potential, for free wiring,
Switching capacitylOA, 250V ~
Possible
with standard
version
2 torque switches and 1 travel switch,

for free wiring, with gold contacts,
for low breaking capacity and in an aggressive atmosphere.
Switching capacity max. 01A, 4-30V
Three-step temperature-controller in microprocessor-technology.
Control range: -200C to 850C (resistance thermometer)
Voltage: 24V, 115V or 230V 50/60Hz
Compatible with resistance thermometers and thermocouples
(provided by customer), or standardized active current or voltage signals.
Actuator with 400V50Hz and 440V-60Hz
Only 1 electronic module possible!
Integrated reversing contactor
Only in addition with

integrated
reversing contactor!
Phase control relay

Control speed and power consumption are 20% higher at frequency of 60 Hz
Page 10
24V - 50Hz
24V - 60Hz*
115V-50HZ
115V-60HZ*
230V - 60Hz*
3~400V - 50Hz
3~400V - 60Hz*
0040501000 2403
4^
bi
D
TI
cp'
/////////////////////
CO
I'
Clearance required for

removal of hood
(D
3
(A
200x175
5"
3
(A
/////////////////////
/////////////////////

removal of hood

removal of hood
in
.165x150
J^K.
236
256
271
286
ARI-PREMIO 2.2 - 5 kN
Nominal stroke max. 30 mm
ARI-PREMIO 2.2 - 5 kN
Nominal stroke > 30 mm - 50 mm
ARI-PREMIO 12-15 kN
Nominal stroke max. 80 mm
..X,
633
653
668
683
h
max. 30 mm
max. 50 mm
max. 65 mm
max. 80 mm

ARMATUREN
5.0 Installation
A
' \
ATTENTION!
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supen/ision of a
qualified electrician in compliance with regional electrical safety requirements
and regulations.
- Valve mountings such as drives, handwheels, hoods must not be used to take
external forces, e.g. they are not designed for use as climbing aids, or as
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
- Actuator components which rotate or move during operation are coloured red.
Crushing and injury hazard!
5.1 General installation data

- In addition to general installation guidelines, the following points are required to be
observed:
- Planners / construction firms and operators are responsible for positioning and installing
the products.
ATTENTION!
- A voltage is induced in the thrust actuator motor This induction voltage may be
higher than the operating voltage.
- For this reason relays and electronic load relays for thrust actuator control
require a protective circuit. The contacts of unprotected relays may stick after a
while.
- This may result in reversed directions of rotation or defective switch-off
Recommended safety circuit for relays and electronic load relays:

Connect a varistor or RC module parallel to each relay point.
Varistor
S10K385 to S10K460
RC module
100 Ohm /10OnF
Where relay points and electronic load relays are particularly sensitive a coil should be
connected in series additionally to each relay point.
Recommended coil:
Toroidal coil
2mH / 2A
- Contactors of 16A and upwards do not need a safety circuit.
- Check thrust actuator for damage prior to fitting.
Damaged parts must be replaced by original spares.
- Existing operating instructions for valve.
- Complete valve with crossarm.
- Valve cone approximately in mid lift position - on no account supported inside a seat!
- Electrical installation in accordance with current regional regulations.
- Conductor cross-section selected to correspond to the given drive power and existing line
length.
Page 12
0040501000 2403
ARMATUREN

- Mains fuse rating max. 6A.

- Circuit breakers in the plant to cut off the mains supply to the actuator.
- Conformity of technical data on thrust actuator with field conditions.
- Mains voltage in accordance with data specified on rating plate of thrust actuator.
- Thrust actuator complete with yoke or distance columns and coupling parts intended for
mounting to the corresponding valve.
- Ease of access to installation site.
- Adequate clearance space above the thrust actuator for removing the hood
(refer to point 4.5 Dimensions).
- Install where there is protection against high-energy heat radiation.
- The ambient temperature must not exceed +70 C.
If installed outdoors, the thrust actuator must be provided with an additional cover to protect
against
- rain,
- direct insulation,
- powerful draughts and
- dust.
In case of widely fluctuating ambient temperatures and high atmospheric humidity, your are
recommended to install a heating resistor to minimise condensation buildup in the actuator.
- Thrust actuator mountable in any position except in downward suspended position.
If installed with a horizontal connecting rod, the thrust actuator must be mounted so both
yoke legs or columns are on top of one another in the vertical plane (see Fig. 4 ).
Correct
Incorrect
Fig. 4
0040501000 2403
Page 13
ARMATUREN

Thrust actuator ARI-PREiVIIO
5.2 iVIanual operation

5.2.1 ARI-PREMIO 2.2 - 5 kN
ATTENTION 1
- The handwheel always rotates during motor-driven operation (running
indicator). Never activate manual operation while the motor is running.
Injury hazard!
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator! Since the
handwheel always follows during motor-driven operation (running indication),
never operate by hand while the motor is running - potential injury hazards!
With the motor in the stationary state, the thrust actuator can be run in the open and closed
state with the handwheel firmly meshed with the gear.
Proceed as follows:
- Swing out lever (50.12.1) from handwheel (50.12).
- Turning in clockwise direction --> closes valve.
- Turning in counter-clockwise direction - > opens valve.
Open
Close
50.121
50.12
Fig. 5
Page 14
0040501000 2403
ARMATUREN

5.2.2 ARI-PREMIO 12 -15 kN
ATTENTION!
- Do not attempt to engage manual operation until the motor has stopped.
Switching over while the motor is running may damage the thrust actuator.
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator!
With the motor in the stationary state, the thrust actuator can be run in the open and closed
state with the engageable handwheel.
Proceed as follows:
- Fold the turning handle out of the handwheel (A)
- Turn the handwheel slightly and push in the engaging button for manual mode (B)
- > the button engages
- Turning in clockwise direction - > closes valve
- Turning in counter-clockwise direction - > opens valve
The motor is no longer in mesh when the handwheel is engaged. The handwheel is
automatically disengaged when the motor starts and the motor is once more in mesh.
Engaging button
for manual mode
50.12.1
Open
Close
Fig. 6
0040501000 2403
Page 15

ARMATUREN
5.3 Installation instructions for mounting to valves

5.3.1 Mounting for valve-lift up to 30 mm (yoke version)
A
B
C
D
turn
50.12.1
50.87
ttf
50.27
nut
s::^Valvespi
Valve spindle
Fig. 7
To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed
as follows:
- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator
(not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A:
- Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (50.27) over valve spindle.

- Screw threaded bush (50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
- Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.
Fig. C:
- Place thrust actuator (50) on valve.

- Mount thrust actuator (50) on fitting with two T-head bolts (50.19), two washers
(50.20), two spring washers (50.21), two hexagon nuts (50.22).
Fig. D/E: - Swing out handwheel lever (50.12.1) and use it to move out the thrust actuator
until the driving spindle (50.30) comes to rest on the threaded bush (50.87).
Fig. F:
- Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and
secure in place using grub screw M6 (50.35).
- Run valve to lowest position.
- Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety
feature is in alignment with tip of arrow mark on lift dial.
- Run valve to both final positions and check to ensure that these are safely
reached
- Carry out electrical connection (see point 5.4 ).
- Set travel switch S3 (see point 5.5.3.2 ).
Page 16
0040501000 2403
ARMATUREN

5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version)

A
B
C
D
E
50.87
50.27
lexagon nut
âive spindle
Fig. 8
To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm,
proceed as follows:
- Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator
(not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A:
- Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (50.27) over valve spindle.

- Screw threaded bush (50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
- Setting dimension (Y) for fitting-projection (X) 83mm = 102mm.
- Setting dimension (Y) for fitting-projection (X) 98mm = 116mm.
Fig. C:
- Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly.
- Screw distance column with 2-ear clamps on opposite side of handwheel into
the flange in such a way that one of the 2-ear clamps is situated above the
torsion safety feature (50.32) and the other below.
- Screw the other distance column into the flange likewise.
- Place thrust actuator (50) with distance columns onto valve and fix into position
with two self-locking hexagon nuts (50.25).
Fig. D/E: - Fold out turning handle of handwheel (50.12.1), slightly turn the handwheel and
press in the engaging button for manual mode (only 1 2 - 1 5 kN) (button
engages). Having done this, move out the thrust actuator until driving spindle
(50.30) comes into contact with threaded bush (50.87).
Fig. F:
- Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure
using grub screw M6 (50.35).
0040501000 2403
Page 17
ARMATUREN
4B!.^^-iiu^r,ii-iii-i>i

Move the valve to the lowest position.

Press 2-ear clamps (50.26) into position according to the stroke so they cannot
slip, with the bottom clamp in the lowest valve position located directly below
torsion safety feature (50.32) and the top clamp in the highest valve position
located directly above the torsion safety feature.
Move the valve to both travel positions and check that it reaches them reliably.
Fold turning handle of handwheel (50.12.1) back in.
Make the electrical connection (see point "5.4 Electrical connection"). The
engaging button for manual mode (only 1 2 - 1 5 kN) disengages when the
motor starts up.
Set standard travel switch S3 (see point 5.5.3.2 ).
Page 18
0040501000 2403
ARMATUREN
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Fig. 9
0040501000 2403
ARMATUREN
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Thrust actuator ARI-PREMiO
5.4.2 Wiring diagram ARI-PREIVIIO 12 -15 kN
0}
en
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0040501000 2403
i Ii
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5.4.2.1 ARI-PREMIO 12 -15 kN 1 Ph~ / 3 Ph~ without reversing contactor
Fig. 10
Page 20
ARMATUREN
CD
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Page 21
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5.4.2.2 ARI-PREIVIIO 12 -15 kN 1 Ph~ / 3 Ph~ with reversing contactor
Fig. 11
0040501000 2403
ARMATUREN

5.4.3 Connection
ATTENTION!
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supervision of a
qualified electrician in compliance with regional electrical requirement and
regulations.
- When connecting the thrust actuator the supply line must be disconnected from
the mains (not live) during connection work. It must be impossible to switch the
power on unintentionally while the mains are disconnected in this way. Failure
to comply may result in death, serious injury or substantial damage to property.
To connect the thrust actuator up to the electrical power supply, proceed as follows:
- Run the thrust actuator a few mm out of the lower final position applying the manual mode.
- Loosen countersunk screw in hood, carefully remove hood in upward direction.
- Screw out one of the two cable inlets and re-assemble in the same way without the
supplied blank flange.
- Insert the connection line through this cable inlet until sufficient conductor length is
available up to the corresponding terminals; then tighten the cable connection until the
connecting cable is clamped in place inside it.
- Strip connecting cable approx. 1-1.5 cm above cable inlet.
- Strip the individual conductors approx. 5mm away from the end and fit with conductor end
sleeves.
- Connect protective conductor of connecting cable up to protective conductor terminal of
thrust actuator.
- Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator
terminal strip.
- Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator
terminal strip.
- Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal
strip.
- Place hood on carefully from above and mount firmly onto thrust actuator with
countersunk screw and rubber gasket.
- Connect supply line to mains and run thrust actuator to each of the final positions so as to
check whether the final-position travel switches effect switching off, also checking to see
whether the direction of movement on the thrust actuator corresponds to the desired
direction.
- If the directions of movement are contrary to those desired, the pulse lines governing the
move-in and move-out connecting rod will need to be exchanged.
Page 22
0040501000 2403
ARMATUREN

5.5 Settings
A
A
ATTENTION!
- The thrust actuator may only be operated for a short time without the hood for
unavoidable setting operations to the potentiometers, travel switches and the
electrical options. While these operations are in progress, the thrust actuator
has hazardous, live, uninsulated parts exposed as well as moving and rotating
parts.
- Improper execution of the setting operations or lack of care may cause death,
grievous bodily injury or substantial property damage.
- Operation of the thrust actuator without the hood for any purpose other than
that described above is strictly prohibited.
5.5.1 Torque and travel switches - standard feature

As standard, thrust actuators are equipped with a load-dependent travel switch for the
closing direction (S1), a load-dependent travel switch for the opening direction (S2) and a
stroke-dependent travel switch for the opening direction (S3).
The load-dependent travel switches (S1, S2) switch off the motor as soon as the factory-set
thrust force is attained.
ATTENTION!
- The settings of the load-dependent travel switches must on no account
whatsoever be changed!
The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke
is attained. If the thrust actuator is supplied on a straight-way valve, the stroke-dependent
travel switch S3 is set in such a way that the motor of the thrust actuator is switched off as
soon as the maximum valve-lift is attained.
If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel
switch S3 is set in the opening direction in the trip slide to such a downward extent that the
upper final position of the valve is attained prior to travel switch S3 being reached, thus
causing the load-dependent travel switch S2 to switch off the motor.
For this function, all three switches reveal interlock-controlled circuitry on the board.
If the standard travel switches are to be integrated directly into the facility control system,
the standard board can be replaced by optional boards PA or NA (only 2.2 - 5 kN).
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN)
On connection boards PA or NA, the standard travel switches S11/S21, S12/S22 and S13/
S23 do not reveal interlock-controlled circuitry and can be integrated individually into the
facility control system.
The 3 contacts on each of the switches S11/S21, S12/S22 and S13/S23, designed as
double-throw contacts, are - in the case of these boards - brought out on terminals 40-48
and can be freely connected.
The switches on the PA optional board (standard-voltage connection board) are designed
for switching capacities of up to 10A, 250V AC.
The switches on the NA optional board (low-voltage connection board) are designed for
switching capacities of up to 0.1 A, 4-30V (gold contacts).
0040501000 2403
Page 23
ARMATUREN

The optional boards may only be installed at the factory due to the switching points of the
load-dependent switches having to be reset following installation of these boards!
" '^
ATTENTION!
- When using optional boards PA or NA, it must be warranted - due to the
operator's individual circuitry- that, when switching the load-dependent travel
switches S11/21, S12/S22 and S13/S23 the motor of the thrust actuator comes
to a standstill without delay.
This function is not provided for on the optional boards PA and NA in the
supplied state!
5.5.3 Travel switch

The thrust actuators can be equipped with an additional stroke-switch board containing two
travel switches (double-throw contact S4 and S5).
These switches can be set on infinitely variable lines over the entire stroke distance in both
lift directions and integrated at will into the facility control system (no interlock-controlled
circuitry).
The maximum switching capacity of the switches (see point "4.4 Technical data") must not
be exceeded.
For low voltage (see point "4.4 Technical data"), the additional travel switches are supplied
with gold contacts (option: low-voltage travel switch).
5.5.3.1 Installation of additional travel switches
To install additional travel switches, proceed as follows.
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen countersunk screw in hood, carefully remove hood.
- Disconnect motor plug and mains connection plug from board.
- Carefully ease open the lock washer (50.56) (open ends) with a screw driver while pulling
the trip slide (50.50) upwards from the board support.
- Remove trip slide (50.50) from board support by pulling upwards.
- Loosen head cap screws (50.57) on board support and remove this from gearbox (only
necessary on 5kN thrust actuator).
- Insert stroke-switch board (50.61) in board support (50.42) and fix in place using the
supplied screws (50.44).
- Mount board support loosely on gearbox cover plate with two head cap screws (50.57)
(only necessary on 5kN).
- Push trip slide (50.50) back into board support (50.42) from above and onto the guide
spindle (50.38).
- Align board support (50.42) on gearbox cover plate in such a way that the guide spindle
(50.38) is centrally situated in the borehole of the board support (50.42); then screw down
tightly on gearbox cover plate (only necessary on 5kN).
- Mount the trip slide (50.50) so that the spring (50.56) clips into the groove of the guide
spindle (50.38).
- Insert 6-pole connector (50.62) in jack strip of stroke-switch board.
Page 24
0040501000 2403

ARMATUREN
Proceed to strip the connecting cable that has been led in through the cable inlet and
fastened, and connect the individual conductors to the terminal strip in accordance with
the desired circuitry and the wiring diagram.
Set switch points on travel switches in accordance with section 6.3.2. Setting the travel
switches
Insert motor connection plug in jack strip (50.43.4) provided for the purpose.
Insert mains connection plug in jack strip (50.43.3) provided for the purpose.
Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket
and countersunk screw.
50.62
50X4
Fig. 12 Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

Designation
Designation
50.38
Guide spindle
50.52 Setting spindle for switch S4
50.42
Board support
50.53 Setting spindle for switch S5
50.43.3
Jack strip for mains connection
50.54 Trip cam
50.43.4
Jack strip for motor connection
50.56 Spring
50.44
Self-tapping screw
50.57
50.50
Trip slide
50.61 Stroke-switch board
50.51
50.62 Connector, 6-pole

(option: travel switch)
0040501000 2403
Head cap screws DIN EN ISO 4762 M4x10
Page 25
ARMATUREN

5.5.3.2 Setting of standard travel switch (S3)

On delivery of the thrust actuator, the standard travel switch (S3) is already set to the
existing valve-lift and the setting spindle for the travel switch S3 (50.51) is sealed with
screw glyptal.
This setting needs no changing for nornnal operation.
If reinstalling the thrust actuator on a straight-way valve, the travel switch S3 needs to be
set as follows:
- Move valve out of the lowest position so as to run valve-lift to up position.
- Using a screw driver, proceed to turn setting spindle for switch S3 (50.51) until the trip cann
(50.54) arriving from below trips the switch (audible click).
- Run thrust actuator briefly in closing direction and then in opening direction once more,
checking to see whether the thrust actuator is switched off at the desired point (nominal
lift).
- If need be, correct the setting as described.
If reinstalling the thrust actuator on a three-way valve, the travel switch S3 needs to be set
as follows:
- Run valve in both final positions and check in each final position whether the valve
switches off via the load-dependent switch.
- Carry out a check in the top final position the see whether, after switching off the thrust
actuator, the trip cam (50.54) of the travel switch S3 is situated below switch S3 and has
not tripped the latter. If the trip cam (50.54) is situated above the travel switch S3 or trips
the same, the setting spindle governing the travel switch S3 (50.51) needs to be turned
until the trip cam is situated below travel switch S3 without tripping it.
- Run the thrust actuator in both final positions once more and check whether thrust
actuator switches off in both final positions via the load-dependent switches.
- If need be, correct the setting as described above.
Page 26
0040501000 2403
ARMATUREN

5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25)

The two additional travel switches can be freely set in both lift directions for indicating
certain valve positions.
To do this, proceed as follows:
- Run valve to desired position due to be indicated by the corresponding switch.
- Proceed to turn the setting spindle belonging to the appurtenant switch until the switch is
tripped (audible click).
- Run thrust actuator briefly in both directions, checking and, if need be, correcting the
setting.
The actuating feature on the travel switches is designed in such a way that both travel
switches can be overrun in both directions.
Standard design:
Forthat reason, care should be taken on additional travel switches to see that the actuating
state of the switches remains active only for a short time while the thrust actuator continues
to run and that switching back takes place afterwards.
The actuating state of the travel switches remains in force over a lift of 4 mm.
Special design:
At additional travel switches with extended switch levers, the actuating state of the travel
switches remains in force over a lift of 49 mm.
0040501000 2403
Page 27
ARMATUREN

5.5.4 Potentiometers
The potentiometers are used for electrical position acknowledgement on the facility control
system or for the options - electronic position controller ES11 or electronic position indicator
RI21
A maximum of 2 potentiometers can be installed (= 1 double potentiometer).
The potentiometers can be supplied with different resistance values (see point 4.4
Technical data").
For the electronic position controller ES11 and the electronic position indicator RI21 use
must be made solely of 1000 ohm potentiometers.
Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by
means of transmission determined in respect of each valve-lift between the toothed rack on
the trip slide and the pinion on the potentiometer shaft.
Use must only be made of the pinion specified for the valve-lift.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer
is assembled and set ready for operation.
To achieve optimal electromagnetic compatibility it is recommended to use shielded cables
for connecting potentiometers or standardized active current or voltage signals.
5.5.4.1 Installing the potentiometer
If retrofitting the potentiometer, proceed as follows:
accidentally.
- Plug in the flat connectors on grey potentiometer cables onto the middle connector pins,
those of the red cables onto the upper connector pins and those of the yellow cables onto
the lower connector pins of the potentiometer (Fig. 13 ).
- Insert the potentiometer into the guide in the way that the pinion (50.73) of the
potentiometer meshes with the gear stick of the trip slide.
- With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand window of board
support (50.42) above the potentiometer guide, insert into the guide between the slide
block and the potentiometer guide and hook into the cut-out below the potentiometer.
With a valve lift between 30 mm and 50mm, hook spiral spring (50.70) into the right-hand
window (for 12 - 15kN middle window) above the potentiometer guide, insert into the
guide between the slide block and the potentiometer guide and hook into the cut-out
below the potentiometer.
With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70) into the middle
window in board support (50.42) above the potentiometer guide, insert into the guide
between the slide block and the potentiometer guide and hook into the cut-out below the
potentiometer.
- Check to see whether pinion (50.73) is pressed into toothed rack by spiral spring (50.70)
and is positioned free from backlash.
- If this is not the case, remove spiral spring (50.70), readjust by bending a little, and place
back in position again.
- Screw jack strip of connecting cable (50.68) to board support (50.42) with two self-tapping
screws (50.69) (single potentiometer connectors 25-27).
- Insert additional 3-pole connector (50.74) in jack strip of connecting cable (50.68).
- Set potentiometer (see point 5.5.4.2 ).
Page 28
0040501000 2 4 0 3 /

ARMATUREN
Place hood carefully onto thrust actuator and fasten it on the actuator with rubber gasket
and countersunk screw.
red
grey
yellow
Fig. 13
X
50.47
50.76
5072
^g'^^
50.67.1
Fig. 14: Switchgear and indicating feature ARI- PREMIO

Designation
50.42
Board support
50.69
50.47
Circuit-diagram sticker
50.70
50.67.1
50.67.2
50.67.3
Hexagon nut
Tooth lock washer
Potentiometer
50.71
50.72
50.73
50.67.4
Washer from PA
50.74
50.68
Connecting cable for option:

potentiometer
0040501000 2403
2.2 - 5 kN
Designation
Self-tapping screw
Spiral spring (option:
potentiometer)
Slide block (option: potentiometer)
Securing ring
Pinion (selection depends on
valve-lift 20, 30, 50, 65 or 80 mm)
Connector, 3-pole
(option: potentiometer)
Page 29

ARMATUREN
5.5.4.2 Setting the potentiometer

To set the potentiometer, proceed as follows:
- Move thrust actuator to closing position.
accidentally.
- Turn potentiometer shaft in counter-clockwise direction until reaching the travel stop.
This places the potentiometer in the initial position (approx. 0 ohm).
- For checking purposes, the resistance of the potentiometer needs to be measured using
an ohmmeter.
- Measure resistance on potentiometer 1 between terminals 25 and 26.
- Measure resistance on potentiometer 2 between terminals 28 and 29.
- In this position of the actuator, the measured value should be approx. 0 ohm.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.
- The resistance values thus measured need to be taken into account for the settings to the
facility control system.
5.5.5 Heating
A heating resistor can be fitted as a means of protection against the formation of
condensation water in cases involving widely varying ambient temperatures and high
atmospheric humidity (outdoor use). The heating resistor is self-regulating so that a
continuous supply of current merely needs to be connected up.
5.5.5.1 Installation of heating
On principle, the heating can be combined with all options. It is completely mounted on a
holding bracket.
If electronic system ES11 or RI21 is already installed, unscrew the electronic system from
the holding bracket, remove it, install the heating and attach the electronic system to the
holding bracket for the heating.
To install the heating proceed as follows:
accidentally.
- Using the supplied screws, mount complete heating (on holding bracket) at the point on
the gearbox cover plate provided for the purpose. (Fig. 16 ).
- Lead continuous-current cable (mains voltage = rated voltage of heating) through cable
inlet into thrust actuator and fix in place with inlet.
- Strip continuous-current cable approx. 1-1,5 cm above cable inlet.
- Strip individual conductors approx. 5mm away from the end and provide with conductor
end sleeves.
- Lay the individual conductors in such a way that they do not come into contact with
moving parts.
- Connect the individual conductors up to the connection terminal block in accordance with
the wiring diagram.
Page 30
0040501000 2403
ARMATUREN
Mounting thread M3
for heating resistor

Mounting thread M3
for thermal circuit breal<er
Mounting thread M4
for options ES 11 and RI21
Mounting thread M3^

for jacl< strip
50.83.6
Fig. 15: Heating installation ARI-PREMIO 2.2-15 kN

50.83.1
50.83.2
50.83.3
Designation
Holding bracket
(Option: heating)
Head cap screw DIN 84-M3x8
Thermal circuit breaker
50.83.4
Designation
Jack strip
50.83.6
50.83.10
Connector, 2-pole
Heating resistor
0040501000 2403
Page 31

ARMATUREN
5.5.6 Electronic position indicator RI21

The electronic position indicator RI21 converts the resistance of the 1000 ohm
potentiometer corresponding to the lift into an optional output control signal 0 (2) ...10V DC
or 0 (4) ...20mA DC. For installing and setting the electronic position indicator RI21 the
operating instructions applicable to this unit must be observed in the appropriate valid
version. The corresponding operating instructions are supplied with each unit.
5.5.7 Electronic position controller ES11
The electronic position controller ES 11 converts continuous input control signals 0 (2)
...10V DC or 0 (4) ...20mA into a 3-point output signal for the motor, In which case
interrogation of the valve position takes place via a 1000 ohm potentiometer. For installing
and setting the electronic position controller ES11 the operating instructions applicable to
this unit must be observed in the appropriate valid version. The corresponding operating
instructions are supplied with each unit.
50,82
50.67
Fig. 16: Installing RI21 / ES11 ARI-PREMIO 2.2 - 5 kN

50.67
Designation
Potentiometer
50.81
50.78/79
Option ES11 orRI21
50.82
50.80
Holding bracket
50.83
Page 32
0040501000 2403
Designation
Head cap screw
; Head cap screw
: DIN EN IS0 4762-M4x12
Heating
ARMATUREN

5.5.8 Electronic position indicator (RI21) and position controller (ES11) together in
the actuator
Except or the 5 kN, 12 kN and 15 kN type in 24V version, the electronic position indicator
RI21 and the electronic position controller ES11 can be build-in together in the ARIPREMIO.
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI21 and ES11 proceed as follows:
accidentally.
- Loosen counter-sunk screw in hood, carefully remove hood.
- Mount RI21 and ES11 with mounting kit according to Fig. 17 .
50,106
50,82
50,67
50,78
Fig. 17: Installing R121 /ES11 at the same time as ARI-PREMIO 2 . 2 - 5 kN

Designation
Designation
50.67
Potentiometer
50.82
Head cap screw

DIN EN ISO 4762-M4x12
50.78/79
Option ES11 orRI21
50.106
Metal sheet ES 11 and RI21
50.81
Head cap screw

50.108
Distance bold
0040501000 2403
Page 33
ARMATUREN

5.5.9 Integrated temperature controller dTRON 16.1

The integrated temperature controller controls temperatures, which are measured by inputconnected temperature sensors, to a manual given setpoint by means of a three-step
output connected with the actuator.
5.5.9.1 Installation of the dTRON 16.1
The dTRON 16.1 can be mounted in the ARI-PREMIO as a complete unit with a mounting
kit.
It cannot be combined with ES11.
To install the dTRON 16.1 proceed as follows:
In addition to "5.4.3 Connection", the electrical connection of the dTRON 16.1 has to be
done in the following way:
- Mount the temperature controller on the gear plate by using the specific installation kit
(Fig. 18).
- Plug in the connector X2 of the dTRON 16.1 to the plug-in connector X1 (1/N, 11, 14) of
the actuator terminal.
- Connect the signal input and the individual wanted additional functions according the
wiring diagram to the dTRON 16.1.
- Connect the power supply LI and N to the dTRON 16.1.
- For changing the working direction to heating signal = extending driving spindle, just
change the wires on the connectors 11 and 14.
50.81
50,97
50,100
50,99
50,98
50.97
50.98
50.99
50.100
Designation
Head cap screw
Temperature controller dTRON 16.1
Fixing bracket (option dTRON)
Holding bracket (option dTRON)
Self-locking nut (option dTRON)
50,81
Fig. 18: Installing dTRON 16.1 ARI-PREMIO 2.2 - 5 kN
Page 34
0040501000 2403
ARMATUREN

5.5.10 Integrated reversing contactor

The integrated reversing contactor is actuated using a 3-step input signal.
The reversing contactor swaps over phases L1, L2 and L3 to achieve the desired direction
of rotation of the three-phase motor.
5.5.10.1 Installing the reversing contactor
The reversing contactor can be mounted in the ARI-PREMIO as a complete unit using a
mounting kit.
The reversing contactor can only be combined with one of the ES11, RI21 or temperature
controller options. It is also possible to install the heating and the phase control relay.
Proceed as follows to install the reversing contactor:
Switch off the mains voltage and take measures to prevent it being switched back on
inadvertently.
ATTENTION!
- When the reversing contactor is installed without a phase control relay, the
thrust actuator may be damaged if phases L1, L2 and L3 are wrongly
connected!
The electrical connection procedure as described in 6.4.3 Connection is supplemented by

the following steps:
- Use the mounting kit to attach the reversing contactor to the gear plate (fig. 19).
- Connect the three-phase connection L I , L2, L3 and the 3-step input signal as shown in
fig. 11.
- Wire up as shown in the table in fig. 10 if you are connecting the reversing contactor
without a phase control relay.
- Refer to "5.5.11 Phase control relay" regarding connecting with a phase control relay.
5.5.10.2 Electrical connection with ES11 or dlRON 16.1
Modify the 3P output cable of the ES11 or the dTRON 16.1 as follows:
- Remove plug X25.
- Strip off the outer cable insulation down to about 18 cm.
- Connect the individual conductors as follows:
Black (LT)
S2/14
Brown ( U )
S1/11
Blue (1/N)
K1/A2, K2/A2
0040501000 2403
Page 35

ARMATUREN
5.5.11 Phase control relay

The phase control relay monitors phases L1, L2 and L3 in the mains input supply. The
reversing contactor is only activated by the phase control relay providing phases L1, L2 and
L3 are connected correctly. This protects the thrust actuator.
5.5.11.1 Installing the phase control relay
The phase control relay is installed in the ARI-PREMIO next to the reversing contactor. It is
only possible to use the phase control relay in conjunction with the reversing contactor. It
cannot be combined with the dTRON 16.1 temperature controller in the actuator.
Proceed as follows to install the phase control relay:
Switch off the mains voltage and take measures to prevent it being switched back on
inadvertently.
The electrical connection procedure as described in 6.4.3 Connection and 6.5.10 Integrated
Reversing Contactor is supplemented by the following steps:
- Attach the phase control relay next to the reversing contactor (fig. 19).
Connect the three-phase connection L I , L2, L3 and the 3-step input signal as shown in fig.
10.
Designation
50.57
Head cap screw

DIN EN ISO 4762-M4x 10
50.59
Head cap screw DIN EN ISO 4762 - M4 x 6
50.81
Head cap screw DIN EN ISO 4762 - M4 x 8
50.102
Reversing contactor
50.103
Fixing plate (option reversing contactor)
50.105
Phase control relay
50.107
Bracket (option phase control relay)
50.105
50.57
Fig. 19: Installing reversing contactor and phase control relay ARI-PREMIO 12 - 15 kN
Page 36
0040501000 2403

ARMATUREN
6.0 Putting the actuator into operation
ATTENTION!
- Actuator components which rotate or move during operation are coloured red.
Crushing or injury hazard!
- all works has been completed!
- Regional safety instructions must be observed as a matter of policy.
- hood of thrust actuator assembled.
When placing into service proceed as follows:

- Using the handwheel, run the thrust actuator to approximately mid lift position.
- Apply brief pulses to the thrust actuator for each direction of movement and check
whether the directions of movement correspond to those desired. If this is not the case,
the pulse lines governing the opening and closing action must be exchanged on the thrust
actuator.
- Run thrust actuator to the final position in each direction of movement and check whether
it switches off automatically and whether all externally moving parts are able to move
freely.
- If failing to function properly, check all installation and setting work previously carried out,
correcting if necessary, and afterwards place into service once again.

The thrust actuator requires very little maintenance. Accordingly maintenance in specified
intervals is not necessary.
Depending on the conditions governing use, the maintenance and maintenance-intervals
have to be defined by the operator.
The thrust actuator must not be cleaned with high-pressure equipment or aggressive
solvents or detergents injurious to health or highly inflammable.
During and after cleaning, an inspection should be carried out of the sealing points on the
thrust actuator.
If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements
must be repaired.
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION I
It is essential that the safety regulations are observed when identifying faults.

"9.0 troubleshooting table", the supplier or manufacturer should be consulted.
0040501000 2403
Page 37

ARMATUREN
A
A
ATTENTION I
- read point 10.0 and 11.0 prior to dismantling and repair work!
- read point 6.0 before restarting the plant!
Fault
Possible Causes
Remedy
Thrust actuator fails to move
Power failure
Ascertain and eliminate cause
Fuse has blown
Replace fuse
Thrust actuator not properly

connected
Rectify connection on thrust

actuator in accordance with wiring
diagram
Short circuit due to:
Ascertain exact cause,
- moisture
- Dry the thrust actuator and

eliminate leakage
- wrong connection
- Rectify connection on thrust

actuator in accordance with
wiring diagram
- motor has burned out
- Check whether the mains voltage

agrees with the voltage specified
on the rating plate. Have motor
changed.
Connector contacts not plugged in/

not properly plugged into jack strip
Insert connector firmly in jack strip

thus affected
(Only for 12-15 kN)

Handwheel is still engaged and
does not disengage when the
motor starts up
Unscrew the motor mounting

screw closest to the cable feedthrough. (Manual release of the
handwheel disengagement
mechanism.)
Thrust actuator alternates

between clockwise and
counter-clockwise rotation
Motor operating capacitor

defective
Have motor operating capacitor

replaced
Thrust actuator fails to run to

final positions and also
produces chatter
Load-dependent travel switches

out of adjustment / defective
Remove thrust actuator and send

to factory for repair
Voltage drop due to excessively

long connecting cables or
inadequate conductor crosssection
Lay connecting cables in

accordance with requisite output
Mains fluctuations beyond

permissible tolerance travels
Arrange for "clean" mains system

within requisite tolerances
System pressure too high
Reduce system pressure
Periodic failure on thrust

actuator
Loose connection on feedline
Tighten connections on terminal

strips
Thrust actuator is switched off

in opening direction prior to
load-dependent switch (threeway valve)
Travel switch S3 not set

corresponding to use
Set travel switch S3 in accordance

with operating instructions
Page 38
0040501000 2403

ARMATUREN
^Bi^^^-i.iiirinn.i-iri
10.0 Dismantlement of thrust actuator
A
A
ATTENTION!
- The supply line for connecting up the thrust actuator must be in the dead state
i.e. disconnected while dismantlement work is being carried out. After being
disconnected, the mains power must be prevented from being switched back
on again accidentally.
- The system must be run down (depressurised state) as the valve cone is not
held without the thrust actuator and would thus be conducted by the system
pressure.
- Valve plug approximately in mid lift position - on no account supported inside a
seat!
To dismantle the thrust actuator proceed as follows:

- Loosen counter-sunk screw in hood, carefully remove hood.
- Disconnect all cables led into thrust actuator from outside and remove from thrust
actuator.
- Place hood on carefully from above and fix in place with counter-sunk screw and rubber
gasket.
- Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety
feature.
- Loosen clamping bolts connecting the thrust actuator to the fitting.
- Remove thrust actuator from valve.

We guarantee freedom of faults in compliance with state-of-the-art technology and the
or disregard of operating and installation instructions, datasheets and relavant regulations.
appointed by us.
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather {o the
else claims for replacements from these companies will be invalidated.
ARMATUREN

0040501000 2403
Page 39

ARMATUREN
12.0 EC declaration of conformity

EC declaration of conformity
as defined by
Directive about electromagnetic compatibility 89/336/EEC and the
EG-Low voltage directive 73/23/EEC
Declaration of the manufacturer

as defined by
Mergeiheide 56-60, 33756 Schlo Holte-Stukenbrock
that the supplied model of
electric thrust actuator ARI-PREMIO
In the delivered version complies with the following regulations:
- Directive about electromagnetic compatibility 89/336/EEC
(amended by 92/31/EEC and 93/68/EEC)
Applied harmonized standards:
EN 55011; EN 50081-1; EN 50082-2
- EG-Low voltage directive 73/23/EEC
(amended by 93/68/EEC)
EN 60204-1, EN 60335-1, EN 60730-1
- EG-Machinery Directive 98/37/EC
EN 292-1; EN 292-2; EN 294; EN 349; EN 60204-1
The supplied model is intended to be incorporated into machinery or assembled with other
machinery to constitute machinery covered by this directive and must be put into service
until the machinery into which it is be incorporated has been declared in conformity with the
provisions of the directive as amended by 98/37/EC.
(neGnmann, Managing director)
Page 40
0040501000 2403
Data sheet
Pressure switches and thermostats, type KPS

Description
.^--,^
. , ^ ^ f c mk
- n H S ^ ^
) f|
'
KPS units are pressure-controlled switches.

The position of the contacts depends on the
pressure in the Inlet connection and the set
scale value. In this series, special attention has
been given to meeting important demands
for:
a high level of enclosure,
robust and compact construction,
resistance to shock and vibration.
U^
The KPS series covers most outdoor as well as indoor

application requirements.
KPS pressure switches are suitable for use in alarm
and regulation systems in factories, diesel plant,
compressors, power stations and on board ship.
Page
Contents
KPS pressure switclies, description
Approvals
Ship approvals
Survey
ISO 9001 quality approval
Technical data and ordering

Terminology
3
3-4
Installation
Function
Dimensions and weight
Accessories
KPS thermostats, description
Approvals
Ship approvals
INDUSTRIAL CONTROLS
^f\M
Function
10
Installation
11
Electrical connection
12
Examples
12
Dimensionsand weight
12
Accessories
13
IC.PD.P10.C1.02-520B1861
Data sheet
Approvals
EN 60 947-4-1
EN 60 947-5-1
Underwriters Laboratories Inc., USA

CCC, China Compulsory Certificate
Ship approvals
American Bureau of Shipping

Lloyds Register of Shipping, UK
Germanischer Lloyd, Germany
Bureau Veritas, France
Includes thermostats with fixed sensor
and pressure controls with armoured
capillary tube.
Reglstro Itallano Navale, Italy
RMRS, Maritime Register of Shipping, Russia

Nippon KaijI Kyokal, Japan
CCS, China Classification Society
Survey
Type KPS pressure switches

1. Standard pressure switches
-1
10
20
30
40
50
60 bar
Range
P
Type
bar
0-2.5
Further
information
page
KPS 31
0-3.5
KPS 33
0-8
KPS 35
6-18
KPS 37
10-35
KPS 39
Type
Further
information
page
2. Type KPS pressure switches for high pressure and strongly pulsating media
Range
-1
-50
10
ISO 9001 quality approval
20
50
30
TOO
40
150
50
200
60 bar
200 "C
P.
bar
1-10
KPS 43
4-40
KPS 45
6-60
KPS 47
Range
Type
Further
information
page
-10-30
KPS 76
20-60
KPS 77
50-100
KPS 79
70-120
KPS 80
60-150
KPS 81
100-200
KPS 83
P.
bar
Danfoss A/S Is certificated by BSI In accordance

with International standard ISO 9001. This means
that Danfoss fulfils the International standard in
respect of product development, design, production and sale. BSI exercises continuous Inspection
to ensure that Danfoss observes the requirements
of the standard and that Danfoss' own quality
assurance system is maintained at the required
level.
IC.PD.P10.C1.02-520B1861
Data sheet

When ordering, please state
type and code number
1. Pressure switches
Setting range
P
[bar]
Adjustable/
fixed
differetial
[bar]
Permissible
operating
pressure P
[bar]
0-2.5
0.1
0-2.5
0.1
0-3.5
0.2
10
0-3.5
0.2
0-8
Pressure
connection
Code no.
Type
G 1/4
060-311066
KPS 31
G 3/8 A
060-310966
KPS 31
10
G 1/4
060-310466
KPS 33
10
10
G 3/8 A
060-310366
KPS 33
0.4-1.5
12
12
Gl/4
060-310566
KPS 35
0-8
0.4-1.5
12
12
G 3/8 A
060-310066
KPS 35
0-8
0.4
12
12
Gl/4
060-310866
KPS 35
6-18
0.85 - 2.5
22
27
Gl/4
060-310666
KPS 37
6-18
0.85 - 2.5
22
27
G 3/8 A
060-310166
KPS 37
10-35
2.0-6
45
53
Gl/4
060-310766
KPS 39
10-35
2.0-6
45
53
G 3/8 A
060-310266
KPS 39
7-
KPS 31,33
Max. test
pressure
[bar]
2 Pressure switches for high pressure and strongly pulsating media

Setting
range P
Permissible
overpressure
[bar]
Max. test
pressure
Min. burst
pressure
[bar]
Adjustable
diff. see aiso
figs. 1,2,
and 3
[bar]
[bar]
Pressure
connection
Code no.
Type
1-10
0.7-2.8
120
180
240
G 1/4
060-312066
KPS 43
4-40
2.2 -11
120
180
240
G 1/4
060-312166
KPS 45
6-60
3.5 -17
120
180
240
Gl/4
060-312266
KPS 47
KPS 35,37,39
Terminology
Range setting
The pressure range within which the unit will give
a signal (contact changeover).
Differential
The difference between make pressure and break
pressure (see also fig. 8, page 6).
KPS 43,45,47
Permissible overpressure
The highest permanent or recurring pressure the
unit can be loaded with.
KPS 43
A: Range setting *'

B: Differential scale
C: Obtained
differential
IC.PD.P10.C1.02-520B1861
Max. test pressure

The highest pressure the unit may be subjected
to when, for example, testing the system for leakage.
Therefore, this pressure must not occur as a
recurring system pressure.
Min. bursting pressure
The pressure which the pressure-sensitive
element will withstand without leaking.
KPS 47
Data sheet
Switch
Single pole changeover (SPOT)
Contact material: Gold-plated silver contact
Ambient temperature
KPS 31-39:-40 to+70 "C
KPS 43-47:-25 to+70 C
Contact load
(when Au surface is burnt away)
1. Alternating current:
Ohmic:
10 A,440V,AC-1
Inductive:
6A,440V,AC-3
4A,440V,AC-15
Starting current max. 50 A (locked rotor)
Temperature of medium
KPS31-39:-40to+100C
KPS 43-47:-25 to+100 C
For water and seawater, max. 80C.
Vibration resistance
Vibration-stable in the range 2-30 Hz,
amplitude 1.1 mm og 30-300 Hz, 4 G.
2. Direct current: 12 W, 220 V, DC-13

Enclosure
IP 67 to IEC 529 an DIN 40050.
The pressure switch housing is enamelled
pressure die cast aluminium (GD-AISi 12). The
cover is fastened by four screws which are
anchored to prevent loss.
The enclosure can be sealed with wire.
1000-
Cable entry
Pg 13.5 for cable diameters from 5 to 14 mm.
Identification
The type designation and code no. of the unit is
stamped in the side of the housing.
Scale accuracy
KPS 31: 0.2 bar
KPS 39: 3.0 bar
KPS 33: 0.3 bar
KPS 43: 1.0 bar
KPS 35: 0.5 bar
KPS 45: 4.0 bar
KPS 37: 1.0 bar
KPS 47: 6.0 bar
Mean value of snap point variation after

400 000 operations
,
, , , ,
*-V
20 1 60 I 1001 1401 1801220
1 |40 80 120 160 200
5 30
Fig. 4. d.c-load
KPS 31: 0.1 bar
KPS 39: 0.7 bar
KPS 33: 0.2 bar
KPS 43: 0.2 bar
KPS 35: 0.3 bar
KPS 45: 1.0 bar
KPS 37: 0.4 bar
KPS 47: 1.5 bar
Curve A gives the maximum load.

Hatched area B: Acceptable load for the gold plating
of the contact.
Materials in contact with the medium
KPS 31,33
Bellows capsule:
Bellows:
Pressure connection:
KPS 35, 37,39
Bellows:
Pressure connection:
Diaphragm capsule:
KPS 43,45,47
Diaphragm:
IC.PD.P10.C1.02-520B1861
Deep-drawn plate, material no. 1.0524 (DIN 1624)

Stainless steel,material no. 1.4306 (DIN 17440)
Steel C20, material no. 1.0420 (DIN 1652)
Stainless steel, material no. 1.4306 (DIN 17440)
Brass,W.No. 2.0401 (DIN 17660)
Nickel-plated brass, DIN 50 968 Cu/Ni 5 (DIN 1756)
Nitrile-Butadien rubber
Data sheet
Installation
Installation
KPS pressure switches are fitted with a 3 mm steel
mounting plate. The units should not be allowed
to hang from the pressure connection.
Pressure connection
When fitting or removing pressure lines, the
spanner flats on the pressure connection should
be used to apply counter-torque.
Steam plant
To protect the pressure element from excessive
heat, the insertion of a water-filled loop is
recommended. The loop can, for example, be
made of 10 mm copper tube as shown in fig. 5.
Setting
When the pressure switch cover is removed, and
the locking screw (5) is loosened, the range can
be set with the spindle (1) while at the same time
the scale (2) is being read. In units having an adjustable differential, the spindle (3) must be used
to make the adjustment. The differential obtained
can be read direct on the scale (4) or, with types
KPS 43,45,47, can be determined by reading the
scale value and using the nomograms In figs. 1,2,
3 (page 3).The working line for determining the
differential must not intersect the shaded areas in
the nomograms.
Fig. 6
Water systems
Water in the pressure element is not harmful, but
if frost is likely to occur a water-fijied pressure
element may burst. To prevent this happening,
the pressure control can be allowed to operate
on an air cushion.
1. Range spindle
2. Range scale
3. Differential spindle
4. Differential scale
5. Locking screw
Selection of differential
To ensure that the plant functions properly, a
suitable differential pressure is necessary.
Too small a differential will give rise to short
running periods with a risk of hunting. Too high
a differential will result in large pressure
oscillations.
KPS pressure switches are fitted with a
Pg 13.5 screwed cable entry that is suitable for
cable diameters from 5 to 14 mm.
Contact function is shown in fig. 7.
Media-resistance
See table of materials in contact with the
medium, page 4. If seawater is involved, types
KPS 43,45,47 are recommended.
Pulsations
If the pressure medium is superimposed with
severe pulsations, which occur in automatic
sprinkler systems (fire protection), fuel systems
for diesel motors (priming lines), and hydraulic
systems (e.g. propeller systems), etc., types
KPS 43,45,47 are recommended. The maximum
permissible pulsation level for these types is
120 bar.
IC.PD.P10.C1.02-520B1861
4 2
IP m
Fig. 7
Data sheet
Function
1.KPS 31
Contacts 1-2 make and contacts 1-4 break when
the pressure falls under the set range value. The
contacts changeover to their initial position when
the pressure again rises to the set range value
plus the differential (see fig. 8).
I. Alarm for falling pressure given at the set

range value.
II. Alarm for rising pressure given at the set
range value plus the differential.
o4
2
Scale setting
Mechanical \^^^^^
differential
Fig. 8
2. All other KPS pressure switches
Contacts 1-4 make and contacts 1-2 break when
the pressure rises above the set range value. The
the pressure again fails to the range value minus
the differential (see fig. 9).
I. Alarm for rising pressure given at the set

rangevalue.
II. Alarm for falling pressure given at the set
range value minus the differential.
Scale setting
Mechanical f^fiai%^
differential
Fig. 9
Example 1
An alarm must be given when the lubricating oil
pressure in a motor fails below 0.8 bar.The alarm is
in the form of a lamp.
Choose a KPS 31 (range 0 to 2.5 bar).
The minimum permissible lubricating oil pressure of
0.8 bar must be set on the range spindle.
The differential is fixed at 0.1 bar, i.e. the alarm will
not cut out before the pressure rises to 0.9 bar. The
lamp must be connected to terminals 1 and 2 in the
pressure control.
Example 2
An alarm must be given by a bell when the pressure
in a boiler rises to 10 bar. The normal operating pressure is 9 bar.
Choose a KPS 36 (range from 6 to 18 bar).
The range value of the pressure control must be set
at 10 bar, the differential at 1 bar.
The bell must be connected to terminals 1 and 4.
Example 3
The pressure in a start air reservoir must be
regulated with a compressor controlled by a KPS
pressure switch so that it lies between 30 and 36 bar.
IC.PD.P10.C1.02-52081861
Choose a KPS 45 (range 4 to 40 bar).

The range value must be set at 36 bar.
The differential of 6 bar must be set in accordance with
the nomogram, fig. 10, at approx. 2 on the differential
scale.
The required start function is obtained by connection to
terminals 1 and 2 in the pressure control.
Data sheet
Dimensions and weigFit

-116-90-68-
-^
KPS 31,33
KPS 43,45,47
1
=\^
0
BJ
Weight:
KPS 31 - 39 approx. 1.0 kg
KPS43-47approx. 1.3 kg
IC.PD.P10.C1.02-520B1861
Data sheet
Accessories
Description
Part
Code no.
Connector with
nipple
@ LD
G 3/8 connector, nipple and washer

(10 mm) o.d. x 6.5 mm i.d.), for brazing
Connector with
nipple
@ @n)^
G 3/8 connector, nipple and washer

(10 mm o.d. X 6.5 mm i.d.) for welding
017-422966
017-436866
Reducer
@>
G3/8 X7/16-20UNF (1/4flare)

reduction with washer
017-420566
Adapter
e#
G 3/8 X1/8 - 27 MPT with washer
060-333466
G 3/8 o.d X 7/16 - 20 UNF (1/4 flare)
060-324066
G 3/8 A -1 /4 NPT with washer
060-333566
G 3/8 X1/4-18 NPT with washer
060-333666
G1/4AxG3/8A
060-333266
G 1 /4 A X o.d. M l 0 X1 with washer
060-333866
^ 0
Nipple
Nipple
Adapter
oD
Nipple
0 @!!@1
Damping coil
Damping coil with 1/4 flare

connectors and 1 m copper capillary
tube. Damping coils used for applications with 3/8 RG
connector requires the use of reducer.
For informations about capillary tube
lengths, please contact Danfoss
Damping coil
Damping coil with G 3/8 connectors

and
1.5 m copper capillary tube
Armoured
damping coil
IC.PD.P10.C1.02-520B1861
Damping coil with G 3/8 connectors

and 1 m armoured copper capillary
tube.
Standard washers included.
060-007166
060-104766
060-333366
Data sheet
Tliermostats
KPS thermostats are temperature-controlled

switches. The position of the contacts depends
on the temperature of the sensor and the set
scale value. In this series, special attention has
been given to meeting demands for:
a high level of enclosure,
robust and compact construction,
resistance to shock and vibration.
The KPS series covers most outdoor as well as

indoor application requirements.
Approvals
EN 60 947-4-1
EN 60 947-5-1
CCC, China Compulsory Certificate

Underwriters Laboratories Inc., USA
Ship approvals
Det norske Veritas, Norway

American Bureau of Shipping
Lloyds Register of Shipping, UK
Germanischer Lloyd, Germany
Bureau Veritas, France
Includes thermostats with fixed sensor and
pressure controls with armoured capillary tube.
Registro Italiano Navale, Italy

RMRS, Maritime Register of Shipping, Russia
Nippon Kaiji Kyokai, Japan
CCS, China Classification Society
Wheno rdering please state type and code number
Description
Setting
range
KPS with rigid sensor
KPS with remote sensor
Mech.
diff.
adjustable/
fixed
Max.
sensor
temp.
Suitable sensor length

see also'Accessories"
'C
KPS thermostats are suitable for use in monitoring,

alarm and regulation systems in factories, diesel
plant, compressors, power stations and on board
ship.
Cap.
tube
length
"C
mm
-10-30
3-10
80
65
75
110
160
20-60
3-14
130
75
20-60
3-14
130
110
3-14
130
20-60
160
20-60
3-14
130
65
75
110
160
20-60
3-14
130
50-100
4-16
200
50-100
4-16
200
50-100
4-16
200
50-100
4-16
200
50-100
4-16
200
50-100
4-16
50-100
Code no.
1
CD i
"fer
JO
nl iKrsio l [
060L311266
OT
o !
I5
Type
oJ
060L311366
KPS 76
060L311866
KPS 77
060L310066
KPS 77
0e0L313666
KPS 77
060L310166
D60L310266
KPS 77
060L311966
060L312066
KPS 77
110
160
75
no
160
65
75
160
060L310466
0601310566
KPS 79
160
060L312266
060L312366
KPS 79
200
160
060L312466
060L312566
KPS 79
4-16
200
65
75
no
no
no
no
160
060L314366
50-100
200
75
70-120
4.5-18
220
70-120
4.5-18
220
110
4.5-18
220
70-120
4.5-18
220
70-120
200
70-120
4.5-18
220
65
75
110
160
060L312866
70-120
4.5-18
220
65
75
160
060L315666
70-120
4.5-18
220
060L313066
060L313166
KPS 80
4,5-18
220
160
70-120
160
060L313266
060L313366
KPS 80
60-150
5-25
250
65
75
160
060L310666
060L310766
KPS 81
60-150
5-25
250
160
060L313466
060L313566
60-150
5-25
250
160
060L311166
60-150
5-25
no
no
no
no
no
no
75
250
100-200 6.5 - 30
300
65
75
100-200
300
65
75
18
'Thermostat with max, reset
KPS with remote sensor and

armoured capillary tube
IC.PD.P10.C1.02-520B1861
160
060L312166
KPS 79
060L310366
KPS 79
060L313766
KPS 79
KPS 79
060L314166'i
KPS 79
0601312666
KPS 80
060L312766
KPS 80
060L313866
KPS 80
060L315766
KPS 80
200
no
no
160
060L310B66
160
060L313966"
060L312966
KPS 80
KPS 80
KPS 81
KPS 81
060L311066
KPS 81
060L310966
KPS 83
KPS 83
Data sheet
Contact load (Alternating current):

(when Au surface Is burned away)
Ohmic:
10 A,440V,AC-1
Inductive:
6 A, 440 V, AC-3
4 A, 440 V, AC-15
Starting current max. 50 A (locked rotor)
nnA
i
1000500
400
300
Ambient temperature -40 to +70 C
200
Vibration resistance
Vibration-stable in the range 2-30 Hz, amplitude
1.1 mm og 30-300 Hz, 4 G.
100
Enclosure
IP 67 to IEC 529 and DIN 40050.
The thermostat housing is enamelled pressure
die cast aluminium (GlD-AISi 12).The cover is
fastened by four screws which are anchored to
prevent loss.
The enclosure can be sealed with fuse wire.
Cable entry
Pg 13.5 for cable diameters from 5 to 14 mm.
60 I 1001 1401180 1220

80 120 160 200
Fig.l
Curve A gives the maximum load.
Hatched area B: Acceptable load for the gold
plating of the contact.
Switch
Single-pole changeover switch (SPOT).
Contact material: Gold-plated silver contact.
Direct current: 12 W, 220 V, DC-13 - See fig. 1
Function
Selection of differential
To ensure that the plant functions properly, a
suitable differential is necessary. Too small a differential will give rise to short running periods
with a risk of hunting.Too high a differential will
result in large temperature variations
Differentials
The mechanical differential is the differential that
is set by the differential spindle in the thermostat.
The thermal differential (operating differential) is
the differential the system operates on.
I. Alarm for rising temperature

given at range setting value.
II. Alarm for falling temperature
given at range setting value
minus the differential.
Scale setting
Mechanical
dlffererentiai
Fig. 6
10
IC.PD.P10.C1.02-520B1861
identification
The type designation and code no. of the unit is
stamped in the side of the housing.
Scale accuracy
KPS 76: 3 "C

KPS 77: 3 C
KPS 79: 3 C
KPS 80: +3 C
KPS 81: 6C
KPS 83: 6 C
Snap point variation after 400 000 operations.

KPS 76-83: max. drift 2 C.
The thermal differential is always greater than

the mechanical differential and depends on three
factors:
1) the flow velocity of the medium,
2) the temperature change rate of the medium,
and
3) the heat transmission to the sensor
Thermostat function
Contacts 1-4 make while contacts 1-2 break when
the temperature rises above the scale setting.The
the temperature falls to the scale setting minus
the differential. See fig. 6.
Data sheet
Installation
Installation
Location of unit: KPS thermostats are designed to
withstand the shocks that occur, e.g. in ships, on
compressors and in large machine installations.
KPS thermostats with remote sensor are fitted
with a base of 3 mm steel plate for fixing to
bulkheads, etc. KPS thermostats with bulb sensor
are self-supporting from the sensor pocket.
Resistance to media
Material specifications for sensor pockets:
Flowvelocity of the medium is also of significance. (The optimum flow velocity for liquids is
about 0.3 m/s).
For permissible media pressure see fig. 2.
yBrass
bar
jStainless stee
.S
20015010080604030-
-i
ii
20-
Sensor pocket, brass

The tube is made of Ms 72 to DIN 17660, the
threaded portion of So Ms 58Pb to DIN 17661.
-40'
6 2 0 ' 60'lbo'l4o'l8o'22o'24o'28o'
Fig. 2. Permissible m e d i a pressure o n t h e

sensor p o c k e t as a f u n c t i o n o f t e m p e r a t u r e
Sensorpod<et, stainless steel 18/8

Material designation 1.4305 to DIN 17440.
Sensor position
As far as possible the sensor should be positioned
so that its longitudinal axis is at right angles to
the direction of flow. The active part of the sensor
is 013 mm x 50 mm long on thermostats with
rigid sensors and 2 m capillary tu be. The active
length on the other thermostats is 70 mm (5 m
and 8 m capillary tubes).
Setting
When the thermostat cover is removed, and the
locking screw (5, fig. 3) is loosened, the range can
be set with the spindle (1) while at the same time
the scale (2) is being read.
In units having an adjustable differential, the
spindle (3) can be used while the scale (4) is
being read.
1.Range
5\^
spindle
2. Range
The medium
The fastest reaction is obtained from a medium
having high specific heat and high thermal
conductivity. It is therefore advantageous to use
a medium that fulfills these conditions (provided
there is a choice).
- 3
Scc7/e correction
The sensor on KPS thermostats contains an
adsorption charge. Therefore function is not affected
whether the sensor is placed warmer or colder than
the remaining part ofthe thermostatic element
(bellows and capillary tube). However, such a charge
is to some extent sensitive to changes in the
temperature and bellows and capillary tube.
Under normal conditions this is of no importance,
but if the thermostat is to be used in extreme
ambient temperatures there will be a scale
deviation. The deviation can be compensated for as
follows;
Scale correction = Z x a
Z can be found from fig. 4, while a is the correction
factor from the table below.
spindle
"C
with 2 and
5 m cap.
tube
with 8 m
cap. tube
KPS 76
-10-+30
KPS 77
20-60
1.0
1.1
1.4
KPS 79
50-100
1.5
2.2
2.9
KPS 80
70-120
1.7
3.1
KPS 81
60-150
2.4
3.7
KPS 83
100-200
6.2
ICPD.P10.C1.02-520B1861
E
i
[A^^\
i
scale
5. Locking
screw
Scale d e v i a t i o n actor
'
1
::;ô!Si!': :
"C%
s^
";
- - -IrfC..
-^"'-'--. - # : : : : : : : :
==:..-.==
- 3Cfc
_-
. = = 2%;- ; - ^ . ' , i 4 , 1 0 0 % - -
^^4^
i.T^sii:
-- - :
:::_-:::
s_^X
Correction factor a
for thermostats
with rigid
sensor
4 . Differential
J =
Type
scale
3. Differential
Fig. 3
Regulation
range
Flg. 4
Relative
-
_,,._
Data sheet
KPS thermostats are fitted with a Pg 13.5 screwed

cable entry suitable for cables from 5 to 14 mm.
Contact function is shown in Fig. 5
Fig. 5
Examples
Example 1
A diesel engine with cooling water temperature
of 85 C (normal). An alarm must be triggered if
the cooling water temperature exceeds 95 "C.
Choose a KPS 80 thermostat (range 70 to 120 C).
Main spindle setting: 95 C.
Differential spindle setting: 5 C.
The required alarm function is obtained by
connecting to thermostat terminals 1 -4. After
the system has been in operation, assess the
operating differential and make a correction if
necessary.
2 1
Example 2
Find the necessary scale correction for a KPS 80
set at 95 C in 50 C ambient temperature.
The relative scale setting Z can be calculated
from the following formula:
Setting value - min, scale value x 100 = %
max. scale value - min. scale value
Relative scale setting: 95 - 70 x100 = 50%
120-70
Factor for scale deviation Z (fig. 4 page 11),
ZsO.7
Correction factor a (table under fig. 4
page 11) = 2.4
Scale correction = Z x a = 0.7 x 2.4 = 1.7 C
The KPS must be set at 95 + 1.7 = 96.7 C
Dimensions and weight
116-906B-
.07
/"
03
U-B13
KPS with remote sensor

Weight: ca 1.2 kg
(Incl. 2 m capillary tube)
12
KPS with remote sensor and armoured

capillary tube
Weight: ca 1.4 kg (Incl. 2 m capillary tube)
IC.PD.P10.a.02-520B1861
KPS with rigid sensor

Weight: ca 1.0 kg
Data sheet
Accessories: Sensor pockets

for KPS thermostats
Sensor
pocket
V~m
M1X1.3
Supplied without gland nut,

gasksts ana wasner
Code no.
Sensor
pocket
A
m
Thread
B
Code no.
65
1/2 NPT
0601326566
Brass
75
75
75
75
1/2 NPT
G 1/2 A
G 3/8 A
G 1/2 A (ISO 228/1)
060L326466
060L326266
060L326666
0601328166
Steel! 8/8
75
G1/2A
060L326766
Brass
no
1/2 NPT
G 1/2 A
G 1/2 A (ISO 228/1)
G 3/4 A (ISO 228/1)
060L328066
060L327166
060L340666
060L340366
Steel 18/8
110
110
G 1/2 A
1/2 NPT
0601326866
060L327066
G 1/2 A
G 3/4 A (ISO 228/1)
060L326366
060L340566
Steel 18/8
160
G 1/2 A
060L326966
Steel 18(8
200
200
G 1/2 A
G 3/4 A
060L323766
060L323866
*'
^ ^
Brass
1/
Thread
B
Brass
Mg
A
mm
110
110
110
160
160
Brass
200
200
200
G 1/2 A
G 1/2 A (ISO 228/1)
G 3/4 A (ISO 228/1)
060L320666
060L340866
060L340266
Brass
250
G 1/2 A
060L325466
Brass
330
G 1/2 A
060L325566
Brass
400
G 1/2 A
060L325666
>
I
-'-lA
Part
Description
Clamping band
For KPS thermostats with remote

sensor (L = 392 mm)
Heat-conductive
compound
(4.5 cm^ tube)
For KPS thermostats with sensor fitted in a sensor pocket. Compound for
filling sensor pocket to improve heat transfer between pocket and sensor.
Application range for compound:between pocket and sensor.
Application range for compound: -20 to +150 C, momentarily up to 220C.
Gasket set
Gasket set
^
j
mi-p'
" w lijs u \i^

lO
n?\
\y
\D
Code no.
017-420466
041E0114
For KPS thermostats without armoured capillary tubes
060L327366
For KPS thermostats with armoured capillary tubes
060L036666
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice.This also applies to products
already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
AH trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
13
IC.PD.P10.C1.02-520B1861
Instructions
Pressure Transmitters
Types MBS 32, MBS 33, MBS 33M,MBS 2050, MBS 2100, MBS 2150, MBS 2200, MBS 2250
MBS 3000, MBS 3050, MBS 3100, MBS 3150, MBS 3200, MBS 3250,
MBS 4010, MBS 4050, MBS 4500, MBS 4510
A
A
Elektrisk tilslutning:
Electrical connection:
Elektrischer Anschluss:
Raccordement lectrique:
Conexin electrica:
Connessione elettrica:
lEC 947-5-2, M12x1
Se produktskilt
See product label
Siehe Produktschild
Voir etiquette du produit
Ver la pecatina en el produao
Vedi etichetta sulla confezione
ISO15170A1-3.2-Sn/Au
(4 pin)
AMP Econoseal, J-Series
AMP Super Seal,

1.5 Series (3 pin)
EN 175301-803
Forbundet til kapsling
Connected to enclosure
Anschluss an das Gehuse
Connect au boi'tler
Conectado a la caja
Coliegato al corpo
Skrmet kabel: Skrm ikke forbundet til kapsling

Screened cable: Screen not connected to enclosure
Geschirmtes Kabel: Schirm nicht mit dem Gehuse verbunden
Blindage: Isol du boitier
Cable apantallado: la pantaila no se conecta a la caja
Cavo schermato: la schermatura non collegata all'involucro
IC.PI.P20.G2.53-520B2361
Instructions
^^
MBS 32, MBS 33

MBS33M
MBS 2100, MBS 2200,

MBS 3000, MBS 3100,
MBS 3200, MBS 4500
MBS 2050, MBS 2150,

MBS 2250, MBS 3050,
MBS 3150, MBS 3250,
MBS 4050
MBS 4010
MBS 4510
MBS4500/MBS4510
^
60 Nm
MBS 4500/MBS 4510
mA
yy
20SPAN
yy^->+5ZF5
4-
[mA]
*-
^
// ^ / ^
20ZERO
^^'~7'^->+20%FS
4
1-
Zero adjustment
0 - 1 - * 0-lObar
-5^+20%FS
0 - 1 6 ^ 0 - 4 0 bar
-5-+10%FS
0-60- 0-600 bar
-5^+2.5%FS
Span adjustment
-5^+5%FS
Australsk godkendelse ihty Australian approval according to/

Australisdi Zulassung gem,/ Homologation australiann selon le plan/ N1297
de acuerdo con la aprovacion australiana / Omologazlone australiana
secondo gll accordi
httpy/lcdanfoss.com/
IC.PI.P20.G2.53-520B2361
Danfoss A/SIC MOmhe,! 0-2005
AALBORG
INDUSTRIES
P.O. Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
E-mail: rtmwaalborg-industries.nl
Account No. 25.75.69.618
BIC Code FTSBNL2R
WORKING PRINCIPLE OF QUICK OPENING VALVE

The Econ quick opening valve Fig. 100/432SO, 100/433SO, 100/436SO and 100/437SO
has been designed to open a thermic oil (fuel) line rapidly in case of emergency.
Operating can be manual, pneumatic or hydraulic. The last two options make it possible
to open the valve by remote controle. Hydraulic operation can be effected by means of
an impulse unit Fig.107 and Fig. 108.
Fluid flow is with the pressure above the disc. The reason for this is that the line
pressure helps closing the disc when the valve is closed.
Let's assume that the valve is open. To get the valve in operational position, start by
pulling the lever nr.17 down (direction to the body). Block nr.7 will move downwards
untU the lever nr. 17 reach the end stop, (spring nr.6 and 9 are under tension).
The valve is now in the operational position.
When cylinder nr.28 is operated (manual, mechanical, pneumatic or hydraulic), the

cylindershaft will come out and pulling the lever nr.17 up and the spring nr.9 will force
the stem upwards.
The valve will open now.
To get the valve back in the operational position repeat the steps described above.
Certified
Company
::::
Differential Pressure Switch
AALBORG
INDUSTRIES
With integral Working Pressure Gauge and Micro Switch
General features
These differential pressure gauges are particularly intended for the
monitoring of differential pressures in filter systems, pumps and
pipeline systems In the heating, climatic and ventilating technology
sector, technical building equipment and in the water management
industry.
Apart from the display of the differential pressure, these applications
require, as a rule, the display of the current working pressure.
For this reason, a working pressure gauge is Integrated in the
differential pressure gauge as a standard feature.
An additional measuring point involving additional expense for piping
and mounting is no longer required.
The black dial of the working pressure gauge distinctly stands out
against the white background of the display of the differential pressure gauge, thus enabling a quick and safe reading of both quantities
to be measured.
Main applications
-
Heating, climatic and ventilating technology
Dust removing technology
Technical building equipment
Filter plants
Drinking and service water treatment
Monitoring and control of pumps In pressure boosting and

fire extinguishing plants
Drawing: D00776
Scale ranges per EN 837

Differential pressure gauge: 0 - 0.6 bar
Working pressure gauge: 0 - 0,6 bar
146
Dimensions in mm
o
o
I
PG 13.5
Electrical connection detoils
î'
2nd contactL
-^^9
_ j ^ "
1st contact
Ternninol box
DRAWN: RM
DATE: 0 1 - 0 2 - 2 0 0 0
DRAWING No: D 0 0 7 7 6
PROJECT
P.O.Box 145, 3200AC Spijkenisse The Netherlands

Phone: +31(0)181620122
1(0)181620122
Fax
: +31(0)181626719
E-mail: wmi@wiesloch.nl
REV. A
SHEET 1 OF
WAfffir^tSn
tfî^l^
\VAy[S,^[LOVi=^lr
Marin & lodysltries B\
A4
FOR THIS DRAWING WE RESERVE A t i RIGHTS. (DIN 34)
AALBORG
I N D U S T R I E S
Design and operating principle.

