MF-82 Instruction Manual For Boiler Plant, Volume 1 (Booklet)

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Instruction manual for boiler plant, volume 1 E
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Boiler type: MISSION™ OL model25000 x 2 + MISSION™ XW = .-
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Burner type: KBSD Burner

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Project No.: RQ 100779 <t=""
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Hull No.: 1338 AIKK Order No. 961416, 961417 m
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Customer: Sumitomo Heavy Industries Marine & Engineering Co., Ltd ·c.
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AALBORG TABLE OF CONTENTS
INDUSTRIES
Table of contents
System concept (vol. 1)

Technical data .............................................................................................................. 1
Flow diagrams ............................................................................................................. 2
MISSION OL boiler (vol. 1)

Descriptions ........................................ ,........................................................................ 3
Operation and maintenance ......................................................................................... 4
Feed and boiler water .................................................................................................. 5
Water level gauge ........................................................................................·................ 6
Safety valves ................................................................................................................ 7
Feed water system ....................................................................................................... 8
Regulating feed water valve ........................................................................................ 9
. Drawings .................................................................................................................... 10
Data sheets ................................................................................................................. 11
KBSD burner (vol. 1)

Descriptions ..................................:············· ............................................................... 12
Operation and maintenance ....................................................................................... 13
Oil flow regulation..................................................................................................... 14
Oil flow meter............................................................................................................ 15
Dp-transmitter............................................................................................................ 16
Regulating valves ...................................................................................................... 17
Combustion air fan .................................................................................................... 18
Drawings .................................................................................................................... 19
Data sheets .................................................................................................................20
Performance curves ................................................................................................... 21
MISSION OL Control system (vol. 2)

MISSION control system ..... ,...................................................................................... 1
Operating principles .................................................................................................... 2
Operation of the panels ............................................................................................... .3
Commisioning and service .......................................................................................... 4
Burner sequence diagram ............................................................................................ 5
Language UK Page 112

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INDUSTRIES
Flame safeguard ........................................................................................................... 6

Menu structure for panels ............................................................................................ 7
PC monitoring system ................................................................................................. 8
Drawings for local panel. ............................................................................................. 9
Drawings for power panel ......................................................................................... 10
Set point diagrams ....................................... ;............................................................. 11
Data sheets ................................................................................................................. 12
MISSION XW boiler (vol. 2)

Descriptions ............................................................................................................... 13
Operation and maintenance ....................................................................................... 14
Safety valves .............................................................................................................. 15
Soot-blower ............................................................................................................... 16
Drawings .................................................................................................................... 17
Data sheets ................................................................................................................. 18
System Accessories (vol. 2)

Sample cooler (CHECK SCOP£) .............................................................................. 19
Circulation flow measurement (XW) ........................................................................ 20
Ignition oil pump unit ................................................................................................ 21
Three-way ball valve HFO-DO (MISSION OL) ....................................................... 22
Heater unit ................................................................................................................. 23
Fuel oil pressure control valve ...................................................................................24
Smoke density equipment (MISSION OL) ............................................................... 25
Common steam pressure indication ........................................................................... 26
Remote start-stop box ................................................................................................ 27
Spare parts (vol. 2)

Spare parts ................................................................................................................. 28
Language UK Page 2/2

MARINE BOILER SERVICE LOCATIONS
EUROPE:
ASIA PACIFIC:
Aalborg Industries A/S
P 0 Box 844, Gasvaerksvej 24 Aalborg Industries Pte. Ltd.
9100 Aalborg, Denmark 14, Tuas Avenue 18A, Singapore 638862
Phone: +45 9930 4000 Jurong Point P 0 Box 259
+45 4016 6686 (24 hrs) Singapore 916409, Republic of Singapore
Fax: +45 9816 8316 (Marine boilers} Phone: +65 6261 9898
+45 9810 2233 (Service & Repair dept.) Fax: +65 6266 1111
+45 9812 2977 (Spare parts dept.) E-mail: sin@aalborg-industries.com.sg
+45 9810 3001 (Heat exchangers) servicesin@aalborg-industries.com.sg
E-mail: aal@aalborg-industries.com fpsosin@aalborg-industries.com.sg
marine-boilers@aalborg-industries.com
heaters@aalborg-industries.com PT Aalborg Industries
fps@aalborg-industries.com n. Rawa Sumur II, Blok III
spares-marine@aalborg-industries.com Kav. CC 6-7, Kawasan Industri Pulogadung
repair-marine@aalborg-industries.com Jakarta Timur 13930, Republic of Indonesia
Phone: +62 21 461 0569
Aalborg Industries Oy Fax: +62 21 461 0568
P 0Box9 E-mail: jkt@aalborg-industries.co.id
Kaivopuistontie 33, Uotila
FIN-2610 1 Rauma, Finland Aalborg Industries Limited
Phone: +358 2 838 3100 Room 1001, Kowloon Plaza
Fax: +358 2 823 1133 485 Castle Peak Road
E-mail: rau@aalborg-industries.fi Kowloon, Hong Kong (SAR)
People's Republic of China
Aalborg Industries BV Phone: +852 2836 3826
P 0 Box 145, Ohmweg 8 Fax: +852 2834 8905
3200 AC Spijkenisse, The Netherlands E-mail: hkg@aalborg-industries.com.cn
Phone: +31 181 650 500
Fax: +31181650 501 Aalborg Industries Ltd, Guangzhou, China
E-mail: rtmw@aalborg-industries.nl ... No address will be published
Mobile tel.: +86 1335 286 0808
Aalborg Industries A/S (branch ofDK office) E-mail: sqm@aalborg-industries.com.cn
364 Denby Dale Road, Durkar
Wakefield WF4 3BB, United Kingdom Aalborg Industries (Shanghai) Ltd
Tel.: +44 1924 381102 F17, Founder Tower
Mobile: +44 796 896 1937 1122 Xin Jin Qiao Road, Pu Dong New Area
Fax: +44 1924 381104 Shanghai 201 206, People's Republic of China
E-mail: jsf@aalborg-industries.com Phone: +86 21 6302 4077
Fax: +86 21 6302 4078
E-mail: sha@aalborg-industries.com.cn
MIDDLE EAST:
Aalborg Industries (Shanghai) Ltd
Aalborg Industries A/S (Dubai branch) Rm 2201, Dalian Gold Name Commercial Tower
P 0 Box 51210, AI JadafShipyard 68 Renmin Road
Dubai, United Arab Emirates Dalian 116001, Liaoning Prov.People's Rep. China
Phone: +971 4 3241 061 Phone: +86 411 8270 9091
+971 50 654 8708 (24 hrs) +86 411 8270 9291
Fax: +971 4 3241 790 Fax: +86 411 8270 9391
E-mail: info@aalborg-industries.ae E-mail: dlc@aalborg-industries.com.cn
sales@aalborg-industries.ae
http:/lwww. aalborg-industries. com

Aalborg Industries' marine After Sales locations
ITH/700/AAL- 11 DEC 2006
ASIA PACIFIC cont'd SOUTH AMERICA:
Aalborg Industries Ltd. Aalborg Industries S.A.

5th Floor, Saesam Bldg. Rua Divino Espfrito Santo, 1.100- Bairro Carangola
1485-1, Ja-Dong, Haeundae-Gu CEP 25715-410 Petr6polis- RJ, Brazil
Busan 612-842, Korea Phone: +55 24 2233 9963
Phone: +82 51 703 6162 Fax: +55 24 2237 6603
Fax: +82 51 704 8184 E-mail: rio@aalborg-industries.com.br
E-mail: · pusan@aalborg-industries.co.kr
Technical service & repair office:
Aalborg Industries K.K. Aalborg Industries S.A.
Makler Kobe Bldg. Avenida Evaldo Costa 1045
2-2, 4-chome, Kumoi-dori Bairro Solymar
Chuo-ku, Kobe 651-0096, Japan CEP 27940-410 Macae- RJ, Brazil
Phone: +81 78 271 5720 Tel.: +55 22 2791 6623
+81 78 271 5728 (Field Service) +55 22 2791 6625
+81 78 271 5727 (Spare parts sales) Fax: +55 22 2759 4220
Fax: +81 78 271 5741 E-mail: crb@aalborg-industries.com.br
E-mail: ukb@aalborg-industries.co.jp
Aalborg Industries K.K. (branch office)

No. 9 Kowa Bldg., Bekkan
6-7, 1-chome, Akasaka Aalborg Industries REPRESENTATIVES:
Minato-ku, Tokyo 107-0052, Japan
Phone: +81 3 3584 8351 Karberg & Schmitz GmbH
Fax: +81 3 3584 8378 Palmaille 112, P 0 Box 50 08 08
E-mail: tokyo@aa1borg-industries.co.jp 22708 Hamburg, Germany
Phone: +49 40 386 0040
Fax: +49 40 389 5097
NORTH AMERICA: E-mail: info@karberg-schmitz.de
http://www.karberg-schmitz.de
Aalborg Industries, Inc.
1300 E 223rd Street, Unit 409 TECHNAVA S.A.
Carson, CA 90745, USA 6, Loudovikou Square, P 0 Box 86012
Tel.: +1310 830 9511 185 31 Piraeus, Greece
Fax: +13108309512 Phone: +30 210 4113 916
E-mail: california@aalborg-industries.com Fax: +30 210 41 22 450
E-mail: info@technava.gr
Aalborg Industries, Inc. · http://www.technava.gr
11824 Miramar Parkway
Miramar, FL 33025, USA Mistral di Marco Zanelli
Phone: + 1 954 435 5999 Via Orsini 2/16
Fax: + 1 954 435 5490 16146 Genova, Italy
E-mail: florida@aalborg-industries.com Phone: +39 010 310 6947
Fax: +39 010 310 6056
Aalborg Industries Houston, Inc. +39 010 370 5488 (repair/spare
6005 South Loop East parts/after sales)
Houston, TX 77033, USA E-mail: info@mistral-srl.it
Phone: +1 713 643 2488 spare@mistral-srl.it
Fax: +1 713 643 4100 aftersales@mistral-srl.it
E-mail: houston@aalborg-industries.com
See "Contact us" on company web page for more

agents ' locations
http://www. aalborg-industries. com

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AALBORG TECHNICAL DATA 809010#00
INDUSTRIES
Technical data for boiler plant
1 General data
• Request No.: ..................................................................................... 100779-1

• ProjectNo./Nos.: .................................................................... 961416/961417
• Hull No./Nos.: ......................................................................................... 1338
2 General plant data
• Classification society: .............................................................................. LRS

• Sub-notification: ...................................................................................... UMS
• Flange standard: ......................................................................................... EN
• Plant supply voltage: ....................................................................... 3 x 440 V
• Plant control voltage: ...................................................................... AC 230 V
• Pilot voltage: ........................................................................................... 24 V
• Frequency: .............................................................................................. 60 Hz
• Pressure gauge calibration: ..................................... ~ ................................. Yes
• Thermometer calibration: ............... :.......................................................... Yes
• Language on signs: .............................................................................. English
• Ambient air temperature: ........................................................................ 45°C
• Panel supply for remote control P.C.: ............................................. AC 220 V
3 Documentation data
• Language for manuals: ......................................................................... English

• Set of technical documentation manuals: .......................... :........................... 5
• Set of approval manuals: ............................................................................... 5
• Set of working manuals: ....................................................................... ;....... 5
• Set of instruction manuals: ............................................................................ 4
• Set of CD-rom instruction manuals: ............................................................ 1

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AALBORG TECHNICAL DATA SD9010#11
INDUSTRIES
Technical data for MISSION™ Ol
1 General data
• Request No.: ..................................................................................... 100779-1

• ProjectNo./N"os.: ................................................................................. 961416
• Hull No./N"os.: ......................................................................................... 1338
2 Dimensions for boiler unit
• Height to top oflocal control panel: ............................................... 9,287 mm

• Diameter incl. insulation: ................................................................ 3,320 mm
• Total height incl. retraction ofburner lance: ................................. 10,050 mm
• Weight of boiler unit excl. water: ...................................................... 30.3 ton
• Weight of boiler unit incl. water: ....................................................... 41.5 ton
3 Water/steam process data
• Steam output per included boiler: ................................................ 25,000 kglh

• Working pressure: .......................................................................... 1.6 MPa(g)
• Working temperature: ........................................................................... 204°C
• Max. allowable working pressure: ................................................ 1.8 MPa(g)
• Feed water operation: .................................................................... Modulating
• Feed water temperature, operation: .................................................... 85-95°C
• Feed water temperature, layout: .............................................................. 60°C
4 Data for pressure part
• Boiler type: ....................... ,............................................. Large oil fired boiler

• Boiler model: ........................................................................ MISSIONTM OL
• Test pressure: ................................................... 1.5 x Design pressure MPa(g)
• Max. allowable shrink: ................... ~ .................................................... 0.49 m3
• Max. allowable swell: ......................................................................... 1.02 m3
• Protection of boiler body: ............................Anti corrosion and heat resistant

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• Insulation thickness: ............................................................................. 75 mm

• Cladding type: ...................................................................................... Trapez
• Colour of insulation plates: ................................................... Blue(RAL5002)
5 Combustion process data
• Min. calorific value of diesel oil: ................................................ 42,200 kJ/kg

• Min. viscosity of diesel oil: ....................................................... 3 eSt. at 40°C
• Max. viscosity of diesel oil: .................................................... 12 eSt. at 15°C
• Density of diesel oil: .......................................................... 900 kg/m3 at 15°C
• Min. calorific value of fuel oil: .......................... ~ ....................... .40,200 kJ/kg
• Max. viscosity of fuel oil: ..................................................... 700 eSt. at 50°C
• Density of fuel oil: ............................................................. 991 kg/m3 at 15°C
• Fuel oil temperature before pre-heater: ................................................... 60°C
• Fuel oil viscosity at burner inlet: ..................................................... 15-20 eSt.
• Fuel oil temperature at burner inlet: ...................................................... 145°C
• Air excess No. at 100% load: ................................................................... 1.15
• Flue gas temperature (clean boiler): ...................................................... 390°C
• Air consumption at 100% load: ................................................... 29,400 kg/h
• Flue gas flow (approx.): ............................................................... 31,300 kg/h
6 Data for pressure loss layout

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• Pressure loss across flue gas system, max.: ................................... 25 mmWC
• Pressure loss across air duct system, max.: .................................... 10 mmWC
7 Data for burner
• Burner type: .......................................................................... Steam atomising

• Burner regulation: ......................................................................... Modulating
• Model: .......................................................................................... KBSD 1900
• Noise level for fan: ......................................................................... 105 dB(A)
• Primary fuel: ................................................................. Heavy fuel oil (HFO)
• Secondary fuel: .......................................................................Diesel oil (DO)
• Burner capacity on diesel oil, max.: ................................................ 1790 kg/h
• Burner capacity on fuel oil, min.: ..................................................... 190 kg/h
• Burner capacity on fuel oil, max.: ................................................... 1900 kg/h
·Language UK. Page 2/3

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• Colour of burner unit: .............................................................. Red RAL3000
8 Data for atom ising steam
• Atomising steam pressure to burner unit, min.: ............................... 0.60 l\.1Pa

• Atomising steam consumption, max.: ................................................. 95 kg/h
• Atomising air pressure to burner unit, min.: .................................... 0.70 l\.1Pa
• Atomising air consumption, max.: .................................................... 170 kg/h
9 Data for control system
• Insulation class: ............................................................................................. F

• Degree of protection: .................................................................................. 54
• Colour oflocal control panel: ................................................ Red(RAL3 000)
• CololJ! of power panel: .................................................... Munsell(7.5BG7/2)
10 Operational data for boiler plant
• Operation: ............................................................................... 24h unattended

• Automatic mode: ....................................................................................... Yes
• Master/slave mode: ................................................................................... Yes
• Inert gas mode: ........................................ , ................................................. Yes
• Manual mode: ........................................................................................... Yes
• Emergency mode: ..................................................................................... Yes
11 Power Panel
• Control of fuel oil pump unit: ................................................................... Yes

• Monitoring of smoke density: ................................................................... Yes
• Am meter for combustion air fan: ............................................................. Yes
• Start method combustion air fan: ............................................. Star delta start

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AALBORG' TECHNICAL DATA 809010#35
INDUSTRIES
Technical data for MISSION™ XW
1 General data
• RequestNo.: ..................................................................................... 100779-1

• ProjectNo./N"os.: ................................................................................. 961417
• Hull No./N"os.: ......................................................................................... 1338
2 Dimensions for boiler unit
• Height excl. mountings and insulation: ........................................... 2,040 mm

• Length excl. insulation and mountings: .......................................... 2,161 mm
• Width excl. Insulation and mountings: ........................................... 1,826 mm
• Tube retraction length: .................................................................... 2,000 mm
• Weight of boiler unit excl. water: ........................................................ 7.5 ton
• Weight of boiler unit incl.water: ......................................................... 8.0 ton
3 Water/steam process data
• Steam output per included boiler: .................................................. 1,100 kg/h

• Working pressure: ....................................................................... 0.70 MPa(g)
• Working temperature: ........................................................................... 170°C
• Max. allowable working pressure: ................................................ 2.2 MPa(g)
• Pressure loss across water/steam side: ........................................ 0.03 MPa(g)
4 Data for pressure part
• Boiler type: .......................................................................... Water tube boiler

• Boiler model: ...................................................................... l\1ISSIONTM "XW
• Test pressure: ................................................... 1.5 x Design pressure MPa(g)
• Protection of boiler body: ............................Anti corrosion and heat resistant
• Insulation thickness: ........................................................................... 150 mm
• Cladding type: ...................................................................... Galvanized plate
• Colour of insulation plates: .............................................. Heat resistant silver

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AALBORG TECHNICAL DATA SD9010#35
INDUSTRIES
5 Combustion process data
• Engine load, design: ........................................................................ 90%MCR

• Design condition: ...................................................................................... ISO
• Exhaust gas flow: ....................................................................... 100,800 kglh
• Inlet temperature of exhaust gas: .......................................................... 228°C
• Outlet temperature of exhaust gas: ........................................................ 198°C

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• Pressur,e loss across boiler at design load: ................................... 105 mmWC

• Pressure loss across inlet box: ....................................................... 9.0 mmWC
• Pressure loss across outlet box: ..................................................... S.O mmWC

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INDUSTRIES
Table of contents
Flow diagrams
Steam/water system ................................................................................ XOl :800036C
List of parts for steam/water flow diagram ............................................. X01:800036C
Exhaust gas economizer ....................................................................... AMB:320159B
Fixed circulation water control ........................................................... AMB:320160A
List of parts for exhaust gas economizer ............................................. AMB:320159B
Oil System ............................................................................................ 92X02:800037
List of parts for fuel oil supply ............................................................. 92X02:800037
Burner unit ........................................................................................... 92X02:029038e
List of Parts for KBSD burner ............................................................. 92X02:029038e

AALBORG
INDUSTRIES
List of parts - steam/water

Boiler plant: ........................................................................ 2 x 11ISSION™ OL + 1 x 11ISSION™ XW
Request No.: .................................................................................................................................. 100779
Configuration No.: ................................................................................................................................... I
Hull No./N"os: .................................................................................................................................... 1338
ProjectNo./Nos.: ........................................................................................................................... 100779
P&I Diagram drawing No.: ................................................................................................... X01:800036
P&l Diagram revision.: ............................................................................................................................ C
Date: ............................................................................................................................. ,.. 17 January 2008
Reading guide:
List of Parts reflects parts delivered by Aalborg Industries.
Tag Numbers are given without the index used on the P&I diagram. E.g. "C2" is found on the P&l
Diagram as "1C2" and "2C2" for boiler 1 and 2 respectively.
MISSIQNTM Ol boiler
Tag No. Qty. Dim (DN) Application Type AI Datasheet or
supply Drawing
Oil-fired boiler (Qty. gives the number of parts per oil-fired boiler)
c 1 N/A MISSIQNTMQL - Yes AMB:250512
Cl 1 65/100 Safety valve Safety Yes 261 1174
C30I I 65/IOO Safety valve Safety Yes 2611174
Cl86 1 N/A Remote pull for safety valve - Yes K03 032121
C486 1 N/A Remote pull for safety valve - Yes K03 032121
C2 1 200 Main steam valve StoJ) Angle Yes 251 1122
C3 1 80 Feed water valve Stop Angle Yes 251 1093
C303 1 80 Feed water valve Stoi>_ Angle Yes 251 1153
C4 1 80 Feed water valve Stop SDNR Yes 264 1093
C304 1 80 Feed water valve Stop_SDNR Yes 264 1153
C6 I 40 Scum valve Stop Angle Yes 265 1090
SDNR
C7 1 40 Blow down valve Stop SDNR Yes 2641090
C307 1 40 Blow down valve Stop SDNR Yes 264 1090
C9 1 112" Sample valve Stop Yes 6220 000002
ClO 1 112" Air escape valve Stop Yes 6220 000002
C11 1 112" Gauge board valve Stop Yes 6220 000002
C13 I 20 Atomizing steam Stop SDNR Yes 264 1087
Cl4 I 200 Valve, Main steam Check Yes 6020 000064
Cl5 I 25 By-pass steam valve angle Stop Angle Yes 251 1088
CI6 1 50 Furnace drain valve Gate Yes 253 1005
Cl7 I 25 Water level gauge left Reflective Yes 7010 000136
CI8 I 25 Water level gauge right Reflective Yes 7010 000135
C187 I N/A Remote pull for water level - Yes K03 032122
gauge
Configumtion sys1cm release DbWork Page 1/3

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AALBORG LIST OF PARTS - STEAMlwATER ,.. ' . . 1oom-~
IN D U S T' R I E· S .
coru:£uraoon "-
Tag No. Qty. Dim (DN) Application Type AI Datasheet or

supply Drawing
C487 1 N/A
Remote pull for water level - Yes K03 032122
gauge '
C19 1 100 Circ. outlet valve Stop SDNR Yes 264 1094
C21 1 125 Circ. inlet valve Stop Yes 250 1095
C22 1 125 Valve, Circ. water inlet Check Yes 6020 000062
C27 1 25 Stop valve, DP Unit Stop Yes 250 1088
C327 I 25 Stop valve, DP Unit Stop Yes 250 I088
C28 I 25 Stop valve, Level Switch Stop Yes 250 I088
C328 I 25 Stop valve, Level Switch Stop Yes 250 I088
WI6 I 25 Water level control DP Yes 70Z 036686
WI4 I 25 Low level alarm Float switch Yes 8100 000008
Smoke densi~ - MISSIONTM OL (Qty. gives the number of parts per oil-fired boiler)
K24 1 NIA Smoke density - Yes -
K24.1 1 NIA Control device - Yes 8210 000028
K24.2 1 N/A Transmitter - Yes 8500 000309
K24.3 1 N/A Receiver - Yes 8500 000310
K24.5 1 N/A Blower - Yes 8500 000312
Heatin coil- MISSIONTM OL (Qty. gives the number of parts per oil-fired boiler)
C24 1 25 Valve for heating coil inlet Stop Yes 250 1088
C25 1 25 Valve for heating coil outlet Stop Yes 250 1088
C26 1 112" I 3/4" Safety valve for heating coil Safety Yes 261 1358
Soot blower- MISSIONTM OL (Q!y. gives the number of_parts per oil-fired boiler)
Cl94 1 65 Stop valve for soot blower Stop Yes 250 1092
C196 1 1/2" Drain valve for soot blower Stop Yes 6220 000002
C199 1 50 Soot blower ball valve Stop Yes 87D3068
C499 1 50 Soot blower ball valve Stop Yes 87D3068
C227 1 65 IGS control valve Control Yes ball113fl
Cl95 1 15 Steam trap for soot blower - Yes 7020 000001
Other Parts
Feed water rel!ulation valve Qty. gives the number of parts per oil-fired boiler)
WI 1 40 Feed Water Control Valve Control Yes 6050 002002
with pneumatic actuator
W2 1 20 Feed Water Control Valve Control Yes 6050 002001
with pneumatic actuator
W3 1 1/4 Filter regulator with 0-10 barg Yes 291 5101
automatic drain
Sample coolers- MISSIONTM OL
1M25 1 N/A Sample cooler - oil-fired SCS20 Yes 875 0005
boiler
Remote indication- Steam pressure and Water level- MISSIONTM OL
H2 2 N/A Remote indication of Steam Digital Yes Output signal only
pressure
W32 2 N/A Remote indication of Water J)igital Yes Output signal only
level
Smoke Outlet- MISSIONTM OL (Qty. gives the number of parts per oil-fired boiler)
Cl79 1 900 Smoke outlet - Yes JIS F 7805A
Gauge board- MISSIONTM OL (Qty. gives the number of parts per oil.jired boiler)
C30 1 N/A Gauge board (Specified on Burner Unit Yes -
Diagram- therefore not shown on Water/Steam
P&I-diagram)
Power panel- MISSIONTM OL
Ll 1 Power panel - Yes -
Local control Jlanel- MISSIONTM OL (Qty. gives the number of parts per boiler plant)
L2 2 Local Control panel - Yes -
Configuration system n:lease DbWork Page 2/3

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AALBORG ~;-- LIST.QF PARTS- STEAMNVATER, ·. "'·. '·.· .·· . . . ·~;~~auon 100779-1 -
iN bU S r'R I E,:s ' ' ~ . \ . .'

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Tag No. Qty. Dim(DN) Application Type AI Datasheet or

sup_l)_ly_ Drawing
Control system - Remote PC
L3 1 N/A Remote PC HP Compaq - Yes 9320 000010
dc7600
L3.1 1 N/A Monitor 15" -Flush mounted - Yes 8500 000387
L3.2 1 N/A Keyboard - Yes 8500 000539
L3.3 1 N/A Trackball - Yes 8500 000129
L3.4 1 230V Converter box - Yes 8500 000130
L3.5 1 N/A Mission installation set - Yes 8500 000388
L3.6 1 N/A PrinterCanon Bubble Jet - Yes 8500 000770
IP4300
L3.7 1 N/A Printer cable - Yes -
L3.8 1 N/A Cable w. Power Box - Yes 8500 000323
L3.9 1 N/A Marine Kit PC D530 - Yes 8500 000540
L3.10 1 N/A Marine Kit Keyboard - Yes 8500 000541
MISSION™ XW boiler
Tag No. Qty. Dim(DN) Application Type AI Datasheet or
s~ Drawing
Exhaust gas fired boiler (Qty. gives the number of parts per exhaust gas boiler)
c 1 MISSION™XW 7.0 barg Yes AMB:250495
Circulation flow measurement - MISSIONTM XWJQ!y._gives the number of_l)_arts___e_er exhaust }!as boiler)
M149 1 80 Orifice - for circulation flow -Yes K18 036327
M136 1 0-1 Differential_l)_ressure switch -Yes 8040 000004
Boiler Plant - Common

Tag No. Qty. Dim Application Type AI Datasheet or
(DN) supply Drawing
Spare part box
S-C-9 1 N/A
Spare part box (not shown on - Yes 649 9402
the diagram)
Common steam pressure Measurement
H3 1 0-25 Pressure transmitter - Yes 8010 000014
H14 1 112" Pressure transmitter valve Stop Yes 254 1002
A80 1 Chemical dosing unit DREW Yes MFB:421161

30gal
Page 3/3
Description Index Date Drown · ··Appr.
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l - I Q
ie
I :
I I r1~c1g- I I
1J~os~size: !.!_3_f~---, ~
1...-T"'I 8 18 I EV1 1 REFER '(0_ BOILER .DBAWING
~__....,.. EV~~ ~~ r'~(25A)
\
,_, r-/
____-+-;l- - - - " : :
~----- ('"lo.Ocul) b == A22 i i 'f------------(125A)_________________ __j ! !
1 r-, · A11 A11 I I 1 1
Ii II
>
~--~L ------
~~
11
~ r!~ r!~
1(..) I I . t + I ______ =fI
~~1 ~~
1
D~N i
c
A20
I I I I
I <'I 1 < aoo*~< 2ooo*1 > I
-:f--W-------- ~ --~~-=--=--=-----Jj}22 1----~~~~- M1<J71:i: : =: j:~=: Jj 1p: t9r=1=60= : : r-·- <- (80A)- ~ 1 /71L L----- i---- ~-- --- -'~
EV5il-<(
- ~ '---,
*1
STRAIGHT
~------«\:::::~II
I
-----,
I
I
I
I
I I
I
I
/
I I~ PIPE I
I /_;--'!'
I
I
I
I
I I
T t c JtM136 h L-----~,J>------..1---e----~ I REFER '(O_BOILER .DBAWING I
I DRAIN f--.1 I I I
I
I
F7805-A 1300A I
I
I
iI I I
I I
L___~::=::~
~H.~ I BOILER W. CIRCUL. PUMP
(27 m3/h X 35 mTH)
ffi~M~ I
---------------------------~
(1300A) I
......... I
;151
~I
~I
'f
To SOOT SEPA
Item I Designation IPes. I Dimension I Material I Article No.
NOTE: Title: Drawn _(~........, Date
1) -.;-u-~,.,.- PIPING AND CABLE ARE NOT

TANK
MISSION~XW SaY\_"~ 2-Nov-2006
SUPPLIED BY MLBORG
INDUSTRIES KK
Customer Sumitomo Heavy Industries Marine &Engineering Co., Ltd. . ....
•••••
•••••••
Exhaust gas economizer
Appr. • ~
M~~)
Date
2-Nov-2006
2) SIZES ON PIPE LINES REFER TO CONN. Society LRS-UMS ••••••• Weight '-="' Scale: Size
OF EQUIPMENTS.
HOWEVER, THE SIZE OF EACH PIPE LINE Newb. No. 1338 illiiiili Flow diagram
1 :10 A3
SHOULD BE DECIDED BY SHIPYARD Project No. 100779 AALBORG r-----------------------------~
Article/Drawing No: Affix
CONSIDERING THE PRESS. DROP INDUSTRIES lHIS DRAWING AND DESIGN SHOWN HERElN IS iHE PROPERTY OF MLBORG INDUSTRIES
IN THE PIPE. Boiler No. 18281 AND MUST NOT BE USED BY OR REPRODUCED FOR lHIRD PARTY AMB: 320159 lB··
Description I Index I Date I tfr~ ~
M136 correcte
M149
10 x DNo st~oight pipe I 25 x DNo stroight pipe I
5 x DNa 2 x DNa
1
To --
evaporator~
¥----~ ~~/ h---r:==----==1----=----~ rh--:::1:=-:--==:==----===---r
1
~" ~~---------t--------~~--~------------------
I I 7 ~-7 ~
--
From
0 i----!=---1 y y 0 Circulating
I I pumps
I ·I
I I
1,..-..... ...--,1
If \I II 1
r
1,_.....1 ' ...._ .... 1
II I
DPS
I
II
II II II I
M171 I I I
I M136
__
I
I
l, __ I
....J
I
l,
I
....J
Pos. 1: Orifice Pos.2: Reducing valve

0 (w. counter flanges) (JIS F7313,needle type)
.....:J
..'i Size DNa Lo kv flow DNP. L H kv flow
(mm) {mm) coeff {mm) {mm) (mm) coeff
Counter flanges for orifice and valve (including
1 32 93 6.83 2D 160 230 7.0 bolts and gaskets) are supplied loose.
2 40 99 10.9 25 180 255 10.5
NOTE: Items not listed below are yard supply
3 50 105 18.6 32 190 270 19
4 65 113 30.0 40 200 290 31
M171 Reducing valve JIS F7313
X 5 80 125 45.0 50 230 305 45
6 100 139 73.0 65 270 345 77 M149 Orifice 1 See table
M136 Diff pressure indicator switch
Conversion factor for flow coefficients: cv=1.17xkv Item Designation Pes. Dimension }. icle No.
('~
1 ~ov-2006
Title: Drown
... MISSIONnt XW SaY

...
Customer um~omo Hemv Industries Marine &Engineering Co., Lt .
......
....
ate
Society
Newb. No.
LRS-UMS
1338
. .
iiiiiiiii
....... Exhaust gas economizer
Welg~
2-Nov-2006
Scale:
1:10
Size
A3
Fixed circulation water control
Project No. 100779 AALBORG 1 - - - - - - - - - - - - - - - I A r t l c l e / D r a w l n g No:
Affix
INDUITIIII 1MIS DRAWIHQ N«J ~ SHCJMrC HEROH CS Tt£ PROPERrY Of' M.BORO HJUmaES
Boiler No. 18281 NfD WST NOT IE USED BY eft REPROOUCm F'OR 1HRD PNnY AMB:320160 A
.
,.. ....
......
.... .
iliiiilia.
AALBORG LIST QF PARTS- STEAM/WATER Configurouon lOOn9-l
I' N b U 5 'r' It I £: 5
List of parts - steam/water

Boiler plant: ........................................................................ 2 x MISSION™ OL + 1 x MISSION™ XW
Request No.: .................................................................................................................................. 100779
Configuration No.: ..................................................... ;: ............................................................................ 1
Hull No./N"os: .................................................................................................................................... 1338
Project No./N"os.: ........................................................................................................................... 961417
P&I Diagram drawing No.: ................................................................................................ AMB: 320159
P&I Diagram revision.: ............................................................................................................................ B
Date: ................................................................................................................................ 26 October 2007
Reading guide:
List of Parts reflects parts delivered by Aalborg Industries K.K. (UKB).
Tag Numbers are given without the index used on the P&I diagram. E.g. "C2" is found on the P&I
Diagram as "1C2" and "2C2" for boiler 1 and 2 respectively.
MISSION™ XW boiler
(DN) supply Drawing
Exhaust gas fired boiler (Qty. gives the number of parts per exhaust gas boiler)
1 MISSION™XW 7 barg Yes AMB:250514
EV1 1 25/65 Safety valve 20k-25A Yes 4-522447
ns B8210
EV5 1 20 Drain valve ns F7421 Yes -
FGU20020F
EV6 1 10 Air vent valve JISF7421 Yes -
FGU200010SC
EV7 1 6 Pressure gauge root valve JIS F7388 Yes -
FGT20006SC
A18 1 1/2" Pressure gauge, 0150 JISB7505 Yes -
BVS1/2x150~x
3.5MPa
A20 1 300mm
Differential pressure indicator UB Yes MFB:420637A
(Exhaust gas side)
A22 2 PT3/4 Thermometer 0-500°C Yes AMB:420143
- 1 - Cautionplate - Yes MFB:420545B
Soot blowers- MISSIONTM XW (Qty. gives the number of parts per exhaust gas boiler)
All 4 50 Soot blower - Full rotating Manual Yes AMB: 320147
EV4 4 50 Soot blower inlet valve ns F7313 Yes -
FG20050
Circulation flow measurement - MISSIONTM XW (Qty. gives the number of parts per exhaust ![as boiler)
Ml71 1 50 Reducing valve ns F7313 Yes -
i FG20050S
Needle
Configmaticm system rel""" DbWort< Page 111

Description Index Date Drawn Appr.
Yard comment. A 10-Jan-2007 SaY MaF
Yard comment. B ~Mar-2007 ~ MaE;:: ,
c~cs}ru~;·:MCi~-a§:e~Jpc;r:··-~·=:·.·:.:.~::·.::: :~::.::·:::~•,:-::.·:~~::~·_:":.··.~·: ..c..,. it:J~~;2oo~ :.s~- ll~MaJ=1~1

1L2g:-- Remote
2t~~==
2L2. - -
2W20--- Local --~L1
- - · L3
Power ==:::8fC2 11'120--- Local --~Lt
- - . L3
l1· - - control
~ -~/
control panel control -- -1W1
-- · 2W1 PC
-- · 2W14 -- ·1W14
panel panel
2~~:~== ==::8~~ri7
-- • 2W16 -- ·1W16
2C30(J--- 2l2 L1 1C3oQ---- 1L2 L3
~ _,....., Service steam

low pressure
common Steam
r-r----------r-----------------------------------------------------------------r,----------.,-----~P~re~ss,ur~e~M~e~as~ur~e~m~en~t------~-------L-------c~J SeNicesteam
Z- ., high pressure
::~
14
0 Instrument
r<1~4
L1 air
~--------------------"' ~4':>.
?C-4'4:> ~
2C304 J ~ ~
~ _ .,rC2 ~I o
To Bumer
L1
1C3D4
1C4
~
g ~
§
!
0
1C2 ~
~ ~ To Bumer
• 0L1 1':::\
®I
I \I/
~f-.:
lnstrumentalr
/A ;7·---~~
-~i >;_s -~
~
;o~ ~
' 1~ ~ z,:L,A-:'~~A-:'4'1
~
ki
~ iJ
~I
~
[!]
lnstrumentalr .-------~-_c._\l'-i1_..c8(Q
/."'·
',~)
"'~~N
511 § H;~ rT~ -§
@' -1 fi'
- ~ 0 III
11
Steam dump valve
1\
2W31 \~/ "!!~----··.::c:; 2L2~-1-----~.:;~.:.-

------~-E---~::::·=!:::::::1 - ji'Y!~
1
....} : 1 L2~
.. 1C27 ~.~~- ------~
~~~.
,_. .....
2L2 0;-- LS : : 2C17 Ll : 1L2 : : 0;- LS : : 1C17 Ll :
0-f- OP : : H><)-: 2C487 : 0-f- OP : : H><f-: 1C487 :
::r_J ~ 2~
2L20---I--_j
~
:2C~7 ~
,;.,;~\{
~ 2C328 ~
:....... : y
~
2C179 I
: :1C327
..: .......: 1C328 ..:
1
1W14y : .•..... :
..:
······I·· 2cY 1cY y 1C179
[\ [\ Y MISSION"' OL .r-·\ \
'I'
y MISSIONTM Ol
··~....·
'---- (Oil-fired boiler) j' '-- ...
Feed water \: Feed water
Ha--¢ cooling
Steam
C>~~+---------
reg, valve
mode {2C227} • J
Closed at IGS lnstru~ent air Steam Dump
Condenser I 'I
V"
water
Soot bl";~; 94 ~I.-. ..., 1C9
~
I
2C199' I' ::1.2C195

2C499 ~ I "17'
~ / 2C196 I
l:!
0 1C25
!"-- ss L1
i: ~L--+----~--+-------~---4_J
y 2C307 2C7
1M25
1C307
!
~
y y
-
Circulation flow
measurement
M171 (>
M149-=-h'b
(1Xt" ToYam
1 r I I
Hot well
I
L-
~~ ~
~~ ~ Important X% return flow
II
II
II
@-txJ- @-txJ-
Circulation pumps
1 t I
Feed water
pumps O.F.
_j
IRQ No. RQ100635 I CFNo. CF1 Hie: Drawn (}J!. 'ate

Signatures: I -!SJ- Check valve
---0 On page electrical connection
NOTE:
Customer Sumitomo Heavy Industries Marine & Enginineering Co.,Ltd P&ID, Steam/ water system SaY\_~, 1-Nov-2006
Steam
Water
--1><1-- Globe stop valve ---E> Off page electrical connection
-The indicated Tag. No. are for
reference to part list only.
Society
Newb. No.
LRS
1338
.....
·••••• · 2 x MISSION™OL + 1 x MISSION™XW
Arr.s "· "--' :tJate
\ JJ\:iaf 2-Nov-2006
Chemicals
Air
Blow down/drain lines
-t::Kl-
--!>+-
Gate valve
Globe stop valve (SDNR)
---0
t
Piping connection
Open drain
-Scope of supply is stated in the
separate List of parts.
- Components: see separate List of parts.
Project No.
Boiler No.
100779
18279
6iiiiiiii
AALIORG
We~; Scale: Size
A2
Oil
-tx:xl- Ball valve
- For electrical connections, see actual
rc.\
rt--------------------------------------~Article/Drawing No:
Index
Exhaust/ Flue gas @ Steam trap electrical wiring diagrams. Boiler No. 18280 INDUITitll!l
j-L_:,P_:r:;:OJc;;'e..;.cl::-:N:..:.::.O:_.r-1;_:0:,::06:;3::5-41-------+l-------t-------t------~~~------JII-----------------l ""'ORAWING AND DESIGN SHOWN HEREIN IS lHf PROPERlY OF MLI!ORG INDUSTRIES
Preassembled Unit t Reducer - Principal diagram only
[Boiler No. 18281 . . _ . _ _ Plot Date: ANIIMUSTNDTBEUSEDBYORREPRoouceoFORllftRDPARTY X01 :800036 ~
Air- Free Air- Free I Description I Index Date I Drawn Appr.
suction suction
~ ~:~~-~······:
......
6--B : 2R
1R
0---
0---
==~· ~m
~~~r--0'"
Locel Locel
Power - - · G224
control control G99 ~-- panel - - . G100
== ...._____, == : ?d~~5
panel ---0 1R panel ---0 2R G28 · - - - - . G147
---0 ---0
2G~~g
1R 2R 1
1L2 2L2 : L
-~······: jL
~
1R 9,-----0L1
d, · I :
1L2 · ·· 1· · • · · • ·
I
••••••••••••••••••••• J•••••• Heavy fuel oil
Diesel fuil oil tank
Viscosity:
settling tank ..8
1F Viscosity: .a
(for pumping)
max. 12cSt
(for pumping) "'c
min. 3 eSt.
max. 380 eSt ~i==
min. 45 eSt.
Burner unit flow diagram Burner unit flow diagram
L
92X02:029038 92X02:029038
L1
<j> 2G145
t t
~.·:····:
j .L I
rr==j;o::F+<JF=!=(
:
t
t t t
J~,·····:
G78
- :. .r
1G145 I1
rD~====~======~
Ignition oil pump

