Fitting & Acc.

HMMCO
INSTRUCTION MANUAL
FOR
AUXILIARY BLOWER WITH MOTOR
HYUDAI MARINE MACHINERY CO., LTD.
-1-
- CONTENTS-
■ AUX-BLOWER
A. OPERATION
1. PREPARATION FOR OPERATION
2. STARTING INSPECTION
3. TROUBLESHOOTING
B. MAINTENANCE
1. T/C REAR SIDE MOUNT TYPE for B&W ENGINE
2. T/C AFT SIDE MOUNT TYPE for B&W ENGINE
3. T/C REAR SIDE MOUNT TYPE for SULZER ENGINE
4. INSTRUCTION FOR DISMOUNTING & MOUNTING OF IMPELLER
■ ELECTRIC MOTOR
A. OPERATION
2. STARTING
3. STOPPING
4. CARE AFTER STOPPING
5. TROUBLESHOOTING
B. MAINTENANCE
1. PERIODICAL MAINTENANECE CHART
2. MAINTENANCE AND REPLACEMENT OF BALL BEARING ON THE MOTOR
3. DISASSEMBLY AND REASSEMBLY OF THE MOTOR
4. DRYING
5. TRIAL RUNNING OF THE MOTOR
6. REFERENCE
-2-
■ AUXILIARY BLOWER
-3-
A. OPERATION
After the fan is left at rest for a long time or subjected to dis-assembly and
assembly, carry out the following inspection.
(1) Make sure that there is no foreign matter in the casing.

(2) Examine if there is a piece of cloth or another thing which may easily
be sucked in, near the suction port.
(3) Inspect the rotating parts for any contact with fixed parts.
(4) Check the power source (Voltage, Cycle). Don't supply different cycle,
power source with motor specification.
2. STARTING INSPECTION
After starting the fan, carry out the following checks.
(1) Check to see if the rotating direction in corret.

(This check is not necessary when no reassembling has been carried out.)
(2) Check for abnormal noise.
(3) Check for abnormal vibration.
3. TROUBLESHOOTING
When the fan is out of order, care for the fan according to the following table.
No. Trouble Probable cause Remedy

Inspect the impeller and related
parts to locate the cause.
Mechanical rastraint Replace with spare bearings.
Impossible or
1 Seizure of bearings Check for motor winding
difficult to start
Trouble of the motor disconnection, insufficient
voltage, cable disconnection,
faulty starter connection, etc.
-4-
No. Trouble Probable Remedy
2 Insufficient Dirt and other foreign Clean the impeller.
capacity or matter attached to the
motor impeller.
overload Rotation reversed. Correct the rotating direction.
Air leakage. Check the air duct connections
ect.
Impeller damaged. Replace the impeller.
Insufficient or Check the motor.
excessive rotating
speed.
3 Abnormal Abnormal speed Check the motor.
vibration Foreign matter Remove the foreign matter.
and noise Loose installing bolts Tighten the installing blots.
Bearing damaged Replace with spar parts.
4. IF YOU HAVE ANY DOUBTS, PLEASE DO NOT HESITATE TO CONTACT.
HYUNDI MARINE MACHINERY CO., LTD.
602-15, GAJWA-DONG, SEO-GU, INCHON CITY, KOREA. (http://hmmco.co.kr)

TEL : +82 - 32 - 583 - 0671
FAX : +82 - 32 - 583 - 06
-5-
B. MAINTENANCE
1. T/C REAR SIDE MOUNT TYPE FOR B & W ENGINE
(1) MOUNTING OF ELECTRIC MOTOR ON B & W AUXILIARY BLOWER

All item numbers refer to drawing No. H-REAR-01/02
1) Place the motor on a table or flat so that shaft is in a horizontal position

and motor shaft is sticking out of the foundation.
2) Remove the groove from the motor.
3) Lubricate the motor shaft with oil or grease.
4) The sealing ring to be pushed over the shaft.
5) The motor to be bolted onto the motor plate. The motor blots should be packed
carefully with teflon or fluid packing substance. Do not forget to placetheterminal
box of the motor correctly in proportion to the drain hole.
6) Mount the gaslock-seal (item 11) in the stuffing box (item 7) the lip towards the
impeller.
If the Gaslock-seal has already been mounted-check the seal lip.
7) Place the Gasket (item 8) between motor plate and stuffing box (item 7) Carefully
push the stuffing box over motor shaft and sealing ring without damaging. the
Gaslock -seal. The stuffing box will automatically centre and then be mounted by
means of 6 bolts with washers made of carbon steel. Lubricate the lip care-fully
with grease from both sides.
8) The groove should be shortened to fit the projecting part of the motor shaft.
9) The impeller should now be carefully pushed over the shaft, while taking care that
the groove and the key way are next to each other.
-6-
When the impeller cannot be pushed up any further, if should be pulled into right
position by means of a bolt.
10) The impeller should be tightened by using a think washer(5-6mm),a lock washer,
and a bolt.
NB : The impeller has been dynamically and statically balanced from
the factory and must not be damaged in any way
11) Th inlet cone to be dismounted.
12) The GASKET (item 5) to be placed in it's right position.
13) The motor plate to bo lowered onto the fan housing and tightened by means of
bolts with washers made of Carbon Steel.
14) Mount the inlet cone. Take care, however, that the distance be ween the impeller
and the inlet cone is the same all the way round.
15) Turn the impeller manually in order to check that it runs smoothly.
16) The motor nay now be started in order to check the fan for excess vibration
and jarring sounds. with an accelleromter it should be checked that the motor has
an effective frequency below 2 mm/sec. Measurements should be made horizontally
and vertically on a level with the motor bearings The impeller has been balanced
in accordance with ISO 1940 and with quality class Q better then 6.3.
Testing period 15-20 minutes.
-7-
-8-
-9-
2. T/C AFT SIDE MOUNT TYPE FOR B & W ENGINE
(1) MAINTENANCE OF B&W AUXILIARY BLOWERS
The auxiliary blowers usually consist of the following main components which
are shown on drawing No. H-AFT-01/02/03
1) Blowers.
2) T-connection.
3) Electric motors.
Your attention is drawn to the fact that some of the minor types of diesel engines
do not require compensator and suction box.
1) Blower.
The blower part consists of the following.
Scroll housing made of heavy steel plate.

Impeller in special welded alu. - alloy.
Suction cone.
Tightening device, intended for pressure of up to 5 Bar

Motor plate.
Motor.
2) T-connection.
The T- connection, which is made of heavy steel plate, serves as connection
piece between the two blowers as well as connection to the outlet pipe of the
air cooler.
The pressure opening surfaces of the two blowers have a parallelism better then
0.1 mm. The parallelism is maintained by 8 conical guide pine, which should be
treated carefully when re-mounting.
- 10 -
(2) MOUNTING OF AUXILIARY BLOWER
1) The two fans have been mounted on the T-connection from the factory and
should not be separated.
2) Lift the whole unit to its right place.

Tighten blowers loosely onto diesel engine.
Tighten all bolts properly.
3) Mount the suction pipe from the air cooler.
4) The unit is now ready to be put into operation.
5) During operation the mechanical seal, which consists of Sealing ring (item 10) and
Gas lock seal (item 11), will leak a bit considerable leakages indicate that the
Gas lock seal is worn out and should be replaced. During this replacement the
Sealing ring should be turned so that the seal gets to work at another spot on
the sealing ring.
NB : The fans are in right and left position respectively, wherefore the impellers
must not be reversed. The impellers are marked with the serial number of
the fan.
- 11 -
- 12 -
- 13 -
- 14 -
3. T/C REAR SIDE MOUNT TYPE FOR SULZER ENGINE
(1) MAINTENANCE OF SULZER AUXILIARY BLOWERS
The auxiliary blowers usually consist of the following main components which
are shown on drawing No. H-WCH-01/02/03
1) Blowers.
2) Joint duct.
3) Suction box.
4) Electric motor.
Your attention is drawn to the fact that some of the minor types of diesel engines
do not require compensator and suction box.
1) Blower.
The blower part consists of the following.

Scroll housing made of heavy steel plate.
Impeller in special welded alu. - alloy.
Suction cone.
Tightening device, intended for pressure of up to 5 Bar
Motor plate.
Motor.
2) Joint duct.
The joint duct consists of two mounting flanges.
3) Suction box.
The suction box consists of a heavy steel box direct mounting onto the main motor,
plus and inspection cover.
The function of the suction box is to combine outlet of the air cooler with the
inlet of the auxiliary blower.
- 15 -
(2) MOUNTING OF AUXILIARY BLOWER
1) Mount joint duct onto suction box.

(Small flange towards suction box.)
2) Mount suction box onto diesel engine.
3) Lift the blower to it's right place and push it towards the joint duct.
Tighten blower loosely onto diesel engine.
Tighten joint duct onto blower so that it does not suffer any harm.
The unit is now ready to be put into operation.
- 16 -
- 17 -
- 18 -
- 19 -
4. INSTRUCTION FOR DISMOUNTING & MOUNTING OF IMPELLER
(1) INSTRUCTIONS FOR DISMOUNTING OF IMPELLER ON AUXILIARY BLOWER
In the following it is recommended to see drawing No.

H-REAR-01/02, H-AFT-01/02/03, H-WCH-01/02/03
1) The electric connection of the motor to be dismounted.
2) The bolt on the motor to be loosened, and motor, motor plate, and impeller to be
raised from the scroll casing by means of a stable lifting device.
3) The bolt on the motor shaft to bo loosened and removed together with the spring
plate.
4) Dismounting tool-as shown on the enclosed sketch No. H-TOOL-01 to be mounted

on the hub of the impeller by means of 2 bolts which are screwed into the
belonging threaded holes.
5) A strong disk is to be placed between the motor shaft and the dismounting tool in
order not to damage the threaded hole in the motor shaft.
6) The impeller to be carefully drawn out by means of tightening the middle bolt.
7) Under normal conditions the sealing ring remains os the motor shaft However,
it comes of when dismounting the impeller, the motor plate must be dismounted
from the motor and the sealing ring must be mounted on the motor shaft. The
motor can now be mounted, however, please take care not to damage the sealing
ring.
- 20 -
- 21 -
(2) INSTRUCTIONS FOR DISMOUNTING OF IMPELLER ON AUXILIARY BLOWER
FOR MAIN DIESEL ENGINES
In the following it is recommended to see drawing No.

H-REAR-01/02, H-AFT-01/02/03, H-WCH-01/02/03
Please note that the new impeller has been statically and dynamically balanced
from the factory, and therefore the impeller must not be exposed to thrust or other
overload.
1) Grease the motor shaft with oil.
2) The impeller to be pressed over the motor shaft by means of a bolt and a
washer plate. Please make sure that the groove fire opposite the key groove.
3) The impeller to be held by means of the original spring plate and bolt.
4) Motor plate to be lifted up carefully from the foundation and to be turned
horizontally
5) The packing between the scroll casing plate and the motor plate to be examined
for porosities and cracks. In case of a defect packing has to be replaced. Please
use a corresponding quality.
6) Impeller, motor, and motor plate to be mounted on the scroll casing plate once
more. Please or take precautionary measures in order not to damage motor or
impeller resulting in unbalance.
7) The motor can now be electrically connected again.
- 22 -
■ ELECTRIC MOTOR
- 23 -
A. OPERATION
If the motor to be operated has been at rest for a long time or disassembled and
reassembled, pay attention to the following.
(1) Check to see that rotary parts such as fan are secured positively, motor installation
is satisfactory, and there is no abnormality on the machine to be driven by the
motor.
(2) Check to see that terminal connections of the motor are sufficiently tight, and
insulation distance between dissimilar poles and ground is not badly small.
(3) Check to see that there is no contact between rotary and stationary parts.
On such motor that has small gaps between the rotor and the stator, both may be
brought into contact by wear of the bearing, and the stator coil burned out by the
resulting heat generation.
(4) Check to see that bearings are normal.
(5) Check to see that there is no ingress of dust or dirt or foreign matter in the
aparatus.
(6) Check to see that there is no part of deteriorated insulation.
(7) Measure the insulation resistance. If the measurement is lower than specified, dry
by proper method.
(8) Check to see that the machiner to be driven by the motor is ready for operation.
(9) Check to see that the direction of rotation of the motor is correct. If the rotationg
direction is reverse in the case of the 3 phase motor, change the connection of
wires for two phases with each other.
- 24 -
2. STARTING
After finishing the preparation for operation, confirm the load to be ready for
starting. Then, turn on the power switch, and after signalling to the rotary part,
operate the operate switch to start the motor points requiring attention during
operation are as follows.
(1) The condition of load, and temperature measurement.
If the motor is provided with an ammeter, the condition of load can be known by
use of meter. If no ammeter is available.
Hear sound or know the temperature of the stator frame.
Note that if an overload is sustained, the temperature of various parts exceeds the
specified value.
Table 1
Temperature Rise at AC Machine Stator Windings Rated below 1,000V
(。C)
TYPE OF MACHINE
MEASURE Not totally enclosed Totally enclosed
RULE
MENT CLASS OF INSULATION
F E B F E B
T 75 55 60 80 60 65
NK (1979)
R 90 65 70 90 65 70
ABS (1978) R 95 60 70 100 65 75
T 80 55 60 80 55 60
LRS (1979)
R 90 65 70 90 65 70
T 75 55 60 75 55 60
NV (1980)
R 90 65 60 90 65 70
T=Measurement by thermometer
R=Measurement by resistance
- 25 -
(2) Sound
The sound of the motor gives a good indication of the condition of rotation.
Especially, the sound of the bearing part is useful in determining troubles.
To hear the sound of the bearing part correctly, apply a metal bar, one end th
the bearing part and the other to the ear.
(3) Vibration
The vibration give another indication of the condition of rotation.

Abnormal vibration of the motor during operation is caused either magnetically
or mechanically. Probable magnetic causes are an air gap unbalance between
the rotor and stator which causes a magnetic attractive force to be exerted
between cores resulting in a vibration of the rotor, ground or wire break which
causes a current unbalance to develop, misalignment of magnetic center, ect.
Probable mechanical causes are broght about a mechanical unbalance of the

rotor, improper installation of the coupling between the motor and the load
(improper centering), loosened motor mounting bolt, improper bearing part, ect.
The rotor is fully balanced during manufacture, and with normal care it should
not be unbalanced.
3. STOPPING
Confirm the load lobe ready for stopping, and after signalling, operate the operate
the operating switch to stop the motor.
4. CARE AFTER STOPPING
After stopping, pay attention to the point given in the paragraph

" Preparation for operation. "
- 26 -
5. TROUBLESHOOTING
Trouble Cause Remedy
Disconnect the motor from the load.
Try to rotate by hand and if it is
difficult, the cause is a mechanical

Mechanical restriction or
restriction.
overload.
Disassemble and investigate. If the
motor without the load can be
started, check the load.
Stator winding broken Replace with a spare one.

Failing or
Measure the motor terminal voltage
difficult to
and read the voltmeter on the
start Switch in poor contact
switchboard. If it is lower then
sprcified, raise.
Fuse blown out Replace with a spare one.
Readjust contact part or replace

Switch in poor contact
with a spare one.
Connecting wire broken Reconnect.
Over current relay operated Remove the cause and reset.
Bearing binding Replace with a spar one.
Grease deteriorated or
Overheating Replace with a spare one.
contaminated
of bearing
Ball bearing damaged Replace with a spare one.
part
Misalignment Alignment.
Abnormal Belt too tightened Reduce belt tension.
sound or
Investigate the cause for overheating
abnormal Heat conducted from other part
of rotor or stator.
vibration
- 27 -
Frequency Check and adjust the line frequency
variation to the rated value.
Abnormal
Load
Check and adjust the machine.
variation
Replace bearing with a spare part.
Air gap part in contact
Check for bearing of shaft.
Ingress of foreign Remove foreign matter.
Loosened
Retighten.
mounting bolt
Misalignment
Vibration
of direct
or rotor Realignment.
connected
machines
Unbalance Rebalance.
Replace bearing with a spare part.
Air gap in unbalance
Abnormal center bracket with frame.
sound or Beating due
abnormal to overload
Magnetic Check and adjust load.
vibration loosened
sound Disassemble and repair.
Laminated
core
Corroision of
ball with Readjust or replace bearing
retainer
Grease
Replace with a spare one.
Abnormal deteriorated
sound Ball surface
from damaged
mall damage by Replace with a spare one.
bearing electrolytic
corroision
Ingress of
foreign Clean bearing and repack with grease.
matter
- 28 -
Overload Reduce load to or below rated value.
Cooling fan defective Disassemble and repair.
Ventilating hole clogged Remove dust or dirt accumulation.
Overheating Replace bearing with a spare part.

Friction between rotor and
Readjust air gap uniform by centering
stator
bracket with frame.
Coil grounded Disassemble and repair coil.
Disassemble and water wash to remove
contaminant, then reassemble and dry in
the case of inundation by sea water,

Inundation
wash and clean in hot water at 60。C to
70。C to remove salt, then reassemble
and dry.
- 29 -
B. MAINTENANCE
1. PERIODICAL MAINTENANCE CHART

Standard checking Standard corrective
Interval Checking of
procedure measure
If abnormal vibration, sound
or bearing heating is noted,
Check for vibration
investigate the cause and
Major motor in and sound, and the
Daily repair.
use temperature of bearing
If overload or other abnor
etc. by touching by hand.
mality is noted, stop at
once and remove the cause.
Rotate the motor by If abnormality is noted,
Major motor
hand and check for investigate the cause and
not in use
abnormality. repair.
Weekly Removal
Measure insulation If insulation is deteriorated
electric
resistance. Check or ground connection is im
apparatus
ground connection. and repair
Measure insulation If insulation is deteriorated,
resistance. investigate the cause and
Motor and Check stator and rotor repair.
Monthly
stater loosened connection. Clean contaminated area.
Check lubrication Add grease and replace
part. bearing.
If the measurement is below
the allowable limit given
Electric Measure insulation below, dry or otherwise
3-monthly
circuit resistance. correct.
(1) Circuit rated about 100V:
1 Mohm or greater
- 30 -
Standard checking Standard corrective
Interval Checking of
procedure measure
(2) Circuit rated below
Electric Measure insulation
3-monthly 100V:
circuit resistance
1/3 Mohm or greater
If operation is abnormal,
Check operation investigate the cause and
Apparatus starter and accessory repair. Repair defective
associated apparatus. or burned part.
with motor Check contact If necessary, replace with
connections. a spare one. Retighen
6-monthly loosened connection.
Check for loosened
bolt or nut in the Retighen loosened bolt or
base mounting part. nut.
Motor
joint, cover mounting Replace defective blot or
part, etc. and for nut with a now one.
correction.
Measure air gap
between stator and Replace defective bearing
Motor rotor. Check for with a spare part, Clean
abnormality shaft and bearing
in bearing part.
Yealy
(1) Check with parts list.
(1) Check the number. (2) If insulation is
Spare part (2) Measure insulation deteriorated, investigate
resistance. the cause and dry or
otherwise correct.
- 31 -
2. MAINTENANCE AND REPLACEMENT OF BALL REARING ON THE
MOTOR
The ball bearing with grease sealing plates is packing with grease during
manufacture, and should not require addition of grease during operation,
unlike the conventional open type bearing.
The ball bearing requires replacement if it produces badly abnormal

during operation. The procedure for bearing replacement is as given
below.
After disassembling the motor by the procedure given later, remove the
defective bearing from the rotor shaft by use of a bearing puller.
Anti-rust grease on the surface of the replacement bearing should be

removed with a cloth. Mount the new bearing on by the shock.
During this procedure, be careful not to give shocks to the sealing plate, as
the searing plate may be deformed or dropped by the shock.
However desirably the bearings may be in use, it is unavoidable for them

to be damaged by fatigue. Nevertheless, an adequate operating method
can reduce the fatigue or can prevent failures due to other causes.
Besides, should a damage to be taken, the cause should be examined in
view of the appearance and character of the damaged part. and care must
be taken not to allow the same trouble to be repeated.
It is very difficult to locate the cause of a trouble, which is usually

attributable to a combination of several causes.
- 32 -
No. Trouble Characteristic Probable cause
Dents formed on the race face owing
to careless installation.
Low noise
Dents formed on the race face by
(rustle or rumble)
external vibration while the fan
1 Noise is at rest
High-pitched noise Too small clearance
Foregin matter included
Intermittent noise Resonance due to careless assembly
about the housing
Insufficient clearance during
Abnormal
2 operation
temperature
Overload
Too tight fitting
Axial crack on the or
Uneven installing surface
outer ring
Housing deformation
Circumferential crack Uneven installing surface
3 Crack
on the inner or outer
Extreme overload
ring
Crack on the retainer or ball due
Irregular crack
to grease aging
Indentation Knock during installation
Indentation of the same
4 on the race Great blow struck on the bearing
pitch as the ball
face with the fan is at rest
Grease aging
Retainer
5 Ball damaged
damaged
Rivet damaged by vibration
Corrosion by acid or moisture
local spots on the
while the fan is at rest for a
6 Rust race face
long time
Surface rust Incomplete contact (Faulty fitting)
- 33 -
3. DISASSEMBLY AND REASSEMBLY IF THE MOTOR]
To disassemble the motor, proceed as follows.