Pressure p' and p^ are given in + and
separated by an elastic diaphragm(l).
measuring medium chambers
The differential pressure (Ap=pi - p^) causes axial movement (measuring

travel) of the diaphragm against the measuring range spring (2).
Illustration of operating principle

3
The transmission of the differential pressure proportional to the the

measuring travel to the movement (4) within the indicating case and to the
plungers of the microswitches (5) and is carried out pressure sealed and
with little friction by means of connection rod (3).
The overpressure protection is provided by contoured metal bolsters for the
elastic diaphragm (6).
The adjustment of the switchpoint is made by setpoint screws accessible
from the front (7). The assistant scales (8) enable a relatively accurate
adjustment of the switchpoints over 270<! and indicate the setpoint that is
momentarily adjusted.
Technical data
Accuracy class
Differential pressure gauge:
Working pressure gauge:
Working pressure max.(static pressure) 25 bar
Pointer
Differential pressure gauge: white aluminium
adjustable pointer
black plastic
Overpressure safety
Must be on both sides max. 25 bar
Zero adjustment for differential pressure gauge

By means of adjustable pointer
Operating temperature
Ambient: -10....+70C
Medium: +90C maximum
Case
GD-AISi 12 (Cu) 3.2982, black painted
2,5
4
Temperature error
Additional error when temperature of the pressure element
deviates from +20C
Rising temperature: +0,5%/lO K of true scale value
Falling temperature: -0,5%/10 K of true scale value
Window
Acrylic
Electrical contact
Micro switch
2 X SPOT
850.3.3
Contact type
Contact functions
Degree of protection
IP 56 per EN 60 529 / IEC 529
Measuring media chamber (exposed to pressure medium)
GD-AISi 12 (Cu) 3.2982, black painted
Pressure elements (exposed to pressure medium)
Compression spring:
stainless steel 1.4301
Separating diaphragm:NBR fabric back stay (optional FPM/Viton)
Load data's
U max.
I max.
P max.
Switching point
adjustment
Links (exposed to pressure medium)

Stainless steel 1.4104, NBR (optional FPM/Viton
Setting range
Movement
Cu-alloy, wear parts German silver
Switching point
repeatability ace.
Dial
Differential pressure gauge: white aluminium with black lettering
white plastic with black lettering
Contact hysteresis
Voltage DC
Voltage AC
30 V
250 V
5A
0.4 A
250 VA
low
from the outside at assistant scale
by means of setpoint screw(s)
from 10% to 100%
of span
< 1.6 %
max. 5% of full scale value
(optional 2.5% max)
Gauge mounting
Pressure entries identified + and
+ high pressure, - low pressure.
AALBORG
INDUSTRIES
Aalborg Industries NL BV
P o Box 145
3200 AC Spljkenisse
Ohmweg 8
3208 KE Spljkenisse
The Netherlands
Tel. +31 181 650 500

Fax +31 181 650 501
E-mail: rtmw@aalborg-industnes.nl
http://www.aalborg-industries.com
No. 24234179
VAT No. NL0081.91.694.B.01
Bankers: Rabobank, Hoogvliet

Account No. 32.95.68.094
Swift-address: RAB0NL2U
Magnetically controlled level Indicator, type ITA

Indicates the fluid level of irritant, toxid or inflammable media with a separation of the measurement and indication area
The magnetic transfer of the fluid level from the tank to the indicator is
continuous and vibration-resistant
May be used for level measurements in non-pressurised and presssurised vessels
perfect legibility of the indicator elements even from some distance away
and after several years since there is no turbidity of the UV radiation
caused by product contamination
Simple, break-resistant and maintenance-free construction
Great reliability even at high temperatures and pressures
Alarm contacts may be secured on any position of the level indicator
The indicator may be fitted with a measurement scale for volume or
height (as required by the client)
Floats without gas prestressing from a minimum density of 0,35 kg/dm^
Maximum process pressure for sealed floats: 220 bar; at higher
pressures the floats must be pressure relieved (not to be used for
condensing media)
Fig. 1: INTRA level indicator, type ITA-3
The photograph shows a crosssection of the Armaflex insulation

so that the hernnetic insulation is
visible.
Fig. 2:
Indicator rail made of
Makroion, for medium
temperatures of up to 100"
Fig. 3:
Indicator rail made of
aluminium, for medium
temperatures of up to 100
Fig. 4:
Level indicator with Armaflex insulation for refrigeration
systems, indicator rail made of aluminium
(Armaflex prevents ice formation).
Magnetically controlled level indicators are used for the following level measurement tasks:
Indicating the fluid level
Monitoring the level with alarm contacts
Transferring the level using measurement value sensors (analog signal 4 20 mA) to electrical display untis
Interfacial level measurement
The magnetically controlled level indicator of type ITA offers considerable benefits for each of these fields
of application:
to
No risk of glass breakage as a result of the separation of the measurement and indicator areas. The float principle
means that changes in density in the medium have very little influence on the measurement accuracy.
f
to
Magnetic level indicators can be equipped with an arbitrary number of switch contacts. In contrast to electric
float switches, switch contacts may be installed at any position of the stand pipe. Wherever additional float
chambers are used for float switches, magnetically controlled level indicators offer a considerable price
advantage.
to
Electrical level measurement transducers which use the displacement principle must be recalibrated each time
the fluid density is changed.
The price of a magnetically controlled level indicator with integral electrical measurement transducer is
considerably lower than level measurement transducers.
The reed chain with an R/l measurement transducer can be changed without interuppting operation.
The measurement chamber is hermetically sealed there is no contact between the fluid chamber and the
reed chain.
Anzeiger
Typ: 4 2 0
1250ir.vî
Fig. 5: Indicator
type 420
With the microprocessor-controlled level indicator

unit type 420, the level can be displayed direct in
any arbitrary physical measurement unit. The indicator has a curve calculator with which nonlinear tank contents can be displayed direct in
cubic metres.
y//////////////////////A
im
o
ro
'
Level indicator with Armaflex insulation
Reliable insulation in the temperature range from -75 to +105C
Use in refrigeration systemes, eg. for ammonia
V
- -1î
r-
1
1
rnl
CTi
:j [tt
:D
1 FTE
^"^fv
S.
-r-ri^-W
Up
f=^
L
" i \ \
n 1
1!
O
T
CM
"0 1
15
Switches/alarm contacts
Secured with pipe clips, can be adjusted to any desired height
Connection using 3-pore cable or

casing terminals
Changeover contact can be used

as opener or closer
Explosion-proof version available
-i+HH
i
k
Kabellonge 3n
(Standcrd)
1 ;
"1" teri "*"
Fig. 6
Fig. 7
li
INTRA level indicators overview of standard deslg

Level indicators for low and medium pressures,
series ITA-3/6/7
Fig.8: ITA-3/PN16
Parts in contact with tine medium made as

standard of stainless steel (316Ti)
Pressure ranges PN16 to PN 64
DIN or ANSI connection flanges
precise float design for the operating conditions
Versions up to 12 m length (in two sections)
Special materials for special operating
conditions:
titanium, Hastelloy C4, Inconel 625, 1.4539
PTFE lining. (PN16 only)
Accessories: vent and drain flanges, valves,
reducer pieces, etc.
In ITA-3.0/6.0/7.0 versions with C-steel flanges
Fig. 9: ITA-7/PN64
Level indicators made of plastic series ITA-8
Plastics is now an essential material in pipline and tank construction
For utility and waste water applications and for use in corrosive media,
level indicators made of plastic replace expensive constructions such as
lined metal tubes, ceramic or glass tubes
Materials:
PVC (polivinyl chloride)
PP
(polypropylene)
PVDF (polyvinylide fluoride)
Connection flange DN15/PN6 to DN32/PN6
1
1
1
1
i
i
JT]
1 i
-J
o
c
:o
i
i
--./} i
}-4
O
CM
"fn
Q ; ^
ry-
/ n
ta
-1
110
IM
,!, 1
;,
Ir" !
S i
Level indicators high pressure range
Types: ITA-lb/11/12/13
i i
r-
-15
:
i
i
i
r^
1
Fig. 11: ITA-10/PN100
\H
I
i
1
J, ^
1.
Fig.lO: ITA-8
Use in the chemical, process and offshore'industries

Sealed float up to 220 bar, open versions up to 400 bar
Minimum operating density 0,5 kg/dm^
Special materials for special operating conditions:
titanium, Hastelloy C4, Inconel 625, 1.4539
Pressure'ranges PN100 to PN320
DIN or ANSI connection flanges
Accessories:
vent and drain flanges, valves, reducer pieces, etc.
'
Uvel indicators - - special versions and additionat equipment

Special versions:
a) Two-piece versions to order or for measurement lengths of over 6 m
b) Steam jacket with thread or flange connection; for heating the indicator with steam or hot water,
eg. for viscous media
c) Level indicator with PTFE lining, for use in corrosive media
d) Level indicator in GL design (Germanischer Lloyd)
e) To act as an overfilling guard for tanks for storing inflammable and non-flammable fluids which pose a
threat to water
f) ITA cryogenic version for refrigerants
g) Special versions to meet the client's requirements for specific operating conditions
Additional equipment:
a)
b)
c)
d)
e)
Heating belt to act as a frost guard for use in the open air
Vent/drain valves, screw or flange connection
Measurement scale, divisions to client's specification
Armaflex insulation
Protective hose, additional protection of the indicator rail against dust, dirt and moisture
Switches/Alarm contacts
Type
1690
Diagram
. y ^
changeover contact, bi-stable
enclosure
max. switch rating
IP 67
250 V AC,
12 V DC
0,8 A
60 VA
IP 67
1690EX
LIVIS-A
0 = ^
Changeover contact, bi-stable
EExd lie T6
0 ^
LMS-AH
a ^
220 V AC/220 V DC
0,6 A/0,4 A
45 VA/20 W
Operating temperature (ambient)

-30... -i-85''C
(medium max. 120 C)
-30... -1-75 C
(medium max. 100 C)
IP65
220 V AC
1,5 A
80 VA
-30... +150 C
1P65
220 V AC
1,5 A
80 VA
-30... +400 C
IP65
see note (1)
-25... + 60C

Proximity initiator
KEI
NAMUR
(1) The proximity initiator can be supplied with a disconnector unit (e.g. WE77Ex). The disconnector unit WE77Ex has a max. switch rating
of 250 V AC/4A/500 VA
Acceptance tests/certificates
Material certificate 3.1B in accordance with DIN 50049
PTB/Ex certificate
X-ray test in accordance with DIN54 111, part 1
Dye penetration test DIN 54 152
Acceptance tests as prescribed by NACE, TRD; construction pressure test by the TV
Magnetically Operated Levelgauges Type ITA-3 ... ITA-13

Installation and operation manual
I.
i-x
Installation
As soon as instrument is received it should be carefully inspected to determine
any damage incurred by shipment.
Check whether the dimensions of the indicator correspond with your order.
After inspection the indicator is installed as per following instructions:
Float (3) and indicator (2) are packed seperately in the same cardboard. Remove
the service flange (5) and put the float into the indicator (2) engraving "TOP"
upwards (Marking example see page 2).
Note, avoid ferrous material coming in contact with the float, since it must be able
to move freely. The magnetic system is exactly installed at immersed level of the
float correspondmg to liquid density.
If the position of the indication rail (4) does not meet with your approval, you can
turn the indication rail arround the pipe. Due to a ring-magnetic-system the
indication rail works in any position of the pipe.
After installing the float (3) tighten service flange
(5).
Adjust magnetic flappers (4) with a magnet in the
way that only the white side is visible.
If liquid raises the float turns flappers from white
to red.
4.
Level gauge type ITA-5 has no side connections

this type must be mounted to the vessel with top
and bottom connections.
II. Special instruction for

type ITA-4
1.
Release split-pin (6) at lower end of guide pipe.

Insert float construction with taller part of the
float to lower end of guide pipe. (Shorter cylinder
includes magetic system).
Lock guide pipe with split-pin (6). Now the

gauge can be mounted to vessel.
i n . Electric alarm contacts

Electric alarm contacts can be mounted in
any position and direction. There is a collection of alarm
contacts selected by temperature and electrical
load.
cable 3m
(standard)
IV. Startup
1.
Close drain valve and service flange
2.
Open valve lA very slowly
3.
Open valve IB very slowly

The liquid inside the float chamber now moves up to the same level as in the vessel.
When the float passes the wafers they rotate 180 showing the observer opposite face.
The wafers turn from white to red, showing the exact tank level.
V. Maintenance
Usually the gauge is maintenance free. If there is dirty liquid, put the gauge out of operation by closing the valves IB
and lA. Then remove service flanges and clean float and gauge pipe.
ATTENTION!
Be sure that vent and drain plugs are tight
and sealed!
The float is only capable for max. working '
pressure. Be sure not to increase working
pressure when float is inside the gauge pipe!
Remove float during pressure test of
the vessel!
Example for marking of the float:
TOP
R
=
=
1.0
16
=
=
11356
Top side
Type of
magnetic system
Density
Working
pressure
Serial-no.
AALBORG
Surface-mounting Thermostat
! N o U s T i t s
Series ATH
^ ^ i^
(*
Description
"
All necessary settings and possible adjustments are described in these Operating Instructions. If, however,
any difficulties should arise during start-up you are asked not to carry out any manipulations on the
instruments which are not permitted.- You could endanger your rights under the instrument warranty.Please contact Aalborg Industries NL B.V.
Phone:
The Netherlands (+31 181 650 500)
Arrangements to DIN 3440 as
Type designation
TW
TB
STW(STB)
ATH.-../
= temperature monitor
= temperature limiter
= safety temperature monitor
with pocket attached to case
Surface-mounting thermostats Series ATH conform

to VDE 0631
-2
temperature monitor TW with

changeover contact
Operation
-20
safety temperature monitor

STW(STB) with changeover
contact.
Lock-out facility
Thermostat, surface-mounting,
with microswitch
When the set temperature limit is exceeded the circuit is

opened and the microswitch is locked out mechanically.
After the temperature has dropped by 10% of span below the setpoint the microswitch can be reset manually.
/u
changeover contact
"Switching point adjusted after removing the

case top by rotating the setpoint spindle with a
screwdriver against an internal scale.
When using the STW(STB) monitor as STB limiter the

lock-out facility to DIN 3440 has to be provided by a
subsequent circuit.
Note: the lock-out circuit must conform to Section 8.7 of DIN 57 116.
Technical data
Current rating
with differentials
3%, 5%, 6%, 9% ; T W
5%, 7%, 9%
; STW(STB)
; TB, STB
10(2) A, 250 VAC, p.f.^ 1(0.6)
0.25 A, 250 V DC
with differentials 1.5%
; TW
2 %
,STW(STB)
6(1.2) A, 250VAC,p.f.=1(0.6)
0.15 A, 250 V DC
0.1
A, 24 VAC/DC
contact resistance 2.5-10mQ
Permitted ambient temperature at

thermostat head and capillary
in operation
liguid-filled or gas-filled
max. +80C
Fuse required
see current rating
AALBORG
I N D U S T R I E S
Temperature probe with and without pocket

The temperature is sensed by means of the temperature
probe. The probe must be immersed in the medium for
its entire length, otherwise there are appreciable
deviations in the switching point.
1 capillary
2 temperature probe
3 pocket
'A/ith probe mounting ES
the probe is secured by fitting attached to the capillary at
the factory.
UJ
w
Securing the thermostat case

Code s (rigid stem)
the boss of the case is secured in the enlarged open
end of the pocket with a fixing screw.
Opening the case
Unscrew the 2 screws 1 (suitable for lead sealing) on
the case top 2 and remove the case top 2
1 screws (suitable for lead sealing)
2 case top
3 case bottom
4 case boss
IVIaking the connections
The electrical connection must only be made by a
qualified electricianl
Connection suitable for fixed wiring. Cable entry without
fixed tension relief. Type X attachment (without special
preparation).
Pass the cable through the clamping gland Pgl 1 and
connect it up according to the connecting diagram. The
connection diagram appropriate to the particular
thermostat is glued into the case top
5 Terminal screw
6 Reset button (must be free to move)
7 Earth connection
for Code s
8 Clamping
Closing the case

Thermostats Code 2, 7, 20, 70
Checl< that the plastic seal in the bottom of the case 3 is
fitted correctly. Place the case top 2 in position and
tighten the two screws 1 (suitable for led sealing)
Thermostats Code 1
Set the internal setpoint spindle and the external
setpoint knob to the same point on the scale. Check that
the plastic seal in the bottom of the case 3 is fitted
correctly.
Place the case top 2 on the case bottom 3. The external
setpoint l<nob must engage with the coupling disk on the
internal setpoint spindle; this is the only way in which the
two parts of the case can be fitted together and screwed
up.
AALBORG
I N D U s T 1 E s
Differential (liquid-filled)
monitor TW
3+1%
6+2%
1.50.5%
monitor
STW(STB)
51%
9+2/-1%
21 %
Differential (gas-filled)
monitor TW
5+5%
9+2%
1.50.5%
monitor
STW(STB)
72%
9+3%
21%
^
Permitted ambient temperature at probe

in operation
max. end of scale +15 C
min, -50C
standard
optional
extra charge
Permitted storage temperature

thermostat head, capillary, temperature probe
max. +50C
min. -50X
standard
optional
extra charge
Operating medium
water, oil, air, dry steam
standard
optional
extra charge
Time constant
in water
standard
optional
extra charge
45 sec max. in oil

60 sec max, in air/dry
120 sec max.
steam
Action
to EN 60 730-1
TW, I B
Type 2BL = automatic action with microdisconnection in operation; no auxiliary energy
supply required.
Switching point accuracy

(in % of span, based on setpoint,
at +22 "C)
controller TR
in upper third of scale
1.5% *
at start of scale
6 %
monitor/limiter TW. STB, TB. STW(STB)
in upper third of scale
+0/-5%
at start of scale
+0/-10%
Protection
IP54 to EN 60 529
Suitable for use in usual (normal) polluted
situation
* Switching point accuracy can be shifted to

different part of scale range
Operating position:
unrestricted
IVIinimum bending radius of capillary 5mm

Note:
To ensure their overall accuracy the thermostats must only be used in conjunction with the pockets supplied by the
factory.
IMean ambient temperature error
referred to scale span
Switching point displacement based on deviation of ambient temperature at thermostat head from +22C
calibration temperature
higher ambient temperature = lower switching point
lower ambient temperature = higher switching point
Note:
At present there is no restrictive statement from the health authorities concerning any danger to health of short
periods and at low concentrations, e.g. after fracture of the measuring system.
Physical and toxicological of the expansion media which may leak in case of a system fracture.
Range
with top end of
scale
C
Liquid filled:
+200 to +350
Gas filled:
+400 to +500
Dangerous
reactions
Water
Fire/explosion
contamination
hazard
Ignition
Explosion
temperature
limit
C
% v/v
+490
1.0-3,5
Toxicological data
irritant
Danger to
health
toxic
AALBORG
: N D ; s : t s
Connection diagrams
,(
Code 2
1 1
1
h
With changeover contact

1
^ r
''
J
1 -4 -
4
i
f^^^
After the temperature has dropped by approx. 10% of

span below set limit (safe temperature limit) the
microswitch can be reset.
- Reset the screw cap 1.
I I
- Push the reset button 2 until the microswitch is reset.
- Screw the cap 1 back into position.
q=^
Monitor and limiter TW, TB.

Code 2
Remove the case top and adjust the setpoint
arm 1 with a screwdriver. Place the case top
bacl< into position and screw it down.
Code?
Remove the case top and adjust the setpoint
arm 1 with a screwdriver. Place the case top
back into position and screw it down.
._
~
1^
%-~(i
-^^ # ^
/I
r^
Maintenance
The surface- mounting thermostat Type ATH requires no maintenance. In case of a fault the staff of
our Technical offices are always available to provide information and servicing facilities.
r)
(iE
Industry controllers KFM 93W0.

operating instructions
1 Digital display actual value

2 2nd digital display attandant unit of
measure or name of input
3 LED-display relais function
4 Key for setpoint and parameter mode
5 Setpoint adjustment
6 Parameter mode lock switch (back face)
- page 1 -
:: Kg
QQ1
DIN-certificate: TR (TW) 949 ..
B 93W0_ E
Controllers type 93W0. are depending on hardware adjusted in one of up to four possible preconfigured
types: 200, 701 700, 700E. The adjusted type can be recognized at the type plate, furthermore at the display
by pressing the P-button longer than 5 seconds if the parameterlevel is locked.
Types -200 and -701 contains additional analog inputs and switching contacts for full load lock and
expansian tank high alarm. In deviation to the preconfigured types it is also possible to use all existing
hardware with special individual adjustments.
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 min
Rate time Tv: 0,0...99,9 min
Sensitivity of response Xsh: 0,1 ...1,0 %
Travel time of the actuator Tm: 6...600 sec
Switching frequency cy: 2... 120 sec
Function characteristics: direct / inverted
Switching inten/al SA (add. contacts): 0..100,0 K
Switching difference Sd: 0,1... 100,0 K
Additional contact functions:
As switching interval above and below setpoint or
independent adjustable with own setpoint and
measuring input, switching function adjustable
(ref. to chapter additional switching contacts)
Installation dimensions:
on
off
stage controller (invers)

Kl
K2
TJ^ TJ^
PSdT
-l>
actual value
|-Sd2^
-SA2
SP (Sollwert)
on
off
three- point- step- controller (invers)

K1(+)
K2(-)
Sh
T^fTT
I
actual value
SP
Other data:
Housing for panel mounting, 96 x 96 mm
Power supply: 230VAC +/-10 %, 48...62Hz
approx. 14 VA
alternative 115 VAC, 48 VAC, 24 VAC, 24 VDC
Protective system DIN 40050: IP54
(terminals IP20)
Permissible ambient temperature: 0...60C
Nominal temperature: 20C
Climatic category: KUF to DIN 40050
Relative humidity <= 75 % yearly average,
no condensation.
EMC: refer to EN 50081-2 and EN 50082-2
Form 9 6 x 9 6 : L= 1 5 0 m m , B = 9 2 m m H = 9 2 m m
Form 7 2 x 1 4 4 : L= 1 7 0 m m , B = 1 6 8 m m H = 1 3 9 m m
data subjects to alteration
93W0_E1.DOC/0310120
Industry controller type 9...

Installation and connection
B 9... E
- page 2 -
Installation:
Before installation inspect the controller for any visible signs of damage caused during transport
Check power supply ace. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the
fastening devices supplied.
Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following the
wiring diagram; wire cross section max. 1,5 mm^
- To avoid cross interference all low voltage measuring lines and pilot wires must be encased
in a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally lo 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 to
the setpoint after some seconds. If nothing happens check the fine-wire fuse on the back panel
of the controller and the electrical wiring. Adjust set value and check other adjustments.
IVIaintenance:
All electronic controllers In the KFM range are virtually maintenance-free. Provided that the
controller is correctly installed and put into operation and is protected against mechanical
damage 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 RTD
Err 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
Err 52
Hardware error in program section

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 setpoint

raise setpoint or lower actual value and start adaptation again
Err 206
Fault on measuring Input during adaptation;

check the wiring and start adaptation again
9_E2.DOC/0211115
Industry controller KFM 9.

Operation
B 9... E
- page 3
Operating status:
The upper display shows the actual value (channel / measuring input 1),
635
the lower display shows the attendant unit of measure (C, F, %, bar...)
(depending on the settings)
types 93W00 200 and 701 only:
Switch over the upper display to the further actual values by pressing the O key,
the lower display shows the number of the attendant measuring input
("Ist2" = return temperature)
or an abbreviation of the input's name ("EPtH" = expansion tank high).
Return to operating level:
Press O - key shortly (or automatically after 30 seconds without any key-action)
Setpoint value setting:

press B - key shortly (do not hold down)
5P
635
The upper display shows the abbreviation of

the activated setpoint adjustment mode,
the lower display shows the adjusted value.
The indicated value can now be changed by the D (lower) and O (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.
Return to operating level:
Press B - key shortly (or automatically after 30 seconds without any key-action)
optional:
Press B - key srtort/y again: *SP =set values of further control loops (*=no.) /
SP* =:further set values of the control loop / SPE =external setpoint (display mode only);
flashing display signifies that the function is nof active at the moment.
l\/lanual operation: (optional)

Hold down Q - key and press Q - key, then release both keys.
(optional: switch on and off using separate * - key)
(for multi-channel controllers first enter the channel number*
and press B - key, then:)
E3.5
The lower diplay shows "H *" and - if activated - the output position.
The upper display stiW shows the actual value. The automatic control is interrupted.
IVIanual control is now possible using the D...D - keys.
Return to operating level only by pressing the
{no automatic return from the manual mode)
key (if present: the - key)
optional: starting the self adaptation (ref. to chapter Optimization):

On manual operation level B - key >5 sec ;
the /ower d/sp/ay indicates "-Ad-".
Cancel: B - key >5 sec again
93W0_E3.DOC / 0411129
Industry controller type KFM 9.

Parameter level
B 9... E
- page 4
Access from operating level.

Unlock the access first:
Turn the switch on the rear panel of the controller to position "U" = unlocked
(Lock access after the adjustments: Switch position to "L" = locked).
P
typ
70 /
After the parameter level (refer to the instructions to each level) has been invoked,
the first setting is shown and can be modified.
It is not possible to invoke the parameter level when the switch is locked.
In this case the display shows the abbreviation of the configured controller type.
Confirm the entry and / or move on to next parameter:
press the Q -key briefly
Settings in detail:fnof available on all types)
Level 1:
Invoke: Hold down the B - key for more than 5 sec until the display changes
Code
Code number, password (1...9999)
Configuration
Sd1
SA2
Sd2
SP4
Sd4
SP5
Sd5
factory setting:
1
200:
switching difference for contact no.1
switching interval for contact no.2
switching difference for contact no.2
set point for independent contact no.4
switching difference for additional contact no.4
set point for independent additional contact no.5
notes:
3,0
5,0*
3,0
80,0
1,0
80,0
1,0
Configuration 701:
proportional range Xp (%) (ref. to chapter "Optimization")
integral action time Tn (min) (ref. to chapter "Optimization")
I
rate time Tv (min) (ref. to chapter "Optimization")
d
sensitivity of response Xsh (%)
Sh
SA3
switching interval for contact no.3
Sd3
SP4
set point for independent contact no.4
Sd4
set point for independent additional contact no.5
SP5
Sd5
25,0
7,0
0,2
0,1
8,0
3,0
80,0
1,0
80,0
1,0
Configuration
P
I
d
Sh
25,0
7,0
0,2
0,1
700 / 70E:
proportional range Xp (%) (ref. to chapter "Optimization")
integral action time Tn (min) (ref. to chapter "Optimization")
rate time Tv (min) (ref. to chapter "Optimization")
sensitivity of response Xsh (%)
Return to operating status:
Briefly press the Q - key (or automatically after 30 sec.)
Level 2:
Invoke: Hold down B - key and press D - key,

hold down both keys for more than 5 sec. until display changes.
Code
Unit
1 bLo/1 bHI
nSt
Lo / HI
dSPL
Code number, password (1...9999)

1
switch-over the displayunit (C/F) for PtIOO-input only
C
start / end of display range for voltage- / current -input (only)
0 / 0,6
modification of decimal point characters ( 0 / 1 / 2 )
0/2
start / end of setpoint range (C /F or value)
ace. to range
select function for lower display (AUS/SP/IST2/IST3/C/F/%/bar)
C/bar
(AUS=off, SP=setpoint, Ist2/3=act. value inp.2/3, C/F/%/bar=text)
Return to operating status:
Briefly press the B - key (or automatically after 30 sec.)
93W0_E4.DOC / 0411129
Industry controller type 9..

Optimization
B 9... E
- page 5 -
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 replaced
by this brief information.
The following informations are for help purpose only:
P = proportional band Xp (%):
/overvalue =/onger impulses, more sensitive reaction
highervalue - srtorfer 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 I n (min):
/oi/vervalue= shorter impulse gaps, faster balancing
higherva\ue= /onger impulse gaps, slower 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-adjusts
the 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), othenwise 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 O - key plus O - key (optional: seperate key).
Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down D - 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 stabilization
of 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 Q - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
to operating level.
Unsuccessful adaptation ( Display shows error code, ref.to chapter error messages):
Press B - key again: Return to manual operation level
eliminate the indicated error
start adaptation again: O - key > 5 sec.
or return to operating level: Q - key shortly
9_E5.DOC / 021 I I 15
Industry controller type KFM 9.

Configuration
B 9... E
- page 6 -
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 O - key and press the D - key,
hold down both keys for more than 5 sec. until the display changes
CodE
0
Enter the code number (password) I1...D (1...9999), factory setting: 1

move on to next input: orieffy press D - key
Cod I
Alternatively: Hold down key after entering code for more than 10 sec.
Possibility to modify code number (optional)
/
ConF
ID I
Select control function (type dependent): the displayed ID number for the configured
control function can be changed by pressing the D - key:
700 - Three point step controller (temperature)
700E= Three point step controller (pressure)
only Type 93W00:
200 = 2 stage controller with additional contacts and advices
701 = Three point step controller (temperature) with additional contacts and advices
Ustl
OB
Ain1
Ain2/3*
lst1/2*/3*
Y"
out
Y_S
reL3*
reL4*
reL5*
Adr
Return to operating level: briefly press the B - key

or
move on to following adjustments: hold down Q - 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: D...Q
(move on to next input: press Q - key shortly)
type of measuring input no 1, rtd/ 0/4-20mA/ 0/2...1 OV
(observe different terminal connection l/U)
status of measuring inputs no 2/3, Aus / rtd
correction value to change the controller display (+ / -)
travel time of the actuator "6...600" (sec.)
adjusting output characteristics direct / inverted "di / in"
behaviour of the output in case of measuring line fault:
relay position:"rel1 / rel2 / AUS" ( AUS = relays off)
function selection for add. switching contact no 3 :
select the corresponding measuring input / control circuit
relay condition In case of measuring line fault: "SiE/SiA"(on/off)
function selection for add. switching contacts :
relay condition in case of measuring line fault: "SiE/SiA"(on/off)
function selection for add. switching contacts :
relay condition in case of measuring line fault: "SiE/SiA"(on/off)
bus adress (adress no.) (for interface equipment only)
factory setting
rtd (700E:4-20mA)
rtd/rtd
0.0
60
in
rel2(70.),rel1(20.)
SoA(701)Aus(200)
Ist1
SI A
USA(200/701)
Ist2
Si A
USA(200/701)
Ist3
Si A
5
Return to operating level: r/effy press the B - key again
*= not available with type 93W01
93W0_E6.DOC / 0411129
Industrial controller type 9..

Facilities for Setting Supplementary Contacts
B 9... E
- page 7 -
Selectable switching functions (depending on version):

For setting please refer to configuration level under reL..'
Switching functions for trailing contacts:
LC A
LC E
Su A
Su E
So A
Break contact on either side of setpoint

(Limit comparator). Relay drops out as
deviation increases (Aus = off)
off
Make contact on either side of setpoint

(Limit comparator). Relay picks up as
deviation increases (Ein = on)
off
Break contact below setpoint. Relay drops

out as actual value decreases (Aus - off)
on
Make contact below setpoint. Relay picks

up as actual value decreases (Ein = on)
on
Break contact above setpoint. Relay drops

out as actual value increases (Aus = off)
St A
Make contact above setpoint. Relay picks

up as actual value increases (Ein - on)
Heating stage below setpoint. Relay
drops out actual value increases (Aus =
off)
XhSd^
^
off
off
on
W IS A -
1 TZI
T^,S A -
^HT
on
iZT
off
off
1 rg
T^d
Relay drops out with increasing actual

value (Aus - off)
US E
Relay picks up with increasing actual

value (Ein = on)
actual value
SP
(setpoint)
Switching functions for independent contacts:

US A
l ^
SA
off
So E
1 x=r
|- S d -
off
|- Sd-
Service function:
Ein/Aus contact is constantly switched on (Ein) or
off (Aus) respectively
actual value
SP
S w i t c h i n g point
Only for units with program option

Pr A
Relay switched off (aus) during SP program level, othenwise switched on
Pr E
Relay switched on (ein) during SP program level, otherwise switched off
Special function:
SF6
as SoA but switching point at setpoint, control output around SA below
In each case additional settings follow under "rEL." after the selection Is acknowledged (P key)
(depending on version):
Ist./Y
assigned value: actual value no.... or Y (actuating signal)
CH../.SP.(only) for trailing contacts: assigned control circuit / channel (no.) or

assigned setpoint (1SP., rSP, SP.1,..)
for independent contacts: assignment of parameter input (channel no..)
SI E
SI A
"Safety" shut down (in case of measuring line fault):

Relay for "Safety" behaviour in event of measuring circuit error: relay on
Relay for "Safety" behaviour in event of measuring circuit error: relay off
Subject to technical changes
9_E7.DOC / 0211115
Industry controller KFM 9.

Wiring diagrams
B9E
page 8 -
Wiring diagram conf "200" (Type 93W00..): Example for connecting a 2 stage burner
controller electronics
A927_WHI0110118
riFuse:
[J230V:T0,1A
measuring inputs
JsM
LLL
1st?
power supply
relay outputs
27 28 29
Rsl 1
Bfil 2
Bel 3
Rfil 4
BaL
50 51
5 l | 52 53 54 55 56 57158 59 6o|61 62 63 64
IsLa
99 10 11
^m^m'S
supply
return
(protect relay outputs by external fuse 2A)
()
exp. tank
stage 1
stage 2
full load expansion

i^^k
tank high
unused
Wiring diagram conf "701" (Type 93W00..): Example for connecting a mod. burner
A927_WMl01101ie
measuring iri p u t s
11+
99 10 11
St 1
t]
supply
mrarmR
power supplj/
relay outputs
St 3
St ?
^tJ
Rel 1
Rel 3
Rel 4
Rel f
50 5 l | 5 2 53 54 55 56 57|58 59 60|61 62 63 64
27 28 29
Rel ?
(protect relay outputs by external fuse ;!A)
return
exp. tank
full load expansion

burner - burner on/off look
tank high
burner +
Wiring diagram conf "700" (Type 93W00.. or 93W01..):

Example for connecting a control valve in a temperature loop
measuring inputs power supply

11+
relay outputs
St 1
99 10 11
Rel ?
Rel 1
50 5 l | 5 2 53 54 55
27 28 29
J- d
'4J
fil
(protect relay outputs

by external fuse 2A)
valve +
temperature
valve -
Wiring diagram conf "70E" (Type 93W00.. or 93W01..):

Example for connecting a control valve in a pressure loop
A927_WMI0110118
[1
alternative
St 1
11+
99 10 11 1 2
I-
measuring inputs power supply
^^
4...20mA
(3-wi re-transmitter)
Fuse:
230V:T0,1A
I.St 1
11+
99 10 11 1 2
x<f
4...20mA
(2-wire-transmitter)
relay outputs
Rel 1
27 28 29
Rel ?
50 51 52 53 54 55
(protect relay outputs
by external fuse 2A)
valve +
valve 93W0_E8.DOC / 0411129
AALBORG:;
INDUSTRIES
Aalborg Industries A/S

Gasvaerksvej 24
P 0 Box 844
9100 Aalborg
Denmark
CVR No. 17830635
Tel. +45 99 30 40 00
Fax +45 98 16 83 16
Telex 69705 albor dk
Giro No. 844-7756
VAT No. DK 17937677
E-mail: aal9aalborg-industries.dk
httpyAmvw.aalborg-lndustries.com
Bankers: Danske Bank A/S, Copenhagen
IBAN: DK 73 3000 3201 669138
Nordea A/S, Copenhagen
IBAN: DK 30 2000 0270 344283
INSTRUCTIONS FOR SHELL & TUBE HEATER
Instruction Manual
for VESTA MX
Table of contents for instruction manual
1. General Description
2. Installation Space Requirements
3. Storage
4. Mounting and Installation
5. Connecting the Heat Exchanger
6. Operation
7. Conservation during shut down periods
8. Maintenance and Cleaning

9. Dismantling and reassembling of the tube section
4
5
10. Spare Parts
Appendix:
- Spare Parts Drawing
Dimensional Drawing
1.
General Description
Aalborg Industries' Vesta MX heat exchangers are of the shell and tube type with
u-tubes.
The Vesta MX heaters range from 0,5 m* to 60 m^ 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 in
tanks.
Vesta MX heat exchangers are primarily used as fuel oil, lubrication oil, or water
heaters (JCW).

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 classification
societies.
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 is
damp the heater must be isolated with bags of silica gel. To avoid damage it is
recommended the heater be stored in the original packaging.
3.2.
Hydrostatic testing
AH Aalborg Industries heat exchangers have undergone hydrostatic pressure
testing before delivery. The testing fluid used contains a certain amount of corrosion protection (Castrol Rustilo Aqua 2); hence no further actions regarding storage are required before installation.
3.3.
Extended storage
When heat exchangers are to be kept in storage for an extended period of time
we recommend Castrol Rustilo Aqua 2 be used as protection against corrosion.
4.
Mounting and Installation

The heat exchanger is designed for vertical or horizontal installations.
In case of horizontal installation the steam inlet pipe and media outlet pipe must
face upwards.
If the heater is placed vertically the inlet and outlet tubes as well as the media
inlet must be at the bottom and the heater must be equipped with an air escape
screw at the top end.
The steam regulator (optional) must always be placed horizontally.
Instruction manual for heat exchanger type VESTA^^ MX

Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 - Project specification deleted
S:\HEATEmMANUALEmNyt IDUMX inslnJ.doc
2/5

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 horizontally.
Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts into the holes and tighten up.
Connecting the Heat Exchanger

5.1.
Preparation and pipe connection of tlie heat exchanger
Remove all plugs and cover flanges before connecting the heater. Make sure
sand and other impurities are removed from all connections. Set up the pipe connections and make sure that no forces are transferred to the heat exchanger.
Operation
6.1.
Commissioning
Before start-up it is important to make sure that all connections are securely
tightened.
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 before 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.
Heater mainflangebolts tightening schedule (dry values) - T16 types
No bolts
Size
Torque [Nm]
Tightening schedule
MXIO
M16
50
14725836
MX15
Nf20
83
14725836
MX20
12
M20
79
171149261251038
MX25
12
M24
137
1 7 1 1 4 9 2 6 1 2 5 1038
MX30
12
M24
186
1 7 1 1 4 9 2 6 12 5 10 38
MX40
16
M27
245
1 9 5 1 3 8 1 6 1 2 4 1 5 7 3 1 1 6 1 4 102
Always use a torque wrench when tightening the flange bolts.

Both sides of the heater must be carefully vented and the circuits carefully inspected for leakage during the whole start-up period.
Instruction manual for heat exchanger type VESTA^** MX

Manufactured in Aalborg, Denmaric
S:\HEATER\MANUALEfNyt ID1MX indrudoe
3/5

6.4.
Output
The output of the heater is subject to the supply of dry saturated steam at the inlet steam valve. The steam pressure applied to be as basis heater size calculation.
The output is furthermore subject to correct tj^pe of steam trap being used. Correct layout of the condensate system avoids negative effect of counter pressure.
Conservation during shut down periods

Corrosion occurrences in shut down periods are mainly caused by oxygen. The
corrosion occurs if non-distilled or alkaline water remains in the heat exchanger.
However, even when fully emptied, heaters are exposed to corrosion caused by
water residues or condensation. Hence, heaters out of service should be protected
against corrosion.
If the heater is out of service for an extended period of time - in particular during
winter seasons withfrost- it must be carefully emptied. Open the air escape
^ ^
valve and check for clogging.
fB^
8.
IVIaintenance and Cleaning

8.1.
Regular cleaning periods
The heater should be cleaned regularly every six months by removing the tube
insert 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 the
tube 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 Industries
recommends the heater chemically cleaned with a carbon remover.
After cleaning has been completed the heater must be flushed carefully with
fresh 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
Instruction manual for heat exchanger type VESTA* MX

S:\HEATER\MANUALERVNyt lOMX lnslnj.doc
4/5
Dismantling and reassembling of the tube

section
The tube section is inserted into the heater and fastened tightly between the shell
flange and the end flange. The back end of the tube section is not fixed.
The steam connection for primary steam must be dismantled before dismantling
the tube section for inspection, cleaning, etc. The tube flange has threaded holes
for dismantling screws and for mounting eyebolts for lifting devices.
Gasket surfaces are to be cleaned and protected against damage. New gaskets are
to be fitted every time the flange connection has been dismantled.
IMPORTANT: Fluid flow through the heat exchanger must be established before the heating medium is applied.
Tighten all mam flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.
Heater main flange bolts tightening schedule (dry values) - T16 types
No bolts
Size
Torque [Nm]
MXIO
M16
50
14725836
MX15
M20
83
14725836
MX20
12
M20
79
171149261251038
MX25
12
M24
137
171149261251038
MX30
12
M24
186
171149261251038
MX40
16
M27
245
19513816 1241573 11614 102
Tightening schedule
Always use a torque wrench when tightening the flange bolts.

A pressure test should be carried out to prove tight joints.
Note: Pressure testing to be carried out only with insert mounted in shell.
Both sides of the heater must be carefully vented and the circuits carefully inspected for leakage during the whole start-up period.
10.
Spare parts
When ordering spare parts please state the serial number of the heat exchanger
(located on the nameplate).
For spare parts and further information please contact Aalborg Industries.
<0
Instruction manual for heat exchanger type VESTA MX

APR. 2001, rev. 3 -Project specification deleted
S:\HEATERUUNUALER\Nyt lOtMX lnstru.doc
5/5
ucav.1 ipiiui
Type number changed
2S0900 \
JBL
,1
Option
pt- 1^4
cq..l
5. Tube insert'
1. Safefy valve
Ref. serial No.
8750032 - 1 0 Bar
8750033 - 1 5 Bar
6. In- and outlet flange gasket's
87S0031 - 16 Bar
8913005 (00 0660 0421 ON 32
87S0027 - 30 Bar
8913006 (00 0660 048), ON 40
2. Manomefer
B9I3007 (00 0660 060) ON SO
88M0001 - 0-16 Bar
8913008 (00 0660 076) ON 65
88M0002 - 0-40 Bar
8913009 (00 0660 089) ON 80
3. Thermomel'er
7. Steam and condens flange gasket's
88T0001
8913002 (00 0660 027) ON 20

8913003 (00 0660 034) ON 25
I,. Flange gaskefs
8913005 (00 0660 042) ON 32
Ref. serial No.
8913006 (00 0660 048) ON 40
Please state the serial number when ordering spare parts.

Project
Boiler data
Scale
Weight kg.
Dept.
1:15
tft*
Drawn
AALBORO
INDUSTRISS
Date
JBL
Approved
/ITAJ
25.09.2000
Date
25.09.2000
Size
AAR
No.
HEAT EXCHANGER
Type MX
Spare parts
15 I 4003
This Drawing and Design shown herein, is the property of Aalborg Industries A/S. and must not be used or reproduced for thii ^ âriy
*>'
Transfer G e a r Pumps
Operating and M a i n t e n a n c e
KF
Instructions
4...80
KRACHT
Transfer Pumps
List of Contents
Safety
Safety Instruction Symbols
1
1
General Safety Instructions
Address of Manufacturer:
The Documentation
Description of Equipment
General
2
2
Specified Use
Construction
Technical Data
Explanation of Type Code
4
4
General Data
Overview of Nominal sizes
Overview of Materials
Overview of Operating Pressures
Pump installation and removal

Mechanical Installation
6
6
Alignment of the Coupling
Determining the Direction of Rotation
Suction Pipework
Pressure Line
Pump Removal
Commissioning
Special feature on sealing variants 4 and 7 (Double radial shaft sealing ring)
Pressure setting of the pressure relief valve
Maintenance
Seals
11
11
12
12
13
13
Maintenance of the seal variants 4 and 7 (Double radial shaft sealing ring)
13
Maintenance of the seal variants 5 and 6 (Slide ring seals)
13
Changing the direction of rotation of the pump
14
Tightening torque for cover fixing screws
14
Change in direction of rotation with sealing variant 5 (Slide ring sealing)
14
Repairs
Elimination of the Fault
14
14
Diagnosis
15
Detection and Elimination of Faults
15
Safety
Safety Instruction Symbols
The safety notes contained in these operating instructions are identified by the following warning symbol.
A
If these warnings are not heeded, the consequence can be danger to life and limb and damage to
equipment..
Other notes, which do not warn of danger, but which provide tips for optimum operation, are symbolised by a hand.
General Safety Instructions
The operating safety of the pump supplied is only guaranteed if the pump is
used as specified (see "Description of equipment"). The stated limiting values
(see "Technical data") must not b.e exceeded under any circumstances.
Personnel having the responsibility for installing, operating or repairing the
pump must possess the appropriate qualifications; these may have been obtained through training or appropriate instruction. Such personnel must be
familiar with the contents of these operating instructions.
During the execution of all work, the prevailing national regulations relating
to accident prevention and safety at the work place and where appropriate,
the internal regulations of the operator must be observed, even if the latter
are not named in these operating instructions.
Leakages of dangerous substances handled by the pump must be contained
and disposed of in such a way that there is no danger to personnel or to the
environment. In so doing, the relevant statutory regulations must be observed.
During all work on the pump and prior to installation, the connecting pipework
must be depressurised and the motor isolated!
The operator must ensure that these operating instructions are accessible at
ail times to personnel concerned with the operation of the equipment.
Address of Manufacturer:
KRACHT GmbH
Gewerbestrasse 20
58791 Werdohl
Tel. O 23 92 / 93 5-0
Fax. O 23 92 / 93 52 09
BKF-0004-07.97-E
The Documentation
These operating instructions describe the installation, the operation and the repair of the KRACHT
KF 4...80 tranfer gear pump.
The equipment is manufactured in various versions. The specific version can be identified from the
type label affixed to the pump. The format of the type designation and a detailed description of the
individual versions and nominal sizes is to be found in the "Technical data" section (see "Description of
equipment").
Description of Equipment
General
KRACHT pumps in the KF Series are outside gear wheel pumps, which operate according to the displacement principle. Two gear wheels which are rotating in mesh with each other cause an increase in
volume to occur as the spaces between the gear wheels are exposed at the pump inlet (suction side),
so that the medium can flow into the pump. Simultaneously, a corresponding volume is displaced at the
pump outlet (pressure side) through rotation of the gear teeth into the filled area vacated by the preceding teeth. The transport of fluid is achieved through the entrainment along the cavities between the
gear teeth and the walls of the gear chambers. The so-called geometric delivery volume V^ is displaced
per revolution of the gearwheels. A value Vg, referred to as the nominal volume, is used in technical
documentation to identify the pump size.
Gear wheel pumps are self-priming over a wide envelope. The described displacement process is initially achieved without noticeable pressure rise. It is only after the burden of external loading is applied,
for example if a delivery head is imposed, there is resistance at the pump outlet, pipeline components,
etc., that a working pressure must be generated to overcome these resistances.
Displacement pumps must never be operated against "closed valves", since

the uncontrollable pressure heads which occur in this case lead to damage to
the pump and to the associated plant elements.
As is usual in the case of so-called rigid pumps, i.e., pumps without compensation for axial play, the
lateral play between the gear wheel contact surfaces is set such that the permissible operating pressure is safely controlled. The directions of rotation and supply of outside gear wheel pumps, when viewed
on the end of the drive shaft, are given as in the following diagrams:
Pressure side
Suction side
Suction side
Pressure side
y
Fig. 1
Shaft rotating to left:
Delivery from right to left
Fig. 2
Shaft rotating to right:
Delivery from left to right
BKF-0004-07.97-E
Specified Use
The KF is a pump for the continuous delivery of fluids. The different types of seals available enable the
pump to be used for various media.
It must be ascertained that the medium to be delivered is compatible with the materials used in the
construction of the pump (see "Technical data").
The maximum permissible operating data given in the "Technical data" section must be unconditionally
adhered to.
Construction
The drawing below illustrates the principle features of the KF pump.
Fig. 3
Drive shaft gear wheel
Driven gear wheel
Housing
End cover
Plain bearing bush
Radial shaft sealing ring

(shaft seal varies to suit sealing requirements)
Retaining ring
BKF-0004-07.97-E
Technical Data
Explanation of Type Code
Example:
KF
40
D15
Product name
Nominal size
Vg=
4/5/6,3/8/10/12,5
16/20/25cm^
Vg= 3 2 / 4 0 / 5 0 / 6 3 / 8 0 c m ^
Direction of rotation
R
L
B
U
=
=
=
=
right
left
right and left
universal
(Direction of flow delivery remains the sarneas the angle of rotation changes)
Mounting
F
G
W
X
=
=
=
=
DIN flange without support bearing

DIN flange with support bearing
mounting angle without support bearing
mounting angle with support bearing
Seal type
1
2
3
4
5
6
7
=
=
=
=
=
=
=
radial shaft sealing ring NBR

radial shaft sealing ring PPM
radial shaft sealing ring PTFE
double radial shaft sealing ring PTFE
GLRD with FPM-secondary seals
GLRD with PTFE-secondary seals
double radial shaft sealing ring FPM
Pressure relief valve

D15 adjustable over 0-15bar
D 25 adjustable over 15-25bar
Special Code - No.
Code-No. for special design
BKF-0004-07.97-E
General Data
Type of construction
External gear pump
Materials
see "Materials" overview
Type of mounting
Flange DIN ISO 3019
Drive siiaft end
ISO R 775 short/cylindrical
Pipe line connection
KF 4 to 25 Whitworth - pipe thread

KF 32 to 80 SAE - flange connection
installed attitude
Arbitrary*
Viscosity
12 mm^/s
20000 mm%
min
V
max
Ambient temperature
-20 'C
60 "C
u mm
Umax
Filtering
Filter fineness < 60 pm
* With exception of universal version (KF. ..U...)
Overview of Nominal sizes

geom. Delivery Volume
"mln
Nominal size
cm^
4,03
5,05
6,38
8,05
10
10,11
12
12,58
16
16,09
20
20,10
25
25,10
32
32,12
40
40,21
50
50,20
63
63,18
80
80,50
perm, radial Force**
RPMFtange
max
1/min
1/min
200
3000
700
200
3000
1500
see Type label on pump: KF...

Radial forces only on version with support bearing. F^^, on central shaft journal.
BKF-0004-07.97-E
'^radial
Overview of Materials
Type of
seal*
Housing /
Cover
Gear
Bearing
O-Ring
Shaft seals
NBR
NBR
FPM
FPM
PTFE
FEP
PTFE
FEP
Carbonaceous (in synthetic resin),

CrMo-Gu.FKM, 1.4571
FP
SiC-Si,FFKM, 1.4571
FEP
FPM
FPM
3
4
Carburising
GG25
steel
P10
(1.7139)
* see Type label on pump: KF...

Overview of Operating Pressures
Operatinc pressure
Type of
sealing*
1
Suctio n side
Pemin** bar
Temper ature of
Pressu re side
bar
Pb bar
e max
Pbn,3x bar
deliverec medium
1^ ,
90
150
3
4
max
200
10
-0,4
25
10
6
7
40
-10
150
200
150
see Type label on pump: KF...

note restriction on p^,. on universal version (KF...U...)
For certain operating conditions, the stated minimum and maximum values
cannot be avoided!
Thus, for example, the maximum operating pressure is not permissible in
conjunction with low rpm and minimal viscosity.
Pump installation and removal

Mechanical Installation
A
A
The pipeline components and connections used must be compatible with the
anticipated operating pressure range.
The relevant manufacturers specifications should be consulted !
Prior to installation, the pump is to be inspected for possible damage and soiling during transportation.
The respective coupling hubs must be mounted on the motor and pump shaft.
When installing the coupling, the hub should be heated up and slid onto the shaft in the heated condition.
The shaft must not be struck during the mounting operation!

Each coupling hub must be secured on the respective shaft against axial
displacement by means of the threaded pin, which presses on the adjusting
spring!
BKF-0004-07.97-E
Alignment of the Coupling

When installing the coupling, care should be taken that the dimension E is precisely maintained, so
that during operation the coupling is free to move axially. In order that the elastic toothed rim is not
exposed to pressure on its face, for axial movement, the dimension "E" is to be taken as a minimum.
Shaft with adjuster spring
Shaft separation "E"
sits in toothed rim ( d j
- ^
r
1 J
1
m?i^^
.1.
rn
E
iKa
Fig. 4
Careful and exact alignment of the shaft prolongs the life of the coupling!
Coupling Type
19
24
28
38
42
48
55
65
75
19/24
24/28
28/38
38/45
42/55
48/60
55/70
65/75
75/90
Dimn.*
16
18
20
24
26
28
30
35
40
Dimn.*
2,5
3,5
4,5
Dimn.*
d^
18
27
30
38
46
51
60
68
80
Dimn.*
d,
12
20
22
28
36
40
48
55
65
max. axial
disp.mt *
AK^
1.2
1,4
1,5
1,8
2,0
2,1
2,2
2,6
3,0
max. radial
AK^
0,20
0,22
0,25
0,28
0,32
0,36
0,38
0,42
0,48
AK,
1,2
0,9
0,9
1,0
1.0
1,1
1,1
1,2
1,2
offset *
n=1500 1/min
max. ang.
offset *
n=150b 1/min
dimensions in mm
BKF-0004-07.97-E
The given permissible misalignment values for the couplings represent general guidelines which take the loading of the coupling into consideration up to the nominal torque T|^^ ,an operating rpm
n = 1500 and an ambient temperature of +30C. For operating conditions outside these limits,
KRACHT GmbH should be consulted.
The misalignment values are individually applicable, in the case of a simultaneous occurrence they
should be applied proportionately.
The couplings can either take up a radial or an angular misalignment.
If the shaft clearance dimension is less than the coupling dimension "E", then one of the shaft ends
can extend into the toothed rim section. The dimension "d" corresponds to the maximum shaft
diameter which, with the adjuster spring, is allowed to penetrate into the toothed rim, dimension "d".
If it is possible to remove the adjuster spring, i.e., only the shaft penetrates into the toothed rim section, then the shaft dimension can be increased to up to 2 mm less than the given dimension "dH",
so that the axial freedom of movement of the toothed rim is not restricted.
Rotating parts must be protected by the customer against unintentional contact!
Mount the pump on the pump supports or feet.
Before installing the pump, clean the pipework, removing dirt, sand, swarf, etc. Welded pipes, in
particular, must be scoured or scavanged. Do not use cotton waste/rags for cleaning purposes.
Remove the protective stoppers in the pump suction and pressure connections.
Determining the Direction of Rotation

The direction of rotation of the pump is determined as follows:
When viewed on the end
of the pump shaft, the direction of supply is from
left to right when the shaft
rotates clocl^wise
When viewed on the end

of the pump shaft, the direction of supply is from
right to left when the shaft
rotates anti-clocl<wise
Without pressure relief valve
suction side ^^^-^^^^^^^^ pressure side

Fig. 5
rotation to right
pressure side^===:==^
suction side
rotation to left
With pressure relief valve
suction side
Fig. 6
rotation to right
pressure side
pressure side
suction side
rotation to left
BKF-0004-07.97-E
Suction Pipework
Provision of the suction pipework should be carried out with great care, since the operational behaviour of the pump is greatly affected by this factor.
The suction pipe should be as short and as straight as possible. Additional sources of pipeline resistance, such as formed parts and valves, should be avoided.
The reduced pressure in the suction pipe depends on the sum of all the resistances in the suction
line and the suction head, taking account of the data specific to the medium in the line.
The suction can be checked by installing a vacuum meter on the pump/suction connection.
The permissible pressure at the pump inlet must not fail below the value p, , given in the "Technical data" section.
The only exception to this is the start-up condition of the pump, when a pressure of - 0.6 bar (suction) is tolerable for up to 30 minutes.
The nominal diameter of the suction line can be chosen to be considerably larger than that of the
pump connection.
'A
If the permissible values (see "Technical data") are exceeded, the consequence is a reduction in the delivery volume (caused by reduced filling of
the pump), higher noise level and cavitation.
If hosing is used on the suction side of the pump, then this must be of adequate stability such that
the hose does not deform and constrict the flow under the suction effect.
The provision of a funnel-shaped suction opening or an oblique intersection at the end of the suction pipe are of value in increasing the cross-section on the suction side.
When laying out the suction pipe in the medium container, attention should be paid to the achievement of unimpaired suction.
There should be no partition walls adjacent to the opening of the
suction pipe.
Laying out the suction pipe as a siphon, whereby the pump is
continually full after start-up, is a possible way of avoiding suction
problems (see Fig. 7).
Pressure Line
The nominal diameter of the pressure pipe should be selected
such that the velocity of flow does not exceed the values given in
the following table.
Pressure
Flow velocity
< 10 bar
<3m/s
< 25 bar
< 3,5 m/s
Fig. 7
The pump pressure should be checked by a manometer installed as close as possible to the pump
connection.
KRACHT pumps are displacement pumps (see "Equipment description" section). This means that the use of a pressure relief valve or some other means of restricting pressure in the system is essential !
In order to avoid overloading the pump due to pressure above the permissible value, a pressurelimiting valve, incorporating return flow to the reservoir, must be installed as near as possible to the
pump pressure connection.
An alternative method of limiting the pressure on KRACHT feed pumps is to install a pressurelimiting valve directly onto the pump.
BKF-0004-07.97-E
When operating a pump which is to feed, via a non-return valve, into a circuit which is under pressure (e.g. reserve pump in a lubrication circuit), suction difficulties can occur if the suction line is filled with air. In these cases, the pressure line should be vented directly before the non-return valve.
This can be achieved, for example, by fitting a venting jet in the circuit (Fig. 8), or by providing a restricted by-pass (Fig. 9).
V^
)(
^
p^
)(
'?,
KM)
Fig. 8
?,
KM)
Fig. 9
The volume in the pressure line between the pump and the non-return valve must be at least 75%
of the volume of the suction line.
Connect the pipelines on the suction and pressure sides of the pump. In doing so, the instructions
of the relevant manufacturer should be followed.
Neither the suction nor the pressure side pipelines shouid transfer loads to
the pump I
The pipelines must connect with the pump supports in an absolutely stress-free condition.
The pipelines are to be constructed in such a way, that even during operation, no stresses can be
transferred through the pipelines, for example through changes in length due to temperature fluctuations.
Damaged pipes and hoses must be replaced immediately !
On installation, it must be ensured that no sealing material can enter the pipeline. Sealing materials
such as hemp and mastic are not permissible, since they can lead to soiling and hence to operating
failures.
Fill the medium container with the prescribed fluid.

Care should be taken that the cleanest possible conditions prevail when filling the fluid container I
Clean filler plugs and caps on fluid transport and storage containers before opening.
Check fluid containers and clean if necessary. The filter gauze on filling tubes and filter inserts on
fitted filters must not be removed under any circumstances.
Attention should be paid to adequate filling of the fluid container!
10
BKF-0004-07.97-E
In order to achieve optimum noise protection, it is recommended that an anti-vibration flange is fitted
between the pump and the pump supports and that damping elements are inserted between the electric motor and the installation.
Likewise, the use of suction and pressure hoses reduces the noise level of an hydraulic installation.
Pump Removal
The cleanest possible conditions should be assured during all work. Prior to loosening screwed connections, their external surroundings should be cleaned.
During all work on the pump and prior to removal, the connecting pipework
must be depressurised and the motor isolated!
In addition, precautions must be taken to ensure that the motor cannot run-up
during work on the pump.
Remove the depressurised pipelines from the pump.
Leakages of dangerous media must be collected and disposed of in such a way

that no danger results to personnel or to the environment. In so doing, the statutory regulations must be observed..
Secure the pump connections and pipelines against the ingress of dirt.
Commissioning
Commissioning is only to be carried out by appropriately trained and qualified

personnel. Prior to starting up plant, it must be ascertained that an adequate
quantity of the operating medium is available, in order to avoid dry running.
Check the permissible operating values against the anticipated operating conditions.
Check all fixing bolts on the pump.
Check the direction of rotation. If the direction of rotation has to be changed, refer to the section on
"Maintenance".
The pumps must only run in the direction of rotation indicated by the arrow /
in the direction of rotation indicated by the symbol on the type plate.
^
Operation of the pump in the opposite direction of rotation to that indicated
will lead to failure of the slide ring sealing in the case of sealing version 5.
Prior to commissioning, the pump must be filled with the fluid medium.
BKF-0004-07.97-E
11
Special feature on sealing variants 4 and 7 (Double radial shaft sealing ring)
The sealing chamber (see Fig. 10) must be filled with a
suitable barrier medium prior to initial operation of the
pump.
Sealing chamber
Before commissioning, the sealing

chamber must be filled with a barrier medium..
The pumps should be started up at either very low or zero pressure

loading. The existing shut-off devices should be fully opened and
the pressure relief valve, installed in the pressure line, should be
adjusted to the lowest opening pressure setting.
Pressure setting of the pressure relief valve
Applies only to pumps with a built-in pressure relief valve
(Pump Type Code: KF ... -D15 and KF ... -D25)
Response pressure lower
Fig. 10
Response pressure higher
Fig. 11
Lock nut
Adjuster screw
securing screw (do not loosen)
CAUTION:
The pressure relief valves on series DKF are purely safety

valves!
These valves only respond briefly!
Continual drawing off of the conveyed fluid medium via the
DKF will result in the destruction of the pump due to overheating!
To adjust the pressure setting on the pressure relief valve (see Fig. 11):
Loosen the lock nut (1).
Set the adjuster screw (2)
Rotation right = higher response pressure
Rotation left = lower response pressure
When the desired pressure has been set, re-lock the adjuster screw (2) with the lock nut (1).
The securing screw (3) must not be loosened!
12
BKF-0004-07.97-E
start-up is achieved by repeated rapid switching on and off of the drive motor (inching mode), without reaching full rpm, until it is apparent that the pump is operating satisfactorily. The satisfactory
operation being detectable either from manometer readings, or from the noise generated by the
pump, and being achieved over a period of not longer than 30 seconds. This particularly applies
when a cold pump must be started-up with a fluid medium that has already been warmed, in order
to achieve a slow heating up of the pump and to prevent jamming of the pump due to heat shock.
After switching on the motor, it is then allowed to run for a few minutes, under zero or low pressure.
The pressure loading can then be increased in stages until the desired operating pressure is reached.
On attaining the required operating values, the temperature of the medium and of the pump should
be checked. The control points on the pump are the shaft bearing positions and the shaft seals. The
temperatures reached on the surface of the pump housing should be approx. 10C greater than the
temperature of the medium.
After several hours of running time, the final operating temperature should be checked (for maximum temperatures, see the section on "Technical data").
Maintenance
Assuming correct installation in accordance with the conditions of use and correct operation, KRACHT
gear pumps are of such construction that a long and fault-free operational life should be obtained. They
require a minimum of maintenance which, however, is necessary for reliable operation, since experience has shown that a high percentage of the faults and damage which can occur are attributable to
the ingress of dirt and inadequate maintenance. The extent of servicing required and the service and
inspection intervals are, in general, laid down by the manufacturer in an appropriate plan.
The regular examination of all operating data, such as pressure, temperature, current consumption,
degree of filter soiling, etc., contributes to the early detection of potential failure.
Extreme cleanliness should be ensured during all work. Before loosening screwed connectins, the
surrounding areas are to be cleaned. All openings are to be closed with protective covers, so that there
is no ingress of dirt into the system.
Leakages of dangerous nnedia must be collected and disposed of in such a way

that no danger results to personnel or to the environment. In so doing, the statutory regulations must be observed.
Seals
Maintenance of the seal variants 4 and 7 (Double radial shaft sealing ring)
The filling level in the sealing chamber should be inspected at regular intervals and the barrier medium replenished if necessary.
Maintenance of the seal variants 5 and 6 (Slide ring seals)

The slide ring sealing is particularly subject to wear, depending on the application and accordingly,
must be carefully checked. Too high an inlet pressure, incorrect direction of rotation or soiling, lead
to increased wear and greater leakage.
Low leakage rates are essential to the functioning of the slide ring sealing. The slide ring sealing
should be renewed if the leakage rate increases.
The installation instructions from the manufacturer of the slide ring sealing should be consulted.
BKF-0004-07.97-E
13
Changing the direction of rotation of the pump

On pump types KF...R... and KF...L... , i.e. pure left or right rotating pumps, a change in the direction of rotation is only possible by re-building the pump.
cover fixing scews
cover fixing scews
cover fixing scews
cover fixing scews
Tightening torque for cover fixing screws

Nominal size**
Tightening torque
4.25
32 ... 80
25 Nm
49 Nm
* see Type code on unit: KF...