L1 0 L1
? L1
L1 ?
Steam
G2~
G19 M I G224
I
~~
xs
ill
t t t t
max. 16 bar
min. 6 bar
"""
-v
L1 L1
I
L-----J><l--+---. ~ ~ 1G23
7
~~
........ ..f. .¥.. .... 0 ~ta.~ stop box G115
9
I
9
I
PI I
I
',fl_
I
I
"~., G~tT~
I I
)...
l=!=..!..=t_,'JJI='--=--,
-
I
Ll
7~ :
G105
PI /~" :
. . . . ... ... -~ ............... : Material for piping system for AI supply
Fuel oil supply pump TvD8 IMatena IStandard
1 Plpeo>012(Maln"'*) 5135.8115137.81 DIN 17175/17177/1630
2 Pipes 012 (lnstnunont pipes) 5137.4 DIN 1630
3 Reclucon > 012 (Bull Mid) 5135.81/5137.81 DIN 17175/17177
4 Elbowll > 012 (Bull Mid) 5I 35.81/5131.81 DIN 17175/17177
L1 5 T• piece >012 (Bull wold) 5I 35.81/5131.81 DIN 17115/17177
a eon.-.(Culllngmg) SloeiDIN3859 DIN 2353/ISO 8434-1 a4
[Gs7--I-G1ooi
I DIN 11243
-
1 Flanges (PN40) C22.8
1 ..
~~~~ 8Th-- 5135.81 150228-1 (Cyt. Maloltuoada)
II~
II II ~
L _______ -1
I
G148
MEDIUM 'NOR KING
Technical Data
DESIGN DESIGN TEST
PRESS. PRESS TEMP. PRESS.
(barg) (barg) ("C) (bar g)
FUEL OIL 15
(suction side)
0-2 10 160
-
FUEL OIL 45/48
(delivery side)
20-28.5 30132 160 NOTE1
NOTE1
STEAM 6-16 19 SAT. 28.5
Note 1.: Design-/ Test pressure (32/48 barg) for class LRS.
Signatures:
I -1><1-
Globe stop valve
Steam ~ Globe stop valve (SDNR)
Drawn Date
Water -co:!- Ball valve Title:
~ [Ra No. I CFNo. P&ID, Fuel oil supply system SaY 2-Nov-2006
Chemicals
---0
Steamtrap NOTE: RQ100779 CF1
.....
..... Appr. Date
·······
Air - Principal diagram only. Customer Sumitomo Heavy Industries Marine & Enginineering Co.,Ltd
On page electrical connection
-All piping carrying heavy fuel oil must be traced and insulated.
For 2 x Steam atomizing burner MaF 2-Nov-2006
Blow down/drain lines
----E) Off page electrical connection - In case of steam tracing it should be possible to control the heat output.
Society LRS ••••••• Size
Oil -The indicated tag nos. are for reference to part list only.
- Scope of supply IS stated in the separate List of parts.
Newb. No. 1338 illllllli Weight Scale:
A2
Exhaust/ Flue gas
- Components: see separate List of parts.
Project No.
Boiler No.
10!ln9
18279
AALBORG 1---------------------l Article/Drawing No:
Index
Preassembled Unn - For electrical connections, see actual electrical wiring diagrams. INDUITIIII
Plot Date: 92X02:800037

....
., •·
•···
Jiiiliii
AALBORG
Jf"-•-;,T• r, "~>''
i:z, LIST.GF PARTS- FUEL OIL SUPPLY.

'l• ''<''' . ,' - ·• • · : " ' - :•' ' ., ' -~•
., : ·.. ·
·"' •
,
< : ' ' > ', " "
. , .confi~>uon'!;o,;~~ ·-.
''''
""\~>;)/~,__,..."'~~!.:r."f .. •"•"<.-.' "~ ... ~ .>-.: .... e11,. r:;;, .. IY,., -.. ··~•"~·- .,. ~ .-:.4~,-:.-':lt,., . . , ,~.. ·~· •. 1 ·,.-t:., t "'· ··.';",., ,. ,
I·NDtJSTRIES
List of parts -fuel oil supply

Boiler plant: ....................................................... ................ 2 x MJSSION™ OL + 1 x MJSSION™ XW
Request No.: .................................................................................................................................. 100779
Configuration No.: ................................................................................................................................... 1
Hull No./Nos.: .................................................................................................................................... 1338
Project No./Nos.: ........................................................................................................................... 100779
P&l Diagram drawing No.: ................................................................................................ 92X02:800037
P&l Diagram revision: ............................................................................................................................. ..
Date: ............................................................................................................................ 21 September 2007
Reading guide:
2 x KIBSD
(DN) supply Drawing
Fuel oil supply
IF 1 1900 Burner unit KBSD Yes 92Y:043986
2F 1 1900 Burner unit KBSD Yes 92Y:043987
Ll 1 N/A Boiler power panel - Yes -
1L2 1 NIA Boiler local panel - Yes -
2L2 1 NIA Boiler local panel - Yes -
lR 1 N/A Fan unit - Yes 9220-2667B
2R 1 N/A Fan unit - Yes 9220-2668B
G224 1 Remote start I stop box Yes 8001 002002
Fuel oil pressure regulation
G99 1 112" Pressure transmitter, FO pressure - Yes 8010 000015
G97 1 25 Ball stop valve Yes 87D3065
GlOO 1 25 Control valve, FO pressure - Yes 6050 000185
GlOl 1 25 Ball stop valve Yes 87D3065
G102 1 25 Ball atop valve Yes 87D3065
G105 1 112" Instrument stop valve - Yes 254 1002
G148 1 25 Fuel oil pressure reg. unit Yes 7IZ 013561
Ignition oil pump
G78 1 112" Pressure relief valve DO I/2" Yes 87S0031
1G145 I 15 Ignition oil pump Flange Yes 663 8I63
2G145 1 15 Ignition oil pump Flange Yes 663 8163
Heat exchanger
G19 I 32 Strainer for steam - Yes 7040 000044
G20 1 32 Temperature control valve - Yes 6050 000060
IG22 1 NIA F.O. heater - Yes 15K6030
2G22 1 N/A F.O. heater - Yes 15K6030
1G23 1 I/2" Safety valve - Yes 87S0041
2G23 1 I/2" Safety valve - Yes 87S004I
1G24 1 1/2" Drain valve - Yes 87D3062
2G24 1 1/2" Drain valve - Yes 87D3062
Configurution system release: DbWork Page l/2

...... .
aidlliii
AALBORG LIST OF PARTS- FUEL OIL SUPPLY configurauon 100779-1
INDUSTRIES

(DN) s~ Drawin!!
G28 1 1/2" Temperature transmitter PTl 00 - Yes 8060 000023
1G40 1 1/2" Air vent valve, heater - Yes 87N6003
2G40 1 112" Air vent valve, heater - Yes 87N6003
Chanee over valve
Gl15 1 65 Three-way valve (incl. micro - Yes 6070 000007
switches)
Configuration system release DbWorlt Page2/2

Initial release A 07.12.03 JGj STh
CR 420. Separate air connection to ilp converter. CR 561. Remove C50 B 01.04.04 JGj JMN
Update for R 5.0. F73, F75, F99 changed to ball valves. c 02.09.04 JGj JMN
Revision according to order D 03.03.05 UMD S!i!K
F101 Stop valve added+ partlist updated E 17.03.05 UMD S!i!K
·>--- --
C35
C48
F91
·>---
· --
Boiler --
--
·
·
·
F100
F95
F7B
F61
F65
·
·
--
--
control --
--
·
·
F153
F150
F59 · -- panel -- · F151
L2 L2
F56
F86
·
·
--
--
--
--
·
•
F1B
F19
--
~~? t~ ·>---
· F149
--
Furnace
pressure lvl ...r----:::::,0f?"f)
~ F7~ L2 L2
0 0
1 I F76
F36
:>-==
·>--- ...!J.
--
--
--
·
·
·
·
F31/F166
F106
F33
F33 L2 L2
Combustion L.r";o"===~=±=="'
F36 Flo/¥33 ? ?
air from fan • il L2 L2
.~ j
~~a_L~wr.=~=======r~~~~======~
FBO F17
I :7 ·~F149
-~49-0L2 [
F19 F18
-~~- ~ F151
F106~ F1SO,~ --0L2
I I
F641 , I
L20---~
F152 -j i Fn
_, L21
F41
F74
F153 t='Oi F?B f-a>-~
I
I
i1 .F~62 I
I I PI I
~~ I I I
~ \ L--=L..I="-~
~~-~--~
I
F73~
I F44 F45
I
I FBS
II xs
L2::r-0--
F86 F67
I
II - - - -I
g_~ I i g~ F95
L2 L2 F56 I 0-~-~ I S?qs-~
-n IF=====~ "' ..,. I -0
L2
<i> <i> 1 F59 ~ F60j' F75 I if
I
C35 PS C49 PT
I
PI C33 ! ! .F65~~~ FS4 ~~~~
C331 '7 C431~? ~'7C31 lI j
i i
--'
i
I
Fs71
I
1:========= I
@] --'---'------' I
I
I
I
i~
L2
<i>
I F100 ( [)--0L2
!i
. . b F91~
Atom1s1ng steam for umer _,., FS~ '~
\ I~ \
... "-.,...----DI<J-1\ I
~clll·)--fXI I ~ I
F43 I F93 F157 I I
1...=J F10B I I I
FB7 I I I
I Jp==~F99 I I
I
I
I i~ r --------- J I
I
I D- F182 I
0' <>
[£] ~ G')sTR
is
[I] ffil []]
~ F101
~ ~
g
c. 0
~
'ffi ''"".c
.0
E E
"'"'0
() ·~
~"' .3
";'! ~ . I!!
11>·5 ~
II>
0
U)EE 1-
NOTE:
- Items: see separate list of parts
- For electrical connections, see actual electrical wiring diagrams.
- For connections: [KJ-
see burner arrangement drawing.
Signatures:
---Steam -w- Globe stop valve (SDNR) Title: Drawn Date
--[><]-- 1 x KBSD JGj 07.12.2003

.....
----Water Globe stop vatve
- - - - Chemicals
===Air
0
1:::)
Onpage
Oflpege
.....
....... Standard
Appr.
STh
Date
07.12.2003
- - - Blow down/drain lines
- - - - - External wiring
8 Water Separator iliilllli Bumer unit Weight Scale: Size
A3R
===Oil
--{)::(}-- Bell valve
AAJ.BORG Flow diagram Index
INDUITitllll ~----------------------------------~A~~~m~ngNo:
~== Exheustgas
f - - - - - - - - - 1 THIS DRAWING AND DESic;N SHOWN HERE1M IS THE PROPERTY OF Ml..BORG INDUSTRIES
Plot Date: AND MUST NOT BE: USED BY DR REPRODUCED FOR THIRD PARTY 92)(02:029038 e
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AALBORG
IN 0 US T R I E·S
List of parts - KBSD burner

Boiler plant: ......... .... .......................................................... 2 x MISSIONTM OL + 1 x MISSION™ XW
Request No.: .................................................................................................................................. 100779
Configuration No.: ................................................................................................................................... 1
Hull No./N'os.: .................................................................................................................................... 1338
Project No./N'os.: ........................................................................................................................... 100779
P&I Diagram drawing No.: ................................................................................................ 92X02:029038
P&I Diagram revision: ............................................................................................................................. e
Date: ............................................................................................................................ 09 November 2006
.i Reading guide:

Tag numbers are shown without the prefix 1 or 2 that indicates whether the tagged item is located on boiler 1
or 2. E.g.
KBSID burner
(DN) supply Drawing
Steam Atomizing Burner (Qty. gives the number of parts per burner)
F1 1 1900 Steam atomizing burner KBSD Yes 92Y:043986/7
F17 1 114" Stop valve, ball, oil ign. burner - Yes 666 6006
F18 1 114 Solenoid valve - oil ign. burner - Yes 663 8147
F19 1 114 Solenoid valve - oil ign. burner - Yes 663 8147
F31 1 N/A Ignition burner - Yes 92Z:020616
' F33 2 N/A Flame scanner - Yes 663 9045
F36 1 N/A Temp. switch- fire in windbox - Yes 663 8211
F41 1 20 Stop valve, ball, atomizing steam - Yes 87D3064
F42 1 20 Stop valve, ball, atomizing steam - Yes 87D3064
F43 1 20 Water separator, atomizing steam - Yes 663 8601
F44 1 20 Shut of valve- purge steam - Yes 87D3064
F45 1 20 Non return valve- purge steam - Yes 87D3093
F50 1 3/8" Instrument st~ valve - Yes 87D3050
F51 1 1/4" Press. transmitt.-Atomizing steam - Yes 8010 000006
F56 1 118 Solenoid valve, air for F57 - Yes 666 6333
F57 1 N/A Pneumatic actuator for F42 - Yes 663 8651
F60 1 N/A Pneumatic actuator for F7 5 - Yes 663 8652
F62.1 1 118" Filter regulator for F148 - Yes 663 9046
F62.2 1 118" Manometer - Yes 663 3015
F63.1 1 118" Filter regulator for valve actuator - Yes 663 9046
F63.2 1 118" Manometer - Yes 663 3015
F64 1 20 Stop valve, ball, FO for burner - Yes 87D3064
F65 1 118 Solenoid valve for F66 - Yes 666 6333
Configuration system release DbWork Page 1/2

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MLBORG :; .IJST OF PARTS.~ KBSD BURNER , -· 'Co~~auo:·IOO~~~-; :-
I N 0 U s'r R I E·S ,· • '. ~ > ' •• ' . • 1 ' ~- "" ' ' , ••••

(DN) supply Drawing
F67 1 20 Ball stop valve , FO for burner - Yes 87D3064
F68 1 1/4" Pressure gauge, FO nozzle press. - Yes 663 3121
F69 1 3/8" Instrument stop valve - Yes 87D3050
F73 1 1/4" Stop valve - Yes 666 6006
F74 1 N/A Position switch, lance in position - Yes 661 4712
F75 1 20 Three way valve, FO return - Yes 87D3071
F76 1 N/A DP transmitter, air flow - Yes 8020 000001
F77 1 12mm Non return valve - Yes 663 8103
F78 1 1/4 Solenoid valve - Yes 663 8147
F80 1 12mm Non return valve - Yes 663 8103
F85 1 N/A Micro switch for F67 - Yes 663 8660
F86 1 N/A Micro switch for F7 5 - Yes 663 8660
F87 1 20 Stop valve, ball - Yes 87D3064
F91 1 20 Pressure control valve - Yes 87A3080
F92 1 20 Stop valve, globe - Yes 250 1087
F93 1 20 Stop valve, ball - Yes 87D3064
F94 1 1" Oil flow regulation valve - Yes 663 5199
F95 1 N/A liP converter - Yes 663 5210
F96.1 1 1/8" Filter regulator - Yes 663 9046
F96.2 1 1/8" Manometer - Yes 663 3015
F97.1 1 1/8" Filter regulator - Yes 663 9046
F97.2 1 1/8" Manometer - Yes 663 3015
F99 1 32 Three-way valve - Yes 87D3086
F100.1 1 32 flow meter, oil - Yes 7060 000012
F100.2 1 N/A Pick-up for flow meter - Yes 8310 000006
F106 1 N/A Flame scanner for ignition burner - Yes 663 9035
F108 1 20 Non return valve - Yes 87D3093
F135 1 1/4" Pressure gauge - Yes 663 3120
F148 1 N/A Actuator - Yes 666 6109
F149 1 N/A Position switch - Yes 666 6110
F150 1 118 Solenoid valve - Yes 666 6332
I
F151 1 1/8 Solenoid valve - Yes 666 6332
F152 1 1/4" Ne.edle valve - Yes 664 1220
F153 1 114 Solenoid valve - Yes 663 9043
F157 1 112 Temperature indicator - Yes 88T0003
F166 1 N/A Transformer for ignition burner - Yes 663 9101
F182 1 Orifice
F101 1 32 Stopvalve (Loose supply) Yes 87D3066
STR 1 32 Strainer (Loose supply) Yes SYL052A-2
(AIKK)_
Gauge Board
C31 1 3/8" Instrument stop valve - Yes 87D3050
C33 1 0-25 Pressure gauge - Yes 663 2990
C35 1 6-18 Pressure switch, max. steam - Yes 631 0330
C48 1 0-25 Pressure transmitter - Yes 663 8233
Local control panel (order on otherpart list)
L2 1 NIA Local control panel - Yes -
Configwation system rdcase DbWotk Page 2/2

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INDUSTRIES
Table of contents
Descriptions .
MISSION™ boiler ....................................................................................................... !
Boiler mountings ......................................................................................................... 2
Water level control ..................................................................................................... .3
Gauge board ................................................................................................................. 4

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AALBORG MISSION™ OL BOILER SD9210#04.3
INDUSTRIES
MISSION™ OL boiler
1 Description
The MISSIQNTM OL boiler is a vertical two-drum boiler, insulated and pre-

assembled with boiler mountings for easy installation and operation.
The boiler is top-fired and equipped with a steam atomising burner. As the burner,
the local control panel and all relevant boiler mountings are mounted on top of the
boiler, this can easily be operated and monitored from the burner platform. Most of
the cabling for instrumentation and drain are pre-wired before delivery.
The control system supplied with the MISSIONTM OL boiler unit provides fully
automatic operation of the boiler and the steam atomising burner.
1.1 Boiler pressure part
The principal drawing of the MISSIQNTM OL boiler is shown in Figure 1. The steam
drum is cylindrical with two flat plates of equal thickness. Because of the internal
pressure, the flat plates are mutually connected by vertical solid stays. The steam
drum is furnished with the necessary internal fittings to ensure an even distribution
of the feed water, of the circulation water from the exhaust boiler and to ensure a
sufficient dryness of steam.
The burner cone in the furnace opening are an integrated part and accordingly no
refractory are provided in the top of the furnace room.
Manholes are conveniently placed in both drums and inside the drums enough space
is available for inspection and maintenance.
The water drum is designed similar to the steam drum. The drum size gives optimal
space for the heating coil and easy access for inspection.
As standard the boiler is prepared for tack welding along the foundation of the boiler
shell. Some boilers may, however, be provided with four support feet instead, one as
fixed foot and the others with the possibility of thermal expansion.
Both the furnace and the generating tube bank are located asymmetrically and are
separated by the screen wall. Besides the screen wall the furnace consists of gas
tight polygon shaped membrane walls. The generating tube bank consists of vertical
pin-tubes arranged in a staggered configuration. To avoid any risk of vibration
problems supports are arranged.
The flue gas passes through the deflected tubes at the bottom of the screen wall, up
through the generating tube bank and out through the smoke outlet box.
An effective circulation in the boiler is achieved bye means of down comers.
The bottom tube plate is first covered with coat of insulation refractory and above
with castable refractory.
Access to the furnace is possible through the access door at the bottom of the
furnace. Inspection of the generating tubes is also possible through the inspection
door at the bottom of the furnace.
Inspection of the burner flame is possible through the two inspection holes arranged
in two heights on the furnace panel wall.

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AALBORG MISSION™ OL BOILER SD9210#04.3
INDUSTRIES
Principal drawing ofMISSIONTM OL boiler
Manhole
Burner
Smoke outlet Steam drum

box\
Access door
Screen
• •
Generating
wall
tube bank
•
0
F=~Wl@Jill~~~~~~fj \ Down comer

Access door
Water drum
Figure 1 miss olb.cdr

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AALBORG BOILER MOUNTINGS SD9220#19.2
INDUSTRIES
Boiler mountings
1 Mountings
The following is a brief description of the most important items of the boiler
mountings. The components mentioned in this section are referring to the general
arrangement drawing of the boiler.
Safety valves
Two safety valves are fitted to the pressure vessel of the boiler. They are installed
for security reasons, and designed to prevent the boiler pressure from rising above
the design value.
The safety valves must be supplied with waste steam pipes and either expansion
devices, or bellows.
Main steam valve
The main steam valve is a shut off valve. When closed, it isolates the boiler from the
main steam line. A check valve is mounted after the main steam valve which
prevents steam from flowing backwards into the boiler.
The steam piping up to the main steam valve must be flexible in order to minimise
external loads on the main steam valve and associated branch. The flexibility can be
achieved with loops build into the main steam line to take up heat expansion from
the boiler and steam piping or with an expansion joint next to or close to the main
steam valve.
By-pass valve
The by-pass valve is a shut off valve. The purpose of the valve is to equalise the
pressure between the boiler and the steam system when the main steam valve is
closed. Please note that the by-pass valve is only supplied for larger boilers.
Feed water valve I feed water valve (sdnr)
Two groups of feed water valves are provided in the boiler. Each group comprises a
shut-offvalve and a non-return valve.
The shut-off valve in the ordinary group must be open when the boiler is in
operation, or if the boiler is used as a steam drum.
The shut-off valves should be closed when the boiler is not in use.
Water level gauges
Two local water level gauges are connected to the front of the boiler, each gauge
being provided with two shut-off valves and a drain valve.
The shut-off valves, fitted at the top and bottom of the sight glass, have a quick-
closing mechanism to be used in case of broken glass.
The pipes from the drain cocks on the water level gauge must lead to an open drain,
visible for inspection.
Blow-down valve
Two blow-down valves are mounted at the bottom of the boiler body. If connected
to a separate drainage system the valves are of the ball type. When connected to a
common drainage system two valves are provided in each group, one shut-off valve

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AALBORG BOILER MOUNTINGS SD9220#19.2
INDUSTRIES
and one shut-off/non-return valve. The shut-off function is for security and the non-
return function prevents steam/water from flowing into an empty boiler by mistake.
Air valve
The air/ventilation valve located on top of the boiler is a shut-off valve. It is
normally closed except when the boiler is being filled or completely drained. The
end of the drain pipe from the air valve must be visible in order to determine when
water or steam is coming out.
Scum valve
The scum valve is mounted at the top of the boiler body. In the event of scum in the
boiler, this scum can be blown off from the water surface by opening this valve. If
connected to a separate drainage system the valve is of the ball type. When
connected to a common drainage system two valves are provided, one shut-off valve
and one shut-off/non-return valve.
Valves for WBR inlet and outlet
The boiler is provided with two circulation valves for inlet and outlet connections to
the exhaust gas boiler(s).
The valves should be shut-off valves, and depending on deviations in the system,
these valves can also have a non-return function.
Sample valve
A sample valve is installed enabling connection to a sample cooler for taking test
samples to perform boiler water analyses.
Inspection hole
Two small inspection holes are provided in the furnace wall to enable inspection of
the burner flame. A proportion of the air supply is bled off from the burner fan to
cool the window of the inspection hole, and prevent soot deposits.
Manhole
Two manholes placed at the boiler top and boiler bottom allow inside inspection of
the steam/water drum.
Access doors
Access to the furnace and smoke outlet box are possible through the access doors
placed at the bottom of the furnace and at the smoke outlet box respectively. Both
access doors enable inspection of the generating tube bank.
Drain for furnace
The furnace bottom is provided with a socket for drain of the washing water.

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AALBORG
INDUSTRIES
Water level control
1 Description
The water level control is a modulating system at this type of boiler. The system is
illustrated in Figure 1. The safety device system for too low water level shut down
and burner stop consists of a level float switch mounted as an external unit. For
measuring and control of the water level, the boiler is equipped with a dp water level
transmitter unit, which includes external reference and variable legs, and a dp-
transmitter. The continuous 4-20 rnA output signal from the dp-transmitter is
processed in the control system, which provides level alarms/shut downs and control
of the regulating feed water valves.
In case of the boiler is firing, the WI regulating feed water valve is control of the
water level. In case of the boiler is not firing, the W2 regulating feed water valve is
control of the water level.
Water level control system
Instrument air Regulating feed water valves

--- -- --------------------,
'
'
Feed water
valves
-------------- ...
'
Reference leg
'
Level float
switch
Variable leg
Boiler
''
'
Valve Control ''
man~old system '
(panel)
·•
dp-transmltter
'-,----.-..-,..v
I
i.
't,.,.,.,.,.,.,.J'
'
' !,.,.,.,.,.,.,.,.,.N••·••••
''
Feed water pumps
,.
'
'' '
l .. --------...... --- .. -- ------------------- ---·-..... --------;
Figure 1 dp_l_mod_2val.cdr

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AALBORG GAUGE BOARD 809240#09.1
INDUSTRIES
Gauge board
1 Description
The function of the gauge board is to control the burner and to give alarm and shut
down for low and high steam pressure.
• A pressure gauge is fitted for analogous reading of the actual steam pressure in
the boiler. The pressure gauge is located on the local control panel.
• A pressure switch "high steam pressure" gives shut down and cut-off the burner
when the steam pressure rises above the pre-adjusted set point (one set point in
high pressure mode). Furthermore, the pressure switch locks the burner in stop
mode. Operation of the burner is only possible when the steam pressure falls
below the differential set point of the pressure switch and the shut down
function is reset.
• A pressure transmitter connected directly on the boiler converts the actual steam
pressure of the boiler into corresponding electric signals. The signals are used to
give alarms for low/high steam pressure and shut down/burner cut-off for high
steam pressure.
• A pressure transmitter is located in the main steam line. The transmitter is
common for both boilers and converts the actual steam pressure in the common
steam line into corresponding electric signals. The signals are used to give
alarms for low/high steam pressure and shut down/burner cut-off for high steam
pressure. Furthermore, the signals are used to control start/stop and modulation
set point of the burners both in low and high pressure mode. The signals from
the transmitter are also used to control the master/slave operation.

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INDUSTRIES
- Table of contents
Operation and maintenance
Start/stop of the boiler
General ........................................................................................................................ 1
Start-up ........................................................................................................................ 2
Boiler stop ................................................................................................................... 3
Boiler maintenance
Boiler maintenance ...................................................................................................... 1

Inspection of the boiler ................................................................................................ 2
Boiling out
Boiling out ................................................................................................................... 1
Water washing
Description .................................................................................................................. 1
Soot blowing
Description .................................................................................................................. 1
Cleaning procedure ...................................................................................................... 2
Preservation
Preservation ofboiler................................................................................................... 1
Boiler repair- plugging of tubes
Plugging of tubes ......................................................................................................... 1
Boiler repair - refractory
Refractory repair .......................................................................................................... 1

Maintenance of repair .................................................................................................. 2
Language UK
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INDUSTRIES
Lighting-up curve
Lighting-up curve ............................................................................... ·.... ·................... 1
Language UK
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AALBORG START/STOP OF THE BOILER OM9210#01.2
INDUSTRIES
Start/stop of the boiler
1 General
The following chapters of the instruction manual describe the operation and
maintenance of the pressure part. As this is only a part of the complete boiler plant,
it is important to study the remaining chapters in this manual very thoroughly. It is
especially important that the operator of the boiler plant becomes familiar with the
operation instructions of the burner and the control panel.
Important: To ensure a safe and reliable operation of the boiler plant, all
operation and/or maintenance of the boiler should be carried out
only by skilled personnel.
2 Start-up
When the boiler is started, the lighten-up rate of the boiler must not be accelerated
too much as this might cause an unnecessary overstrain of the boiler material by
quick and uneven temperature rises. It might be necessary to perform a number of
start/stop sequences to reduce the lighten-up rate.
Attention: At the commissioning start-up of the boiler and after any repair
work of the refractory, it is very important to further reduce the
lighting-up rate. This is because the new refractory still contains a
small amount of water. When heated the water vaporises and
expands which might cause fissures and cracks in the refractory.
The burner must therefore only be operated at minimum load and
in intervals of 1-2 minutes for the first hours. Between each
operation interval the burner should remain stopped for
approximately 8-10 minutes.
Before start-up of the boiler plant, some general work and check procedures must be
considered.
Step A: Check that the main steam valve, by-pass valve and circulation valves if
provided, scum valve, and blow-down valves are closed.
Step B: Open the feed water valves and the air valve. Fill the boiler with feed water
to approximately 50 mm below normal water level. The water level rises
due to expansion when the boiler is heated. If the temperature difference
between the boiler and feed water exceeds approximately 50°C, the boiler
must be filled very slowly.

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INDUSTRIES
Note: When filling a pressure less boiler, the shut-off valve after the feed water
pump must be throttled. Otherwise the pump motor will be overloaded.
Step C: Check the water level in the water level gauges. Check frequently during
the complete start-up. The water level gauges should be blown down
several times to ensure a correct indication.
Step D: Check that the water level control system is connected and operational.
Step E: Check the oil system and start the fuel oil supply pump. Pre-heat the fuel oil
if the burner should operate on heavy fuel oil.
Step F: Check the burner and the safety functions according to the separate
instruction.
2.2 Start and pressure rise
The following work procedures must be followed during start-up of the boiler.
Step A: Check that the gauge board valve and pressure gauge valves are opened.
Step B: Check that the air valve is open if the boiler pressure is below 1.0 barg.
Step C: Start the burner on manual control and on low load. Check that the water
level does not rise too high during the pressure rising period.
Step D: Drain via the blow down valves if the water level is too high.
Step E: If the air valve was opened close it when only steam blows out. A pressure
reading should be indicated on the boiler pressure gauge before the air
valve is closed.
Step F: Tighten all covers such as manholes, hand holes, inspection doors, etc.
during the pressure rising period. If required, check all flange joints on the
plant.
Step G: Change to automatic control of the burner when the boiler pressure is 0.5
barg lower than the working pressure of the boiler.
Step H: Open the by-pass valve slowly to heat-up and pressurise the steam system.
If the boiler is not provided with a by-pass valve, the main steam valve
should be used to heat-up and pressurise the steam system.
Step 1: Open the main steam valve and close the by-pass valve.
Step J: Open the valves to the steam consumers carefully in order to avoid water
chocks.
Step K: When the boiler is in normal operation, check that the water level control
system and the gauge board functions are fully operational.

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AALBORG START/STOP OF THE BOILER . OM9210#01.2
INDUSTRIES
Note: After 3-4 weeks in operation, mud and deposits in the piping system may
have accumulated in the boiler water. This may cause level variations
which disturb the steam generation, and it is therefore recommended to
blow down the boiler. It should then be inspected, cleaned, and refilled
with boiler water.
3 Boiler stop
3.1 Normal boiler shut down
If necessary, the boiler can be shut down at any load without special preparations.
Note: When the boiler is stopped, sudden temperature and pressure drops
should be avoided as they might expose mountings, pipe lines, and the
boiler plant to inadmissible temperature gradients.
Step A: When minimum load is obtained, stop the burner.
Step B: Keep the water level at normal level until the boiler stops producing steam.
Step C: Stop the feed water pump and close the feed water valves.
Step D: Close the main steam valve.
3.2 Emergency shut down
The boiler must be taken out of service immediately if:

• parts of the heating surface have been glowing or the boiler shows recognisable
deformations. The supervising authorities must be informed, and the boiler must
not be used until approval from these authorities is available
• a substantial loss of water is noted
• the feed water system is unable to provide the necessary amount of feed water,
e.g. due to failure of parts
• the safety valve cannot function
• sudden cracks or damage are noted in the refractory, and if steam or moisture is
coming out of the refractory
• oil in the feed water is detected
• too high salinity level is detected
If an emergency shut down must be carried out, the fuel supply should be stopped.
The main steam valve should be closed gradually, and the boiler must be cooled.
The safety valves must not be operated. Parallel working boilers should be
disconnected at once.

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INDUSTRIES
3.3 Stop for repair or inspection
The following describes the measures to be taken when the boiler is shut down for
repair or inspection.
Step A: Clean the boiler from soot with water.
Step B: Operate the burner for at least 15 minutes after the soot removal to dry out
the remaining water.
Step C: Stop the boiler as mentioned previously.
Step D: Check the furnace and the pin tubes with regard to cleanliness.
Step E: Empty the boiler from water and clean it. Check if lime stone appears.
Step F: Check and clean the outer fittings. Change gaskets where required.
Step G: Clean the feed water tank and feed water pipes.
Step H: Clean and grease the bearings of motor, pump, and fan.
Step 1: Check and align the burner, if necessary.
Step J: If the boiler is shut down for a long period of time, the pin tubes must be
thoroughly cleaned.
Step K: Check that the necessary spare parts are available. Order complementary
parts in time.
Warning: It is of extreme importance that the boiler is NOT operated without

water when the oil burner is in operation, e.g. due to disconnection
of the water level safety devices. This will immediately cause
complete break down of the boiler.

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AALBORG BOILER MAINTENANCE OM9210#10.0
INDUSTRIES
Boiler maintenance
1 Boiler maintenance
The boiler maintenance should always be executed with skill and in accordance with
valid rules and regulations from the authorities, and below are gtven some
recommendations for periodical inspections and maintenance.
1.1 Daily operation
During normal operation of the boiler some work and check procedures have to be
considered every day.
Step A: Check the boiler steam pressure and the water level.
Step B: Check that the feed water control system is operational, see separate
instructions.
Step C: Check the boiler water condition and make necessary countermeasures with
regard to the feed and boiler water treatment. If necessary blow-down the
boiler.
Step D: Check the function of the oil burner at different capacities through the
inspection holes on the boiler.
Step E: Check the flue gas temperature after and/or the draft loss across the boiler.
If either the temperature or the draft loss is too high, the pin-tube section
must be cleaned.
1.2 Weekly routine checks
Step A: Drain each water level glass for about 10-15 seconds.
In case of contaminated boiler water or insufficient water treatment, the draining of
the water level glasses must be done more often.
Step B: Check the safety water level device.
Step C: Depending on the boiler water tests blown-down the boiler. Open the blow-
down valves quickly for a few seconds, and then close and open again for
about 5-10 seconds.
Repeat this operation when required according to the boiler water tests.
Step D: Perform scum blow out by means of the scum valve when required. The
scum blow out must be carried out until the drained water is clean.

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INDUSTRIES
1.3 Monthly routine checks
Step A: Test all stand-by pumps.
Step B: Check all boiler mountings for damage or leaks and repair/replace if
necessary.
Step C: Check the function of the high steam pressure switch by lowering the set
point or by raising the steam pressure, e.g. by closing the main steam valve
slowly.
The burner must stop automatically.
2 Inspection of the boiler
2.1 Inspection of furnace
The furnace should be inspected at least twice a year. During this inspection the
following issues should be taken into consideration:
• Check for cracks at the refractory lining and that the furnace walls are free from
excessive soot deposits.
• Examine carefully the area opposite the burner. Too much soot deposits indicate
that the burner should be adjusted.
• Check that the pin-tube elements are intact and that soot deposits are within
normal limits.
2.2 Inspection of boiler water side
The boiler water side (interior) must be carefully inspected at least twice a year. This
inspection of great importance and no doubt the most important of all the
maintenance measures, since it has a direct influence on the boiler longevity and on
the security.
At these inspections, hard deposits, corrosion and circulation disturbances can be
found at an early stage, and preventive measures must be taken to avoid unexpected
material damage and boiler breakdown.
Presence of hard deposits at the furnace wall and the pin-tubes reduces their heat
transfer properties and decrease the capacity of the boiler.
Further, it is possible to make out if the feed water treatment has been satisfactory
and if the blow-down has been carried out sufficiently.
Incorrect feed water treatment is commonly causing hard deposits or corrosion.
Insufficient blow-down will cause sludge deposits in the tubes and accumulation of
sludge in the bottom of the boiler.
If hard deposits are not removed, it may lead to overheating in the boiler plate
material which is exposed to the flame in the furnace wall area. This may cause
material damages.
Incorrect feed water treatment does not always lead to hard deposits. For example, a
too low or too high a pH-value may give an electrolytic reaction, causing corrosion
in the boiler.

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INDUSTRIES
When the boiler interior is inspected, examine all parts carefully and be attentive to
deposits, corrosion and cracks. It is advisable to pay special attention to this
inspection. If any unusual signs are found, contact Aalborg Industries at once for
advice.
2.3 Procedure and remarks for inspection
Step A: Shut off the boiler and allow it to cool (below 100°C).
Note: The boiler should NOT be depressurised by lifting the safety valves and
then filled with cold feed water since the stress induced by too rapid
cooling may cause damage.
Step B: Empty the boiler and close all valves.

If the boiler is connected to a second boiler, check that the valves between them are
closed.
Step C: Unscrew and remove the manhole hatch(s) on the boiler and enter the boiler
when it is sufficiently cold.
Check the welding in the boiler. A careful examination should be carried out with
respect to any possible corrosion or crack fomiation.
Special care should be taken to the water line area in the pressure vessel where
oxygen pitting may occur.
If deposits are found to be forming in the boiler tubes, the boiler should be
chemically cleaned.
It is advisable to consult a company of cleaning specialists who will examine the
boiler deposits and treat the boiler accordingly.
Note: After chemical treatment the boiler should be blown-down at least twice
a day for approximately one week. This will ensure that excessive sludge
deposits due to chemical treatment do not collect in the bottom of
pressure vessel.
2.4 Contamination
If the boiler is contaminated with foreign substances like oil, chemicals, corrosion
products etc., it is very important to act immediately to avoid damages to the boiler.
Layers of thin oil films, mud, etc. exposed to the heating surfaces causes a bad heat
transfer in the boiler, leading to overheating followed by burned out pressure parts.
In order to remove such contamination, a boiling out or acid cleaning have to be
performed immediately.
Note: Corrosion products from the pipe system or insufficient boiler water
treatment may result in corrosion in the boiler itself. It is therefore
important to observe that such circumstances do not occur in the system.

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AALBORG BOILING OUT OM9210#11.0
INDUSTRIES
Boiling out
1 Boiling out
Before putting the boiler into operation for the first time, it should be boiled out to
remove all protecting remedies and impurities on the boiler waterside.
The boiling out procedure is recommended to be carried out as described below:
Caution: Extreme care should be taken while handling the chemicals. The
person handling the chemicals/solution should be properly
dressed/protected.
Step A: Fill the boiler with a solution consisting of 4-5 kg trisodiumphosphate

Na3P04 per 1000 kg water. The chemicals can be added through the
manhole.
Step B: Add feed water until the solution is visible in the water gauges above
"lower water level".
Step C: Close the feed water valve (pump stopped).
Caution: Do never fill feed water into the boiler if the temperature difference
between boiler and feed water exceeds 50°C.
Step D: Raise steam pressure slowly to working pressure, and keep the pressure for
approx. 3-4 hours with closed main steam valve.
Step E: Scum until water level is between "Normal water level" and "High water
level".
By this procedure grease and other impurities are removed from the internal surfaces
ofthe boiler.
Step F: Start skimming by opening the scum valve, and lower the water level to
lower edge of''Normal water level" mark.
Step G: Close the scum valve.
Step H: Refill the boiler with feed water and start skimming again in intervals of 30
minutes for a period of two hours.
Step 1: Stop the boiling out procedure by switching off the burner.
Step J: Let the boiler water rest for about five minutes.

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.AALBORG BOILING OUT · OM921 0#11.0
INDUSTRIES
Step K: Carry out a fmal skimming.
Step L: Blow off the boiler water by opening the blow down valves.
Step M: Remember to open the air escape valve, to avoid a vacuum in the boiler
when the boiler pressure decreases to approx. depressurised/atmospheric
pressure.
Step N: Open the manhole and let the boiler cool down to approx. 100°C.
Step 0: The boiler is to be flushed with clean water on the boiler waterside, when
the temperature has decreased. The flushing removes remaining impurities.
StepP: Dismantle the bottom blow down valves, for cleaning and inspection
because deposits/foreign substances will usually be accumulated in these
valves and cause leaking if not cleaned.
Step Q: Inspect the boiler and remove any remaining deposits and foreign
substances.
Step R: Finally, new gaskets to be fitted in all hand- and manholes before refilling
the boiler with water to upper edge of"Low water level".
The boiler is now ready to be taken into service.
Note: During the first two weeks in operation we recommend to carry out
frequently skimming and bottom blow down to remove impurities
entering the boiler from the pipe system.

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iii I ii
AALBORG WATER WASHING OM9210#30.1
INDUSTRIES
Water washing
1 Description
In order to keep the heat transfer area sufficiently clean the boiler is designed with a
high flue gas velocity through the generating tube bank. Therefore fouling will be
minimised, under normal circumstances, with a correct combustion. However, after
long term operation, e.g. during combustion of poor quality oil or with reduced
combustion quality, deposits can be formed on the heating surface.
The most effective way of soot cleaning is water washing, as most of the deposits
consist mainly of non-soluble particles held together by a water soluble bonding
material. Water washing will have the following benefits:
• Dissolves the bonding material.
• Washes the loosened insoluble deposits away.
Water washing of the generating tube bank
Smoke outlet
Water
washing
hose
Drain
Figure 1 ol_wash2.tif

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AALBORG WATER WASHING OM9210#30.1
INDUSTRIES
The MISSION™ OL boiler is easily cleaned from the smoke outlet box with a water
hose. Water washing must be carried out when the oil burner is stopped and the
boiler has been cooled down to a temperature below 100°C. The boiler should,
however, be warm enough for the water to evaporate so that the generating tube
bank and furnace will not remain moist after washing.
Both fresh and sea w~ter can be used. If sea water is used, the boiler must be
thoroughly washed afterwards with fresh water in order to remove all salt deposits.
Where deposits are highly corrosive or bonded, a soaking spray with a 10% soda ash
solution is advisable before washing.
At the beginning of the water washing procedure the water supply should only be
slightly opened, until it is ensured that the drain and soot collecting system are
working properly.
Warning: When the generating tube bank is water washed, there is a risk of
generating steam. It is therefore very important that all of your body
is outside the smoke outlet box in order not to get your skin burned
by the steam.
When the water washing has begun, it must be completed until the generating tube
bank is thoroughly washed and all deposits are removed. This is because some types
of coatings hardens and accordingly get very difficult to loosen when they first have
been saturated and then dry out.
After the water washing procedure is completed the refractory at the furnace bottom
must be cleaned with alkaline water because the washing water is very corrosive. It
must be observed that all the washing water and loosened deposits are removed from
the boiler.
The · boiler must be dried out immediately after the water washing has been
completed in order to avoid damage on refractory and heating surfaces. The boiler
must be lightened-up and pressurised as described in the chapter "Start/stop of the
boiler".
Important: The refractory in the furnace must be heated slowly up in order to

let the water absorbed by the refractory evaporate slowly.

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· AALBORG SOOT BLOWING OM921 0#28.1
INDUSTRIES
Soot blowing
1 Description
Generally, there will be a self cleaning effect of the generating tube bank due to the
high flue gas velocity. However, deposits are formed on the heating surfaces, e.g.
due to combustion of poor quality oil or reduced combustion quality. These deposits
will accumulate on the heating surface of the generating tube bank if not removed by
cleaning.
The MISSION™ boiler is equipped with soot blowers for cleaning of the generating
tube bank The soot blowers are manually operated and are arranged for direct
connection to the steam system of the ship. In order to obtain an efficient soot
cleaning, the steam pressure must be at normal working pressure. Furthermore, the
boiler load should not be lower than 50%. This ensures a sufficiently high velocity
of the flue gas, which is necessary to carry loosened soot deposits out of the boiler.
Figure 1 shows a soot blowing arrangement.
Because of the varying combustion parameters, it is impossible to specify exact time
intervals between soot blowing. In general soot blowing is recommended every 24
hours.
Note: Excessive soot blowing by means of steam might cause erosion damage
on the generating tube bank.
During operation of the boiler plant, the operating personnel should determine the
necessity with regard to time intervals for soot blowing. This interval should then be
increased or decreased to fit the specified plant.
2 Cleaning procedure
Step A: Check that the steam pressure is at normal working pressure.
Step B: Check that the main valve for soot blower and the two manually operated
ball valves are closed.
Step C: Open the drain valve to drain water from the main tube for a few seconds
and close it again.
Step D: Open the main valve.
Step E: Open the lower manually operated ball valve and soot blow for
approximately five seconds.
Step F: Close the lower manually operated ball valve again.

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Step G: Open the upper manually operated ball valve and soot blow for
approximately five seconds.
Step H: Close the upper manually operated ball valve again.
Step 1: Repeat step "D" to "G" 3-4 times.
Step J: Close the main valve.
Step K: Check that both ball valves are closed.
Dlustration of a soot blowing arrangement
f- ~~ :p~:~ ~~:.- -~ -!
I ..,....-.~1
~------------------_I
Manual
valve
Manual
valve
0000000000000000000000000
Figure 1 sootblowla.cdr

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AALBORG PRESERVATION OM9210#13.1
INDUSTRIES
Preservation
1 Preservation of the boiler
If the boiler is to be shut down for a period of 1-30 days, it should be top filled to
prevent corrosion. Before top filling, it should be cleaned from soot deposits.
If the boiler is to be shut down for more than one month, different methods to
prevent corrosion can be applied:
• Dry preservation.
• Wet preservation.
• Nitrogen preservation.
• VCI preservation.
The work procedures related to each of these preservation methods are described in
the following:
1.1 Dry preservation
When this method is applied the boiler should be totally emptied off water and dried
out.
Step A: Empty the water/steam contents inside the boiler by means of the bottom
blow down at a boiler pressure of 3-5 barg. Open the boiler when it is
depressurised and drain off any remaining water.
Step B: Manhole doors and hand hole covers should be opened when the boiler is
still hot. If there is water left in the bottom of the boiler it must be removed,
e.g., by using a vacuum cleaner.
Step C: If the boiler is cold, drying of the boiler can be done by either circulating
dried air from a fan or by placing bags of silicagel inside the boiler.
Step D: Before the manhole doors and hand hole covers are closed, place a tray with
burning charcoal to remove oxygen. As soon as the tray with charcoal is in
position, close the manhole doors and hand hole covers using new gaskets.
Step E: Alternatively, a small steam phase inhibitor can be added to the boiler after
cooling and careful draining. Afterwards the boiler should be closed
completely.
1.2 Wet preservation
While dry preservation is a question of draining off water to avoid corrosion, the
principle of wet preservation is to prevent oxygen from entering the boiler.
This method can be used for a short period of'lay-up' (1-3 months).

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AALBORG PRESERVATION OM9210#13.1
INDUSTRIES
Step A: The boiler is filled with treated boiler water and hydrazine is added until an
excess of 100-200 ppm is obtained.
Step B: The water should be circulated continuously or at least once per week to
avoid corrosion from any penetration of oxygen, and it is necessary to
check the hydrazine concentration and add the necessary amount to have an
excess of 100-200 ppm. Other oxygen binding agents can also be used.
The pH-value should be 9.5-10.5.
Note: H there is any risk of the temperature falling back below O"C, this
method should not be used to avoid frost damages.
As this preservation method involves applying hydrazine to the water inside the
boiler, the boiler must be completely drained and refilled with fresh water before
taken into service again.
1.3 Nitrogen preservation
The boiler should be drained, dried and sealed in the same way as mentioned in
section "1.1, Dry preservation".
Step A: Make a connection point to the bottom of the boiler and open the air escape
valve on top of the boiler.
Step B: Connect cylinders with nitrogen to the bottom connection point via a
reduction valve and purge the boiler until there is no oxygen left.
Step C: Close the air escape valve.
Step D: Leave a cylinder with nitrogen connected to the boiler via a reduction valve
and keep an overpressure of approximately 0.2 bar inside the boiler.
1.4 VCI preservation
An alternative to the above mentioned preservation methods may be the use of a so-
called volatile corrosion inhibitor (VCI).
The VCI is a water soluble chemical which partly evaporates and protects both the
water and steam spaces of the boiler. It should be able to eliminate the need for
complete drainage and/or application of nitrogen, and may in particular be
interesting when a forced circulation type exhaust gas boiler is installed in the steam
system. The boiler must be effectively sealed from the atmosphere to maintain the
corrosion protection.
The VCI is offered by various chemical companies and must be used in accordance
with their recommendations.

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AALBORG BOILER REPAIR- PLUGGING OF TUBES OM9210#21.2
INDUSTRIES
Boiler repair- plugging of tubes
1 Plugging of tubes
In case of a leakage on a boiler tube, the burner must be stopped and the pressure
lowered to atmospheric pressure.
If the leaking tube cannot be located immediately the boiler should be set on
pressure by means of the feed water pumps so that the leakage will indicate which
tube is damaged.
Step A: When the boiler is emptied of water remove the manhole covers in the
steam drum and the water drum.
Step B: When the damaged tube is located it must be plugged with a conical tube
plug. Before the tube plug is mounted clean the inside of the tube ends with
a steel brush, so that no deposits are present in the tube.
Note: Plugging of tubes results in reduced efficient heating surface and

accordingly the boiler efficiency will decrease. Temporary repairs
require more attention than a normal working boiler.
Attention: The classification society should be notified about the repair work
and a schedule must be made for exchange of the damaged tubes.
Note: Only skilled personnel with knowledge and qualifications to perform

certified welding should perform repair work.
1.2 Plugging of furnace panel wall tubes
When a furnace tube has been plugged the furnace side of the damaged tube should
be cut vertically along the connections with the fms between the tubes in the panel
wall, see Figure 1.
Inside the rest of the tube and on the fms next to the damaged tube a number of
anchors of heat resistant or stainless steel must be welded on.
Afterwards erection of refractory against the damaged tube and the neighbouring
fins must be carried out in the full height inside the furnace.

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Plugging of furnace tubes
Figure 1 plugOla.cdr

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INDUSTRIES
1.3 Plugging of generating tubes
Plugging of the generating tubes are shown in Figure 2. From an operational point of
view up to 10% of all generation tubes can be plugged with a conical plug but if
more tubes are damaged, an exchange of tubes are necessary.
Plugging and replacement of generating tubes
·-------·------------·---------,
I
--·--·-------·-J
I
Figure2 plug04a.cdr

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AALBORG BOILER REPAIR- REFRACTORY OM9210#25.0
INDUSTRIES
Boiler repair - refractory
1 Refractory repair
The furnace floor is lined with an insulating material (Verilite R6), close to the
casing covered with a layer of castable refractory (Plicast 31 ).
The refractory is made with expansion joints, which should under no circumstances
be blocked or filled on purpose.
Even though the refractory is made with expansion joints, it will tend to make
additional natural expansion joints, which will be seen as fissures. However, the
fissures will generally close when the boiler is put into service~ Please note the
following guidelines when examining the fissures:
• white/light fissures, which are getting darker over the time and are closing when
the boiler is in service and opening in cold condition, need no further attention.
• dark/black fissures suddenly occurred, seen in cold condition and are not closing
when boiler is in service need to be repaired/filled up with refractory (Plicast
31).
All refractory subjected to wear will, eventually, need to be repaired. This can be
done as a temporary repair or on a permanent basis.
1.1 Temporary repair
Smaller areas can be temporarily repaired making use of the repair mix Plistix 14,
supplied separately with the boiler equipment.
The durability of such a repair depends on the location, but the more exposed to
heat, the shorter lifetime. Generally, it is recommended to replace a temporary repair
with a repair on a permanent basis within one year.
Temporary repairs in vertical places ought to be made "swallow tailed", see Figure
1, if possible. This secures a better attachment to the existing refractory.
Sketch indicating a "swallow tail" repair
Refractory Swallowtail
(filled in with Plistix 14)
Figure 1 swaltail.cdr

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INDUSTRI.ES
The surface to which the temporary repair is performed, must always be clean, dry
and rugged.
Mixing instructions for the castable refractory appears from the instruction on the
plastic bucket.
Note: Plistix 14 must be applied to the site immediately when mixed.
The boiler can be lightened-up approx. 1 hour after the refractory has been applied.
The refractory needs no further time for hardening.
If the boiler is pressurized, the lighting-up should be started with the burner in "on"
position for one (1) minute and then in "off" for two (2) minutes, during the first
half (Y:z) hour. Then it can be started up according to the ordinary lighting-up
procedure.
Note: Observe the safety rules regarding the refractory which can be seen on
the plastic bucket.
1.2 Permanent repair
Major repairs and renewal of temporary repairs shall always be carried out and
supervised by maker's specialists, among other things securing that correct drying-
out time and lighting-up is observed.
1.3 Boilers with membrane furnace wall
The refractory applied to a damaged membrane furnace wall must be carried out as
shown in Figure 2.
Refractory applied to a membrane furnace wall
Furnace tube
Failed tube
Plicast 31
Figure 2 plugrefrac.cdr

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INDUSTRIES
Warning: Failed Y-anchors must only be replaced by Y-anchors made from

heat resistant steel. Y-anchors made from incorrect materials will
cause damage to the refractory.
2 Maintenance of refractory
Note: The refractory should be inspected once a year for shape and wear. It is
recommended to carry out an inspection in due time prior to long repair
periods such as dry docking, etc. Should a repair be required castable
refractors and bricklayers can then be ordered on short notice.
If the refractory has been exposed to water, the refractory should be dried out as
soon as possible. The drying out can be done by hot air (approx. 50°C) or by
operating the oil burner.
Warning: However, if the burner is being used, the burner should be operated
with great care.
Warning: Generated steam evaporated from water absorbed into the

refractory might cause fissures and cracks when expanding, if the
heat input from the oil burner is too heavy.
2.1 Typical refractory data
Below in Table 1 is a list of typical refractory data shown.
Table 1

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AALBORG LIGHTING-UP CURVE · OM921 0#31.1
INDUSTRIES·
Lighting-up curve
1 Lighting-up curve for MISSIQNTM OL boiler
Figure 1 shows the lighting-up curve for the MISSION™ OL. When the burner is
started the firing capacity must be adjusted to match the lighting-up curve. Further
start/stop instructions are described in the chapter "Start/stop of the boiler".
Lighting-up curve for the MISSION™ OL boiler
Boiler pressure (barg) t Boiler temperature at start Temperature ("C)

25 - - 225
-
100 50
iI I I I l)
20 - -
18 - -
16 - -
14 200
-
12 -
- I VI /;1/
-
-
-
10 -
I I I
/; v; /
- -
8 175
1/
7-
6-
5-
I/ I -
-
-
-
v
4- I 150
I II I;
3- -
-
2- -
-
v
/ 125
I I; /
- I-
I-
I-
0 / I-
100
I I I;
1-
1-
1-
v
1-
75
I
v /;vI;
1-
1-
1-
1-
50
~/
1-
1-
1-
~ 1-
v v I-
I-
c-
25
/ c-
0
0 15 30 45 60 75 90 105 120 135 150
Time (min.)
Figure 1 startcur2.cdr
Language UK Page Ill

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INDUSTRIES
Table of contents
Feed and boiler water

General ........................................................................................................................ l
Layout of the treatment system ................................................................................... 2
Feed and boiler water characteristics .......................................................................... .3
Feed and boiler water maintenance ............................................................................. 4
Treatment systems I injection points ........................................................................... 5

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AALBORG FEED AND BOILER WATER OM9210#99.2
INDUSTRIES
Feed and boiler water
1 General
Note: The recommended feed and boiler water characteristics are only valid
for boilers with a working pressure below 20 barg.
There is a number of ways to produce good quality feed water for boiler plants.
Methods such as e.g. reverse osmosis plants or ion exchange plants produce good
quality distillate. Also evaporators generally produce good distillate. The important
thing is that the distillate used should be clean and without foreign salt
contamination.
In practice most distillates used contain minor parts of various salt combinations
which can and must be chemically treated away. Furthermore, the distillate may
contain dissolved gases like for example oxygen (02) and carbon dioxide (C02)
which may lead to corrosion in the boiler, steam, and condensate system.
Important: Boiler and feed water must be chemically tJ:-eated_ in order to avoid
corrosion and scaling in the boiler.
2 Layout of the treatment system
The condition of the feed and boiler water is an essential part of the boiler operation
and operation philosophy. The design and construction of the treatment system
should therefore be considered carefully during layout of the plant. Aalborg
Industries gives some general requirements and recommendations regarding the
conditions of the feed and boiler water. However, there is several ways to obtain this
results, or similar, by using different treatment systems. The following should
therefore be considered already at the layout stage:
- Choose the treatment system that should be used.
Present the condensate and feed water system to the supplier of the treatment
system and inform about the operation philosophy of the plant.
Let the supplier indicate where the injection points should be located and also
inform if special equipment is required.
- Let the supplier inform about which test facilities is needed.
- Purchase the recommended equipment and install it in the correct way.
- Use the treatment system as soon as the boiler is taken into operation.

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AALBORG
INDUSTRIES
3 Feed and boiler water characteristics
The following text regarding feed and boiler water treatment is the normal
recommendations given by Aalborg Industries. These recommendations should be
followed strictly in order to have the best working conditions for the boiler plant and
to extend the working life of the plant. The requirements/recommendations of the
various values for feed and boiler water are listed in Table 1 below.
Table 1
If hydrazine (N2~) is not used, sodium sulphate (Na2S03) can be used instead, and
the excess should be 30 - 60 ppm.
In cases where other kinds of oxygen binding agents are used, it is recommended
that an excess of oxygen binding agents can be measured and indicates that no
oxygen has been dissolved in the boiler water.
If it is requested to measure the content of dissolved oxygen directly, it is
recommended to keep the value < 0.02 ppm.
In addition to the above values, the various water treatment companies will add
further demands, depending on the method used for treatment of feed and boiler
water.
However, the most important point is that the above values or their equivalents are
observed and that a regular (daily) test of feed and boiler water is carried out.
3.1 Units of measurement
Concentrations are usually expressed in "ppm" i.e. parts solute per million.
Concentrations for parts solution by weight are the same as "mg/litre".
3.1.1 Specific gravity

As guidance the following conversion can be used:
o 1 Be0 = 10.000 mg/1 total dissolved solids (TDS)
o 1 mg/1 total dissolved solids = 2 J.!S/cm
o 1 J.!S/cm = 1 J.!mhO

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INDUSTRIES
4 Feed and boiler water maintenance
The following are recommended water maintenance instructions. More exact details
concerning analyses and blow downs should be set up together with the supplier of
chemicals for water treatment.
4.1.1 Daily
Step A: Analyses of feed and boiler water.
4.1.2 Weekly
Step A: Skimming (surface blow down) according to analyses, but at least once per
week (2 minutes with fully open valve).
Step B: Blow down (bottom blow down) according to analyses, but at least once per
week (each blow down valve 1 minute in low load condition).
4.1.3 Monthly
Step A: Check the functions for salinity and oil detection systems.
4.1.4 Every six months
Step A: The boiler water side (interior) must be carefully inspected at least twice a
year.
4.1.5 Yearly
Step A: Check of the water side of the boiler and hotwelVdeaerator for corrosion
and scaling.
Step B: Check the chemical pump unit.

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5 Treatment systems I injection points
In the following tables and illustrations a number of different feed and boiler water
treatment systems are shown together with the recommended location for the
injection point of the individual chemicals as stated by the manufacturer. The
general information regarding the injection point principle can be used as guidelines
for the most common systems. But should there be any doubt for a specific system
the manufacturer/supplier should be consulted in order to obtain the correct result.
Notes for tables/illustrations:
• Note No. 1: the preferred injection point of chemicals stated by the
manufacturer/supplier.
• Note No. 2: the alternate injection point of chemicals stated by the
manufacturer/supplier.
• Note No.3: Valid for modulating feed water systems.
• Note No. 4: valid for on/off operating feed water systems. The chemical pump
starts/stops together with the feed water pump.
• Note No. 5: valid for two boiler installation. Control of the chemicals in
question work properly at an equal load condition (feed water flow) on the two
boilers.
How to use the tables:
The tables can be used in different ways but the main idea is to do following:
Step A: Discover which manufacturer and type of chemicals that should be used for
the actual boiler plant.
Step B: Use the name of the manufacturer and type of chemicals to select which
tables that can be used.
Step C: Check the flow diagrams (Figure 1, Figure 2, or Figure 3) to find a diagram
that matches the actual boiler plant.
Step D: Find in the selected tables the table which includes the matching diagram.
Step E: If more than one table is found to match the actual boiler plant in question it
is recommended to use the method/table which includes note No. 1.
Step F: If no table is found to match the actual boiler plant in question it is

recommended to seek assistance by the chemical manufacturer/supplier.

II
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AALBORG
INDUSTRIES
Manufacturer I supplier: Ashland Chemical/ Drew Marine Division I TableNo.2
Product name I method: Standard with Amerzine

Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No.
AdjunctB 3, 3a, 3b X 1
GC 3, 3a, 3b X 1
1, 2, 3
SLCC-A 3, 3a, 3b X 1
Arnerzine 2, 2a, 2b X 1, 3, 4
Manufacturer I supplier: Ashland Chemical/ Drew Marine Division

I Table No.3

AdjunctB 3 X
GC 3 X
1
SLCC-A 3 X
Arnerzine 1 X 2,3,4

I TableNo.4

Chemical name ln_jection point No. Continuous Batch Note No. Valid flow diagram No.
AdjunctB 3a, 3b X
GC 3a, 3b X
2,3
SLCC-A 3a, 3b X
Arnerzine 1 X 2, 3, 4, 5

I TableNo.5
Product name I method: Drewplex AT I OX

DrewplexAT 3, 3a, 3b X I
DrewplexOX 2, 2a, 2b X 1 3 4
1, 2, 3

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AALBORG
INDUSTRIES

I Table No.7
Product name I method: Drewplex AT with Amerzine

Chemical name Injection point No. Continuous Batch Note No. Valid flow dia2ram No.
DrewplexAT 3, 3a, 3b X 1, 3, 4
Amerzine 2, 2a, 2b X 1, 3, 4
1, 2, 3

I Table No.8

DrewplexAT 2, 2a, 2b X 2, 3, 4
Amerzine 2, 2a, 2b X 3, 4
1, 2, 3

I Table No.9

DrewplexAT 2 2a, 2b X 2,3,4
Amerzine 1 X 2, 3, 4, 5
1, 2, 3

I Table No. 10
Product name I method: AGK-100 with Amerzine

AGK-100 2 2a, 2b X I, 3 4
Amerzine 2, 2a, 2b X 1, 3, 4
1, 2, 3

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AALBORG
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I Table No. 12
Product name I method: AGK-100 with Amerzine

Chemical name Injection point No. Continuous Batch Note No. Valid flow diae:ram No.
AGK-100 1 X 2, 3, 4, 5
Arnerzine I X 2, 3, 4, 5
1, 2, 3
Manufacturer I supplier: Marich em

I Table No. 13
Product name I method: Standard

Alkalinity control 3, 3a, 3b X 1, 3, 4
Phosphate 3, 3a, 3b X 1, 3, 4
1, 2, 3
Oxycontrol 2, 2a, 2b X 1, 3, 4
Marichem CCI 2, 2a, 2b X 1, 3, 4
Manufacturer I supplier: Marichem

I Table No. 14
Product name I method: Standard

Alkalinity control 1 X 2, 3, 4
Phosphate 1 X 2, 3, 4
1
Oxycontrol 2 X 3,4
Marichem CCI 2 X 3,4

I Table No. 15
Product name I method: BWT new formula

Chemical name Injection point No. Continuous Batch Note No. Valid flow diae;ram No.
B.W.T. new formula 2 2a, 2b X 1, 3 4
Marichem CCI 2 2a, 2b X I, 3, 4
1, 2, 3

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AALBORG
INDUSTRIES
Manufacturer I supplier: Marich em

I Table No.17
Product name I method: BWT

B. W. T. powder 2, 2a, 2b X I, 3, 4
Marichem CCI 2, 2a, 2b X I, 3, 4
I, 2, 3

I Table No. 18
Product name I method: BWT

B.W.T. powder I X 2, 3, 4, 5
Marichem CCI 2, 2a, 2b X 3,4
I, 2, 3
Manufacturer I supplier: Unitor Chemicals

I Table No. 19
Product name I method: I

Hardness control 3, 3a, 3b X l
Alkalinity control 3, 3a, 3b X l
l, 2, 3
Oxygen control 2, 2a, 2b X l, 3, 4
Condensate control 2, 2a, 2b X l 3, 4

I Table No. 20

Hardness control l X 2
Alkalinity control l X 2
l
Oxygen control 2 X 3, 4
Condensate control 2 X 3,4

.....
0 0 0
Jiiiiili
AALBORG
INDUSTRIES

I Table No. 22
Product name I method: II

Hardness control 1 X 2
Alkalinity control 1 X 2
1
Cat sulphite L (CSL) 2 X 3, 4

l Table No. 23
Product name I method: Liquitreat

Chemical name Injection JlOint No. Continuous Batch Note No. Valid flow diae:ram No.
Liquitreat 3, 3a, 3b X 1
Condensate control 2, 2a, 2b X 1, 3, 4
1, 2, 3
(Oxygen control) 2, 2a, 2b X 1, 3, 4

I Table No. 24
Product name I method: Liquitreat

Liquitreat 1 X 2
Condensate control 2, 2a, 2b X 3, 4
1
(Oxygen control) 2, 2a, 2b X 3, 4

I Table No. 25
Product name I method: Combitreat

Combitreat 3, 3a, 3b X 1
Condensate control 2, 2a, 2b X 1 3, 4
1, 2, 3
Oxygen control 2, 2a, 2b X 1, 3, 4

.
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AALBORG
INDUSTRIES
Manufacturer I supplier: Uniservice Group

I Table No. 27

Hardness control 3, 3a, 3b X I
Alkalinity_ control 3, 3a, 3b X I
I, 2, 3
Hydrazine 2, 2a, 2b X I, 3, 4
Condensate control 2, 2a, 2b X I, 3, 4

I Table No. 28

Hardness control I X 2
I
HydraziDe 2 X 3,4

I Table No. 29

Hardness control 3 3a, 3b X I
Alkalinity control 3, 3a, 3b X I
1, 2, 3
Oxygen control 2, 2a, 2b X 1, 3 4
Condensate control 2, 2a, 2b X 1, 3, 4
Manufacturer I supplier: Uniservice Group l Table No. 30

Hardness control I X 2
1
Oxygen control 2 X 3, 4
Condensate control 2 X 3, 4
Language UK Page IOI14

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AALBORG FEED AND BOILER WATER . OM9210#99.2
INDUSTRIES

I Table No. 32
Product name I method: One Shot

BWTOne Shot 1 X 2
Alkalinity control 2, 2a, 2b X 3, 4
1
(Hydrazine) 2, 2a, 2b X 3, 4

I Table No. 33
Product name I method: Organic Treatment

OBWT3 3, 3a, 3b X 1
OBWT4 2, 2a, 2b X 1, 3, 4
1, 2, 3

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INDUSTRIES
Flow diagram No.: 1
Boiler
I I 1
1
I ------1
I
Single boiler operation with or without

forced circulation exhaust gas boiler
Figure 1 tlowdiag_1.cdr

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iliiiiili
INDUSTRIES
Flow diagram No.: 2
steam
!~~3b
. [~~3a ~ _L
I
.'
I
I
I'
I'
I'
-!.,1iT
dump
valve
i
l !
L...
Condenser [ } : ; : Cooling
I water
i
I u
( Condensate
l "'"
., I
BoISrj !;fu Bo iler' \.% II I I ]_r-<= Make-up
~ Overflow
I Hot well
~ Drain
- --
- 1
r~
~----1
2a ;' ~~;
[~
i i
'
!_. ____ j '
6<1
,.--.. ,.--.. ,.--.. ,.--.. ,---.. ,.....___ I jll

[~-c2b
. I
~1'1~~-
iPS
_! ~II
Double boiler o peration with separate feed water purn ps
1' 1 P
Feed water
pumps
with or without forced circulation exhaust gas boiler
Figure2 flowdiag_2.cdr

.....
....
.
. 11.11·1·.
iii I ii
INDUSTRIES
Flow diagram No.: 3

Service
steam
i~-~3b
.' I
. 1
~-~3a
'
I ~ )_
-·
I
-I
I'
-----I'
Seamj ~
dump : ~
vatve ; !
~
,_ _ !T
: ! '
~~Cooling
~
( Condenser water
u
, I
__.,_
Condensate
\5lo ~ I I Make-up
Bo iler Bo iler rl I
Hot well
f---<> Overflow
f---<> Drain
=
-
reEl/
In.1
2a i
i
i~
i
I I
I'
'
--- ~
i
!
-
I
I I'
Feed water
,-... .. ~ ,-... r "'. . --
'
I
pumps
2b
I TV~. J
~~
I
I'
I'
----- r
I'
' VV~.J
Double boiler operation with common feed water pumps
with or without forced circulation exhaust gas boiler
Figure3 flowdiag_3.cdr

5
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INDUSTRIES
Table of contents
Water level gauge

Maintenance and service instructions .......................................................................... 1

.
.........
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AALBORG WATER LEVEL GAUGE . · OM7010#01.1
INDUSTRIES
Water level gauge
1 Maintenance and service instructions
This section describes the maintenance and service instructions for the water level
gauge.
Illustration of the water level gauge
1- Nut
2- Box heads
3 - Joint rings
4- Box heads
5- Tubes
6- Screws
7- Screws
8- Cock plug
D - Drain cocks
G - Gauge body
S- Cocks
W-Cocks
Figure 1 kli Ole.cdr
1.1 Maintenance
The item nos. mentioned in the following maintenance instructions refer to Figure I.
When out of service with the gauge body in cool and depressurised condition the
hexagon screws (6) can be re-tightened. · \

.
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iliiiiili
AALBORG WATER LEVEL GAUGE · OM7010#01.1
INDUSTRIES
Step A: Start at the centre, working to opposite sides alternately. Max torque: 26
Nm in cold and under working conditions.
1.1.2 Maintenance during service check-up
Step A: Tighten the nuts (1 ).
Step B: Bolts on boiler flanges.
Step C: Union nuts (4).
Step D: Bolt form screws (7) with cocks in open positions.

If a leak cannot be stopped by tightening the bottom screws (7), the sealing surface
of the cock plug (8) may be damaged or corroded. It can also be necessary to change
the packing (3).
1.2 Blowing down
The item nos. mentioned in this following blowing down procedures refer to Figure
1.
Step A: The gauge should be blown down before lighting up the boiler and just
before closing down the boiler.
1.2.2 Cleaning the water side:
Step A: Shut the cockS and open the cock W.
Step B: Open the drain cock D for a short time. This sucks the water out of the glass .
without, however, totally depressurising the gauge body.
Step C: Shut the cock D and then water is forced upwards into the glass again.
Step D: Repeat this procedure several times, opening and shutting the cock D. The
water level in glass rises and falls.
1.2.3 Cleaning the steam side:
Step A: Shut the cock W.
Step B: Open the cock S.
Step C: Blow through the steam side and gauge body by opening the drain cock D
for 1-2 seconds.
Step D: A steam blowing of longer duration is not advisable considering the service
life of glass.
Step E: Turn the cocks to operating position.

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AALBORG WATER LEVEL GAUGE 0 • • - - OM7010#01.1 ·
INDUSTRIES
1.3 Dismantling
The following dismantling instructions refer to Figure 1 and Figure 2.
Sectional view of the water level gauge
6- Screws
9 - Wedge piece
10 - Centre piece
11 -Reflex
12 - Sealing gasket
13- Cushion gasket
14 - Cover plate
Figure2 kli_05e.cdr
Step A: Shut the cocks Sand W.
Step B: The drain cock D to be opened until the glass is completely emptied.
Step C: Remove nuts (1) and lift off stuffing box heads (2) together with the gauge
body from the cocks S and W.
Step D: Slacken the union nuts (4) and pull off the stuffmg box head (2).
Step E: Place the gauge body (G) horizontally with the screws (6) turning upwards
and loosen the screws.
Step F: Move the wedge piece (9) length wise and lift upwards.
Step G: Lift off centre piece (10) reflex glass (11) and gaskets (12 and 13).
Step H: Clean sealing surface of cover plate (14) and centre piece (10) and examine
for through going scars.
1.4 Assembling
The following assembling instructions refer to Figure 2.

Step A: Insert following items into the centre piece (10): sealing gasket (12) reflex
glass (11) cushion gasket (13).

...
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AALBORG WATER LEVEL GAUGE
~
.
.
OM7010#01.1
INDUSTRIES
Step B: Place cover plate (14) on top.
Step C: Insert wedge piece (9) and move length wise for correct position.
Step D: Tighten screws (6) evenly starting at the centre, working to opposite
alternately. Max torque: 26 Nm in cold and under working conditions.
1.5 Maintenance of the straight-through cock
1.5.1 Operation principle and maintenance

The following assembling instructions refer to Figure 3.
Detail drawing of the straight-through cock
15
15- Screw ./
16- Split ring
17 - Packing sleeve
18- Plug
19 - Bottom screw
Figure3 kli_06e.cdr
The cylindrical plug (18) is sealed with a resilient packing sleeve (17).
Should leakage arise during service the packing sleeve must be further compressed
by tightening the bottom screw (19) until the leakage is stopped. This must only be
done with the cock in open position.
1.5.2 Dismantling
Step A: Remove bottom screw (19).
Step B: Remove screw (15), washer and handle.
Step C: Knock the plug (18) together with split ring (16) and packing sleeve (3) out
of the cock body by means of a soft mandrel.
Step D: Remove split ring and knock plug out of the packing sleeve.
Step E: Clean all sealing surfaces carefully and lubricate threads with a high
temperature grease before installation.

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AALBORG WATER LEVEL GAUGE .·. OM7010#01.1
INDUSTRIES
1.5.3 Assembly
Step A: Place the split ring {16) in the recess of the plug (18).
Step B: Push new packing sleeve onto plug.
Step C: Press the complete unit into cock body.
Note: Turn the packing sleeve until the ridge fits with the groove in the cock
body. The eyelets of the packing sleeve must neither protrude nor be
tilted.
Step D: Screw in bottom screw (19).
Step E: Place the handle and washer on the plug and fit screw (15).
Step F: Tighten the bottom screw (19) and check if the plug can be turned.

6
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iliiiiiii
INDUSTRIES
Table of contents
Safety valves
General ........................................................................................................................ l
Maintenance and start-up of boiler .............................................................................. 2
Adjustment and dismantling ....................................................................................... .3
Temporary locking of a safety valve

· General ........................................................................................................................ l

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AALBORG SAFETYVALVES . OM6040#01.1'
INDUSTRIES
Safety valves
1 General
In the following the measures required to achieve a safe and reliable operation as
well as maintenance of the safety valves will be described, together with adjustment
and dismantling instructions. An installation example of the safety valve is shown in
Figure 1.
Mounting of safety valves, example
Waste steam pipe

Support
Expansion joint
with sealing ring
Drain
Figure 1 safe_Olc.cdr
2 Maintenance and start-up of boiler
A regular inspection of the safety valve is recommended at least once a year. Some
media and appliances require a more frequent inspections, this is according to the
experience of the supplier.

.
. ...
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ill I IIi
AALBORG SAFETY VALVES . . . ·. ' OM6040#01.1
INDUSTRIES
Warning: Prior to any handling and dismantling of the safety valve ensure that
the system is depressurised.
Before lighting-up the boiler, pipe connections must be thoroughly cleaned for dirt
and foreign bodies. If the valve is not completely tight, which often is the case after
start up of the plant, this is usually caused by impurities between the seat and the
cone. In order to remove these impurities the valve must be heavily blown out by
means of the lifting device. If the valve is not tight after several blows, it may be due
to the fact that a hard foreign body has got stuck between the cone and the seat, and
it will then be necessary to dismount the valve for overhaul. ·
Warning: In case of a leaking safety valve the valve must be inspected and
over-hauled as soon as possible. It must be ensured that the boiler is
totally depressurised before dismounting the valve.
Note: Before dismantling the safety valve in the workshop the position of the
adjusting screw must be measured and noted which will facilitate the
adjustment later when the valve is to be adjusted when in service.
In case the facings between the cone and the seat have been damaged, they must be
grinded.
Step A: The cone can be grinded against a cast iron plate, using a fine grained
carborundom stirred in kerosene.
Step B: The seat in the valve body can be grinded in the same way by using a cast
iron punch of suitable size.
Note: Never use the cone itself when grinding the seat.
Warning: The spindle and the valve cone must always be secured against
turning as the seat and the cone may thus be damaged.
Step C: Before assembly the valve must be thoroughly cleaned, and all traces of
grinding material and impurities must be removed.
Step D: When the valve has been mounted and the boiler is commissioned, the
valve must be checked for leakage and adjusted to the set pressure.
Step E: The adjustment screw is secured by means of its lock nut, and the valve is
sealed.

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i.
AALBORG SAFETVVALVES · . . OM6040#01.'1.
INDUSTRIES
2.2 Routine check
The following should be regarded as recommendations of routine checks on the

safety valves, in order to secure a correct function:
Monthly
Step A: Examine the safety valves for any leaking, such as:
- Is water seeping from the drain plug at the valve body?

- Is the escape pipe hot due to seeping steam from the valve seat?
Step B: Examine the drain and expansion device at the escape pipe.
Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts.
Yearly
Step A: The safety valve should be tested in operation by raising the boiler pressure.
Step B: Expansion and exhaust pipe should be examined at the same time.
3 Adjustment and dismantling
Safety valves are delivered with the required spring setting and sealed against
unauthorised adjustment. Adjustments are only allowed in the spring margins.
Outside the margin a new spring is required. The pressure in a system should not
exceed 90% of the set pressure.
All item numbers mentioned in the following sections refer to Figure 2.
3.1 Dismantling of lifting device
Safety valve with open cap:

Step A: Remove bolt (39) and remove lift lever (41)
3.2 Set pressure change without spring change
Note: Pay attention to spring range.
Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21 ).
Step C: Tum the adjusting screw (17) clockwise for higher and anticlockwise for
low set pressures.
Step D: Secure the new setting with the lock nut (21) and reassemble lifting device.

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ii.I·I·I1.Iii
AALBORG SAFETY VALVES ·, OM6040#01.1 ,
INDUSTRIES ' '
3.3 Spring change
Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21) and turn adjusting screw (17) anticlockwise, then the
spring (3 7) is not under tension.
Step C: Loosen the nuts (8) and remove the bonnet (42).
Step D: Remove the upper spring plate (26), spring (37), spindle (14) with disc (12),
guide plate (4), and lower spring plate (26).
Step E: Clean the seat (2) and disc (12).
Step F: Remount the spindle unit with the new spring and upper spring plate.
Assemble bonnet (42) and adjust to the spring range.
Step G: Secure the spring setting through the lock nut (21) and remount lifting
device.
Assembling drawing of safety valve
47 Ball
42 Bonnet
41 Lifting lever
40 Split pin
39Bolt
38 Screw
37 Spring
29Cap
· 27 Gasket
26 Springplate
23 Lead seal 23
22 Drain saew
21 Locknut 26
18 Ball
17 Adjusting screw 27
16 Slotted pin
15 Gasket
14 Spindle 37
13 Lift aid
12Disc 42
10/25 Split cotters
14
9 Lift limitation ring
8 Hex. nut 10,25
7 Gasket
4 Spindle guide 8
3 Stud
2 Seat 7 26
1 Body
9 4
3
16
18
12
13
15,22
Figure 2 safe 03a.cdr

.
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AALBORG TEMPORARY LOCKING OF A SAFETY VALVE . · OM6040#02.0
INDUSTRIES
1 General
During commissioning work or later tests of the opening pressure for the safety
valves, only one safety valve should be checked at a time. This means that the other
safety valve must be locked. The following instruction describes the temporary
locking of a safety valve.
1.1 Procedure for locking of a safety valve
Step A: Remove the bolt (39) and split pin (40), see Figure 1.
Step B: Remove the lifting lever (41).
Step C: Unscrew the screw (38) and break the lead seal (23), if provided.
Step D: Unscrew the cap (29).
Step E: Place one or two bolts ( 48) on top of the spindle. The height of the bolts
should be approximately 1-2 mm higher than the normal distance between
the top of the spindle and the inside top of the cap (29).
Step F: Carefully screw on the cap until the spindle and bolts are locked. The safety
valve will be completely locked when the bolts cannot be moved anymore.
Step G: The other safety valve can now be tested without any interference from the
locked safety valve.
1.2 Procedure for unlocking of a safety valve
Warning: As soon as the test procedure for the safety valve has been carried
out the locked safety valve must be unlocked.
Step A: Unscrew the cap (29) and remove the bolts (48).
Step B: Mount the cap (29) again and screw in the screw (38).
Step C: Mount the lifting lever (41 ), bolt (39), and split pin (40).
Step D: Provide the safety valve with a lead seal (23), if necessary. This depends on
the local rules of the classification society.

...
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AALBORG JEMP.ORARY LOC.KING QF A SAFETY VALVE OM6040#02.0
INDUSTRIES
23
Figure 1 safe_06.cdr

7
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AALBORG TABLE OF CONTENTS .
INDUSTRIES
Table of contents
Feed water system

Description .................................................................................................................. 1
Level float switch

General ........................................................................................................................ l
Commissioning ............................................................................................................ 2
Operation and maintenance ........................................................................................ .3
dp water level transmitter unit

General ........................................................................................................................ l
Commissioning ............................................................................................................ 2
Operation and maintenance ........................................................................................ .3

illliilli
AALBORG
INDUSTRIES
'WATER LEVEL CONTROL
';. - ' J "'-..
· · :, Water level controi:1~SHI '
Water level control
1 Description
The water level control is a modulating system at this type of boiler. The system is
illustrated in Figure 1. The safety device system for too low water level shut down
and burner stop consists of a level float switch mounted as an external unit. For
measuring and control of the water level, the boiler is equipped with a dp water level
(
I
transmitter unit, which includes external reference and variable legs, and a dp-
transmitter. The continuous 4-20 rnA output signal from the dp-transmitter is
processed in the control system, which provides level alarms/shut downs aild control
of the regulating feed water valves.
In case of the boiler is firing, the WI regulating feed water valve is control of the
water level. In case of the boiler is not firing, the W2 regulating feed water valve is
control of the water level.
Water level control system
Instrument air Regulating feed water valves

--- -- -------------------.,
'
'
rr=======---=--=---,----------1
Feed water
valves
'
Reference leg
Level float
swHch
Variable leg
Boiler
:·'····:=~~--~:-:::!.':i:r~:c.::,~;;,,.
Valve Control
manifold system
(panel)
dp-transmitter
'
: ! ;
' I '"-------'
' ----------------
'
'
' Feed water pumps
!
L --------- ·- ----- • •• ·7·· ----------...-- -· ----- • • ·- :-------
Figure 1 dp_l_mod_lval.cdr

.
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iliiiiili
AALBORG LEVEL FLOAT SWITCH , . OM8210#15.1
INDUSTRIES
Level float switch
1 General
The level float switch of type RBA 24 supervises the water level in the boiler. It is
installed in a vertical position and connected to the boiler sockets, provided for this
purpose, by means of shut-off valves.
A float and float rod carry a transmitting magnet which runs in a stainless steel
transmitting tube. The transmitting magnet operates the externally installed magnet
switches. When the magnet switches have been triggered, they remain in that
position until trigged again. Figure 1 illustrates the level float switch.
Illustration of the level float switch
------------------
~
~~~~mil
~
1 j Transmitting
~ tube
__ Float rod
Transmitting
magnet
Level float
Drain valve
Figure 1 rba24.cdr
2 Commissioning
2.1 Electrical connection
When installing the level float switch use acetic acid-free silicon cable in the
internal part of the switch housing.
Step A: Unscrew the switch housing and check for correct assembly and wiring.

........
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AALBORG LEVEL FLOAT SWITCH OM8210#15.1.
INDUSTRIES
2.2 Adjusting the switch point
The switch point of the level float switch should be pre-adjusted before the boiler is
pressurised and started for the first time.
Step A: Open both shut-off valves and close the drain valve.
Step B: Open the feed water valves and the air valve. Fill the boiler with evaporated
water until the "Too low water level" mark has been reached and adjust the
magnet switch to the switch point. It should be moved in upwards direction
until the switch is trigged and secured in this position. The magnet switch
must rest against the transmitting tube.
Note: If the temperature difference between the boiler and feed water exceeds
approximately 50°C, the boiler must be filled very slowly. When filling a
pressure less boiler, the shut-off valve after the feed water pump must be
throttled. Otherwise the pump motor will be overloaded.
2.3 Function test
During commissioning a live test of the level float switch must be carried out before
the boiler is put into normal operation. The purpose of the live test is to check that
the shut down for too low water level and cut out function of the burner is
operational. When the boiler is pressurised and the burner is in operation carry out
the following work steps:
Step A: Slowly decrease the water level in the boiler by means of the blow down
valves until the water level has fallen to the "Too low water level" mark.
Ensure that the boiler is not refilled with water by closing the feed water
valves.
Step B: Note that both the shut down and cut out function is delayed via a timer in
the control panel. ·
Step C: Adjust the switch point, if necessary.
Step D: After completion of the function test open the feed water valves fully and
raise the water level to the normal level.
3 Operation and maintenance
Attention: Both shut-off valves must always be fully open during normal
operation of the boiler.
To ensure a safe and reliable operation of the boiler plant check the level float
switch whenever an opportunity occurs by comparing the magnetic switch function
with the level indicated in the water level gauges.

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AALBORG LEVEL FLOAT SWITCH OM8210#15.f
INDUSTRIES
A great difference in the water levels may indicate either blocked connections to the
float chamber or a water filled level float. Therefore it is recommended to blow-
through the level float switch and connection pipes frequently (see below). The
blow-through procedures can be performed, e.g. in connection with stopping the
boiler plant, in order to get rid of dissolved particles that could settle during the stop
periods. In case of prolonged standstill the level float switch should be checked for
the correct function before the boiler plant is restarted.
3.1 Blow-through procedure
The blow-through procedure with cleaning of the float chamber should be

performed as describe below when the boiler plant is in operation. The procedure
should be carried out at least once each week.
Step A: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds.
Step B: Close the drain valve again.

In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through
procedure of the level float switch must be done more often.
3.2 Blow-through and test procedure
The blow-through procedure with test of the shut down and burner cut out function
should be performed as describe below when the boiler plant is in operation. The
procedure should be carried out at least once each month.
Step A: Fully close the upper shut-off valve.
Step B: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds.
Step C: Then close the drain valve and open the upper shut-off valve again.
Step D: Fully close the lower shut-off valve.
Step E: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds. As the water level falls inside the float
chamber check that the shut down function is activated and the burner cuts
out. Please note that both the shut down and cut out function is delayed via
a timer in the control panel.
Step F: After performing the blow-through and test procedure close the drain valve
and open the lower shut-off valve again.
procedure of the level float switch must be done more often.
3.3 Cleaning
The float chamber, transmitting tube, and transmitting magnet must be opened,
checked, and cleaned from dirt at least once a year. Carry out the following work
procedures:

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AALBORG LEVEL FLOAT SWITCH ~ ·. . . .·· OMS210#15.1
INDUSTRIES
Step A: Perform a blowing-through procedure as described above.
Step B: Close the two shut-off valves and slowly open the drain valve.
Step C: Remove the top flange of the chamber.
Step D: Loosen the float and float rod with transmitting magnet from the top flange.
Step E: Clean the transmitter tube and transmitting magnet.
Step F: Clean the float chamber for any fossilised mud.
Step G: Check the condition of the float and that it is not water filled.
Step H: Check the condition of the electrical wiring. Exchange damaged wires if
necessary.
When the cleaning procedure is completed the level float switch must be assembled
as follows:
Step 1: Assemble the transmitting magnet in the top flange.
Step J: Assemble the top flange on the float chamber.
Step K: Perform a function test as described previously when the boiler is

pressurised.

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iii
AALBORG DP WATER LEVEL TRANSMITTER UNIT . OM8210#16.1.
INDUSTRIES
dp water level transmitter unit
1 General
The dp water level transmitter unit controls and supervises the water level in the
boiler. The complete unit is installed in a vertical position and connected to the
boiler sockets, provided for this purpose, by means of shut-off valves (see Figure 1).
The dp water level transmitter unit includes reference leg, variable leg, transmitter
connection valves mounted on a manifold, and a differential pressure transmitter.
The differential pressure transmitter converts the detected water level into an
analogue signal (4-20 rnA) which is transmitted to the control system. The signal
can also be used for remote level indication in the engine control room.
Illustration of the dp water level transmitter unit

Shut-off valves
Filling p l u g - - \
Reference leg~...F'= ~ I I
Drain valve~'7J
u
-··.
FDiing plug---+--~
Drain valve-- t---

-u~
Boiler
Valve manifold"\..
;~~~:d~n l;u
Equalising valve~r
dp-transmitter- V
Figure 1 dpunit.cdr
The differential pressure transmitter is installed with the process connections upward
to prevent trapping of air. The pipes are mounted with continuous fall (at least 5°)
from the boiler connections to the transmitter also to prevent trapping of air.
The reference impulse leg (upper connection point) is connected to the high pressure
connection (+), and the variable impulse leg (lower connection point) to the low
pressure connection (-).
Note: The dp water level transmitter unit or any part of it must not be
insulated to ensure the correct function.

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AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1
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2 Commissioning
2.1 Initial commissioning
Before the boiler is pressurised and started for the first time some initial
commissioning procedures can be performed with regard to the valves of the dp
water level transmitter unit. The shut-off valves, transmitter connection valves, and
equalising valve should be operated in the following sequence during the initial
commissioning:
Step A: Initial setting; all valves of the dp water level transmitter unit closed (see
Figure 1).
Step B: Open the equalising valve located on the valve manifold.
Step C: Unscrew the filling plugs for the reference leg and variable leg. Fill the legs
with feed water.
Step D: Open the transmitter connection valve and venting facility on the reference
leg side of the transmitter.
Step E: Close the venting facility on the reference leg side of the transmitter when
no more air escapes.
Step F: Open the venting facility on the variable leg side of the transmitter.
Step G: Close the transmitter connection valve on the reference leg side of the
transmitter when no more air escapes.
Step H: Open the transmitter connection valve on the variable leg side of the
transmitter.
Step 1: Close the venting facility on the variable leg side of the transmitter when no
more air escapes.
Step J: Close the transmitter connection valve on the variable leg side of the
transmitter.
Step K: Close the equalising valve.
Step L: Refill the legs with feed water and screw on the filling plugs for the
reference leg and variable leg.
Step M: Open both transmitter connection valves fully.
2.2 Commissioning of the differential pressure transmitter
The differential pressure transmitter can be commissioned either through "blind

calibration" or "live calibration". In the following sections both methods are
described.

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AALBORG DP WATER LEVEL TRANSMITTER UNIT OM821 0#16.1
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2.2.1 Blind calibration

Blind calibration of the differential pressure transmitter can be performed if no
pressure source is available. This means when the boiler cannot be operated at
normal working pressure and the water level cannot be increased/decreased. The
"start of scale" an<i "full scale" differential pressures are calibrated on the basis of
calculated values. The start of scale value should be calibrated to obtain a 4 rnA
output signal from the transmitter when the water level is at the lower connection
point and the full scale value to obtain a 20 rnA output signal when the water level is
at the upper connection point. To ensure an accurate calibration it is necessary to
take the density difference between the water in the reference leg and in the boiler
into consideration when calculating the differential pressure values.
4 rnA output signal from the differential pressure transmitter:
When the water level in the boiler is at the lower connection point the pressure
difference over the transmitter is equal to the height between the connection
points (column of water) corrected with the density of the water in the reference
leg. The value must be specified and entered in engineering unit, e.g. in mm
H20.
20 rnA output signal from the differential pressure transmitter:
When the water level in the boiler is at the upper connection point the pressure
difference over the transmitter is equal to the height between the connection
points corrected with the density difference between the water in the reference
leg and in the boiler. The value must be specified and entered in engineering
unit, e.g. in mm H20.
Figure 2 indicates the calculation procedures of the differential pressures. As
standard it is assumed that the temperature in the reference leg (condensate receiver)
is 40°C. Table 1 shows the calculated values for some standard heights between the
connection points. If the actual boiler plant does not fit any of the standard
calculations the specified calculated values can be entered in the table for calibration
record purpose.
If the boiler plant is intended to operate at different set points (high/low pressure
mode) the differential pressure transmitter must be calibrated so that the minimum
indicated "Too low water level" on the control system not is lower than the actual
"Too low water level" mark. Because of the density difference in the boiler water at
different working pressures/temperatures the indicated water levels will not be
identical. This means that the differential pressures for start of scale and full scale
should be calculated using the parameters from operation in high pressure mode.
When the differential pressures corresponding to the "start of scale" and "full scale"
have been calculated carry out the following work steps (please also see the specific
instruction for the differential pressure transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential
pressure transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys t and ,!.. are used to change the mode
value.

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Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select e.g. "mm H 20" as engineering units.
Step D: Select mode 5 using the "M" key.
Step E: Use the t or{.. key to set the start of scale in the selected engineering unit. If
mm H 20 is selected as engineering units, then set the start of scale to the
calculated value in mm H 20 (differential pressure at 4 rnA).
Step F: Press both the t and {.. keys simultaneously for about 2 seconds, and the
start of scale is set to zero (in the selected engineering unit).
Step G: Select mode 6 using the "M" key.
Step H: Use the t or {.. key to set the full scale in the selected engineering unit. If
mm H 20 is selected as engineering units, then set the full scale to the
calculated value in mm H 20 (differential pressure at 20 rnA).
Step 1: Press both the t and {.. keys simultaneously for about 2 seconds, and the full
scale is set to the upper limit (in the selected engineering unit).
Step J: Mount the protective cover of the differential pressure transmitter again.
Table 1
Language UK Page4/10
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AALBORG DP WATER LEVEL TRANSMITTER UNIT OM821 0#16.1
INDUSTRIES
Calculation of the differential pressures
t, =40'C, density: 992.2 kglrn'
~ =not existing
Differential pressure
I
between connections:
Height between
525 X 0.9922 =
connections, e.g.:
525rnrn
521 rnm H,O (at 4 rnA)
water level
t,
\
=170'C at 7 barg,
204'C at 16 barg
t, =40'C, density: 992.2 kglrn' t, = not existing
Vllaterlevel
between connections
(at 7 barg):
525 X (0.9922- 0.8970) =
Height between
50.0 mm H,O (at 20 mA) connections, e.g.:
525rnrn
between connections
(at 16 barg):
525 X (0.9922- 0.8596) =
69.6 rnrn H,O (at 20 rnA)
\
t, = 170'C at 7 barg,
density 897.0 kglrn'
204'C at 16 barg,
density 859.6 kglrn'
Figure2 dpunit_calil.cdr
2.2.2 Live calibration

Live calibration of the differential pressure transmitter can be performed when a
pressure source is available. This means when the boiler can be operated at normal
working pressure and the water level can be increased/decreased. The "start of scale"
and "full scale" output signals of the differential pressure transmitter are set during
actual operating conditions. It is therefore not necessary to take the density
difference between the water in the reference leg and in the boiler into consideration.
However, if the boiler plant is intended to operate at different set points (high/low
pressure mode) the differential pressure transmitter must be calibrated so that the

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AALBORG DP WATER LEVEL TRANSMITTER
. UNIT OM8210#16.1
.
INDUSTRIES
minimum indicated "Too low water level" on the control system not is lower than
the actual "Too low water level" mark. Because of the density difference in the
boiler water at different working pressures/temperatures the indicated water levels
will not be identical. This means that the differential pressure transmitter should be
calibrated when the boiler plant operates in high pressure mode.
When the boiler operates at normal working pressure carry out the following work
steps (please also see the specific instruction for the differential pressure
transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential
pressure transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys t and -1,. are used to change the mode
value.
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select "rnA" as engineering units.
Step D: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.
Step E: Slowly decrease the water level in the boiler until the lower connection
point is reached (socket centre line of the variable leg). The water level can
be decreased by means of the blow down valves.
Step F: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step G: Select mode 2 using the "M" key.
Step H: Set the output current corresponding to the start of scale using the t and -1,.
keys. Or set the output current to 4 rnA by pressing the t and -1,. keys
simultaneously for about 2 seconds.
Step 1: Slowly increase the water level in the boiler until the upper connection point
is reached (socket centre line of the reference leg). The water level can be
increased by means of the feed water pumps.
Step J: When the water level is increased operate the burner so that the boiler
pressure is kept at normal working pressure.
Step K: Select mode 3 using the "M" key.
Step L: Set the output current corresponding to the full scale using the t and -1,.
keys. Or set the output current to 20 rnA by pressing the t and -1,. keys

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.AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1
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Step M: Mount the protective cover of the differential pressure transmitter again.
2.3 Final commissioning
During fmal commissioning a function test of the dp water level transmitter unit
must be performed before the boiler plant is put into normal operation. The purpose
of the function test is to check that the output signals from the differential pressure
transmitter are correct. Furthermore, it should be checked that the connected
alarms/shut downs and control functions are operational. The boiler should be
operated at normal working pressure during the test to provide for correct
indications. When the boiler is at normal water level and the burner is in operation,
carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
reached. The burner should stop, and a shut down should be indicated on
the control system, (if provided).
Step C: Increase the water level somewhat until the upper connection point is
reached (socket centre line of the reference leg). Check that the output
signal from the differential pressure transmitter is at 20 rnA or the full scale
value in the selected engineering units.
Step D: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step E: Ensure that the boiler cannot be filled with feed water by closing the feed
Step F: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the " Low water level " level. The control
system should indicate an alarm.
Step G: Decrease the water level somewhat until the "Too low water level" mark is
the control system.
Step H: Decrease the water level somewhat until the lower connection point is
reached (socket centre line of the variable leg). Check that the output signal

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AALBORG DP WATER LEVEL TRANSMITTER UNIT - OM8210#16.1
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from the differential pressure transmitter is at 4 rnA or the start of scale

value in the selected engineering units.
Step 1: After completion of the function test open the feed water valves or start the
feed water pumps.
3 Operation and maintenance
Attention: Both shut-off valves between the boiler and impulse legs must
always be fully open and the reference leg must be totally filled with
water during normal operation ofthe boiler.
To ensure a safe and reliable operation of the boiler plant check the dp water level
transmitter unit whenever an opportunity occurs by comparing the water level
indicated by the control system with the level indicated in the water level gauges.
A great difference in the water levels may indicate blocked connections to the
differential pressure transmitter. Therefore it is recommended to blow-through the
impulse legs and connection pipes frequently. The blow-through procedures can be
performed, e.g. in connection with stopping the boiler plant, in order to get rid of
dissolved particles that could settle during the stop periods. In case of prolonged
standstill the dp water level transmitter unit should be checked for the correct
function before the boiler plant is restarted.
3.1.1 Blow-through procedure of the impulse legs

The blow-through procedure should be performed as describe below when the boiler
plant is in operation and in steady load condition. The procedure should be carried
out at least once each month. When the blow-through procedure is carried out, it is
very important that the water level in the boiler is carefully and continuously
supervised by the ship engineering personnel. The feed water control valve must be
operated manually, if necessary.
Step A: Isolate the differential pressure transmitter by closing the two transmitter
connection valves in the manifold. The equalising valve must remain closed
during the blow-through procedure and normal operation.
Step B: Slowly open the drain valves of the impulse legs, and allow the legs to
blow-through for a few seconds.
Step C: Close the shut-off valve for the reference leg.
Step D: Close the drain valves again when the reference leg is completely
depressurised.
Step E: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step F: Screw on the filling plug and slowly open the shut-off valve for the
reference leg.
Step G: Open the two transmitter connection valves in the manifold.

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AALBORG DP WATER lEVEL TRANSMITTER UNIT . OM8210#16.1
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Step H: After performing the blow-through check that the dp water level transmitter
unit and feed water control valve are fully operational.
procedure of the impulse legs must be done more often.
3.1.2 Blow-through procedure of the connection pipes

The blow-through procedure should be performed as describe below when the boiler
plant is stopped, but still pressurised. The procedure should be carried out at least
once each year.
Step A: Open the venting facilities located on the valve manifold for the impulse
legs. The transmitter connection valves must remain open and the
equalising valve closed during the blow-through procedure.
Step B: Close the venting facilities on the valve manifold when only clean water
escapes.
Step C: Close the shut-off valve for the reference leg.
Step D: Slowly open the drain valve of the reference leg.
Step E: Close the drain valve again when the reference leg is completely
depressurised.
Step F: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step G: Screw on the filling plug and slowly open the shut-off valve for the
reference leg.
procedure of the connection pipes must be done more often.
3.1.3 Function test ofthe dp water level transmitter unit

During normal operation of the boiler plant a function test of dp water level
transmitter unit should be carried out at least once each month. The purpose of the
function test is to check that the connected alarms/shut downs and control functions
are operational. The boiler should be operated at normal working pressure during the
test to provide for correct indications. When the boiler is at normal water level and
the burner is in operation, carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
the control system, (if provided).

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AALBORG DP WATER LEVEL TRANSMITTER UNIT .. OM8210#16.1
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Step C: Ensure that the boiler cannot be filled with feed water by closing the feed
Step D: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the "Low water level" level. The control
system should indicate an alarm.
Step E: Decrease the water level somewhat until the "Too low water level" mark is
the control system.
Step F: After completion of the function .test open the feed water valves or start the
feed water pumps.

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Table of contents
Regulating valves
Control valves, type 470/471
General ........................................................................................................................ !
Operation ..................................................................................................................... 2
Maintenance ................................................................................................................ .3
Pneumatic actuator, type dp
General ........................................................................................................................ !
Reversal of the actuator action .................................................................................... 2
Manual operation device ............................................................................................. 3
Maintenance ................................................................................................................. 4
Positioner, SIPART PS2 6DR5000
General ........................................................................................................................ !
Mechanic connection of the positioner ........................................................................ 2
Electric connection of the positioner ........................................................................... 3 ·
Pneumatic connection ..................................................................................................4
Commissioning ............................................................................................................ 5
Diagnosis ..................................................................................................................... 6
Service and maintenance ............................................................................................. 7

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AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0
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1 General
This type of control valve is suited to regulate fluids, gases and steams. The valve
plug is normally a parabolic plug, but can also be supplied in a perforated design.
Both types of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always against the closing direction.
However, with perforated plugs for steam and gases, it is in the closing direction. If
a valve with a perforated plug is operated by means of a pneumatic actuator with the
flow in the closing direction, the pneumatic actuator should have a stronger thrust
force. This is necessary to prevent thumping near to the closing position.
All control valves can be fitted alternately with manual-, pneumatic-, electric- or
hydraulic operation devices.
lllustration of control valves type 470 and 471
Control valve, type 470 Control valve, type 471

_,....------ 7.1
~----10.1
~----15.1
_,...---------6
;----:-------- 7 ~--.---; - - - - - - - - - 17.1
~-------8 - - - - - - - - 3.1
llfT:7"'7FFf?'l-----10 1-ir~:h------- 6.1
,------15 '-------4
.,------17 '------14.1
"/7+Ti:h.....----3
>------26
~+'iii"~. &J:::l:::l,~:;==;::---14
1:.+----T------ 25
:¥t-+'i-tli::'J"-+~--4
~~~~ 1 ..------15
'---~~-"t---19
----17
~~~~----~--5 ~~~-----4
~~--~~~~~~~~-2
~~~~~~~----19
~~~_____;:::,_ __ 5
~-~~ ~~==9r---2
Figure 1 val47x.cdr

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Table 1
2 Operation
2.1 Fitting instructions
The valve should be inserted so that the spindle has a vertical position together with
the actuator. The valve can also be tilted to a maximum horizontal position if the
installation point does not allow any better condition.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length (min. two times the pipe
diameter by inlet and six times by outlet). The piping should be rinsed to clear out
any pollution, welding beads, rust, etc. before inserting the control valves. A strainer
should be fitted in front of the control valve to catch the remaining particles. Bolts
should be tightened after taking into operation.
The flow direction is signalled by an arrow on the valve body. The valves should be
insulated against high temperatures to guard the actuator.
2.2 Actuator assembly
The control valves are normally delivered with actuators already fitted. For
alternations or maintenance of actuator, the assembly should occur in accordance
with the operation instructions for the actuator.
2.3 Setting into operation
When the piping system is filled, the spindle sealing should be checked for leakage
and, if necessary, tightened. A PTFE-V -ring unit does not require any tightening as
the spring tension maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter
than it is necessary for the sealing. Flange connection bolts should never be loosened
or tightened when the valve is under temperature or pressure even if a leakage may
arise.
For actuators please see to the appropriate actuator operation instructions.