(1) Disconnect the motor from the power supply.
(2) Remove the direct coupling, and place the motor in a ares
suitable for disassembling.
(3) Remove the bearing cover and the oil thrower on the direct coupled
side.
(4) Remove the bearing bracket.
(5) Pull out the rotor as a whole in the direction toward the fan.
(6) Place the rotor on a cleam stand, and pull out the ball bearing
with a tool.
Be careful not to contaminate disassembled bearing part, etc. with

dust or dirt. Also, take care not to damage the insulation when pulling
out the rotor.
The reassembly should be done by reversing the disassembling procedure,

taking care to insure positive assembling of bearing part or other fits.
4. DRYING
Before starting the motor which han been at rest long or is suspected
of moisture absorption, measure the insulation resistance of the winding
and if the measurement is below he limit given below, it is necessary
to dry the winding by the procedure given in the following paragraphs.
□ Circuit rated above 100V:1 Mohn or greater
□ Circuit rated below 100V:1/3 Mohn or greater
(1) Hot air or external heating method :

Place a well ventilated sheet over the motor.
The insulation should not be heated about 90。C
(2) Current method:
With the rotor locked, apply a low voltage to allow a short circuit
current to flow in the winding. The winding is then dried by it's own
heat generation. Start at low current, increasing the current
gradually until the temperature approaches 90。C, then keep the current
- 34 -
so that the insulation resistance reaches a constant
value sefely.
5. TRIAL RUNNING OF THE MOTOR
The motor which has been dried or disassembled and reassembled should
be cleaned thoroughly, checked for loosened screw, etc. and then placed
in trial running.
If the trial running is satisfactory, the motor may be directly coupled
with the load.
6. REFERENCE
(1) Insulation resistance test for stator winding

Remove the cables from terminals and measure resistance beween
earth and stator winding by D. C. 500V megger.
The resistance should be more than follows.
R= Machine rated voltage x 3

Machine rated output(kw) + 1000
Note : R : Insulation resistance for stator winding.
If the resistance is too low ( less then 1 MΩ ) it should be dried

by the procedure of item 4.
Typical trend of insulation resistance.
- 35 -
Caution
1. During drying, carefully heat up to exceed 90。C at any

points of winding.
2. It should be continued to dry that the resistance measured
are saturate.
(2) Re-greasing
Following grease should be used. Refer to the attached Table 2.
Recommended Grease.
(3) Period of re-greasing

Operate frequently Every 3 month
Operate intermittentry Every 6 month
- 36 -
Table 2.
RECOMMENDED GREASE
Insulation Class E. B. Insulation Class F

Manufacturer
Grease Soap Grease Soap
NIPPON OIL MULTINOC NO.2 NITUM MULTINOC WIDE 2 LITUM
MARUXXEN OIL WR-3 NATRIUM WR-3 NATRIUM
DAPHNR CORONEK
IDEMISHUKOSAN LITUM DAPHNE GERASE BENTON
GREASE NO.2
ESSO REACON NO. 325 LITUM TEMPREX N2 LITUM
SHELL ALVANIA NO. 2 LITUM DOLIUM GREASE 2 PORIYUA
CARBURETTING
MOBIL MOBILUX NO. 2 LITUM MOBIL GREASE 28
HYDROCARBON
DAINAMIC GREASE DAINMIC GREASE
DAIKYO OIL LITUM LITUM
MP-2 MP-2
ANTER MULTISERVICE LITUM
BP ENEREASE BP ENERGREASE
BP LITUM BENTNITE
LS-2 HTB 2
REGAL STARFAL
CALTEX
PREMIUM NO. 2
CASTROL
CASTROL
SPHEEROL AP2
DURA-LITH
CHEVRON LITUM
GREASE 2
TEXACO
TEXACO
REGAL AFB2
GULF CROWN
GULF LITUM
GREASE N2
TOTAL MULTIS
TOTAL
EP22
DIAMOND DIAMOND
MISHUBISHI
MULTIPUROPOSE LITUM MULTIPUROPOSE
OIL
GREASE NO.2 GREASE NO. 2
- 37 -
- 38 -
- 39 -
Pressure and Temperature Controls
Data sheet
Pressure transmitters
MBS 5100 and 5150
Danfoss block
components
The block concept has been developed to The range contains pressure controls,
save space, weight, and costs. pressure transmitters, test valves and
The product is intended for use in many accessories.
applications, for example: monitoring, alarm
indication, shut-down, diagnosing on The concept meets the strict demands on ma-
equipment such as motors, gears, thrusters, rine equipment, including EU stipulations on
pumps, filters, compressors, etc. such products.
MBS 5100 and MBS 5150 MBS 5100 and MBS 5150 are block transmit- Advantages
block transmitters ters designed for use in the marine industry. • Compact design
MBS 5150 has a built-in pulse-snubber. • Low installation costs
The transmitters can be easily mounted • Fast and easy to operate
directly on the MBV 5000 block test valve or • Version with pulse-snubber (MBS 5150)
the threaded pressure connection can be used. • Zero point and span adjustment
• Ten ship approvals
• High accuracy and small thermal drift
Approvals • Lloyd’s Register of Shipping • Bureau Veritas

• Det Norske Veritas • NKK, Nippon Kaiji Kyokai
• Germanischer Lloyd • Polski Rejestr Statków
• RINA, Registro Italiano Navale • MRS, Maritime Register of Shipping
• American Bureau of Shipping • Korean Register of Shipping
Dimensions
Plug Pg 13.5, DIN 43650 Plug Pg 9-11, DIN 43650
February 2001 DKACT.PD.P20.Q2.02

520B0787
Data sheet Pressure transmitters MBS 5100 and MBS 5150
Technical data Performance

Accuracy (Incl. non-linearity, hysteresis and repeatability) ±0.1% FS (typ.)
±0.3% FS (max.)
Non-linearity (Best fit straight line) < ±0.2% FS
Hysteresis and repeatability £ ±0.1% FS
Thermal zero point shift £ ±0.1% FS/10K (typ.)
£ ±0.2% FS/10K (max.)
Thermal sensitivity (span) shift £ ±0.01% FS/K (typ.)
£ ±0.02% FS/K (max.)
Response time < 4 ms
Max. operating pressure See ordering table, page 4
Burst pressure See ordering table, page 4
Electrical specification
Rated output signal 4 to 20 mA
Supply voltage, Vsupply (polarity protected) 10 to 32 V d.c.
Voltage dependency < 0.01% FS/V
Current limitation (linear output signal up to 1.5 ´ nom range) 28 mA (typ.)
V supply - 10 V
Max. load, RL RL £ ____________ -10 [W]
0.02 A
Environmental conditions
Operating temperature range -40 to 85°C
Compensated temperature range 0 to 80°C
Transport temperature range -50 to 85°C
EMC - Emission EN 50081-1
Air 8 kV EN 50082-1 (IEC 801-2)
Electrostatic discharge
Contact 4 kV EN 50082-1 (IEC 801-2)
field 10 V/m, 26 MHz - 1 GHz EN 50082-1 (IEC 801-3)
EMC - Immunity
RF conducted 3 Vrms, 150 kHz - 30 MHz EN 50082-1 (IEC 801-6)
conducted 1 Vrms, 10 kHz - 50 MHz RINA, Lloyds Reg.
LF conducted 3 Vrms, 50 Hz - 10 kHz RINA, Lloyds Reg.
burst 4 kV (CM), Clamp EN 50082-1 (IEC 801-4)
Transient
surge 1 kV (CM,DM) at Rg = 42W EN 50082-1 (IEC 801-5)
Insulation resistance > 100 MW at 100 V d.c.
Mains frequency 500 V, 50 Hz SEN 361503
Sinusoidal 20 g, 25 Hz - 2 kHz IEC 68-2-6
Vibration stability
Random 7,5 g rms, 5 Hz - 1 kHz IEC 68-2-34, IEC 68-2-36
Shock Shock 500 g / 1 ms IEC 68-2-27
resistance Free fall IEC 68-2-32
Enclosure IP 65 - IEC 529
Mechanical specification
Pressure connection G 1/4, ISO 228/1 or flange
Electrical connection DIN 43650 plug
versions without flange connection AISI 316L, W.no 1.4404
Pressure connection AISI 316L
Wetted parts,
Plug ETG 88 Zn 10F
material versions with flange connection
Plug gasket W.no. 1.0388 Sn5
O-ring for flange NBR
Housing material Anodized AIMgSiPb
Weight 0.4 kg
Electrical connection
2-wire, 4 - 20 mA
1. Supply +
2. Supply -
3. Function test
Connected to MBS transmitter enclosure
2 DKACT.PD.P20.Q2.02 ã Danfoss 02-2001

MBS 5150 with integrated MBS 5150 has an integrated pulse snubber
pulse snubber for protection of the sensor element against
extreme pressure peaks and pulsations. Such
conditions may be caused by pumps or fast
operating valves in both high and low pres-
sure plants.
The integrated pulse snubber is designed as

an 0.3 mm orifice mounted in the pressure
connection. The medium should not contain
particles which may clog up in the orifice. The
viscosity has only little effect on the response
time. Even at viscosities up to 100 Cst. the
response time will not exceed 4 msec.
Mechanical connection
Thread Flange
Adjustment
Span
–5 ... + 5 % FS
Zero
Pressure range Adjustment
0-1 to 0-10 bar –5 ... +20 % FS
0-16 to 0-40 bar –5 ... +10 % FS
0-60 to 0-600 bar –5 ... +2.5 % FS
DKACT.PD.P20.Q2.02 ã Danfoss 02-2001 3

Ordering of standard
MBS 5100 and MBS 5150
Relative pressure version, G 1¤4 with flange connection, DIN 43650 Pg 11 plug, 4 - 20 mA output
Pressure Max. operating Min.burst MBS 5100 MBS 5150
range pressure pressure
bar bar2) bar1) Type no. Code no. Type no. Code no.
0 to 1 2 50 MBS 5100-1011-1DB04 060N1032 MBS 5150-1011-1DB04 060N1081
0 to 2,5 8 50 MBS 5100-1411-1DB04 060N1033 MBS 5150-1411-1DB04 060N1083
0 to 4 8 50 MBS 5100-1611-1DB04 060N1034 MBS 5150-1611-1DB04 060N1084
0 to 6 20 50 MBS 5100-1811-1DB04 060N1035 MBS 5150-1811-1DB04 060N1063
0 to 10 20 50 MBS 5100-2011-1DB04 060N1036 MBS 5150-2011-1DB04 060N1064
0 to 16 50 100 MBS 5100-2211-1DB04 060N1037 MBS 5150-2211-1DB04 060N1065
0 to 25 50 100 MBS 5100-2411-1DB04 060N1038 MBS 5150-2411-1DB04 060N1085
0 to 40 80 800 MBS 5100-2611-1DB04 060N1039 MBS 5150-2611-1DB04 060N1066
0 to 60 200 800 MBS 5100-2811-1DB04 060N1040 MBS 5150-2811-1DB04 060N1086
0 to 100 200 800 MBS 5100-3011-1DB04 060N1041 MBS 5150-3011-1DB04 060N1087
1)
200 bar for abs. pressure versions
2)
FS £ 300 bar min. 2 x FS; FS > 300 bar min. 1,5 x FS
Ordering of customized
types Type no: MBS 5100- xx x x- x xxxx
Type no: MBS 5150- xx x x- x xxxx
Measuring 0 - 1 bar 10 CA05 M 10 ´ 1 female Pressure

range 0 - 1.6 bar 12 CA07 M 12 ´ 1.5 female connection
0 - 2.5 bar 14 CB02 G 1/8 female
0 - 4 bar 16 CB04 G 1/4 female
0 - 6 bar 18 CC04 NPT 1/4 female
0 - 10 bar 20 DA05 M 10 ´ 1 female with flange
0 - 16 bar 22 DA07 M 12 ´ 1.5 female with flange
0 - 25 bar 24 DB02 G 1/8 female with flange connection
0 - 40 bar 26 DB04 G 1/4 female with flange connection
0 - 60 bar 28 DC04 NPT 1/4 female with flange connection
0 - 100 bar 30
0 - 160 bar 32
0 - 250 bar 34 0 No plug (DIN 43650 A) Electrical
0 - 400 bar 36 1 Pg 11 plug (DIN 43650 A) connection
0 - 600 bar 38 2 Pg 13.5 plug (DIN 43650 A)
Others xx 3 Pg 9 plug (DIN 43650 A)
Pressure Relative 1 1 4-20 mA Output

reference Absolute 2 signal
An order form has been worked out The order form with code no. 991L1099 can
PRESSURE SWITCH TYPE
Specification form
Order specification MBC5000 and MBC5100
DSC Contact person Customer
Order No. Order date Quantity
Code No. Type No. Delivery week

0 6 1 B M B C 5 0 0 - -
Approvals Pressure connection

No approvals ............................................. 0 C A 0 5 M10 x 1 female *
Ship-approvals .......................................... 1 C A 0 7 M12 x 1,5 female *
Other ** ..................................................... X C B 0 2 G1/8 female *
C B 0 4 G1/4 female
C C 0 4 NPT 1/4 female *
to facilitate specification of special be ordered from Danfoss.

Measuring range D A 0 5 M10 x 1 female with flange *
-1 - 1 bar ..................................................................... 1 0 D A 0 7 M12 x 1,5 female with flange *
-1 - 4 bar ..................................................................... 1 2 D B 0 2 G1/8 female with flange connection *
-1 - 10 bar ..................................................................... 1 4 D B 0 4 G1/4 female with flange connection
1-6 bar ..................................................................... 2 2 D C 0 4 NPT 1/4 female with flange connection *
1 - 10 bar ..................................................................... 2 4 X X X X Other **
5 - 20 bar ..................................................................... 3 2
5 - 30 bar ..................................................................... 3 4
5 - 40 bar ..................................................................... 3 6 Electrical connection
10 - 100 bar ..................................................................... 4 2 0 No plug (DIN 43650 A)
Other ** ........................................................................... X X 1 Standard plug (DIN 43650 A), PG11
2 GL approved plug (DIN 43650 A), PG13,5
X Other **
Type
Low pressure below (-1 - 10 bar) ............................................... 1
High pressure below (-1 - 30 bar) ............................................... 2
Low pressure diaphragm (1 - 20 bar) ......................................... 3 Microswitch
MBS block transmitters.

High pressure diaphragm (5 - 100 bar) ...................................... 4 1 0,1A, 250V (AC11); 12W, 125V (DC11)
Other ** ....................................................................................... X X Other **
* On request
** Please state below
Application Medium Medium temperature
Comments / special requirements

991L1100 udg. 12.94
For DN use only

OB-nr. Dato Bekræftet uge Prod. spec. udsendt dato NSP AG-S sign.
ISO 9001 quality approval

Danfoss A/S is certificated in accordance with international standard ISO 9001.
ISO This means that Danfoss fulfils the international standard in respect of product develop-
9001 ment, design, production and sale.
4 DKACT.PD.P20.Q2.02 ã Danfoss A/S AC-TMP 02-2001

Data sheet
Heavy duty pressure controls

MBC 5000 and MBC 5100
Features • Designed for use in severe industrial
environments
• High vibration stability
• Part of the Danfoss block system,
consisting of MBC pressure controls,
MBS pressure transmitters and MBV test
valves
• MBC 5100 with 10 ship approvals
• High repeatability
• Optimal compact design for machine
building purposes
• Intended for alarm indication, shut down,
control and diagnostics in many
applications - motors, gears, thrusters,
pumps, filters, compressors etc.
Ship approvals Lloyd’s Register of Shipping DNV, Det Norske Veritas

MBC 5100 Germanischer Lloyd BV, Bureau Veritas
RINA, Registro Italiano Navale American Bureau of Shipping
NKK, Nippon Kaiji Kyokai KRS, Korean Register of Shipping
Polski Rejestr Statków MRS, Maritime Register of Shipping
For high pressure MBC (piston type) ship approvals are
expected in the second half of 2004
Technical data Performance

± 0.2 % FS (typ.)
Bellows versions
Repeatability ± 0.5 % FS (max.)
± 0.5 % FS (typ.)
Diaphragm versions
± 1 % FS (max.)
± 1 % FS (typ.)
Piston versions
± 1 % FS (max.)
Response time < 4 ms
Max. switch frequency 10/min (0.16 Hz)
Differential see page 3
Permissible operating pressure see page 3
Burst pressure see page 3
Mechanical for diaphragm and bellows > 400,000 cycles
Life time Mechanical for piston type >1 million cycles
Electrical at max. contact load > 100,000 cycles
Electrical specifications
Switch SPDT
AC15 0.5 A, 250 V
Contact load
DC13 12 W, 125 V
Environmental conditions
Bellows versions -40 to +85 °C
Operation
Temperature Diaphragm versions -10 to +85 °C
Piston versions -40 to +85 °C
Bellows versions
Diaphragm versions -50 to +85 °C
Transport
Piston versions -50 to +85 °C
-40 to +85 °C
Enclosure IP 65, IEC 529
20 g, 25 Hz - 2 kHz IEC 68-2-6
Vibration stability Sinusoidal
piston type 4.4g, 25-200 Hz IEC 60068-2-27
INDUSTRIAL CONTROLS IC.PD.P10.A1.02- 520B1771

Data sheet Pressure controls, types MBC 5000 and MBC 5100
Technical data Mechanical characteristics

(continued) Pressure connection Standard G 1/4 female (ISO 228/1) or flange
Option see specification form, page 3
Electrical connection Plug DIN 43650, Pg 9 / Pg 11 / Pg 13.5
Housing Anodized AIMgSi1
Bellows 1.4306 (18/8)
Wetted parts material Diaphragm Viton
Piston Steel
O-ring NBR
Housing AIMgSi1
Enclosure material Plug fixture Glass filled polyamid, PA 6.6
Contact system Silver (AG) microprofile
Weight 0.4 kg
Electrical connection
Adjustment
Mechanical difference
One full turn (360°) of MBC setting screw is approx. equal to 7% of the setting range
Mechanical connection
Thread Flange connection
on MBV Test Valve
Not applicable for piston type
2 IC.PD.P10.A1.02- 520B1771
How to choose To achieve the best operating conditions for MBC pressure controls, it is recommended to apply the
following rules of thumb:
Choose: • the MBC type/types which meet the demands for the operating pressure
• the MBC version with the lowest possible setting range
• a diaphragm type, if pressure peaks and pulsations occur in the system
(if possible)
• bellows types, if low differential is needed
• piston type for high pressure
Ordering
standard types
Type: Setting Fixed Permissible Min. Type MBC 5100 MBC 5000
LP = Low pressure range differential operating burst designation Ship approved Standard
HP = High Pressure Pe [bar] Pe [bar] pressure pressure MBC 5000-/
(typ) Pe [bar] Pe [bar] MBC 5100- Code no. Code no.
LP bellows -0.2 to 1 0.15 to 0.451) 15 30 1011-1DB04 061B000566 061B200566
LP bellows -0.2 to 4 0.15 to 0.451) 15 30 1211-1DB04 061B0004662) 061B200466
LP bellows -0.2 to 10 0.15 to 0.601) 15 30 1411-1DB04 061B0002662) 061B200266
LP bellows -0.2 to 10 0.15 to 0.601) 15 30 1411-1CB04 061B000066 061B200066
LP bellows 0.5 to 3 0.15 to 0.301) 15 30 2011-1DB04 061B002966
LP bellows 1 to 6 0.15 to 0.451) 15 30 2211-1DB04 061B000766
HP bellows 5 to 30 0.40 to 1.51) 45 90 3421-1DB04 061B0003662) 061B200366
LP diaphragm 0.5 to 3 0.25 to 0.801) 150 300 2031-1DB04 061B101766
LP diaphragm 1 to 6 0.30 to 2.01) 150 300 2231-1DB04 061B100966
LP diaphragm 1 to 10 0.30 to 2.01) 150 300 2431-1DB04 061B1004662) 061B300466
LP diaphragm 5 to 20 0.4 to 2.51) 150 300 3231-1DB04 061B1002662) 061B300266
LP diaphragm 5 to 25 0.4 to 2.51) 150 300 3331-1DB04 061B102466
HP diaphragm 5 to 30 1.0 to 7.01) 150 300 3441-1DB04 061B101066
HP diaphragm 5 to 40 1.0 to 7.01) 150 300 3641-1DB04 061B1005662) 061B300566
HP diaphragm 10 to 100 1.7 to 141) 150 300 4241-1DB04 061B1003662) 061B300366
HP piston 16 to 160 12 to 30 600 1200 5251-1CB04 061B500266
HP piston 25 to 250 12 to 40 600 1200 5451 - 1CB04 061B500166
HP piston 40 to 400 15 to 50 600 1200 5651 - 1CB04 061B500066
Lowest differential at min. setting range, highest differential at max. setting range
1)
Preferred versions
2)
Ordering MBC 5000- -

customized types
MBC 5100- -
Pressure connection
Setting range C A 0 5 ............... M10x1 female
-0.2 - 1 bar ..................................................................... 1 0 C B 0 4 ............... G 1/4 female
-0.2 - 4 bar ..................................................................... 1 2 D A 0 5 ............... M10x1 female with flange connection
-0.2 - 10 bar................................................................... 1 4 D B 0 4 ............... G 1/4 female with flange connection
0.5 - 3 bar ..................................................................... 2 0 x x x x ............... Others
1 - 6 bar ..................................................................... 2 2
1 - 10 bar................................................................... 2 4 Electrical connection
2 - 6 bar ..................................................................... 2 6 0 ........................................................ No plug (DIN 43650 A)
5 - 20 bar................................................................... 3 2 1 ........................................................ Pg 11 plug (DIN 43650 A)
5 - 25 bar................................................................... 3 3 2 ........................................................ Pg 13.5 plug (DIN 43650 A)
5 - 30 bar................................................................... 3 4 3 ........................................................ Pg 9 plug (DIN 43650 A)
5 - 40 bar................................................................... 3 6 x ........................................................ Others
10 - 100 bar ................................................................ 4 2
16 - 160 bar ................................................................ 5 2 Microswitch
25 - 250 bar ................................................................ 5 4 1 ....................................................................... 0.5 A, 250 V (AC 15)
40 - 400 bar ................................................................ 5 6 ....................................................................... 12 W, 125 V (DC 13)
Others................................................................................. x x x ....................................................................... Others
Type
Low pressure bellows (-0,2 to 10 bar) ............................................. 1
High pressure bellows (2 to 30 bar)................................................. 2
Low pressure diaphragm (0.5 to 25 bar) ........................................ 3
High pressure diaphragm (5 to 100 bar)........................................ 4
High pressure piston (40 to 400 bar)............................................... 5
IC.PD.P10.A1.02- 520B1771 3
Dimensions
©Danfoss A/S (IC-MC, mr) 01-2004
4 IC.PD.P10.A1.02- 520B1771
Pressure and Temperature Control
Facts and Function
Thermostats and
Pressure controls
Facts and Function
July 1998 IH.20.B2.02