If the direction of rotation of a pump is required to be changed, the cover and the pressure relief
valve on the pump housing must be freed, in order that they can be rotated through 180 and refitted.
On pumps without a pressure relief valve, the leakage oil bore on the inside of the cover must be on
the suction side of the pump.
On pumps with a pressure relief valve, the relief valve adjuster screw must point towards the pressure side of the pump (see the section on "Mechanical installation". Fig. 6 on page 8).
This conversion of the pump must only be carried out by appropriately

trained and experienced personnel!
Change in direction of rotation with sealing variant 5 (Slide ring sealing)

A change in the direction of rotation on sealing variant 5 cannot be carried out immediately!
In this case, in order to carry out the rotation of the cover and the relief valve, as detailed above, in
addition the slide ring seal must be exchanged (note the direction of coiling of the spring).
When exchanging the slide ring seal, the installation instructions of the seal manufacturer should be
consulted.
Repairs
A repair comprises:
Diagnostic examination,
Elimination of fault,
i.e. isolation of the fault. Determining and localising the cause

of the fault.
i.e. replacement or repair of defective components and
elimination of the primary cause.
Elimination of the Fault

The elimination of the fault takes place on site, predominantly through exchange of the defective component/s. The repair of components is generally undertaken by the manufacturer..
14
BKF-0004-07.97-E
Repairs must only be carried out by trained specialist personnel.
Given the appropriate know-how and adequate equipment, the repair may also be carried out by the
end user or the initial equipper. Assistance in this is available in the form of spares lists and repair
instructions.
Diagnosis
Lack of adequate sealing is a frequent source of failure. If this occurs at the pipeline connections, it
may be eliminated by simply tightening the screwed fittings.
In the case of a lack of sealing on the pump, the respective seals must be replaced (see spares list).
Detection and Elimination of Faults
The following list gives the causes of faults which are most frequently encountered during operational
failures together with an indication of the problem areas to be rectified.
In the event of the occurrence of a fault which cannot be identified, please request assistance from
KRACHT.
Fault
Increased noise
Possible cause
Pump cavitation
Suction level too high
> Suction filter blocked or too small

> Internal dia. Suction line too small
> Suction line too long
Too many curves in suction line
> Too many local constrictions in suction line
> Suction line blocked or not sealed
> Viscosity too high
> Viscosity too high
Formation of foam or
> Suction line not sealed
Inclusion or air in Medium ,> Fluid reservoir level too low
Tank return line not sealed
> Incorrect container layout
Lack of sealing, suction side or shaft seal
> Return line ends above level of fluid in reservoir
> Inadequate venting
Mechanical vibrations
< Faulty aligned or loose coupling

Faulty or inadequate pipeline fixing
Mechanical vibrations
Installation not optimised for noise (lack of damping elements)
Pump installed in unfavourable position
Pump worn out, tooth flank wear
BKF-0004-07.97-E
15
Fault
Possible cause
Fluid level in reservoir too low
Incorrect direction of rotation
Throttling element in suction line
Foreign body in suction line
Volume of the pressure linebetween pump and
non-return valve too small, pump cannot compress the air found in the suction line into the
pressure line
Non-return valve in the pressure line not vented
Pump does not suck
Insufficient supply flow
Insufficient pressure
Supply flow too low

Working resistances In
pressure line too low
Pow/er consumption too

high
Operating tempertature
too high
Pump heat-up above

Permissible level
Leakage at the shaft

sealing
Coupling wear
16
>
>
>
'
>
>
>
>
'
'
>
>
Throttling element in suction line

Fluid level in reservoir too low
Suction filter blocked or too small
Viscosity too high
Rpm too high
Pressure too high
Pressure relief valve set too low
Pump sucks air
Pump is worn out
Viscosity too low
Rpm too low
Drive power too low
Pump worn out
Pressure too high
Viscosity too high
Drive power too low
Motor winding defective
Cooling and heat dissipation inadequate
Fluid supply too low
Fluid conveyed under load into the reservoir via
pressure relief valve
Built-in pressure relief valve set too low
Pressure too high
Viscosity too low
Spectacle gland tightened excessively
Pump worn out
Inlet pressure above permissible value
Incorrect direction of rotation
Shaft radial loading too high
Seal wear
Seal temperature too high
Incorrect seal material
Incorrectly aligned or loose coupling
Inadequate axial play in coupling
Coupling overloaded
Temperature too high
BKF-0004-07.97-E
il{ll{lti
I l^^^k
RIES
P o Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 181 650 500

Fax +31 181 650 501
E-mail: rtmw@aalborg-industrles.nl
http://www.aalborg-industries.com
No. 24234179
VAT No. NL0081.91.694.B.01
Bankers: Rabobank, Hoogvliet

Account No. 32.95.68.094
Swift-address: RABONL2
Oil Burner Controls
153
LAL...
Series 02
ISO 9001
Supplementarv data sheets 7713 and 7714
Oil burner controls designed for use with atomizing expanding flame burners of
medium to high capacity (intermittent operation*) with air checic supervision for
supervised air damper control. Flame supervision with photoresistive detector
QRB..., blue flame detector QRC1... or selenium photocell detector RAR...
The oil burner controls are tested and certified in accordance with EN 230. They
carry the CE mark in compliance with the directives on electromagnetic
compatibility.
*
Use
For reasons of safety, at least one controlled shutdown must be carried out every
24 hours!
The burner controls of the LAL... range are designed for the control and supervision of
atomizing expanding flame burners of medium to high capacity. They are universally
applicable and can be used for both multi-stage and modulating burners as well as for
burners ofstationary air heaters (WLE according to DIN 4794).
For special applications, e.g. burners of incinerator plants, type LAL3.25 is available.
For detailed information refer to Type summary and Notes.
Please refer to data sheet 7785, types L0K16..., for burner controls used with burners
that operate continuously.
Mechanical design
The burner controls are of plug-in design. Housing and plug-in baseplate consist of
shock- and heat-resistant black plastic.
The lockout indicator, the fault signal lamp and the reset button are located in the
viewing window of the unit. The burner control is equipped with an exchangeable unit
fuse and a spare fuse.
LAL3.25
For special applications, e.g. burners of incinerator plants, type LAL3.25 is available. In
contrast to LAL1... and LAL2..., extraneous light during the burner off period or the prepurge time does not initiate lockout, but prevents burner start-up.
1/16
M o d e of operation
The diagrams above show both the connections and the control program of the
permissible or required input signals to the control section of the bumer control as well
as to their flame supervision circuit. If the required input signals are not present, the
burner control interrupts the start-up sequence at the points marked by the symbols and
initiates lockout where this is required by the safety regulations. The symbols used are
identical to those on the bumer control's lockout indicator.
Start command (e.g. given by the control thermostat or pressurestat R of the installation)
A-B
Start-up sequence
B-C
Burner operation (according to the control commands given by load controller LR)
Controlled shutdown through R
C-D
Sequence switch runs into start position A, post-purge

During burner off periods the flame supervision circuit is under voltage, in order to carry
out the detector and extraneous light test.
Prerequisites for burner

start-up
- Burner control not interiocked in lockout position

- Sequence switch in start position (with LAL1... indicated by voltage on terminals 4
and 11; with LAI_2... indicated by voltage on temninals 11 and 12)
- Air damper closed. Limit switch zfor the CLOSED position must feed voltage from
terminal 11 to terminal 8
- The contact of the limit thermostat or pressure monitor W as well as the contacts of
any other switching devices in the control loop between terminal 4 and terminal 5
must be closed (e.g. control contact for oil pre-heated temperature)
Additional prerequisites for start-up of LAL2...:
- Control contacts between temninal 12 and the air pressure monitor LP must be closed
- The normally closed contact of the air pressure monitor must be closed (LPtest)
Start-up sequence
A
Start command by R
{R closes the control loop between terminals 4 and 5).
The sequence switch starts to run. At the same time the fan motor receives voltage via
temninal 6 (only pre-purge). After t7 has elapsed, the fan motor or the flue gas fan also
receives voltage via terminal 7 (pre- and post-purge).
On completion of t16, the control command to open the air damper is given via
terminal 9. During the actuator's running time the sequence switch stops, as temiinal 8 via which the motor of the sequence switch is at first supplied with voltage - does not
receive any voltage during this time. Only after the air damper has fully opened, the
sequence switch continues to run.
t1
Pre-purge time with air dumper fully opened

During the pre-purge time the correct functioning of the flame supervision circuit is
tested. The burner control goes to lockout, if the relay does not function correctly.
2/16
With LAL2...:
t3'
Shortly after the beginning of the pre-purge time, the air pressure monitor must change
over from terminal 13 to terminal 14, as otherwise the bumer control initiates lockout
(start of air pressure check).
Long pre-ignition time
(Ignition transformer connected to terminal 15)
With the LAL1... bumer controls the ignition transformer is switched on with the start
command; with the LAL2... types only when the air pressure monitor LP has changed
over, that is on completion of tlO at the latest.
After completion of the pre-purge time, the burner control drives the air damper via
tenminal 10 into the low flame position which is determined by the changeover point of
auxiliary switch m. During the running time the sequence switch stops until terminal 8
receives voltage via m. Then the motor of the sequence switch is switched to the control
section of the bumer control. Hence, from now on control signals to terminal 8 do not
affect the further start-up of the burner and the subsequent bumer operation.
t3
t2
Short pre-ignition time, provided Z i s connected to terminal 16; then release of fuel at
terminal 18.
Safety time
On completion of the safety time, a flame signal must be present at terminal 22. It must
be present until controlled shutdown takes place, otherwise the burner control initiates
lockout and interiocks itself in lockout position.
tSn
t5
Pre-ignition time, provided the ignition transformer is connected to terminal 15. With
short pre-ignition (connection to terminal 16), it remains switched on only up to the end
of the safety time.
interval. On completion of t4, terminal 19 is under voltage. Thus the fuel valve at
auxiliary switch vof the air damper actuator is supplied with voltage.
Interval. After ts has elapsed, terminal 20 receives voltage; at the same time control
outputs 9 to 11 and input 8 are galvanically separated from the control section of the
bumer control, so that the latter is protected against reverse voltages from the load
control circuit.
With the release of load controller LR at terminal 20, the start-up sequence of the burner
control ends. After a few so-called idle steps, i.e. steps without change of the contact
positions, the sequence switch switches itself off.
Operating position of the burner
B-C
Burner operation
During bumer operation the load controller drives the air damper to the nominal load or
low flame position, depending on the demand for heat. The release of the nominal load
is carried out by the auxiliary switch v in the air damper actuator.
t4
In the event of loss of flame during operation the burner controls initiate lockout
If, instead, automatic repetition of the start-up sequence is required (start
repetition), it is necessary to cut away the clearly marked wire link on the plug
section of the burner control (wire link B).
Controlled shutdown
ts
During controlled shutdown the fuel valves are immediately closed. At the same time the
sequence switch starts and programs the
Post-purge time (fan M2 connected to tenninal 7).
t13
D-A
Shortly after the start of the post-purge time, terminal 10 receives voltage, so that the air
damper is driven to the MA/ position.
The complete closing of the air damper starts only shortly before the post-purge time
has elapsed, initiated by the control signal on terminal 11, which also remains under
voltage during the following burneroff period.
Permissible after-burn time. During this time the flame supervision circuit may still
receive a flame signal without initiating burner lockout.
End of control program (start position)
As soon as the sequence switch has reached the start position, having thereby switched
itself off, the detector and extraneous light test start again.
Voltage at temiinl 4 with the LAL1... (terminal 12 with the LAL2...) is the signal
indicating that the start position has been reached.
3/16
Functions
With regard to
standards
With regard to the

control of the burner
With regard to flame

supervision
With regard to mounting

and electricaf installation
Baseplate with:
With regard to service:
The following LAL... features exceed the standards, thus offering a high level of
additional safety:
- Detector and extraneous light test are restarted immediately after the tolerated afterburn time. This means that open or not fully closed fuel valves initiate lockout
immediately after this time has elapsed. The test ends only on completion of the prepurge time of the next burner start-up
- The correct functioning of the flame supervision circuit is automatically checked
during each burner start-up sequence
- The control contacts for the fuel release are checked for welding during the postpurge time
- A built-in unit fuse protects the control contacts against overloading
- The units permit burner operation with or without post-purge
- Fan motors with an amperage of up to 4 A (starting current 20 A max.) can be directly
connected
- Separate control outputs for: pre-ignition from start command, post-ignition until
shortly before completion of the burner start-up program as well as for short preignition with post-ignition to the end of the safety time
- Separate control outputs for OPEN, CLOSE and MA/of the air damper actuator
- Checked air damper operation to ensure pre-purge with the nominal amount of air.
Checked positions: CLOSED or MIN (low flame position) at the start, OPEN at the
beginning and MIN on completion of the pre-purge time. In case the actuator does not
drive the air damper to the required position, the burner start-up sequence will be
intermpted
- Two control outputs for the release of the 2nd and, if necessary, 3rd output stage (or
load control)
- When load control is enabled, the control outputs for the air damper actuator are
galvanically separated from the control section of the unit
- Connection facilities for a remote lockout warning device, remote reset and remote
emergency shutdown
- With the LAL2... types in addition: possibility of air pressure supervision with
functional test of the air pressure monitor at start-up as well as possibility of semiautomatic burner start-up
- Methods of flame supervision:
1) With a photoresistive detector QRB1.... For detailed information, refer to data
sheet 7714
2) With blue flame detector QRC1..., for the supervision of blue burning oil burners.
For detailed information, refer to data sheet 7716
3) Only with ILAL2...: with a selenium photocell detector RAR... (active detector). For
detailed information, refer to data sheet 7713
Detector and extraneous light tests are carried out automatically during the burner off
periods and the pre-purge time.
- In case loss of flame occurs during operation, the LAL... bumer controls initiate
lockout. If, instead, automatic repetition of the start-up sequence is required (start
repetition), it is necessary to cut away the clearly marked wire link on the plug
section of the burner control
- Mounting location and orientation are optional (degree of protection IP40)
-
4/16
24 connection terminals
2 auxiliary terminals, galvanically separated, marked 31 and 32
3 earth terminals in the form of a latch for earthing the burner
3 neutral terminals, pre-wired to terminal 2 which is the neutral input
14 knock-out entries for the cable entry by means of cable grommets, 8 of which at
the side and 6 in the bottom of the baseplate
6 lateral knock-out entries threaded for cable entry glands Pgl 1
A lockout indicator - coupled to the spindle of the sequence switch and visible in the
transparent lockout reset button - indicates, my means of easy-to-remember symbols,
information on the kind of faults and their time of occurrence
The design of the plug-in baseplate and the plug section make it impossible to plug in
by mistake a burner control that is not permitted for the burner
Oil burner controls carry a white type field - in contrast to gas burner controls which
carry a yellow type field
Technical data
U^ns voltage AC 220 V -15 % ... 240 V + 10 %.

LAL2... also
AC100 V -15 % ... 110 V + 10%
Mains frequency
50 Hz- 6 % ... 60 Hz + 6 %
Consumption
3.5 VA
Unit fuse, built-in
T6, 3H 250 V according to IEC 127
Unit fuse, external
10 A max.
Radio interference protection
N according to VDE 0875
Weight
approx. 1000 g
approx. 165 g
- Burner control
- Baseplate
Required switching capacity of switching devices

- Between terminals 4 and 5
1 A
1 A
5 A, peaks 20 A
Pennissible mounting position
optional
Degree of protection
IP 40
Permissible input current to tenninal 1

5 A permanently, peaks of up to 20 A max.
Permissible current load of control terminals
4 A permanently, peaks of up to 20 A max.
total 5 A max.
Environmental conditions
- Transport
Climatic conditions
Temperature
IEC721-3-2
class 2K2
-50...+60 C
CE conformance
Accordng to the dreclives of the European Community
Electromagnetic compatibility EMC
89/336 EEC include. 92/31 EEC
Gas appliance directive
90/396 EEC
Emissions
EN 50081-1
Immunity
EN 50082-2
Humidity
< 95 % r.h.
Mechanical conditions
class 2M2
- Operation
IEC721-3-3
Climatic conditions
class 3K5
Temperature
-20...+60 C
Humidity
< 95 % r.h.
Condensation, formation of Ice and ingress of water are not permitted.
QRB...
See data sheet 7714
QRC...
See data sheet 7716
RAR...
See data sheet 7713
Type summary
Switching times are given in seconds, in the sequence of burner start-up, valid for a frequency of 50 Hz. in
case of 60 Hz, the times are reduced by approx. 20 %.
Univ.
application
L A U .25
Rame supervision with photoresistive

detector QRB1..., or for blue flame
burners with blue flame detector
QRC1....
Flame supervision with photoresistive

detectors QRB..., or for blue flame
burners with blue flame detector
QRC1... or selenium photocell
detector RAR...
Possibility to supervise the air pressure
Possibility of semi-automatic start-up
Same as LAl.2.25 with one exception:

extraneous light does not cause
burner lockout, but prevents bumer
start-up
t1
t2
t3
t3'
t3n
t4
t5
t6
17
t8
tio
t11
t12
t13
t16
t20
Rash
steam
generator
LAL2.14
Univ.
application
LAL2.2S
Medium
and heavy
oil burners
LAL2.65
Spec, application, e.g.

incinerator
plants
LAL3.25
10
4
2
from start*
10
8
4
10
2
30
6
optional
optional
10
4
32
22.5
5
2.5
from start*
15
7.5
7.5
15
2.5
47.5
10
optional
optional
15
5
35
67.5
5
2.5
from start*
15
7.5
7.5
15
2.5
92.5
10
optional
optional
15
5
12,5
With air pressure monitor, from receipt of air pressure signal
5/16
Connection
diagrams
LAL1...
|fe(|biy=a'
D ^
[1
(ZJOC
BV1
BV2
X LK
7153a01/0496
LAL2...
0RC1.
Control signals from the burner control

Permissible input signals
7153^0200895
6/16
Required input signals: if these signals are missing at the points in time
marked by symbols or during the shaded phases, the burner control
interrupts the start-up or initiates lockout
Flame supervision
LAL1... with detector
QRB..
QRC1.
Required min. detector cun^nt at AC 230 V

lâx. perm, detector current without flame
Max. possible detector current
+pole of instrument
Length of detector line
In the same cable as the control lines
Separate cable in cable duct
- Three-core cable
Two-core cable for the detector line
(bl, sw], separate one-core cable
for the phase (br)
95 Â
BOpA
12nA
23
LAL1...I I 22
23
160 |iA
to term. 23
to term. 23
30 m max.
1000 m max.
1 mmax.
20 m max.
1 LAL1...|
QRB1..
LAIZ... with detector
QRB..
QRC1...
RAR...
Required min. detector current at AC 230 V

Itâx. pemi. detector current without flame
+pole of instalment
length of detector line
In the same cable as the control lines
Separate cable in cable duct
Shielded cable
(e.g. RG62, insulated shielding)
8 ^
3.9 nA
0.8 tiA
6.5 MA
Shielding to terminal
23
35 pA
to term. 22
to tenri. 22
not perm.
20 m
200 m
25 Â
to term. 22
RAR7: 30 m
RAR8; 100 m
20 m*
* 1 phase laid separately!
24
IA1.2...I
22
23
1 I-AL2...I
7153v(M/1185
7/16
Connection
diagrams
LAU...
QRC1...
EKI*
LAL2...
EK1*
* Do not press EK for more than 10 seconds!
8/16
Legend
for the entire data sheet
Changeover limit switch for OPEN position

of the air damper
AL
Remote lockout warning device (alarm)
AR
Main relay (load relay) with contacts ar...
AS
Unit fuse
B
Wire link
(on the plug section of the burner control)
BR
Lockout relay with contacts br...
BV...
Fuel valve
d.;.
Contactor or relay
Etc.. Lockout reset button
FR
Rame relay with contacts fr...
FS
Rame signal amplifier
H
Mains isolator
L... ' Fault signal lamp
L3
Operational readiness indication
UK
Air damper
LP
Air pressure monitor
LR
Load controller
M...
Fan or burner motor
bl
br
sw
Blue core
Brown core
Auxiliary switch for the MIN position of

the air damper
NTC
NTC resistor
QRB...
Photoresistive detector
QRC1..., Blue flame detector
R
Control thermostat or pressurestat
RAR...
Selenium photocell detector
RV
Continuously adjustable fuel valve
S
Fuse
SA
Air damper actuator
SB
Safety limiter (temperature, pressure, etc.)
SM
Synchronous motor of the sequence
mechanism
V
Rame signal amplifier
V
In the actuator auxiliary changeover
switch for the release of fuel in function
of the air damper position
W
Limit thennostat or pressure monitor
Z
Ignition transformer
z
In the actuator limit switch for the
CLOSED position of the air damper
Black core
For circuit variants refer to "connection examples"
Warnings
In the geographical areas where DIN standards are in use, the installation must
be in compliance with VDE requirements, particularly with the standards
DIN/VDE 0100 and 0722!
The electrical wiring must comply with national and local standards.
The LAL... is a safety device. It is therefore not permitted to open, interfere with
or modify the unit!
ignition cable must always be laid separately, observing the greatest possible
distance to other cables!
Electromagnetic emissions must be checked from an application point of view.
Check wiring carefully before putting the unit Into operation!
The LAI must be completely isolated from the mains before performing any
work on it!
Check all safety functions when putting the unit into operation or after having
replaced any fuses!
Ensure protection against electric shock on the unit and on all electrical
connections by appropriate mounting!
Condensation and ingress of humidity must be avoided!
9/16
Control program
under fault conditions
and lockout indication
In case of any disturbance, the sequence switch stops and with it the lockout indicator.
The symbol above the reading mark of the indicator gives the type of disturbance:
^
^
No start, because one contact has not been closed (see also "Prerequisites for
burner start-up") or lockout during or after, completion of the control sequence
due to extraneous light (e.g. non-extinguished flame, leaking fuel valves, defects
in the flame supervision circuit, etc.).
J^
Interruption of start-up sequence, because the OPEN signal has not been
delivered to terminal 8 by limit switch a. Terminals 6, 7 and 15 remain under
voltage until the fault has been corrected!
With LAL2...: lockout, because there is no air pressure indication at the beginning
of air pressure control. Every air pressure failure after this moment In time
leads to a lockout, too!
Lockout due to a fault in the flame supervision circuit.
y^
Interruption of start-up sequence, because the position signal for the low flame
position has not been delivered to terminal 8 by auxiliary switch m. Terminals 6, 7
and 15 remain under voltage until the fault has been corrected!
Lockout, because no flame signal is present after completion of the safety time.
Lockout, because the flame signal has been lost during burner operation.
a-b
Start-up sequence
b-b'
Idle steps (without contact confirmation)
b(b')-a
Post-purge program
LAL1
LAL2, LAL3
The burner control can be reset immediately after a lockout has occurred. After
resetting (as well as after correction of a fault which resulted in a controlled shutdown or
after each mains failure) the sequence switch always returns to its start position,
whereby only terminals 7, 9, 10 and 11 receive voltage in accordance with the control
program. It is only then that the burner control begins with a new burner start-up.
Note: do not press the lockout reset button for more than 10 seconds!
10/16
Notes
Engineering
LAL2
7
(T)
7153s03ffl396
15
16 17 18
Switches, fuses, earthing, etc. must be in compliance with the local regulations. For the connection of valves
and other components, the diagram provided by the burner manufacturer is valid.
G) Phase and neutral may not be interchanged!
Max. permissible input current: 5 A permanently, peaks of 20 A max.
Safety limit thermostats (manual reset, e.g. STB) are normally connected in the line.
(D Remote reset: when button EK2 is connected to terminal 3, only remote reset is possible; when
connected to tenTiinal 1, emergency shutdown is possible, too.
(D Required switching capacity
of switching devices connected between temfiinal 12 and l-P (with LAL2...) 1 A
of air pressure monitor LP (with I^L2...): 5 A
of switching devices connected between temilnals 4 and 5:1 A
Control contacts of other devices in the burner installation are to be connected in series as follows:
To terminal 4 or 5: contacts which must be closed from start-up to the controlled shutdown (othenwise no
start or controlled shutdown).
To terminal 12 with LfiLZ...: contacts which must be closed only during start-up (othenwse no start).
To terminal 14 with LAL2...: contacts which must be closed at the beginning of the pre-ignition time, at
the latest and which must remain dosed until controlled shutdown occurs (otherwise lockout). This is valid
for both long and short pre-ignition.
lUlaximum loading of the control terminals 3,6,7, 9,10,11,15 to 20: 4 A each terminal, total 5 A max.;
peak currents of 20 A max. (e.g. starting current of M^ or M2).
Z connected to terminal 15: long pre-ignition t3' and post-ignition t3n. In compliance with EN230, postignition is only permitted with bumers having an oil throughput of no more than 30 kg/h.
Connection of a fuel valve to terminal 20: see "connection examples".
In case of bumers without air damper or with an air damper not controlled and supervised by the bumer
control, tenninal 8 must be connected to terminal 6.
Wire link B: the bumer controls go to lockout, if flame failure occurs during operation; if, instead,
repetition of the start-up sequence is desired, the cleariy mariced wire link B on the plug section of the
bumer control must be cut away (just cutting is not pemiitted)!
Mlax. permissible length of detector lines: see 'Technical data'.
11/16
Connection
examples
19
20 9 1 1 1 0
SAEV
TIT^
Connection of actuators without changeover

limit switch for the CLOSED position
^ ^ ^-
z is adjusted to the air volume required for low

flame operation.
iwg
18
TlK
19 17 9 20 11 10 8 6
LR
N^^^^_5>^1K
19
i^
20
Control of the air damper actuator during

operation by control signals at terminal 17.
Signal path: refer to "connection diagrams".
9 11 10 8 6
Control of a fuel valve via terminal 20

(Burner without air damper or with an air damper
not controlled by the burner control). The relay is
not required if the valve connected to terminal 20
is hydraulically connected in series, with a
valve controlled via terminal 18 or 19.
i^
1312 14 4
UTTf
6(7) Wiring required with LAL2... for operation

without air pressure supervision
If an auxiliary contact of the fan contactor is
included in the circuit as shown in the diagram,
ignition and fuel release are possible only when
the contact is closed.
12
mj
N
12/16
13 14
H<
L3
LP
4 5
|W
Semi-automatic start-up
The burner is switched on manually by pressing
button /. Then, the burner control initiates the startup sequence and flame supervision. The burner is
also switched off manually by pressing button 0, or
automatically when limit thermostat or pressure
monitor W responds. L3 indicates when the burner
is ready to be started; it extinguishes shortly after
the burner is switched on. For other connections,
refer to "connection diagrams".
Connection
examples
Two-stage expanding
flame burner
1 5(13"/t3n)
16(13)
17
19 9 2 0 11
18
10
LR
SA 11
Mi^m
IV
U'>
[^lE
[A
311rx
^VJ
^^f^-Hi
7153a05/1195
;*TK
Load control with an on/off controller. The air dannper is closed during burner off
periods.
Control of actuator SA according to the single-wire control principle. (Actuator SA type

SQN... according to data sheet 7808). For other connections, refer to "connection
diagrams".
11 MIII Pre- and post-ignition when the ignition transformer is connected to terminal 15.
13/16
Modulating expanding
flame burner
16 17 18
19
U LR
SA
LR
N'
-M^M
20
BV1
^ (f> jyHE
^-z-
1110
SA
,a.^z.
Rv LK
7153a06/119S
Load control with a modulating controller with galvanically separated control contacts for
OPEN and CLOSED positions.
GO
CEl
XLK
The air damper is closed during burner off periods. In the case of actuators without
changeover limit switch zfor the CLOSED position, temiinal 10 must be connected to
terminal 11. For other connections, refer to "connection diagrams".
14/16
Sequence diagram
A
1
...
f7\(Pfi'
II
"
Sb
(A) (35
III
lull
Of
J?.
IV
ir
1311
116
"
iSSk
Till
VI
VII I
IIIM
LLLLU
IH
.I2_
l l l l l l
XII I *
IJJIM
Mill
tio*
XIII I
IIIM
"
inn
n-rm
XIV ^
MIMI
u
7153d01E/0197
Positions of the lockout indicator
I
^
t1
t2
t3
t3'
t3n
t4
t5
t6
t7
tS
t10
t11
t12
t13
t16
t20
Mill
XI =
Legend for the times
BO
IX
(S9
VIII I
X
Control output
D at termin
"IT
"
\
II ^
\
iiiiiiMiiiiiiiiii P iiiiiiiii
1
iiiiiiiiiiiiiiii ^
iiiiiiimiiiiiiiiiii
^ 1 iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii ["-(iiiiMiiiiiiiiiiiiiiiiiniiii
Pre-pure time with air damper fully open

Safety time
Pre-ignition time, short (ignition transfomier connected to terminal 16)
Pre-ignition time, long (ignition transformer connected to terminal 15)
Post-ignition time (ignition transformer connected to terminal 15)
Interval between voltage at terminals 18 and 19 (BV1 - BV2)
Interval between voltage at terminals 19 and 20 (BV2 load controller)
Post-purge time (with M2)
Intenîl between start command and voltage on terminal 7 (start delay time for fan motor IWI2)
Duration of start-up sequence (excluding t11 and t12)
Only with LAL2...: interval from start-up to beginning of air pressure check
Running time of air damper into OPEN position
Running time of air damper into low flame position (MIN)
Permissible after-bum time
Interval to the OPEN command for the air damper
Interval to the self-shutdown of the sequence switch (not with all bumer controls)
* These data only apply to LAL2... typesi
15/16
Dimensions
Dimensions in mm
LAL... with baseplate AGM410490550
123
27,5
/^
7153m 02/0396
27,5
wm)
V
31
103
7,5
-d
103
Baseplate AGI\/I410490550
40
5,2x6,7
_ ^ 18,5 __13,5
^5.7
26.8
51,6
5,7
12,8
51.5
71S3m01/0396
March 07,1997 Landis & Gyr Deutschland Produktion GmbH
16/16
AALBORG
INDUSTRIES
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
Tlie Netherlands
No. 24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.618
BiC Code FTSBNL2R
E.S1SO
9001:2000
m
Certified
Company
MgilltT MOBRiV:
Jj,
'S^-
^,îeli.;-
^' i-.-
4^*^^/
LIQWIKlpfit; AiARMTilil PUJHI eONTROL
^^S^
GENEJ
i?faS.^^POSEPROOF AND SUBMERSIBLE

ipS AREA FLAMEPROOF
CHEMICAL Duty EXTERNAL CHAMBERS ACCESSORIES
|]2[MEGGITT
f""
THE COMPLETE MOBREY HORIZONTAL FLOAT SWITCH RANGE
OPERATION
One permanent magnet forms part of a float
assembly which rises and falls -with changing liquid
level. A second permanent magnet is positioned
within the switch or air pilot valve so that the
adjacent poles of the two magnets repel each other
through a non-magnetic diaphragm. A change of
liquid level which moves the float through its
permissible travel will cause the float magnet to
move and repel the switch magnet to give the snap
action operation.
Switching is accomplished by the angular
movement of the switch magnet being used to
operate "push-rods". These rods bear on contact
blades and break one set of contacts whilst
allowing the other set to make. The benefit of this
arrangement is that contact force is independent of
the magnet.
Contact BB
Fkat
Contact AA
SWITCH SELECTION
ALARM SWITCHING ELECTRICAL OR PNEUMATIC
Horizontal or vertical:
High or low alarm switches are of
robust construction, making them ideal
for a wide range of liquids in industrial
applications.
Dirty liquid applications:
The shrouded model should be
specified, thus eliminating fouling of
the float movement due to deposits or
large particles becoming wedged.
Submersion:
For those applictions where the
equipment may be subject to occasional
or continuous submersion the
submersible model should be specified.
Hoseproof marine applications:
Switches have been specifically designed
for the reqtiirements of these markets
& approval authorides, (for details of
approvals contact the &ctory).
Vacuum applications:
All metallic floats are capable of
operating in full vacuum conditions.
High Alarm
High or Low
Aiarm
Low Aiarm
Viscous liquids
Cranked arm float units should be

specified to enable the operating
mechanism to be kept clear of the
liquid. Rod extensions shaped to
individual requirements are available
to fit all Mobrey level switches.
PUMP CONTROL ELECTRICAL OR PNEUMATIC

Horizontal mounting:
(a) Horizontal large differential, two
switches are used to control the
pump for emptying or filling
requirements,
(b) Horizontal limited differential,
(555mm maximum) can be
controlled with one switch and a
variable differential float unit.
Vertical mounting:
(c) Vertical variable differential,
controlled by using one switch
vertically mounted and the
appropriate adjustable variable
differential vertical float unit.
|(c)
/ \ (ilhrrf
W-n
,'J\
Pump on
\h%:~ j (b)
Pump off
^ % ^
Wl|p[
(' -
LOW TEMPERATURE APPLICATIONS

Mobrey level switches are suitable for
below 0C applications.
Standard switch mechanisms type D, P,
D6, P6 may be specified for low
temperature duty down to -30C
ambient and wetside, except in
flameproof switches, when H6 must be
specified, allowing use down to -60C.
Note: If the wetside temperature
remains below that of the switch
enclosure for any extended period, then
there is the possibility of gradual build
up of frozen condensation.
TTiis is due to the breathing which wl
naturally occur through any degree of
enclosure protection (IP? or less) and
will eventually impair the correct
movement of the operating magnet
To prevent this, we strongly

recommend the use of the hermetically
sealed switch mechanism type H6, B6,
suitable for use down to -60 C
ambient
Gasket Materials:
Mobrey switches with flanges ANSI
#600, #900 and BS 4504 PN64 are
fitted with spiral wound non-asbestos
filled gaskets rated to 400C.
All other switches are fitted with nonasbestos sheet material gaskets to BS
7531 Grade X, which has upper
temperture limits of 250C forgas,
vapour & steam, and 440''C for liquids.
If the switch will experience gas vapour
or steam temperatures above ZSO'C,
then a suitable alternative gasket must
be fitted.
Cable gland:
A cable gland is supplied in the box
with the SOIDB, S179, Mini-switch,
and S36 range.
It is a brass cable gland, nickel plated,
with a fully insulated neoprene seal and
with clamping range to suit 8mm to
13mm O D cable.
The cable gland has type IP68
protection to 3m head of water (1 bar),
and maximum 80C as a permanent
temperature on application.
For submersible switches in
applications greater than 3m (1 bar)
submersion, the fitting and testing of
customers supplied cable and gland is
the customer's responsibility.
CHOICE OF SWITCH MECHANISMS

ELECTRICAL
TYPED
For alternative make and break circuits.
Function: 2 independent single pole
single throw contact sets: "Snap Action".
May be wired S.P.C.O. on site.
TYPED6
For switching two independent circuits.
Function: Double pole change over (2
independent circuits): "Snap Action".
TyPEP&P6
As type D & D6 but with gold plated
contacts for switching low power (e.g.
intrinsically safe) electrical circuits.
TyPEH6
For use in corrosive area and/or low
temperature applications. As type D 6
but with gold plated contacts and all
moving parts housed in an inert gas
filled hermetically sealed enclsoure.
WARNING
The plating of gold contact switches
may be permanendy damaged if this
mechanism is used to switch circuits
above the following limits:
300V: 12mA Resistive
24V:
2mH/200mA Inductive
24V:
250mA Resistive
24V:
750mH/10mAInductive
L V D - L o w Voltage Directive .
These switches complywith the^|;|;.^?',
provisions of the machinery directive
89/392/EEC and the Low Volt^V.'
Directive 73/23/EEC.
' -^-^r '
Standardsapplied: EN60947Parts 1
and 5.1
TYPEB6
For use in Zone 11 Hazardous Areas.
As type H6 but BASEEFA approved
coded EX NIIT6 to BS 4683: Part 3:
1972.
RATING
Mechanism Type
D&D6
Contact material
Temp.
Medium
Ambient
Insulation Value
Terminals DJP
D6,P6,H6,B6
Fine silver
Gold plated
Gold plated
-30C to + 400C
-100Cto + 250C
-30C to + 70C
-60Cto + 70C
(live to earth) > 100 MEG OHM
M4 screws with non-rotational clamp plates
6 way terminal block with pressure plates
Max. Voltage V
Max. Current A
Max. Power
H6&B6
P&P6
AC
D C Inductive
DC Resistive
440
5.0*
2000VA
Power fector 0.4 Min
240
1.0
35 Watts
Time constant 40ms Max.
240
20
70 Watts
* Note: Max. current for Type D is 8.0A up to 210C

PNEUMATIC
TYPEAP
For switching air druits.
Function: Change over.
Air pressure
Max. air presstire through valve: 7 bar
(lOOpsi). Max. air flow through valve:
66 litres/min at 7 bar. Air must be clean
and dry. Nominal leakage rate 0.2%.
TYPE AM
For modulating air controlled circuits.
Function: Continuous modulation.
Air pressure
Max. air pressure throtigh valve: 1.4 bar
(20psi).
Modulation: linear: 0 bar to 1.4 bar
0.2 bar to 1.4 bar available on request
CONNECTIONS
Brass compression couplings to suit
6.0mm copper or nylon pipe (coupling
thread %" BSP).
TEMPERATURE
M e d i u m + r C + 400''C
A m b i e n t + r C + 60C
Lower ambient temperature can be tolerated
provided the air supply is 100% dry.
GENERAL PURPOSE APPLICATIONS

ALUMINIUM BRONZE WETSIDE MODELS
S01DB/F84
4 Contact switch
Eifrl
-^3
ttru
sUJZi
f llWMd
1MZO X t.5
10BS3M3
S01D6B/F84
6 Contact switch
Weatherproof toIEC144:IP66
SPECIFICATIONS
ELECTRICALMODELS
Enclosure & wetside:
End cap
Short
End cap
Long
Maximum temp:
Aluminium bronze to BS1400 - ABl max. iron content 2.5%

e.g. SOIDB Aluminium BS1490 - grade LM24
e.g.S01D6B Brass BS1400-DCB3
210C except shrouded float F93 = 180C
AIR PILOT VALVE MODELS

Enclosure:
Valve block:
Finish:
(air pilot valves only)
Maximum temp:
Aluminium Alloy to BS 1490: Grade LM24

Aluminium alloy to BS 1490: Grade LM25
All external aluminium surfaces are Chromate phosphate treated then externally painted.
See page 5 for switch insert
Maximum temperature: dependent upon switch mechanism, gasket and gland - see pages 4 and 5
APPROVALS
UK
Germany
Canada
USA
France
Italy
Russia
Norway
Lloyds Register of Shipping

Germanischer Lloyd, TV
CSA
ABS
BV
RINA
RM
DNV
Other approvals available. Please contact us with your requirements.
ra
ORDERING INFORMATION
Code
S
General purpose aluminium bronze wetside models

Switch
Code
01
Flange (Head)
Size
Rating
MobreyA
18 bar
Code
DB
PB
D6B
F6B
APA
AMA
Switch mechanism
4 Contact-generali short end cap
4 Contact - gold plated contacts 1> short end cap
6 Contact - general 1> long end cap
6 Contact - gold plated contacts t long end cap
Pneumatic on/off
Pneumatic modtating
CODE
F84
F185
F68/+
F264
F21/+
F104/+
F93
V ^
tr
Standard
Mobrey
1J
1J
i5
01
DB /
F84
Float - application information

High or low alarm or 2 off
for pump control wide differential
Horizontal pump control
Horizontal limited differential
Verticat pump control or alarm
Cranked arm vertical or horizontal ( See page 19 for arm lengths)
Shrouded for dirty liquids Silicone rubber gaiter with 316 stainless steel
shroud and float
Typical ordering information
+ Refer to pages 18,19 & 20 for technical float details and length options
Refer to page 14 for nozzle and smd lengths.
SWITCH/FLOAT COMBINATION CHART
SOI
F84
F185
F68/+
F264
F21/+
F104
F93
-0Z
This is the most popular switch in the

Mobrey range. Its size and robust
construction make it ideal for a wide
range of general purpose and industrial
applications such as pump control and
high or low level alarm on tanks and
pressure vessels. The dimensions for
the float in the diagram left can be
found on fold out page 20.
* Preferred combination
FLANGE DIMENSIONS
STOCK AVAILABILITY
^-
S01DB/F84
S01DB/F18S
92
o.
Models
available from
stock
S01DB/F93
S01DB/F68/1
S01DB/F68/4
"
Mobrey 'A' flange

4 off 14mm holes 0 holes equispaced on 92mm PCD
S01DB/F21/1
S01DB/F21/2
S01DB/F21/3
MARINE APPLICATIONS
SUBMERSIBLE HOSEPROOF MARINE
Aluminium bronze submersible/hoseproof
i S03*B
,: S179*B
1 S195*B
103
Stainless steel submersible/hoseproof
"1^
Sld3*
S181*
101
IT
ConduKanry
PQisteDttMtwao
SPECIFICATIONS
ALUMINrUM BRON2 WETSIDE MODELS
End cap
Maximum temp:
Aluminium bronze to BS1400 - ABl max. iron content 2.5%

Brass BS1400-DCB3
210C except shrouded Boat. F93 = 180C
STAINLESS STEEL WETSIDE MODELS

Endcap:
Type 316 Stainless steel

Aluminium bronze BS1400 A B l / C
CABLE SPECIFICATION 3m standard where fitted. Longer lengths available upon request up to max. submersion depths.
Mice
Temperature limit 80C

600V light dutj' grade mineral insulated copper clad cable.
CSP
Temperature limit 50C

600/1OOOV grade ethylene-propylene rubber insulated flexible cable.
Maximum temperature: dependent upon switch mechanism and gasket - see pages 4 and 5
MARINE APPROVALS
Altuninium bronze wetside/endosure models
Type
No.
S03
S179
S19S
Head LP.
rating
Duty
Submeisible
Hoseproof
Submetsihie
68 (30m)
66*
68 (30m)
Max temp Cable
c
21(>f
210
210i-
Tbox
IP rating
M i c e (3m) 44
None fitted
44
CSF (3m)
Stainless steel wetside/enclosure models

S163
S181
Submersible
Hoseproof
68 (30m)
66*
M i c e (3m) 44
None fitted
210t210
* May be submerged to 30m head of water with temperatures between 1C and 100C.
Fitting and testing of customers siipplied cable and gland is the customer's responsibility,
t Totally submerged applicadons.

Germanischer Lloyd
esA
DNV
ABS
BV
RINA
RM
Other approvals available. Please
contact us with your requirements.
'j;-
ORDERING INFORMATION
Code
S
General purpose, submerisble. hoseproof & marine applications

S^witch
Code
03
179
195
163
181
1J
1J
Standard
Plange (bead)
Size
Rating
MobreyA
Mobrey
18 bar
MobrejrA
Mobrey
18 bar
MobrevA
Mobrey
18 bar
MobreyA
Mobrey
18 bar
MobreyA
Mobrey
18 bar
Code Switch mechanism
D
4 contact - general
4 contact - gold plated contacts
P
*6 contact - general
D6
P6
*6 contact - gold plated contacts
* Note: not for use with stainless steel wetside/enclosure models SI 63 & S181
Code Enclosure bousing
B
Aluminium bronze: no code letter with 5163 or 5181 stainless steel models
Code
Float - application information
F84
General purpose high or low alarm
F185
or 2 off for pump control
F98
F68/+ Horizontal pump control
F21/+ Vertical pump control or alarm
F264
F104+ Cranked arm vertical or horizontal
F93
Shrouded for use with dirty Hquids, silicone rubber gaiter with 316SS shroud and float
tr
t7
03
B /
X
F84
+ refer to pages 18,19 and 20 for technical float details and lengths options.
Refer to page 14 for nozzle and stud lengths.
\^^
F \ ^ No.
S
1/5
F84
F185
ro
ON
Vi
en
CA
F98
00
F68/+
F21/+
F264
F104/+
F93
Shrouded floats type F93 maybe fitted

to any of the aluminium bronze wetside
switches t>pe 503,5179 & 5195.
Shrouded floats for stainless steel
switches 5163 & SI 81 are available only
on request
STOCK AVAILABILITY
Models available
from stock
C.
Hoseproof
S179DB/F84
S179DB/F18S
S179DB/F93
S179DB/F104/1
S181D/F84
Submersible
S03DB/F84
S03DB/F18S
S03DB/F93
S195DB/F93
S19SDB/F84
S163D/F84
GENERAL PURPOSE APPLICATIONS

STAINLESS STE^L WETSIDE MODELS
TTvead
M20x1.5-6n
toBS3643
S36DA/F84
Weatherproof to E C 144:IP66
126
T7^
TKHEAO
TO B.S.3M3
S440DA/F84
SPECIFICATIONS
EICTRICALMODELS
Back flange (where fitted)
Wetside material
Enclosure housing mateiiak
Carbon steel to BS 1501:224 Grade 430B LT50. This material has guaranteed
properties at both high (400Q and low (-50Q temperatures.
Painted surfaces are stove paint finish. All unpainted surfaces are corrosive protected.
Stainless steel to BS 1504: 316 C16.
Stainless steel to type 316 to Mobrey standard (S36 model only).
Aluminium alloy to BS1490: Grade LM24
AIR PILOT VALVE MODELS

Valve block
Finish:
Aluminium alloy to BS 1490: Grade LM25 - Chromate phosphate treated.

All surfaces are Chromate phosphate treated then externally stove painted.
Maximum temperature dependent on switch mechanism, gasket and gland - see pages 4 and 5
APPROVALS
Germanischer Uoyd
CSA
DNV
ABS
BV
RINA
RM
STOCK AVAILABILITY
Models available
from stock
Other approvals available.

Please contact us with your requirements.
10
General purpose
S36DA/F84
S36DA/F104/1
S190DA/F93
S428DA/F84
S429DA/F84
S440DA/F84
S36DA/F68/1
S36DA/F68/4
S36DA/F21/1
S36DA/F21/2
S36DA/F21/3
3.1.1. ORDERING IIIFOR MiUTIO H

_
.
i
CODE
S
Genual purpose stainless steel wetside models

Switch
CODE
i-lange (Head)
Rating
Size
3
Mobrey A
33.8 bar
190
Mobrey A
33.8 bar
440
3"
150 RF
441
4"
I50RF
424
3"
300 RF
425
4"
300 RF
489
3"
600 RF
490
3"
900 RF
428
DN65
DN80
429
430
DNIOO
PN 16
431
DN12S
432
DNI50
417
DN65
418
DN80
419
DNIOO
PN 40
433
DN125
434
DN ISO
488
DN80
435
DNIOO
PN 64
DN125
436
DN150
437 V
CODE Switch Mechanism
D
4 Contact - General
P
4 Contact - Gold Plated Contacts
D6
6 Contact - General
P6
6 Contact - Hermetically Sealed
H6
6 Contact - Zone II Areas
B6
Pneumatic - On/Off
AP
Pneumatic - Modulating
AM
CODE Enclosure / Housins
A
Aluminium allov
CODE
F84
General Purpose
F96
High alarm or
F98
Low Alarm or
F106
2 off for Pump
F107
Control Wide, Differential
IJ
36
1r
F68/+
F21/+
F104/+
F88
F93
I.J
Standard
Mobrey
Mobrey : Use float F93 only
To BS 1560
or
ANSI
B16.S
to BS 4504
or DIN 2633
To BS 4504
or DIN 2635
To BS 4504
or DIN 2636
Pump Control Horizontal

Vertical : Pump Control or Alarm
Cranked Arm : Horizontal or Vertical
Interface Duty
Shrouded for dirty liquids (S190 only) Silicone mbber gaiter with 316SS shroud and float.
irV
I
A
tJ
/
F84
+ Refer to pages 18,19 and 20 for technical float detaus and length options
Refer to page 14 for noz2le and stud lengths.
'"^"--^^^ s No.
FNo>^..^
F84
F96
F98
mo6
F107
F68/+
F21/+
F104/+
F88
F93
Notes:
en
05
1i
11
tn
C/3
CO
w-t
CO
00
00
35.
* Preferred combination
' Non-preferred combination
11
HAZARDOUS AREA APPLICATIONS

FLAME PROOF ZONE 1 GAS GROUP I & |IC MODELS
133
IJhM
S2S0DA/F84
Weatherproof to IEC 144: IP66
Conduit entry thread

Gunmetal body 25tnm
Aluminium body 20nim
/365
For mining applications

S276 & S277 are supplied with flanged
adaptor suitable for a bander type cable
gland, the use of which is obligatory
SPECIFICATIONS
Back flange
(where fitted)
Wetside matedal
Enclosure/housing
material
Ambient temperatures
below 0C
( '-
Carbon steel to BS 1501:224: Grade 430B LT50. This material has guaranteed properties
at both high (400Q and low (-50Q temperatures. Painted surfaces are stove paint finish whilst
all unpainted surfaces are corrosion protected.
Stainless steel to BS 1504:316 CI 6
Max. working temp*:
Aluminium body 400C
Gunmetal body 350OC
Gunmetal to BS 1400: Grade LG2.
Max. working temp*:
S275&S277
200C
Aluminium alloy to BSl 490: LM25
Finish is Chromate phosphate treated and externally stove painted
Gunmetal to BS 1400: LG2
Natural finish
i) Down to -20 C
standard enclosure/housing codes A or G are suitable.
if) Down to -60C
Specify enclosure/housing codes AX or GX which are as standard but with BASEEFA/
CENELEC certification to use to -60C. Note: -50 C unless 'G' flange or low temperature back
flange is specified.
*See page 4 for gasket temperature limits.

CERTIFICATION
Z o n e 1 G a s g r o u p IIC
B A.S.EJEJIA. / CENEUEC
P.T.B.
CSJL
LR.S.
J.I.S.
Gas Group I (Mining)
M:.C.S. ( H &
N.C.B.
G.MJE.
SJE.)
Department of Trade and Industry (Health & Safety Executive) Certificate No. EX92C1510X
(EX 811118X) to BS 5501 :Parts 1 & 5:1977: E Exd lie T6.
Certificate of Confomty CENELEC. EN50 014 &
EN 50 018. For ambient temperatures +60C to -60C. Certificate No. Ex90C 1287 applies.
PhysikaHsh Technische Bundedsanstalt Certificate No. P.T.B. IIIB/S1678. E Exd lie T6
(Float in Zone 0)
Canadian Standards Association Guide No 184-N-90.8 File N a LR 12965 Qass 1: Group C D .
Standards Association of Australia Certificate No. EX 186 Exd B T6.
Lloyds Register of Shipping Certificate No. 88/0226
Certificate No. 39056 Code 3nG4
Health & Safety Executive Certificate No. FLP 81039 to BS 4683 F t 2.
National Coal Board Acceptance No. 1410
Government Mining Engineer (South Africa) SA.B.S. 314 (1971) CertifieateNo. VM1077
Class A : Groups 1 lA. 1 IB, 1IC.
N o t e : < > For gas group 1 (mining) S276 & S277 only should b e specified (includes obligatory flange adaptor)
12
to
O R D E R I N G I N F O RMlATIO N
1CODE S
Switclf for hazardous area applications, flameproof zone 1 gas e>"P I " d l i e models
Flange ( H e a d )
Size
CODE
Ratinfr
Wetside
Mobrey G
250
21 bar
Stainless steel
Mobrejr G
275
21 bar
Gunmetal
Mobrey G
276 < >
21 bar
Stainless steel } ^ o n e 1 gas group I models
Mobrev G
277 < >
21 bar
Gunmetal
3"
256
150 RF
4"
257
150 RF
To BS 1560
6"
278
150 RF
or
3"
251
300 RF
ANSI
4"
254
300 RF
B16.5
3"
260
600 RF
3"
261
900 RF
O N 80
253
ro BS 4504
DNIOO
255^
PN40
or D I N 2635
DN125
26
DN80
272'
DNIOO
268
DN125
270
P N 64
To BS 4504
DNISO
271
or D I N 2636
CODE
Switch M e c h a n i s m
D
4 Contact - General
Note: The BASEEFA/CENELEC
P
certification covering use -20C to -60C
6 Contact - General
D6
ambient temperature requires the
P6
6 Contact - Gold Plated Conucts
hermedcally sealed switch mechanism type
H6
6 Contact - Heimedcally Sealed
H6 to be fitted.
CODE
A
G
X
ti
tJ
Enclosure / H o u s i o e
- J
Aluminium Alloy
Gunmetal (mandatory on gas group 1 switches: <>)
Suffix X must be specified for applications with ambient temperatures -20C to -60C
CODE
Float - Application Information
F84
F185
General purpose high alarms or low alarms
F98
or 2 off for pump control
F106
F107
F96
F68/+
Horizontal pump control
F264
F21/+
Vertical pump control or alarm
F104/+
Cranked arm: horizontal or vertical
F88
Interface duties
251
F96
Typical ordering informarion
+ Refer to pages 18,19 and 20 for technicalfloatdetails

Refer to page 14 for nozzle and stud lengths.
o
No.
NC
^"^-^..^
NO
sn
F84
F185
F98
F106
00
(0
lA
09
S3
-.ii'n.
CO
VS
1 -
SO ;
o-
SO : B
F107
F68/+
F21/+
F104/+
F88
F96
F264
* Preferred combinadon
Non-preferred combination
POPULAR COMBINATIONS
Popular combinations
S2S0DA/F84
S2SODA/F104/1
S276DG/F84
S27SDA/F84
S275DG/F84
S277DG/F84
13
CHEMICAL APPLICATIONS
P.T.F.E. WETSIDE
297
124
18
1
\\
1
^^gJL
71
- 1
S3S7D/F317.
S357P/F317
-^
Mr
ST'
112
1063
1 Conduit entry
^Pg16toDIN40430
SPECIFICATIONS
Type number
S357D/F317
S357P/F317
Switch mechanism
Housitigniatedal Wetside matezial
Finish
: .
I P rating
General
Aluminium alloy
PTFE
Chromate phos/painted
IP66
Gold plated
Aluminium alloy
PTFE
Chromate phos/painted
IP66
Notes:
1. S357D level switch has a combinedMobrey A & E flange and may be used with either mounting flange.
2. Mobrey offers a wide range of "Engineer to order" level switches for chemical applications with higher pressures or
temperatures. Consult factory for details.
STOCK AVAILABILITY
Models available from stock
S357D/F317
S357P/F317
NOZZLE AND STUD LENGTHS

Maximum nozzle length allowable (dimension 'A").
Please refer to page 21 for companion flanges and accessories.
""^"--x^^^ Float
Flange^''~~v.,^
Minimum
sUd
projecon
;^
.*"
1
:
<^v
'
+
CO
IT)
00
CH
00
65
65
75
75
DNIOO
DN125
70
95
105
105
140
105
DN150
224
180
180
200
200
3 " 300 & 150
70
80
80
170
4 " 300 & 150
95
105
105
200
3 " 600
62
70
70
130
Mobrey A
DN65
DN80
75
75
80
80
140
00
135
135
170
200
75
-
75
a,
90
90
92
92
90
105
98
110
190
70
(fa
^
75
75
90
100
75
80
105
140
140
140
180
80
170
200
90
98
105
105
110
70
85
89
70
85
89
118
75
90
92
75
190
3 " 900
62
70
70
130
Mobrey G
65
75
75
135
6" 150
224
200
140
90
100
70
M i n i m u m stud projection (mm)

Rating
Size
Stud
35
30 40 40 40 40
PN16
PN64
PN40
65 80 100 125 150 65
80
100 125 150 80 100 125 150 3"
44 42
42
46
14
52
54 52 55
62
300;
600
!m
4"
3" 4"
3"
46
54 56
64
74
159;
67
46
FLOAT CHAMBERS
UITHORAUAL
Fabricated chambers
175
Cast chambers
Switch
mounting
flange
Process
connections
INTRODUCTION
Float chambers are used to feidlitate the external mounting of a
Mobrey Magnetic level switch on to a tank or pressure vessel,
particularly where space inside the vessel is restricted or where
the control must be isolated for routine maintenance whilst the
plant is in operation.
A wide range of cast or fabricated chambers is available.
Process connections may be specified top and bottom or side
and side, and can be flanged, screwed or butt welded in a choice
of si2es to suit most plant installations.
Exotic materials are also available.
Standard finish
Black stove paint. 2 pack epoxy or hot dip galvanised available
at extra cost
Pressure testing
All chambers are fiill pressure tested at the relevant coimection
flange test pressure.
Operating pressure
Note that the pressure/temperature ratings of the switches and
chambers are not aKpays compatible so that the lower rating will
be the governing factor in selection.
Low temperature use
Low operating temperatures as permitted by national standards
for a given fabricated carbon steel chamber, vary as follows:
ANSIB31.3: -28.9''C
ASMEVIIL -7C
BS5500:0C
If for use at temperatures below the various limits, LT50,
LTIOO or stainless steel can be specified.
Process
connections
Switch
mounting
flange
SELECTION
The choice of chamber will depend on the type of MOBREY
Magnetic level switch to be used and the form of connections
required. For example, if S424DA/F96 is selected then a 145
chamber can be used with the connections of your choice in
respect of pipe size, flange rating and connection arrangement.
FEATURES
Varier.' of connection configurations available.
Welding in accordance with A.S.M.E. EX and BS 5500.
Welding procedures approved by Doyds Register.
Welders qualified to Lloyds Register and ASME EX
All materials used are to A.S.M.E. and BS 5500
requirements.
Material certification, BS. EN102043.1B
Chambers can be manufactured in a wide variety of
materials, including 321 and 316 stainless steel, Incoloy
Monel, CrMo steels and other more exotic materials
Paint finish to customers specifications
Coded welders available if required
Chambers may be supplied in accordance with NACE
recommendations for sour service
N D T to CSWIP and ASNT is available for radiographic,
ultrasonic, mag particle and dye penetrant
Customers and nominated inspection agencies are welcome
to wimess pressure testing or welding procedure
acceptance test
Switches and chambers are individually pressure tested at
the relevant flange test pressure. Combinations may
be pressure tested as an assembly on request, otherwise
they are supplied loosely assembled for transit and
flange bolts must be tightened on site before
commissioning.
15
FABRICATED CHAMBER DIMENSIONS
FABRICATED CHAMBERS Standard dimensions: Ref. onlv - must b e certified on order

Model
144C
145C
148C
ISOC
ISlC
Sw Mounting Fig
ANSI 3" # 1 5 0
ANSI 3" # 3 0 0
MOBREY'A'
MOBREyB/R'
MOBREY'G'
Pressure
19.6 bar
Slbar
18 bar
34.5 bar
21 bar
X
143
143
143
143
143
Y
185
185
169
169
169
Z
168
168
168
168
168
Model
305C
306C
307C
308C
309C
u. X
Pressure
64 bar
40 bar
102 bar
153 bar
16 bar
Sw Mounting fig
BS4504 80-64
BS 4504 65-40
ANSI 3" # 6 0 0
ANSI 3" # 9 0 0
BS 4504 65-16
X
143
143
143
143
143
Y
183
162
162
164
163
Z
168
168
168
168
168
Y-
~]
Nominal ref. dimensions
VSi /-.
azPro :ess corinection s
^^^
S witch mounting flang e
' CAST CHAMBERS Standard dimensions: Ref. only - must be certified on order
802-S01DB/F84
802 without drainage
201 -with drainage
Switch
mounting
flange
Process connections
Process connections
Switch
mounting
flange
Drainage
Maximum working
Suitable Mobrey level switches >
conditions for chamber
Typical combination
Temp.
Pressure
Switch flange
With
at210C
201-S0tDB/F84
13.4 bar
Mobrey A
Type
no.
Material
Cast iron
Process
connections
201
BS1452 Grade 17
Screwed 1" BSP
802
Cast iron
BS1452 Grade 17
Flange 20-16/11 13 bar

BS4504
at 210C
Mobrey A
802-S01DB/F84
Without
Minimum working temperature 0C
16
r
v.
--.
<>
FABRICATED CHAMBERS : ORDERING INFORMATION

MatSial switch flange
max. Pressure aO'C Max Temp C
See page 4 for gasket limits
Code
144C
Carbon steel/ANSI 3" Class 150
19.6 bar
400C
14SC
51 bar
400''C
148C
Carbon steel/Mobrey'A'
18 bar
400C
150C
Carbon steel/Mobrey TB/R'
34.5 bar
400C
ISlC
Carbon steel/Mobrey'G'
21 bar
400C
305C
Carbon steel/BS 4504 DN80 PN64
64 bar
400C
306C
Carbon steel/BS 4504 DN65 PN40
40 bar
400''C
307C
102 bar
400''C
308C
Carbon steel/ANSI 3" Qass 900
153 bar
400C
309C
Carbon steel/BS 4504 DN65 PNI 6
16 bar
400''C
CODE Process Coimecdon Style
1
Side & top or side & bottom
Flanged
2
Side & side
Flanged
3
Flanged 'with %" flanged vent/drain
4
Flanged with %" threaded vent/drain
5
Top & bottom
Flanged
6
Flanged (dose centres)
7
Top & bottom stub pipe
Top & bottom threadolet or sockolet
8
9
Side & side
Flanged with '/" flanged vent/drain
0
Side & side
Flanged with %" threaded vent/drain
CODE
Process Connection size/ratins
1"NB Sockolet
00
CHAMBER OPTIONS TO
01
1" NPT threaded (female)
CUSTOMER ORDER
02
1 'A" NPT direaded (female)
Chambers can be manufactured in
03
2" NPT threaded (female)
a wide variety of materials,
04
1" BSPT threaded (female)
08
l"NBSch80smhpipe
including 321 & 316 stainless steel,
10
2" NB Sch 80 stub pipe
Incoloy Monel CrMo steels &
11
ANSI 1" Qass 150 RF Weld Neck
other more exotic materials.
12
ANSI 1" Class 300 RF Weld Neck
Paint finish to customer
13
spedficarions.
IS
BS 4504 DN25 PNI 6 RF Weld Neck
NDTtoCSWIPandASNT
16
BS 4504 DN25 PN25 RF Weld Neck
is available for radiographic
17
ultrasonic, mag particle and dye
18
19
BS 4504 DN25 PNI 00 RF Weld Neck
penetrant.
21
ANSI 1 'A" Qass 150 RF Weld Neck
Coded welders available if required.
22
ANSI 1 Vz" Qass 300 RF Weld Neck
Chambers may be supplied in
25
BS 4504 DN 40 PNI 6 RF Weld Neck
accordance with NACE
31
recommendations for sour service.
32
33
34
35
36
37
JJ
B
145C /
12

Process connection sizes and dimensions for fabricated cfaaiztbers
Dim
B
C
D*
E
F
H
150
212
139
108
212
60
278
1"
300
218.5
145.5
112
218.5
60
291
DN25
600
225
152.5
117
225
60
305
PN16
196
123
196
60
246
PN25
198
125
198
60
250
PN40
198
125
198
60
250
Butt w eld
300
Screwed
NPT
24C
API
240
BSP
240
1.5"
PNIOO
216
143.5
216
60
287
150
218.5
143.5
108
218.5
54
287
300
225
150
112
225
54
300
DN40
PN16
200
125.5
200
54
251
Butt weld
300
Sctewed/SW
>3PT API
244
244
DN50
PN16 PN25
178 206
203 130
127 206
203 48
260
48
254
I Jutt weld
300
Screwed or socket weld
NPT
API
250
250
2"
150
220
144
108
220
48
288
300
178
226
150.5
112
226
48
301
600
236
161.5
117
.
323
900
265
190
133
380
FN40
206
130
206
48
260
Tolerance
+
0
3
0
1.5
0
2
0
2
1
1
0
3
-
0
- ;
'
* V*" N3. Vent/drainflangeof relevantratingas shown. AH dimensions shown are nominal and should be certified on ordet
17
FLOAT SPECIFICATION
HORIZONTAL F8 PUMP CONTROL AND ALARM FLOAT
r
L
/
>
-IWEW
S36DA/F68/4 with rod cut t o / 3 dimension
10 B.S.3M3
Switches fitted with F68 tj^pe float unit may be adjusted on site to meet pump control differential requirements.
The float is available as a F68/1 or F68/4.
The F68/4 has pre-diilled holes along the rod to allow the user to achieve the / 2 and / 3 differentials in the table below:
Maximum intrusion
\^tside(mnn)x "::/:',".'-'^";^;;> " .''^'"^^*
Minimum SG
Minimum tank dimension
above/below centre line (mm)
Maximum differential (mm)
F68/1
F68/2
F68/3
F68/4
360
0.72
216
470
0.8
292
590
0.82
368
643
0.85
406
247
360
483
555
Full details of the operating levels and differentials are in the manual. Note, these dimensions are approximate for cold water and
will vary for liquids of different SG.
VERTICAL F21 PUMP CONTROL AND ALARM FLOAT
rF=fi=o> Low level alarm

I
Normal (left) and
.''Ts
alarm positions
pJiL=Si!>
ÎfTtr^
-tnr
?p-
,.==o
..
I
I
i
I
High level alarm

Nonnal (left) and
alarm positions - -(jj-
Pump control
.jeX
Low level (left) and
Nf^
Nghleval
switching posWons
Note: Float assembly must be fitted from inside if for use in a vessel, or complete
switch and float assembly may be mounted on a suitable bracket or manhole cover.
Float rod lengths available :F21/I: 1524mm (5)

F21/2: 3048mm (lO")
F21/3: 4570mm (15) max.
Type
Number
F21/*
Float rods may be cut to length on site and switches set to

operate at required level in either pump control or alarm mode
by following the setting instructions supplied.
Pump
Differential "S"
AlarmLevels
Miniintim "T"
13^1420*
172
Maximum "S"
4400*
' When maximum rod length specified
18
,,W
;;
~\
CRANKED ARI^ FLOATS F l 04

HOW TO ORDER: Specify - F104 float with:
1. A and B or V and W dims. 4. Mobrey magnetic switch head
2 Liquid in contact
type no. (eg. SOIDB/F)
3. Specific gravity of liquid
5. State land or marine application
A + B , Must not
f exceed
V + W
750inm
A or V ' Should not
be less
B or W
than 75mm
For Straight arm float, suffix float number with "B' dimension as required
HORIZONTALLY MOUNTED SWITCHES
Forland application
A and B dimensions with relevant minimum specific gravity
A ^ 75 100 125 190 17520022525027530)325350375400425 450|475 500|S25|5SO|575| eOo|625|6So| 675l'B'rriril

J64
7
SB
71 .72 .73 .73 .74 .75 .76
.64
ISO
.71
.73
.70
er
200
.72
.80
^.73
IS
.76
.78
.78 X * l
.70
250
.73
300
.72
.73
.74
325
.70
yr
79 X
.80
Si
.78
sr
.84
.79
S7
.80
.82 .84
sa
sa JM
.78
76
.73
.78
.77
.75
.74 .78
500
.76 .80 .83 .86

.77
.77
32
.78 S2
.90
-W
JO .92
55
.90
32.
>^l
30 51 .33
0179
100
125
150
175
.82
525
For miarine application
S3
.85
450
4^
.86
.85
X
SB
sa
575 W
WS 7F IS IS
75
.67
.68
.69
.71
100 125
jsr .68
.68 .9
.70 .71
.71 .72
.73 .74
250 275 300

.71 .72 .73
.73 .74 .74
.75 .76 .76
.77 .78 .78
.79 JO .81
.76
.78 .79 M i l
.79 X .81 .83 .84 .85 X
.83 M JBS .86 sr ssr X
.88 X i X m ay
Si 33 i i 34 X
)S&
.n
225
ess
2S0
St
msIS
425 450 4 ^ sn 525 550 srs

.77 .78 .79 .79 30 31 32
.79 .80 .81 31 32 33 34
a\ .82 .83 34 34 35 36
36 37 38 39
X .84 X
X .86 SI 3 8 3 9 30 31
.S4 S6 ~SS~SI X iS .90 Sb "ST TZ
X
SI X X X 31 32 3 3 .94
m X SI 32 X 34 3 5 35
34 .95 X 3 6 .97
sH
.99 3 9
.S
~sf
For intermediate
.tM JS6 3i Sk JSAS6 IM LM 11
1.04 1.03 1.02 1.03 1.03 1.03 1.04 1.04
1.09 1.08 1.07 1.07 1.07 1.08
1.15 1.13 1.12 1.12
1.20 1.18
1^
150 175 200

.68 .69 .68
,7o .70 .71
.71 .72 .73
.73 .74 .75
.75 .76 .77
Ht
225
.70
.72
.74
.76
.78
325 350 375

.73 .74 .75
.ii ~M .77
.77 .7 .79
.79 X S\
JS2 X X
400
.76
.78
.80
S2
M
375
400
425
A'
625 650 675 "B'minl

.84 3 5 .86
36 .87
.88
a &
.sa
~m ~m
\!&
sm
350
6G0
33
35
37
39
dimensions select
f"
mm
^ 3,
^
VERTICALLY MOUNTED SWITCHES V and W dimensions with relevant minimum specific gravity
For land application
75
37
75
100 .67
125 3 7
150 .67
175 .67
200 .67
225 .66
250 3 6
275 3 7
300 3 7
325 3 7
350 3 7
375 .68
400 .68
425 3 8
450 3 8
475 .68
SB 38
525 3 8
560
100
37
36
36
36
.66j
.66
36
.66
36
.67
.67
.67
37
.67
.68
38
38
38
125 ISO 175

.66 .66 .66
. .66 .66
.66 .66 .66
3 6 36 .66
36 .66 .66
.66 .66 .66
36 36 36
36 36 37
~IS "37
~m
.66 sr .67
.67
.67
37
37
38
38
.67
37
.67
37
38
38
isi .68
x 38'
.9' .69 3 9
39
38
37
.67
.67
.68
.68
38
.66
3^'
.69
.68
200 225 250

36 3 7 3 7
~S 3 7 3 7
X 37 37
.66 3 7 .67
.66 3 7 3 7
37 3 7 3 8
37 3 7 .68
.67 3 7 3 8
IS .68 .68
sr 3 8 3 8
.67 .68 .68
.68 .68 3 8
38 38 38
38 3 8 3 8
3 8 .68 3 8
38 38 3 8
33 3 9 .70
SB 3 8 .70
3 9 .70
.70
Z7S 300 325

.68 3 8 3 9
.6 3 8 3 8
s 3 8 .69
.a .68 .68
.68 3 9 3 9
'ee .69 .68
.68 .68 .70
3 8 3 8 .70
SB ~ S "??5
.69 .68 .70
39 .70 .70
39 .70 .70
3S .70 .71
.70 .70 .71
.70 .70 .71
.70 .71
.70
"SB
60O
eta
660
.To .
.71
.70 .70
.71
.71
.71
.71
.71
.71
375
.70
.70
.70
.71
.71
.71
.71
.71
400
.71
.71
.71
.71
.71
.72
.72
.72
.h .72
.71 .72
.72 .72
.72 .72
.72
Vf
r
a 1
2)
WS
HA
.71
V -f w '
/summ
A ot V ^ Should not be less

B or W ^ than TStiun
425
.72
.72
.72
.72
.72
.72
.72
.73
.73
.73
.73
450 475 500 525 550

.73 .73 .74 .75 ~?6
TTs .'f3 .74 ".76 .76
.73 .74 .74 .75 .76
.73 .74 .74 .re .76
.73 .74 .75 .75 .76
IS ~J .75 .75 .76
.73 .74 .75 .76
.73 .74 .75
325
350
375
400
425
V
575 600 625 650 675 WmuJ

.77 .77 .78 .79 30
.77 .77 .78 .75
.77 .78 .78
.77 .7t
.77
1^
/
(
13 14
.74
ine application
ISO 175 7m 77S W 775 vn 125 390
400 4KS 4SD 475 500 525 550 575 600 625 650 675 Wmml
3 8 3 8 .68 3 8 38 38
.70 .71 .71 .72 .73 .74 .74 .75 .76 .77 .78 .79 .79 3 0 31
"6fl ft7 6R 68 .68 .e6 70 Ti TT .Ti .73 ,T3 .74 IS "76 77 77
~7s 30 31
67 fi7 68 68 69 m 70 7t .72 .72 .73 74 .75 .75 .76 .77 .78 .79 3C 30
,67 3 7 .68 3 8 .68 .70 .71 .71 .72 .73 .74 .74 .75 .76 .77 .78 .78 .79 3 0
.67 .66
i9 .76 .To .71 .74 IS
-ys -Ji :7s "7? "75 T5 TB
.7'< .75 .TS IS
.67
.X ISO .Tfl .To .71 .72 .7*
.77 .75 "75 75
.68 .68 .70 .70 .71 .72 .72 .73 .74 .74 .75 .76 .rr .78 .78 .79
.68 .70 .70 .71 .71 .72 .73 .74 .74 -IS "ITS .77 IT "75 T3
.70 .71 .71
.73 .73 .I .W .76 "78 .77 .78 .79
TS .76 IS "77 .78 "75
.71 .J2 .74 .73
.73 .73 .74 .75 .75 .76 .77 .78 .78
.74 .75 .75 .76 .77 .78 .78
.75 .76 .77 .77 .78
For intermediate dimensions select
.77 .77 .78
the next longer sis;e on chart
.78
7S im 17S
75 .75 .72 .70
100 76 77 .7f
125 77 77 m
150 .79 .72 St
.71 St
1?
225
mm
350
.70
.70
.70
.70
.70
.70
.70
.70
-%
-a
^ m
"a
"ns.
.a
mm
19
.r*
F L O A T S FOR U S E WITH S T A I N L E S S S T E E L W E T S I D E S W I T C H E S
Max..
Ptessure
at 20C
(BAR)
34.5
74.0
34.5
74.0
200.0
34.5
Min.
S.G.
Float
Type
F84
F96
F98
F106
F107
F68/+
F21/+
F14/+
F88
F93
F317
n?5
F264
0.65
0.60
0.45
0.51
0.71
0.72 to
0.82
0.70
Various
0.8/1.0
0.75
0.7
0.65
0.85
Temperature
>c
Differential
(mm)
Dimension X
L e n g t h from
Privot P o i n t
13
13
14
164
164
184
185
172
294 to 522
Maximum
400
400
400
400
400
400
30.0
34.5
74.0
Atmosphcctc
0.6
34.5
32.0
13
13
15 to 483
400
400
400
180
60
210
210
13 to 4420
26
13
13
13
23, 29 or 33
Dimension
Y
Maximum
Travel
119
119
127
108
120
204 to 736
Variable
As ordered
359
183
229
164
179
198
124
112
119
Variable
Dimension Z
Max.
External
Diameter
65
65
65
65
65
65
129
65
65
65
67
65
63.5
.Float
Material
316
Stainless
Steel
PTFE
Monel
Monel
' "
Y
\^
MOBREY FLANGES
kA
*
'
(V r
VJ i^
Jr
FLOAT SWITCH RANGE
92
J- Mobrey
A'flange
4 off 14mm 0
5j holes equispaced
on 92mm PCD
Mobrey
'G' flange
4 off 14mm 0
holes equispaced
on 98mm PCD
SWITCH MECHANISMS
D&Ptype
B
D6,P6,H6&B6type
7 / oâ?
B
A
K makes on rising level
B
A
B
A
RR makes on fafimq levd
B,
t,
B,
AP&AMtype
A,
A,
" ^
* , -A, B, -B, Make on riling level
B,
A,
A,
A|-A| B,-Bj Make on faffing levd
20
Supply -Port A or B
Outlet - Port C
ACCESSORIES
a_
Test devices for Mobrey 'A'flangedswitches to facilitate mechanical testing of electrical circuit
'T
a r-
11
..1.
-ei-
TD lOOM (Sandwich)
TO ioi/A(wad)
Vessel Flange
Type
T D 100/A
TDIOI/A
T D 102/10
T D 1(^/16
^1.-'_.
Mobrey'A'
Weld on
PN10DN80
PN16DN80
b j
rD102/10 & /16 ( F l a i ^
Max. Pressure
Bar
18"
18
10
16
Max.
Temp.C
120
120
120
120
120
85
200
200
d
nun
155
155
155
155
35
64
85
85
92
92
92
21
21
67.5
67.5
67.5
67.5
Note: Maximum temperature can be increased to 210C with Viton 'O' ring. Please state when ordering.
MATERIALS
TD 100/A
Carbon steel
BS1501-151-360
TDIOI/A
Cast steel
BS1504-161-430A
T D 102/10 and TD 102/16

Cast steel body-BS1504-161-430A
Carbon steelflange- BS1503-22W30
COMPANION FLANGES
Welding and backing companion flanges are available as extra items to facilitate the direct mounting of mobrey A and G flange
switches.
'A' flange models
Welding pad J l 84
Welding nozzle J786
BackingflangeJ863
V I M - M Uui MhdttCiV unh
21
n>nVn>Mrftong
!
kz.^
HI2 STUD OH 12
gui ciRaE oiA
J184 in 316SS: 71020/107
(Not suitable with Mobrey "M switch SMA*)
'G' flange modeb

Welding pad J800
Welding nozzle J799
21
J863 in 316SS: 71030/900

All flanges manufactured in
mild steeL
Backing flange zinc plated iand
passivated.
Welding types supplied
complete with studs and nuts.
Backing type supplied with
bolts, sealing washers and full
&ce gasket
WeldmgPadJ800in316SS: 71020/111
Othermatetials available upon request
APPLICATIONS
ALARM DUTY
Perhaps the most common application for the original Mobrey float switch is liquid
level detection for alarm duty. Whether for high or low alarm, the "Mobre/' is one of
the most reliable and cost effective instruments available today Using the time
proven principle of magnetic coupling, the switch is gjandlcss, snap-acting and
suitable for almost any liquid. Manufactured with a range of wetside materials and
with a choice of electrical or pneumatic output, side or top mounting models have a
tough IP66 weatherproof housing and are flange mounted to provide the "fit and
forget" solution for liquid level alarm.
R u ^ e d , Reliable, Glandless, Weatherproof
PUMP CONTROL
Mobrey switches maybe specified with pump control float mechanisms which can be
site adjusted to give control over the required liquid differential. Side moimting
models operate over 500mmideal for small header or filling tanks, and vertical
mounting models with cfferenrials up to 4500mm are commonly used in sumps
and storage tanks.
Side mount, Top mount. Site iadjustable
SUBMERSED APPLICATIONS
If it is not possible to side or top mount a switch, then specify the Submersible model
This switch is watertight IP68 to 30m submersion, and may be tank floor mounted to
provide low level alarm or pump cut-off/pump protection in sumps and pits. For
heavily fouled liquids, a shrouded model is ideal as all the moving parts are protected
inside an and-fouling shroud. Switches may be supplied with or without factory fitted
and tested cable, with the option of Rubber or copper Pyrotenax cable to suit.
These models are also ideal for applications exposed to pressure hosing or occasional
submersion, and as such have become an industry standard for shipboard use.
IP68 / 30nQ, Factory fitted cable, Hoseproof
I/X
pJ'M^
HAZARDOUS AREA USE

Mobrey switches are classed as simple switching apparatus and may be used in
Intrinsically Safe circuits when wired to a suitably protected supply. In these cases, specify Gold Plated contacts which are suited to the low power in such circuits.
A range of switches is also available with Flameproof (Explosionproof) approval,
certified by most of the worid's leading authorities.
Mobrey certification covers use in all Gas Groups, including Mining, and in all Zones,
including Zone 0.
Pressures to 350bar and temperatures to 400C are possible with Mobrey float
switches.
International approvals, High pressure. H i g h temperature
CHAMBER MOUNTING
If it is required to mount the float switch outside of the main vessel, for example to
fadlitate isolation for routine maintenance or simply because the vessel is too small to
accommodate the float, then specify a Mobrey chamber. Available in almost any
conceivable shape and process connection arrangement, chambers are designed,
manufactured and tested in accordance with international standards. Coded welders
will construct a chamber from the material of your choice, including Stainless, LT
Carbon, IncaUoy, Monel and High Chrome steels, certified and identified to your
instructions.
Custom design, Coded construction, N ^ C JE.
MEGGITT MOBREY
AALBORG
INDUSTRIES
P.O. Box 145

3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
The Netherlands
Tel. +31 (0)181 650 500

Fax +31 (0)181 650 501
No. 24234179
VAT No. NL0081.91.694.B.01
Account No. 25.75.69.618
BIC Code FTSBNL2R
P O Box 145
3200 AC Spijkenisse
Ohmweg 8
3208 KE Spijkenisse
Tlie Netherlands
AALBORG
INDUSTRIES
^m
REX OMEGA COUPLINGS

N O OTHER COUPLING C A N OFFER
A L L THESE FEATURES & BENEFITS
rifif W
Features
Benefits
Split-In-Half Flex Element Design
Easy replacement without moving the hubs or connected equipment
Polyurethane Flex Element
No lubrication required, excellent chemical resistance
Torsionally Soft
Protects equipment by cushioning shock loads and torsional vibration
High Misalignment Capacity
Accommodates unavoidable misalignment with low reactionary forces
Visual Inspection
No need for coupling disassembly to inspect
Interchangeable Hubs
Standard and spacer coupling hubs are identical
Adjustable Spacer
One spacer coupling size can accommodate different shaft separations
Rex Omega Standard Coupling
Rex Omegja Spacer Coupling
standard "close coupled" design available in 15 sizes covering

applications up to 48,000 Nm torque and bores up to 229mm.
Spacer design available In 12 sizes covering applications up to

5,580 Nm torque and bores up to 155mm.
O Reversible hubs are available from "stock" with rough bore,

finished straight bore, or bored to accept compression bushings.
Consult factory for tapered bores, splines and other special bore
requirements.
@ Premium grade capscrews with self-locking patches. Also available
in stainless steel.
Tough, two-piece urethane flex element transmits torque, accepts

misalignment, reduces vibration and noise and is not seriously
affected by petroleum products or most chemicals.
O Formed metal shoes with optional hub mounting patterns satisfy
ANSI, DIN and ISO spacer requirements. Shoes are coated to help
resist corrosion. Available in stainless steel.
Table of Contents
Installation and Misalignment Ratings
Standard Close Coupled Design
Spacer Design
Extended Spacer Design
Floating Shaft Design
Selection
Ordering and Alignment Instructions
Technical Infornnation
Special Designs
Sales and Warehouse Locations
E-3
E-4,5
E-6,7,8
E-9
E-10,11
E-12,13
E-14
E-15
E-16
E-19
Rexnord
E-2
Ifffif
REX OMEGA COUPLINGS

INSTALLATION...AS SIMPLE AS PEELING AN ORANGE
Mount one hub to shaft, leave other

hub loose for adjustment of spacing.
Place half of the Omega element

around hubs and secure with selflocking capscrews. Omega element
will space the other hub. Now secure
the other hub.
Mount other half of the Omega

element. Tighten all capscrews to
recommended torques (below) and
you're done!
Tested Tough
Rigorous testing demonstrates that the

Rex Omega coupling protects connected
equipment from the damaging effects of
misalignment, vibration, and gross
overload. Where other coupling designs
might allow equipment damage, the
super flexible element of Rex Omega
couplings minimizes bearing and shaft
overloading under severe misalignment
conditions and won't transmit excessive
shock overloads.
Severe static testing (5 x rating)
shows element flexibility, rugged
design, and positive adhesive bond to
the metal shoes.
Demonstrates coupling's ability to

accept unavoidable misalignment.
Omega Coupling
IMPORTANTRECOMMENDED CAPSCREW TORQUE

FOR PROPER INSTALLATION
Allowable Misalignment
Parallel
OMEGA
HUB
OMEGA
HUB
Angular
COUPUNG
SIZE
2
3
4
5
10
20
30
40
50
60
70
80
100
120
TORQUE
Nm - DRY
140
800
23
40
100
370
NOTE: Capscrews have self-iocking patches

which should not be reused more than twice.
Capscrews can be further used if a thread
loclting adhesive is applied.
Do NOT Lubricate Capscrem Thads
1.6
IJ
2.4
Parallel
3.2
4.8 mm
WARNING
Failure to secure capscrews properly could cause
coupling component(s) to become dislodged during
operation, resulting in personal injury.
Note:
Note:
Any combination of parallel and angular misalignment which

falls under the triangle will not cause a premature fatigue
failure of the flexible element in normal use.
Coupling alignment is directly related to smooth, efficient

equipment operation. Care should be taken for best possible
alignment.
E-3
OMEGA STANDARD COUPLING

With Straight Bore Hubs
Note: l-lub/shoulder design

varies per coupling size.
Consult Rexnord for specific size assembly drawings.
(Hubs Outboard)
(Hubs Inboard)
Specification Data With Straight Bore Hubs
OMEGA
COUPLING
NO.
RECOM.
MAX.
BORE
mm
MIN.
BORE
mm
E2-M
E3-M
E4-IVI
E5-M
E10-M
E20-M
E30-M
E40-M
E50-M
E60-M
E70-M
E80-M
E100-M
E120-M
E140-M
28
34
42
48
55
60
75
85
90
105
120
155
171
190
229
13
13
13
13
13
21
21
26
26
31
31
31
48
48
48
POWERO TORQUE
RATING
RATING
KW
(Nm)
RPM
0.0023
0.0043
0.0066
0.011
0.017
0.027
0.043
0.066
0.090
0.148
0.262
0.467
1.0
2.0
4.0
21.5
41.2
62.0
104.5
163.8
260
412
622
864
1412
2486
4463
9605
19221
38442
A
MAX
RPM
7500
7500
7500
7500
7500
6600
5800
5000
4200
3800
3600
2000
1900
1800
1500
OUTER
DIA. -
DIMENSIONS IN MILLIMETERS
F
C
D
E
SHAFT
MAJ. MIN. TOTAL
WEIGHT
SPACING HUB HUB LENGTH
HUB
Kg.
IN OUT DIA. DIA. IN OUT
LENGTH
89
102
116
137
162
184
210
241
279
318
356
406
533
635
762
24
38
38
44
44
50
58
63
70
82
85
114
140
152
178
36
8
8
8
8
13
12
8
11
8
18
17
44
57
76
46
46
46
59
59
65
69
75
91
97
109
149
95
124
127
47
59
66
80
93
114
138
168
207
222
235
286
359
448
530
38
50
57
70
84
102
118
146
152
165
175
240
267
305
381
84
84
84
97
97
113
125
135
151
173
189
245
324
362
432
94
122
122
147
147
165
182
202
230
262
281
377
375
429
483
0.55
1.1
1.4
2.5
3.7
5.9
9.6
15.9
24.5
32.8
39
77
111
193
339
O Service factor = 1.0.