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AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0 .-
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3 Maintenance
Before any maintenance of the control valve is carried out, the piping system must
be shut off and pressure free.
3.1 Exchange of the stuffing-box packing
A leak stuffing-box packing should initially be carefully tightened to stop the

leakage. If this does not help, a new layer should be inserted, or the complete
packing should be replaced.
3.1.1 Additional packing layer
Step A: Open the valve fully and unscrew the hexagon nuts (17).
Step B: Lift the gland flange (7) and the spindle guiding (8) upwards.
Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting

at 180° to avoid overlapping).
Step D: Fix the hexagon nuts (17) properly.
3.1.2 Exchange
Step A: Drive the actuator into middle position and dismantle the actuator.
Step B: Unscrew the hexagon nuts (17) from the studs (15).
Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffing
box ( 10) and clean the packing compartment.
Step D: Clean the valve spindle and check for damage and if necessary replace. If
the damaged spindle is not replaced, the new packing will leak after a short
period.
Step E: Insert the new packing rings (split ring-displacement, splitting at 180° to
avoid overlapping).
Step F: Fix the hexagon nuts (17) properly.
Note: Strenuous tightening will prevent leakage, but will also have a brake
effect on the spindle which aggravates the movement of the spindle.
3.2 Exchange of a PTFE-V-ring sealing unit
A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good
seal even by low operation pressures. It is replaced as mentioned above.
The PTFE-V -ring sealing unit should be lubricated before it is inserted. The sealing
lips must face against the pressure direction.

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AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02,.0
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Note: Special care should be given to the spindle surface. Rough surfaces wear
the sealing lips enormously and can be due to failure ofthe packing unit.
3.3 Exchange of the bellow unit
Step B: Unscrew the screw joint (7.1).
'step C: Unscrew the hexagon nuts (17) and remove the bellow housing (25).
Dismantle the plug as described in the next section.
Step D: Unscrew the hexagon nuts (17 .1) and dismantle the mounting bonnet (3 .1 ).
Step E: The bellow unit (26) is removed from the bellow housing (25).
Step F: Replace the two gaskets (14.1) and the gasket (14).
Step G: When the bellow unit (26) is replaced, the proper position of the anti-
twisting device must be observed.
Step H: The set pins (21) have to drive within the slots of the anti-twisting device.
Check for friction-free movement.
Step 1: Replace mounting bonnet (3 .1) and screw down the hexagon nuts (17 .1)
crosswise.
3.4 Exchange of the plug-spindle unit
Step B: Unscrew the gland flange (7).
3.4.2 Control valve type 470
Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).
Step B: Pull out the plug with the spindle and exchange this unit.
Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6).
Step D: Replace the old parts and assemble it.
Step E: Drill a hole through the plug shaft and insert a new pin.
Step F: Replace the gasket (14) and assemble the mounting bonnet (3).
Step G: Tighten the nuts (17) evenly, crosswise.

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AALBORG CONTROL VALVES, TYPE 470/471 . OM6010#02.0
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Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with
plug (5).
Step B: Drive the spindle in the bottom position and remove the spring-type straight
pin (19).
Step C: Unscrew the plug.
Step D: Screw a new plug at the spindle and drill through the shaft. Drive the
spring-type straight pin (19) into the hole.
Step E: Replace the gasket (14).
Step F: Assemble the bellow housing (25) with plug (5) together with the body (1)
and fix it by screwing the hexagon nuts (17) crosswise.
The spindle can only be completely replaced together with the bellow.
3.5 Changing the seat ring
The seat ring is screwed into the valve body. The seat ring can be obtained after
removing the bonnet and can then be refinished or replaced as required.
Step A: Clean and lubricate the thread and conical sealing surface before insertion.

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AALBORG PNEUMATIC ACTUATOR, TYPE DP , , OM5520#01.0
INDUSTRIES
Pneumatic actuator, type dp
1 General
The pneumatic linear actuator is designed to be mounted directly on a control valve.

The pneumatic actuator converts positioning command signals into stem thrust
forces. The required back setting force is produced by the spring arrangement inside
the actuator. The rolling-diaphragm produces linear spindle movements over the
complete stroke.
The preferred mounting position is with the actuator and valve spindle in vertical
position.
The mode of operation for the actuator depends on how the springs are inserted
when the actuator is assembled. Even when the actuator is fitted in a piping system,
the mode of operation can be changed.
The pneumatic actuator can be operated as:
• Spring opens valve/air closes valve operation mode
• Air opens valve/spring closes valve operation mode
lllustration of a pneumatic actuator
Operation mode:
Spring opens - Air closes Air opens - Spring closes
19
4
2
1
1
21
22
26
21
5
18
16
10
15
11
Figure 1 d pactuat.tif

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AALBORG PNEUMATIC ACTUATOR, TYPE DP · . OM5520#01.0
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Table 1 below shows a list of the position numbers in Figure 1 and Figure 2.
Table 1
1.1 Pneumatic connection
The air supply should be dry and at a low service temperature. A heat-guard should
be installed to prevent high service temperature.
The pneumatic supply tube must be connected to the diaphragm housing (2) by
operation mode "spring closes" and to the diaphragm lid (3) by operation mode
"spring opens".
By air failure the stem automatically returns into the original position caused by the
inserted springs.
Warning: The actuator diaphragm may only be pressure loaded on the side
opposite of the springs. The vent hole in the other connection must
remain open.
1.2 Assembly of the actuator on the valve
The assembling of the actuator on the valve is shown in Figure 2. For both "spring
closes" and "spring opens" operation modes the following assembling procedure
should be followed:
Step A: If the actuator and the valve are separated, press the plug and spindle unit
(5) into the closed position for operation mode "spring closes" or into the
open position for operation mode "spring opens".
Warning: Make sure that the plug does not turn while pressing on the seat
during assembly.
Step B: Loosen the socket screws (13), remove the rotation guard (12) and the guide
flange (11). The threaded bushing (14) is now free.

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AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01 .. 0
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Step C: Tum the locking hexagon nut (30) onto the valve spindle. Place the rotation
guard (12) and the guide flange (11) over the valve spindle and then tum
the threaded bushing ( 14) onto the valve spindle.
Step D: Check the actuator for proper operation mode and connect the pneumatic
supply to the connection piece in the diaphragm housing (2) for operation
mode "spring closes" or in the diaphragm lid (3) for operation mode "spring
opens".
Step E: Drive the actuator into approximately mid-stroke position over the air
supply and mount it onto the valve (read the value from the pressure gauge
- middle of the spring range).
Step F: Tighten the hexagon nuts (31 ).
Assembly of the actuator on the valve
Operation mode: Spring closes valve - Air opens valve Operation mode: Spring opens valve- Air closes valve
Pneumatic connection
-----16
____...., L-----16
~~~~+-----10
M---:l::::!:::::i----- 10
~rr·--;;.---1s
>---15
'--.J.~:r-----13
'-'1"'""=1'----- 13
""d-·t-it--1~--- 14
~tt:::r--,-----14
---30
rlw+rk--<:"ttl IF::~I!Jl~~~- 30
l!-M~..._ _ _ _ 31 '{;:.mtn----- 31
Ht-<-..::...l.h---J.L-:t---- 5
Figure2 dpactspr.tif
Language UK . Page 3/6

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AALBORG PNEUMATIC ACTUATOR, TYPE DP , OM5520#01.0
INDUSTRIES
1.3 Adjustment of the starting pressure signal
Step A: Drive the actuator to the required spring-starting point over the air supply.
Step B: Turn the threaded bushing (14) up against the coupling flange (10) so that
the collar enters into the flange and presses against it. Make sure that the
plug is lying on the valve seat.
Attention: Note that sufficient thread of the valve spindle is inside the threaded
bushing (14). H not, turn the coupling flange (10) downwards from
the actuator spindle and pull the threaded bushing (14) against it.
Step C: For operation mode: "spring closes":
- Attach the guide flange (11) and the rotation guard (12) with the socket screws
(13) to the coupling flange (10).
- Check that the plug lifts off the seat at the required spring starting point.
Step D: For operation mode: "spring opens":
- Check that the plug leaves the end position at the required spring starting point,
and fmishes the valve stroke at the spring-range end value .
•
- The plug must then also press on the valve seat.
Step E: After the test operation set the stroke indicators (15) into the end positions.
Step F: Lock the hexagon nuts (16 + 30) at the valve mid-stroke.
Step G: Do not turn the plug on the seat when it is under force.
2 Reversal of the actuator action
The actuator action can be reversed even when the valve is installed in a piping
system. The position numbers mentioned in this section refer to Figure 1 and Figure
2.
Step A: Drive the actuator into approximately mid-stroke position with the air
supply.
Step B: Loosen and remove the socket screws (13) from the coupling flange (10)
and drop the rotation guard (12) over the valve spindle.
Step C: Remove the hexagon nuts (31) from the actuator and lift off the valve.
Step D: Reduce the air supply until the chamber is pressure free.

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AALBORG PNEUMATIC ACTUATOR, TYPEDP OM5520#01.0
INDUSTRIES
Step E: Loosen and remove the diaphragm lid screws.
Step F: Remove the diaphragm lid (3).
Warning: The actuators DP 32 and DP 33 have two longer screws when fitted
with stronger spring ranges. The actuator DP 34 has four. These
screws should be the last screws to be loosened, and must be
loosened evenly to reduce the high spring tension.
Step G: For reversal from "spring closes" into "spring opens":
- Remove the springs (7) and the diaphragm plate (4) with the diaphragm (1) and
the spindle ( 5).
- Loosen and remove the seal lock nut (19) and remove the spindle (5). Tum over
the diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping
flange, and place it over the spindle (5).
Tighten with the seal lock nut (19). Make sure that the spindle surface is not
damaged.
- Grease the spindle surface and the 0-ring.
- Place the diaphragm plate (4) with the diaphragm (1) into the diaphragm lid (3).
- Arrange the springs (7) onto the moulds pressed into the diaphragm plate (4).
- Place the diaphragm housing with the spindle sealing unit over the spindle, and
screw it together. Make sure that the springs stay properly arranged.
- Tum the hexagon nut (16) and the coupling flange (10) onto the spindle (5).
- Mount the actuator as described previously, and connect the air supply tube to
the diaphragm lid (3).
Step H: For reversal from "spring opens" into "spring closes":
- Remove the diaphragm (1) and the diaphragm plate (4) with the spindle (5) and
the springs (7).
- Loosen and remove the seal lock nut (19) from the spindle (5). Tum over the
diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping flange,
and place it on the spindle (5).
- Tighten with the seal lock nut (19). Make sure that the spindle surface is not
damaged.
Grease the spindle surface and the 0-ring.
Stick the diaphragm plate (4) with the diaphragm (1) and the spindle (5) into the
diaphragm housing (2).
- Arrange the springs (7) onto the moulds pressed into the diaphragm plate ( 4).

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AALBORG PNEUMATIC ACTUATOR, TYPE DP , OM5520#01.0
INDUSTRIES
Place the diaphragm lid (3) on the top, and screw it together. Make sure that the
springs (7) stay properly arranged.
- Tum the hexagon nut (16) and the coupling flange (10) onto the spindle (5).
- Mount the actuator as described previously, and connect the air supply tube to
the diaphragm housing (2).
3 Manual operation device
Some actuators are fitted with a manual operation device. The device is connected to
the actuator by means of a new diaphragm lid, a spindle extension with a USIT-ring
and a spindle sealing unit.
The manual operation device is equipped with stroke indicators. The stroke
indicators of both the actuator and the manual operation device must be in the same
end positions when the actuator is pressure free.
The manual operation device must be set into neutral position when the actuator is
running automatically.
The locking device of the manual operation device must be unlocked before
operating.
The locking device prevents an unwanted disarrangement of the setting during
operation, e.g. due to vibration, etc.
4 Maintenance
The pneumatic actuator is maintenance free. To maintain a disturbance free

operation, the air should be supplied by an air-supply station.
The diaphragm, spindle sealing unit and springs are wear parts and should be
replaced when necessary.
4.1 Exchange of spindle sealing
When the spindle sealing is changed, the slotted PTFE-guide bearing and the 0-ring
should be replaced. The spindle surface must be clean and undamaged. Before the
actuator is assembled, the spindle unit and the spindle must be greased.

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AALBORG POSITIONER, SIPART PS2 6DR5000 OM551 0#05.1
I N DUST R.l E S
1 General
The following instruction is a general description of SIPART positioners and covers

the complete range in the PS2 6DR5000 series.
The electronic pneumatic positioner is used as the final control element of a
pneumatic linear actuator or a part-tum actuator (rotary movements). The positioner
converts a current output signal (4 to 20 rnA) from a process controller or control
system to a set point value and into a corresponding movement. The positioner
changes the pressure in a pneumatic actuator chamber or cylinder until the position
corresponds to the set point value.
The positioner can be set up either as a single-action positioner or a double-action
positioner. The single-action positioner is mainly used together with a control valve.
The opposite movement for the control valve is supplied by means of springs. The
double-action positioner is mainly used to control an air damper via a pneumatic
cylinder (actuator). All movements of the pneumatic cylinder are supplied by the
positioner. An illustration of the function diagram for the positioner is shown in
Figure 1. The function diagram is shown with option modules.
1.1 Mode of operation
Comparison of the set point and the actual value takes place electronically in a micro
controller. If the micro controller detects a deviation, it uses a 5-way switch
procedure to control the piezoelectric valves, which in tum regulate the flow of air
into the actuating chambers. When connected in a two-wire system, the SIPART
PS2 draws its power exclusively from the 4 to 20 rnA set point signal.
The piezoelectric valve converts the command into a pneumatic positional
increment. The positioner outputs a continuous signal in the area where there is a
large control deviation (high-speed zone). In areas of moderate control deviation
(slow-speed zone) it outputs a sequence of pulses. No positioning signals are output
in the case of a small control deviation (adaptive or variable dead zone).
Commissioning (initialisation) is carried out automatically to a large extend. During
initialisation, the micro controller automatically determines the zero, full-scale
value, direction of action, and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, thus optimising the control.
The positioner can also be operated manually by the pushbuttons and the LCD of the
SIPARTPS2.
The installation of the positioner must be carried out in the following order:
• Mechanic connection
• Electric connection
• Pneumatic connection
• Commissioning

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Dlustration of a function diagram
1 Motherboard with microcontroUer and input circuit

2 Control panel with LC-display and momentary action switch
3 Plezo-valve unit, always built-In
4 Valve unit with double action posilloner always built- in
5 ly-module for positioner SIPART PS2
6 Alarm module for three alarm outputs and one digital input
7 SIA-module (Slot Initiator-Alarm-module)
8 Spring-loaded pneumatic actua1or (single action)
9 Spring-loaded pneumatic actuator (double action)
Figure 1 sips2_5a.tif
2 Mechanic connection of the positioner
Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the .
installation guide lines below.
2.1 Mechanic connection to an actuator
Figure 2 shows the mechanic connection of the positioner to an actuator for a control
valve.
Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and
· lock washers (16) on the actuator spindle.
Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly.
Set the necessary length and tighten the screws so that the pick-up bracket
can still be shifted.

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AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.1
INDUSTRIES
Step C: Push the roll (5), spring (13), and guide washer (22) onto the pin (4).
Step D: Insert the pin in the lever (6) and assemble with nut (18), spring washer
(14), and U-washer (12).
Step E: The value of the stroke range specified on the actuator should be set or if
this does not exist as a scaling value, the next greatest scaling value should
be set. The centre of the pin must be in line with the scaling value. The
same value can be set later under parameter "3.YWAY" in commissioning
to display the way in [mm] after initialisation.
Step F: Assemble the hexagon socket cap screw (17), spring washer (16), washer
(12), and square nut (19) on the lever.
Step G: Push the pre-mounted lever onto the positioner axis up to the stop and fix
with the hexagon socket cap screw ( 17).
Step H: Fit the mounting bracket (l) with two hexagon head screws (9), lock
washer (10), and flat washer (11) on the rear of the positioner.
Step 1: Selection of the row of holes depends on the width of the actuator yoke. The
roll (5) should engage in the pick-up bracket (2) as close as possible to the
spindle but may not touch the clamping assembly.
Step J: Hold the positioner with the mounting bracket on the actuator so that the pin
(4) is guided within the pick-up bracket (2).
Step K: Tighten the pick-up bracket.
Step L: Position the mounting parts according to the type of actuator.
- Actuator with ledge: hexagon head screw (8), flat washer (11), and lock washer
(10).
- Actuator with plane surface: four hexagon head screws (8), flat washer (11), and
lock washer (10).
- Actuator with columns: two U-bolts (7), four hexagon nuts (21) with flat washer
(11), and lock washer (10).
Step M: Secure the positioner onto the yoke using the previously positioned
mounting parts.
Note: Set the height of the positioner so that the horizontal lever position is
reached as close to the stroke centre as possible. The lever scale can be
used as orientation. It must be guaranteed that the horizontal lever
position is passed through within the stroke range.

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Mechanic connection of the positioner (linear actuator)
1)
3)
4)
As required
Figure 2 sips2_5b.tif

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.INDUSTRIES
2.2 Mechanic connection to a pneumatic cylinder
The positioner is connected to a pneumatic cylinder by means of fixing bracket,

lever arm with Allen screw, extension arm, and roller.
The pneumatic piston is connected to a guide rail with an oblique angle via a
linkage. The guide rail moves together with the piston, and the roller/lever
connection senses the position of the piston. By operating both sides of the
pneumatic cylinder, the set point is reached. A spring inserted between the fixing
bracket and the lever arm secures that the roller is pressed down against the guide
rail.
2.3 Mechanic connection to a rotary actuator
Figure 3 shows the mechanic connection of the positioner to a rotary actuator.

Step A: Attach the mounting console (9, actuator specific) onto the rear of the
positioner and secure using the hexagon head screws (14) and lock washers
(15).
Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centring
hole.
Step C: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mm
and tighten the hexagon socket head screw (18) with the Allen key
provided.
Step D: Place the carrier (3) onto the end of the actuator and secure using Fillister
head screw (16) and washer (17).
Step E: Carefully place the positioner with mounting console onto the actuator such
that the pin of the coupling wheel engages in the driver.
Step F: Align the positioner/mounting console assembly in the centre of the actuator
and screw tight (screws are not included in the delivery, they are part of the
actuator mounting console).
Step G: Follow the start-up sequence as described later. Drive the actuator to the
end position and adhere the scale (4.1) onto the coupling wheel (2)
according to the direction of rotation and rotary actuator. The scale is self-
adhesive.

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Mechanic connection of the positioner (rotary actuator)
1)
3)
Figure3 sips2_ Sc.tif

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AALBORG POSITIONER, SIPART PS2 6DR5000 · OM5510#05.1
·INDUSTRIES
3 Electric connection of the positioner
When the positioner is connected in a two-wire system, the positioner draws its
power exclusively from the 4 to 20 rnA set point signal. Figure 4 indicates the input
circuits for the positioner.
View of the controls and connections
i• •. . · . ..
·• ~. ·. Mli~:~sron~i9:sel~r
· • lnpul:Suppl}t air
·. · ootput:.Acillaiingprt~Ssur~vt··
·
•·
· · ~•· g=n~~~~!ng~essure~2~···.
,s crutCh ··
10 Terttii ..
~; ·~~~w~~~g¥,~ 9iatJt1.
..
•6 · R~trlct6i •· ··.. •·. •· ·. ·.• ·
i).1 .·. Re~tlicior Yt ·.· ..· . 14 •·. Tef1ninru ~laJ~:6n covE\r ) ·.
6,2 RQstrictor Y:.! ·r ,15 · Purgihg lii(sVtliieh ·· ·
Figure4 sips2_5d.tif
4 Pneumatic connection
Ensure that the air quality is suitable. Grease-free instrumental air with a solid
content < 30 Jlm and a pressure dew point 20 K below the lowest ambient
temperature must be supplied.
Warning: For reasons of safety, pneumatic power may only be supplied after
assembly when the positioner is switched to operating level "P
manual" operation with electrical signal applied.
4.1.1 Selection of P manual mode

Before pneumatic power is connected, the positioner must be in P manual mode.
The display must show "NOINIT" in the bottom line.

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AALBORG POSITIONER, SIPART PS2 6DR5000 . OM551 0#05.1
INDUSTRIES
4.1.2 Pneumatic connections

Figure 4 shows a view of the positioner controls and connections.
Step A: If required, connect a manometer block for supply air and actuating
pressure.
Step B: The silencer in the exhaust output can be removed if necessary.
Step C: Connect actuating pressure Yl and/or Y2 (Y2•) is only used with double-
acting actuators) according to the desired safety position.
Step D: Connect the supply air (1). The pressure should be between 1.4 to 7 bar.
Note: In order for spring-loaded pneumatic actuators to be able to reliably

exploit the maximum possible actuating path, the supply pressure must
be sufficiently greater than the maximum required final pressure of the
actuator.
4.1.3 Safety position when the electric power supply fails

For a single-action actuator is Yl deaerated. For a double-action actuator is Yl
equal to the supply air pressure and Y2 is deaerated.
4.1.4 ltestrictors
To increase the positioning times for fast actuators when necessary, the air flow can
be reduced with the restrictors Yl and Y2 (only for double-action valves). Turning
the restrictors in the clockwise direction reduces the air flow until it is shut off. To
set the restrictors it is recommended to first close them and then open them again
slowly (see initialisation process RUN 3).
4.1.5 Purging. air switcbover

The purging air changeover switch located above the pneumatic terminal block on
the valve manifold can be accessed when the housing is open. When the switch is in
position "IN" the interior of the housing is purged with very small quantities of
clean and dry instrument air. In position "OUT" the purging air is led directly out of
the instrument.
5 Commissioning

initialisation, the micro controller automatically determines the zero value, full-scale
value, direction of action and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, hereby optimising the control.
SIPARTPS2.
The commissioning ofthe positioner can be divided into the following steps:
• Preparation for initialisation
• Start the automatic initialisation procedure

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INDUSTRIES
• Set additional parameters if required

• Select automatic mode
Figure 5 shows the possible operation modes for the positioner and gives an
overview of how to change between them. The levels are P-manual mode,
configuration and initialisation, manual mode, automatic mode, and diagnostic
display. From these modes it is possible to select operation mode, set operation
parameters, restore to factory setting, run an automatic initialisation, etc.
Operation levels
Figure 5 sips2_5e.tif
5.1 Preparation for initialisation
Step A: Check and set the gear transmission switch to the correct position. Figure 4
{position 8) indicates the location of the switch. For linear actuators the gear
transmission switch is set according to the stroke range as described in
Table 1 for the parameter "3.YWAY''. For part-tum actuators 90° must be
selected.
Step B: Check that the pneumatic supply power (inlet air) is present. The operating
pressure should be at least one bar greater than is necessary for
closing/opening the valve during initialisation.

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AALBORG•. POSITIONER, SIPART PS2 6DR5000 OM5510#05.1
INDUSTRIES·'
Step C: Without initialisation the positioner is in "P manual mode" and "NOINIT"
flashes in the display. This level can also be reached by using "55.PRST"
function (see Table 1).
Step D: Check the free running of the mechanics in the whole actuating range by
moving the actuator with the keys "j" and"!" and driving to the respective
end position.
Step E: With linear actuators drive the actuator to horizontal lever position. The
display must indicate 48% to 52%. If necessary, correct the value by
adjusting the sliding clutch. After the check is completed, the actuator must
be approximately half way along its stroke. This is due to establishment of
the action direction during automatic initialisation.
5.2 Automatic initialisation
Figure 6 shows the configuration mode including the operation in this mode and
Table 1 shows the parameter/configuration list. Figure 7 shows the initialisation
process of the positioner. The initialisation process is stored in the microprocessor.
This means that an additional initialisation only is necessary if any parts of the unit
have been changed.
Note: The numerical values used in Figure 5, Figure 6, and Figure 7 are
examples.
Step A: Call the configuration mode by pressing the hand symbol key for longer
than 5 seconds.
Step B: Set the actuator type, linear or part-tum, in the menu item line "l.YFCT".
Step C: Switch to the second parameter by pressing the hand symbol key briefly.
Step D: Set the rated angle of rotation for feedback in the menu item line
"2.YAGL". It is vital that this value corresponds to the setting of the gear
transmission ratio selector (Figure 4, position 8), 33° or 90°.
Step E: Switch to the next parameter by pressing the hand symbol key briefly.
Step F: This parameter ("3.YWAY'') is only set for linear actuators and if the total
stroke in mm should be displayed at the end of the initialisation phase. To
do this, select the same value in the display to which the carrier pin to the
scale on the lever is set to.
Step G: Switch to the following parameter by pressing the hand symbol key briefly.
Step H: Start the initialisation ("4.INITA") by pressing the "j" key for longer than 5
seconds.

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Step 1: During the initialisation phase "RUNl" to "RUNS" appear one after another
in the bottom of the display. Please note that the initialisation process may
last up to 15 minutes depending on the actuator.
Note: The ongoing initialisation can be aborted at any time by pressing the
hand symbol key. The previous settings are retained. All the parameters
are reset to the factory setting only after performing a preset
"55.PRST".
Step J: If problems occur, carry out the measures as described in the table "Possible
messages" shown in Figure 7.
Step K: The initialisation is completed when "FINSH" appears in the bottom of the
display.
Step L: When pressing the hand symbol key briefly the menu item line "4.INITA"
is displayed.
Step M: To exit the configuration operating mode, press the hand symbol key for
longer than 5 seconds. The software version is displayed after about 5
seconds. The instrument is in manual operation after releasing the key.
Step N: The positioner can be changed to automatic mode by pressing the"!" key
once as indicated in Figure 5.
Step 0: The automatic mode is the normal mode. In this mode the positioner
compares the set point current with the current position and moves the
actuator until the control deviation reaches the dead zone.
Operation in the configuration mode
~"\7
'2::: at the same time '2::: at the same time
~8.~m~~ ~"7--_&_+~ ~8.~~~~

I '2:::'7
1 at the same time
Figure 6 sips2_ Sf.tif

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Initialisation process
Automatic Initial start-up (slarting wi1h facbry setting) Possible messages
Step Meaning Display Meaning Measures
~~
1.) Parttum AcknC>Nied ge me""'!Je
~
a::tuator using the hand syrrt>ol key
2 YAGL Actuator does
~ 1 not move Check restrictor (~ and open
~[llJG_g]
Unear if necessary
~
a::tuator 2 YAGL 3 Y'MY
Dnve a::tuator to v.orking range
R using the up and dawn keys
2)~
Press tte up key for> 5 sec. Restart initi alisati:n
4 IN"DI Remaining steps are earned out automaticaly
Ctungegeanng (7)
Ccntinue usng up key

~~ 32~1
~~~
Dlrectim of action is delannired
•> RUN 1
88A Down tolerance Or a~ slidng clltch up
d1U IU band violated to dsr;lay ~~ 6.4,]
92.~12
~) [,~ RUN Checkilg of travel and ad)Jstrrentof
z..-o andstroke(from stop to stop)
d10 IU
-'
S) [,':'
!..I
82~13
RUN
Deterrrire tion and dispiB)' ct IJ)Sitioring time
down (dl<X.x), up (uxx.x). Stop with 1he do;m key
Pressing the up key inliates leakage measu-ement
- Thenooy
Conti rue us ng the down key
Unearactuator. set pick-up

Olcetheslipping lever nto to nzonlal position
K) ~~~ RUN
32~14 Del..-rrina tion ct mnimum ncre ment length ~ L
dutch has been
aljusted
using the up and dC>Nn keys
Continueusng hand syrrlld key
7.) [~ RUN
52~15 Optirrisati on ct transient re"!Xlll se AcknC>Nied ge rressage
,P 98.3 Up tolerance band
liolated
using the hand syrrllol key
Set 1he next tighest travel
a)~
lnliaiisalon tenninated suocessfuly
(travel in m m for linear actual as)
(angleofrotation for part-tum a:tuators)
" UP >
valuaonthe l<l\€1"
FINlH Restart iriti ali sa ion
Continueusng tend syrrllclley
Additionally possible with rotary
a::tuators:
Adjust using up and dC>Nn keys
uptodisplay: [P 92.8]
" 90_95
Continue u sng hand syrrllol key
AcknC>Niedge message
using the Ill nd syrrllol key
[~ ~~] Up/down span
\lolated Set 1he re<t IC>Nest travel
value on till lev..-
Restart inlli alisation
~
Ad)Jst positioning time u!i"lg
~ ZZl.
Actuator does
not move.
restictor(s)
Alsitloning Continue us ng the
up ordC>Nn key
~
time is posslbl e
to adjust
ZZl.
Figure 7 sips2_Sg.cdr
5.3 Parameters
Table 1 shows the parameter list for the positioner. The parameter name is written in
plain text in the "menu line" column. The function of the parameter is described
briefly in the "Function column". In addition, the possible parameter values, the
physical unit and the factory setting of the parameters are shown.
After the initialisation process, the positioner can be configured to meet the
requirements of a specified task. The factory settings correspond to the requirements
for a typical application. This means that normally only a few parameters will need
to be changed.
The positioner can be installed and configured to fit linear and part-tum actuators
with reverse action. E.g. linear actuators with the set point in the falling direction or

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AALBORG
INDUSTRIES
part-tum actuators for counter clockwise operation direction. In this case the
parameters "7.SDIR" and 38."YDIR" should be set to "FALL".
'2Q)•c;,·.;·;·i•
1%: ) lllt:l •'•(''•'•···~·············''
Menu line Function Parameter values Unit Factory setting C;;~l:~~·
turn (part-tum actuator)
WAY (linear actuator)
LWAY (linear actuator
without sine correction)
l.YFCT Type of actuator WAY
neSt (part-tum actuator
withNCS)
-neSt (part-tum actuator
with NCS, inverted)
Rated angle of rotation for feedback 90°
2.YAGL 1> (must Ito gear ratio) Degrees 33°
33°
Stroke range (optional setting) OFF
------------------------
When used, the value must correspond with 5' 10' 15' 20
the set of the leverage ratio on the actuator ____ _(~~P_I! )~.Y~!-~~~}----
3.YWAY2> 25' 30' 35 mm OFF
Driver pin must be set to the value of the ---- _(~~P.I! )~.Y~!-~Q~}----
actuator travel or, ifthis value is not scaled, 40 ' 50 ' 60 ' 70 '
to the next lager scale value 90' 110' 130
(long lever 90°)
4.INIT.A tmttallsation. (aL'tnm<>tically) noini I no I###.# I Strt no
S.INITM 1n1t1a11sation. (manually) noini I###.# I Strt no
Oto20mA OMA
6.SCUR Current range of set point 4MA
4to20mA 4MA
7.SDIR Set point direction
f~~:: :xL
riSE
8.SPRA Set point for start of split range 0.0 to 100.0 % 0.0
9.SP]iE Set point for end of split range 0.0 to 100.0 % 0.0
Auto
lO.TSUP Set point ramp up s 0
0 to 400
ll.TSDO Set point ramp down 0 to 400 s 0
Set point function
Linear Lin
12.SFCT Equal-percentage 1:25, 1:33, 1:50 1-25 ' 1-33 ' 1-50 Lin
Inverse equal-percentage 1:25, 1:33, 1:50 nl-25, nl-33 , nl-50
Fre~:ly auJu:sU1ut~: FrEE
13.SL03 > Set point turning point at 0% 0.0
14.SL1 5% 5.0
to to O.Oto 100.0 % to
32.SL19 95% 95.0
ll ST.?.O 100% 100.0
Auto
34.DEBA Dead zone of controller % Auto
0.1 to 10.0
35.YA Start of -' variable limiting O.Oto 100.0 % 0.0
3§.¥g_ End ofmanirmlatetl. variable limiting 0.0 to 100.0 % 100.0
C'< -'i~..tinn of To mech. travel MPOS
37.YNRM MPOS
. variable .To flow FLOW
~~:: F~L
Direction or maJ 1mu1atec
38.YDIR riSE
variable for display
Without no
Tight closing with Top only uP
39.YCLS no
manipulated variable Bottom only do
Top and bottom uP do

...........
aliiiWn
AALBORG
INDUSTRIES
None OFF
Only message (NO/NC contact) on/-on
Block configuring (NO contact) bLocl
42.BINt 4> OFF
Block configuring and manual (NO contact) bLoc2
Drive valve to pos. up (NO/NC contact) uP /-uP
Drive valve to pos. down (NO/NC contact) doWn/-doWn
StoP/- StoP
None OFF
4 Only message (NO/NC contact) on /-on
43.BIN2 > OFF
Drive valve to pos. up (NO/NC contact) uP /-uP
Block movement StoP /-StoP
Without oFF
AI =min. A2=max. N,NA
44.AFCT5> Alarm function _ OFF
Al =min. A2=min. N,N
t,
t,nA
t,nAb
Monitoring time for fault message Auto

48.t, TIM s Auto
"control deviation" 0 to 100
Response threshold for fault message Auto
49.t,LIM % Auto
"control deviation" 0.0 to 100.0
OFF
50.t,STRK Limit for stroke integral OFF
51. t, DCHG Limit for direction change OFF
52. t, ZERO Limit for end stop monitoring, bottom % OFF
53. t,OPEN Limit for end stop monitoring, top % OFF
54. t, DEBA Limit for dead zone monitoring % OFF

Preset (factory setting)
"no" nothing activated no
"Strt'' start of factory setting after pressing
55.PRST key for 5 sec. Strt
"oCAY" display following successful
factory setting oCAY
CAUTION: results in "NO INlT"
Ifturn is selected it is not possible to set 33°.
2
>Parameter does not appear if l.YFCT =turn has been selected.
3
>Turning points only appear with selection 12.SFCT =FrEE.
4
>Alternatively "no" if initialisation has not yet been carried out
S) NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level.
6) Normal means: level without fault. Inverted means: low level without fault.
Table 1

...........
aA
AALBORG
INDUSTRIES
6 Diagnosis
In the diagnostic mode the current operating data (such as number of strokes,
number of changes in direction, number of fault messages, etc.) can be displayed.
From the automatic or manual modes the diagnostic mode can be reached by
simultaneously pressing all three keys for at least 2 seconds.
Table 2 shows an overview of the displayable values. The diagnostic display has a
similar structure as the parameter menu displays. The respective next diagnostic
value can be selected with the hand symbol key. Certain values can be set to zero by
pressing the "j" key for at least 5 seconds. These are menu item line "1, 2, 3, and 4".
Some diagnostic values may be greater than 99999. In this case the display switches
to exponential display.
Table 2

........
iliiiiili
INDUSTRIES
7 Service and maintenance
The positioner is largely maintenance-free. The positioner is fitted with filters in the
pneumatic connection as protection against coarse particles of dirt. If the pneumatic
energy supply contains particles of dirt, the filters may be clog and impair the
function of the positioner. In this case the filters can be cleaned as follows:
Step A: Switch off the pneumatic power supply and remove the pipes.
Step B: Unscrew the cover.
Step C: Remove the three screws from the pneumatic connector strip.
Step D: Remove the filters and 0-rings behind the connector strip.
Step E: Clean the filters (e.g. with compressed air).
Step F: After cleaning first insert the filters in the recesses in the housing and then
place the 0-rings on the filters.
Step G: Align the pneumatic connector strip on the two lugs and screw tight with
the three self-tapping screws.
Note: Make sure that the same thread is used. To do this, turn the screws anti-
clockwise until they snap into the thread audibly. Only then should the
screws be tightened.

9
.
•iilihii
INDUSTRIES
Table of contents
Drawings
General arrangement ................................................................... ;....... AMB: 250512A
2 boiler arrangement .............................................................................. AMB: 320158
Thermal expansion ............................................................................. 03KOO: 023604a

Ahera:tion Am. O..lf
Clddct~ ... -.··:-;:::::_::;:.,:;.:.•::.·::;.:::;,::.:.;....-.=:=...:.:..-,~ "".:.".i. .. ~. se
Dimensfon of vaNes see watedsteam diagram

Max allowable wartdng pressure: 18 bar.
Handrail
'
~ lA
~
~
~
0
~
M
g ~
~ ~
0
~
;:
:ill
In case of two boilers no. 2 boiler can

be mirrored.
Exhaust gas 9DDA, ace. to JIS F 7805 Flange code A
Industries M&E Co.,Ltll.
ONSO PN10 Drain with blind flange

Description
Forward ship
Port side boiler Starboard boiler
Title: Drawn
Customer UKB Sumitomo-Yokosuka ...

MISSION™OL
Society LRS ..
•••••
. . .. Large oilfired boiler 2-Nov-2006
Newb. No. 1338
•••••••
• •••••• Weight Size
25000 kg/h 1.8 MPa 03150
Project No. 100779 illIIIIIi 2 boiler arrangement
1:25 A3
Port side boiler Boiler No. 18279 AtLBORG Article/Drawing No: Affix
INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERlY OF AALBORG INDUSlRIES
Starboard boiler Boiler No. 18280 AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY AMB :320158
Initial release a 030225 LHJ MRJ
9 bar j18ba~
10000-~- 21,6 1-25,2
9000 -~ - 19,4
I1-22,7
>':><
8000- 9< - 17,3 1-20,2
~
-
I
7000 - ~ - 15,1 1-17,6
6000 - )< - 13,0 1-15,1

)<
)< I
5000- ~ - 10,8 1-12,6
~ I
4000- ~ -8,6 1-10,1
[>
3000-
R -6,5 I
1-7,6
2000- -4,3 1_5 0

I .
1000- -2,2 1-2,5
I
0 - -0,0 bo_R_j
Boiler Thermal
length expansion
mm mm
~-~ ---q-<0~ ]l
Thermal o N LO r-.... cx:>l
expansion Ll - -
I I I ...--
- - - .....
mm 0
0
N~
N
('t')
.q~ <0
LO
ro
.0
I I112$XXXX"X'J
I I (j)
Boiler 0
I 0
I 0
I 0
I
0 0 0
radius 0 0 0
mm ...-- N ('t')
Title: Drawn Date
MISSION™OL LHJ 25.02.2003

Appr. Date
. ; :::; . Large Oilfired boiler MRJ 25.02.2003
~ 9/18bar Weight Scale: Size
1:135 A4R
AALIORG Thermal expansion Article/Drawing No: Index
INDUSTRIES
1 - - - - - - - - - - - l THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
Plot Date: AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 03K00:023604 a
10
......
"11:1:1:1.
iii ~ Iii
AALBORG TABLE OF CONTENTS SHI M&E 1338
INDUSTRIES
Table of contents
Data sheets for Mission TM OL boiler

Safety valve, DN 65/100, PN 40/16 (Cl, C301) ........................................... .261 1174
Remote pull for safety valve (C186, C486) ............................................... K03:032121
Stop valve, angle, DN 200, PN25 (C2) ............................................................. :.......... .
Main steam valve ......................................... ;.................................................. 2511122
Stop valve, angle, DN 80,.PN25 (C3) .......................................................................... .
Feed water valve ............................................................................................. 251 1093
Stop valve, angle, DN 80, PN40 (C303) ...................................................................... .
Feed water valve ............................................................................................. 2511153
Stop valve straight, non return DN 80, PN25 (C4) ....................................................... .
Feed water valve ............................................................................................. 264 1093
Stop valve straight, non return DN 80, PN40 (C304) ................................................... .
Feed water valve ............................................................................................. 264 1153
Stop valve angle, non return DN 40, PN 25 (C6) ....................................................... ..
Scum valve .....................................................................................................265 1090
Stop valve, straight, non return, DN 40, PN25 (C7, C307) .......................................... .
Blow down valve ............................................................................................ 264 1090
Stop valve, straight, DN 8, PN 160 (C9, Cl 0, Cll, C196) .......................................... .
Sample valve, Air escape valve, Gauge board valve, Drain valve for soot lower ........ .
.................................................................................................................. 6220 000002
Stop valve, straight, non return, DN 20, PN 25 (C13) ................................................. .
Atomizing steam ....... ;..................................................................................... 264 1087
Check valve, DN 200, PN25 (C14) .............................................................................. .
Check valve for Main steam valve ........................................................... 6020 000064
Stop valve, straight, DN 25, PN25 (C24, C25, C27, C327, C28, C328) ...................... .
By-pass steam valve, Valve for heating coil inlet/outlet, Valve for DP unit ................ .
Valve for level switch ..................................................................................... 250 1088
Stop valve, angle, DN 25, PN 25 (CIS) ...................................................................... .
By-pass.steam valve .......................................................................................2511088
Stop valve straight, DN 50, PNlO (Cl6) ...................................................................... .
Furnace drain valve ........................................................................................253 1005
Water level gauge, left, model26 DN 25, PN25 (C17) ............................ 7010 000136
Water level gauge, right, model26 DN 25, PN25 (C18) .......................... 7010 000135
Remote pull for water level gauge (C187, C487) ...................................... K03:032122
Stop valve, straight, DN 100, PN25 (C19) ................................................................... .
Circulation water outlet valve, ........................................................................ 264 1094
Stop valve, straight, DN125, PN25 (C21) .................................................................... .
Circulation water inlet valve ........................................................................... 250 1095
Check valve, DN 125, PN25 (C22) ............................................................................. .

.....
...
:il.il·i:
ill I IIi
AALBORG TABLE OF CONTENTS - SHI M&E 1338
INDUSTRIES
Check valve for Circulation water inlet valve ......................................... 6020 000062
DP water level control unit (W16) ............................................................. 70Z:036686
Level float switch RBA 24, DN 25, PN40 (W14) .................................... 8100 000008
Safety valve, DN 15, PN 40 {C26) ............................................................................... .
Safety valve for heating coil.. ........................................................................ .261 1358
Stop valve, straight, DN 65, PN 25 (C194) ................................................................ ..
Stop valve for soot blower ............................................................................. .250 1092
Stop valve, ball, straight, DN50 (C199, C499) ............................................................. .
Soot blower ball valve .................................................................................... 8703068
IGS Control valve for soot blower, DN65 (C227) ...................................................... ..
...................................................................... ballll3jisfl; AT400da, solval230, BoxM
Steam trap (C195) .................................................................. ."...................................... .
Steam trap for soot blower ........................................................................ 7020 000001
i
\.

........
:il.il·i:
ill I IIi.
AALBORG DATA SHEET
INDUSTRIES
Type:
• Safety valve, full lift
.5
• 25.912
~r---------------~~
Size:
• Nominal diameter: DN 65/100
Application:
• To blow off saturated steam, air or water
Material:
• Body: GGG 40.3
DIN-Material No.: 0.7043
• Seat: X6 Cr Ni Mo Ti 17122
DIN-Material No.: 1.4571
• Disc: X35 Cr Mo 17
DIN-Material No.: 1.4122.05
Technical data:
• Nominal pressure: PN 40/16
• Weight: 40 kg
• Flanges according to DlN
• Inlet: DN 65, PN40
• Outlet: DN 100, PN16 Disc
C1 C301
Type No.: 6040
Version: A Safety valve, ON 65/1 00, PN 40/16 2611174

Description I Index I Date I Drawn I Appr.
C186.2/C486.2 ~»
C186.3/C486.3 ____----1
C 186 .4/C486 .4
C186.5/C486.5 C186.5/C486.5
C186.4/C486M
/~ I~'-__...._;
C186.4/C486.4 11'-. '"lJ-

C186.3/C486.3
r. 18 B.S/C486 .S Pulley Hot-dip galvanized
2
4337301
~· eSO mm vertical Steel
C186.2/C486.2 r.r- 186•41c486 •4 Wire stainles.s ste.el 4551052
e3 mm SpeCified m metre 8 AISI316
~
186 . 31C486 . 3 Wi1re clip Hot-dip galvanized
3 mm
2 Steel
4576110
~ 186 . 21C 4 S 6 . 2 ~~~:kle Hot-dip galvanized 2

4573311
Steel
C186 1/C486 1 Handle 6451004
C186.1/C486.1 • • e6x261 1
Designation Material code Article No.
Tag No. Pes. Cert.
Dimension Material type Detail drawing No.
Title: Drawn Date
JA 040608
......
.·······
..... STANDARD
Appr.
Weight
BZ
Dale
040608
Scale: Size
iiiiiiili Remote pull for safety valve
1:1 A3
AALBORG 1-------------~Article/Orawfng No: Affix
INDUSTRIES THIS DRAWIHG NI/J DESIGH SHOWN HEREfl JS THE PR0P£RTY a: AAl.BORG HJUSTRrES
AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY K03:032121
......
iliiiilli
AALBORG
' -
. DATASHEET
-
- . ,
'
- _>
INDUSTRIES
Type: Material:
• Stop globe valve, angle • Body: GS-C25 N
• 34.007 Din-Material No. 1.0619.1
• Seat: X20 Cr13
Size: Din-Material No. 1.4021.05
• Nominal diameter: DN 200 • Disc: X20 Cr13
Application: DIN-Material No. 1.4021.05
• For steam and/or water flow Technical data:
• Nominal pressure: PN 25
• Weight: 138 kg
• Flanges according to DIN
400
1J
Seat
Body
1-----_?7-'-"5---o.-~
C2
Type No.: 6010
Version: A Stop valve, angle, DN 200, PN 25 2511122

...
illliilli
AALBORG
INDUSTRIES
Type: Material:
• Stop globe valve, angle • Body: GGG 40.3
• 23.007 DIN -Material No. 0. 7043
• Seat: X20 Cr 13
Size: DIN -Material No. 1.4021.05
• Nominal diameter: DN 80 • Disc: X20 Cr 13
Application: DIN -Material No. 1.4021.05
• Nominal pressure: PN25
• Weight: 22.6 kg
....
"'
.,.,
\0
"'
----·-·Body
.,.,
.,.,
-
1-
~--·· _ _,_,15=5- - - - 1
C3
Type No.: 6010
Version: A Stop valve, angle, DN 80, PN 25 2511093

... .
illiiilli
AALBORG . --_: ·.- ; · . - . - -.-DATA SHEET : ~ .
L. •,
-. ·:
-
.·
• ' • :
. ----
INDUSTRIES • 0 < • • ' • ,' 0 :: ,•
·Type: Material:
• Stop globe valve, angle • Body: GS-C 25 N
• 35.007 DIN -Material No. 1.0619.01
• Seat: X20 Crl3
• Nominal pressure: PN40
• Weight: 25 kg
• -. Flanges according to DIN
··;·-· '.·
!....- 155
C303
Type No.: 6010
Version: A Stop valve, angle, ON 80, PN 40 2511153

.....
:il.il.
ill I IIi
i:
AALBORG
INDUSTRIES
Type: Material:
• Stop check globe valve, screw down non • Body: GGG 40.3
return, straight DIN -Material No. 0.7043
• 23.006 R • Seat: X20 Cr 13
DIN -Material No. 1.4021.05
Size: • Disc: X20 Cr 13
• Nominal diameter: DN 80 DIN -Material No. 1.4021.05
Application: Technical data:
• For steam and/or water flow • Nominal pressure: PN 25
• Weight: 23 kg
• Flanges according to DThf
0 200
0
(J)
N
-----·-· B::ldy
310
C4
Type No.: 6030 Stop valve, straight, non return,
Version: A 2641093
ON 80, PN 25

illililli
AALBORG .. '_- -:- -, ',-_--DATA SHEET, _- - -- ·_-_-._
INDUSTRIES ·_, . -,- - " ' ~-. - - =- l -..' •
Type: Material:
• Stop check globe valve, screw down non • Body: GG-C 25 N
return, straight DIN -Material No. 1.0619.01
• 35.006 R • Seat: X20 Cr 13
Size: • Disc: X20 Cr 13
• Nominal diameter: ON 80 DIN -Material No. 1.4021.05
• Weight: 27.5 kg
0
0\
('I
C304
Version: A 2641153
DN 80, PN 40

.
........
. 1·1·11·i·
ii I Iii
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
return, angle DIN -Material No. 0.7043
• 23.007R • Seat: X20 Cr13
Size: • Disc: X20 Cr13
• N aminal diameter: DN 40 DIN -Material No. 1.4021.05
• Weight: 9.7 kg
j2S 160
....
N
0
0
N
........
It')
c5
Type No.: 6030 Stop valve, angle, non return, 2651090
Version: A DN 40, PN 25

...........
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• 23.006 R • Seat: X20 Cr13
• N aminal diameter: DN 40 DIN -Material No. 1.4021.05
• Weight: 10 kg
0
!!.l
-
00
lSI
><
Disc
Seat
~
.....
lSI
-
0
lSI
Body
200
C7 C307
Version: A 2641090
DN 40, PN 25

.
.......
:il. il. i:
ill I IIi . . - . .
AALBORG . DATA SHEET · .. · <
INDUSTRIES
Type: Material:
• Instrument stop cone valve, straight, with • Body: C 22.8
security plate DIN- Material No. 1.0460
• Seat: X20 Cr 13
Size: DIN- Material No. 1.4021
• G Y:z" X 0 12 • Needle tip: X35 CrMo17
• Nominal diameter: DN 8 DIN- Material No. 1.4122
• For steam, water and/or air • Nominal pressure: PN 160
• Inlet: G Y:z" male DIN
19207, form R
• Outlet: For steel tube 0 12
• Weight: 0.8 kg
075
)( )(
1/2" BSP
90
C9,C10,C11 C196
Type No.: 6220
Version: E Stop valve, straight, ON 8, PN 160 6220 000002

...........
)
11
ii. 1·1·I1.Iii.
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• 23.006R • Seat: X20 Crl3
• Weight: 4.3 kg
• Flanges aceording to DIN
-
0
QO
-
0
-
""'
.,... lSI
><
Disc
Seat
lSI
""'
.._
.,...
t'-
lSI
Body
150
C13
Version: A 2641087
DN 20, PN 25

............
iliiiiiii
AALBORG DATA SHEET
INDUSTRIES
Type:
• Opening pressure (63° open): 19 mbar
• Wafer check valve, type WCV 6140 3
• Standard Kv value: 1036 m 1h
Application: • Operating temperature max.: 250°C
• Operating temperature min.: -1 ooc
• For steam and .liquid media
• Weight: 8.8 kg
Design: Installation:
• The wafer check valve is designed to be • The check valve can be installed
sandwiched between welding neck sandwiched between welding neck
flanges or slip-on flanges, with flanges or slip-on flanges
horizontal flow. The disc is eccentrically • Determine the correct installation
placed in relation to the body to obtain a situation and the direction of flow. It
self-centring effect at installation must be installed in a horizontal flow
Size: • The valve is self-centring. However, it
must always be ensured that it is
• Nominal diameter: DN 200
completely centred in relation to the
Connection requirements: connection pipe/flange. Use the body
• Min. inline diameter of connection rim (external) diameter for this purpose
pipe/flange: 206.5 mm . • The check valve can be installed directly
• Length of required min. inline diameter: on a valve, but a distance of2-3 times
160mm the pipe diameter is preferable.
Material:
• Body: carbon steel
• Wafer disc: carbon steel
• Disc seating: metallic
Technical data:
• Operating pressure max: 25 bar
• Max. cold hydraulic test pressure: 37.5
bar
~.-.-- Eye bolt
Hinge plug
Disc
~
Flow
direction
C14
Type No.: 6020

Version: C Check valve, DN 200, PN 25 6020 000064

.. ..
AALBORG
INDUSTRIES
Installation examples:
285
Welding neck flange Welding neck flange

installation installation with
recessed pipe
SliP'Jn flange Slip-on flange

installation installation with
recessed pipe
C14
Type No.; 6020

Version: C Check valve, DN 200, PN 25 6020 000064

........
:il.il.i:
ill I IIi
AALBORG _- - -.' _-._ DATA SHEET'- .. - . :
INDUSTRIES : - ~ ' ' '
Type: Material:
• Stop globe valve, straight • Body: GGG 40.3
• 23.006 DIN -Material No. 0.7043
• Seat: X20 Cr 13
• Weight: 5.4 kg
"'140
~-------------~=---~~~
0
(J)
..--
Disc
160
Type No.: 6010

Version: A Stop valve, straight, ON 25, PN 25 2501088

........
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop globe valve, angle • Body: GGG 40.3
• 23.007 Din-Material No. 0. 7043
• Seat: X20 Crl3
Size:
Din-Material No~ 1.4021.05
• Nominal diameter: DN 25 • Disc: X20 Crl3
Application: DIN-Material No. 1.4021.05
• Weight: 5.6 kg
"25
l!l85/4xl!l14
"115
,.. 100
C15
Type No.: 6010
Version: B Stop valve, angle, DN 25, PN 25 2511088

........
:il.il·i:
ill I IIi ' . . ' ~
AALBO.RG .: . ' . ' DATA SHEET - . ' '- ' . '• .

INDUSTRIES
Type:
• Stop valve, gate straight
Size:
Application:
• Sea water, fresh water, oil, steam etc.
Material:
• Body: GG 25
Technical data:
• Max. temperature: 150 oc
• Weight: 11.5 kg
150
C16
Type No.: 6010

Version: B Stop valve, straight, ON 50, PN 10 253 1005

........
1 i.
ii.I·I·I1.Iii . ' '
AALBORG DATA
. - SHEET
.
INDUSTRIES
Material:
Type:
• Body: Carbon steel
• Reflective water level gauge, left
• Drain valve body: ASTMA105
• Model26
Technical data:
Size:
• Nominal diameter: ON 25
• Weight: 22 kg
Application: • Connections between body and cocks are
• For boiler water level indicator made by end tubes and stuffing boxes _
0
<0
.....
Drain connection 111 10 x 2.5

mild steel
C17
Type No: 7010 Water level gauge, left, model 26
Version: B 7010 000136
ON 25, PN 25

......
illiiilli
AALBORG · . .
' .
DATA SHEET
.
. . --~. ·.>· ..
INDUSTRIES
Material:
Type:
• Body: Carbon steel
• Reflective water level gauge, right
• Drain valve body: ASTM Al 05
• Model26
Technical data:
Size:
• Weight: 22 kg
Application: • Connections between body and cocks are
• For boiler water level indicator . made by end tubes and stuffing boxes
160
0
0
r--
0
10
N
...
0
(I)
Drain connection I!J 10 x 2.5

mild steel
C18
Type No: 7010 Water level gauge, right, model 26,
Version: B
7010 000135
ON 25, PN 25
Language UK Page 1/l

Description Index I Date r Drawn I Appr.
~ -$
v ;=:
C187.3/C487.3 ~
C187.4/C487.4 ~¥
»
~~ ~~ i
~
C 187 .5/C487 .5 ___--

-'--
-,
n' r,
C187.4/C487.4 1-
~~
0
0
C187.3/C487.3 ....
1.()
~ f-- x
~~
C187.1/C487.1 A~ C187.2/C487.2
f
~~
~
ea.
a.
<(
OPEN HUT
I
'~
\ I Wire stainless steel 4551052
p187 .5/C487 .5 20
~ ~ ~
li!3 mm Specified in metre AIS1316
Wire clip Hot-dip galvanized 4576110
p187.4/C487.4 8 Steel
3mm
Shackle Hot-dip galvanized 4573311
\ I \ I !J187.3/C487.3 8 Steel
3/16"
~ ~ ~-~
Handle - "SHUT" 6451003
p 187 .2/C487 .2 2
Handle - "OPEN" 6451002
p187.1/C487.1 2
Designation Material coda Article No.
Tag No. Pes. Cert
Dimension Material type Datall draWing No.
TiUe: Drawn Date
JA 040608
...
...
.....
.......
Appr. Date
.......
iiiiiiiii
STANDARD
Weight
BZ 040608
Scale:
1:1
Size
A3
Remote pull for water level gauge
AALBORG Article/Drawing No: Affix
INDUSTRIES THIS DRAWING AHD DESIGN SHOWN HEREIN IS THE PROPERTY Of MLBORO INDUSTRIES
AND M.IST NOT BE USED BY OR REPRQOIJCI::D fOR TMRD PARTY K03:032122
........
i.
ii..1·1·Iil"Iii
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
return, straight DIN -Material No. 0. 7043
• 23.006 R • Seat: X20 Cr13
• Weight: 39 kg
N
N
lSI -Dis::
LO
-
t") X
N !X) - S3at
lSI
0 lSI
0)
.....
lSI
BJdy
350
C19
Version: A
2641094
DN 100, PN 25

.
........
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• 23.006 DIN -Material No. 0. 7043
• Seat: X20 Cr13
• Weight: 58.5 kg
co --Disc
N
61
X 10 Seat
0
......
N
61
-
tO
0
N
N
N
61
61
Body
C21
Type No.: 6010
Version: B Stop valve, straight, DN 125, PN 25 2501095

....
...
.....
iliiiiili
AALBORG
INDUSTRIES
·Type: Technical data:

• Operating pressure max: 25 bar
• Wafer check valve
• Operating temperature max.: 250°C
• WCV6140
• Weight: 3.2 kg
Size:
Installation:
• The check valve can be installed,
Application: · sandwiched between flanges with
• For steam and liquids media horizontal flow.
Material:
• Body: carbon steel
• Wafer disc: carbon steel
a Disc seating: metallic
-........_
-........_ -........_
-........_ -........_
-........__-:::::;
C22
Type No.: 6020

Version: A Check valve, DN 125, PN 25 6020 000062

Description Appr.
Alternative DIN material

Item DIN Material
DIN 17177
1 St.37.81
DIN 17177
2 St.37.81 Note!
3
DIN 1629 Item 4, 5 and 6 not shown.
St.37.4
Wlb
Nut ISO 898-2 3292124
6 16
M12 5
Stud ISO 898-1 3271382
5 M12x55 8 5.6
Gasket for pipe flange 3510000008
4 DN25 PN40 t=3.2 2 SS316/graphit
Level tube EN10216·2 4000000390
3 11112 L=1446 P235TR2
DP water level control unit _C 70Z:034478
2 DN25 31
Upper level tube EN10217-2 _C 70K02:012084
31
DN25 P235GH
Designation Material code Miele No.
Item Pes. Cert.
Title: Drawn Date
DP water level control unit JA 050415

.....
.......
.......
Appr. Date
Note! - side to be connected to lower level tube STANDARD BiL 050415

Scale: Size
+ side to be connected to upper level tube Socket distance: 525-1300 Weight
iiiiliiii Assembly drawing
1:5 A3 ·
*-Drain connection: 012 tube AALBORG Affix
r - - - - - - - - - - - - - - - - { M l c l e / D r a w l n g No:
INDUSTRIES THIS ORAWINO AND DESIGN SHOVWN HEREIN IS THE PROPERTY OF MLBORO INDUSTRIES
NiD WST NOT BE USED BY OR REPROOUCeD FOR 1'tiiRO PARTY 702:036686
.
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:iiiii:
illll IIi
AALBORG DATA SHEET
INDUSTRIES
Type:
• Level float switch
• RBA24
Size: 10
.....
• DN25 .....
10
N
Application:
• Low water level switch
Material:
0
• St. 35.9
• c 22.8
Technical data:
• Drain connection: 0 12 mm
• Cable connection: PG 11
• Max. working pressure: 32 bar
• Max. working temperature: 239°C 10
0
• Flanges according to DIN 2635-C 0> N
10
• Magnetic switch: 2 x M130
• Switching voltage: 6-250V
• Switch current max: lA ac; O.SA de
• Protection of switch housing: IP 54
0
C')
"<t
.....
284
W14
Type No.: 8100
Version: C Level float switch RBA 24, DN 25, PN 40 8100 000008

.
. ...
...
ii'l"l"il"i·
I Iii
AALBORG . DATA SHEET , ·, .· : .·
INDUSTRIES . . ' ~
Type:
• Safety valve, full lift 0
N
• 25.941 .....
Size:
Application:
• To blow off steam and/or air.
Material:
• Body: GGG 40.3
• DIN-Material No.: 0. 7043
Technical data:
• Weight: 3.5 kg
C26
Type No.: 6040
Version: A Safety valve, DN 15, PN 40 2611358

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ii.l"l"il·i·
I Iii ' ' . ' ' .
AALBORG - DATASHEET ...
.
-· . .: - :.·_
'.::· .
·
INDUSTRIES ' -'
Type: Material:
• -Stop globe valve, straight • Body: GGG 40.3
• 23.006 DIN -Material No. 0. 7043
• Seat: X20 Cr 13
• Weight: 18.4 kg
13 180
~l
10
co
N
T-
co
.....
lSI
X
10
co
lSI I
-
co
10
'V
Body
lSI
I
I
L_
290
C194
Type No.: 6010
Version: A Stop valve, straight, DN 65, PN 25 2501092

.
.......
:il. il. i:
ill I IIi
AALBORG ' - . - .·DATA SHEET .. . ." .
INDUSTRIES - -
Type: Installation:
• Stop ball valve, straight
Information and caution before installation
• 113 BW, full bore
of the valve:
Size: • Pipe must be free of tension.
• DNSO • Pipe must be flushed to clean the dirt,
burrs calamines, welding residues etc.
Application: which would damage the ball and seat.
• For air, steam, or oil flow • The valve must be kept in open position
during installation. Protective plastic
Material
covers must not be removed before the
• Body: ASTM AI OS installation work commences.
Technical data: • At the moment of the shipment the ball is
lubricated with a pure vaseline oil,
• Temperature: - 29°C to+ 230°C
which can be easily removed with a
• End connections: Butt weld according to
solvent, if required.
ASME/ANSI Bl6.25- XS-80
• Ball valves normally have a space
• Pipe size: DN 50
between ball and inside cavity of the
• Weight: 9.5kg
body, which could trap the product, care
should be taken to drain the cavity.
Instruction for welding the valve on the pipe
line:
Detail A • Tack weld in four points on both end-
connections.
• Lift out the centre part to protect the
gaskets against damage and complete
the welding.
• Insert the centre part and ensure easy
operation.
225
Detail A
End connection ;
192 132
C199 C499
Type No.: 6010
Version: A Stop valve, ball, straight, ON 50 8703068

BALL VALVE
Dimensions
ON 25-100
Full Reduced H I L M N 0 ISO
bore bore 5211
ON 25 ON 32 M12 X 1.25 7.5 20.0 10.0 42 M5 F04
ON32 ON 40 M15 X 1.5 8.9 27.0 13.0 50 M6 F05
ON40 ON 50 M15 X 1.5 8.9 28.0 14.0 50 M6 F05
ON 65 M15 X 1,5 8.9 25.0 12.5
•
ON 50 50 M6 FOS
ON65 ON 80 M22 X 1,5 16.0 35.0 17,0 70 M8 F07
ON80 DN 100 M24 X 1.5 18.0 37.5 15.0 70 M8 F07
DN 25-100
Flanged connections - PN 16-40

Full bore
DN A B c D E F Weight
•
50 230 118 225 50 165 125 17.5
65 290 136 350 64 185 145 23.0
80 310 150 500 78 200 160 28.5
Reduced bore
DN A B c D E F Weight
65 290 118 225 50 185 145 14.0

80 310 136 350 64 200 160 20.0
100 350 150 500 78 235 190 24.5
D&nensions In mm. Weights In kg.
Flanged connections
Arrangement of bolts
4+4bolts: Kv factor
ON 15-50 reduced bore (Kv = Water flow in m3/h at a pressure drop of
ON 8-40 full bore 1 bar and a temperature of 20°C)
ON Full Reduced
6+6 bolts:
8 6.8 -
ON 65-80 reduced bore
10 6.8 -
15 12.8 6.8
• ON 50-65 full bore
20 29.1 12.8
25 50.0 29.1
32 72.6 50.0
40 106.8 72.6
8+8bolts:
50 213.7 106.8
ON 100 reduced bore
65 275.0 213.7
ON 80 full bore '
80 500.0 275.0
Aalborg Industries Data sheet No. ball113fl 1/2

C227
BALL VALVE
Parts/Material specifications
Shown with enca sulated seat on the end ieee
2A••
MARI<BRICKA
I
12 11.1&· 10" 19" 13 16
Standard versions
Item Quant.
1 1
Part
Handle
•
Body- Carbon steel
Galvanized and plastic-
coated carbon steel
Body- Stainless steel
Galvanized and plastic-coated
carbon steel (Stainless steel
A 316 to special order)
2"" 1+1 Handle retaining nut (2A) Cadmium-plated Stainless steel A 316
locknut (28) carbon steel
3 1 Stem packing Graphite Graphite
4""
. 2
1
Spring washer
Antistatic stem
Stainless steel A 302
1 Packing ring Stainless steel A 316 Stainless steel A 316
7" 1 Thrust washer PTFE PTFE
8" 1 0-ri~- Viton PTFE
g•• 1 Ball Stainless steel A 316 Stainless steel A 316
10" 2 Seat seal PTFE + 20% carbon + PTFE + 20% carbon +
5% graphite 5% graphite
11" 2 Primary body seal PTFE + 20% carbon + PTFE + 20% carbon +
5%graphite 5% graphite
12 1 Body Carbon steel A 105 Stainless steel A 316
13 2 End piece Carbon steel A 105 Stainless steel A 316
14 1 Antistatic spring Stainless steel A 316 Stainless steel A 316
unit in stem
15" 4+4or Body bolt (see • Arrange- Stainless steel A 193 87 Stainless steel A 193 B8
6+6or ment of boitsj
8+8
16 4+4or Bolts Carbon steel Carbon steel
6+6or
8+8
n•• 1 lockwasher Stainless steel A 316 Stainless steel A 316
18"" 2 Secondary body seal Graphite Graphite
19"" 2 Seat seal PTFE or graphite PTFE or graphite
* Recommended spare parts after 2 years of service

**Recommended spare parts after 5 years of service
Aalborg Industries Data sheet No. ball113fl 212

ModeiAT401 DAand SR-90°
llJZStd. 56 Available Flange: F10

F07-F10
4x4 136
-1 r-
Flange Dimensions
r-=----o.
.., L[ l
0 ISO 5211 F07 FlO
rl 1- /
I \
d f8 55 70
Q1 70 102
-~
~p
'211- 0 0 ~~ ~ W1 M8x12 ~10x15
MSxB \ ...
!2
I
Square
55
22
70
22 27
V
~-r- l r
- ~b{i
Lortz Port'4' Lmin. 24 24 2S
~
1- hmln. 1.5 1,5
-~
~""--i j h1 2.5 2
• r- ~ ~si~ion .l~p~cator
or rox1m1
Z=&S
t
l J
•.
12 121 \ G1/4" 150228 -1 I Pressure connection BZ
I
345 69.5 82 Ancillary Attachment AA Z
,
~
0 ~
T~r
~1 ~~
-+-
-+-
~~
~w
gt
_;,~pqj I "'
~-~ ~~~~
Q1
~c.,- ~
.~ .l#t(_
h-~ \ ~~
~~
T ao T
Spigot optional
lYPE Output Torque for Double Acting and Spring Retum In Nm Spring
r--
Pressur 2,5 bar 3 bar 3,5 bar 4 bar 4,2 bar 4,5 bar 5 bar 5,5 bar 6 bar 7 bar 8 bar stroke Weight
o· so· o· so· o· so· o· so· o· so· o· so· o· so· o· so· o· so· o· so· o· so· so· o· (Kg)
D 138 166 194 222 233 249 277 305 332 388 443 . 10.2
End Start
sos 86 56 114 84 141 111 16S 13S 180 150 1S7 167 224 1S5 82 53 11
SO& 75 40 103 67 131 S5 15S 123 170 134 186 150 214 178 242 206 99 63 11.1
S07 S3 51 120 79 148 106 15S 117 176 134 203 162 231 18S 25S 217 115 74 11,3
SOB 110 62 138 90 149 101 165 117 1S3 145 221 173 248 201 304 256 132 84 11,4
S09 127 73 138 84 155 101 182 12S 210 156 238 184 2S3 23S 34S 2S5 148 95 11.6
S10 144 84 172 112 200 140 227 168 283 223 338 278 165 105 11.8
S11 161 S6 189 123 217 151 272 206 328 262 181 116 11.S
0 S12 17S 107 206 135 262 1SO 317 245 198 126 12.1
Max. Rotation Screw stroke Chamber Air Volume (L) Moving nme (Sec.) (A) Operating Temperature ("C) (B)
0
Pressure Adjustment 0(mm) Opening Closing Opening Closing STD (standard) HT (high temp.) LT (low temp.)
90" ±4" For 1" D 0,90 D 1,1 NBR "0" -Rlng FPM "0"-Ring Silicon "0"-Ring
8 bar at o· and so need 1/4 Tum 125 1,54 2,34 s 1,20 s 1,40 ·ZOto +80 -15t0+150 -40t0+80
Notes: (A) The above indicated moving tlme of tlhe actuator. are obtained In tlhe following test condltlons(1) Roam Temperature. (2) Actuator Stroke so·.
(3) Solenoid Valve wltlh Orifice Of 4 mm and a flow capac~y On 400 Llmln(4) Inside pipe diameter 8 mm, (5) Medium clean air,(&) I'Jr supply pressure
5.5 bar (79,75 Psl)(7) Actuator w~hout external resistance load.
Cautions: obviou~y on the field ~plicatlons when one or more of tlhe above parameter are different. tlhe moving tlme will be different
(B) For HT (high temperature) an LT Oow temperature) services. a special Lubricant Is requested. Please contact Air Torque factory.
Aalborg Industries Data sheet No. AT400da 1/1

EGO SWITCHBOX
TYPEM
Description:
EGO switchbox with integrated mikroswitches to be used

for remote as well as visual indication of valve position
The switchbox include bracket for mounting on a
pneumatic actuator. With use of a special bracket the box
can be mounted on a gearbox or directly on a valve.
Specifi kations
Bus Polycarbonat
Aksel POM
Kamskive Nylon
Bundplade Pertimax
Kamhoved Messing
T~etningsgrad IP 65
lndikator POM
0-rings t~etning Viton

EGO SWITCHBOX
TYPEM
Teknisk data:
EGOBOXM EGO BOX I EGO BOXN
Kontakt antal 1+ 1 1+ 1 1+1
Kontakttype Mikroswitch PNP induktiv Namur
Fabrikat Honeywell Honeywell Pepperl +Fuchs
Type V5C010TB1C 992FS2-A9PV3-L NJ2-V3-N-V5
Sp~nding max. 250VAC 9,6-SOVDC 8VDC
Forbrug - ~ 10mA -
Max. belastning 10 (3) A 200mA -
Max. frekvens - 2KHz 1KHz
Ambient temperatur + 55°C til +85°C + 25°C til + 75°C + 25°C til +100°C
Dimensioner LxBxH 82x80x67 82x80x67 82x80x67
r
.-----------------------------------------------------------,
CONNECTION DIAGRAM
fill i+ i+
Micro switch Inductiv Namur
EGO Box DWG NO: 04.98.06-EGO BOX

DRAWING B'f DRIIWliiG IlliTE
06-04-1998·
_j
5/2
SOLENOID VALVES •3/2
pilot operated, spool type · ~ 5/2
single/dual solenoid
aluminium body
FEATURES
• Solenoid valves comply with all applicable EC Directives
• The solenoid operated spool valves have threaded port connections and NAMUR
interface
• The same spool valve can be adapted for 312 NC or 5/2 functions for controlling
double-acting and single-acting actuators
• All the exhaust ports of this spool valve are pipable, providing better environmental
protection, particularly recommended for sensitive areas such as clean rooms, and
applications in the pharmaceutical and food processing sectors
• It is necessary to connect pipes or fittings to the exhaust ports to protect the internal
parts of the spool valve and its pneumatic operator if used outside or in harsh
environments (dust, liquids etc.)
• The return-spring chambers of the single-acting operators "breath" through the
spool valve, isolating them from the outside atmosphere
• Manual operator as standard
GENERAL
Differential pressure 2 - 10 bar [1 bar = 100 kPa]
Flow (Qv at 6 bar) 700 Vmin (ANR)
fluids (*) temperature range (TS) seallngs (*)
air, Inert gas, filtered -2s•c to +so·c + NBR (nitrile)
PUR (polyurethane)
MATERIALS IN CONTACT WITH FLUID

(*) Ensure that the compatibility of the fluids in contact with the materials is verified
Body Aluminium, black anodized
End covers + interface plates Glass-filled polyamide (PA/FG)
Internal parts Zamak, stainless steel, acetal (POM), aluminium
Sealing NBR + PUR
Core and core tube Stainless steel
Shading coil Copper
ELECTRICAL CHARACTERISTICS
Coil insulation class F
Coil Epoxy resin
Spade plug connection coil 3 x DIN 46244
Connector Type 22, spade plug (Pg 9P)
Electrical safety VDE 0580
Standard voltages DC (=):24V Monostable version
AC (-)· 230V I 60Hz
power ratings ambient
coli Inrush holding hot/cold temperature protection
type - - = range (1) (TS)
0/A) (VA) I (W) (W) (•C)
CM22·2,5W 6 3,5 I 2,5 2,5/3 -25 to +60 moulded IP65
SPECIFICATIONS
operating pressure
pipe orifice flow differential (bar)
coefficient coli
size size maximum (PS) type catalogue number
Kv
min. air(*)
~~(~G~)----r~(~m-m~)-+~(-m~
3~~)-~I(V~m~in~)~ -1= -1=
Single solenoid pilot operated -spring return (monostable), with or without exhaust reducers
Dual solenoid pilot operated and air return (bistable), with or without exhaust reducers
(C) Construction type e : screw-type manual operator .C. : exhaust reducer

SOLENOID OPERATED SPOOL VALVES- ALUMINIUM BODY
OPTIONS AND ACCESSORIES

• Explosionproof enclosures according to "CENELEC" EEx d, m, em, I
• Explosionproof and watertight enclosures according to "NEMA" standards
• Coil comply with "UL" standard
• Coil type CM25 with connector type 30 ISO 4400 (Pg 11 P)
• Polyamide coil
• Versions : pneumatic operated, spring return: without exhaust reducer
• Set of stainless steel mounting screws

• Set of two exhaust reducers
• 1/8 exhaust fittings
• Plug with visual indication and with peak voltage suppression or with cable length of 2m
INSTALLATION
• The solenoid spool valves can be mounted in any position
• Spool valve supplied with two interface plates with mating surfaces. Depending on function (NC 3/2 or 5/2),
position one of the two plates on the spool valve body before installing on actuator
• Dowel pin (if necessary), bolts and gaskets are standard supplied
• Connect or protect the exhaust ports to isolate the internal atmosphere of the internal parts of the spool valve.
Range of 1/8 fitting available
• Pipe connections have standard thread according to ISO 228/1
• The third digit in the catalogue number indicates the standard pipe connection
• Other pipe threads are available on request
• Installation/maintenance instructions are included with each solenoid spool valve
• Replacement coils are available
DIMENSIONS (mm), WEIGHT (kg) ~ .
·- ~
C\1
"" Cn
v
10
v
Port 1 : G1/4
Ports 3 and 5: G1/8
(C)1: monostable
(C)2: bistable
CD Interface plate Bistable version

® Mounting: 2 M5 x 35 screws
engaged lenght: 7 mm
weight (1)
®Connector rotatable 2 x 180°, CM8 (Pg 9P) catalogue number (C)
3/2 5/2
0 2 0-ring seals (supplied) • SC G551A001 MS 1 0,339 0,339
® One 5 mm dla. hole for dowel pin SC G551A001 MS M 1 0,349 0,359
- In position A 1: 3/2 function plate
SC G551A002 MS 2 0,457 0,457
• in position A2: 5/2 function plate
SC G551A002 MS M 2 0,467 0,477
® Manual operator screw-type (1) Incl. coil(s) and connector(s)
0 Pilot exhaust connection port: 0 M5, equipped with drain protector
(C) Construction type
®Exhaust reducers or protectors G1/8 adaptable on orifices 3 and 5 (on request)

* + 15 mm for connector removal
TD 32F Thermodynamic Steam Trap
Description
The TD 32F is a medium pressure flanged thermodynamic steam
trap with integral strainer screen suitable for mains drainage.
Sizes and pipe connections

DN 15LC, 15,20 and 25
Standard flange:- BS 4504 PN 40, BS 1560 Class 150 and 300
Limiting conditions
Maximum body design conditions PN 40
PMA - Max. allowable pressure 40 bar g
TMA - Max. allowable temperature 4oo•c
Cold hydraulic test 60 bar g
Operating range
~ 400
~ 300-1-----t------+-----'""'
~
~200+---~~~------+=======~~
o. Steam
~ 100~;...._-----f-Saturation-+----+-+----t
Curve
0~---------f--------~-------+-+----~
0 10 20
Pressure bar g
Note: Minimum operating pressure for satisfactory operation is 025 barg

PMOB - Max. operating back pressure is 80% of upstream pressure
Capacities
~
Cl
2000 ..,..... 0.5 .!e
Cl
""'
OJ
..,.......,.... 0.4 ""'
~c 1000
0.3
*
-- -
U>
c
OJ 0.2 OJ
""0
c 1-oN zs ""0
c
u
0 500
1-"
.,.... 0
u
--
400 oNzo 0.1
~
300 .,.... I-"
v ,.,........ L...--
200
~ 0.05
0.04
....... ~ 0.03
100 oN \S \.C
0.02
50
40 0.01
30
0.7 1 2 3 4 5 10 20 32
Differential Pressure bar (x 100 = kPa)
Materials
No Part Material
1 Body Stainless Steel
DIN 17445 G-X20 Cr14 Ws 1.4027
2 Cap Stainless Steel AISI416
3 Disc Stainless Steel BS 1449 420 845
4 Strainer Screen Stainless Steel ASTM A240 316L
5 Strainer Cap Stainless Steel AISI 416
6 Strainer Cap Gasket Stainless Steel BS 1449 304 S16
7 Insulating Cover Aluminium
(optional extra. Not DN 25)
8 Flanges Steel DIN 17243 C22.8 Ws 1.0460
C195
Aalborg Industries Data sheet No. 7020 000001 1/2
Withdrawal
distance Withdrawal
Dimensions (approximate) In milllmetres for cap distance for
insulating cover
Size-ON A 13 c D E F G H Weight
15LC 150 55 41 40 80 57 38 55 2.3 kg -~·· ~-·
.15 150 55 41 40 80 57 38 55 2.4 kg
20 150 60 47 40 95 57 38 61 3.1 kg
25 160 65 53 40 100 4.2kg
Installation
Preferably fitted in a horizontal pipe but can be frtted in other c H
positions.
Optional extras
Insulating cover:- to prevent the trap being unduly influenced by
excessive heat loss such as when subjected to low outside
temperatures, wind, rain etc. (Not available for ON 25)
Note: The internal blowdown valve is not available for the TO 32F 8 E
Spare parts
The spare parts available are shown in heavy ouUine. Parts drawn in
broken line are not supplied as spares.
AVAILABLE SPARE
Disc (Pkt of 3)
ITEM
3
I j
Strainer Screen and Gasket 4,6 Withdrawal
Strainer Cap Gasket (Pkt of 3) 6 distance
Insulating Cover (Not available for ON 25) 7 for Strainer
1-------7
Maintenance
Before undertaking any maintenance on the trap it must be isolated
from both supply line and return line and any pressure allowed to
safely normalise to atmosphere. The trap should then be allowed to
cool.
How to service
Remove insulating cover if fitted and unscrew cap using spanner.
Do not use Stillsons or a wrench of similar type which may cause
distortion of the cap. If the disc and body seating faces are only
slightly worn they can be refaced by lapping individually on a flat
surface such as a surface plate. A figure of eight motion and a little
grinding compound such as the Carborundum Co's Compound I. F.
gives the best results.
If the wear is too great to be rectified by simple lapping, the seating
faces on the body must be ground flat and then lapped and the disc
replaced by a new one. The total amount of metal removed in this
way should not exceed 0.25 mm.
When re-assembling, the disc is normally placed in position with the
grooved side in contact with body seating face. Screw on cap, no
gasket is required but a suitable high temperature anti-seize grease
should be applied to the threads.
To clean or replace strainer

Unscrew strainer cap using spanner, withdraw screen and clean, or
if damaged replace with new one.
To re-assemble, insert screen into cap, then screw cap into place. A
fine smear of 'Molybdenum Disulphide' grease should be applied to
the first few threads. Care should be taken to ensure that the gasket
and gasket faces are dean. Tighten cap to the recommended torque.
Recommended Tightening Torques
Item ON Nm
or ~
@ mm ·
2 15LC 36 135-150
e15 36 180-200
20 41 180-200 ----4
25 55 250-275
5 32 170-190
Aalborg Industries Data sheet No. 7020 000001 212

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iliiiiili
INDUSTRIES
Table of contents
Descriptions
Steam atomising burner, type KBSD ........................................................................... l

........
:il.il·i:
ill I IIi
AALBORG STEAM ATOMISING BURNER, TYPE KBSD 805580#01.4
INDUSTRIES
Steam atomising burner, type KBSD
1 General
The burner is a steam atomising burner for modulating operation. The burner is
capable of burning both diesel oil and heavy fuel oil. An illustration of the KBSD
burner is shown in Figure 1.
The burner system consists of the burner unit, combustion air fan, and supply
systems for oil, steam, and combustion air. The burner unit is mounted on top of the
boiler and connected to the combustion air fan via an air duct.
The design of the KBSD burner ensures that the flame is kept highly stable at all
loads. Due to the advanced wind-box and oil flow control system, the KBSD burner
can provide inert gas at low loads and has an increased tum down ratio.
Illustration of the KBSD burner

Atomising steam inlet
-common steam line
Atom ising air inlet
Oil flow
meter
Fuel oil
control valve
Small size KBSD burners Large size KBSD burners are

are equipped with two swirlers equipped with one flame stabiliser
Figure 1 burner2d.cdr

.....
.il.11·1·.
iii I ii
AALBORG STEAM ATOMISING BURNER, TYPE KBSD SD5580#01.4
INDUSTRIES
1.1 Burner design
1.1.1 Wind-box design

When the combustion process in an oil burner is controlled, it is essential to have a
stable and uniform distribution of the combustion air in the burner register and the
air duct. A badly shaped air duct can cause instability of the flame, and therefore the
burner has been designed with a dynamical wind-box, as shown in Figure 2. This
wind-box, shaped as a spiral, in combination with the radially fixed guide vanes
ensure a uniform air distribution in the burner register. This is an efficient way to
achieve a stable combustion.
Illustration of the dynamical wind-box

Swirlers or flame stabiliser
Guide vanes
Air inlet
Figure 2 windbox3.cdr
1.1.2 Burner register

The burner register is the duct between the wind-box and the furnace. The burner
lance with atomiser, swirlerslflame stabiliser, and ignition burner are placed in the
burner register. Small size burners are fitted with divided swirlers - one primary air
swirler and one secondary air swirler, whereas large size burners are fitted with only
one flame stabiliser.
For maintenance and inspection purposes the burner lance can be dismounted
separately from the top of the wind-box. This makes replacement of the atomiser
very easy.
The swirlers/flame stabiliser are designed to create an internal re-circulation of hot
gases, which provides the continuous ignition, and hereby to stabilise the flame
resulting in less pulsation.
1.1.3 Ignition burner

The ignition burner is a separate diesel oil burner with its own oil supply system.
When the burner is started, and the ignition sequence step is reached, the ignition
burner is moved into position by means of the air servo cylinder.
The diesel oil flame is ignited by an electric spark between two electrodes which are
connected to a high voltage ignition transformer.

