Aux Boiler Final DWG Kangrim PA0501P32

Customer : Hyundai Heavy Industries Co.
,Ltd SPECIFICATION
Hull No : 2660
2656~58 Type No. - PA0501P32 x 1 set/ship
Classification : ABS Capacity - 3,000 kg/hr
2660
Work order No. : PAW13HD2656~58 Working pressure - 6kg/㎠.G
Burner type - RP-250M x 1 set/ship
Auxiliary Boiler
40,WOUNGNAM-DONG,CHANGWON CITY,KOREA
TEL : 055) 269 ~ 7700(REP) / 760(DIR)
FAX : 055) 269 ~ 7795~9
E-MAIL: tech1@kangrim.com
CONTENTS
1. DESIGN DATA
2. DRAWINGS
3. ACCESSORIES
4. BURNER SPECIFICATION
5. F.O SYSTEM WITH ACCESSORIES
6 CONTROL PANEL
6.
7. SPARE PARTS AND TOOLS
8. INSTRUCTION MANUAL
*NOTE
If we may be of further assistance, please do not hesitate to contact Mr. Dae-Young, Byun at 82-55-269-7774.
PLAN HISTORY
0 14.05.30 FOR FINAL D.Y.BYUN K.J.AHN B.J.KIM

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
KANGRIM HEAVY INDUSTRIES CO., LTD.

DESIGN DATA
1. DESIGN DATA

DESIGN DATA
LIST OF DESIGN DATA
NO DRAWING NO. TITLE REV. REMARK
1 - Technical data 0
2 MB-TE-01 Design data
- Information table of insturments 0
- proposal water level 0
- Proposal drum pressure setting point 0
- Thermal expansion of boiler 0
3 MB-INT-001 Installation 0
4 MB-MN-01 Preservation 0
5 MB-MN-05 Soda boiling procedure 0
6 MB-BIO-001 Burner lnstallation Guide 0

DESIGN DATA
TECHNICAL DATA
General description
The PA type boiler is a pin tube type vertical cylindrical boiler. The steam generating section
consists of straight tubes with pin that provide a high heat transfer. On the water side the heat is
transferred by evaporation of the saturated water adjacent to the furnace shell or pin tube wall
where steam bubbles are formed. The boiler is insulated and preassembled with boiler mountings
for easy installation and operation. The boiler is side - fired and equipped with a burner. (Refer to
Fig.1)
1. Design data
Number of boiler / ship 1 Set
Steam production 3,000 kg/hr
Working pressure / Design pressure 6/8 kg/㎠.G
Feed water temperature 60 ℃
2. Oil Fired section data

Fuel oil consumption (at H.F.O) 226 kg/hr
Air consumption at 45℃ 3,676 kg/hr
Flue gas flow 3,888 kg/hr
Flue gas temperature Max. 450 ℃
Recommend for flow gas duct draft loss Max. 15 mmAq
3. Dimension
Diameter excl. of insulation 1,950 mm
Height excl. of smoke uptake 4,550 mm
Water volume at normal water level 6.39 m³
Weight of boiler including of burner and fittings (dry) 10.5 Ton
4. Classification
Hull No. 2656~58 ABS
5. Paint color
Body Heat resistance paint silver
Contol panel RAL 7032

DESIGN DATA
PA type boiler lay out.(Only reference)

DESIGN DATA
Information table of instruments

Meas. Item Set Burner Alarm limit
NO. Item Unit Location
Range No. Point trip Low High
Diff.pressure transmitter 400 ~

1 mmH 2O A29 - - - - Boiler
For water level +400
High water level - - - +250 - - ●
Normal water level - - - 0 - - -

Control
panel
Low water level - - - 180 - ● -
Low low water level - - - 220 - ● -
Water level switch

2 mmH 2O - A31 220 ● ● - Boiler
For low low water level
Pressure transmitter
3 kg/㎠.G 0~16 A32 - - - - Boiler
For steam drum
Pressure switch
4 kg/㎠.G 1~10 A32 7.5 ● - ● Boiler
For high steam pressure
Pressure switch Control
5 kkg/㎠.G
/㎠ G 1 10
1~10 - 45
4.5 - ● -
For low steam pressure panel
Control
6 Burner start / stop control kg/㎠.G 1~10 - 5.5/6.5 - - -
panel
Thermostat
7 °C 0~200 - 105 ● ● - Burner
for low oil temperature
Thermostat
8 °C 40~300 - 180 - - ● Burner
for high oil temperature
Pressure switch
9 kg/㎠.G 0~6 - (1.5) ● ● - F.O. Pipe
for low oil pressure In ringline
Pressure switch
10 kg/㎠.G 0~6 - (2.0) - ● - F.O. Pipe
for F.O. pump auto changed
11 Burner swing out - - - - ● ● Burner
12 Flame failure - - - - ● ● Burner
13 Quick closing valve closed - - - - ● ● F.O. Pipe
Burner motor failure Control

14 - - - - ● ●
(F.D fan failure) panel
15 Low comb. air press. mbar 0~50 - (15) ● ● - Burner
*NOTE : ( ) ~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.

DESIGN DATA
Meas. Item Set Burner Alarm limit

NO. Item Unit Location
Range No. Point trip Low High
16 Low oil pressure in burner kg/㎠.G 2~40 - 20 ● ● - Burner
17 High salinity in feed water PPM 0~200 W03 (80) - - ● F.W. Pipe
18 High oil content in feed water - - W04 - - - ● F.W. Tank
Thermostat
19 ℃ 20~150 F13 (55) - - ● F.O. Pipe
for high M.G.O temp.
Control
20 Emergency stop - - - - ● ●
panel
Control
21 PLC fail - - - - ● ●
panel
Control
22 Power failure - - - - ● ●
panel
*NOTE : ( ) ~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.

DESIGN DATA
Proposal water level
(20 mA)
+400 mmH₂O
High Water Level (17.6 mA)

BOILER LEVEL GAUGE C TO C : 800
+250 mmH₂O
(
Normal Water Level (10.7 mA))
0 mmH₂O
Low Water Level (7.5 mA)

180 mmH₂O
Low Low Water Level (6.9 mA)

220 mmH₂O
(4 mA)
400 mmH₂O

DESIGN DATA
Proposal drum pressure setting point
☞ 8.0 Safety valve open / Design pressure
☞ 7.5 High steam pressure
☞ 6.6 Dumping v/v open
☞ 6.5
6 5 Burner stop
☞ 6.0 Boiler working pressure
☞ 5.5 Burner start
☞ 4.5 Low steam pressure
PRESSURE UNIT : kg/㎠.G

DESIGN DATA
Thermal expansion of boiler
Design Specification
Boiler Type : PA0501P32
Boiler steam production (Oil fired / exh gas) : 3,000 kg/hr
Boiler working / design pressure :6/8
Steam temperature at W.P / D.P : 164.2 / 174.7
Ambient temperature Max. : 45 ℃
unit : mm
Point Design length Expansion at W.P Expansion at D.P
H1 4,250 6.3 7.0
H2 4,550 6.7 7.5
H3 5,385 7.9 8.9
L1 1,187 1.8 2.0

DRAWINGS
2. DRAWINGS

DRAWINGS
LIST OF DRAWINGS
NO DRAWING NO. TITLE REV. REMARK
1 - Part list of steam / water piping system 0
2 PA-PI-01 Piping system diagram 0
3 PA-GA-01 Arrangement 0
4 PA-TH-01 Top grating & handrail 0
5 PA-BF-01 Base & Foundation 0
6 PA-OI-01 Outside Insulation 0
7 PS-SU-01 Smoke Uptake 0
8 STD-003 Lifting lug Type-C 0
9 STD-004 Lifting lug Type-D 0

ACCESSORIES
3. ACCESSORIES

F.W. SYSTEM WITH ACCESSORIES
PART LIST OF F.W. SYSTEM
PART NO. DRAWING NO. TITLE TYPE / SPEC. QT'y REV.
< Mounting List >
A01 MB-DP-01 Safety valve with drip pan JIS B8210, 20K-50/80A 2 0
A02 MB-JF-7314 Main steam valve JIS F7314, 20K-125A 1 0
A04 MB-JF-7313 Feed water valve JIS F7313, 20K-40A 2 0
A05 MB-JF-7473 Feed water check valve(SDNR) JIS F7473, 20K-40A 2 0
A06 MB-JF-7313 Scum valve JIS F7313, 20K-40A 1 0
A07 MB-JF-7473 Scum check valve(SDNR) JIS F7473, 20K-40A 1 0
A08 MB-JF-7313 Blow down valve JIS F7313, 20K-40A 1 0
A09 MB-JF-7473 Blow down check valve(SDNR) JIS F7473, 20K-40A 1 0
A11 MB-JF-7303 Water level regulation valve JIS F7303, 16K-25A 2 0
A12 MB-JF-7303 Low water level switch valve JIS F7303, 16K
16K-25A
25A 2 0
A13 MB-JF-7421 Sampling valve JIS F7421, 20K-15A 1 0
A14 MB-JF-7388 Air vent valve JIS F7388, 20K-6A 1 0
A15 MB-JF-7388 Pressure gauge valve JIS F7388, 20K-6A 1 0
A16 MB-JF-7388 High pressure switch valve JIS F7388, 20K-6A 1 0
A17 MB-JF-7367 Furnace side drain valve JIS F7367, 5K-40A 1 0
A20 MB-JF-7314 Circulation inlet valve JIS F7313, 20K-125A 1 0
A21 MB-JF-7313 Circulation outlelt valve JIS F7313, 20K-50A 1 0
A27 MB-CR-01 Condensate reservoir - 1 0
A28 MB-CR-01 Connection bend - 1 0
A29 DPT-01 Differntial pressure transmitter PMD75 1 0
A30 MB-RLG-02 Water leve gauge C to C 800, Illuminated 2 0
A31 MB-LS-01 Water level switch C to C 525 1 0
A32 MB-GB-01 Gauge board "AA"Type 1 0

F.W. SYSTEM WITH ACCESSORIES
PART LIST OF F.W. SYSTEM
PART NO. DRAWING NO. TITLE TYPE / SPEC. QT'y REV.
< Loose supply List >
A01.01 MB-EG-01 Remote device for safety valve - 2 0
A03 MB-SCV-01 Swing check valve 20K-125A 1 0
E06 MB-RL-01 Remote level indicator 144SPDA 1 0
E07 MB-PI-01 Steam pressure indicator 0~16 Kg/㎠ 1 0
S02 MB-SIS-01 Steam injection system IN-25 1 0
S06 MB-SC-01 Sampling cooler 100A 1 0
W01 MB-PC-03 Feed water control valve 16K-25A, L-Type 1 0
W02 MB-DU-01 Dosing unit CONc 1602 PP2 1 0
W03 MB-SI-01 Salinity indicator SI-30

SI 30 1 0
W04 MB-OD-01 Oil detector CLS-112-2 1 0
E01 - Control panel - 1 0

8
8 Cable gland - PG 16
BURNER SPECIFICATION
4. BURNER SPECIFICATION

BURNER SPECIFIATION
BURNER TECHNICAL DATA & SPECIFICATION
1. Fuel oil data

Diesel Oil Marine gas oil Heavy fuel Oil
(M.D.O) (ISO 8217 "DMA") (H.F.O)
Viscosity 6 3.0 700
(cSt) (at 40℃) (at 40℃) (at 50℃)
Specific gravity 0.9 0.89 0.98
Low calorific value

10,200 10,700 9,700
(kcal/kg)
2. Fuel oil consumption

Diesel Oil Marine gas oil Heavy fuel Oil
(M.D.O) (ISO 8217 "DMA") (H.F.O)
Max. consumption 215.1 205.0 226.2
(kg/hr)
Min. consumption (kg/hr) 71.7 68.3 75.4
3. Burner specification
Number of burner / ship :1 Set
Burner type (Pressure jet) : RP-250M (OILON)
Burner control type : Modulating
Burner range : 58~282 kg/h
Turn down : apprix. 1:3
Burner motor : 8.6 kW
Pre-heater : 14.4 kW
Weight of burner with motor : 195 kg
4. Electric data
Power source : AC440, 60Hz, 3ph
Control source : AC220, 60Hz, 3ph
Motor insulation : Class F
Enclosure type : IP 55

BURNER SPECIFIATION
5. F.O Pump
Number of pump / ship :2 sets / ship
Type : DS3-1100
Pump capa(at H.F.O used) : 1446 l/hr
Pump capa(at M.G.O used) : 1020 l/hr
Discharge pressure :6 bar
Normal pressure :5 bar
Operating pressure :4 bar
Pump motor : 0.66 kW
Motor insulation : Class F/B
Enclosure type : IP 55
Weight : 99.5 kg
6. Paint color
Burner body : Maker standard
F.O Pump : Maker standard

8 7 6 5 4 3 2 1
5 34 27
MAXIMUM WORKING PRESSURE OF THE BURNER 30 BAR PI PI
F MAXIMUM OIL ATOMIZING TEMPERATURE +150°C 20 16 19
6 M
32 M 32
bar MPa,kp/cm2 17
PRESSURE GAUGE UNITS9
DPS
OPTION SELECTION
E NO.
25/0
26/0 31
33 18 RE RE
EL.TR
35/0 EV1112 EV1111
28
D
15
14
34 5 7
21 EL.TR
11
PI PI PS 13
4 8 10 TZA
EV1101 EV1102 30 29
TI
C
EL.TR
23 6 EL.TR PT TT TE
OIL TO 3 2 9
BURNER TE
35 25 26
EL.TR EL.TR OPTION OPTION OPTION
24
ZA
12
B OIL TO EL.TR
1 22
TANK
Osa/no Osan tai jaoksen nimitys Piir. ja osan no Laatu Muoto, mitat, malli, koodi Massa Kpl
Part/No Part or Group Drw. and Part No Material Shape, Dimensions, Code Weight Pcs
(netto)
Osan aines työvaroineen
Material incl.working allowance
Yleistoleranssit Massa Tilaaja Suhde Suunn. MPE 2012-05-24
General toler. Weight Client Scale Design
Työno Piirt.
Project Drawn
Merkki Hyv.
kg Ref. Appr. HN 2012-05-24
Valmiste ATK
Product RP-250 M ABS
A Versio Piir.no Drw. No
Rev.
Nimitys 0
Title PI-DIAGRAM B-569T
Korvaa n:on Korvattu n:olla
LAHTI FINLAND HP-PUMP Supersedes Drw. Superseded by Drw.
Versio Muutos Muuttaja Hyv. Pvm Koord. Lkm Merkki Micro
Rev. Description Drawn Appr. Date Coord. Pcs Mark film O
This document is property of OILON OY, Lahti,