Dimensions with shaft ends flush with hub face. See bottom of page E-8 for optional spacings.
Weight with max. bore hubs.
Split-In-Half Flex Element

Allows disassembly and replacement without disturbing
hubs or connected equipment.
Reversible Hubs
Accommodates different shaft spacing requirements.
Straight Bore Hubs

Note: Dimensions subject to change. Certified dimensions of ordered material furnished on request.
E.4
ftexnofcf
ifffflll
OMEGA STANDARD COUPLINGS

With Compression Buslied Hubs
Specification Data Witii TAPER-LOCK Hubs
OMEGA
BUSHING
COUPLING
NO.
NO.
E3-iVl
:E4-M
:'E5-M
-E10-M
E20-M
E30-M
E40-M
E50-M
E60-M
E70-M
E80-M
E100-M
E120-M
E140-M
RECOM. POWER
TORQUE
MAX
RATING
RATING
BORE
KW
(Nm)
mm
RPM
1008
1008
1210
1610
1610
2012
2517
2517
3020
3535
4040
25
25
32
42
42
50
60
60
75
90
100
0.0043
0.0066
0.011
0.017
0.027
0.043
0.066
0.090
0.148
0.262
0.467
4545
5050
7060
110
125
178
1.0
2.0
4.0
41.2
62.0
104.5
163.8
260
412
622
864
1412
2486
4463
9605
19221
38442
A
MAX
RPM
D
C
B
OUTER
DIA.
HUB
LENGTH
7500
7500
7500
7500
6600
5800
5000
4200
3800
3600
2000
102
116
137
162
184
210
241
279
318
356
406
22
22
25
25
25
32
45
45
51
89
102
1900
1800
1500
533
635
762
114
127
152
SHAFT
SPACING
43
43
52
52
64
65
60
76
84
60
95
In* Out*
152
38
181
51
76
178
HUB
DIA.
TOTAL
LENGTH
59
66
80
93
114
138
168
207
222
235
286
87
87
102
102
114
129
150
166
186
238
299
In* Out*
267 381
304 435
381 483
359
448
533
WEIGHT
Kg.
1.0
1.3
2.0
2.8
4.2
6.4
10.1
14.6
21.4
31.0
38.0
113.8
185.8
294
O Service Factor = 1.0.

Weight without bushings.
Inboard hub mounting requires bushing installation from coupling ends. Allow space (extra "B" dimension) between coupling ends and equipment for bushing assembly/disassembly. Reverse taper hubs are available; consult Rexnord.
TAPER-LOCK is ttie Trademark of J.H. Fenner & Co. Limited, England.
Split-ln-Half Flex Element

Allows disassembly and replacement without disturbing
hubs or connected equipment.
Reversible Hubs
Bushings can be mounted from either direction.
NOTE: Bushings are "NOT" included with hubs.
TAPER-LOCK" Hubs and Bushings
Rexnofd
Mflffffl
E.5
OMEGA SPACER COUPLING

With Straight Bore Hubs
Note: Hub/shoulder design
varies per coupling size.
Consult Rexnord for specific size assembly drawings.
Specification Data With Straight Bore Hubs
RECOM.
MAX
BORE
mm
MIN.
BORE
mm
POWER
RATING
KW
RPM
ES2-R-M
28
13
0.0023
21.5
7500
89
24
91
100
47
38
146
ES3-R-M
34
13
0.0043
41.2
7500
102
38
85
140
59
50
184 216
1.8
ES4-R-M
42
13
0.0066
62.0
7500
116
38
85
140
66
57
184 216
2.3
ES5-R-M
48
13
0.011
104.5
7500
137
44
89
140
80
70
184 228
3.4
ES10-R-M
55
13
0.017
163.8
7500
162
44
89
140
93
84
184 228
4.7
ES20-M
60
21
0.027
260
4800
184
50
67
180
114
102
238 280
7.1
ES30-M
75
21
0.043
412
4200
210
58
54
180
138
118
238 293
11.4
ES40-M
85
26
0.066
622
3600
241
63
41
180
168
146
238 307
18.2
ES50-M
90
26
0.090
864
3100
279
70
28
180
207
152
238 319
27.3
ES60-M
105
31
0.148
1412
2800
318
82
66
250
222
165
318 415
38.2
ES70-M
120
31
0.262
2486
2600
356
85
59
250
235
175
318 421
46.4
ES80-M
155
31
0.467
4463
1800
406
114
37
250
286
240
318 478
81.8
TORQUE
RATING
(Nm)@
D
E
F
C
TOTAL
SHAFT
MAJ. MIN.
WEIGHT
SPACINGO HUB HUB LENGTH
HUB
Kg.
MIN MAX DIA. DIA. MiN.@ MAX
LENGTH
OMEGA
COUPLING
NO.O
MAX
RPM
OUTER
DIA.
149
O Suffix "R" designates high speed ring design. Rings are furnished as standard for sizes ES2-R to ES10-R, optional on sizes ES20 to ES80.
Service factor = 1.0.
High speed rings are standard with ES2-R to ES10-R, optional on sizes ES20 - ES80.
Spacer couplings furnished with high speed rings can be operated up to maximum allowable speeds for standard series couplings.
O Dimensions with shafts flush with hub face. See page E-8 for optional shaft spacings.
Overall length of element.
Weight with max bore hubs.
Adjustable Spacer Design

Optional hole mounting positions and reversible hub features allow adjustment to
accommodate most shaft s p a c i n g requirements (see Page E-8).
Universal Hubs
Standard and spacer elements use the
same hub design. This means maximum
utilization of off-the-shelf inventory.
Straight Bore Hubs

Note: Dimensions subject to change. Certified dimensions of ordered material furnished on request
E-6
R&monI
M/fflfl
1.0
OMEGA SPACER COUPLINGS

With Compression Bustled Hubs
Specification Data With TAPER-LOCK Hubs
OIVIEGA
COUPLING
NO.O
ES3-R-M
ES4-R-M
ES5-R-M
ES10-R-M
ES20-M
ES30-M
ES40-M
ES50-M
ES60-M
ES70-M
ES80-M
BUSHING
NO.
1008
1008
1210
1610
1610
2012
2517
2517
RECOM.
MAX
BORE
mm
POWER
RATING
KW
RPM
25
25
32
42
42
0.0043
41.2
7500
0.0066
0.011
0.017
0.027
0.043
62.0
104.5
163.8
260
412
622
7500
7500
7500
4800
4200
3600
50
60
3020
3535
60
75
90
4040
100
0.066
0.090
0.148
0.262
0.467
TORQUE
RATING
(Nm)
864
1412
2486
4463
A
MAX
RPM
3100
2800
2600
1800
OUTER
DIA.
102
116
137
162
184
210
241
279
318
356
406
C
D
F
SHAFT
TOTAL
WEIGHT
HUB
SPACINGO
HUB
LENGTH
Kg.
MIN. MAX
DIA.
LENGTH
MIN. MAX
B
22
22
25
25
25
32
45
45
51
89
102
97
97
94
94
123
117
104
104
155
116
104
137
137
133
133
172
165
153
153
223
185
172
59
66
80
93
114
138
168
207
222
235
286
184 184
184 184
184 184
184 184
238 238
238 238
238 244
1.5
2.0
3.4
3.7
5.8
8.8
238 244
318 326
318 364
13.0
18.0
29.7
39.4
318 377
46.4
O Suffix "R" designates high speed ring design. Rings are furnished standard for sizes ES2-R to ES10-R, optional for sizes ES20 to ES80.
Service factor = 1.0.
High speed rings are standard with ES2-R to ES10-R, optional on sizes ES20 - ES80.
Spacer couplings furnished with high speed rings can be operated up to maximum allowable speeds for standard series couplings.
O Dimensions with shafts flush with hub face. See page E-8 for optional shaft spacings.
Weight without bushings.
TAPER-LOCK is the Trademark of J.H. Fenner & Co. Limited, England.
Adjustable Spacer Design

Optional hole mounting positions and reversible hub features allow adjustment to
accommodate most shaft spacing requirements (see Page E-8).
Universal Hubs
Standard and spacer elements use the
same hub design. This means maximum
utilization of off-the-shelf inventory.
NOTE: Bushings are "NOT" included with hubs.
T A P E R - L O C K " Hubs and Bushings
Note: Dimensions subject to change. Certified drawings of ordered material furnished on request.
Hexnofcf
//////ffliff
-7
OMEGA SPACER COUPLING "ADJUSTABILITY"

Shaft Spacing Possibilities
(Using Straight Bored Hubs)
The Omega spacer coupling design provides a clear space between hubs. The element is split longitudinally and there are no
interfering center members or spools. Thus, shaft spacings as small as 6 mm can be achieved by recessing the hubs on the
shaft (see Figure F below). However, for such small spacings, use of the standard Omega coupling would be recommended.
The maximum shaft spacing ("C" dimension) for each coupling is shown on page E6 and E7. However any ANSI, ISO or DIN
spacing between 6 mm and the maximum listed can be achieved without any additional parts. Hubs can be placed on the shafts
as shown below.
Figure B
One hub mounted Inward
One hub mounted outward
Figure A
Both hubs mounted outward
Figure C
Both hubs mounted inward
Use one half of the flex element to establish shaft spacing and appropriate mounting position. Optional hole mounting positions
and reversible hubs allow adjustments as needed. Select the combination which most closely matches the dimensions desired
between shafts (Figure D). Drawings with specific mounting positions/dimensions are available from Rexnord.
Figure D
A Note: Optional capscrew hole mounting

I positions allow easy on-site adjustment to
meet various shaft spacing requirements.
Hubs can be flush with the shaft end (not shown), extended beyond the end of the shaft (Figure E) or recessed behind the
shaft end provided there is sufficient keyway engagement (Figure F). Special sleeve extensions (See Page E-9) are available
for spacing requirements in excess of those listed on pages E-6 & E-7.
mvTx
, V^^ZVT
Note: Shaft engagement should be

equal to or greater than .8 times shaft
diameter for straight bore hubs. 100%
shaft engagement is suggested for
compression bushed hubs.
Figure E
E-8
Figure F
Rsxnord
OMEGA EXTENDED SPACER COUPLING
i/fffffl
Omega extended spacer couplings are designed to connect equipment with shaft spacing requirements beyond the Omega
spacer coupling capabilities. They are ideal for applications with wide non-standard shaft gaps, and can be an economic
alternative to floating shaft couplings (i.e. stock pump applications).
Sleeve extensions ("SE") are furnished in steel. They mount to regular Omega spacer elements (standard elements for sizes
El 00 & El20) and cast iron or steel hubs straight bore or compression bushed design. By adjusting the hub/shaft
engagement (see figures E & F on page E-8) and spacer element mounting position, the Omega extended spacer coupling
can be utilized for many shaft spacing requirements.
C
rm
^.fCT.
j^K^j^yf, F=Ci^5n-l
'Z/^'///.^?^%:^5^^
^-
, \,,x-
ee
V
Single Extension
&
Double Extension
Maximum Spacing O
"C" Dimension - Millimeters
WITH SHRB / SHRB HUBS
SPACER
COUPLING
SIZE
MAX
RPM
STD.
MAX RPM
MATCHED
MACHINED
STD.
SPACING
ES3-R-M
ES4-R-M
ES5-R-M
ES10-R-M
1800
1800
1800
1800
3600
3600
3600
3600
140
140
140
140
ES20-M
ES30-M
ES40-M
ES50-M
ES60-M
ES70-M
ES80-M
1800
1800
1800
1800
1800
1800
1800
3600
3600
3600
3600
3200
3000
2000
E100-M
E120-M
1500
1500
1800
1800
With HTUHTL Hubs
WEIGHT
(Kg.)
ONESE
TWOSE
EXT.
STD.
SPACING
ONESE
EXT.
TWOSE
EXT.
190
190
190
190
240
240
240
240
137
137
133
133
187
187
183
183
237
237
233
233
0.55
0.84
0.68
0.73
180
180
180
180
250
250
250
250
250
250
250
367
386
393
320
320
320
320
484
522
536
172
165
153
153
223
185
172
242
235
223
223
340
321
315
312
305
293
293
457
458
458
1.88
2.05
2.41
3.64
9.45
15.73
21.00
95
124
228
251
361
378
152
181
285
308
418
435
34.55
36.95
ONESE
EXT.
O Maximum spacings shown are with hubs mounted outward and flush with shaft ends. Longer custom length extensions are available; consult Rexnord.
Hub/sleeve extension assembly precisely machined and matched to obtain higher speed rating. Specify "Matched Assembly" and hub type when ordering.
NOTE: For applications operating In excess of 1800 RPM requiring sleeve extension(s), consult factory.
ORDERING INFORMATION: When ordering, be sure to specify whether one or two sleeve extensions are required. If custom length,
specify distance between shaft ends.
Optional sleeve extensions ("SE")
An economical alternative to floating shaft couplings (i.e., stock pump applications).
E-9
OMEGA PILOTED
FLOATING SHAFT COUPLINGS
Super Flexible Polyurethane Elements:
Protects equipment from the damaging effects of misalignment
and shock loads. Elements are split longitudinally for easy
assembly/disassembly.
Specially Designed Capture Feature:
Minimizes chances for catastrophic failures resulting from
fatigue or excessive misalignment.
Optional Center IVIembers:
Steel, stainless steel or composite materials are available
depending on application and environmental requirements.
Rex Omega Piloted floating shaft couplings are utilized to
connect equipment which is relatively far apart. Such
arrangements are particularly suited to transmit torque into
areas where moisture, dust or corrosive conditions would be
detrimental to driving machinery.
Typical applications Include cooling tower drives, steel mill roll
drives and paper machine drives.
The Omega coupling's floating center member may be either
solid or tubular, depending upon the system requirements. The
assembly is piloted at each end by a resilient rubber bushing
No Lubrication:
Pilot bushing and polyurethane element do not require
lubrication.
Corrosion Resistance:
Zinc plated steel, stainless steel, composite material, or acid
and alkali protective coatings are available.
Long Span Capability:
Optional composite tubes allow significantly longer span
capabilities than conventional steel tubes.
assembly which eliminates the need for intermediate support

bearings.
Besides reliability, safety was engineered into the design by
incorporation of the captured center member feature, which
minimizes the possibility of a catastrophic failure due to fatigue
or severe misalignment.
Omega Piloted floating shaft couplings are designed to
alleviate situations where excessive misalignment in cooling
tower applications are trouble-some.
Self aligning: Omega Piloted Floating

Shaft couplings allow up to 1.50
angular misalignment. The Piloted
Rubber Bushings are press fit into the
bushing housing to allow for axial
movement due to possible changes in
thermal or dynamic conditions.
Captured Center iUlember

Feature: Minimizes chances
for catastrophic failure
resulting from fatigue or
excessive misalignment.
o Lubrication:
Rubber bushings and
polyurethane flex
elements do not require
lubrication.
Corrosion Resistant: Stainless

steel element shoes and
capscrews are supplied as
standard equipment with the
FTA&GFTA designs.
Vibration Dampening:
The torslonally soft
polyurethane elements
absorb vibration and
shock loads. This results
in extended life of
connected equipment.
Precision Balanced: All steel,

stainless steel and composite
tubular center members are
dynamically balanced for
smooth operation.
Optional: Backstop rotation device - eliminates windmilling effect. Consult Rexnord.

o
Consult Rexnord for torsional stiffness rate and application requirements.
Equivalent to .023 mm per mm of shaft spacing (L dimension). *Note: Coupling alignment is directly related to equipment and coupling life. Care should be taken
for best possible alignment.
Rexnofd
E-10
mum
OMEGA PILOTED
FLOATING SHAFT COUPLINGS
(COOLING TOWER DRIVE COUPLINGS)
Floating Tubular Assembly

(FTA)
Omega Composite Floating Tubular Assembly

(CFTA)
SPECIFICATION DATA
Omega
Size
No.
PowerO
Rating
KW
RPM
E10-M
E20-M
E30-M
E40-M
0.017
0.027
0.043
0.066
164
260
412
622
1800
1800
1800
1800
E50-M
E60-M
E70-M
E80-M
0.090
0.148
0.262
0.467
864
1412
2486
4463
EIOO-M
E120-M
E140-M
1.000
2.000
4.000
9605
19,221
38,442
"*
Torque
Capacity
(Nm)
Dimensions
(mm)
A
Minimum
Span
(L)
mm
55
60
75
85
162
184
210
241
43
48
54
59
1800
1800
1800
1800
90
105
120
155
279
318
356
406
1500
1200
1200
171
190
229
533
635
762
Max
RPIVI
Max@
Bore
(mm)
Maximum Span (L) in mm

@MaxRPM@
Steel
FTA
Composite
(CFTA)
213
251
267
292
1905
2159
2286
2540
2642
2642
3277
3277
65
78
87
119
337
365
400
527
2540
2718
2870
3124
3277
3988
3988
4623
135
148
178
495
543
3581
3734
***
***
***
***
***
Service Factor - 1.0 (2.0 Service Factor recommended for cooling tower applications).
With straight bore hubs.
Longer spans are possible at slower speeds or with special "EL" (extra long/oversize) tubes. Adjustable length center tube design is also available.
Consult factory.
Also available in two solid shaft arrangements

Consult Rexnord for specifications and application assistance.
FTA and CFTA Material Classification

(hubs and piloted bushing support hardware)
Class D
Type 303-304 Stainless Steel Tube, Nickel

Plated Hubs & Bushing Assemblies with
Stainless Steel Elements & Hardware
Class E
Type 303-304 Stainless Steel Tube, Hubs &

Bushing Assemblies with Stainless Steel
Elements & Hardware.
Class DC
Composite Tube, Nickel Plated Hubs & Bushing

Assemblies with Stainless Steel Elements &
Hardware.
Class EC
Composite Tube, Type 303-304 Stainless Steel

Hubs & Bushing Assemblies with Stainless Steel
Elements & Hardware.
Piloted Shaft Assembly (PSA)
Floating Shaft Assembly (FSA)
Rexnord
//////flffff
E-11
COUPLING SELECTION
SELECTION PROCEDURES
Table 1
1. Calculate KW/RPM
Size
2. Determine service factor from table on page E-13. If not listed,

see load classification table below. Remember to consider both
driver and driven equipment and temperature limitations.
standard
3. Multiply KW/RPM by the service factor to get equivalent

KW/RPM.
4. Select coupling size from Table 1 with a rating equal to or
greater than the equivalent KW/RPM determined in step 3.
5. Be sure that the operating speed of the coupling does not
exceed maximum RPM ratings.
6. Select desired hub type from description on page E-14. Check
maximum allowable coupling bore.
OR
KW
1. Calculate operating torque
RPM
KW/RPM
Spacer
E2
E3
E4
E5
E10
ES2
ES3
ES4
ES5
ES10
0.0023
0.0043
0.0066
0.011
0.017
E20
E30
E40
E50
E60
ES20
ES30
ES40
ES50
ES60
0.027
0.043
0.066
0.090
0.148
E70
E80
El 00
E120
El 40
ES70
ES80
NA
NA
NA
0.262
0.467
1.0
2.0
4.0
(9550)
Table 2
TORQUE CAPACITY
2. Multiply operating torque by service factor obtained from table

on page E-13.
3. Select coupling size from Table 2 with a capacity equal to or
greater than determined in step 2.
4. Follow steps 5 and 6 above.
Size
Torque (Nm)
Size
2
3
4
5
10
20
30
21.5
41.2
62
104.5
163.8
260
412
40
50
60
70
80
100
120
140
Torque (Nm)
622
864
1412
2486
4463
9605
19221
38442
SERVICE FACTORS
SERVICE FACTORS are means of classifying different equipment and applications into various load
classifications. Due to variations in application of equipment, service factors are used to adjust equipment ratings to
accommodate for variable loading conditions. This is a general guide. More specific factors are given on page E-13.
Load Classifications
Continuous service and running loads vary only slightly.
A-^-w.^-
Service
Factors
1.0
Omega Element
Temperature Range
(Ambient)
Torque loading varies during operation of the equipment.
1.5
+200F
-40F
to
/W^
ArV
^Y^
V
-40C
Torque loading varies during operation, frequent stop/start cycles are encountered.
2.0
High Temperature
Service Factor
Adjustment*
For shock loading and substantial torque variations.
For heavy shock loading or light reversing drives.
2.5
Ambient Temp.
S.F. Adjust.
3.0
+150F(66C)
+165='F(74''C)
+180^(82=0
+200F (93C)
+0.25
+0.50
+0.75
+1.00
/IAA/^
m\i
Reversing torque loads do not necessarily mean reversal of rotation.

Depending upon severity of torque reversal, such loads must be classified
between ''medium" and "extreme".
Consult
Rexnord
* In general, the service factor adjustment for high temperature is in addition to the service factor consideration for the driver
and driven equipment. However, if high temperatures are typical for a specific application, maximum temperature
consideration is Incorporated into the "typical" service factor listing on page E-13. I.E. Steel mill runout tables.
E-12
+93C
Rexnoid
fffll
HP
Rexnoid
//////ffffii
COUPLING SELECTION
TYPICAL SERVICE FACTORS* MOTOR AND TURBINE DRIVEN EQUIPMENT

General Applications
Typical
Service Factor
AGITATORS
Vertical and Horizontal Screw Propeller, Paddle
1.5
BLOWERS
Centrifugal
Lobe or Vane
1.0
1.5.
CAR DUMPER AND PULLER
2.0
CLARIFIER OR CLASSIFIER
1.0
COMPRESSORS
Centrifugal
Rotary, Lobe or Vane
Rotary, Screw
Reciprocating
,.
CONVEYORS
Apron, Assembly, Belt. Chain Fligtit, Oven
Reciprocating
Screw
1.0
2.0
1.25
**
1.5
**
1.25
CRANES AND HOISTS

Main Hoist IVledium Duty
Main Hoist Heavy Duty
Skip Hoist
Bridge, Travel or Trolley
2.0
2.5
2.0
2.0
DREDGES
Cable Reel, Conveyor
Cutter Head Drive, Jig Drive
Pump, Screen, Drive, Stacker, Utility Vînch
2.0
3.0
2.0
DYNAMOMETER
1.0
ELEVATORS
Bucket, Freight
2.5
EXCITER, GENERATOR
1.0
EXTRUDER, PLASTIC
2.0
FANS
Centrifugal
Cooling Tower
Forced Draft and Induced Draft
Large Mine
Propeller
1.0
2.0
1.5
2.0
1.5
GENERATORS
Even Load
Hoist or Railway Service
Welder Load
1.0
2.0
2.5
PRINTING PRESS
2.0
PUMPS
Centrifugal
Positive Displacement
Rotary Gear. Lobe, Vane
Reciprocating
Progressive Cavity
Peristaltic
3.0
1.0
2.0
5.0
SEWAGE DISPOSAL EQUIPMENT
1.5
STOKER
1.5
Industry Applications
Ser^ceFactor
AGGREGATE PROCESSING, CEMENT

Concrete Mixers
Crushers, Ore or Stone
Dryer, Rotary
Grizzly
Hammermill
Mining Kilns
Tube, Rod and Ball Mills
Tumbling Mill or Ban-el
2.0
3.0
2.0.
3.0
2.5
2.5
2.5
2.0
BREWERY AND DISTILLING

Bottling and Can Filling Machinery, Brew Kettle, Cooker, Mash Tub.
Scale Hopper (frequent peaks)
1.0
2.0
Typical
Service Factor
FOOD INDUSTRY
Bottle and Can Filling
Cereal Cooker
Dough Mixer, Meat Grinder
1.0
1.0
2.0
LUMBER INDUSTRY
Band Resaw, Circular Resaw
Edger, Head Rig, Hog, Log Haul
Planer
Rolls, Non-Reversing
Rolls, Reversing.
Sawdust Conveyor
Slab Conveyor, Sorting Table
2.0
2.5
2.0
2.0
2.5
1.5
2.0
OIL INDUSTRY
Chiller
1.0
POWER INDUSTRY
Ash Handling Conveyors
Baghouse Air Handling Fans
Ball Mill
Belt Conveyors
- Circulating Pumps (centrifugal)
Coal Grinders and Crushers
Coal Pulverizers and Hammermills
Cooling Tower Fans
FGD Slurry Pumps (centrifugal)
Forced Draft Fan and Induced Draft Fan
Primary Air, Recycling Fans
Traveling Water Screens
1.5
1.5
2.5
1.5
1.0
2.5
2.5
2.0
1.0
1.5
1.5
1.0
-.:
PULP & PAPER MILLS

Agitator
Barking Drum
Beater and Pulper
Bleacher
Calendar
Chipper
Couch, Cylinder Dryer
Felt Stretcher
Fourdrinier
Jordan
Press
Pulp Grinder
Stock Chest
Stock Pump
Centrifugal
Reciprocating
Rotary
Suction Roll
Winder
1.0
1.5
1.5
**
1.25
1.5
SCREENS
Air Washing
Grizzly
Coal and Sand (Rotary)
Vibrating
Industry Applications (cont'd)
The service factors listed are intended only as a general guide and for smooth power
sources such as electric motors and steam turbines. For reciprocating prime movers,
such as diesel or gas engines, add the following to the service factor
For 8 or more cylinders, add 0.5
For 6 cylinders, add 1.0
For 4 cylinders, add 1.5
For less than 4 cylinders, consult Rexnord
If both driver and driven equipment are reciprocating, consult Rexnord.
Add .50 to service factor if drive is a hydraulic motor.
* * Consult Rexnord Engineering
1.5
3.0
2.0
1.0
2.5
3.5
2.0
1.0
2.0
2.5
2.5
2.5
1.5
1.0
2.5
2.0
2.5
2.0
RUBBER INDUSTRY
Banbury Mixer
Calendar
Cracker, Mix Mill, Plasticator Refiner, Sheeter, Tire Building Machine
Tire and Tube Press Opener
Tuber and Strainer
Wanning Mill
Washer
3.0
2.5
2.0
1.0
2.0
2.5
3.0
STEEL INDUSTRY
Goiiers
Draw Benches
Edger Drives
Reel Drives
,
Runout Tables (Non-Reversing)
Runout Tables (Reversing)
Soaking Pit Cover Drives
Tube Conveyor Rolls
Wire Drawing
2.0
2.0
2.0
2.0
3.0
4.5
3.0
2.5
2.0
TEXTILE MILLS
Batcher, Calendar, Card Machine, Dry Can
Dyeing Machinery
Loom
Mangle, Napper, Soaper
Spinner, Tenter Frame
2.0
1.0
2.0
1.5
2.0
IMPORTANT NOTE The coupling selection criteria provided Is intended for the
detennination of the coupling size and style only. It is also recommended that the system
be analyzed for torsional and lateral stability using the specific coupling mass-elastic data
available from Rexnord. This analysis is the responsibility of the user since the coupling is
only a single component in the system.
CAUTION in drive systems sensitive to axial movement {i.e., sleeve bearing
equipment), it may be necessary to limit axial force and/or displacement. Consult Rexnord
for proper installation procedure.
Rexnoid
i/ffffli
E-13
ORDERING INSTRUCTIONS
STANDARD A N D SPACER COUPLINGS
When ordering a complete coupling, specify size/type of element and hubs (two hubs per complete coupling) options include:
Element [E2-M - E140-M] standard (close coupled)
[ES2-R-M - ES80-M] SPACER
Hub
[2MSHRB - 140MSHRB] straight hub-rough bore

[2MSHCB - 140MSHCB] straight hub-custom bore (specify bore & keyway)
[3MHTI
-140MHTL ] hub-TAPER-LOCK" (bushing not included)
OTHER AVAILABLE DESIGNS (Consult Rexnord)

Sleeve Extensions [3SE - 120SE]
[10FTA - 140FTA] specify bore, shaft spacing & material class
Floating Piloted Shaft Couplings [10PSA-140PSA] specify bore, shaft spacing & material class
[1OFSA -140FSA] specify bore, shaft spacing & material class
GENERAL ALIGNMENT INSTRUCTIONS

CALIPER A N D STRAIGHT EDGE METHOD
EQUIPMENT ALIGNMENT
Coupling alignment is directly related to equipment and coupling life.
Although Omega couplings can withstand gross misalignment, care should be taken for best possible alignment to assure
optimum performance. The caliper/straightedge alignment procedure is described below. If greater alignment accuracy is
desired, a dial indicator method is recommended. There are occasions when equipment manufacturers require more specific
alignment tolerances, in which case the manufacturer's recommendations should be followed.
1 .To correct for angular misalignment, use calipers to check the gap between hubs. Adjust or shim equipment until the gap is
the same at all points around the hubs.
2.To correct parallel offset, place a straightedge across the hub flanges in two places at 90 to each other. Adjust or shim
equipment until the straightedge lays flat on both sides.
3. Tighten down connected equipment and recheck alignment.
4. Install elastomer element, tightening all capscrews to the recommended torque values on page E-3.
5. If practical, recheck and tighten capscrews after several hours of operation.
PARALLEL
r~ OFFSET
E-14
Rexnord
//////flllf
TECHNICAL INFORMATION
Physical Parameters
Cplg.
Size
Max
Norn.
Torque
(Nm)
Torque
(Nm)
21.5
53.8
41.2
103.0
62.0
155.0
104.5
261.3
163.8
409.5
260
650
412
1030
622
1555
864
2160
1412
3530
2486
6215
E80
4463
11 158
ES80
E100
E120
E140
9605
19211
38442
24 013
48 028
96 105
E2
ES2-R
E3
ES3-R
E4
ES4-R
E5
ES5-R
E10
ES10-R
E20
ES20
E30
ES30
E40
ES40
E50
ES50
E60
ES60
E70
ES70
Moment
Max
Max
Static** Static**
Max
of Inertia Axial
Radial Angular Torsional Axial
Speed
J
Misalign Misalign Misalign Stiffness Stiffness
(RPM) (Kgm=)
(mm)
(mm) rad deg (Nm/rad) (N/mm)
Max
Static**
Radial
Stiffness
(N/mm)
Static**
Angular
Stiffness
(N/rad)
7500
7500
7500
7500
7500
7500
7500
7500
7500
7500
.000323
.000528
.000733
.001670
.001230
.002670
.003230
.005860
.006450
.009970
4.7
1.6
.070 4
433
105
226
102
4.7
1.6
.070 4
842
114
235
133
4.7
1.6
.070 4
777
123
245
175
6.3
1.6
.070 4
1490
181
264
264
6.3
1.6
.070 4
1750
251
468
654
6600
4800
5800
4200
5000
3600
4200
3100
3800
2800
.016100
.021100
.033700
.044000
.080600
.100000
.158000
.188000
.267000
.343000
6.3
2.4
.052 3
2460
272
482
822
6.3
2.4
.052 3
4855
280
503
971
6.3
2.4
.052 3
7315
314
522
1754
6.3
2.4
.052 3
15 200
409
543
3470
9.5
3.2
.035 2
27 200
446
560
6195
3600
.366000
2600
.470000
2000 1.050000
1800 1.140000
1900 2.200000
1800 2.930000
1500 6.740000
9.5
3.2
.035 2
34 300
527
591
6603
9.5
3.2
.035 2
45 300
883
622
11 000
15
15
4.8
4.8
4.8
.026 1.5 90 600

.026 1.5 194 000
.026j 1.5
1050
1226
700
762
###
###
###
###
15 -
###
1 ###
Static stiffness figures are 20%

### Consult Rexnord
TAPERED BORES
Supplemental Taper Bore Information
Information Required
1. Drawing of HUB showing complete bore and Iceyway details.
OR
2. Drawing of SHAFT with dimensions shown below, allowing
Rexnord to bore hubs to suit.
With connected equipment in fixed position, the following additional

information is necessary:
Dimensions "V" and "X" must be given when one or both connected
machines are fixed on their bases. Advise if dimension "X" is fixed, or
if variable between what limits.
I
I
(LD) Large Diameter, Specify in Decimals.

(S) Length of Taper, Measure parallel to Shaft centerline.
(T) Taper per unit length.
(P) Clearance space for drawing Hub up on tapered shaft.

Keyway: Width, Depth.
Note: Specify if keyway is parallel to Taper or if parallel to shaft
center line.
Specify depth at larger diameter of Taper if keyway is parallel
to shaft center line.
AVAILABLE
LENGTH,
OF SHAFT
A fixed "X" dimension may require altered or special coupling hubs.

Often the straight bored hub can be positioned on its shaft allowing
the use of a standard coupling. See illustrations below.
HUBCOUNTERBORED
SHAFT PROJECTS
[-1
^
^
HUB SHORTENED
I '
Hi
IP
TP'
Ê3E-15
Rexnofd
SPECIALDESIGNS'
i/ffllffl
Stainless
Steel
Omega Stainless S t e e l Element

Corrosion resistant stainless steel shoes
for severe environments i.e: cooling towers.
Stainless steel hubs & capscrews also available.
Omega Mill Couplings

Tapered hub design for mill motor applications,
(i.e., steel mill roll table drives).
Omega Heavy-Duty Element

25% higher torque capacity.
Fits standard hubs.
Available in all sizes.
Omega Positive Drive Coupling

With interlocking drive for short-term emergency use.
Omega Light-Duty Element

Minimized O.D. for tight applications.
Available in size E2LD only.
Omega Torque Limiter Coupling

Adjustable torque limiter hub.
Used with standard Omega components.
*Contact factory for further information.
E-16
83040202-1/99
Installation and operating instructions

Weishaupt oil burners L, RL, M/MS. RM/RMS,
Sizes 5 to 11
weishaupt-
Contents
Conformity certification
We hereby confirm that Weishaupt oil burners conform to
the basic requirements of the following EU guidelines:
- 98/37/EC Machinery Directive
- 89/336/EEC Electromagnetic Compatibility
- 73/23/EEC Low Voltage Directive
Therefore the burner carries the CE Label.
Extensive quality assurance is guaranteed by a certified
Quality Management System to DIN ISO 9 0 0 1 .
Max Weishaupt GmbH
Burner and Heating Systems
D-88475 Schwendi
1. General instructions
2. Burner installation
3. Oil supply
4. Installation instructions for metallic oil hoses
5. Oil preheating system

5.1 Preheaters
5.2 Heated components
10
10
10
6. Oil pumps
12
7. Attaching the fan
14
8. Burner fuel systems
15
9. Regulating systems
9.1 Regulating system-RL5 and RL717
9.2 Regulating system - RL8 to RL11,
RMS7toRMS11
9.3 Oil meters and oil regulators
17
17
10.Nozzle recirculation on MS burners
20
11.Capacity graphs
11.1 Capacity graphs
for burner types L and RL
11.2 Capacity graphs
for burners type M/MS and RM/RMS
23
29
12. Nozzle selection

12.1 Two and three stage burners
12.2 Sliding two stage and modulating burners
33
33
35
13. Adjustment of the combustion head
37
14.lgnition electrode setting
39
15. Air regulation, two and three stage burners

15.1 Description of functions for
servomotor type 1055
15.2 Setting the cam's limit and auxiliary
switches on servomotor type 1055
40
16.0il/air compound regulation, sliding two stage

and modulating burners
16.1 Setting the cam's limit and auxiliary
switches on servomotor type SQM
18
19
23
42
43
44
45
17. Commissioning
17.1 Checks prior to first commissioning
172 Setting
46
46
46
1 S.Sequence of operations
18.1 Prerequisites for burner start
18.2 Symbols on the lockout indicator
18.3 Basic wiring diagram for
LAL 2 / LOK 16... burner controllers
18.4 Switching times
18.5 Technical data
48
48
49
19.Fault conditions and procedures
53
50
52
52
1. General instructions
Safety
To ensure safe burner operation, the burner has to be
installed and commissioned by qualified personnel
and all guidelines in these operating instructions have
to be followed.
In particular, attention must be paid to relevant
installation and safety requirements (e.g. DIN, VDE).
Flame monitoring devices, limit controls, correcting
elements and all other safety devices may only be
commissioned by the manufacturer or their authorised
agent.
Failure to comply can lead to serious injury or death
and can cause considerable damage to the plant.
Qualified personnel
Qualified personnel according to this operating
manual are persons who are familiar with the
installation, mounting, setting and commissioning of
the product and who have the necessary qualifications
such as:-
Persons who are trained to operate electrical

circuits and units to the safety standards given and
are qualified to earth and mark these.
Operating instructions
The operating instructions included with each burner must
be displayed clearly in the boiler room. In conjunction with
this we refer to DIN 4755, Point 5. The address of the
nearest service centre must be entered on the reverse side
of the operating instructions.
Instruction of personnel
Problems are often caused by incorrect burner operation.
The operating staff should be thoroughly instructed with
regard to the operation of the burner. With frequently
occurring burner faults, the nearest service centre must be
notified.
Installation
The installation of oil fired plant must be carried out in
accordance with extensive guidelines and regulations. It is
the duty of the installer to familiarise her/himself with all
regulations. Installation, commissioning and maintenance
must be carried out with care. Fuel oils used must comply
with DIN 51 603.
Electrical wiring diagram
A detailed electrical wiring diagram is included in every
burner delivery.
Maintenance and service
In accordance with DIN 4755, the whole installation
including the burner should be inspected once a year by a
representative of the manufacturer or a competent and
qualified person. The combustion figures should be
checked after every service and each time a fault has been
rectified.
Ambient requirements
The burners material, construction and type of protection is
designed for use indoors. The permissible ambient
temperature is - 1 5 C to +40C.
Electrical installation
When installing the electrical connection cables ensure
that these are long enough to allow the burner and boiler
door to be hinged open.
Control circuits, which are taken from one of the supply
phases, must only be connected with an earthed neutral
conductor.
On an unearthed mains supply, the control voltage must be
supplied via an isolating transformer.
The pole of the transformer that is to be used as a
neutral conductor must be earthed.
The control circuit phase and neutral conductors must
be connected correctly.
Ensure the correct fuse ratings are not exceeded. Earthing
and neutral conductors must conform to local regulations.
2. Burner installation
The drawing is an example of refractory for a heating
appliance without cooled front. The refractory must not
extend beyond the front edge of the combustion head
(dimension IJ. The refractory may, however, take a conical
shape from the combustion head front edge (> 60).
Refractory may not be required on boilers with water
cooled fronts, depending on the boiler manufacturers
instructions.
Mounting the burner on the heat exchanger

Example of installation on a
heating appliance with refractory
Sizes
5-10
The boiler front plate must be prepared in accordance with

the above dimensions. The burner hinged flange can be
used as a template for the drilling. The threads of the bolts
and tappings must be coated with graphite prior to fitting.
Example for burners with head extension see page 13.
The gap between combustion head and refractory must
be filled with flexible insulating material. Do not make
solid.
Burner
size
Combustion Dimensions in mm
d2
head type
di
d3
d4
ds
1^ Combustion head
open
closed
5
5
M5/1a
M5/2a
180
160
MIO
M10
210
210
185
185
220
190
145
130
154
144
7
7
M6/1a
M7/1a
200
220
MIO
MIO
235
235
210
210
240
260
216
226
228
238
8
8
8/2
8/2
8/2
M7/1a
MB/la
M9/1a
U2/1
G7/2a
220
240
240
220
265
MIO
MIO
M12
M12
M12
235
235
298
298
298
210
210
275
275
275
260
280
280
260
300
226
236
226
229
264
238
248
251
239
270
9
10
11
M9/1a
M l 0/2
M11/1
240
265
325
M12
M12
MIO
330
330
400
278
278
340
280
300
365
225
268
362
240
-
Hinged flange
The burner can be hinged to the left or right depending on
the position of the hinge pin and by releasing the locking
nut.
Locking nut
Limit switch
The limit switch is arranged so that the electrical circuit is
closed when the burner is hinged closed. The circuit is
broken by the release of the tripping pin in the limit switch
as the burner is hinged open.
Hinge pin
Tripping pin
* . - '
:rtit.
3. Oil supply
Operational safety depends to a large degree on the oil
supply. Pipe system layout and dimensions can be found in
our technical worksheets.
Termination of the oil supply pipes must allow tension free

connection of the flexible oil hoses. Both oil and electrical
connections must allow the burner to swing open.
Ring main system

The use of a ring main system for oil supply to the burner is
recommended.
Pressure regulating valve in the ring main

Setting for oil EL
Ring main pressure 1 - 1 . 5 bar
Note
The installation dependent ring main pressure increases
the factory pre-set burner pump pressure.
Setting for oil S

To avoid vaporisation of water in the fuel oil, the minimum
ring main pressure, including a safety margin, must be set
according to the following table. It is based on the
pressure which is measured at the burner pump inlet (ring
main pressure).
Single pipe installation on request.

Suction lift operation
Suction lift operation is possible for individual burners
operating on distillate oil EL. For installation and functional
diagrams for ring main and suction lift operation, see
technical worksheets 5
Strainer
A strainer is fitted into the burner oil pipework (flow) to
prevent debris, such as loosened swarf from the welded
joints, from reaching the solenoid valves. The strainer
should be cleaned periodically, particularly during initial
operation.
Air/gas separators
A Weishaupt air/gas separator should be fitted at the point
at which the burner two pipe system is connected. The
air/gas separator should be installed as close to the burner
as possible (see technical worksheets). This is particularly
important on residual fuel oil installations. The air/gas
separator must be installed in the correct direction, as
indicated on the separator.
Filter
A filter must be installed at the end of the oil supply line,
before the pump. It prevents particles in the oil and
impurities from the pipeline from reaching the burner. The
following problems can occur if a filter is not fitted:
Seizing of the pump drive
Blocking of solenoid valves and nozzles
Oil temperature
at the burner C up to
Ring main pressure

bar
125
130
135
2.5
2.7
3.2
140
145
150
3.8
4.4
5.0
Note
Isolating devices in the return flow line must be
protected from unintentional closure (e.g. ball valves
with mechanical connection or burner interlock
switch).
Shut-off combination before the burner
The ball cock is normally only closed during lengthy service
work or shut down periods. They are mechanically
connected and equipped with a limit switch. The limit
switch prevents the burner operating whilst the ball cock is
closed.
Attention!
If the shut-off combination is used as a function test
for the limit switch during burner operation, the hand
lever must only be closed until the limit switch has
responded. The shut-off combination can only be
completely closed once the burner pump has stopped.
Otherwise pressure surges and cavitation can damage
the burner pump.
The fitting of non-return valves on burners fitted with
return flow nozzles is not permitted.
Residual oil installation must have adequate heating of
the pipework.
Oil hose connection according to burner type

Oil hoses
DN
Length nnm
Supply
Return
Connection
thread
punnpside
Connection
thread
installation side
L5Z
L5T
L7Z
L8Z
L8Z/2
L9Z
13
13
13
13
13
13
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
R 11T
R1/2"
R 11T
R 11T
R1/2"
R1/2"
R1/2"
R1/2"
R1/2"
R1/2"
R1/2"
R1/2"
L7T
L8T
L8T/2
L9T
L10T
13
13
13
13
13
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
R 11T
R1/2"
R1/2"
R1/2"
M 30x1.5
R1/2"
R1/2"
R1/2"
R1/2"
R1/2"
RL5
RL7
RL8
RL8/2
RL9
RL10
RL11
13
20
20
20
20
20
25
1000
1000
1000
1000
1000
1000
1300
1000
1000
1000
1000
1000
1000
1300
R1/2"
M 30x1.5
M 30x1.5
M 30x1.5
M 30x1.5
M 30x1.5
M 38x1.5
R 11T
R1"
R1
R1
R1
R1
R1
M5Z
MS7Z
IVIS8Z
MS8Z/2
MS9Z
13
20
20
20
20
1000
1300
1300
1300
1300
700
1000
1000
1000
1000
R
M
M
M
M
11T
30x1.5
30x1.5
30x1.5
30x1.5
R1/2"
R1"
R1"
R1"
R1"
RIVIS7
RMS8
RMS8/2
RMS9
RIVISIO
RMS11
20
20
20
20
20
25
1300
1300
1300
1300
1300
1500
1000
1000
1000
1000
1000
1300
M
M
M
M
M
M
30x1.5
30x1.5
30x1.5
30x1.5
30x1.5
30x1.5
R1"
R1"
R1"
R1"
R1"
R1"
4. Installation instructions for metallic oil hoses (residual oil S)

General
The oil and pressure hoses used are of corrugated high
grade steel with a high grade woven wire sleeve cover.
Example
The oil hoses and pressure hoses are well suited for
residual oil operation if the following application rules are
observed. Resistance against the chemical effects and
temperature of the fuel oil is designed for long term
service.
The new TRD 4 1 1 , DIN 4787 and DIN 4755 standards
specify metallic hoses for residual oil installations.
Oil and pressure hoses must be protected from external
mechanical damage. When installing care must be taken
that the hose is not twisted. It must not receive torsion
strain either during installation or during later movement. It
is important that the two hose ends and the movement
lie at one level.
Use second spanner for counter holding
In order to guarantee torsion free installation, the hose

should first be only loosely fixed at one end, then moved
through the required hose movement 2 to 3 times so that
the hose can align without distortion, and only then be
tightened in position.
It is important to use a second spanner to counter hold
when tightening.
Care should be taken that the hoses do not come into
contact with each other or other equipment (burner, oil
lines or boiler) during operation.
Connect hose without twisting
Adequate curve radii and minimum hose lengths must be

adhered to during installation. In addition the hose must in
most cases be supported when installed horizontally.
i=^
The hose connection can be installed for either burner

hinge direction as required.
ft
Specifications and technical data
For oil EL, oil hoses to DIN EN ISO 6806 are supplied.
Oil hoses in oil supply installations (flow and return)
Technical data:
On installations using residual oil S the hoses must be

suitable for an operation pressure of 10 bar and an
operating temperature (medium) of 160''C.
Nominal pressure
Test pressure
When allowing for the temperature factor for high grade

steel the following applies for these hoses:
Pressure hoses (between pump and nozzle)
Nominal pressure.
Test pressure
Operating pressure
_PN = 16 bar
_PP = 21 bar
_PT = 10 bar
_TT = 1 6 0 C
When installing the oil hoses In the flow and return

(between pump and rigid pipe installation) the product
related technical drawings should be observed.
PN = 10 bar
_PP=15bar
T T = 70 C
For this application the pressure hose should be suitable

for an operating pressure of 30 bar and an operating
temperature of 160C.
When allowing for the temperature factor the following
applies:
Nominal pressure
Test pressure.
Operating pressure
PN = 64 bar
_PP = 82bar
_PT = 30 bar
TT=160C
The minimum curve radius of the hose depends on the

nominal clearance on the application, the material and the
type of manufacture.
The hose application on our products has been agreed
with the manufacturer, using original parts.
For free usage and installation, the following minimum radii
must be adhered to as given in the installation instructions.
Minimum radii
DN
r = Minimum
curve radius in mm
6
8
10
70
100
110
12
16
20
25
110
210
240
250
Hoses should be selected of sufficient length. An

additional length must be allowed for on the hose ends.
This length must remain straight, i.e. the curve radius must
not commence until after this straight section.
Additional length
DN
When installation has been carried out the minimum radii

must be checked in the most adverse position. If
necessary a fixed stop must be fitted on site to limit the
movement.
Z = Additional length in mm
6
8
10
80
85
90
12
16
20
25
100
125
130
135
5. Oil preheating system

5.1 Preheaters
The oil can be heated electrically or with a heating medium,
or by a combination of both electrical and media preheater.
Hot water, low pressure steam, high pressure steam or
thermal fluid can be used as heating media.
The ball valve fitted between the media and electrical

preheater (see technical description of electrical and
media preheaters) is closed when the heating medium is
available. The valve must only be open during start up on a
cold plant and remain open until the final working
temperature or pressure of the installation is reached.
During this period only the electric preheater heats the oil
and the throughput of the burner must be adapted to the
preheat capacity of the electrical preheater during the
starting time of the cold plant.
On installations with a media preheater and without

electrical preheater, the following minimum pressures and
temperatures are required for heating the residual oil S:
High pressure steam over 7.5 bar
Hot water from 180 - 200 C
Thermal fluid from 200 - 300 C
On downward firing burners, media preheaters are rotated

through 90C. The oil preheaters MV9 and MV10 can only
be fitted with the media outlet on top for liquid media or
below when using steam. If the burner is ordered for
downward firing, this is already allowed for. If the burner to
be changed to downward firing at a later stage, then extra
brackets are required to fix the media preheater.
These temperatures and pressures must always be

available so that the oil can be heated to the temperature
and viscosity required for atomisation.
5.2 Heated components

All burners have nozzle head heating controlled by an NTC
sensor. The ROB regulating control can be set to 65 or
130C and is pre-set to 65C for delivery. The heating
elements in the burner are usually controlled by the burner
operating switch.
heating elements in the pump body as standard. Heating

allows the oil to be kept in a pumpable condition and the
pump to be protected from damage. The heating
cartridges in the nozzle head and pump are active as long
as the burner operating switch is on.
Pump heating
When oil viscosities of 152 mmVs at 50C are exceeded,
we recommend heating the pump. Pumps are always fitted
with heating facilities. On type E pumps the gearing cover
has a pocket for the heating element, and if required, the
element can thus be fitted. TA pumps are fitted with
Burner heating elements
Heat rating in W
Burner
Burner
type
pump type
Heating
Nozzle
head
Solenoid valve
flow/return
Valve
block
Oil
regulator
Pressure
regulator
M5Z
MS7Z
MS8Z
MS8Z/2
MS9Z
E4
E6
E7
E7/TA2
E7/TA2
80
80
80
80/100
80/100
100
100
100
100
100
20
20
20
20
20
20
20
20
20
20
20
20
20
20
RMS7
RMS8
RMS9
RMS10
RMS11
TA2
TA3
TA3
TA3
TA4
100
100
100
100
100
100
100
100
100
100
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
10
Nozzle head heating M5Z to MS9Z
Nozzle head heating RMS7 to RMS11
i-;,,- I
NTC sensor
iw*
NTC sensor
Heating cartridge
Heating cartridge
Valve block heating RMS7 to RMS11
Valve block heating M5Z to MS9Z
Heating
cartridge
tm,.
ult
- .
Km
il-l
I Heating cartridge
Pump heating M5Z to MS9Z
Pump heating RMS7 to RMS11
-*SIH
Heating
cartridge
^^:
Heating
cartridge
Solenoid valve flow and return M5Z to MS9Z, RMS7 to

RMS 11
Oil regulator RMS7 to RMS11
\
Heating cartridge
Heating cartridge
11
6. Oil pumps
The pumps are supplied suitable for connection in a two
pipe oil system.
Pumps are supplied with pressure regulating and shut off
valves. The pressure regulating valves keep the pressure
constant.
Adjustment
The oil line on the suction side must be primed and the
pump vented prior to commissioning, otherwise the
pump will be damaged due to running dry.
Insert gauge to check the vacuum or supply or ring

main pressure on the suction side of the pump.
A pressure gauge must be connected into tapping (5)

to measure the pump pressure.
To adjust the oil pressure, remove cap nut (4) and set
the required pressure.
Clockwise rotation
= pressure increase
Anticlockwise rotation = pressure decrease
. 2.0 bar
5.0 bar
Maximum oil supply temperature

on pumps type E and TA
90C
Filter for J and E pumps

A filter is incorporated in the pump to protect the pump
gears.
There are two different types of filters. The filter for E
pumps has a large mesh.
12
After replacing the filter erasure that the pump cover is

tightly sealed.
Single pipe operation
In some instances when operating with oil EL, J and TA
pumps can be used with one pipe systems.
The following should be noted:
As there is no suction lift by the pump in a single pipe
system, the oil supply must have a guaranteed positive
head at the pump inlet.
The bypass plug in the pump should be removed and the
pump return connection plugged.
The supply line should always be vented when
commissioning.
The suction resistance should not exceed 0.4 bar.