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INDUSTRIES
After the ignition period has expired, the ignition burner is purged with air and
retracted again.
1.1.4 Atomiser
The burner lance contains the Y-jet atomiser, in which steam and fuel are mixed and
ejected. This oil mist is then mixed with combustion air, and the combustion is
completed. The requested oil capacity of the burner unit determines the number and
bore of discharge ports in the atomiser.
The oil flow regulation is based on flow measurements, and therefore the oil
pressure is of little importance to the atomisation quality. As a consequence of this,
the atomisation quality does not vary over the burner tum down range even with the
oil pressure operating between 2 and 25 bar.
1.1.5 Flame failure equipment

Flame failure during light up and normal operation is detected by photo electric cells
mounted on the burner unit and coupled to an amplifier mounted inside the local
control panel. By loss of flame, this flame failure equipment will automatically shut
down the burner.
1.2 Supply systems
1.2.1 Oil and atomising systems

The atomising medium and oil are supplied from valves through flexible hoses to
the burner lance.
The automatic shut-off valves, re-circulation valve, solenoid valves, and the rest of
the necessary burner mountings are all fixed on the wind-box. All shut-off valves are
standard ball valves, and the automatic valves are with electric/pneumatic actuators.
The arrangement of the components on the burner is made as simple as possible and
is therefore very user friendly regarding operation and maintenance.
The oil flow control valve is fitted together with a pneumatic converter/positioner.
To obtain a very accurate regulation of the oil flow, which is very important to have
a large tum-down ratio, the valve is also fitted with an adjustable Cv-adjuster. This
Cv-adjuster makes it possible to adjust the pressure loss coefficient of the valve
whereby the oil flow regulation can be optimised to each single installation. The oil
flow is measured by a screw-type flow meter.
The fuel oil pressure control loop includes a motorised control valve to ensure the
correct pressure at the fuel oil inlet of the burner, and thereby providing a larger
tum-down ratio of the control valve. A single loop Pill-controller and a standard 4-
20 rnA pressure transmitter ensure optimum and accurate functionality.
The fuel oil temperature before the burner inlet is kept precisely at the desired value
by means of a motorised flow control valve, a single loop Pill-controller, and a
Pt 100 temperature transmitter.
The atomising steam is supplied through a motorised control valve. The steam
pressure is kept constant at high burner load, but at low burner loads, the steam
pressure is reduced. A single loop Pill-controller with external set point and a
standard 4-20 rnA pressure transmitter ensure optimum and accurate functionality.
The external set point is related to the fuel oil flow and changes together with this,
making regulation more optimal.
Both steam and compressed air can be used for atomisation of the fuel oil. Normally
steam is used for the atomisation, which is supplied from the steam line. When

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INDUSTRIES
connecting to the common steam line in plants with two boilers, boiler No. 2 can be
started by using steam from boiler No. 1 and visa versa.
Atomisation of the fuel oil by compressed air should only be used during start-up or
due to failure of the steam supply.
1.2.2 Combustion air system

The combustion air system supplies air to the burner according to the demands of
the control system. The draft loss of the burner air register is measured by a
differential pressure transmitter, which converts the signal to a flow signal used by
the control system for automatic air/oil ratio control.
The combustion air is supplied by a directly driven centrifugal fan. The fan is
mounted on a common bed frame with motor, inlet vanes, and servo-drive unit. The
fan impeller inside the spiral housing is mounted directly on the motor shaft. The air
flow to the burner is regulated by inlet vanes mounted on the fan suction side.
The inlet vanes are of a multi-blade design and regulated by a servo-driven unit
comprising an air cylinder and an liP positioner. A silencer can be mounted on the
fan suction side.

12
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INDUSTRIES
Table of contents
Operation and maintenance

Steam atomising burner ............................................................................................... 1
Handling fuel oil .......................................................................................................... 2
Ignition burner ............................................................................................................ .3
Photo cell ..................................................................................................................... 4
Burner lance ................................................................................................................. 5
Viscosity- temperature chart ....................................................................................... 6
Fuel oil supply system ................................................................................................. 7
Burner supply systems ................................................................................................. 8
Commissioning ............................................................................................................ 9
Operating instructions ................................................................................................ 10
Manual operation ....................................................................................................... II
Maintenance ............................................................................................................... l2
Faults and rectifying faults ........................................................................................ 13
Measurements and settings ........................................................................................ 14

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AALBORG STEAM ATOMISING BURNER OM5580#01.0
INDUSTRIES
Steam atomising burner
1 General
The steam atomising burner is capable of burning both diesel oil and heavy fuel oil.
As the burner is a very vital component of the boiler plant, the operating staff should
be thoroughly instructed with regard to the operation of the equipment and the safety
regulations. This is due to the fact that burner problems are often caused by incorrect
burner operation. With frequently occurring burner faults, the nearest service centre
should be consulted.
To ensure a safe and reliable function of the burner it must be inspected at least once
a year, in addition to the normal maintenance intervals. The inspection should be
carried out by a representative of the supplier or by another competent and qualified
person.
It should be clearly understood that for a plant of this complexity it is not practicable
to anticipate all the possible circumstances which may arise during the operation life
of the plant. Therefore, should circumstances arise in plant operation and
maintenance which are not specifically covered by these instructions, the matter
should be referred to Aalborg Industries for consideration and advice.
Repairs, adjustments, alterations or changes to plant operations not covered by these
instructions should not be effected without reference in writing to Aalborg
Industries.
Information in this manual is subject to changes without notice and does not
represent a commitment on the part of Aalborg Industries. It is not allowed to copy
this manual or part hereof for any purpose other than the purchaser's personal use.
Aalborg Industries shall not be held responsible for any damage or losses caused by
the use of this manual.
1.1 Safety regulations
Caution: To ensure a safe burner operation, the burner has to be installed and
commissioned by qualified personnel, and all guidelines in these
instructions have to be followed.
All safety equipment such as flame sensor equipment and correcting elements may
only be replaced by qualified personnel.
Warning: Repair of any of the safety components is NOT permitted. Failure to

comply may result in serious injury or death and may cause
considerable damages to the boiler plant.

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AALBORG STEAM ATOMISING BURNER OM5580#01.0
INDUSTRIES
If any unexpected plant behaviour, deterioration or similar event should occur giving
rise to any reasonable doubt as to the continued safety of the plant, the matter should
be reported at once to Aalborg Industries for their advice.
1.2 Qualified personnel ·
Qualified personnel according to these operating instructions are persons, who are
confident in installing, regulating and commissioning the burner, and who have
qualifications to carry out this work, i.e.:
• Persons who are trained to operate electric circuits and units according to the
safety standards.
• Persons who are qualified in the use of dangerous fuel according to the relevant
laws and regulations.

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AALBORG HANDLING FUEL OIL OM9280#02.0
INDUSTRIES
Handling fuel oil
1 Precautions to be taken with fuel oil
Fuel oil is usually the residue of crude oil after the removal by distillation of the
most volatile oils and gasses. Fuel oil in its liquid state is very difficult to ignite in
bulk and not capable of spontaneous combustion. However, the vapour is explosive
when mixed with air, and being heavier than air, it tends to accumulate in low levels
such as bilges and bottoms of tanks where it may remain undiscovered until ignited
by a naked light or spark. It is always present in a partly filled oil tank or in a tank
which has contained fuel oil and is given off through the vents from tanks in the
process of being filled.
If allowed to continue, a leak in any part of the oil burning system may result in an
accumulation ofthis explosive vapour.
Ignition of the vapour can be caused by an open light, electric spark, smoking, spark
caused by striking metal, heat from the filament of a broken electric lamp, sparks
from funnel or can be communicated from galley or fires under boilers.
Note: An oil fire cannot be extinguished by water, but may be extinguished by

sand, steam or chemical fire extinguishers.
An intelligent appreciation of the properties of fuel oil as described above is a better

prevention of accident than adherence to any set of rules that may be pre-described.
However, the following detailed precautions should be rigidly enforced:
• When oil is being received, no naked light or electric apparatus liable to spark
should be permitted within 20 meters of the oil hose, tank or compartment,
containing the tank or the vent from the tank, except when special arrangements
are carried out.
• While receiving fuel oil, the storage tank must be closely watched for leaks, and
care must be taken that all outlets from the tank, except the vents, are closed.
• No naked lights or electric apparatus liable to spark should be permitted at any
time in a compartment containing a fuel oil tank. Electric lamps used in such
compartments should have a wire protector around the bulb or be of a type that
will ensure the breaking of a circuit through the lamp in the event of the lamp
being broken.
• No one should be allowed to enter a fuel oil tank until it has been gas-freed, and
any person then entering the tank must have a properly tended life line around
his body in order to be hauled out if overcome by gas.
• Electric fuses and switches, unless the enclosed type, should not be permitted in
compartments containing fuel oil pumps or piping.
• Care must be taken that the wire-gauze protectors in vent pipes from fuel oil
tanks are intact at all times.

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AALBORG HANDLING FUEL OIL OM9280#02.0
INDUSTRIES
• Dampers, where fitted in the uptakes of the boilers, must be kept fully open
while burning oil. Otherwise, this may result in dangerous accumulation of gas
in the furnace with a resultant blowing out into the boiler or engine room.
• The valves on glass gauges in fuel oil storage or settling tanks should be kept
habitultllY shut. When a reading of the gauge is desired, the valves may be
opened, but must be shut again at once.
• In each boiler or engine room fitted for oil burning there should be fire
extinguishing apparatus in accordance with the requirements/rules from the
authorities and classification societies in question such as, e.g.: Fire hose,
permanently coupled and of sufficient length to reach all parts of the boiler or
engine room, and either:
(a) a box containing at least 85 litres (2 cubic ft) of dry sand with a large scoop
(b) a chemical fire extinguisher of the tank type
• When the fuel oil system has not been in use for a long period, or after joints in
the piping have been re-made, the system should be tested "cold" under a
pressure at least equal to the working pressure before fires are ignited. During
the test a careful inspection for leaks should be carried out.
• Fuel oil should not be habitually heated above 65°C for light oils and l20°C for
heavy oils and never above its flash point in any part of the system except in the
burners.
• Care must be taken to prevent accumulation of oil or vapour in any place outside
the system and in ships particularly in bilges under the furnace. This can be
accomplished by rigid cleanliness.

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AALBORG IGNITION BURNER OM5580#22.2
INDUSTRIES
Ignition burner
1 General description
The ignition burner is a separate diesel oil burner with its own oil supply system. It
operates on the principle of mechanical pressure jet atomisation. The ignition burner
is retractable and inserted/drawn back by an air servo cylinder. Both in automatic
and emergency operation mode the ignition burner is fully automatic. An illustration
of the ignition burner is shown in Figure 1.
The ignition system always operates on diesel oil whether the steam atomising
burner operates on diesel oil or heavy fuel oil. This secures a reliable ignition. The
diesel oil is supplied by an ignition oil pump, which only operates in ignition mode.
The pump pressure should be set to 8-10 bar.
The combustion air to the ignition burner is supplied from the compressed air
system and can be adjusted by means of the throttle valve placed after the solenoid.
At the end of the furnace purge period, the solenoid valves for diesel oil and
combustion air open, and the diesel oil flame is ignited by an electric spark between
two electrodes which are connected to a high voltage ignition transformer. The
ignition burner is simultaneously moved into ignition position. The ignition burner
must ignite the main burner within the present ignition period. At the end of the
ignition period, the solenoid valves are closed, and the ignition burner is purged by·
compressed air through the solenoid valve in the purge air inlet. After the purge
period the ignition burner is drawn back.
1.1 Commissioning
During commissioning the position of the nozzle and the electrodes should be
checked and adjusted if necessary (see Figure 1).
1.2 Maintenance
As the ignition burner is one of the most exposed components, it needs frequent
inspection and maintenance.
• The electrodes should be cleaned, and the insulation material checked for
damages.
• The nozzle should be checked and cleaned. If the spray pattern hits other parts
of the ignition burner despite cleaning it, the nozzle should be changed.
Note: Be careful not to change position of electrodes as this may cause, e.g.
ignition problems, instability or build-up of carbon deposit.

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AALBORG IGNITION BURNER OM5580#22.2
INDUSTRIES
lllustration of the ignition burner

Air servo cylinder
Hose for air servo cylinder
Hose for air servo cylinder (up)
Hose for purge air
Throtlle valve for Caps for

Hose for diesel oil electrodes
combustion air
Flame scanner
ignition burner
Hose for
combustion air
Range at wind box

Diesel oil inlet
Ignition burner
Ignition electrodes
Nozzle
10-12 mm
Figure 1 igniburnkbsd2.cdr

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AALBORG PHOTO CELL OM8630#01.0
INDUSTRIES
Photo cell
1 Description
The RAR7 detector is used for supervision of yellow burning oil flames. Ifthe photo
cell detects a missing flame, the burner stops instantaneously. It is not possible to
start the burner before the control system has been reset.
With this type of detector, the radiation of the oil flame in the visible band of the
light spectrum is used to generate a flame signal. The light-sensitive element is a
selenium photo cell. When illuminated, it generates DC voltage which causes a
current to flow to the input of the flame signal amplifier in the control unit. Hence,
the selenium photo cell is an active detector.
The cell is insensitive to infrared radiation. If the burner is started with an
illuminated combustion chamber, e.g. due to glowing firebrick, the start sequence of
the burner commences, but an alarm for flame failure will be indicated.
The number of photo cells for automatic operation and emergency operation depend
on the classification society.
1.1 Commissioning
The intensity of the light radiation can be checked by measuring the detector current
by means of a DC ammeter (internal resistance 5000 W). Figure 1 shows the
measuring circuit. The photo cell is adjusted by changing the position in proportion
to the oil flame in order to obtain the maximum detector current.
Note: If the wiring of the photo cell is connected incorrectly, it is not possible to
start the oil burner.
Measuring circuit
9 10 LAE10
22 24 LAL 2... , LOK16...
Ammeter
connection
~: !LA DC
RAR7
+
//
Figure 1 photcirc.cdr

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AALBORG BURNER LANCE OM5580#35.0
'INDUSTRIES
Burner lance
The burner lance contains theY-jet atomiser in which steam and fuel are mixed and
ejected into the furnace. An illustration of the burner lance is shown in Figure 1.
During normal start, the burner lance is purged with atomising steam through the
steam pipe line. This heats the burner lance and makes ignition of the main flame
more reliable. During normal stop, the oil pipe is purged with steam. By this, the
remaining fuel oil in the lance will be atomised into the furnace. The combustion air
fan, which also operates during this period, purges the furnace for the ejected
oil/steam mist.
For maintenance and inspection purposes, the lance can be extracted from the wind-
box, and the atomiser can be dismounted from the lance. This is done, by
unscrewing two Allen screws in the flange connection and unscrewing the screw
cap.
Eventually, the atomiser will be covered with a layer of carbon deposits. To remove
these deposits, paraffin or carbon remover should be used. It is also possible to use a
soft metal scraper. A hardened scraper should not be used as it could damage the
atomiser. The cleaned atomiser should then be examined for damage, and the holes
checked for wear. It should be replaced if necessary.
The 0-rings must be replaced every time the atomiser has been dismounted. Before
mounting the screw cap, the thread should be covered with an unhardening high
temperature compound.
When the burner is commissioned, the atomiser must be thoroughly cleaned before
any attempt is made to start the burner.
lllustration of the burner lance
Protection Screw cap Atomiser

Flanges
Handle
Oil
0-ring Packing
Figure 1 burnlance.cdr

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AALBORG VISCOSITY- TEMPERATURE CHART OM9280#01.1
INDUSTRIES
Viscosity- temperature chart
1 Description
The preheating temperature can be determined by means of the viscosity -

temperature chart shown in Figure 1. In order to use the chart, the viscosity of the
fuel oil must be known at a reference temperature.
It should be noted that the preheating temperature should be set somewhat higher
than the temperature shown in the chart due to the heat loss between pre-heater and
nozzle/cup.
1.1 Example
The example is based on a pressure jet burner.

Known:
Oil viscosity: 380 eSt. at 50°C
Required:
Preheating temperature in ac
Procedure to be followed:
Step A: Follow the reference temperature line at 50°C vertically down to the
intersection with the 380 eSt. viscosity line.
Step B: From this point move parallel down with the nearest fuel grade line.
Step C: When the line meets the recommended nozzle viscosity line, go vertically
up to the temperature axis.
Step D: At this point read the desired preheating temperature of 150°C.
Language UK Page l/2

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AALBORG VISCOSITY- TEMPERATURE CHART OM9280#01.1
INDUSTRIES
Viscosity - temperature chart
~~ <1l
:IS ·10
'Centigrade
30 40 60 90 100 110 120 !30 I 10 160 70
·c
18
<1l
7i
\. \. \.
115
~~ 4,000
3:soo 3,500
'\ 3,000
'\ \. \.
..
2.500
' \. ' \. 2,500
' \. 1\
\. 1\. \
'\ \.
2,000
1,500
\ \ I'\.' '\
1\.
""
'\. ·"-
1,000
900
800
700
600
500
450
400
350
300
'\. '\. '\. '\. '\. '\. '\. I'\. 250
~~ ' '[\.. "' "' "' ""-""" I

"'
200
'\. ~ ""- 150
~ " ""' "' "~ "" ~""" ·"""~ 100
~
~-~,H~
90
80
70
60
50
~
45
40
35
30
25
20
15
·~8
7
6
5
•
r--- --:-- --:-- ---t-- r-- -r---
2
28.5 I
"Fahrc:Dhcit TBMPERA111RB 'F
0 Recommended cup viscosity for rotary cup burners

(D Recommended nozzle viscosity for steam atomising burners
(D Recommended nozzle viscosity for pressure atomising burners
Figure 1 viscl.cdr

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.11.11·1·.
iii I ii
AALBORG FUEL OIL SUPPLY SYSTEM OM5580#40.3
INDUSTRIES
Fuel oil supply system
This section describes the oil system in general terms together with some of the
requirements needed to have a safe and reliable burner operation.
The burner and the oil system are designed for both diesel oil and heavy fuel oil
operation. A diagram of the oil system for steam atomising burners is shown in
Figure 1. The diagram shown is for a plant with two steam atomising burners.
The oil system consists of oil tanks for diesel oil and heavy fuel oil, mixing tube, oil
pumps, heaters, ignition oil pumps, and equipment for oil pressure and temperature
control.
Illustration of the oil system
,-·•-··-···-·+··-, Combustion r··f··············l··-,: Combustion

air tan unit ! air fan unit
!
Figure 1 F_ oilsys_ b.cdr

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INDUSTRIES
1.1 Oil tanks
The heavy fuel oil tank may be provided with a heating coil for heating up the fuel
oil in the tank to at least 50°C, at which temperature it will be possible to pump the
oil. The oil temperature in the tank should not exceed approximately 60°C in order
to keep the oil temperature controlled by the heater units.
Whenever a boiler plant is intended to operate on heavy fuel oil, all pipes carrying
fuel oil must be insulated and traced in order to keep a sufficiently low viscosity of
the oil. The tracing can be done either by means of steam heating or by means of
electric heating cables.
1.2 Fuel selection
The fuel type is selected by manually operating the three-way valve (Gll5) in the
oil system.
In an emergency case, heavy fuel oil can be taken from the heavy fuel oil settling
tank. In this case, the valve (G49) in the suction line from the mixing tube to the
pump suction side must be closed so that any return flow is led back to the heavy
fuel oil tank. In this mode, the tank temperature must be observed so that the
temperature is kept below the fuel oil flash point.
1.3 Return flow from the burner
When the burner is in stand-by mode, a minimum of fuel oil is returned via the oil
return line to the three-way valve (Gill). From here the fuel oil is either led to the
pump suction side via the mixing tube (G 11 0) for degassing or to the heavy fuel oil
settling tank. The three-way valve normally returns the fuel oil to the mixing tube.
If the fuel is changed to diesel oil or heavy fuel oil by means of the three-way valve
(G 115), the three-way valve (G 111) automatically changes position and returns the
oil to the heavy fuel oil settling tank for a period of time.
The three-way valve is a pneumatically operated actuator controlled by a solenoid
valve (G 113). The solenoid valve has a manual switch for emergency operation.
This arrangement is necessary to avoid a continuous heating of the re-circulated
diesel oil when the fuel is changed from diesel oil to heavy fuel oil. The viscosity of
the re-circulated diesel oil decreases and with it also the lubrication characteristic.
This wiii cause damage to the oil pumps.
The arrangement is also necessary when the fuel is changed from heavy fuel oil to
diesel oil because the temperature of the re-circulated heavy fuel oil will decrease
and might cause blockage of the piping system.
After the pre-set time period has expired, the three-way valve (G 111) returns to
normal position, and the fuel flows to the mixing tube ( G 11 0).
The time period must be set with regard to oil pressure and the quantity of oil in the
system.
1.4 Fuel oil supply pump
The oil system is fitted with one set of supply oil pumps common for both diesel oil
and heavy fuel oil (G05 and G 12).
The supply oil pump unit (G147) is a twin type package unit in which two screw
pumps with driving motors are connected by a switch across the valve housing. Each
pump is fitted with a pressure safety valve, a filter (G02 and G09), a mano/vacuum
gauge (G04 and G 11) at the filter, and non return valves (G07 and G 14).

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INDUSTRIES
The pumping capacities for the pumps are calculated in such a way that there will be
sufficient oil flow to the burner and the pressure regulating valve in full load
condition.
The control system receives a signal from the pressure transmitter (G99). If the
pressure drops below a pre-adjusted set point, the operating pump stops, and the
other pump starts. If the pressure continues to drop, the control system gives shut
down for low oil pressure and stops the bumer(s).
1.5 Fuel oil pressure control
A part of the fuel oil returns to the pump suction side through the oil pressure
control valve (G 100) which keeps a pre-set pressure in the fuel oil system.
The fuel oil pressure control loop includes a motorised control valve (GIOO) to
ensure the correct pressure at the fuel oil inlet of the burner. This provides larger
tum-down ratio of the oil flow regulation valve. A single loop PID-controller and a
standard 4-20 rnA pressure transmitter (G99) ensure optimum and accurate
functionality.
1.6 Pre-heater
The oil system is provided with pre-heater(s) (G22) heating the heavy fuel oil to the
correct temperature/viscosity by means of steam.
The fuel oil is changed by means ofthe manually operated three-way valve (G115).
When diesel oil is selected, the manually operated three-way valve (G51) must be in
a position which by-passes the pre-heater(s), and the stop valve(s) (G25) must be
closed. When heavy fuel oil is selected, the stop valve(s) (G25) must be opened, and
the manually operated three-way valve (G51) must be in a position in which the oil
flows through the pre-heater(s).
1.7 Fuel oil temperature control
The heavy fuel oil temperature after the pre-heater(s) is kept precisely at the desired
value by means of a motorised flow control valve (G20), a single loop PID-
controller, and a Ptl 00 temperature transmitter (G28).
1.8 Ignition oil system
The ignition system always operates on diesel oil whether the steam atomising
burner operates on diesel oil or heavy fuel oil. This secures a reliable ignition.
The diesel oil is supplied by an ignition oil pump (G72) with filter (G70). The pump
is only operated in ignition mode. The ignition oil pump is a gear pump fitted with a
pressure limiting valve and a filter inside the housing. The pump should be set to 8-
10 bar.
A plant with two boilers is provided with two ignition oil pumps. If a pump fails, the
other can be selected to supply diesel oil for the ignition to both burners.

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AALBORG BURNER SUPPLY SYSTEMS OM5580#45.4
INDUSTRIES
Burner supply systems
This section describes the burner supply systems in general terms together with
some of the requirements needed to have a safe and reliable burner operation.
The burner and the oil system are designed for both diesel oil and heavy fuel oil
operation. An illustration of the burner supply systems for the steam atomising
burner(s) is shown in Figure 1.
The burner supply systems consist of a fuel oil system, a steam atomising system, a
combustion air system, an ignition system, and a compressed air system.
Illustration of the KBSD burner
. _ _ - - - - - - - - - - ·¢ Condensate
Furnace pressure
Figure 1 burnoilsy_ d.cdr

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INDUSTRIES
1.1 Fuel oil system
From the pre-heater(s) or the pre-heater by-pass line, fuel oil flows through the
three-way valve (F99), the flow meter (FlOO), and the oil flow regulation valve
(F94) to the pneumatic three-way shut-off valve (F75). From this point, the fuel oil
either returns to the fuel oil supply system (burner stopped) via stop valve (F93) or
to the burner lance (burner in operation) via the pneumatic shut-off valve (F67) and
the stop valve (F64). All pipes are traced to avoid blockage ofHFO.
Both the fuel oil and the atomising medium are supplied from the stop valves (F41
and F64) through flexible hoses to the burner lance.
The burner lance contains theY-jet atomiser where steam and fuel are mixed and
ejected. This oil mist is then mixed with combustion air, and the combustion is
completed.
The burner load is controlled by the control system, which receives a continuous
signal from a steam pressure transmitter. This signal is compared to different set
points, feed back signals, and parameters in the control system. The output from the
control system is used to control the oil regulation valve (F94), which is
pneumatically operated by an liP positioner. To obtain a very accurate regulation of
the oil, which is very important to have a large tum-down ratio, the valve is also
fitted with an adjustable Cv-adjuster.
The signal from the pressure transmitter together with feed back signals from the oil
flow meter and the differential pressure transmitter for combustion air are handled in
the control system to obtain a correct combustion with regard to air/oil ratio and
atomising steam pressure.
When the burner is in ignition position, minimum position, maximum position, etc.
the air/oil flow is fixed by settings in the control system.
Furthermore, the control system is designed to prevent poor combustion (black
smoke), which may arise during start-up, stop, and load alterations.
The oil pressure is of little importance to the atomisation quality as the oil flow
regulation is based on flow measurements. As a consequence of this, the atomisation
quality does not vary over the burner tum down range.
1.2 Steam atomising system
From the boiler drum, the atomising steam flows through the steam regulating valve
(F91), the pneumatic shut-off valve (F42), and the stop valve (F41) to the burner
lance. The steam pressure is controlled by the regulating valve (F91). The steam
pressure is kept at a constant level at high burner load, but at lower burner loads, the
steam pressure is reduced by the control system. A single loop Pill-controller with
external set point and a standard 4-20 rnA pressure transmitter ensure optimum and
accurate functionality. The external set point is related to the fuel oil flow and
changes together with this, making regulation more optimal.
During normal stop of the burner, the lance is purged with steam. The pneumatic
shut-off valve (F44) opens, and the remaining fuel oil in the lance will be atomised
into the furnace. The combustion air fan, which also operates during this period,
purges the furnace for the unburned ejected oiVsteam mist. The valve F44 is closed
after the end of the purge period.
Atomising steam is supplied from the steam system via the stop valve (F92).
Compressed air can also be used as atomising medium (e.g. at start-up) and is
supplied via the stop valve (F87). Compressed air for atomising should only be used
if steam is not available.

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IND.USTRIES
1.3 Combustion air system
The combustion air fan draws air from the engine room through the inlet vanes. The
inlet vanes regulate the necessary air flow for the combustion by means of an air
cylinder and an liP positioner. The liP positioner receives a 4-20 rnA signal from the
control system.
From the fan discharge side, the combustion air flows through the air duct into the
burner wind box. From here the combustion air is distributed to the burner register,
the swirlers/flame stabiliser, and the furnace through the radially fixed guide vanes
to ensure a uniform air flow.
The draft loss across the burner is measured by a differential pressure transmitter,
which converts the signal to a flow signal used by the control system for automatic
air/oil ratio control.
1.4 Ignition system
The ignition burner is a separate diesel oil burner with its own oil supply system
which operates on the principle of mechanical pressure jet atomisation. The ignition
burner is retractable and inserted/retracted by an air servo cylinder. The diesel oil
flame is ignited by an electric spark between two electrodes which are connected to
a high voltage ignition transformer. The combustion air to the ignition burner is
supplied from the compressed air system.
At the end of the furnace purge period, the solenoid valves (Fl8, Fl9, and F153)
open, and the ignition burner is ignited and inserted.
The ignition burner must ignite the main burner within the present ignition period.
At the end of the ignition period, the solenoid valves (F18and F19) to the ignition
burner are closed, and the ignition burner is purged by compressed air through the
solenoid valve (F78) and the non-return valve (F77). After the purge period the
ignition burner is retracted.
1.5 Compressed air system
The compressed air system consists of four systems which operate with different
pressures. The air system for atomising is a separate system, which includes the stop
valve (F87) and the non return valve (F 108).
The air system for the ignition oil burner comprises the stop valve (F73), the throttle
valve (F152), the solenoid valves (F78 and F153), and the non return valve (F77).
The air system for control of the pneumatic shut-off valves consists of the air
filter/reduction unit (F63), the solenoid valves (F61, F65, F56, and F59), and the
pneumatic actuators (F60, F66, F57, and F58). These components are used for the
three-way shut-off valve (F75), the shut-off valve (F67), the shut-off valve (F42),
and the shut-off valve (F44) respectively.
The air system for the oil flow control includes the air filter/reduction units (F96 and
F97), the liP converter (F95), and connections to the oil flow regulating valve (F94 ).
Note: liP converters and/or positioners must be supplied with instrument air.

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AALBORG COMMISSIONING OM5580#50.6
INDUSTRIES
Commissioning
1 General
The following commissioning instructions are valid for steam atomising burners
type KBSD with Y-atomisers and with a standard delivery of individual parts for the
burner unit and supply systems from AALBORG INDUSTRIES.
Prior to the commissioning, the instructions for the individual parts of the burner
unit and supply systems should be studied. The special instructions for the boiler and
the control system should also be consulted. The instructions should only be
considered as a guideline. This is due to the fact that each plant should be
commissioned individually to obtain the best burner performance for the specific
plant.
Attention: If the burner unit and supply systems include parts, which are not
standard delivery from AALBORG INDUSTRIES, the specific
instructions for these parts should be ignored in the following
sections. The actual instructions for the specific parts should. be
thoroughly studied and followed during commissioning.
During commissioning of the burner unit and supply systems, it might be necessary
to adjust some regulation parameters, timer settings, etc. in the control system to
optimise the function of the plant. These adjustments are not described in the
following sections, but should be carried out as the optimisation requirements
emerge. Please see the instructions for the control system.
1.1 Pre-service checks
Before commissioning, the following work steps must be carried out:

Step A: Check that the boiler is ready for operation according to the special
instructions for the boiler
Step B: Increase or decrease the water level in the boiler to approximately 50 mm

below normal water level.
Step C: Check the electric wiring.
Step D: Switch on the power for the boiler plant and reset the system on the local
panel or the computer.
Step E: Check that the control system is operational according to the special
instructions for the control system.
Step F: Pre-adjust the pressure switch and pressure transmitter set points for boiler
operation.

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INDUSTRIES
The position numbers mentioned in the following sections refer to the illustrations in
Figure 1 and Figure 2. The position numbers consist of an identification letter and a
position number code. Position numbers with the identification letters "G and R"
refer to Figure 1, and position numbers with the identification letter "F" refer to
Figure 2. The oil system is shown as a plant with two boilers, but is also valid for a
plant with only one boiler.
lllustration of the oil system
Combustion ,··+·-···-··--i·-, Combustion

air fan unit air fan unit
Figure 1 F_oilsysl b.cdr

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IND USTRIES
Illustration of the burner unit and supply systems

F17
F1
.___ _ _ _ _ _ _ _ _ _ _ ,::J Condensate
Figure 2 Burnoilsyld.cdr
2 Commissioning
2.1 Commissioning adjustments of the burner unit
On delivery from Aalborg Industries, the burner unit has been pre-adjusted to fit the
task. Even though the burner unit has been pre-adjusted, it is advisable to carry out
additional checks during commissioning. These checks should be carried out with
regard to adjustment of the atomiser and swirlers/flame stabiliser, and ignition
electrodes, etc. This means that it is necessary to pull out the burner lance, swirlers
/flame stabiliser, and ignition burner.

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INDUSTRIES
2.1.1 Dismantling
Step A: Remove the flame scanners.
Step B: Close the stop valves (F41 and F64).
Step C: Dismount the flexible hoses for fuel oil and atomising steam to the burner
lance.
Step D: Dismount the flexible hose for combustion air to the ignition burner.
Step E: Dismount the flexible hoses for ignition oil and purge air to the ignition
burner.
Step F: Dismount the flexible hoses for the air servo cylinder on the ignition burner.
Step G: Dismount the cable for the magnetic switch on the ignition burner.
Step H: Remove the two spark plug caps from the ignition burner.
Step 1: Note the position of the front plate and unscrew the bolts from the front
plate.
Step J: Lift up the front plate in the lifting eyes including the burner lance, swirlers
/flame stabiliser, and ignition burner by means of a tackle. Be careful not to
damage the packing between the wind-box and front plate.
2.1.2 Adjustment of atomiser and swirlers distance (small size burners)
Attention: This section is only valid for burners equipped with primary and
secondary swirlers. For burners with flame stabiliser please see
section 2.1.3.
Step A: Check the distance between the atomiser tip and the inner ring of the
primary swirler. The factory setting is 25 mm. Adjust if necessary.
Note: An exact distance cannot be given, but has to be determined when the
burner is in operation. H the flame has a tendency to pulsate at low
loads, it might be necessary to readjust the distance.
Step B: Loosen the bolt, which fixes the primary swirler to the burner lance
protection tube. Adjust the primary swirler to the desired position, and
tighten the bolt again.
Step C: Loosen the bolt, which fixes the secondary swirler to the burner lance
protection tube. Adjust the secondary swirler into a position in which the
inner ring of the secondary swirler and the outer ring of the primary swirler
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INDUSTRIES
are at the same level. Tighten the bolt again. This corresponds to an equal
movement of the secondruy swirler to the same numerical distance as the
primruy swirler movement. Tighten the bolt again.
Step D: Loosen the bolt, which fixes the burner lance protection tube to the front
plate. Adjust the protection tube into a position in which the outer ring of
the secondruy swirler and the beginning of the quart (burner cone) are at the
same level. This corresponds to an opposite movement of the protection
tube to the same numerical distance as the swirlers movement. Tighten the
bolt again.
Step E: If an adjustment is carried out, loosen the fixing screws that hold the air
servo cylinder of the ignition burner. Move it in the same direction and to
the same numerical distance as the primruy swirler movement. The factory
setting between the ignition burner and the primary swirler is 5 mm.
Tighten the fixing screws again.
2.1.3 Adjustment of atomiser and flame stabiliser distance (large size burners)
Attention: This section is only valid for burners equipped with flame stabiliser.
For burners with swirlers please see section 2.1.2.
Step A: Check the distance between the atomiser tip and the inner ring of the flame
stabiliser. The factory setting is 25 mm. Adjust if necessary.
Note: An exact distance cannot be given, but has to be determined when the
burner is in operation. If the .flame has a tendency to pulsate at low
loads, it might be necessary to readjust the distance.
Step B: Loosen the bolt, which fixes the flame stabiliser to the burner lance
protection tube. Adjust the flame stabiliser to the desired position, and
tighten the bolt again.
Step C: Loosen the bolt, which fixes the burner lance protection tube to the front
plate. Adjust the protection tube into a position in which the front of the
flame stabiliser and the beginning of the quart (burner cone) are at the same
level. This corresponds to an opposite movement of the protection tube to
the same numerical distance as the flame stabiliser movement. Tighten the
bolt again.
Step D: If an adjustment is carried out, loosen the fixing screws that hold the air
servo cylinder of the ignition burner. Move it in the same direction and to
the same numerical distance as the flame stabiliser movement. The factory
setting between the ignition burner and the flame stabiliser is 5 mm.
Tighten the fixing screws again.

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INDUSTRIES
2.1.4 Adjustment of the ignition burner
Step A: Check the position of the oil nozzle for the ignition burner. The oil nozzle
tip should be at the same level as the end of the ignition burner mixing tube.
Adjust if necessary.
Step B: Check the position of the ignition electrodes. The ignition electrodes should
be 10-12 mm in front of the atomiser tip and 8-12 mm above the atomiser
tip. The distance between the electrodes should be adjusted to 4 mm. Adjust
if necessary.
Note: An exact setting of the ignition electrodes cannot be given, but has to be
established when the ignition burner is in operation.
Step C: Unscrew the two screws that fix the mixing tube to the electrode holder and
pull out the mixing tube.
Step D: Loosen the centre screw that fixes the oil supply pipe and adjust to the
desired position. Tighten the centre screw again.
Step E: Dismount the oil nozzle from the oil supply pipe and check that the nozzle
is clean. Assemble after check/cleaning.
Step F: Loosen the two Allen screws that ftx the ignition electrodes and adjust to
the desired position. Tighten the Allen screws again.
Step G: Assemble the electrode holder and the mixing tube. Screw in the two
screws on the mixing tube.
2.1.5 Measurements
Step A: Before the burner unit is assembled, check and note the commissioning
measurements. The obtained measurements should be inserted in the
chapter "Measurement and settings".
2.1.6 Assembling
Step A: Check the condition of the packing between the wind-box and the front
plate. Replace ifnecessary.
Step B: Mount the front plate including the burner lance, swirlers/flame stabiliser,
and ignition burner onto the wind-box. The front plate should be mounted
in the same position as before.
Step C: Screw in the bolts on the front plate. The nuts must be tightened crosswise.
Step D: Mount the flexible hose for combustion air to the ignition burner.
Step E: Mount the flexible hoses for ignition oil and purge air to the ignition burner.

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I N D U S T. R I E S .·
Step F: Mount the flexible hoses for the air servo cylinder on the ignition burner.
Step G: Mount the cable for the magnetic switch on the ignition burner.
Step H: Mount the two spark plug caps on the ignition burner.
Step 1: Insert the flame scanners.
2.1.7 Clean the burner lance and atomiser
Step A: Unscrew the two Allen screws on the burner lance flange and pull out the
burner lance.
Step B: Dismount the atomiser and screw cap from the burner lance and check that
the lance is clean.
Step C: Clean the atomiser and screw cap. The factory has greased the atomiser to
protect it from corrosion.
Step D: Replace the two 0-rings on the atomiser and assemble the atomiser, screw
cap, and burner lance.
Step E: Insert the burner lance into the protection tube and screw in the two Allen
screws into the flange connection.
Step F: Mount the flexible hoses for fuel oil and atomising steam to the burner
lance.
2.2 Commissioning of the oil system
When the oil system is commissioned, it should initially be flushed by means of an

external pumping system. This must be done to ensure that the oil system is not
clogged-up and to prevent foreign objects from entering the pump unit which might
cause damage.
On delivery the oil system of the burner unit is by-passed by means of the three-way
valve (F99). This prevents foreign objects from entering the flow meter, oil flow
regulation valve, etc. The position of the valve should not be changed before
flushing of the oil system is completed. The valve is locked in this position by
means of a screw.
Warning: When the oil system is commissioned on diesel oil, the tracing of the
piping system must be off.
2.2.1 Commissioning
Step A: Check that oil is present in the diesel oil tank. Open the quick closing valve
(G94), which connects the diesel oil tank to the oil system.

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INDUSTRIES
Step B: Select diesel oil on the manually operated three-way valve (G115). Check
that the local panel and computer indicate diesel oil operation. Open the
stop valve (G49) for the mixing tube.
Step C: Tum the manually operated three-way valve (G24 7) for oil flow through
both pumps.
Step D: Open the stop valves for the pressure gauges (G04, Gll, G16, and G47).
Note: The stop valves for the pressure gauges on the pump unit should only be
opened for pressure control purposes. The stop valves should be closed
during normal operation.
Step E: Close the stop valves (G97 and G101), and slightly open the by-pass valve
(G102).
Step F: By-pass the pre-heaters by means of the manually operated three-way valve
(G51 ), and close the stop valves (G25 and G26) for both pre-heaters.
Step G: Open the stop valves for the pressure gauge (G44) and the pressure
transmitter (G99).
Step H: Check that the three-way valve (F99) is locked in a position which by-
passes the oil system of the burner unit.
Step 1: Apply air to the pneumatic three-way valve (G 111 ). Adjust the air pressure
to 5-10 barg on the air filter/reduction unit (Gll4).
Step J: Check the position of the pneumatic three-way valve (G 111 ). In normal
position, the return oil is led to the mixing tube. The micro switch box
mounted on the valve and the control system should also indicate this
position.
Note: When the fuel is changed by means of the three-way valve (Gl15), the
three-way valve (Glll) automatically changes position and returns the
fuel oil to the heavy fuel oil settling tank for a period of time. This time
period is set in the control system.
Step K: Rotate the oil pumps by hand to ensure a free and an uninterrupted rotation.
Step L: Adjust the circuit breakers for both pumps to suit full load current of the
motors. The current appears from the motor identification plate and/or the
electric diagrams.
Step M: The oil pumps must be filled with diesel oil prior to operation. The vent
valve installed on the outlet side of the pump unit must be opened until the
air has escaped from the suction side of the pump. As soon as diesel oil
emerges, the vent valve may be closed.

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2.2.2 Flushing the oil system
Step A: Set the burner into manual operation mode on the local panel or the
computer.
Step B: Start one of the oil pumps and check that it is running with the correct
direction of rotation. Open the vent valve again until only diesel oil
emerges.
Step C: Immediately adjust the oil pressure to a suitable level on the by-pass valve
(G 102). At the first start up, each pump must run for minimum 5 minutes at
a differential pressure of approx. 20 bar to ensure an adequate flushing of
the mechanical seal chamber. Thereafter the pressure can be reduced to 5
bar to avoid excessive over-heating during continuous flushing of the oil
system.
Step D: Stop the pump and start the other oil pump. Perform the same check and
venting procedures.
Note: The pressure relief valve installed in each pump is factory set and
checked and should not be adjusted during commissioning.
Step E: Flush the oil system for a few hours with one oil pump in operation. The
total flushing time should be determined with regard to the size of the oil
system and the amount of impurities (particles, grease, etc.). Check the
complete oil system for leaks.
Step F: Close the stop valves (G53, G54, and G109). These valves must be kept
closed during the complete flushing period.
Step G: After 114 of the pre-determined flushing period, open the stop valves (G25
and G26) for one of the pre-heaters. Tum the three-way valve (G51) for oil
flow through the pre-heaters.
Note: The set points for the pre-heater safety valves are factory set and
checked and should not be adjusted during commissioning.
Step H: After 112 of the pre-determined flushing period, open the stop valves (G25
and G26) for the other pre-heater. Close the stop valves (G25 and G26) for
the frrst pre-heater.
Step 1: After 3/4 of the pre-determined flushing period, stop the operational oil
pump.
Step J: By-pass the pre-heaters by means of the manually operated three-way valve
(G51 ), and close the stop valves (G25 and G26) for both pre-heaters.

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INDUSTRIES
Step K: Commission the oil pressure regulating valve (G100). Set the valve into
manual mode on the local panel or computer.
Step L: Move the actuator mounted on the valve into mid-stroke position by means
of the hand wheel. By use of the local panel, apply short impulses in each
direction of the movement and check that the directions of movement are
correct.
Step M: Set the oil pressure regulating valve (G 100) into automatic mode on the
local panel or computer again. Move the actuator to the end positions
(open/closed) by means of the digital output test menu in the local panel.
Check that it is switched off automatically. Check that external moving
parts are able to move without obstruction.
Note: In a double boiler plant one of the local panels must be switched off
when the digital output test menu is used. Otherwise the valve moves
continuously up and down because one panel sends up signals, and the
other sends down signals.
Step N: Open the stop valves (G97 and G101), and close the by-pass valve (G102).
Step 0: Adjust the set point to be 20-25 bar measured at the burner inlet flange.
Note: An exact value cannot be given. If the pressure loss in the actual oil
system is high, the oil pressure must be set at a higher level to ensure
that the burner receives a sufficient amount of oil. H, on the other hand,
the pressure loss is low, the oil pressure must be set at a lower level to
ensure that the oil flow regulation valve is operating within a suitable
range.
Step P: Start one of the oil pumps for fmal flushing.
Step Q: When flushing is completed, stop the operational oil pump and clean the oil
filters in the fuel oil supply pump unit. Vent the oil pumps after the filters
have been cleaned.
Step R: Commission the steam regulating valve (G20) as described for the oil
pressure regulating valve (G 100).
Step S: Open the stop valves (G53, G54).
2.2.3 Check and adjust the pressure transmitter
Step A: Check that the oil pressure indicated on the local panel and computer is
identical to the pressure indicated on the pressure gauge (G44).
Step B: Adjust the range of the pressure transmitter (G99) in the calibration menu of
the local panel if necessary.

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INDUSTRIES
Note: H the pressure transmitter (G99) and pressure gauge (G44) are mounted
at different height levels and far apart, the pressure loss resulting from
height difference and friction should be taken into consideration.
2.2.4 Check the low alarm and start of stand-by oil pump function
Step A: Adjust the set point for low alarm and start of the stand-by oil pump on the
local panel or the computer.
Step B: Start one of the oil pumps and set the other pump into stand-by mode.
Step C: Set the oil pressure regulating valve (G 100) into manual mode on the local
panel or computer and decrease the pressure gradually until the set point is
reached. The operating oil pump should stop, and the pump in stand-by
mode should start. The local panel and the computer should indicate a low
alarm. Readjust if necessary.
Step D: Switch operation mode of the pumps and carry out the same procedure.
2.2.5 Check the low oil pressure shut down and trip function
Step A: Adjust the set point for low shut down and trip on the local panel or the
computer.
Step B: Decrease the pressure somewhat until the set point is reached. The
operating stand-by pump should stop, and a shut down should be indicated
on the local panel and the computer. Readjust if necessary.
Step C: Set the oil pressure regulating valve (GlOO) into automatic mode and reset
the shut downs.
2.2.6 Check the trip function for overload
Step A: Check the trip function for overload by pressing the test button for the
pump in operation on the circuit breaker.
Step B: The pump stops, and a shut down for pump failure should be indicated on
the local panel and the computer.
Step C: When the stand-by pump is started, perform the same test with this pump.
Step D: Reset the circuit breakers and all shut downs after testing.
2.2. 7 Commissioning of the oil system on the burner unit
Step A: Check that the oil pumps are stopped.
Step B: Open the stop valves for the pressure gauge (F68).

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Step C: Unscrew the screw that locks the position of the three-way valve (F99).
Tum the three-way valve for oil flow through the burner unit. Lock the
valve in this position. Open the stop valve (F93).
Step D: Apply air to the pneumatic shut-off valves (F42, F44, and F67) and the
pneumatic three-way shut-off valve (F75). Adjust the air pressure to 5-10
barg on the air filter/reduction unit (F63).
Step E: Check the position of the pneumatic three-way shut-off valve (F75) and the
pneumatic shut-off valve (F67). The valves must be in position closed
which means that the oil is led back to the oil system. When the micro
switches on the valves (F67 and F75) are activated, the position is indicated
on the local panel and computer.
Step F: Commission the oil flow meter (F 100). Check that the oil flow meter and
pick-up sensor are installed correctly. The flow meter equipment sends a
continuous pulse signal to the control system. This signal must be converted
into an analogous flow by settings in the control system.
Step G: Set the values for max. oil and beats/litre in the local panel or computer.
The max. oil value is the maximum oil flow in 1/h at 100% burner load on
heavy fuel oil. The value for beats/litre can be taken from the identification
of the oil flow meter.
Step H: Unscrew the pick-up sensor from the oil flow meter.
Step 1: Tap the pick-up sensor quickly against an object and check that it records the
signals. The red LED flashes.
Step J: Mount the pick-up sensor again.
Step K: Check and adjust the oil flow settings for minimum load, ignition load, etc.
in the local panel or computer.
Step L: Commission the oil flow regulation valve (F94 ). Check that the output
signal range from the liP converter (F95) corresponds to the instrument
input signal range on the oil flow regulation valve (F94). The pressures
appear from the identification plates.
Step M: Disassemble the cover of the oil flow regulation valve by unscrewing two
cover screws and lift up the cover. See also the specified instruction for the
oil flow regulation valve.
Step N: Check and adjust Cv (valve characteristic) to fit the plug and seat ring by
moving the adjustment knob along the Cv scale. Table 1 shows the Cv
setting for each burner size.

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Table 1
Step 0: Apply air to the liP converter (F95). Adjust the air pressure on the
filter/reduction unit (F96). The pressure setting appears from the
identification plate on the converter.
Step P: Apply supply air to the oil flow regulation valve (F94 ). Adjust the air
pressure on the filter/reduction unit (F97). The pressure setting appears
from the identification plate on the valve.
Step Q: Set the oil flow into manual mode on the local panel or computer.
Step R: Set the regulation output to 0% (4 rnA) by means of the soft keys on the
local panel or by settings on the computer.
Step S: Adjust the pressure indicated on the instrument gauge to the low input
signal range, by means of the zero adjustment screw on the liP converter.
The instrument gauge is the left pressure gauge on the oil flow regulation
valve, and the low input signal range appears from the identification plate.
Step T: Set the regulation output to 100% (20 rnA) by means of the soft keys on the
Step U: Adjust the pressure indicated on the output gauge to the high input signal
range, by means of the span adjustment screw on the liP converter. The
output gauge is the right pressure gauge on the oil flow regulation valve,
and the high input signal range appears from the identification plate.
Step V: Repeat the work steps "S", "T", and "U" several times until the adjustments
are acceptable.
Step W: Set the oil flow regulation valve into automatic mode on the local panel or
computer.
Step X: Start one of the oil pumps. Set the stand-by oil flow to 0% in the local panel
or computer.

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Step Y: Adjust the tum take-up screw of the oil flow regulation valve until the
piston rod just begins to move. The local panel and computer must indicate
0% oil flow. Tighten with the lock nut.
Step Z: Set the stand-by oil flow back to the original set point.
2.3 Commissioning of the ignition oil system
When the ignition oil pumps are commissioned, the burner should be operated in
emergency mode. This is because the ignition oil pumps only operate in the ignition
sequence during burner start, and a number of start/stop operations are necessary to
check and adjust the system.
2.3.1 Commissioning
Step A: Tum the key placed inside the local control panel into emergency operation.
Step B: Check that the quick closing valve (G94) is open and open the stop valves
(G69 and G77).
Step C: Open the stop valve for the pressure gauge (G75).
Note: The stop valve for the pressure gauge should only be opened for pressure
control purposes. The stop valve should be closed during normal
operation.
Step D: Close the stop valve (F17) on the burner unit.
Step E: Rotate the ignition oil pump by hand to ensure a free and an uninterrupted
rotation.
Step F: Adjust the circuit breaker for the ignition oil pump to suit full load current
of the motor. The current appears from the motor identification plate and/or
the electric diagrams.
Step G: When the ignition oil pump is commissioned, the pump and the pipe system
must be filled with diesel oil and ventilated. The vent valve installed in the
pump must be opened until the air has escaped. As soon as diesel oil
emerges, the vent valve may be closed.
Step H: Press the ignition button on the emergency panel for the pump, and keep it
pressed.
Caution: The ignition oil pump should only be operated for a limited period of
time during the foUowing commissioning procedure. Due to a
continuous re-circulation, the diesel oil is eventually heated. This
could damage the pump due to the low viscosity of the heated diesel
oil.

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Step 1: Check that it is running with the correct direction of rotation. Open the vent
valve again until only diesel oil emerges.
Step J: Adjust the opening pressure on the pump to 8-10 bar.
Note: The pressure at the ignition oil burner should be approximately 8 bar.
This means that the pressure loss resulting from height difference and
friction should be taken into consideration.
Step K: Stop the pump and turn the key into automatic operation.
Step L: Open the stop valve (F17).
Note: The pressure relief valve (G78) is factory set and checked and should not
be adjusted during commissioning.
Step M: In plants with two ignition oil pumps, the previously described procedures
should be performed.
Step A: Check the trip function for overload by pressing the test button on the
circuit breaker.
Note: A shut down for ignition oil pump failure will not be indicated. H this
failure arises during normal start-up sequence, the burner will trip due
to ignition flame failure. ·
Step B: Reset the circuit breaker after testing.
2.4 Commissioning of the combustion air system
When the combustion air system is commissioned, it should be checked that the
combustion air fan and the air duct system have been installed and supported
correctly. If possible, an inside inspection of the air duct system should also be
carried out to ensure that it is free of obstacles, e.g. loose parts, insulating material,
etc.
2.4.1 Commissioning of the liP positioner
Step A: Check that the liP positioner (R16) is connected as a 2-wire system and
apply electric power to the liP positioner.
Step B: Check that the I/P positioner is in P manual mode. The display must show
"NOINIT". If this is not the case press the hand symbol key once. This key
is located behind the cover of the liP positioner.

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Step C: Apply air to the liP positioner and adjust the air pressure to 4-6 bar on the
filter/reduction unit (Rl5).
Step D: Unscrew the cover of the liP positioner. Use the push buttons AT to
carefully move the actuator and check that the mechanics is functioning.
Step E: Carry out an automatic initialisation of the liP positioner. Call configure
mode by pressing the hand symbol key (>5sec.). See the specified
instruction for the liP positioner.
Step F: Set the actuator type to linear (WAY) in the menu item "l.YFCT".
Step G: Set the rated angle of the feedback in menu item "2.YAGL". The value
should be set to 90°.
Step H: Check that the ratio selector arm is set to 90° on the liP positioner devise.
Step 1: Set the leverage (stroke range) in menu item "3.YWAY". The stroke range is
the height difference of the guide rail.
Step J: Start the automatic initialisation with the parameter value "Strt" in menu
item "4.INIT". The liP positioner then runs through the initialisation steps
"RUN 1" to "RUN 5".
Step K: Set the liP positioner into manual mode. Open and close the inlet vanes
(R07) several times by manually operating the liP positioner to demonstrate
an uninterrupted operation.
Step L: Set the liP positioner into automatic mode and mount the cover again.
Step M: Check that the micro switch, which controls the closed position of the inlet
vanes, is activated. The inlet vanes must be in closed position when the
burner is in normal stop mode. If the burner is started during normal
operation condition, and the micro switch is deactivated, a sequence failure
shut down will be indicated.
2.4.2 Commissioning of the differential pressure transmitter

It is possible to set the start of scale and full scale of the dp-transmitter even if there
is no pressure source available ("blind" calibration). Please also see the specified
instruction for the dp-transmitter.
Step A: Set the air flow into manual mode on the local panel or computer.
Step B: Set the regulation output to 0% (4 rnA) by means of the soft keys on the
Step C: Unscrew the screws that hold the protective cover of the dp-transmitter for
access to the push buttons.
Step D: Use the "M" key to select modes on the dp-transmitter. When a mode is
selected, the keys t and .J,. are used to change the mode value.

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Step E: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 12 (transition point
characteristic), 13 (value displayed), and 14 (engineering units). mm H20
can e.g. be selected as engineering units in mode 14.
Step F: Select mode 5 using the "M'' key.
Step G: Use the tor ..1- key to set the start of scale in the selected engineering unit.
If mm H 20 is selected as engineering units, then the set start of scale to 0
mmH20.
Step H: Press both the t and ..1- keys simultaneously for about 2 seconds, and the
start of scale is set to zero (in the selected engineering unit).
Step 1: Set the regulation output to 100% (20 rnA) by means of the soft keys on the
Step J: Select mode 6 using the "M" key.
Step K: Use the tor ..1- key to set the full scale in the selected engineering unit. The
full scale value should normally be set to 300 mm H 20.
Step L: Set the regulation output to 0% ( 4 rnA) again by means of the soft keys on
the local panel or by settings on the computer.
Step M: Set the air flow into automatic mode on the local panel or computer.
Step N: Mount the protective cover of the dp-transmitter again.
Important: The set range of the dp-transmitter should be checked when the
burner is in operation at 100% load on heavy fuel oil. The actual
differential pressure must not exceed or be too far below the set
range of the dp-transmitter. If this is the case, the full scale value
must be corrected. This will affect all settings made of the air/oil
ratio and they must adjusted once more.
2.4.3 Commissioning checks and operation
Step A: Rotate the combustion air fan by hand to ensure a free and an uninterrupted
rotation.
Step B: Check the electrical wiring at the terminals of the combustion air fan. The
wiring must be performed according to the wiring shown in the electrical
diagrams.
Step C: Adjust the circuit breaker for the combustion air fan to suit full load current
of the motor. The current appears from the motor identification plate and/or
the electric diagrams.

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Step D: Turn the keys placed inside the local control panel and the power panel into
emergency operation.
Step E: Close the inlet vanes by means of the potentiometer inside the local control
panel.
Step F: Start the combustion air fan (R09) on the operating switch inside the power
panel and check that it is running with the correct direction of rotation.
Step G: Check that the combustion air fan and the air duct system do not produce
any abnormal mechanical noises.
Step H: Check the combustion air fan and the air duct system for any abnormal
vibrations.
Step 1: Check the air duct system for leaks.
Step J: Open the inlet vanes for the combustion air fan fully by means of the
potentiometer.
Step K: Check the current consumption of the combustion air fan. The current must
not exceed the full load current stated on the motor identification plate
and/or the electric diagrams.
Step L: Set the combustion air fan to minimum load by means of the potentiometer.
Step M: Check the temperature of the fan bearings. The bearing temperature must
be at a constant level after approximately 30 minutes of operation. If the
temperature continues to increase, stop the combustion air fan and check
the bearings.
Step N: Close the inlet vanes for the combustion air fan by means of the
potentiometer inside the local control panel and stop the combustion air fan
on the operating switch inside the power panel.
Step 0: Turn the keys placed inside the local control panel and the power panel into
automatic operation.
Step A: Start the combustion air fan by means of the digital output test menu in the
local panel.
Note: In a double boiler plant, one of the local panels must be switched off
when the digital output test menu is used. Otherwise the fan
continuously starts and stops because one panel sends start signals, and
the other sends stop signals.
Step B: Press the test button on the circuit breaker for the combustion air fan.

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Step C: The fan stops, and a shut down for combustion air fan failure should be
indicated on the local panel and computer.
Step D: Reset the circuit breaker.
2.5 Commissioning of the steam atom ising system
In normal operation, atomising steam is supplied from the steam system. When the
burner is commissioned, atomising steam may not be available. If this is the case,
compressed air can be used as the atomising medium.
The function of the steam regulating valve can, however, be checked at this point.
2.5.1 Commissioning of the steam regulating valve
Step A: Commission the steam regulating valve (F91). Set the valve into manual
mode on the local panel or computer.
Step B: Move the actuator mounted on the valve into mid-stroke position by means
of the hand wheel. By use of the local panel, apply short impulses in each
direction of the movement and check that the directions of movement are
correct.
Step C: Set the steam regulating valve (F91) into automatic mode on the local panel
or computer again. Move the actuator to the end positions (open/closed) by
means of the digital output test menu in the local panel. Check that it is
switched off automatically. Check that external moving parts are able to
move without obstruction.
Step D: Check and adjust the pressure settings in the control system. At low loads,
the steam atomising pressure should be set to approximately 2-3 bar. The
pressure settings should be gradually increased to 6-7 bar at full load. The
fmal settings must be determined during burner operation.
Step E: Check and adjust the setting for low steam atomising pressure shut down on
the local panel or computer. The shut down function. should be checked
when the burner is in automatic operation.
2.5.2 Commissioning without atomising steam
Step A: Close the stop valve (F92), and open the stop valves (F87 and F41).
Step B: Open the stop valve for the pressure transmitter (F90).
Step C: Check that the pneumatic shut-off valve (F42) opens and closes when
signals are applied to the valve by means of the digital output test menu in
the local panel.
Step D: Open the non-return valve (F45), and check that the stop valve (F64) is
open.

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Step E: Check that the pneumatic shut-off valve (F44) opens and closes when
signals are applied to the valve by means of the digital output test menu in
the local panel.
3 Start-up
To continue the commissioning procedures, the oil system must be in normal

operation, and the atomising system must be set to compressed air operation if
atomising steam is not available. Furthermore, the ignition oil system and
combustion air system must be operational.
Prior to the actual start-up of the burner, some additional checks should be carried
out with regard to the ignition oil burner and the burner start-up sequence. When
these checks are completed, the burner should be commissioned on diesel oil and
fmally on heavy fuel oil.
Attention: Before and during start-up, the furnace must be checked with
regular intervals for oil spillage. If an oil spillage is present in the
furnace, the cause must be determined and the failure must be
rectified. The furnace should be purged until it is free of oil.
3.1 Additional commissioning checks
3.1.1 Check the ignition burner
Step A: Tum the keys placed inside the local control panel and the power panel into
emergency operation.
Step B: Close the inlet vanes of the combustion air fan (R09) by means of the
potentiometer inside the local control panel. Start the combustion air fan on
the operating switch inside the power panel.
Step C: Open the inlet vanes for the combustion air fan to approximately 15-20%
by means of the potentiometer.
Step D: Open the throttle valve {Fl52) for combustion air to the ignition burner.
Step E: Close the stop valve (F17) to the ignition burner.
Step F: Press the ignition button on the emergency panel and keep it pressed.
Step G: Check that the ignition burner is inserted.
Step H: Check the ignition spark between the electrodes. Use the inspection holes to
visually check the ignition spark. The ignition electrodes should be adjusted
if necessary.
Step 1: Release the ignition button and check that the ignition burner is drawn back
after the time period for purge has expired.

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Step J: Open the stop valves (F17 and F73).
Step K: Press the ignition button again and keep it pressed. Check that the solenoid
valves (F18, Fl9, and F153) are opened and that the ignition burner is
inserted at the same time.
Step L: Check the ignition flame. Use the inspection holes to visually check the
ignition flame. Adjust the ignition electrodes, the throttle valve for
combustion air, or the opening pressure on the ignition oil pump if
necessary.
Step M: Release the ignition button and check that the solenoid valves (Fl8, F19,
and Fl53) close.
Step N: Check that the solenoid valve (F78) opens and that the ignition burner is
purged with air.
Step 0: Check that the ignition burner is drawn back after the end of the purge
period.
StepP: Adjust the time period for purge to a suitable level on the timer placed
inside the local control panel.
Step Q: Check the ignition burner several times to ensure a reliable ignition.
Step R: Close the inlet vanes for the combustion air fan by means of the
potentiometer inside the local control panel and stop the combustion air fan
on the operating switch inside the power panel.
Step S: Turn the keys placed inside the local control panel and the power panel into
automatic operation.
3.1.2 Check the burner start-up sequence

In automatic mode, the start/stop sequences of the burner are carried out by the
control system. A condition for the initiation of the start-up sequence is that no
safety interlock shut downs are present. If a safety interlock shut down is present,
the cause must be corrected.
The following check of the start-up sequence should be carefully monitored on site
to demonstrate the correct function of the start-up sequence locally. The start
sequence is also indicated on the local panel and computer.
Step A: Close the stop valve (F64).
Step B: Check that the air damper (R07) is in closed position.
Step C: Set the burner into manual operation mode on the local panel or computer.
Step D: Start one of the oil pumps.
Step E: Check that the oil flow regulation valve (F94) is in stand-by position (stand-
by oil flow).