Thermostats and Pressure Controls – Facts and Function
Contents
Foreword Summary .................................. 3 Insulation capability .............. 23
This publication was prepared by Alfred Application ...................................
Renner, Manager for Electromechanical Contact functions ....................... 3 Accuracy – stability – drift .... 24
Laboratory, with the task of coordinating Other selection parameters ....... 4
laboratory activities concerning thermostats Environmental effects ........... 25
and pressure controls. Thermostats/pressure Temperature – humidity –
controls .................................... 5 barometric pressure ................ 25
The publication primarily describes factors that
The three main elements ........... 5 Vibration – shock – pulsation ... 26
are not covered in the data sheets issued for
individual Danfoss products.
Regulation ................................ 6 EMC ........................................ 28
The summary on pages 3 and 4 gives the Regulation – Time constant –
reader an overview of the contents of this Thermostat ................................ 6 Short-circuit resistance ........ 29
publication.
Monitoring Temperature/ Durability ................................ 30
pressure ................................... 9
Competition parameters ....... 31
Reliable alarm ........................ 10
Standards – approvals –
Switch functions .................... 12 EN – CE .................................. 32
Contact main parameters ........ 12
The good class A principle ....... 13 Time constant table ............... 33
The poorer class B principle .... 14
Load categories ..................... 34
Electrical load ........................ 15 Excerpts from EN 60-947-1 ..... 34
Pilot duty ................................. 15 Contact heating – thermal
Factors of significance temperature ............................. 34
in contact failure ...................... 15
Load categories ....................... 16 Index ....................................... 35
Higher electrical
contact loads ........................... 16
The charge in Danfoss (AG)

thermostats ............................ 18
Installation ............................... 20
Grade of enclosure ................ 22

IP xx to IEC 529 ...................... 22
2 © Danfoss A/S 07-1998 IH.20.B2.02

Summary
Pressure/
temperature
Application
Regulation of pressure/temperature
Regulation Important parameters such as the working range and differentials are described in
the respective data sheets. The time constant influences the differential. Its
influence is described on pages 7 and 8.
Tid
Pressure/ Monitoring of pressure/temperature

temperature The required pressure or temperature must be compared with the values given in
Monitoring
our data sheets. Consideration must be given to whether an especially large
Regulation differential or manual reset is required. For this reason, most units can be supplied
with min. or max. reset.
The time constant can be important. Especially with temperature sensors in
Tid air, the time constant can be the cause of the cut-in/cut-out temperature being
exceeded or not being reached. Read more about this subject on pages 7 9. Time-
Pressure/ constant values are given in the tables on page 33.
temperature
Alarm
Monitoring Alarm for too high/too low pressure and temperature
Regulation The same considerations apply to monitoring, except that here it must be decided
whether the following functions are required:
Fail-safe bellows element (both for pressure and temperature) see page 10.
Extra-reliable switch function see page 11.
Tid A short-circuit-protected contact system see page 29.
Contact functions
More than 90% of all Danfoss thermostats/pressure controls incorporate an SPDT
Read more about this subject on page 13
(Single Pole Double Throw) contact system. The contact arrangements shown in
the illustration below are used, but may not be available in all units.
Contact force
Danfoss type KP
Danfos
s type
RT Contact quality
Mikro All contact systems in Danfoss regulating units incorporate a snap-action system
switc Pressure/ that maintains the contact force until the moment of contact break. This
h
temperature
distinguishes them from the many competing products in which microswitches are
Break point used.
Contact force break characteristics of different
contact systems. For further information about
the outstanding qualities of Danfoss Electrical load
thermostats/pressure controls, refer to: For small electrical loads (mA, mV) Danfoss offers units with gold-plated and even
Vibration resistance page 26 double-acting, gold-plated contacts for high cut-in (make) reliability. If these gold-
EMC page 28
plated contacts are used for electrical loads higher than their design load, the thin
Short-circuit protection page 29
layer of gold burns away and the contact then operates as a silver contact. For
heavier duty, most units are equipped with silver-cadmium (AgCdO) contacts.
These are very resistant to contact welding, as described on pages 12 and 16.
IH.20.B2.02 © Danfoss A/S 07-1998 3

Other selection parameters

Temperature The minimum and maximum permissible ambient temperatures from the point of
view of durability, transport and function are given in the data sheets.
See page 25 about changes to the regulation/ As for thermostats, please note that the sensor for certain units must be placed in a
alarm level. colder or warmer environment than the unit housing (bellows) to obtain correct
An explanation of the sensor placement in reaction.
relation to the bellows is given on page 18-19. Other types of thermostats, especially CO2-charged units, can change the
regulation/alarm level depending on the ambient temperature.
Pressure All pressure controls will withstand a certain under/overpressure in relation to their
range setting. In general, their regulation/monitoring parameters are not markedly
affected by up to 1.5 ´ max. range setting. At higher pressure, some deviation of the
set values must be expected. The bursting pressure most often lies >4 ´ the max.
range value.
Vibration If thermostats/pressure controls are installed on vibrating parts of machines, an

assessment must be made as to whether vibration will affect control function and/or
durability. A KP/KPS thermostat/pressure control is vibration-proof in the range
20-1000 Hz, up to an acceleration of 4 g, and consequently it will not cause
problems within these limits. Therefore KP/KPS units are very suitable where
ships approvals are required. The RT series is also very reliable when exposed to
Refer to page 26 for more details on vibration other than its resonance frequency of about 100 Hz.
vibrations.
Where a capillary tube from a control is fastened to a wall, a loop must be fitted. In
particularly severe conditions the use of a steel capillary tube should be considered.
Pulsations High pressure pulsations can impair pressure control function and endurance. The
user must be aware of pulsations and if necessary make sure they are damped.
Damping can be provided by using an orifice in the vapour phase of the pressure
See page 28 for more details on pulsations. medium. Alternatively, a unit less sensitive to pulsations can be used. Danfoss
manufactures pressure controls specially suitable for plant where pulsations are
severe (KPS 43, 45, 47 and CAS 143, 145, 147).
EMC EMC (Electro-Magnetic Compatibility) is a phenomenon associated with electrical

equipment. In the case of pressure controls and thermostats, the contact system cuts
See page 27 for details on EMC in an electrical load and thereby creates an arc. As all contact changeovers occur
within 10 milliseconds in Danfoss products, all EMC standards are automatically
complied with except in the case of types CAS and MP 54/55. However, neither
of these types are used for regulating purposes, and consequently they have an
extremely low frequency of operation.
Physical environment The grade of enclosure, IP, must be chosen to suit the degree of cleanliness,
More details about IP enclosures are given on humidity, etc. in which the thermostat/pressure control is to operate. The range of
page 22. enclosures is from IP 20 (MP 54/55) to IP 67 (KPS).
Installation Installation advice for wall and bracket mounting are given in the instructions
See page 20 – 21 for details. accompanying the units. The physical orientation of units is also given when such
information is required.
Short-circuit protection According to the new standard, IEC 947-5 (EN 60-947-5), suppliers of automatic
controls must state the maximum size of prefuse to ensure that thermostat/pressure
See page 29 for a description of short-circuit
protection. control contacts do not weld together when conducting a momentary short circuit
current.
4 © Danfoss A/S 07-1998 IH.20.B2.02

Thermostats/pressure controls
The three main elements
1. Setting element
2. Switch element
3. Sensor element
(the driving element)
The illustration shows an actual pressure control of

the RT type.
5. Setting knob
12. Main spring
15. Main spindle
17. Guide bush
19. Differential setting nut
23. Bellows element (Sensor element)
27. Connection (Pressure/Temperature)
Pressure/temperature
IH.20.B2.02 © Danfoss A/S 07-1998 5

Regulation
All Danfoss thermostats and pressure controls have a given temperature-pressure
range which can be set by the user from a scale on the unit. The given cut-in/cut-out
pressure/temperature is indicative only. For accurate settings a pressure gauge or a
thermometer must be used.
Range Differential Differential

(Lower pressure/temperature = constant) (Upper pressure/temperature = constant)
Read-off value Read-off value Read-off value
t
poin Max. Min.
wi tch Min. Max.
er s diff. diff.
Upp diff. diff.
int
itc h po
e r sw
Low
Set value Set value Set value
Turning the range screw (spindle) moves The pressure/temperature for falling value The pressure/temperature for rising value
both contact switch points. remains constant when the differential remains constant when the differential
Most thermostats and pressure controls setting is changed. It therefore represents setting is changed. It therefore represents
incorporate SPDT contacts, and the range scale reading. the range scale reading.
consequently the switch point Pressure/temperature for rising value can Pressure/temperature for falling value can
designations for make and break must be be changed with the differential setting be changed with the differential setting
supplemented by information stating spindle. spindle.
whether these functions apply to rising or This is the principle on which the KP/KPS
falling temperature/pressure. This applies to most RT types. series is based.
Switch function In control and regulation tasks it is important that contacts operate in accordance
See page 13 for a description of the Class A with the Class A principle. This ensures that contact pressure is maintained until the
principle switch function starts. It is on this principle that Danfoss types such as RT, KP, KPS
and CS operate.
Regulation – Time Constant – Thermostats

This chapter provides insight for those who t is significant, not only for the
would like to further explore details and for those regulation technician(t: time constant).
who would like to know why a thermostat set for,
say, 60°C does not always cut out at that A classic example of this can be
temperature. The laws of nature can indeed
observed when a thermostat with an
cause significant deviations.
immersion sensor in a pocket is to
control a modern boiler unit with very
little water volume. As an example, let
us choose a time for setting when the
heating consumption is very low, e.g. a
spring or autumn day. The temperature
of the medium (water) can then rise by
several degrees C per minute and an
otherwise correctly set break
temperature of, say, 60°C will be
increased several degrees.
The following two pages deal with this

subject.
6 © Danfoss A/S 07-1998 IH.20.B2.02

Definition Fig. 1
The time constant of a thermostat is an thermostat. In practice, the time
expression of the rate at which it reacts to a constant is not a certain figure for a
temperature change. certain thermostat but rather a
In the following, t (tau) represents the time magnitude associated with the
constant and ] (theta) the temperature. conditions in which the thermostat
When the thermostat sensor is subjected to a operates. Thus the time constant
sudden temperature change (step function in depends on air/liquid flow, sensor
fig. 1, on the right), the time constant t is location in the sensor pocket and
equal to the time elapsed from start until 63% similar factors.
of the change has been registered by the
Measured function
E-function
Bath Pocket Sensor
Parallel resistance caused

by physical contact
The temperature gradient in a thermostat a pocket) reveals the many combined e-function precisely because the charge is not
sensor seldom occurs as a pure e-function thermal resistances and capacities. In subjected to the step function as the last part in
conditional on an R-C link, i.e. a thermal electrical terms, it can be clearly seen that the thermal chain. Such a step function
resistance and a thermal capacity. the temperature change in the C4 charge of (conditional for the e-function) is only “perceived”
The example illustrated above (i.e. a sensor in the sensor cannot follow the applied as such by components r1 and C2 in the sketch.
Time constant – practical In practice, temperature step functions such as those explained in the above box
significance occur only rarely. On the contrary, we normally see temperature changes at
different rates, socalled temperature gradients.
The three figures below show the temperature gradient (K = -t/min) in a bath or air
duct and the reaction of a random thermostat sensor (sensor temperature) to the
gradient.
Sensor temperature
Sensor temperature
Sensor temperature
Fig. 2a Rising temperature Fig. 2b Falling temperature Fig. 2c Rising and falling temperature
IH.20.B2.02 © Danfoss A/S 07-1998 7

In other words, the sensor temperature always lags behind the temperature of the
The following formula is useful to calculate
medium. Thus, in fig. 2c the curve 'sensor temp.' is after the curve 'K = -t/min.'
the correct differential:
(temperature of medium). The thermostat reacts when the sensor temperature has
Dx = D0 + 2 ´ t ´ Dt/min reached ]2 and ]3 respectively.
where The difference between ]2 and ]3 is the differential of the thermostat itself, Do, and
Dx = the differential observed by the it is the values for Do that are given in Danfoss data sheets.
customer = differential of medium
Do = the inherent differential (factory-set However, the customer will take the difference between ]4 and ]1 (temperature of
by Danfoss) medium) as being the differential of the thermostat and compare it with values
t = time constant under actual conditions provided in Danfoss data sheets.
(Normally available from Danfoss) The cause of this nonconformity is precisely the effect of the time constant and
-t/min = actual temperature change rate
temperature gradients on the differential.
observed by the customer.
Note: The temperature gradients for rising The diagrams in the boxes below may also be used to determine switch
and falling temperatures are not always temperatures and differentials.
identical. When they are not, both switch
points must be calculated separately using Example 1 Ds, Df = t x Dt/min
the following formula. In the example, the desired
On rising temperatures: cut-out temperature of an
RT4 thermostat is 60°C.
Sx = S0 + t ´ Dts/min
Temperature gradient:
0.8°C/min.
on falling temperatures:
Fx = F0 – t ´ Dtf/min Media flow: 1.5 m/s

As appears from the table on
page 33:
and then
\ = 1.5 min (90 seconds at
1.5 m/s)
Dx = Sx – Fx
As appears from the
Tables of time constants are given on page 33. diagram, -S = 1.2°C
Result: The thermostat must be set at 58.8°C
Eksempel 2
Dd = Ds + Df = 2 x t x Dt/min
If conditions are the same as
in the the example above,
then how large will the actual
differential be when the
inherent differential D0
(according to the data sheet)
is 3°C?
(Temperature gradient on
rising and falling temperatures
is the same: 0.8 °C/min.)
As appears from the diagram,

-d = 2.4°C
Result: Actual differential = 5.4°C
8 © Danfoss A/S 07-1998 IH.20.B2.02

Monitoring temperature/pressure
Pressure/
Definition temperature
If a thermostat/pressure control is used to
monitor whether a temperature or pressure-
regulated magnitude is maintained under or
over a given limit the unit is called a limiter. Monitoring
Regulation
(Limiting)
Tid
Selection parameters 1. Using the data sheets, the correct temperature/pressure range must be selected
in order to meet the monitoring level requirements.
2. It must then be decided whether the unit must automatically or manually reset
on receiving a fault (warning) signal.
2.1 If automatic reset is required, the next step is to decide the temperature/
pressure at which reset is to occur. The differential setting of the unit must
make reset possible.
2.2 If automatic reset must not occur, a manual reset unit (rising or falling
temperatures/pressures) must be selected.
2.3 It must be decided whether a manual reset function is to be performed only
with the aid of a tool, and, for example, only after the cover has been
removed.
2.4 With thermostats/pressure controls for monitoring it must not be possible to
override (sustain cut-in) by activating the reset function. Reset must only be
possible after the temperature/pressure change has reached a certain value on
the good side (reset differential). The value is always stated in the data sheet.
3. To avoid unintentional change of the setting parameters, units can be lead-
sealed.
4. Consideration must be given to whether the monitoring function is so
important that a fail-safe bellows element is required. See next page.
The photo shows

units for oil/water/
fuel monitoring for
a diesel engine.
IH.20.B2.02 © Danfoss A/S 07-1998 9

Reliable alarm
Function A thermostat/pressure control can be set to trigger an alarm when a set limit value
for temperature/pressure is exceeded or not reached.
Pressure/
temperature
Regulation Alarm
Tid
Because operational failure is a threat to
life and might mean serious economic
consequences, it is important that
consideration be given to the following
points when selecting components for
alarm systems:
• Fail-safe bellows
• Reliable switch function
• Short-circuit protection
• Low and known time constant (thermostat)
• High grade of enclosure
Fail-safe bellows element Within the RT and KP series, Danfoss offers pressure controls with double bellows.
The inner, smallest bellows is the operating bellows (refer to the illustration, where
the medium is hatched in dark grey). In the event of leakage from the inner bellows
The fail-safe function in Danfoss

thermostats (refer to text on next
page):
There is vacuum between the two
bellows (the lightly hatched area in
the sketch) and if the outer bellows
begins to leak, air at atmospheric
pressure (1 bara) enters the bellows.
The bellows will thus activate the
contact system to signal that fail-safe
is out of action.
10 © Danfoss A/S 07-1998 IH.20.B2.02

the medium escapes into the outer (largest) bellows which, because of its large area,
immediately moves to activate the contact system.
In this way the pressure control signals that it is defective - without allowing the
escape of the medium into the atmosphere.
In thermostats, the fail-safe function is provided by allowing the thermostat charge

to act on the vacuum side. In the event of bellows leakage, air at atmospheric
pressure will enter and cause contact break.
These products can be justifiably called Safety units and fulfil the requirements
of VBG20 and DIN 32733.
Reliable switch function Alarm sources are often designed for 12-24 V supply voltage. At such voltages,
switch function can be problematic, e.g. because of oxidising of the contacts.
Hence, Danfoss has introduced gold-plated contacts that are more resistant to the
aggressive gases that may be used in these types of applications.
Ordinary
switch
Another and yet more reliable way is to allow the thermostat/pressure control to cut
out a 3-pole relay on 230 V. In an alarm situation the relay can cut in current to the
alarm source by coupling all three contact sets in parallel. This significantly
increases the cut-in reliability of the 12-24 V alarm source.
A third alternative is very simple and reliable. The alarm source, which here lies
directly above the switch, is activated when the switch contacts open. However, a
resistance, R, must be calculated and inserted to adjust the impedance of the alarm
source so that when the contacts close the current is the least possible, and so that
when the contacts open no more than about 10% of the supply voltage is applied to
the resistance R while the remaining about 90% of the supply voltage is applied
to the alarm source.
Short-circuit protection All thermostats/pressure controls must be prefused so that short-circuit current
cannot cause contact welding. In case of contact welding, the alarm system will fail
See page 29. because mechanical contact separation becomes impossible.
Time constant A thermostat with a small time constant must be selected (preferably without
pocket for sensor) or, when setting the alarm temperature, account must be taken of
the time constant - as appears from the formulas on page 8: Sx = So + \ ´ -t/min or
Fx = F0 \ ´ -t/min..
Enclosure It is important that the thermostat enclosure be tight and robust because the contact
system especially if it is to perform a cut-in function must be protected against
dust, dirt and oxidising.
IH.20.B2.02 © Danfoss A/S 07-1998 11