Max. supply pressure on pump type J
on pumps types E and TA
(measured at the pump).
The pump filter will require cleaning from time to time,

depending on the degree of fouling. With a high degree of
fouling, the vacuum on the suction side increases. To
remove the filter for cleaning, extract the eight screws (1 2)
on the pump cover.
As it is not possible to vent via the pump return on single

pipe installations, the supply line must in this instance be
fully vented when commissioning.
Pump coupling
A flexible coupling is fitted between fan rotor and pump.
When adjusting the intermediate coupling ensure that
there is no axial tension on the pump drive shaft.
The coupling element on the pump should have an axial
movement of 1.5 mm.
Pump coupling
Pump J6 + J7
10
.sP
Pump E4, E6, E7
11
t
Pump TA2, TA3, TA4
2a 3
Legend
1 Suction connection
2 Return connection
2a Spill back connection
3 Nozzle supply line
4 Pressure adjusting screw
5 Pressure gauge connection
6 Vacuum gauge connection
12
5 2a 3
7 Locking screw
8 Intermediate coupling piece
9 Axial movement 1.5 mm
10 Socket head screw
11 Pump coupling
1 2 Cover screw
13
7. Attaching the fan

Attaching the fan
Rennoving the fan
Burner size 5
The fan fits onto a cylindrical shaft. A key on the shaft
transmits the power. The fan is secured to the motor shaft
by an M6 x 25 screw with washer.
Burners sizes 5 and 7 - 8

The extractor part No. 111 111 0001/2 can be applied to
the two MB threaded holes and the fan removed.
Burner sizes 7-8 and 9-11

On burners size 7 to 8 the fan fits onto the cylindrical shaft.
A key on the shaft transmits the power. The fan is secured
to the motor shaft by an MB countersunk screw and
washer.
Burners sizes 9 - 1 1
To remove the fan, the extractor part No. 121 362 0 0 1 3 / 2
is applied to the two M l 0 threaded screws.
On burners size 9 to 11 the fan fits onto a cone shaft. The

self locking cone transmits the power to the motor fan. The
coupling piece is connected to the fan cylindrical pins. For
security, the coupling piece is connected to the motor
shaft by an M l 0 X 40 screw with left hand thread.
Burner size 5
14
Burner sizes 7 - 8
Burner sizes 9 - 1 1
8. Burner fuel systems

L5Z
L7ZtoL9Z
<
<
I.
t I
<
<
t*
L7TtoL10T
L5T
<
<
<
<
<
<
11
t i
RL5 to RL7
RL8toRL11
10
115V
13
12
115V
<
115V
115V
17
15
Burner types RL5 to RL7

The two solenoid valves (3) are electrically connected in
series. Solenoid valves (3) and (5) are fitted in the return
line against the flow direction.
Burner types RL8 to RL11

Solenoid valve (6) in the supply and (7) in the return are
electrically connected in series. Solenoid valve (7) is
fitted in the return line against the flow direction.
15
M5Z
MS7Z to MS9Z
16
11
115V
115V
{H-
11
<
<
t>><i-
-ce-
<
<
n
I\^
t i
' E ^
t I
17
RMS7 to RMS11
14
Z,
16
18
13
17
Burner types M5Z, MS7Z to MS9Z, RMS 7 to

RMS11
Solenoid valve (5) / (6) in the supply and (5) / (7) in the
return are electrically connected in series. Solenoid
valve (5) / (7) is fitted in the return line against the flow
direction.
12
115V
KJ
t!!i"'!'!!t
<
-0^
115V
17
15
1 Pump without integral solenoid valve

2 Solenoid valve type 121C2323 9 W coil
(normally closed) Rp 1/8*
3 Solenoid valve type 121K2421
19 W coil
4 Solenoid valve type 122K9321
19 W coil
(normally open) Rp 1/8*
5 Solenoid valve type 121K6220 20 W coil
6 Solenoid valve type 321H2322 20 W coil
7 Solenoid valve type 121G2320 20 W coil
(normally closed) Rp3/8*
8 Two stage EL nozzle head
(without integral shut off device)
9 Three stage EL nozzle head
(without integral shut off device)
10 Nozzle head R (without integral shut off device)
11 Two stage nozzle head M (with integral shut off device)
1 2 Nozzle head R (with integral shut off device) in flow and
return
13 Restricting orifice
14 Filter
15 Oil regulator
16 Oil preheater
17 Pressure switch 0 10 bar
(set to 5 bar for EL
Return
set to 7 bar for MS)
18 Thermostat
16
Rp = Whitworth pipe thread (internal) DIN 2999
The given voltages refer to 230 V. For 1 1 5 V control

voltage, 115V and 55 V devices are used.
9. Regulating systems
9.1 Regulating system - RL5 and RL7
The oil system is not fitted with a nozzle shut off valve.
The solenoid valves control the oil shut off function.
Operation
During prepurge solenoid valves (3) and (5) are closed. Oil
is supplied under pressure by the pump to the closed
solenoid valve in the supply (5). Solenoid valves (3) and (5)
are electrically connected in series.
Operational diagram 1
After the prepurge period has elapsed, solenoid valves (3)
and (5) open. Oil flows to the nozzle via the nozzle supply
and to the oil regulator (15) via the return. The oil regulator
is in the open position (ignition load position). Due to the
lower return flow pressure, less oil leaves the nozzle. The
greater proportion of oil flows via the nozzle return to the oil
regulator or the pump return line. The return flow pressure
is approx. 8 bar at partial load position. The integral oil
pressure switch (17) shuts down the plant if the pressure
is too high.
Full load is obtained by reducing the metering slot in the oil
regulator. This is done rotation of the oil regulator
(clockwise as viewed from the shaft). This throttles the flow
of oil in the return and the oil quantity increases at the
nozzle outlet. On shutdown the solenoid valves close and
shut off the flow of oil to the nozzle and from the oil supply.
For legend and notes on the wiring and installation
direction of the solenoid valves see Chapter 8
RL5 and RL7 nozzle head

Nozzle flow
Regulating nozzle
Nozzle return
+ 4
17
9.2 Regulating systenn - RLS to RL11, RMS7 to RMS11

Operation
During burner shutdown and the prepurge period, the shut
off devices (6), (3) and (7) are closed and shut off device
(4) is open.
Attention!
The shut off devices (solenoid valves (6) and (7)) are
electrically connected in series. The voltage of the
solenoid coils is therefore 115V with 230 V mains voltage
The ring main pressure during burner shutdown or the

pump pressure during prepurge is present at shut off
devices (6) or (7).
On the shut off device (solenoid valve) (7), the directional

arrow > on the solenoid valve must point towards the
nozzle. This means that the solenoid valve in the nozzle
return is fitted against the flow direction -4 during burner
operation.
After the prepurge period has elapsed on RL burners (the
servomotor is in ignition position), the shut off devices (6),
(3) and (7) open and shut off device (4) closes. The fuel is
then released for combustion.
The shut off device in the nozzle head (nozzle shut off
valve) acts as a safety shut off device in the flow and the
return.
On RMS burners, shut off devices (6) and (7) only open for
oil circulation. After the oil circulation period has elapsed
(max. 45 s), shut off device (3) opens and shut off device 4
closes and releases the fuel oil for combustion.
The integral pressure switch (17) checks the pressure in
the return. If the pressure increase is too high, the burner
shuts down. In shutting down, Shut off devices (6), (3) and
(7) close and shut off device (4) opens simultaneously.
Together with the safety shut off devices (6) and (7) and
the safety shut off device in the nozzle head, the
requirement for two shut off devices in both the supply and
return is fulfilled.
For legend and notes on the wiring and installation
direction of the solenoid valves see chapter 8.
RL and RMS burner nozzle head

Supply control circuit
Ci
Return control circuit

Operational diagram 1 (RL)
+ I
18
Re1urn
"^"1 1 :
Regulator nozzle type W
Operational diagram 2 (RL)
i I
9.3 Oil meters and oil regulators

Installation of oil meter
When meters are fitted in the supply and return, the system
must be protected from excess pressure by a pressure
relief valve installed in the return (see pipeline diagrams in
our work sheets).
Setting example: key on number 00

Primary setting
shaft identification No.
oil regulating cam
A blocked return meter can cause the following:

-
Bursting of oil hoses

Pump damage (glands on pump leaking).
Changes to the oil flow without changes in combustion
air can occur during burner operation if the meter is
blocked. The return pressure which results renders the
oil regulator ineffective. Renewed burner start may lead
to an explosion.
Isolating elements in the return should be protected from

unintended closing (e.g. ball valves by mechanical
connection). Non-return valves must not be installed. With
residual oils all pipework and fittings must be adequately
heated.
Oil regulator - RL5 to RL11; RMS7 to RMS11
The oil regulator is driven by the servomotor. The variable
oil throughput is controlled by a V-slot grove.
Each regulator has two regulating groves, which can be
changed. Each regulator has two identification numbers
marked on the shaft, e.g. 00-0 (see illustration).
The slot depths are assigned by both identification
numbers. The following illustration shows the assignment
to the oil throughput.
Oil regulator
identification number
Selected shaft identification No. visible from above
Cam identification
e.g. cam 6
Primary setting
regulating cam 1
Use
oil throughput kg/h
00
0
0
51
50
70
1
2
71
121
120
280
3
4
5
281 -380
381 -420
421 - 700
Shaft key
'. >
In order to regulate the oil quantity via the correct

metering slot, the key has to be set to the appropriate
identification number.
If radiated heat affects the nozzle head, the oil regulator
can be limited in its regulating movement (e.g. to position
100, see servomotor). This results in a greater oil spill back
which cools the sealing ring and pressure spring in the
nozzle head.
Full load setting
19
10. Nozzle recirculation on MS burners

Nozzle recirculation on two stage MS burners
After the minimum temperature has been reached by the
thermal switch contact in the ROB regulating control and
oil preheater, burner start is released. The two switches are
switched in series. The oil pump circulates the oil via filter
and solenoid valve to the oil preheater, the oil is heated and
the viscosity reduced.
The heated oil forces the oil in the supply system through
the burner supply, nozzle head, the normally open solenoid
valve 1 to the pump return. Hot oil is now present
throughout the whole system. The shut off device in the
nozzle head remains closed and oil cannot flow through
the nozzle.
Various burner components are also heated by a heating
cartridge (see chapter 5.1).
After termination of the pre-purge period, the solenoid
valve (3) in the nozzle return is energised and closes. The
oil pressure increases in the nozzle shut off valve and at a
pressure of approx. 1 2 bar the nozzle shut off valve opens
to commence stage 1 operation.
After a delay the solenoid valve (2) for stage 2 is opened
by the burner control. Oil pressure is applied to the nozzle
shut off valve which opens stage 2. Nozzle dribble is
largely prevented by the secure closure of both nozzles.
When the burner shuts down solenoid valve (3) is deenergised and opens. The atomising pressure reduces
immediately and the nozzle shut off valves close.
Nozzle head maintenance and cleaning
Both nozzles can be replaced without affecting the
function of the hydraulic nozzle shut off valves.
If the nozzle shut off valves 1 or 2 are removed, the
isolating device in the oil supply and return must first be
closed.
Nozzle head heating on RMS7 to RMS 11 burners
As with two stage burners, regulating burners for residual
oils are also fitted with temperature controlled nozzle head
heating. This enables the nozzle head to be kept at a
constant temperature. The heating cartridge, whose
thermal output is controlled by the ROB regulating control,
has a 100 W capacity. The ROB control can be set to a
temperature of 65C or 130C. The factory pre-set is
65C.
An NTO sensor is fitted on the heating cartridge support to
measure the temperature.
The temperature release switch in the regulating control is
connected in series with the oil preheater release
thermostat and only allows burner start after the selected
nozzle head temperature and minimum oil preheater
temperature has been reached.
Nozzle head heating

Heating takes place directly in the nozzle head which is
insulated. A heating cartridge with a 100 W capacity is
fitted in the nozzle body. The nozzle temperature is
controlled by an electronic P type controller. The sensor is
fitted adjacent to the oil line inlet. The ROB control can be
set to a temperature of 6 5 0 or 130C according to the fuel
quality (Factory pre-set 650).
Dse 2
Pump without integral solenoid valve
Solenoid valve type 121K2421
19 W coil
(normally closed) Rp 1/8
19 W coil
(normally open) Rp 1/8
20 W coil
Solenoid valve type 321H2322
20 W coil
Solenoid valve type 121G2320 20 W coil
7 Nozzle head as shut off device
8 Filter
9 Oil preheater
10 Pressure switch 0 10 bar
(set to 5 bar for EL, set to 7 bar for MS)
11 Thermostat
Solenoid valves (4) / (6) in
1 2 Heat insulation
the return are fitted
13 Heating cartridge
against the direction of
14 Nozzle shut off valve
flow.
20
Cold start with 2 purge times

Pre-purge
120
100
80
O
*->
60
E
o
>
0)
Second purge
40
First purge
Post heating time
Safety valve open -Safety valve closed
20
Safety valve open
Burner start
>
Time [ s ]
35
40
Start up time approx. 175 s.
Start in warm
conditions
with oil line temperature
in supply
>
60C
120
100
Vo
E
o
<u
CO
80
60
40
20
Time [ s ]
21
Additional start circuit with two purge times for RMS7

to RIVIS11 burners, DIN 4787
Operation
After prepurge has taken place and the ignition position
has been reached, the safety valves are opened for 35 s to
enable the burner fuel system components to be heated.
The safety solenoid valves are then closed for approx. 40
s. In the meantime the oil preheater will regain heat and
can give the maximum temperature after the 40 s have
elapsed.
After this period the safety solenoid valves are re-opened
and at the same time a return signal is given to the burner
control to continue the start up sequence. An interval,
determined by the burner controller, of about 6 s produces
a second purge time up to the oil release where the
temperature peak of the oil preheater is utilised for the
moment of ignition.
So that the cold start process does not take place when
starting from warm conditions or after a short shut down
period, a thermostat fitted in the burner fuel line system
between oil preheater outlet and distribution piece
determines whether it is a cold start or a warm start with
short purge period. The thermostat switching point is
approx. 55 - 60C. If the oil line temperature is more than
this figure before the boiler regulator switches on, then
only the short purge time of 6 s is used for the subsequent
burner start. This monitoring assures that there will be no
unnecessary delays during the start process.
Nozzle heads are tested safety devices and according

to DIN 4787 nnust not be interfered with.
22
iii.:-
sm: X
= , - i ..*.*.
>{
/;,...*..
.
: ,* .
" :
::i^
: : ; ? . . .
' '
'
M4vt * : ^ "*"
' .
. ^ t *> fc'irl"**'" *
V.
'
"
r^
T!
. / ' . . :
K
', *. V*
'
; *
* ***.*
>. , .^
-' ihi'.:...:
-..rrr--
>
The circuit is designed in such as way that there is a ballast

effect as far as the switching condition of the thermostat is
concerned. This means that once start up has begun, any
thermostat response will not produce an alteration in the
sequence of operations, so that either a cold or a warm
start always clearly takes place.
If the oil temperature stipulates a warm start, the start up
time of the burner is shortened by 45 s, the time usually
used as the delay period.
The circulation return is always fitted into the pump return.
11. Capacity graphs

11.1 Burner types L and RL
Fig. II
Fig. I
Fig. Ill
,^
Fig. IV
"^ t
-m
'
^ 1
-J '^
0-10
0-10
0-10
0-10
Important infornnation relating to capacity charts

The capacity charts show the oil throughput relative to the
combustion chamber pressure. They are maximum values
measured on idealised test flame tubes to DIN 4787.
All ratings data given relate to an air temperature of
20C and an installation elevation of 500 m.
Sizes
Dimensions mm
No.
Combustion head
(1) + (2)
M5/2a-1 2 5 x 4 0
M5/1a-1 2 5 x 4 0
M5/1a-145x40
Fig.
II
II
II
50
65
65
160
180
180
(2)
(1)
mbar
Burner types
Comb, head
Rating kg/h
kW
L5Z, L5T
M5/2a-125x40
15-68
180-810
mbar
M5/1 a - 1 4 5 x 4 0
18-77
215-915
M5/1 a - 1 2 5 x 4 0
2 6 - 100
310 1 1 9 0
Burner types
Comb, head
Rating kg/h
kW
kW
-2 -]
0
M5/1a-145x40
16-79
190-940
M5/1 a - 1 2 5 x 4 0
2 5 - 100
300 1 1 9 0
zz
VI
/y
/ /
/
RL5
M 5 / 2 a - 1 25x40
15-70
180-835
/
/ /
/
-2
1000
1200
1000
1200
23
Size 7
Dimensions mm
No.
Combustion head Fig.
No.
Combustion head
Fig.
(1)
M6/1a-155x50
M7/1a-155x50
11
11
90
90
200
20
(4)
M6/1a-155x50
M7/1a-155x50
90
90
200
200
(2)
M6/1a-165x50
M7/1a-165x50
11
11
90
100
200
220
(5)
M6/1a-165x50
M7/1a-165x50
90
100
200
220
(3)
M6/1a-175x50
M7/1a-175x50
11
11
90
100
200
220
(6)
M6/1a-175x50
M7/1a-175x50
90
100
200
220
(4)
(1)
mbar
Burner types
Comb, head
Rating kg/h
kW
L7Z,L7T
M6/1 a - 1 5 5 x 5 0
41-150
490-1785
mbar
Burner t y p e s
Comb, head
Rating kg/h
kW
M7/1a-155x50
55-165
655-1965
RL7
M6/1a-155x50
42-155
500-1845
M7/1a-155x5C
55-165
655-1965
/
i
/
/
^
-2
kW
-2
200
kg/h
600
800
1000
1200
1400
1600
600
1800
2000
kW
200
400
1000
1200
1400
1600
1800
1800
(2)
mbar
L7Z, L7T
M6/1a-165x50
34-120
405-1430
Burner types
Comb, head
Rating kg/h
kW
(5)
bar
Burner types
Comb, head
Rating kg/h
kW
M7/1a-165x50
52-165
620-1965
N,
J
/
/
/
/
RL7
M6/1a-165x50
39-129
405-1535
y!
M7/1a-165x50
48-165
570-1965
'
/
-
-2 -
-2
600
800
1000
1200
1400
1600
1800
2000
kW
200
400
1000
1200
1400
1600
1800
(3)
mbar
2000
L7Z, L7T
M6/1a-175x50
27-105
320-1250
Burner types
Comb, head
Rating kg/h
kW
2000
(6)
mbar
M7/1a-175x5C
50-160
595-1905
Burner types
Comb, head
Rating kg/h
kW
RL7
M6/1a-175x50
27-110
320-1310
M7/1a-175x5C
48-165
570-1965
14
^/
y /
V
^
-2
-2
600
24
800
1000
1200
1400
1600
1800
2000
kW
200
400
1000
1200
1400
1600
1800
2000
Sizes
Dimensions mm
No.
Combustion head Fig.
No.
Combustion head 1-ig-
(1)
M7/1a-155x50
M8/1a-155x50
11
11
100
110
220
240
(4)
M7/1a-155x50
MB/la-l 5 5 x 5 0
11
11
100
110
220
240
(2)
M7/1a-165x50
M8/1a-165x50
11
1i
100
110
220
240
(5)
M7/1a-165x50
iVIS/la-l 6 5 x 5 0
11
11
100
110
220
240
(3)
M7/1a-175x50
M8/1a-175x50
11
11
100
110
220
240
(6)
M7/1a-175x50
M8/1a-175x50
11
11
100
110
220
240
(4)
(1)
mbar
Burner types
Comb, head
Rating kg/h
kW
L8Z, L8T
M7/1 a - 1 55x50 M8/1a-155x50
57 -195
70 - 230
680 - 2320
835 - 2740
mbar
Burner types
Comb, head
Rating kg/h
kW
RL8
M7/1a-155x50
51-210
605 - 2500
10
M8/1a-155x50
65-230
775-2740
>
^5^
-2
-2
(2)
mbar
Burner types
Comb, head
Rating kg/h
kW
L8Z, L8T
M7/1 a 165x50
53-181
630-2155
(5)
mbar
M8/1a-165x50
65 - 220
775-2620
10
10
yy
Burner types
Comb, head
Rating kg/h
kW
RL8
M7/1a-165x50
50-190
595 - 2265
M8/1a-165x50
63-225
750-2680
J 1
-2
-2
(3)
mbar
Burner types
Comb, head
Rating kg/h
kW
10
8
6
/
/
LBZ, LBT
M7/1 a -175x50
50 -166
595 -1975
V
(6)
mbar
M8/1a-175x50
60-197
715-2345
Burner types
Comb, head
Rating kg/h
kW
RLS
M7/1 a-175x50
50-169
595-2015
M8/1a-175x50
57-210
680-2500
\,
10
8
6
2
0
-2
-1
25
Sizes 8/2
Dimensions mm
No.
Combustion head
Fig.
No.
Combustion head
Fig.
(1+5)
M9/1a-165x50
IVIQ/la-l 8 5 x 5 0
Ill
III
90
90
240
240
(4)
U2/1-165x50
G7/2a-165x50
85
120
220
265
85
220
(6)
U2/1-155x50
G7/2a-165x50
85
120
220
265
U2/1-165x50
G7/2a-175x50
85
120
220
265
U2/1-145x40
(2)
U2/1-155x50
G7/2a-175x50
(3)
II
85
120
220
265
(7)
(4)
(1)
mbar
Burner types
Comb, head
Rating kg/h
kW
L8Z/2, L8T/2
M9/1a-165x50
64 - 240
760-2860
mbar
M9/1a-185x50
52 - 203
620-2420
L8Z/2, L8T/2
U2/1 -165x50
52 - 200
620-2380
Burner types
Comb, head
Rating kg/h
kW
G7/2a-165x50
90-265
1070-3155
in
S,
^-
f^
s.
sV
\
\
-2 KW 500
\,
\
^V
V
N,
S
S,S,
-2
(2)
mbar
Burner types
Comb, head
Rating kg/h
kW
L8Z/2, L8T/2
U2/1 -145x40
60-217
715-2585
(6)
mbar
Burner types
Comb, head
Rating kg/h
kW
RL8/2
U2/1 -155x50
52 - 230
620-2740
G7/2a-165x50
90-277
1070-3300
10
S,
s.\
\ ,1
-2 -
-2
(3)
mbar
Burner types
Comb, head
Rating kg/h
kW
L8Z/2, L8T/2
U2/1 -155x50
57 - 220
680-2620
(7)
mbar
G7/2a-175x50
80-258
955-3075
Burner types
Comb, head
Rating kg/h
kW
RL8/2
U2/1 -165x50
48-205
570-2440
G7/2a-175x50
80-266
955-3170
in
\
\,
>*
\
S,
\,
SS
-2
26
-2 -
_l
(5)
mbar
Burner types
Comb, head
Rating kg/h
kW
RL8/2
M9/1a-165x50
58-248
690-2955
M9/1a-185x50
52-218
620-2595
-2 -
Size 9
Dimensions mm
No.
Combustion head
(1-3)
M9/1a-165x50
M9/1a-185x50
Fig.
90
90
240
240
(2)
(1)
bar
L9Z
M9/1a-165x50
68-260
810-3095
Burner types
Comb, head
Rating kg/h
kW
mbar
M9/1a-185x50
63 - 250
750-2980
Burner types
Comb, head
Rating kg/h
kW
/
/
-9 -
//I
f/
>'
L9T
M9/1a-165x50
67-290
800-3455
M9/1a-185x50
63 - 2 5 0
750-2980
/
/_
,, ^
r
-2
(3)
mbar
Burner types
Comb, head
Rating kg/h
kW
19
12
/
r
>
/
//
If
V
RL9
M9/1a-165x50
63-310
740-3690
M9/1a-185x50
60 - 250
715-2980
^
f
-2 -
27
Sizes 10 and 11
Dimensions nnm
No.
Combustion head
M10/2-185x50
M l 0/2-200x50
(1+2)
Fig.
No.
Combustion head
Fig.
iV
IV
140
140
265
265
(3)
M11/1-245x70
Mil/I-260x70
IV
IV
170
170
325
325
(3)
(1)
mbar
Burner types
Comb, head
Rating kg/h
kW
L10T
Ml 0/2-185x50
95 - 380
1130-4525
mbar
Ml 0/2-200x50
8 5 - 325
1010-3870
1o
1K
ID
1 4
.i n
lU
RL11
M l 1/2-245x70
130-440
1550-5240
Burner types
Comb, head
Rating kg/h
kW
''
TC.
M l 1/2-260x70
1 20 - 3 8 5
1430-4585
"
S^:^
' /
,
^
1000
1500
2000
2500
3000
3500
4000
4500
5000
(2)
mbar
Burner types
Comb, head
Rating kg/h
kW
RL10
Ml 0/2-185x50
90 - 380
1070-4525
Ml 0/2-200x50
80-315
955-3750
10
12
.I
i
i
-2
1000
28
S
1
-2
-2
1500
2000
2500
3000
3500
4000
4500
5000
1600
2000
4000
4500
5000
5500
11.2 Burner types M/MS and RM/RMS

Combustion of residual oil
With residual oil burners types MS and RMS, the oil
throughput in relation to nominal rating must not be
less than 100 kg/h. It is also recommended that sliding
two stage RMS burners are used when burning this
fuel.
Sizes
Dimensions mm
No.
Combustion head
(1)
M5/2a-125x40
M5/1a-1 2 5 x 4 0
M5/1a-145x40*
Fig.
II
II
II
50
65
65
160
180
180
* Special combustion head
(1)
mbar
Burner types
Comb, head
Rating kg/h
kW
M5Z
M5/2a - 1 2 5 x 4 0
20-70
225-810
M5/1 a -125x40
2 8 - 06
3 1 0 1190
M5/ a-145x40
2 5 - 81
280 - 9 1 5
v^~
-2
1000
1200
Note burner M5Z

Size 5 M burners cannot be used in Germany. The data
given in the capacity charts are the maximum values. The
figures actually obtainable depend on the combustion
chamber and should be determined by testing on the
appropriate heating appliance.
29
Size?
Dimensions mm
No.
Combustion head
Fig.
(1)
M6/1a-155x50
M7/1a-155x50
II
II
100
100
220
220
(2)
M6/1a-165x50
M7/1a-165x50
II
1
90
100
200
220
(3)
M6/1a-175x50
M7/1a-175x50
II
II
90
100
200
220
(2)
(1)
mbar
MS7Z, RMS7
M6/1a-155x50
50-159
560-1785
Burner types
Comb, head
Rating kg/h
kW
mbar
Burner types
Comb, head
Rating kg/h
kW
M7/1a-155x50
70-175
785-1965
14
MS7Z,RMS7
M6/1a-165x50
45-127
505-1430
M7/1a-165x50
65-175
730-1965
14
/
~L
7L.
/
,, '
y.
'
\
-2 H
kW
200
400
600
800
1000
1200
1400
1600
1800
2000
(3)
mbar
Burner types
Comb, head
Rating kg/h
kW
MS7Z, RMS7
M6/1a-175x50
40 -111
450-1250
/ /
'
M7/1a-175x50
60-170
675-1905
,, >
/
/^
-2
kW
30
-2
200
400
800
1000
1200
1400
1600
,
1800
2000
kW
200
400
600
800
1000
1200
1400
1600
1800
2000
Sizes 8 , 8 / 2 and 9
Dimensions mm
No.
Combustion head
Fig.
No.
Combustion head
Fig.
(1)
M7/1a-155x50*
M8/1a-155x50
11
11
100
110
220
240
(4)
G7/2a-165 x 50
G7/2a-175x50
II
II
120
120
265
265
(2)
M7/1a-165x50
M8/1a-165x50*
11
11
100
110
220
240
( 5 + 7 + 8)
M9/1a-165x50
M9/1a-185x50
III
II
90
90
240
240
(3)
M7/1a-175x50
M8/1a-175x50
11
11
100
110
220
240
(6)
U2/1-155x50
U2/1-165x50
85
85
220
220
Special combustion head
(4)
(1)
mbar
Burner type:
Comb, head
Rating kg/h
kW
MS8Z, RMS8
M7/1a-155x50
70-206
785-2320
mbar
M8/1a-155x50
75-244
845 - 2740
Burner types
Comb, head
Rating kg/h
kW
MS8Z/2, RMS8/2
G7/2a-165x50
G7/2a-175x50
95-280
90-274
1070-3155
1010-3075
10
^_
>^
C^
2
0
-2
\ \
^\
\\
\ \
S.S
-2 -
(2)
mbar
Burnertypes
Comb, head
Rating kg/h
kW
MS8Z, RMS8
M7/1a-165x50
65 -192
730-2155
(5)
mbar
Burnertypes
Comb, head
Rating kg/h
kW
MS8Z/2, RMS8/2
M9/1a-165x50 M9/1a-185x50
60-254
60-215
675-2860
675-2420
mbar
Burnertypes
Comb, head
Rating kg/h
kW
MS8Z/2, RMS8/2
U2/1-155x50
U2/1-165x50
80-233
85-212
900-2620
955-2380
IV18/1 a - 165x 50
65 - 233
730 - 2620
8
6
4
2
-2
(3)
mbar
Burner types
Comb, head
Rating kg/h
kW
10
8
6
4
/
/
MS8Z, RMS8
M7/1a-175x50
60-176
675-1975
>S
\
(6)
IVI8/1a-175x50
65-209
730 - 2345
'
/
//
/ /
//
//
/ /
/
2
0
-2
1 1
-2
31
(8)
(7)
mbar
Burner types
C o m b , head
Rating kg/h
kW
14
MS9Z
M9/1a-165x50
90-275
1010-3095
7~
/L_
/ /'T
/
(
mbar
M9/1a-185x50
80 - 2 6 5
900-2980
Burner types
Comb, head
Rating kg/h
kW
14
N,
'
RMS9
M9/1a-165x50
90-328
1010-3690
M9/1a-185x50
80 - 265
900-2980
cz
!'
/^
/
>
/
/>
/7
y/
/
"2 -
-2
Sizes 10 and 11
Dimensions mm
No.
Combustion head
M10/2-185x50
Ml 0/2-200x50
(1)
Fig.
IV
IV
No.
140
140
265
265
Combustion head
(2)
M l 1/1-245x70
M l 1/1-260x70
Fig.
IV
IV
170
170
325
325
* Special combustion head
(2)
(1)
mbar
Burner types
Comb, head
Rating kg/h
kW
RMS10
Ml 0/2-185x50
100-403
1125-4525
mbar
Ml 0/2-200x50
90-334
1010-3750
Burner types
Comb, head
Rating kg/h
kW
RMS11
Ml 1/2-245x70
140-466
1575-5240
JO
1 R
1 D
1 A
14 H
.. -
.
^
^
>
,^
/
^
/ ,'
'*
-^
-2 J
-2 J
1000
32
Ml 1/2-260x70
130-408
1460-4585
1500
2500
3000
4000
4500
5000
K W 1000
3500
4000
4500
5000
5500
12. Nozzle selection

12.1 Two and three stage burners
It is recommended that solid or semi-solid nozzles are used
with a spray angle of 60 or 45. Due to the various
configurations of combustion chambers encountered on
individual heating appliances, no binding information can
be given.
Please note that nozzle spray angles and patterns alter
with the atomising pressure. The data given on the nozzle
only applies with a pressure of 7 bar.
On two stage burners the total burner capacity must be
divided between two nozzles. Usually nozzle 1 is sized to
have sufficient capacity for basic load at approximately 2/3
of the total load. At peak demand nozzle 2 is added to the
throughput of nozzle 1. A different nozzle ratio may be
required depending upon the heat demand and the design
of the heating appliance (e.g. boilers with high combustion
chamber resistance).
Nozzle spray characteristic
Hollow spray
Semi-solid spray
Solid spray
Spray angle
Nozzle selection for residual fuels

Nozzles that are too small are frequently used for residual
fuels and therefore soon become blocked. We recommend
the following nozzles sizes as minimum sizes:
from 2 - 3 USgph up to approx. 76 mm2/s at 5 0 C
from 3 USgph up to approx. 450 mm2/s at 5 0 C
On two stage burners neither nozzle should be smaller
than indicated.
The charts are based on distillate oil EL with a viscosity of
4 mmVs at 20C.
Removing and replacing nozzles
When removing the nozzle, the nozzle head must be held
with a spanner. Before replacing the nozzle ensure that the
nozzle insert is a tight fit.
Cleaning the nozzle
It is not recommended to clean the nozzles. A new nozzle
should be used.
Atomising pressures
Oil EL
OilM-hS
10 16 bar
20 25 bar
Note
On type T burners we recommend the higher
atomising pressure is set.
Nozzle selection charts
The charts are based on details supplied by the nozzle
manufacturer. With variations in viscosity and
manufacturers tolerances a deviation in throughput of
10% may result. It should be noted that on residual oil
burners variations in throughput may occur.
These variations are due to differences in fuel density and
viscosity range (atomising viscosity up to max. 17 mmVs
depending on burner size). Pressure losses in the
preheater and burner fuel system should be taken into
account. The precise oil throughput can only be
determined by weighing.
33
t'S
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12.2 Sliding two stage and modulating burners

The charts shows the throughput of the spill type nozzle in
relation to the supply pressure. The pump pressure on RL
burners should be between 20 and 30 bar.
It should be ensured that the minimum pressure does
not fall below 20 bar even at the lowest regulator cam
position.
On RMS burners the pump pressure must not fall below
25 bar. When, due to nozzle sizing, the burner rating with
the return flow closed (regulator position 10) can only be
achieved at a pressure below 25 bar, the pump pressure
must be increased to 25 bar and the higher oil throughput
that results is reduced by limiting the oil regulator
movement. This is done by adjusting the limit switch in the
servomotor to the appropriate lower regulating position.
The range of regulation is reduced by this action.
Nozzle return pressure
Spill type Nozzle K3 / WB3
The nozzle return pressure must be measured when
commissioning. In normal cases it should not be set below
5 bar for partial load.
Spill type nozzle WS4
The nozzle return pressure must be measured when
commissioning. In normal cases it should not be set below
8 bar for partial load.
Solenoid valve group, sizes 5 to 7
Relurn pressure
test point
Solenoid valve group, sizes 8 to 11
,mMt
Atomising pressure
Burner type
Atomising pressure
bar (approx.)
RL5toRL11
RMS7toRMS11
20-30
25-30
Spill type nozzles
TypeWB3/K3
TypeW
Note
Each burner is additionally subjected to an oil throughput
ratings test with the spill type nozzle during final testing.
This ratings test is usually carried out with oil EL. The
differences which occur on oil S, i.e. on RMS burners
(density and viscosity) are taken into account with a
correcting factor. These test bed measurements can only
be used as guidelines. Exact measuring has to be carried
out on site. Site specific conditions, such as oil quality and
ring main pressure must be taken into account.
Cleaning the nozzles
The nozzle is dismantled into its individual parts and
washed in petrol or paraffin. The filter should always be
changed. If other individual parts are faulty or worn, the
nozzle should be replaced.
Nozzle selection charts
The charts are based on details supplied by the nozzle
manufacturer. With variations in viscosity and
manufacturers tolerances a deviation in throughput of
10% may result. It should be noted that on residual oil
burners variations in throughput may occur.
These variations are due to differences in fuel density and
viscosity range (atomising viscosity up to max. 17 mmVs
depending on burner size). Pressure losses in the
preheater and burner fuel system should be taken into
account. The precise oil throughput can only be
determined by weighing.
di -'
Return pressure 1/4" t(^t point
35
Nozzle selection chart type WB3/K3

Spill type nozzle type W B 3 to 70 kg/h
type K3 80 to 180 kg/h
Spray angle 50
Nozzle selection chart type W, series 4

Spill type nozzletype W, series 4
Spray angle 50
190
190
W460
460
440
y^ A2Q
420
400
W390
380
W360
360
340
W330
320
W300
300
280
CO
)^
260
Q.
240
N
N
O
220
200
180
CO
160
a>
Q.
>
140
0)
N
N
O
i
-^^ -M
w^
4-
0)
a
N>
(A
0)
N
N
W200
W 180
W160
W140
WHO
W 100
W90
W80
W70
W60
W55
W50
W45
W40
100
CO
CO
W225
>
W250
W 125
120
W275
O)
80
^
:3
O)
3
O
JZ
60
40
-l-i
Si
O
CO
O
0)
.>
+J
iS
N
'
N
N
;^
20
20
25
30
20
Supply pressure bar

Example of nozzle selection, type WB3
Oil throughput required:
Nozzle size from chart:
Supply pressure from chart:
36
25
30
Supply pressure bar
. 50 kg/h
55
. 24 bar
Example of nozzle selection, type W

Oil throughput required:
Nozzle size from chart:
Supply pressure from chart:.
160 kg/h
_W160
24 bar
13. Adjustment of the combustion head

Weishaupt Monarch and R type oil burners are delivered
with different combustion heads and diffusers for each size
and capacity range. It is advisable to check whether the
correct combustion head is fitted. Combustion heads and
diffusers are marked with their type designation. The
identification of the flame tube is on the neck. The external
diameter of the diffuser is stamped on the side towards the
burner.
The combustion head can be adapted to the combustion

chamber conditions as follows:
Dimensions for adjustment can be taken from the capacity

charts (see Ch. 11).
Both combustion head fixing screws should be

unscrewed. The combustion head or diffuser can be
moved or replaced. This reduces the air gap and adapts
the air velocity to the corresponding lower oil throughput
range.
The measurements given are empirical values, which

usually meet the requirements of most combustion
chambers.
The combustion head for each burner is designed for the
maximum oil throughput indicated in each case.
Moving the combustion head from the basic position in the

direction of the combustion chamber.
Fitting the next size diffuser or smaller combustion head
(see capacity chart).
Sizes 9, 10 and 11 also offer the advantage that the

combustion head with intermediate ring can be pulled
through the hinged flange opening, after unscrewing both
holding screws.
If the burner is operated in the middle or lower oil

throughput range, the air gap between diffuser and
flame tube must be altered.
Flame tubes made of steel with a higher resistance to

temperature are available for special requirements.
Diffuser distance
Removal of combustion liead, sizes 9, 10 and 11
I i .*-* J TMTr^tfci*
37
Connbustion head extensions

Combustion head extensions are required on boilers with
very thick doors and on reverse flame boilers. When
combustion head extensions are fitted it is no longer
possible to hinge the burner open.
Designation and dimensions
* To enable installation and service work to be carried out,

the refractory should not be longer than dimension I4.
This only applies for standard burners, not for special
combustion chambers, ovens, etc.
1
2
3
4
5
6
7
8
9
Oil line extension

Ignition line plug connection
Burner flange
Flange gasket
Burner plate
Ignition line extension
Combustion head extension
Refractory
Movable insulation material (e.g. Cerafelt), under no
circumstances make solid
10 Nozzle support
Burner
size
Combustion
liead type
2 3 4 5 6
789
10
Dimensions in mm
I2
Total length
l3
U*
Is Combustion head
open
closed di
ds
d6
5
5
5
5
M5/1a
M5/1a
M5/1a
M5/1a
100
150
200
250
252
302
352
402
103
153
203
252
245
295
345
395
254
304
354
404
180
180
180
180
220
220
220
220
140
140
140
140
5
5
5
5
M5/2a
M5/2a
M5/2a
M5/2a
100
150
200
250
240
290
340
390
103
153
203
253
230
280
330
580
244
294
344
394
160
160
160
160
200
200
200
200
140
140
140
140
7
7
7
7
M6/1a
M6/1a
M6/1a
M6/1a
120
150
200
250
343
373
423
473
128
158
208
258
336
366
416
466
348
378
428
478
200
200
200
200
240
240
240
240
180
180
180
180
7
7
7
7
M7/1a
M7/1a
M7/1a
M7/1a
120
150
200
250
353
383
433
483
128
158
208
258
346
376
426
476
358
388
438
488
220
220
220
220
260
260
260
260
180
180
180
180
8
8
8
8
M7/1a
M7/1a
M7/1a
M7/1a
120
150
200
250
353
383
433
483
128
158
208
258
346
376
426
476
358
388
438
488
220
220
220
220
260
260
260
260
180
180
180
180
8
8
8
8
M8/1a
M8/1a
M8/1a
M8/1a
120
150
200
250
363
393
443
493
128
158
208
258
356
386
436
486
368
398
448
498
240
240
240
240
280
280
280
280
180
180
180
180
8/2
8/2
M9/1a
M9/1a
150
250
373
473
192
292
376
476
401
501
240
240
280
280
220
220
8/2
8/2
G7/2a
G7/2a
150
250
414
514
192
292
414
514
420
520
265
265
300
300
220
220
9
9
M9/1a
M9/1a
150
250
385
485
204
304
375
475
390
490
240
240
280
280
220
220
10
10
Ml 0/2
Ml 0/2
150
250
426
526
198
298
418
518
265
265
300
300
265
265
11
11
Ml 1/1
M11/1
150
300
520
670
257
407
512
662
325
325
365
365
325
325
,1R
14. Ignition electrode setting

The distance of the ignition electrodes to the nozzle and
diffuser should be checked.
The ignition electrodes must not be touched by the
atomised oil spray.
The distance of the ignition electrode to the diffuserand
the nozzle must always be greater than the distance of the
spark gap.
Setting the ignition electrodes on sliding two stage and modulating burners
3.5-4
Setting the ignition electrodes on two and three stage burners
3.5-4
Nozzle 2
Nozzle 1
Nozzle 3
39
15. Air regulation, two and three stage burners

Two and three stage oil burner with two air dampers
Sizes 5 to 11
The air intake has two air dampers.
Both air dampers are connected by a rod so that they are
operated in parallel by the servomotor.
When commissioning the installation, the following
mechanical settings are necessary:
Set the air damper for partial load operation (operation

with nozzle I) by adjusting the cam switch II - partial
load in the servomotor.
Set the air damper for full load operation (operating

with both nozzles) by adjusting the air damper for full
load via the servomotor cam switch III - full load.
Set the switch point for solenoid valve 2 to about 1 /3 of

the way between stage 1 and stage 2.
The final setting of the cam switches in the servomotor

for full load - switch III and partial load - switch II takes
place after the flue gas measurements.
On L7T to LI OT (three stage) burners, a type 1055/80

servomotor is used. This servomotor is the same
construction as the 1055/23 but has a running time of 8
s and an additional limit switch related to 90 angle of
rotation.
40
Two and three stage oil burner with two air dampers
Sizes 5 to 11
Servomotor type
1055/23
Bottom of housing
Servomotor
.
^ 'S,,
Switch position
indicator
Gear wheel (may be
uncoupled for manual
adjustment)
Control cams:
Auxiliary switch II
partial load
Air damper
position indicator
Socket pin (must
be removed
when changing
printed circuit
board)
....:-^,rt
rmm
Fixing for air

damper shaft
H- ..
Auxiliary switch full

load valve
Limit switch III full load
Limit switch IV closed
Printed circuit
board cover
Servomotor type
Terminal rail
1055/80
Bottom of housing
Servomotor
Switch
identification
Control cam aid

Air damper
position indicator
Socket pin (must
be removed
when changing
printed circuit
board)
Fixing for air

damper shaft
Switch position
indicator
Gear wheel (may be
uncoupled for manual
adjustment)
Control cams:
Auxiliary switch VI
stage 3 valve
Auxiliary switch V
intermediate load
Auxiliary switch II
partial load
Auxiliary switch I
stage 2 valve
Limit switch III
full load
Terminal rail
Printed circuit
board cover
Limit switch IV closed
Servomotor limit switch

Open
-^
v , ^
T
\
Partial load
>i s N.
Closed
_
CO
to
<D
I - (D
>
03 ^
CM
en
CD
B
CO
41
8. After the burner is shut down voltage from terminal 11

of the LAL closes the air damper until the limit switch IV
switches off the servomotor.
15.1 Description of functions for servomotor

type 1055
Burner control with LAL2 control box
Sequence of operations:
1. After the boiler regulator has closed betw/een terminals
4 and 5, terminal 6 of the burner control is energised.
Version T
6. The servomotor opens the air damper with voltage from
terminal 20 via switch S4, intermediate load regulator
(see burner wiring diagram)and limit switch III.
2. The burner motor starts. The voltage from terminal 11 of

the LAL2 controller is supplied via the closed switch IV
to terminal 8 of the LAL.
7. The intermediate load solenoid valve is switched on by

auxiliary switch I.
8. Depending on the setting of the regulator for partial load
the servomotor is stopped at the switching point of
auxiliary switch V or the air damper is opened further.
3. After a short delay the air damper is opened to the

switch point of full load limit switch III with voltage from
terminal 9. A return interlock signal is given to terminal 8
of the burner control.
9. On demand for heat from the full load regulator, the

servomotor opens the air damper with voltage from
terminal 20 via switch S2, to the switching point of the
limit switch III.
4. After the pre-purge terminal 9 is de-energised. By

energising terminal 10, the servomotor closes the air
damper to the partial load switching point. Auxiliary
switch II.
5. After flame establishment terminal 19 on the LAL
controller is energised to control stage 2 or intermediate
load but remains without function.
Version Z
6. The servomotor opens the air damper with voltage from
terminal 20 via switch S2 and stage 2 regulator to the
switching point of limit switch III.
10. When the auxiliary switch VI is overrun, the full load

solenoid valve is switched on.
1 1 . After the burner is shut down the voltage on terminal II
of the LAL closes the damper until the limit switch IV
switches off the servomotor.
7. When the auxiliary switch I is overrun, the stage 2

solenoid valve is switched on.
A i / LAL 2
20
10
11
19
Basic wiring diagram for

version Z
S2|^
F16
(1
l^
XI '
X30
Y6|
; X4 (12
ie
05
)>3
64
()12
1)11
\^Q
1
-0
42
1 >7
Y2^-c: I]H2 (^
15.2 Setting the cams limit and auxiliary

switches on servomotor type 1055
The air damper position is indicated on a scale of 0 to 90
by a pointer on the shaft.
There is a setting scale between the cam switches. The
setting knobs on the cam switch point to this scale with a
small pointer and give the switching point of the
appropriate switch in relation to the air damper position.
The cam switches are set as follows using the setting
scale:
Cam switches
* VI - Auxiliary switch
Stage 3 valve
Dependent on burner rating,

but set below V
*v-
Auxiliary switch
Intermediate load air

set between i and IV
for air setting
IV-
Limit switch closed
III-
Limit switch
Full load

up to 80
II-
Auxiliary switch
Partial load

between 0 and approx. 50
Auxiliary switch
Stage 2 valve

between partial and
intermediate load at approx.
10 to 40
* only used for version T

The limit switches and cam switches are marked in all
wiring diagrams with I, II, III, IV* and VI and have the
function laid down in the connection diagram.
The connection diagram is also shown on the cover of the
servomotor.
43
16. Oil/air compound regulation, sliding two stage and modulating burners
The cam segment is driven clocl<wise by the
servomotor to the full load position. The adjustable
spring band on the cam segment operates the air
damper linkage and holds the damper open during full
air prepurge.
Adjusting the air quantity

The cam has an adjustable spring band on its side,
which adjusted with settable cams. The air quantity is
matched to the oil throughput required by adjusting the
spring band.
At the end of the prepurge period, the servomotor

brings the oil regulator, which is on the same axis of
rotation as the cam disc, and the air damper to the
ignition load position. In this position the oil regulator is
wide open, which means that only a small quantity of oil
is atomised at the nozzle, the larger proportion flows
back via the return.
The air damper is closed so that the air supplied is

matched to the atomised oil quantity.
The setting of the spring band is determined at various

load positions by flue gas measurements.
The outer scale on the camshaft serves as a position

indicator.
With the lever fitted to the gear box the cam shaft can be
disengaged from the drive. This makes it possible to
manually adjust the cam to any position required.
The servomotor drives the compound mechanism in a

continuous movement from partial load to full load. In
other words, the air damper is opened and the oil
regulator closes and less oil flows to the return line.
Compound
regulation
Full load (100%)

Partial load (from 30 - 70%)
Ignition load (from 20-30%)
Basic setting
Air damper rod with linkage
Nozzle return
Metering slot
Oil regulator
Cam disc
Adjustable spring band
Air regulation on burners sizes 5 to 11
Setting the spring band
U.'
,-**&**&"
^
^ft, V*S'
^
?
-.--
44
16.1 Setting the cams limit and auxiliary switches on servomotor type SQM
Description
The limit and auxiliary switches are set manually on the
adjustable cams. The cams have a small pointer which
indicates the appropriate switch point on a scale between
the cam discs.
When commissioning, these settings must be adjusted to

the requirements of the installation.
The servomotors are supplied with the following standard

settings:
The connection diagram is also shown on the servomotor

cover.
I
II
III
IV
V
VI
VII
The outer scale on the cam shaft serves as a position

indicator.
Open 120
Closed 0
Ignition load 30
Free
Free
Free
Partial load e.g. 50
Setting the limit and auxiliary switches
Disengaging the drive

.^-.r|flT;..-
.8.-
Connection
diagram
21 1 11 22 2 12 23 3 13 24 4 14 25 5 15 26 6 16 27 7 17 a
ON
O O O O Q O O Q O Q O Q O O Q O Q Q Q Q O Q O Q
I
I
I
UI
I
/I
IV
Open
Closed
Ignition load
VI
I
I
I
I
I
I
Lgii^gJ
VII
IV - Free
V - Free, VI-Free
VII - Partial load
45
17. Commissioning
17.1 Checks prior to first commissioning
The whole installation must be checked prior to the
first commissioning.
Has the heat exchanger been installed ready for

operation?
Are the heat exchanger and system filled sufficiently
with medium?
Are the flue gas ways free from obstruction?
Are movable explosion flaps fitted?
Is the flue gas damper open?
Are the fans of air heater operating correctly?
Is there sufficient ventilation to the plant?
Have you taken the operating requirements of the heat
exchanger into account?
Has the whole installation been wired correctly?
Have the temperature switch, pressure switch, and
safety limiting systems been set to operating
requirements?
Is sufficient load available?

Has the low water safety interlock been adjusted
correctly?
Have all fuel carrying parts been vented (free of air)?
Check rotation of burner motor.
Is there enough fuel oil in the tank?
Has the soundness of the oil hydraulic system been
checked?
Is the oil supply pump (where fitted) switched on?
Are the oil shut off devices open?
Have the oil lines and pump been primed with oil?
Have the correct oil nozzles been fitted?
It is possible that other site-specific tests will have to be
carried out.
Refer to the operating instructions of individual site
components.
17.2 Setting
General
Before commissioning can commence, the entire plant
must be ready for operation and handed over by the
installer.
The solenoid valves fitted on the burner and the isolating
valves in the oil supply line should be tested for correct
operation.
Full load setting:

After approx. 11 s the servomotor runs from ignition
(partial) load to full load (ensure that this is carried out with
excess air reducing the selected pump pressure
beforehand). For full load the required oil throughput has to
be set and measured (the nozzle selection tables are only a
guideline for setting and testing).
Carry out combustion test:
The direction of rotation of the burner motor should be

verified before commissioning. With control circuit and
operating switch closed the burner should be briefly
actuated by the burner control switch. The rotation of the
burner motor must be in the same direction as the
directional arrow on the motor flange.
Switch on procedure:
Open shut off valve (shut off assembly) in the oil line. Set
selector switch in the control panel to stage 2 or full load.
Reset installation.
Switch on burner.
Ignition:
After prepurge await flame formation.
If start problems occur:
L- (M-/MS-) burners:
Check stage 1 nozzle size, if necessary select
different nozzles. Check position of auxiliary
switch II on the servomotor, if necessary adjust
to air requirement.
RL-(RM-/RMS-) burners:
Check position of ignition load switch on the
servomotor (No. III). Reset burner if necessary.
Test sensor current with microammeter.
46
L-(M-/MS-) burners:
The oil throughput is set by adjusting the
pump pressure (EL = 1 0 - 1 4 bar, M/MS =
20 - 25 bar), if necessary select different nozzle size.
Set combustion values by adjusting
servomotor, auxiliary switch No III and the
position of the flame tube (see chapters 11
and 13), so that with the air damper opened as
much as possible, a smoke number < 1 and
CO2 > 13 Vol. % can be achieved with good
flame stability.
RL-(RM-/RMS-) bumers:
Set oil throughput by adjusting the pump
pressure (20 - 30 bar). Set combustion
values by adjusting the air curve band and the
position of the flame tube (see chapters 11
and 13) so that with the air damper opened as
much as possible, asmoke number< 1 and
CO2 > 13 Vol. % can be achieved with good
flame stability.
The pump pressure and flame tube position set for full load
must not be adjusted.
Intermediate control (Full load to partial load) only for

sliding two stage and modulating burners:
A step by step combustion control is required for the
whole of the burner regulating range. Set the cam
sequence step by step by hand in the direction of ignition
load (selector switch to STOP, disengage servomotor,
adjust by hand, re-engage). Regulate combustion values
by adjusting the air band. Ensure that the cam bands
scribe a smooth arc.
Partial load setting:
Set selector switch in the control panel to stage 1 or partial
load.
L-(M-/MS-) burners:
Adapt excess air to the oil throughput of the
selected nozzles with the auxiliary switch for
partial load (No. II).
Measure oil throughput, if necessary select
different nozzles. Set the switch point for the
start of the second nozzle with auxiliary switch
No I so that the excess air phase before the
switch point is not too large to extinguish the
flame, but on the other hand that there is not
too much smoke after the connection has
been made.
Three stage burners:
L7T to LI OT:
in the same way the excess air of the
intermediate load is set with the auxiliary
switch V and with the moveable auxiliary
switch on the air damper shaft (S8 on wiring
diagram) the connection point for the third
stage is set.
Finalising work:
Test ignition load setting when burner has been
commissioned. The setting is correct if the burner starts
without start impact.
Sliding two stage and modulating burners:
If necessary correct setting at auxiliary switch
No. III.
Two and three stage burners:
If necessary select new nozzles. Setting of full
load and partial load will then have to be
repeated.
Test and check the function of all safety equipment (i.e. oil
pressure switch, thermostat, pressure stat, etc.) when the
plant is in operation.
Documentation:
On full and partial load the following values have to be
noted in the commissioning report:
Oil throughput
Type of nozzle
Pump pressure
Ssupply and return pressure (on RL burners)
CO2
Smoke
Flue gas temperature
Fan pressure
Draught or pressure in the combustion chamber
Sensor current
Room temperature
Atomising temperature (on MS and RMS burners)
Air damper setting
Cam setting on the air band (on R burners)
RL-(RM-/RMS-) burners:
Set and measure the required oil throughput
for partial load with auxiliary switch No. VII.
If the nozzle has been changed for partial load or
intermediate load (two/three stage burners) the full load
setting has to be tested and if necessary reset. For partial
load setting the lower ratings limits given in the graph, the
flue gas temperature as well as the instructions of the
boiler manufacturer have to be noted.
47
18. Sequence of operations for LAL 2 and LOK 16 burner controller

Version Z oil burner
Servomotor sequence diagram
Air
Regulator
On
Nominal load
prepurge
ignition and fuel

release
Capacity regulation
Regulator Off
Full load
Switch points I - IV
/
-If
Ignition load /Partial load
LAL2 .../
LOK16.
Closed
Position indicator 1> I 1 1 ^ 111 11 I I P I D I I I I I I I I I I I V I I I I I I I

12/4/5^^^
14 I
8 I
9 :
Time sequence indicator for
10 :
servomotor
11 I
20:
regulator circuit
6i
Burner fan
7:
Oil sequence diagram
Sequence diagram for ignition

and fuel release
15'
ô
19
The LAL 2 burner control units are designed for control

and supervision of multistage and modulating burners.
They are only suitable for burners with intermittent
operation. The self-checking LOK 16 burner controller is
used for continually operating burners.
18.1 Prerequisites for burner start

Control unit reset
- Air damper closed. The limit switch for the CLOSED
position must supply voltage from terminal 11 to
terminal 8.
- The check contacts for the closed position of the fuel
valve and or other contacts between terminal 12 and
LP must be closed. Terminal 4 must supply voltage.
48
I] I II111II'
18.2 Symbols on the lockout indicator

In the event of fault conditions the fuel supply is always
interrupted immediately. Simultaneously the sequence
switch stops and thus lockout is indicated. The symbol
appearing above the reading mark indicates the kind of
fault.
M No start, because a contact has not been made
between terminals 1 2 and 4 or 4 and 5, or because the
closed signal has not been supplied to terminal 8 by
the limit switch / auxiliary switch.
Controlled shut down because the open signal has

not been supplied to terminal 8 by the limit switch.
Lockout on burners fitted with air switch because the

air pressure signal has not been received at the start of
the air pressure check. Any pressure failure after this
point in time also causes the control to go to
lockout!
Lockout due to a fault in the flame supervision circuit.
Controlled shutdown because the position signal has

not been supplied to terminal 8 by the auxiliary switch.
Lockout because no flame signal has been received

on completion of the 1 st safety period. Any flame
signal failure after completion of the first safety
time also causes the control to go to lockout!
Lockout because the flame signal has been lost during

burner operation or air pressure failure has occurred.
a - b Start up sequence
b - a Post purge sequence after controlled shut down. In
start position a the sequence switch switches itself
off automatically.
A Lockout on completion of control programme

sequence due to extraneous light or fault in flame
supervision circuit.
If lockout occurs at any point between start and preignition, which is not marked by a symbol, there is normally
a premature or faulty flame signal.
49
18.3 Basic wiring diagram for LAL 2 / LOK 16... burner controllers
Legend
AR
Load relay (main relay)
B1
Flame sensor
BR
Lockout relay
F
Fuse in burner control
F4
Temperature or pressure switch
F5
Temperature or pressure regulator
F6
Temperature or pressure regulator, full load
FR
Flame relay
H
Fault indication lamp
H6
Remote indication of fault
K1
Motor contactor
LK
Air damper
Ml
Fan or burner motor
S
Reset button
SI
Remote reset
S10 Air pressure switch
50
T1
Y6
Y11
Y12
Ignition transformer
Servomotor
Partial load solenoid valve
Full load solenoid valve
Wire link
RAR
9, t6 ?
t12
ti
til
-(^f^
t4
nnn
II
llllU
III
i^
IV
t3"
-60)
t3n
mm
JM.
VI
t5
-()
iiiiii
^
VII ,
nnn
Mill
nnn
t20
VIII,
IX
.t2.
X
- @
'^~^~^m
TTIfTT
XI
nnn
XII
nnn
^^-
mm
tioJ
^
M-
rmn
XIII
t13 . "Q5.
mm:
"5 'S
-t to
XIV
nnn
t8
^^^^^^^^^^^^M
nnn
S c
"
Position of locl<out indicator
_*
^ 1111AI
Piiiiiiii iiiiiiiiiiiiii'îiiiiiiiiiiiiiii
1 II i i i i i i i i i i i i i i i i i i i i i i > 1111111111111111
Legend for switch sequence diagram

ti
Prepurgetime
t2
Safety time
t3
Pre-ignition time
t4
Interval between voltage on terminals 18 and 19
t5
Interval between voltage on terminals 19 and 20
t6
Post purge time
t7
Interval from start up to voltage on terminal 7
tS
Duration of start-up sequence
t i O Interval to start of air pressure control
t i l Air damper run time (Open)
t i 2 Air damper run time (Min.)
t i 3 Permissible after burner time
t i 6 Interval to OPEN command for air damper
t20 Interval to the self shutdown of the sequence switch
(not on all controls)
Burner controls are safety devices! Do not open!
Unauthorised intervention can have unforeseen
consequences!
51
18.4 Switching times

Switching times in seconds* in start up sequence.
t7
t16
til
tlO
t1
t12
t3"
t3
t2
t3n
t4
t5
t20
t6
t13
LAL 2.14/
LOK 16.140
Start up delay for burner motor G2

Interval from start to OPEN command for air damper
Running time for air damper to OPEN position
Interval from start to start of air pressure check (if provided)
Prepurge time with air damper open
Running time for air damper to MIN position
Pre-ignition time long (Z on terminal 15)
Pre- ignition time short (Z on terminal 16)
(1 st) safety time
Post ignition time (Z on terminal 15)
Interval BV1 - BV2
Interval between end of t4 and release of load controller
or valve at terminal 20
Interval to self shutdown of sequence switch after
burner start up (idle steps, i.e. no change in the
controller position)
Duration of start up (without t11 and 12)
Post purge time
Permissible after burner time
LAL 2.25/
LOK 16.250
LAL 2.65/
LOK 16.650
2
2
2,5
4
5
5
optional
optional
optional
6
10
10
10
22,5
67,5
optional
optional
optional
from start orderfrom start orderfrom start order
2
2,5
2,5
4
5
5
10
15
15
8
7,5
7,5
32
30
10
10
7,5
7,5
35
47,5
15
15
12,5
92,5
15
15
' Valid where mains frequency is 50 Hz. For 60 Hz frequency switching times are reduced by approx. 20%.
18.5 Technical data

Nominal voltage
. 220 V - 15% to 240 V + 10%
Frequency
50 Hz - 6% to 60 Hz + 6%
Consumption
Fuse (inbuilt)
Flame supervision with QRB (not on LOK 16)

Recommended illumination in Lux
3.5 VA

Flame indication during operation
Permissible loading
of control terminals
max. 10A
5 A continuous
Peaks up to 20 A max.
> 3 Lux at 2856 K
Max permissible detector wiring length
20 m
Max. permissible ambient temperature
- 20 to + 70C
Minimum required detector current
6 |JA

1A
1A
.5 Acontinuous,
peaks of 20 A
Mounting position
.Optional
Type of protection
IP40
Permissible
ambient temperature
160|JA
Flame supervision with RAR...
. 4 Acontinuous,
Peaks up to 20 A max.
Total max. 5 A
Required switching capacity

- between terminals 4 and 5 _
- between terminals 4 and 1 2
- between terminals 4 and 14
BijA
Response sensitivity of the amplifier
M 6.3/250 E
(according to DIN 41571, sheet 2)
External fuse
Permissible input current
40
Permissible cable length
25 |JA
30 m RAR 7
Permissible ambient temperature
20 to + 60C
Note:
Flame detector wiring must not be bunched together with
other wiring.
20 to + 60C at 230 V
Permissible ambient conditions for electrical components

Temperature
In operation:
-20G to -l-40G
Transport/Storage
-40C to -1-60C
52
Humidity
max. 8 0 % rel.
Chumidity
Requirements
magnetic compatibility
Directive 89/336/EEC
EN 50 081-1
EN 50 082-1
re. electro-Low Voltage Directive

Directive 72/23/EEC
EN 60 335
19. Fault conditions and procedures

If faults occur the basic requirements for correct operation
must first be examined:
When it is established that the fault is not due to external

conditions, the operation of individual burner parts must be
checked.
1. Check the electrical wiring

2. Ensure oil supply is available
3. Check that all components, e.g. thermostats, water level
interlocks, limit switches or set correctly.
Condition
Cause
Remedy
1. Ignition
No ignition
Ignition electrodes too far apart
Adjust
Ignition electrodes dirty or damp
Clean and adjust
Burner control faulty
Replace burner control
Isolating body cracked
Replace
Ignition transformer faulty
Replace
Ignition cable charred
Replace, find and remedy cause.
Overload tripped
Check setting
Contactor defective
Replace
Capacitor faulty
Replace
Burner motor faulty
Replace
Gears damaged
replace pump
Suction valve leaking
Remove and clean or replace
Oil lines leaking
Tighten joints
Shut off valve closed
Open
Filter blocked
Clean
Filter leaking
Replace
Quick action valve faulty
Replace pump
Reduced capacity
Replace pump
Air in pump
Tighten joints and purge
Vacuum in oil line too high
Clean filter, open valves fully
2. Burner motor
Does not start
3. Pump
Supplies no oil
Mechanical pump noise
53
Condition
Cause
Remedy
4. Nozzle
Uneven atomisation
Swirl disc loose
Remove nozzle, tighten swirl disc
Orifice partly blocked
Remove and clean
Filter blocked
Remove and clean
Worn due to use
Replace
No oil flow
Nozzle blocked
Remove and clean
Nozzle leaking
Nozzle cut off faulty
Replace
5. Burner control with flame sensor

Does not respond to flame
Flame sensor obscured
Clean
Thermally overloaded
Replace
Interruption in sequence of operations
See chapter 18
Check connections and voltages
Lockout lamp on
Flame fault
Reset
6. Combustion head
contaminated with oil or has
heavy carbon deposits
Incorrect setting
Correct setting measurements.
Incorrect combustion head
Replace
Nozzle size incorrect
Replace
Combustion air quantity

incorrect
Readjust burner
Boiler room not adequately ventilated
The boiler room ventilation must be

via a permanent opening, the cross
section of which must be at least
5 0 % of all chimney cross sections
relating to the plant
7. Solenoid valve
Does not open
Coil faulty
Replace coil
Does not close tightly
Particles on the valve seat or filter
Dismantle valve, remove

foreign bodies
Temperature switch for oil

release does not close
Increase oil temperature on the start

temperature adjusting screw of
temperature regulator

release faulty
Replace

release loose
Tighten
Temperature switch for oil release

with incorrect temperature range
Replace
Heater element burnt out
Replace preheater
Temperature set too low
Increase temperature at thermostat
8. Oil preheater
Burner does not
Poor combustion
For adjustment see oil preheater brochure.
54
Condition
Cause
Remedy
9. Cleaning and lubrication requirements

Depending on the environment, fan rotor, ignition electrodes, flame sensor and air intake should be cleaned as required.
Moving parts of the burner require no lubrication.
Motor bearing damage which is recognised and remedied quickly, prevents more extensive damage to the burner.
Development of noise in the motor bearings must be investigated immediately.
55
Weishaupt products
and service
Max Weishaupt GmbH, D-88475 Schwendi

Tel. (0 73 53) 8 30, Fax (0 73 53) 8 33 58
Print No. 402 GB, February 99
Printed in Germany. All rights reserved
Weishaupt (U.K.) Ltd
Stoke Gardens, Slough SL1 3QD
Tel. (01753)51 23 45
Fax (01753) 51 25 85
Neachells Lane, Willenhall
West Midlands WL13 3 RG
Tel.(01902)60 98 41
Fax (01902) 63 33 43
weishauptOil, gas and dual fuel burners types W and WG/WGL

up to 570 kW
They are used mainly in houses and small buildings.
Advantages: fully automatic, reliable operation, individual
components easily accessible, easy to service, quiet operation.
Oil, gas and dual fuel burners types Monarch

R, G, GL, RGL - up to 10.900 kW
These are used on all types and sizes of central heating
plant. The basic model which has proved successful over
many years is the basis for a variety of versions. These
burners have founded the outstanding reputation of
Weishaupt products.
DP'
(nT
Oil, gas and dual fuel burners types WK up to 17.500 kW

VVK types are decidedly industrial burners.
Advantages: Built to the modular system, load dependent
variable combustion head, sliding two stage or modulating
operation, easy to service.
Weishaupt control panels, the proven complement to
Weishaupt burners
Weishaupt burners and Weishaupt control panels form
the ideal unit, a combination which has already proved
successful in hundreds of thousands of combustion
installations. The advantages: Cost saving during planning,
installation, servicing and guarantee work. The responsibility
belongs to one manufacturer.
II i| II
:: .:
::
Weishaupt Thermo Unit / Weishaupt Thermo Gas.

These Units combine the technical innovations and operating
efficiencies developed from over 1 million installations.
Weishaupt Thermo Gas and Weishaupt Thermo Unit
provide the ideals of complete heating centres for houses
and appartments.
Product and service are the complete

Weishaupt achievement
An extensive service organisation guarantees Weishaupt
customers the greatest possible reliability. In addition
our customers are looked after by heating firms who have
been working with Weishaupt for many years.
^ ^
weishaupt ^ ^
Mai 1996
Ersatzteile fr
Weishaupt Brenner
Gren 5 bis 11
Spare parts
for Weishaupt burner
Sizes 5 to 11
Pieces de rechange
pour brleurs types
Grandeurs 5 11
weishaupt
Sachgruppe / Subject index / Famille
Bitte geben sie in der Bestellung an:
Kindly indicate in the order:
Indiquer galement:
Bezeichnung des Ersatzteiles

Bestellnummer
Brennertyp
Fabriknummer
Bitte beachten Sie in Verbindung mit Bestell-Nr. und Preis:

E = Ersatzteil
Z = Zubehrteil
Designation of the spare part

Order-No.
Burner type
IVIanufacturing-No.
In connection with ordering number and

price, please note:
E = Spare part
Z = Accessory
Designation de la piece
No de reference
Type brleur
No de fabrication
Attention: bien faire la difference pour

chaque numro de reference
E = Pieces dtaches
Z = Accessoires
"ftSSST"
J
1.4
1.1
1.10
Bild
Piet.
Photo
1.
1.1 i
Bezeichnung
Brenner-Typenreihe
Burner serie
Type brleur
1.3
1.4
1.5
1.7
i G r e ; Bestell-Nr.
! Size
j Order-No.
! Grand, i No de commande
0103/2
0103/2
0102/2
0104/2
0102/2
13,850
20,780
20.400
31,880
48,000
5
7-^8
151 5 1 8 0 1 0 4 / 2
151 707 0 1 0 4 / 2
151 9 0 7 0 1 0 4 / 2
10,600
15,600
28,800
552
652
862
974
174
0 mm
242
281
350
380
450
5
7-H8
8/2
9-HO
11
111
111
111
111
181
552 0102/7
652 0102/7
862 0101/7
974 0102/7
1740102/7
1,650
2,780
5,160
3,880
5,900
G. GL, RGL
G. GL, RGL
G, GL, RGL
G, RGL
242
281
380
450
5
7-H8
9-1-10
11
151
151
151
191
5180105/7
707 0 1 0 3 / 7
907 0101/7
107 0 1 0 1 / 7
6,600
7,400
4,000
13,900
5
7 1-8
9-HO
11
151
151
151
161
5180107/7
707 0 1 0 5 / 7
907 0110/7
3 0 8 1499/7
0,048
0,050
0,066
0,075
111 9 7 4 0 1 0 3 / 7
181 0 7 4 0 1 0 1 / 7
181 174 0 1 0 3 / 7
2,820
2,300
5,700
Klemmschraube
G. GL, RGL
G, GL. RGL
G, GL. RGL (G7-NA)
G, RGL
Flammkopfhalter
L MS, RL, RMS
RL. RMS
RL, RMS
Flanschdichtung
L, M, RL
L, MS, RL, RMS
L, MS, RL, RMS
L, MS, RL, RMS
RL, RMS
0 mm
160x242
202 X 280
255x350
302 X 380
450x341
5
7-1-8
8/2
9-)- 10
11
111
111
121
111
181
552
652
262
974
174
0012/7
0012/7
0003/7
0007/7
0003/7
0.218
0,225
0,387
0,313
0,573
G,
G,
G,
G,
202 X 260
255x330
302 X 380
450 X 341
5
7-t-8
9-HO
11
111
151
111
191
612
707
974
107
0010/7
0005/7
0007/7
0003/7
0,189
0,287
0,313
0,586
5-8
9-11
111 652 0 1 0 4 / 7
111 9 7 4 0 1 0 5 / 7
0,243
0.462
700 903
0.024
GL, RGL
GL, RGL
GL, RGL
RGL
Schwenkbolzen
L, MS, RL, RMS, G GL, RGL
L. MS, RL, RMS, G,GL, RGL
Stopfen fr Brennergehuse
fr Bohrung
0 14,7
0 15.6 rot
0 15,5 schwarz
0 18,4
0 20.0
0 20,7
fr
Verschraubung
I 111 151 0004/7

i 452 873
i 446 001
452 847
M i l 151 0008/7
' 446 004
11 1 01 1 0115/7
11 1 512 0007/7
. 452 859
0 6,5
0 6,9
G 1/8"
Schaurohrdeckel mit Schauglas

L, M. RL. G. GL, RGL
L, MS. RL. RMS. G. GL, RGL
L, MS, RL, RMS, G. GL, RGL
1.12
111
111
111
111
181
Schwenkflansch
L, M, RL
L, MS, RL, RMS,
L, MS, RL, RMS
L, MS, RL, RMS
RL, RMS
Schalter mit Stobolzen
1.9
ca. kg
appr. kg
env. kg
Designation
Designation
Burner casing and Carcasse Brleur

individual parts
et pieces dtaches
7-H8
8/2
9 + 10
11
G, GL, RGL
G, GL, RGL
G, GL, RGL
1.,
1.12
Brennergehuse und
Einzelteile
Brennergehuse
L, M, RL
L, MS, RL, RMS,
L, MS, RL, RMS
L, MS, RL, RMS
RL, RMS
1.2
1,7
1,5
i 5
7-H8
' 9-11
II 1 552 0102/2
III 652 0102/2
II 1 974 0102/2
III
jij
iZ \
z\
\ E
I E
i E
Burner casing
Carcasse de brleur
Swivel flange
Bride a charnire
Locking screw
Bouchon hexagonal
Intermediate ring
for swivel flange
Bague intermdiaire
pour bride charnire
Flange sealing
Joint
Swivel bolt
Axe de charnire
Switch with push bolt
Interrupteur de fin de
course
Closing plug for burner
Bouchon obturateur
0,001
0.001
0,001
0.001
0,002
0.001
0.001
0,001
0,001
0.691
0,793
1.480
Inspection tube cover

corr.plete with sight glass
Couvercle d'inspection
i complet avec visiere
Verre de visiere pour

icouvercie d'inspection
Schauglas
fr Schaurohrdeckei
III
151 0 1 0 9 / 7
0,004
Clear sight glass for

inspection tube cover
Abdeckblech
111 311 011 1/7
0,020
Cover sheet for
PIaquette cache visiere
^9
1.M-1.15
Btld
Pict.
Photo
1.16
I Bezeichnung
I Brenner-Typenreihe
i Burner sene
! Type brieur
1.17
%JStf
l.li
: Gre I Bestell-Nr.
i Size
I Order-No.
I Grand, j No de commande
1.20
OD
1.21
j ca. kg
I appr. kg
I env. kg
Verschludeckel
fr Brennergehuse
L (zweistufig)
5-10
111 361 0004/2
0.040
1.15
RL, M. MS, RMS

GL
RGL
5-11
5-9
8-11
112 361 0005/2

155 327 0002/2
112 361 0005/2
0.040
0,100
0,040
1.16
G
RGL (o. Bild)
5-11
5-7
151 327 0009/7

156 3 2 7 0 0 0 1 / 2
0,045
0,045
Blinddeckel 1 x 40 x 60 (Gas)
5-11
151 5 1 8 0 1 0 8 / 7
0,019
1.14
1.17
1.18
1.19
1.20
1.21
Tlle
fr Brennergehuse
L, M, MS, RL, RMS, GL, RGL
L, G L
L, G L
M, MS, RL, RMS, RGL
1.22
Luftleitblech
L, M, RL, G, GL, RGL
5-11
5-9
111 3 5 1 0004/7
111 3 5 1 0 0 0 5 / 7
5-9
5-11
111 351 0006/7

112 351 0010/7
0,002
0,002
0,004
0,004
5
7-^8
111 552 0009/7

111 652 0008/7
0,084
0,097
1.22
Designation
; Designation
Closing cover
for burner casing
two stage
< Plaque de fermeture

{pour carcasse de brieur
deux allures
(without picture)
(sans photo)
Cover
Plaque pour carcasse
Transition nipple
for burner casing
Joint de passage
pour carcasse de brieur
Sheet metal air deflector
Tle de guidage d'air
% /
2,10
2,15
2,16
2.13-2,14
Bild
Piet,
Photo
2.
' Bezeichnung
Brenner-Typenreihe
Burner serie
i Type brieur
1 Gre 1 Bestell-Nr,
1 Order-No,
{ Size
1 Grand, j No de commande
Luftregelung
2,2
2,3
2.4
2,5
2,6
2,7
2,8
2,9
2,10
2.11
2.12
2.13
2,14
2,15
2.16
5
7-f8/2
9-t-IO
7T-fST
9T-H0T
111
111
111
111
111
564
764
964
794
994
0401/0
0401/0
0402/0
0402/0
0401/0
5,480
6,317
9,634
6,402
11,500
G
G
GL
GL
5
7-(-8
5
7-1-8
151
151
155
155
518
716
518
716
0202/0
0202/0
0201/0
0202/0
E
E
E
E
4,510
5,000
4,560
5,264
gleitend-zweistufige Brenner
RL
RL, R M S
RL, R M S
5
7-H8/2
9-11
111 5 8 2 0 2 0 2 / 0
111 7 8 2 0 2 0 3 / 0
111 9 7 4 0 2 0 2 / 0
E
E
E
4,380
5,141
8,420
G
G
G
G, Ausf, ZMI
G, Ausf, ZMI
GL, RGL
GL. RGL
GL, RGL
5
7-1-8
9-11
5
7-8
5
7-1-8
9-11
151
151
151
151
151
155
155
156
0203/0
0201/0
0201/0
0204/0
0203/0
0202/0
0201/0
0201/0
E
E
E
E
E
E
E
E
4,578
4,650
8,239
4,500
6,500
5,190
5.010
8,226
Luftregelgehuse
L, M, RL, G, GL. RGL
L, MS, RL, RMS, G, GL, RGL
5
7-1-8
9-11
111 5 5 2 0 2 0 1 / 7
111 762 0 4 0 2 / 7
111 9 7 4 0 2 0 7 / 7
E
E
E
3,350
3,900
6,200
Versctiludecl<el
9-11
11 1 9 7 4 0 2 0 8 / 7
0,155
Ansauggitter
L, M, RL, G, GL, RGL
5
7-f8/2
9-11
111 5 7 4 0 2 0 1 / 2
111 774 0 2 0 1 / 2
111 9 7 4 0 1 0 7 / 2
E
E
E
0,062
0,070
0,138
EInlaufdse
L, M, RL, G , GL, RGL
5
7-1-8/2
9-11
111 5 5 2 0 2 0 6 / 7
111 762 0 4 1 0 / 7
111 9 7 4 0 1 0 7 / 7
E
E
E
0,145
0,992
0,992
5-11
111 6 5 2 0 2 0 4 / 2
7-8/2(T) 111 794 0 4 0 2 / 2
E
E
0,170
0.166
452 873
111 O i l 0 2 0 7 / 7
111 151 0 0 0 8 / 7
Z
' E
\ E
0.001
0.008
0,002
111
I 11
111
111
II 1
i E
E
Abdeckblecfi mit Lagerbuchse
Stopfen
L, M, M S , RL, RMS, G, GL
L, MS. RL, RMS, G, GL. RGL
0 mm
15,6
35,0
20,0
5-11
5-8
9-HO
Luftklappe
Abmessung mm
1 L,M,RL,G,GL,RGL
128x226 5
60 x 2 2 7 j 5
; L,M,RL,G,GL,RGL
1 50 x 2 4 0 j 7-1-8
1 L,MS,RL,RMS,G,GLRGL
L,MS,RL,RMS,G,GL,RGL
64 x 2 4 0 7-(-8
LMS,RL,RMS,G,GLRGL
1 0 7 x 3 7 0 9-11
Luftklappenwelle
Lnge
zwei- und dreistufige Brenner
L, M
8x296,0 5
L,
6x261,5 ' 5
G, GL, RL
8x289,0 i 5
G. GL, L, MS
L. MS
L, MS
L, MS
518
707
907
518
707
518
707
907
562
562
762
762
974
0403/2
0404/2
0409/2
0408/2
0203/2
111
111
111
111
:
i
'
i
A i r r e g u l a t i o n c o m p l e t e , [ R e g u l a t i o n d'air
i complete
two and three
brCileurs deux et
stage burners
trols allures
sliding two stage

burners
brleurs deux allures

progressives
Air regulation casing
Carcasse de regulation
d'air
Closing cover
Couvercle
Air intake protection
Grille de protection
Inlet nozzle
Couronne d'aspiration
Sheet cover
Tle protectrice
Closing plug
Bouchon
Air flap
Clapet d'air
E1
0.159
0.056
i 0,183
: 0,063
0,576
i
E I
E i
E :
: 0.112
: 0.068
^ 0.128
782
764
964
974
0203/7
0401/7
0402/7
0210/7
E
E
E
E
i
;
j
i
0,072
: 0.141
i 0.209
: 0.190
111 582
I I 1 582
I I I 782
111 782
111 974
111 974
0221/7
0206/7
0203/7
0206/7
0210/7
0213/7
E
E
E
E
E
E
i
i
:
i
;
i
i
i
5
:5
: 7-8/2
i 7 -(- 8
! 9-11
| 9-11
[Regulation d'air
'
i
i I I 1 564 0401/7
I I I 582 0206/7
111 5 8 2 0 2 2 1 / 7
6 X 274,0 7 - 8 / 2 1
8 X 3 0 8 , 0 i 7 8/2
8 x 4 5 0 , 0 ; 9 + 10
8x424,0 ] 9
8 x 289.0
RL. G, G L , RGL
6x261.5
RL. GL, RGL
6 x 274,0
RL, RMS, G, GL, RGL
8 x 303,5
RL, RMS, G, GL, RGL
8 x 424,0
RL, RMS, G, GL, RGL
8 x 434,0
1 RL, G, GL, RGL
Designation
Air regulation
1
i
i
1 zwei- und dreistufige Brenner