Finland. Multiplication or information of its
contents to the third parties in any form whatever
is not allowed without a written authorization by the owner.
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ELECTRICAL CABLE (CUSTOMER) 1.1
1.20 1.19
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135 7.2 6.19 3.1009 14

A
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G 6.17
24
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9.1001
99 6.2.14
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221
13.1
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B
13.6 13.8 13.9 7.1003 7.1 7.1001 7.3 7.1004 2.2 7.1005 11.1.1005 8.1002 8.12 8.1001
11.1.1008
365
18
A OIL TO BURNER D22
B OIL TO TANK R1/2"
319 226 417 300

E 365
15.13 15.12 15.15 1.7 1.13
PARTIAL SECTION
A-A
15.14
15.2
SCAVENGING AIR
PIPE D12
B
TRACE HEATING OF OIL LINE
13.1002
Maximum operating pressure of the burner: 30bar

Maximum oil atomizing temperature: 150°C
7.1002 8.3 8.2

│ │ │ │
1. REV. SUHDE PAPERIKOKO
1ST REV. Ltuominen 23/05/2012 SCALE 1:5 PAPER SIZE A1
MUOKANNUT VIIVAKOODI , BAR CODE
MODIFIED BY Ltuominen 23/05/2012
YLEISTOLERANSSIT , GENERAL TOLERANCES
OILON OY
ISO 2768-m NIMITYS , TITLE
A
RASKASÖLJYPOLTIN , *D031328*
HEAVY OIL BURNER PIIR.NO , DRW.NO REV
BURNERS MANUFACTURED ACCORDING TO IP44 D031328 A
3D-MAL.NO , 3D-MODEL.NO REV
Rev Comment Modified By Date
Configurated from master drawing D026372 MASSA (KG) KORVAA N:ON RP-250 M ABS A020078 A
WEIGHT SUPERSEDES DRW. NIMIKE , ITEM
MARINE BURNER RP250M050_157938_1
THIS DOCUMENT IS PROPERTY OF OILON OY, LAHTI FINLAND.

MULTIPLICATION OR INFORMATION OF ITS CONTENTS TO THE
THIRD PARTIES IN ANY FORM WHATEVER IS NOT ALLOWED
WITHOUT A WRITTEN AUTHORIZATION BY THE OWNER.
DocID:A020078AD031328A OILON CAD
Marine partlist RP250M050_157938_1 Latest view of documentation 29.5.2012 15:52:01
Part Item code Name Manufacturer Standard Qty

Manufacturer's type Remark Unit Of
Technical data Measure
1.1 30401003 FRAME 1

pcs
1.3 -C467B01 AIR CONE 1
pcs
1.7 36432012 IGNITION TRANSFORMER Siemens 1
ZM 20/12 pcs
230V 2*6kV
1.13 37177010 LIMIT SWITCH Telemecanique 1
XCK-M510 pcs
1.19 36215042 FLAME DETECTOR Siemens 2
RAR9 pcs
1.20 36216030 RUBBER GASKET 2
QRA, RAR7, RAR9: IP44 pcs
2.2 30129014 PREHEATER Oilon 2
ML6 ABS pcs
6.0/7.2 kW 400/440 V
3.1 34029037 NOZZLE VALVE Oilon 1
RPL-1-350 pcs
3.5 30125045 IGNITION ELECTRODE 1
pcs
3.1001 35455054 PRECISION STEEL PIPE EN 10025, DIN 2391 0,38
DIN2391 ZN 12.0*3.0 MARINE D025858 m
12mm 3mm ST37.4 Zinc coated
DIN2391 ZN 12.0*3.0 MARINE D025859 m
3.1003 35455047 PRECISION STEEL PIPE Mannesmann EN 10025, DIN 2391 0,28
NBK 0355027 D024638 m
8mm 1,5mm ST37.4 Zinc coated
NBK 0355027 D024639 m
NBK 0355027 m
3D Model Title Page

1(6)
Drw no. Item Code Item
Rev
LAHTI FINLAND
Document
MARINE PARTLIST RP250M050_157938_1 0

NBK 0355027 m
DIN2391 ZN 12.0*3.0 MARINE m
3.1009 37068010 HEATING CARTRIDGE 1
40W230V STP10*50 L1500 pcs
230VAC 40W 1500mm
5.2 V36961274 ELECTRIC MOTOR 1
pcs
5.3 34367049 FAN WHEEL Punker DIN 1304, DIN24163 1
PUHALLINPYÖRÄ TLR 280*102 pcs
280mm 102mm 38mm
6.2 -B309Y20 OIL REGULATOR Oilon 1
REGULATING SHAFT 20 pcs
6.2.14 34247223 NON-RETURN VALVE Bell DIN 2353 1
RHV 12-PLR-ED R3/8 VITON pcs
R 3/8" PN 300 12mm
6.9 36962058 SERVOMOTOR Siemens DIN 40050 1
SQM10.16502 pcs
10Nm 3.1°/s
6.17 34035106 GAUGE VALVE Tognella 1
FT 290-1/4 VITON pcs
G 1/4" PN 400 Thread
6.19 V34021225 PRESSURE GAUGE Wika EN 837-1 1
233.50.63.XX pcs
-20...150°C 0...6000kPa G 1/4" (Item is virtual / alternative)
6.19.1 34021200 PRESSURE GAUGE Wika EN 837-1 1

233.50.63.60 bar LM G1/4B ALTERNATIVE (units bar) pcs
-20...150°C 0...6000kPa G 1/4"
3D Model Title Page

2(6)
Rev
LAHTI FINLAND
Document


233.50.63.6 MPa /Kp/cm2 LM ALTERNATIVE (units MPa) pcs
-20...150°C 0...6000kPa G 1/4"
233.50.63.60 bar /Kp/cm2 LM G1 ALTERNATIVE (units bar/Kp/cm²) pcs
-20...150°C 0...6000kPa G 1/4"
DIN2391 ZN 12.0*3.0 MARINE D027511 m
7.1 34024340 OIL PUMP 1
UHE-A3-P-I pcs
4000kPa 408kg/h 2800rpm
7.2 -B497C DEAERATOR Oilon 1
pcs
7.3 36751036 SOLENOID VALVE Lucifer 2
321H2522 R1/2 pcs
7.21 34035106 GAUGE VALVE Tognella 1
FT 290-1/4 VITON pcs
7.22 V34021225 PRESSURE GAUGE Wika EN 837-1 1
233.50.63.XX pcs
-20...150°C 0...6000kPa G 1/4" (Item is virtual / alternative)

233.50.63.60 bar LM G1/4B ALTERNATIVE (units bar) pcs
-20...150°C 0...6000kPa G 1/4"
233.50.63.6 MPa /Kp/cm2 LM ALTERNATIVE (units MPa) pcs
-20...150°C 0...6000kPa G 1/4"
233.50.63.60 bar /Kp/cm2 LM G1 ALTERNATIVE (units bar/Kp/cm²) pcs
-20...150°C 0...6000kPa G 1/4"
7.29 34033173 3-WAY VALVE MHA-Zentgraf DIN 3230, ISO 228 1
BK3-DN6-G1/4-1145 L pcs
3D Model Title Page

3(6)
Rev
LAHTI FINLAND
Document

7.30 37175032 PRESSURE SWITCH Trafag 1

P40 900.2381.907 pcs
4...40bar 40bar
7.1001 37068016 HEATING CARTRIDGE 1
HHP 12*60 110W 230V UHE pcs
230VAC 110W 12*60mm
DIN2391 ZN 12.0*3.0 MARINE D030656 m
DIN2391 ZN 12.0*3.0 MARINE D030658 m
DIN2391 ZN 12.0*3.0 MARINE D030657 m
121K6423-876023-483824T1 pcs
122K8321-876024-483824T1 pcs
8.12 -A269R03 THERMOMETER Wika 1
0..+200C D12MM L=78MM pcs
0...200°C
DIN2391 ZN 12.0*2.0 MARINE D024650 m
DIN2391 ZN 12.0*3.0 MARINE D030652 m
3D Model Title Page

4(6)
Rev
LAHTI FINLAND
Document

11.1.9 36325199 SOLID-STATE RELAY Carlo Gavazzi 2

RM1A48D50 pcs
42...440VAC 50A s
11.1.11 37175015 DIFFERENTIAL PRESSUR Dungs 1
LGW50 A2 pcs
0.25..5kPa MAX 50kPa
11.1.12 37178076 LIMIT THERMOSTAT Trafag 1
ISN300 472.1253.122 pcs
11.1.15 37178076 LIMIT THERMOSTAT Trafag 1
ISN300 472.1253.122 pcs
11.1.1005 37068010 HEATING CARTRIDGE 1
40W230V STP10*50 L1500 pcs
230VAC 40W 1500mm
11.1.1008 36217098 TEMPERATURE SENSOR Müller 1
TE-K1G THERMOCOUPLE K pcs
13.1 -B361T01 FILTER Oilon 1
KSF-25H-125 R1' pcs
R 1" 125µm
13.6 -A220X BALL VALVE Oras 1
DRILLED ø1,5 pcs
R1/2"
13.8 V34015280 HOSE Prospero DIN 17441 1
TRACE HEATED pcs
2000mm (Item is virtual / alternative)
13.9 V34015256 HOSE DIN 17441 1

TRACE HEATED pcs
2000mm (Item is virtual / alternative)
13.1002 -B486T08 HEATING CABLE 1

pcs
14 V34031347 NOZZLE Fluidics 1
pcs
15.1 -D456F PROTECTIV COVER Purvac 1
pcs
15.2 -C480H SIDE COVER Purvac 1
pcs
3D Model Title Page

5(6)
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LAHTI FINLAND
Document

15.11 37294142 BUSHING SEAL 1

M25X1,5 pcs
25mm
15.12 37294121 BUSHING SEAL 1
PG36 pcs
47mm
15.13 37294108 BUSHING SEAL 1
PG29 pcs
37mm
15.14 37294110 BUSHING SEAL 2
PG21 pcs
28,3mm
15.15 37294105 BUSHING SEAL 3
PG16 pcs
22,5mm
3D Model Title Page

6(6)
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LAHTI FINLAND
Document
- 2096 -
L2000
L2000
OILON Burner L.O chart
1. Recommended L.O chart 2012-12-12
Application
No. Sets Q'ty/set Initial filling Q'ty/Burner Oil changining interval Remark
Point
Adjusting lever
1 2 10 g by maker 2 1 time / year
bearing
2 Compound regulator 1 10 g by maker 2 1 time / year
2. Recommended L.O grade
No. Maker Update L.O grade REMARK
1 Viso VISO 812-2C
MOBILGREASE
2 MOBIL
XHP220
3 SHEEL GADUS S2 V220 2
Energrease
4 BP
MP-MG 2
5 TOTAL CERAN WR 2
6 CHEVRON MULTIFAK EP2
7 CASTROL SPHEEROL SX2
8 FUCHS RENOLIT CXI 2

F.O SYSTEM WITH ACCESSORIES
5. F.O SYSTEM WITH ACCESSORIES

F.O SYSTEM WITH ACCCESSORIES
PART LIST OF F.O SYSTEM
PART NO. DRAWING NO DESCRIPTION QT'y REV. REMARK
F01 BNR-BV-01 3-Way valve with L/S 1 0 16K-25A
F03 BNR-OS-01 Y-Type oil strainer 1 0 16K-15A
F04 BNR-FM-01 Flowmeter (Local reading type) 1 0 16K-15A
F04.03 BNR-JF-7303 Flowmeter by-pass valve 1 0 16K-15A
F05 BNR-FP-02 Oil pump unit 1 0 DS3-1100
F07 BNR-PS-01 Press. switch for F.O p/p stand-by 1 0 904 type
F08 BNR-PS-01 Press. switch for F.O low press. 1 0 904 type
F13 BNR-TS-01 Temp. switch for MGO high 1 0 471 type
F15 BNR-PR-01 Press. relief valve 1 0 30K-20A
F18 BNR-OF-01 Oil filter 1 0 B-361T
F22 BNR-QV-01
BNR QV 01 Quick closing valve 1 0 PN16 - DN25
F23.01 BNR-FH-01 Oil hose (INLET) 1 0 ø15 x 2000L
F23.02 BNR-FH-01 Oil hose (OUTLET) 1 0 ø12 x 2000L
F32.13 BNR-NV-01 3-Way test cock 2 0 PF3/8" x ø 10

CONTROL PANEL
6. CONTROL PANEL

SPARE PART AND TOOLS
7. SPARE PART AND TOOLS

INSTRUCTION MANUAL
8. INSTRUCTION MANUAL

CONTENTS
1. Boiler
2. Safety valve
3. Diff. Pressure Transmitter
4. F.W Control Valve
5. Dosing Unit
6 Salinity Indicator
6.
7. Oil detector
8. Flow meter
9. Oil Pump Unit
10. Burner

Auxiliary Boiler
OPERATION AND MAINTENANCE
1. General -----------------------------------------------------------------3
2. Preparation for service ----------------------------------------------3
3. Lighting-up and service -------------------------------------------4
4. Taking out of service --------------------------------------------- 6
5. Cleaning ----------------------------------------------------------------7
6. Boiling out -------------------------------------------------------------9
7. Limits of chemical concentration ---------------------------------10
8. Repair of pin tube element ------------------------------------- 11
9. Preservation procedure of boiler ---------------------------------12