Switch function
Contacts The heart of all contact systems is of
course the contact set. Danfoss uses three
Danfoss has accumulated a great deal of
knowledge on contacts, the theory behind
forms of contact:
Contacts for welding or riveting in. 0.3 mm AgCdO on a base of Fe
them, their manufacture, suitability and
application possibilities. Silver wire which is welded and Contact material is selected to suit the ex-
formed into contacts. pected application of the unit. Danfoss uses
Danfoss also cooperates widely with contact The production is carried out in contacts made of the following materials:
suppliers and closely follows what is Danfoss' own factories Ag : 99% Ag (high-purity silver)
happening within international research in this Contacts from a subsupplier, on AgNi : 90% Ag, 10% Ni
area. AgCdO : 90% Ag, 10% CdO
a finished base.
AgAu : 3-5 Tm Au plating on an Ag,
AgNi or AgCdO contact
Contact main parameters

1. Contact resistance The area over which contacts actually meet (contact spot) is microscopic. It is
important that the contact resistance over these areas remains low typically
0.1-1 mA so as to avoid harmful voltage drop across the contact and consequent
heating up.
2. Contact cut-in reliability With monitoring and alarm applications in particular it is important that electrical
contact be made when the contacts are correctly brought together by mechanical
means. Oxidising caused by different gases as well as the presence of dust particles
can obstruct this process.
3. Contact welding When electrical loads are high, so much heat is generated in the areas where
contacts meet that the contact material can melt. This heat generation comes mainly
from the energy content of the arc formed when the current is cut in. It is important
that this does not lead to local contact welding and consequent obstruction of the
break function. One way of avoiding contact welding is the presence of oxygen in
the AgCdO contact surface (see illustration at top of page).
4. Contact life Danfoss normally designs thermostats/pressure controls to give 10 years of contact
Danfoss regularly conducts life tests, see life. The contact must be capable of operating for this length of time under max.
page 17. rated electrical load.
It is impossible to fulfil all these conditions to the optimum with one contact
Warning material. Generally, requirements/capabilities are listed as follows:
Here, we must point out the danger of using
silicone oils. The least amount of silicone can Function requirement Most suitable material Danfoss recommends/supplies
lead to contact damage after just a few Low contact resistance Ag
operations. Au plating on Ag or AgNi contact
High cut-in (make) reliability Au
The reason is that heat from the break arc
creates silicon which in connection with No contact welding AgCdO
AgCdO
atmospheric oxygen becomes SiO2 = quartz. Long contact life AgNi
The quartz crystals are deposited on contact
surfaces and because of their high transition In cooperation with contact suppliers, our aim is to replace the not very
resistance generate very high temperatures. environmentally friendly AgCdO (silver cadmium oxide) with another material
This gives good conditions for arcing which having the same good properties as regards the avoidance of contact welding.
again creates SiO2 – and so on. However, this
process starts only when the load across the
contacts is so high that arcing occurs on
break.
12 © Danfoss A/S 07-1998 IH.20.B2.02

Contact system types

EN 50005:
Designation used: SPST SPDT DPST DPDT TPST

Single pole Single pole Double pole Double pole Three pole
Single throw Double throw Single throw Double throw Single throw
Contact system classes Cutting electrical current in and out nearly always involves a momentary contact
changeover, i.e. a snap action contact system. As shown below, there is good
reason to divide this momentary contact changeover into two widely differing
classes: Class A and Class B.
The good Class A principle

Contact force K On the diagram, the contact force is shown as a function of the
pressure/temperature of the bellows:
a gives the maximum contact force immediately after the cut-
in function.
Diff.
b gives the minimum contact force immediately before the
Pressure/ cut-out function.
temperature
The diagram shows that the contact force is always positive.
As shown on the oscilloscope readout (illustration below) the
switch function is instantaneous.
Break time < 1 ms The time during which the contact force approaches 0 is very
short. The oscilloscope readout shows that the break time is £ 1
millisecond.
1 tern = 1 ms
The diagram shows the contact force curves for three Danfoss
Contact force K
units, KP, KPS and RT.
On the diagram,
a gives the maximum contact force immediately after the cut-
in function.

cut-out function.
Pressure/
temperature As appears from the diagram, the contact force is sustained until
a b the moment of break.
Therefore, this system is a typical Class A system.
IH.20.B2.02 © Danfoss A/S 07-1998 13

Contact force K
The poorer Class B principle
Diff. Pressure/temperature change rates determine for how long
time the contact forces approximate 0.
In the diagram,
Pressure/ a gives the maximum contact force immediately after the
temperature cut-in function.
cut-out function.
As shown on the oscilloscope readout (illustration below)
the switch function takes a considerable time.
Initiation Cut-out
The oscilloscope readout illustration shows that the break
time lasts several seconds. This is because the contact force
gradually approaches 0 before the break snap occurs.
1square = 2 s Break time

approx. 14 s.
Contact force K
The curves in the diagram show contact forces going
towards 0 in selected Class B contact systems. It is on this
principle that nearly all thermostats and pressure controls
with a microswitch or similar device operate. Various
Class B
problems can arise from this principle, as described in the
contact systems
box below.
On the diagram,
a gives the maximum contact force immediately after the
cut-in function.

a b Pressure/
temperature
cut-out function (»0).
Many manufacturers of thermostats and pressure controls do use a Class B Summary Class A Class B
contact system for regulating purposes in their units. Vibration resistance Good Poor
The reasons are:
EMC resistant Yes No
The good Class A system
1. is more expensive to manufacture, Suitable for relay control Yes No
2. all other things being equal, it operates with larger pressure Electrical load stability Good Poor
and temperature differentials. Short-circuit protection Good Poor
14 © Danfoss A/S 07-1998 IH.20.B2.02

Electrical load
Pilot duty (dry circuits)
Contact reliability at low The use of PLC or corresponding electronic control is spreading rapidly. This in-
voltages creases the use of signalling devices in the low voltage area. If standard pressure
controls/thermostats are used on low voltages and currents there is a risk of electrical
contact function not being performed even though the mechanical arrangement of
the contact system is correct. Typically, we are dealing with a low-energy area (dry
circuits) with voltages between 5 and 24 V and currents of a few milliamperes.
Control load
The electrical load comes from contactors, solenoid valves, transformers, etc.
In this load category small voltages are used to an increasing extent, as one
consequence of the requirements of EN 60 204-1, clause 9. Here, contact failure as
mentioned under Signal load will occur very seldom since current from control
loads (and low voltage) will be significantly higher and thus have a cleaning effect.
Factors of significance in contact failure

1. Voltage/current level No lower limit can be given for signal/control voltages, but lower voltage across
the contacts increases the risk of contact failure. The size of current has no direct
influence on the occurrence of contact failure, but higher current will be better from
the point of view of preventing oxidation, dirt deposition, etc.
2. Choice of contact material Normal contact materials are chosen to withstand high make and break currents,
e.g. 16 A full load current and 112 A start current. However, units can often be
supplied with gold contacts which are particularly suitable for low voltages. The
contact resistance is low and the contacts are not susceptible to oxidising.
3. Selected contact force The typical maximum contact force for common thermostats and pressure controls
is in the range 0.2 - 0.3 N (20 - 30 pond). This contact force falls perhaps right to 0
as the break pressure or temperature is approached. KP units have a high contact
force of 0.3 - 0.5 N (30 - 50 pond) and sustain it right up to the moment of contact
changeover, as described on page 13.
4. External environment The external environment can subject contact surfaces to oxidising and dirt deposition.
The former can be prevented by using gold contacts, the latter by tight and robust
enclosures that minimise the ingress of dirt and the risk of contact obstruction.
IH.20.B2.02 © Danfoss A/S 07-1998 15

Load Categories
AC11à AC14/15 It can be seen from apparatus/contact system marking, data sheets and international
DC11à DC13/14 standards (IEC) that these signal loads are designated AC14, AC15, DC13, DC14
(previously AC11 and DC11).
AC14: Control of smaller electromagnetic AC loads (£72 VA).

See page 34 for more details. AC15: Control of electromagnetic AC loads (> 72 VA).
DC13: Control of electromagnetic DC loads.
DC14: Control of electromagnetic DC loads with economy resistor in the circuit.
Customer selection Since there is no definable limit for minimal currents and voltages a contact system
is able to deal with reliably, the following table gives indicative values.
Load examples Expected no. of operations per year

10 1.000 10.000 >>10.000
12 V - 5 mA Au Au Au Au
12 V - 10 A Au Au Au Au
48 V - 1 A Au Au Au Ag
48 V - 10 A Au Au Ag/AgCdO Ag/AgNi/AgCdO
230 V - 1 A Au Ag/AgNi/AgCdO Ag/AgNi/AgCdO Ag/AgNi/AgCdO
230 V - 10 A Au AgCdO AgCdO AgCdO
Au: Gold-plated contacts
Ag: Silver contacts
AgCdO: Oxidised silver cadmium contacts
AgNi: Silver nickel contacts
For a description of the composition of the contact material, see page 12.
In many cases where Au contacts are recommended, the gold plating will be burnt
away before the end of the life of the unit. This is correct but without significance
because it has to be remembered that under the gold plating is an Ag, AgNi or
AgCdO contact which might have been chosen in any case.
Therefore the conclusion must be: If in doubt, use gold-plated contacts.
Higher electrical contact loads

All thermostats/pressure controls are marked with a max. electrical load.
The table shows the max. electrical load for KP units.
Load category max. electrical load Load
AC1 16 A - 400 V Ohmic load
AC3 16 A - 400 V Motor load
AC15 (previously AC11) 10 A - 400 V Coil/trafo/control load
Max. L.R. load 112 A - 400 V Max. start current (locked rotor)
DC13 (previously DC11) 12 W - 220 V Direct current load
Contact bounce The most important factor in achieving good electrical switch characteristics is the
contact bounce times within the unit concerned. Bounce time is the time that a pair
of contacts take to fall to rest after a cut-in (make) function (A useful analogy is a
hammer and an anvil).
16 © Danfoss A/S 07-1998 IH.20.B2.02

Contact bounce Typical bounce times lie in the range 1 - 10 ms. During some of the bounce time,
when the contacts are open (lowest line on the oscilloscope readout) an amount of
energy is generated, Uarc x Ilocked rotor. This may lead to light contact welding. To a
certain extent, such welding is countered by contact material AgCdO (see page 12).
The oxygen content of AgCdO has this favourable effect.
However, it is always better to tackle the problem of contact welding at its root in
this case contact bounce.
After extensive research we have been successful in reducing bounce times in KP

units to the Ts range. KP bounce times thus lie in the range 10 - 15 Ts and since the
x-axis: 1 ms (millisecond) per square locked rotor current (inductive load) reaches its peak value only after about 5 ms, it
can be seen that KP bounces and cuts in long before current arc energy builds up.
Contact welds Contact welds seldom consist of total surface welding. The condition nearly always
involves small, local welds that can be broken again by light impact. In most cases
the user will not register such lighter welds.
At Danfoss we define harmful contact welding thus:
A contact is welded if its own force is not sufficient to separate it, even though the
pressure/temperature has exceeded the break setting by +30% of the differential
pressure/temperature.
General on AC load The current to be cut in is important. Take account of the start currents of motors/
coils/transformer/lamps and compare them with the marking on the unit. The
normal absence of problems at break is because the arc is extinguished on the zero
passage of the sinusoidal curve. The max. rated voltage of the unit is determined on
the basis of insulation capability, creep distance and contact gap. Thus, in practice,
using the unit on voltages lower than actual rated voltage does not allow the
switching of higher currents, nor does it give longer operating life.
General on DC load Here the condition is reversed: The current to be cut out is important.
1. The problem is that the arc is not automatically extinguished on cut-out. (Here,
both current and voltage are equally important parameters).
2. Contact material migration (since anode and cathode always lie on the same
contact) limits contact life.
All normal thermostats/pressure controls have a low rating for direct current. The
reason for this is that the requirement for the lowest possible differential results in
small contact gaps (0.2-0.5 mm).
An accelerated life test takes 8 days to

perform. During that time, data on the
following fault possibilities are collected
automatically:
1. Contact welding.
2. Burning away of contact material.
3. Changes in set pressure/temperature.
The photo shows some of the test

equipment. 6 x 10 thermostats/pressure
controls can be tested at the same time.
The build-up and operation of the test
equipment and the entire test procedure
meet the requirements of international
standards EN 60 730 and EN 60 947.
These standards have been drawn up to
replace many different national standards.
See page 32 for a description of national and
international standards.
IH.20.B2.02 © Danfoss A/S 07-1998 17

The charge in Danfoss (AC) thermostats

Charge Charge Charge Charge
Name Content Behaviour Function
The element contains a small quantity

of liquid and its saturated vapour.
Gas
Condensation always occurs at the
Vapour coldest point in the element and
Vapour therefore the sensor must be the
charge Saturated
coldest part.
vapour
Pressure in the element is determined
liquid only by the temperature of the liquid.
Principle as above, but the liquid

quantity is large enough to fill the
bellows element when it is coldest.
The transition liquid/vapour then lies
in the warmer sensor and therefore it
Partial is here the pressure is determined.
charge
Here the sensor must always be the
warmest part.
Principle as above, but the sensor and

liquid quantity are so large that the
transition liquid/vapour is always in
Universal the sensor, i.e. at level 1 when the
sensor is coldest and at level 2 when
charge the bellows is coldest and thereby
(cross- filled with liquid. Hence the name
ambient) cross-ambient.
The carbon particles, always in the

sensor, have a very large surface
area. In the rest of the element there
is superheated gas, normally CO2
Carbon (carbonic acid gas).
charge
(adsorption) The ability of the carbon to bind/
release CO2 molecules varies with the
temperature, in accordance with the
S-curve shown on the left.
18 © Danfoss A/S 07-1998 IH.20.B2.02

Selection parameters
constant
Time
limitation
Pressure
differential
Min.
volume
Sensor
when
in sensor
Reaction
temp. influence
Ambient
Charge Charge Examles of
Advantages Disadvantages DANFOSS
thermostats
Fast reaction charge. Use units with this charge only RT 3, 4, 9, 10 Very low in Extre- Least Yes Sensor No
where the sensor is the coldest RT 11, 17, 13 warm part of mely colder
Pressure limitation at part of the element. range low than
overtemperature. KP 61, 62, 63 bellows
KP 68, 69
Element pressure completely Because of vapour pressure
independent of ambient gradient, differential very
temperature. dependent on range setting.
Very small sensor.
Fast reaction charge. Use units with this charge only RT 107, 120 Very low in Low Normal No Sensor No
be where the sensor is the RT 123, 124 warm part warmer
Element pressure completely warmest part of the element. of range than
independent of ambient bellows
temperature. Because of vapour pressure
gradient, differential very
dependent on range setting.
Reaction always in sensor. Has very large time constant RT 106 Very low in High Highest No Always No
when the liquid must “move” warm part
from bellows to sensor and vice of range
versa.
Very large sensor volume.
Reaction always in sensor. Low element pressure gradient RT 2, 7, 8, 12, Higher than Normal/ Normal Partly Always Yes
most often means slightly higher 14 above, but high
Differential mostly independent min. obtainable differential. RT 15, 23, constant in Infor-
of range setting. 101, 140 range mation
Element pressure also affected available
Quite good pressure limitation by bellows temperature, which KP 62, 71, 77, in
because of low element leads to a certain degree of 79 Danfoss
pressure gradient at high capsule sensitivity. KP 75, 81, 98 data
temperatures. sheets
KPS 76, 77,
79
KPS 80, 81,
83
IH.20.B2.02 © Danfoss A/S 07-1998 19

Installation
Ideal and unsatisfactory In general, Danfoss thermostats and pressure controls can be installed in any
installation position.
Note however: for thermostats in particular the physical orientation can be
important in ensuring optimum control and making full use of the excellent
parameters of the unit. External factors are often the reason why the required
function cannot be obtained as shown in the illustration below.
Properly installed unit Unsatisfactory installation

1. Insulated wall and sensor pocket entry. This illustration shows how not to install a
2. Sensor well immersed. The medium, air thermostat. Here, a large quantity of heat is lost
or liquid, right up to bath/channel wall. from the medium to the surroundings via the
3. Correct flow direction over whole sensor pocket/sensor. This heat flow creates a
length. temperature gradient that together with
4. Use of contact compound (metal paste) inadequate immersion in the medium means
between sensor and pocket. many °C deviation and a significant increase in
the differential.
Installation tips and tricks Remember that the differential is affected by air circulation around the sensor.
Excessively low air circulation can increase the differential by several degrees C.
Consequently, place the room thermostat so that air is able to circulate freely
around the sensor. Also make sure that the thermostat is not exposed to draughts
from doors or radiation from heating or cooling surfaces.
Never place the thermostat directly on a cold wall. Such a placement increases
the differential. Instead, mount the unit on an insulating board.
When selecting a thermostat/pressure control it is necessary to take account of

which media the driving element (sensor/pocket/bellows element) will be
Place the room thermostat so that air is exposed to.
able to circulate freely around the sensor.
20 © Danfoss A/S 07-1998 IH.20.B2.02

Installation tip for pressure controls: To avoid dirt entering the regulating or monitoring pressure control,
always use counter-force when tightening always connect pressure lines on the top of main pipes.
pipe joints.
Pressure controls and When selecting a thermostat/pressure control it is necessary to take account
thermostats in contact with the of which media the driving element (sensor/pocket/bellows element) will be
medium exposed to.
For NH3 (ammonia) use only pressure controls with an A after the type
designation and thermostats with sensor pockets made of 18/8 steel never brass.
For seawater mainly use pressure controls with a brass capsule, e.g. RT 200, KPS
43, 45 or 47. Thermostats should have a brass sensor pocket.
For the food and chemical industries, pressure controls with an isolating
diaphragm should be used for reasons of hygiene, to facilitate cleaning, etc.
Naturally, many other media can come into contact with the drive element or
sensor/pocket, and therefore the data sheets give the material combinations Danfoss
uses for components in contact with media.
IH.20.B2.02 © Danfoss A/S 07-1998 21

Grade of enclosure
IP xx to IEC 529
IP testing All products must undergo a number of tests to obtain an IP grade of enclosure
certification. The IP classification contains two digits, the first IP digit denoting the
IP: Ingress Protection
degree of enclosure against foreign bodies, the second digit denoting the degree of
watertightness. The two photographs show the test equipment, whereas the table
shows the requirements to the unit:
IP 1st IP 2nd
digit Foreign body Test digit Watertightness Test1)
0 No test 0 No test
1 A ball of Æ50 mm cannot enter 1 Vertically falling drops, dripping water
2 A ball of Æ12.5 mm and a test probe of Æ12 mm, 2 Vertically (±15°) falling drops
L = 80 mm, cannot be inserted
3 A rod of Æ2.5 mm cannot enter 3 Water sprays ±60° from vertical
4 A wire of Æ1 mm cannot enter 4 Water sprays from all directions
5 As 4 + Dust in amounts that might cause damage 5 Water jets from all directions, 12 l/min
cannot enter
6 As 4 + Dust cannot enter 6 Water jets from all directions, 100 l/min
7 Immersion in 1 m water
8 Subject to agreement
1) After all these tests, water in amounts that might cause damage must not have entered the enclosure and not have collected in electrically conductive
parts or cable entries.
Danfoss IP classification After being subjected to the above tests in Danfoss laboratories, Danfoss
thermostats/pressure controls have been given the following IP classifications:
KP standard: IP 33
MP 54/55: IP 20 KP with top plate: IP 44
KP with enclosure: IP 55
RT standard: IP 66 KPS: IP 67
RT with ext. reset: IP 54 CAS: IP 67
When selecting enclosures for thermostats/pressure controls it must be emphasized

that a higher IP classification not only gives a higher degree of sealing against
foreign bodies and water, but also a higher degree of robustness as regards
mechanical influences such as shock and impact.
22 © Danfoss A/S 07-1998 IH.20.B2.02

Insulation capability
The insulation capability of a thermostat/pressure control is determined by the
creepage distance, clearances and distance through insulation between conductive
parts and the frame, by the resistance to heat and tracking test of the plastics used,
and also by the gap between open contacts.
High voltage test Insulation capability is given by a voltage, Ue, that might well be higher than Un as
given together with the various load categories (AC1, AC3, etc.).
The size of the test voltage that thermostats/pressure controls must be able to resist
between electrically conductive parts and parts that might be touched (frame)
depends on the insulation voltage, Ue.
EN 60 947-5 (IEC 947-5) gives the following test voltages:
Insulation voltage (V) of unit Test voltage Ueff. (V)