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Step F: Start the burner on the local panel or computer.
Step G: Check that the combustion air fan (R09) starts.
Note: The combustion air fan is set for a minimum operation time of 20
minutes in automatic mode to avoid more than three starts per hour.
Step H: Check that the pneumatic shut-off valve (F42) opens and that the burner is
supplied with the atomising medium.
Step 1: Check that the air damper is moved into purge position.
Step J: Check that the combustion air fan damper is moved into ignition position
after the furnace purge period.
Step K: Check that the oil flow regulation valve is in ignition position (ignition oil
flow).
Step L: Check that the ignition burner is inserted and ignited.
Step M: Check that the pneumatic three-way valve (F75) and the pneumatic shut-
off valve (F67) change position.
Step N: Check that diesel oil to the ignition burner is shut-off and that it is purged
with air.
Step 0: Because the stop valve (F64) is closed, the burner start-up fails due to flame
failure. Check that the pneumatic three-way valve (F75) and the pneumatic
shut-off valve (F67) change position immediately after the flame failure
shut down appears. ·
StepP: Open the stop valve (F64) and reset all shut downs.
3.2 Commissioning on diesel oil
When the burner is commissioned, the boiler pressure and temperature must not be
intensified too rapidly as this might cause stresses in the boiler. The burner should
be kept in minimum firing position during the first commissioning period. In manual
operation mode, the burner load can be controlled by means of the soft keys on the
local panel and/or by settings on the computer.
When the burner is stopped during normal operation, the burner lance is purged with
atomising steam, and the remaining oil in the lance is atomised into furnace and
burned. To ensure a complete combustion of the oil during steam purging, it is
important to carry out this procedure with the correct air/fuel ratio. If the combustion
air flow is too low, the combustion produces black smoke, and if the air flow is too
high, the flame blows out before the combustion is completed.
The correct air flow for the combustion can be determined by comparing the oil
pressure at the atomiser and the steam atomising pressure. When these pressures are
identical, the oil flow atomised into the furnace does not change when steam purging

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is initiated. This means that the present air flow suits the combustion. This load is
the steam purge position load and must be set in the control system.
When the burner is commissioned on diesel oil and/or when the atomising medium
is compressed air, the steam purge position should be pre-adjusted to approximately
25%. The fmal setting should be determined when the burner is commissioned on
heavy fuel oil, and the atomising medium is steam.
3.2.1 Operation of the burner

Due to the risk of stresses in the boiler, the burner should only be operated at
relatively short intervals during the initial start-up. When the burner is stopped
during this ftring-up procedure, the remaining safety interlock shut downs can be
checked and adjusted.
Step A: Check and adjust the steam purge position on the local panel or computer.
Step B: Start the burner in manual operation mode on the local panel or computer.
Step C: Check that the burner ignites when the oil valves open and that it remains
ignited when the ignition burner is shut-off and retracted.
Note: A number of starts may be necessary before the burner ignites. H

ignition of the burner fails despite ofseveral attempts, adjust the ignition
oil flow, the correction factor for air/fuel ratio, or the atomising pressure
on the local panel or computer.
Step D: Check that the burner is in minimum ftring position after start-up.
Step E: Check that the flame does not pulsate. Adjust the correction factor, air/fuel
ratio, and/or minimum load if necessary
Step F: Check the shape and colour of the flame. Measure the C02 and/or the 0 2
content and adjust the correction factor or air/fuel ratio if necessary.
Step G: Check the colour of the flue gas. Measure the soot spot No. It should not
exceed a soot spot No. of 1-3 (Bachrach). Adjust the correction factor or
air/fuel ratio if necessary.
Note: The final adjustment of the combustion parameters, e.g. air/fuel ratio,
minimum load, steam atomising pressure, etc. should be carried out
when the burner operates on heavy fuel oil and with steam as atomising
medium. It is therefore advisable to adjust the correction factor instead
of the air/fuel ratio when the burner is commissioned on diesel oil.
3.2.2 Check the stop sequence
Step A: The stop sequence should also be carefully monitored on site. Operate the
burner for a few minutes.

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Step B: Set the burner load to steam purge position and stop the burner.
Step C: Check that the pneumatic three-way valve (F75) and the pneumatic shut-off
valve (F67) change position.
Step D: Check that the pneumatic shut-off valve (F44) for steam purge opens at the
same time as the oil valves close. The flame failure equipment is inactive
when the burner is purged.
Step E: Check that the pneumatic shut-off valve (F42) for atomising steam closes
after the end of the steam purge 1 period.
Step F: Check that the pneumatic shut-off valve (F44) for steam purge closes after
the end of the steam purge 2 period.
Step G: Check that the air damper moves to post purge (purge) position if this
sequence step is active.
Step H: Check that the oil flow is in stand-by position and that the air damper is
. closed after the end of the steam purge 2/post purge period.
Step 1: Check that the combustion air fan stops. The fan only stops if it has been
operating more than 20 minutes.
Step J: Check that the furnace is free of oil spillage.
3.2.3 Check the safety interlock shut down for flame failure equipment
Step A: When the burner is in operation, check the flame failure equipment by
removing one of the flame scanners from the holder and cover the sensor.
The burner stops, and a shut down for flame failure is indicated on the local
panel and computer. Reset all shut downs.
Step B: Check and simulate a glowing furnace by using a flash light pointed directly
at the flame scanner.
Step C: Set the burner into start mode. The local panel and computer should
indicate a shut down for flame failure.
Step D: Mount the flame scanner into the holder and reset all shut downs.
Step E: Perform the same checks with the other flame scanner.
3.2.4 Check the safety interlock shut down for lance inserted
Step A: When the burner is in operation, unscrew the two Allen screws on the
burner lance flange. Carefully lift the lance a few [m.m]. The burner stops,
and a shut down is indicated on the local panel and computer.
Step B: Screw in the two Allen screws into the flange connection and reset the shut
down. Start the burner again.
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3.2.5 Check the safety interlock shut down for oil valves
Step A: Set the burner into stop mode, tum the pneumatic shut-off valve (F67) a
few degrees from closed position by means of a tool. A shut down for oil
valve not in position should be indicated on the local panel and computer.
Reset the shut down after testing and start the burner again.
Step B: Set the burner into stop mode, tum the pneumatic three-way valve (F75) a
few degrees from the present position by means of a tool. A shut down for
oil valve not in position should be indicated on the local panel and
computer. Reset the shut down after testing.
3.2.6 Check the safety interlock shut down for low oil pressure
Step A: When the burner is in operation, check the low oil pressure shut down and
trip function as described in the paragraph "Commissioning of the oil
system". The burner stops, and a shut down for low oil pressure is indicated
on the local panel and computer. Reset the shut downs after testing.
3.2.7 Check the safety interlock shut down for too low water level
Step A: When the burner is in operation, perform a live test of the water level safety
devise. The other too low water level shut down actuated by the water level
controller must be deactivated. This can be done by temporarily lowering
the shut down set point in the local panel or computer. Decrease the water
level until the burner stops, and a shut down for too low water level is
indicated on the local panel and computer.
Step B: Increase the water level in the boiler and reset the shut down. Adjust the set
point for too low water level actuated by the water level controller to the
original set point.
Step C: When the burner is in operation, perform a live test of the water level
controller. The too low water level shut down actuated by the safety device
must be deactivated like described above. Decrease the water level until the
burner stops, and a shut down for too low water level is indicated on the
local panel and computer.
Step D: Increase the water level in the boiler and reset the shut down. Adjust the set
point for too low water level actuated by the safety device to the original
level.
3.2.8 Change to atomising steam supply

When the boiler pressure is approximately 3 bar, the atomising medium should be
changed to steam supply.
Step A: Stop the burner and close the stop valve (F87).
Step B: Check that the steam regulating valve (F91) is in automatic mode on the
local panel or computer.

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Step C: Open the valve for atomising steam from the steam supply system.
Step D: Open the valves for the steam trap.
Step E: Start the burner and carry out the remaining commissioning procedures.
Note: H the burner load is increased during start-up, the air/fuel ratio should
be checked and adjusted at the different loads.
3.2.9 Check the safety interlock shut down for low steam atomising pressure
Step A: Set the steam regulating valve (F91) into manual mode on the local panel or
computer.
Step B: Lower the steam atomising pressure gradually until the set point for low
alarm is reached. The local panel and computer should indicate a low alarm.
Step C: Lower the steam atomising pressure somewhat until the set point for low
shut down is reached. The burner stops, and a shut down is indicated on the
local control panel and computer.
Step D: Set the steam regulating valve (F91) into automatic mode on the local panel
or computer and reset the shut down.
3.2.10 Check the safety interlock shut down for high steam pressure
Step A: When the burner is in operation, raise the boiler pressure until the set point
for high alarm is reached. The local panel and computer should indicate a
high alarm.
Step B: With the burner in operation, check the shut down and trip function for high
steam pressure. Deactivate one of the shut downs. Raise the steam pressure
until the burner stops, and a shut down is indicated on the local panel and
computer.
Step C: Perform the same check with the other high steam pressure shut down.
Step D: With both shut downs activated, reset all shut downs.
3.2.11 Check the active safety interlock shut downs in emergency operation
Step A: When the burner is stopped, turn the keys placed inside the local control
panel and power panel into emergency operation.
Step B: Operate the burner as described in the chapter "Manual operation".
Step C: When the burner is in operation, check the safety interlock shut downs for
flame failure and too low water level as described previously.

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Step D: When the safety interlock shut downs have been tested, tum the keys into
automatic operation and reset all shut downs.
3.3 Commissioning on heavy fuel oil
When the burner has been commissioned on diesel oil and when steam is available
for heating, the commissioning on heavy fuel oil can be carried out.
3.3.1 Change of fuel

The change of fuel from diesel oil to heavy fuel oil is achieved by manually
operating the three-way valve (G115). When heavy fuel oil is selected, the three-
way valve (Gill) automatically changes position and returns the oil to the heavy
fuel oil settling tank for a period of time. This arrangement is necessary to avoid a
continuous heating of the re-circulated diesel oil when the burner is in stop mode.
The viscosity of the re-circulated diesel oil decreases and with it also the lubrication
characteristic. This will cause damage to the oil pumps.
After the pre-set time period has expired, the three-way valve (Glll) returns to
normal position. The time period must be set with regard to minimum oil flow and
the quantity of oil in the system.
Step A: Stop the burner.
Step B: Check that oil is present in the heavy fuel oil tank. Open the quick closing
valve (G95) which connects the heavy fuel oil tank to the oil system. To
avoid cavitation of the oil pumps, the viscosity of the oil in the heavy fuel
oil tank should not exceed 380 eSt. If necessary, the oil tank should be
heated.
Step C: Check and adjust the switchover time for the three-way valve (GIll) on the
local panel or computer.
Step D: Select heavy fuel oil on the manually operated three-way valve (G115).
Check that the local panel and computer indicate heavy fuel operation.
Step E: Check that the three-way valve (Gill) changes position. It should also be
checked that the valve is changed back to normal position when the time
period has expired.
Step F: Select one of the pre-heaters for operation. The other pre-heater should be in
stand-by mode.
Step G: Open the stop valves (G25 and G26) for the operational pre-heater and
check that the stop valves (G25 and G26) are closed for the stand-by pre-
heater.
Step H: Turn the three-way valve (G51) for oil flow through the pre-heaters.
Step 1: Check that the steam regulating valve (G20) for the pre-heaters is in
automatic mode on the local panel or computer.
Step J: Close the stop valve (G73) for the stand-by pre-heater and open the stop
valve (G73) slowly for the operational pre-heater.

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Step K: Adjust the temperature set point for the steam regulating valve (G20) on the
local panel or computer. The viscosity of the oil at the atomiser should be
between 15-20 eSt. The pre-heating temperature can be determined by
means of the chart in the chapter "Viscosity-temperature chart".
Step L: Check that the tracing systems for the oil system and the burner unit are
operational.
Step M: Check that the temperature is raised to the desired set point. Adjust if
necessary.
Step N: Check the set points for low shut down, low alarm, and high shut down on
the local panel or computer. Adjust if necessary.
3.3.2 Operation on heavy fuel oil

When the burner is commissioned on heavy fuel oil, final adjustments of the
combustion process should be carried out to achieve high quality performance data.
The aim is to operate the burner with lowest possible 0 2 content and highest
possible C02 content without the risk of an uncompleted combustion (black smoke).
At the same time the reliability of the burner must be ensured.
A number of initiative actions can be performed to improve and optimise the
combustion process such as adjusting the air/fuel ratio, the steam atomising
pressure, and the position of the swirlers/flame stabiliser. Adjustments of the air/fuel
ratio and the steam atomising pressure are made by settings in the control system.
The air/fuel ratio should be checked and adjusted through the complete burner range
to ensure a correct combustion. The air/fuel ratio can be checked by measurements
of the soot spot No. and the 0 2 content and/or the C02 content in the flue gas. The
visual appearance of the flame should also be checked. If the amount of combustion
air to the burner for a given oil flow is too low, the combustion will be uncompleted,
and it produces black smoke. Although the 0 2 content is low, and the C02 content is
high, the air flow should be increased. If, on the other hand, the 0 2 content is high
and the C02 content is low, it indicates that the air flow for the combustion process
must be decreased.
It is not only the air/fuel ratio which is an important factor for the combustion
process, but also the pressure of the atomising steam. ~
The steam atomising pressure should be adjusted and optimised to suit the
combustion process through the complete burner range. The pressure can be checked
by measurements of the soot spot No. and visible control of the flame. If the steam
a
atomising pressure is too low at a given burner load, the flame has tendency to
sparkle, and the soot spot No. increases. Furthermore, the flame becomes unstable at
low loads due to poor atomisation of the oil. If the steam atomising pressure is too
high, the combustion zone is cooled, and the flame becomes unstable at low loads.
The shape of the flame can be adjusted by changing the position of the
swirlers/flame stabiliser. The flame should be adjusted to a shape in which minimum
contact to the furnace walls and bottom is achieved. The adjustment should be
checked when the burner is in full load condition. An adjustment of the
swirlers/flame stabiliser towards the furnace results in a slim and long flame, and the
opposite movement results in a wide and short flame. An adjustment of the
swirlers/flame stabiliser also results in a change of the distance between the atomiser
and the root of the flame.

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The following commissioning steps imply that the lighting-up procedure of the
boiler is completed and that a sufficient load demand is present to cany out
adjustments at 100% load.
Step A: Set the correction factor of the air/fuel ratio in neutral position (correction
factor= 100) on the local panel or computer. The correction factor is used
to adjust the air/fuel ratio if the calorific value of the oil is changed, e.g.
when the bunker type is changed.
Step B: Start the burner in manual operation mode and check that it ignites when the
oil valves open and remains ignited when the ignition burner is shut-off and
retracted. Adjust the ignition oil flow, the air/fuel ratio, or the steam
atomising pressure if necessary.
Step C: Start the burner several times to ensure a reliable ignition of the burner.
Step D: Adjust the oil flow to minimum load.
Step E: Check that the flame is stable and cany out measurements of the soot spot
No. and 0 2 content and/or C02 content. Adjust the minimum oil flow, the
air/fuel ratio, or the steam atomising pressure if necessary.
Step F: Carry out the same measurements through the complete burner range in
steps of 10%. Adjust the air/fuel ratio and/or the steam atomising pressure if
necessary. At full load the shape of the flame should be checked, and the
swirlers/flame stabiliser should be adjusted if necessary.
Step G: The measurements obtained for the combustion process through the
complete range together with a number of comparable combustion data
should be noted and inserted in the chapter "Measurements and settings".
3.3.3 Adjust the steam purge position
Step A: When the burner is in operation, increase or decrease the load until the oil
pressure at the atomiser and the steam atomising pressure are identical.
Step B: Set this load as the steam purge position load on the local panel or
computer.
Step C: Stop the burner and check it during steam purging. The burner must not
produce black smoke or blow out the flame before the combustion is
completed. Adjust the steam purge position load if necessary.
3.3.4 Check the safety interlock shut down for high and low oil temperature
Step A: When the burner is in operation, set the steam regulating valve (G20) into
manual mode on the local panel or computer.
Step B: Increase the temperature gradually until the set point for high shut down is
reached. The burner stops, and a shut down is indicated on the local panel
and computer.

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Step C: Decrease the temperature and reset all shut downs. Start the burner again.
Step D: Decrease the temperature gradually until the set point for low shut down is
reached. The burner stops, and a shut down is indicated on the local panel
and computer. The set point for low alarm should also be checked during
this test.
Step E: Set the steam regulating valve (G20) into automatic mode on the local panel
or computer and reset all shut downs.
3.3.5 Additional function checks
Step A: Check/adjust additional safety interlock shut downs if provided. A number

of shut downs might be included in the safety interlock circuit depending on
the specified function and/or the classification society.
Step B: If the boiler is intended to operate in a master-slave operating system, the

function of this system should be checked with regard to operation mode
and burner load.
Step C: If the boiler is intended to operate in inert gas mode, the function of this
operation mode should be checked with regard to operation and burner
load.

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AALBORG OPERATING INSTRUCTIONS OM5580#60.4
INDUSTRIES
Operating instructions
1 General
The following operation instructions are valid for steam atomising burners of type
KBSD with Y-atomisers and with a standard delivery of individual parts for the
burner unit and supply systems from AALBORG INDUSTRIES.
Attention: H the burner unit and supply systems include parts, which are not
standard delivery from AALBORG INDUSTRIES, the specific
instructions for these parts should be ignored in the following
sections. The actual instructions for the specific parts should be
thoroughly studied and followed during operation of the burner.
The operation instructions in the following sections describe the normal burner
operations with regard to preparation for start-up on the selected fuel type, normal
start/stop, change of fuel, etc. It is implied that the boiler, burner, control system,
and additional equipment for the boiler plant have been commissioned and are fully
operational.
1.1.1 Descriptions
In the following sections various operating procedures are described such as:
• Diesel oil mode
• Heavy fuel oil mode
• Normal start/stop
• Change from diesel oil operation to heavy fuel oil operation
• Change from heavy fuel oil operation to diesel oil operation
• Change of operational pre-heater
• Change of heavy fuel oil bunker type
• Prolonged stop
1.1.2 Position numbers

The position numbers mentioned in the following sections refer to the illustrations in
Figure 1 and Figure 2. The position numbers consist of an identification letter and a
position number code. Position numbers with the identification letters "G and R"
refer to Figure 1, and position numbers with the identification letter "F" refer to
Figure 2. The oil system is shown as a plant with two boilers, but is also valid for a
plant with only one boiler.

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Illustration of the oil system
Combustion ,···•··-··-···--!····· Combustion

alrfanunlt air fan unit
Figure 1 F _ oilsys2b.cdr

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Illustration of the burner unit and supply systems

7
F1
oil
Furnace pressure
Figure2 Burnoilsy2d.cdr
2 Operating Instructions
2.1 Diesel oil mode
This section describes the actions that must be carried out before the burner unit and
oil system are operational on diesel oil.
Step B: Select diesel oil on the manually operated three-way valve (Gl15).
Step C: Open the stop valve (G49) for the mixing tube.

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Step D: Turn the manually operated three-way valve (G247) for oil flow through
both pumps.
Step E: Open the stop valves for the pressure gauges (G04, Gll, G16, and G47).
opened for pressure control purposes. During normal operation, the stop
valves should be closed.
Step F: Open the stop valves (G97 and G101), and close the by-pass valve (G102).
Step G: By-pass the pre-heaters by means of the manually operated three-way valve
(G51), and close the stop valves (G25 and G26) for both pre-heaters (G22).
Step H: Check that the stop valve (G 109) is closed.
Step 1: Close the stop valves (G73) for both pre-heaters.
Step J: Open the stop valves for the pressure gauges (G44 and F68) and the pressure
transmitter (G99).
Step K: Open the stop valves (G69 and G77) for the ignition oil pumps (G72).
Step L: Open the stop valves (F93 and F64).
Step M: Check the position of the three-way valve (F99). The position must be set
for oil flow through the burner unit.
Step N: Open the stop valves (F17 and F73).
Step 0: Check that the throttle valve (F 152) is not in closed position.
Step P: Open the stop valve for the pressure transmitter (F90).
Step Q: Open the stop valve (F41) and the non-return valve (F45).
Step R: Open the stop valve (F92) for atomising steam supply from the steam
system.
Step S: Open the valves for the steam trap.
Step T: Set one of the oil pumps into operation mode and the other oil pump into
stand-by mode. If the burner is in automatic operation mode, the oil pumps
will not be operational before start-up of the burner is initiated.
Note: H atomising steam is not available from the steam system, close the stop
valve (F92) and open the stop valve (F87) for supply from the
compressed air system. Compressed air for atomising should only be
used if steam is not available.

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2.2 Heavy fuel oil mode
This section describes the actions, which must be carried out before the burner unit
and oil system are operational on heavy fuel oil. It is implied that steam is available
for heating and atomising.
Step A: Check that oil is present in the heavy fuel oil settling tank. Open the quick
closing valve (G95) that connects the heavy fuel oil settling tank to the oil
system.
Step B: Select heavy fuel oil on the manually operated three-way valve (G 115).
Step C: Open the stop valve (G49) for the mixing tube.
Step D: Tum the manually operated three-way valve (G247) for oil flow through
both pumps.
Step E: Open the stop valves for the pressure gauges (G04, G 11, G 16, and G4 7).
opened for pressure control purposes. During normal operation, the stop
· valves should be closed.
Step F: Open the stop valves (G97 and G101), and close the by-pass valve (G102).
Step G: Open the stop valves for the pressure gauges (G44 and F68) and the
pressure transmitter (G99).
Step H: Open the stop valves (F93 and F64).
Step 1: Check the position of the three-way valve (F99). The position must be set
for oil flow through the burner unit.
Step J: Open the stop valves (G25 and G26) for the pre-heater (G22), which should
be in operation and check that the stop valve (G25) is closed for the stand-
by pre-heater.
Step K: Tum the manually operated three-way valve (G51) for oil flow through the
pre-heaters.
Step L: Check that the valves in the drain pipes from the pre-heaters are closed and
that the valves from the pre-heaters to the steam trap are open.
Step M: Open the stop valves (G53 and G54) and close the stop valve (G 109).
Step N: Open the stop valve (G73) for the operational pre-heater and close the stop
valve (G73) for the stand-by pre-heater.
Step 0: Start one of the oil pumps and set the other into stand-by mode.

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Step P: Check that the tracing systems for the oil system and the burner unit are
operational.
Step Q: Open the stop valves (G69 and G77) for the ignition oil pumps (G72).
Step R: Open the stop valves (F17 and F73).
StepS: Check that the throttle valve (F152) is not in closed position.
Step T: Open the stop valve for the pressure transmitter (F90).
Step U: Open the stop valve (F41) and the non-return valve (F45).
Step V: Open the stop valve (F92) for atomising steam supply from the steam
system.
Step W: Open the valves for the steam trap.
2.3 Normal start/stop
The control system automatically starts, stops, and regulates the burner in normal
operation depending on the steam demand. When the steam pressure is below the set
point for operation, the burner commences the start-up sequence. If the main steam
valve and by-pass valve are closed, the burner operates in minimum firing position
after start-up until the differential pressure between the boiler and the main steam
line is within the set point for which modulation free mode is allowed. If, on the
other hand, the main steam valve and by-pass valve are open prior to burner start-up,
the pressure in the boiler and the pressure of the main steam line are equalised, and
the burner operates in modulation free mode.
In modulation free mode, the control system attempts to maintain the steam pressure
at the desired set point by regulation of the burner load. The burner can be regulated
through the complete load range from minimum firing load to full load.
However, should the steam demand decrease below the minimum firing load of the
burner, the steam pressure will increase to the set point for burner stop. The burner
stops and remains stopped until the set point for burner operation is reached again.
2.4 Change from diesel oil operation to heavy fuel oil operation
When the fuel supply is changed from diesel oil operation to heavy fuel oil
operation, the following work steps should be carried out:
Step A: Check that oil is present in the heavy fuel oil settling tank. Open the quick
closing valve (G95) which connects the heavy fuel oil settling tank to the
oil system. To avoid cavitation of the oil pumps, the viscosity of the oil in
the heavy fuel oil tank should not exceed 380 eSt. If necessary, the oil tank
should be heated.
Step B: Select heavy fuel oil on the manually operated three-way valve (G115).
When heavy fuel oil is selected, the three-way valve (G 111) automatically
changes position and returns the oil to the heavy fuel oil settling tank for a
period of time. This arrangement is necessary to avoid a continuous heating
of the re-circulated diesel oil when the burner is in stop mode. The viscosity

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of the re-circulated diesel oil decreases and with it also the lubrication
characteristic. This will cause damage to the oil pumps. After the pre-set
time period has expired, the three-way valve (GIll) returns to normal
position.
Note: When the fuel type is changed from diesel oil to heavy fuel oil, a shut
down for low oil temperature may arise. H the burner is in operation, it
will stop due to this shut down. To prevent burner cot off, the set point
for low oil temperature can be temporarily decreased in the control
system.
Step C: Select one of the pre-heaters for operation. The other pre-heater should be
in stand-by mode.
Step D: Open the stop valves (G25 and G26) for the operational pre-heater and
check that the stop valve (G25) is closed for the stand-by pre-heater.
Step E: Tum the manually operated three-way valve (G51) for oil flow through the
pre-heaters.
Step F: Check that the valves in the drain pipes from the pre-heaters are closed and
that the valves from the pre-heaters to the steam trap are open.
Step G: Check that the stop valves (G53 and G54) are open and that the stop valve
(G 109) is closed.
Step H: Check that the steam regulating valve (G20) for the pre-heaters is m
automatic mode.
Step 1: Open the stop valve (G73) for the operational pre-heater and close the stop
valve (G73) for the stand-by pre-heater.
Step J: Check that the tracing systems for the oil system and the burner unit are
operational.
Step K: Check the heavy fuel oil temperature. The viscosity of the oil at the
atomiser should be between 15-20 eSt. The pre-heating temperature can be
determined by means of the chart in the chapter "Viscosity-temperature
chart".
2.5 Change from heavy fuel oil operation to diesel oil operation
When the fuel supply is changed from heavy fuel oil operation to diesel oil
operation, the following work steps should be carried out:
Step B: Select diesel oil on the manually operated three-way valve (G115). The
three-way valve (G 111) automatically changes position and returns the oil

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to the heavy fuel oil settling tank for a period of time. After the pre-set time
period has expired, the three-way valve (GIll) returns to normal position.
Ifthe burner is in stop mode, the oil pumps will not be operational, and the
pump will stop.
Step C: By-pass the pre-heaters by means of the manually operated three-way valve
(G51 ), and close the stop valves (G25 and G26) for both pre-heaters (G22).
Step D: Close the stop valve (G73) for the operational pre-heater and check that the
stop valve (G73) for the stand-by pre-heater is closed.
Step E: Check that the tracing of the piping system is off when the burner is in
diesel oil operation.
Caution: Heating of diesel oil in the piping system must be avoided.
2.6 Change of pre-heater
,When the pre-heater is changed, the following work steps should be carried out:
Step A: Open the stop valves (G25 and G26) for the pre-heater which should be
operational.
Step B: Open the stop valve (G73) for the pre-heater which should be operational.
Step C: Close the stop valve (G73) for the pre-heater which should be in stand-by
mode.
Step D: Close the stop valve (G25) for the pre-heater which should be in stand-by
mode.
2.7 Change of heavy fuel oil bunker type
If the heavy fuel oil bunker type is changed and the calorific value of the oil
changes, the air/fuel ratio should be adjusted to obtain the correct combustion data.
This is done by changing the correction factor of the air/fuel ratio on the local panel
or computer. If the correction factor is set to a value above 100, the air flow for the
combustion process decreases. If the correction factor is set to a value below 100,
the air flow for the combustion process increases. This means that if the calorific
value of the oil increases, the value of the correction factor should be decreased to
obtain the same combustion data and visa versa.
2.8 Prolonged stop
When the boiler plant is stopped for a long period of time, the oil system including
the pre-heaters should be flushed with diesel oil before the plant is shut down.
Furthermore, the tracing must be switched off.

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AALBORG EMERGENCY OPERATION OM5580#70.2
INDUSTRIES
Emergency operation
1 General
In the rare event of a total break down of the control system, the burner unit with
belonging systems can be operated in emergency operation. Due to the fact that the
majority of the safety interlock trips and shut downs are overruled in emergency
mode, the safety precautions for the plant must be observed very carefully.
Please note that in emergency operation mode the safety interlocks are reduced to:
• Too low water level
• Flame failure
Warning: When the burner operates in emergency mode, it is very important

that the boiler plant is carefully and continuously supervised by the
ship engineering personnel. Pay special attention to the steam
pressure and water level.
In emergency mode, the burner unit and supply systems are operated from inside the
local control panel and the power panel. Various operating switches and
potentiometers are provided inside the panels for operating purposes.
Before emergency operation of the burner is initiated, attempts to restart the control
system must be performed. If restart of the control system is impossible, the work
steps of the following sections must be followed.
1.2 Manual operation of the burner supply systems
Step A: Turn the key placed inside the power panel into emergency operation.
Step B: Start one of the oil pumps on the operating switch inside the power panel.
Step C: Adjust the oil pressure on the pressure regulating valve to a level of 20-25
bar at the burner unit inlet flange. The adjustment is carried out by means of
the manually operated hand wheel on the actuator.
Step D: If the burner is operating on heavy fuel oil, the oil temperature must be
adjusted on the steam regulating valve for the pre-heaters. The viscosity of
the oil at the atomiser should be between 15-20 eSt. The pre-heating
temperature can be determined by means of the chart in the chapter
"Viscosity-temperature chart". The adjustment is carried out by means of
the manually operated hand wheel on the actuator.

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AALBORG EMERGENCY OPERATION . OM5580#70.2
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Note: The automatic water level regulation is not operational in emergency

mode. This means that the water level in the boiler must be adjusted in a
similar way as the regulation of the oil pressure and oil temperature. H
supplied by Aalborg Industries the feed water pumps can be set into
operation by means of the operating switches inside the power panel.
1.3 Manual operation of the burner unit
Step A: Turn the key placed inside the local control panel into emergency operation.
Step B: Close the inlet vanes for the combustion air fan by means of the
potentiometer inside the local control panel. The inlet vanes should be in
closed position before start-up to reduce the current consumption.
Step C: Start the combustion air fan on the operating switch inside the power panel.
Step D: Purge the furnace with combustion air by opening the inlet vanes to
maximum position on the potentiometer for the combustion air fan. The
combustion air flow should be kept at maximum flow for at least 60
seconds.
Warning: Insufficient purging may cause danger of furnace explosions.
Step E: Close the steam regulating valve for atomising steam. The valve can be
closed by means of the manually operated hand wheel on the actuator.
Step F: Push the button for steam atomising inside the local control panel.
Step G: Adjust the steam atomising pressure on the steam regulating valve to a level
of2-3 bar. The adjustment is carried out by means of the manually operated
hand wheel on the actuator.
Step H: Set the air flow to ignition load position, approximately 15-20% load, by
reducing the position of the inlet vanes on the potentiometer for the
combustion air fan. When the percentage value of the air flow is unreadable
due to break down of the control system, the scale of the potentiometer can
be used as a frrst-hand percentage indicator for the combustion air flow.
The final setting of the potentiometer for ignition load and all other loads
must be determined by visual checks of the flame and the flue gas when the
burner is in operation. The percentage values from the control system and
the percentage values of the settings on the potentiometer are incomparable.
This is because the values from the control system are the feed back signals
from the combustion process {dp-transmitter), and the values from the
potentiometer are output signals to the positioner which operates the inlet
vanes for the combustion air fan.

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Step 1: Set the oil flow to ignition load position, approximately 15-20% load, by
means of the potentiometer for the oil flow regulation valve. When the oil
flow is unreadable due to break down of the control system, the pressure
indicated on the pressure gauge just before the burner must be used as an
indicator for the oil flow.
Step J: Press the button for ignition inside the local control panel and keep it
pressed.
Step K: When the ignition flame is established, push the button for oil valves inside
the local control panel.
Step L: Release the ignition button when the lamp that indicates flame on is
illuminated.
Step M: The burner is now in operation, and adjustments of the burner load must be .
carried out as described in the following section.
1.4 Operating instructions in emergency mode
The request for regulations of the burner load should be deducible from the actual
demand for process steam. The optimal operation form for the burner is to minimise
the number of load alterations as this will facilitate the burner operation in
emergency mode. Regulations of the burner load must be performed by manual
adjustments of the combustion parameters, e.g. oil flow, air flow, atomising steam
pressure, etc.
When the burner load is changed, it is important to differentiate between increases
or decreases of the load. This is due to the fact that an incorrect air/fuel ratio towards
a rich oil mixture causes an incomplete combustion that will produce black smoke.
If the burner load is increased, the air flow should be regulated before the oil flow,
and opposite the oil flow should be regulated before the air flow if the burner load is
decreased.
Step A: Adjust the air flow and oil flow to the desired load by means of the
potentiometers inside the local control panel. The scale of the potentiometer
for the combustion air fan and the oil pressure indicated on the pressure
gauge just before the burner can be used for frrst-hand settings. The fmal
settings must be determined by visual checks of the flame and the flue gas.
Step B: Adjust the steam atomising pressure on the steam regulating valve to suit
the combustion. The adjustment is carried out by means of the manually
operated hand wheel on the actuator. If the steam atomising pressure is too
low at a given burner load, the flame has a tendency to sparkle.
Furthermore, the flame becomes unstable at low loads due to poor
atomisation of the oil. If the steam atomising pressure is to9 high, the
combustion zone is cooled, and the flame becomes unstable at low loads.
Step C: Readjust the oil pressure if necessary. When the burner operates at
increased loads, the oil pressure to the burner will fall due to the increased
amount of oil for the combustion. To ensure that the burner receives a
sufficient amount of oil, it might be necessary to adjust the oil pressure on
the pressure regulating valve. If the load decreases, a reduction of the oil

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pressure might also be necessary. The adjustments are carried out by means
of the manually operated hand wheel on the actuator.
Step D: If the burner is operating on heavy fuel oil, adjustments of the oil
temperature might be necessary at large burner load variations. The oil
temperature should be adjusted on the steam regulating valve for the pre-
heaters by means of the manually operated hand wheel on the actuator.
Step E: Adjust the water level in the boiler if necessary. The water level must be
carefully and continuously supervised during operation of the boiler plant.
When one of the feed water pumps is in operation, the water level can be
regulated on the feed water control valve by means of the manually
operated hand wheel on the actuator.
1.5 Stop the burner in emergency mode
Step A: Adjust the air flow and oil flow to steam purge position load by means of
the potentiometers inside the local control panel.
Step B: Adjust the steam atomising pressure on the steam regulating valve to the
same level as the oil pressure just before the burner.
Step C: Press the button for steam purge inside the local control panel and keep it
pressed. The oil valves close immediately, and the valve for steam purge
opens.
Step D: When steam purging is completed, the release the button. The purging is
completed when the remaining oil in the burner lance is atomised into the
furnace which is indicated by the extinction of the flame.
Step E: Push the button for atomising steam inside the local control panel.
Step F: Close the inlet vanes for the combustion air fan by means of the
potentiometer.
Step G: Stop the combustion air fan. The fan should be kept in operation if it is
contemplated to operate the burner with frequent intervals. This is because
it should be avoided to start the fan more than three times per hour.
Step H: Adjust the oil pressure and temperature if necessary.
Step 1: When the burner is in stand-by mode, and oil is circulated in the oil system,
the oil flow must be adjusted to minimum oil flow position by means of the
potentiometer for the oil flow regulation valve.
Note: H the burner operates on diesel oil, the oil system should stopped if
burner operations are of infrequent occurrences. A continuous re-
circulation of the diesel oil might damage the oil pumps due to heating of
the oil.

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Step J: If the fuel supply is changed from diesel oil to heavy fuel oil, the position of
the pneumatic three-way valve, which leads the return oil to the mixing tube
or the heavy fuel oil settling tank, should be changed for a period of time ..
The position of the three-way valve can be changed by means of a manual
switch on the solenoid valve. The time period must be determined with
regard to minimum oil flow and the quantity of oil in the system.

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AALBORG MAINTENANCE OM5580#85.2
INDUSTRIES
Maintenance
1 Recommended maintenance intervals
To ensure a safe and reliable function of the burner, inspection must take place with
frequent intervals as described below. The inspection should be carried out by
competent and properly trained personnel familiar with the operating and
maintenance procedures relevant for this type of plant.
1.1 Safety regulations for maintenance work
Always ensure that the electrical power is off and that nobody can start the boiler
unit before commencing maintenance work.
All pipes, drums, etc. must be depressurised before any maintenance work is carried
out on these.
1.2 Continuous maintenance
• Control panels and other electrical equipment should be kept clean and dry.
Check that no foreign matter accumulates in or around them.
• Replace lamps, contactors, and other components when they cease to function or
show signs of deterioration. A part, replaced before it actually fails, could save a
costly delay.
1.3 Periodical maintenance
The following check list should be followed every two weeks. Dependent on the
operation conditions, however, some items may need more frequent attention.
For maintenance work procedures, we refer to the separate instructions concerning
each item.
1.3.1 Periodical maintenance - burner and fuel oil supply system
• Check that all connections are tightened and that the wiring IS in a good
condition.
• Check that the fan inlet is kept clean of unintended obstructions.
• Check pipe work for leaks, particularly on flanges, joints, and connections.
Repair any leaks which may cause safety risks.
• Check the general condition of pipe work, lagging, and tracing.
• Check that the glands of manual valves are tight enough to prevent easy
operation of the valve.
• Oil filters should be inspected and cleaned.

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AALBORG MAINTENANCE OM5580#85.2
INDUSTRIES
• Manually operated valves should be periodically operated, if possible, to ensure

free movement.
• Check the pneumatic shut-off valves, placed just before the burner lance, for
leaks.
• Check and clean the flame scanner.
1.3.2 Burner air register and swirlers/flame stabiliser

If the burner plant is to perform according to the specification, it is important that
the burner register and the swirlerslflame stabiliser are kept clean and in good
condition. Inspection should be carried out at regular intervals.
Large quantities of dust-laden air will pass through the register, and inevitably this
tends to build up deposits. These deposits should be brushed off.
The swirlers/flame stabiliser and all other surfaces exposed to radiation heat should
be checked for being free of carbon or heat erosion.
1.3.3 Atomiser
Before any examination can be made, the atomiser must be cleaned. This is
normally done by soaking in a paraffin or carbon remover to wash off any oil films.
This also has the purpose of loosening carbon deposits. It may also be necessary to
use a soft metal scraper to lift away any heavy carbon deposits. A hardened scraper
should not be used as it could possibly damage the atomiser.
The cleaned atomiser should then be examined for damage, and the holes checked
for wear.
The 0-ring must be replaced every time the atomiser is disassembled.
Before fitting the cap nut, the thread should be covered with an unhardening high
1.3.4 Ignition burner

The ignition burner is one of the most exposed items and needs a frequent
maintenance.
• The electrodes should be cleaned and the insulation material checked for any
damage. Be careful not to damage the ceramic insulation pieces.
• The nozzle should be checked and cleaned.
• If the spray pattern hits the other parts of the igniter despite it is cleaned, the
nozzle should be changed.
Note: Be careful not to change position of nozzle and electrodes as this may
cause problems with, e.g. ignition, instability, or build-up of carbon
deposit.
1.3.5 Electrical system
• The electrical and mechanical connections of the local panels and power panels
must be checked and tightened at least once a year.

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AALBORG FAULTS AND RECTIFYING FAULTS OM5580#90.0
INDUSTRIES
Faults and rectifying faults
1 Trouble shooting
The trouble shooting list is based on a proper set-up of the burner plant during
commissioning and/or service and that no further adjustments of the air/fuel ratio,
etc. have taken place.
Please note that the trouble shooting list is general for steam atoniising burners and
has not been made for any particular plant, but is based on several years of
experience. Therefore, the cause for your specific problem may not be mentioned
and vice versa. You are always welcome, however, to contact our Service
department for advice or service assistance.
Check availability of power and fuel supplies before cortrmencing detailed checks.
Ensure that burner plant wiring diagrams relevant to the particular installation are
available.
When the cause of a lockout should be located, it can be of assistance to know the
start/stop cycle or at which point of operation the lockout occurred, e.g. modulating.
The trouble shooting list can be seen in Table 1.
No ignition/ignition flame Ignition burner oil pump faulty Repair or replace oil pump/ motor
failure Oil pressure too low Restore oil pressure
Oil nozzle blocked/worn out Clean/replace nozzle
Ignition electrodes dirty/out of adjustment Clean/readjust
Ignition transformer faulty Replace ignition transformer
Solenoid valve faulty Exchange solenoid valve unit
Burner control · control unit
Flame failure of main flame not established
during ignition Oil valves not open
Atomising air/steam pressure too low
Purge steam valve open
Oil temperature too high/low
Oil flow too low
Unstable main flame Oil amount too low
Oil temperature too low/high
Blocking of some ofthe steam/oil holes in the
atomiser
Water in the
to the electrical layout/diagram

information
Table 1

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Table of contents
Oil flow regulating valve

General ........................................................................................................................ l
Cv-adjustrnent.............................................................................................................. 2
Installation ................................................................................................................... 3
Commissioning ............................................................................................................ 4
Manual operation ......................................................................................................... 5
Calibration ................................................................................................................... 6
Maintenance ................................................................................................................. 7

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AALBORG OIL FLOW REGULATING VALVE OM6050#04.0
INDUSTRIES
Oil flow regulating valve
1 General
The burner load is controlled by the control system, which receives a continuous
signal from a steam pressure transmitter. This signal is compared with different set
points, feed back signals, and parameters in the control system. The output from the
control system is used to control the oil flow regulation valve, which is
pneumatically operated by an liP converter.
To obtain a very accurate regulation of the oil flow, which is very important to have
a large tum-down ratio, the valve is fitted with an adjustable Cv-adjuster. This Cv-
adjuster makes it possible to adjust the pressure loss coefficient of the valve
whereby the oil flow regulation can be optimised to each single installation.
The position numbers referred to in the following sections appear from the
illustrations shown in Figure l, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6.
2 Cv-adjustment
2.1 Mid band setting
During calculation of the valve sizing, a trim set should be chosen so that the mean
estimated Cv will be at the mid band setting. This is called the risk-free setting since
it provides the means to either increase or decrease the available Cv if the actual
conditions change.
Figure 1 shows an example ofthe possible settings for a trim set. A mean Cv of0.07
for a trim No.5 allows subsequent adjustment to Cv 0.10, if the flow coefficient is
increased, or to Cv 0.04 in the opposite case.
2.2 Adjustment setting at maximum Cv
The adjustment knob should be set towards maximum Cv making it possible to scale
downwards, if desired. This should be done if valve sizing calculations and actual
service conditions indicate that the full rated Cv of the valve will initially be required
but may subsequently lessen
2.3 Adjustment setting at minimum Cv
The adjustment knob should be set towards minimum Cv making it possible to scale
upwards, if desired. This should be done if valve sizing calculations and actual
service conditions indicate that initial conditions require a relatively low Cv but will
then increase to a higher maximum

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Example of a valve adjusted at mid band setting
Cv/slgnal Cv p)ate Recommended Example Adjustment

adjustment of application option
0.10 1-----,--,.-----.--/,· '¢.':'.1i

;L_,f:lil Nominal Cvto
(\Max ![2 !li besubsequenUy
;.I ·..J··-· --- 1·' reduced
0.091--+---+---+-ff-
D
0.081--t--+--W- Mid band setting:
0.071--+---t---fff---...,j
111 ~ Service conditions
111 Hmay vary, Cv to be
Cv o.o6 f-------t--+-ff--+-£,Y.~
adjusted upwards
or downwards
D
0.051---l--;¥.------;,ffl---! -~
/ L, r----, f1 Nominal Cv to
0.041--+---t'i-1--7:7'---t---71,- «~:J]
/:....
<Min 1 ~e subsequenUy
! 3 ill Increased
\ ,--·- L~ w
//' >
()
\j
_,..-;,...../
_.,-:/
/ Cv adjustment knob
NoS
Signal ~
200 400 600 800 1000 mbar
3 6 9 12 15 psi
4 8 12 16 20 MA
Figure 1 cvsignal.cdr
Dlustration of the name plate
Figure2 namevari.cdr

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Dlustration ofthe oil flow regulation valve (front view)
23 116 117115120119 118121122112c 124 22
110
21
105
112a
104a
103
102
106 104b
108 126
101 125
107 131
7 134
8b 136
10
Ba
9
6
5
4
12d
3d
13a
2
Figure3 vari 04.cdr

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Dlustration of the oil flow regulation valve (side view)
116
117
115
22 21
112c 23
124 24
104b 126
114
151 127
150
109
135 152
148 153
149 154
147 156
146 155
145 157
144 158
141a
138a
Figure 4 vari_07.cdr

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Dlustration of the coupling details of lever No. 1 and 2
108
104a
10/
102
22
Pivot pin No. 3 Lever No.2
Figure 5 vari_06.cdr
Dlustration of the air connections
109
@
144
Figure 6 vari_ OS.cdr

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INDUSTRIES
Table 1
3 Installation
The oil flow regulating valve must be installed as flange connected. Place the
gaskets according to the process between the valve body and the pipe flanges.
3.1.1 Alignment
Hold the valve body during installation of the studs. Special bosses are provided to
centre the valve in the line and prevent rotation before final tightening of the studs.
The valve must be installed with the flow tending to open. The flow arrow stamped
on the valve body must be pointing in the direction of the flow. Install bolting and
tighten evenly in a cross fashion.
3.1.2 Air piping

Install pipe supply and instrument signal lines to the appropriate connections in the
positioner Block (144), see Figure 6. Use 114" O.D. tubing or equivalent for air lines
Important: Air supply to the oil flow regulating valve must be instrument air.

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4 Commissioning
In the following the work procedures for commissioning of the oil flow regulation
valve are described:
Step A: Check that the output signal range from the I/P converter corresponds to the
input signal range on the oil flow regulation valve. The pressures appear
from the identification plates.
Step B: Loosen the cover screws (109). Back off the hand wheel lock (121) and turn
the hand wheel anti-clockwise until the cover floats free. Remove the cover
(110).
Step C: Check and adjust the valve characteristic (Cv). To adjust the Cv, loosen and
move the adjustment knob (24) along the scale (25) fixed to the top oflever
No. 1 (21). The adjustment scale (25) shows the available Cv values for the
specified valve, and Table 2 shows the Cv setting for each burner size.
When the knob (24) is at the required position, tighten the knob.
Table2
Step D: Apply air to the liP converter. Adjust the air pressure at the belonging
filter/reduction unit. The pressure setting appears from the identification
plate on the converter.
Step E: Apply supply air to the oil flow regulation valve. Adjust the air pressure at
the belonging filter/reduction unit. The pressure setting appears from the
identification plate on the valve.

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Step F: Set the oil flow regulation valve into manual mode on the control system.
Step G: Set the regulation output for the oil flow to 0% (4 rnA) on the control
system.
Step H: Adjust the pressure indicated on the instrument gauge (143) to the low
input signal range by means of the zero adjustment screw on the liP
converter. The instrument gauge (143) is the left pressure gauge on the oil
flow regulation valve. The input signal range appears from the
identification plate.
Step 1: Set the regulation output for the oil flow to 100% (20 rnA) on the control
system.
Step J: Adjust the pressure indicated on the output gauge (142) to the high input
signal range by means of the span adjustment screw on the liP converter.
The output gauge (142) is the right pressure gauge on the oil flow
regulation valve. The input signal range appears from the identification
plate.
Step K: Set the oil flow regulation valve into automatic mode on the control system.
Step L: Start one of the oil pumps. Set the stand-by oil flow to 0% on control
system.
Step M: Adjust the tum take-up screw (116) of the oil flow regulation valve until
the piston (131) just begins to move. The control system must indicate 0%
oil flow. Tighten with the lock nut (117).
Step N: Set the stand-by oil flow back to the original set point.
Note: H the Cv setting is changed after the above-mentioned work procedures

have been carried out, a new zero adjustment might be required to
recalibrate the closing point.
5 Manual operation
5.1 Hand wheel
The oil flow regulation valve can be manually operated in case of a failure on the
control system by means of the hand wheel. The hand wheel is located on top of the
cover and fitted with a locking lever. Direct access to it does not require removal of
parts.
It basically consists of a threaded rod fitted with a hand wheel (120) and a lever arm
stop (122). The threaded rod freely rests on the actuator bracket (108) and is guided
through the cover (110) by means of the hand wheel bushing (119). The stop (122)

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consists of a block screwed on the threaded rod guided in translation by the actuator
bracket (1 08).
Clockwise rotation of the hand wheel (120) moves the stop (122) up along the
threaded rod and drives up the lever No.2 (22) compressing the spring (134).
This action provides for the opening of the valve if it is an open-on-air actuator and
also the closing of the valve if it is a close-on-air actuator.
The return to automatic operation (neutral position) is accomplished by turning the
hand wheel anti-clockwise until the stop (122) contacts the bracket (108).
Note: During this operation the compression releases when the stop (122) no
longer contacts the lever (22). Then, continue this operation until a slight
tension reappears and tighten the hand wheel lock (121).
6 Calibration
The oil flow control valve is factory calibrated. If, for some reason, the calibration
has been disturbed (e.g. due to repair, change of parts, etc.), it is necessary to carry
out some adjustments. In the following the work procedures for adjustments are
described:
6.1.1 Adjustment of the piston rod clevis (104b)
Note: This adjustment should not be changed unless the piston (131) has been
disassembled. Then, it should be made during assembly before coupling
the levers to the clevises.
Step A: With the piston against the diaphragm cover (137), turn the clevis (104b) in
such a manner that the distance between the actuator bracket top (1 08) and
the indicator bottom (126) is between 0.5 mm and 1 mm. The use of a shim
will facilitate the operation.
Step B: Couple lever No. 2 to the clevis. Admit sufficient air pressure to disengage
the nut (125) and tighten it against the indicator. Take care that the indicator
(126) is correctly positioned. Release the air pressure.
6.1.2 Plug stem adjustment

With levers No. 1 and 2 coupled, proceed as follows:
Step A: Admit sufficient air pressure to the actuator to extend the piston rod and
place a shim under the indicator (126). Use a 1.5 mm shim for air-to-open
actuators or a 25 mm shim for air-to-close actuators. Release the air
pressure after placing the shim.

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Note: At this closing point without seating force, the slides of levers No. 1 and 2
must be strictly parallel. This characteristic permits to change the
adjustment knob position to obtain the truly required Cv.
Step B: Loosen the adjustment knob (24) and slide over the lever No. 1 to the
position of maximum Cv on the Cv adjustment plate (25). Tighten the knob
(24).
Step C: Loosen the lock nut (103) by using a screwdriver applied to the plug stem
end, and tum it until the plug slightly touches the seat ring. If the valve was
removed from the pipe, a bubble leakage test performed on a calibration
bench will permit a very accurate adjustment. By using the screwdriver,
keep the plug stem in position and tighten the lock nut (103) against the
clevis (104a).
Step D: Admit air pressure again to disengage the shim, and release the air pressure
again.
Note: On air-to-open actuators, the shim thickness can be changed plus or

minus 0.1- 0.2 mm so that the levers No.1 and 2 are in parallel position.
This is done to obtain the required tightness at closing.
6.1.3 Positioner start-up pressure adjustment
Step A: Pipe air supply and instrument signal lines to the positioner. Set the supply
pressure in relation to the valve Cv. See Table 3.
Step B: Set the signal to minimum value if it is an air-to-open actuator, or set the
maximum value if it is an air-to-close actuator. Tum take-up screw (116)
until the piston rod just begins to move. Tighten the lock nut ( 117).
6-24 Red 2100 30

1660
207
3-15 Green 1250 18
1035
Table3

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7 Maintenance
Warning: Maintenance and/or disassembly should be performed with the

valve, actuator, and positioner free from all pressures.
7.1 Actuator diaphragm replacement
Step A: Unscrew the two pressure connection nuts (138a) and pull the tubing (140)
out. Remove the four cap screws (139), the diaphragm cover (137), and the
diaphragm (136).
Step B: Form a new diaphragm and insert it over the piston (131). Place the
diaphragm roll into the bracket groove. Take the necessary steps not to twist
or bend the diaphragm during its replacement.
Step C: Replace the diaphragm cover (137) with the four screws (139) and
reconnect the pressure connection nuts (138a); Check the tightness of the
connections.
7.2 Adding packing
Step A: To add a ring of packing, depressurise the valve, and back off the packing
flange nuts (8b) all the way.
Step B: Lift the packing flange and follower and insert one ring of packing. Tighten
the nuts (8b) finger tight plus one full tum.
7.3 Disassembly
In some cases, it may be necessary to disassemble the valve, e.g. to replace the plug
and seat ring assembly or to change packing in case of a Cv max. < 0.6.
Note: In the case of a Cv max. > 0.6 a quick way to replace the packing
prevents full disassembly of the valve (see the section "Packing quick
change method").
Step A: Loosen the cover screw (109}. Back off the hand wheel lock (121} and tum
the hand wheel anti-clockwise until the cover floats free. Remove the cover
(110).
Step B: Adjust the signal for closing of the valve. Slightly change the signal so that
the plug barely moves off the seat ring. Tum the adjustment knob (24) to
minimum Cv position.

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Step C: Loosen lock nut (1 03) and tum anti-clockwise through 1 3/4 turns by using
a screwdriver applied at the plug stem end. Shut off the signal and pressure
supplies. Slightly retighten the lock nut (103) against the clevis.
Step D: Loosen the lock nut (117) and fully unscrew the take-up screw (116).
Remove the spring clamp (115) from lever No. 2 and force the balance
spring (114) from the positioner.
Step E: Remove the retainer clips (112b) from the two pivot pins (184) and pull
them out from lever No. 1 and clevis (1 04a).
Note: This operation will be facilitated by relieving the load on the plug clevis
exerted by the conical compression spring (106). While driving out the
pins, using a screwdriver, push on the plug stem end.
Step F: Remove the two retainer clips (112c) from pivot pin No. 4 (124) and
disengage it to the uncouple piston clevis (1 04b) from lever No. 2 (22).
Step G: Remove the two retainer clips (112a) from pivot pin No. 1 (105) and
disengage it to the uncouple lever No. 1 from the actuator bracket (108).
Disengage the adjustment pin smooth end (23) from the lever line No.2 and
remove the adjustment knob (24) and adjustment pin (23) from lever No. 1.
Step H: Drive out the pivot pin No. 3 (18) and remove lever No. 2 (22).
Step 1: Hold the plug stem in place by using a screwdriver put to its end and unlock
the nut (103). Unscrew the clevis (104a) and lock nut (103). Remove the
spring button (102), spring (106), and grommet plate (101).
Step J: Remove the two packing flange nuts (8b), packing flange (10), and packing
follower (9). Remove the two bracket securing nuts (8a) as well as the
bracket (108).
Step K: By using a packing hook, remove the largest number of packing rings (6)
from the packing box. Remove the safety pin (11) and pull the plug stem to
remove the packing spacer (5), plug and stem, together with the rest of the
packing rings.
Step L: By using a 9/16" or 14 mm piece of hex stock and a wrench, unlock and
pull out the seat ring retainer (4).
Step M: Pull out the seat ring (3) and then the gasket (2) by using a hook made from
steel wire (diameter approximately 3 mm). Carefully fettle the hook end.

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Note: The seat ring with a Cv max.< 0.10 consists of two parts; The seat ring
proper (3e) and a spacer (3f). The small size of the orifice of these parts
does not allow for their removal by means of a hook. Therefore, it is
necessary for this operation to remove the body from the pipe and turn it
over and, if needed, to hit the bottom by means of a wooden mallet.
Should the seat ring be jammed in its housing, it is possible to move it
using a screwdriver inserted through the outlet orifice. Valves with Cv
max. 3.8 do not feature any seat ring gasket (2).
7.4 Assembly
Before assembly, clean thoroughly the inside of the valve body and parts. Gasket
seating surfaces and surfaces in contact with others must be thoroughly cleaned. On
assembly, a new seat ring gasket (2) and a new packing (6) must be used.
Step A: Place a new seat ring gasket (2) in the valve body (13) and install the seat
ring (3) taking care to correctly centre the gasket on the seat ring shoulder.
Orient it in such a manner that one of its ports lines up with the body outlet
orifice.
Note: In the event of a maximum Cv smaller than 0.10, the seat ring (3e) must
first be positioned on the new gasket (2) taking the same precautions as
shown above. Secondly, engage the spacer (3f) and orient one of its ports
towards the body outlet orifice. Valves with Cv max. 3.8· do not feature
. I
any seat ring gasket (2). ·
Carefully apply grease (Never Seez or equivalent) on the threads and bottom of the
retainer (4). With a 9116" or 14 mm piece of hex stock and a wrench, torque the
retainer to 8 Nm if equipped with a graphite gasket st. reinforced, or to 5.5 Nm if
equipped with a glass filled P:T:F:E: gasket.
Note: In case of a valve with maximum Cc 3.8, torque the retainer to 2 Nm.
Step B: Engage the plug and stem assembly in the seat ring. In the case of a
maximum Cv < 0.1 0, ensure that there is no hard point during the stocking
of the plug. In case of a hard point, loosen the retainer (4) and replace the
seat ring (3e) in the correct position until the stem smoothly slides. Align
the hole in the spacer (5) with the safety pin (11) hole in the valve body.
Note: In the event of a maximum Cv smaller than 0.10 ensure that the
retaining ring (182) is placed on the plug before engaging it in the spacer
(3f). If the retainer ring is damaged, replace it.
Step C: Wrap the safety pin (11) with two turns ofP:T:F:E: tape (Teflon). Screw it
into the bonnet five and a half to six turns from where the thread

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engagement starts. To fmd the start of the thread engagement screw on the
safety pin about one turn and pull the safety pin outwards while unscrewing
it.
Step D: Install packing, positioning the skive cut of each packing ring 120° away
from the cut of an adjacent ring. Slightly push down the rings one after
another by using a tube W' sch. Size 160. Install the packing follower (9) on
the plug stem.
Step E: Install the actuator bracket (108) and secure it with the two nuts (Sa). Install
the packing flange nuts (10) on the plug stem. Hand tighten the two packing
flange nuts (8b) adding one full tum with a wrench.
Step F: In the following sequence, place the grommet plate (101), spring (106), and
its spring button (102). Screw the nut (103) and clevis (104a) on the plug
stem. Adjust the nut and clevis without locking them together until the
clevis holes are about 1.5 mm above the alignment of the pin holes in the
actuator bracket (108).
Note: Measuring this distance can be made easier by engaging the pins (105,
184, and 18) in their respective hole.
Step G: Pin lever No.2 (22) to the bracket (108) by using the pin (18). Ensure that
the hole oflever No.2 destined for spring clamp (115) is located on the top
and aligned with the force balance spring (114).
Step H: Place the adjustment pin (23) in the slide of lever No. 1 and screw the knob
(24) on its threaded end. Engage the pin smooth end (23) into the slide of
lever No. 2 and mount lever No. 1 on the bracket (1 08). Couple lever No. 1
to the bracket (108) by using the pin (105) and the two retainer clips (112a).
Note: Ensure that the clevis (104a) is correctly positioned before placing lever
No.1 on the actuator bracket (108).
Step 1: Set the adjustment knob (24) on minimum Cv position.
Step J: If the piston rod clevis (104b) has not been disturbed during disassembly,
couple it to the end of lever No. 2 by using the pin (124) and the two
retainer clips (112c).
Note: This operation will be facilitated by placing the piston rod in an

intermediate position by admitting air to the diaphragm and by setting
the knob in a position where the end of lever No. 2 is left most accessible.
H the clevis (104b) has been disturbed, proceed with adjustment and
coupling as described in the section "Calibration".

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Step K: Couple the clevis (104a) to lever No. 1. To perform this operation push to
align the holes in the clevis and lever No. 1 by means of a screwdriver on
the plug stem end. Couple by means of the two pins (184) and retainer clips
(112b).
Note: Insert the clips on the pins between the slides of the clevis and lever No.
1.
Step L: With the take-up screw ( 116) fully unscrewed from the spring clamp ( 115),
place the latter in position after hooking the force balanced spring (114)
first on the positioner spring bracket (151) and secondly on the spring
clamp (115).
Note: The spring clamp (115) has two holes. If it is a close-on-air failure
actuator the spring must be hooked in the upper hole. In case of valve
open-on-air failure, the spring must be hooked in the lower hole.
Step M: Admit supply and signal pressures and complete the calibration. Replace
the cover (11 0) and turn the hand wheel clockwise to engage it in the lever
arm stop (122). Tighten the cover screws (109).
Step N: If the valve has been removed from the line, reinstall it according to the
section "Installation" and then set the valve back into service.
7.5 Packing quick change method
The fastest and simplest way to replace the packing is to remove the entire actuator
without disturbing the actuator parts or calibration. However, this is not
recommended for valves with a small Cv (Cv < 0.6) due to the very fineness of their
plug. Vent the valve pressure and proceed as follows:
Step A: Be sure that the plug is off the seat ring. With an air-to-open valve, admit
air pressure under the diaphragm or turn the hand wheel to move the plug
off its seat ring.
Step B: Remove the safety pin (11) from the body. The safety pin engages the
packing spacer (5). The function of the safety pin and spacer is to prevent
the plug from being pushed out if the actuator is removed while the valve is
still pressurised. The valve internal parts cannot be removed unless the
safety pin is removed first. Remove the two packing flange nuts (Sb) and
back off the two mounting nuts (Sa) as far as possible.
Step C: With a block of wood and a mallet, tap the actuator plug assembly off the
valve. Clean the packing box and plug stem and carefully place the new
rings of packing around the stem. Position the skive cut of each packing
ring 120° from that ofthe adjacent ring.

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Step D: Assemble the actuator/plug assembly to the valve taking care to align the
hole in the spacer (5) with the safety pin hole and to replace the two
mounting nuts (Sa) during assembly. Take extra care in guiding each ring
into the packing box.
Step E: Wrap the safety pin (11) with two turns of P.T.F.E. tape (Teflon). Screw it
into the bonnet five and ·a half to six turns from where the thread
engagement starts. To fmd the start of the thread engagement screw the
safety pin about one turn and pull the safety pin outwards while unscrewing
it.
Step F: Replace the packing follower, packing flange, and flange nuts (8b). Tighten
the nuts fmger tight plus one full turn. With an air-to-open actuator, vent the
air pressure or turn the hand wheel to move the plug back in contact with
the seat ring. Set the valve back into service.
7.6 Positioner maintenance
Note: Shut off supply and signal pressures. By-pass and depressurise the valve
body.
Step A: Unscrew the two pressure connection nuts (138a) and pull out the tubing
(140).
Step B: Unscrew the cap screws (141a) and remove the manifold block (144),
spring (158), gasket inclusive three 0-rings (146), pilot valve assembly
(155, 156, 157), shims (145), and 0-ring (153).
Caution: Handle the shims (145) carefully.
Step C: Loosen lock nut (117) and take-up screw (116) and unhook the spring
clamp (115) from the lever (22).
Step D: Unscrew the cap screws (141b) from the positioner block (147) and remove
it from the actuator bracket. Remove the screws (148) to separate the
positioner diaphragm assembly (152) and spring (154) from the positioner
block. Examine all parts for wear and replace, if necessary.
Step E: Assemble the positioner diaphragm assembly (152) with the spring (154) to
the block and tighten the screws (148). Be sure that the small signal port 0-
ring is in its recess in the diaphragm assembly.
Step F: Assemble the block assembly to the actuator bracket.
Note: Orient the block (147) so that when the manifold block (144) is bolted on,
the gauges will face in the right direction.

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Step G: Install 0-ring (153), shims (145), pilot valve assembly (155, 156, 157),
gasket including three 0-rings (146), spring (158), and manifold block
(144). Tighten the cap screws (141a), replace the tubing (140), and tighten
the pressure connection nuts (138a).
Note: Gasket ports in (146) must align with the ports in the block (147).
Step H: Hook up the spring (115) on lever No. 2 (22). Admit supply and signal
pressures. Adjust start-up pressure as described in the section "Calibration".
Set the valve back into service.

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Table of contents
Oil flow meter

General ........................................................................................................................ l
Commissioning ............................................................................................................ 2
Dismounting and mounting instructions ..................................................................... .3
Trouble shooting .......................................................................................................... 4

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AALBORG OIL FLOW METER OM8160#01.4
INDUSTRIES
Oil flow meter
1 General
The oil flow meter unit is equipped with a set of spindles (M), pole wheel (P), and
pick-up sensor (1), see also Figure 1. The measuring principle is positive
displacement.
The oil flow causes the measuring spindles (M) to rotate, and in front of the pick-up
sensor (I) the pole wheel (P) is turning in an exactly defmed distance (a). The pick-
up sensor (I) records an impulse for every pole which moves along. This electronic
impulse is then sent to the control system. With each rotation an exact volume is
given, and by settings in the control system the impulses are converted into a 4-20
rnA flow signal.
lllustration of the oil flow meter unit
Control
system
Figure 1 omg03a.cdr
The oil flow meter can be installed in any position. But it must always be free from
tensions to prevent distortion of the oil flow meter. Furthermore, it should be located
in a position from where it is possible to dismount the pick-up sensor.
As shown on the nameplate indicated in Figure 2, both flow directions are possible.
But the preferable flow direction is indicated by the all white arrow symbol.
The accuracy of the oil flow meter depends on the momentary flow. Figure 3 shows
the characteristic for the oil flow meter.
The oil flow meter is very sensitive towards larger objects in the oil, and these
objects can cause a total blockage of the oil flow meter. To prevent large objects
from entering the oil flow meter, the oil system must be provided with a filter (max.
0.3-0.5 mm mesh). The filters located in the oil pump unit will usually provide for
an adequate filtration.
The dry sleeve is mounted, adjusted, and tested with the pick-up sensor as a unit.
The pick-up sensor, including the milled nut and spring, is screwed into the dry

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INDUSTRIES
sleeve. The spring must be able to press the pick-up insert smoothly to the front side
of the dry sleeve. It is important for the function of the sensor system that the dry
sleeve is free of foreign substance. The sensor system is shown in Figure 4.
The sensor system (pick-up sensor and cable) must not be in an area of
electromagnetic field pulses with high intensity. This could cause measuring errors
or even destruction of the sensor system.
Dlustration of the nameplate
XXX
XX PJij 231.1
·c I 1-1 150
40 I mm2/sl 4 1-1 25
Figure2 omg02.cdr
Accuracy - diagram
+0.3
-
~
~
+0.2
+0.1
>- "--:-:: """:-- ~= -:-::::-
=--
0
~
::s
0
0
<(
0
-0.1
---~ -.,..
/
-..:..:
F..:..: ... -
-·!'-...
1000 mm2/s
150 mm2/s
40 mm2 2/s
5 mm /S
-0.2
-0.3
50 100 150
Flow rate(% Qmax.)
Figure3 omgOl.cdr
Dlustration of the sensor system
3 4
1. Dry sleeve
2. Pick-up sensor
3.Spring
4. Milled nut
Figure 4 beg44.cdr

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lllustration of the oil flow meter, type OMG 20
Flange
:L.::t:...tt---- Socket screw
,,..,..'--+-r-.........,.. 0-ring
Grooved pin
Spacer
Circlip
Circlip ~~~~~~~~~-----Spacer
Spacer
Deep groove
ball bearing
f1~~~~======-Spindle set
Deep groove
ball bearing
Socket screw
0-ring
Circlip
Flange
FigureS omg04a.cdr
lllustration of the oil flow meter, type OMG 32
Flange
Socket screw -----fl,..+,,J..UJ.-.I 0-ring
End cover-----.~,,
Head bolt
Pole wheel
Grooved pin
Deep groove
ball bearing
~~WhLTJ------"""Spindle set
Deep groove
ball bearing
0-ring
Head bolt
Circlip
Flange
Figure 6 omg05a.cdr

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2 Commissioning
Step A: Ensure that the oil system has been thoroughly flushed for impurities and
that it is free from air.
Note: Impurities cause the oil flow meter to be blocked, and air affects the
accuracy of the oil flow meter.
Step B: Check that the oil flow meter and pick-up sensor are installed correctly.
Step C: Set the values for max. oil and beats/10 litre in the control system. The max.
oil value is the maximum oil flow in 1/h at 100% burner load on heavy fuel
oil (provided this is the main fuel). The value for beats/litre can be taken
from the identification of the oil flow meter (see Figure 2).
Step D: Unscrew the pick-up sensor from the oil flow meter.
Step E: Tap the pick-up sensor quickly against an object and check that the control
system records the signals.
Step F: Mount the pick-up sensor again.
Step G: Check and adjust the oil flow settings for minimum load, ignition load, etc.
in the control system.
3 Dismounting and mounting instructions
For dismounting and mounting the oil flow meter and sensor system please also see
Figure I, Figure 4, Figure 5, and Figure 6.
3.1 Oil flow meter
3.1.1 Dismounting
Step A: Remove the oil flow meter from the pipe line.
Step B: Remove the flange covers and end covers.
Step C: Press out the spindle set with rolling bearings and distance sleeve from the
measuring casing.
Note: If the spindle set or measuring casing must be replaced, the oil flow
meter must be re-calibrated.
Language UK Page4/7
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3.1.2 Change of bearings
Step A: Remove the pressed-on pole wheel from the measuring spindle.
Step B: Remove the circlips, spacers, and rolling bearings.
Step C: Remove the 0-rings.
Note: The 0-rings are specially designed for the oil flow meter. If a
replacement is necessary, only original 0-rings must be used.
Step D: Clean all parts carefully, take care not to scratch the sealing surfaces.
3.1.3 Mounting
Step A: Mount the 0-rings.
Step B: Press the rolling bearings on the measuring spindle and mount the circlips
and spacers.
Step C: Press on the pole wheel.
Step D: Insert the spindle set into the measuring case.
Step E: Press the distance sleeve into the measuring case.
Step F: Mount the end covers and flange covers.
Step G: Tighten the screws crosswise.
Step H: Install the oil flow meter in the pipe line again.
3.2 Pick-up sensor
3.2.1 Cleaning/replacing the pick-up sensor
Step A: Dismount the pick-up sensor by unscrewing the milled nut.
Step B: Clean or replace the pick-up sensor. The pick-up sensor can be changed
without performing any regulation of the distance between the pick-up
sensor and pole wheel.
Step C: Mount the pick-up sensor and screw on the milled nut.
Note: The dry sleeve must not be turned.

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3.2.2 Dismounting of the dry sleeve
Step A: Empty the oil flow meter.
Step B: Dismount the pick-up sensor.
Step C: Note the position of the gap in the dry sleeve. From factory a red painting
dot marks the sleeve screw-in depth and position.
Step D: Open the counter nut by means of a wrench size 24.
Step E: Turn out the dry sleeve by means of a wrench size 15.
3.2.3 Mounting of the dry sleeve
Step A: Turn in the dry sleeve until the 0-ring is sealing.
Step B: Fill the oil flow meter with oil and start one of the oil pumps.
Step C: Turn the dry sleeve carefully until it gazes softly on the rotating pole wheel.
Then turn it one full turn back and tighten the counter nut. Use the red
marking dot as guidance. The distance of the dry sleeve to the pole wheel
must be 1.00 mm and the position of the gap has a maximum deviation
tolerance of± 10°.
Step D: Mount the pick-up sensor again.
Step E: Check that the signal from the pick-up sensor is functioning. If not, adjust
the distance between the pole wheel and pick-up sensor again.