Auxiliary Boiler
VERTICAL WATER TUBE BOILER

TYPE PA
2
Auxiliary Boiler
1. General
1.1 It rests with the boiler attendant to see to service and supervision of the
boiler plant. He is to see to it that all parts of the plant are properly
maintained, if the task has not been assigned to other persons. On sea-
going vessels the tasks and responsibility of the boiler attendant rest with
the ship's officer from the machine section on duty.
1.2 The boiler attendant is to follow the below working and operation
instructions. If there are interruptions of service and damages and other
irregularities this must be reported to the nearest superior after, of course,
the operational measures, which are necessary in order to obviate a
situation of danger, have been carried out.
2. Preparation for service

2.1 Before filling of water it must be checked that all strange objects have been
removed from the interior of the boilers, that all drain mountings are closed,
that all loose parts have been fastened, and that built–in blind flanges, if
any, have been removed. If the boiler has been out of service fore quite a
long time the walls are to be examined for possible damages arisen during
the standstill period. The temperature of the water which is to be led into the
boiler is to be fairly corresponding to the temperature of the walls. If there is
a bigger difference than about. 50℃ the boiler is to be filled quite slowly.
2.2 Before heating is begun it must be checked if the gas openings are open
(danger of explosion), that all safety devices are OK, accurately adjusted
and ready for service, and that the water in the boiler is between the lowest
and normal water level.
2.3 Valves and shut-off devices ought to be served slowly, connection pipes
must, if necessary, be emptied of water and ventilated.
( water chock, coolings, at sudden differences in temperature ).
2.4 Before the boiler is used for the first time it must be boiled out in order to
remove all protecting materials and dirt in pipes and drums.
See paragraph about boiling out.
2.5 During the first filling with boiler water the water level indicators to be
controlled by opening the blow–off valve and upper and lower water level
valve to open by turns. a weak air flow should then be heard.
3
Auxiliary Boiler
3. Lighting - up and service

3.1 This boiler is provided to work :
A) As a separate oil fired boiler.

B) As a combined oil fired / exhaust gas boiler.
C) As a separate exhaust gas boiler
The mode of operation of A) and B) will required constant water level of the
boiler. Because of danger of burning down in operation. Constant water
level is not required at C). However, this is recommended, as the most
favorable water circulation and most be stable operating conditions will be
obtained. As to the construction and the strength it is fully proper at C) to
lover the water level of the exhaust tube section and even empty the boiler
from water, while the whole gas volume flows through the tube section. The
boiler will in such case, gradually, get the same temperature as that of the
exhaust gas.
The boiler should be cooled before refilling it with feed water. where this
could not be done the feed water is to be preheated, and the feeding should
commence very carefully ( slowly ).
3.2 When the boiler has been ignited the lighting-up rate must not be speeded
up too much in order not unnecessarily to overstrain the boiler material by
quick, uneven temperature rises.
The lighting–up time ought to be about. 1 1/2 hours.
3.3 The air escape valve at the boiler is to be kept open until a heavy steam
jet is flowing out, this occurs at a steam pressure of abt.1, 5 bar.
3.4 The pressure gauge and its connecting pipe line are regularly to be tested
carefully as regards free passage. By this must be stated if the indicator can
reach the O-point without obstructions at slow relief of the pressure gauge,
and if it can reach its former position at slow load.
Further, it must be stated if the pressure gauge shows the indicated
allowable working pressure. At and after every blow-through of the
connecting pipe line the pressure gauge may not be connected until
sufficient steam is condensed in the pipe loop.
4
Auxiliary Boiler
3.5 During service the water level may not fall below the mark for lowest water
level. If the water level cannot with certainty be said to be sufficient the
firing must be stopped at once ( see also paragraph 4.1 ) and the nearest
superior informed immediately.
If the water level goes beyond the top visible water level without perceptible
reason the firing must be stopped at once if you cannot with other
measures again reduce the water level.
3.6 All the water level indication instruments are currently used and have,
therefore, to be kept clean.
The same thing applies for water level regulator and limiter.
Cocks and valves are to be opened slowly and to be closed in the same
way.
Lacks, especially obstructions, are to be removed at once.
3.7 Before the boiler is connected it is necessary that the safety valves are
adjusted so that they can begin to function at the prescribed pressure.
Alteration of the adjustment is to be carried out only by an expert from the
local classification society.
If the steam pressure rises above the allowable working pressure, which is
marked by a red line
line, the firing I reduced and the feeding intensified
intensified.
If the safety valves do not blow, they are to be checked at once.
If the cause is not stated the firing must be stopped and the superior
informed.
3.8 Once a day mud is blown from the boiler through the bottom blow-off valve
until clear water is coming.
3.9 If priming takes place as a consequence of pollution of oil or the like in the
boiler water ( is normally seen as a brown layer in the water gauge glasses),
the impurities are blown out through the scum valve ( see paragraph about
boiling out ).
3.10 Should the firing fail, for some reason, during a heavy steam demand
period, then the steam outlet valve is to be closed immediately, and the
feed pump is to kept in service until a normal water level is reached.
3.11 If priming takes place because of a sudden pressure drop in the pipe, the
firing to be reduced, the feeding increased and if necessary the steam
outlet to be reduce, too.
5
Auxiliary Boiler
4. Taking out of survice

4.1 The boiler must be taken out of service immediately and the superior
informed as soon as possible if you have a suspicion that something
dangerous is arising.
The applies especially when :
A) Heating or deformation of the boiler walls are found somewhere

B) A big loss of water is noted.
C) The feed water system is unable to provide the necessary feed water
due to failure of parts.
D) The safety valve cannot function
E) Sudden cracks or big damages are noted in the refractory on the furnace
or steam or moisture is coming out of the refractory.
This can also be the case when pipe damages, plate crack or the like ( l. e.
at steam outlet ) are stated.
4.2 If the boiler is to be taken out of service in emergency the fuel supply is
The steam valve is to be closed gradually and the boiler must stand until it
is cooled. The safety valves may not be touched.
P ll l working
Parallel ki b boilers
il are to b
be di
disconnected
d at once.
4.3 If part of the heating surface has been glowing or the boiler shows
recognizable deformations the supervising authorities must be informed,
and the boiler is not to be used until approval from these authorities is
available.
4.4 When stopping the service, so much feed water to be filled on that a
suitable water level is present at next firing ( between lower and normal
water level ).
6
Auxiliary Boiler
5. Cleaning of fired section

5.1 If the feed water is properly treated the possibility of impurities
at the water and steam side of the boiler should be minimal.
5.2 Deposits in the tubes are notoriously extremely small owing to the heavy
water circulation.
If impurities which cannot be boiled out should come inside the tubes, the
tubes can be cleaned by scraper and brush.
5.3 Once a day mud is blown from the boiler through the bottom blow–off valve
until clear water is coming.
5.4 If the oil burner is functioning correctly and the combustion is complete the
soot deposit on the tubes will be minimal, but in practice it can hardly be
avoided that soot will deposit in the course of time, I. e. due to the starting
periods of the oil burner. Attached soot deposits can be removed by water
washing with a 10 percent soda solution through the inlet door in the
uptake, drain pipe at the bottom of the fire box is available.
5.5 Cleaning of exhaust gas fired section outside the tubes are to be cleaned
by boiling out, possible by using scraper and brush.
5.6 Inside the tubes can be cleaned for attached soot deposits by washing
with water with a 10 percent soda solution through the inlet door of the
uptake, drain pipe at the bottom of the boiler is available.
The cleaning can possibly be mode by brushes mounted in chains.
5.7 Cleaning of pin tubes

The outside of pin tubes shall be inspected visually and cleaned up, the
flue gas temperature is too high compared with the temperature at
Normal operation as well as dry docking time or periodic inspection time.
7
Auxiliary Boiler
The cleaning procedure (caution: be careful not to scald yourself)

A. Turn off the burner and wait for hours until cool down.
B. Swing out the burner to access to furnace.
C. Open drain valve and access door of smoke uptake.
D. Jet directly the pin tubes with fresh water (6bar, 50 l/min ).
E. Check that drain pipe is blocked and repeat water washing.
F. After all washing water is drained away, close the drain valve and door.
G. Turn on the burner (Approx. 5 minutes ).
H. Open the drain valve to remove residual water.
I. Close the valve and turn on the burner (Approx. 15 minutes ).
J. Check that the flue gas temperature correct . And check that all door and
valve are closed.
8
Auxiliary Boiler
6. Boiling out
The boiling out is made in the following way :
6.1 In the boiler is to be filled a solution consisting of 4-5 kg.

Tri-sodiumphosphate ( Na3 Po4 ) per 1000kg water.
It is preferable to add the chemicals through the manhole.
Then water is filled in, until the solution is just visible in the water gauge.
Untreated water can be use.
6.2 The boiler is slowly brought on working pressure and kept on this pressure
in abt. 6-8 hours with closed main stop valve, after which fat and other
impurities should be boiled out of the interior surfaces of the boiler.
6.3 Then to be skimmed of ( through the scum valve ), However, it must be
seen that before the water level is 20-30 mm above the scum funnel. If the
boiler is equipped with automatic water level control it may be necessary to
close for this unit during the skimming.
6.4 After the boiling out the burner is switched off, and after abt.1 quarter
the bottom blow-off valve and the air valve at the boiler top is to be opened,
and all the water is to be blown out of the boiler.
Then the boiler is washed and brushed inside, and the bottom blow-off
valve is examined in such a way that possible oxide scales and welding
pearls, which have been collected there, can be removed ( if necessary the
bottom blow-off valve is to be dismounted ).
The hand-holes in the bottom of the boiler is to be opened and the boiler
cleaned.
6.5 Treated, softened water to be added to a little below normal water level
when the bottom valve and hand-holes have been closed.
6.6 If the boiler shows a tendency to priming it is recommended to carry out an
boiling out. Besides, it is recommended to carry out another boiling out after
a time of operation of 2 to 3 months with a subsequent inside cleaning and
inspection.
9
Auxiliary Boiler
7. Limits of chemical concentration.
Boiler water Feed water to boiler

PH(at 25°C) 10.8~11.3 7.0-9.0
Phenolphthalein Alkalinity(CaCO3) Max.500 -
Total Alkalinity(CaCO3) / ppm Max.600 -
Chloride (Cl-) /ppm Max.300 -
Total solid / ppm Max.2000 -
Excess Phosphate (PO₄² )/ ppm 20~40 -
Hardness(CaCO3) / ppm - Max.1.0
Oxygen / mg/l - Max.500
Hydrazine / mg/l - -
Table .1] Recommend limits of chemical contcentration.
NOTICE!
Estimate the pH value from alkalinity tends to give pH readings
varying with silica, Ca, Mg, and other salt contents of boiler
water and dhhence iis not necessarily
il ddeemed d appropriate
i : resort
to this method only as a means to obtain a rough guide
(alkalinity serves merely as an auxiliary means in determining
the pH level). Also, be sure to control pH to the target value
while, on the other hand, Keeping alkalinity at the minimum
necessary level. Limiting the P alkalinity to within a certain
range would make it possible to inhibit the alkali corrosion even
if boiler water concentration should take place on the heating
surface, etc.
10
Auxiliary Boiler
8. Repair of pin tube element

8.1 In case of leakage on a pin tube, the pressure is to be removed from the
and the oil burner is to be dismantled.
8.2 If the tube in question cannot be pointed out immediately, the boiler is
to be put on pressure by means of the feed pump so that the leakage will
which tube has been damaged.
8.3 The boiler is emptied of water, and the manhole cover is dismantled.
8.4 The gas pipe and pin tube inside are cleaned and two holes in the gas pipe
are cut. ( Ref. to Fig. 1 )
8.5 The plugging plates are welded and check for leaks when the boiler is
pressured. ( Ref. to Fig. 1)
** Note **
A) A new pin tube element should be replaced as soon as possible.
B) The boiler should not be operated with more than one plugging tube.
C) If flue gas temperature exceeds 450℃ the burner must be stopped or
at low load.
11
Auxiliary Boiler
9. Preservation procedure of boiler

The boiler shall be preserved properly as mentioned below, If the boiler
is not used for a long time or short period.
9.1 Shut-down for a period of 30 days or less.
Filled up the boiler with boiler water to prevent corrosion.
The boiler should be cleaned before filling.
9.2 Lay-up for more than one month
The one of following methods shall be applied to prevent corrosion:
A. Dry preservation.
B. Nitrogen preservation.
C. Wet preservaiton.
The work procedures for these preservation are described in the following:
9.2.1. Dry preservation

a) Open the bottom blow down valve at 3-5 bar pressure to empty of
the boiler and drain out, if water is remaining in the boiler.
b) Open Manhole doors and hand hole covers to cool down and if there
is water left in the bottom it should be removed.
c) Drying the boiler by either circulating dried air from a fan or by placing
bags of silica-gel in the boiler.
d) Put a tray with burning charcoal to remove oxygen before
closing manhole doors and hand hole covers.
e) Close manhole doors with new gaskets as soon as you have placed
the charcoal.
f) Alternatively, VCI (Volatile Corrosion Inhibitor) can be used after
cooling and careful draining, and the boiler shall be closed completely.
12
Auxiliary Boiler
9.2.2. Nitrogen preservation

The boiler should be drained, dried and sealed in the same way as
mentioned above for Dry Preservation.
a) Open a air vent valve on the top of the boiler.

b) Make a connection for nitrogen supply to the bottom of the boiler.
c) Connect cylinders with nitrogen to the bottom via reduction valve and
purge the boiler until you are sure that no oxygen is left in the boiler.
d) Close air vent valve.
e) Leave a cylinder with nitrogen connected to the boiler via reduction valve
and keep an overpressure of approx. 0.2 bar in the boiler.
9.2.3. Wet preservation