Ue £ 60 1.000
60 < Ue £ 300 2.000
300 < Ue £ 690 2.500
A test voltage of 2 x Ue between open points of contact is normally the requirement.
High voltage test
Unit pulse voltages (Uimp) can be given on request. Danfoss has equipment able to
produce the special pulse form with half-period times of 1.2 and 50ms.
Tracking index test The tracking index safety of the insulation material is tested in accordance with
IEC 112. Two electrodes with a gap of 4 mm between them are led down towards
the insulation material. Fifty drops of dissolved ammonium chloride (NH4Cl) are
dripped down between the electrodes. Two seconds after each drop fall, the
creepage current, through the insulation material, must be less than 0.5 A.
The voltage across the electrodes that does not produce current of >0.5 A is the
approved CTI value of the unit. CTI stands for Comparative Tracking Index.
RT and KP/KPS contact systems contain basic materials with CTI values of CTI
225 and CTI 375 respectively.
Tracking index test
Glow-wire test The fire resistance of the insulation material is examined using standard glow-wire
test equipment. The equipment build-up and the test are in accordance with
EN 60 730 and IEC 695 part 2.
Test sequence: When the glow-wire has reached the required temperature
(e.g. 850°C) a piece of insulating material is pressed against it with a force of
1 N (100 p). After 30 seconds, the glow-wire is removed. The test is passed if fire
or smouldering ceases not later than 30 seconds after removal of the glow-wire.
Thus, as regards insulation capability, the customer does not face making a choice.
All materials used, gaps and designs ensure that authority requirements are met
and that in practice no problems occur with units.
In addition to the tests described on this page, Danfoss of course ensures that the
plastics used for safety purposes are resistant to cold, heat, humidity, mechanical
effects, etc., and that the electrical resistance measured at 500 V lies in the MW
Glow-wire test area.
IH.20.B2.02 © Danfoss A/S 07-1998 23

Accuracy – stability – drift

Note: accuracy, stability and driftt are three With electronic temperature/pressure meters (also known as transmitters) the output
sides of the same thing accuracy, stability, linearity, temperature drift and long-term drift are often given as
a percentage of the max. range. Such earnestness is unknown among manufacturers
of thermostats and pressure controls, a normal set of specifications being far less
comprehensive. The following describes how Danfoss thermostats/pressure controls
look in the light of some of the above factors.
Pressure/
temperature
Cut-out
setting
Cut-in
setting
Inaccuracy Instability Drift
Switching time
Accuracy – also known as The term accuracy applies to unit scales. The cut-in/cut-out pressures/
„Deviation“ temperatures are set on the scale and thus it is expected that the operation
concerned will occur when the settings are reached. In other words, we talk about
scale accuracy. However, scale values are only indicative. It is often necessary to
use a thermometer/pressure gauge when setting working points.
The scale accuracy of Danfoss units are as follows (approx. values):
Adjustable units Factory-set units

KP/KPS : ±10% of max. KP/KPS : ±5% of actual
RT : ± 6% range RT : ±3% set value
Stability If stability is to be understood as how stable the working points of the unit are
for, say, ten continuous operations, then Danfoss products are outstanding. For
example, the stability of the RT series is better than 0.5% of the actual working
point.
Some types of thermostats in particular are
prone to inaccuracy and instability as a result The instability (expressed by the figure 0.5%) will not be experienced in real-life
of changes in the ambient temperature: see situations, because working points are always affected to some extent by factors
pages 18-19. such as the ambient temperature, the barometric pressure, extraordinary
temperature/pressure variations, shocks/pulsations, etc. Observations in Danfoss
Refer to page 12 and 17 for a description of laboratories often show high instability after contact welding as a result of high
contact welding. electrical load. Typical examples here are thermostats and pressure controls with
contact systems in the form of microswitches or similar arrangements.
Drift The following factors might produce drift in the working points of a thermostat/
pressure control as a function of time or number of operations:
Settling of bellows or spring.
Wear/friction in moving parts.
Contact wear.
In Danfoss thermostats/pressure controls such drift is minimal. Most bellows have
undergone pretreatment and all bellows and springs use only a minor part of their
possible working range.
Contact wear even 100% does not affect the working points in Danfoss products
described in this leaflet.
For exact information on thermostat/pressure
control accuracy, please contact Danfoss. All
replies will take full account of the above
Conclusion
parameters in relation to the application. Because of their simple design, where accuracy, stability and drift are concerned,
RT units are among the best of their kind.
24 © Danfoss A/S 07-1998 IH.20.B2.02

Environmental effects
Temperature – humidity – barometric pressure
Temperature The maximum temperature limits for operation and storage are provided in Danfoss
data sheets and must not normally be departed from. Within these limits, variations
in the ambient temperature can affect the function of the unit.
Pressure controls Thermostats
The set working points (pressure) can change as a function of the Thermostats react the same way as described for pressure controls.
ambient temperature, the reason being the different coefficients of Furthermore the reaction of the charge in relation to the ambient
expansion of the different materials. Lubricating oil viscosity temperature must be taken into consideration.
changes can also cause changes in friction conditions. In Vapour pressure charge: Here the ambient temperature has no effect on
addition, high temperature can reduce the spring force in highly working points, provided the sensor is colder than its surroundings, i.e.
loaded springs. Working point deviation per 10°C change in pressure control values apply.
ambient temperature for Danfoss products is as follows:
Partial charge: The ambient temperature has no effect on working points,
RT : 0.2% provided the sensor is warmer than its surroundings, i.e. pressure control
KP : 0.4% values apply.
KPS : 0.3% Universal charge: Here the ambient temperature never affects the
CAS : 0.3% working points, i.e. pressure control values apply.
Given deviation is in % of pressure range. Carbon charge: Depending on the carbon quantity, CO2 pressure and
To avoid working point deviation, many of our main springs are of sensor/bellows volume ratio, the working temperature of the unit will vary
stainless steel that has been subjected to heat pretreatment. with ambient temperature. Correction values are given in our data sheets
and it is important that these temperature influences be taken account of
since regulation, monitoring and alarm levels can change several °C for
only 10°C change in ambient temperature.
Humidity The function of Danfoss thermostats and pressure controls remains unaffected
by relative humidity. This is made possible by the choice of plastics we applied
in the design: their form and strength are not affected by relative humidity. In
addition, the electrical insulation capability is in accordance with the moisture
resistance requirements of the EN 60730 norm. Moisture tests are undertaken in the
range 30 - 98% RH (Relative Humidity).
Barometric pressure The maximum occurring barometric pressure variation at the same height above sea
level is assumed as ±0.06 bar. Note that a change in height of 1000 m corresponds
to a barometric pressure change of 0.12 bar.
These pressure variations can cause changes in working points, as described below:
Thermostats Pressure controls

Sensitivity depends on the charging medium/pressure used. Pressure controls are not generally sensitive to variations in barometric
It is generally highest in the lowest part of the scale pressure. Like pressure gauges, they measure relative pressure (i.e. in
temperature range. relation to atmospheric pressure).
However, if the evaporating temperature of a refrigeration system is
Rising barometric pressure will always cause higher working controlled by regulating the suction pressure with a pressure control, a
points; falling barometric pressure will always give lower variation in atmospheric pressure should not be observable on the
working points. pressure gauge. But rising atmospheric pressure gives rising suction
Danfoss is always ready to give information on the magnitude pressure and with it rising evaporating temperature. Here then is a
of the barometric pressure dependence of units. sensitivity to barometric pressure corresponding fully to the sensitivity
obtained by using a thermostat.
Fail-safe pressure controls (see p. 10) are sensitive to barometric
pressure variations because the safety bellows that is affected by the
barometric pressure has an area about three times as large as that of the
working bellows. Other than the above, barometric pressure variations
will cause no problems for regulating/monitoring pressure controls.
IH.20.B2.02 © Danfoss A/S 07-1998 25

Vibration – shock – pulsations

Vibrations If a thermostat/pressure control is to be installed on a vibrating machine it would be
difficult to find a unit more suitable than Danfoss type KP/KPS. These units are
Note: Compared with KP/KPS most other completely vibration-proof within a frequency band of 20 1000 Hz with an
types may suffer contact problems because acceleration level as high as 4 g.
certain frequencies produce serious
resonance oscillation in some parts of the Consequently, even under such extreme vibrations the KP/KPS unit is not subjected
unit.
to:
Working point change
Damaging contact bounce
Other mechanical defects
The Danfoss laboratory has analysed vibration conditions on rotating machines

including refrigeration compressors and diesel engines and has come to the
surprising conclusion that on rotating machines it is possible to measure many
frequencies at the same time, all with almost the same accelerations. Older theories
said that on any machine there was only one dominating frequency, i.e. the one that
resulted from the speed of rotation.
The photo shows a KP unit subjected to a

sinusoidal acceleration of 4 g at 200 Hz. The
oscilloscope shows that the contact changes
over instantaneously without bounce – see
lower curve on the oscilloscope.
The function test is normally performed using
sinusoidal vibration, and the whole frequency
range of 20-1000 Hz is investigated to reveal
possible resonance frequencies in test units.
Cut-in and cut-out functions are performed at
the frequencies most dangerous for the test
unit. It is a Danfoss requirement that the
working points must not change more than 20%
of the pressure/temperature differential, and
that contact changeover must not last more
than 50 ms.
Testing with sinusoidal vibration is also used by
approval authorities and ships’ classification
companies, because this method gives the
most reproducible results.
A newer test method which is very close to
practical reality is the random vibration test.
Here, units are subjected to many different
frequencies and accelerations at the same time.
At Danfoss this test is often used in durability
investigations and to reveal mechanical defects.
When installing units on vibrating machines the customer must be aware that
certain forms of fixing can intensify vibrations. Short, solid and securely bolted/
welded fittings with a natural frequency higher than 1000 Hz are recommended.
Alternatively, damping materials can be used (springs, rubber).
26 © Danfoss A/S 07-1998 IH.20.B2.02

Shocks, impact, etc. Within certain limits, thermostats/pressure controls must be able to withstand the
shock/impact/vibration that occurs under normal transport, installation and
Where shock/impact is concerned, operation. A distinction is made between shock on units themselves and shock on
EN 50015/IEC 68-2-27/32 applies. packaged units (transport problems).
The illustrated machine

subjects units to a particularly
severe test. It produces
shocks of more than 1000 g.
By applying shocks of this
magnitude we are capable of
simulating even the most
severe shocks encountered
in real life, such as the firing
of naval guns aboard
warships.
Transportation tests on packaged units are performed as follows:

11-point test where units are orientated in 11 different directions and allowed to
fall freely 0.6 m.
Pallet test where the pallet is lifted 0.3 m and allowed to fall freely.
Using a vibrating table, road and rail transport at random vibrations is simulated.
The vibration is controlled by a recording of actual road and rail vehicles.
Pulsations Problem:
Pressure pulsations can reduce the life of pressure controls and produce bounce on
the contact system. In this case, bounce means continuous contact changeover from
make to break as if the unit were being subjected to pressure variations larger
than the differential setting values.
An actual situation:
A pressure control is set for 2 bar differential. A pressure variation (pulsation) of
0.3 bar comes from the compressor discharge. The pressure control bounces and
pulsations higher than 2 bar are measured where the pressure control is connected.
In other words, the 0.3 bar pulsations from the compressor produce steady
oscillations in the discharge lines. Depending on the pulsation frequency, pressure
minimums and maximums will appear at regular distances from the compressor.
The pressure maximums have an amplitude that can be many times greater than the
start surge (0.3 bar).
Cause:
Pressure amplification in the discharge line.
Solution:
1. Choose another point on the discharge line for the pressure control connection.
2. Insert damping in the form of an orifice followed by a volume of 2-3 cm³.
Using electrical terminology, this creates an RC-link (low-pass filter).
IH.20.B2.02 © Danfoss A/S 07-1998 27

EMC is an acronym for Electro Magnetic

Compatibility EMC
When the contacts in a thermostat/pressure control switch in an electrical load, they
will send out noise pulses. This kind of emission comes from the arc produced on
contact break. It increases proportionally with the current, voltage and power factor
of the electrical load. Noise emission spreads via the supply leads, and
electromagnetically via the air and in this way disturbs sensitive electronic
equipment and radio/television equipment. That is why the phenomenon was once
called Radio noise.
Danfoss thermostats/pressure controls are seldom used in the vicinity of radio or

television receivers, but with the rapid spread of electronic equipment, the problem
has made itself felt: current cut-in and cut-out disturbs electronic circuits and
actually produces functional faults. Therefore EMC is an essential quality
parameter for thermostats/pressure controls.
National and international standards such as DS, VDE, IEC and EN lay down limits
The photo shows the EMC laboratory with
screened rooms and test set-ups for for and requirements on damaging EMC radiation. The factors are:
immunity and emission. Strength of noise signals (dB mV).
Duration of noise signals (ms).
The many years of EMC experience is also Frequency of noise signals (click noise pulses/min).
used externally in EMC standardisation work.
A distinction is made between:
Click noise, with pulses of less than 10 ms.
Click noise with pulses of less than 200 ms.
Permanent noise (pulses lasting more than 200 ms).
The cut-in and cut-out functions of Danfoss thermostats/pressure controls cause

click noise lasting less than 10 ms. This characteristic is called instantaneous
For a description, see page 13, the passage: contact changeover. It is favourable as far as fulfilling emission requirements is
'Class A'. concerned, i.e. the click noise frequency of less than 5 clicks/min does not infringe
the stipulated click noise level (dB mV) and as a consequence, no tests are
necessary. This exemption from tests (justified because make and break noise time
is less than 10 ms) does not apply to type CAS. However, since this unit has an
extremely low frequency of operation (it is not used for regulating functions) high
noise signals are permitted (> 90 dB mV).
An EU directive on EMC was laid down on 1 January 1992 and is put into effect
from 1 January 1996.
Danfoss thermostats and pressure controls cannot be CE marked according to the
EMC directive, because the directive does not apply to components. Consequently,
Danfoss cannot issue an EU declaration based on the EMC directive.
The main philosophy of the directive is that if electrical plant fulfils and
harmonises with the EN standard (e.g. EN 50081-1) the producer may mark units
CE. This certifies that the plant is in line with the directive. The types of plant
covered may only be marketed or used if they meet the requirements.
As far as EMC is concerned, Danfoss thermostats and pressure controls can be

used without problems in plant that is to carry the CE mark.
Stop-press According to EN 60 730 Pr.A13:1997, all thermostats and pressure controls for
regulation/control purposes shall meet a max. noise time requirement of 20 ms. EN
60 730 specifies strict test conditions. Of course only class A contact systems will
be able to meet these requirements.
28 © Danfoss A/S 07-1998 IH.20.B2.02

Short-circuit resistance
A practical example A thermostat/pressure control, which under cut-in conditions is exposed to short-
circuit current, must itself after such exposure be able to perform contact break
(The relevant standard is known as EN 60-947-5).
Therefore the standard EN 60-947-5 stipulates: The manufacturer shall state the
max. fuse for preventing harmful contact welding.
The test to EN 60-947-5 means that to prevent contact welding the following max.
fuses must be installed ahead of Danfoss thermostats/pressure controls:
Product KP KPS RT
Max. fuse ahead of product 20A 16A 10A
A brief explanation of why contacts can weld even though they do not cut in the
short-circuit current:
A simple motor installation
A pressure control monitors the pressure in a To understand the process, it is
machine and must break contact 1-2 when necessary to recall the physical law on
this pressure reaches a set limit value. magnetic fields around conductors: The
illustration shows the cut-in contact set
A matter of safety
and at the near-parallel contact
A fuse may blow as a result of short-circuiting
(not overload) in an installation, in parts of it, surfaces. Magnetic fields form around
or in an appliance. The cause could be a fault these surfaces (conductors).
or incorrect lead connection.
The illustration shows a direct short-circuit By applying the corkscrew rule to these opposite current flows it can be seen that
between A and B in a motor installation. identical magnetic poles are formed in both contact halves. They thus repel each
Thermostat/pressure control contacts 1-2 other.
now conduct this current until the fuse blows.
The cause of the short-circuit is found, the A simplified formula gives the relation between current and force for the contact
fault remedied, the fuse replaced, and no one
surfaces:
at all gives a thought to what can happen
now.
Contacts 1-2 might be lightly welded together Fk = 0.8 x I²
so that a subsequent signal to cut out the
motor because of excessive pressure might where
not be performed! Fk = The electrodynamic force in N acting on the contacts.
I = The momentary value of the current in kA through the cut-in contacts.
It can be seen that a break (contact lift) occurs at the moment force Fk exceeds the
inherent contact force of the unit (the force that holds the cut-in contacts together).
Calculation example
Assuming: From the fuse table it can be seen that the
1. Expected short-circuit current: 1 kA short-circuit current at the moment the fuse
2. Prefuse: 16 A blows = 800 A.
According to the above formula, this current
creates a force:
Fk = 0.8 x 0.82 = 0.51 N (51 p)
If the inherent contact force is less than this value, the contacts lifts and the short-
circuiting arc produce melting in small patches. When the fuse blows, the contacts
cut in mechanically again, and the melted contact particles stiffen to (possibly)
form welds.
Because it is the result of many factors, the contact force in a given product cannot
be directly increased. If these factors are changed (i.e. greater contact force) the
result will always be higher temperature/pressure differential.
IH.20.B2.02 © Danfoss A/S 07-1998 29

Durability
Mechanical and electrical life The durability of a thermostat/pressure control is defined as the mechanical and
electrical life of the unit. At Danfoss, this life is laid down as >10 years and must be
regarded as valid when the following two tests have been passed.
1. Electrical test The unit must perform at least 100,000 operations under the max. rated electrical load
(see photo on p. 17) and most unfavourable range and differential settings.
With this test it is mainly current-conducting parts that are tested. For KP units the test
conditions are as follows:
Cut-in : 6 x 16 = 96 A - 230 V cos 0.65.
Cut-out : 16 A - 230 V cos = 0.95
The test simulates motor start and stop an AC3 load. Contact welding must not occur
during the test (see p. 12/17) and contact material must not be totally consumed when
the test is over. Contact wear must not cause range and differential drift.
2. Mechanical test The unit must perform at least 400,000 operations under low load AC15, but with
max. range and differential setting, i.e. the unit is subjected to the worst possible
bellows movement at the highest possible pressure level.
With this test it is mainly the pressure/temperature-sensitive and mechanical moving
components that are tested.
Under all these tests both thermostats and pressure controls are subjected to
compressed air. All life testing is performed so that all test units are self-operating.
This means that any failure at any time is revealed and registered, and stops pressure
activation. Automatic failure registration makes it possible to run tests throughout
the week, without manual supervision.
Duration of the tests Frequency of operation Test time

Electrical life test 10 operations/min 7 days
Mechanical life test 60 operations/min 5 days
Danfoss continuously performs these tests to ensure that changes in contact materials,
other components, or adjustment procedures do not unfavourably affect thermostat/
pressure control life.
As implied, tests 1 and 2 are typical worst case tests.
If a customer uses a thermostat/pressure control with min. differential and at 50% or
less electrical load, the life of the unit will typically be over 1 million operations.
Test 2
The photo shows a section of test equipment
for the mechanical testing of CS pressure
controls.
30 © Danfoss A/S 07-1998 IH.20.B2.02

Competition parameters
To be able to offer the market a product that fulfils customer expectations, a
knowledge of the quality level of competing products is essential.
Within the last few years, ten of our competitors within the refrigeration and
industrial sectors have been the subject of thorough investigations so that we know
their characteristics in all important areas (function and life).
The boxes show the most carefully investigated parameters.
Minimum Differential
(Low columns are better)
The differential diagram shows minimum
differential measured on 15 types/makes of
pressure controls with a pressure range of
Min. differential (bar)
approx. 0-8 bar.
Types in order of merit
Vibration resistance
(15 - 1000 Hz range)
Failure criteria under test have been:
1. Unstable cut-in/cut-out pressure/
Acceleration (g)
temperature
2. Contact bounce
The order of merit follows the acceleration
levels withstood and the number of
resonance frequencies. Thus, RT has only
one resonance frequency, in which the
failure acceleration is 0.1 g. With all other
frequencies the acceleration level is > 1 g.
Electrical Life
(at max. electrical load)
The columns give the shortest life of five
units without failure. The five best types
Number of operations (´ 1000)
withstood 100,000 operations without

failure (indicated by an arrow).
In weighting for order of merit, account was

taken of the fact that all types do not have
the same current rating. A low number of
performed operations might therefore mean
that the units have performed many more
operations, but on low current.
IH.20.B2.02 © Danfoss A/S 07-1998 31

Standards – Approvals – EN – CE
Standards The basis of obtaining approval has usually been testing in accordance with
acknowledged and often international standards, for example:
CEE 24 and 124

IEC 158 and 337
VDE 631 and 660
DIN
UL 508 and 873
CSA 22.2-24
Approvals Danfoss thermostats/pressure controls are approved by a substantial number of

national authorities. These are given in Danfoss data sheets. The same data sheets
also give approvals obtained from ships classification companies.
EN (Europa Norm) In the future, significant simplification can be expected as a result of the new IEC
730 and 947 standards. These have been widely adopted by the American UL and
Canadian CSA so that in the long term they will become international.
The simplification lies in the fact that IEC 730/947 has already been adopted by the
European standard EN, with the following result:
A test performed in a laboratory authorised in relation to these new EN standards

forms the basis of approval by the authorities of member countries, without
additional testing.
For thermostats/pressure controls the relevant EN-standards are:
EN 60730-2-9 Thermostats for household use and similar