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4 Trouble shooting
If a fault occurs, the basic and necessary conditions for operation must be checked:
• Is electric power supply available?
• Is oil available in the tanks?
• Are the oil pumps running correctly?
• Are all the regulating controls correctly adjusted?
If the cause of the fault is not due to any of these conditions, the fault fmding chart
in Table 1 can be consulted.
Viscosity of the medium and/or temperature

Too high pressure flow rate is too high
drop
Seal is not tightened enough Tighten screws

Leakage Seal is damaged Change seal
Check chemical resistance
Foreign substance Clean flow meter
Use filtration
Blocked flciw meter Pick-up sensor mounted too far Adjust pick-up sensor
inside
Not Raise inlet
Remove air
Degassing Raise system pressure, reduce temperature
Too high pulsation Change oil pump, modify system
Operation: Change of operating conditions
Too high measuring
• high flow fluctuation
default
• Quantity too small
• Differing operating data
High wear New oil flow meter
Filtration of abrasive material
Defective pick-up insert Screw out the pick-up and check it tapping the pick-up
sensor quickly against an object (control system records)
No signal from pick-
Defective connection Luminous diode
up sensor
Check connections
electronics
Defective pick-up insert New pick-up insert
Defective contacts Check contacts
No ordinary signal
External interference Install cables
from pick-up sensor
Distance to the pole wheel not
correct Correct distance
Table 1

15
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Table of contents
Differential transmitter
General ........................................................................................................................ !
Technical description ................................................................................................... 2
Installation .................................................................................................................. .3
Commissioning ............................................................................................................ 4
Operation of the transmitter ........................................................................................ .5
Maintenance ................................................................................................................. 6

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AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0
INDUSTRIES
Dp-transmitter, type 7MF4433
1 General
The following description is valid for a differential pressure transmitter SITRANS P,

type 7MF4433.
Warning: This device may only be assembled and operated after qualified
personnel has ensured, by providing suitable power supplies, that no
hazardous voltages can get into the device in normal operation or in
the event of a failure of the system or parts thereof.
Warning: The device may be operated with high pressure and corrosive media.
Therefore serious injuries and/or considerable material damage
cannot be ruled out in the event of improper handling of the device.
The perfect and safe operation of this equipment is conditional upon proper
handling, installation, and assembly as well as on careful operation and
commissioning.
2 Technical description
2.1 Application
The SITRANS P transmitter can be used to measure:

• the differential pressure, e.g. the active pressure,
• a small positive or negative excess pressure,
• flow q- p0·5 (together with a flow control valve)
of non-corrosive and corrosive gases, vapours, and liquids.
Measuring spans are possible between 1 mbar and 30 bar depending on the type.
The output signal is a load-independent direct current of 4 to 20 rnA. A linear
(proportional to the differential pressure) or square rooting characteristic
(proportional to the rate of flow) can be selected.
Transmitters conforming to the type of protection "Intrinsic safety" and "Explosion-
proof'' may be installed within potentially explosive atmospheres zone 1 or zone 0.
The transmitter is provided with an EU prototype test certificate and comply with
the corresponding harmonised European standards of the CENELEC.

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AALBORG. DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0
INDUSTRIES
Figure 1 shows a function diagram of the SITRANS P differential pressure and flow
transmitter. The item numbers referred to in the following description are those
mentioned in the in the figure.
The differential pressure is applied via the diaphragms (4) and the filling liquid (3)
to the silicon pressure sensor (7). If the measuring limits are exceeded, the overload
diaphragm (6) is flexed until one of the diaphragms (4) rests on the measuring cell
body (2), thus protecting the silicon pressure sensor (7) from overloading.
The measuring diaphragm of the silicon pressure sensor is flexed by the applied
differential pressure. The resistance of four piezo-resistors fitted in the diaphragm in
a bridge circuit th+us changes. This change in resistance results in a voltage output
from the bridge proportional to the differential pressure. This voltage is amplified
and converted into a frequency by means of a voltage-to-frequency converter (9).
This signal is evaluated by a micro controller (10), and its linearity and temperature
effect corrected.
The processed signal is converted by a digital-to-analogue converter (11) into an
output signal of 4 - 20 rnA.
The data specific to the measuring cell as well as the parameters of the transmitter
are stored in a non-volatile memory (EEPROM).
The cable termination point and the electronics are arranged opposite one another.
Parameterisation of the transmitter is performed using a laptop, PC, HART®
Communicator, or the input keys. Normally the input keys are used to set-up the
transmitter.
Function diagram
8 9
~}~
I
+ } Differential pressure 50-Ring

- as Input variable 6 Overload diaphragm
/A Output signal 7 Silicon pressure sensor
UH Power supply 8 Instrument amplifier
9 Voltage-to-frequency converter
1 Process flange 10 Microcontroller
2 Measuring cell body 11 Digital-to-analog converter
3 Filling liquid 12 LCD (option)
4 Diaphragm 13 Analog indicator (option)
Figure 1 7mt33 Ol.tif

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The following parameters can be set or their current interrogated:

• measuring range
• measured value in rnA, %, and unit of pressure
• unit of pressure
• linear or square rooting characteristic
• application point of the square rooting characteristic
• electric damping
• current transmitter
• output current in the event of an error
• disabling input keys and/or functions
2.3 Dimensions
SITRANS P, differential pressure and flow transmitter, dimensions
10
a
1
i
L~
4
• 181 for aeries OS wHh PROFIBU5-PA

.. 45 for Pg 13,5 wHh adapter
Process connection~ ·18 NPT 5 Connection side

for absolute pressure (+) side 6 Electronics side, digital display
2 Mounting thread M10, M12 or 7118 • 20 UNF (greater length for cover wHh window)
3 Dummyplug 7 Protective cover over keys
4 Electrical Connection: 8 Sealing screw
Screwed gland Pg 13.5 (adapter) 9 Side vent for measuring liquid
M20 x 1.5 orY:t ·14 NPT or 10 Side vent for measuring gas (supplement H02)
Han 70/Han 8 U plug 11 Mounting bracket (optional)
Figure 2 7mf33 02.tif

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3 Installation
3.1 Place of installation
The transmitter can be installed above or below the pressure tapping point. When
measuring gases, it is recommended to install the transmitter above the pressure
tapping point and the pressure pipe to be laid so it runs down to the pressure tap.
This will permit any condensation in the pipe to drain off and not affect the
measurement. When measuring liquids, the transmitter should be installed below the
pressure taping point and the pipe laid so it rises up to the pressure tap, thus enabling
any gas in the pipe to dispersed.
The point of installation should be easily accessible, preferably close to the
measuring point and free from vibration. The permitted ambient temperature limits
must not be violated. Protect the transmitter from direct heat sources. Before
installing the transmitter, compare the process data against the data on the rating
plate. Keep the transmitter closed during the installation process.
The transmitter can be fitted directly to the valve manifold or secured with a
mounting bracket.
3.2 Fixing with a mounting bracket
The mounting bracket is fixed to either

• a wall or mounting frame using 2 screws,
or to
• a vertical or horizontal mounting pipe (50 to 60 mm in diameter) using aU-bolt
(see Figure 3).
The transmitter is fastened to the mounting bracket using the four screws supplied.
Fixing the transmitter using a mounting bracket
Figure3 7mt33_03.tif
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3.3 Rotating the measuring cell in relation to the housing
If necessary, the measuring cell of the transmitter can be rotated in relation to the
electronics housing, so that the digital display is visible and/or access the input keys
and the current connection for an external measuring instrument is possible.
Only a limited rotation is permitted. The range of rotation (7), see Figure 4, is
marked at the base of the electronics housing. At the neck of the electronics housing
there is an orientation mark (6) which always must be within the marked range when
rotated.
Step A: Loosen the locking screw (8).
Step B: Rotate the electronics housing in relation to the measuring cell (only within
the marked area.
Step C: Tighten locking screw (torque 3.5+0.1 Nm).
Rotating the measuring cell in relation to the housing
-< " --r- I -r- -,_
-~-8
Figure 4 7mf33_04.tif
Warning: Observe the relevant regulations during the electrical installation. In

hazardous areas, pay particular attention to:
• the regulations governing electrical systems in hazardous areas (Elex V),

• the specifications regarding the installation of electrical systems in hazardous
areas (VDE 0 165), and,
• the EC type examination certificate

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Warning: Check that the auxiliary power supply matches that specified on the
rating plate.
The transmitter should be powered from a SELV (safety extra-low voltage) source.
If other power sources are used, it is recommended to earth the transmitter housing
and PE connection. The earth terminal in the connection box must be connected
internally to the PE connection.
Please note that:
• The sealing caps in the cable entries have to be replaced by relevant cable
glands or blanking plugs, which must be certified when using transmitters
conforming to protection type "Flame-proof enclosure".
• The following general guidelines apply when laying terminal (maximum cross
section 2.5 mm2)/signal cables:
lay the signal cable separately from cables carrying voltages> 60 V
use twisted-pair cables
do not lay cables close to large electrical systems, or use screened cable
3.4.1 Connection to screw terminals
Electrical connection
Figure 5 7mt33_OS.tif
Step A: Unscrew the cover of the connection box (marked "FIELD TERMINALS"
on the housing).
Step B: Insert the connecting cable through the cable gland.
Step C: Connect the wires the "+" (2) and "-" (3) to the terminals, see Figure 5 and
observe the polarity. Position (4) is a test plug for an external DC amp-
meter.
Step D: Connect the screen (1) to the screen screw, if necessary.
Step E: Screw on the housing cover.

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Note: In explosion-proof transmitters the housing cover must be screwed on

tightly and secured with the cover catch.
3.4.2 Connect with plug

The contact parts for the coupling socket are enclosed packed in a bag. Please note
that these must not be used for explosion-proof transmitters.
Step A: Push the sleeve and screwed gland onto the cable.
Step B: Insulate the cable ends approximately 8 mm.
Step C: Crimp or solder the contact parts to the cable ends.
Step D: Assemble the coupling socket.
Connection with plug
lA output current
VH auxiliary power
3.5 Turning the digital display
If the device cannot be operated in a vertical position the digital display can be
turned to make it easier to read. To do this, proceed as follows:
Step A: Unscrew the cover from the electronics housing.
Step B: Unscrew the digital display. Depending on the position of the transmitter it
can be screwed back in four different positions (rotation by ±90° or ±180°
are possible).
Step C: Screw on the housing cover.

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4 Commissioning
The process data must correspond to that on the rating plate. The transmitter
functions as soon as the power is turned on.
Warning: Serious injury or considerable material damage may result if:
• the venting valve and/or the sealing screw are missing or not tight enough
and/or
• the valves are operated wrongly or improperly
Warning: When working with a hot medium, the individual steps described
below must be performed in quick successions, otherwise the valves
and transmitter may overheat and be damaged.
4.1 Measuring gases
The isolating valves should be operated in the following sequence, see Figure 7:
Measuring gases
10
4 4
1 Transmitter
2 Equalizing valve
3 Pressure Inlet valves
4 Impulse lines
5 Isolating valves
7 Outlet valves
9 Condensate traps
10 Pressure source
10
Transmitter above Transmitter below

pressure source pressure source
(normal configuration) (non-standard)

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Step A: Initial setting: all valves closed.
Step B: Open both isolating valves (5) at the pressure tapping points.
Step C: Open the equalising valve (2).
Step D: Open the pressure inlet valve (3A or 3B).
Step E: Check the zero point (4 rnA) at start of scale (0) and correct if necessary.
Step F: Close the equalising valve (2).
Step G: Open the other pressure inlet valve (3A or 3B).
4.2 Measuring liquids
Measuring liquids
1 Transmitter
2 Equalizing valve
3 Pressure inlet valves
4 Impulse lines
5 Isolating valves
7 Outlet valves
8 Venting valves
10 Pressure source
12 Gastrap
10
4 4
7A
Transmitter below Transmitter above

pressure source pressure source
(normal configuration) (non-standard)
Figure 8 7mt33_ 08.tif
Step C: Open the equalising valve (2).

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Step D: If the transmitter is below the pressure source: open both outlet valves (7)
slightly, one after the other, until no more air escapes.
Step E: If the transmitter is above the pressure source: open both venting valves (8)
slightly, one after the other, until no more air escapes.
Step F: Close both outlets (7) or venting valves (8).
Step G: Open the pressure inlet valve (3A) and venting on the positive leg of the
transmitter (1) slightly until no more air escapes.
Step H: Close the venting valve.
Step 1: Open the venting valve on the negative leg of the transmitter slightly until no
more air escapes.
Step J: Close pressure inlet valve (3A).
Step K: Open the pressure inlet valve (3B) slightly until no more air escapes, close
after.
Step L: Close the venting valve on the negative leg of the transmitter (1).
Step M: Open the pressure inlet valve (3A) Y2 a rotation.
Step N: Check the zero point (4 rnA) against start of scale (0) and correct if
necessary.
Step 0: Close the equalising valve (2).
Step P: Open the pressure inlet valves (3A and 3B) fully.
4.3 Measuring steam
Caution: The result will only be correct when the impulse lines (4) contain an
identical head of condensate at identical temperatures. Zero point
calibration should be repeated, if necessary, when this condition is
satisfied.
Caution: The flow of steam may damage the transmitter if the equalising valve
(2) is opened when both the isolating valves (5) and pressure inlet
valves (3) are open!

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Measuring steam
1 Transmitter
2 Equalizing valve
3 Pressure inlet valves
4 Impulse lines
5 Isolating valves
7 Outlet valves
10 Pressure source
13 Condensate reservoir
14 Jacket
Step C: Open the equalising valve (2)
Step D: Wait until the steam in the impulse line (4) and in the condensate reservoirs
(13) has condensed.
Step E: Open the pressure inlet valve (3A) and venting valve on the positive leg of
the transmitter slightly until no more air escapes.
Step F: Close the venting valve.
Step G: Open the venting valve on the negative leg of the transmitter slightly until
no more air escapes.
Step H: Close pressure inlet valve (3A).
Step 1: Open the pressure inlet valve (3B) slightly until no more air escapes.
Step J: Close the venting valve on the negative leg of the transmitter.
Step K: Open the pressure inlet valve (3A) Y2 a rotation.
Step L: Check the zero point (4 rnA) against start of scale (0) and correct if
necessary.
Step M: Close the equalising valve (2).
Step N: Open the pressure inlet valves (3A and 3B) fully.

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5 Operation of the transmitter
5.1 General
The differential pressure and flow transmitter is adjusted in the field by three input
keys, located on the outside of the instrument, with which the start of scale and full
scale values are set or adjusted. By means of the digital indicator (optional)
additional parameters can be adjusted. The input keys can be accessed, by undoing
the two screws holding the protective cover in place, which can then be moved out
oftheway.
Transmitter controls and displays

3 4 5
1)
Symbols for
Input keys
0
1 Digital display
2 Connecting plug
for digital display
3 Mode key
4 Increment key
5 Decrement key
00002
[}!®-
The functions listed in Table 1 can be selected using the "M" key. When pressing
the "M" key (Mode) 2 appears in the bottom left comer on the LCD display. Every
additional key press increases the mode by one. The parameters, the current value,
or the unit of pressure can be modified using the t and -!- keys. In case of error
situations "Error" is displayed on the display, (see section 5.2.7). It generally
applies that:
• The transmitter changes to function "Measured value", if mode 14 is passed by
pressing the "M" key or if 2 minutes elapse without a key being pressed. In case
of the 2 minutes being passed the setting is automatically saved.
• The key lock must be released for keyboard operation.
• Numerical values are always set from the least significant digit still displayed. In
the case of an overflow in the key repetition mode it switches to the next
significant digit and only this continues to be counted. This procedure serves for
fast rough setting over a wide numeric range. For fme setting the desired key (t

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AALBORG
INDUSTRIES
or ..!.) have to be released and pressed again. Exceeding of the upper and lower
measured value limits are shown on the display with the signs t or ..!. .
o If the input pressure is displayed, selected in mode 13 (see section 5.2.10), and
the square rooting characteristic in mode 11 (see section 5.2.9) the differential
pressure corresponding to the flow and additionally the sign "--./" is displayed on
the display.
Section
Measured value 5.2.10

disturbed. Moving text
Error display 5.2.7
Start of scale 2 5.2.2
Full scale 3 Output current in rnA 5.2.2

smaller
Damping Time constant T63 m seconds
Elecnicaldamping 4 5.2.3
smaller Parameter 0.0 to 100.0
Pressure Set to start
5 smaller ofsca1e 0
Start of scale in selected unit of pressure 5.2.4
Set to upper
Full scale Pressure Pressure
6 measuring Full scale in selected unit of pressure 5.2.4
"blind setting" greater smaller
limit
Zero adjustment
Vent transmitter (start of scale remains unaffected).
(position 7 Execute 5.2.5
Measuring value in unit of pressure
Constant output current in rnA
Current Current
Current transmitter 8 Switch on 3.6- 4.0- 12.0- 20.0- 22.8 5.2.6
greater smaller
Switch
Output current in Change between the Selected output current
9 5.2.7
the event of an error two values Possible: fault current limits set user
"0" =none
"LA"= all disabled
"LO" =all disabled except start of scale
Keys and/or Change between the
10 "LS" = all disabled except start of scale and full 5.2.8
function disable five functions
scale
"L" =write protection, operation by HAR~ not
"Lin"
"SrLin" =square rooting
Change between the
Characteristic 11 (linear up to application point) 5.2.9
three functions
"SroFF" = square rooting
off
12 Greater Smaller Parameter range 5 to 15% flow 5.2.9
Unit of pressure (input value) or output current in

13 5.2.10
rnA or%
Unit of pressure 14 Change Technical units of pressure 5.2.11
I) Change mode by pressing the "M" key.

2
>The start of scale is in a vacuum in absolute pressure transmitters. The zero adjustment in ventilated transmitters leads to mis-adjustments.
Table 1

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5.2 Operation with LCD display
5.2.1 General
• Please note that the input keys might be disabled. To cancel a set keyboard
disable press the "M" key for 5 seconds.
Step A: Undo the two screws holding the protective cover in place, which can then
be moved out of the way.
Step B: On completion of calibration replace the protective cover and tighten both
screws.
5.2.2 Set/adjust start of scale and full scale

The start of scale and full scale can be set or adjusted with the input keys. Modes 2
and 3 (see Table 1) are available for this. This allows implementation of rising or
falling characteristics.
Setting (theoretical relationship)
In setting, a desired start of scale and/or a desired full scale are assigned to the
standard current values (4 mN20 rnA). Pre-requirements: two reference pressures
(Prb pr2) provided by the process or generated by a pressure transmitter.
Note: The measuring span is not changed when setting the start of scale. By
setting the full scale the start of scale remains unchanged. Therefore the
start of scale should be set first and then the full scale.
The relationship between the measured pressure and the generated output current is
linear. Please note that this does not apply if square rooting characteristic is selected.
In case of linear relationship the output current can be calculated with the following
equation shown in Figure 11:
Equation for calculation of current output
1• output current
p =pressure
MA =start of scale
p-MA "16mA+4mA
I= ME-MA I
I ME =full scale
Example
Given a transmitter with a measuring span of 0 to 16 bar. Set to a measuring span of
2 to 14 bar.
Step A: Apply 2 bar process pressure. Set the device to mode 2 with the "M" key.
The display shows the set mode at the bottom left. Set the start of scale by
pressing the t and ..!.. keys on the value for about 2 seconds. An output
current of 4 rnA is then generated at 2 bar input pressure.

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Step B: Apply 14 bar process pressure. Set the device to m:ode 3 with the "M" key.
The full scale is set by pressing the t and J.. keys on the value for about 2
seconds. An output current of 20 rnA is then generated at 14 bar input
pressure.
Step C: The output current for any input pressure can be calculated with the
specified equation shown in Figure 11.
Adjusting (theoretical relationship)

When adjusting, the start of scale and/or the full scale can be assigned to any desired
current value using one reference pressure. This function is particularly suitable if
the pressures necessary for start of scale and full scale are unavailable.
Requirements: applied pressure (reference pressure) and the set start of scale and full
scale are known. Please note that after adjusting, the measuring range specified on
the measuring point plate may no longer match the setting.
Using the following equation shown in Figure 12 the current that should be adjusted
for the desired start of scale and full scale can be calculated.
Equation for calculation of current (set the start of scale and full scale)
)
currenllo be
set alMA..., I= P,., -MA...., *16mA+4mA
ME.ct-MAa
1)
oorrent to be
setetME...., I= P.., ·MAnam *16mA+ 4 mA
Me..,..- 1M_,
I = output amant MEoc~ =old lulls<:ale

P..r " applied refenii1Q8 pressure MA"" =old start of scale
ME,.,. =new ful scale
W.,... = naw s1arlofscale
11To calculate the output cunenls when aeting etart of scale and run scala, the reference praesure must
be selectad so lhat a value between 4 and 20 rnA 18 obtained for lhe current.
Example
Given a transmitter with a measuring span of 0 to 16 bar. Adjust to a measuring span
of2 to 14 bar. A reference pressure of 11 bar is available.
Step A: Set the device to mode 2 with the "M" key. Using the equation from Figure
12 first calculate the current that should be adjusted for the desired start of
scale (2 bar) at the applied reference pressure and then adjust it with the t
and J.. keys (13 rnA in this example).
Step B: Set the device to mode 3 with the "M" key. Using the equation from Figure
12 calculate the current that should be adjusted for the desired full scale (14
bar) at the applied reference pressure and then adjust it with the t and J..
keys (16 rnA in this example).

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Set start of scale and full scale (practical application with actual pressures
available)
The device sets the output current for the start of scale to 4 rnA and the full scale to
20 rnA when the input keys are pressed according to the following instructions.
The start of scale is set by:
Step A: Apply the corresponding pressure.
Step B: Select mode 2 using the "M" key.
Step C: Set the start of scale to 4 rnA with the t and .J.. keys.
Step D: Save with "M".

The full scale is set by:
Step E: Apply the corresponding pressure.
Step F: Select mode 3 using the "M" key.
Step G: Set the full scale to 20 rnA with the t and .J.. keys.
Step H: Save with "M".
Set start of scale and full scale (practical application with reference pressure
available)
If the output current is not set but adjusted continuously, the currents must be
calculated so they can be adjusted mathematically. It is possible to make an
adjustment for the start of scale, the full scale, or both values one after the other.
The start of scale is adjusted by:
Step A: Apply the reference pressure.
Step C: Adjust the output current for the start of scale with the t and .J.. keys.

The full scale is adjusted by:
Step E: Apply the reference pressure.
Step F: Select mode 3 using the "M" key.
Step G: Adjust the output current for the full scale with the t and .J, keys.
Step H: Save with "M".
5.2.3 Electric damping

The time constant of the electric damping can be set in steps of 0.1 second between
0 and 100 seconds with the input keyboard. This damping acts additionally to the
device-internal basic damping.
The electric damping is set by:

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Step A: Select mode 4 using the "M" key.

Step B: Set the desired damping with the t and .J- keys.
Step C: Save with "M".
5.2.4 Blind setting of start of scale and full scale

In modes 5 and 6 the start of scale and full scale can be set/adjusted with the input
keys and without applying pressure. It is also possible to change between rising and
falling characteristics.
Theoretical relationship
First select the desired physical unit. The two pressure values can then be
set/adjusted with ·the t and .J- keys and saved in the device. These theoretical
pressure values are assigned to the standard current values 4 mA and 20 rnA.
The relationship between the measured pressure and the generated output current is
linear. Please note that this does not apply if square rooting characteristic is selected.
Example
Given a transmitter with a measuring span of 0 to 16 bar. Adjust it to a measuring
span of 2 to 14 bar without applying pressure.
Step A: Set the device to mode 5 with the "M" key. Set the start of scale to 2 bar by
pressing the t or .J- key. If 2 bar input pressure are applied later, an output
current of 4 mA is generated.
Step B: Set the device to mode 6 with the "M" key. Set the full scale to 14 bar by
pressing the tor .J- key. If 14 bar input pressure are applied later, an output
current of 20 mA is generated.
Set start of scale and full scale, blind (practical application)

The device sets the start of scale to the lower and the full scale to the upper sensor
limit when the keys are operated as follows:
The start of scale (blind) is set by:
Step B: Press the t and .J- keys simultaneously and hold for 2 seconds. The start of
scale is set to the lower sensor limit.
The full scale (blind) is set by:
Step C: Select mode 6 using the "M" key.
Step D: Press the t and .J- keys simultaneously and hold for 2 seconds. The full
scale is set to the upper sensor limit.
Adjust start of scale and full scale, blind (practical application)

If the pressures for the start of scale and full scale are not to be set but adjusted
continuously, the keys should be operated as follows:
The start of scale (blind) is adjusted by:

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Step B: Adjust the pressure value of the start of scale with the t or -1, keys.

The full scale (blind) is adjusted by:
Step E: Adjust the pressure value of the full scale with the tor -1, keys.
Step F: Save with "M".
5.2.5 Zero adjustment (position correction)

The zero error resulting from the installation position can be corrected with a zero
adjustment. To do this, the device must be ventilated to correct the existing offset so
that the value 0 bar (or other unit of pressure) appears in the display. The setting of
the start of scale and full scale remain the same.
The zero adjustment is set by:
Step A: Vent the transmitter.
Step C: Set zero with the t and -1, keys.
5.2.6 Current transmitter

The transmitter can be switched to constant current mode with the "M" key. In this
case the current no longer corresponds to the process variable. The following output
currents can be set independently of the input pressure:
- 3.6 rnA- 4.0 rnA- 12.0 rnA- 20.0 rnA- 22.8 rnA
The current transmitter function can be cancelled again with the "M" key.
The constant current is set by:
Step B: Activate the constant current mode by pressing the t and -1, keys
Step C: Activate the constant current level by pressing the tor -1, key.
Step D: Turn off the constant current mode with the "M" key.
Step E: Exit the constant current mode with the "M" key.
5.2. 7 Failure current

In mode 9 it is possible to select whether the upper or lower fault current should be
the output in the event of a fault or an alarm. The current can be set to 3.6 rnA or
22.8 rnA. The default is the lower fault current.
The fault current is set by:

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Step B: Select the fault current with the t or .J... key.
5.2.8 Key and/or function disable

In mode 10 it is possible to disable several functions which are generally possible
with keyboard operation. In addition a write protection to protect the saved
parameters can be activated. The following settings are possible:
"0" no disabling.
"LA" input keys disabled, operation via HART® possible.
"LO" input keys disabled, only start of scale can be set. Operation via HART®
possible.
"LS" input keys partly disabled, only start of scale and full scale can be set.
Operation via HART® possible.
"L" write protection, operation via HART® not possible.
A set keyboard disable (LA, LO, LS) or a write protection for HART® (L) can be
cancelled with the input keys. To do this, press the "M" key for 5 seconds.
Note: H the "LO" or "LS" disable is selected, it is recommended to select the

measured value display "Current" in mA or % first in mode 13.
Otherwise a change in the output variable is not detected when pressing
the t and .J... keys.
The key/function disable is set by:

Step B: Select the disable mode with the tor .J... key.
Step C: Save the disable mode with the "M" key.
Note: When delivered with a blanking cover, the disable mode "LS" is active,
i.e. only zero and span can be changed. H the device permanently is
operated with a blanking cover, make sure that the disable mode "LS"
remains set.
5.2.9 Flow measurement

The characteristic of the output current can be selected as:
• Linear (proportional to the differential pressure), or
• Square rooting (proportional to the flow)
Below the application point of the square rooting characteristic the output current
can either be output linearly or switched off. When "SrLin" is selected the output

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current is linear up to the application point (see Figure 13 a) and when "SroFF" is
selected the output current is switched off up to the application point. The
application point can be set between 5% to 15% of the flow.
The characteristic is set by:
Step B: Select the characteristic type with the t or -!,. key.

The root application point is set by:
Step E: Select the application point between 5% and 15% with the tor-!,. key.
Step F: Save with "M".
Note: Mode 12 cannot be selected when the "linear" measuring mode 11 is set.
If the input pressure is selected as a display in mode 13 and square
rooting characteristic in mode 11, the differential pressure
corresponding to the flow and root sign are displayed.
Transition point of square rooting characteristic
Output[%]
square
root
•. 15 ••..•.••...
Adjusting
range for Transition
10
transition point
point
_..J'-... .....
--,..... , .... "
2 3 4
a: linear below translffon point
: 20 40 60 80 100
20
pressure{%]
square
root
15
Transition
point
0
0 2 3 4
b: cut-elf below trans/ffon point
Figure 13 7mf33 11.tif

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5.2.10 Measured value display

In mode 13 one of three display types can be set with the input keys.
• Display in rnA.
• Display in % (of the set measuring range).
• Display in a unit of pressure (selectable in mode 14).
The unit type is set by:
Step B: Select the type unit with the t or ..1- keys.
5.2oll Selection of unit of pressure

In mode 14 it is possible to select a desired unit of pressure for the display from a
list with the input keys. The following unit of pressure can be chosen:
Bar, mbar, mm H2o*>, in H2o*>, ft H 2o*>, mm Hg, in Hg, psi, Pa, kPa, Mpa, g/cm2,
kg/cm2, Torr, ATM, in WC, mm WC.
*)Reference temperature 20°C.
The unit of pressure is set by:
Step B: Select the unit of pressure with the tor ..1- key.

If the display capacity of the digital display is exceeded, "9o9o9o9.9" appears in the
display. Please note that in the measuring mode the selected unit is only visible in
the display if a unit of pressure display is selected in mode 13. Otherwise "rnA" or
"%" is displayed.
5o3 Operation without LCD display
5o3o1 Setting start of scale and full scale without LCD display
• Please note that the input keys might be disabled. To cancel a set keyboard
disable press the "M" key for 5 seconds.
Step A: Undo the two screws holding the protective cover in place, which can then
be moved out of the way.
Set start of scale (4 mA) and full scale (20 mA)

Assuming the input keys are pressed as described below, the transmitter sets the start
of scale to 4 rnA and the full scale to 20 rnA. An ammeter is not required.
Start of scale
Step A: Apply a differential pressure corresponding to the start of scale to the

transmitter.

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Step B: Press the t and .!.. keys simultaneously for about 2 seconds.
Full scale
Step A: Apply a differential pressure corresponding to the full scale to the

transmitter.
Step B: Press all three input keys, making sure that the "M" key is pressed frrst,
hold it, and press both the other keys (t and .!..).
Calibrate start of scale and full scale

If the output current is not to be set but freely adjusted continuously, the currents
must be calculated for mathematical adjustment. It is possible to make an adjustment
for the start of scale, the full scale, or both values one after the other.
Warning: It is forbidden to screw off the transmitter cover when working in

hazardous locations and using transmitters conforming to protection
type "Flame-proof enclosure" (Explosion-proof).
Step A: Clean the transmitter to prevent the ingress of dirt.
Step B: Unscrew the cover from the electrical connection box.
Step C: Connect a DC meter to the test plug (see Figure 5).
Warning: For intrinsic safe current circuits only certified current meters are
permitted.
Start of scale
Step A: Apply a differential pressure corresponding to the start of scale to the

transmitter.
Step B: Set the output current for start of scale using the t and .!.. keys.
Step C: The set output current is saved automatically when the key is released.
Full scale
Step A: Apply a differential pressure corresponding to the full scale to the
transmitter.
Step B: Set the output current for full scale using the "M" key and the t key or the
"M" key and the.!.. key. Always press the "M" key frrst, hold it, and press
either the t or the .!.. key.
Step C: The set output current is saved automatically when the key is released.

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6 Maintenance
The transmitter requires no maintenance. However, the start of scale value should be
checked occasionally.
If an error occurs:
• the output current is set to 22.8 rnA or 3.6 rnA, depending on the selection (see
section 5.2.7)
• using SIPROM P an appropriate message is displayed in the "Measured values"
field
• "Error" is displayed on the LCD display

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Table of contents
Regulating valves
Electrical actuator, type Premia
General ........................................................................................................................ l
Description .................................................................................................................. 2
Installation .................................................................................................................. .3
Settings ........................................................................................................................4
Starting up .................................................................................................................. .5
Care and maintenance .................................................................................................. 6
Dismantlement of the thrust actuator ........................................................................... 7
Troubleshooting ........................................................................................................... 8
General ........................................................................................................................ l
Operation ..................................................................................................................... 2
Maintenance ................................................................................................................ .3

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AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2
INDUSTRIES
Electrical actuator, type Premio
1 General
These operating instructions contain information necessary to install and operate the
thrust actuator both safely and effectively. If problems arise which cannot be solved
with the aid of this operating instruction, please contact Aalborg Industries for
further information.
1.1 Qualified personnel
This refers to personnel possessing corresponding qualifications and familiar with

the processes of installing and assembling the product as well as with putting the
product into service and operating the same, e.g.
Training, instruction, or authorisation to switch on and off electric circuits and
equipment/systems and to disconnect, ground, and identify the same in
accordance with VDE 0100, the regulations stipulated by the local electricity
generating boards as well as technical safety standards.
Instruction and obligation to comply with all regulations and requirements
pertaining to use as well as regional and in-house regulations and requirements.
Training or instruction in accordance with technical safety standards in the use
and maintenance of pertinent safety equipment includingjob-safety equipment.
1.2 Handling
Storage
• Storage temperature: -20"C to +70"C dry, free of dirt.
• Do not damage packing.
• A desiccant or heating to prevent condensation is necessary in damp rooms.
Transport.
• Transport temperature: -20"C to +70"C.
• Protect against external force (impact, vibration, etc.).
• Do not damage packing.
Handling before installation
• Protect against atmospheric conditions e.g. wetness.
• Correct handling protects against damage.
• Do not soil or damage type identification plate and wiring diagram on the
controller.

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2 Description
2.1 Field of application
The PREMIO linear thrust actuators are employed to actuate control or shut-off
valves requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2
kN to 15 kN. The thrust actuators are set to the thrust forces specified in the
technical data. If supplied with the valve, the lift of the thrust actuator will be set to
the stroke distance of the valve. Selection of the proper actuator version in alignment
with the corresponding fitting as well as use of the thrust actuator in accordance with
the specified technical data is the responsibility of the systems engineer.
Attention: Any use of the thrust actuator beyond the specified technical data
or improper use of the actuator is deemed to be not for the intended
purpose.
The ambient conditions have to be conformed to the actual electromagnetic

compatibility directives. Additional the compatibility to this directive has to be
maintained in case of expansion or other changing of the ambient conditions.
2.2 Method of functioning
The thrust actuator, fitted with a yoke or columns, is mounted to the valve. Transfer
of force is affected via a coupling safeguarded against torsion. The torsion
safeguarding feature also serves as a lift indicator. The lift settings can be read off
on a lift dial attached to the yoke or between the 2-ear clamps mounted to the
column.
The electrical components are accommodated separately from the gearbox
underneath a sealed hood, thus being protected against operating and environmental
effects. Following removal of the hood, easy access is provided to the switch gear
and indicating feature.
The rotary motion of the motor is transmitted to the spindle nut by means of spur
gear. The drive spindle, which is safeguarded against torsion, screws its way into the
spindle nut and thus performs a pull or push motion depending on the sense of
rotation. In the fmal positions of the valve, the spindle nut is pressed against a set of
springs so as to produce closing force.
The motor is switched off by means of two load-dependent switches and one stroke-
dependent switch. The load-dependent switches will also switch off the motor if
foreign bodies have lodged themselves between the valve seat and cone.
The load-dependent switches serve to protect the valve and thrust actuator against
damage.
2.3 Technical data
The technical date for the thrust actuators is appears from Table I. Actuator
diagrams are illustrated in Figure 1 and Figure 2 and the part list is shown in Table
2. Finally a dimension drawing can be found in Figure 3.

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24 v- 50160 Hz
115 v - 50160 Hz
Additional voltages I frequencies
3-400 v- 50 Hz
3-440 v- 60 Hz
Standard-voltage connection PA
2 torque switches and I travel switch, zero potential, for
Low-voltage connection board
free wiring, with gold contacts, switching capacity max.
(electronic system), NA
0.1 4-30 V de
Temperature controller (three-point controller) in micro process technologies.
Three-step temperature-controller in microprocessor-technology.
Integrated temperature-controller Control range: -200°C to 850°C (resistance thermometer).
dTRON 16.1 Voltage: 24 V, 115 V, or 230 V 50/60Hz.
Compatible with resistance thermometers and thermocouples (provided by customer), or
standardised active
Actuator with 400 V - 50 Hz and
Integrated reversing contactor 440V -60Hz.
Phase control relay
Table 1

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Diagram for actuators type 2.2 - 5.0 kN
Yoke Version Column Version
50.9
,..--1\:=:t~{::=~= 50.96
50.8
llli-~----r-- 50.10
50.6
50.7 50.1:Z.1
50.5
50.12 50.4
50.2
50.1
50.16
50.30
50.17
50,34.
50.23
50.31
50.32
50.87
50.35
50.27
50.19
5020
~¥===-- 50.21
50.22
Figure 1 premio_l.tif

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Diagram for actuators type 12.0 - 15.0 kN
50.9
50.96
--;rt---1---50.8
IJ.JI.--J-1---t---50.10
50.12
50.1
50.2
50.53
50.55
50.52
5051 50.56
50.54
50.50
50.42
50.47
50.38
50.101
1.1
50.45 50.36
50.57
50.58
Figure2 premio_2.tif

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Table2
Dimensions diagram
Clearance required for

removal of hood
•200x175

~ removal of hood
removal of hood c165x150
ARI·PREMIO 2,2 • 5 kN ARI·PREMIO 2,2 • 5 kN ARI·PREMIO 12 ' 151tN

Nomioal stroke max. 30 mm Nomioal stroke> 30 mm ·SO mm Nominal stroke max. 80 mm
Figure3 premio_3.tif

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3 Installation
Note: Safe operation of the actuator is only ensured if it is installed, put into
operation, and maintained by qualified personnel. In addition, care must
be taken to ensure that the general equipment and safety regulations for
electrical lines and installations are complied with and that tools and
protection devices are used professionally. The operating instructions for
the electronic actuator must be observed when carrying out all work on
and when handling the electronic actuator. Disregard of these
instructions can result in injury to persons or damage to property.
3.1 General installation notes
In addition to general installation guidelines, the following points are required to be

observed:
- Existing operating instructions for valve.
- Complete valve with cross-arm.
Valve cone approximately in mid lift position - on no account supported inside a
seat.
Electrical installation in accordance with DJN VDE 0100 and regulations of the
local electricity generating board.
Conductor cross-section selected to correspond to the given drive power and
existing line length.
- Mains fuse rating max. 6 A.
- Circuit breakers to EN 60335-1 in the plant to cut off the mains supply to the
actuator.
- Conformity of technical data on thrust actuator with field conditions.
- Mains voltage in accordance with data specified on rating plate of thrust
actuator.
- Thrust actuator complete with yoke or distance columns and coupling parts
intended for mounting to the corresponding valve.
- Qualified personnel possessing knowledge of the regulations pertaining to the
erection of power installations.
- Ease of access to installation site and adequate clearance space above the thrust
actuator for removing the hood.
- Install where there is protection against high-energy heat radiation.
- The ambient temperature must not exceed +7o·c.
- In case of widely fluctuating ambient temperatures and high atmospheric
humidity, user is recommended to install a heating resistor to minimise
condensation build-up in the actuator.

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- Thrust actuator mountable in any position except in downward suspended

position.
- If installed with a horizontal connecting rod, the thrust actuator must be
mounted so that both legs of the yoke or columns are on top of one another in
the vertical plane.
3.2 Manual operation
For actuators type 2.2 -5.0 kN

With the motor in the stationary state, the thrust actuator can be run in the open and
closed state with the hand wheel firmly meshed with the gear. Proceed as follows:
Step A: Swing out lever (50.12.1) from hand wheel (50.12), see Figure 4.
Turning in clockwise direction --> closes valve.

Turning in counter-clockwise direction --> opens valve.
Hand wheel operation (actuator type 2.2 - 5.0 kN)
.. ·. n . . . CloSe . ·· ·
..n....
. .~· ... ··
. so:1Z.1·.·
50.12
Figure 4 premio_4.tif
In the manual operating mode pay careful attention in the final positions that the
hand wheel is only turned to the point where the torque switch trips (audible click)
as otherwise damage will be caused to the thrust actuator. Since the hand wheel
always follows during motor-driven operation (running indication), never operate by
hand while the motor is running -potential injury hazards.
For actuators type 12.0 -15.0 kN
With the motor in the stationary state, the thrust actuator can be run in the open and
closed state with the engage able hand wheel. Proceed as follows:
Step A: Fold the turning handle out of the hand wheel (A), see Figure 5.
Step B: Turn the hand wheel slightly and push in the engaging button for manual
mode (B)--> the button engages.
- Turning in clockwise direction --> closes valve.

- Turning in counter-clockwise direction --> opens valve.
The motor is no longer in mesh when the hand wheel is engaged. The hand wheel is
automatically disengaged when the motor starts and the hand wheel is once more in
mesh.

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Hand wheel operation (actuator type 12o0 -15o0 kN)
Engaging button
for manual mode
50.12.1
Figure 5 premio_ 5otif
In the manual operating mode pay careful attention in the fmal positions that the
hand wheel is only turned to the point where the torque switch trips (audible click)
as otherwise damage will be caused to the thrust actuator.
3o3 Installation instructions for mounting to valves
3o3o1 Mounting for valve-lift up to 30 mm (yoke version)

To mount the thrust actuator to a valve having a nominal lift of up to 30 mm,
proceed as follows (Fig. and position numbers refer to Figure 6):
Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust
actuator (not illustrated).
Step B: Set valve cone position to approximately mid lift position.
Step C: Tum flat hexagon nut if not present on valve spindle (Fig. A).
Step D: Slip coupling (50.27) over valve spindle (Fig. A-B).
Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut. Setting
dimension (Y) for fitting-projection (X) are 60 and 83 mm = 102 mm.
Step F: Place thrust actuator (50) on valve (Fig. C). Mount thrust actuator on fitting
with two T-head bolts (50.19), two washers (50.20), two spring washers
(50.21), and two hexagon nuts (50.22).
Step G: Swing out hand wheel lever (50.12.1) and use it to move out the thrust
actuator until the driving spindle (50.30) comes to rest on the threaded bush
(50.87), (FIG. D-E).
Step H: Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and
secure in place using grub screw M6 (50.35), (Fig. F).
Step 1: Run valve to lowest position.
Step J: Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety
feature is in alignment with tip of arrow mark on lift dial.

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Step K: Run valve to both final positions and check to ensure that these are safely
reached.
Step L: Carry out electrical connection (see section 3.4) and set travel switch S3
(see section 4.3).
Mounting for valve-lift up to 30 mm (yoke version)
A B c D E F
Figure 6 premio_ 6.tif
3.3.2 Mounting for valve-lift over 30 mm to 80 mm (column version)

To mount the thrust actuator to a valve having a nominal lift of over 30 mm to 80
mm, proceed as follows (Fig. and position numbers refer to Figure 7):
Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust
actuator (not illustrated).
Step B: Set valve cone position to approximately mid lift position.
Step C: Tum flat hexagon nut if not present on valve spindle (Fig. A).
Step D: Slip coupling (50.27) over valve spindle (Fig. A-B).
Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut. Setting
dimension (Y) for fitting-projection (X) is 83 mm = 102 mm or 98 mm =
116mm.
Step F: Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very
lightly (Fig. C).
Step G: Screw distance column with 2-ear clamps on opposite side of hand wheel
into the flange in such a way that one of the 2-ear clamps is situated above
the torsion safety feature (50.32) and the other below.
Step H: Screw the other distance column into the flange likewise.

........
iliiiiiii
INDUSTRIES
Step 1: Place thrust actuator (50) with distance columns onto valve and ftx into
position with two self-locking hexagon nuts (50.25).
Step J: Fold out turning handle of hand wheel (50.12.1), slightly turn the hand
wheel and press in the engaging button for manual mode (only 12- 15 kN)
(button engages). Having done this, move out the thrust actuator until
driving spindle (50.30) comes into contact with threaded bush (50.87), (Fig.
D-E).
Step K: Screw coupling (50.27) ftrmly into torsion safety feature (50.32) and secure
using grub screw M6 (50.35), (Fig. F).
Step L: Move the valve to the lowest position.
Step M: Press 2-ear clamps (50.26} into position according to the stroke so they
cannot slip, with the bottom clamp in the lowest valve position located
directly below torsion safety feature (50.32} and the top clamp in the
highest valve position located directly above the torsion safety feature.
Step N: Move the valve to both travel positions and check that it reaches them
reliably. Fold turning handle ofhand wheel (50.12.1) back in.
Step 0: Make the electrical connection (see section 3.4). The engaging button for
manual mode (only 12- 15 kN) disengages when the motor starts up.
StepP: Set standard travel switch S3 (see section 4.3).
Mounting for valve-lift over 30 mm to 80 mm (column version)
A B c D E F
so
Figure 7 premio_7 .tif

...... ..
iliiiiili
INDUSTRIES
Figure 8 and Figure 9 illustrate the wiring diagrams for actuators type 2.2- 5.0 kN
and actuators type 12.0- 15.0 kN respectively. To connect the thrust actuator up to
the electrical power supply, proceed as follows:
Step A: Run the thrust actuator a few mm out of the lower fmal position applying
the manual mode.
Step B: Loosen countersunk screw m hood, carefully remove hood in upward

direction.
Step C: Screw out one of the two cable inlets and re-assemble in the same way
without the supplied blank flange.
Step D: Insert the connection line through this cable inlet until sufficient conductor
length is available up to the corresponding terminals. Then tighten the cable
inlet until the connecting cable is clamped in place inside it.
Step E: Strip connecting cable approx. 1 - 1.5 em above cable inlet.
Step F: Strip the individual conductors approx. 5 mm away from the end and fit
with conductor end sleeves.
Step G: Connect protective conductor of connecting cable up to protective

conductor terminal of thrust actuator.
Step H: Connect neutral N/MP conductor of connecting cable up to terminal 1/N of

thrust -actuator terminal strip.
Step 1: Connect pulse line for move-out connecting rod up to terminal 11 of thrust-
actuator terminal strip.
Step J: Connect pulse line for move-in connecting rod up to terminal 14 of thrust-
actuator terminal strip.
Step K: Place hood on carefully from above and mount firmly onto thrust actuator
with countersunk screw and rubber gasket.
Step L: Connect supply line to mains and run thrust actuator to each of the final
positions so as to check whether the fmal-position travel switches effect
switching off, also checking to see whether the direction of movement on
the thrust actuator corresponds to the desired direction.
Step M: If the directions of movement are contrary to those desired, the pulse lines
governing the move-in and move-out connecting rod will need to be
exchanged.

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INDUSTRIES
4 Settings
4.1 Torque and travel switches -standard feature
Thrust actuators are as standard equipped with a load-dependent travel switch for the
closing direction (Sl), a load-dependent travel switch for the opening direction (S2),
and a stroke-dependent travel switch for the opening direction (S3). The load-
dependent travel switches (Sl, S2) switch off the motor as soon as the factory-set
thrust force is attained.
Note: The settings of the load-dependent travel switches must on no account

whatsoever be changed.
The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or
stroke is attained. If the thrust actuator is supplied on a straight-way valve, the
stroke-dependent travel switch S3 is set in such a way that the motor of the thrust
actuator is switched off as soon as the maximum valve-lift is attained. If the thrust
actuator is supplied on a three-way valve, the trip cam belonging to travel switch S3
is set in the opening direction in the trip slide to such a downward extent that the
upper final position of the valve is attained prior to travel switch S3 being reached,
thus causing the load-dependent travel switch S2 to switch off the motor.
For this function, all three switches reveal interlock-controlled circuitry on the
board. If the standard travel switches are to be integrated directly into the facility
control system, the standard board can be replaced by optional boards PA or NA
(only 2.2-5.0 kN).
4.2 Connection boards PA or NA (only 2.2 - 5.0 kN)
On connection boards PA or NA, the standard travel switches Sll/S21, S12/S22,

and S13/S23 do not reveal interlock-controlled circuitry and can be integrated
individually into the facility control system. The 3 contacts on each of the switches
S11/S21, S12/S22, and S13/S23, designed as double-throw contacts, are, in the case
of these boards, brought out on terminals 40 - 48 and can be freely connected.
The switches on the PA optional board (standard-voltage connection board) are
designed for switching capacities of up to 10 A, 250 Vac. The switches on the NA
optional board (low-voltage connection board) are designed for switching capacities
of up to 0.1 A, 4-30 V (gold contacts). The optional boards may only be installed
at the factory due to the switching points of the load- dependent switches having to
be reset following installation of these boards~
Note: When using optional boards PA or NA, it must be warranted -due to the
operator's individual circuitry- that, when switching the load-dependent
travel switches 811/21, S12/S22, and S13/S23 the motor of the thrust
.actuator comes to a standstill without delay. This function is not
provided for on the optional boards P A and NA in the supplied state.

. ..........
iliiiiili
INDUSTRIES
4.3 Setting of standard travel switch (53)
On delivery of the thrust actuator, the standard travel switch (83) is already set to the
existing valve-lift and the setting spindle for the travel switch (83) is sealed with
screw glyptal. This setting needs no changing for normal operation.
If reinstalling the thrust actuator on a straight-way valve, the travel switch (S3)
needs to be set as follows:
Step A: Move valve out of the lowest position so as to run valve-lift to up position.
Step B: Using a screw driver, proceed to turn setting spindle for switch (83) until
the trip cam arriving from below trips the switch (audible click).
Step C: Run thrust actuator briefly in closing direction and then in opening direction
once more, checking to see whether the thrust actuator is switched off at the
desired point (nominal lift).
Step D: If needed, correct the setting as described.

If reinstalling the thrust actuator on a three-way valve, the travel switch (83) needs
to be set as follows:
Step E: Run valve in both final positions and check in each final position whether
the valve switches off via the load-dependent switches.
Step F: Carry out a check in the top fmal position the see whether, after switching
off the thrust actuator, the trip cam of the travel switch (83) is situated
below switch (83) and has not tripped the latter. If the trip cam is situated
above the travel switch (83) or trips the same, the setting spindle governing
the travel switch (83) needs to be turned until the trip cam is situated below
travel switch (83) without tripping it.
Step G: Run the thrust actuator in both fmal positions once more and check whether
thrust actuator switches off in both fmal positions via the load-dependent
switches.
Step H: If needed, correct the setting as described above.
4.4 Potentiometers
The potentiometers are used for electrical position acknowledgement on the facility
control system or for the options, electronic position controller ES 11 or electronic
position indicator Rl21. A maximum of 2 potentiometers can be installed (= 1
double potentiometer). The potentiometers can be supplied with different resistance
values.
For the electronic position controller E8 11 and the electronic position indicator RI21
use must be made solely of 1000 ohm potentiometers. Conversion of the relevant
valve-lift to the potentiometer angle of rotation is effected by means of transmission
determined in respect of each valve-lift between the toothed rack on the trip slide
and the pinion on the potentiometer shaft. Use must only be made of the pinion
specified for the valve-lift.

..........
iliiiiili
INDUSTRIES
If the thrust actuator is supplied with the valve and built-in potentiometer, the
potentiometer is assembled and set ready for operation. To achieve optimal
electromagnetic compatibility it is recommended to use shielded cables for
connecting potentiometers or standardized active current or voltage signals.
4.4.1 Installing the potentiometer

If retrofitting the potentiometer, proceed as follows:
Step A: Switch off mains voltage and safeguard to prevent it from being switched
back on again accidentally.
Step B: Loosen countersunk screw in hood, carefully remove hood.
Step C: Plug in the flat connectors on grey potentiometer cables onto the middle
connector pins, those of the red cables onto the upper connector pins and
those of the yellow cables onto the lower connector pins of the
potentiometer (see Figure 10, Figure 11, and Table 3).
Step D: Insert the potentiometer into the guide in the way that the pinion (50.73) of
the potentiometer meshes with the gear stick of the trip slide.
Step E: With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand
window of board support (50.42) above the potentiometer guide, insert into
the guide between the slide block and the potentiometer guide and hook
into the cut-out below the potentiometer.
Step F: With a valve lift between 30 mm and 50 mm, hook spiral spring (50.70) into
the right-hand window (for 12.0 - 15.0 kN middle window) above the
potentiometer guide, insert into the guide between the slide block and the
potentiometer guide and hook into the cut-out below the potentiometer.
Step G: With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70)
into the middle window in board support (50.42) above the potentiometer
guide, insert into the guide between the slide block and the potentiometer
guide and hook into the cut-out below the potentiometer.
Step H: Check to see whether pinion (50.73) is pressed into toothed rack by spiral
spring (50.70) and is positioned free from backlash.
Step 1: If this is not the case, remove spiral spring (50.70), readjust by bending a
little, and place back in position again.
Step J: Screw jack strip of connecting cable (50.68) to board support (50.42) with
two self-tapping screws (50.69), (single potentiometer connectors 25-27).
Step K: Insert additional 3-pole connector (50.74) in jack strip of connecting cable
(50.68).
Step L: Set potentiometer.
Step M: Place hood carefully onto thrust actuator and fasten it on the actuator with
rubber gasket and countersunk screw.

.
........
iliiiiili
INDUSTRIES
Installation of potentiometer
50.67.3
50.71
50.67.2
50.73 50.67.1
50.72 50.95
Figure 10 premio_1 O.tif
Potentiometer connection cable
red grey
~:
~yellow
yellow
Figure 11 premio_ll.tif
50.74
50.95 Spring washer
Table3
4.4.2 Setting the potentiometer

To set the potentiometer, proceed as follows:
Step A: Move thrust actuator to closing position.
Step B: Switch off mains voltage and safeguard to prevent it from being switched
back on again accidentally.

........
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INDUSTRIES
Step C: Using a screw driver, turn slotted potentiometer shaft in counter-clockwise

direction until reaching the travel stop. This places the potentiometer in the
initial position (approx. 0 ohm).
Step D: For checking purposes, the resistance of the potentiometer needs to be

measured using an ohmmeter.
Step E: Measure the resistance on potentiometer 1 between terminals 25 and 26.
Step F: Measure the resistance on potentiometer 2 between terminals 28 and 29.
Step G: In this position of the actuator, the measured value should be approx. 0
ohm.
Step H: Run thrust actuator to upper final position and read off corresponding
resistance value on ohmmeter.
Step 1: The resistance values thus measured need to be taken into account for the
settings to the facility control system.
5 Starting up
Check the following before starting up a new system or restarting a system after
repairs or conversion:
• Correct completion of all installation/assembly work.
• Circuits of the system in accordance with DIN VDE regulations and regulations
of the relevant power supply company as well as compliance with all safety
regulations.
• Hood of thrust actuator assembled.
• Start up only by qualified personnel.
Warning: While in operation, the thrust actuator has moving and rotating
parts as well as being integrated in an electrical network system.
Improper handling or failure to observe the operating instructions
or the valid regulations may lead to death, grievous bodily injury or
substantial property damage
When placing into service proceed as follows:

Step A: Use the hand wheel, to run the thrust actuator to approximately mid lift
position.
Step B: Apply brief pulses to the thrust actuator for each direction of movement and
check whether the directions of movement correspond to those desired. If
this is not the case, the pulse lines governing the opening and closing action
must be exchanged on the thrust actuator.

..........
-.
iliiiiili
INDUSTRIES
Step C: Run thrust actuator to the final position in each direction of movement and
check whether it switches off automatically and whether all externally
moving parts are able to move freely.
Step D: If failing to function properly, check all installation and setting work
previously carried out, correcting if necessary, and afterwards place into
service once again.
6 Care and maintenance
The thrust actuator requires very little maintenance. Accordingly maintenance in

specified intervals is not necessary. The thrust actuator must not be cleaned with
high-pressure equipment or aggressive solvents or detergents injurious to health or
highly inflammable. During and after cleaning, an inspection should be carried out
of the sealing points on the thrust actuator. If there is any sign of lubricant escaping
or dirt having accumulated, the sealing elements must be repaired.
7 Dismantlement of the thrust actuator
In addition to general installation guidelines, the following points are required to be

observed:
• Dismantlement of the thrust actuator from the fitting must only to be carried out
by suitably qualified personneL
• The supply line for connecting up the thrust actuator must be in the dead state
i.e. disconnected while dismantlement work is being carried out. After being
disconnected, the mains power must be prevented from being switched back on
again accidentally.
• The system must be run down (depressurised state) as the valve cone is not held
without the thrust actuator and would thus be conducted by the system pressure.
• Valve cone approximately in mid lift position - on no account supported inside a
seat.
To dismantle the thrust actuator proceeds as follows:
Step A: Loosen counter-sunk screw in hood, carefully remove hood.
Step B: Disconnect all cables led into thrust actuator from outside and remove from
thrust actuator.
Step C: Place hood on carefully from above and fix in place with counter-sunk
screw and rubber gasket.
Step D: Loosen grub screw inside torsion safety feature; screw coupling out of
torsion safety feature.
Step E: Loosen clamping bolts connecting the thrust actuator to the fitting.
Step F: Remove thrust actuator from valve.

.
.......
iliiiiili
INDUSTRIES
8 Troubleshooting
In the event of malfunctions or disturbances in operation, first check whether the

installation and adjustment work has been carried out and concluded in accordance
with these operating instructions. Compare the data referring to operating voltage,
actuating signal and temperature to the data specified on the layout drawing of the
control system. Also check whether the given operating conditions correspond to
those specified on the type identification plate.
Warning: All relevant safety regulations must be observed when carrying out
the troubleshooting procedure.
Contact the supplier/manufacturer if faults cannot be rectified on the basis of the

following troubleshooting table:
Short circuit due to:

-moisture
-wrong connection
Thrust actuator fails to move
-motor has burned out
(Only for 12.0- 15.0 kN)

Hand wheel is still engaged and does
not disengage when the motor starts up
Thrust actuator alternates between
clockwise and counter-clockwise Motor operating capacitor defective
rotation
Thrust actuator fails to run to final

positions and also produces chatter
Set travel switch (S3) in accordance

opening direction prior to load-
with operating instructions
switch
Table 4

........
iliiiiili
INDUSTRIES
1 General
This type of control valve is suited to regulate fluids, gases and steams. The valve
plug is normally a parabolic plug, but can also be supplied in a perforated design.
Both types of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always against the closing direction.
However, with perfomted plugs for steam and gases, it is in the closing direction. If
a valve with a perforated plug is operated by means of a pneumatic actuator with the
flow in the closing direction, the pneumatic actuator should have a stronger thrust
force. This is necessary to prevent thumping near to the closing position.
All control valves can be fitted alternately with manual-, pneumatic-, electric- or
hydraulic operation devices.
lllustration of control valves type 470 and 471
Control valve, type 470 Control valve, type 471