This method can be used for a short period (1-3 months) of lay up but shall
not be applied when the surrounding temperature of the boiler is lower than
0℃ to avoid frost damage.
a) Open a air vent valve at top of the boiler.

b) Filled up with treated boiler water and hydrazine is added until
concentration is obtained 100-200 PPM.
c) The water should be circulated continuously or at least once per week to
avoid corrosion from any penetration of oxygen.
d) Check the hydrazine concentration and add the necessary amount to
have an excess of 100-200 PPM. Other oxygen binding agents can be
used too.
The pH-value should be kept 9.5-10.5.
** The boiler shall be completely drained and refilled with boiler feed water
before re-operation.
13
SAFETY VALVE
INSTALLATION OPERATION
AND MAINTENANCE INSTRUCTION
SAFETY VALVE

SAFETY VALVE
TABLE OF CONTENTS
PAGE
1. Design/Construction -------------------------- 3
2. Operating Cycle -------------------------- 6
3. Installation -------------------------- 8
4. Caution on Hydraulic Test -------------------------- 10
5. Adjustment -------------------------- 11
6. Troubles and Shooting

g -------------------------- 13
7. Repair and Lapping -------------------------- 14
8. Reassembly -------------------------- 15
2
SAFETY VALVE
1. DESIGN / CONSTRUCTION
Full Bore Type is provided that Seat Opening Diameter (SOD) is not less
than 1.15 times the throat Opening Diameter(TOD), and that the steam
passage area of the seat when opened is not less than 1.05 times of the
throat opening area, and that the area of the valve inlet and the connection
nozzle are not less than 1.7 times of the throat opening area.
Those valves have a unique Nozzle Seat which provides maximum

capacity obtainable. The discharge through this nozzle enters a body
chamber which is carefully proportioned in the internal contours and in the
ratio of inlet to outlet area to minimize flow restriction and body pressure.
Especially for the positive proper adjustment of operating characteristic on

fluid, One Ring is adopted to obtain substantial adjustment to its pop action.
For easy access to resume normal seating face. if need due to failure of its
trueness, the most important characteristic of Flat Seat Nozzle Valve is the
ease with which seating surface can be reconditioned the slight deviation
from the specific angles can lead leakage and faulty operation.
All important part are thermally balanced and precisely machined, thus
assuring accurate alignment regardless of temperature variation.
1.1 Valve trim

Trim parts in a safety relief valve include disc and nozzle seat only.
1) Disc
A disc acts as the top guide and is guided by a cylindrical valve guide,
standard construction of safety relief valves includes metal-to-metal seats in
a view of tightness which provide commercial tightness acceptable for most
applications or special bubble tightness under certain conditions.
For reinforcement of seating faces both on disc and nozzle seat to insure
their trueness from violent and rapid shout down force during operating,
3
SAFETY VALVE
Surfaces are carefully stilted and precisely lapped.

Maintaining the necessary operating clearance between disc and its guide
assures free movement under a certain temperature ranges given.
Please refer to limiting service conditions for keeping them from exposing
thermal expansion trouble as specified in catalog.
2) Nozzle seat
As the nozzle seat is fully and tightly screwed up into the main body
keeping seating face same contour parallel, it will not come out of the
position and any deviation from disc contacting center.
Also, with a view to avoid any malfunction, leaks, or other problems which
may be caused by stress from the outlet piping or by thermal strains, the
seat surface is designed to occupy a position at the center of the body
cylinder and separated as far as possible from the contact position with
body.
Since the fluid channel from the throat to the valve seat is the most
important part determining the performance of the valve, a logical Shape is
provided so that there will be no interruption in the fluid expansion.
4
SAFETY VALVE
1.2 Adjust Ring

The ring screwed onto the circumference of nozzle seat,
The area expansion due to a small amount of fluid leakage just before the
blow-off produces pressure enough to lift the disc. this force causes a quick
popping action of the valve. The ring adjusts the simmer of the fluid.
The other name is (popping) Control Ring or Nozzle Ring.
1.3 Body
The body maintains tightness with its precise finishing and its stout
construction ensures safety against thermal stress due to the rapid variation
in the temperature of the fluid to be blown off as well as securing it against
the reaction strength resulting from a large amount of fluid blown off.
1.4 Bonnet
Standard construction of bonnet includes closed one to protect the internal
spring and support the adjusting screw.
On model SSRF open and yoke bonnet can be provided to ensure safety
against
i thermal
h l stress d
due to rapid
id variation
i i iin the
h temperature off the
h
discharging flow during blowing off.
1.5 Cap construction and Lever

Standard caps for pressure relief valve are screwed or Bolted Top and
Open Lever Top to provide periodical test, for usage of which hermetic
sealing is not required (with most uses for steam and air) Adopted Test Gag
on two kinds o top cap, when required, is handy for use in hydraulic test.
On standard open lever, Fork lever are adopted to larger size valve.
5
SAFETY VALVE
1.6 Adjust cock (or needle)

When the safety valve is blowing off fluid, back pressure is applied to the
back of disc and the guide. The back pressure interferes with the valve
when it is being lifted but assists it when the valve is being closed.
To apply the back pressure most effectively, on additional cock which can
be handled from the outside, can be provided. Safety valve can be suitable
provided with the adjust needle on construction of open bonnet to prevent
any trouble in the operation of it even if the throttle is closed too much.
2. OPERATING CYCLE
All of safety-relief valves are of the direct spring loaded construction. The
operating mechanism of each type is as follows:
Should the pressure upstream of the valve rise abnormally and reach near
to the set pressure, it cause the balanced spring to push upward and the
valve disc be slightly lifted up to make an initial opening. Steam or gas
gushing out of this initial opening will be guided by the properly adjusted
lower ring to exert dynamic pressures on the valve disc and the valve disc
will be lifted quickly, the valve will start to discharge.
I case off the
In th Full
F ll Bore
B Type
T Valve.
V l operating
ti characteristic
h t i ti off which
hi h iis
controlled by the ring, fluid discharged by the initial blowing-out will be
deflected in a downward direction through upper ring and this deflection as
well as pressure generated between two ring are exerted on the face of the
valve disc to lift it to a higher position.
As the Low-Lift Type Valve is not provided with an upper ring, the fluid is
deflected through a chamber formed by the lower face of the valve disc and
the lower ring. The valve disc is lifted by static and dynamic pressure.
2.1 when inner pressure is lower than set pressure, the valve disc keeps the
condition of full close due to differential power between the fluid pressure
and the condition of full close due to differential power between the fluid
pressure and the counter-pressure by the adjusted spring
6
SAFETY VALVE
2.2 Initial open

(Commence-to-blowout)
In case that the inner fluid pressure reaches near the set pressure, the
power retaining valve closed by the spring will be gradually overcome by the
inner pressure allowing a little fluid leakage into accumulating chamber
which is formed between the lower and upper rings.
2.3 Full open

The pressure condensed in the accumulating chamber makers greater
force to lift the disc upward against spring force. This pressure leads
popping action to lift up the disc quickly in this case, the full open can be
easily attained at the given overpressure above the set pressure.
2.4 Re-seating
Re-seating will be duly obtained at the adjusted ring mechanism after
enhancement of blow-off.
7
SAFETY VALVE
3. INSTALLATION
3.1 Storage and Conveyance
Safety-relief valve are often off hand at the job site several months before
they are actually installed. Unless they are properly stored and protected
their performance may be affected deadly. Roughness in handling may
damage valve appearance sharp, worst to crack, or cause misalignment of
the valve part. Furthermore carrying by pulling up the lever may cause
change of the spring set pressure and alignment of the stem.
3.2 Inlet side piping

It is the best practice to directly mount the safety and safety-relief valve in
vertical position on a nozzle of pressure vessel or a short connection which
smooth flow of fluid.
Where rounded or beveled approaches can not be provided ahead of the
safety-relief valve, it is recommended that one size larger riser or fitting be
used. The pressure drop in the valve inlet piping should not exceed 3% of
the set pressure.
Valves are sometimes badly damaged just as they go into service because
of failure to clean the connections.
It is essential that the boiler, pressure vessel, valve inlet, and all
connections should be cleaned thoroughly before the valve is mounted.
1) Caution at inlet piping

Most of leak on valve performance are caused from failure to clean. Many
valve are damaged when first placed in service or even hydraulic pressure
test under undue preparation due to failure to properly clean the
connections and piping when installed.
3.3 Outlet side piping

When arranging the discharge piping, pay due attention to the following
points talking into consideration that discharge piping should be simple and
direct :
1) Minimize the length and the number of bends of discharge piping so as to

reduce the back pressure of the valve to a minimum. Especially, when a
silencer is used, note that the discharge pipe tends to be long and gives a
large pressure drop due to discharge exceed 10% of the set pressure
8
SAFETY VALVE
2) Discharge piping should be so designed that the weight of the piping will at
no time be taken up by the valve body.
A sufficient flexibility to the discharge piping is also essential to avoid strain
on the valve caused by thermal pipe expansion.
3) Care on multi installation

When two more valves are installed to discharge into a common header
the discharge pressure due to the opening pressure of the remaining valves
in the system.
a. Valve with bonnet not vented
The discharge line pressure of these valves will increase the opening
pressure by the amount (kg/cm2) of the discharge pressure.
b. Valve with bonnet vented

The set pressure of the remaining valves in the system will be reduced by
the amount (kg/cm2) of the discharge pressure.
9
SAFETY VALVE
※ Where either of the above conditions are unacceptable, the use of

balanced bellows valves is recommended.
Conventional valve with vented bonnet is not suitable for continuous back
pressure. Therefore never try to arrange discharge pipe from two or more
valves into a common header.
4. CAUTION on HYDRAULIC TEST

When hydraulic pressure test on the pressure vessel is conducted without
removing the safety valve installed on it. increase inner pressure of the
vessel to 80 to 90% of the set pressure of the valve, then mount the test
gag to hold the end of the stem lightly in order to protect the valve from
damage caused by undue load.
Removal of the gag shall also be conducted at 80 to 90% of the set
pressure.
When several valves are installed on a vessel or pipe line and one of the
valves is being on adjustment. The same caution should be taken at the
mounting of the test gag or gags on the other valve or valves to prevent it or
them from blowing off.
4.1 Cautions
The test gag can not be mounted on the ordinary type caps. Therefore, the
caps should be replaced with those made for the purpose.
In case of pressure test for pressure vessels without using test gag, test
them without the safety valves for safety of it.
Removed valve should be covered at the flange parts against intrusion of
dusts, etc.
Replace with a plug and gasket in case of closed top (or take off when
open top) after the test, otherwise the valve will not operate thereby creating
a dangerous situation.
10
SAFETY VALVE
4.2 Test gag

- Test gag should be used only when hydrostatic testing is performed
at field
- Safety valve & Safety relief valve are usually shipped with this gag
- The Test gag should be furnished in accordance with following
5. ADJUSTMENT
Consideration of service pressure characteristic(differential between
operating and set pressure)
In order to avoid unsatisfactory operation of safety relief valves in normal
processing service. the operating pressure of the system should not exceed
90% of the set pressure. in the pump and compressor delivery line,
however, the difference between the set pressure and the operating
pressure should be made large on account of the pulsation attributable to
the pump delivery pressure is a better method.
Before re-adjustment, remove a Pb seal to cap and set screws which is
sealed to prevent arbitrary adjustment by an incompetent and visual check
of any external changes of set pressure or blowdown pressure.
5.1 Adjustment of set pressure

The set pressure of each safety valve has precisely been adjusted and
sealed.
At our factory before the shipment, however in case that it is necessary to
readjust at the job-site to the state of the exhaust pipe, the amount of
blowing capacity, and other factors, readjustment can be done in the
following procedure :
11
SAFETY VALVE
Take off cap, loosen lock nut and turn down the adjusting screw to the
right(clockwise viewing from above) to raise set pressure and turn up the
left (anti-clockwise viewing from above) to lower the set pressure.
At the readjustment, be sure to lower the pressure of the system at below
90% of the set pressure.
After completion of re-adjustment, screw up the adjusting screw with lock
nut.
Tolerance of set pressure

unit : kg/cm2
SET PRESSURE TOLERANCE
5 excl. and under ± 0.14
over 5 and 23 excl. ± 3% (of set pressure)
12
SAFETY VALVE
6. TROUBLES and SHOOTINGS

6.1 Leakage
The most frequent causes of leakage are from damages on the valve seat
and adhering of foreign materials on it. In these cases, pull the lever to blow
off the dirt sticking from the seat. If the leakage does not stop, the seat
must have been damaged.
To avoid seating surfaces damaged by foreign materials. care should be
taken thoroughly from storage to installation which is the best practice after
completely flushing out.
Refer to, when it is need, the repair and lapping procedures in para 7 for
reconditioning.
6.2 Incorrect popping pressure
If the safety valve does not operate at specified pressure, a major cause is
accumulation of dirt or scale between the disc and the guide or the change
of the spring load due to bent of stem. in the case, cleaning or dismounting
for servicing is required.
6.3 Unstable operation

Unstable operation often results from wrong adjustment. the followings are
the state of unstable operation and its remedy.
1) Simmer
When a simmer is present raise the lower ring(push the notches to the right
while viewing in front of notch) by one noter at a time. ( Never set the lower
ring in contact with the valve disc) this is the case of the slightly weakening
dynamic power to lower accumulation not enough to lift up the disc.
2) Chattering
This is a rapid reciprocating variations in valve lift during which the disc
repeatedly contacts the seat. It is because popping power is weak. In this
case, bring up the lower ring (closer to the bottom face of the disc but never
contact each other)
3) Hunting
This is the states where the disc repeats violent vertical motion during
operation as if it beat the seat violently. This is often caused when there is
much flow restriction in the piping connected with inlet and discharge side
of the safety valve or when blowdown is excessively too short, in this case,
open the gland cock or needle valve or bring down the upper ring to
increase blowdown.
If hunting is not ceased despite the above adjustment, rechecking of the
piping is necessary.
13
SAFETY VALVE
7. REPAIR and LAPPING