EN 60730-2-6 Pressure controls for household use and similar
EN 60947-4-1 Thermostats/pressure controls for industrial use (motor circuits)
EN 60947-5-1 Thermostats/pressure controls for industrial use (control circuits)
These EN standards are almost identical to IEC 730, IEC 947 and VDE 0631/VDE 0660.
The following standards will form the basis of future approvals:
EN 60730 for units to which the layman has access, that is:
Apparatus for household use, for agriculture, horticulture and light industry.
EN 60947 for units to which the layman has no access, that is:
Apparatus for diverse industrial applications.
CE marking Not later than January 1st 1997, all units named above will carry the CE mark. No
other national approvals are required after this date.
With CE marking, Danfoss declares that the low voltage directory has been
complied with, i.e. documentation exists to show that the requirements of the above
EN standard have been fulfilled.
Danfoss is also able to certify that this is the case by issuing a declaration of
conformity.
32 © Danfoss A/S 07-1998 IH.20.B2.02

Time constant table

Danfoss thermostats \ in seconds with sensor in liquid \ in seconds with sensor in air
Sensor Sensor In pocket In pocket Medium Air velocity in m/s
Unit type Charge1) alone without with
Form L Ø compound compound ~0 0.5 1.5 5.0
CAS 26 50 40 Water
50 13 350 160 110 80
KPS 37 75 65 Oil
RT
80 - 9.5 2, 7, 8, 14, 15, CO2 18 30 24 Water 220 110 80 50
210 12, 21, 23,
24, 101, 108
4 RT 140 180 70 45 25
4 RT 34 300 104 70 40
4 RT 102 170 65 41 28
RT 16L 680 270 140 53
4
RT 103 640 250 107 40
4 RT 4, 11, 17 135 90 55
76 - 9.5 - RT 3 Vapour 4 29 8 Water
100 13 RT 13, 106 5 29 13 Spirit
80 - 9.5 - RT 107, 11 - 21 40 - 55 38 - 52 Oil 220 110 70 40
110 11 120, 123, 124
KP 61, 63, 69 250 43 26 16
KP 62 CO2 90 40 24
1)
Charge: CO2 charge acts by adsorption of CO2 in active carbon (C).
“Vapour” in the table is a designation for all vapour pressure charges, i.e. also partial/universal charges (except solid charge).
Time constant t The table shows that the time constant depends on many different factors:
Physical dimensions of sensor (surface/volume ratio).
Sensor charge (CO2 versus vapour pressure charge).
Medium: Water, oil, brine, gas, etc.
Velocity of medium especially gases in m/s.
Sensor pocket dimensions and material.
Contact compound between sensor and pocket.
The selected temperature level (CO2 charge is faster at high temperatures).
The electrical equivalent diagram on page 7 will help readers understand that there
is never an exact answer to the questions:
What % is t higher in oil than in water?
By how much does t increase by placing the sensor in a pocket, etc?
because there is no knowledge of the other R and C magnitudes in the complete

sensor/media system.
In other words, for some sensor/pocket relations the time constant will increase 50%
by going from water to oil, while with other sensor/pocket conditions the observable
difference will be only 10%.
The Danfoss laboratories know a good deal about the influence of different factors
and will gladly be of assistance with further information, and in determining the
time constant of given thermostats for given applications.
IH.20.B2.02 © Danfoss A/S 07-1998 33

Load categories
Extract from EN 60 947-1
Alternating current AC Direct current DC
Category Application Category Application
AC-1 Approximate ohmic load DC-1 Approximate ohmic load
AC-2 Slipring motors
AC-3 Switching running squirrel-cage motors DC-3 Switching series mot. incl. start/rev./tip/brake
AC-4 Switching blocked squirrel-cage motors
AC-5a Switching gas-filled lamps DC-5 Switching shunt mot. incl. start/rev./tip/brake
AC-5b Switching filament lamps
AC-6a Switching transformers DC-6 Switching filament lamps
AC-6b Switching capacitor blocks
AC-7a Light ind. load in household apparatus
AC-7b Motor load for household apparatus
AC-8a Switching mot. for herm. comp. man. reset
AC-8b Switching mot. for herm. comp. aut. reset
AC-12 Control of input circuits for optocouplers DC-12 Control of input circuits for optocouplers
AC-13 Control of semiconductor load for transformer isolation DC-13 Control of DC electromagnetic loads
AC-14 Control of electromagnetic load £72VA DC-14 As DC-13, but with economy resistor
AC-15 Control of electromagnetic load >72VA
AC-20 Switching in no-load condition DC-20 Switching in no-load condition
AC-21 Switching ohmic load incl. some overload DC-21 Switching ohmic load incl. some overload
AC-22 Switching mixed load incl. some overload DC-22 Switching mixed load incl. some overload
AC-23 Switching motor load or other strongly ind. load DC-23 Switching strongly ind. load (series motors)
Note: Standard types are highlighted
Contact heating – Terminal temperature

Contact heating Contact heating is a product of the contact resistance (see pages 12 and 15) and the
load current. Even though the contact resistance is a few milliohms, quite high
temperatures can arise. These high temperatures shorten contact life because the arc
remains on the contact surface longer as the temperature rises. There is no standard
requirement for such maximum temperatures, provided the contacts are made of
silver or silver alloy.
The terminal temperature Because of the external cable connections the terminal temperature is subject to
strict requirements. The requirements are laid down in the standards EN 60 947 and
EN 60 730, and according to the standards the temperature rise on terminals must
not exceed 65°C. It is often the terminal temperature that limits the rated current of
a unit. It is determined by different factors: Contact resistance, dimensions of
internal current paths, terminal resistance, the size of external leads, and of course
the size of the current. Under test, units are connected to leads that correspond to
the max. rated current and are exposed to loads with max. rated current.
34 © Danfoss A/S 07-1998 IH.20.B2.02

Index
Accuracy ................................................ 24 IEC 529 .................................................. 22
AC load designations ............................. 34 IEC 947 .................................................. 32
AC marking, general .............................. 17 Impact .................................................... 25
Alarm system ......................................... 10 Installation tips ....................................... 20
Ambient temperature ............................. 25 Insulation capability ................................ 23
Approvals ............................................... 32 Insulation voltage ................................... 23
Barometric pressure .............................. 25 IP classification, Danfoss ....................... 22
Bursting pressure ..................................... 4 IP enclosures ......................................... 22
IP XX ...................................................... 22
CE marking
–Low Voltage Directive ..................... 32 Life, mechanical ..................................... 30
–EMC Directive ................................. 28 Life, electrical ............................. 17, 30, 31
Charge ........................................... 18 – 19 Load categories ............................... 16, 34
Class A principle .................................... 13 Low Voltage Directive ............................ 32
Class B principle .................................... 14 Low voltages, contact reliability ............. 15
Click noise ............................................. 28 Oxidation of contact surfaces .......... 12, 15
Comparative Tracking Index .................. 28
Pilot duty ................................................ 15
Competitors ............................................ 31
PLC/PC control ...................................... 15
Contact ........................................... 12 – 17
Pocket sensor effect .................... 7, 20, 33
–Bounce ............................................ 16
Pulsations .............................................. 27
–Force ............................................... 15
Pulse voltage .............................................
–Heating ........................................... 34
–Life .................................................. 12 Radio noise ............................................ 28
–Load .......................................... 15, 16 Range ...................................................... 6
–Material ........................................... 15 Regulation ............................................ 6, 7
–Reliability .................................. 12, 15 Reset function .......................................... 9
–Resistance ................................ 12, 15 Safety thermostat ............................. 10, 11
–Symbols .......................................... 13 Safety pressure control .................... 10, 11
–System types .................................. 13 Shocks ................................................... 26
–Welding ..................................... 12, 17 Short-circuit protection ........................... 11
Contact with medium ............................. 20 Stability .................................................. 24
CTI ......................................................... 23 Standards ............................................... 32
DC load designations ............................. 34 –DIN 32733 ....................................... 11
DC marking, general .............................. 17 –EN 12263 ........................................ 11
Declaration of conformity ....................... 32 –EN 500/15 ....................................... 26
Definitions –EN 60730 ............................ 25, 32, 34
–Reset ................................................ 9 –EN 60947 .................................. 32, 34
–Thermostat/pressure control ............. 9 –EN 60947-4 ..................................... 32
–Time constant ................................... 7 –EN 60947-5 ........................... 4, 29, 32
Deviation ................................................ 24 –EN 12263 ........................................ 11
Differential ................................................ 6 –IEC 112 ........................................... 23
Differential, minimum ............................. 31 –IEC 730 ........................................... 32
Drift ........................................................ 24 –IEC 947 ........................................... 32
Dry circuit ............................................... 15 –IEC 947-5 ........................................ 23
Durability ................................................ 30 –VDE 0631 ....................................... 32
Dust, ingress .......................................... 22 –VDE 0660 ....................................... 32
–VBG 20 ........................................... 11
Electrical load ......................................... 15
Switch function ................................... 6, 11
Electro Magnetic Compatibility .............. 28
EMC ....................................................... 28 Temperature dependence .......... 18, 19, 25
Encapsulation sensitivity .......... 18 – 19, 25 Terminal temperature ............................. 34
Enclosure ............................................... 11 Time constant .......................... 6, 7, 11, 33
EN standards ......................................... 32 Transport protection ............................... 26
Tracking Index test ................................. 23
Fail-safe ................................................. 10
Foreign body test, IP .............................. 22 Vibration resistance ......................... 26, 31
Glow-wire test ........................................ 23 Watertightness ....................................... 22
Gold contacts ................................... 12, 15 Welding of contacts .......................... 17, 29
Grade of enclosure, IP ........................... 22
High-voltage test .................................... 23
Humidity ................................................. 25
IH.20.B2.02 © Danfoss A/S 07-1998 35

IH.20.B2.02 © Danfoss A/S AC-SP. Kaa 07-1998. AO

Damper
G e i s l i n g e r Co u p l i n g
Geislinger Damper
G e i s l i n g e r G e s i l co
G e i s l i n g e r Fl e x l i n k
G e i s l i n g e r M o n i to r i n g
G e i s l i n g e r Ca r b o to rq
Geislinger Vdamp
Geislinger GmbH
A - 5 3 0 0 H a l l w a n g / S a l z b u rg, Au s t r i a • H a l l w a n g e r L a n d e s s t ra s s e 3
Te l . + 4 3 / 6 6 2 / 6 6 9 9 9 - 0 • Fa x + 4 3 / 6 6 2 / 6 6 9 9 9 - 4 0
i n fo @ g e i s l i n g e r. co m • w w w. g e i s l i n g e r. co m
Monitoring
G e i s l i n g e r Co u p l i n g
Geislinger Damper
G e i s l i n g e r G e s i l co
G e i s l i n g e r Fl e x l i n k
G e i s l i n g e r M o n i to r i n g
G e i s l i n g e r Ca r b o to rq
Geislinger Vdamp
Geislinger GmbH
A - 5 3 0 0 H a l l w a n g / S a l z b u rg, Au s t r i a • H a l l w a n g e r L a n d e s s t ra s s e 3
Te l . + 4 3 / 6 6 2 / 6 6 9 9 9 - 0 • Fa x + 4 3 / 6 6 2 / 6 6 9 9 9 - 4 0
i n fo @ g e i s l i n g e r. co m • w w w. g e i s l i n g e r. co m
Victron Energy
USER MANUAL
GEBRUIKSAANWIJZING
GEBRAUCHSANWEISUNG
SKYLLA-TG 24/80
SKYLLA-TG 24/100
SKYLLA-TG 24/100 3-Phase
TITAN 48/50
SECTIONS Page
English 3
Nederlands 31
Deutsch 59
Manual Titan 1
Copyrights  2004 Victron Energy B.V.
All Rights Reserved
This publication or parts thereof, may not be reproduced in any form, by any method, for any
purpose.
VICTRON ENERGY B.V. MAKES NO WARRANTY, EITHER EXPESSED OR IMPLIED, INCLUDING

BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, REGARDING THESE VICTRON ENERGY PRODUCTS AND MAKES
SUCH VICTRON ENERGY PRODUCTS AVAILABLE SOLELY ON AN “AS – IS” BASIS.
IN NO EVENT SHALL VICTRON ENERGY B.V. BE LIABLE TO ANYONE FOR SPECIAL,

COLLATERAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR
ARISING OUT OF PURCHASE OR USE OF THESE VICTRON ENERGY PRODUCTS. THE SOLE
AND EXCLUSIVE LIABILITY TO VICTRON ENERGY B.V., REGARDLESS OF THE FORM OF
ACTION, SHALL NOT EXCEED THE PURCHASE PRICE OF THE VICTRON ENERGY PRODUCTS
DESCRIBED HEREIN.
For conditions of use and permission to use this manual for publication in other than the
English language, contact Victron Energy B.V.
Victron Energy B.V. reserves the right to revise and improve its products as it sees fit.
This publication describes the state of this product at the time of its publication and may
not reflect the product at all times in the future.
2 Manual Titan
Victron Energy
USER MANUAL
SKYLLA-TG 24/80
SKYLLA-TG 24/100
SKYLLA-TG 24/100 3-Phase
TITAN 48/50
Manual Titan 3
USER MANUAL TITAN GENERATION CHARGERS
1. INTRODUCTION 5
1.1 Victron Energy 5
1.2 The Titan Generation chargers 5
1.3 Warnings 5
2. DESCRIPTION 7
2.1 The Titan battery charger 7
2.2 The battery 8
2.3 Protection 9
3. DIRECTIONS FOR USE 11
3.1 Installation 11
3.2 Operation 15
3.3 Maintenance 16
4. OPTIONS 17
4.1 Permanent boost-charge 17
4.1 Permanent boost-charge 18
4.2 Adjusting the charge voltage 18
4.3 Adjusting the equalize-charging mode time 19
4.4 Diode-splitter charge voltage compensation. 19
4.5 Traction battery compensation 20
4.6 Use as a power-supply 20
4.7 Use of a temperature sensor. 20
4.8 Charging batteries with voltage sensing 21
4.9 Intelligent startup 21
4.10 Connecting the output voltage alarm 22
4.11 Connecting remote panels 22
4.12 Connecting a remote on/off switch 23
4.13 Connecting a remote boost switch 23
4.14 Connecting a voltmeter 24
4.15 Connecting a ampèremeter 24
5. FAULT TRACING 25
6. TECHNICAL SPECIFICATIONS 26
6.1 General 26
6.2 Input 26
6.3 Output 26
6.4 Mechanical 27
4 Manual Titan
1. INTRODUCTION
1.1 Victron Energy

Victron Energy has established an international reputation as a leading designer and
manufacturer of power systems. Our R&D department is the driving force behind this
reputation. This department is continually seeking new ways of incorporating the latest
technology in our products.
A Victron Energy power system can supply high-quality energy at places where there is no
permanent mains power source available.
An automatic stand alone operating energy supply system can consist of: a Victron Energy
inverter, a Victron Energy battery charger, if required a Victron Energy Mains Manager and
batteries with sufficient capacity.
Our equipment can be used in numerous situations, in the field, on ships and in other places
where mobile power is indispensable.
Victron Energy equipment can be used for all kinds of electrical appliances for household,
technical and administrative purposes and instruments susceptible to interference.
1.2 The Titan Generation chargers

This manual contains directions for installing the following chargers: Skylla-TG 24/80,
Skylla-TG 24/100, Skylla-TG 24/100 3-Phase and the Titan 48/50. It describes the
functionality and operation including their protective devices and other technical features.
1.3 Warnings
The cover of the battery charger may only be removed by a qualified

technician. Before obtaining access to the battery charger the mains
supply circuit must be disconnected.
Explosive gasses can occur during charging a lead-acid

battery. Prevent flames and sparks.
Provide adequate ventilation during charging.
The battery charger can not be used to charge non-rechargeable

batteries.
victron energie Manual Titan page 5

There is a dangerous voltage present on some of the metal parts
inside the battery charger.
The battery charger is NOT protected against reverse battery polarity.

("+" connected to "-" and "-" connected to "+").
Follow the installation procedure. The warranty expires when the
battery charger becomes defective due to reverse battery polarity.
The on/off switch at the front of the cabinet does not switch off the
mains supply.
Disconnect the mains supply before making or breaking the

connections to the battery.
Do not use the voltage sense facility in combination with the diode-
splitter compensation. This will raise the output voltage, which
could damage the battery.
6 Manual Titan
2. DESCRIPTION
2.1 The Titan battery charger

The Titan battery charger is a fully automatic charger for 24V or 48V batteries and is
powered by a mains voltage of 230Vac, 50Hz. It charges the battery according to the IUoUo
characteristic, which is a 3-stage charging characteristic. This characteristic is shown in
illustration 1. While charging, the Titan continuously measures the battery voltage and
current and bases the charging voltage and current on the measured values.
Illustration 1.
The IUoUo charge
characteristic.
Type Boost voltage Float voltage Minimal

voltage
24V / 80A 28,5 Vdc 26,5 Vdc 25 Vdc
24V / 100A 28,5 Vdc 26,5 Vdc 25 Vdc
24V / 100A 3-Ph 28,5 Vdc 26,5 Vdc 25 Vdc
48V / 50A 57 Vdc 53 Vdc 50 Vdc
Assuming that the battery is discharged, the Titan charger starts charging in the boost-charge
mode. In this mode the battery is charged until the battery voltage reaches the boost voltage.
At this point the battery is charged to approximately 80% of its maximum capacity. This is
the end of the boost-charge mode and the Titan charger automatically switches to the
equalize-charge mode.
During the equalize-charge mode the charging voltage stays the same as the boost voltage but
the charge current slowly decreases. The duration of this mode is pre-selectable to 4, 8 or 12
hours. The standard time of the equalize-mode is 4 hours. After this time the Titan charger
automatically switches into the float-charge mode.
In the float-charge mode the charge voltage changes into the float voltage and the charge
current continues to decrease. This mode lasts for 20 hours.
After the float-charge mode the charger returns to the equalize-charge mode for 30 minutes,
this is to compensate for the normal leakage or self discharge of the battery.
Manual Titan 7
The Titan charger can remain connected to the battery continuously, without gas formation
taking place, caused by overcharging. It is not necessary to disconnect the battery from the
charger during long time storage, for example during the winter storage of a ship. The Titan
charger will keep your battery in optimum condition under all circumstances and will prolong
the lifetime of your battery.
A parallel load connected to the battery can cause a voltage drop. The Titan charger
automatically switches into the boost-charge mode when the battery voltage drops below the
minimal voltage.
The Titan charger is equipped with a separate starter-battery connection to charge an extra
battery, like a starter-battery. You can use this battery for starting machines, like a boat
engine for this application.
The Titan charger has a stabilised output voltage. Therefore the Titan charger can also be
used as a DC power supply in applications where no battery is present.
2.2 The battery

The Titan charger can charge various batteries. The recommended battery capacity is
indicated in the table below:
Type Recommended capacity
24/80 300 - 600 Ah
24/100 500 - 1000 Ah
24/100 3-Ph 500 - 1000 Ah
48/50 200 - 400 Ah
The charge voltages of the Titan charger are factory set. Most battery manufactures
recommend these charging voltages for optimal charging of 24V or 48V lead-acid batteries.
It is possible to charge different types of batteries, like traction batteries. To charge these
batteries the charging voltages of the charger have to be changed. Contact your Victron
Energy dealer or battery dealer for more details about the recommended charging voltages.
8 Manual Titan
2.3 Protection
The battery charger is safe to use due to its robust design and its internal electronic
protection. This chapter describes the various internal electronic protective devices.
Maximum charge current protection

The battery charger provides a maximum charge current of 50A for the 50A charger,
80A for the 80A charger, or 100A for the 100A charger. This level is electronically
limited and is factory set.
The maximum output current can also be limited by using an external potentiometer-
panel, the Victron Energy COV panel.
Short circuit protection

The charger output is protected against short-circuits. The short-circuit current is
electronically limited at 50A, 80A or 100A, according to the model. In this condition the
output voltage approaches 0 Volt. The battery charger resumes normal operation when
the short circuit is removed.
The short circuit current can also be reduced by the Victron Energy COV panel.
Input protection
The charger mains-input is protected with a fuse.
The charger will not be damaged by using input voltage between 0 and 300 Vac.
The charger will not be damaged by using input voltage frequency between 0 and 65
Hz.
Over voltage protection

The charger switches off automatically when the battery voltage becomes higher than the
over voltage value. The charger switches back on when the battery voltage becomes less
than the raise value. See the table below.
Model Over voltage value Raise value

24V 35,5 Vdc 33,5 Vdc
48V 68,1 Vdc 64.1 Vdc
The charger output is protected with a fuse.
Starter battery protection

The output current of the starter battery output is electronically limited at 4A. The starter
battery output is also protected against wrong connections by means of a 10A fuse.
Manual Titan 9
Temperature protection
The internal temperature of the charger is measured continuously. However, due to a
high ambient temperature outside the cabinet the temperature within the battery
charger can rise. When the external temperature of the battery charger becomes higher
than 40°C, the output current decreases and the Failure led flashes.
Before the internal temperature becomes too high due to extreme conditions the
charger switches off and the Failure led illuminates continuously. The charger
resumes operation when the internal temperature is restored within limits.
Voltage sense protection

When the voltage sense facility is used the charger automatically decreases the output
voltage when the voltage loss over the battery cables is more than 2 Volt in total.
Battery watchdog timer
The charger is equipped with a battery watchdog timer. This timer measures the
duration of the boost mode. The moment the boost mode lasts longer than 10 hours,
the charger will switch to float mode. The charging voltage will then become the float
voltage. In this way it is prevented that a defective battery is needlessly charged with a
high charging voltage.
10 Manual Titan
3. DIRECTIONS FOR USE
3.1 Installation
Find a dry and well-ventilated area to mount the Titan charger and battery. Keep the distance
between the charger and the battery less than 6 meters.
The charger may be wall or floor mounted. Mounting on a wall improves the air circulation
within the charger cabinet and will prolong the lifetime of the battery charger.
The holes for the mains cable, the battery connections, the remote connections and the earth
connection are located at the bottom of the battery charger housing, see illustration 2.
Illustration 2,
Location of the charger
connection holes
Connecting earth
Connect the earth screw to a real earth-point. Connections to earth have to be according to
applicable safety standards.
On a ship: Connect the earth screw to the earth plate or to the hull of the ship.
On land: Connect the earth screw to the earth of the mains.
Mobile applications (a vehicle, a car or a caravan): Connect the earth screw to the frame
of the vehicle.
Connecting the battery

The connections between the Titan charger and the battery are essential for a good operation
of the charger. Therefore the battery connections need tightening well. It is important to use
short and thick battery cables to minimise the voltage losses in the cable. Cable resistance
decreases accordingly as the cables become shorter and thicker. Therefore it is not
recommended to use cables longer than 6 meters. The table below shows the recommended
cable core thickness.
Type core diameter of cables until 1,5m core diameter of cables between 1,5m and 6m
2 2
24/80 16 mm 25 mm
2 2
24/100 35 mm 50 mm
2 2
24/100 3-Ph 35 mm 50 mm
2
48/50 10 mm 16 mm2
Manual Titan 11
The battery connection sequence
The Titan is NOT protected against reverse battery polarity.