L, M
L, MS,
L. M S ,
L
L
Designation
! appf- 1*9
[ env, kg
Luftregler komplett
2,1
1 ca, kg
1
1
1
0,128
0,068
0.072
0.135
0.190
0,192
Air flap shaft

two and three
stage burners
Axe clapet d'air

i arijieurs deux et
trois allures
sliding two stage

burners
jrleurs deux allures

! progressives
tf
2.17
2.19
2.18
2.20
2.22
2.23
2.24
2,25
2.26
2.27
2.28
2.29
O
2.30
2.31
O
2.33
2.34
2.35
1 Bezeichnung
Bild
Piet.
Photo
; Brenner-Typenreihe
i Burner sene
j Type bruleur
Gre
Size
Grand.
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
Designation
Designation
,
2.17
Lagerschraube
L, M, MS, G, GL, RGL, RL, RMS
5-8
111 582 0207/7
0,021
2.18
2.19
Lagerbuchse
RL. RMS, G, GL, RGL
5-8
9-11
111 151 0204/7

111 974 0205/7
0,010
0,025
2.20
Nadelhlse
9-11
460 027
0,011
2.21
Antriebshebel
zweistufige Brenner (ohne Bild)
G, GL
5-8
151 518 0211/7
0,034
111
111
111
111
582 0216/7
582 0217/7
582 0218/7
582 0219/7
0,022
0,025
0,040
0,045
2.22
2.23
2.24
2.25
RL,
RL,
RL,
RL,
RMS, G, GL, RGL

RMS, G, GL, RGL
RMS, G, GL, RGL
RMS, G, GL, RGL
7,0 x 155-11
5,5 x 155-8
5,5 x15 5-8
7,0 x 159-11
2.26
2.27
2.28
Verbindungsleiste
RL, G, GL, RGL
RL, RMS, G, GL, RGL
5
7-H8
9-11
111 582 1504/7

111 782 1503/7
111 974 1502/7
0,039
0,045
0,041
2.29
Lagerbolzen
L, RL, M, RMS, G, GL, RGL
5-11
111 582 0220/7
0,016
2.30
Grenztaster
7-1OT
111 794 0403/2
2.31
Schaltring
7-1OT
2.32
Stellring 18 x 35 x 11
2.33
Blech 1,5x50x230
1,5x62x242
2.34
Bearing screw
Vis paller
Bearing bush
Logement axe
Needle sleeve
Douille aiguille
Drive lever
two stage burners
(without picture)
Levier de mouvement
brleurs allures
(sans photo)
sliding two stage b
brleurs deux allures

progressives
Connection strip
Barette de jonction
Bearing bolt
Vis tete plate
0,144
Limit switch
Interrupteur
111 381 0201/7
0,027
Contact ring
Came bruleur
7-1 OT
111 794 0402/7
0,023
Adjusting ring
Rondelle gradu
5
7-8
151 5180210/7
151 707 0204/7
0,059
0,060
Sheet
Tle
Einstellknopf mit Zeiger
211 153 0212/7
0,007
Adjusting knob
Bouton
2.35
Ring 10,2 x 17x6
211 153 0213/7
0,006
2.36
Antriebshebel
Ausf. T 7 x 1 8 x 1 5
ZMI
ZMI
7-10
111 794 0403/7
0,021
Ring
Rondelle
Drive lever
Levier de mouvement
2.32
3,4
Bild
Piet.
Photo
Bezeichnung
Brenner-Typenreihe
Burner serie
Type brleur
3.5
Gre
Size
Grand.
Besteil-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
Stellantrieb f. Olbrenner
zweistufige Brenner
Stellantrieb 1055/23
110V 50 Hz
110V 60 Hz
230V 50 Hz
230V 60 Hz
110
110
110
110
0009/2
0010/2
0011/2
0012/2
1,140
1,131
1,183
1,185
3.2
Stellantrieb 1055/80
110V 50-60 Hz
230V 50-60 Hz
110 500 0013/2

110 500 0014/2
1,125
1,195
3.3
Abdeckhaube 1055/23, 1055/80

SQM10
651 399
651 428
0,140
0,267
3.1
500
500
500
500
3.4
3.5
3.6
Stellantrieb SQM10, komplett

RL
RL
RL
RL
RL
RMS
RMS
RMS
Stellantrieb SQM10
220-240 V/50-60 Hz
(42 Sek. Laufzeit)
110 V/50-60 Hz
(42 Sek. Laufzeit)
220-240 V/50-60 Hz
(mit 20 Sek. Laufzeit)
110 V/50-60 Hz
Heizpatrone 20 W (o. Bild)
RMS
5
7
8
9-HO
11
7-8/2
9/10
11
7-11
111 574
111 774
111 782
111 974
181 174
112 774
112 974
182 174
1501/0
1501/0
1503/0
1503/0
1502/0
1501/0
1501/0
1501/0
Designation
Designation
Servo drive for

oil burners
Servo-moteur pour
bruleur fuel
two stage burners

Servo drive
type 1051/23
bruleurs deux allures

Servo moteur
type 1051/23
Servo drive
type 1051/80
Servo moteur
type 1051/80
Cover
Capot
sliding two stage burners
bruleurs deux allures

progressives
Regulating drive SQM10,

complete
Organe de rglage
SQM10, complet
Servo drive SQM10
Servo-moteur SOM10
Heating cartridge
Cartouche chauffante
6,969
6,984
7,300
6,840
7,000
6,940
6,964
6,964
651 418
1,700
651 417
1,700
651 422
1,700
651 423
1,700
112 381 1302/2
0,124
3.36
3.38
3.40
3.30
3.31
3.32
3.33
3.35
3.43
: Bezeichnung
1 Brenner-Typenreitie
i Burner sene
I Type brleur
3.37
i4.
3.46
3.45
1 Gre
Size
Grand.
3.39
^*-.
^-.s
3.41
Biid
Piet.
Photo
3.33
3.34
3.32
3.31
3.47
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
3.48
i Designation
3.49
Designation
Stellantrieb fr Gas- und

Zweistoffbrenner
Servo-drive for gas

Servo-monteur pour
and dual fuel burners brleurs gaz et mixtes
mit Regelgestnge fr
zweistufige Brenner
with regulating rod for

two stage burners
avec tige de rglage

pour brleurs 2 allures
Stellantrieb Typ 1 0 5 5 / 8 0
komplett
G
Servo drive Type

1 0 5 1 / 8 0 , complete
Servo-moteur Type
1051/80, complete
without regulating rod for

two stage burners
Servo drive
Type 1 0 5 1 / 8 0
sans tIge de rglage

pour brleurs 2 allures
Servo moteur
Type 1 0 5 1 / 8 0
Servo drive
type 1 0 5 1 / 8 0
Servo moteur
type 1 0 5 1 / 8 0
5
7-8
151 5 1 6 1 5 0 2 / 0
151 716 1 5 0 2 / 0
E
E
3,445
3,470
GL
GL
5
7-8
155 5 1 6 1 5 0 2 / 0
155 7 1 6 1 5 0 2 / 0
E
E
3,343
3,370
ohne Regelgestnge fr
zweistufige Brenner
StellantriebTyp 1 0 5 5 / 8 0
G, GL
5-8
151 101 1 5 0 4 / 2
2,926
StellantriebTyp 1 0 5 5 / 8 0
110V 50-60 Hz
230V 50-60 Hz
5-8
5-8
110 5 0 0 0 0 1 3 / 2
110 5 0 0 0 0 1 4 / 2
E
E
1,125
1,195
651 3 9 9
651 4 2 8
E
E
0,139
0,267
Cover
Capot
151 101 1 5 0 6 / 2
0,390
Control segment
Disque de rglage
3.34
Abdeckhaube fr Typ 1 0 5 5 / 8 0
frTypSQMIO
3.35
Reglerscheibe
5-8
3.36
Stahlband
5-8
151 101 1528/7
0,012
Steel band
Lame d'acier
3.37
Fhrungsstck
5-11
211 3 7 3 1514/7
0,023
Guide piece
Bute guide
3.38
Befestigungsstck
5-8
151 101 1 5 1 5 / 7
0,010
Attachment piece
Bute de fixation
3.39
Federscheibe
5-8
431 6 1 5
0,001
Spring plate
Disque ressort
3.40
Platte (o. Bild)
151 101 1505/2
0,402
Plate
Plaque
3.41
Reglerhebel
151 101 1 5 0 7 / 2
0,117
Regulating lever
Levier de rglage
3.42
Greifring G 10 x 1,2
435 3 8 2
0,001
Grip screw
Rondelle ressort
3.43
Welle 8 X 8 X 105
151 101 1 5 1 4 / 7
0,046
Shaft
Bouchon
3.44
Anschlukabel (ohne Bild)

9x0,75x810
9x0,75x920
1-8
9-11
151 101 1 5 1 4 / 2
211 163 1 5 0 4 / 2
E
E
0,075
0,120
Connection cable
(without picture)
Cable de raccordement
(sans photo)
Regelgestnge Luft und Gas

G, GL
G, GL
Regulating rod
Tige de rglage
3.45
5
7-8
151 5 1 6 1 5 0 1 / 2
151 7 1 6 1 5 0 2 / 2
E
E
0,231
0,258
Gewindestange
M6 X 103
M6x143
Threaded rod
Axe filete
3.46
5
7-8
151 101 1 5 1 1 / 7
151 101 1 5 1 2 / 7
E
E
0,019
0,028
3.47
Gelenkkopf SFEV6
499 0 0 1
0,025
Hinge rod head
Rotule d'accouplement
3.48
Bundbolzen M6 x 63,0
M6x32,5
151 101 1 5 1 0 / 7
151 3 2 7 1 5 0 7 / 7
E
E
0.027
0,012
Flange bolt
Goujon filete
with regulating rod

for sliding-two stage
burners
Servo drive
TypeSQMIO
avec tige de rglage

pour brleur progressif
mit Regelgestnge fr
3.49
Stellantrieb Typ SQIVIIO

G, GL
G. GL
G. GL
5
7-8
9-11
151 5 1 8 1 5 0 4 / 0
151 707 1 5 0 3 / 0
151 9 0 7 1 5 0 3 / 0
E
E
E
4,826
4,888
5,378
RGL
RGL
RGL
RGL
RGL
5
7
8
9-1-10
11
156
156
156
156
196
1502/0
1503/0
1501/0
1502/0
1502/0
E
E
E
E
E
9,323
9,334
8,711
8,735
8,759
RGMS
RGMS
RGMS
7-8
9-10
11
158 707 1 5 0 1 / 0
158 9 0 7 1 5 0 1 / 0
198 107 1 5 0 1 / 0
E
E
E
8,835
8.859
8,883
G (Ausf. ZMI)
G (Ausf. ZMI)
5
7
151 5 1 8 1 5 0 5 / 0
151 7 0 7 1 5 0 5 / 0
E
E
4.592
4,638
518
707
807
907
107
Servo moteur
TypeSQMIO
,1r
t
3,51
'NW/
3.56
3.53
3.52
3.58
3.54
3.64
3.65
3.67
3.66
3.68
3.70
).69
i Bezeichnung
^ Brenner-Typenreihe
Burner serie
j Type brleur
Bild
Piet.
Photo
Gr6e ; Bestell-Nr.
1 Order-No.
Size
Grand. , No de commande
ohne Regelgestnge fr gleitendzweistufige Brenner (o, Bild)

G. G L
3.50
i RGL
RGL
'' RGL
RGL
1
1
: 151 3 2 7 1510/2
4,408
5
7
8-10
11
: 156
1 156
' 156
196
E
E
E
E
8,884
9,000
8,259
8,263
651 418
651 417
651 422
E
E
E
1,700
1,700
1,700
651 423
1,700
518
707
807
107
1508/2
1504/2
1501/2
1502/2
3.52
Grundplatte
5-11
151 3 2 7 1522/7
0,365
3.53
Nabe G
GL
5-11
5-9
151 3 2 7 1511/2
0,108
lregler
bis 70 kg/h Welle 0 0 / 0
RGL, R G M S bis 280 kg/h
1/2
bis 280 kg/h
1/2
bis 420 kg/h
3/4
5
7
8-10
11
111
111
111
181
E
E
E
E
2,370
2,360
2,380
2,400
7-11
3.54
574
774
874
174
1501/2
1501/2
1501/2
1504/2
! Designation
! ca. kg
i appr- kg
j env. kg
5-11
Stellantrieb Typ SQIM10

220 -240V/50-60 Hz (42 Sek. Laufzeit)
110 V/50-60 Hz (42 Sek. Laufzeit)
2 2 0 240V/50-60 Hz
110 V/50-60 Hz
(mit 2 0 Sek. Laufzeit)
3.51
3.63
1 Designation
!
! without regulating rod
for sliding two stage
burners (without picture)
Servo drive
TypeSQMIO
isans tige de rglage

I pour brleur progressif
j (sans photo)
Servo moteur
TypeSQMIO
(
Base plate
Plaque de base
Hub
Moyeu
Oil regulator
Rgulateur fuel
3.55
Heizpatrone 20 Watt (o. Bild)
112 3 8 1 1302/2
0,124
Heating cartridge
3.56
Dichtung
4 4 3 11 7
0.002
Lip ring
Joint levre
3,57
O-Ring 4 2 x 2 (o. Bild)
445 034
0,002
O-Ring
Joint torique
Control segment
Disque de rglage
Reglerscheibe
G
GL
RL, RGL, RMS
5-11
5-9
5-11
3.59
Fhrungsstck
5-11
211 373 1514/7
0,023
Guide piece
Bute guide
3.60
Sicherungsscheibe
4 3 1 601
0,001
Locking washer
Circlips
Verstellspindel M6/S0.
5 0 lang
55 lang
60 lang
6 5 lang
75 lang
Adjusting spindle
Vis de rglage
121
121
121
121
121
2178/7
2179/7
2180/7
2181/7
2182/7
E
E
E
E
E
0,011
0,012
0,013
0,014
0,016
Fhrungswinkel
121 3 6 2 2 1 8 5 / 7
0,017
Angular guide piece
3.58
3.61
3.62
3.63
3,64
' Stahlband
362
362
362
362
362
0,930
0,730
1
i
1
121 3 6 2 2195/7
0,021
Steel band
Pascheibe
1 21 3 6 2 2 1 8 7 / 7
0.001
Shim
121 3 6 2 2184/7
0.009
Attachment angle
151 3 2 7 1517/7
| E
0,030
Lever
3.65
Befestigungswinkel
3.66
Hebel
3.67
Schraubbolzen
3,68
Kupplungsstck
j E
Platte
151 327 1525/7
3,70
Welle 56 mm (G. GL)

66 mm (RGL. RGMS)
142 mm
212mm
151
156
151
156
Scheibenfeder
5 X 6.5
:
;
^1
121 464 2114/7

151 327 1527/7
3.69
3,71
E
E
151 3 2 7 1506/2
121 3 6 2 2 1 0 3 / 2
327
327
327
327
4 9 0 151
4 9 0 157
1526/7
1507/7
1528/7
1504/7
0.006
E
E
E
E
i
:
i
;
1
1
1
'
iZ 1
1Z 1
Lame d'acier
i Rondelle plate
1
1 Equerre de fixation
.evier
Screwing bolt
Boulon
Coupling piece
Accouplement
0,208
Plate
Plaque
0,081
0.080
0.082
0,123
Shaft
3ouchon
1 0,085
|
j
j
| Equerre de rglage
i
'
1
i
0.003
0,001
Woodruff key
Rondelle
3x3.7
mm
f
3.72
3.74
3.73
;.75
3.78
3.77
3.76
H-
A
i
Bild
PiCt.
Photo
3.83
3.82
3.81
3.79
i Bezeichnung
1 Brenner-Typenreihe
Burner serie
1 Type brleur
Gre
Size
Grand.
3.S4
3.36
3.S7
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
3.80
fil
3.89
i Designation
3.72
Buchse
121 464 2 1 1 2 / 7
0,001
! Sleeve
3.73
Gleitlager
499 089
0.005
\ Bearing
3.74
Lagerbuchse
151 327 1 5 1 2 / 2
0,098
Bearing sleeve
3.75
Buchse
156 327 1 5 0 5 / ?
0,048
Sleeve
; Designation
Coussinet
'Axe
I
I Axe coussinet
Coussinet
3.76
Hebel! 27 mm
156 327
1506/?
0,086
Lever
Levier
3.77
Reglerhebel
151 32? 1 5 1 3 / 2
0,143
Regulating lever
Levier de rglage
3.78
Reglerhebel
151 518 1507/2
0,194
Regulating lever
Levier de rglage
3.79
Stellring
151 327 1 5 3 2 / 7
0,013
Adjusting ring
Rondelle gradu
3.80
Stehbolzen M8 x 134
M8 X 2 0 4
151 327 1 5 2 4 / 7
156 327 1 5 0 3 / 7
0,238
0,327
Stay bolt
Entretoise
3.81
Leiste
151 327 1 5 3 3 / 7
0,060
Strip
Bornier
Regulating rod (air)
Tige de rglage (air)
5
7-8
9-11
151 518 1508/2

151 70? 1503/2
151 90? 1505/2
0,120
0,135
0,139
Regulating rod (gas
Tige de rglage (gaz)
G, GL
G, GL
G, GL
5
7-8
9-11
151 518 1509/2

151 707 1 5 0 4 / 2
151 907 1 5 0 6 / 2
0,166
0,180
0,174
RGL
RGL
RGL
5
?-10
11
156 518 1 5 0 7 / 2
156 70? 1 5 0 3 / 2
196 10? 1 5 0 3 / 2
0,120
0,118
0,138
Gewindestange (Luft u. Gas)

M6x115
M6 X 240
IV16 X 283
M6 X 200
111
111
151
196
0,022
0,042
0,058
0,036
Threaded rod
(air and gas)
Tige de rglage
(air et gaz)
3.85
Gelenkkopf SFEV6 (Bild s. Seite?)
4 9 9 001
0,025
Hinge rod head
3.86
Distanzrohr
151 101 1 5 2 0 / 7
151 327 1535/7
0.001
0,005
Distance sleeve
Entretoise
3.87
Lagerbolzen
151 32? 1 5 0 8 / 7
0,008
Bearing bolt
Axe galet
3.88
Anschlukabel
(ohne Bild)
9xO,75x
12x0,75x
151 101 1 5 1 4 / 2
151 90? 1 5 0 2 / 2
0.075
0,164
Connection cable
(without picture)
Cable raccordement
(sans photo)
3.89
Verschraubung
P G 1 1 X 6-9
PG11 x6-11
730 009
730 110
0,018
0,016
Screwing
3.90
Potentiometer (ohne Bild)

ASZ8
2 2 0 Ohm
ASZ12
1000 Ohm
651 434
651 435
0.02?
0,027
3.82
Regelgestnge (Luft)
G, GL, RL, RGL
G, GL. RL, RGL
G, GL, RL, RGL
Regelgestnge (Gas)
3.83
3.84
6.1 X l O x 4
6.2 X 8 X 28
810
980
582
974
516
107
1 506/7
1508/7
1501/7
1501/7
Positions indicator
I Rotule d'accouplement
Presse toupe
indicateur de position
4.6
4.5
4.4
^T*
5.1-5.5
Bild
Pict.
Photo
5.8
5.6
! Bezeichnung
j Burner serie
i Type brleur
Bestell-Nr.
Order-No.
No de commande
Designation
Brennermotor
Burner motor
Moteur de brleur
Bei Bestellung Spannung und

Frequenz angeben.
When ordering indicate

voltage and frequency
A la commande indiquer
la tension et la frequence
Brennermotoren,
50 Hz, 2 8 0 0 1/min.
Typ
DK08/90-2/3
Burner motor
Moteur de brOleurs
V
230/400
111 554 0 7 6 3 / 0
11.140
4.2
DK2-2
DK3/115-2
DK3/115-2a
DK3/115-2a
DK3/115-2
230/400
230/400
230/400
380/660
380/660
7
8/2
8
8
8/2
111
111
111
111
111
0703/0
0702/0
0708/0
0706/0
0714/0
25,120
33,520
34.060
34,020
34,060
4.3
D132/120-2a
D I 32/120-2
D I 32/150-2
380/660
380/660
380/660
9
10
11
111 9 7 4 0 7 0 6 / 0
181 0 7 4 0 7 1 2 / 0
181 174 0 7 0 5 / 0
44,500
45,500
54,000
Intermediate ring
Bride intermdiaire
1,015
762
866
862
862
866
; ca. kg
i appr. kg
i env. kg
4.4
Zwischenring
111 552 0 1 0 3 / 7
4.5
Scheibenfeder
5x6,5
4 9 0 151
0,003
Woodruff key
Clavette disque
4.6
Pafeder
6 X 6 X 45
7-8/2
490 316
0,012
Adjusting spring
Clavette
111 5 5 2 0 8 0 4 / 2
111 5 5 2 0 8 0 5 / 2
Geblse
Blower
Ventilation
Geblserad
0 mm
248x100 36Sch.
248x100 36Sch.
Farbe
verzinkt
rot (60 Hz)
1,957
1,239
Blower w h e e l
Color
galvanized
red
Turbine
Couleur
zingue
rouge
268x100 30Sch.
248 X 100 3 6 S c h .
verzinkt
rot (60 Hz)
111 612 0 8 0 4 / 2
111 6 1 2 0 8 1 0 / 2
3,120
2,393
red
rouge
5.3
3 3 0 X 100 4 2 S c h .
3 3 0 X 100 4 2 S c h .
grn
rot (60 Hz)
111 974 0 8 1 4 / 2
111 974 0 8 1 5 / 2
5.002
3.877
green
red
verte
rouge
5.4
3 4 5 X 100 3 8 S c h .
3 3 0 X 100 4 2 S c h .
blau
rot (60 Hz)
211 504 0 8 0 8 / 2
111 974 0 8 1 6 / 2
3.760
3,860
blue
red
bleue
rouge
5.5
3 4 5 X 100 3 8 S c h .
3 3 0 X 100 4 2 S c h .
blau
rot (60 Hz)
211 504 0 8 0 8 / 2
211 504 0 8 1 0 / 2
3,760
3,760
blue
red
bleue
rouge
Blower w h e e l remover
Arrache turbine
5.1
5.2
7-1-8
7 + 8
Abziehvorrichtung f. Geblserad
5.6
5.7
10.
5.11 5.12
Designation
4.1
Gre
Size
Grand.
5.10
5.9
5.8
Kupplungsstck D132
5.9
Unterlegscheibe
fr Geblseradbefesfigung
5.10
Schraube M 1 0 x 4 0 links
5-8
9-11
111 111 0 0 0 1 / 2
121 3 6 2 0 0 1 3 / 2
9-11
111 974 0 8 1 1 / 7
i
!
0,194
0,687
0,063
5
7 +1
111 512 0 8 0 3 / 7
111 6 1 2 0 8 0 9 / 7
0,005
0.011
9-11
4 0 2 630
0.032
5.11
i Sicherungsscheibe S6
5.12
! Schraube M6 x 25
I
M8 X 2 0
5
7-f8
i 4 0 2 371
' 404 408
;z
I
'z
5.13
; Fcherscheibe (o. Bild) V8,4
7-t-8
4 3 1 704
:Z
i
5.14
; Federring (o. Bild) A I 0
9-11
4 3 5 301
4 9 0 003
iZ j
!z I
Coupling piece
Piece d'accouplement
Washer for blower wheel

attachment
Rondelle plate pour

fixation turbine
Screw
Vis
0,001
Spring plate
Disque a ressort
0.007
0.009
Screw
Vis
0.001
Fan disc washer
Rondelle eventoil
0.002
Spring ring
Disque ressort
w 4k
6.1-6.3
6.8
6.9
6.10
6.11
6.12
GAwK^fKm
6.25
6.21.-6.22
6.26
Bezeichnung
Bild
Piet.
Photo
GrBe
Size
Grand.
Brenner-Typenreihe
Burner serie
Type brieur
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
Pumpen
6.1
Pumpentyp
J6
J6
LGL
L, GL
L. GL
J7
5
7
8-9
601 005
601 005
601 006
3,720
3,720
3,900
5
7
8-9
601 047
601 048
601 049
4,050
4,165
4,290
601 049
4,290
7
8-10
11
601 050
601 051
601 052
5,470
5,760
6,040
5-9
10T
5
7-9
5
7-10
11
111 564 0602/2

181 094 0603/2
112 564 0602/2
112 764 0605/2
111 574 0602/2
111 774 0603/2
181 174 0602/2
111 774 0604/2
0,190
0,275
0,600
0,560
0,605
0,590
0,720
0,608
6.2
M,
MS
MS
E4
E6
E7
6.3
RL, RGL
E7
6.4
RL, RMS, RGL

RL, RMS, RGL
RL, RMS, RGL
TA2
TA3
TA4
6.5
AnschluBteile fr Pumpe: (o. B.)

J6, J7
L
TA2
L
E4
M
E6/E7
MS
E7
RL, RGL
TA2, TA3
RL, RMS
TA4
RL, RMS
TA2 (RL7 mit K3 Dse)
6.6
Sieb (ohne Bild)

fr Pumpe J3, J4, J6
E4, E6, E7, J7
601 066
601 067
0,015
0,042
6.7
Deckeldichtung J-H-E (o.Bild)
601 069
0,001
6.8
6.9
Pumpenkupplung
L, M, MS. GL
RL, RGL
RL, RMS
5-9
5
7-11
111 011 0902/2

111 782 0901/2
0,033
0,134
GL (mit Magnetkupplung), RGL
7-H8
155 707 0902/7
0,095
Kupplungsmittelstck
Lnge
mm
141
188,5
208,5
200
6.10
L,M,RL,GL,RGL
L,MS.RL,RMS,GL
L,MS
RL,RMS,GL,RGL
6.11
Kupplungskreuz, L,M,R,GL,RGL
6.12
Befestigungsflansch
RL, RMS
GL mit J-Pumpe
6.20
6.21
6.22
5
7-t-8
9
9-11
7-1-8
7-9
363 0903/2
764 0903/2
964 0903/2
974 0901/2
0,150
0,173
0,183
0,181
111 151 0901/7
0,005
111 882 0601/2
0,225
211
111
111
111
Pumpenheizung
Heizpatrone
komplett
220 V/ 8 0 W (E)
220 V/ 8 0 W (E)
220 V / 1 0 0 W (TA)
Heizpatrone
110
110
220
220
V/ 8 0 W
V/1 00 W
V/ 8 0 W
V/100 W
5
7-9
7-11
Designation
Designation
Pumps
Pompes
P u m p type
P o m p e type
Connection parts
for pump
Elements de raccordement pour pompe
Filter (without picture)

for pump
Filtre (sans photo)

pour pompe
Sealing (without picture)
Joint (sans photo)
Pump coupling
Accouplement de
pompe
(with magnet coupling)

Coupling center piece
Length mm
avec accouplement
magntique)
Accouplement intermediaire Longueur mm
Coupling cross
Croislllon
Attachment flange
Flasque de fixation
Pump heating
Chauffage de pompe
Heating cartridge
complete
complet
112 151 0605/2

11 2 764 0604/2
112 774 0603/2
0,176
0,210
0,213
794
794
794
794
0,035
0,035
0,035
0,035
Heating cartridge
226
228
227
229
6,23
j Druckring (ohne Bild)
122 364 1001/7
0,002
Pressure ring
Bague de pression
5,24
: Lackschlauch, Preis pro Meter

i (ohne Bild)
750 754
0,018
Varnishing hose
Galne isolante
6.25
i Verschraubung, Pg 9
491 301
0,014
Screwing
Presse toupe
6.26
Metallschlauch, DN 9
Preis pro Meter
491 040
0.026
Metal hose
Galne mtallique
11
tfe
6.41
6.43
1 Bezeichnung
j Burner serie
! Type bruleur
6.40
M a g n e t k u p p l u n g (Gleichstrom)
WMK1
RGL
WMK 2
GL
WMK 2 / 1
RGL
Lagerflansch
GL, RGL
GL, RGL
GL, RGL
5
7-9
7-11
155 101 0 9 0 3 / 2
155 707 0 9 0 2 / 2
155 907 0 9 0 3 / 2
E
E
E
0,615
1,100
1,099
5
7-8
9-11
155 5 1 8 0 9 0 1 / 2
155 707 0 9 0 1 / 2
155 907 0 9 0 1 / 2
E
E
E
0,850
1,100
1,050
6.43
Halteschelbe
GL, RGL
5-11
155 101 0 9 0 3 / 7
0,005
6.44
Distanzscheibe
GL, RGL
155 101 0 9 0 4 / 7
0,011
6.45
Pumpenflansch
GL, RGL
GL, RGL
5
7-11
155 101 0 6 0 1 / 7
155 907 0 6 0 1 / 7
E
E
0,555
0,723
6.46
Gleichrichtergert
D G / 2 , 220 V - 2 4 0 V/24 V
D G / 2 , 110 V - 1 2 0 V/24 V
710 565
710 566
E
E
1,810
1,862
155 907 0 0 0 2 / 2
0,210
6.42
Designation
Magnet coupling
lAccouplement
magntlque
l\âgnet coupling
(direct current)
lAccouplement m a g n tlque (courant continu)
Holding disk
Rondelle de maintien
Distance shim
Entretoise
Pump flange
Support de pompe
Rectifier aggregate
Redresseur
Remover
Arrache accouplement
6.47
Abziehvorrichtung
W M K 1 , WMK2, WMK2/1
6.50
lschluche
Oil h o s e s
Flexibles fuel
lschluche fr lpumpe als

Ansaug- und Rcklaufschlauch
Oil hoses for oil pump

as suction intake and
return h o s e
For fuel oil EL up to
max, 7 0 C
Lenght mm Connection
Flexibles pour pompe

aspiration et refoulement
Pour fuel EL
max. 70-C
Longeur mm
For fuel oil MS up to
Pour fuel MS
max. 150C
max. 150C
6.51
6.52
6.53
5-11
Fr Heizl EL bis max. 70

DN
L, GL
Gl/2
13
L, GL
G 1/2
13
Lnge mm
1000
1300
5-9
5-9
491 019
491 031
E
E
0,476
0.647
RL,
RL,
RL,
RL,
RL,
1000
1300
1000
1300
1300
5
5
7-10
7-10
11
491
491
491
491
491
E
E
E
E
E
0,476
0,647
1,052
1,245
2,360
RGL G 1/2
RGL G 1/2
RGL M30x1,5
RGL M30x1,5
RGL M38x1,5
13
13
20
20
25
019
031
009
032
029
Fr Heizl MS bis max. 150 drfen nicht in Feuerungsanlagen

innerhalb der BRD eingebaut
werden
M
G 1/2
13
1000
M
Gl/2
13
1300
MS
M30x1,5
20
1000
MS
M30x1,5
20
1300
5-9
5-9
7-9
7-9
491
491
491
491
078
079
081
082
E
E
E
E
0,643
0,710
0,976
1,219
RMS
PMS
RMS
7-10
7-10
11
491 081
491 082
491 084
E
E
E
0,976
1,219
1,780
M30x1,5
M30x1,5
M38x1,5
20
20
25
1000
1300
1300
Schiffsausfhrung fr Heizl EL
und MS bis max. 150C (Edelstahl)
1M
Gl/2
12
700
M. MS
Gl/2
12
1000
M, MS
Gl/2
12
1300
MS
M30x1,5
20
1000
MS
M30x1,5
20
1300
RMS
RMS
RMS
RMS
M30X1.5
M30x1,5
M38x1,5
M38x1,5
20
20
25
25
1000
1300
1150
1500
491
491
491
491
491
5-9
5-9
i 7-10
\ 7-10
! 7-10
\ 7-10
11
11
119
093
094
095
096
' 491 095

! 491 096
! 491 097
491 109
E
E
E
E
E
0.290
1 0,800
1,000
1,200
1,200
j
E
E
i E i
i 1,200
1 1,200
1,600
1.427
6,54
6,55
: Einschraubstutzen
G l / 2 " X G l / 2 " X 3 7 DN13
M 3 0 x 1 , 5 x R 1 x 4 1 DN20
M 3 8 x 1,5 x R 1 x 4 3 DN25
Rohrbogen (o. Bild)
DN 13
i DN20
DN26
!
;
i
111 512 0 0 0 3 / 7
112 151 0 0 0 5 / 7
122 362 0 0 0 7 / 7
1
i 453
i 453
250
251
4 5 3 252
E 1
' E
1E
E
i
i
Ship's execution for fuel

oil EL and M S up to
max. 1 5 0 C
1
I
1
j
;
i
i
I
i
Adaptor
0,070
0.169
0,174
! Raccord droit
[
j
Tube bend
E
E
E
Execution navire pour

1 Fuel EL et MS
max. 1 5 0 ' C
Tube c o u d e
0,126
0,216
0,350
I
1
12
.^.ar
6.53
Designation
ca. kg
appr. kg
env. kg
Magnetkupplung
6,41
6.51
6.52
6.46
Besteil-Nr.
Order-No.
No de commande
Gre
Size
Grand.
6.44
6.45
Bild
Piet.
Photo
^ \
6.63
6.64
; Bezeichnung
Bild
Piet.
Photo
6.60
6.61
6.62
6.63
Bestell-Nr.
Order-No.
No de commande
I ca. kg
lleitungen ohne Schneidring und

berwurfmutter zum selbstbiegen
6 x 1 , X 625 mm
8 x 1 X 625 mm
l O x 1 X 625 mm
1 2 x 1 5 X 625 mm
1 8 x 1 5x 625 mm
111
111
111
111
111
111
111
111
111
111
4919/7
4920/7
4921/7
4922/7
4923/7
E
E
E
E
E
0.078
0,110
0,131
0,242
0,380
6x1
X 1250 mm
8x1
X 1 250 mm
10x1
X 1250 mm
12 X 1 , 5 x 1 2 5 0 mm
18 X 1,5 X 1250 mm
111
111
111
111
111
111
111
111
111
111
4914/7
4915/7
4916/7
4917/7
4925/7
E
E
E
E
E
0,165
0,226
0,288
0,477
0,739
452
452
452
452
452
770
771
772
773
775
Z
Z
Z
Z
Z
0,002
0,002
0,002
0,003
0.005
452 801
452 809
Z
Z
0,002
0.003
452
452
452
452
452
834
829
828
836
803
Z
Z
Z
Z
Z
0,010
0,015
0,018
0,025
0,025
452 800
452 816
Z
Z
0,006
0,007
Schneidring
DPR-L
IJberwurfmutter
M-L
M-LL
6L
8L
10L
12L
18L
6LL
8LL
6L
8L
10L
12L
18L
6LL
8LL
I Designation
: Designation
I appr- l^g
! env. kg
lleitungen
D-LL
6.64
I Gre
I Size
I Grand.
] Brenner-Typenreihe
I Burner serie
j Type brijieur
Oil lines
jCanalisation fuel
Oil lines
for self bending
(without picture)
jConduite de fuel
ja former
(sans photo)
Cutting ring
Olive
Union nut
Centre cren
f***^
7.1
Bild
Piet.
Photo
7.1
7.2
7.3
7.4
7.5
7.6
7.7
14
Bezeichnung
Brenner-Typenreihe
Burner serie
Type bnjleur
i Gre
I Size
Grand.
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr, kg
env. kg
Designation
Designation
Magnetventile fr l
Solenoid vatves
for oil
Vannes magnetiques pour fuel
Magnetventil Typ 121 C 2 3 2 3 , 1 / 8 "

mit Spule 3 7 6 4 , 9 Watt, IP65
stromlos geschlossen
110V/50-60HZ
187-240 V/50-60 Hz
Solenoid valve
with coil 3 7 6 4
currentless closed
Vanne magntique
Solenoid valve
with coil 3 8 2 4 ,
currentless closed
stage 2
Vanne magntique avec

avec bobine 3 8 2 4
ferme hors tension,
allure 2
Solenoid valve
with coil 3 8 2 4
currentless open
stage 1
Vanne nnagntique
avec bobine 3 8 2 4
ouverte hors tension
allure 1
Solenoid valve
with coil 3 5 4 1
currentless closed.
Vanne magntique
avec bobine 3541
ferme hors tension
Solenoid valve
with coil 3 5 4 1
currentless closed
Vanne magntique
avec bobine 3541
ferme hors tension
Solenoid valve
with coil 3 5 4 1
currentless closed
Vanne magntique
avec bobine 3541
ferme hors tension
Solenoid valve
with coil 3 5 4 1
currentless closed
Vanne magntique
avec bobine 3541
ferme hors tension
Magnetventil Typ 121 K 2 4 2 3 , 1 / 8 "

mit Spule 4 8 3 8 2 4 , 19 Watt
Stufe 2
5 5 V / 5 0 Hz*
5 8 V / 6 0 Hz*
110 V/50 Hz*
115 V/60 Hz*
220 V / 5 0 Hz*
2 3 0 V/60 Hz*
5 8 V/60 Hz**
55 V/50 Hz**
11 5 V/60 Hz**
110 V/50 H z "
2 3 0 V/60 Hz**
220 V/50 Hz**
Magnetventil Typ 122 K 9 3 2 1 , 1 / 8 "
mit Spule 4 8 3 8 2 4 , 19 Watt
stromlos offen
Stufe 1
110 V/50 Hz*
115 V/60 Hz*
220 V/50 Hz*
2 3 0 V/60 Hz*
110 V/50 Hz**
115 V/60 Hz**
220 V / 5 0 Hz**
2 3 0 V/60 Hz**
MagnetventilTyp 121 K 6 2 2 0 , 1 / 4 "
mit Spule 4 8 3 5 4 1 , 2 0 Watt
5 5 V / 5 0 Hz*
5 8 V / 6 0 Hz*
110 V/50 Hz*
115 V/60 Hz*
220 V/50 Hz*
2 3 0 V/60 HzMagnetventil Typ 121 K 6 2 2 0 , 1 / 4 "
mit Spule 4 8 3 5 4 1 , 2 0 Watt
55 V/50 H z "
5 8 V/60 Hz**
110 V/50 H z "
115 V/60 H z "
220 V/50 H z "
2 2 0 V/60 Hz**
MagnetventilTyp 321
mit Spule 4 8 3 5 4 1 , 20
5 5 V/50 Hz*
58
110 V / 5 0 Hz*
115
220 V / 5 0 Hz*
230
604 450
604 451
604 601
604 602
604 603
604 604
604 605
604 606
604
604
604
604
597
598
599
600
604 512
604 513
604 514
604 515
604 516
604 517
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
0,480
H2322, G 3 / 8 "
Watt
V/60 Hz*
V/60 Hz*
V/60 Hz*
Magnetventil Typ 321 H2322, 3/8"

mit Spule 4 8 3 5 4 1 , 2 0 Watt
55 V/50 H z "
58 V/60 Hz**
110 V/50 H z "
115 V/60 Hz**
220 V/50 Hz**
2 3 0 V/60 H z "
604 530
604 531
604 532
604 533
604 534
604 535
ferme hors tension
0,250
0,250
0,450
0,950
1,000
0,450
0,998
0,450
' Spulen-Gehuse Standard IP44
* Coil casing standard
** Spulen-Gehuse wasserdicht IP67
" Coil casing waterproof
Boitier de bobine
standard
Boitier de bobine
tanche l'eau
0^
7.8
7.9
.-._-..
^
^
Bild
Piet.
Photo
I Bezeichnung
Brenner-Typenreihe
Burner serie
Type brleur
7.8
7.9
7.10
7.11
7.12
! Gr8e
1 Size
j Grand.
Magnetventil Typ 121 G2320, G 3 / 8 "

mit Spule 4 8 3 5 4 1 , 20 Watt
55 V/50 Hz',
5 8 V / 6 0 Hz*
110 V/50 Hz*,
115 V/60 Hz*
220 V/50 Hz*,
230 V/60 Hz*
7,13
Bestell-Nr.
Order-No.
No de commande
604 518
604 519
604 520
Magnetventil Typ 121 G 2 3 2 0 , G 3 / 8 "

mit Spule 4 8 3 5 4 1 , 20 Watt
55 V/50 Hz**,
5 8 V / 6 0 Hz**
110 V/50 Hz**, 115 V / 6 0 Hz**
220 V/50 H z " ,
2 3 0 V / 6 0 Hz**
604 521
604 522
604 523
7.22
ca. kg
appr. kg
env. kg
Designation
1 Designation
1
1
Solenoid valve currentless closed
Vanne magntique
ferme hors tension
Solenoid valve currentiess closed
Vanne magntique
ferme hors tension
0,330
0,930
0,930
0,930
1,039
0,930
** Spulen-Gehuse Standard IP44
* Coil casing standard
** Spulen-Gehuse wasserdicht IP67
** Coil casing waterproof
Magnet-Spule
Typ 3764 9 Watt
11OV/50-60 Hz
220V/50-60 Hz
Solenoid valve coil
Bobine de vanne
magntique
604 452
604 453
0,135
0,130
Typ 483824, 19 Watt

55V/50-60 Hz
11 OV/50-60 Hz
1 87-240V/50-60 Hz
604 551
604 552
604 553
0,075
0,150
0,140
T y p 4 8 3 5 4 1 , 2 0 Watt
55V/50 Hz,
58 V / 6 0 Hz
110V/50HZ,
115 V / 6 0 Hz
220V/50 Hz,
230 V/60 Hz
604 554
604 555
604 556
0.140
0,140
0,140
Schmutzfnger
3/8", PN 50
1/2", PN 50
Filter
Filtre
499 042
499 043
0,205
0,330
7.14
Steckdose fr Ventil 121 C 2 3 2 3
716 104
0,064
7.15
Anschlukabel fr Magnetventil
(ohne Bild)
L
L (dreistufig)
RL, RGL
5-9
7-10
5-7
111 764 1302/2
0,060
RL, RGL
MS, RMS, RGMS
8-10
5-8
112 151 1307/7
0,054
7.17
MS, RGL
9-11
112 261 1305/7
0,094
7.18
RMS
9-11
112 964 1301/7
0,139
7.19
Magnetventil (ohne Bild)

RL8, RL8/2, RGL8-RGL10
RL9-RL11,RGL11
7.10
7.11
7.12
7.13
7.16
M
MS
RMS
7.20
7.21
7.22
15
7-9
7-10
9-11
Verteilerstck (ohne Bild)

RL5-RL8/2, RGL8-RGL10
RL9-RL11,RGL11
Solenoid valve
(without picture)
jVanne magntique
; (sans photo)
112 564 1302/2

112 764 1301/2
2,513
2,520
112 574 1305/2

182 174 1301/2
2,872
2,969
111 574 1303/7

111 974 1304/7
1.508
1.457
112 564 1301/2
1,000
RMS
7-8/2
9-11
212 374 1301/7

112 974 1302/7
1,430
1,382
Thermometer 0-160 C
Prise de courant
Cable de raccordenpour vanne
(sans photo)
2.800
2,897
5-9
5
7-9
7-8/2
9-11
Plug socket
Connection cable
for solenoid valve
(without picture)
111 774 1305/2

111 974 1304/2
M, MS
AnschluBteile fljr Verteilerstck

RL5-RL8/2, RGL8-RGL10
RL9-RL11.RGL11
M
MS
RMS
Boitier de bobine
standard
** Boitier de bobine
etanche
111 574 1305/2

111 974 1303/2
112 564 1306/2
112 764 1302/2
112 574 1306/2
11 2 974 1304/2
0,400
0,500
0,700
0,700
0,500
0,610
642 011
0,065
Distributor
(without picture)
: Rpartiteur
(sans photo)
1
i
Connection parts for
distributor
Elements de
;raccordement pour
repartiteur
i
Thermometer
"hermomtre
m^
~-T3C O
7,23
7.26
7.39
Bild
Piet.
Photo
7.23
B O"
7.27
7.28
7.29
7.30
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
112 151 1 3 1 7 / 7
111 5 7 4 1 3 0 7 / 7
0,064
0,013
5-11
7-11
7-10
111 3 8 1 1 3 0 7 / 7
111 574 1 3 0 8 / 7
112 261 1 3 1 0 / 7
0,017
0,015
0,059
5-11
9-11
111 574 1301/7

111 974 1302/7
0,039
0,083
5-10
9-11
121
121
111
111
464 8502/7
464 8505/7
574 1302/7
974 1303/7
0,045
0,020
0,038
0,053
Gre
Size
Grand.
i Einschraubstutzen
j 6 L L M 1 0 x 1 x G 1/8" x 71
6 L L M l O x 1 x G 1/8' x 23
8LLM 12x 1
8LLM 12x 1
8LLM 12x 1
x G 1/8" x 23,5
x G 1/8" x 25
x G 1/8" x 71
10LLM 16x 1 , 5 x G 1/4"x35

1 0 L L M 16x 1 , 5 x G 1/4"x71,5
12 X G
12XG
12LLM
12LLM
1/4" X 4 2
3/8" X 46
1 8 x 1 . 5 x G 1/4" x 35
1 8 x 1,5 x G 3/8" X 36,5
'.33
7.35
Designation
Designation
Adapter
Raccord droit
7.24
Bundschraube G 1/8"
(ohneBild)G 1/4"
5-11
5-9
111 574 1304/7

112 564 1305/7
0,008
0,026
Collar screw
(without picture)
Ecrou
(sans photo)
7.25
Gewindebuchse G 1 / 4 "
M 2 0 x 1,5 (ohne Bild)
5-9
112 564 1307/7
0,026
Threaded sleeve
(without picture)
Douille filete
(sans photo)
7.26
Aufnahmehlse fr Heizpatrone
5-9
112 564 1304/7
0,110
7.27
Dichtring C U
10,0 X 14 X 1.5
13,5 X 17 X 1,5
13,5 x 2 5 x 2 , 0
16,0 x 2 0 X 1,5
17,0 x 2 1 X 1,5
21,0 x 2 6 X 1,5
22,0 x 2 7 X 1,5
7.36
5-11
5-11
5-11
5-11
5-11
5-11
5-11
440 034
440 010
440 014
440 048
440 003
440 020
440 004
0.001
0,001
0,006
0,001
0,003
0,001
0,002
Mounting socket
Support
Copper ring
Joint cuivre
7.28
Schneidring
M 10
M 12
5-11
5-11
452 772
452 773
0,001
0,003
Cutting ring
Rondelle de cisaillement
7.29
berwurfmutter
M 10
M 12
5-11
5-11
452 828
452 836
0,018
0,025
Union nut
Raccord union
7.30
Heizpatrone komplett
M. RMS
MS
20 Watt
20 Watt
5-11
5-9
112 381 1302/2

112 564 1303/2
0,124
0,188
Heating cartridge
complete
complete
7.31
Heizpatrone 2 3 0 V / 2 0 W ,
Heating cartridge
7.32
lleitung 6 x 1
Magnetventil-Dse
Oil line
Solenoid valve nozzle
Conduite de fuel
vanne magntique gicieur
7.33
lleitung 6 x 1 x 3 0
Verschraubung-Magnetventil
Oil line
pump-oil counter
Conduite de fuel
pompe-compteur d'huile
Oil line
solenoid valve
Conduite de fuel
vanne magntique
7.34
7.35
7.36
7.37
794 211
5-11
111 163 0002/8
L5-9
L5-9
0,048
0,022
111 163 1305/8
0,016
lleitung Magnetventil
6x1
8x1x26
8x 1
L5-9
L5-10
L7-10T
111 564 1301/8

111 662 0004/8
111 794 1301/8
0.024
0,029
0,026
lleitung 8 x 1 x 41
L7-10T
111 794 1302/8
0.023
5-9
I 155 101 1303/7
0,040
7-1 1
1 176 208 0002/7
0,290
i
I 1 76 208 0003/7
Valve seating
(without picture)
Support de vanne
I (sans photo)
0.016
Holding clamp
(without picture)
: Crampon ressort
:(sans photo)
0.005
Closing screw
;Vis obturateur
Pressure monitor
for fuel oil
i Pressostat
' Hlse
; GL. RGL
: Ventiltrger,
(ohne Bild)
7.38
' Federklammer (ohne Bild)
7.39
i Verschluschraube NPG9
7,40
Druckwchter
, fr Heizl EL. M und S
h 10 bar, Typ USA 4 6
; 3 25 bar, Typ DSA 58
1
I Temperaturschalter 6 0 ' C , RMS7-11
7,41
7,42
16
7.32
7.34
7.42
7.41
; Bezeichnung
i Burner serie
; Type brijleur
7,31
S3
,0-
7.40
(D
; Heizkrper 230V, 20 W
l fr Druckwchter
! 730 209
640 096
; 640 097
Oil line
: Conduite de fuel
Sleeve
I Douille
0.565
0.538
112 774 1303/2
0,080
170 105 1001/2
0,375
Temperature switch
Heating element
Thermostat
'' Element chauffante
>/
;.il
U
i.401
8.6
8.8
8.9
3.10
3.11
8.3
8.2
111
-If*
8.12
8.13
8.15
8.16
;,14
j Bezeichnung
Bild
Piet.
Photo
8.
8.1
8.2
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
Designation
I Designation
Magnetventile fr Gas
Solenoid valves
Vannes magntiques DMV
Magnetventile
Baugruppe A mit Mengeneinstellung
Druckbereich 0 - 5 0 0 mbar
Typ
Rp
Spannung/Frequenz
DMV-D 5 0 7 / 1 1 1/2-1
230V/50-60 Hz
DMV-D 5 1 2 / 1 1 1
230V/50-60HZ
DMV-D 5 2 0 / 1 1 1 1/2-2 230V/50-60 Hz
Solenoid valves quality

class A with quantity
adjustment Pressure
Type
ID
Vannes magntiques
classe A, rglables
Pression d'utilisation
Type
DN
Vannes magntiques
gaz de mise I'air
libre classe A
ouvertes hors tension
Vannes magntiques
gaz de mise I'air
libre classe A
i Burner serie
I Type brleur
DMV-D
DMV-D
DMV-D
DMV-D
DMV-D
DMV-D
5040/11
5050/11
5065/11
5080/11
5100/11
5125/11
DN40
DN50
DN65
DN80
DN100
DN125
230V/50-60
230V/50-60
230V/50-60
230V/'50-60
230V/50-60
230V/50-60
Hz
Hz
Hz
Hz
Hz
Hz
605 204
605 206
605 208
2,200
4,700
5,800
212
214
216
218
220
222
9,000
9,400
14,700
23,700
30,700
50,700
605 465
60,875
605
605
605
605
605
605
8.3
MVD5150/5
8.4
Magnetventil zur Entlftung Baugruppe A

stromlos offen
LGV 5 0 7 / 5 Rp 3 / 4 " mbar
605 707
1,147
Solenoid valve for

venting quality class A
currentless open
Magnetventil fr Zndgas, Baugruppe A

MVD 5 0 7 / 5 Rp 3 / 4 " mbar
605 453
4,740
Solenoid valve for

venting quality class A
Dichtheitsanzeigegert
ohne Glyzennfllung
151 327 8501/0
0,875 Tightness indicating
Stecker 4-polig, 2 5 0 V, 16 A, schwarz
217 304 2601/2
!.401
8.5
8.6
8.7
Flansch
Rp 1/2'
Rp 3/4"
Rp 1
Rp 1"
fr
fr
fr
fr
aggregate without
glycerine filling
DMV
DMV
DM\J
DMV
8.8
Zndgasflansch fr DIv1V507 - DI^V520
8.9
Hydraulikbrenrtse
Set fr DMV 5 0 7 / 1 1
DMV 5 0 4 0 / 1 1
DMV 5 1 0 0 / 1 1
8.10
8.11
i.12
.13
8.14
226
227
233
228
0,181
0,173
0,163
0,266
605 232
0,083
605
605
605
605
507
507
507
51 2
605 237
605 238
605 239
Magnet komplett,
Typ
DMV-D 5 0 7 / 1 1
DMV-D 512/11
DMV-D 520/11
fr
Nr.
1111
1211
1212
Spannung/Frequenz
2 2 0 - 2 4 0 V / 5 0 - 6 0 Hz
220-240V/50-60 Hz
220-240V/50-60 Hz
605 941
605 942
605 943
DMV-D
DMV-D
DMV-D
DMV-D
DMV-D
DMV-D
1311
1311
1411
1511
1611
1711
220-240V/50-60
220-240V/50-60
220-240V/50-60
220-240V/50-60
220-240V/50-60
220-240V/50-60
605
605
605
605
605
605
5040/11
5050/11
5065/11
5080/11
5100/11
5125/11
i Magnetspule
Spulentyp
) 61
MOO
200
Hz
Hz
Hz
Hz
Hz
Hz
mit eingebautem Gleichrichter

fr Magnetventiltyp
DN
MVD 5 1 5 0 / 5
150
LGV 5 0 7 / 5
3/4"
MVD507/5
3/4"
Leiterplatte
' fr Spule Nr. 100
8.15
, 0-Ringe zwischen Ober- und

' Unterteil der Magnetventile
507/5
! LGV
0
8.16
Distanzring, fr Magnetspule
Nr. 100
55x2
0,064
944
944
945
946
947
948
Indicateur visuel de
fuite {sans glycerine)
Plug
Fiche
Flange
Bride
Ignition gas flange
Bride
Hydraulic brake
Cartouche hydraulique
Solenoid, complete for

Type
No
ID
Bobine, complet pour

Type
No
DN
0,274
0,273
0,612
0,795
1.800
4,500
3.240
3,240
5,600
10,366
26,000
40,000
Solenoid with incorporated rectifier
605 830
605 904
605 906
20,860
0,559
1,524
605 922
0.015
Bobine de vannes
magntiques avec
Conductor plate
i Platine
Broucles d'tancheit
lentre partie superleure
Ipour vanne magntique
JDouille pour bobine no.
445 057
0,004
Sealing rings, between

upper- and lower part
for solenoid valves
605 893
0,008
Distance ring for

solenoid no.
17
'J.
TI'
9.1
9.2
9.5
9.3
9.6
9.7
fc
10.'
10.2
Bezeichnung
Bild
Pict.
Photo
Brenner-Typenreihe
Burner serie
Type brOleur
9.
Druckwchter
fr Luft und Gas
9.1
Druckwchter
ca. kg
appr. kg
env. kg
Besteli-Nr.
Order-No.
No de commande
Typ L G W 50 A2P
691 353
0,190
Typ G W 50 A4
Typ G W 150 A4
Typ G W 500 A4
691 355
691 356
691 357
0,258
0,256
0,275
Typ G W 50 A2
Typ G W 150 A2
Typ G W 500 A2
691 367
691 368
691 369
0,207
0,256
0,275
I Designation
Pressure monitor
for air and gas
j Pressostat pour
air et gaz
Pressure monitor
Pressostat
9.2
Kappe fr L G W
446 011
0,001
Cap
Capuchon
9.3
Stecker 4-polig, 2 5 0 V, 16 A
217 304 2 6 0 2 / 2
0,064
Plug
Fiche
Connection parts
for pressure monitor-air
Raccords
p o u r p r e s s o s t a t d'air
Connection cable
Cable de raccordement
Pipe flange
Bride tube
Anschluteile fr Druckwchter
Luft
9.4
Anschlukabel 4 x 0,75 x 750

G, GL, RGL
9.5
Rohrflansch konnplett
9.6
9.7
5-11
151 316 2 4 0 1 / 2
0,064
151 313 2 4 0 2 / 2
0,055
Doppelnippel R 1/4" x 50 (Gas)
139 0 0 0 2 6 0 1 / 7
0,028
Double nipple
Mamelon double
Einbauschraubstutzen R1/8"
4 5 3 003
0,001
Threaded socket
Raccord droit
9.8
Silikonschlauch 3,5 x 2 (o, Bild)
750 4 1 8
0,029
Silicon-hose
Flexibles silikon
9.9
Schlauch klemme
790 218
0,001
Clamp
Crampon
10.
Gasdrossel
Gas throttle
Clapet gaz
Gas throttle, complete
Clapet gaz, complet
10.1
Gasdrossel, komplett
G, GL, RGL
G, GL, RGL
G, GL, RGL
G, RGL
DN
50
65
80
100
5
7 -f 8
9-H 10
1 1
151
151
151
191
2506/0
2506/0
2506/0
2506/0
E
E
E
E
2,460
2,894
2,900
3,871
G, GL, RGL
G, GL, RGL
50/25
50/40
5
5
151 518 2 5 0 8 / 0
151 518 2 5 0 7 / 0
E
E
2,627
65/40
65/50
80/50
80/65
7-f8
7-1-8
9-1-10
9-HO
151
151
151
151
2508/0
2507/0
2508/0
2507/0
E
E
E
E
80
100
9-HO
11
151 907 2 5 0 9 / 0
191 107 2 5 0 9 / 0
I E
iG
i G, RGL, RGMS
: G. RGL. RGMS
100/65
1 00/80
11
5
191 107 2 5 0 8 / 0
151 518 2 5 0 7 / 0
i G. Ausf. ZMI
50
65
5
7
151 518 2 5 0 9 / 0
151 707 2 5 0 9 / 0
50
65
80
100
5
151
7 + 8
M51
9 -f 10 i 151
11
; 177
G,
G,
G,
G.
GL,
GL,
GL,
GL,
RGL,
RGL,
RGL,
RGL,
RGMS
RGMS
RGMS
RGMS
iG
10.2
18 ,
Designation
, Dichtung fr Gasdrossel
j G, GL, RGL
G, GL, RGL
G, GL, RGL
I G, RGL
518
707
907
107
707
707
907
907
518
707
907
205
'E I
3,430
2,961
3.872
i 1
IE
\^\
JE
2,460
3,023
0012/7
0002/7
0001/7
0003/7
li
0.045
0,053
0.059
0.074
0.076
: E
10,3
i Antriebsnabe
5-11
i 151 101 2 5 0 4 / 2
iE
10.4
\ Verstellhebel
5-11
h 6 1 208 2 5 3 0 / 7
0,034
10.5
: Drehfeder 0,8 x 12 x 12
5-11
^ 151 101 2 5 0 8 / 7
0.022
iE
1
Sealing r i n g for gas
throttle
Joint d'tanchite pour

clapet gaz
\ Driving h u b
M o y e u de m o u v e m e n t
Adjusting lever
Levier de rglage
Spring
Ressort
1 1.1-1 1.3
1 1,17-1 1.9
11.5
11,6
1 1.1 1
11.12
11.13-1 1.15
1 1.17
1 1.18
1 1.19
1,16
11.2C
Bild
Piet.
Photo
Bezeichnung
Brenner-Typenreihe
Burner serie
Type brleur
11.
Flammkopf fr Olbrenner
Combustion head
for oil burners
Tete de combustion pour bruleurs
Flammrohr, ohne Stauscheibe
Flame lube, without

air diffuser disk
Flame
tube type
Tube de combustion,
sans dflecteur
Tube de
combustion type
Flame tube, without air

diffuser disk, for higher
thermal stress (f.i. fireclay lined combustion
Tube de combustion,
sans dflecteur pour la
puissance calorifique
suprieure (par exemple:
Air diffuser disk complete

for flame tube
Dflecteur complet
pour tube de combustion
Reducing
from construction
size
to
Reduction
De grandeur.
Gre
Size
Grand.
L, M, RL
L, M, RL
Flammrohrtyp
M5/1a
M5/2a
11.2
L, MS, RL, R M S
L, MS, RL, R M S
L, MS, RL, R M S
MB/Ia
M7/1a
M8/1a
11.3
L, MS, RL, R M S
L, MS, RL, R M S
G7/2a
U2/1
11.4
L, MS, RL, R M S
M9/1a
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
5
5
111 512 1 4 1 2 / 7
151 327 1 4 0 2 / 7
1,340
1,128
7
7-h8
8
111 612 1 4 0 1 / 7
111 762 1 4 0 4 / 7
111 862 1 4 0 3 / 7
2,190
2,408
2,720
8/2
8/2
121 262 1 4 1 3 / 7
121 262 1 4 1 0 / 2
2,900
2,390
111 964 1 4 0 1 / 7
2,275
11.5
L, RL, R M S
MIO/2
10
181 074 1 4 0 3 / 2
3,403
11.6
RL, RMS
M11/1
11
121 3 6 2 1 4 0 5 / 2
6,500

fr hhere Wrmebelastung
(z. B.: schamottierte Brennkammern)
L, M, RL
H1M5/1a
L, M, RL
H1M5/2a
5
5
111 5 1 2 1 4 1 5 / 7
111 512 1 4 1 6 / 7
1,330
1,130
11.8
L, MS, RL, R M S
L, MS, RL, R M S
L, MS, RL, R M S
H1M6/1a
H1M7/1a
H1M8/1a
7
7-H8
8
111 612 1 4 0 8 / 7
111 762 1 4 0 6 / 7
111 862 1 4 0 4 / 7
2,200
2,380
2,720
11.9
L, MS, RL, R M S
L. MS, RL, R M S
H1G7/2a
H1U2/1
8/2
8/2
111 862 1 4 0 5 / 7
111 862 1 4 0 5 / 2
2,640
2,160
11.10
L. MS, RL, R M S
H1M9/1a
111 964 1 4 0 4 / 7
2,280
11.11
RL, R M S
H1M10/2
10
181 074 1 4 0 4 / 2
3,600
11.12
RL, R M S
H1M11/1
11
121 366 1 4 1 2 / 2
6,000
Stauscheibe komplett
fr Flammrohr
M5/1a, M5/2a
M5/1a
0 mm
125x40
145x40
5
5
111 512 1 4 0 7 / 2
111 512 1 4 1 1 / 2
0,404
0,453
M6/1a
M6/1a, M7/1a, M 8 / 1 a
M6/1a, M7/1a, M 8 / 1 a
M6/1a, M7/1a, M 8 / 1 a
145 X 4 0
155x50
165x50
175x50
7
7-1-8
7-H8
7 + 8
111
111
111
111
0,602
0,694
0,742
0,799
11.13
11.14
614
614
614
862
1405/2
1403/2
1404/2
1401/2
11.15
| G 7 / 2 a . U2/1
' G7/2a, U2/1
j G7/2a, U2/1
155x50
1 65 X 50
175x50
8/2
8/2
8/2
121 262 1 4 0 8 / 2
121 262 1 4 1 1 / 2
121 262 1 4 1 2 / 2
11.16
M9/1a
; M9/1a
165x50
185x50
8T/2, 9
8T/2, 9
111 964 1 4 0 4 / 2
111 964 1 4 0 5 / 2
1.102
1,200
11.17
I MIO/2
185x50
10
181 074 1 4 0 1 / 2
1,386
E
E
E
11.18
MIO/2
200 X 50
10
181 074 1 4 0 2 / 2
1,456
M11/1
245 X 70
260 X 70
11
1 1
181 174 1 4 0 2 / 2
181 174 1403/2
1,862
1,965
111 762 0 0 0 4 / 7
2,057
Reduzierung
von Baugre 7 -I- 8 auf 5
Designation
0,480
0,540
0,580
11.19
11.20
Designation
IS
Bild
Piet.
Ptioto
i Bezeichnung
i Brenner-Typenreihe
Burner serie
! Type brCileur
i Gre ; Bestell-Nr.
: Size
: Order-No.
1 Grand. i No de commande
ca. kg
appr. kg
env. kg
11.30 Flammkopfverlngerung
11.31
11.32
; Flammkopfverlngerung, kompl.'
' fr Brenner Veringerung mm
L5Z
100
RL5
110 000 2 9 0 1 / 2
110 009 8 1 0 1 / 2
E
E
2.100
2,100
110 000 3 0 0 1 / 2
1100105801/2
110 000 3 3 0 1 / 2
110 000 3 4 0 1 / 2
110 000 4 6 0 1 / 2
110 006 7501/2
E
E
E
E
E
E
2,690
2,750
2,428
2,920
3,000
3,000
110
110
110
110
8201/2
5901/2
4201/2
4601/2
E
E
E
E
3,500
3,500
3,640
3,650
RL9
RL10
RL11
110 006 7 6 0 1 / 2
180 000 4 6 0 1 / 2
180 000 2401/2
E
E
E
4,320
4,100
4,300
M5Z
MS7Z/MS8Z
MS8Z/2
MS9Z
1100108101/2
1100108301/2
1100108501/2
110 010 8 7 0 1 / 2
E
E
E
E
3,420
4,109
4,883
4,922
RMS7/RMS8
RMS8/2
RIVIS9
RMS10
RMS11
1100109001/2
1100109201/2
1100109401/2
180 000 8 4 0 1 / 2
180 000 8 6 0 1 / 2
E
E
E
E
E
4,000
4,100
4,200
4,300
4,400
110 005 9 3 0 1 / 2
1110 005 9 5 0 1 / 2
I 110 005 9 7 0 1 / 2
180 000 4 4 0 1 / 2
I
110 000 3 7 0 1 / 2
110 000 3 8 0 1 / 2
110 009 8 3 0 1 / 2
1100106001/2
E
E
E
E
4,500
4,700
4,900
5,000
E
E
E
E
3,000
3,500
3,000
3,320
1100004101/2
110 000 4 2 0 1 / 2
110 000 4 3 0 1 / 2
110 000 4 3 0 2 / 2
E
E
E
E
3,100
3,740
4.660
4,500
; RL5
! RL7
i RLS
RL8/2
; RL9
' RL10
' M5Z
I MS7Z/MS8Z
MS8Z/2
j MS9Z
i 110 0098 4 0 1 / 2
I 110 0106101/2
I 110 002 4 4 0 1 / 2
i 110 0072401/2
i 110 0028 7 0 1 / 2
4701/2
: 1 80 000
110010 8 2 0 1 / 2
110010 8 4 0 1 / 2
110 010 8601/2
I 1 10 0108801/2
E
E
E
E
E
E
3,100
3,750
4,630
4,000
5,450
5,500
4,056
4,905
6,068
6,107
I RMS7/RMS8
RMS8/2
I RMS9
i RMS10
1100109101/2
1100109301/2
1100109501/2
180 000 8501/2
' L7T, L8T

L8T/2
L9T
L10T
110
110
110
180
L7Z/L8Z
RL7
L5Z
L7Z/L8Z
L8Z/2
L9Z
RL5
RL7
RLS
RL8/2
120
150
Verlngerung 1 50 mm
L7T, L8T
L8/2T
L9T
L10T
11.33
L5Z
L7Z/L8Z
RL5
RL7
200
11.34
L5Z
i L7Z/L8Z
1 L8Z/2
i L9Z
250
11 35
11.36
20 .
' RL11
: RMS11
fohne Bild)
; andere Lngen bzw. Ver\ ingerungen fr andere
Brennertypen auf Anfrage.
Stauscheibe (ohne Biid)

fr Fiammrohrverl.
; M 5 / 1 a , M5/2a
i
300
0 mm
125x40
135x40
009
010
002
002
E i
E \
E '
iE!
E
' E
4,000
4,100
4,200
6.600
9401/2
9601/2
9801(2
4501/2
IE
; E
E
E
4.000
4.100
4.200
4.400
180 000 0107/2

180 000 8701/2
'E
4,700
4,900
005
005
005
000
111 512 8304/2

111 512 8306/2
lE
0.41 7
0,422
Designation
Designation
Combustion head
extension
Rallonge tete de
combustion
Combustion head
extension complete"
for burner
Rallonge tete de combustion, complete*

pour brleur
(without picture)
' Other lengths or resp.
extensions for other
burner types on
inquiry.
.(sans photo)
' des longueurs resp.
rallongements uitereu,res pour autres types
ide brleur a derrande.
i Air diffuser disk