In practice, the main necessary repair work will be lapping on the sealing
surfaces of disc and nozzle seat. Its procedure is as follows:
7.1 Kind of
No. 1 Lapping compound:
Pasty mixture of compound No. 200 kneaded with rape oil into a cream
form.
Pasty mixture of compound No. 800 kneaded with rape oil into a form
between cream and liquid.
Pasty mixture of compound No. 4000 kneaded with rape oil into a form
between cream and liquid.
7.2 Lapping procedure

1) Coat a surface of lapping block thinly with No.1 lapping compound.
Elliptically move the lapping block to remove large scratches.
2) Use No.2 lapping compound and make lapping in the same manner as
procedure 1 to reduce scratches in size.
3) Finish with No.3 lapping compound. The lapping manner is the same as
procedure 1.
4) Finally, use No.3 lapping compounds and make mutual lapping of the valve
disc and the valve seat to finish them.
Mutual lapping is effected by lightly turning and reversing the valve disc on
the valve seat. The width of turning and reversing motion is 5 to 10mm, and
mutual lapping should not be continued too long. If it is continued too long,
the outer side of the seating surface will become dull. When the lapping is
felt heavy by hand, stop doing it.
7.3 Washing
Carefully wash the valve seat and valve disc with cleaning oil or liquid after
lapping to make them completely free from lapping compound.
7.4 Inspection of lapped surfaces
Inspection of lapped surface is extremely difficult. Try the following method:
Lighten the lapped surface. If the brightness is even all over the surface,
the lapping is complete. If any shady portion is present, the lapping is
incomplete.
14
SAFETY VALVE
Especially the following attention should be paid:

a) Pay extra care not to damage or soil the lapped surfaces of valve disc and
valve seat.
b) Properly center the tip end of the valve spindle on the valve disc.
c) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
8. REASSEMBLY
Reassembly will be made following the reverse order of disassembly.
Especially the following attention should be paid:
1) Care should be taken not to damage or soil the lapped surfaces of valve
disc and valve seat.
2) Properly center the tip end of the valve spindle on the valve disc.
3) Evenly and alternately lock up nuts to tighten the bonnet or yoke bolts.
15
Operating Instructions
Deltabar S FMD76/77/78, PMD70/75
Differential pressure measurement
BA00270P/00/EN/15.13
71204581
valid from Software version:
02.11.zz
Overview documentation Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
Overview documentation
Device Documentation Content Remarks
Deltabar S Technical Information TI00382P Technical data The documentation is available on the Internet.
4...20 mA HART → See: www.endress.com → Download
Operating Instructions BA00270P – Identification – The documentation can be found on the

– Installation supplied documentation CD.
– Wiring – The documentation is also available via the
– Operation Internet. → See: www.endress.com
– Commissioning, Description of
Quick Setup menus
– Maintenance
– Trouble-shooting and spare parts
– Appendix: Illustration of menu
Operating Instructions BA00274P – Examples of configuration for – The documentation can be found on the
pressure, level and flow supplied documentation CD.
measurement – The documentation is also available via the
– Description of parameters Internet. → See: www.endress.com
– Trouble-shooting
– Appendix: Illustration of menu
Brief Operating Instructions KA01018P – Installation – The documentation is supplied with the
– Wiring device.
– Operation on-site – The documentation can be found on the
– Commissioning supplied documentation CD.
– Description of Quick Setup menus – The documentation is also available via the
Internet. → See: www.endress.com
Leporello KA00218P – Wiring – The documentation is supplied with the

– Description of operating elements device. See cover of the terminal
– Operation HistoROM®/M-DAT compartment.
– The documentation can also be found on the
supplied documentation CD.
Functional Safety Manual SD00189P – Safety function with Deltabar S – The documentation can be found on the
– Behaviour in operation and failure supplied documentation CD.
– Commissioning and iterative tests It applies to the devices showing version "E" in
– Settings feature 100 "Additional options 1" or in
– Technical safety characteristic feature 110 "Additional options 2".
quantities → See also Technical Information TI00382P,
– Management Summary chapter "Ordering information".
2 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Table of contents
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . 4 8.2 Response of outputs to errors . . . . . . . . . . . . . . . . . 72
8.3 Confirming messages . . . . . . . . . . . . . . . . . . . . . . . 74
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8.4 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.2 Installation, commissioning and operation . . . . . . . . 4
8.5 Repair of Ex-certified devices . . . . . . . . . . . . . . . . . 75
1.3 Operational safety and process safety . . . . . . . . . . . . 4
8.6 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.4 Notes on safety conventions and icons . . . . . . . . . . . 5
8.7 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Identification . . . . . . . . . . . . . . . . . . . . 6 8.9 Software history . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Device designation . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 Technical data . . . . . . . . . . . . . . . . . . . 80
2.3 CE mark, declaration of conformity . . . . . . . . . . . . . 9
2.4 Registered trademarks . . . . . . . . . . . . . . . . . . . . . . . 9
10 Appendix . . . . . . . . . . . . . . . . . . . . . . . 80
3 Installation . . . . . . . . . . . . . . . . . . . . . 10 10.1 Operating menu for on-site display, FieldCare and HART
handheld terminal . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Incoming acceptance and storage . . . . . . . . . . . . . . 10
3.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . 10
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . 10
3.4 Post-installation check . . . . . . . . . . . . . . . . . . . . . . 22
4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Connecting the device . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Connecting the measuring unit . . . . . . . . . . . . . . . 25
4.3 Potential matching . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Overvoltage protection (optional) . . . . . . . . . . . . . . 27
4.5 Post-connection check . . . . . . . . . . . . . . . . . . . . . . 27
5 Operation . . . . . . . . . . . . . . . . . . . . . . 28
5.1 On-site display (optional) . . . . . . . . . . . . . . . . . . . . 28
5.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 On-site operation –
on-site display not connected . . . . . . . . . . . . . . . . . 33
on-site display connected . . . . . . . . . . . . . . . . . . . . 37
5.5 HistoROM®/M-DAT (optional) . . . . . . . . . . . . . . 39
5.6 Operation via SFX100 . . . . . . . . . . . . . . . . . . . . . . 43
5.7 FieldCare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.8 Locking/unlocking operation . . . . . . . . . . . . . . . . . 44
5.9 Factory setting (reset) . . . . . . . . . . . . . . . . . . . . . . 45
6 Commissioning. . . . . . . . . . . . . . . . . . 47
6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 Selecting language and measuring mode . . . . . . . . 47
6.3 Position adjustment . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4 Flow measurement . . . . . . . . . . . . . . . . . . . . . . . . 49
6.5 Level measurement . . . . . . . . . . . . . . . . . . . . . . . . 52
6.6 Differential pressure measurement . . . . . . . . . . . . . 59
7 Maintenance. . . . . . . . . . . . . . . . . . . . 62
7.1 Exterior cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8 Trouble-shooting . . . . . . . . . . . . . . . . 63
8.1 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Endress+Hauser 3
Safety instructions Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
1 Safety instructions
1.1 Designated use

The Deltabar S is a differential pressure transmitter for measuring differential pressure, flow and
level.
The manufacturer accepts no liability for damages resulting from incorrect use or use other than that
designated.
1.2 Installation, commissioning and operation

The device has been designed to operate safely in accordance with current technical, safety and EU
standards. If installed incorrectly or used for applications for which it is not intended, however, it is
possible that application-related dangers may arise, e.g. product overflow due to incorrect
installation or calibration. For this reason, the instrument must be installed, connected, operated
and maintained according to the instructions in this manual: personnel must be authorised and
suitably qualified. The manual must have been read and understood, and the instructions followed.
Modifications and repairs to the device are permissible only when they are expressly approved in
the manual. Pay particular attention to the technical data on the nameplate.
1.3 Operational safety and process safety

Alternative monitoring measures must be taken to ensure operational safety and process safety
durng configuration, testing and maintenance work on the device.
1.3.1 Hazardous areas (optional)

Devices for use in hazardous areas are fitted with an additional nameplate (→ ä 6). If the device is
to be installed in an explosion hazardous area, then the specifications in the certificate as well as all
national and local regulations must be observed. The device is accompanied by separate "Ex
documentation", which is an integral part of this Operating Instructions. The installation
regulations, connection values and Safety Instructions listed in this Ex document must be observed.
The documentation number of the related Safety Instructions is also indicated on the additional
nameplate.
• Ensure that all personnel are suitably qualified.
1.3.2 Functional Safety SIL3 (optional)

If using devices for applications with safety integrity, the Functional Safety Manual (SD00189P)
must be observed thoroughly.
4 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Safety instructions
1.4 Notes on safety conventions and icons

In order to highlight safety-relevant or alternative operating procedures in the manual, the following
conventions have been used, each indicated by a corresponding icon in the margin.
Safety conventions
#
Warning!
A warning highlights actions or procedures which, if not performed correctly, will lead to personal
injury, a safety hazard or destruction of the instrument.
"
Caution!
Caution highlights actions or procedures which, if not performed correctly, may lead to personal
injury or incorrect functioning of the instrument.
!
Note!
A note highlights actions or procedures which, if not performed correctly, may indirectly affect
operation or may lead to an instrument response which is not planned.
0
Device certified for use in explosion hazardous area
If the device has this symbol embossed on its nameplate, it can be installed in an explosion
hazardous area or a non-explosion hazardous area, according to the approval.
Explosion hazardous area
- Symbol used in drawings to indicate explosion hazardous areas.

– Devices used in hazardous areas must possess an appropriate type of protection.
Safe area (non-explosion hazardous area)
. Symbol used in drawings to indicate, if necessary, non-explosion hazardous areas.

– Devices used in hazardous areas must possess an appropriate type of protection. Lines used in
hazardous areas must meet the necessary safety-related characteristic quantities.
% Direct voltage
A terminal to which or from which a direct current or voltage may be applied or supplied.
&
Alternating voltage
A terminal to which or from which an alternating (sine-wave) current or voltage may be applied
or supplied.
)
Grounded terminal
A grounded terminal, which as far as the operator is concerned, is already grounded by means of
an earth grounding system.
*
Protective grounding (earth) terminal
A terminal which must be connected to earth ground prior to making any other connection to the
equipment.
+
Equipotential connection (earth bonding)
A connection made to the plant grounding system which may be of type e.g. neutral star or
equipotential line according to national or company practice.
Temperature resistance of the connection cables

t >85°C
States, that the connection cables must be resistant to a temperature of at least 85 °C (185 °F).
Safety instruction
For safety instructions refer to the manual for the appropriate instrument version.
Endress+Hauser 5
Identification Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
2 Identification
2.1 Device designation
2.1.1 Nameplate
! Note!
• The MWP (maximum working pressure) is specified on the nameplate. This value refers to a
reference temperature of 20°C (68°F) or 100°F for ANSI flanges.
• The pressure values permitted at higher temperatures can be found in the following standards:
– EN 1092-1: 2001 Tab. 18 1)
– ASME B 16.5a – 1998 Tab. 2-2.2 F316
– ASME B 16.5a – 1998 Tab. 2.3.8 N10276
– JIS B 2220
• For PMD70 and PMD75, the MWP applies for the temperature ranges specified in the Technical
Information TI00382P in the "Ambient temperature range" and "Process temperature limits"
sections.
• The test pressure corresponds to the over pressure limit (OPL) of the device = MWP x 1.5.
• The Pressure Equipment Directive (EC Directive 97/23/EC) uses the abbreviation "PS". The
abbreviation "PS" corresponds to the MWP (maximum working pressure) of the measuring
device.
1) With regard to their stability-temperature property, the materials 1.4435 and 1.4404 are grouped together under 13EO
in EN 1092-1 Tab. 18. The chemical composition of the two materials can be identical.
Aluminium housing (T14/T15) and stainless steel housing (T14)
R1 55
1
Order Code: 2
4
Ser.-No.: 3 6
23,5
MWP 5 Span 7
8 15
14
2,5
9 U= 11
Mat. 10
12 13
2,1 -0,1
26
P01-XMX7Xxxx-18-xx-xx-xx-000
Fig. 1: Nameplate
1 Device name
2 Order code
See the specifications on the order confirmation for the meanings of the individual letters and digits.
3 Serial number
4 Degree of protection
5 MWP (Maximum working pressure)
6 Symbol: Note: pay particular attention to the data in the "Technical Information"!
7 Minimum/maximum span
8 Nominal measuring range
9 Electronic version (output signal)
10 Wetted materials
11 Supply voltage
12 GL-symbol for GL marine certificate (optional)
13 SIL-symbol for devices with SIL3/IEC 61508 Declaration of conformity (optional)
14 Approval ID and ID numbers
15 Address of manufacturer
6 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Identification
Devices for use in hazardous areas are fitted with an additional nameplate.
1
2
4 5 Dat.: 6
P01-xMD7xxxx-18-xx-xx-xx-002
Fig. 2: Additional nameplate for devices for hazardous areas

1 EC type examination certificate number
2 Type of protection e.g. II 1/2 G Ex ia IIC T4/T6
3 Electrical data
4 Safety Instructions number e.g. XA00235P
5 Safety Instructions index e.g. A
6 Device manufacture data
Devices suitable for oxygen applications are fitted with an additional nameplate.
Bei Sauerstoffeinsatz/
for oxygen service
Pmax 1 3
Tmax 2
P01-xxxxxxxx-18-xx-xx-xx-000
Fig. 3: Additional nameplate for devices suitable for oxygen applications

1 Maximum pressure for oxygen applications
2 Maximum temperature for oxygen applications
3 Layout identification of the nameplate
Endress+Hauser 7
Identification Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
Hygenic stainless steel housing (T17)
13
1 19
2 20
Order Code: 3 21
Ser.-No.: 4
MWP 5 22
6
Span 7
8 23
9 U= 10
Mat.
24 - 25
11
12 Dat.: 26
15 16 Bei Sauerstoffeinsatz/for oxygen service:

14 17
13 Tmax 27 Pmax 28
18 13
P01-XMX7Xxxx-18-xx-xx-xx-001
Fig. 4: Nameplate
1 Device name
2 Address of manufacturer
3 Order code
See the specifications on the order confirmation for the meanings of the individual letters and digits.
4 Serial number
5 MWP (Maximum working pressure)
6 Symbol: Note: pay particular attention to the data in the "Technical Information"!
7 Minimum/Maximum span
8 Nominal measuring range
9 Electronic version (output signal)
10 Supply voltage
11 Wetted materials
12 Degree of protection
Optional:
13 Approval ID and ID numbers
14 3A-symbol
15 CSA-symbol
16 FM-symbol
17 SIL-symbol for devices with SIL3/IEC 61508 Declaration of conformity
18 GL-symbol for GL marine certificate
19 EC type examination certificate
20 Type of protection
21 Approval number for WHG overspill protection
22 Temperature operating range for devices for use in hazardous areas
23 Electrical data for devices for use in hazardous areas
24 Safety Instructions number
25 Safety Instructions index
26 Device manufacture data
27 Maximum temperature for devices suitable for oxygen applications
28 Maximum pressure for devices suitable for oxygen applications
2.1.2 Identifying the sensor type

See parameter "Sensor Meas.Type" in Operating Instruction BA00274P. The Operating Instruction
BA00274P can be found on the supplied documentation CD.
8 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Identification
2.2 Scope of delivery

The scope of delivery comprises:
• Deltabar S differential pressure transmitter
• For PMD70 and PMD75 with side flanges made of AISI 316L or C22.8: additional 2 vent valves,
AISI 316L
• PMD75 with side flanges made of AISI 316L or C22.8 and side vent: additional 4 locking screws,
AISI 316L
• For devices with the "HistoROM/M-DAT" option:
CD-ROM with Endress+Hauser operating program and documentation
• Optional accessories
Documentation supplied:
• The Operating Instructions BA00270P and BA00274P and the Safety Instructions, Functional
Safety Manual and brochures can be found on the supplied documentation CD.
See also → ä 2, "Overview documentation" chapter.
• Brief Operating Instructions KA01018P
• Leporello KA00218
• Final inspection report
• Also Safety Instructions with ATEX, IECEx and NEPSI devices
• Optional: factory calibration form, test certificates
2.3 CE mark, declaration of conformity

The device is designed to meet state-of-the-art safety requirements, has been tested and left the
factory in a condition in which it is safe to operate. The device complies with the applicable
standards and regulations as listed in the EC declaration of conformity and thus complies with the
statutory requirements of the EC Directives. Endress+Hauser confirms the successful testing of the
device by affixing to it the CE mark.
2.4 Registered trademarks
KALREZ, VITON, TEFLON

Registered trademarks of E.I. Du Pont de Nemours & Co., Wilmington, USA
TRI-CLAMP
Registered trademark of Ladish & Co., Inc., Kenosha, USA
HART
Registered trademark of the HART Communication Foundation, Austin, USA.
Endress+Hauser 9
Installation Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
3 Installation
3.1 Incoming acceptance and storage
3.1.1 Incoming acceptance

• Check the packaging and the contents for damage.
• Check the shipment, make sure nothing is missing and that the scope of supply matches your
order.
3.1.2 Transport
" Caution!
Follow the safety instructions and transport conditions for devices of more than 18 kg (39.69 lbs).
Transport the measuring device to the measuring point in its original packaging or at the process
connection.
3.1.3 Storage
The device must be stored in a dry, clean area and protected against damage from impact
(EN 837-2).
Storage temperature range:
• –40 to +90°C (–40 to +194°F)
• On-site display: –40 to +85°C (–40 to +185°F)
• Separate housing: –40 to +60°C (–40 to +140°F)
3.2 Installation conditions
3.2.1 Dimensions
→ For dimensions, please refer to the Technical Information for Deltabar S TI00382P, "Mechanical
construction" section. → ä 2 "Overview documentation.
3.3 Installation instructions

! Note!
• Due to the orientation of the Deltabar S, there may be a shift in the measured value, i.e. when
the container is empty, the measured value does not display zero. You may correct this zero point
shift either directly on the device using the "E"-key or by remote operation. → ä 31, "Function
of the operating elements – on-site display not connected" or → ä 48, "Position adjustment".
• For FMD77 and FMD78, please refer to → ä 17, Section 3.3.4 "Installation instructions for
devices with diaphragm seals (FMD78)".
• General recommendations for routing the impulse piping can be found in DIN 19210 "Methods
for measurement of fluid flow; differential piping for flow measurement devices" or the
corresponding national or international standards.
• Using a three-valve or five-valve manifold allows for easy commissioning, installation and
maintenance without interrupting the process.
• When routing the impulse piping outdoors, ensure that sufficient anti-freeze protection is used,
e.g. by using pipe heat tracing.
• Install the impulse piping with a monotonic gradient of at least 10%.
• To ensure optimal readability of the on-site display, it is possible to rotate the housing up to 380°.
→ ä 22, Section 3.3.9 "Rotating the housing".
• Endress+Hauser offers a mounting bracket for installing on pipes or walls. → ä 20, Section 3.3.7
"Wall and pipe-mounting (optional)".
10 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Installation
3.3.1 Installation for flow measurement
! Note!
For more information about flow measurement with the Deltabar S differential pressure transmitter
• Deltabar S with orifice plate (TI00422P, Deltatop DO6x)
• Deltabar S with Pitot tube (TI00425P, Deltatop DP6x)
Flow measurement in gases with PMD70/PMD75
➁
➂
+ – ➃
P01-PMD75xxx-11-xx-xx-xx-000
Fig. 5: Measuring layout for flow measurement in gases with PMD75

1 Deltabar S, here PMD75
2 Three-valve manifold
3 Shut-off valves
4 Orifice plate or pitot tube
• Mount the Deltabar S above the measuring point so that the condensate can run off into the
process piping.
Flow measurement in steam with PMD70/PMD75
➁
➂ ➂
➃
+ –
➄ ➄
➅ ➅
➆
Fig. 6: Measuring layout for flow measurement in steam with PMD75

1 Condensate traps
3 Shut-off valves
5 Separator
6 Drain valves
• Mount the Deltabar S below the measuring point.

• Mount the condensate traps at the same level as the tapping points and at the same distance to
the Deltabar S.
• Prior to commissioning, fill the impulse piping to the height of the condensate traps.
Endress+Hauser 11
Flow measurement in liquids with PMD70/PMD75
➁ ➁
+ ➂ –
➃ ➃
➄ ➄
➅
Fig. 7: Measuring layout for flow measurement in liquids with PMD75

2 Shut-off valves
4 Separator
5 Drain valves
• Mount the Deltabar S below the measuring point so that the impulse piping is always filled with
liquid and gas bubbles can run back into the process piping.
• When measuring in media with solid parts, such as dirty liquids, installing separators and drain
valves is useful for capturing and removing sediment.
3.3.2 Installation for level measurement
Level measurement in an open container with PMD70/PMD75
patm
min. + patm ➀
➃ ➁
➄
➂
Fig. 8: Measuring layout for level measurement in open containers with PMD75
1 The negative side is open to atmospheric pressure
3 Shut-off valve
4 Separator
5 Drain valve
• Mount the Deltabar S below the lower measuring connection so that the impulse piping is always
filled with liquid.
• The negative side is open to atmospheric pressure.
12 Endress+Hauser
Level measurement in an open container with FMD76/FMD77
patm
min.
+ ➀
–
patm
➁
P01-FMD76xxx-11-xx-xx-xx-003
Fig. 9: Measuring layout for level measurement in open containers with FMD76
1 Deltabar S, here FMD76
2 The negative side is open to atmospheric pressure
• Mount the Deltabar S direct on the container. → ä 19, Section 3.3.5 "Seal for flange mounting".
• The negative side is open to atmospheric pressure.
Level measurement in a closed container with PMD70/PMD75
–➀
max.
min. ➀
+
➁
➂ ➂
➃ ➃
➄
Fig. 10: Measuring layout for level measurement in a closed container with PMD75
1 Shut-off valves
2 Deltabar S, PMD75
3 Separator
4 Drain valves
filled with liquid.
• Always connect the impulse piping of negative side above the maximum level.
Endress+Hauser 13
Level measurement in a closed container with FMD76/FMD77
➀
–
max.
min.
➁
+ ➂
➃
Fig. 11: Measuring layout for level measurement in a closed container with FMD76
1 Shut-off valve
2 Separator
3 Drain valve
Level measurement in a closed container with FMD78
–
max.
➀
+
min.
Fig. 12: Measuring layout for level measurement in a closed container with FMD78
• Mount the Deltabar S below the lower diaphragm seal. → ä 17, Section 3.3.4 "Installation
instructions for devices with diaphragm seals (FMD78)".
• The ambient temperature should be the same for both capillaries.
! Note!
Level measurement is only ensured between the upper edge of the lower diaphragm seal and the
lower edge of the upper diaphragm seal.
14 Endress+Hauser
Level measurement in a closed container with superimposed steam with PMD 70/
PMD75
– ➀
max.
➁
min. ➁
+
➂
➃ ➃
➄ ➄
➅
Fig. 13: Measuring layout for level measurement in a container with superimposed steam with PMD75
1 Condensate trap
2 Shut-off valves
4 Separator
5 Drain valves
filled with liquid.
• A condensate trap ensures constant pressure on the negative side.
Level measurement in a closed container with superimposed steam with FMD 76/
FMD77
– ➀
max.
➁
min.
➂
+ ➃
➄
Fig. 14: Measuring layout for level measurement in a container with superimposed steam with FMD76
1 Condensate trap
2 Shut-off valve
3 Separator
4 Drain valve
Endress+Hauser 15
• A condensate trap ensures constant pressure on the negative side.
3.3.3 Installation for differential pressure measurement
Differential pressure measurement in gases and steam with PMD70/PMD75
➁
+
➂ ➂
➃
Fig. 15: Measuring layout for differential pressure measurement in gases and steam with PMD75
3 Shut-off valves
4 e.g. filter
• Mount the Deltabar S above the measuring point so that the condensate can run off into the
process piping.
Differential pressure measurement in liquids with PMD70/PMD75
➀
➁ ➁
+ –
➂
➃ ➃
➄ ➄
➅
Fig. 16: Measuring layout for differential pressure measurement in liquids with PMD75
1 e.g. filter
2 Shut-off valves
4 Separator
5 Drain valves
• Mount the Deltabar S below the measuring point so that the impulse piping is always filled with
liquid and gas bubbles can run back into the process piping.
16 Endress+Hauser
Differential pressure measurement in gases, steam and liquids with FMD78
➀
➁ ➁
+ –
➂
➃
Fig. 17: Measuring layout for differential pressure measurement in gases, steam and liquids with FMD78
1 Diaphragm seal
2 Capillary
3 e.g. filter
• Mount the diaphragm seal with capillaries at the top or on the side on the piping.
• For vacuum applications: mount the Deltabar S below the measuring point. → ä 17,
Section 3.3.4 "Installation instructions for devices with diaphragm seals (FMD78)", "Vacuum
application" part.
• The ambient temperature should be the same for both capillaries.
3.3.4 Installation instructions for devices with diaphragm seals

(FMD78)
! Note!
• The diaphragm seal, together with the pressure transmitter, forms a closed, calibrated system,
which is filled through openings in the diaphragm seal and in the measurement system of the
pressure transmitter. This openings are sealed and must not be opened.
• Do not clean or touch diaphragm seals with hard or pointed objects.
• Do not remove the protection of the process isolating diaphragm until shortly before installation.
• When using a mounting bracket, sufficient strain relief must be ensured for the capillaries in order
to prevent the capillary bending down (bending radius ≥ 100 mm (3.94 in)).
• Please note that the hydrostatic pressure of the liquid columns in the capillaries can cause zero
point shift. The zero point shift can be corrected. → ä 48, Section 6.3 "Position adjustment".
• Please note the application limits of the diaphragm seal filling oil as detailed in the Technical
Information for Deltabar S TI00382P, Section "Planning instructions for diaphragm seal systems".
→ → ä 2 "Overview documentation".
In order to obtain more precise measurement results and to avoid a defect in the device, mount the
capillaries as follows:
• vibration-free (in order to avoid additional pressure fluctuations)
• not in the vicinity of heating or cooling lines
• insulate if the ambient temperature is below ore above the reference temperature
• with a bending radius of ≥100 mm (3.94 in).
• The ambient temperature and length of both capillaries should be the same when using two-sided
diaphragm seal systems.
• Two diaphragm seals which are the same (e.g. with regard to diameter, material, etc.) should
always be used for the negative and positive side (standard delivery).
Endress+Hauser 17
–
≥ 100 mm
+ –
Fig. 18: Mounting Deltabar S, FMD78 with diaphragm seals and capillary, recommended mounting for vacuum
applications: mount pressure transmitter below the lowest diaphragm seal!
Vacuum application (FMD78)

For applications under vacuum, Endress+Hauser recommends mounting the pressure transmitter
underneath the lower diaphragm seal. A vacuum load of the diaphragm seal caused by the presence
of filling oil in the capillaries is hereby prevented.
When the pressure transmitter is mounted above the lower diaphragm seal, the maximum height
difference H1 in accordance with the illustration below on the left must not be exceeded. The
maximum height difference is dependent on the density of the filling oil and the smallest ever
pressure that is permitted to occur at the diaphragm seal on the positive side (empty container), see
illustration below, on the right.
12.0
Low temperature oil
10.0
Height difference H1 [m]
Vegetable oil
8.0
– Silicone oil
6.0
High temperature
– + oil
4.0
+ –
H1 Inert oil
2.0
+
0.0
50 100 200 300 400 500 600 700 800 900 1000
Pressure, diaphragm seal positive side [mbarabs]
P01-FMD7xxxx-11-xx-xx-xx-001 P01-FMD7xxxx-05-xx-xx-xx-002
Fig. 19: Installation above the lower Fig. 20: Diagram of maximum installation height above the lower
diaphragm seal diaphragm seal for vacuum applications dependent on
the pressure at the diaphragm seal on the positive side
18 Endress+Hauser
3.3.5 Seal for flange mounting
➀ ➁
P01-FMD7xxxx-11-xx-xx-xx-002
Fig. 21: Mounting the versions with flange or diaphragm seal