("+" connected to "-" and "-" connected to "+").
Follow the installation procedure. The warranty expires when
the Titan becomes defective due to reverse polarity.
Disconnect the mains supply The on/off switch at the

before making or breaking front of the cabinet does
the connections to the not switch off the mains
battery. supply.
Check if the charger is switched off and if the mains supply is disconnected.
Remove the front of the battery charger to access the battery connections.
If not placed, place the connection tool to the negative battery connection (-) of the
charger, see illustration 3.
Connect the positive battery-cable (+) to the positive battery connection terminal on the
charger printed circuit board, see illustration 3.
Hook the negative battery-cable (-) to the connection tool, see illustration 3.
Check if the green led illuminates, see illustration 3. If not the positive and negative
battery cables have been reversed.
Disconnect the connection tool and connect the negative battery cable (-).
The battery disconnection sequence

Switch off the charger.
Disconnect the mains supply.
Disconnect the negative battery-cable.
Disconnect the positive battery-cable.
- starter battery connection

+ starter battery connection
Green led
Negative battery connection
Output fuses
Positive battery connection
Illustration 3.
Red led
Location of the battery
connections
Connection tool
12 Manual Titan
Connecting the starter battery
The starter battery has to be connected using wire with a core of at least 1.5 mm2.
Connect the positive (+) battery-pole to the right side of the starter battery connector, see
illustration 3.
Connect the negative (-) battery-pole to the left side of the starter battery connector, see
illustration 3.
Connecting the mains

Check if the battery is already connected to the charger.
Remove the front of the battery charger to access the AC input connector.
Connect the mains PE cable (green/yellow) to the AC input connector located on the
circuit board, see illustration 4.
Connect the mains neutral cable (blue) to the AC input connector.
Connect the mains line cable (brown) to the AC input connector.
Plug the mains cable into the mains socket. Make sure that the mains socket is connected
to earth. The connection to the earth of the mains has to be according to applicable safety
standards.
N L
AC input connector
Illustration 4. PE connection
Location of the neutral connection
AC input connector. line connection
Manual Titan 13
illustration 4b
Connecting the 3phase mains
Check if the battery is already connected to the charger.
Remove the front of the battery charger to access the AC input connector.
Connect the mains PE cable (green/yellow) to the AC input connector located next to the
Magnetic Circuit Breaker, see illustration 4b.
Connect the 3 mains line cables to the Magnetic Circuit Breaker.
Plug the mains cable into the mains socket. Make sure that the mains socket is connected
to earth. The connection to the earth of the mains has to be according to applicable safety
standards.
14 Manual Titan
3.2 Operation
Located on the front of the Titan charger are an on/off switch and three rows of leds, as
shown in illustration 5.
The battery charger can be switched on and off with the on/off switch.
The “output voltage” leds indicate the output voltage value.
The “output current” leds indicate the output current value.
The other leds indicates the state of the charger.
Illustration 5. Example of the battery charger front panel.

The operation sequence:
Explosive gasses can occur during charging a lead-acid

battery. Prevent flames and sparks.
Provide adequate ventilation during charging.
Switching the charger on with the on/off switch results in the following:
The “on” led will flash for about 2 seconds. In these first 2 seconds the charger reads all
input signals and calculates the necessary output voltage. After 2 seconds the charger
will switch on and the “on” led illuminates.
According to the condition of the battery the charger will start in the boost-charge mode
or at float-charge mode. If the battery is not full the “boost” led illuminates and the
charger will start boost-charging the battery.
A dip switch can be used to set the charger so that it will always start charging in the
boost mode, irrespective of the condition of the battery.
When the battery voltage has reached the boost voltage the charger will change into the
equalize-charge mode and the “equalize” led illuminates. This mode will last for a pre-
selectable time of 4, 8 or 12 hours.
After this time the charger will enter the float-charge mode and the “float” led will
illuminate.
Manual Titan 15
After the batteries are charged the Titan charger does not have to be switched off and the
batteries can stay connected to the battery charger.
3.3 Maintenance
The Titan charger does not require any specific maintenance. However an annual check of
the battery connections is recommended.
Keep the charger dry, clean and free of dust. If any problems arise, use the fault finding
procedure to trace the fault, see chapter 5.
16 Manual Titan
4. OPTIONS
The Titan charger is factory set to standard values. Some of these standard values can be
changed by a qualified electrical technician into customised values. This chapter describes
which values can be changed and how to change them.
The cover of the Titan may only be removed by a qualified

technician. Before obtaining access to the Titan the mains supply
circuit must be disconnected.
There is a dangerous voltage present on some of the metal parts

inside the battery charger.
Attention ! The value of the potentiometers I, Vboost and Vfloat

may only be adjusted by a qualified electrician. The remaining
potentiometers may not be adjusted at any case.
Opening of the battery charger cabinet

In order to change the standard values the front of the charger has to be removed.
Disconnect the mains from the charger and wait two minutes.
Unscrew the 4 screws on the front of the cabinet, see illustration 6.
Remove the front panel of the battery charger.
Adjustments can be made by means of turning a potentiometer or by changing the position

of a switch on the DIP-switch.
See illustration 7 for the location of the DIP-switch and the potentiometers.
DIP switch
I
Vboost
Vfloat
Illustration 6.
Removing the front. Illustration 7.
Location of the DIP-switch and potentiometers.
Manual Titan 17
4.1 Permanent boost-charge
In some cases, for example when the battery is almost empty, it is recommended to permanent
boost-charge the battery for 10 hours. Do not permanently boost-charge sealed lead-acid
batteries. Contact your Victron Energy dealer or battery dealer for more information on
charging the battery.
To set the charger into the permanent boost-charge mode :

Place the DIP switch number 8 “R boost” to the left. In this mode the
battery is being charged to the boost voltage.
Do not permanent boost-charge the battery for longer than 10 hours
as this can cause long term gas formation in the battery and will
damage the battery.
While a battery is being boost-charged, check the water level of the
battery frequently and if necessary add distilled water to the battery.
4.2 Adjusting the charge voltage

The battery charger has a factory set float and boost voltage. The boost-voltage is always
higher than the float-voltage. These charging voltages are the recommended values from
almost every battery manufacturer. Before adjusting the charge voltage disconnect the
temperature sensor and/or the voltage sense wires.
To change the float-voltage:

Remove all batteries and other users that are connected to the output of
the battery charger.
Plug the AC plug into the mains and switch on the charger.
Place DIP-switches 7 “Eq2” and 6 “Eq1” to the left position, this will
reduce the equalize time to 0 hours. The charger switches into the
float-charge mode.
Place DIP-switch 4 “fine” to the left position in order to accurately
adjust the output voltage.
Measure the float-voltage on the charger output by using a precision
voltage meter.
Adjust the float-voltage by turning the “V float” potentiometer until the
recommended voltage is reached.
Correct the equalize time by moving DIP-switch 7 “Eq2” and 6 “Eq1”.
Place DIP-switch 4 “fine” to the right position. In this position the
output voltage is less sensitive to influence of temperature.
18 Manual Titan
To change the boost-voltage:
Place DIP-switch 7 “Eq2” to the right and place DIP-switch 8 “R
boost” to the left. The charger switches into the boost-charge mode.
Place DIP-switch 4 “fine” to the left position in order to accurately
adjust the output voltage.
Measure the boost-voltage on the charger output by using a precision
voltage meter.
Adjust the boost-voltage by turning the “V boost” potentiometer
until the recommended voltage is reached.
Replace DIP-switch 8 “R boost” to the right.
Correct the equalize time by moving DIP-switch 7 “Eq2” and 6 “Eq1”.
Place DIP-switch 4 “fine” to the right position. In this position the output
voltage is less sensitive to influence of temperature.
4.3 Adjusting the equalize-charging mode time

The duration of the equalize-charge mode can be changed to fit the specifications of the
battery. The duration of the equalize-charge mode can be set to 0, 4, 8 or 12 hours. When
selecting 0 hours, the charger will skip the equalize-charge mode and will directly switch
into the float-charge mode. The standard equalize-time is 4 hours.
According to the table below the duration of the equalize-charge mode can be set by
moving the DIP-switches 7 “Eq2” and 6 “Eq1” in the corresponding way:
0 hours 4 hours 8 hours 12 hours
4.4 Diode-splitter charge voltage compensation.

If a diode-splitter (Victron Energy Argo) is connected to the Titan
charger the charge voltage have to be raised to compensate for the
voltage loss over the diode-splitter.
If the voltage-sense option is used, do not use the diode-splitter
compensation. When both options are used simultaneously the output
voltage will be too high.
To select the diode-splitter option:

Place DIP switch 5 “split” to the left.
Manual Titan 19
4.5 Traction battery compensation
If a Traction-battery is connected to the Titan charger the charge
voltages have to be changed. The output voltage has to be raised to
correctly charge the traction-battery. It is possible that the charge
voltages are not correct after activating this compensation. See for
adjusting the charge voltages chapter 4.2.
To set the charger into the traction mode:

Place DIP-switch 3 “trac” to the left.
4.6 Use as a power-supply

The Titan charger can be used as a power supply without the obligation to connect a
battery to the charger output.
To use the charger as a power supply:

Put the charger into the permanent boost-charge mode, see chapter 4.1.
Adjusted the output voltage to the desired voltage, see chapter 4.2.
With the above mentioned procedure the output voltage range is limited. When the full
output voltage range is required please contact your Victron Energy dealer. See chapter
6.3 for details.
4.7 Use of a temperature sensor.

The temperature sensor supplied with the charger can be
connected to the charger by using the 3 meter cable with
stripped and tinned cable ends. This sensor should be
mounted on the battery. The temperature sensor adjusts
the charging voltage according to the battery
temperature.
To connect the temperature sensor:

Disconnect the mains,
Connect the - (black wire) of the temperature
sensor to the “-tmp” connector, see illustration 8.
Connect the + (red wire) of the temperature sensor
to the “+ tmp” connector, see illustration 8.
Switch on the mains.
If the temperature sensor is correctly connected the
“TMP OK” on the printed circuit board led
illuminates. If this led does not illuminate or
flashes, the sensor is not connected correctly.
Illustration 8.
Location of the external connections.
20 Manual Titan
4.8 Charging batteries with voltage sensing
Do not use the voltage sense facility in combination with the diode-
splitter compensation, as this will raise the output voltage.
When high current runs trough a thin cable between the charger and the battery there will
be a voltage loss in the cables. The charging voltage measured at the battery poles will be
lower than the specified voltage and this will result in a longer charging time. However,
the charger is equipped with a voltage sense facility. The battery voltage is exactly
measured and the charger increases the output voltage to compensate for the voltage loss
across the cables.
The charger can compensate for a maximum of 2V voltage loss over the cables. When the
voltage loss is bigger than 2V the “on” led flashes and the failure led illuminates. The
charge voltage will decrease until the voltage loss becomes maximum 2 Volt. The “on” led
flashes and the failure led illuminates until the charger is manually switched off. When this
occurs the battery cables have to be replaced because they are too thin or have bad
connections.
To install the voltage sense option:

Disconnect the mains.
Connect a red 0,75 mm2 wire to the positive battery pole and the “+Vse” connector of
the charger, see illustration 8.
Connect a black 0,75 mm2 wire between the negative pole of the battery and the “-
Vse” connector of the charger, see illustration 8.
For properly functioning both wires have to be connected.
Switch on the mains.
The “VSE OK” led on the printed circuit board illuminates when connected correctly.
If this led does not illuminate the voltage sense wires are wrongly connected.
4.9 Intelligent startup

The factory setting of the charger is such that the battery voltage is
checked when the charger is switched on (intelligent startup). In the case
of a flat battery, the charger will start charging in the boost mode. If the
battery voltage is sufficiently high during charger startup, the charger
will be charging in the float mode.
In some situations it may be desirable for the charger not to check the
battery voltage upon startup. With this charger this function is enabled
by sliding dip switch 2 “Watch” to the left.
When this dip switch is positioned on the left, the charger will always
start charging in the boost mode.
Manual Titan 21
When dip switch 2 “Watch” is positioned on the right, it is checked upon startup whether
the battery voltage is sufficiently high to enable a start in the float mode. If it is not, the
charger is started in the boost mode as yet.
4.10 Connecting the output voltage alarm

The charger is equipped with a potential free alarm contact (change over type).
If the battery voltage is in between Vmin and Vmax the contact is activated.
(See figure 8, remote connections: NO, NC, COM).
Model Vmin Vmax

24V 23,8 Vdc 33,5 Vdc
48V 47,6 Vdc 67 Vdc
4.11 Connecting remote panels

Victron Energy provides four optional remote panels that can be connected to the charger.
See illustration 8 for the circuit board connector where the remote panels have to be
connected to.
The COV panel:

The maximum charging current of 50A, 80A or 100A, according to the model, can be
limited with an external panel. This panel, the Victron Energy COV panel, contains an
adjustable potentiometer. Limiting the maximum charging current can be useful to meet
the batteries specifications, or to make sure the shore fuse does not blow.
To connect the panel:

Connect the panel to the “+ pot” and “-pot” connector.
The CMV panel:

This panel indicates the charging mode and possible failures.

Connect the boost led to the “ L_BO” connector.
Connect the equalize led to the “L_EQ” connector.
Connect the float led to the “L_FL” connector.
Connect the failure led to the “L_FA” connector.
Connect the ground of the panel to the “GND” connector.
The CSV panel:

With the CSV panel the charger can be switched on or off. On the panel a green “on” led
is present. To operate the CSV panel you first have to switch the charger on with the
on/off switch located on the front panel of the charger.
22 Manual Titan
Disconnect the mains
Connect the on led to the “L_ON” connector.
Connect the “TG switch” to the “REM” connector.
The SKC panel:

This panel indicates if the charger is on or off, it indicates the charging mode and it
contains an adjustable potentiometer. Limiting the maximum charging current can be
useful to more accurately charge the batteries according the manufacturers specifications,
or to make sure the shore fuse does not blow.

Connect the on led to the “L_ON” connector.
Connect the boost led to the “ L_BO” connector.
Connect the float led to the “L_FL” connector.
Connect current control to the “+ POT” and “-POT” connector.
4.12 Connecting a remote on/off switch

A remote switch can be connected to the charger so the charger can be switched on and off
from a remote location. To operate the switch, first switch the charger on with the on/off
switch located on the charger.
To connect the remote on/off switch:

Connect the switch in between the “REM” and the “GND” connector.
4.13 Connecting a remote boost switch

A remote switch can be connected to the charger so the charger can be switched
permanently into the boost-charge mode. Due to parallel loads connected to the battery it
is advised to switch the charger into the permanent boost-charging mode in order not to
discharge the battery.
If the switch is closed the charger switches into the permanent boost-charge mode. If the
switch is opened again the charger will automatically go to the float-charge mode. This in
order not to overcharge a battery with charging it to long with higher charging voltage.
To connect the boost switch:

Connect one pole of the switch to the “RBOO” connector.
Connect the other pole of the switch to the “GND” connector.
Manual Titan 23
4.14 Connecting a voltmeter
The remote-connector offers a possibility to connect a voltmeter. It is possible to connect a
digital as well as an analogue voltmeter. This output can only be used when the voltage-
sense is connected. The voltage at this output is equal to the voltage measured at the point
where the voltage sense wires are connected.
Connecting a voltmeter
Disconnect the mains voltage.
Make sure that the voltage sense wires are connected, see chapter 4.8.
Connect a black wire between the “-” connection of the voltmeter and “-VM” at the
remote connector.
Connect a red wire between the “+” connection of the voltmeter and “+VM” at the
remote connector.
Connect the mains voltage.
4.15 Connecting a ampèremeter

The remote connector offers a possibility to connect an ampèremeter, which indicates the
output current of the charger. For the 50A charger an ampèremeter, which indicates 50A at
60mV input voltage is required. For the 80A charger an ampèremeter, which indicates
80A at 60mV input voltage is required, likewise for the 100A charger an ampèremeter,
which indicates 100A at 60mV input voltage is required.
Connecting an ampèremeter
Disconnect the mains voltage.
Connect a black wire between the “-” connection of the ampèremeter and “-AM” at
the remote connector.
Connect a red wire between the “+” connection of the ampèremeter and “+AM” at the
remote connector.
Connect the mains voltage.
24 Manual Titan
5. FAULT TRACING
When a fault occurs in the battery charger, the following table can be used in order to find the
fault. Before the Titan is being checked, make sure that all the devices connected to the
battery charger are removed. If the fault can not be solved contact your Victron Energy
dealer.
Problem Possible cause Solution
The charger does not The mains voltage has to be in between Measure the mains voltage and make sure it is in
operate 185Vac and 265 Vac. between 185Vac and 265Vac.
A broken input fuse. Return the charger to your dealer.
The battery is not The equalize-charge mode is set to Set the equalize-charge mode to a longer time.
being fully charged a too short period.
A bad battery connection. Check the battery connections.
The boost charge voltage is Adjust the boost charge voltage to the right
set to a wrong value. value.
The float charge voltage is Adjust the float charge voltage to the right
The capacity of the battery is too large. Connect a battery with a smaller capacity or
install a larger charger.
The output fuses are broken. Replace the output fuses.
The battery is being The battery charger is set into the Deselect the permanent boost DIP-switch
overcharged permanent boost-charge mode. (Rboost).
The boost charge voltage is Adjust the boost charge voltage to the right
The float charge voltage is Adjust the float charge voltage to right value.
set to a wrong value.
A bad battery. Check the battery.
The battery is located in a warm place Connect a temperature sensor
The battery is too small. Reduce the charge current.
The failure led The charger is switched off as a result Place the charger in a cooler, or better ventilated
illuminates of a high ambient temperature. place.
The failure led The charger is reducing the output Place the charger in a cooler, or better ventilated
flashes current as a result of a high ambient place.
temperature.
The failure led The output fuses are broken. Replace the output fuses.
flashes in a code1
The failure led There is a voltage drop higher than 2V Turn the charger off, replace battery cables and
illuminates in across the battery cables. connect them well.
combination with a
blinking on/off led
A qualified technician may only remove the cover of the Titan. Before
obtaining access to the Titan the mains supply circuit must be
disconnected.
1
Flashing code sequence is two times on in one second and then one second off.
Manual Titan 25
6. TECHNICAL SPECIFICATIONS
6.1 General
Switch on behaviour Charger can switch on under every load
Efficiency 24/80 85 % at 230Vac and 30Vdc 80A
24/100 85 % at 230Vac and 30Vdc 100A
48/50 85 % at 230Vac and 60Vdc 50A
Temperature range 0 °C until +40 °C, decreasing output power if temperature
> +40ºC
EMC According Council Directive 89/336 EEG
Emission EN 55014 (1993)
EN 61000-3-2 (1995)
EN 61000-3-3 (1995)
Immunity EN 55104 (1995)
Vibration IEC 68-2-6 (1982)
Safety EN 60335-2-29 (1991)
6.2 Input
Input voltage range 185 - 265 Vac, full output power available
Input voltage range 3-Ph 320 - 460 Vac 3-Ph, full output power available
Frequency range 45 - 65 Hz, full output power available
Maximum Input current At 230V ac input voltage :
model: 24/80 12A at 30V / 80A
24/100 16A at 30V / 100A
24/100 3-Ph 3x 3A at 30V / 100A
48/50 16A at 60V / 50A
Input fuse
model: 24/80 250Vac/8A and 12A fast 6,3x32mm, or equivalent
24/100,48/50 2 x 250Vac /12A fast 6,3x32mm, or equivalent
24/100 3-Ph 2 x 250Vac /12A fast 6,3x32mm, or equivalent
and 3-Ph MCB 6A B
Cos phi / power factor 1,0
6.3 Output
Model TG 24/80 TG 24/100 TG 48/50
TG 24/100
3-Ph
Boost charge voltage 28,50 Vdc 28,50 Vdc 57 Vdc