---------7.1
,.------10.1
,--------6 ,.------15.1
~------7 ~U+'"'/ _ , - - - - - - 17.1
~----3.1
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-------17
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~~~~~~~r----19
~~~___::::~~-- 5
~-~~ 2
Figure 1 val47x.cdr

.
...........
iliiiiiii
AALBORG
INDUSTRIES
Table 1
2 Operation
2.1 Fitting instructions
The valve should be inserted so that the spindle has a vertical position together with
the actuator. The valve can also be tilted to a maximum horizontal position if the
installation point does not allow any better condition.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length (min. two times the pipe
diameter by inlet and six times by outlet). The piping should be rinsed to clear out
any pollution, welding beads, rust, etc. before inserting the control valves. A strainer
should be fitted in front of the control valve to catch the remaining particles. Bolts
should be tightened after taking into operation.
The flow direction is signalled by an arrow on the valve body. The valves should be
insulated against high temperatures to guard the actuator.
2.2 Actuator assembly
The control valves are normally delivered with actuators already fitted. For
alternations or maintenance of actuator, the assembly should occur in accordance
with the operation instructions for the actuator.
2.3 Setting into operation
When the piping system is filled, the spindle sealing should be checked for leakage
and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as
the spring tension maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter
than it is necessary for the sealing. Flange connection bolts should never be loosened
or tightened when the valve is under temperature or pressure even if a leakage may
arise.
For actuators please see to the appropriate actuator operation instructions.

...........
1
ii'1·1·I 1·i· Iii
INDUSTRIES
3 Maintenance
Before any maintenance of the control valve is carried out, the piping system must
be shut off and pressure free.
3.1 Exchange of the stuffing-box packing
A leak stuffmg-box packing should initially be carefully tightened to stop the

leakage. If this does not help, a new layer should be inserted, or the complete
packing should be replaced.
3.1.1 Additional packing layer
Step A: Open the valve fully and unscrew the hexagon nuts (17).
Step B: Lift the gland flange (7) and the spindle guiding (8) upwards.
Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting

at 180° to avoid overlapping).
Step D: Fix the hexagon nuts (17) properly.
3.1.2 Exchange
Step B: Unscrew the hexagon nuts (17) from the studs (15).
Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffmg
box ( 10) and clean the packing compartment.
Step D: Clean the valve spindle and check for damage and if necessary replace. If
the damaged spindle is not replaced, the new packing will leak after a short
period.
Step E: Insert the new packing rings (split ring-displacement, splitting at 180° to
avoid overlapping).
Step F: Fix the hexagon nuts (17) properly.
Note: Strenuous tightening will prevent leakage, but will also have a brake
effect on the spindle which aggravates the movement of the spindle.
3.2 Exchange of a PTFE-V-ring sealing unit
A PTFE-V -ring unit is spring loaded and has enough set pressure to ensure a good
seal even by low operation pressures. It is replaced as mentioned above.
The PTFE-V -ring sealing unit should be lubricated before it is inserted. The sealing
lips must face against the pressure direction.

.
..........
iliiiiili
INDUSTRIES
Note: Special care should be given to the spindle surface. Rough surfaces wear
the sealing lips enormously and can be due to failure of the packing unit.
3.3 Exchange of the bellow unit
Step B: Unscrew the screw joint (7 .1 ).
Step C: Unscrew the hexagon nuts (17) and remove the bellow housing (25).
Dismantle the plug as described in the next section.
Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1).
Step E: The bellow unit (26) is removed from the bellow housing (25).
Step F: Replace the two gaskets (14.1) and the gasket (14).
Step G: When the bellow unit (26) is replaced, the proper position of the anti-
twisting device must be observed.
Step H: The set pins (21) have to drive within the slots of the anti-twisting device.
Check for friction-free movement.
Step 1: Replace mounting bonnet (3 .1) and screw down the hexagon nuts (17 .1)
crosswise.
3.4 Exchange of the plug-spindle unit
Step B: Unscrew the gland flange (7).
Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).
Step B: Pull out the plug with the spindle and exchange this unit.
Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6).
Step D: Replace the old parts and assemble it.
Step E: Drill a hole through the plug shaft and insert a new pin.
Step F: Replace the gasket (14) and assemble the mounting bonnet (3).
Step G: Tighten the nuts (17) evenly, crosswise.

........
iliiiiili
INDUSTRIES
3.4.3 Control valve type 471 .
Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with
plug (5).
Step B: Drive the spindle in the bottom position and remove the spring-type straight
pin (19).
Step C: Unscrew the plug.
Step D: Screw a new plug at the spindle and drill through the shaft. Drive the
spring-type straight pin (19) into the hole.
Step E: Replace the gasket (14).
Step F: Assemble the bellow housing (25) with plug (5) together with the body (1)
and fix it by screwing the hexagon nuts (17) crosswise.
The spindle can only be completely replaced together with the bellow.
3.5 Changing the seat ring
The seat ring is screwed into the valve body. The seat ring can be obtained after
removing the bonnet and can then be refinished or replaced as required.
Step A: Clean and lubricate the thread and conical sealing surface before insertion.

17
...........
iliiiiili
INDUSTRIES
Table of contents
Combustion air fan ·
Technical data for combustion air fan
General data ................................................................................................................. I

Data for combustion air fan ......................................................................................... 2
Data for fan motor ....................................................................................................... 3
Pressure loss layout ..................................................................................................... 4
Combustion air fan
General ........................................................................................................................ !
Storage ......................................................................................................................... 2
Installation .................................................................................................................. .3
Prior to start-up ............................................................................................................ 4
Initial start-up .............................................................................................................. 5
Normal operation ......................................................................................................... 6
Vibration control .......................................................................................................... 7
Maintenance ................................................................................................................. 8
General ........................................................................................................................ !
Mechanic connection of the positioner ....................................................................... .2
Electric connection of the positioner ......................................... :................................ .3
Pneumatic connection .................................................................................................. 4
Commissioning ............................................................................................................ 5
Diagnosis ..................................................................................................................... 6
Service and maintenance ............................................................................................. 7

........
:il. il. i:
ill I IIi
AALBORG TECHNICAL DATA FOR COMBUSTION AIR FAN 809010#14.1
INDUSTRIES
Technical data for combustion air fan
1 General data
• Project No.: ......................................................................................... 100779

• Hull No.: .................................................................................................. 1338
• Classification society: .................................................................... LRS-UMS
• Pressure gauge calibration: ...................................................................... M:Pa
• Thermometer calibration: ............................................................................ oc
• Language for signs: .................................................................................... UK
• Colour of combustion air fan unit: ............................. MUNSELL 7.5 BG 7/2
2 Data for combustion air fan
• Fan type: .................................................................................. HN 675-560/D

• Actual position designation: ......................................................... LGIRD 270
• Static pressure: ............................................................................. 634 mmWC
• Air flow at 45°C: ........................................................................... 27664 m3/h
• Vibration damper type: ....................................................................... AR 200
• Numbers of vibration dampers: ..................................................................... 6
\.
3 Data for fan motor
• Motor make: ............................................................................................ MEZ

• Motor type: .............................................................................. 14BG280-2AB
• Power supply: ...................................................................... 3 x 440 V, 60 liz
• Rated output for motor: ......................................................................... 82 kW
• Revolutions: .................................................................................. 3570 r.p.m.
• Ambient air temperature: ........................................................................ 45°C
• Starting method: ............................................................................... Star/delta
• Starting current: ..................................................................................... 3 60 A
• Operating current (full load): ................................................................ 130 A
• Power consumption at l5°C: .............................................................. 70.5 kW
• Power consumption at 45°C: .............................................................. 65.0 kW

.........
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AALBORG TECHNICAL DATA FOR COMBUSTION AIR FAN SD9010#14.1
INDUSTRIES
• Insulation class: ............................................................................................. F

• Degree ofprotection: .............................................................................. IP 54
• Air duct system (from fan to wind box): ........................................ lO mmWC

• Boiler (from furnace to outlet at full load): .................................. 262 mmWC
• Flue gas system: ............................................................................. 25 mmWC

145 500 605
Cleo.n-out door
In
ru
In
In
(')
In
"'" Qj
""0
(I) Iii
l
I'
C) C)
....
C) C)
In
Connection Foro
•End-stop switch
IIF"Il ter-regulo.tor
C)
•Servo-drive Unit
~
0
710
Flex,outlet
"'"
LTF140 770
FAN .... 350 KG.

~ MOTOR .... 500 KG.
G ~-------4--------~
w FOUNDATION .... zoo KG.
lt 40x8 :3: SILENCER .... 100 KG.
'\
11115 - 16 pes
BARKER J0RGENSEN A/S
In TEMPOvtJ 23 • DK-2750 IIAU.ERUP • 1lF (+45) # 97 41 92 • FAX (+45) 44 97 41 93
'IJ..o
oM
In)( AALBORG INDUSTRIES A/S
REF.
"'"
506 C)
ru
20 4x136.5
Inlet vane control
Silencer XKA 200-250-2-L
Inlet with
605 500 145
Clean-out door
In
C\J
In
In
l"l
Ql
1:1 "'" In
Vi (X)
r-..
0 0
In ~
0
Connection for•
•Enol-stop switch
•Filter-regula. tor
•Servo-olrlve Unit 0
1 ....
(X)
0
710
770 "'"
Flex.outlet LTF140
FAN .-.350 KG.

~
(!)
MOTOR .-.500 KG.
[jJ FOUNDATION .-.200 KG.
II 40x8 3::: SILENCER .-.100 KG.
11115 - 16 pes.
"\ In
o,l)..D
ol"l
ln ....
X
BARKER J0RGENSEN A/S
mtPOVE:J 23 • DK-2750 BAU.ERUP ·ltf (+45) 44 97 41 92· FAX (+45) 44 97 41 93
AALBORG INDUSTRIES A/S

REF.
"'"
506 0
C\J 145~
20 4x136.5
.
......
.
iliiiiiii
AALBORG COMBUSTION AIR FAN OM5550#01.2
INDUSTRIES
Combustion air fan
1 General
The purpose of the combustion air fan is to supply combustion air to the burner. The
air is supplied by a directly driven centrifugal fan. The fan is mounted on a common
bed frame with motor, inlet vanes, and servo-drive unit. The fan impeller inside the
spiral housing is mounted directly on the motor shaft. The air flow to the burner is
regulated by inlet vanes mounted on the fan suction side.
The inlet vanes are of a multi-blade design and regulated by a servo-driven unit
comprising an air cylinder and liP positioner. A silencer can be mounted on the fan
suction side.
Figure 1 shows an illustration of the combustion air fan (shown without silencer)
and the location of markings and warning signs.
lllustration of the combustion air fan
Direction arrow
&
Clean-out door Frent of casing
Figure 1 bar_02a.cdr
2 Storage
If the combustion air fan unit is stored for a period of time prior to installation, a
number of initiatives must be observed and considered. They are described in the
following sections.
2.1.1 Combustion air fan (normal conditions)

When the combustion air fan unit is delivered, it is provided with the correct
quantity and type of grease. The optimum storage temperature is l5°C.

.
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INDUSTRIES
The impeller axle must be rotated at regular intervals during storage. This prevents
the motor bearings from being damaged if the axle is kept in the same position
constantly. The maximum rotation interval is 4 to 5 weeks.
2.1.2 Combustion air fan (extreme conditions)

Storage at temperatures above +35°C and below -5°C have a negative effect on the
state of the bearing grease. By storage in these conditions the maximum rotation
interval is 2 to 3 weeks.
After start-up of the combustion air fan the motor bearings (if provided with
lubricating nipples) should be greased with a small quantity of grease (4 to 5 grease
gun shots).
2.1.3 Prolonged standstill

Rotate the impeller axle at the intervals described above.
3 Installation
The fan unit must be placed on a plane and sufficiently strong surface. For repair
purposes the distance from the fan unit to the surrounding walls must be sufficient to
disassemble any parts of the fan unit.
Normally the combustion air fan is fixed to the bed at delivery. However, the
vibration dampers are supplied loose. Before installing the fan unit, the vibration
dampers must be fixed to the bed by means of the included bolts. The position of the
vibration dampers can be seen in the fan drawing.
After fixing the vibration dampers to the bed, place the fan unit on the installation
place and mark out the bolt holes which fix the dampers to the surface. This will
prevent twisting of the rubber compartment. When fixing the fan unit to the surface,
use an adequate size of bolts.
3.1.1 Connection of the motor

Figure 2 shows the possible wiring connections at the terminal rows of the motor.
The electrical wiring diagram indicates the actual connection of the motor for the
specified plant.
Electrical connection diagrams
y Y/!J.
l2 L3 L1
1N2 U2 V2 liN2lU2lV2
IO Ol Ol 000
U1 V1 W1 U1 V1 W1
000 000
i i i
L1 l2 L3
i i i
L1 l2 L3
Figure2 bar_07.cdr

.....
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INDUSTRIES
4 Prior to start-up
Prior to the first start-up of the combustion air fan, the following procedures must be
performed:
• Check that the combustion air fan and the air duct system have been installed
and supported correctly. If possible, an inside inspection of the air duct system
should also be carried out to ensure that it is free from obstacles, e.g. loose parts,
insulating material, etc.
• Check that the inlet net has been mounted.
• Check that the electrical wiring at the terminals of the combustion air fan is
performed according to the wiring shown in the electrical diagrams.
• Adjust the circuit breaker for the combustion air fan to suit full load current of
the motor. The current appears from the motor identification plate and/or the
electric diagrams.
• Commission the liP positioner and dp-transmitter and check that the micro
switch, which controls the closed position of the inlet vanes, is activated.
• Rotate the combustion air fan by hand to ensure a free and an uninterrupted
rotation.
• Ensure that all safety circuits are activated and functional.
• Ensure that all loose items have been removed in the proximity of the suction
side of the combustion air fan.
• Ensure that the operating personnel have been notified about the coming start-up
and that the location of the emergency switches is known to the personnel.
5 Initial start-up
When the combustion air fan is started for the first time, the following procedures
must be performed:
• Start the combustion air fan and check that it is running with the correct
direction of rotation (see the direction arrow).
• Check that the combustion air fan and the air duct system do not produce any
abnormal mechanical noise.
• Check the combustion air fan and the air duct system for any abnormal
vibrations.
• Check the air duct system for leaks.
• Set the fan load to approximately 10-15%. Check the temperature of the fan
bearings. The bearing temperature must be at a constant level after
approximately 30 minutes of operation. If the temperature continues to increase,
stop the combustion air fan and check the bearings.

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INDUSTRIES
• Set the fan load to 100%. Check the current consumption of the combustion air
·fan. The current must not exceed the full load current stated on the motor
identification plate and/or the electric diagrams.
• Set the fan load to 0% (inlet vanes closed) and stop the combustion air fan.
6 Normal operation
To ensure a safe and reliable function of the combustion air fan, inspection must
take place with frequent intervals as described below.
Step A: Check the motor temperature (maximum 80°C).
Step B: Check for vibrations by touching the combustion air fan.
Step C: Check that the vibration absorbers and flexible connection are intact.
Note: H a fault is observed, it must be corrected at once.
7 Vibration control
If the fan is operating in a dusty and/or fatty air environment, coats may occur on the
impeller. This might cause abnormal vibrations, which eventually will cause break-
down of the combustion air fan. The cause must be examined immediately.
At the factory the fan has been weighed statically and dynamically in accordance
with the VDI 2056 - G, Standard. Figure 3 shows vibration curves for the fan
according to VDI 2056-G Standard.
Vibration curves for fan
CURVE No.1: MAX. No. OF VIBRATIONS PERMISSIBLE
CURVE No.2: MAX. No. OF VIBRATIONS PERMISSIBLE IN TEST RUN
Figure3 bar_03a.cdr

.
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INDUSTRIES
8 Maintenance
8.1 Cleaning of impeller
Step A: Ensure that the combustion air fan is not unintentionally started during this
repair work.
Step B: Access to the impeller is obtained by dismounting the clean-out door.
Step C: The cleaning procedure can be performed with a high-pressure cleaner

combined with scraping of the rebellious coat. In connection with this
ensure that any water in the spiral casing is drained off.
Step D: Before starting the combustion air fan again, it is important to check that
the impeller is clean and that the dismounted parts have been remounted.
Note: If the impeller has not been carefully cleaned, the residual coat might
cause a lack of balance. If the vibration level exceeds the maximum level
of 11 mmls, it might result in a breakdown of the combustion air fan.
Therefore, it is important to take precautions by inspecting the impeller
before starting up.
8.2 Dismounting of impeller
The impeller is mounted directly on the motor shaft. The dismounting of the fan
impeller are described below and illustrated in Figure 4.
Step A: Ensure that the combustion air fan is not unintentionally started during this
repair work.
Step B: Dismount the nuts which fix the front plate. Remove the front plate by
means of a lifting device or tackle.
Step C: Dismount the end bolt and plate of the shaft, and replace the end bolt by a
similar short bolt.
Step D: Mount a wheel-puller. The impeller is provided with threaded wholes

(MlO) located on the hub plate. Tighten the wheel-puller until the impeller
is loose.
. .
Step E: Then dismount the wheel-puller and end bolt. Finally, the impeller can be
pulled out from the spiral casing.

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INDUSTRIES
Dlustration of fan impeller dismounting
Figure 4 bar ll.cdr
8.3 Electric motor
Normally, electric motors need no special maintenance except cleaning and

lubrication of the bearings. If motors and/or bearings are dismantled, please contact
an expert (electromechanical workshop).
8.3.1 Lubrication of bearings

Motors without grease nipples are pre-lubricated for approximately 10,000 hours or
three years of operation. Motors with grease nipples should be lubricated at the
monthly intervals shown in Table 1:
Table 1
Note: Suitable lubrications must be used, such as e.g., SKF-LGMT 2.

.
........
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~AALBORG POSITIONER, SIPART PS2 6DR5000 OM551 0#05.1
INDUSTRIES
1 General
The following instruction is a general description of SIPART positioners and covers

the complete range in the PS2 6DR5000 series.
The electronic pneumatic positioner is used as the final control element of a
pneumatic linear actuator or a part-tum actuator (rotary movements). The positioner
converts a current output signal (4 to 20 rnA) from a process controller or control
system to a set point value and into a corresponding movement. The positioner
changes the pressure in a pneumatic actuator chamber or cylinder until the position
corresponds to the set point value.
The positioner can be set up either as a single-action positioner or a double-action
positioner. The single-action positioner is mainly used together with a control valve.
The opposite movement for the control valve is supplied by means of springs. The
double-action positioner is mainly used to control an air damper via a pneumatic
cylinder (actuator). All movements of the pneumatic cylinder are supplied by the
positioner. An illustration of the function diagram for the positioner is shown in
Figure 1. The function diagram is shown with option modules.
Comparison of the set point and the actual value takes place electronically in a micro
controller. If the micro controller detects a deviation, it uses a 5-way switch
procedure to control the piezoelectric valves, which in tum regulate the flow of air
into the actuating chambers. When connected in a two-wire system, the SIPART
PS2 draws its power exclusively from the 4 to 20 rnA set point signal.
The piezoelectric valve converts the command into a pneumatic positional
increment. The positioner outputs a continuous signal in the area where there is a
large control deviation (high-speed zone). In areas of moderate control deviation
(slow-speed zone) it outputs a sequence of pulses. No positioning signals are output
in the case of a small control deviation (adaptive or variable dead zone).
initialisation, the micro controller automatically determines the zero, full-scale
value, direction of action, and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, thus optimising the control.
SIPARTPS2.
The installation of the positioner must be carried out in the following order:
• Mechanic connection
• Electric connection
• Pneumatic connection
• Commissioning

....
a • • • •
iliiiiili
INDUSTRIES
lllustration of a function diagram
1 Motherboard with microcontroller and input circuit

2 Control panel with LC~isplay and momentary action switch
3 Plezo-valve unit, always buill-In
-4 Valvo unit with double action positioner always buill-In
5 ly-module for positioner SIPART PS2
6 Alarm module for three alarm outputs and one digital Input
7 SIA-modula (Slot Initiator-Alarm-module)
8 Spring-loaded pneumatic actuator (single action)
9 Spring-loaded pneumalic actuator (double action)
Figure 1 sips2_5a.tif
2 Mechanic connection of the positioner
Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the
installation guide lines below.
2.1 Mechanic connection to an actuator
Figure 2 shows the mechanic connection of the positioner to an actuator for a control
valve.
Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and
lock washers ( 16) on the actuator spindle.
Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly.
Set the necessary length and tighten the screws so that the pick-up bracket
can still be shifted.

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INDUSTRIES
Step C: Push the roll (5), spring (13), and guide washer (22) onto the pin (4).
Step D: Insert the pin in the lever (6) and assemble with nut (18), spring washer
· (14), and U-washer (12).
Step E: The value of the stroke range specified on the actuator should be set or if
this does not exist as a scaling value, the next greatest scaling value should
be set. The centre of the pin must be in line with the scaling value. The
same value can be set later under parameter "3.YWAY'' in commissioning
to display the way in [mm] after initialisation.
Step F: Assemble the hexagon socket cap screw ( 17), spring washer ( 16), washer
(12), and square nut (19) on the lever.
Step G: Push the pre-mounted lever onto the positioner axis up to the stop and fix
with the hexagon socket cap screw (17).
Step H: Fit the mounting bracket (1) with two hexagon head screws (9), lock
washer (10), and flat washer (11) on the rear of the positioner.
Step 1: Selection of the row of holes depends on the width of the actuator yoke. The
roll (5) should engage in the pick-up bracket (2) as close as possible to the
spindle but may not touch the clamping assembly.
Step J: Hold the positioner with the mounting bracket on the actuator so that the pin
(4) is guided within the pick-up bracket (2).
Step K: Tighten the pick-up bracket.
Step L: Position the mounting parts according to the type of actuator.
- Actuator with ledge: hexagon head screw (8), flat washer (11), and lock washer
(10).
- Actuator with plane surface: four hexagon head screws (8), flat washer (11), and
lock washer (10).
- Actuator with columns: two U-bolts (7), four hexagon nuts (21) with flat washer
(11), and lock washer (10).
Step M: Secure the positioner onto the yoke using the previously positioned
mounting parts.
Note: Set the height of the positioner so that the horizontal lever position is
reached as close to the stroke centre as possible. The lever scale can be
used as orientation. It must be guaranteed that the horizontal lever
position is passed through within the stroke range.

.
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INDUSTRIES
Mechanic connection of the positioner Qinear actuator)
17
16~
12 "'I
19
1)
3)
11 10
Mounting on yoke
11 with ledge
10
7
21
4)
As required
Figure2 sips2_Sb.tif

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INDUSTRIES
2.2 Mechanic connection to a pneumatic cylinder
The positioner is connected to a pneumatic cylinder by means of fixing bracket,

lever arm with Allen screw, extension arm, and roller.
The pneumatic piston is connected to a guide rail with an oblique angle via a
linkage. The guide rail moves together with the piston, and the roller/lever
connection senses the position of the piston. By operating both sides of the
pneumatic cylinder, the set point is reached. A spring inserted between the fixing
bracket and the lever arm secures that the roller is pressed down against the guide
rail.
2.3 Mechanic connection to a rotary actuator
Figure 3 shows the mechanic connection of the positioner to a rotary actuator.

Step A: Attach the mounting console (9, actuator specific) onto the rear of the
positioner and secure using the hexagon head screws (14) and lock washers
(15).
Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centring
hole.
Step C: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mm
and tighten the hexagon socket head screw ( 18) with the Allen key
provided.
Step D: Place the carrier (3) onto the end of the actuator and secure using Fillister
head screw (16) and washer (17).
Step E: Carefully place the positioner with mounting console onto the actuator such
that the pin of the coupling wheel engages in the driver.
Step F: Align the positioner/mounting console assembly in the centre of the actuator
and screw tight (screws are not included in the delivery, they are part of the
actuator mounting console).
Step G: Follow the start-up sequence as described later. Drive the actuator to the
end position and adhere the scale (4.1) onto the coupling wheel (2)
according to the direction of rotation and rotary actuator. The scale is self-
adhesive.

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INDUSTRIES
Mechanic connection of the positioner (rotary actuator)
1)
3)
Figure3 sips2_ 5c.tif

........
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INDUSTRIES
3 Electric connection of the positioner
When the positioner is connected in a two-wire system, the positioner draws its
power exclusively from the 4 to 20 rnA set point signal. Figure 4 indicates the input
circuits for the positioner.
View of the controls and connections
Figure4 sips2_5d.tif
4 Pneumatic connection
Ensure that the air quality is suitable. Grease-free instrumental air with a solid
content < 30 Jlm and a pressure dew point 20 K below the lowest ambient
temperature must be supplied.
Warning: For reasons of safety, pneumatic power may only be ~upplied after
assembly when the positioner is switched to operating level "P
manual" operation with electrical signal applied.
4.1.1 Selection ofP manual mode

Before pneumatic power is connected, the positioner must be in P manual mode.
The display must show "NOINIT" in the bottom line.

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INDUSTRIES
4.1.2 Pneumatic connections

Figure 4 shows a view of the positioner controls and connections.
Step A: If required, connect a manometer block for supply air and actuating
pressure.
Step B: The silencer in the exhaust output can be removed if necessary.
Step C: Connect actuating pressure Yl and/or Y2 (Y2•) is only used with double-
acting actuators) according to the desired safety position.
Step D: Connect the supply air (1). The pressure should be between 1.4 to 7 bar.
Note: In order for spring-loaded pneumatic actuators to be able to reliably

exploit the maximum possible actuating path, the supply pressure must
be sufficiently greater than the maximum required final pressure of the
actuator.
4.1.3 Safety position when the electric power supply fails

For a single-action actuator is Yl deaerated. For a double-action actuator is Yl
equal to the supply air pressure and Y2 is deaerated.
4.1.4 Restrictors
To increase the positioning times for fast actuators when necessary, the air flow can
be reduced with the restrictors Yl and Y2 (only for double-action valves). Turning
the restrictors in the clockwise direction reduces the air flow until it is shut off. To
set the restrictors it is recommended to first close them and then open them again
slowly (see initialisation process RUN 3).
4.1.5 Purging air switchover

The purging air changeover switch located above the pneumatic terminal block on
the valve manifold can be accessed when the housing is open. When the switch is in
position "IN" the interior of the housing is purged with very small quantities of
clean and dry instrument air. In position "OUT" the purging air is led directly out of
the instrument.
5 Commissioning

initialisation, the micro controller automatically determines the zero value, full-scale
value, direction of action and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, hereby optimising the control.
SIPARTPS2.
The commissioning of the positioner can be divided into the following steps:
• Preparation for initialisation
• Start the automatic initialisation procedure

........
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i.
INDUSTRIES
• Set additional parameters if required

• Select automatic mode
Figure 5 shows the possible operation modes for the positioner and gives an
overview of how to. change between them. The levels are P-manual mode,
configuration and initialisation, manual mode, automatic mode, and diagnostic
display. From these modes it is possible to select operation mode, set operation
parameters, restore to factory setting, run an automatic initialisation, etc.
Operation levels
FigureS sips2_Se.tif
5.1 Preparation for initialisation
Step A: Check and set the gear transmission switch to the correct position. Figure 4
(position 8) indicates the location of the switch. For linear actuators the gear
transmission switch is set according to the stroke range as described in
Table 1 for the parameter "3.YWAY". For part-tum actuators 90° must be
selected. ·
Step B: Check that the pneumatic supply power (inlet air) is present. The operating
pressure should be at least one bar greater than is necessary for
closing/opening the valve during initialisation.

.
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INDUSTRIES
Step C: Without initialisation the positioner is in "P manual mode" and ''NOINIT"
flashes in the display. This level can also be reached by using "55.PRST"
function (see Table 1).
Step D: Check the free running of the mechanics in the whole actuating range by
moving the actuator with the keys "t" and ''!'' and driving to the respective
end position.
Step E: With linear actuators drive the actuator to horizontal lever position. The
display must indicate 48% to 52%. If necessary, correct the value by
adjusting the sliding clutch. After the check is completed, the actuator must
be approximately half way along its stroke. This is due to establishment of
the action direction during automatic initialisation.
5.2 Automatic initialisation
Figure 6 shows the configuration mode including the operation in this mode and
Table 1 shows the parameter/configuration list. Figure 7 shows the initialisation
process of the positioner. The initialisation process is stored in the microprocessor.
This means that an additional initialisation only is necessary if any parts of the unit
have been changed.
Note: The numerical values used in Figure 5, Figure 6, and Figure 7 are
examples.
Step A: Call the configuration mode by pressing the hand symbol key for longer
than 5 seconds.
Step B: Set the actuator type, linear or part-tum, in the menu item line "l.YFCT".
Step C: Switch to the second parameter by pressing the hand symbol key briefly.
Step D: Set the rated angle of rotation for feedback in the menu item line
"2.YAGL". It is vital that this value corresponds to the setting of the gear
transmission ratio selector (Figure 4, position 8), 33° or 90°.
Step E: Switch to the next parameter by pressing the hand symbol key briefly.
Step F: This parameter ("3. YWAY") is only set for linear actuators and if the total
stroke in mm should be displayed at the end of the initialisation phase. To
do this, select the same value in the display to which the carrier pin to the
scale on the lever is set to.
Step G: Switch to the following parameter by pressing the hand symbol key briefly.
Step H: Start the initialisation ("4.INITA") by pressing the "t" key for longer than 5
seconds.

.
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INDUSTRIES
Step 1: During the initialisation phase "RUNl" to "RUN5" appear one after another
in the bottom of the display. Please note that the initialisation process may
last up to 15 minutes depending on the actuator.
Note: The ongoing initialisation can be aborted at any time by pressing the
hand symbol key. The previous settings are retained. All the parameters
are reset to the factory setting only after performing a preset
"55.PRST".
Step J: If problems occur, carry out the measures as described in the table "Possible
messages" shown in Figure 7.
Step K: The initialisation is completed when "FINSH" appears in the bottom of the
display.
Step L: When pressing the hand symbol key briefly the menu item line "4.INITA"
is displayed.
Step M: To exit the configuration operating mode, press the hand symbol key for
longer than 5 seconds. The software version is displayed after about 5
seconds. The instrument is in manual operation after releasing the key.
Step N: The positioner can be changed to automatic mode by pressing the 'T' key
once as indicated in Figure 5.
Step 0: The automatic mode is the normal mode. In this mode the positioner
compares the set point current with the current position and moves the
actuator until the control deviation reaches the dead zone.
Operation in the configuration mode
~
'2::v
at the same time ~
'2::v
at the same time
8.8.8.8.8 ~v--_&~ 8.B8.8.8

BB ~m~ BB ~~~
to
~I I
~v ~I
~ 1 at the same time ~ 1 at the same time
~8.~~~ ~&-~ ~B.~~~~

Figure 6 sips2_5f.tif

........
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INDUSTRIES
Initialisation process
Automatic Initial start-up (starting with factlry setting) Possible messages
.
Step Meaning Display Meaning Measures
~~
1.) Partturn Acknowledge rressage
~
actuala" using the hand syrTbol key
2 YAGL Actuator does
1 not move Chact< restricta (~ and open
[?;J~I Strt if necessary

Unear
actuata 2 YAGL . 3 Y'MY I ~ R
Olive actuata to \\OI"king range
using tha up and down keys
2)~
Press Ita up key fa > 5 sec. Restart initi alisatkn
4 INll\ Remainhg steps are carried out autanaticaly
Ctangegearing (7)
Cmtinueushg up key
•> ~~ RUN
32~11 Directim of action is delennired 1-
p Or adjJst slidhg ci.Jich up
88A Down tolerance
4.) I~~_I RUN

92.~12 Checking of travel and adj.Jstrrentof
zero andstroke(rran stop to stop) lY ', d1u IU band viola led to dsjiay
1 6.4)1
~
d10 IU
~) [,~ 82~13
RUN
Deterrrira tion and display c1JDsitioring time
down (dx<.x~ up (uxx.x). Stop with the down key - Thanoriy
Conti rue us hg the down key
-' Pressing t ha up key inliates leakage measurement I Unearactuator. set picl<-up
~
Olcethesllpplng lever hto In rizontal position
d u1ch has bee n using tha LP and down keys
&) ,,~ 32~1 Deterrrination c1 mi1imumi1crement length DL adjusted
RUN 4
Continue us hg hand symbol key
7.) ,,~ 52~1 Optirrisati on of transient response Acl<nowled ge ITBSsage

RUN 5
~
~tolerance band using tha hand symbol key
lniialisalon tenninated successfuly > liolated Set the next tlghast travel
a)~ (travel inmmfalinear actuatas) value on the IEMll'

FIIISH (angle ofrotation for Jat-lum a:tuatas)
Restart iriti alisabn
Continueu silg hand symbol key
Additionally possible y.jth rotary
actuatas:
Adjust using up and down keys
up to display: IP 92.81
, 111_95
Continue u shg hand symbol key
rn
Acknowledge rressage
using tha ta nd symbol key
~/down span
Set the re<t lowest travel
< liolated
valueontte lever
Restart inti alisatbn
~
Adj.Jst posltloring time ushg
~ ZZI.
Actuator does
not move.
resticta(s)
Fbsltloning Continueushg the
up adown key
~
time Is posslbl e
ID adjust
ZZI.
Figure 7 sips2_5g.cdr
5.3 Parameters
Table 1 shows the parameter list for the positioner. The parameter name is written in
plain text in the "menu line" column. The function of the parameter is described
briefly in the "Function column". In addition, the possible parameter values, the
physical unit and the factory setting of the parameters are shown.
After the initialisation process, the positioner can be configured to meet the
requirements of a specified task. The factory settings correspond to the requirements
for a typical application. This means that normally only a few parameters will need
to be changed.
The positioner can be installed and configured to fit linear and part-tum actuators
with reverse action. E.g. linear actuators with the set point in the falling direction or

.
........
iliiiiili
AALBORG
..'5 "'
~-'POSITIONER,
''.!J.•,!,.,.i:~~t;;'~ ~ J';"*"':o. ~·l 1 ~~~·~•"'.ti}.<J~jl,~!~':'~,:·~,.-J,<~
SIPART PS2 6DR5000 , .,·-..:: .. <::OM5510#05 ..1·'!:-\'J

* •e~'1"'J,t~ 1 ,,• '•;;>·i•,-.:,~;:'~.~:~~.~ 1 '!:;!\:' :,;r•tf.1"'~~ ~.-
1
INDUSTRIES ~-:::-;:., ,.~~\ti1;2-i:;,·~~.~--~lt\~~v;..:~), ;m,~-~~.~-~J::f~""'.UA~""·JiCZr::t.~ .:.,.~~ ~~~Hr."'~!r.ir.'...i ~·: ;..,.;:t..if~~ !r~sJ~~::;_;_~:t:•~~~r .;\l:t,.... ;, ·~J~~·'
part-tum actuators for counter clockwise operation direction. In this case the
parameters "7.SDIR" and 38."YDIR" should be set to "FALL".
tum (part-tum actuator)

WAY (linear actuator)
L WAY (linear actuator
without sine correction)
l.YFCT Type of actuator WAY
neSt (part-tum actuator
withNCS)
-neSt (part-tum actuator
with
Rated angle for feedback
2.YAGL 1l Degrees
(must ratio)
Stroke range (optional setting) OFF
5' 10' 15 '20

When used, the value must correspond with
the set of the leverage ratio on the actuator
____ s~~~_f!_l~Y~!}~~} ___ _
3.YWAY2l 25' 30' 35 mm OFF
Driver pin must be set to the value of the ---- _(~~~-"! )~Y~!-~Q~}----
actuator travel or, if this value is not scaled, 40 ' 50 ' 60 ' 70 '
to the next lager scale value 90' 110' 130
4MA
Linear Lin
12.SFCT Equal-percentage 1:25, 1:33, 1:50 1-25' 1-33' 1-50 Lin
Inverse equal-percentage 1:25, 1:33, 1:50 n1-25, n1-33 , n1-50
FrEE
13 Set point turning point at 0% 0.0
14.SLI 5% 5.0
to to 0.0 to 100.0 % to
32.SL19 95% 95.0
33.SL20 100%
riSE
38.YDIR riSE
FALL
no
Tight closing with uP
39.YCLS no
manipulated variable do
uP do

........
iliiiiila
AALBORG
INDUSTRIES
None OFF
Only message (NO/NC contact) on/ -on
Block configuring (NO contact) bLocl
42.BIN1 4> OFF
Block configuring and manual (NO contact) bLoc2
Drive valve to pos. up (NO/NC contact) uP I -uP
Block movement
Function ofBI 2:
None OFF
4 Only message (NO/NC contact) on/ -on
43.BIN2 > OFF
Drive valve to pos. up (NO/NC contact) uP I -uP
Drive valve to pos; down (NO/NC contact) doWn/-doWn
Block movement StoP I -StoP
A1=min. A2=max.
44.AFCT5> Alarm function OFF
L,
47.t,Fc~> L,nA
L,nAb
Monitoring time for fault message Auto

48.L,TIM s Auto
"control deviation" 0 to 100
Response threshold for fault message Auto
49.L,LIM % Auto
"control deviation" 0.0 to 100.0
OFF
50.L,STRK Limit for stroke integral OFF
51. L, DCHG Limit for direction change OFF
52. L, ZERO Limit for end stop monitoring, bottom % OFF
53. L, OPEN Limit for end stop monitoring, top % OFF
54. L, DEBA Limit for dead zone monitoring % OFF

0.0 to 100.0
Preset (factory setting)
"no" nothing activated no
"Strt'' start of factory setting after pressing
55.PRST key for 5 sec. Strt
"oCAY" display following successful
factory setting oCAY
CAUTION: results in "NO INIT'
If turn is selected it is not possible to set 33°.
2
>Parameter does not appear if l.YFCT =turn has been selected.
3
>Turning points only appear with selection 12.SFCT =FrEE.
4
>Alternatively "no" if initialisation has not yet been carried out
S) NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level.
6
>Normal means: level without fault. Inverted means: level without fault.
Table 1

...........
iliiiiili
INDUSTRIES
6 Diagnosis
In the diagnostic mode the current operating data (such as number of strokes,
number of changes in direction, number of fault messages, etc.) can be displayed.
From the automatic or manual modes the diagnostic mode can be reached by
simultaneously pressing all three keys for at least 2 seconds.
Table 2 shows an overview of the displayable values. The diagnostic display has a
similar structure as the parameter menu displays. The respective next diagnostic
value can be selected with the hand symbol key. Certain values can be set to zero by
pressing the "i" key for at least 5 seconds. These are menu item line "1, 2, 3, and 4".
Some diagnostic values may be greater than 99999. In this case the display switches
to exponential display.
Table2

...........
iliiiiili
INDUSTRIES
7 Service and maintenance
The positioner is largely maintenance-free. The positioner is fitted with filters in the
pneumatic connection as protection against coarse particles of dirt. If the pneumatic
energy supply contains particles of dirt, the filters may be clog and impair the
function of the positioner. In this case the filters can be cleaned as follows:.
Step A: Switch off the pneumatic power supply and remove the pipes.
Step B: Unscrew the cover.
Step C: Remove the three screws from the pneumatic connector strip.
Step D: Remove the filters and 0-rings behind the connector strip.
Step E: Clean the filters (e.g. with compressed air).
Step F: After cleaning first insert the filters in the recesses in the housing and then
place the 0-rings on the filters.
Step G: Align the pneumatic connector strip on the two lugs and screw ti.ght with
the three self-tapping screws.
Note: Make sure that the same thread is used. To do this, turn the screws anti-
clockwise until they snap into the thread audibly. Only then should the
screws be tightened.

18
C33 View A-A
Detail D View E-E
Wind box top
Center of wind box
View F-F
Baile
Detail C ViewG-G
-------, F62 F153 F78 F152 F166
i
i
i
-.. i
- •.
i
i
i
i F18
i
NOTE:
Steam atomising bumer 1900

L15
ARRANGEMENT DRAWING - LEFT

SERVICE AIR INLET BITE lYPE JOINT 10 MM YARD CONNECTION
View A-A
Yard supply
IIIII
Tag no. L2
Detail D View E-E
Wlndbox top
Center Of wind box
View F-F
F6B
Boiler
DetaiiC ViewG-G
F62 F153 F78 F152 F166

Detail B
416
-t
'·
F1B
PIPING CONNECTIONS
NOTE:
Steam atomising burner 1900
ARRANGEMENT DRAWING- RIGHT

Description I Index Date I Drawn I Appr.
CR 1298 - Nozzle type changed I a 24-02-0SJ KTN I JMN
JL
= ·~- -----------j ~--------{
II
~ I
A
~
~ ~ F74
3
DETAIL A
1
~U///-
r---
'L'U////- 0
·- IH
~
r Position switch
1
6614712
F74
~
I 4 5
Flexible hose
2
6666082
Screw cap 6666005

4 1
Gasket 6637130
3 1
10-ring 6637059
2 2
Nozzle See schematic view
1 1
Designation Material code Article No.
Tag No. Pes. Cart.
Title: Drawn Date
...
... KBSD BURNER MaM 26.01.2004
.....
•••••• 0
STANDARD
Appr.
ToG
Date
26.01.2004
Boiler Caoacitv I 16.01 20.01 25.01 30.01 35.0\ 40.01

iiiiiiiii
45.0 AALBORG
Weight Scale:
1:5
Size
PJ
BURNER LANCE, ARRANGEMENT Article!Drawlng No: Index
Burner Size I 12001 15001 19001 22501 2650\ 3000! 3350 INDUSTRIES THIS DRAWING AND DESIGN SHOWN ~IN 1S THE PROPERTY OF Ml80RG ltCDUSTRIES
Nozzle article No. l6666057al6666062al6666050al6666051 al6666079al6666074al6666090o Plot Date: N«J MUST NOT BE USED BY' OR REPRODUCED FOR niiRO PAATY 92Y :030045 a
lnde• Oate Drawn Appr.
F148 F149 7 8 F106 6 5
4 3
F166
..
F153
F152 ,
f1.51
-... .....
~v•tv.
c-
F150
F62.1 F62.2 F153 F152 F1<19
F73
H48
FUl6
F80
F78
--
,.....,
.,_ft,
'"
6&38103
F77
F13
........
,...,
E F6Z.2
PrftJingaugeM3
0·12e.t,psiQ119"-m ""'"
F78
F62.1
"'
F18
F17
--
Fllerreguto:tar10!Uidmol
0-IOW
........
1,14".(
IQnllonburr.r--~
"
13 1H"•750'""
Fie.,._ hal<,
12
.,.,.,_
B<nnL,.750
0038121
•o
.,.,.,_ 6638122
.,.._
•12hi10-L.
.,......
F166
-·-
Adjuslabk!T-conneciDf
""
--··-...
S~ptog-
,
hflmi2L•1500
-
•tii.Ol2.0l-.o:.IO~Jtot-a
G 0"7.5USOIJ
""""""""
220'L~160Hz
UemF18
llemF19
""""'
6638148
ltemF150
ltemF151
6666232
llemft50
llemft51
Snare valve
ll<66230
llemf153
66390<CO
llemf166
6639100
= Standanl
110V50160Hz 6638147 6666332 '"'"30 6639043 6639101 iilliihi
AAUIOIIO lgnitionbvmerspareparts
••• CIIIl.IU
Initial release In according to CR 502 a 29.04.04 JGj JMN
Changed shield plate to shielding tape b 24.09.04 RTh MRJ
Article No. added c 11.10.04 JGj JMN
1-
160" overlap
~; '.
Sh Ieiding tape
Section A-A
Note:
Spray shields are to be fitted around flexible hose, flanged joints, flanged bonnets, and
any other flanged or threaded connections In fuel oil piping systems which are located
above or near units of high temperature (surface temperature which may exceed 220 1-
•c in case of defective or insufficient insulation). .'-:.
The need and extent of spray shield required is therefore depending of the actual arrangement.
8500000627
Yard is to. verify if burner fuel piping is so arranged that spray can reach units of high temperature
(oil fired boiler exhaust gas outlet box I piping system or orther units arranged by yard near to
Pes. Material code Cert. -Article No. ··
burner fuel piping). MateMal type Daten drawing No.
Title: Drawn Date
If actual arrangement requires spray shields due to units of high temperature units, KBSD BURNER JGj 28.04.2004
the shielding tape can be used to prevent spray. . .... Appr. Date
STANDARD
Flanged joints, flanged bonnets, and other flanged or threaded connections, compression
fittings ar~ shielded by wrapping tape around joint with a overlap of 180 %. iliiliili
AALBORG
Spray shields for fuel oil system Weight
JMN 29.04.2004
Scale:
2:1
Size
A3
, Index
INDUSTRIES f - - - - - - - - - - - - - - - ; A r t l c t e / D r e w t n g No:
Tape is to be fitted by yard after final pressure test of piping system at yard.
f--Pio-10-at-e:----l:::rw::o=::=::=:NUOOo~u 92K :031534 c
I
19 I
.....
0 0 0
0 il.il·l· 0
iii I ii
INDUSTRIES
Tabl.e of contents
Data sheets for KBSD burner unit

Burner lance ........................................................................................... OM5580#35.0
Full bore ball valve, EURO SFER 1720 (F17, F73) ....................................... 666 6006
Solenoid valve, 114" (Fl8, Fl9, F78) ............................................................. 663 8146
Ignition burner (F31) ................................................................................. 92Z:020616
Selenium photocell detectors RAR7713 (F33) ............................................... 663 9045
Thermostats, type RT (F36) ............................................................................ 663 8211
Stop valve, ball, straight, DN20 (F41, F42, F44, F64, F67, F87, F93) .......... 87D3064
Filter, DN 20, PN 40 (F43) ............................................................................. 663 8()01
Non return valve, RK 76, DN20 %" (F45, F108) ........................................... 87D3093
Needle valve straight, 3/8".
x 3/8", PN400 (F50, F69, C31,. C331, C431) ..... 87D3050 ..
~ressure transmitter, 0-25 bar (F51) ......................·................ ~ ...... ;~ .. :....... 8010 000006
i~So.lenoid valve, 638M-150-A6E (F56, F59, F61, F§~S)" ...... ~-.: ........ :................666 6233
Actuator, AT201 S12 (F57, F58, F66) ........................................................... 663 8651 ...
Actuator, AT251 S12 (F60) ............................................................................ 663 8652
Filter regulator with automatic, manual drain (F62.1, F63.1, F96.1, F97.1) .. 663 9046
Pressure gauge, 0 40 (F62.2, F63.2, F96.2, F97.2) ......................................... 663 3015
Pressure gauge, 0 63, type P 1116 (F68) ......................................................... 663 3121
Inductive proximity sensor (F74) ................................................................... 661 4712
Three-way valve, ball DN20 (F75) ................................................................. 87D3071
Deferential pressure transmitter; type 7MF4433 (F76) ............................ 8020 000001
Check valve, 3/8", PN 250 (F77, F80) ........................................................... 663 8103
Position switch RC-E4L (F85, F86) ............................................................... 663 8660
Control valve, straight wa.?', with electric actuator, DN 20, PN 25 (F91) ...... 87A3038
Stop valve, straight, DN 20, PN 25 (F92) ....................................................... 250 1087
Oil flow regulation valve (F94) ...................................................................... 663 5199
IIP converter, TD7800-401 (F95) ................................................................... 663 5210
Three-way valve, ball DN 32 (F99) ................................................................ 87D3086
Oil flow meter, OMG 20 (F100.1) ............................................................ 7060 000012
Oil flow meter, BEG 44 (F100.2) ......................................................... ."... 8310 000006
Photoresistive detectors, QRB1A-A050B70A2 (Fl06) ............ ~ ..................... 663 9035
DISCO Non-Return Valves RK 76 (F108) ..................................................... 87D3093
Pressure gauge, 0 63, type P1116 (F135) ....................................................... 663 3120
Actuator- air cylinder, 41M-2P-050A0200 (F148) ....................................... 666 6109
Proximity sensors (F 149) ................................................................................ 666 6110
Solenoid valve, type 638M-101-AGE (F150, F151) ...................................... 666 6232

... .
illliilii
INDUSTRIES
Flow control valve, 2830 -1/4" (F152) ......................................................... 664 1220

Solenoid valve, EV210B (F153) .................................................................... 663 9040
Thermometer, straight (F157) ......................................................................... 88T0003
Ignition transformer E25 (F166) ..................................................................... 663 9100
Pressure gauge, e 160, (C33) .......................................................................... 663 2990
Pressure switch KPS 37 (C35) ........................................................................ 631 0330
Pressure transmitter, 0-25 bar (C48) ............................................................... 663 8233
Data sheets for KBSD burner unit

(Loose supply)
Stop valve, ball, straight, DN32 (F101) .......................................................... 87D3066
Strainer (SIR) ..................................................................... :...................... SYL052A-2

.
.........
.l"l.il·i·
ii I Iii
AALBORG BURNER LANCE OM5580#35.0
INDUSTRIES
Burner lance
The burner lance contains theY-jet atomiser in which steam and fuel are mixed and
ejected into the furnace. An illustration of the burner lance is shown in Figure 1.
During normal start, the burner lance is purged with atomising steam through the
steam pipe line. This heats the burner lance and makes ignition of the main flame
more reliable. During normal stop, the oil pipe is purged with steam. By this, the
remaining fuel oil in the lance will be atomised into the furnace. The combustion air
fan, which also operates during this period, purges the furnace for the ejected
oi]/steam mist.
For maintenance and inspection purposes, the lance can be extracted from the wind-
box, and the atomiser can be dismounted from the lance. This is done, by
unscrewing two Allen screws in the flange connection and unscrewing the screw cap.
Eventually, the atomiser will be covered with a layer of carbon deposits. To remove
these deposits, paraffm or carbon remover should be used. It is also possible to use a
soft metal scraper. A hardened scraper should not be used as it could damage the
atomiser. The cleaned atomiser should then be examined for damage, and the holes
checked for wear. It should be replaced if necessary.
The 0-rings must be replaced every time the atomiser has been dismounted. Before
mounting the screw cap, the thread should be covered with an unhardening high
When the burner is commissioned, the atomiser must be thoroughly cleaned before
any attempt is made to start the burner.
Illustration of the burner lance
E Protection tube Screw cap Atomiser

I'll Flanges
'
~
/Handle
i
w
Oil
0-ring
I
Packing
Figure 1 bumlance.cdr

.
.....
0 0 0
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type:
• Full bore ball valve,
• EURO-SFER 1720
Size:
Application:
• Assembly in rigid pipe system
• Direction of flow in both directions
Specification:
• Thread ends: female- female UNI ISA 7/1-rp
• Lever: aluminium handle UNI 5076
painted black with epoxy powder
CH ..c:
.,...
j:::
J:
& ~
z
,::)
F17 F73
Type No.:6666
Version:A
Full bore ball valve 666 6006
EURO-SFER, 1720

..........
.I·I·11. i.
ii I Iii
AALBORG DATA SHEET
INDUSTRIES
Type:
• Solenoid valve
• BV01
Size:
• G 114" -f
Application:
• For oil burners with small and medium
capacity.
• The valve is protected against oil-
impurities.
Material:
• House: Brass
• Core: Stainless steel
Technical data:
• Kv value with a viscosity at 30 eSt.:
1.4 Vmin.
• Valve opening diameter: 2 mm
• Working pressure: 0 - 24 bar
• Working temperature: + 15°C to + 70°C
• Ambient temperature: : + 20°C to + 40°C
• Viscosity max.: 150 eSt.
• Degree of protection: IP 54
• Input voltage: 230 V AC
• Input frequency: 50/60 Hz
• Power consumption: 8 W
Type No.: 6240

Version: A Solenoid valve 663 8146
· Language UK Page 1/1

Oescrtptlon Index Date Drawn Appr.
Item 16 added B 01.02.03 KTN STh
Chaoged acconflog lo CR 87- aocke1 lor F149 eraaad 18.03 KTN STH
Chooged acconflog to CR 457. Rlog wtlh perforutad plata _...04.04 JGJ JMN
TIUe: ....... D111
..... KBSD BURNER

..... KTN 19.06.2002
.,..,
iliiiiili
STANDARD 5Th
w.....
27.06.2002
Scala:
1:2.5
...
A2
AALBORG IGNITION BURNER ARRANGEMENT MkiWDnnYI"III No: lndn
INDUIIIIII
'MIDIWIIIIII'II:I~IIIIM!II'IIIIUIIIHI"'''III"''V'r.NILICININIUIIJIID
: PlcrtO.t.: NOIINifmnucmiYCII.IIDI'CICIJCIDfGIIInaa'Nfn 92Z:020616 d

........
.•••••
····:··
iilllllii
AALBORG DATA SHEET
INDUSTRIES
Type:
• Photo cell
• RAR7
Application:
• The RAR7 detector is used for
supervision of yellow burning oil
flames.
Technical data:
• Length of detector lead: up to 20 m
• Permissible ambient temperature: -20°C
to+ 60°
• Protection standard: I
• Degree of protection: IP 40
• Weight: approx. 85 g
130
10
49...73 25
30
co
.,....
...,
co
co
~ It)
& ~
&
F33
Type No.: 8630

Version: A Photo cell 663 9045

Thermostats, type RT
Technical data and When ordering, please state type and code number. Types of charge
code nos. A: Vapour charge- sensor must not be the warmest
part
B: Adsorption charge
C: Partial charge - the sensor must not be the
coldest part
Thermostats with cylindrical remote sensor Bt.'t. Preferred charge
Code nos.
Adjustable
differential range1 •
ff'2;2.. ~'i!]•.. ~
Max. Type- Capftlary Type
Setting
range sensor of lube
temp. charge length
at lowest at highest
range
setting
range
setting max. Aset
·•
'2}•
SPOT
SPOT
·c ·c ·c ·c m SPOT
-60- -25 1.7-7 1-3 150 A 2 017-5077 RT10

--45- -15 2.2- 10 1-4.5 150 A 2 017-5066 RT9
--30- 0 1.5-6 1- 3 150 A 2 017-5097 RT13
-25- 15 2.8- 10 1-4 150 A 2 iiQ.1:tii®H:n RT3
-25- 15 2.8- 10 1-4 150 A 5 017-5016 RT3
-25- 15 2.8- 10 1-4 150 A 8 017-5017 RT3
RT107 -25- 15 5- 18 8-20 150 B 2 017-5008 RT2
with cylindrical remote sensor, cover
with windows, and hand setting knob -25- 15 2- 10 2.5- 14 150 B 2 017-5053 RT7
-25- 15 2- 10 2.5- 14 150 B 5 017-5055 RT7
-25- 15 2- 10 2.5- 14 150 B 8 017-5056 RT7
-20- 12 1.5-7 1.5-7 145 B 2 017-5063 RT8
-5- 10 1-3.5 1- 3 65 B 2 017-5089 RT12
-5- 30 2-8 2- 10 150 B 2 &'OJ7l$.!i~~~ RT14
-5- 30 2-8 2- 10 150 B 3 017-5100 RT14
-5- 30 2-8 2-10 150 B 5 017-5101 RT14
-5- 30 2-8 2- 10 150 B 8 017-5102 RT14
-5- 30 2-8 2- 10 150 B 10 017-5103 RT14
-5- 50 2-9 3- 19 150 B 2 017-5180 RT26
5- 22 1.1- 3 1-3 85 B 2 017-5278 RT23
8- 32 1.8-8 1.8-8 150 B 2 017-5115 RT15
0- 85 6.5 fixed 200 B 2 017-5264') RT109
25- 90 2.4- 10 3.5-20 300 B 2 J0~7.:2$1!Q3'1! 017-5004 017-5005 RT101
25- 90 2.4- 10 3.5- 20 300 B 3 017-5006 RT101
25- 90 2.4- 10 3.5-20 300 B 5 017-5022 017-5023 RT101
25- 90 2.4- 10 3.5- 20 300 B 8 017-5024 RT101
25- 90 2.4- 10 3.5-20 300 B 10 017-5025 RT101
20- 90 4-20 2-7 120 c 2 017-5048 017-5049 RT106
20- 90 4-20 2-7 120 c 3 017-5051 RT106
20- 90 4-20 2-7 120 c 5 017-5050 RT106
30- 140 5-20 4- 14 220 B 2 017-5060 RT108
• 70-150
70- 150
70-150
8-25
8-25
8-25
1.8- 8
1,8-8
1.8- 8
215
215
215
c
c
c
2
3
5
':l!~t.§.t~l! 017-5136
017-5139
017-5140 017-5141
017-5137
017-5143
RT107
RT107
RT107
70- 150 8-25 1.8- 8 215 c 8 017-5144 RT107
70-150 8-25 1.8-8 215 c 10 017-5145 RT107
120-215 7-30 1.8-9 260 c 2. 017-5205') 017-5211') 017-5210 RT120
120- 215 7-30 1.8-9 260 c 5 017-5206') RT120
120-215 7-30 1.8-9 260 c 8 017-5207') RT120
120- 215 7-30 1.8- 9 260 c 2 017-5208 017-5214') RT120
120- 215 7-30 1.8-9 260 c 5 017-5209 RT120
150-250 6.5-30 1.8-9 300 c 2 017-5220 017-5224 017-5225 RT123
150-250 6.5-30 1.8-9 300 c 5 017-5222 RT123
150-250 6.5-30 1.8-9 300 c 8 017-5223 RT123
200-300 5-25 2.5- 10 350 c 2 017-5227 017-5231 RT124
200-300 5-25 2.5- 10 350 c 5 017-5229 RT124
')Thermostats fil1ad with neon lamp conneeted to tennlnal4

')Thennostat with tamper-proof seal cap
')Thennostat with max. reset has fixed dlflerenllal corresponding to min. seUlng dlfi>renllal
')FaR sale thennostat

Nomograms for obtained differentials A= Range seWng

B =Obtained orfferentiaJ
C = Differential setting
RT 2 RT 3 •c 4 RT 7
'C •c 'C 'C RT 'C 'C •c
15
- 5 -25 1 -5 1
1.2
15
- 2
~I
6 3
2
10 7 -20 10
..,"'
I
0
"
.., 8 3
2 4
5
.. 9
10
-15
4
5
3
5 .... 5
6
(}
"'
11
12
-10
5 10
0 (Q "' 7
-s
10
OD
.....
.,
13
14
15
-s
0 .c 6
7
15
4
5
-s
-10
"
"'
8
9
15 16 5 8
20 c -15
"'
:=c
10
11
20
"'0 17
18 10 9 25 6
-20
12
-c 19 13
2SA 20 15 10 30 -25 A
8 A 8 A 87 814
RT 8 RT 9 RT 10 •c RT 11 •c
'C 'C 'C 'C 'C 'C
-20 - 1,5 -45 1 -60 1
-30 1
I
2 2
I I
N
-15 -55 -25
.... 2 2
3
-10 ... 3
-35 4 -50
3
-20
3
5
-s "'
OD
4
6
-45
4
-15
-40 4
0 ..... 5 -c -10 c
-25 7 c 5
5 ., 8
-35
-5 5
6 6
9 -30
10 "'0 0 6
7 -15 10
12
A c B A 8 -2sJ. 87 A B
RT 12 RT 13 RT 14 •c RT 15
•c •c •c 'C •c •c 'C
-5
-4
-1
N-j
-3D- 1 30
"'
- 2 32
30
- 1.5
2
I
3
-3
-2 1,5
-25
2
25 28 "'...,
-1 ... -20
20
4 26
24 ...
3
0 5
1 2 3 22 4
15
2
3
-15 6 20 "' 5
4 10 18
OD
4 2,5 7
5 -10 c 16 ..... 6
6 0>
5
5 8 14 .,
7 3 -s
8
0
-c 0 c 9
12 7
9 10 "'
10 A 83,5 0
A : -sA 810 8
A -c
0
8
8
RT 17
•c 'C •c RT 23 •c •c RT 26 •c •c
RT 34
-so 1.5
2
5 - 1 so 2 15 - •c 2
~'
.,"' 5 10
I
3 1,5 40 4
-40 10 ... 5
30
4 "' 2 0 6
...."'
10
20 -s
-30 15
5 2,5 8
00 10
c
c 6 3
10
15 15
-20 ~ := 10
20 c 0 20
-15 7 22 a 3,s -s
A a19 25 12
A B A
RT 101 RT 103 •c RT 106 •c • RT 107
•c •c •c •c •c •c
9(} 2 10 1 20 2 70 1,8
1.3 ...
~'
4 4
I
80 15 30 80
2
I
5
70
6
2(} ... 40
6
8
90
8 3
10 25
., so 10
100 10
60
4
60
~0, 12
110
so
12 30
c ;:· 15
c 14 5 70
14. 120 c
35 0
40 16 -c 1.6 130
6 20
40 80
18 18 140
30
20 45 7 90 20 150 A 25
25A B B A B a
A

Technical data Designation RT thennostats

Ambient temperature -50to70"C.
Contact system
Line ;;;:;-a- SPOT

I--
Single-pale changeover switch (SPDn

Contact load Alternating current: A
AC-1: 10A,400V
AC-3: 4A,400V
AC-15: 3A,400V •..
••• a-O..S -
0,3
I
I
I
Fig.6
I
Contact material: Direct current: 0, I
I 12W
AgCdO DC-13: 12 W, 230 V o.oss~·.! I
(see fig. 6) --r--------------- v
20 ,~ 60 0~ IOO,l, 1<D,!,1BDJ 230
2
~ 40 80 120 HiD 200
Cable entry 2 PG 13.5 for 6-14 mm diameter cable

Enclosure IP66 ace. to IEC 529 and DIN 40050. Units with external reset IP54.
Thennostat housing is made of bakelite ace. to DIN 53470, while the
cover is made of polyamid.
Approvals
RT2 RT4 RT3 RT12 RT16 RT34 RT101 RT106 RT120 RT124
RT23 RT10 'Rr7 RT13 RT102 RT103 RT107
RT26 RT11 RT8 RT14 RT141 RT115 RT123
RT108 RT16L RTBL RT14L RT271 RT140 Approvals
RT17 RT9 RT15 RT270
RT140L
X X· X X X X X X X X DEMKO, Denmark. CE-mart<et ace. to Bl60947-4/-5,EN 6073().,2,.1/-9

X X X X Det Norske Verilas, Norway
X Uoyds Rsglsler of Shipping, UK
X X X x· X ® Germanlscher Uoyd, Germany
Bureau Verilas, Fiance
X X X X X X "
X X X X Reglslro llallano Navale, llaly
X X X X X X X ® Polski Rejeslr Stalk6w, Poland
X X X X X X X X X X RMRS, Russian Msrillme Register of Shipping,
X X X X X X X Nippon Ka!JI Kyoka~ Japan
Nola: In addftlon we refer 1o the certifiCBies, the copies of which can be ordered
GL approval is conditional on the use of a ship's cable enlry
Identification The type designation of the units is given on the

setting scale. The code no. is stamped on the
bottom of the thermostat housing
r~---1~
I
-
: ~ . .
r-'-t--+/
Type 017-XXXX
RTxxx

Dimensions and weight
RT 101, 107, 120, 123

special versions With
1!15 seal cap and blank cover
1!18.5
RT4 RT2
RT11 RT106
RT3
RT16, RT107 RT9
RT16L RT120
RT17 RT123
RT34
RT103
RT115
Special sensor Special sensor
W.no.
.s~
W.no. Material
lf
I' . 0 0
.... t-,,- .... II)
~-
l
2.0090 1.4301 18/8
RT 7 copper steel
RTB, RTBL
RT10
RT12
RT13
RT 14, RT 14L
RT15 RT 140/140L RT124
RT21
RT23
RT24
RT26
RT 101, RT 101L
RT10B
RT124
RT 140, RT 140L Weight approx. 1 kg
Choice of suitable sensor pocket
W.no. Type Capillary L Suitable Material W.no. L a, d

tube length mm sensor pocke mm mm mm
m Code no.
lf
RT2/3fl/9/ 2, 3, 5, 017-4370 Brass 2.0321
10/13/26/120 8,10 80 017-4369 18/8 steel 1.4301 112 G% 11
RT1011101L 2,3 017-4370 Brass 2.0321 112 G% 11
p
017-4369 18/8 steel 1.4301
RT8,8U14114L, 2, 3, 5, 8,10 017-4370 Brass 2.0321
2.0090 15,107, 123,271 110 017-4369 18/8 steel 1.4301 112 G% 11
copper RT101 5,8,10 017-4370 Brass 2.0231
017-4369 18/8 steel 1.4301 112 G% 11
RT141271 10 150 017-4367 182 G% 11
RT271 10 180 017-4216 Brass 2.0321
RT12/23 2 210 017-4216 465 G'lz 11
RT108 2 410 017-4216
m·13 2.0240
2.3 76
060L3330
060L3327
060L3331
Brass
18/8 steel
2.0235
1.4301
M1Bx1.5
110
160
110
G'lz
G'lz
15
15
brass RT106 060L3329 160
t
060L3330 110
060L3327 Brass 2.0235 G'l• 15
160
5 86
060L3331 110
060L3329 18/8 steel 1.4301 G1/z 15
160
Sensor pocket, sor.d version. internal diameter 13.1 mm 017-4218 AISI316L 1.4435 108 G'/z 15.7

...........
.....
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type: Installation:
of the valve:
• DN20 • Pipe must be flushed to clean the dirt,
Material
covers must be removed before the
• Body: ASTM Al05 installation work commences.
• End connections: Al05 • At the moment of the shipment the ball is
Technical data: lubricated with a pure vaseline oil,
• Min./max. temperature at 30 bar:
- 29°C to + 230°C
• -Ball valves normally have a space
ASME/ANSI B 16.25 - XS-80
• Weight: 2.3 kg
instruction for welding the valve on the pipe
Detail A
line:
• Tack weld in four points on both end-
connections.
the welding.
operation.
193
Detail A
End connection 1
100
F41
Type No.: 6010

Carbon Steel Separator, type 55
Description
The S5 is a carbon steel baffle type separator used for the removal
of entrained Hquids in steam, compressed air and gas systems.
Sizes and pipe connections

Yz", "h", 1", 1%", 1Yz", 2", 2Yz" and 3"
Screwed BSP or NPT, butt weld, socket weld.
DN15, 20, 25, 32, 40, 50, 65 and 80.
Flanged BS 4504 (DIN) PN16 (DN65 and 80 only) or PN40 with
screwed BSP drain and air vent
Aanged BS 1560 (ANSI B 16.5) Class 150 or 300 with
screwed NPT drain and air vent
Ranged JIS 22011KS 1OK and 20K with
screwed BSP drain and air vent
Optional extras
Insulation jackets are available which will increase the performance
of the separator.
Limiting conditions
Body design conditions PN50 I ANSI 300
Maximum design temperature
Ranged JIS IKS 10K 20.6 barg
Flanged PN 16 24.0 barg
Designed for a Aanged ANSI Class 150 30.0 barg
maximum cold
hydraulic test Ranged JIS I KS 20K 50.0 barg
pressure ot Flanged DIN PN40 60.0 barg
Flanged ANSI Class 300 76.6 barg
Screwed, socket weld and butt weld 76.6 barg
Operating range Flanged 55 shown

425
p 400
~ 300
::I
"§ 200
Q)
c.
E
Q) 100
1-
1 Pressure bar g
Ifill The product must not be used in this region.
"'PMO Maximum operating pressure when used for steam service.
A -A Flanged JIS I KS 10K
B -B Flanged ANSI Class 150
C - C Aanged PN16
D - D Aanged JIS I KS 20K
E - E Aanged DIN PN40
F. - F Aanged ANSI Class 300, screwed BSP, NPT, socket weld Certification
and butt weld This product is available with cetification to EN 10204 3.1.B.
Note: All certification/inspection requirements must be stated
at the time of order placement
Materials
No. Description Material
1 Body Carbon steel DIN 17245 GS C25NIASTM A216 WCB
2 Flange Carbon steel DIN 17243 C22.81ASTM A105N
3 Cover Carbon steel DIN 17243 C22.8 (1.0460)1ASTM A105N
4 Cover gasket Reinforced exfoHated graphite
5 Bolt Steel ASTMA193B7
F43
Dimensions {approximate) in mm
Screwed ANSI ANSI JIS/KS
Size SW,BW PN16 PN40 150 300 10K&20K
A A A A A A B c D F G
DN15-Yz" 130 204 204 204 204 162 292 90 1" Yz"
DN20-%" 130 212 212 212 212 158 345 90 1" Yz"
DN25-1" 178 260 260 260 260 184 387 90 1" Yz"
DN32-1%" 190 274 304 320 274 209 438 90 1" %"
DN40 -1Yz" 220 310 344 396 310 221 508 90 1" 1"
DN50-2" 214 310 342 354 310 221 558 90 1" 1"
DN65-2Yz" 319 419 419 419 419 419 270 663 90 1" %"
DNB0-3" 379 489 489 489 489 489 329 764 90 1"
·~·
Weights /volume {approximate) in kg and litres GAirvent
Size Weight Volume
Scrd/SW/BW Flanged Scrd/SW/BW Flanged
DN15-Yz" 3.3 4.5 0.84 0.85
.DN20-%" 3.8 5.0 1.00 1.03
DN25-1" 7.0 9.5 2.50 2.60
DN32-1%" 14.0 19.0 4.50 4.60
DN40 -1Yz" 22.0 27.0 7.70 7.90
DN50 -2" 23.0 29.0 8.40 8.70
DN65-2Yz" 65.0 70.0 17.50 18.00
DNS0-3" 82.0 90.0 31.00 32.00
Safety information c
When replacing the product ensure any pressure is isolated and
safely vented to atmosphere. Allow time for temperature to nonnalise
after isolation to avoid danger of bums and consider whether
protective clothing Is required (including safety glasses).
(
Warning: The cover gasket contains a thin stainless steel support
ring which may cause physical injury if not handled and disposed
of carefuDy. B
Installation
Install in a horizontal pipeline with the drain directly below.

To en5ure that any separated Hquid is drained quickly, a suitable
steam trap/liquid drainer must be connected to the drain connection.
For those steam systems where air can be present, air can collect
in the upper portion of the separator. In this situation a suitable
air vent should be connected to the air vent connection.
If an air vent is not being fitted then the connection must have the
plastic transit protection plug removed and must have a carbon
A Scrd/SW/BW
steel class 3000 lb plug fitted.
1 + - - - - - - A Aanged -----~
Disposal
The product is recyclable. No ecological hazard is anticipated with Recommended tightening torques
disposal providing due care is taken. or
Item Nm
mm
5 19A/F M12x35 40-45
Aalborg Industries • Data sheet No. 663 8601 2/2

DISCO Non-Return Valves RK 76
Application for liquids, gases and vapours.

Pressure/Temperature Rating
mm 15-100
Nominal sizes ON in 1fz-4"
Nominal pressure PN 4Q1)
Max. service pressure barg 40 33 31 30

forRK76 psig 580 480 450 435
·c 20 100 200 300

Related temperature "F 68 212 392 572
Minimum temperature Z) -1o ·c (14 "F)

') Also rated for ANSI dass 300, but see flange details below.
') Minimum temperab.Jre at nominal pressure rating.
Connections of wafer-type valves 3)

Valves for universal fitting between flanges to
DIN BS ANSI
DIN 2501 (BS 4504) BS10 ANSI B 16.1 class 125 FF
PN 6/10/16/25/40 tables D. E. F. H. J ANSI B 16.5 class 150/300 RF
') DN15-100mm (1Jz-41 with universal centering ring.
Dimensions 0
mm 15 20 25 32 40 50 65 80 100
ON
in '/z 'I· 1 1'1· 1'/z 2 2'/z 3 4
Dimensions L ") 16 19 22 28 31.5 40 46 50 60

inmm D 45 55 65 75 85 98 118 134 159
Weight kg 0.18 0.3 0.45 0.7 0.9 1.5 2.1 3.4 5.2
Materials
ON 15-100mm (Vz-4") DIN reference ASTM equivalent
Body. seat
G-X 8 CrNi 13 1.4008 A217-CA 15
and guide ribs
Valve disc. spring retainer A 182 F 316

X 6 CrNiMoli 1712 2 1.4571
Spring A313Type316
Centering ring X 12 CrNi 17 7 1.4310 Type 302
Opening pressures
Differential pressures at zero volume flow
ON Opening pressures in mbar

Direction of flow
with springs
mm in t -t ,J,.
15 Yz 25 22.5 20
3
020 /4 25 22.5 20
25 1 25 22.5 20
32 11f4 27 23.5 20
40 11h 28 24.0 20
50 2 29 24.5 20
65 2 1h 30 25.0 20
80 3 31 25.5 20
100 4 33 26.5 20
DN15-100mm
1 mbar : 0.0145 psi :. 10 mm w.g.::. 0.4 in w.g. ('k-4}
F45
IAalborq Industries I
Data sheet No. 8703093
......
.....
;liiiiili
AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure gauge valve needle straight.
Size:
• 3/8" X 3/8"
Application:
• For instrument connections
Material:
• Body: C22.8
• DlN-material No. 1.0460
Technical data:
• Test connection: M20 x 1.5 mm threaded male
• Weight: 0.4 kg
G 3/8,-f
0
0
.....
G 3/8 ·,-m
79
M 20 X1.5
FSO,F69,C 31 C331 C431

Type No.: 6210
Version: A Needle valve, straight, 3/8" x 3/8", PN 400 8703050

........
.....
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure transmitter
• MBS 5100
Size:
• 0-25 bar
Application:
• The pressure transmitter converts pressure to an electric signal. This is proportional to, and linear
with, the value of the pressure to which the pressure-sensitive element is subjected by the
medium. The units are supplied as two wire transmitters with an output signal of 4-20 rnA. The
transmitters have a zero-point displacement facility for equalizing static pressure.
Span adjustment is also possible.
lP""' II' "'-liJ c--+~

I
I
P' I
l.C)
N
I
I
I
@] I
I
~J/ I
(J)
I
I
I I I
I nrnn
I
I
l.C)
It')
N
Pg~ I ~@~ l
l.C)
.....
"5.5/ I
'
~'
ct)
G 1/4" -f I z'o I
30
30
73
84
F51
Type No.: 8010 Pressure transmitter
Version: A 8010 000006
0-25 bar

...
0 0 •
iliiiilli
AALBORG DATA SHEET
INDUSTRIES
Material:
• Housing material: Anodized AlMgSiPb
Technical data:
Performance:
• Accuracy (incl. non-linearity, hysteresis and repeatability): ±0.1% fs (typ.) I ±0.3% FS (max.)
• Non-linearity (best fit straight line): < ±.2% FS
• Hysteresis and repeatability:~ ±0.1% FS
• Thermal zero point shift:~ ±0.1% FS/lOK (typ.) I~ ±0.2% FSI10K (max.)
• Thermal sensitivity (span) shift: ~ ±0.01% FSIK (typ.) I~ ±0.02% FSIK (max.)
• Response time: < 4 rms
·Electrical specification:
• Rated output signal: 4 to 20 mA
• Supply voltage, Vsupply (polarity protected): 10 to 32 V d.c.
• Voltage dependency:< 0.01% FSN
• Current limitation (linear output signal up to 1.5 x nom range): 28 mA (typ.)
• Max. load RL: RL ~ [(Vsupply -10V)I0.02A] -10 n
Mechanical:
• Connection: G 114" -f
• Max. operating pressure: 50 bar
• Min. burst pressure: 100 bar
• Operating temperature range: - 40 to 85°C
• Compensated temperature range: 0 to 80°C
• Transport temperature range: - 50 to 85°C
• Cable entry: PG 11
• Enclosure: IP 65
• Weight: 0.4 kg

Version: A 8010 000006
0-25 bar

..... .
.....
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Installation:
• There are facilities for adjusting zero point and span.
Zero point adjustments is necessary to equalise pressure arising from any differences in level
between the pressure transmitter and the medium being measured.
Zero point adjustment results in a parallel displacement of span.
Both zero point and span must be adjusted on the side of the unit with cover removed
mA
20
Span
Po P' p p
I
[rnA]
20
Zero
4
~O%FS
Po Po p P'
40 ·200 mV
+
4·20mA
1. Supply+
2. Supply -
3. Function test
.,!, Connected to MBS transmitter enclosure

Version: A 8010 000006
0-25 bar

The N.C. (closed) 3f2.way solenoid valve for manifold
assembly is available with G1/8 inlet ports and with G1/8
outlets or with a dia. 4 cartridge.
These solenoid valves are equipped with an over ride 70
which must be manually operated using a small screwdriver.
46
The body is supplied complete with screws and O·ring.
"~ l 1
• Qn = determined with supply pressure of 6 bar and with ll.p = 1 bar.
F56,F59,F61,F65
Voltage
Voltage tolerance
LINE
SERIES 6 SOLENOID VOLTAGE

B • 24V 50/60 Hz
' C • 48V 50/60 Hz
D • 11 OV 50/60 Hz
E • 22DV 50/60 Hz
N' OF PORTS AND FUNCTIONS ' 2 • 12V DC
0 =interfa~e 3 • 24V DC
1 = 2 way normally open '4=48V DC
2 • 2 way normally ~losed '6•110VDC
3 = 3 way normally closed
4 • 3 way normally open • special voltages only on request.
PORTS
0 • lnterla~e SOLENOID DIMENSIONS
3· G3/8 6 • 32 X 32
8. G1/8
C• carttridge e4
M • manifold COIL MATERIALS

A • PPS
TYPE OF DESIGN OF BASE

150 = threaded body 107 • 7 • part manifold
450 • base with rotatable inter. 108 • 8 • part manifold
457 • base with fixed interla~e 109 • 9 . part manifold
101 =single manifold 110 ·10 ·part manifold
102 • 2 • part manifold 111 •11 ·part manifold
103 • 3 ·part manifold 112 =12-partmanifold
104 • 4 · part manifold 113 ·13 ·part manifold
105 = 5 · part manifold 114 =14-partmanlfold
106 • 6 • part manifold 115 • 15 • part manifold

Model AT201 DA and SR-90°
11140
AvaDable Flange: FOS
4x4 84.5 F05-F07
-!'-
I~
Flange Dimensions
ISO 5211 FOS F07
II- / \ d fB 35 NA
0 0 Q1
W1
50 70
M6x9 M8x12
35 35
Square 14 17
Lmln. 16 1g
hmln. 1,5 1,5
I \ r- h1 2
~2 _121 \ G1/8" IS0228 -1 Pressure connection B1
42.5 52 AnciRa!)' Attachment AA 1

210.5
-----~---
)~~~~:c
'f\ I j-r l11d2f8
"C/ Spigot optional
I BOT
lYPE Output Torque for Double Acting and Spring Return in Nm Spring
~
Prescun 2,5 bar 3 bar 3.S bar 4 bar 4.2 bar 4,5 bar 5 bar S.S bar 6 bar 7bar 8 bar stroke Weight
o· go· o· go· o· 90" o· 90" o· 90" o· go• o· 90" o· 90" o· go· o· go· o· go• go• o· ( Kg >
D 29,1 35 40,7 46.S 49 52 58.2 64,0 69,8 81,4 93,1 2.74

EndeStart
sos 18,0 11,8 23.8 17,6 29.7 23.4 35.5 29.2 37.8 31,6 41,3 35,0 47,1 40,g 17,3 11,1 z.g2
SOB 15,8 8,3 21,6 14,1 27.5 1g,g 33,3 25.8 35.6 28,1 39,1 31.6 44,g 37.4 50,7 43,2 20,8 13 2,gs
S07 1g,4 10,7 25.2 16,5 31.1 22.3 33.4 24,6 36,9 28.1 42.7 33,9 48,5 3g,8 54,3 45,6 24,2 15.S 2.99
SOB 23,0 13,0 211.8 18.8 31.2 21,2 34.7 24,7 40,5 30,5 46,3 36,3 52.1 42.1 63.7 53,7 27,7 17,7 3,02
S09 26.6 15.4 2g,o 17,7 32.5 21,2 38,3 27.0 44,1 32.8 4g,g 38.6 61,5 50,3 73.2 61,9 31.2 19,9 3,06
S10 30.2 17.7 36,1 23,6 41,g 29,4 47,7 35,2 sg,3 46,8 71.0 58,5 34,6 22,1 3.09
S11 33,8 20.1 39,7 25,9 45,5 31,7 57,1 43,4 68,7 55,0 38,1 24,3 3,13
eS12 37.5 22.4 43,3 28,3 54,9 39,9 66,5 51,5 41.S 26,5 3,17
Max. Rotation Screw stroke Chamber Ai"Volume (L) Moving nme (Sec.) (A) Operating Temperature ("C) (B)
Pressure Ac:Uustment I2J (mm) Opening Closing Opening Closing sm (:andard) I

HT (high temp.) LT Oow temp.)
goo :t4" For 1• o 0,30 o 0.35 NBR ·o·-Ring FPM ·o·-Ring lsmcon "0"-Ring
Bbar ato•andgo need1/6Tum 75 0,31 0,49 S 0,40 S D.SD -20to+BD -15to+150 -4Dto+BD
Notes: (A) lhe above Indicated moving time of the actuator. are obteined in the foDowlng test condltlons{1) Room Temperature, (2) Actuator Stroke 90".
(3) Solenoid Valve with Orifice Of 4 mm and a now capacity Qn 400 Umln(4) Inside pipe diameter 8 mm, (5) Medium dean air, (6) />Jz supply pre.,.ure
5.5 bar (79,75 Psl)(7) Actuator without external resistance load.
Cautions: obviously on the field applications when one or more of the above parameter are cflfferent. the moving time will be dlflerent.
F57,F58 F66
!Aalborg Industries Data sheet No. 663 8651,
Model AT251 DA and SR-90°
040 Available Range: F07

F05-F07
-tr- lhT--1
97.5
,..----.,
Range Dimensions
0
"' l[[ I I 1505211 F05 F07
rl 1- / '\ d f8 NA 55
'2! - 0 0 - ss ',fc= :;~00 - Q1

W1
50 70
M6x9 M8x12
MSxB ~ ~
I 40 55
Square
·~ ~
17 17
Port'Z' ~~± ~~
lmln. 19 19
~- ~~--~-+\ hmin.
h1
1,5
.
1,5
2
~U----L-*---r~+-;---~--ur
Pressure connection 81
12 12! \ G1/8" IS0228 -1 I I I I
Anciftary Attachment AA1
247.5 49.5 56.8
T 80
T
lYPE Output Torque for Double Acting and Spring Return in Nm Spring
-
Pressur 2.5 bar 3 bar 3,5 bar 4 bar 4,2 bar 4.5 bar 5 bar 5,5 bar 6 bar 7 bar Bbar stroke Weight
o· 90" o· 90" o· 90" o· 90" o· 90" o· 90" o· 90" o· 90" o· 90" o· 90" o· 90" 90" o· (Kg)
D 45,8 55 64,1 73,2 n 82 91,5 101 110 128 146 - 3.86

End Start
sos 27,4 16,9 36.6 26.0 45,7 35.2 54.9 44.3 58,5 48,0 64,0 53.5 73.2 62.6 211.9 18,3 4.12
SO& 23.8 11.1 32,9 20,3 42.1 29,4 51.2 38,6 54.9 42.2 60,4 47.7 69,5 56,9 78,7 66,0 34,7 22 4.17
S07 29.2 14,5 38,4 23,6 47.5 32.8 51.2 36,4 56.7 41,9 65.8 51.1 75,0 60.2 84.2 69.4 40,4 25,7 4.22
SOB 34,7 17.9 43,9 27.0 47,5 ,30,7 53,0 36.2 62.2 45,3 71,3 54,5 80,5 63,6 98.8 81,9 46,2 29,3 4,28
S09 40.2 21.2 43,9 24.9 49,4 30,4 58.5 39,5 67.7 48.7 76.8 57.8 95,1 76,1 113.4 94,5 52.0 33,0 4,33
S10 45,7 24.6 54,8 33,8 64,0 42.9 73.1 52.1 91.5 70.4 109,8 88.7 57,8 36,7 4,38
Sf1 51,2 28,0 60,3 37,1 69.5 46.3 87,8 64,6 106,1 82.9 63,5 40,3 4,44
eSf2 56,7 31.4 65,8 40.5 84.1 58.8 102.4 n,1 69,3 44,0 4,49
Max. Rotation Screw stroke Chamber JlJr Volume (1.) Moving lime (Sec.) (A) Operating Temperature ("C) (B)
Pressure Actiustrnent 0 (mm) Opening I Closing Opening I Closing sm (~ndard) Hr (high temp.) Ill (low temp.)
90" :t:4" For 1" I o 0,40 1 o o,s NBR "O"·Ring FPM ·o·.Rfngl smcon ·o·-Ring
8 bar at o· and 90 need 115 Turr 85 0.51 0,78 S o.so Is 0,60 - 20 to + 80 - 15 to + 150 - 40 to + 80
Notes: (A) The above Indicated moving lime of the actuator, are obtained In the foDowlng test condl11ons{1) Room Temperature, (2) Actuator Stroke 90",
(3) Solenoid Valve with Orifice Of 4 mm and a flow capacity Qn 400 llmin(4) Inside pipe diameter 8 mm. (5) Medium dean air, (6) Alr supply pressure
5,5 bar (79,75 Psl)(7) Actuator without extemal resistance load.
caudans: obviously on the field applications when one or more of the abOve parameter are cfofferent. the moving lime wiD be different.
F60
IAalborg Industries Data sheet No. 663 86521
....
.....
iliiiiiii
AALBORG DATA SHEET
INDUSTRIES
Type:
• Filter regulator with semi-automatic,
manual drain
Size:
• Connection ports 118"
• Gauge ports 1/8"
Application:
• Instrument air for regulating pressure
Technical data:
• Medium: instrument air only
• Max. inlet pressure: 16 bar
• Operating temperature: 0-60 ac at 10 bar
• Filter element: 5 J.UD. .
• Outlet pressure: 0.5 -10 bar
• Pressure gauge: 0 - 10 bar Bin
• Weight: 0.37 kg
Material:
• Handle: Nylon
• Bin: Grillamid
• Body: Metal
45
r-·-·-·- -·-·-·-,
i ~iJ
~
o-1
! i!
L . ..J!.J
!t______________
Type No.: 8000

Version: A Filter regulator with automatic, manual drain 663 9046

........
.....
iliiiiili
AALBORG DATASHEET -
I N D_ U S T R I E S
Technical data:
Type:
• Measuring unit: bar, psi
• Pressure gauge
• Measuring range: 0 - 12
Size: • Connection: G 1/8" -m
• !ll40 • Ambient temperature: - 20 to + 80°C
• Weight: 0.048 kg
Application:
• For air
Material:
• Case: Black plastic
• Socket: Brass
43
II 1- G 1/8 -m
I I
JQ..
F62 a2. F63. 2. F96.2" F97.2

Type No.: 8050
Version: A Pressure gauge, " 40 663 3015

.......
......
.
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure gauge, type P1116
Size:
• SlS 63
Application:
• For all gaseous and liquid media
Material:
• Case: Stainless steel
• Socket: Cu-alloy
• Liquid filling: Glycerine
Technical data:
• Connection: G 1/4"-m (114 BSP)
• Measuring unit: bar- Mpa- kg/cm2
• Measuring range: 0- 25 /2.5 /25
• Pressure utilisation:
Static pressure: 75% of Pmax.
Dynamic pressure: 66% of P max.
• Operating temperature: -20 to +80°C
• Accuracy: EN 837 Class 1,6
F68
Type No.: 8050
Version: B Pressure gauge, 0 63 663 3121
Type P1116

........
.....
iliiiiiii
AALBORG DATA SHEET
INDUSTRIES
Type: Installation:
• Three-way valve, ball
• LB 183 BW, full bore
of the valve:
Material
• Body: ASTM A105 installation work commences.
• End connections: ASTM A105 • At the moment of the shipment the ball is
solvent, if required. ·
- 29°C to + 230°C
ASME/ANSI B16.25- XS-80
• Weight: 3 kg
Detail A
line:
connections.
the welding.
operation.
L-Bore
Centre part
Port1~Port2
t
Bolt
Detail A
Port 3
Port 1 Port 2
114
Port3
F75
Type No.: 6070

Version: B Three-way valve, ball ON 20 8703071

Technical data for differential pressure transmitter, type 7MF4433
Mode of operation
Measuring prindple Piezo-resistive
Input
Measured variable Differential pressure and flow
Measuring range
• Span (continuously adjustable}
- Nominal pressure PN 32 1 mbar to 20 mbar

- Nominal pressure PN 160 1 mbar to 30 bar
- Nominal pressure PN 420 2.5 mbar to 30 bar
• Lower measuring limit
- Measuring cell with silicone oil filling -100 % of max. span or 30 mbar (absolute)
- Measuring cell with inert filling liquid
For process temperature
-2o ·c < , s 60 ·c 30 mbar (absolute)
For process temperature 30 mbar (abs.) + 20 mbar (abs.) · (,- 60 "C)I"C
+60 ·c < ,s 100 ·c (max. +85 ·c
for 30-bar measuring cell}
• Upper measuring limit 100 % of max. span (max. 160 bar with oxygen measurement
and inert filling liquid)
• Start-of-scale (continuously adjust.) Between the measuring limits
0 utput
Output signal 4 to 20 rnA
..
• Lower fimit (continuously adjustable) 3.55 mA. factory-set to 3.84 rnA
• Upper limit (continuously adjustable) 23.0 mA. factory-set to 20.5 rnA or optional 22.0 mA
.• Ripple (without HART communication) leo.~ 0.5 % of max. output current
• Electric damping
- Adjustable time constant (T6 Jl 0 to 100 sin steos of 0.1 s. factorv-set to 0.1 s
• Current transmitter Adjustable from 3.55 to 23 rnA
• Signal on alarm Adjustable from 3.55 to 23 mA
Load
• Without HART communication Rs s (UH- 10.5 V) I 0.023 A inn. UH: power supply in V
Characteristic Unear rising or Falling or square-rooted
A ccuracy
Reference conditions Increasing characteristic, start-of-scale value 0 bar, stainless steel seal diaphragm (with level:
mounting fta~e without tube), silicone oil filling and room temperature (25 "C)
r = max. spa set span = span ratio
Error in measurement with fixed-point
setting [Including hysteresis and
repeatability)
- Unear characteristic
rS10 S0.1%
10<rS30 S0.2%
30<rS100 s (0.005 · r + 0.05 %}
- Square-root characteristic
Flow> 50% s 0.1% atrs 10
s0.2 %at
10<rS30
Flow 25 to 50 % s0.2%atrs10
S0.4 %at
10<rS30
• Repeatability Included in error in measurement

• Hysteresis Included in error in measurement
Response time Approx. 0.2 s. approx. 0.3 s with 20- and 60 mbar measuring cells
(T63• without electric damping)
Long-term drift per 12 months s (0.1 · r)%
- 20-mbar measuring cell S(0.2 · r)%
Ambient temperature elfect
• At -1 oto +60 ·c s (0.1 · r + 0.2) %1>
·At -40 to -10 ·c and +60 to +85 ·c s (0. 1 · r + 0.1 5} % I 10 K1l
F76
Influence of static pressure
• On start-of-scale s (0.15. r)% per 100 bar
- 20-mbar measuring cell s (0.15. r)% per 100 bar
• On span s 0.2% per 100 bar
- 20-mbar measuring cell s 0.2 % per 32 bar
Influence of mounting position s 0. 7 mbar per 10" Inclination
Influence of power supply 0.005 % per 1 V change In voltage
Rated operating condHions
Installation conditions
• Installation Instructions Arry mounting position
Ambient conditions
• Ambient temperature
(observe temperature dass in
potentially explosive atmospheres)
- Measuring cell with silicone oil filling -40to +85 ·c
30-bar measuring cell -2oto +85 ·c
- Measuring cell with inert filling liquid -20 to +85 ·c
- Digital disP,Iay -3oto +85 ·c
• Ambient temperature limits See ambient temperature
• Storage temperature -5o to +85 ·c
• Climate class
- Condensation Permissible
• Degree of protection (to EN 60 529} IP65
• Electromagnetic compatibility
- Emitted interference To EN 50 081-1
- Noise immunity To EN 50 082-2 and NAMUR NE 21
Medium conditions
• Process temperature
- Measuring cell with silicone oil filling -40 to+ 100 ·c
30-bar measuring cell -40 to +85 ·c (-20 to +85 ·c for 7MF4533)
- Measuring cell with inert filling liquid -20 to+ 100 ·c
30-bar measuring cell -20to +85 ·c
• Process temoerature limits See process temperature
• Process pressure limits Nominal pressure (PN)
Design
Weight (without options) Approx. 4.5 kg
Dimensions See drawing
Material
• Wetted parts materials
- Seal diaphragm Stainless steel, mat No. 1.4404, Hastelloy C276, mat No. 2.4819,
Monet. mat No. 2.4360, tantalum or gold
- Process flanges and Stainless steel, mat No. 1.4408, Hastelloy C4, mat No. 2.4610 or Monet. mat No. 2.4360
sealing screw
- 0-ring FPM (VIton) or as option: PTFE. FEP. FEPM and NBR
• Non-wetted parts materials
- Electronics housing Ole-cast aluminium, low In copper, GD-ALSI12, or stainless steel precision casting,
polyester-based lacquer, stainless steel rating plate
- Process flange screws Steel, galvanized and yellow-passivized, or stainless steel
- Mounting bracket (option) Steel, galvanized and yellow-passlvized, or stainless steel
Measuring cell filling Silicone oil or inert fining liquid (max. 160 bar with oxygen measurement)
Process connection Female thread ~ - 18 NPT and flange connection to DIN 19 213 with
mounting thread M10 (M12 for PN 420) or 7/16-20 UNF
Electrical connection Screw terminals. cable inlet via screwed gland Pg 13.5 (adapter),
M20 x 1.5 or ll -14 NPT. or Han 70/Han 8UJllug-
Displays and controls
Input keys 3 for local programming directly on transmitter
Digital display Built-in, cover with window (option)
p ower supply (U Hl
Terminal voltage on transmitter DC 10.5 to 45 V and DC 10.5 to 30 V In intrinsically-safe mode
Ripple Upp s 0.2 V (47 to 125Hz)
Noise Unns s 1.2 mV (0.5 to 10kHz)

Certificates and approvals Exclusively decisive are the data In the official EU prototype test certificate
and the respectively valid supplements
CENELEC To DIN EN 50 014: 1997. EN 50 020:1994 and EN 50 284: 1999
• Intrinsic safety G 111/2 G EExla IIC T4/T5/T6
- EU prototype test certificate T()V 99 ATEX 1494
- Max. ambient temperature +85 ·c temperature class T4
+70 ·c temperature class T5
+60 ·c temperature class T6
- Connection to certified Intrinsically- u, = 30 v. ~ = 100 rnA.
safe circuits with maximum values P1- 750 mw. ~ = 300 n
- Effective Internal inductance L1=0.25 mH
- Effective Internal capacitance Cj=6nF

• Explosion-proof G 111/2 G EExd IICT4/T6
- Conformity certificate PTB 99 ATEX 1160
- Max. ambient temperature +85 ·c temperature class T4
+60 •c temperature class T6
138 _ _ _.,
I
I 4
I
I
! 9
! 10
I 8
I
I
I
I
l__ ~ T'---.-1fll"'o-,----LP....::- --;;\
\'i
4 ~-- _i
• 45 for Pg 13.5
1a Process connection of low-pressure side r.. - 18 NPT 5 Terminal side

1b Process connection of high-p~ssure side r.. - 18 NPT 6 Electronics side. digital display
2 Mounting thread M10, M12 or 116 - 20 UNF 7 Protective cover over keys
3 Blanking plug 8 Seafing screw with valve
4 Electrical connection: 9 Vent on side for fiquld measurements
screwed gland Pg 13.5 (adapter), M20 x 1.5 or 10 Vent on side for gas measurement (suffix H02)
l2- 14 NPT or Han 70/Han BU plug 11 Mounting bracket (option)

........
.....
iliiiiiii
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Check valve • Steel
• RD12L
Technical data:
Size: • Nominal working pressure: PN 250
• Diameter 3/8" • Weight: 0.21 kg
Application:
• For oil and/or air flow
across flats 22
Width across flats 30
across flats 27
direction
F77 F80
Type No.: 6020
Version: A Check valve, 3/8", PN 250 663 8103
Language UK. Page 1/1

Position switch RC-E4L
DeScription: The RC-E4L is a position switch mounted on actuators
or directly on valves, for limit indication via mechanical or inductive
switches.
Technical data
Material Shaft: stainless steel
Consol, bottom plate, house: aluminium
Min. lift height (house) 35mm
Switches Type V3, 2 st
Power consumption 10A,250V
0,6A, 125 v =
0,3 A, 250V = Standard
wiring
Protection IP67 diagram
Special made for IFM NS 5002 NAMUR
inductive switches IFM NS 500110-30V DC PNP 3-wire
IFM NS 5026 5-36V DC 2-wire
Quadronorm
IFM IN 0081 20-250 AC/DC (E4)
Pepperl + Fuchs NJ2-V3-N
Pepperl + Fuchs NBB2-V3-E2
RCE4L
F85,F86
Aalborg Industries Data sheet No. 663 8660
..
.......
ii.I·I·Iil.Iii
i.
AALBORG DATA SHEET
INDUSTRIES
Type:
• Straightway control valve with electric
actuator
• 23.470 PREMIO
Size: ~ = 150x165 .,
Application:
• For steam and/or fluid flow
Material:
• Body: GGG 40.3
DJN -Material No. 0.7043 -Hand operating
device
• Seat: X20 Cr13
DJN Material No. 1.4021.05
• Disc: X20 Cr13
"'
CD
DJN Material No. 1.4021.05 "'

• Stuffmg box: PTFE-V -ring unit ( -1 0°C
to +220°C)
Technical data, valve:
• Position ratio: 50:1
• Flow characteristic: Equal percentage
• Standard Kv value: 4.0 m3/h
Seat
• Stroke: 20 mm
• Plug type: Parabolic shaft guided
-Body
• Flanges according to DJN
Technical data, actuator: 150
• Voltage: 230V- 50/60Hz

I
• Thrust: 2.2 kN ~
1/N N (MP)
• Closing pressure: 25 bar WE
• Power input: 11.7/14 W 11 •+=;•~ 53
~'*
14
• Protection: IP 65
• Ambient temperature:
- 20°C up to + 70°C
• Operating time: 53/44 sec
• Cable glands: 2 x PG 11
Technical data:
• Weight: 14 kg incl. actuator
Installation:
DE Torque switch
• Only as shown in the picture WE (53) Umit switch for limiting the stroke
distance in opening direction
F91
Type No.: 6050 Control valve, straight way, with electric 87A3038
Version: A actuator, DN 20, PN 25

.
........
.l·l·il·i·
ii I Iii
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• 23.006 DIN -Material No. 0. 7043
• Seat: X20 Crl3
• Nominal diameter: DN 20 • Disc: X20 Cr 13
• Weight: 4.3 kg
0120
0
CX)
......
F92
Type No.: 6010

Version: A
Stop valve, straight, ON 20, PN 25 250 1087

F94
IAalborg Industries Data sheet No. 663 5199 1/4 I
VariPak - General Characteristics
General Data Body
Intrinsic Type: . .sl•=

now charac- globe style with Integral · a)· stanc:fard :
terlaUcs: linear (triJ!I No. 0 to 5) bonnet 2S mm (1")
modified linear Materials: b) optional :
(trim No. 6 to 9) a) standard : 15 and 20 mm
1
type 316L austenitic st. st. ( /2" and 3/./')
Cv ratio: 500/1 at max. Cv b) optional:
(with a . 200/1 at min. Cv Monel•, OpUonal: ·
positioner) Hastelloy 8 C, etc. • flanged valve: p. 11
• anticavitatlon 'Varilog' : p. 12
Flow Body
rating: • high pressure: p.13
direction: flow-to-open
a) standard : • bellows seal: p. 14
Seat ISO PN 250 · • cryogenic: p.15
leakage: a) standard : (ANSI Class 1500) • an.gle valve
ANSI B 16.104 Class IV b) high pressure : • H2S version
maximum leakage 0,01% of ISO PN 420 • steam jacketed (flanged
nominal valve flow at (ANSI Class 2500) valves)
3.5 bar g (50 psi g) air to
atmosphere
Connections:
b) optional :
ANSI B 16.104 Class V. • flangeless (1", 3/4'' and w· • flanged (1" body) of the
3 x 10-4 cm3 water/minute bodies): following ratings ISO PN 20,
per mm orifice diameter of - The 1" body can be: 50 and 100 (ANSI Class 150,
· the seat and per differential • standard: clamped 300 and 600).
pressure bar between line flanges of Other standards on option. ·
the following ratings:
ISO PN 20 to 250 (ANSI
Class 150 to 1500)
• optional : threaded to
accept screwed-end
- 21o·c fittings
- optional : the 1/t' and 3/4"
* For other tell'lperatures, consult Masoneilan bodies may be threaded
to accept screwed-end
Packing Box
fittings
Type: bolted - threaded connections· are
not available in bar stock
Packing: split-rings, braided PTFE body
jacketed asbestos
.lg Seat
Type: top entry Materials: a) standard :
Materials: a) standard : 17-4PH st.st. (trim No. 0 to 5)
StelliteeNo. 6 (trim No. 0 to 5) Stelllte• No. 6 (trim No. 6 to 9)
Stellite•No. 12 (trim No.6 to 9) b) optional: .
b) optional: Monere, Hastelloy• C, etc.
440C st. st., Monel•, Hastelloy•c, etc.
Actuator Spring range

(according
Type: spring-opposed rolling to Cv}: 207 to 1035 mbar (3 to 15 psi)
diaphragm with force 414 to 1660 mbar (6 to 24 psi)
amplifying lever and Cv
adjustment knob
Air
connection: 1N' NPT
Material: die-cast aluminium-anodized, Protection
epoxy painted for corrosive
AcUon: direct or reverse: action can atmosphere: the cover of the actuator is
easily be reversed without Optlonala: slightly over-pressured and
additional parts - limit stop, mandatory with purged by supply air from the
handwheel and electro- positioner
·pneumatlc positioner
- electric actuator
IAalborg Industries Data sheet No. 663 5199 214

VariPak - Accessories
Pneumatic positioner Electropneumatic positioner

(model 7700) (model 8013)
Fig. 7 Model noo pneum~tic positioner Fig. 8 Model 8013 electropneumatic positioner
mounted on VariPak mounted on VariPak
Type: pneumatic, force balance Type: electropneumatic, force

Mounting: bracket actuator built-in balance
Action: direct: increasing instrument Mounting: compact, without external
signal increases output air linkage to the actuator (see
Fig. B)
Charac-
teristics: linear Action: direct:. increasing in!)trument
Instrument signal increases output air
signal: 200 to 1000mbar, reverse : increasing instrument
400 to 2000 mbar signal decreases output air
or 200 to 1800 mbar Charac-
(3 to 15, 6 to 30 teristics: linear
or 3 to 27 psi) equal percentage (optional)
200 to 600 mbar Instrument
and 600 to 1000 mbar signals: 4-20 rnA, 1Q-50 rnA
(3 to 9 and 9 to 15 psi) Air
split range connections: 1/4'' NPT
Connections: 1/4'' NPT instrument Average air
and supply consumption: 0.4 Nm 3/h
Average air Explosion
consumption: 0.26 Nm~/h · proof
designs: - flameproof enclosure
Maximum air - intrinsically safe
output: 7 Nm~/h
Supply
pressure
effect: 0.07% of full stroke variation
Other accessories (optional)
per 100mbar supply
pressure change (0.05% per Limit switches
psi) Handwheel
Open loop Proximity sensors

gain: 70
Unearity: ± 0.5%
Sensitivity: 0.1% .
Repeatability: 0. 1% Weight
Full stroke Complete

time: less than one second valve: 8 kg
IAalborg Industries Data sheet No. 663 5199 3/4

Standard VariPak
-20-25 mm (W'- 3/4"- 1") ISO PN 250 (ANSI Class 1500)
The standard VariPak valve is the most widespread in

use. This valve is used for most applications because of
its stainless steel body.
Fig. 9 Standard VariPak
Maximum allowable pressure drops (.6.P)

Upstream pressure (P1) must not exceed LlP max.
Dimensions- mm- Bar stock body

(for non-castable materi~l)
Handwhee/ (optional) -c:!:l
. '•'
2 holes tapped
Sfi6" -18 UNC -.;;_...._,
depth 11 1'/u"l
G)t/4" NPT
Supply
Connection
@I/4"NPT
Instrument
Connection
1
!2" NPT
3(4 • NPT
1" NPT
I
optional
Provide a removal clearance of 140 mm (5.5 inches)

COMPACT VR EIP TRANSDUCER MODEL T7800·
.WITH FEEDBACK SERI·ES
____
.._
I APPLICATIONS ___, I
The T7800 Series of electro-pneumatic transducers
transmits a pneumatic signal which is linearly.proportional
to a DC current or DC voltage input.
These high quality rapid response controls use low pow-
ered microelectronics and pressure feedback control to pro-
vide a stable, accurate pneumatic output for the operation of
actuated valves, final control elements, input signal for pneu-
matic positioning, or conversion of current to pressure.
Compact size increases accessibility of controls in small
spaces and simplifies the piping layout to the unit. External
access to the restrictor simplifies unit maintenance.
Manifold assemblies are available for 3,5, 10 or 15
transducers and include quick plug-in adapter kits. One
set of mounting brackets extends the manifold two inches
from the mounting surface to permit use of the rear output
ports on the manifold, which allows high density vertical
mounting of multiple manifolds.
A TR7800 Rack Unit is also available that will allow
plug in of up to ten TR7800 transducers into a standard
19 inch rack.
______
.._ MAJOR FEATURES
I ___... I ____
I.
.__
BENEFITS ___. I
1: Internal electronic feedback 1: Precise, accurate control of output pressure
F Piezoelectric Controlled Flapper nozzle 1: Provides extreme stability regardless of
and Solid State Control circuit vibration or position
1: Housed in NEMA 4X (IP65) enclosure (TA, TD) 1: Permits outdoor and indoor installations
F RFIIEMI Protected P Reduced susceptibility to electromagnetic and
radio interference
1: 6 Output Ranges available (Jumper P Field select. output to match final control element
Selectable) requirements
1: Field Reversible P Provides output which is directly or inversely propor-
tional to input signal
1: Split Range Operation P Permits two or more functions to be controlled from
common signal source
F Compact Size P Permits use in restricted areas
1: 51nput Ranges Available 1: Covers standard process and industrial inputs
F Input and output ports on both ends 1: Simplifies pneumatic piping
1: Conduit Fitting, Terminal Strip or DIN 1: Allows easy wiring
Connector available
1: May be wall, panel, DIN rail, Rack or Manifold mounted F Allows installation flexibility for most applications
F95
'····
FUNcnONAL SPECIFICATIONS. Supply Voltaae (3 wire voltage input)

7-30VDC, Tess
. than
.,_ 3mA .
Input
4-20 rilA DC 0.19'1 DC, 1·9V DC, 0-5v DC, 1·5v DC Signal Impedance.·(~ wire voltage input) .
10 Kilonms . ·
Pneumatic OutpQt!Supply Pressure
Output R•nge Supply Pressure*
psig [BAR] (kPa) psig [BAR] (kPa) PeRFORMANCE SPECIFICATIONS
3-15(0.2·1.01
3-27 0.2·1.8 {2().;100}·············20.120 1.5-8.01 ~5(),.8001
20.180 ........ ~ .... 32·120 2.2~8.0 220-800
Accuracy_ {Dar ISA S51.1)
:1: 0.25% Fun Scale Guaranteed
6-30 0.4-2.0 40-200 ............. 35-120 2.4-8.0 240-800 : 0.15%. Full Scale Typical
Q-30 (D-2.0ll0·200J............. 35-150 2.5-10 { 50-:1000~
Q-60 o-4.0 0-400 ............. 65·150 4.6-10 460-100o . Hysteresis (per ISA S51.1J
. D-120 D-8.0 0-800 ........ ~ .... 125-150 8.8-10 BBo-1000 0.1% Full scale • Standaitl
*NO~: auP.ply pre$S~re must be 5 psig [o.;*; BAR] (35kPa) 0.25% FUll Scale • Ext. Range
(mlnnnurn) liliove rnaxJmum output. Deadbanci
0.02% Full Scale '
Minumum Output Span
. Output Range Minimum Span . ', ReDUtabilitv (p_er ISA S51.1)
· M% Full Scale · ,
psig · [BAR] . (kPa)
3-15 (Q.2-1.0 20-100 ............... 5
3-27 0.2·1.8 20-180 .~ ............. 10
psig [BAR]
{0.35]
~0.~
ml(kPa)
0
Position EffeCt ·
No measurable effect • Standard
11
6-30 0.4-2.0 40-2001............... 10 0. . . 0 . 0.125% ~ .90' & 0.25%@ 180', Ext. Range~
0.30 (Q-2.0~ ~Q-200}·:· ............. 12.5 . [ .8 J 85
Q-60 o-4.0 D-400 .. '..... ... ... .. 25 [31• _5]0 (30150
_0) VIbration Effect .
D-120 Q-8,0 0~00 ................ 50 [ 0) { ) Less than :1:1% of Span under the foilowing conditions:
5-15Hz@ 0.8 inches constant displacement .
15-500 Hz@ 10 g'S
Set Point·
3 9 15. 30 60· 120 Reverse Polarity Protection .
[0.2) [0.6] [1.0) [2.0) [4.0] [8.0) No damage occurs from reversal of normal suQj>ly cur-
(20) (60) (100) (200) (400) . (800) rent (4·20" rnA) or from misapplication of .up to 60 inA.
Range . · · · RFIIEMI Effect · .
Less than 0.5% of span @ 30VM class 3 Band ABC (20 to .
a-15,3-27;8-30 3.5 (;to)l7.o (.20) 9.5 {~ 3.5~~ 1000 mHz) per SAMA PMC 33.1 1978 and Jess than 0.5%
o-30 3.1 {'09l 7.8 .22 1.8 .33 of span @10YA~Ievel, 27 to 500 mHz Band per IEC Standard
Q-60 1.6 .()4 4.7 .13 7.8 .22 13.3{.37)
D-120 0.5 .01 . 3.8 .11 7~{.21) 15.1 (A2) . 801-3 1984 Cwire .in CQnduit) EMC Directive 891336/EFC
European NO'AMS EN 50081·2 antf EN 50082·2. · ·
NOTE: Values for listed Set Points are Indicated as Supply Pressure Effect
SCFH (m3/HR).. .
No measurable effeCt~. Standard
Flow Rate 0.1 psig change for 10 psig supply_ change • Ext Range
Output Range · Flow Rate (SCFM)
psig [B~) (kPa) · . Tem~ Effect . ·
3·15 [0.2·1.01 i2D-100)................... 2.5f4.25~R) 025psjg :1: [0.5_% tQ.040faiF' Temp. Change) of Span g·uaranteed •
Standard ' . .
3-27 [0.2·1.8 2D-180) · [1.7 BAR (170 kPa) supply ana :1: [0.5% +0.06%/F'Temp. Change] of Span guaranteed·
6-30 [0.4-2.0 4D-200) 9 psig [0.6 BAR] (60 kPa) output. E_Xt. Range .· .
·or 9.0 (15.3nl1/HR~120 psig
. [8.0 BAA] (800 kPa supply and Frequenc-Y Response
·9 psig [0.6 BARJ (60 a) oiJtp~ Ran~
Q-30 [0·2.0) (o-200!.................11.0 (18.7rrllAiR} @150 psig pslg_ [BAR) (kPa)
o-so [D-4.0]" (D-400 [10 BAR]{1000 kPa) supplY 3-15 (0.2·1.0~ {20·100t ........ ~3 db @5Hz per ISA 826.4.3.1
o-120 [0·8.0} (D-800 and inldscale outpuf. 3-27 0.2~1.8 20.180 . load configuration A· Standard
6-So 0.4-2.0 4D-200 ' ' . ·. .
Temperature Umlts D-30 (D-2.0~ ~(),200~ ..........·3 db @2Hz. per ISA 826.4.~.1 .
Operating..... :.............-40 to +160 tteg F{-40 to +71.2 deg C) o-so D-4.0 D-400
o-120 o-s.o . o-soo
load configuration A • Ext Range
·. · ·. .
Storage ... ,....... ,....... -40 to +1.80 deg F (-40 to+ 82.2 deg C)
Materials of Construction . . ,.
Span/Zero Adjustments BodY and Housing .................... chromate treated aluminum
Screwdriver adjustments located on frQnt of the unit. _Or:fflce .. ~ .. ,....... ;............ :.. ·•·· nickel plated b~s& sapphire
Tnm ........................ sta1nless steel, brass, zmc plated ~eel-
Required Operating Voltages (two wire current Input) 8astomers...........................................,................ Buna N
. 7.2V DC @ 20 mA (4-20 mA signal} · Flnish.;............................................. epoxy powder"coating
Data sheet No. 663 5210 . . 2131
~[_c_R_o_s~_;s_e_.c_n_oN_s___··--~/ I PRINCIPLES OF OPERATION/
The unit uses a piezoelectric ceramic disk as a flapper in

conjunction with a nozzle to control pressure in the booster signal
chamber. ·
This signal pressure acts on a diaphragm assembly which
in tum controls the pressure in the output chamber.
Output pressure is sensed by the. lower control diaphragm
FEEDBACK & CONTROL to maintain the output pressure. Output pressure is also sensed
ELECTRONICS
by the feedback control circuit, which compares the output
ELECTRONIC FEEDBACK pressure and input signal (setpoint) to maintain a constant output
~~~~~~~~===~R
pressure. · .
______
NOZZLE Extended range transducers include an additional booster
section as shown in the outline dimensions.
FLAPPER
UPPER DIAPHRAGM
LOWER CONTROL
I __,
._ ORDERING INFORMATION I
DIAPHRAGM
To order, please refer to the example outlined below. Specify
input range, output range· and electrical connections with
appropriate numbers or le!ters.
CataiC)g Nu·mber .T A ' 7800- 4 01
Transducer . T T
I TYPICAL APPL}CATIONS 7
Electrical Connections _ j
1/2 NPT condt. fitting
with pigtail
Terminal strip
(A)
(T)
DIN 43650 Conn (D)
Rack Moun.t (R)
PROCESS CONTROL APPLICATION Underwriting Group - - - - - '
Factory Mutual (F)
4-20MA
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 'l
Canadian Standard (C)
CENELEC (E)
' Approval C l a s s - - - - - - - - '
COMMON
100PSI
SUPPLY
.. '
:
:
I
I
(Leave Blank)
Series
Intrinsically SafeiD ( I ) - - - - '
Non lncendive
(Div 2) ®N
Input - - - - - - - - - - - - - - - - '
(Specify Reference No.)
.
I
Range
·-".......................PI'.....- ................ ;=~ 4-20 rnA