1 Process isolating diaphragm
2 Seal
# Warning!
The seal is not allowed to press on the process isolating diaphragm as this could affect the
measurement result.
3.3.6 Heat insulation – FMD77

The FMD77 must only be insulated up to a certain height. The maximum permitted insulation
height is labelled on the devices and applies to an insulation material with a heat conductivity
≤ 0.04 W/(m x K) and to the maximum permitted ambient and process temperature (→ see table
below). The data were determined under the most critical application "quiescent air".
TA λ ≤ 0.04 W
m•K
TP
P01-FMD77xxxx-11-xx-xx-xx-000
Fig. 22: Maximum permitted insulation height
FMD77
Ambient temperature (TA) ≤ 70°C (158°F)
Process temperature (TP) max. 400°C (752°F), depending on the

diaphragm seal filling oil used (→ see Technical
Information TI00382P Deltabar S)
Endress+Hauser 19
3.3.7 Wall and pipe-mounting (optional)

Endress+Hauser offers a mounting bracket for installing the device on pipes or walls. A bracket with
mounting accessories for pipe mounting is included with the device.
! Note!
When using a valve block, the block's dimensions must be taken into account.
37.5
➀
12
135
74
12 74
4 6
10
Fig. 23: Mounting bracket for wall and pipe mounting

1 Device mounting
Please note the following when mounting:

• Devices with capillary lines: mount capillaries with a bending radius of ≥ 100 mm (3.94 in).
• To prevent the mounting screws from scoring, lubricate them with a multi-purpose grease prior
to mounting.
• In the case of pipe mounting, the nuts on the bracket must be tightened uniformly with a torque
of at least 30 Nm (22.13 lbf ft).
20 Endress+Hauser
3.3.8 Assembling and mounting the "separate housing" version
5
7
4
1 r ³ 120 mm
Fig. 24: "Separate housing" version

1 In the "separate housing" version, the sensor is supplied with process connection and cable fitted.
2 Cable with connection jack
4 Plug
5 Locking screw
6 Housing fitted with housing adapter, included
7 Mounting bracket suitable for wall and pipe mounting, included
Assembly and mounting

1. Connect plug (item 4) into the corresponding connection jack of the cable (item 2).
2. Plug the cable into the housing adapter (item 6).
3. Tighten the locking screw (item 5).
4. Mount the housing on a wall or pipe using the mounting bracket (item 7). When mounting
on a pipe, tighten the nuts on the bracket uniformly with a torque of at least 5 Nm (3.69 lbs ft).
Mount the cable with a bending radius (r) ≥ 120 mm (4.72 in).
Endress+Hauser 21
3.3.9 Rotating the housing

The housing can be rotated up to 380° by loosening the Allen screw.
max. 380°
Fig. 25: Aligning the housing

– T14 and T15 housing: Loosen setscrew with a 2 mm (0.08 in) Allen key.
Hygenic T17 housing: Loosen setscrew with a 3 mm (0.12 in) Allen key.
– Rotate housing (max. up to 380°).
– Retighten setscrew with 1 Nm (0,74 lbf ft).
3.3.10 Close cover on a hygenic stainless steel housing (T17)
! Note!
When closing the housing cover, please ensure that the thread of the cover and housing are free
from dirt, e.g. sand.If you feel any resistance when closing the cover, check the thread on both again
to ensure that they are free from dirt.
Close cover on a hygenic stainless steel housing (T17)
+–
Fig. 26: Close cover
The covers for the terminal and electronics compartment are hooked into the casing and closed with
a screw. These screws should be finger-tightened (2 Nm (1.48 lbf ft)) to the stop to ensure that the
covers sit tightly.
3.4 Post-installation check

After installing the device, carry out the following checks:
• Are all screws firmly tightened?
• Are the housing covers screwed down tight?
• Are all locking screws and vent valves firmly tightened?
22 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Wiring
4 Wiring
4.1 Connecting the device

# Warning!
If the operating voltage is > 35 VDC: Dangerous contact voltage at terminals.
Risk of electric shock!
In a wet environment, do not open the cover if voltage is present.
# Warning!
Risk of electric shock and/or explosion in hazardous areas! In a wet environment, do not open the
cover if voltage is present.
! Note!
• When using the measuring device in hazardous areas, installation must comply with the
corresponding national standards and regulations and the Safety Instructions or Installation or
Control Drawings.
• Devices with integrated overvoltage protection must be earthed.
• Protective circuits against reverse polarity, HF influences and overvoltage peaks are installed.
• The supply voltage must match the supply voltage on the nameplate. (→ ä 6, Section 2.1.1
"Nameplate".)
• Switch off the supply voltage before connecting the device.
• Remove housing cover of the terminal compartment.
• Guide cable through the gland. Preferably use twisted, screened two-wire cable.
• Connect device in accordance with the following diagram.
• Screw down housing cover.
• Switch on supply voltage.
➀ ➅ 10.5 V DC
➆ 11.5 V DC
4…20 mA
Test
Test
➁ 4... 20mA Test
➂ ➄
➇
4... 20mA Test
➃
P01-xMx7xxxx-04-xx-xx-xx-001
Fig. 27: Electrical connection 4...20 mA HART

→ Observe also sSection 4.2.1 "Supply voltage", → ä 25,.
1 Housing
2 Jumper for 4...20 mA test signal.
→ ä 25, Section 4.2.1 "Taking 4...20 mA test signal" part.
3 Internal earth terminal
4 External earth terminal
5 4...20 mA test signal between plus and test terminal
6 minimum supply voltage = 10.5 V DC, jumper is inserted in accordance with the illustration.
7 minimum supply voltage = 11.5 V DC, jumper is inserted in "Test" position.
8 Devices with integrated overvoltage protection are labelled OVP (overvoltage protection) here.
Endress+Hauser 23
Wiring Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
4.1.1 Connecting devices with Harting plug Han7D
+ – 7
– 8 6
1
2 5
Han7D 3 4
+ –
P01-xxx7xxxx-04-xx-xx-xx-001
Fig. 28: Left: electrical connection for devices with Harting plug Han7D
Right: view of the plug connector at the device
4.1.2 Connecting devices with an M12 connector
PIN assignment for M12 connector
PIN Meaning
1 Signal +
4 3 –
2 Not assigned
3 Signal –
1 + 2 nc
4 Earth
A0011175
24 Endress+Hauser
4.2 Connecting the measuring unit
4.2.1 Supply voltage
! Note!
• All explosion protection data are given in separate documentation which is available upon
request. The Ex documentation is supplied as standard with all devices approved for use in
explosion hazardous areas.
• When using the measuring device in hazardous areas, installation must comply with the
corresponding national standards and regulations and the Safety Instructions or Installation or
Control Drawings.
Electronic version Jumper for 4...20 mA test signal in Jumper for 4...20 mA test signal in
"Test" position (Delivery status) "Non-Test" position
4...20 mA HART, for non-hazardous 11.5...45 V DC 10.5...45 V DC

areas
Taking 4...20 mA test signal

A 4...20 mA signal may be measured via the positive and test terminal without interrupting the
measurement. The minimum supply voltage of the device can be reduced by simply changing the
position of the jumper. As a result, operation is also possible with lower voltage sources. To keep
the measured error below 0.1%, the current measuring device should display an internal resistance
of < 0.7 Ω. Observe the position of the jumper in accordance with the following table.
Jumper position for test signal Description
– Taking 4...20 mA test signal via plus and test terminal:

Test possible. (Thus, the output current can be measured without
interruption via the diode.)
– Delivery status
– minimum supply voltage: 11.5 V DC
– Taking 4...20 mA test signal via plus and test terminal:

Test not possible.
– minimum supply voltage: 10.5 V DC
4.2.2 Cable specification

• Endress+Hauser recommends using twisted, screened two-wire cables.
• Terminals for wire cross-sections 0.5...2.5 mm2 (20 to 14 AWG)
• Cable external diameter: 5...9 mm (0.2 to 0.35 in)
Endress+Hauser 25
Wiring Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
4.2.3 Load
➀ RLmax ➁ RLmax
[Ω] [Ω]
Test 1500 Test
1456
1282 1239
847 804
➃ ➃
413
➂ 369
➂
10.5 20 30 40 45 U 11.5 20 30 40 45 U
[V] [V]
U – 10.5 V U – 11.5 V
RLmax ≤ RLmax ≤
23 mA 23 mA
Fig. 29: Load diagram, observe the position of the jumper and the explosion protection (→ ä 25, Section 4.2.1
"Taking 4...20 mA test signal".)
1 Jumper for 4...20 mA test signal inserted in "Non-Test" position
2 Jumper for 4...20 mA test signal inserted in "Test" position
3 Supply voltage 10.5 (11.5)...30 V DC for 1/2 G, 1GD, 1/2 GD, FM IS, CSA IS, IECEx ia, NEPSI Ex ia
4 Supply voltage 10.5 (11.5)...45 V DC for device for non-hazardous areas, 1/2 D, 1/3 D, 2 G Ex d,
3 G Ex nA, FM XP, FM DIP, FM NI, CSA XP, CSA Dust Ex, NEPSI Ex d
RLmaxMaximum load resistance
U Supply voltage
! Note!
When operating via a handheld terminal or via PC with an operating program, a minimum
communication resistance of 250 Ω must exist within the loop.
4.2.4 Screening/potential matching

• You achieve optimum screening against disturbances if the screening is connected on both sides
(in the cabinet and on the device). If you have to reckon with potential equalisation currents in
the plant, only earth screening on one side, preferably at the transmitter.
• When using in hazardous areas, you must observe the applicable regulations.
Separate Ex documentation with additional technical data and instructions is included with all Ex
systems as standard.
4.2.5 Connecting Field Xpert SFX100

Compact, flexible and robust industry handheld terminal for remote parametrization and measured
value inspection via the HART current output (4-20mA).
For details refer to Operating Instructions BA00060S/04/EN.
4.2.6 Connecting Commubox FXA195

The Commubox FXA195 connects intrinsically safe transmitters with the HART protocol to a
computer's USB port. This allows remote operation of the transmitter using Endress+Hauser's
FieldCare operating program. Power is supplied to the Commubox through the USB port. The
Commubox is also suitable for connection to intrinsically safe circuits. → See Technical Information
TI00404F for further information.
26 Endress+Hauser
4.2.7 Connecting Commubox FXA291/ToF Adapter FXA291 for

operation via FieldCare
Connecting Commubox FXA291

The Commubox FXA291 connects Endress+Hauser field instruments with CDI interface (=
Endress+Hauser Common Data Interface) to the USB interface of a personal computer or a
notebook. For details refer to TI00405C/07/en.
! Note!
For the following Endress+Hauser instruments you need the "ToF Adapter FXA291" as an additional
accessory:
• Cerabar S PMC71, PMP7x
• Deltabar S PMD7x, FMD7x
• Deltapilot S FMB70
Connecting ToF Adapter FXA291

The ToF Adapter FXA291 connects the Commubox FXA291 via the USB interface of a personal
computer or a notebook to the following Endress+Hauser instruments:
• Cerabar S PMC71, PMP7x
• Deltabar S PMD7x, FMD7x
• Deltapilot S FMB70
For details refer to KA0271F/00/a2.
4.3 Potential matching

Ex applications: Connect all devices to the local potential matching.
Observe the applicable regulations.
4.4 Overvoltage protection (optional)

Devices showing version "M" in feature 100 "Additional options 1" or feature 110 "Additional
options 2" in the order code are equipped with overvoltage protection (see also Technical
Information TI00382P "Ordering information".
• Overvoltage protection:
– Nominal functioning DC voltage: 600 V
– Nominal discharge current: 10 kA
• Surge current check î = 20 kA as per DIN EN 60079-14: 8/20 μs satisfied
• Arrester AC current check I = 10 A satisfied
# Warning!
Devices with integrated overvoltage protection must be earthed.
4.5 Post-connection check

Perform the following checks after completing electrical installation of the device:
• Does the supply voltage match the specifications on the nameplate?
• Is the device connected as per section 4.1?
• Are all screws firmly tightened?
• Are the housing covers screwed down tight?
As soon as voltage is applied to the device, the green LED on the electronic insert lights up for a few
seconds or the connected on-site display lights up.
Endress+Hauser 27
Operation Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
5 Operation
Feature 20 "Output; operation" in the order code provides you with information on the operating
options available to you.
Versions in the order code Operation
A 4...20 mA HART; external operation, LCD Via on-site display and 3 keys on the exterior of the device
B 4...20 mA HART; internal operation, LCD Via on-site display and 3 keys on the inside of the device
C 4...20 mA; internal operation Without on-site display, 3 keys on the inside of the device
5.1 On-site display (optional)

A 4-line liquid crystal display (LCD) is used for display and operation. The on-site display shows
measured values, dialog texts, fault messages and notice messages.
The display of the device can be turned in 90° steps.
Depending on the installation position of the device, this makes it easy to operate the device and
read the measured values.
Functions:
• 8-digit measured value display including sign and decimal point, bargraph for current display
• simple and complete menu guidance thanks to separation of the parameters into several levels and
groups
• each parameter is given a 3-digit ID number for easy navigation
• option for configuring the display according to individual requirements and desires, such as
language, alternating display, contrast setting, display of other measured values such as sensor
temperature
• comprehensive diagnostic functions (fault and warning message, peak-hold indicators, etc.)
• rapid and safe commissioning with the Quick Setup menus
Measured value display Parameter

Identification
Function name Value number
Header line
Main line
Unit
Information
line
– + E Symbol
Bargraph
Editing modes
Operating keys
Selection
options
Value that
can be edited
Current measured value

28 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Operation
The following table illustrates the symbols that can appear on the on-site display. Four symbols can
occur at one time.
Symbol Meaning
Alarm symbol
– Symbol flashing: warning, device continues measuring.
– Symbol permanently lit: error, device does not continue measuring.
Note: The alarm symbol may overlie the tendency symbol.
Lock symbol
The operation of the device is locked. Unlock device, → Section 5.8.
Communication symbol
Data transfer via communication
Note: The alarm symbol may overlie the communication symbol.
Square root symbol

Active measuring mode "Flow measurement"
The root flow signal is used for the current output.
Tendency symbol (increasing)

The measured value is increasing.
Tendency symbol (decreasing)

The measured value is decreasing.
Tendency symbol (constant)

The measured value has remained constant over the past few minutes.
Endress+Hauser 29
5.2 Operating elements
5.2.1 Position of operating elements

With regard to aluminium housings (T14/T15) and stainless steel housing (T14), the operating keys
are located either outside the device under the protection cap or inside on the electronic insert. In
hygenic stainless housings (T17), the operating keys are always located inside on the electronic
insert.
➃➄
t ➅
on
➀
➀ ➁
off
➂
1 2
PC
P01-xxxxxxxx-19-xx-xx-xx-056 P01-xxxxxxxx-19-xx-xx-xx-104
Fig. 30: Operating keys, external Fig. 31: Operating keys, internal
1 Operating keys on the exterior of the device under 1 Operating keys
the protective flap 2 Slot for optional display
3 Slot for optional HistoROM®/M-DAT
4 DIP-switch for locking/unlocking measured-value-
relevant parameters
5 DIP-switch for damping on/off
6 Green LED to indicate value being accepted
30 Endress+Hauser
5.2.2 Function of the operating elements –

on-site display not connected
Press and hold the key or the key combination for at least 3 seconds to execute the corresponding
function. Press the key combination for at least 6 seconds for a reset.
Operating key(s) Meaning
Adopt lower range value. A reference pressure is present at the device.