Float charge voltage 26,50 Vdc 26,50 Vdc 53 Vdc
Output voltage range 24-33Vdc 24-33Vdc 48-66Vdc
Output voltage range supply 0-33Vdc 0-33Vdc 0-66Vdc
2
mode
Charge characteristic IUoUo IUoUo IUoUo
2
Contact your Victron Energy dealer for this option.
26 Manual Titan
Voltage compensation for + 0,6 V + 0,6 V + 0,6 V
diode-splitter, via DIP-switch
Model TG 24/80 TG 24/100 TG 48/50
Current/voltage stability ±1% ±1% ±1%

Boost charge voltage
compensation for traction + 2,0 V + 2,0 V + 4,0 V
battery, via DIP-switch
Maximum output current 80A 100A 50A
Output current range 0-80A 0-100A 0-50A
Output voltage ripple
measured with a 50A, 80A or <100mVtt <100mVtt <200mVtt
100A resistive load
Maximum output power 2250W 3000W 3000W
Short circuit current 80A 100A 50A
Maximum starter battery 4A 4A n/a
current
Low battery alarm relay 23,8 Vdc 23,8 Vdc 47,6 Vdc
±0,8Vdc ±0,8Vdc ±1,6Vdc
High battery alarm relay 33.5Vdc 33.5Vdc 67 Vdc
± 0,8Vdc ± 0,8Vdc ± 1,6Vdc
Output fuse (flat car fuse) 6 x 20A 8 x 20A other *
Leakage current from battery
when the battery charger is ≤ 6,4 mA ≤ 6,4 mA ≤ 6,4 mA
turned off
* 6,3mm x 32mm fuse 30A slow
6.4 Mechanical
TG 24/80 TG24/100 TG48/50 TG 24/100 3-Ph
Cabinet Aluminium sea water resistant Aluminium sea water resistant

Protection IP 21 IP 21
Colour Blue (RAL5012), epoxy coated Blue (RAL5012), epoxy coated
Dimensions 368 x 250 x 257mm 515 x 260 x 265mm
Dimensions 438 x 320 x 330mm 645 x 370 x 375mm
including box
Weight 9.8 Kg 23 Kg
Weight including 10.5 Kg 24,3 Kg
box
Input 230Vac Connection block, suitable for Connection block, suitable for
connection wires up to 4 mm² wires up to 10 mm²
Battery connection M8 bolts M8 bolts
Earth connection M5 hole at bottom of the cabinet M5 hole at bottom of the cabinet
Temperature Connection block Connection block
sensor connection
Starter battery Connection block, suitable for Connection block, suitable for
Manual Titan 27
connection wires up to 1,5mm² wires up to 1,5mm²
Cooling Forced air cooling Forced air cooling
Noise < 45dB(A) < 45dB(A)
Relative humidity 95% (maximal) 95% (maximal)
28 Manual Titan
250
25 200 250 7
309
365
23
Ø6
220
25
200
Ø8
All measurements in mm.
drawing no.: TI020000

© victron energy b.v. Skylla-TG 24/80, 24/100 and Titan 48/50 dimensions date: 220703
revision.: 01
Manual Titan 29
258
29 200 250 7
5 9
1 5
5 4
3
2
Ø6
220
5
2
0
0
2
Ø8
All measurements in
drawing no.: TI030000
© victron energy b.v. Skylla-TG 24/100 3-Phase dimensions date: 130504
revision.: 00
30 Manual Titan
Connect the Internal Battery
®
The Back-UPS RS is shipped with one battery wire disconnected. To connect the internal battery, proceed as follows:
Note: Connecting the battery is a safe procedure. However, small sparks may occur during the process. This is normal.
w w w.apc.com
1 2 3 4
Back-UPS™
RS 500
User’s Manual
Place the unit on its side. Slide Pull the battery partially out of the Connect the black battery wire to the Align the battery compartment cover
the battery compartment cover chassis, exposing the battery terminals as Ground (-) terminal. Slide with the grooves in the Back-UPS RS.
upward and off of the UPS. terminals and wires. the battery back into the chassis. Slide the cover down until it locks.
990-9217A 1/04
Installation
1 Placement / Power 2 Connect Equipment 3 Connect Phone Lines 4 Switch on the
Avoid placing the Back-UPS RS in: to the Back-UPS RS to Surge Protection Back-UPS RS
Note: Allow the Back-UPS RS to charge a full eight
• Direct sunlight The rear panel of the Back-UPS RS consists of the The telephone ports provide lightning surge protection hours prior to use.
following elements: for any device connected to the telephone line
• Excessive heat Press the push-button on the front panel of the Back-
(computer, modem, fax or telephone). The telephone
• Excessive humidity or in contact with fluids of Battery Back Up Outlets (qty. of 3). These outlets ports are compatible with Home Phoneline Networking UPS RS.
any type provide battery back-up, surge protection, and Electro- Alliance (HPNA) and Digital Suscriber Line (DSL)
magnetic Interference (EMI) filtering. In case of standards, as well as all modem data rates. Connect as
power outage, battery power is automatically provided shown.
to these outlets. Power (utility or battery) is not ON LINE
supplied to these outlets when the Back-UPS RS is
switched Off. Connect a computer, monitor, and Wall Outlet ON BATTERY
external disk or CD-ROM drive to these outlets.
OVERLOAD
Surge Only Outlet. This outlet is always On (when
utility power is available) and is not controlled by the
Plug the Back-UPS RS into a wall outlet, as shown. On/Off switch. This outlet does not provide power REPLACE BATTERY
during a power outage. Connect a printer, fax machine

or scanner to this outlet.
Modem/Phone/Fax
Observe that the following events occur after
pressing and releasing the push-button:
• The green On-Line indicator flashes.
• The yellow On Battery indicator lights while
the Self-Test is being performed.
Your computer’s power cord. • When Self-Test has successfully completed,
only the green On Line indicator will be lit.
• The Back-UPS RS charges the internal battery
any time it is connected to a wall outlet. • If the internal battery is not connected, (see Step
1 above) the green On Line indicator will light
and the red Replace Battery indicator will flash.
5 Connect USB Cable and Install Software (optional) Back-UPS RS Storage

Before storing, charge the Back-UPS RS for at least
Follow the
eight hours. Store the Back-UPS RS covered and
RJ-45/USB Cable
on-screen upright in a cool, dry location. During storage,
to Back-UPS RS
Data Port instructions. recharge the battery in accordance with the following
table:
To Computer
Storage Recharge Charging
USB Port If Autoplay is not enabled on the computer, proceed as follows: Temperature Frenquency Duration
1. On the computer desktop of the display, double-click on My Every 6 months 8 Hours
Computer. -5 to 30oC
2. Double-click on the CD-ROM drive icon and follow the on- 23 to 86oF
screen instructions.
30 to 45oC Every 3 months 8 Hours
Status Indicators and Alarms 86 to 113 Fo
There are four status indicators (lights) on the front panel of the Back-UPS RS (On Line, On Battery, Overload, and Replace Battery). Please contact APC Online Technical Support to
troubleshoot the unit before returning it to APC.
On Line (green) - is lit whenever utility
power is powering the Battery Backup Overload (red) - is lit whenever power Replace Battery (red) - is lit whenever
outlets. demand has exceeded the capacity of the the battery is near the end of its useful life, Order Replacement Battery
Back-UPS RS. or flash if the battery is not connected (see
On Battery (yellow) - is lit whenever above). A battery that is near the end of its
the battery of the Back-UPS RS is useful life has insufficient run-time and The typical battery lifetime is 3-6 years (depending on
powering equipment connected to the Continuous Tone - this alarm is sounded should be replaced. the number of discharge cycles and operating
Battery Backup Outlets. whenever the Battery Backup Outlets are temperature). A replacement battery can be ordered
overloaded. over the phone from APC, or the battery can be
Chirps for 1 Minute Every 5 Hours - this
alarm is sounded whenever the battery has ordered on-line from the APC web site (see below, a
Continuous Beeping - this alarm is valid credit card is required).
sounded whenever a low battery condition failed the automatic diagnostic test.
is reached. Battery run-time is very low. Circuit Breaker - the circuit breaker
button located on the rear panel of the When ordering, please specify Battery Cartridge
Promptly save any work in progress and RBC2.
exit all open applications. Shutdown the Back-UPS RS will stick out if an
operating system, computer and the Back- overload condition forces the Back-
UPS RS. UPS RS to disconnect itself from
utility power. If the button sticks out,
disconnect non-essential equipment.
Four Beeps Every 30 Seconds - this Reset the circuit breaker by pushing
alarm is sounded whenever the Back-UPS the button inward.
is running On Battery. Consider saving
work in progress.
Troubleshooting Transfer Voltage and Sensitivity Adjustment (optional)
Use the tables below to solve minor Back-UPS RS installation and operation problems. Consult APC On-line In situations where the Back-UPS or connected equipment appears too sensitive to input voltage, it may be
Technical Support or call APC Technical Support for assistance with problems that cannot be resolved using necessary to adjust the transfer voltage. This is a simple task requiring use of the front panel pushbutton. To
this document: adjust the transfer voltage, proceed as follows:
1. Plug the Back-UPS into the utility power source. The Back-UPS will be in a Standby Mode (no indicators lit).
2. Press the front panel pushbutton fully inward for 10 seconds. All indicators on the Back-UPS will flash to
Possible Cause Procedure acknowledge going into Programming Mode.
Back-UPS will not switch on 3. The Back-UPS will then indicate its current Sensitivity Setting, as shown in the following table.
Back-UPS RS not connected to an Check that the Back-UPS RS power plug is
AC power source. securely connected to the wall outlet. Indicators Sensitivity Input Voltage Use When
Flashing Setting Range (for utility
operation)
1 Low 156 - 300 Vac Input voltage is extremely low or high. Not
(yellow) recommended for computer loads.
Back-UPS RS circuit breaker Disconnect non-essential equipment from the 2 Medium 176 - 294 Vac Back-UPS frequently goes On Battery.
“tripped”. Back-UPS RS. Reset the circuit breaker (yellow, and red) (factory default)
(located on the rear panel of the Back-UPS
RS) by pushing the circuit breaker button 3 High 176 - 288 Vac Connected equipment is sensitive to voltage
fully inward until it catches. If the circuit (yellow, red, and red) fluctuations (recommended).
breaker resets, switch the Back-UPS RS on
and reconnect the equipment one-at-a-time. If 4. To select the Low Sensitivity setting, press the pushbutton until the yellow indicator is flashing.
the circuit breaker trips again, it is likely that 5. To select the Medium Sensitivity setting, press the pushbutton until the yellow and red indicators (second and
one of the connected devices is causing the third from the top) are flashing.
overload.
6. To select the High Sensitivity setting, press the pushbutton until yellow and both red indicators (bottom
Very low or no utility voltage. Check the wall outlet that supplies power to three) are flashing.
the Back-UPS RS using a table lamp. If the 7. To exit without changing the Sensitivity Setting, press the pushbutton until the green indicator is flashing.
lamp bulb is very dim, have the utility voltage 8. Once in Programming Mode, if the pushbutton is not pressed within 5 seconds, the Back-UPS will exit
checked by a qualified electrician. Programming Mode; all indicators will extinguish.
Back-UPS does not power computer/monitor/external drive during an outage

Specifications
Internal battery is not connected. Check the battery connections. (See “Connect the Battery” under
“Installation” on the front page of this document. Output Voltage Regulation 166 - 278 Vac (default setting)
Computer, monitor or external disk/ Move computer, monitor, or external drive power cord plug to the Frequency Limits (on line) 47 - 63 Hz (autosensing)
CD-ROM drive is plugged into a Battery Backup outlets. On Battery Waveshape Stepped Sine Wave
Surge Only outlet.
Maximum Load 500 VA - 300 W
Back-UPS operates on battery although normal utility voltage exists
Typical Recharge Time 8 Hours
Back-UPS RS circuit breaker Disconnect non-essential equipment from the
“tripped”. Back-UPS RS. Reset the circuit breaker Operating Temperature 0o to 40oC (32o to 104oF)
(located on the rear panel of the Back-UPS
RS) by pushing the circuit breaker button Storage Temperature -5o to 45oC (23o to 113oF)
fully inward until it catches. Operating and Storage 0 to 95% non-condensing
Relative Humidity
The wall outlet that the Back-UPS Connect the Back-UPS RS to another wall outlet or have a qualified
RS is connected to does not supply electrician check the building wiring. Size (H x W x D) 3.6 x 6.5 x 11.2 in. (9.1 x 16.5 x 28.4 cm)
utility power to the unit. Weight 15.87 lb (7.2 kg)
Back-UPS does not provide expected backup time Shipping Weight 500 VA - 15.3 lb (7.0 kg)
Back-UPS RS is excessively Unplug non-essential Battery Backup connected equipment, such as EMI Classification EN 50091-2, Class B
loaded. printers and plug them into Surge Only outlets.
Note: Devices that have motors or dimmer switches (laser printers, On Battery Run-Time 19 Minutes typical - desktop computer and 15 inch (38.1 cm) monitor.
heaters, fans, lamps, and vacuum cleaners, for example) should not be
connected to the Battery Backup outlets.
Back-UPS RS battery is weak due Charge the battery. The battery charges whenever the Back-UPS RS is Service
to recent outage and has not had connected to a wall outlet. Typically, eight hours of charging time are
time to recharge. needed to fully charge the battery from total discharge. Back-UPS RS Note: If the Back-UPS RS requires service, do not return it to the dealer.
run-time is reduced until the battery is fully charged. The following steps should be taken.Consult the Troubleshooting section to eliminate common problems.
Determine if the circuit breaker is tripped. If the circuit breaker is tripped, reset the breaker and determine if
Battery requires replacement. Replace battery (see Order Replacement Battery). Batteries typically
last 3-6 years, shorter if subjected to frequent power outages or the problem still exists.
elevated temperatures. 1. If the problem persists, consult the APC Worldwide Web site (www.apcc.com) or call customer service.
• Record the model number of the Back-UPS RS, the serial number, and the date purchased. Be prepared
A red indicator is lit to troubleshoot the problem over the telephone with a technician. If this is not successful, the technician
The Overload indicator is lit if Move one or more equipment power plugs to the Surge Only outlets. will issue a Return Merchandise Authorization Number (RMA#) and a shipping address.
equipment connected to the Battery • If the Back-UPS RS is under warranty, repairs are free. If not, there is a repair charge.
Backup outlets is drawing more 2. Pack the Back-UPS RS in its original packaging. If the original packing is not available, ask customer
power than the Back-UPS RS can
provide. service about obtaining a new set. Pack the UPS properly to avoid damage in transit.
Note: Never use Styrofoam beads for packaging. Damage sustained in transit is not covered under warranty
TM
Battery requires replacement. The battery should be replaced within two weeks (see "Order (insuring the package for full value is recommended).
Replacement Battery"). Failure to replace the battery will result in 3. Write the RMA# on the outside of the package.
reduced run-time during a power outage.
4. Return the Back-UPS RS by insured, prepaid carrier to the address provided by customer service.
Back-UPS RS failure. Call APC for service.
Replace Battery indicator flashing and an alarm sounds when the Back-UPS is turned on
Warranty
Internal battery not connected. Check the battery connections. The standard warranty is two (2) years from the date of purchase. APC’s standard procedure is to replace the
original unit with a factory reconditioned unit. Customers who must have the original unit back due to assigned
asset tags and set depreciation schedules must declare such a need at first contact with an APC Technical
A red indicator is flashing with any other indicator flashing Support representative. APC will ship the replacement unit once the defective unit has been received by the
Back-UPS RS failure. Contact APC Online Technical Support. repair department, or cross ship upon the receipt of a valid credit card number. The customer pays for shipping
the unit to APC. APC pays ground freight transportation costs to ship the replacement to the customer.
Replace the Internal Battery APC Contact Information

To replace the internal battery, proceed as follows:
USA/Canada 1.800.800.4272
Note: Replacing the battery is a safe procedure. However, small sparks may occur during the process. This is normal.
Worldwide 1.401.789.5735
1 2 3 4 Home Page http://www.apc.com
Technical Support http://www.apc.com/support
ESupport esupport@apcc.com
Place the unit on its side. Slide Pull the battery out of the Back-UPS Slide the new battery into the battery Align the battery compartment cover
the battery compartment cover up RS. Disconnect the wires from the compartment. Connect the battery wires with the grooves in the Back-UPS RS.
and off of the Back-UPS RS. terminals. to the terminals as follows: Slide the cover down until it locks.
Black wire to Ground (-) terminal Copyright © 2004 American Power Conversion. All rights reserved.
Red wire to Positive (+) terminal APC, Back-UPS, and PowerChute are registered trademarks of American
Power Conversion. All other trademarks are property of their respective owners.

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HMMCO

HYUDAI MARINE MACHINERY CO., LTD.

1. PREPARATION FOR OPERATION

(1) Make sure that there is no foreign matter in the casing.

After starting the fan, carry out the following checks.

(1) Check to see if the rotating direction in corret.

No. Trouble Probable cause Remedy

4. IF YOU HAVE ANY DOUBTS, PLEASE DO NOT HESITATE TO CONTACT.

HYUNDI MARINE MACHINERY CO., LTD.

602-15, GAJWA-DONG, SEO-GU, INCHON CITY, KOREA. (http://hmmco.co.kr)

1. T/C REAR SIDE MOUNT TYPE FOR B & W ENGINE

(1) MOUNTING OF ELECTRIC MOTOR ON B & W AUXILIARY BLOWER

1) Place the motor on a table or flat so that shaft is in a horizontal position

2) Remove the groove from the motor.

3) Lubricate the motor shaft with oil or grease.

4) The sealing ring to be pushed over the shaft.

If the Gaslock-seal has already been mounted-check the seal lip.

11) Th inlet cone to be dismounted.

12) The GASKET (item 5) to be placed in it's right position.

(1) MAINTENANCE OF B&W AUXILIARY BLOWERS

Scroll housing made of heavy steel plate.

Tightening device, intended for pressure of up to 5 Bar

2) Lift the whole unit to its right place.

3) Mount the suction pipe from the air cooler.

4) The unit is now ready to be put into operation.

(1) MAINTENANCE OF SULZER AUXILIARY BLOWERS

do not require compensator and suction box.

The blower part consists of the following.

The joint duct consists of two mounting flanges.

1) Mount joint duct onto suction box.

(1) INSTRUCTIONS FOR DISMOUNTING OF IMPELLER ON AUXILIARY BLOWER

In the following it is recommended to see drawing No.

1) The electric connection of the motor to be dismounted.

4) Dismounting tool-as shown on the enclosed sketch No. H-TOOL-01 to be mounted

In the following it is recommended to see drawing No.

1) Grease the motor shaft with oil.

4) Motor plate to be lifted up carefully from the foundation and to be turned

7) The motor can now be electrically connected again.

1. PREPARATION FOR OPERATION

(4) Check to see that bearings are normal.

(6) Check to see that there is no part of deteriorated insulation.

(1) The condition of load, and temperature measurement.

Hear sound or know the temperature of the stator frame.

Temperature Rise at AC Machine Stator Windings Rated below 1,000V

The vibration give another indication of the condition of rotation.

Probable mechanical causes are broght about a mechanical unbalance of the

the operating switch to stop the motor.

4. CARE AFTER STOPPING

After stopping, pay attention to the point given in the paragraph

Trouble Cause Remedy

Disconnect the motor from the load.

Try to rotate by hand and if it is

difficult, the cause is a mechanical

motor without the load can be

started, check the load.

Stator winding broken Replace with a spare one.

Fuse blown out Replace with a spare one.

Readjust contact part or replace

Connecting wire broken Reconnect.

Over current relay operated Remove the cause and reset.

Bearing binding Replace with a spar one.

Abnormal Belt too tightened Reduce belt tension.

Overload Reduce load to or below rated value.