1~5 v DC. {~~
(~
POSmONER ORIFicE PLA'IC 0-Sv DC
1-9v DC
0·10V DC (0)
TA7800 mounted directly on a valve positioner with Output
common supply to liP and positioner. 1/P provides a 3-15 Psig (01
signal to operate· positioner and valve. 3-27 Psig 02
6-30 Psig 03
0-30 Psig 04
0·60 Psig 05
.I SERVICE INFORMATION I
0·120 Psig
0.2-1.0 BAR
0.2·1.8 BAR
0.4-2.0 BAR
0-2.0 BAR
06
11
12
13
14
0-4.0 BAR (15
It is recommended that the T7800 Transducer be re- 0-8.0 BAR (16
turned to the factory for repair. 20-100 kPa 21
20-180 kPa 22
49:200 kPa 23
·0"200 kPa . 24
0·400 kPa 25
O·BOO.kPa 26
· ~ '4-~0'Ma units·onJy..:.. iflcludes·non-incendive{Division 2) approval.
® For non lncendive (DMsion 2) approval on FM voltage input units only.
IAalborg Industries Data sheet No. 663 521 0 3/31

........
.....
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type: Installation:
• Three-way valve, ball
• TB 283 BW, reduced bore
of the valve:
Material covers must not be removed before the
• End connections: ASTM A lOS • At the moment of the shipment the ball is
- 29°C to + 230°C
ASME/ANSI B16.25- XS-80
• Weight: 7 kg
Detail A line:
connections.
the welding.
operation.
Detail A Port 1 -r
T-Bore
Port 3
Port2
158
~------~~----~~~
Port 3
F99
Type No.: 6070
Version: A
Three-way valve, ball ON 32 8703086

·.. ·
MaBblatt ./ dimensional drawing

OMG32
OMG32 • OMG~2+1.)0003
R 1• 250bar DN 32/PN 16
DN 32/ PN 40
DN 25/PN 64
DN25/PN 100
DN25/PN 160
. ,:..... r-81001
4XM18. \J.-
f t
I
832-
A 1" •
25 I ~ .•iI I !
I I I '
~...
l 18
t
•.
285 215
2 15
M18x1
~
-3 .
M18x .:;..j
tTi 25 f! ~ ! : ~ il
1-- e104L -
T c 8140 ::J
OMG 32 + UOD 04
DN25/PN250
27's 21s
.
M18x1
*zweites Sensorgewinde tor DrE!hrichtungserkennung .und lmpulsOberWachuhQ' (Option)

. . . . . . .
*2nd senSor thre~d for Identification of flow direction and ssnsormonltorlng (option)
F 10 0.1
IAalborg Industries Data sheet No. 7060 000012
Auswahl BaugroBe I selection of size
Technlsche Daten I technical data OMG 13- OMG 140
•
Omax
OnannlOnom
Omln
max. Druck
max. pressure
Temperaturberelch
temperature range
VlskosltAtberelch
viscosity
MeBkammervolumen
measuring chamber
Drehzahl
speed range
n {Qmax)
n (Onann I Onom)
n {Omln)
Polzahl
number of poles
K1
K2
K3*
K-Faktor
K-fsctor
K1
K2
K3*
Milliliter pro lmpuls

ml///1/tre per pulse
K1
K2
K3*
lmpulsfrequenz
pulse frequency
f1 {Omax)
f1 (Ontnn/ Onom)
f1 {Om!n)
f2 {Omax)
f2 (On•nn/ Onom)
f2 {Omin)
f3* {Oinax)
f3* (Onenn I Onom)
f3* {Omtn)
• DurchfluBbereich beachten: Unterschreltung von Omin

• pay attention to flow range: values below Omm
lAalborq Industries Data sheet No. 7060 000012 2121

Daten blatt I data sheet
BEG44
AnschluBschaltbild (siehe unten)

wiring information (see below)
elektrische Spezifikation electrical specification

Sensorspezifikation sensorspecificafion
Arbeitsprinzip Halldifferenz working principle Hall difference
Arbeitsschaltabstand <0,5mm working switching distance <0,5mm
Ausgang output
Schaltung PNP Rechtecksignal circuit PNP square wave
max. L.aststrom 10mA max. load current 10mA
Frequenzbereich 0 ... 5000 Hz frequency range o...SOOOHz
Spannungsbereich 10... 30VDC voltage range 10... 30 VDC
Stromaufnahme {ohne Last) <18mA current consumption (without load} <1BmA
Spannungsabfall <4,5V voltage drop <4,5V
KurzschluBschutz bissooc short circuit protecfion uptosooc
Verpolschutz ja reverse battery protection yes
mechanische Spezifikation mechanical specification

Einsatzbereich operating range
max. Druck auf Stimflache 420 bar max. pressure onto frontside 420bar
Betriebstemperatur Stimflache -40 ...+150°C working temperature frontside -40... +150°C
Gehausewerkstoff {TrockenhOise) A reap casing material {dry sleeve) Arcap
Kabelmantel Teflon- PTFE wire covering Teflon - PTFE
{4X0,24 mm 2) (4x0,24 mrr1)
Kabellange 3m wire length 3m
Schutzart IP67 type of protection IP67
AnschluBschaltbild I wiring information
3
+U8 10·30VDC
Jl..Signal
3 ••. rolf ted
Gnd
CE 1 ... gelb I yellow
5 ... Schwarz I black
F100.2
IAalborq Industries Data sheet No. 831 0 0000061
Photoresistive Detectors QRB ...
Photoresistive flame detectors for use with Aalborg Industries burner .controls,
for the supervision of oil flames in the visible light spectrum. The flame detectors
are used primarily in connection with burner controls for small burners and
ignition burners.
Function
With this type of flame supervision, the radiation of oil flames in the visible light spectrum
is used for generating the flame signal. The light-sensitive element is a photoresistor.
When there is no light, the detector's resistance is in theM. range. he resistance drops
as the intensity of illumination increases (k. range). Glowing firebrick in the combustion
chamber can be detected.
Mechanical design
Compact photoresistive detector with infused two-wire thermoplastic cable. The flame
detector is available with normal sensitivity and with or flange I clamp. The detector is
with the help of a securing flange. A guide groove in the securing flange and a cam on
the detector clamp ensure vibration-free mounting and make certain that the detector
is always correctly sited towards the flame.
Technical data
General detector data Degree of protection IP40

Mounting orientation optional
Cable length for detectors used in max.1.5 m
Detector cable 2 x 0.75 mnr; 5.1 mm dia.

Weight
QRB1 ... (depending on type) approx. 20 ...35 g
Environmental Transport IEC 721-3-2

conditions Climatic conditions class 2K2
Temperature range -2o ...+6o ·c
Humidity < 95% r.h.
Operation IEC 721-3-3
Climatic conditions class 3K5
Mechanical conditions class 2M2
Temperature range -2o...+6o ·c
Humidity < 95% r.h.
Measurement circuit
J))mcldem:e of fight (also laterally)

QRB1 .. Awith large flange CJ®
and clamp
F106
Dimensions
Dimensions in mm
424116000
418610960
QRB1-A
Type summary
QRB1A-A050B70A2
L
Accessory
1: small flange I clamp
2: large flange I clamp
Plug
A: without plug
B: with plug
Stripped length "m" in mm
' - - - - - End of cable

A: unstripped
B: with terminating sleeves
L------ Visible cable length "I" in em

'-------Type of casing
A: standard casing length "g" 50 em =
B: standard casing length "g" =65 em
'--------Sensitivity
A: normal (colour of casing: black)
B: high (colour of casing: red)
Accessories
, Item
Flange with 36 mm spacing

For use with
QRB1 ..•
Part number
4 2411600 0
#J3 Clamp QRB1 ..• 41861096 0

DISCO Non-Return Valves RK 76
Application for liquids, gases and vapours.

Pressure/Temperature Rating
mm 15-100
Nominal sizes ON in lfz-4·
Nominal pressure PN 401)
Max. service pressure barg 40 33 31 30

for RK 76 psig 580 480 450 435
Related temperature
·c 20 100 200 300
"F 68 212 392 572
Minimum temperature 2) -1o ·c (14 "F)

') Also rated for ANSI class 300, but see flange details below.
') Minimum temperature at nominal pressure rating.
Connections of wafer-type valves 3)

Valves for universal fitting between flanges to
DIN BS ANSI
DIN 2501 (BS 4504) BS10 ANSI B 16.1 class 125 FF
PN 6/10/16/25/40 tables D. E, F. H. J ANSI B 16.5 class 150/300 RF
') DN15-100mm (1f2- 4·) with universal centering ring.
Dimensions
ON
mm
in ,,
15
•
20 25
1
32
1'/,
40
1 ,,
50
2
65
2'{,
80
3
100
4
'I·
Dimensions
L') 16 19 22 28 31.5 40 46 50 60
inmm D 45 55 65 75 85 98 118 134 159
Weight kg 0.18 0.3 0.45 0.7 0.9 1.5 2.1 3.4 5.2
Materials
ON 15-100mm (Vz-4") DIN reference ASTM equivalent
Body, seat
G-X 8 CrNi 13 1.4008 A 217-CA 15
and guide ribs
Valve disc, spring retainer A182F316

X 6 CrNiMoTi 17 12 2 1.4571
Spring A 313 Type 316
Centering ring X 12 CrNi 17 7 1.4310 Type 302
Opening pressures
Differential pressures at zero volume flow
ON Opening pressures in mbar

Direction of flow
with springs
mm in t 4 .,j.
15 Yz 25 22.5 20
3
20 /4 25 22.5 20
25 1 25 22.5 20
32 11f4 27 23.5 20
40 11fz 28 24.0 20
50 2 29 24.5 20
65 21fz 30 25.0 20
80 3 31 25.5 20
100 4 33 26.5 20
DN 15-100mm
1 mbar ~ 0.0145 psi~ 10mm w.g. ~ 0.4in w.g. ('/z-47
........
.....
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure gauge, type P1116
Size:
• s?S63
Application:
• For all gaseous and liquid media
Material:
• Case: Stainless steel
• Socket: Cu-al1oy
• Liquid filling: Glycerine
Technical data:
• Connection: G 1/4"-m (1/4 BSP)
• Measuring unit: bar - Mpa, - kg/cm2
• Measuring range: 0-16/1.6/16
• Pressure utilisation:
Static pressure: 75% ofPmax.
Dynamic pressure: 66% of P max.
• Operating temperature: -20 to +80°C
• Accuracy: EN 837 Class 1,6
32
6.5
rl,-- = = - - { f - - - . - · · - - - · -
0
!X)
.. .• . . <0
&
'C;:;::f G 1/4" A
F135
Type No.: 8050

Version: B Pressure gauge, 0 63 663 3120
Type P1116

Air cylinders Series 61
GENERAL DATA
Type of construction with lie-rods

Operation single-acting or double-acting
Materials aluminium end-blocks other parts see coding
Type of mounting with tie-rods, front flange, rear Hange, feet, centre trunnion,
front and rear trunnion, swivel combination
Stroke standard see table
Bore g 32, 40, so. 63, 80, 100, 125, 160, 200
Ports 32 = Gl/8, 40/SO = Gl/4, 63/80 = G3/8,
100/12S =Gl/2, 160/200 = G3/4
Assembly position any position
Operating temperature 0 + BO"C (with dry air -20"C)
Special designs for applications in damp, dusty or aggressive environments
PNEUMATIC SPECIFICATIONS
Operating pressure 1 + 10 bar

Speed 10 + 1000 mmisec (NO LOAD)
Fluid dean air, with or without lubrication
DIMENSIONS
Series s A KK D G AM H WH L1 L2 M N P Q TG SW1 SW2 Cushion
stroke
61 SO 20 M16x1.5 40 18.3 4.5 2S 32 Gl/4 37 106 143 S 30 MB 16 46.S 65 17 10 22
p
11W'//J~
I liD : I
AM L2+ H
lm
I
: I
II~ I
I I
:I
IW' : I
DIMENSIONS
IJ c SA:t 1,25 XA :t 1,25 Tl!JS 14 G A8 AH JS 1S AD
so 3.S 170 175 4S 63 9 45 12
SA •
(+ add lhe stroke) XA •
Mounting bratkets part No.: 6666150
~
6X •
Part No.: 6666149 [D

Part No.: 6666148
F148
TABLE SHOWING THE OUTPUT FORCE OF SERIES 61
8 Cyl. 8 Rod Operatin9 pressure in bar

inmm. inmm. Working area in em'. 2 3 4 5 6 7 8 9 10
Output force in N(efficiency factor = 0,9)
50 20 Thrust side 19.6 173 346 518 692 865 1037 1210 1382 1556 1729
Traction side 16.48 145 290 436 582 727 872 1017 1163 1308 1454
(D'· d')· lt
THE VALUES SHOWN IN THE TAB!£ WER£ OBTAINW USING THE FOllOWING FORMUlAE: Ss=----·P·'l St. • p. '1
Ss • output force on tlvust side P • operating pressure in bar d • diameter or rod in an

St • oulplll force on traction ~de 0 = diameter on lhnrst side in an '1 • efficiency factor
TABLE SHOWING AIR CONSUMPTION OF SERIES 61
8 Cyl. 8Rod Operating pressure in bar

inmm. inmm. Working area in em'. 2 3 4 5 6 7 8 9 10
Air consumption in Nllmin. for each 10 mm. of stroke
50 20 Thrust side 19.6 0.039 0.059 0.079 0.098 0.118 0.137 0.157 0.177 0.196 0.216
Traction side 16.48 0.033 0.050 0.066 0.083 0.099 0.115 0.132 0.148 0.165 0.182
D'· 1t • (P + 1) (D'-d')·1t · (P + 1)
THE VALUES SHOWN IN THE TAB!£ WER£ OBTAINW USING THE FOllOWING FORMUlA[; Qs = ·H Qn = (Qs+Qt) · n Ql• ·H
4•1000 4 ·1000
Qs • mnsumption on thrust side Qt = mnsumption on traction side Qn = mnsumption or cylinder n = number or cydes per minute
D • diameter on thrust side in an. d = diameter or rod in an H = cylinder stroke in em. P = operating pressure in bar
ffiiNOER CODING
SERIES S = special to be indicated

61 •B from 32 + 125 STROKE in mm V • seals rod viton
VERSIONS N =tandem
DIN/ISO 6431 l>lc standard. magnetic R • seals rod NBR
W• aU seals in viton
TYPE Of BRACKET
OPERAnON BORE inmm A = standanllott nut for rod
1 • single-acting (tiont spring) 8 • feet
2 • double-acting C • rear trunnion. female
(tiont and rear cushions) D • rear flange
3 = double-acting (no cushion) MATERIAlS E • tiont flange
4 • double-acting (rear cushions) P • roDed stainless steel rod H • tiont trunnion. female
5 • double-acting (tiont cushion) anodized prome aluminium tube I • swivel combination
6 • double-acting NBR seals • rod seals polymethane L • rear trunnion. male
(through rod with tiont and rear cushions) nuts and lie-rods lint-plated steel R • trunnion baiJ:ioint
7 • single-acting (through rod} R• roDed stainless steel rod Z • 90" swivel combination
anodized prome aluminium tube ZC • 90" male trunnion
NBR seals • rod seals polyurelhane G • rodforlt end
nuts and de-rods zinc-plated stainless steel GA = swivel ball jllint
GY • piston rod socket joint
s devis pin
D

Proximity sensor
Descripticm
No. of conductors 2 2 conductors
Integral cable :
I.Dcking system snap spring +sarm PVC grey CEI 2022 2x0,14mm2
Fixing saew material Cu Zn nickelplated

Housing in black
Locking screw: Cu Zn/Ni
Housing material PA
Insulating material epoxy resin Conductor colour code: according EN 50044

Operating temperature: PVC cable : -1s·c I +Bo·c
Protection dass IEC60529 IP67 Stranding: 36x0,07 mm2
Cable insulation: 300V
34
5.3
A) Insert the sensor into the groove from above as indicated in drawing
B) Rotate the body ofthe sensor through !Iff keeping the screw head visible
Q l..owflthe sensor completely into the groove
D) When sensor is in required position lighten lOOng screw
E) l.Di:lsen the screw and release the spring lug on the sensor body next to the cable
F) At the same lime lift the sensor using the cable to help
G} Rotate the sensor through 90"
H) Remove from groove
A B c D E F G H
Aalborg Industries Data sheet No.: 666 6110

F149
1/1
The N.C. (closed} 3/2-way solenoid valve for manifold
assembly is available with Gl/8 inlet ports and with Gl/8
outlets or with a dia. 4 cartridge.
These solenoid valves are equipped with an over ride 70
which must be manually operated using a small screwdriver. 46
The body is supplied complete with screws and 0-ring.
M4 ~~
• 4
~MJ
12~ l I
• Qn = determined with supply pressure of 6 bar and with ap = 1 bar.
Aalborg Industries Data sheet No. 666 6232

F150 ,F151
1/2
lrtretm•rr_llllll,-_-
~;:M..~~,.~~"ti·"'i •• . . . . · • , ..· ' ~ l!¥.· ~~ ., • Jf:;;. '· . ')$,; ~ t' '-~ h; ~ '""@';
Voltage AC standard: 24V, 50/60Hz, 110V ·50/60Hz, 220V ·50/60Hz

DC standard: 24V
Voltage tolerance AC ± 10%; DC ± 10%
·15%
Power consumption AC (at inrush) =19 VA durin~ operation= 12 VA· DC 10 W
Dutv cvcle 100% continuous operation
Class of insulation dass H
Protection dass IP54 DIN 40050 (IP65 with DIN 43650/ PG9 connector)
Connector Mod. 124-BOD
LINE
( ~38M-10j-A~~ )
----------------------~1 ~~----------------
'
SERIES 6
'
SOL£NOID VOLTAGE
B • 24V 50/60 Hz
' C • 48V 50/60 Hz
'
D• 110V 50/60Hz
E • 220V 50/60 Hz
N" OF PORTS AND FUNCTIONS '2 • 12V DC
0 • Interface 3•24V DC
1 • 2 way normally open '4•48V DC
2 • 2 way normally dosed ' 6 • 110V DC
3 • 3 way normally dosed
4 • 3 way nonnaDy open • special voltages only on request
'
PORTS
0 • lmerface
3= G3/8
8· GV8
C• carttridge s4
6·32x32 '
SOLENOID DIMENSIONS
'
M • manHold
'
TYPE OF DESIGN OF BASE
150 • lhreaded body 107 a 7 • pan manifold
450 • ba with rotatable imer. 108 • 8 • pan manHold
457 • ba with fixed lmerface 109 • 9 • pan manHold
101 a single mannold 110 •10-panmanifold
102 • 2 ·part manHold 111 • 11 • pan manifold
103 • 3 • pan manlold 112 a12-partmannold
104 • 4 • part manifold 113 •13. part manifold
1OS • 5 • pan manHold 114 •14-partmanHold
106 a 6 • pan manifold 115 • 15 ·part manifold

Type: 28301/4
GENERAL CHARACTERISTICS
type of construction taper construction
materials nichel-plating brass body - nylon knob - NBR seals
ports G1/4
type of mounting any
mounting panel
operating temperature . oo + 80° c (with dry air -20°C}
Pneumatic i:lata
operatil'lg pressure 0 + 10 bar
nominal flow On 530 NVmin determined with 6 bar with P=1 bar
Aalborg Industries Data sheet No.: 664 1220

F152
1/1
212-way direct-operated valves
Type EV210B NC
De-energized
for neutral liquids and gases
closed
DN 1.5-25 B
Features • For robust industrial application, such as

control and dosage
• For water, oil, compressed air and similar
neutral media
• Kv-value up to 8.0 m 3/h
• Differential pressure: Up to 30 bar
• Viscosity: Up to 50 eSt
• Ambient temperature: Up to +Bo•c
• Coil enclosure: Up to IP 67
• Thread connections: From G 1/ 8 to G 1
• Also available with NPT thread.
Type EV210BI EV210B I EV210BI EV210B EV210B EV210B EV210B

Technical data 1.5-2 B 3-4.5 B 68 8-10 B 15 B 20 B 25 B
Installation Optional, but vertical solenoid svstem Is recommended
Pressure ranqe 0-30bar
Max. test pressure 50 bar so bar 50 bar 50 bar 12 bar 12 bar 12 bar
Time to open 10 ms 20ms 20ms 20ms 30 ms 40ms 40 ms
Time to close 20ms 20ms 20ms 30ms 50ms 50ms 70ms
Ambient temperature Max. +BO"C(depending on coil type, see data for the coil selected)
Medium temperature See specific valve data
·Viscosity max. 50 eSt
Materials Valve bodv: Brass W.no. 2.0402
Armature: Stainless steel: W.no. 1.4105/AISI 430FR
Armature tube: Stainless steel W.no. 1.4306/AISI 304L
') The times are indicative and Armature stop: Stainless steel W.no. 1.4105/AISI 430FR
apply to water.
The exact times will depend on Sprinqs: Stainless steel W.no. 1.4310/AISI301
the pressure conditions. Seal material: See soecific valve data
Coil options
u
Type: BD
{]
Type: BA
~
Type: BB
ill] qd II II
Type: BE (IP67)
I
Type: BG
15Wac 9Wac 10Wac 10Wac 12Wac
15Wdc 18Wdc 18Wdc 20Wdc
L B 8 1 [mm] H, H Weight without

Type coD
Coll~e Coll~e Co~~e
[mm] [mm] BA/ D BB/ E [mm] [mm) [kg]
EV21 08 1.5/28 35.0 34.0 32 46 66 12.0 70.0 0.15
• EV21 OB 3/4.58
EV210B 68
38.0
45.5
34.0
43.5
32
32
46
46
66
66
13.0
13.0
71.0
74.0
0.20
0.22
EV21 OB 8/1 08 49.0 48.0 32 46 66 13.0 77.0 0.29
EV210B 158 58.0 53.0 32 46 66 15.0 80.0 0.45
EV2108 208 90.0 58.0 32 46 66 23.0 100.0 1.10
EV2108 258 90.0 58.0 32 46 66 23.0 100.0 1.10
F153
212-way direct-operated valves
Type EV210B NC De-energized
for neutral liquids and gases closed
DN1.5-25B
Function Coil voltage disconnected {closed):

When the voltage is disconnected, the arma-
ture (2) with the valve plates (3) is pressed
down against the valve orifice (4) by the clos-
ing spring (1) and the medium's
pressure. The valve will be closed for as long
as the voltage to the coil is disconnected.
Coil voltage connected (open):

When voltage is applied to the coil (5), the
armature (2) with the valve plates (3) is lifted
" clear of the valve orifice (4).
J The valve is now open for unimpeded flow
es and will be open for as long as there is
1. Closing spring
2.Armature
a5 voltage to the coil.
3. Valve plate
4. Valve orifice
5. Coil
Com: Seal Kv DN lllled"l<l temD Type desiqnation Code no. Permissible differential pressure !Bar /Coil type
material Nin. Max. Main type Specification withol.a
all BA BD eBB BG
m'Jh nm ·c ·c WI 15\V 15\V 10W 18W 12\N 'li1N
a.c. d.c. a.c. a.c. d.c. a.c. d.c.
G'/8 8'DM" 0.08 1.5 -30 +120 EV210B1.5B G18ENCODO 032U5701 30.0 30.0 30.0 30.0 30.0 30.0 30.0
FKM 0.08 1.5 -10 +100 EV210B1.5B G18FNCOOO 032U5702 30.0 30.0 30.0 30.0 30.0 30.0 30.0
G'/8 8'DM" 0.15 2.0 -30 +120 EV21082.0B G18ENCOOO 032U5714 30.0 20.0 30.0 30.0 30.0 30.0 30.0
FKM 0.15 2.0 -10 +100 EV21082.0B G18FNCOOO 032U5704 30.0 20.0 30.0 30.0 30.0 30.0 30.0
G'/8 EPDM* 0.30 3.0 -30 +120 EV21083.0B G18ENCOOO 032U5705 15.0 9.0 24.0 20.0 13.0 30.0 25.0
FKM 0.30 3.0 -10 +100 EV21083.0B G18FNCOOO 032U5706 15.0 9.0 24.0 20.0 13.0 30.0 25.0
G1/ 4 8'DM" 0.15 2.0 -30 +120 EV210B2.0B G14ENCOOO 032U5707 30.0 2D.O 30.0 30.0 30.0 30.0 30.0
FKM 0.15 2.0 -10 +100 EV21082.0B G14FNCODO 032U5708 30.0 20.0 30.0 30.0 30.0 30.0 30.0
G'/4 8'DM" 0.30 3.0 -30 +120 EV21083.0B G14ENCODO 032U5709 15.0 9.0 24.0 20.0 13.0 30.0 25.0
e FKM 0.30 3.0 -10 +100 EV21083.08 G14FNCODO 032U5710 15.0 9.0 24.0 20.0 13.0 30.0 25.0
G'/4 I3"DM" 0.55 4.5 -30 +120 EV21084.5B G14ENCOOO 032U3600 8.0 3.5 12.0 10.0 4.5 13.0 9.0
G'/4 I3"DM" 0.70 6.0 -30 +120 EV21086.08 G14ENCODO 032U3602 2.5 1.0 3.3 4.0 2.0 6 4.5
FKM 0.70 6.0 -10 +100 EV21086.08 G14FNCODO 032U3603 2.5 1.0 3.3 4.0 2.0 6 4.5
~/8 EPDM* 0.55 4.5 -30 +120 EV21084.5B G38ENCODO 032U3605 8.0 3.5 12.0 10.0 4.5 13.0 9.0
~/8 8'DM 0.70 6.0 -30 +120 EV210B6.0B G38ENCOOO 032U3607 2.5 1.0 3.3 4.0 2.0- 6 4.5
FKM 0.70 6.0 -10 +100 EV21086.0B G38FNCOOO 032U360B 2.5 1.0 3.3 4.0 2.0 6 4.5
G3/8 8'DM 1.00 8.0 -30 +120 EV21088.0B G38ENCOOO 032U3609 1.5 0.5 2.0 2.0 1.2 3 2.5
FKM 1.00 8.0 -10 +100 EV210B8.08 G38FNCODO 032U3610 1.5 0.5 2.0 2.0 1.2 3 2.5
~/8 8'DM 1.50 10.0 -30 +120 EV210810B G38ENCODO 032U3611 0.8 0.3 1.1 1.2 0.6 1.6 1.3
FKM 1.50 10.0 -10 +100 EV210810B G38FNCOOO 032U3612 0.8 0.3 1.1 1.2 0.6 1.6 1.3
~/8 8'DM 2.50 15.0 -30 +120 EV210815BD G3BENCODO 032U3613 0.25 - 0.4 0.3 0.15 0.45 0.4
A<M 2.50 15.0 -10 +100 EV210815BD G38FNCOOO 032U3614 0.25 - 0.4 0.3 0.15 0.45 0.4
G'/2 EPDM 1.00 8.0 -30 +120 EV21088.0B G12ENCOOO 032U3615 1.5 0.5 2.0 2.0 1.2 3 2.5
A<M 11.00 8.0 -10 +100 __EV21_0B 8.0 B G12FNCOOO 032U3616 1.5 0.5 2.0 2.0 1.2 3 12.5
G '/2 8'DM 1.50 10.0 -30 +120 EV210B10B G12ENCOOO 032U3617 0.8 0.3 1.1 1.2 0.6 1.6 1.3
FKM 1.50 10.0 -10 +100 EV210810B G12FNCOOO 032U3618 0.8 0.3 1.1 1.2 0.6 1.6 1.3
G '/2 8'DM 2.85 15.0 -30 +120 EV210B15BD G12ENCOOO 032U3619 0.25 - 0.4 0.30 0.15 0.45 0.4
FKM 2.85 15.0 -10 +100 EV210815BD G12FNCOOO 032U3620 0.25 - 0.4 0.30 0.15 0.45 0.4
~/4 8'DM 4.5 20 -30 +120 EV210B20BD G34ENCOOO 032U3621 - - - 0.28 0.12 0.4 0.35
A<M 4.5 20 -10 +100 EV210820BD G34FNCOOO 032U3622 - - - 0.28 0.12 0.4 0.35
G1 8'DM 8.0 25 -30 +120 EV210825BD G 1 ENCOOO 032U3623 - - - 0.25 0.09 0.35 0.2
FKM 8.0 25 -10 +100 EV210B25BD G 1 FNCOOO 032U3624 - - - 0.25 0.09 0.35 0.2

Coils type BB
10Wac
18Wdc
F~atures • Windings of class H insulated wire moulded

in the coil body
• Ambient temperature: Up to +80°C
• All usual ac and de voltages
• IP 00 version with spade connector in
accordance with DIN 43650, form A.
• IP 20 version with protective cap
• IP 65 version with mounted cable plug
• Most common voltages as clip-on coil
Technical data Design In accordance with VDE 0580

Voltage tolerance 220/380 Vac coils: +10%, -15%.230/400 Vac coils: +6%, -10%.
Other ac coils with NC valve: + 10%, -15%
Other ac coils with NO valve and all de coils: ±1 0%
Power consumption, cut-in ac:44VA
Power consumption, holding ac: 21 VA, 10W I de: 18W
Insulation of coil windings Class H according to IEC 85
Connection Spade connector in accordance with DIN 43650 form A
Enclosure, IEC 529 IP 00 with spade connec. IP 20 with protective cap; IP 65 with cable plug
Ambient temperature Max • +50/+Bo•c -see table below for details
Duty rating Continuous
Ordering
10Wac
18Wdc
Symbol Description Enclosure grade Code no.
Protective cap
0 (pack of 100 pes.) IP20 018Z0282
!I Cable plug
according to
DIN 4365D-A Pg 11
IP65 042N0156
46=--1
L
Wrthout cable plug 62mm
Wrth protective cap 77mm
Weight: 024 kg Wrth cable_Q(ug 85mm

........
.•••••
··:·:··
iilllllii
AALBORG DATA SHEET
INDUSTRIES
Type: ------.
• Thermometer, straight
Size:
• DN150
Application:
• For liquid
Material: 0
ll)
.....
• Case material: Aluminium, gold coloured
anodized
• Numerals: Black figures
• Glass inserts: Solid glass
• Capillary fluid: Blue fluid
• Immersion tubes: Brass ~-;-~, .
'
'
Technical data: '
• Connection: G l/2"BSP GW-m

• Range: 0 - 200°C
• Accuracy: Class 1,6
~,
F157
Type No.: 8080
Version: A Thermometer, straight 88T0003
''-------------~----------------------------------------~--------------/
.. 110 .
8,5
90
73,5
100
·TECHNICAL DA T A/TECHNISCH ·DATEN

TYPE PRMARY PRMARY SECCNlARY SEC~DARY ED CABLE KB
VQ.TAGE. CURRENT VQ.TAGE CURRENT F~ LeiGTH PART NO.,
PRMAR
-- - -
PRMAR SEKUNDAR SEKUNDAR ED KABEL
E25 SPANNUNG STRQ.1 SPANNUNO STRCJ-1 F~ LANGE
KS
NUMMER
v A KV · mA 5mh an. NO.
0003 220 1.4 10 . 23 20 52 6639100
0021 115 10 20 20 52 6639101
... F166
Data sheet
_.tiilih Ignition transformer E25 8: 3091.0
iiiUIIIi
AALBORG Page 1 of 1
INDUSTIIES ·
.
...........
iliiiiili
AALBORG DATA SHEET - -
INDUSTRIES
/
·Technical data:
Type:
• Measuring unit: bar- Mpa - kg/cm2
• Pressure gauge
• Measuring range: 0 - 25 /2.5 /25 with
Size: mechanical stop
• !ll160 • Connection: BSP 112"-m
• Operating temperature:
Application: Ambient: 0 to + 60°C
• For all gaseous and liquid media Medium: 0 to + 70°C
The mean value of the maximum
Material: ambient temperature and the medium
• Case: Black enamelled steel temperature must not exceed the
• Socket: Brass maximum ambient temperature.
• Liquid filling: Glycerine • Weight: 0.6 kg
G 196
55
23
I BSP 1/2" -m
I I
C33
Type No.: 8050
Version: D Pressure gauge, 0 160 663 2990

...........
.•••••
•••••••
iilliiiii
AALBORG
INDUSTRIES
Type:
• Pressure switch 116
90
• KPS 37 68.
Application:
The units are pressure-controlled switches.
u
y. I
-f
The pressure controls are suitable for use in ~ ~ 03
alann and regulation system. . I"'
/r--
I~
Enclosure: ~ [~ r=~
• IP 67 to IEC 529 and DlN 40050.
• The pressure control housing is I
enamelled pressure die cast aluminium
(GD-AISi 12). The cover is fastened by
four screws which are anchored to 8.1 68
prevent loss.
The enclosure can be sealed with fuse
wire.
Adjustment:
• When the pressure control cover is
removed, and the locking screw (5) is
loosened, the range can be set with the
spindle (1) while at the same time the
scale (2) is being read. In units having
an adjustable differential, the spindle (3)
must be used to make the adjustment.
The differential obtained can be read
1 Range spindle
direct on the scales (4) .. 2 Range scale
• To ensure that the plant functions 3 Differential spindle
properly, a suitable differential pressure 4 Differential scale
is necessary. Too small a differential 5 Locking screw
will give rise to short running periods
with a risk of hunting. Too high a
differential will result in large pressure
oscillations.
Technical data:
Operating pressure: 6- 18 bar
Differential: 0.75-2.5 bar
Test pressure: 27 bar
Pressure connection: G 3/8 -m
Cable entry: Pg 13.5 for cable
diameters 5 to 14 mm.
Weight: 1 kg
C35
Type No.: 8030 Pressure switch
Version: B 631 0330
KPS37

.
........
.....
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure transmitter
• MBS 5100
Size:
• 0-25 bar
Application:
• The pressure transmitter converts pressure to an electric signal. This is proportional to, and linear
with, the value of the pressure to which the pressure-sensitive element is subjected by the
medium. The units are supplied as two wire transmitters with an output signal of 4-20 rnA. The
transmitters have a zero~point displacement facility for equalizing static pressure.
Span adjustment is also possible.
Material:
• Housing material: Anodized AlMgSiPb
r.>- ljl ~ r -t-.

I
I
r T
I
1.0
I @] I
I
1.0 I
m
I
r---tl I I
~.. ·
I
I 1.0
Lr.i
I
Pg 11
I.
lo@¢ ~
I N 1.0
..-
r<J5.5/ I
I
co 11 Jli l 11[
0
N ~II I ~ II I I
p
L~
30 "" G 1/2" -m
73
w 30
84
C48
Type No.: 8010
Version: A
Pressure transmitter 6638233
0-25 bar
Language UK. Page 1/3

........
......
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Technical data:
Performance:
• Accuracy (incl. non-linearity, hysteresis and repeatability): ±0.1% fs (typ.) I ±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% FSI10K (typ.) I:::;; ±0.2% FSilOK (max.)
• Thermal sensitivity (span) shift::::;; ±0.01% FSIK (typ.) I:::;; ±0.02% FSIK (max.)
• Response time: < 4 rms
Electrical specification:
• Rated output signal: 4 to 20 mA
• Supply voltage, Vsupply(polarity protected): 10 to 32 V d.c.
• Voltage dependency:< 0.01% FSN
• Current limitation (linear output signal up to 1.5 x nom range): 28 mA (typ.)
• Max. load RL: RL :::;; [(Vsupply -10V)I0.02A] - 10 Q
Mechanical:
• Connection: G 112" -m (EN 837-1-G lh A)
• Max. operating pressure: 50 bar
• Min. burst pressure: 100 bar
• Operating temperature range: - 40 to 85°C
• Compensated temperature range: 0 to 80°C
• Transport temperature range: - 50 to 85°C
• Cable entry: PG 11
• Enclosure: 1P 65
• Weight: 0.4 kg
Type No.: 8010

Version: A Pressure transmitter 6638233
0-25 bar

.
.......
.....
illiiiili
AALBORG DATA SHEET
INDUSTRIES
Installation:
• There are facilities for adjusting zero point and span.
Zero point adjustments is necessary to equalise pressure arising from any differences in level
between the pressure transmitter and the medium being measured.
Zero point adjustment results in a parallel displacement of span.
Both zero point and span must be adjusted on the side of the unit with cover removed
mA
20
Span
4
~%FS
Po P' p p
I
(mA)
20
Zero
Po Po p P'
u.
4-20rnA
1. Supply+
2. Supply -
3. Function test
-,1 Connected to MBS transmitter enclosure
Type No.: 8010

Version: A
Pressure transmitter 6638233
0-25 bar

.
...........
iliiiiili
AALBORG DATA SHEET
INDUSTRIES
Type: Installation:
of the valve:
Material
• End connections: ASTM Al 05 • At the moment of the shipment the ball is
- 29°C to+ 230°C
AS:ME/ANSI B16.25- XS-80
• Weight: 4.3 kg
line:
Detail A connections.
the welding.
operation.
225
l
J }
Bolt
Detail A IX)
0
......
'
End connection 1
120 85
F101
Type No.: 6010


MODEL
SIZE
CONNECTION
MAX. PRESS.
L MAX. TEMP.
TEST PRESS.
8
ALLOWABLE DIFF. PRESS.

AT SCREEN: 0.1MPa
STR
6 NUTS S4GC 4
6 BOLTS SNaT 4
4 GASKET i
3 SCREEN j. ldesh
2 COVER 1
i BODY 1
r PNrr NAME R£QO
HO, HO, REMARKS
SIZE
L H d Q. 8 0 01 @GASKET WBGHT
MOPEL
A ( 8) (kg)
32 (f V4) 160
·~
120 39 70 12.7 43.2. 58 ¢54X¢40Xt2
YSOOWCBSW-L 6
rw.tC
40<1 Vo) 170 135 44 75 12.7 49.1 65 062X 045Xt2
6
Y-STRAINER
501 2 I 2.1_0 160 56 90 15.9 61.1 78 '/!77X¢57Xt2 DAlE 7, Mar. 2001
NO. DESCRIPllOH BY OAT£
0\VC,NO. REV.
M.H SYL052A--:-2
20 I
..• .
...
• ••• • Performance Calculation Date:
•iiliibi
AALBORG
MISSION TM OL
Standard Size: 25000 kg/h
14/11/2006
User Initials:
INDUSTRIES aky
Project Name: Sumitomo 1338 Project no: 100779
Fuel type Heavy Fuel Oil

Calorific value 40200 [kJ/kg]
Working pressure 16 [bar g]

Feed water temperature 60 [0 C]
93,-------------------,----------------------------,---.
420
400
380
91 360 ,.......,
340 0
90
,..;..., 320 ~
~
........ 89 300 ~
>-
(.)
. _________________________ _,___________ _
280 .a
~ 88
-------------------------'------ ---------------
' __ ,__
I
_____________________ ,_1 ________________________
I
'
I
'
I
260 ~
~
I I I I
(.)
I
I
I I
I
I
I
I
I
I
I
I 240
~
I I I I
~ 87
..
I I I I I
-------------------------~--------------------------:---------------------- -:-------------------------r-------------------------~------------ 220

Ql
200 ..
=...
E
86 -------_------------------r------------------------r-----------------------r---------- ------------r-------------------------:------------ 180
160
Ql
:;;
85 -------------------------r------------------------r----------------------r----------------------- :--------------------------~------------
Ql
..c
1-
140 ...°
120 ~
84 -------------------------r-------------------------1-------------------------r------------------------~------------ -----------i------------
100 °
80 aJ
83 ------------------------r------------------------r------------------------r-----------------------r-----------------------r--------- 60
82 -------------------------~-------------------------~-------------------------~------------------------r------------------------ ------------ 40
81 1 20
0
0 5,000 10,000 15,000 20,000 25,000
Steam output [kg/h]
• Thermal efficiency 0 Boiler outlet temperature
Version no.: 4.0 Page 1 of 4

...
•
••• Performance Calculation Date:
• ••• •
14/11/2006
•UiiHii
AALBORG
MISSION 1M OL
User Initials:
INDUSTRIES
Standard Size: 25000 kg/h aky


Feed water temperature 60 [°C)
i i ! i 32,000
:::::::::::::::::::::::i:::::::::::::::::::::::J::::::::::::::::::::::::[:::::::::::::::::::::::t:::::::::::::::-:::::_:1::::::::::: 30,000
5,000 10,000 15,000 20,000 25,000

Steam output [kg/h]
• Fuel mass flow ° Flue gas mass flow • Flue gas volume flow

...
•
••• Performance Calculation Date:
•••••
14/11/2006
,aUiUii
AALBORG
MISSION TM OL
User Initials:
INDUSTRIES

Working pressure 16 [barg]

260
-_:- : _:_: _: _ :~ r _: ::-:: _: ::r::·:- : : :: t : _: :- ::r::::

1 1 1 : :
24,000
,...., 22,000
: r:_ : :::
.c
........ 20,000
-c-.
..5 18,000 ::::::::::::::::::::::::r:::::::::::::::::::::::1::::::::::::::::::::::::1:::::::::::::::::::::::-r:::::::-__::_::::::::::1::::::::::: 2oo 0
0
180 3:
I 16,000 ---------------------- --~------ --------------- --~--- --------------------- ~----- -------- ---------- ~- --------------------- -~---- ------- E
0
-:;; 14,000
i
------------------------:----------------------
i ----------------------;--'
--~-- ----------------
: i
- ----------------------:------------
-~--
160 .§
c.
;:: ! ! ; ! ! 14o e
~
~ 12,000
Ll.
Cl) 10,000 ::::::::::::::::::::::::t:::::::::::::::::::::: ;: :::::--::::::::::_ ::::::l::::::---:::::-:::::::::t:::::::::::::::::::::::I::::::::::: 12 o
100 Ill
E Ill
::s
0 8,000 ...
Cl)
a.
>
... 6,000
<
4,000
2,000
04-~~~~--~~~~~~--~+-~~~~~~~~~--~o
0 5,000 10,000 15,000 20,000 25,000
Steam output [kg/h]
• Air mass flow 0 Pressure drop I

•
....
.
•
•••
. • Performance Calculation Date:
•aUiiki
AALBORG
MISSION™ OL
14/11/2006
User Initials:
INDUSTRIES


7~--------~--------~--------------------------------r15
6 --------------- ·-·--- ·--+- ·----------··----··-----·----------------------·-· r···-··-. ·-----· ·---------·---- ---------------r·------··· 14
~ 5 ------------------------ ,_____ ----- -------- ----i--------------- -----·r··-------------_________ !_ _ _ _ _ _ _ - - - - - - - ·- - - - - -

13 >....
~ : :-:: : : : : : :::::r : : : : : : _ ::::::::;:::: :: : : : :~: : : : : ' : ::: 12

"C
........
~
::; N
0
0
2 -- - ---- ------ - - ~ - --- - ----- -. ----------- ------- ·- -- --- -- --·- - - -- - ·- --- -
' ' 11
--------------------------~---- • Valid for fuel qualities: DO up to 380 eSt HFO -----------f------------
1 e Valid for fuel qualities: 380 eSt up to 700 eSt HFO i
'' '
'
o~~~~~+·~--~~~~~--~~~~~~+-~~~~·~--~10
0 5,000 10~00 15~00 20,000 25,000
Steam output [kg/h]
• Min. 02 %(dry) • Max. 02 %(dry) o C02 %(dry) I

MF-82 Instruction Manual For Boiler Plant, Volume 1 (Booklet)

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MF-82 Instruction Manual For Boiler Plant, Volume 1 (Booklet)

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Q)

Burner type: KBSD Burner

System concept (vol. 1)

MISSION OL boiler (vol. 1)

KBSD burner (vol. 1)

MISSION OL Control system (vol. 2)

Language UK Page 112

Flame safeguard ........................................................................................................... 6

MISSION XW boiler (vol. 2)

System Accessories (vol. 2)

Spare parts (vol. 2)

Language UK Page 2/2

http:/lwww. aalborg-industries. com

Aalborg Industries Ltd. Aalborg Industries S.A.

Aalborg Industries K.K. (branch office)

See "Contact us" on company web page for more

http://www. aalborg-industries. com

Technical data for boiler plant

• Request No.: ..................................................................................... 100779-1

2 General plant data

• Classification society: .............................................................................. LRS

• Language for manuals: ......................................................................... English

Language UK Page 111

Technical data for MISSION™ Ol

• Request No.: ..................................................................................... 100779-1

2 Dimensions for boiler unit

• Height to top oflocal control panel: ............................................... 9,287 mm

3 Water/steam process data

• Steam output per included boiler: ................................................ 25,000 kglh

4 Data for pressure part

• Boiler type: ....................... ,............................................. Large oil fired boiler

Language UK Page 1/3

• Insulation thickness: ............................................................................. 75 mm

5 Combustion process data

• Min. calorific value of diesel oil: ................................................ 42,200 kJ/kg

6 Data for pressure loss layout

7 Data for burner

• Burner type: .......................................................................... Steam atomising

·Language UK. Page 2/3

• Colour of burner unit: .............................................................. Red RAL3000

8 Data for atom ising steam

• Atomising steam pressure to burner unit, min.: ............................... 0.60 l\.1Pa

9 Data for control system

• Insulation class: ............................................................................................. F

10 Operational data for boiler plant

• Operation: ............................................................................... 24h unattended

• Control of fuel oil pump unit: ................................................................... Yes

Language UK Page 3/3

Technical data for MISSION™ XW

• RequestNo.: ..................................................................................... 100779-1

2 Dimensions for boiler unit

• Height excl. mountings and insulation: ........................................... 2,040 mm

3 Water/steam process data

• Steam output per included boiler: .................................................. 1,100 kg/h

4 Data for pressure part

• Boiler type: .......................................................................... Water tube boiler

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5 Combustion process data