I for combustion head
I extension (without picture)
i
Dflecteur
ipour rallongement comde tube debustion
I (sans photo)
12.5
! Bezeichnung
j Burner sene
[ Type brleur
Bild
Piet.
Photo
Bestell-Nr,
Order-No.
No de commande
M5/1a
lM6/1a
M6/1a, M7/1a. M 8 / l a
M5/1a, M7/1a. M8/1a
M6/1a, M7/1a, M8/1a
12.
i Designation
j oa. kg
1 appr. kg
! env. kg
145x40
145x40
111 512 8 3 0 5 / 2
111 762 8 3 0 3 / 2
E1
E
0,463
0,615
155x50
165x50
175x50
111 762 8 3 0 2 / 2
111 762 8 3 0 4 / 2
111 8 6 2 8 3 0 2 / 2
E
E
E
0,719
0,759
0,783
Ignition lines for extensions see pos, 12.60
Lignes d'allumage pour

rallongements voir
pos. 1 2.60
Flammkopf fr
G/GL/RGL-Brenner
Combustion head
for G/GL/RGLburner
Tete de combustion pour brleurs

G/GL/RGL
Mixing chamber,
complete
Chambre de melange,
complete
Mixing chamber
Chambre de melange
5
5-NA
7
7-NA
8
9 + 10
11
151
151
151
151
151
151
191
518
518
707
707
807
907
107
1421/2
1428/2
1413/2
1428/2
1407/2
1401/2
1401/2
E
E
E
E
E
E
E
3.840
2,163
4,700
4,079
5,286
7,383
11,150
12.2
GL
GL
GL
GL
GL
GL
5
7
8
8-T
9
9-T
155
155
155
155
155
155
518
707
807
808
907
908
1407/2
1405/2
1403/2
1403/2
1401/2
1401/2
E
E
E
E
E
E
4,100
4,940
5,526
5,736
7,327
5,206
12.3
RGL
RGL
RGL
RGL
RGL
5
7
8
9 + 10
1 1
156
156
156
156
196
518
707
807
907
107
1406/2
1406/2
1401/2
1401/2
1401/2
E
E
E
E
E
4,292
5,100
6,693
8,065
11,689
G,
G
G,
G
G,
G.
G.
151
151
151
151
151
151
161
518
518
707
707
707
907
308
1437/7
1428/1
1420/7
1428/1
1436/7
1401/7
1483/7
E
E
E
GL, RGL
GL, RGL
RGL
5
5-NA
7
7-NA
8
9 + 10
11
E
E
E
0,805
1,511
1,065
3,169
1,005
1,920
2,920
12.4
Designation
Zndkabel fr Verlngerungen
siehe Pos. 12.60
Mischgehuse, komplett
G
G
G
G
G
G
G
12.1
12.6
Mischgehuse
GL. RGL
GL, RGL
12.5
Mischrohr auen
G,
G,
G,
G.
G,
GL. RGL
GL, RGL
GU RGL
GL, RGL
RGL
5
7
8
9 + 10
11
151
151
151
151
161
518
707
707
907
308
1439/7
1421/7
1435/7
1407/7
1493/7
E
E
E
E
E
0,781
0,915
0,971
0,959
1,240
Mixing tube outside
Tube de melange
12.6
Mischrohr innen
G,
G.
G,
G,
GL, RGL
GL, RGL
G L RGL
RGL
5
7
8-10
11
151
151
151
161
518
707
907
308
1443/7
1422/7
1408/7
1494/7
E
E
E
E
0,613
0,689
1,162
1,740
Mixing tube inside
Tube de melange
Interieur
Stauscheibe
9-10
11
151 518
151 5 1 3
151 327
217304
151 707
151 518
151 707
150 807
151 907
191 107
1420/2
1453/7
1417/2
1419/7
1421/2
1417/2
1409/2
1410/2
1405/2
1402/2
Air diffuser assembly

complete
Dflecteur complet
5
5-NA
7
7-NA
8
E \
GL. RGL
GL. RGL
GL. RGL
GL. RGL
GL. RGL
RGL
0 mm
lOOx
162x
IIOx
190 X
120x
125x
135x
155x
130x
155x
GL. RGL
GL, RGL
GL, RGL
GL, RGL Einsch.
GL, RGL
GL, RGL Einsch.
RGL
173x100
213x110
213x120
270 x 70
270x130
255 x 70
315x155
5
7
8
9 + 10
9 + 10
9 + 10
11
151
151
151
158
151
158
161
518
707
707
907
907
907
308
1425/2
1410/2
1420/2
1403/2
1406/2
1404/2
1444/2
i
!
|
1
5
7
8
9 + 10
11
151
151
151
161
161
518
707
707
208
308
1427/7
1413/7
1443/7
1454/7
1484/7
Socket
Oouille
12.7
! G. GL. RGL
1G
f G. GL. RGL
12.8
12.9
G
G,
G.
G,
G.
G,
G.
G.
G,
G,
G,
G.
j G,
G.
Hlse
G, GL, RGL
G, GL, RGL
i G, GL, RGL
1 G, GL, RGL
G, RGL
1
50
50
50
60
50
50
50
50
70
70
Ei
0,097
0,334
0.129
0,640
0,151
0,170
0,169
0.317
0.150
0,283
E
E
E
E
E
E
E
E
1
i
:
i
:
:
'
i
i
;
;
i
1
i
!
1
E
E
E
E
E
i E
E
;
'
^
:
i
1 0.407
! 0.600
0,541
1,263
1,036
1.167
1.254
E
i E i
E
j E
: E '
0.197
0,170
0,428
0,313
0,328
'
i
!
:
1
f
21
^ o ^-^
12.10
12,11
12.15
12.12
3>
12.1;
12.U
O
12.20
12.19
12.16
12.22
12.23
Bezeichnung
Bild
PiCt.
Photo
1 Groe 1 Bestell-Nr.
j Size
j Order-No.
1 Grand. ; No de commande
Brenner-Typenreihe
Burner serie
Type brleur
12.10
\ Regulierhlse
1 G, GL. RGL
i G, G L , RGL
G, G L , RGL
G, R G L
ca. kg
appr. kg
env. kg
Designation
Designation
5
7-8
9-10
11
151
151
151
161
1453/7
1425/7
1420/7
1429/7
E
E
E
E
0,302
0,292
0,580
1,080
Regulating socket
Pipe de rglage
327
707
907
408
12.11
Dseneinsatz G {o. Bild)

G
5-NA
7-NA
151 518 1454/7

151 707 1451/7
E
E
0.054
0,120
Nozzle insertion
Element de gicleur
12.11
Dsenring
5
7
8
9
11
151
151
151
151
161
518
707
807
907
308
1447/7
1445/7
1405/7
1421/7
1474/7
E
E
E
E
E
0,174
0,213
0,205
0,246
0,241
Nozzle ring
Rondelle de gicleur
12.12
Elektrodenhalter komplett
G
G
G
G
G
5
7
8
9+10
11
151
151
151
151
161
518
707
707
907
308
1422/2
1406/2
1419/2
1402/2
1442/2
E
E
E
E
E
0,540
0,359
0,580
0,770
2,000
Electrode holder
complete
Support electrodes
complet
Dsenkopf, komplett
GL
GL
GL
GL
GL, Ausf. T
GL, Ausf. T
Nozzle head complete

5
7
8
9
8
9
155
155
155
155
155
155
518
707
707
907
808
908
1408/2
1406/2
1408/2
1402/2
1402/2
1402/2
E
E
E
E
E
E
0,731
0,750
0,820
0,769
1,030
1,131
Ligne de gicleur
complet
RGL
RGL
RGL
RGL
RGL
5
7
8
9-H 10
11
156
156
156
156
196
518
707
707
907
107
1407/2
1407/2
1409/2
1402/2
1402/2
E
E
E
E
E
0,932
0,920
1,987
1,760
2,539
RGMS
RGMS
RGMS
7-H8
9-H 10
11
158 707 1410/2

158 907 1406/2
198 107 1403/2
E
E
E
2,313
2,308
2,809
12.15
Verschlukrper, G
9-10
11
151 907 1406/7

161 3 0 8 1457/7
E
E
0,236
1,310
Closing plug
Bouchon opturateur
Dsenkopf
RGLohne Absperrvorrichlung
RGL, R G M S mit Absperrvorrichtung
Nozzle head
Ligne de gicleur
12.16
5-7
8-11
156 327 1403/2

111 381 1009/2
E
E
0,229
0,899
Zndelektroden
G
G
Ignition electrodes
Electrodes d'allumage
12.17
5-8
5/7-NA
151 327 1433/7

132 101 1403/7
E
E
0,042
0,012
111 9 7 4 1007/7
111 974 1008/7
E
E
0,090
0,090
Sensor electrode
Sonde d'ionisation
12.13
12.14
12.18
links
rechts
9-11
9-11
GL
links
rechts
5-9
5-9
! 151 3 2 7 1433/7
j 155 327 1420/7
E
E
0,042
0,042
links
rechts
5-7
8-11
8-11
! 151 327 1433/7

i 111 974 1007/7
1 1 1 1 974 1008/7
E
E
E
0,042
0,090
0,090
RGL
i
12.19
Fhlerelektrode
G
! 5-NA
i 7-NA
15-7
j8
1 9-11
i 232
I 132
151
; 151
151
1420/7
1404/7
1434/7
1435/7
1419/7
E
E
I E
E
E
0,011
0.013
0.047
0,052
0,097
Scheibe (Zndelektrode)
G, G L
j
i 5-9
\ 151 327 1436/7
0,010
Bgel (ohne Bild)

G, R G L
GL. RGL
i
9-11
! 5-7
1 1 1 1 011 1012/7
; 155 103 1404/7
G
G
G
G
12.20
12.21
12.22
12.23
12.24
22
85 X 150
85x200
200x220
Klemmstck (Fhie'elektrode)
G
G
! Elektrodenhalter
1 G. G L
! G L Ausfhrung T
RGL
\ G9. RGL8-10
>
! 5-11
5-7-NA
100
101
327
327
327
151 327 1437/7

251 303 1408/7
i
j
!
Ei
E 1
Disk (electrode holder)
; Rondelle (support
; electrodes)
Bracket (without picture)
i Etrier (sans photo)
Shim (electrode holder)
1
| Rondelle (support
elektrodes
0,013
0,009
E^
\ E I
0,009
0,005
0,005
E
i E
!E
! E
0,060
0,148
0,067
0,135
Elecirode holder
5-7
8-1-9
5-7
: 251 103 1401/7

j 155 808 1401/7
1 156 327 1401/7
151 907 1409/7
Support electrodes
i ' ^ n
3su
12.27
-O
12.24
12.25
12.28
12.29
B^%
12.30
12.32
12.33
12.34
rxs:
12.36
12.35
Bild
Piet.
Photo
12.25
12.27
12.28
12.29
1 Bezeichnung
j Brenner-Typenreihe
i Burner sene
I Type brQteur
12.38
12.39
1 Gre ; Bestell-Nr.
i Size
j Order-No.
I Grand. 1 No de commande
12.40
ca. kg
appr. kg
env. kg
G, GL
G, RGL
8 + 9
11
Haltering
G, GL
G, GL, RGL {o. Bild)
G, RGL (o. Bild)
5-7
8-10
11
151 101 1 4 2 5 / 7
151 907 1 4 0 2 / 7
161 308 1 4 8 2 / 7
E
E
E
0,026
0,060
0,101
5
7
8
8
11
151
151
151
155
156
196
1446/7
1442/7
1426/7
1401/7
1407/7
1402/7
E
E
E
E
E
E
0,063
0,082
0,067
0,072
0,034
0,115
5
7
8-9
155 518 1 4 0 9 / 2
155 707 1 4 0 9 / 2
155 327 1 4 1 4 / 2
E
E
E
0,074
0,084
0,060
Stehbolzen
G, GL
G, GL
G, GL
G, GL
RGL
G, RGL
Lnge mm
177
219
218
236
113
192
Dsenkopf
GL
GL
GL
1 155 907 1 4 0 6 / 7
161 308 1488/7
9 + 10
DsenabschluB, 2,5 bar

Druckschlauch
GL, RGL
GL, RGL
RGL
DN
6 X 600/ 8mm
6 X 800/ 8mm
8 x 640/10mm
12.31
Schneidring
12.32
berwurfmutter
12.33
Verschraubung
GL
RGL
12.34
12.35
12.30
12.37
518
707
707
907
707
107
112261 1010/2
12.41
Designation
Designation
Support ring
Rondelle support
Threaded rod
TIge filete
Nozzle tube
Tube gicleur
0,131
0,202
0,013
Nozzle closure
Blocage gicleur
Pressure hose
Flexible pression
491 214
491 227
491 220
0.099
0,131
0,174
D 08-LL
D 10-L/S
452 809
452 772
0,001
0,001
Cutting ring
Olive
M 04-LL
M 10-L
452 816
452 828
0,007
0,018
Union nut
Contre crou
Screwing
Presse-etoupe
5-8
9-11
11
12.43
GR 8/6LL
GR10/8PL
5-9
11
450 107
452 048
0,024
0,023
Zndrohr
G, GL, RGL
G, GL, RGL
G, GL, RGL
5
7
8
151 518 1 4 4 0 / 7
151 707 1424/7
151 707 1 4 3 4 / 7
0,048
0,085
0,086
Pilot tube
Tube pilote
Zndrohr,
G, GL, RGL
G, RGL
161 208 1 4 6 6 / 7
161 308 1 4 9 5 / 7
0,113
0,140
Ignition pipe
Tube de allumage
11
10
12.36
AnschluBflansch,
G, GL, RGL
8-11
161 208 1463/7
0,155
Connection flange
Bride raccords
12.37
Anschluwinkel,
G, GL, RGL
8-11
161 208 1 4 3 1 / 2
0,189
Connection angle
Tube raccords
12.38
Spannhlse,
G, GL, RGL
8-11
161 208 1 4 6 5 / 7
0,061
Clamping sleeve
Entrtoise
12.39
Druckschlauch
DN 1 2 X 350
DN 1 2 X 400
8-10
11
491 202
491 201
0,064
0,070
Ignition gas hose
Flexibles vanne
d'allumage
G, GL, RGL
G, GL, RGL
5
7 + 8
151 327 1 4 5 4 / 7
151 907 1419/7
0,012
0,042
Closing plug
Bouchon obturate!
I 151 3271420/2
151 707 1414/2
' 150 0074402/2
i 161 2081430/2
i 191 1071404/2
0,015
0.061
0,030
0,065
0,055
Ignition head
Tete a l l u m a g e
Ignition line extension

(w)thout picture)
Prolongateur pour
lignes d'allumage
(sans photo)
Arresting bolt
Manchons de fixati
12.40
! Verschlustopfen
12.41
Zndkopf
G, GL. RGL
G.. GL, RGL
;G,, GL. RGL
G.. GL, RGL
G,, R G L
12.42
12.43
12.44
' Zndkabel (o.B.)

: G, GL, RGL
G, GL, RGL
G. RGL
G
Fixierbolzen
G, GL, RGL
G, GL, RGL
G. GL, RGL
G. GL, RGL
G, RGL
i lonisationskabel
(ohne Blid)
I 290 mm lang
; 340 mm lang
390 mm lang
j 4 4 0 mm lang
9-10
: 11
mm lang
290
340
390
440
5
7-10
11
7-NA
111
111
111
111
151
151
151
151
5733/2
5734/2
5735/2
5716/2
15
i 151 518 1438/7
:7
' 151 707 1423/7
IB
151 707 1432/7
19 + 10 151 907 1403/7
' 11
i 161 308 1490/7
0,047
0,049
0,052
0,059
0.012
0,017
0,018
0,024
0,027
Ionization line
(without picture)
251 103 1403/2

i 251 103 1404/2
I 250 103 1425/2
250 303 1413/2
Ligne d'ionisation
\ (sans photo)
0,043
0.046
0,035
0,037
23
^^^g^s:^
-mjf
12.52
12.54
12.56
12.53
12.55
12.44
12.45
Bild
Piet.
Photo
12.44
12.45
Bezeichnung
Brenner-Typenreihe
Burner serie
Type brleur
0 mm
G5/3-a
200
G5/1a
250
G7/1a
G7/3-A
265
G7/2a
325
UG2/1a
UG3/1a
G
G, GL.RGL
G, GL, RGL
G
G, GL, RGL
G, GL, RGL
G, RGL 380

fr hhere Wrmebelastung (z. B.:
schamottierte Brennkammern)
0 mm
G, GL, RGL 200
H1M6/1a
G, GL, RGL 250
H1G7/1a
G, GL, RGL 265
H1G7/2a
G, GL, RGL 325
H1UG2/1a
G, RGL
H1UG3/1a
Gre
Size
Grand.
Bestell-Nr.
Order-No.
No de commande
5-NA
5
7
7-NA
8
9 + 10
11
151
111
151
151
121
161
161
5
7
8
9+10
11
518
612
707
707
262
208
308
111 612
151 707
111 862
161 208
161 309
ca. kg
appr. kg
env. kg
1432/2
1401/7
1412/7
1427/2
1413/7
1462/7
1471/7
1408/7
1430/7
1405/7
1471/7
1401/7
E
E
E
E
E
E
E
E
E
E
E
E
2,200
2,980
2,640
3,480
7,450
12.51
G
G
G
G
G
G
5
5-NA
7
7-NA
8
9 + 10
150 003
150 518
150 003
150 707
150 007
150 002
0901/2
1406/2
1101/2
1422/2
6001/2
4401/2
E
E
E
E
E
E
4,876
2,345
5,600
4,693
6,560
8,720
12.52
GL
GL
GL
GL
GL, Ausf. T
GL, Ausf. T
5
7
8
9
8
g
150 003
150 003
150 007
150 002
150 007
150 006
1001/2
1201/2
6801/2
5001/2
7601/2
9701/2
E
E
E
E
E
E
5,080
5,980
6,900
8,750
7,040
9,020
RGL
RGL
RGL
RGL
5
7
8
9 + 10
150 006
150 006
150 007
150 002
3201/2
3501/2
8401/2
5601/2
E
E
E
E
5,389
6,085
8,050
9,950
5
5-NA
7
7-NA
8
9+10
11
5
7
8
9
8
9
150 001
150 518
150 001
150 707
150 007
150 002
190 000
0901/2
1407/2
1001/2
1423/2
6101/2
4501/2
1401/2
E
E
E
E
E
E
E
5,840
2,538
6,870
5,230
8,000
11,200
13,800
150 001
150 001
150 007
150 002
150 007
150 006
1401/2
1501/2
6901/2
5101/2
7701/2
8901/2
E
E
E
E
E
E
6,026
7,100
9,300
11,200
9,000
11,500
5
7
8
9 + 10
11
150 006
150 006
150 007
150 002
190 000
3301/2
3601/2
8501/2
5701/2
1601/2
E
E
E
E
E
6,294
7,200
10.500
12.500
12,300
5
5-NA
7
7-NA
8
9 + 10
11
150 002
150 518
150 001
150 707
150 007
150 001
190 000
3801/2
1408/2
1101/2
1424/2
6201/2
2701/2
1501/2
E
E
E
E
E
E
E
5,724
8,000
5,611
9,210
17,500
16,548
GL
GL
GL
GL
GL, Ausf. T
GL. Ausf. T
5
7
8
9
8
9
150 002
150 001
150 007
150 001
150 007
150 006
3901/2
1601/2
7001/2
2801/2
7801/2
9001/2
E
E
E
E
E
E
7,100
8,300
9,600
17,500
9,800
1 7,900
RGL
RGL
5
7
150 006 3401/2

150 006 3701/2
E
E
6,199
6,500
12.53
12.54
G
G
G
G
G
G
G
GL
GL
GL
GL
GL, Ausf. T
GL, Ausf. T
200
RGL
RGL
RGL
RGL
RGL
12.55
12.56
24
G
G
G
G
G
G
G
300
1 Designation
1
Flame tube, without
air diffuser disk
Tube de combustion,
sans deflecteur
Flame tube, without air

diffuser disk for higher
thermal stress (f.i. fireclay lined combustion
chambers)
Tube de combustion
sans deflecteur pour la
puissance calorifique
suprieure (par exempie: chambre de comchamotte)
Combustion head
extension
Rallonge tete de
combustion
Combustion head
extension complete
Extended by mm
Rallonge tete de com

bustion, complete
Rallonge mm
2,012
2,190
2,720
5,840
2,900
3,500
7,410
12.50 Flammkopfverlngerung
Mischgehuse, komplett
Verlngerung mm
100
Designation
12.57
12.58
12.59
1 Bezeichnung
Bild
Piet.
Photo
1 Burner serie
1 Type brijleur
Gre
Size
Grand.
Bestel l-Nr.
Order-No.
No de commande
8
9+10
11
150 007 8601/2

150 001 2901/2
190 000 1701/2
E
E
E
10,800
12,986
1 7,000
200
5
7+ 8
9+10
5
7+ 8
9 + 10
11
150 518
150 707
150 907
150 518
150 707
150 907
160 001
1405/7
1406/7
1421/7
1406/7
1407/7
1422/7
3101/7
E
E
E
E
E
E
E
1,400
1,752
2,285
2,190
2,716
3,520
6,280
300
150 518
150 707
150 907
160 001
1401/2
1408/7
1423/7
0101/7
E
E
E
E
3,120
3,780
4,920
8,740
Zndkabel, komplett (ohne Bild)

Verlngerung mnn
340
390
111 151 5734/2

111 151 5735/2
E
E
0,049
0,052
440
490
540
590
640
111
111
111
111
111
151
151
151
151
151
5736/2
5737/2
5738/2
5739/2
5740/2
E
E
E
E
E
0,055
0,058
0,062
0,065
0,066
690
740
790
840
890
111
111
111
111
111
151
151
151
151
151
5741/2
5742/2
5743/2
5744/2
5745/2
E
E
E
E
E
0,069
0,071
0,072
0,077
0,083
940
990
1040
1090
1140
1190
1340
111
111
111
111
111
111
111
151
151
151
151
151
151
151
5746/2
5747/2
5748/2
5749/2
5750/2
5751/2
5752/2
E
E
E
E
E
E
E
0,083
0,088
0,086
0.093
0,093
0,097
0,127
RGL
RGL
RGL
|
i
i ca. kg
appr. kg
1 env. kg
Veringerungsrohr
12.57
12.58
12.59
12.60
G, GL
GL
GL, RGL
GL
GL
GL, RGL
RGL
G, GL
G, GL
G, GL, RGL
G, RGL
100
7+ 8
9 + 10
11
Designation
Designation
Extension pipe
Tube de rallonge
Ignition line, complete

(without picture)
Ligne d'allumage
complete (sans photo)
Rallonge mm
25
13.1-13,3
13.4
l<||MHMMM##MP~*'
13.5
13.6
13.9
" R
13.12
13.10
13.-
13.20/13.21
Cy
' 3.17
13.14-13.15
13.18
13.19
13.22
ItJl
13.23
13.24
Designation
1 Designation
13.25
Bild
Piet.
Photo
1 Bezeichnung
Brenner-Typenreihe
j Burner sene
1 Type bruieur
13.
Dsenstock
13.1
Dsenkreuz
L
0
140
111 552 1001/7
0.273
13.2
13.3
L
L
180
180
7-1-8
8/2
111 652 1002/7

111 862 1001/7
E
E
0,390
0,365
13.4
234
111 964 1 0 0 1 / 7
0,557
13.5
13.6
13.7
13.8
RL
RL, RMS
RL.RMS
RL.RMS
140
180
234
234
5
7-8/2
9H-10
11
111
111
111
181
552
782
974
174
1001/7
1001/7
1001/7
1001/7
E
E
E
E
0,273
0.360
0,557
0,600
5
7-f-8
8/2
9
11 2
112
112
112
564
764
866
964
1003/7
1003/7
1003/7
1021/7
E
E
E
E
0,377
0,496
0,482
0,671
5
7-H8
8/2
9
111
111
111
111
562
752
862
964
1003/2
1001/2
1002/2
1002/2
E
E
E
E
0,820
0,970
0,959
1,175
RL ohne Absperrventil
RL mit Absperrvorrichtung
RMS mit Absperrvorrichtung
MS (beheizte Ausfhrung) o. Bild
5-7
8-11
7-11
5-9
111
111
111
212
273
381
381
163
1001/2
1009/2
1009/2
1001/2
E
E
E
E
L (dreistufig) o. Bild
7-1-8
8/2
9-t-IO
111 794 1001/2

111 896 1001/2
111 994 1 0 0 1 / 2
13.13
zum selbstbiegen (o. Bild) L
5-9 Z
7-10T
111 261 5 7 0 1 / 2
110 005 9 8 0 2 / 1
13.14
5-9
112 261 1016/2
0,011
13.15
DsenabschluS fr Dse 2
Monarch-Dsen
M, MS (zweistufig) 2,5 bar
Steinen-Dsen
M, MS (zweistufig) 2,5 bar
5-9
112261 1017/2
0,012
13.17
Heizpatrone M, MS (Z)
100 Watt, 220V
5-9
112 564 1005/2
0.082
13.18
Heizkrper 100 Watt, RMS
7-11
112 574 1001/2
0,192
Heating element
Resistance
13.19
Temperaturfhler
112 564 1004/2
0,018
Temperature sensor
Contact thermique
Zndelektroden
L (Z)
111
111
111
111
211
211
564
564
764
764
163
163
1001/7
1002/7
1003/7
1004/7
1011/7
1012/7
E
E
E
E
E
E
0,058
0.057
0.056
0,057
0,046
0.046
Ignition electrode
links = left
rechts = right
Electrodes d'allumage
13.20
111
111
111
111
794
794
994
994
1004/7
1005/7
1004/7
1005/7
E
E
E
E
Dsenkopf
L (zweistufig) mit Dsenkreuz
13.10
13.11
13.12
L (Z) (Z/2)
L (Z)
13.21
L (T) (T/2)
13 23
links
rechts
links
rechts
links
rechts
5
7-t-8
19
|
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env. kg
Nozzle assembly
Ligne de gicleur
Nozzle support
Croisillon porte ligne

gicleur
Nozzle support hole 55 0
Croisillon 0 55
Nozzle head
(two stage) with nozzle
support
Ligne de gicleur
(deux allures)
0,420
0,899
0,899
1,126
without shut-off
with equipment
sans blocage
avec blocage
(heated version) without pict.
sans photo
E
E
E
0,900
1,000
2,309
(three stage) without pict.
(trois allures)
sans photo
E
E
0.673
0,817
(for self bending)
links
rechts
links
rechts
7-f-8
1
|9-f10
i M/MS
!
links
rechts
i 5-9
|
| 212 163 1020/7

' 212 163 1021/7
E
E
;
i
0,056
0.058
:
; RL
i
i
1
links
rechts
links
rechts
i
:5
!
I 7
'
i
i 121
\ 121
1 211
I 211
EI
:
:
0.059
0.059
0.054
0.054
L(T)
13.22
Gre
Size
Grand.
Dsenkreuz, Bohrung 55 0
M
MS
MS
MS
13.9
RL 8 - 1 1 . RMS 7-11
26
13.7
13.8
links
rechts
ZRdelektroden fr Gasbrenner
siehe Seite 22
13.24
Befestigungsbgel
'r Zndelektroden
13.25
Druckring. RMS
\
j
|
'
364
364
404
404
1006/7
1007/7
1020/7
1021/7
111 974 1007/7

11 1 974 1008/7
E 1
E
E
E
E
5-11
122 364 1001/7
Blocage gicleur
pour gicleur 2
Gicleur Monarch
Gicleur Steinen
(deux allures
Heating cartridge
0.057
0,057
0,055
0.056
1
1
1
0,090
0.090
Ignition electrodes for gas

bur.êrs see page 22
( Electrodes d'allumage
' JOur brijleurs gaz voir
Dage 22
0.013
Attachment bracket
'or ignition electrode
0.002
Pressure ring
| Etrier de fixation
: :our electrodes
lallumage
Rondelle de pression
!
111 011 1012/7
Nozzle closure
for nozzle 2
Monarch nozzles
Steinen nozzles
(two stage)
5P
14.1
Bezeichnung
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env, kg
Bild
Piet.
Photo
Brenner-Typenreihe
Burner serie
Type brleur
Designation
Designation
14.
Dsen
Nozzles
Gicieurs
14.1
Dsen Fabrikat Monarch

Gre in US Gph bei 7 bar
Monarch manufacture
Size in US G p h at 7 bar
Solid spray
Fabrication Monarch
grandeur en US Gph
7 bar
Cne-plein
Typ R - 45 Vollstrahl
3,50
602 314
0,027
Typ R - 60 Vollstrahl
3,50
602 366
0,027
Solid spray
Cne plein
Typ PLP - 45 Halbstrahl
3,50
4,00
4,50
5,00
602
602
602
602
014
015
016
017
0,027
0,027
0,027
0,027
Semi-solid spray
Cne 112 creux
5,50
6,00
6,50
7,00
602
602
602
602
018
019
020
021
0,027
0.027
0,027
0,027
7,50
8,50
9,50
602 022
602 023
602 024
0,027
0,027
0,027
3,50
4,00
4,50
5,00
602
602
602
602
215
216
217
218
0,027
0,027
0,027
0,027
Semi-solid spray
Cne 1/2 creux
5,50
6,00
6,50
7,00
602
602
602
602
219
220
221
222
0,027
0,027
0,027
0,027
7,50
8,50
9,50
10,50
602
602
602
602
223
224
225
226
0,027
0,027
0,027
0,027
12,00
13,50
15,50
17,50
602
602
602
602
227
228
229
230
0,022
0,022
0,022
0,022
19,50
21,50
24,00
28,00
602
602
602
602
231
232
233
234
0,023
0,023
0,023
0.023
30,00
35,00
40,00
45,00
602
602
602
602
235
236
237
238
0,023
0,030
0,030
0,035
50,00
60,00
602 239
602 240
0,035
0,040
3,50
4.00
4,50
5,00
602
602
602
602
603
604
605
606
0,022
0.022
0,022
0,022
Hollow spray
Cne creux
5,50
6,00
6,50
7,00
602
602
602
602
607
608
609
610
0,022
0,022
0,022
0,022
7.50
8,50
9,50
10,50
602
602
602
602
611
612
613
614
0,022
0,022
0.022
0,022
12,00
13,50
15,50
17,50
602
602
602
602
615
616
617
618
0,022
0,022
0.022
0,022
19,50
21,50
24,00
28,00
30,00
602
602
602
602
602
619
620
621
622
623
0.022
0,022
0,022
0.022
0,022
Typ PLP - 60 Halbstrahl
I Typ PLHO 45Hohistrahl
27
14,2
Bezeichnung
Bild
Piet.
Photo
Typ PLHO - 60 Hohlstrahl
14.2
i Bestell-Nr.
I Order-No.
I No de commande
Brenner-Typenreihe
Burner sene
Type brOleur
Designation
Hollow spray
Cne creux
Steinen manufacture
Size in US G p h at 7 bar
3,50
4,00
4,50
5,00
602
602
602
602
653
654
655
656
0,022
0,022
0,022
0,022
5,50
6,00
6,50
7,00
602
602
602
602
657
658
659
660
0.022
0,022
0,022
0,022
7,50
8,50
9,50
10,50
602
602
602
602
661
662
663
664
0,022
0,022
0,022
0,022
12,00
13,50
15,50
17,50
602
602
602
602
665
666
667
668
0,022
0,022
0,022
0,022
19,50
21,50
24,00
28,00
30,00
602
602
602
602
602
669
670
671
672
673
0,022
0,022
0,022
0,022
0,022
Designation
Typ S 45 Vollstrahl
3,50
4,00
612021
612 022
0,025
0,025
Solid spray
Fabrication Steinen
grandeur en US Gph
7 bar
Cne plein
Typ S - 60 Vollstrahl
3,50
4,00
612 220
612221
0,025
0,025
Solid spray
Cne plein
4,50
5,00
5,50
6.00
612
612
612
612
023
024
025
026
0,025
0,025
0,025
0,025
Semi-solid spray
Cne 1/2 creux
6,50
7,00
7,50
8,00
9,00
612
612
612
612
612
027
028
029
030
032
0,025
0,025
0,025
0,025
0,025
10.00
11,00
12,00
13,00
612
612
612
612
034
035
036
037
0,025
0,025
0,021
0,021
14,00
15,00
16,00
18.00
612
612
612
612
038
039
040
041
0,021
0,021
0,021
0,021
20,00
22,00
24.00
26,00
612042
612 043
612 044
612 045
0,021
0,021
0,021
0,021
Semi-solid spray
Cne 1 /2 creux
Dsen Fabrikat Steinen

Gre in US Gph bei 7 bar
Typ SS - 45 Halbvollstrahl
} Typ S S - 60 Halbvollstrahl
4,50
5.00
5.50
6.00
6.50
7.00
7.50
8.00
28
I ca. kg
I appr. kg
I env. kg
612
612
612
612
222
223
224
225
E
:E
E
0,025
0,025
0.025
0.025
612 226
612 227
; 612 228
I 612 229
0.025
0.025
0,025
0,025
9.00
10.00
11,00
: 612231
! 612 233
612 234
0,025
0,025
0.025
12.00
13,00
14.00
15,00
612 235
612 236
612 237
612 238
0.021
0,021
0.021
0.021
"'I
14.14
14.1 1
Bild
Piet.
Photo
14.15
! Bezeichnung
i Burner serie
1 Type brOleur
Bestell-Nr.
Order-No.
No de commando
16,00
18,00
20,00
22,00
24,00
26,00
Typ SS - 60 Halbvollstrahl
612
612
612
612
612
612
239
240
241
242
243
244
i ca. kg
Typ WB3, 45
14.12
Typ K3, 50
14.13
Typ W 50
15
20
25
30
35
40
45
50
55
60
65
70
0,021
0.021
0.021
0,021
0,021
0,021
kg/h
kg/h
kg/h
kg/h
kg/h
kg/h
kg/h
kg/h
kg/h
kg/h
kg/h
kg/h
602
602
602
602
602
602
602
602
602
602
602
602
570
571
572
573
574
575
576
577
578
579
580
581
0,030
0,030
0,030
0,030
0,030
0,030
0,030
0,030
0,030
0,030
0,030
0,030
80 kg/h
90 kg/h
100 kg/h
110 kg/h
1 20 kg/h
130 kg/h
602
602
602
602
602
602
558
559
560
561
562
563
0,030
0,034
0,034
0,034
0,034
0,034
140 kg/h
150 kg/h
160 kg/h
1 70 kg/h
180 kg/h
200 kg/h
602
602
602
602
602
602
564
565
566
567
568
569
0,034
0,034
0,034
0,034
0,034
0,034
612
612
612
612
612
967
988
968
989
969
0,100
0,100
0,100
0,100
0,100
612 970
612971
612972
612 973
612 974
0,103
0,104
0,104
0,110
0,110
125 kg/h
140 kg/h
1 60 kg/h
1 80 kg/h
200 kg/h
612
612
612
612
612
975
976
977
978
979
0,110
0,110
0,110
0,110
0,110
225
250
275
300
330
kg/h
kg/h
kg/h
kg/h
kg/h
612
612
612
612
612
980
981
982
983
984
0,110
0,110
0,110
0,110
0,110
360
390
420
460
kg/h
kg/h
kg/h
kg/h
612
612
612
612
985
990
991
992
0,110
0,110
0,110
0,110
40
45
50
55
60
kg/h
kg/h
kg/h
kg/h
kg/h
70 kg/h
80
90
100
110
kg/h
kg/h
kg/h
kg/h
Bitte beachten
Dsen knnen nicht gegen Gutschrift
oder Umtausch zurckgenommen werden.
14.14
14.1 5
Anschluschlauch komplett fr
ldurchsatzmessung
fr RL-Brenner mit Regeldse
\ 0-Ring 7 x 1,5 aus Viton fr Regeldse W
111 574 0 0 0 1 / 2
0,382
445 040
0,002
Siebfilter fr Regeldse (ohne Bild)

Maschen
Maschen
Maschen
Maschen
bis 125 kg/h, Dse W

ab 140 kg/h, Dse W
fr Dse K3 ber 70kg/h
fr Dse W B 3 bis 70 kg/h
Semi-solid spray
C 6 n e 1/2creux
Regulating nozzles
Gicleur retour
Kindly observe
Nozzles can not be
returned for credit or
exchanged.
14.16
80
40
80
120
612
612
602
602
966
965
543
544
Designation
1 env. kg
14.10 Regeldsen
14.11
Designation
I appr. kg
0,017
0,017
0,004
0,010
Connection hose compl.

for oil througput
I detemiination for RL burners
with regulating nozzle
Observations:
Les gicleurs ne peuvent
pas tre repns ou faire
I'objet d'un avoir.
Flexible complet pour
mesure du debit
sur gicleur a retour
0-Ring 7 X 1,5 made of

Viton for regulating nozzle
Joint 0 en viton pour

gicleur retour
Screen filter for regulating nozzle (without pict.)

80 meshes up to 1 25 kg/h
40 meshes from 140 kg/h
80 meshes for nozzle
110 meshes for nozzle
Filtre en tamis pour

gicleur a retour (s. photo)
8 0 Mailles e 125 kg/h
40 Mailles de 140 kg/h
80 Maiiles pour gicleur
110 Mailles pour gicleur
29
^"ii.mi'-'
^w^*
i>i
15.8
15.14
15.15
15,16
15.17
i Bezeichnung
; Burner serre
} Type bruleur
Bild
Piet.
Photo
15.
Bestell-Nr.
Order-No.
No de commande
15.19
15.20
15.22
15.23
j ca. kg
! appr. kg
1 env. kg
15.10
15,24
15.25
o
15.26
15.27
15.11
15.12
15,28
Designation
Designation
Feuerungsautomaten
Burner controls
Coffret de scurit
Preise fr
Sonderspannungen auf Anfrage
Price for
special voltages on inquiry
Prix pour tension

speciale demande
Burner control
Coffret de scurit
CableAGM19
CbleAGM19
Program mechanism
Progammateur
Flame detector
Dtecteur de flamme
Terminal socket
Bornier socle
Feuerungsautomat, 220-240V
LOA 24.171
50-60 Hz
LOA 25.173
50-60 Hz
LOA 44.252
50-60 Hz
600 206
600 208
600 213
0,180
0,184
0,140
15.2
LAL
LAL
LAL
LAL
15.3
15.1
50-60
50-60
50-60
50-60
Hz
Hz
Hz
Hz
600 1 75
600 177
600 1 78
600 1 79
1,000
0,892
1,000
1,040
LFL1.122
LFL 1.322
LFL 1.335
LFL 1.622
LFL 1.635
50-60
50-60
50-60
50-60
50-60
Hz
Hz
Hz
Hz
Hz
600 161
600 163
600 1 72
600 165
600 1 74
1,000
1,000
1,000
1,000
1,000
15.4
LOK 16.250
LOK 16.850
50-60 Hz
50-60 Hz
600 192
600 220
0,989
1,000
15.5
LGK 16.122
LGK 16.322
LGK 16.622
50-60 Hz
50-60 Hz
50-60 Hz
600 200
600 195
600 201
0,986
0,990
0,992
15.6
Steckerkabel AGM19 fr L G K 1 6 / Q R A 5 5
600 579
0,341
15.7
Steuergert, 220-240 V
LEGI
LEGI
50 Hz
6 0 Hz
600 1 24
600 1 25
1,530
1,530
Flammenwchter, 220-240 V
LAE10
LFE10
50-60 Hz
50-60 Hz
600 118
600 121
0,310
0,400
600 527
600 516
111 552 1 203/7
600 521
600 523
600 509
600 511
0,070
0,160
0,164
0,120
0,166
0,350
0,080
Flammenfhler
QRB1 (Kabel 800 mm)
QRB3
RAR7(Selenzelle)
RAR8
UV-Fhler fr Q R A 5 5
Flame feeler
Sonde de Ionisation
111 964 1201/2

111 151 1203/2
111 974 1201/2
110 564 1201/2
600 587
0,030
0,059
0,089
0,091
0,005
(Selenium cell)
(Cellule)
15.17
QRA{UV-Zelle)
600 501
0,032
(UV-Cell)
(Cellule UV)
15.18
QRA 55 (UV-Zelle)
600 578
0,985
15.19
15.20
15.21
Bride fr ORB 1
QRB3
QRA und RAR
600 566
600 569
600 601
0,002
0,006
0,009
Flange for
Bride pour
600
600
600
600
0,003
0,008
0,019
0,007
Holder for
i Support pour
111 974 1201/7
0,033
0.089
Connect, cable for QRA

for burner control
Cable pour QRA,

pour coffret de scunt
730 002
730 004
0.022
0,029
Cable screwing
Presse toupe
15.8
15.9
15.10
2.14
2.25
2.65
3,25
Klemmensockel
15.11
15.12
15.13
15.14
15.15
15.16
LOA
LFL
LAL
LOK
LGK
LEC
LAE/LFE
15.22
15.23
15,24
15.25
: Flansch fr QRB1
i
QRB3
QRA und RAR (gewlbt)
i
(flach)
15,26
15,27
15,28
Anschlukabel fr QRA
RAR
Verschraubung PG 13.5
PG 16x6-14
30.
15.1
15.9
15.13
!tfttl'
564
568
600
602
155 313 1201/7
o^
16,5
16.6
16i
16,9
Bild
Piet.
Photo
16.
16.1
I Bezeichnung
i Burner sene
1 Type brijleur
1 Gre
Size
j Grand.
Bestell-Nr
Grder-No.
No de commande
ca. kg
appr, kg
env. kg
Zndtrafo
Zndtrafo, 230V/50-60 Hz (2 x 5000V)
5-8
L. G. GL
603 100
5-7
RL, RGL
5/7-.NA
603
077
G (2 X 7000V)
Designation
Designation
Ignition
transformers
Transformateur
d'allumage
Ignition transfornners
Transformateur
Attachment bracket
Etrier de fixation
2,120
0,946
Zndtrafo (2 x 7000 V mit 100% ED)

L
RL, RGL
9-1OT
8-11
M
MS
RMS
5
7-9
7-11
G, GL, RGMS
9-11
16.4
Trafobgel
L
G,GL,RGL
G
G,GL,RGL
5-7
5-7
5/7-NA
7-11
16.5
Tlle LW 0 8
756 122
0,003
Bushing
Passage
16.6
Dictitungstlle
111 351 0010/7
0,008
Sealing sleeve
Presse toupe
16.7
Zndleitung (ohne Bild)

Preis pro Meter PVC-schwarz
Preis pro Meter Silikon rot
(auch fr Ionisation)
743 200
743 202
0,056
0,048
Ignition cables
Price per meter
(without picture)
Cables d'allumage
Prix du metre
(sans photo)
16.8
Steckerkupplung
716018
0,014
Plug coupling
Fiche embrochable
16.9
Zndstecker
716017
0,019
Ignition plug
Prise d'allumage
16.10
Zndkabelstecker
G
794 005
0,003
Ignition cable plug
Prise cable d'allumage
16.2
16.3
5/7-NA
603 112
111 211 1102/7

251 103 1101/7
151 907 1101/7
6,140
0,140
0,122
0,169
31
/f^
ri
r?-^-W-^si-Tfl***
17 1
17.2
17.9
Bild
Piet.
Photo
17.12
17.4
17.3
17.13
Bezeichnung
Brenner-Typenreihe
Burner serie
I Type brleur
17.14
17.15
Gre I Bestell-Nr.
Size
Order-No.
Grand, i No de commande
ca. kg
appr. kg
env. kg
Designation
\ Designation
Terminals incorporation box
jBornier de
iraccordement
17.
Einbauklemmleiste
17.1
Einbauklemmleiste komplett
fr l-, Gas- und Zweistoffbrenner ohne Schalteinrichtung.
Bei Bestellung Brennertype
und Spannung angeben.
auf Anfrage
Terminals incorporation
box, complete for OilGas- and Dual fuel burners
without switching equipment. W h e n ordering
indicate burner type and
voltage.
Bornier complet pour

brleurs fuel, gaz et
mixte sans commande
incorpore. Lors de
commande preciser le
type du brleur et la
tension.
17.2
Einbauschaltteil komplett fr
G5-7. Bei Bestellung Brennertype und Spannung angeben.
auf Anfrage
Built in switching component complete, for

G5-7 when ordering
indicate burner type and
voltage.
Commande incorpore
complet pour G5-7 lors
de commande preciser
le type du brleur et la
tension.
17.3
EinbauschalttetI komplett fr
ibrenner. Bei Bestellung
Brennertyp und Spannung
angeben,
auf Anfrage
Switching equipment
complete for oil burners
burner type and voltage.
Commande incorpore
complet pour brleur
fuel inquer le type
du brleur et la tension.
Cover plate
Tle protectrice
17.4
17.5
17.6
17.7
17.8
17.9
17.10
Abdeckplatte
L,G,GL,RL,RGL
L,MS,G,GL,RL,RGL,RMS
L
L,G,MS
Einbauklemmleiste, G
28-polig
28-polig
28-polig
38-poiig
41-polig
41-polig
0106/2
0105/2
2207/2
0106/2
0,752
0,860
1,466
1,733
150 0 0 9 1 3 0 1 / 2
1,540
2,177
0,734
0,781
0,947
0,835
Terminal strip
28-pole
28-pole
28-pole
38-pole
36-pole
45-pole
Bornier de
28-ples
28-ples
28-ples
38-ples
36-ples
45-ples
735 078
735 077
0,013
0,069
Terminal strip
2-pole
12-pole
Bornier
2-ples
12-pi3les
111 564 2204/7

111 764 2204/7
0,200
0,240
Installation bracket
for switching equipment
Etrier pour bornier
5
7-8
5-11
111 564 1 703/7
0,321
151 101 0108/7
0,150
5
7-8
9-11
5
7-8
5-8
5-8
9-11
9-11
Klemmleisten
2-polig
12-polig
Montagebgel fr Schaltteil
L,I^S,G
L,MS
L,MS,RL,RMS,G,GL,RGL,
fr Klemmleiste
Platte (ohne Bild)
111
111
111
111
552
652
964
974
150 009
151 516
111 574
111 974
157 518
1401/2
1702/2
1710/2
1716/2
1704/2
Befestigungsschelle
H3P
H4P
H5P
H6P
H 7P
790
790
790
790
790
252
253
254
255
270
0,001
0,001
0,001
0,001
0,001
17,13
Beschriftungsleiste
12-polig
20-po!ig
736 196
736 197
0,002
0,003
17.14
Krallenscheibe
M4
M5
I 431 900
431 901
0,001
0,001
736 038
0,001
17.12
17.15
32
17.7
17.6
i Spreizniet SN 2001
raccordement
for terminal strip

Plate (without picture)
Plaque (sans photo)
Cable clamp
Collier pour cable
Lettering strip
1 2-pole
20-pole
Etiquette bornier
! 12-ples
j20-ples
Toothed arresting disk
[Rondelle ventail
Spreader rivet
\ Rivet
17.1'
Bild
Piet.
Photo
nn
17.1J
17.19
Bezeichnung
Brenner-Typenreihe
Burner serie
Type bruleur
17.21
'.20
Gre
Size
Grand.
Bestell-Nr.
Order-No.
No de commande
ca. kg
appr. kg
env, kg
auf Anfrage
Uberstromrelais
(ohne Bild)
Bei Bestellung Brennertype,
Motortype, Stromstrke und
Spannung angeben.
Designation
Designation
Overload relay
(without picture)
burner type, motor type,
amperage and voltage.
Relais
Air break contactor
Contacteur
(sans photo)
Prciser le type du
brCileur moteur, intensit
et tension.
Leistungsschtz
230/380V, 50-60 Hz
8 9-30-10
B12-30-10
B12-30-22
B16-30-32
B16-30-10
825-30-10
8 3 0 - 30 - 22
701
701
701
701
701
701
701
897
901
903
908
905
898
900
0,310
0,307
0,346
0,354
0,305
0,460
0,588
17.18
Hilfsschtz K22 E 2 S -H 2
701 930
0,305
Auxiliary contactor
Relais auxiliaire
17.19
Schalter 1300 Ziffer 1

1302 Ziffer 2
700 914
700 916
0,010
0,012
Switches
interrupleur
17.20
Zeitzhler 5 0 Hz
60 Hz
709 574
709 575
0,044
0,044
Service hours counter
Compteur d'heures
17.21
Temperaturregler Typ ROB

220-240V/50-60 Hz, 65-130G
691 120
0,189
ROB type
Regulateur de
temperature ROB
17.17
5-11
33
Bezeichnung
Bild
Piet.
Photo
Gre 1 Bestell-Nr.
Size
1 Order-No.
Grand. i No de commande
Brenner-Typenreihe
Burner serie
Type brleur
1 ca. kg
17.52
17.53
17.54
34 .
Brenner - Endschalter, 2 x 0,75

L, M, MS und
RL, RMS und
G, GL und
RGL und RGMS
750
5-9
5-11
5 - 10
9-11
111 974 1 2 0 1 / 7
0,089
Olvorwrmer - Einbauschaltteil
fr Steuerung
M
980
MS
1040
5
7-1-8
2 1 2 364 2 2 0 4 / 2
112 762 0 0 0 3 / 2
0,180
0,160
fr Heizung
M
MS
5
7-1-8
112 552 0 0 1 3 / 2
11 2 762 0 0 0 2 / 2
0,152
0,240
1140
1110
Olvorwrmer - Einbauklemmleiste
fr Steuerung
M, MS, RMS
6 X 1,5 X 1100
6 X 1,5x1300
6 X 1,5 X 1320
5-8
9-10
11
11 2 964 0 0 0 2 / 2
112 964 1 7 1 8 / 2
112 882 0 0 0 4 / 2
0,175
0,214
0,214
fr Heizung
M
MS, RMS
MS, RMS
RMS
5
7-8
9-10
11
112
112
112
182
0,152
0,237
0,348
0,530
4
4
4
4
X 2,5 X 1140
x 4 X 1100
x 4 X 1 300
X 6 X1400
552
652
964
174
0013/2
0003/2
1717/2
0005/2
1 Designation
1 env. kg
17.50 Anschlukabel
17.51
Designation
appr. kg
1
Connection cable
Cable raccordement
Burner - limit switch
Brijleur-contact de bride
Oil preheater - Switching

equipment for control
Rchauffeur - commande
incorpore pour
commande
for heating
pour puissance
Oil preheater - Terminals

incorporation box
for control
Rchauffeur - bornier
sans commande incorpore pour contrie
for heating
pour puissance
C
18,4
18.12
18.5
18.6
18.7
18.9
18,10
18,1 1
18.13
18,101
Bezeichnung
B.ld
Piet.
Photo
Brenner-Typenreihe
Burner sene
Type brleur
18.
Besteil-Nr,
Order-No.
No de commande
Designation
Designation
Olvorwrmer EV2B-D
Oil preheater
EV2B-D
Rchauffeurs
EV2B-D
Bei Bestellung Spannung angeben
When ordering Indicate

voltage
la commande indiquer
la tension
Olvorwrmer komplett,
jedoch ohne labgang
Type
EV2B/01
-80C
80-100C
EV2B/01
100-160C
EV2B/01
Oil preheater complete

however without oil
outlet
Type
Rchauffeur complet
sans depart fuel
Type
Oil preheater
rriarlne execution
Type
Rchauffeur
execution maritime
Type
Temperature regulator
Regulateur de
temperature
Temperature switch
for burner release
Thermostat
minimum
Connection cable
Cable
Holder
Support
EV2C
EV2C
EV2C
EV2D
EV2D
EV2D
-80C
80-100C
loo-ieo'C
-80C
80-100"C
100-160C
380/400V
380/4 00 V
380/400V
511 221 0 1 0 1 / 0
511 222 0 1 0 1 / 0
511 220 0 1 0 1 / 0
16,400
16,400
14,539
380/400V
380/400V
380/400V
511 231 0 1 0 0 / 0
511 232 0 1 0 0 / 0
511 230 0 1 0 0 / 0
14,760
14,760
14,760
380/400V
380/400V
380/400V
511 241 0 1 0 0 / 0
511 242 0 1 0 0 / 0
511 240 0 1 0 0 / 0
23,880
23,880
23,880
511 2 2 5 0 1 0 1 / 0
511 225 3 1 0 1 / 0
511 225 4 1 0 1 / 0
16,400
16,400
16,400
511 235 0 1 0 0 / 0
511 235 3 1 0 0 / 0
511 235 4 1 0 0 / 0
15,800
15,800
15,800
511
511
511
511
511
511
26,960
26,060
27,000
25,870
26,980
26,310
Olvorwrmer in Schiffsausfhrung
Typ
380/400V
EV2B/01
240/41 5V
EV2B/01
254/440V
EV2B/01
EV2C
EV2C
EV2C
380/400V
240/415V
254/440V
EV2D
EV2D/R
EV2D
EV2D/R
EV2D
EV2D/R
380/400V
380/400V
240/415V
240/415V
254/440V
254/440V
ca. kg
appr. kg
env. kg
liegend angeb.
liegend angeb.
liegend angeb.
245
246
245
246
245
246
0100/0
0100/0
3100/0
3100/0
4100/0
4100/0
Temperaturregler
RAG4/6360
20 - 9 0 C
RAG4/6331
60-130C
RAG4/6330
90-1 eO'C
690 051
690 048
690 045
0,140
0,136
0,142
18.4
Temperaturschalter fr Brennerfreigabe
F 5 5 - 17(EV1B)
F 65 - 1 7 (EV2A/B/C/D)
AnschluBlitze fr EV2B-D
690 166
690 167
0511 210 0 0 2 / 2
0,004
0,004
0,003
18.5
Halter fr EV2B-D
0 5 3 3 001 0 0 3 / 7
0,003
Scheibe
0 5 3 3 001 0 0 6 / 7
0,002
18.2
18.3
18.6
Disk
Rondelle
Temperature limiter
temperature
Limiteur de
0,010
Holder for temperature

limiter
Support pour limltateur

de temperature
Temperaturbegrenzer
LI 35
0,005
0,005
L I 70 (EV2D)
690 172
690 1 73
Halter fr Temperaturbegrenzer
fr EV2D
0511 240 010/7
18,10
Befestigungsschelle fr EV2D
0511 240 006/7
0,006
Attachment clamp
Collier de fixation
18.11
Verschraubung PG 13,5 fr EV2C-D

PG11 frEV2B-D
730 111
730 110
0,022
0,016
Screwing
Presse toupe
18.12
Sechskantmutter MPg 13,5
730 405
0,003
Locknut
Contre-crou
18.13
Reduktion HPg 13,5-Pg 11
730 451
0,005
18.14
Haube
fr EV2B-EV2C
fr EV2D
0511 220 003/2

0511 240 003/7
0,520
0,444
18,15
Haube fr Vorw. in Schiffsausfhrung

EV2B/C
EV2D
0511 220 002/2

0511 240 002/2
0,520
0,440
18.7
18.9
EI
Reducing
Rducteur
Cover
Ca pot
Cover for preheater in

marine execution
Capot pour rchauffeur

en execution maritime
35
18.16
18.U
18.21
Bild
Piet.
Photo
Bezeichnung
Brenner-Typenreihe
Burner serie
Type brleur
Bestell-Nr.
Order-No.
No de commande
j ca. kg
! appr. kg
1 env. kg
Heizeinstze
18.16
EV2B
EV2C, EV2D
18.17
Heizeinstze fr Schiffsausfhrung
EV2B
230
240
254
EV2C, EV2D
230
240
254
Watt
1500
1500
1500
1500
2200
2200
2200
2200
0511
0511
0511
0511
230
220
220
220
102/2
107/2
105/2
104/2
0,878
0,889
0,878
0,857
0511
0511
0511
0511
210
210
220
220
101/2
107/2
102/2
103/2
0,893
0,880
0,907
0,868
1500
1500
1500
0511 220 108/2

0511 220 110/2
0511 220 109/2
1,065
1,063
1,045
2200
2200
2200
0511 210 105/2

0511 210 109/2
0511 210 108/2
1,092
1,066
1,082
Designation
Heating elements
(for mains voltage 220V)
j Elements chauffants
i (pour voltage 220V)
Heating elements
Elements chauffants
18.18
Kabelschuh (AMP), M5, fr EV2B-EV2D
794 400
0,001
Cable socket
Cosses
18.19
Isolierschlauch (2 Stck erforderlich)

(ohne Bild)
0511 210 006/7
0,001
Isolation hose
(without picture)
Flexibles d'isolement
(sans photo)
lwendel komplett
EV2B
EV2C
EV2D
Oil coil complete
Serpentin complet
0511 220 111/2

0511 230 101/2
0511 240 101/2
5,200
5,120
10,320
Dessinblech
EV2B
EV2C
EV2D
EV2D (Schiffsausfhrung)
Design sheet
Tle d'habillage
0511
0511
0511
0511
103/7
111/7
103/7
111/7
0,232
0,420
0,400
0,920
Umbausatz (o. Bild)

Temperaturbegrenzer L 135
Temperaturbegrenzer L 170
Alteration set
Jeux de transformation
511 201 0001/2

511 201 0002/2
0,016
0,025
18.20
18.21
18.22
36.
Volt
230
240
254
290
230
240
254
290
Designation
230
220
240
240
18.40
Brid
Piet.
Photo
Bezeichnung
Brenner-Typenreihe
Burner sene
Type brtjleur
18.4:
i Besteii-Nr.
j Order-No.
1 No de commande
:S.42
18.43
I oa. kg
i appr. kg
i env. kg
18.30
lvorw/rmer
WEV 2.2/01 und WEV 3 / 0 1
18.31
WEV 2.2/01
380/400V
240/415V
254/440V
290/500V
512
512
512
512
220
220
220
220
0102/0
3102/0
4102/0
5102/0
26,500
26,500
26,500
26,500
18.32
WEV 3 / 0 1
380/400V
240/41 5V
254/440V
290/500V
512
512
512
512
300
300
300
300
0102/0
3102/0
4102/0
5102/0
45,500
46,000
46,000
46,000
18.33
Olvorwrmer WEV 2.2/01 und WEV 3 / 0 1

in Schiffsausfhrung
WEV 2.2/01
(mit Schlauchverschraubung)
380/400V
254/440V
290/500V
WEV 2.2/01
18.35
13.36
WEV 3/01
WEV 3/01
Heizkrper
WEV 2.2/01
5 1 2 225 0 1 0 2 / 0
5 1 2 225 4 1 0 2 / 0
5 1 2 225 5 1 0 2 / 0
26,550
26,500
26,550
(mit Schiffsverschraubung)
380/400V
254/440V
5 1 2 229 0 1 0 2 / 0
512 229 4102/0
28,400
28.400
(mit Schlauchverschraubung)
380/400V
254/440V
290/500V
5 1 2 305 0 1 0 2 / 0
512 305 4102/0
512 305 5102/0
46,200
46,200
46,200
(mit Schiffsverschraubung)
380/400V
254/440V
290/500V
512 309 0102/0

512 309 4102/0
512 309 5102/0
45,700
46,100
46,100
230V
240V
254V
290V
6900
6900
6900
6900
512 2100122/7
5122100128/7
512 2 1 0 0 1 2 3 / 7
512 2100124/7
0,757
0,768
0,795
0,785
230V
240V
254V
290V
5600 W
5600 W
5600 W
5600 W
512
512
512
512
0,630
0,630
0,630
0,630
W
W
W
W
18,44
Designation
!8,45
Designation
Oil preheater
WEV 2.2/01 and
WEV 3/01
Rchauffeurs
WEV 2.2/01 et
WEV 3 / 0 1
Oil preheater
in marine execution
Rchauffeur execution
maritime
Heating body
Corps chauffant
18.38
WEV 3/01
18.39
Temperaturbegrenzer EMF-5U
691 115
0,113
Temperature limiter
temperature
Limitateur de
18.40
Temperaturregler C R O w - 5 4 / 2
691 116
0,460
Regulateur de
temperature
18.41
Fhler PT100
512 2 1 0 0 1 4 1 / 7
0,012
Sensor PT100
Sonde PT100
18.42
18.43
Halter fr Temperaturbegrenzer
512 2100142/7
512 2100118/2
0.006
0.014
Holder
Support
300
300
300
300
0126/7
0132/7
0127/7
0128/7
18.44
I Bgel WEV 2 . 2 / 0 1 . W E V 3 / 0 1 . RMS 7-11
112 8 7 4 0 1 0 2 / 7
2,621
Bracket
Etrier
18.45
I Bgel WEV 2.2/01 fr RMS9. RMS10
112 9 6 4 0 1 0 1 / 7
2,449
Bracket
Etrier
37
s*4%t
18.54
18.51- 8,53
Bezeichnung
Brenner-Typenreihe
Burner sene
Type brieur
Bild
Piet.
Photo
18.50 Olvorwrmer MV9C, MVI CA

undMVIOB
18.53
1 Bestell-Nr.
Order-No.
1 No de commande
ca. kg
appr. kg
env. kg
1
I
523 9 3 0 0 1 0 2 / 0
543 0 1 0 0 1 0 0 / 0
543 0 2 0 0 0 0 1 / 0
E
E
E
38,340
74,200
63,400
18.54
Kugelhahn ND64, PN 100 M18 x 1,5

G 1/2", PN 250
454 0 4 0
454 181
Z
Z
18.55
Thermometer 0-160C
642 0 0 9
18.56
Einschraubstutzen
fr Thermometer
585 101 0 0 0 2 / 7
Schneidring (ohne Bild) DPR 12-L
4 5 2 773
18.58
berwurfmutter (ohne Bild) M I 2 L
4 5 2 836
18.59
Temperaturregler ATH-2
50-250 C
Fhlerlnge 280 mm
690 247
18.60
Temperaturregler EMF-23
50-250'C
Fhleringe 100 mm
690 248
18.61
Einschraubstutzen 22 x G 1 / 2 ' x 52
122 3 6 4 0 0 7 0 / 7
18.62
Reduzierschraube M20 x 1.5 x M l 2
18.63
Befestigungsbgel M5Z
18.64
18.65
18.66
Bgel MS7-RMS8
MS9-RMS10
RMS11
18.57
18
65
18.66
Designation
iRchauffeur
MV9C, MVIOAet
MV10B
Oil preheater. without

connection parts and
without armatures
Rchauffeurs, sans
raccords et sans
accessoires
0,727
0,805
Bali cock
Robinet a bille
0,085
Thermometer
Thermomtre
0,095
Adapter for thermometer
Raccord pour thermomtre
0,003
Cutting ring
(without picture)
Rondelle
(sans photo)
0,025
0,467
Union nut
(without picture)
temperature
Raccord union
(sans photo)
Rgulateur de
0,489
temperature
Rgulateur de
0.093
Threaded bush
Douille filete
0523 9 2 0 0 0 6 / 7
0,026
Reducing screw
Vis de regulation
1 10 5 6 4 0 1 0 1 / 2
6,380
Attachment bracket
Etrier de fixation
110 7 6 4 0 1 0 1 / 2
110 964 0 1 0 2 / 2
180 174 0 1 0 3 / 2
E
E
E
12,840
15,220
18,180
Bracket
Etrier
38
Designation
Oil preheater
MV9C, MVIOAand
MV10B
Olvorwrmer. ohne
Anschluteile und ohne Armaturen
MV9C
MV10A
MV10B
18.51
18.52
18.53
18.64
1
f
"'
r-"'y
19.1
19.3
19.1 1
19.17
J^-^j
'19.12
Fo
I- M
'
i%
19.14
19.25
,q
^ ^6
19.22
19.27
'
^.-,
'
.,
j1
19.13
'
19.20
19.8
19.10
39
f!
1916
9.26
9.31
19.15
19.21
'^^ r-^
1 l
''nr
A,
1
a
19.2
19.4
. mB
^~
ly-i
""
1,
1919
^^
'9-3
19.28
19.24
19.29
iqgn
Bezeichnung
MV
Bild
PiCt.
Ptioto
Brenner-Typenrethe
Burner serie
Type brCileur
Gre
Size
Grand.
19.
Armaturen fr
Medium-lvorwrmer
mit nachgeschaltetem
Elektro-Vorwrmer
Valve train for

iTuyauterie et
medium oil preraccord pour reheater with added chauffeur fluide
electric preheater avec rchauffeur
lectrique en serie
Warmwasser bis 110'C
Warm water
up to 1 1 0 ' C
Eau chaude
jusqu' 110'C
Ball cock
Robinet bille
Hot water
above 110-180C
Ball cock
Eau surchauffe
110-180=C
Robinet bille
Regulator for hot water
Rguiateur eau chaude
Heat carrier oil

up to 2 5 0 ' C
Ball cock
Thermofluide
250'C max.
Robinet bille
Regulator for heat

carrier oil
Rguiateur d'huile
Heat carrier oil

up to 300 C
Bellows valve
Regulator for heat
carrier oil
Thermofluide
300 C max.
Vanne soufflet
Rguiateur pour
hulle
Low pressure steam

up to 0,5 bar
Highi pressure steam
up to 1,5 bar
Ball cock
Vapeur basse pression jusqu'a 1,5 bar

Vapeur haute-pression
jusqu'a 1,5 bar
Robinet bille
Condensate checking
device
Condensate trap
Controleur de
condensat
Organe d'vacuation
1,780
High pressure steam

above 1,5-12 bar
Ball cock
Dirt trap
Steam pressure regulator
Condensate checking
aggregate
Condensate trap
sup. 1,5-12 bars
Robinet bille
Tamis
Reg. vapeur
Controleur de
condensat
Organe d'vacuation
2,440
! 2.350
! 14.380
6.200
i
3,900
High pressure steam

above 12-20 bar
i Ball cock
1 Dirt trap
Steam pressure regulator
Condensate chocking
aggregate
Condensate trap
; Vapeur haute-pression
sup. 12-20 bars
j Robinet bille
1 Tamis
i Reg.vapeur
j Controleur de
: condensat
\ Organe d'vacuation
Besteli-Nr.
Order-No.
No d e commande
ca. kg
appr. kg
env. kg
1 Designation
1 Designation
19.1
19.2
Kugelhahn
9-HO
9-HO
G 1/2"
DN 15
454 1 8 8
454 191
Z
Z
0,807
2,440
Heiwasser ber 1 1 0 - 1 8 0 0
19.3
19.4
Kugelhahn
19.6
Regler fr Heiwasser
G 1/2"
ON 15
DN 20
DN 20
9-1-10
9-HO
9-HO
9-1-10
454
454
454
690
188
191
1 92
Ol 7
Z
Z
Z
Z
0,807
2,440
3,480
5,300
DN 15
DN20
DN 1 5
DN 20
9
10
9
10
454
454
690
690
191
192
019
021
2,440
3,480
4,460
5,480
DN 15
DN 15
9-t-IO
9+10
454 138
690 0 1 9
Wrmetrgerl bis 250=0

19.7
Kugelhahn
19.8
Regler fr Wrmetrgerl
z
z
z
Wrmetrgerl bis 300 C

19.9
19.10
Faltenbalgventil
Regler fr Wrmetrgerl
3,800
4,460
z
z
Niederdruckdampf bis 0,5 bar

und
Hochdruckdampf bis 1,5 bar
19.11
19.12
19.13
19.14
19.15
19.16
Kugelhahn
Kondensatkontrollgert
Kondensatabieiter
G 1/2"
DN 15
G 1/2"
DN 15
Rp 112"
DN 15
9-1-10
9-HO
9-HO
9 -HO
9-HO
9-1-10
454
454
699
699
499
499
188
191
021
022
038
039
0,807
2,440
3,020
6,200
1,780
3,900
z
z
z
z
z
z
Hochdruckdampf ber 1,5-12 bar

19.17
19.18
19.19
19.20
Kugelhahn
Schmutzfnger
Druckregler
G 1/2"
G 1/2"
Rp 1/2"
G 1/2"
19.21
Kondensatabieiter
Rp 1/2"
Hochdruckdampf ber 12-20 bar

19.22
19.23
19.24
19.25
19.26
1 Kugelhahn
Schmutzfnger
Druckregler
Kondensatabieiter
9 -HO
9-1-10
9-HO
9-I-10
454
499
605
699
9-HO
499 0 3 8
188
084
354
021
0,807
0,420
2,060
3.020
z2
z
z
z
i
DN15
DN15
DN15
DN15
9-HO
| 9+10
9+10
j 9+10
454
499
640
699
191
087
019
022
DN15
: 9 +10
499 0 3 9
i
;
1Z
iZ ;
Z :
!
'. z i
39
* >
19.42
19.46
:9.5 t
19.56
19.62
19.69
19.4"
:9.45
9.55
'9.6'
0 8
.^
i
'^<-'
19 58
9.48 19.64
19.53 19.72
i 9.70
MV
Bestell-Nr,
Order-No.
No de commande
Gre
Stze
Grand.
' Brenner-Typenreihe
Burner sene
Type brCiieur
19.40 Armaturen fr
I IVledium-Vorwrmer
ohne nachgeschaltetem
; Elektro-Vorwrmer
^ 9.50
19.44
Bezeichnung
B<\
Pict.
Photo
19.49
19.54
19.67
19.75
1
i
; Kugelhahn DN 15
Schmutzfnger DN 15
Regelventil 15/6 H1F
Thermostat 4.05
'
9+10
; 9-HO
9-HO
9-HO
i 4 5 4 191
i 499 087
6 0 5 105
690 002
z
z
z
2.440
2,350
3,200
3,000
Wrmetrgerl bis 2 5 0 C
19.45
19.46
19.47
19.48
19.49
Kugelhahn DN 15
Schmutzfnger DN 15
Regelventil 15 H l F
Thermostat 4.05
Khlstcl( KS5
Faltenbalgventil DN 15
Schmutzfnger DN 15
Regelventil 15/6 H l F
Thermostat 4.05
j Khlstck KS5
Hot water
up to 200 C
Ball cock
Dirt trap
Regulating valve
Thermostat
Eau surchauffe
2 0 0 0 max.
Robinet bille
Tamis
Soupape
Regulateur
9+10
9+10
9+10
9+10
9+10
454
499
605
690
605
191
087
102
002
111
z
z
z
z
z
2,440
2,350
3.100
1 3.000
\ 0,600
Heat carrier oil

up to 250 C
Ball cock
Dirt trap
Regulating valve
Thermostat
Intermediate piece
Thermofluide
250'C max.
Robinet bie
Tamis
Soupape
Regulateur
Piece intermedlaire
9+10
9+10
9+10
9+10
9+10
454
499
605
690
605
138
087
105
002
1 11
z
z
z
z
z
3,800
2,350
3,200
3,000
0,600
Heat carrier oil

250-300 C
Sipon valve
Dirt trap
Regulating valve
Thermostat
Intermediate piece
Thermofluide
250-300 C
Vanne a souffiet
Tamis
Soupape
Regulateur
Piece intermediaire
High pressure steam

upto 13 bar
Ball cock
Dirt trap
Regulattngvalve
Thermostat
Condensate checking
aggregate
Condensatetrap
13 bar max.
Robinet bille
Tamis
Soupape
Regulateur
Controleur de
condensat
Organe d'vacuat.on
High pressure steam

13-20 bar
Ball cock
Dirttrap
Regulating valve
Thermostat
Condensate checking
aggregate
Condensate trap
Intermediate piece
13-20 bar
Robinet a bille
Tamis
Soupape
Regulateur
Controleur de
condensat
Organe d'evacutation
^lce intermediaire
Wrmetrgerl 250-300 C
19.50
19.51
19.52
19.53
19.54
Designation
1 Valve train for medium Tuyauterie et raccord

i preheaters without
pour rchauffeur
1 added electric
fluide sans rchauf fer
i preheater
lectrique en serie
, Heiwasser bis 200 C

19.41
19.42
19.43
19.44
Designation
i '^3- ^9
i appr. kg
env. kg
i
j
Hochdruckdampf bis 13 bar

19.55
19.56
19.57
19.58
19.59
Kugelhahn DN 15
Schmutzfnger DN 15
I Regelventil 15/6 m F
Thermostat 4.05
, Kondensalkontrollgert DN 1 5
9+10
9+10
9+10
9+10
9+10
454
499
605
690
699
191
087
106
002
022
z
z
z
z
z
2.440
2,350
3,400
3,000
6,200
19.60
; Kondensatabieiter DN 1 5
9+10
499 039
3,900
19.61
19.62
19.63
19.64
19.65
I Kugelhahn D N 15
! Schmutzfnger DN 1 5
I Regelventil 15/6 H1 F
I Thermostat 4.05
Kondensatkontrollgert DN 15
9+10
9+10
9+10
9+10
9+10
454
499
605
690
699
191
087
105
002
022
z
z
z
z
z
2,440
2,350
3,200
3,000
19.56
19.67
! Kondensatabieiter DN 15
I Khlstck KS4
9+10
9+10
499 039
605 112
i Hochdruckdampf 13-20 bar
I 6,200
! 3.900
Z [
!
;
0.500
I Hochdruckdampf 20-25 bar

19.68
19.69
19.70
19.71
19.72
1 9.73
: Kugelhahn DN 15
Schmutzfnger DN 15
I Druckregler"DN 15
, Regelventil 15/6 H1 F
: Thermostat 4.05
Kondensatkontrollgert DN 1 5
9+10
9+10
9+10
9+10
9 + 10
9+10
19.74
19.75
19.76
Kondensatableiter DN 15
' Khistck KS4
Kopfstck
9+10
9+10
9+10
14 5 4
i
1
i
!
191
087
016
105
002
022
499
640
605
690
i 699
1
499 039
605 112
690 004
! Z
i Z
! z
1Z
i Z
;Z
i
1
j
1
i
'
! Z 1
i Z i
i Z
'
,
:
;
2.440
2.350
8.220
3.200
3.000
6.200
3.900
. 0.500
0.365
High pressure steam

20-25 bar
Ball cock
: Dirt trap
; Steam pressure regulator
j Regulating valve
1 Thermostat
j Condensate checking
aggregate
! Condensate trap
' Intermediate p^cce
, Head piece
Max Weishaupt G m b H . D-88475 S c h w e n d i . Tel. (07353) 8 3 0 . Telefax (07353) 8 3 3 5 8 . Druck-Nr 214 Mai1996
20-25 bar
' Robinet bille
Tamfs
Regulateur vapeur
Soupape
Regulateur
Controleur de
' condensat
Organe d'evacuation
êce intermediaire
Tie de thermostat 4.05
Nachdruck verboten
weishaupt
manual
f
^
Installation and operating instruction
Weishaupt Electric & Media Oil Preheaters
83001802- 1/2005
Contents
1 General instructions
2 Safety information
3 Technical description
3.1 Permissible applications
4 Electric oil preheater type EV2...

4.1 Safety instructions
4.2 Function
4.4 Safety instructions for initial commissioning
4.5 Commissioning
4.6 Technical data EV2...
7
7
7
8
9
9
11
5 Electric oil preheater type WEV2.2/01 and WEV3/01

5.2 Function
5.5 Commissioning
12
12
12
13
14
14
6 Media oil preheater type MV9C and MV1 OA

6.1 Safety instruction
6.2 Function
6.3 Media fittings
6.3.1 Connection variations
6.3.2 Fittings
6.5 Commissioning
6.5.1 Hot water and thermal fluid operation
6.5.2 Steam operation
6.5.3 Ratings and pressure loss diagram
6.6 Technical data MV
6.7 Saturated steam and condensate line
17
17
17
18
18
20
22
22
22
23
24
25
26
Appendix
Viscosity - temperature diagram
27
27
General instructions
These installation and operating instructions
are an integral part of the equipment and must be kept
permanently on site.
are to be used by qualified personnel only.
contain the relevant information for the safe assembly,

commissioning and servicing of the equipment.
are for the attention of all personnel working with the

equipment.
Hand over and operating instructions

The contractor is responsible for passing the operating
instructions to the plant operator prior to hand-over. He
should also inform the plant operator that these
instructions should be kept with the heating appliance. The
address and telephone number of the nearest service
centre should be entered on the reverse of the operating
instructions. The plant operator must note that an agent of
the contractor or other suitably qualified person must
inspect the plant at least once a year. To ensure regular
inspections, -weishaupt- recommends a service contract.
Explanation of notes and symbols

This symbol is used to mark instructions,
which, if not followed, could result in death or
serious injury.
The contractor should instruct the plant operator in the use

of the equipment prior to hand-over and inform him as and
when necessary of any further inspections that are
required before the plant can be used.
DANGER
A
A

which, if not followed, could result in life
threatening electric shock.
DANGER
which, if not followed, could result in damage
to, or the destruction of the equipment and
environmental damage.
ATTENTION
This symbol is used to mark procedures,

which you should follow.
1.
2.
3.
Procedures with more than one step are

numbered.
This symbol is used when you are required to

carry out a test.
This symbol is used to list points.
This symbol indicates detailed information.
Abbreviations
Tab.
Table
Oh.
Chapter
Guarantee and liability

Weishaupt will not accept liability or meet any guarantee
claims for personal injury or damage to property arising as
a result of one or more of the causes below:
Failure to use the equipment as intended
Improper assembly, commissioning, operating or
servicing of the equipment.
Operating the appliance with defective safety
equipment, or with non-recommended or nonfunctioning safety and protection devices
Failure to follow the information in the Installation and
Operating Instructions
Alterations made to the construction of the equipment
by the plant operator
Fitting additional components not tested or approved
for use with the equipment.
Alterations made to the equipment by the plant
operator (e.g. motor ratio - rating and speed)
Alterations made to the combustion chamber, which
hinders constructive, predetermined flame formation
Inadequate monitoring of parts liable to wear and tear
Improperly executed repairs
Acts of God
Damage caused by continued use despite the
occurrence of a fault
Use of incorrect fuel
Obstruction or damage of the supply lines
Use of non-original -weishaupt- spare parts
2 Safety information
Dangers when using the equipment
Weishaupt products are manufactured in accordance with
the relevant existing standards and guidelines and the
recognised safety laws. However, improper use of the
equipment could endanger life of the user or a third party,
or result in damage to the plant.
To avoid unnecessary danger, the equipment is only to be
used:
for its intended purpose
under ideal safety conditions
with reference to ail the information in the installation
and operating instructions
in accordance with inspection and service woric
Faults, which could affect the safe operation of the burner,
should be rectified immediately.
Personnel training
Only competent personnel may work on the appliance.
Competent personnel according to this operating manual
are persons who are familiar with the installation,
mounting, setting and commissioning of the product and
have the necessary qualifications such as: Training, instruction or authorisation to switch electrical
circuits and electrical devices on and off, to earth them
and to mark them in accordance with the safety
standards.
Organisational measures
Everyone working on the plant should wear the
necessary protective clothing.
All safety devices should be checked regularly.
informal safety measures
In addition to the installation and operating instructions,
local codes of practice should also be adhered to.
Special attention should be paid to the relevant
installation and safety guidelines given.
All safety and danger notices should be kept in a
legible condition.
Safety measures in normal operation

The unit gets dangerously hot during operation.
Do not touch.
Only use the equipment when all the safety devices
are fully functional.
At least once a year the equipment, including the
safety devices, should be checked for signs of visible
damage and to ensure that the safety devices are
operating correctly.
More frequent safety check may be required
depending on plant conditions.
Electrical safety
Before starting work - isolate plant and protect
against reactivation, check voltage is isolated, the unit
is earthed, and protected from adjacent equipment
that might still be under voltage!
Work on the electrical supply should be carried out by
a qualified electrician.
Electrical components should be checked during
servicing. Loose connections and heat damaged
cables should be dealt with immediately.
The control panel should be locked at all times.
Access should be restricted to authorised key holder
personnel.
Should it be necessary to carry out work on live parts,
country specific safety regulations must be observed
and tools to EN 60900 must be used. A second
person should be present to switch off the mains
supply in an emergency.
iVIaintenance and fault rectification

Allow the unit to cool prior to servicing and
maintenance work to avoid injury through high
temperatures.
Necessary installation, service and inspection work
should be carried out at the specified time.
Inform the operator before beginning any service work.
For all service, inspection and repair work, electrically
isolate the equipment and ensure the mains switch
cannot be accidentally switched back on. Cut off the
fuel supply.
If, during servicing or testing, control seal joints have to
be opened, these have to be thoroughly cleaned to
ensure tight sealing when re-assembling.
Damaged seals must be replaced. Carry out a
soundness test!
Flame monitoring devices, limit controls, correcting
elements and all other safety devices must be
commissioned by, and may only be replaced by, the
manufacturer or an authorised agent.
Screwed connections, which have been loosened,
must be re-tightened without cross-threading.
Following service work, all safety devices should be
tested to ensure they are functioning correctly.
Alterations to the construction of the equipment

No alterations to the equipment are to be made without
the approval of the manufacturer.
All conversions require written confirmation from
Max Weishaupt GmbH.
Any parts not in perfect working order should be
replaced immediately.
No additional components may be fitted, which have
not been tested for use with the equipment.
Use only -weishaupt- replacement and connection
parts. Parts from other manufacturers are not
guaranteed to be suitable to meet the necessary
operational and safety requirements.
Waste disposal
All materials used should be handled and disposed of
correctly, with due regard to the environment.
Technical description
On burners for use with medium and heavy residual fuel

oils the oil has to be preheated to the temperature required
for atomisation.
Oil preheating can be carried out electrically or with
heating medium, as well as with a combination of electric
and media heaters. Hot water, low and high pressure
steam or thermal fluid oil are used as heating media.
3.1 Permissible applications

Weishaupt oil preheaters are suitable:
for residual fuel oils:
In their standard version for a viscosity up to
5 0 mm^/s at 100G (approx. 570 mm^/s at 50G)
In special versions for a viscosity of up to
60 mm^/s at 10O'C (approx. 700 mmVs at 50C)
for installation on Weishaupt medium and heavy
residual oil burners
for a maximum oil temperature of 160 C
Any other application is only permitted with prior written
agreement of Max Weishaupt GmbH.
The oil preheater must only be used within the ratings

given on the name plate.
The oil preheater is not suitable for operation out of
doors.
The oil preheater must not be operated outside of its
permitted temperature range.
4 Electric oil preheater type EV2.

Electrically
TT
I
Xj\
X J \
^ ^ "
isolate plant
Prior to commissioning and service switch off
the mains switch and the safety switch.
Failure to comply could cause death or
serious injury by electric shock.
Allow oil preheater to cool

TT
I Allow the oil preheater to cool prior to
# l \
commissioning and service work.
X J \
The hot surfaces and the hot oil could lead to
" ^ ^ "
burns if touched.
4.2 Function
Heat exchanger
The heat produced by electrical energy is conducted by a
copper plate to the oil pipe coil.
Electric oil preheater EV2A
The oil preheater has a large heat exchange surface with

relatively small oil volume. It is therefore possible to heat
the fuel oil up to the necessary atomising temperature
within a short period of time. The heat distribution prevents
localised overheating. The fuel oil will not carbonise.
The maximum achievable oil temperature at the nozzle is
approximately 150 C and depends on the oil throughput
and the temperature of the fuel oil inlet.
The oil outlet temperature is set at the temperature
controller . This operates the heat elements via a
contactor. The temperature controller is equipped with an
integrated temperature switch for burner release. The
switch point for the release contact is 30 K below the
temperature set point.
Temperature switch
To ensure stable operating behaviour the oil preheater has
been fitted with two temperature switches for burner
release and these are switched in sequence. The burner is
only released once both temperature switches have
reacted.
Electric oil preheater EV2B, EV2C and EV2D
The temperature switch (3) is connected to the heat

exchanger via compensation plate. This ensures that the
burner starts only once the minimum operating
temperature of the oil preheater has been reached.
(Prerequisite: The second temperature switch has also
switched).
This reduces temperature deviations following fuel release.
Temperature limit switch

The temperature limit switch (g) reacts, if the fuel oil
temperature exceeds the set value.
The temperature limit switch acts, either directly (EV2A) or
indirectly via a safety relay (EV2B, EV2C and EV2D) on the
heat elements.
Reset is carried out mechanically direct at the temperature
limit switch.
Temperature controller with integrated temperature

switch for burner release.
(D Temperature limit switch
(3) Temperature switch on compensation plate

Connection diagram EV2A
230V/1 ~N
NL1
2 3a
-Io
1 o
o 2 o
6A
O 3 O
O 4 O
O S O
O 6 O
Col
mj[f^
X J I
1 - ^ -
I I
[1
6A
v^
5^
-10
EV2A
Connection diagram EV2B, EV2C and EV2D

400V/3~N
6
N L I L2 L3
-4
6A
(EV2B/EV2C)
OA (EV2D)
U1
U2
VI
V2
W1
W2
' I Ul Tai
o =
o =
o ,_,
^g)-H
EV2B
U1
o
U2
O
VI
cp
V2
cp
W1
O
^k
o ^^
"S-k
o o
W2
O
^^
o E
10
EV2C
U1U2 U1U2 VI V2 VI V2 W1W2W1W2
OO
0 0
0 0
0 0
O
I^TI^TI^Tlî ?
o
= o
= o
O
O
CM
CM
Temperature limit thermostat
Temperature control contact
Temperature switch (compensation plate)
Terminal strip
Control circuit (burner control box, burner release)
U2
oo
o-l-o
W2
W1
VI
U1
11
EV2D
1
2
3
3a
4
5
V2
6
7
8
9
10
11
Fuse
Indicating lamp ' O N '
Contactor
Safety contactor
Heating element
Bridge loops for 220V- 290V/3-
4.4 Safety instructions for initial connmissioning

The initial commissioning of the oil preheater must only be
carried out by the supplier, manufacturer or their appointed
agent. During this initial commissioning, all regulating,
control and safety devices must be checked to ensure
correct operation and, if it is possible to adjust them,
it should be checked that they have been set correctly.
Furthermore the correct fusing of the circuits and the

measures for contact protection of electrical equipment
and of all wiring must be checked.
4.5 Comnnissioning
Check oil inlet temperature
Determine minimum inlet temperature into the oil preheater
for the required oil throughput and adjust if necessary (see
ratings diagram).
Temperature controller and limit control EV2A

Reset button
Determine pressure loss

Determine pressure loss using the oil throughput and
increase the pump pressure accordingly (see pressure
loss diagram).
Fill oil preheater with oil

Ensure the oil preheater is filled with oil prior to the first
heat-up procedure.
If the oil preheater is heated up empty it could
damage the heating elements.
Check hydraulic connections

Ensure the correct type of hydraulic connections are used.
Danger of getting burnt!

Leaking connections can allow hot oil to
escape, which can lead to burns.
Set temperature controller

Set controller to the required atomising temperature (see
Appendix Viscosity - Temperature chart).
The oil outlet temperature can deviate from the value set at
the temperature controller by 10 K. Therefore the oil
outlet temperature should be measured, and if necessary
the temperature controller setting should be corrected
accordingly.
Note
Temperature controller and limit control EV2B, EV2C, EV2D
Reset button
The temperature controller should always be

set below the limit control and should not
exceed 160 C to ensure that the limit control
does not switch during normal operation and
thus initiate a lockout.
Check and set temperature limit control

To check the operation of the temperature limit control set
it below the value set at the controller. The limit control
must switch before the controller shuts off.
The temperature limit control should then be set approx.
4 0 " K above the value set at the regulator and the reset
button should be pressed.
Temperature limit control
Ratings diagram EV2...

Oil throughput depending on At at maximum rating
S
3
Q.
360
340
320
300
280
260
240
220
200
180
160
140
120
100
^*^^ÊV2D
'
-^-^
'-...,,..,ÊV2C
.^^ÊV2B
80
60
40
20 40
50
60
70
80
90
100
120
110
Temperature increase At [K]
Pressure loss EV2.
4,0
3,5
3,0
2,5
<^&y
2,0
1,5
0^
1,0
0,5 _
20
Y'
40
60
80
100
120
140
160
180
200
220
240
260
280
Burner oil throughput [kg/h]

The value for type EV2A has been determined with
medium fuel oil M (viscosity 37 mmVs at 50" C)
Oil inlet temperature:
Oil outlet temperature:
Note
20* 0
95 C
The values for type EV2B to EV2D have been determined

with fuel oil S (viscosity 450 mmVs at 50 C)
60 C
150 0
For values above the oil preheater's nominal rating the oil
inlet temperature has to be increased accordingly.
10
Due to the different oil throughputs and the

varying inlet viscosities, the data given relating
to the pressure losses of the preheaters
should be used as guide values.
4.6 Technical data EV2.

Oil preheater type
EV2A/01
EV2B/01
EV2C
50
100
150
EV2D
Oil throughput
kg/h
Heat rating
kW
2.2
Oil pressure
max. bar:
30
30
30
30
Oil content
cm^
240
800
800
1600
approx. k g :
15
15
24
Weight
4.5
270
13.2
6.6
Dimensions EV2.
202
_l
_ ^ Oil outlet
M20x1.5
55
98-
&
430
100
rt -
i
50
/ ^
Vvv^
TTTfT
Jjt
toil inlet
Oil preheater
type
Dimension in mm
a
b
c
EV2A/01
105
305
162
65
G1/4"
EV2B/01
135
305
172
112
G1/4"
EV2C
135
310
172
112
G3/8"
EV2D
195
310
172
184
G3/8"
11
Electric oil preheaters type WEV2.2/01 and WEV3/01

Electrically isolate plant
Prior to commissioning and service switch off
' serious injury by electric shock.

^T
I Allow the oil preheater to cool prior to
X l \
^ ^ \
^ ^ ^ "
burners if touched.
5.2 Function
Heat exchanger
The heating oil is heated to the required atomising
temperature by electric heating elements via pipe coils
cast in an aluminium alloy plate.
Due to the even and rapid transfer of heat, local
overheating is prevented.
Via the bridging loop of the terminal strip @, the electrical
connection of the heating elements (5) (Ch. 5.3) can be
star switching (e.g. 400 V mains voltage) or delta
switching (e.g. 230 V).
Electric oil preheater
WEV2.2/01

The temperature limit control Q switches, if the oil
temperature exceeds the set value and acts on the control
voltage of the contactor, as well as the safety contactor
and thus switches the heating elements off.
Restart is only possible once the temperature limit control
has been reset.
The required oil temperature is set on the digital controller
DR 100 with FID control behaviour (setting range 20 170 C) fitted in the control panel. In Standby an
automatic set value reduction by -30 K is initiated via the
potential free contact , this reduces the losses as well
as the loading of the preheater at burner shutdown.
The switch point for the release contact is set
automatically by the controller DR 100 to 5 K below the
set value.
The oil temperature is determined by a Pt100 resistance
temperature sensor (2) and compared to the set value.
If the oil temperature in the preheater is less than the
selected set value, the release contact @ in the controller
is opened and the contactor @ is activated.
The safety contactor is activated by the limit control
(normal operation) and the oil preheating is in operation.
Once the minimum oil temperature in the oil preheater
(10 K below the set value) has been reached, the release
contact of the controller (terminals 11/12) is closed.
Once the oil temperature reaches the value set at the
controller, the heating is switched off by the contactor.
The controller is designed in such a way, that if a short
circuit of the the sensor line or the sensor occurs, the
sensor monitoring switches off the heating via the
contactor and opens the release contact.
If the heating of the preheater stops during operation, and
if the fixed temperature differential of the set value is not
achieved, the release switch of the controller opens and
the burner shuts down.
Electric oil preheaters WEV3.1/01 and WEV3/01

(5) Resistance temperature sensor PT100
12

Connection diagram
WEV2.2/01
Other voltages
available on
request
PE N LI L2 L3
I
I I
U::^
I I
U1
K-n
V2
Z
VI
W .
W2
T71J
V. V.
'
W1 U2
61 62 63 64
,^
U1 V2
VI
V\/2
W1 U2
380 -500V~
VI
W2
W1 U2
3A
220 - 290V-
fifin
K2
J
61 7 LI
U1 V2
lOr-
Controller
DR100
W\^'
Connection diagram WEV3.1/01 and WEV3/01
Other voltages
available on
request
(D
PE N LI L2 L3
.J
.J
V \L^VI
U1 V2
W2
W1 U2
U1 V2
VI
W2
W1 U2
U1 V2
VI
W2
W1 U2
V-
Vk
uil ^
IZ 0
.^
ZlA
380 -500V~
ii1i;
]A
'220 -290V~
(5)
(3)
! tl
61 62 63 64

Temperature sensor PT100
Heating element
Terminal strip
Control circuit (burner control box, burner release)
61 7 LI
Controller
DR100
K2
10c
&
(6)
@
(8)
(9)
(10)
m
v-\
K1
Potential free contact (set value change over)

Fuse carriers
Safety contactor
Contactor
Indicating lamp ' O N '
13

Furthermore the correct fusing of the circuits and the

measures for contact protection of electrical equipment
and of ail wiring must be checked.
5.5 Commissioning
Check oil inlet temperature
Determine minimum inlet temperature into the oil preheater
for the required oil throughput and adjust if necessary (see
ratings diagram).
Determine pressure loss

Determine pressure loss using the oil throughput and
increase the pump pressure accordingly (see pressure
loss diagram).
Temperature controller DR 100
eee
5 6 7 8
@ 9
Fill oil preheater with oil

Ensure the oil preheater is filled with oil prior to the first
heat-up procedure.
If the oil preheater is heated up empty it could
damage the heating elements.
K1@
Check hydraulic connections
Ensure the correct type of hydraulic connections are used.
Danger of getting burnt!

Leaking connections can allow hot oil to
escape, which can lead to burns.
K2@
Note
The temperature controller DR 100 should

always be set below the limit control and
should not exceed 160 C to ensure that the
limit control does not switch during normal
operation and thus initiates a lockout.
Check and set temperature limit control

To check the operation of the temperature limit control set
it below the value set at the controller. The limit control
must switch before the controller shuts off.
The temperature limit control should then be set approx.
4 0 * K above the value set at the DR 100 controller and the
reset button should be pressed.
14
10 11 12
M
LI
Set temperature controller D R 1 0 0

The set value SP1 should be set to the required atomising
temperature (see Appendix Viscosity temperature chart).
Documentation relating to the set value setting is enclosed
with controller.
Ratings diagram WEV..

Oil throughput depending on At at maximum rating
1600
1500
1400
1300
1200
S
\ ^ .
*vV
1100
\ %
a. 1000
3
%f,
900
800
700
600
500
400
300
200
100
V-ÎS?'
F^t^>^
"
20
30
40
60
50
70
80
100
90
Temperature increase At [K]
Pressure loss WEV...

3,0
4
<>
2,5
f
(0
2,0
sx
in
(0
_o
1,5
3
(0
(0
0>
>1f\
1,0
>
^^
^
*^
^^
** ^
^^
0,5
100
200
300
400
500
600
700
800
900
1000
Burner oil througliput [kg/li]

The values of types WEV2.2/01 to WEV3/01 have been
determined with fuel oil S (viscosity 450 mmVs at 50 C)
60 C
150 C
Note
Due to the different oil throughputs and the

varying inlet viscosities the data given relating
to the pressure losses of the preheaters
should be used as guide values.
For values above the oil preheater's nominal rating the oil
inlet temperature has to be increased accordingly.
15
Oil preheater type
WEV2.2/01
Oil throughput
kg/h
Heat rating
kW
13.8
170
22.4
Oil pressure
max. bar:
32
32
32
Oil content
cm^
750
1550
1550
27
42
42
Weight
300
approx. k g :
WEV3/01
WEV3.1/01
500
500
Dimensions WEV...
WEV2.2/01
I nff
ro
OilinletGI/2"
-@>-
r-
_f._
i_.
-i-i>i
M10I
wU
J^
WEV3.1/01
WEV3/01
r^
1.
Oil outlet G 1/2"
liL^TL
^r
"T^
Oil outlet G 1/2"
T"'
m.
f-
-f-
-l-H
i_.
J..
OilinletGI/2"
-U
Oil preheater
type
Dimensions in mm
a
b
c
WEV2.2/01
610
126
254
42
148
100
112
33
231
12
58
WEV3.1/0.1
WEV3/01
724
140
314
43
148
100
110
13
288
12
58
16
6 Media oil preheaters type MV9C and MV1 OA

Electrically isolate plant
^^
I Prior to commissioning and service switch off
^ j \
X t \
" ^ ^ ^
serious injury by electric shock.

Allow the oil preheater to cool prior to
burners if touched.
6.2 Function
Heat exchanger
The compact media oil preheaters are high efficiency heat
exchangers with flow according to requirements.
The media (hot water, steam or thermal fluid oil)
heats the oil flowing through the pipe coils to the required
atomising temperature.
The oil preheaters guarantee an almost constant oil
temperature and therefore good combustion values.
Application
The universal media oil preheaters can be used alone or in
addition to an electric oil preheater.
The preheaters are equipped with the fittings required for
the relevant media used. The media can be changed at any
time by fitting new fittings accordingly.
Installation position
The unit can be installed vertically or horizontally. The
condensate outlet (steam) must always be downwards,
the water or thermal fluid outlet always upwards.
Installation position and connections

Outlet for
liquid heating
medium
Ratings range
See ratings diagram Ch. 6.5.3
Electric preheating
If operating with steam or hot water and sufficient
temperature is available, or if the start is effected with
distillate oil an electric oil preheater is not required. In this
case the media oil preheater should be fitted with an
additional temperature switch for oil release.
If the media temperature is not sufficient to heat the fuel oil
adequately, then the electric preheater continues the
heating up of the oil.
The electric oil preheater heats up the oil to start the plant.
If the required media temperature is available, change over
to the media preheater takes place. This saves expensive
electric energy.
Outlet for steam
Inlet
medium
Heating oil outlet
Heating oil inlet
Media preheater with electric oil preheater
Media preheater without electric oil preheater
Included in delivery:
2 Oil hoses
1 Ball valve
1 Thermometer
+ screwed unions and pipe connections
Included in delivery:
2 Oil hoses
1 Thermometer
1 Temperature controller
1 Temperature controller with change-over contact for
burner release
+ screwed unions and pipe connections
17
6.3 Media fittings

6.3.1 Connection variations
The fittings are selected depending on the type of media
used.
Please note that the dimensions of the fittings are not

determinative when sizing the connection lines.
On installations to TRD 4 1 1 a condensate sight glass is

necessary when the heating media is returned back into
the boiler. This unit is supplied at extra cost.
Version
Fittings
1 - Warm water up to 110 C

IXB- ^
WW-inlet
Ball valve
DN
DN
IVIV9C
MV10A
R1/2"
R1/2"
f ^ i X WW-outlet
2. Hot water above 110 - 180 C

IXB- ^
No. per
preheater
Ball valve
Regulator for thermal fluid
2
1
15 + 20
20
20
20
Ball valve
Strainer
Reg. valve with thermostat
2
1
1
15
15
15
15
15/6
15/9
Ball valve
2
1
15
15
20
20
Bellows valve
2
1
15
15
20
20
Ball valve
Strainer
2
1
1
15
15
15
20
20
20
Bellows valve
Strainer
2
1
1
15
15
15
15
15/6
15/9
Ball valve
Condensate sight glass
Steam trap
2
1
1
R1/2"
R1/2"
R1/2"
R1/2"
R1/2"
R1/2"
^ i ^ ^ X WW-outlet
HW-inlet
3.Hot water up to 200"* C
[><HH~<HH><}tt '7 - H t x WW-outlet

HW-lnlet
4. Thermal fluid oil up to 250 C

X H t
- t H ^ 4 H > < ] Thermal fluid oil outlet
Thermal fluid oil inlet

C X ^
- H ^ - H - ^ - C ] Thermal fluid oil outlet
Thermal fluid oil inlet
><Htr"<M^<Ht]^^ [tij>< Thermal fluid oil outlet

Thermal fluid oil
inlet
7. Thermal fluid oil 250 - 300 C
[ X H t f ~ < H H > ^^^ [4tJX Thermal fluid oil outlet

Thermal fluid oil
inlet
8. Low pressure steam up to 0.5 bar

high pressure steam up to 1.5 bar
><>
Steam inlet
18
zz
\Y
' i ) ( ^ M N - . 0 Condensate
' outlet
6
Version
Fittings
No. per
preheater
Ball valve
9. High pressure steam 1.5 - 1 5 bar
DN
MV9C
H PS inlet
\t^ ^
Condensate
' outlet
10. High pressure steam 6 - 2 5 bar

T .
H PS Inlet
Strainer
Pressure controller
Pressure gauge
Steam trap
R1/2"
R1/2"
R 3/4"
R1/2"
R 3/4"
R 3/4"
R1/2"
R1/2"
R1/2"
R1/2"
Ball valve
15
15
15
15
15
15
15
15
15
15
15
15
15/6
15
15
15
15
15
15
15
15
15
15/6
15
15
15/9
15
15
15
15
15
15
15/6
15
15
15/9
15
15
15
15
Ball valve (outlet)

\ K >l \f'~^
,, ^ ~ ^ 1 1 / ^ ^ i i i ^ ^
Condensate
outlet
'^'
I / ^ M | ^ ^ ^ Condensate
outlet
7
HPS
inlet
l><JfOlHH><KH+
ixWI<WYiJ|^[*H<K^tx SS
Condensate
HPS inlet
13. High pressure steam 20 - 25 bar*
[XHOiMEHH><H4tt ^
tt<^4Hx ^têr ^'^
HPS inlet
D Q ;r.l
Strainer
Pressure gauge
Steam trap
Ball valve
12. High pressure steam 13 - 25 bar*
9^ I
Strainer
Pressure controller
Manometer
Steam trap
Ball valve
11. High pressure steam 7,5 - 1 3 bar*
'
IVIV10A
R1/2"
Ball valve (inlet)
zz
DN
Strainer
Pressure gauge
Steam trap
Ball valve
Strainer
Pressure gauge
Steam trap
' only with preheating without electric, oil preheater

Description of fittings
Ball valve or bellows valve:
Control valve with thermostat:
-Xh
Controller for hot water and thermal fluid oil
or pressure controller for steam:
->fh
i"
- ^ Strainer:
Condensate sight glass:
-C<h
Pressure gauge:
Steam trap:
0
Oil preheater:
19
6.3.2 Fittings
Sliut off devices:
Ball valve R 1 / 2 "
R 3/4"
Ball valve DN15
Bellows valve DN15
Ball valve DN20
' ,1ft^r~"
CO
01
w
in
in*
-r^X^
CM
2
Q *
77
Q:
150-
Operating pressure max.:

15barat200*C

25 bar at 250*'G

25 bar at 250''G
Nominal diameter R 3 / 4 "
Nominal diameter DN15
-130Operating pressure max.:

13barat300C
Strainer:
Nominal diameter R 11T
72
-82-
>
in i
CM
L
njîj
^ \ \ ^

15 bar at 200''G

25 bar at 250C

25 bar at 250''C
Nominal diameter R 3/4"
Pressure controller:
Nominal diameter R 1 / 2 "
-130
OO
0C5 0
in
in
CD"
co"
CM
CM
I]
m,
in
in
S|
o
CO
CO
CM
CO
T YT ^
'^^'Yj
Inlet pressure max.:

19 bar at 210C

19 bar at 210C
Reduced pressure range:

1.3 - 4 bar (green spring*)
3.5 - 1 0 bar (orange spring)
* at inlet pressure < 5 bar

1.3 - 4 bar (green spring*)
3.5 - 1 0 bar (orange spring)
* at inlet pressure < 5 bar

below 3 bar (blue spring)
3.0 - 1 0 bar (red spring)

3 . 0 - 1 0 bar
Nominal diameter R 11T
Nominal diameter R 3/4"
- 8 3 -
-96-
J ~ C
CO
nr
-185'
Inlet pressure max.
20 bar at 230''C
II
II
114*
25 bar at 250C
Pressure gauge
A pressure snubber is
connected before the
pressure gauge.
100
20
Control valve:
130
in
-150-^
0 22
in
0 22
with intermediate piece

onHPS13to20bar
and thermal fluid oil
with intermediate piece

on HPS 13 to 20 bar
and thermal fluid oil
}
Operating pressure max.

TypeM: 1 3 b a r a t 2 0 0 C
TypeH: 25 bar at 250 C
Set value range with thermostat: 40-160" C
Operating pressure max.

TypeM: 13 bar at 200''C
TypeH: 25 bar at 250 0
Set value range with thermostat: 40-160 0
Controller for thermal fluid oil
Controller for hot water
II II
o
J'
S.^
-V1
150 >
17 bar

17 bar
150
Operating pressure max.;
22 bar
Supply temperature max.:

320 C

320 C

180 C
Temperature adjustment
range:
range:
100... 170C
100...170C
range:
70...145C
Steam trap

Nominal diameter 1 / 2 "
00
CN
IL\
-95
20 bar at 250C

20 bar at 250G

15 bar
Operating temperature:
100 K above relevant
saturated steam temp.
Condensate cooling:
8 K (not adjustable)
in \_
M.
(O
00
J50Operating pressure max.:

25 bar
Differential pressure max.
17 bar
Operating temperature:
100 K above relevant
saturated steam temp.
Condensate cooling:
8 K (not adjustable)
21

Furthermore, it should be checked that the hydraulic
connections have been made correctly.
Danger of getting burnt

If touched, the hot surfaces of the individual
components and fittings can cause burns.
6.5 Commissioning
6.5.1 Hot water and thermal fluid operation
Hot water and thermal fluid oil operation with
combined electric preheater
Hot water and thermal fluid oil operation without

combined electric preheater
The media oil preheaters are supplied with the fittings in

position 1, 2, 4 or 5 (Ch. 6.3.1) depending on the
operating medium used.
By setting the relevant closing temperature of the
controller fitted in the media outlet, the desired or highest
possible oil temperature is attained.
The controller senses the media outlet temperature and
only releases the heating media once it has cooled to
below the closing temperature setting.

position 3, 6 or 7 (Ch. 6.3.1)depending on the operating
medium used.
The desired oil temperature is attained and maintained by
a temperature controller without auxiliary energy.
This temperature controller consists of a regulating valve
with thermostat and sensor. The sensor located in the oil
outlet flow monitors the oil temperature and controls the
regulating valve in the medium inlet via the thermostat. The
regulating valve controls the media flow accordingly.
With hot water, the differential pressure at the control valve
should be approx. 1 bar, with thermal fluid oil at least
0.5 bar.
With hot water, the differential pressure at the controller

should be approx. 2 bar, with thermal fluid oil at least 1
bar.
The combined electric oil preheater carries out any
additional heating which may be required and monitors the
oil temperature.
Setting the oil temperature
The closing temperature of the conroller should be set to
approx. 10" K above the required or maximum possible oil
temperature. However, the closing temperature must
always be below the media inlet temperature, so that the
controller closes at burner shutdown (no heat demand on
the preheater).
The oil temperature attained during operation should be
measured and if necessary adjusted at the controller.
The setting of the hot water controller is carried out to
scale. The external adjusting device of the thermal fluid oil
controller (not available with scale) is set to a closing
temperature of 150 C as supplied.
One rotation of the adjusting screw is equal to 30 K
closing temperature alteration.
Clockwise rotation
Anti clockwise rotation
22
_ Increase
, Decrease

The required oil temperature is set by turning the knob of
the thermostat within the set value range of 4 0 to 160 C.
6.5.2 Steam operation

With steam operation, care should be taken
that dry steam is available at the media fittings.
Steam operation with combined

electric oil preheater
Steam operation iv/f/iouf combined

electric oil preheater
The media preheaters are supplied with the fittings in

position 8, 9 or 10 (Ch. 6.3.1) depending on the available
steam pressure.
The desired oil temperature is achieved by the appropriate
steam pressure setting of the pressure controller.

position 1 1 , 12, or 13 (Ch. 6.3.1) depending on the
available steam pressure. The desired oil temperature is
achieved and maintained by a temperature controller
without auxiliary energy. This temperature controller
consists of a regulating valve and thermostat with sensor.
The sensor located in the oil flow outlet monitors the oil
temperature and controls the regulating valve in the
medium inlet via the thermostat. The regulating valve
controls the media flow accordingly.
The condensate that forms is drained via the steam trap,

cooled 8 K below the actual saturated steam temperature.
It is not possible to adjust the opening temperature of the
steam trap. Due to the steam pressure in the oil preheater
the condensate is forced into the condensate line via the
steam trap. Therefore the pressure in the condensate line
must always be lower than the steam pressure in the oil
preheater (see Tab. Condensate line pressure). The
maximum differential pressure of 17 bar must not be
exceeded.
Pre-set pressure controller to Ratings diagram (Ch. 6.5.3).
The oil temperature attained during operation should be
measured and if necessary adjusted at the controller.
With a steam pressure of up to 13 bar the differential

pressure at the regulating valve should be 2 bar, and at
13 to 20 bar it should be approx. 4 bar.
If the steam pressure available is between 20 and 25 bar, a
pressure reducing valve should be fitted before the
regulating valve, because the temperature controller does
not work satisfactorily in this pressure range.
The condensate that forms is drained via the steam trap,
cooled 8" K below the actual saturated steam temperature.
It is not possible to adjust the opening temperature of the
steam trap. Due to the steam pressure in the oil preheater
the condensate is forced into the condensate line via the
steam trap. Therefore the pressure in the condensate line
must always be lower than the steam pressure in the oil
preheater (see Tab. Condensate line pressure). The
maximum differential pressure of 17 bar must not be
exceeded.
The required oil temperature is set by turning the knob of
the thermostat within the set value range of 40 to 160 C.
Condensate line pressure

Steam pressure
Pressure in the
in the oil preheater condensate line
up t o l .5 bar
approx. 0 bar
from 1.5 bar
approx.. 1/3 of the steam pressure in the oil preheater; but maximum 17 bar pressure differential
23
6
6.5.3 Ratings and pressure loss diagram
Ratings diagrams (maximum actiievable oil temperature with hot water and steam)
Hot water
Saturated steam
The H W temperatures and steam
pressures must be available at the
oil preheater inlet.
IVIVSC
700
S
in
1-
O"
(B
on
O
CO
Co
J3
in
()
o
CN
Co
X!
O
in
in
CO
I
CO
CB
J3
in
IS"
JQ
in
600
500
a
.c
O)
3
O
400
300
200
100
80
100
90
^k
110
120
_^
130
140
il
150
^ .
160
Oil temperature max. [C]
MV10A
CO
J^
CO
J3
in
1000
800
"
o
^
*
I
a
.c
o>
700
\
\
\
\
\
\
\
*
\
3
O
600
\
\
t
500
^
in
Ol
b
in
CO
JJ
O
C)
O
O
Si
in
in
PC
-^
\
x
\
\
\
\
\
\
\
\
CO
CO
JO
J3
in
\
\
\
<
\
\
\
\
\
\
\
\
\
\
\
\
\
CO
\
\
\
\
\
1
\
\
\
\
\
\
\
*
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
O
00
900
CO
(o)
400
80
90
100
110
120
130
Oil temperature max. [''C]
24
140
150
160
Fuel oil pressure losses MV9C / MV10A

The values have been determined using fuel oil S
(max. viscosity 150 mmVs at 50 C and an outlet
temperature of 130 C).
I
100
200
300
400
500
600
700
800
900
1000
Burner oil throughput [kg/h]
6.6 Technical data MV

Oil preheater
type
Contents
oil coil [dm^]
MV9C
2.6
MV10A
7.5
Dimensions
Oil pressure
max. [bar]
Medium pressure max.

at 250C [bar]
at 300C [bar]
7.8
40
25
25
18.0
40
25
20
Contents
cover space [dm^]
MV9C1MV10A
Outlet for liquid heating media

i t^
Heating media
inlet
Oil inlet
kt^
-HIIL.
h b
Triir
Trixr
Steam outlet
Oil preheater
type
Dimensions in mm
a b
c
MV9C
640
222
170
108
16
55
Gl/2"
Gl/2"
Gl/2"
M12
300
MV10A
800
287
250
135
55
84
Gl/2"
G3/4"
Gl/2"
M12
300
25
6.7 Saturated steam and condensate lines

Application example for the diagram below
An oil preheater type MV1 OA is used to preheat 900 kg/h
residual oil from 60 C to 130 C.
Saturated steam withi 0 bar pressure is available.
At the end of the condensate line a pressure of 0 bar
(1 bar absolute pressure) will exisit.
Saturated steam quantity required
With an oil throughput of 900 kg/h and a At oil of 70 K a
saturated steam quantity of 68 kg/h is required.
Nominal diameter of the condensate line

With 11 bar absolute pressure and a condensate cooling
of 8 K the condensate temperature prior to the pressure
release amounts to 175 C.
Based on this temperature and with 1 bar absolute
pressure at the end of the condensate line, the
condensate line at 68 kg/h condensate flow must be
DN25.
Nominal diameter of saturated steam line

For a saturated steam quantity of 68 kg/h and a pressure
of 10 bar (11 bar absolute pressure) the saturated steam
line must be DN 15.
2600 Saturated steam quantity

2400
2200
2000
1800
1600
250 "
1400 _::
1200
1100 -:
1000
900
800
700 :
Nominal diameter of saturated steam line
DN40
DN50
^
7^
400-
'^
_c
"3
300
-&
20-
:.
DN10
,*
:;:;:_::::::::
70
60
1'
c
, E
50
40
"
Q.
30
10-
3
O
-C
- CO
<
0,5 0,6
0,8 1,0
Steam pressure in bar
absolute pressure in bar
(end of condensate line)
DN15
au
^^*"*****.0 "
500
\
\
\
DN20
^!:::::::::::::
^ - ' '
30-
\\
DN2E
,.'
50"
40"
DN32
_ _
-~III
600-1
^
200
required
\
\
\
^\ V
\
\
s.
,,
\
S
\
1,5^
Nominal diameter
of condensate line
-N
s
2^
^s--
^ 5v
s ; : : ^-=;::::: : -
'-10
'=:^... !. s ^ s
*. S , ^ ..!...
'^^ .....^ "'-.
\
_..:;.. :::.
10
DN10
DN15
20
DN20
30
DN25
,,,
' s
3s
DN32
'7..
4:^.__5,._
DN40
DN50
\ ,^v
0,5
./.
^
--- -^
V
...!-...
=^;::::::
3
4 5 6 78910
absolute pressure in bar
(condensate before pressure release)
I
100 110 120 130 140
160
180
1r
220
Temperature in "C (condensate before pressure release)

26
- .
15 20 25
200
__,<::
/
10
20
30 40 50 60
Condensate flow in kg/h
80100
200
400
600 800
Appendix
Viscosity - temperature cliart
Temperature [F]
40
60
80
100
120
140
160
180
200
220
240
260
280 300
320 340
1
200
150
1 000
120
Max. pump viscosity
-1
"\
1 '"v
200
100
__
8
in
V X. "
\
^
40
LS
60
^
V
:s;
V.
\
^ ^
\
VV
C?
\
\
\ .
^\
?,
^\
*''>'<^
^.
N < %'^''
\
\,
s
b\ %
V
\
^:
\
30
1,6
1,5
%>
%
\
\
1,2
1,1
s
\\
\,
^^^
v !:s;
^
- -
S,
\
N.
50
1,3
40
1,4
"x \
\
\ ^
\
XN
w
T
\
20
1\
_
INL*
\
10
1,8
^s
<
p uV^^
'V^'^-
^\ \
\ ^^
\\
s:
'sm
if
>
. v^
X\
\
3
2,5
Vs
\^
e viscosity
(I
B
. C
k'^^ N ^ '
'
\
^
\
^;-^^^s.%.
^ V '^JS^"7
>.
^'^^^S,.
Recomiiici"- -
- (1
- aa
. N % \ '^?
><cs:%.
.
\ ^ S^SbV
s
10
8
6
B
- 3
s. ^
iI
10
- -D
%^
-%>?
>
S\
\
\
-u
f
c
>
jiw'
>
40
30
20
a
K
60
70
80
90
100 110
j.
1,0
120 130 140 150 160 170 180

Temperature ['C]
Determination of the prelieating temperature

The preheating temperature to be determined can be
taken from the viscosity - temperature chart. The viscosity
of the fuel oil available must be known at a reference
temperature. It should be noted that the thermostat must
be set higher on account of the heat loss between oil
preheater and nozzle.
Example
Known:
Fuel oil viscosity: 3 0 0 mmVs at 5 0 " C
Required:
Preheating temperature in "C
Procedure to be followed:
From the viscosity reference temperature of 50 C
vertically up to the intersection with the viscosity of 3 0 0
mmVs, from there parallel to the nearest fuel grade,
intersect the line "Recommended nozzle viscosity". From

this intersection vertically to the temperature axis. There
read the desired preheating temperature of 147 C.
Recommendation
The following maximum viscosities in relation to nozzle size
are to be noted:
In the area between the oil grade lines use:
A and B nozzles > 0.85 US-gph
B and C nozzles > 2.00 US-gph and
over C nozzles > 3.00 US-gph.
*
Due to the components selected a preheating

temperature of 160C should not be exceeded.
27
Weishaupt products
and service
Max Weishaupt GmbH

D - 88475 Schwendi
Tel.: (07353) 830, Fax.: (07353) 83358
www.weishaupt.de
Print No. 83001802, July 2005
Printed in Germany. All rights reserved.
Neachells Lane, Willenhall, WV13 3RG
Tel: (01902) 609841, Fax: (01902) 633343
-weishaupt
Product
1.
r
<lP
Description
Performance
W-Bumers
The compact series, proven millions of times over:

Economical, reliable, fully automatic. Gas, oil and
dual fuel burners for domestic and commercial
applications.
Up to 570 kW
Monarch and
industrial burners
The legendary industrial burner:

Tried and tested, long lived, clear construction.
Gas, oil and dual fuel burners for district heat provision.
Up to
10900 kW
multiflam burners
Innovative Weishaupt technology for large burners:

Minimal emission values particularly at ratings
over one megawatt. Oil, gas and dual fuel burners with
patented fuel distribution system.
Up to
1 2000 kW
WK
industrial burners
Modular powerhouses:
Adaptable, robust, powerful.
Oil, gas and dual fuel burners for industrial plant.
Up to
17500 kW
Tiiermo Unit
The Thermo Unit heating systems from cast iron or

steel: Modern, economic, reliable.
For environmentally friendly heating.
Fuel: Gas or oil as desired.
Up to 55 kW
Thermo Condens
The innovative condensing boilers with the SCOT system:

Efficient, low in emissions, versatile.
Ideal for domestic heating.
Fuel: Gas.
Up to 240 kW
Solar systems
Free energy from the sun:

Perfectly coordinated components, innovative, proven.
Pleasantly shaped flat roof collectors to support
heating and of domestic water
Water heater /
energy reservoir
The attractive domestic water heating range

includes classic water heaters which are supplied
through a heating system and energy reservoirs which
can be fed through solar systems.
Control technology /
building
management
From control panels to complete building management

systems - at Weishaupt you can find the entire
spectrum of modern control technology.
Future oriented, economical and flexible.
Service
Customer service completes the Weishaupt range.

Weishaupt customer service is available 24/7.
We're there when you need us. Everywhere.
4 L ''"
D
in
IUP
'""^jpi
1/81 GB
Instructions for
fitting Fiigh grade steel hoses and
pressure hoses
-weishaupt1. General
Contents
Title
Page
1. General
2. Application possibilites
2.1 Axial turning movements
1/2
2.2 Lifting movements
2/3
3. Specifications and
technical data
3.1 Hoses in oil supply
installations
3.2 Pressure hoses
The oil and pressure hoses are corrugated

high grade steel with a high grade steel
woven wire sleeve cover.
With adherence to the following application
rules, the oil hoses and pressure hoses are
extremely well qualified for residual oil
app/ications. The stability, against chemical
and temperature effects of fuel oil, is
designed for long term service.
The TRD 4 1 1 , 7/81 edition recommends
metal hoses for residual oil plants.
The oil and pressure hoses should be protected from external mechanical damage.
To guarantee a strain-free assembly, the

hose should first be installed loosely at each
end, then moved through the required hose
movements two or three times so that the
hose can align without distortion and then
tighten.
A spanner should be used to counterhold
when tightening.'
Particular care should be taken that hoses
do not foul each other, or other equipment (burner, oil lines or boiler).
During installation, sufficient curve radii
and minimum hose lengths should be
allowed. For horizontal fitting the hose
should, in most cases, be supported.
When fitting, care must be taken to ensure

the hose is not twisted. It must not during
f ifting. or during later movement, receive
torsional strain, it is important that both
hose ends and movement lie in one plane.
Example
Connect hoses without twisting.
For turning connections, use second spanner
to counterhold.
2. Application Possibilities
2.1 Bending movement along the axis
Example
For angular movement ability, fit hose with
sufficient tension free ends. Take into
consideration the required curve radius.
Calculation of nominal length and installation distances follows according to the
formula for angular movement.
NJ=
Example
Angular movement and hose curves must lie
in one plane. Damaging torsional strain is
thus avoided.
t
Example
By ensuring tension free hose ends, the
angular movement can be enlarged
accordingly . The simultaneous extension
of the nominal i.e. installed length, should
be noted. It is not permitted to bend the
hose excessively.
2.2 Lifting Movements

Example
Fit an 180 curve with sufficient tension
free hose ends. The length is determined
according to the formular for an 180.
Determine the distance for fitting according
to the required curve radius.
LJ
Example
By installing rigid pipes, avoid inadmissible
bending directly behind the hose connections. The minimum curve radius must not
be exceeded.
Example
Movement direction and hose axis must lie
in on plane. Damaging torsional strain is
thus avoided.
<
as
=
Example
By installing rigid pipes, there is no varying
curve strain and no very sharp bends directly
behind the hose connections.
Example
Direction of movement and hose curve must
lie in one plane. Damaging torsional strain is
thus avoided.
Example
Arrange the hose in a loosely hanging curve
so that even on extended movements it
does not come in contact with the wall,
floor or other objects.
"<:
f l ^Jk
^''
TV / .
/
/
7-r-r/
/ / ^ f
2.3 Instructions on Application and

Installation
Example
If external mechanical strain (e.g. pulling on
the ground) cannot be avoided, the hose
should be protected from damage either by
an external round wire coil or a guard hose,
according to the degree of strain.
\-\\\\\V.\S'\V
TT-Trv^TTvcvr'rr^'r-
Example
During manual use, protect hose ends from
undue curve strain with rigid pipes.
C3:
CX
=dt>|
3. Specifications and Technical Data

3.1 Oil hoses in oil supply installations
(flow and return)
3.2 Pressure hoses (between pump and

nozzle)
The hoses on residual oil plants should be

designed for a working pressure of 10 bar
and a temperature (medium) of 150C.
For this application, the pressure hose is

designed for a working pressure of 30 bar
and 150C temperature.
With consideration of the temperature factor

for high-grade steel, the following is
stipulated for these hoses:
With consideration of the temperature

factor, the following is stipulated for these
hoses:
Nominal pressure.
Test pressure
Working pressure
Working temperature.
Nominal pressure.
Test pressure.
Working pressure
Working temperature.
_ P N = 16 bar
. PP = 21 bar
. PB = l o b a r
. TB = 150C
For the installation of oil hoses in flow and

return (between pump and rigid pipe
Installation), please observe the installation
diagrams relating to the product:
must be allowed for. This length must stay

straight, i.e. the curve radius may not start
until after this straight section.
. PN = 64 bar
. PP = 82 bar
. PB = 30 bar
. T B = 150OC
~1
The minimum curve radius is dependent on

the nominal clearance, the application, the
material, and on the type of manufacture.
The hose application on our products is
agreed with the manufacturer using the
original equipment.
For free use i.e. installation, with regard
to the fitting assembly instructions, the
following minimum radii must be
maintained:
Minimum radii
DN
r = minimum
curve radius
6
8
10
70
100
110
12
16
20
25
110
210
240
250
Length
DN
Z = length
6
8
10
80
85
90
12
16
20
25
100
125
130
135
After assembly is complete, the maintenance

of minimum radii should be checked in the
most adverse position and if need be, a
fixed mechanical stop must be made to limit
the movement.
The length of hose chosen must be sufficiently long. On each hose end,a Z section
IVIax Weishaupt GmbH, D-7959 Schwendi 1

Tel. (07353) 831, Telex 71 832
Print-No. 784 GB Dec. 81
Printed in W-Germany.
TYPE FT 3L
.mm
-LENGTH IN MM
-3 WIRE
PT 100 Ohm
ACCURACY : IEC 751 class B

STANDARD : TYPE PT 3L = 215 mm
ENCLOSURE CLASS IP54
MAX. TEMPERATURE 550c
CONNECTION DIAGRAM
1 or 2 Measuring elements
3 or 4 Wires
Ohm
-220
-200
-180
-160
140
-120
-100
-80
-60
-50
-40
-30
-20
10.41
18.53
C
-10
35.48
43.80
52.04
60.20
68.28
76.28
80.25
84.21
88,17
92.13
UUiib
AALBORG
INDUSTRIES
"C
Ohm
120
130
140
150
160
170
180
146.06
149.82
153.57
157.32
161.04
164.76
190
172.16
175.84
179.51
183.17
186.82
100.00
103.90
107.79
1.67
115.54
119.40
123.24
127.07
130.89
134.70
138.50
142.28
10
20
30
40
50
60
70
80
27.05
Ohm
96.07
90
100
110
168.47
200
210
220
230
240
190.46
DRAWN: RM
SCALE: none
DRAWING No:
DATE:
05-10-1999
941071
REV.
THERMAL FLUID
HEAT TECHNOLOGY
C
250
260
270
280
290
300
310
320
330
340
350
360
370
Ohm
.08
197.70
201.30
204.88
208.46
212.03
215.58
219.13
222.66
226.18
Fax
E-mail
540
Ohm
240.15
243.61
247.06
253.93
260.75
267.52
274.25
280.93
287.57
294.16
229.69
233.19
236.67
Temperature sensor
PT100 Ohm Single element
PO Box 145, 3200 AC Spijkenisse, The Netherlands

Tei
380
390
400
420
440
460
480
500
520
+31 181 650 500

+31 181 650 501
rtmw@aalborg-industries.nl
SHEET 1 OF
W I S DRAWING AND DESIGN SHOWN
HEREIN IS THE PROPERTY OF AALBORG
INDUSTRIES AND MUST NOT BE USED
BY OR REPRODUCED FOR THIRD PARTY
A4
ISO-
VIEW A - A
comrafponv M M offsnl
laon ony^ on ipvcnlc
knulatlcn 1Ncknii 120 nwn
kwiiiUw IMclaiw bockiM 80
jacM HSA B/I0O-11B IW50a2
0'
^
Eitiptyinl^ : 3000 Kg
: STJUIra
CO
o
a
z
a.
z
>
ThWTTKll fluid OUtlSt

DN80/t'N25 occardHa to DIN 2634
Section B B
Lifting E y for ha<lr

Iharniol fluM OMtlat
DNaO/('N25 aeconllna to DIN 2634
Flu ga ampta pip 1 / 2 *
YAIW
: Minq Shk)yarti
At
: Nanng - RR. of China
CLASS
: Germanischer Uoyd + UCE.AU1(SBG)
Baler no.
Newbuldhg
Aabcrg ProiKt
15393
PP573a659A.00
JLZ04-04O9
15395
PP5738660A.00
JLZ0*-0410
15397
PP5738661A.W
JLZ0*-0413
15399
PP5738662A.00
Z04-0414
15610
PP573BB41A.00
1204-0411
15612
PP5738B42KO0
1204-0412
16939
052352-1
1204-0415
16605
PP5739698A.00
1204-0416
16941
052352-2
1204-0417
Hull nra added
Dnwiinq updated
DESCaPTKlW
Uiliiii
PJ
CE
13-02-2006
19-04-2005
THERMAL FLUID
w
AAIBORG HEAT TECHNOLOGY
INDU<TII*
MISSION TFO
V4-0-TF0-010
PATt
ORAWtCE
SCME None
DATE 1 6 - 0 3 - 2 0 0 5
:4ama
REWn SHEET
DRMMGNE
D53717
MHicnoanrvMMH
1
ori
AI
CQ2 Conn. R 5 / 4 "
Nozzle TF14XW 3 / 8 " ( 2 x )

Immersion tube
Gasl<et DN 25
Marking of orificeploat
Section
B B
Extinguish nozzle
View A - A
01366
022 (36x)
P.C. 01310
fleu gas flanges

ace DIN86044
CD. 01226
O
in
in
DN25 PN40
Detail
cleaningnozzle
DN80 PN40
40
17
Thermal Fluid
Inlet
CD
Cleoningnozzle.
Draw
turned 45
See topview.
iXXM>i>3.
Stainless steel pipe

021.3X2.65
NUMBER OF ECONOMISERS : 1
HEAT CAPACITY : 1000 kW
INLET TEMP. : 150 C
OUTLET TEMP. : 200 "0
WEIGHT EMPTY : 5800 kg
LIQUID VOLUME : 1553 Itr
FLANGES AGO DIN
mmersion tube.
o
LO
LO
<-
Nozzle TF14XW 3 / 8 "
CD
CM
o
o
oo
to
DN80 PN40
Detail I n s p e c t i o n
O
Thermal Fluid
Outlet
<>
DN40 PN40
Cleaningnozzle.
Draw
turned 15
See topview.
o
IT)
>, r-p ,r-\
i>- 4~ "^
LfU
550
470
10
4
CM
O
O
CM
hole
CO 2
Connection R 3 / 4 "
See view AA
YARD
: Jinling Shipyard
At
CLASS
Newbuilding
Boiler no.
Aalborg Project
PP5758661A.00
JLZ04-0413
15398
PP5738662A.00
JLZ04-0414
15400
PP5738841A.00
JLZ04-0411
15611
15613
PP5758842A.00
JLZ04-0412
16940
052552-1
JLZ04-0415
16606
PP5759698A.00
JLZ04-0416
16942
JLZ04-0417
052352-2
CO
o
in
400
CM
CM
CM
CO
40 1
in
CD
o
CM
of
20
o k
U-
300=
to
lO
170 170 170
(lOx) Hex, head bolt M10x40

Test connection
Immersion tube
100
1226
P.C. 01310
01366
I
Flue gas
Inlet
+ nut + washer(DIN931,934,125)
+ gasket(glasscord8)
See view A - A
PJ
Hull nrs. added

REV.
NAME
DESCRIPTION
PROJECTION
iiUUib
AALBORG
INDUSTRIES
14-02-2006
DATE
Economiser
EXV660-43-57,0-600
DRAWN: CE
SCALE: none
DATE: 1 1 - 1 1 - 2 0 0 5
THERMAL FLUID
DRAWING No:
D54051
PO Box 145, 3200 AC S)>lj(enisse^ The Netherlands

Td
: +31 181 650 500
REVISION SHEET
I L V ^ n i N U L U U I E_,ap. rimwft10lborg-lndu3Wes.nl
0F1
IHIS DRAMNG AND DESIGN SHOWN

HERQN IS THE PROPERTY OF AALBORG
INDUSTRES AND MUST NOT BE USED
MLH I
BY OR REPRODUCED FOR THIRD PARTY
AI
1739
CLOSED FRESH
WATER SYSTEM
YARD
: Ming Shipyard
At
CLASS
Newbuilding
Aalborg Project
JLZ04-0409
PP5738659A.00
PP5758660A.00
JLZ04-0410
PP5738661A.00
JLZ04-0413
PP5758662A.00
JLZ04-0414
PP5738841A.00
JLZ04-0411
PP5738842A.00
JLZ04-0412
052352-1
JLZ04-0415
PP5739698A.00
JLZ04-0416
JLZ04-0417
052352-2
Detail "a''
1^
o
CM
CM
Holes 26x18
TUBES
SHE LL
FRESI- WATER
THERMAL FLUID
FLUID
28
34
FLUID FLOW
80 DIN 86030
C o n n e c t i o n DN
65 DIN 86030
250
38.0
TEMP. IN
68.0
195
TEMP. OUT
300
160
DESIGN TEMP.
10
10
DESIGN PRES.
15
15
TEST PRES
11.8
27.4
CONTENT
C-STEEL
C-STEEL
MATERIAL
197
WEIGHT EMPTY
DELIVERY EXCL. INSULATION
CAPACITY
1000
KW
m3/h
c
c
c
BARG
Hull numbers added

REV.
DESCRIPTION
NAME
PROJECIW
BARG
LTR.
KG
PJ
#3
14-02-2006
DATE
DRAWN: CE
SCALE: none
DATE:
16-03-2005
iililiiii THERMAL FLUID

AALBORG
INDUSTRIES
Dumpcooler
Type:MX20/L T10/1200
HEAT TECHNOLOGY
DRAWING No:
D53719
REVISION SHEET
1
0F1
PO Box 14% 3200 AC SplJwilM 1hl Nttlwlanill 1HS DRAMG AW DESKN SHOW
Til :+3i imesosoo
HEREM IS IHE PROFERTY OF AAUORG
MUSUCS AM) UUST NOT BE USED
F
:+31 1B1690501
BY OR REPRODUCED FOR IHRD PARTY
E-nwl: rtmw qdbofy-fcidurtriitjil
A3
#
YARD
: Jinling Shipyard
At
CLASS
Newbuilding
Aalborg Project
PP5738659A.00
JLZ04-0409
PP5738660A.00
JLZ04-0410
PP5758661A.00
JLZ04-0413
PP5738662A.00
JLZ04-0414
JLZ04-0411
PP5738841A.00
PP5738842A.00
JLZ04-0412
052352-1
JLZ04-0415
PP5739698A.00
JLZ04-0416
JLZ04-0417
052352-2
CIRCULATING PUMP
Type:
NTT 50-200
CAP.:
34
myh
Del.head:80
m.l.c.
E-motor:15.0
kW
Siemens
Current: 3x440V-60Hz
Weight: 231.5 kg
Hull numbers added

REV.
DESCRIPTION
PJ
NAME
PROJECIKM
14-02-2006
CIRCULATING PUMP
Type: NTT 5 0 - 2 0 0
DATE
DRAWN: CE
SCALE: none
DATE: 1 6 - 0 3 - 2 0 0 5
DRAWING No:
D53720
REVISION SHEET
1
0F1
1HS nUMNG M O DESKN SHOWN
^ ' ^ l ^ ^ ' " - " " ' * - ^ HBSM E 1NE PROPERTY OF AAUORG
AALBORG THERMAL FLUID
DUSIRES NO MUST NOT BE USED
HEAT
T
E
C
H
N
O
L
O
G
Y
^
l^riJ^r;-.^.
BY OR REPROniCED FDR 1HRD PARTY
INDUSTRIES
A3
POSITION
DIM E -
1 Level switch
2 Level indicator
MAN/INSPECTIONHOLE ORIENTATION
DRAINLINE
EXPANSION LINE
IN ACCORDANCE WITH DIN 4 7 5 4

DN A
DN E
KW
DN
TUBE
DN
TUBE
65
76.1 X 3.2
50
60.3 X 2.6
2400
2 / 3 xF
'^Ôi
CM
welding detail:
DETAIL A
SHELL
Thermal fluid filling contents of the

system in litres at 200'C supply temp,
with a safety of 30% on thermal
expansion of the fluid
welding detail:
Thermal fluid filling contents of the system

in litres at 300'C supply temp,
with a safety of 30% on thermal
expansion of the fluid
**
TYPE
SVE 5950
Content
1430
A
505
D
900
6 600
NOZZLE
2860
100*100*10
N
1700
* *
* * *
Weight Weight
700
1065
NW
4000 DN400
* *
EMPTY WEIGHT IN K g
* * * WET WEIGHT IN K g
* Contents of expansion tank in litres
DO NOT INSULATE EXPANSION VESSEL
YARD
! Jinling Shipyard
At
! Nanjing - P,R, of China
CLASS ' Germanischer Lloyd + MCE.AUTCSBG)
tiewbuilding
Aalborg Project
PP5738659A.00
JLZ04-0409
PP5738660Am
JLZ04-0410
PP5738661Am
JLZ04-0413
PP5738662Am
JLZ04-0414
PP5738841A.00
JLZ04-0411
PP5738842A.00
JLZ04-0412
052352-1
JLZ04-0415
JLZ04-0416
PP5739G98Am
052352-2
JLZ04-0417
Hull numbers added
REV.
DESCRIPTION
^
PJ
NAME
PROJECTION
DN25 PNI6
13-02-2006
DATE
EXPANSION VESSEL
TYPE: SVE 5950
DRAWING No:
DRAWN: C E
SCALE: n o n e
iiiiiiiit
^ ^
DATE: 16-03-2005
PC Box 145, 3200 AC
INDUSTRIES
Tel
D53721
Spijcenisse, The Netheriands
THERMAL FLUID
TECHNOLOGY'" ='"'''''''
AALBORG HEAT
lll_/-\l
I U V > ^ I I M V l _ W I E_m(,||. rtmw9aalborg-industries.nl
: +31 181 650 500
REVISION SHEET
1
0F1
THIS BRAVING AND DESIGN SHDVN

HEREIN IS THE PRDPERTY DF AALBDRp
INDUSTRIES AND MUST NDT BE USED
BY GR REPRDDUCED FDR THIRD PARTI
A3

M14 Thermal Fluid

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Your Preferred Partner

Tel, +31 (0)181 550 500

DESCRIPTION AND MAINTENANCE

Tel. +31 (0)181 550 500

DESCRIPTION OF THE INSTALLATION

START UP THE INSTALLATION

BOILING OUT THE SYSTEM

10. GENERAL SETPOINTS

Tel. +31 (0)181 650 500

Aalborg hidustries B.V.

PP5738841-01 A.OO (hull no. JLZ04-0411)

Main flow diagram

Fuel oil diagram

P\PP\PP2005',PP05 738841 .Aalborg HKG_JLZ04041 l\l 1 Tekmingen PP05,738S41\Jinling PP5738841-01_inanual.doc

Tel. +31 (0)181 650 500

Thermal fluid heater

Temperature controller oil fired heater

Flue gas thermostat

Maximum thermal fluid thermostat

P\PP\PP20O5\PPO5.738841 Aalborg HKG_JLZ0404II\11 Tekeningen PP05.738841Uinling PP5738841-01_niaiiual doc

Tel. +31 (0)181 650 500

Leakage device for oil fired heater

Flue gas thermostat

Fire alarm thermostat

Maximum thermal fluid thermostat

P:\PP\PP2005\PP05 738841,Aalborg HKG_JLZ040411\11 Tekeningen PP05 73884l\Jmling PP573884I-01_manual.doc

Tel. +31 (0)181 650 500

Flow switch economiser

Leakage alarm exhaust gas heater

Auto stand-by pressostat

Temperature controller dumpcooler

P:\PP\PP2005\PP05.738841 Aalborg HKOJLZ040411\11 Tekeningm PP05 73884IVIinling PP573884l-01_maiiual.doc

Tel. +31 (0)181 650 500

Threeway control valve for dumpcooler

Pressure controller minimum flow

Control valve minimum flow

Pressure transmitter minimum flow

P:\PP\PP2005\PP05,738841 Aalborg HKG_JLZ040411\11 Tekeningcn PP05 738841VIinling PP573884l-01_nMnual.doc

Tel. +31 (0)181 650 500

P.O. Box 145

Fax +31 (0)181 550 501

Bankers: Fortis Bank, R o t t e r d a m

IBAN No. NL85FT5B0257569618

VAT No. NL0081.91.694.B.01

BIC Code FTSBNL2R

Level switch expansion vessel

Quick opening valve expansion tank

Tel. +31 (0)181 650 500

DESCRIPTION OF THE INSTALLATION

In the thermal oil system the following components are installed:

Oil fired thermal fluid heater 800 kW with Weishaupt bumer.

Circulating pumps (one pump automatically standby).

P.\PP\PP20O5\PP05 73884) Aalborg HKG_JLZ04041 l\l 1 Tckcningen PP05.738841Jinling PP5738841-OI_manual doc

Tel. +31 (0)181 650 500

3.1.1. Oil fired heater

Modulating between 30 % and 100 %;

P:\PP>PP2005\PP05 738841 Aalborg HKGJLZ0404I IM I Tekeningcn PP05 738841'Jinling PP5738841-01_manual.doc

Tel. +31 (0)181 650 500

The economiser in combination with the dumpcooler maintains a constant supply

PAPP\PP20O5\PP05.73884I.AalborgHKG JLZ0404n\ll TekenmgeiiPP05.738841VJinlingPP5738841-01 manual.doc

Tel. +31 (0)181 550 500

P\PP\PP200J>PP05.738841 Aalborg HKG_JLZ0404n\l I Tekeningen PP05 738841\Jinling PP5738841-0I maimal.doc

Tel. +31 (0)181 550 500

3.1.4. Minimum flow control set