→ ä 33, Section 5.3.1 "Pressure measuring mode", → ä 34, Section 5.3.2 "Level
measuring mode" or → ä 36, Section 5.3.3 "Flow measuring mode".
Adopt upper range value. A reference pressure is present at the device.

→ ä 33, Section 5.3.1 "Pressure measuring mode", → ä 34, Section 5.3.2 "Level
measuring mode" or → ä 36, Section 5.3.3 "Flow measuring mode".
Position adjustment
Reset all parameters. The reset via operating keys corresponds to the software reset code
and and 7864.
Copy the configuration data from the optional HistoROM®/M-DAT module to the device.
and
Copy the configuration data from the device to the optional HistoROM®/M-DAT module.
and
– DIP-switch 1: for locking/unlocking measured-value-relevant parameters

τ on Factory setting: off (unlocked)
– DIP-switch 2: damping on/off,
Factory setting: on (damping on)
1 2 off
Endress+Hauser 31
5.2.3 Function of the operating elements –

on-site display connected
Operating key(s) Meaning
O – Navigate upwards in the picklist

– Edit the numerical values and characters within a function
S – Navigate downwards in the picklist

– Edit the numerical values and characters within a function
F – Confirm entry
– Jump to the next item
Contrast setting of on-site display: darker
O and F
Contrast setting of on-site display: brighter
S and F
ESC functions:
– Exit edit mode without saving the changed value.
– You are in a menu within a function group. The first time you press the keys
simultaneously, you go back a parameter within the function group. Each time you press
O and S the keys simultaneously after that, you go up a level in the menu.
– You are in a menu at a selection level. Each time you press the keys simultaneously, you
go up a level in the menu.
Note: The terms function group, level and selection level are explained in section 5.4.1,
page 37.
32 Endress+Hauser

on-site display not connected
! Note!
To operate the device with a HistoROM®/M-DAT module → ä 39, Section 5.5 "HistoROM®/M-
DAT (optional)".
5.3.1 Pressure measuring mode

If no on-site display is connected, the following functions are possible by means of the three keys
on the electronic insert or on the exterior of the device:
• Position adjustment (zero point correction)
• Setting lower range value and upper range value
• Device reset, → ä 31, Section 5.2.2 "Function of the operating elements – on-site display not
connected", Table.
! Note!
• The operation must be unlocked. → ä 44, Section 5.8 "Locking/unlocking operation".
• The device is configured for the Pressure measuring mode as standard. You can switch measuring
modes by means of the MEASURING MODE parameter. → ä 47, Section 6.2 "Selecting
language and measuring mode".
• The pressure applied must be within the nominal pressure limits of the sensor. See information
on the nameplate.
Carry out position adjustment.1) Setting lower range value. Setting upper range value.
Pressure is present at device. Desired pressure for lower range Desired pressure for upper range
value is present at device. value is present at device.
↓ ↓ ↓
Press "E"-key for 3 s. Press "–"-key for 3 s. Press "+"-key for 3 s.
↓ ↓ ↓
Does the LED on the electronic insert Does the LED on the electronic insert Does the LED on the electronic insert
light up briefly? light up briefly? light up briefly?
Yes No Yes No Yes No
↓ ↓ ↓ ↓ ↓ ↓
Applied pressure Applied pressure Applied pressure Applied pressure Applied pressure Applied pressure
for for position for for for for
position adjustment has lower range value lower range value upper range value upper range value
adjustment has not been has been has not been has been has not been
been accepted. accepted. accepted. accepted. accepted. accepted.
Observe the input Observe the input Observe the input
limits. limits. limits.
1) Observe "Warning" on page 47 in Chapter 6 "Commissioning".
Endress+Hauser 33
5.3.2 Level measuring mode

• Set the lower and upper pressure value and assign to the lower and upper level value
connected", Table.
! Note!
• The "-" and "+"- keys only have a function in the following cases:
– LEVEL SELECTION "Level Easy Pressure", CALIBRATION MODE "Wet"
– LEVEL SELECTION "Level Standard", LEVEL MODE "Linear",
CALIBRATION MODE "Wet"
The keys have no function in other settings.
The following parameters are set to the following values in the factory:
– LEVEL SELECTION: Level Easy Pressure
– CALIBRATION MODE: Wet
– OUTPUT UNIT or LIN. MEASURAND: %
– EMPTY CALIB.: 0.0
– FULL CALIB.: 100.0.
– SET LRV: 0.0 (corresponds to 4 mA value)
– SET URV: 100.0 (corresponds to 20 mA value)
These parameters can only be modified by means of the on-site display or remote operation such
as the FieldCare.
on the nameplate.
• → ä 52, Section 6.5 "Level measurement". For parameter description see Operating Instructions
BA00274P.
• LEVEL SELECTION, CALIBRATION MODE, LEVEL MODE, EMPTY CALIB., FULL CALIB, SET
LRV and SET URV are parameter names used for on-site display or remote operation such as
FieldCare for instance.
34 Endress+Hauser
Carry out position adjustment.1) Setting lower pressure value. Setting upper pressure value.
Pressure is present at device. Desired pressure for lower pressure Desired pressure for upper pressure
value (EMPTY PRESSURE2)) is value (FULL PRESSURE1) is present
present at device. at device.
↓ ↓ ↓
Press "E"-key for 3 s. Press "–"-key for 3 s. Press "+"-key for 3 s.
↓ ↓ ↓
Does the LED on the electronic insert Does the LED on the electronic insert Does the LED on the electronic insert
light up briefly? light up briefly? light up briefly?
Yes No Yes No Yes No
↓ ↓ ↓ ↓ ↓ ↓
Applied pressure Applied pressure The pressure The pressure The pressure The pressure
for for position present was saved present was not present was saved present was not
position adjustment has as the lower saved as the as the upper saved as the
adjustment has not been pressure value lower pressure pressure value upper pressure
been accepted. accepted. (EMPTY value. Observe (FULL value. Observe
Observe the input PRESSURE1) and the input limits. PRESSURE1) and the input limits.
limits. assigned to the assigned to the
lower level value upper level value
(EMPTY (FULL CALIB.1).
CALIB.1).

2) Parameter name used for the on-site display or remote operation such as the FieldCare.
Endress+Hauser 35
5.3.3 Flow measuring mode

• Set the maximum pressure value and assign it to the maximum flow value
connected", Table.
! Note!
• The "-"- key does not have any function.
on the nameplate.
• → ä 51, Section 6.4.3 "Quick Setup menu for the Flow measuring mode" and Operating
Instructions BA00274P, parameter descriptions MAX. PRESS. FLOW, MAX. FLOW, SET LRV –
Flow and LINEAR/SQROOT.
Carry out position adjustment.1) Setting maximum pressure value.

Pressure is present at device. Desired pressure for the maximum
pressure value (MAX. FLOW2)) is
present at device.
↓ ↓
Press "E"-key for 3 s. Press "+"-key for 3 s.
↓ ↓
Does the LED on the electronic insert Does the LED on the electronic insert
light up briefly? light up briefly?
Yes No Yes No
↓ ↓ ↓ ↓
Applied pressure Applied pressure The pressure The pressure

for for position present was saved present was not
position adjustment has as the maximum saved as the
adjustment has not been pressure value maximum
been accepted. accepted. (MAX. PRESS pressure value.
Observe the input FLOW1) and Observe the input
limits. assigned to the limits.
maximum flow
value (MAX.
FLOW.1).

2) Parameter name used for the on-site display or remote operation such as
the FieldCare.
36 Endress+Hauser

on-site display connected
If the on-site display is connected, the three operating keys are used to navigate through the
operating menu, → ä 32, Section 5.2.3 "Function of the operating elements – on-site display
connected".
5.4.1 General structure of the operating menu

The menu is split into four levels. The three upper levels are used to navigate while you use the
bottom level to enter numerical values, select options and save settings. The entire menu is
illustrated in section 10.1 "Menu for on-site display, FieldCare and HART handheld terminal".
The structure of the OPERATING MENU depends on the measuring mode selected, e.g. if the
"Pressure" measuring mode is selected, only the functions necessary for this mode are displayed.
Measured value
GROUP SELECTION
LANGUAGE MEASURING MODE QUICK SETUP OPERATING MENU
➁
➀ SETTINGS DISPLAY
POSITION ADJUSTMENT BASIC SETUP EXTENDED SETUP
POS. ZERO ADJUST
➂
➃ POS. INPUT VALUE
CALIB. OFFSET
Fig. 32: Structure of the operating menu

1 1. Selection level
2 2. Selection level
3 Function groups
4 Parameter
! Note!
The LANGUAGE and MEASURING MODE parameters are only displayed via the on-site display on
the 1st selection level. In the digital communication, the LANGUAGE parameter is displayed in the
DISPLAY group and the MEASURING MODE parameter is displayed in the QUICK SETUP menus
or in the BASIC SETUP function group. → See also Section 10.1 "Operating menu for on-site
display, FieldCare and HART handheld terminal".
Endress+Hauser 37
5.4.2 Selecting an option

Example: select "English" as the language of the menu.
On-site display Operation
German is selected as the language. A ✓in front of the

menu text indicates the active option.
Select English with "+" or "–".
1. Confirm your choice with "E". A ✓ in front of the

menu text indicates the active option. (English is now
selected as the menu language.)
2. Jump to the next item with "E".
5.4.3 Editing a value

Example: adjusting DAMPING VALUE function from 2.0 s to 30.0 s. → ä 32, Section 5.2.3
"Function of the operating elements – on-site display connected".
The on-site display shows the parameter to be changed.

The value highlighted in black can be changed. The "s" unit
is fixed and cannot be changed.
1. Press "+" or "–" to get to the editing mode.

2. The first digit is highlighted in black.
1. Use "+" to change "2" to "3".

2. Confirm "3" with "E". The cursor jumps to the next
position (highlighted in black).
The decimal point is highlighted in black, i.e. you can now

edit it.
1. Keep pressing "+" or "–" until "0" is displayed.

2. Confirm "0" with "E".
The cursor jumps to the next position. ↵ is displayed
and is highlighted in black. → See next graphic.
38 Endress+Hauser
Use "E" to save the new value and exit the editing mode.
→ See next graphic.
The new value for the damping is now 30.0 s.

– Jump to the next parameter with "E".
– You can get back to the editing mode with "+" or
"–".
5.4.4 Taking pressure applied at device as value

Example: configuring upper range value – assign 20 mA to the pressure value 400 mbar.
The bottom line on the on-site display displays the pressure

present, here 400 mbar.
Use "+" or "–" to switch to the "Confirm" option. The active

selection is highlighted in black.
Use "E" to assign the value (400 mbar) to the GET URV
parameter. The device confirms the calibration and jumps
back to the parameter, here GET URV (see next graphic).
Switch to the next parameter with "E".
5.5 HistoROM®/M-DAT (optional)

HistoROM®/M-DAT is a memory module, which is attached to the electronic insert and fulfils the
following functions:
• Back-up copy of configuration data
• Copying configuration data of a transmitter into another transmitter
• Cyclic recording of pressure and sensor-temperature measured values
• Recording diverse events, such as alarms, configuration changes, counters for measuring range
undershooting and exceeding for pressure and temperature, exceeding and undershooting the
user limits for pressure and temperature, etc.
# Warning!
Detach HistoROM®/M-DAT from the electronic insert or attach it to the insert in a deenergised
state only.
Endress+Hauser 39
! Note!
• The HistoROM®/M-DAT module may be retrofitted at any time (Order No.: 52027785).
• The HistoROM data and the data in the device are analysed once a HistoROM®/M-DAT is
attached to the electronic insert and power is reestablished to the device. During the analysis, the
messages "W702, HistoROM data not consistent" and "W706, Configuration in HistoROM and
device not identical" can occur. For measures, → ä 63, Section 8.1 "Messages."
5.5.1 Copying configuration data
➁
on
t
off
➀
1 2
PC
R
HART
250002271-–
FIELD COMMUNICATION PROTOCOL
HW-Version: 1
SW-Version: 2
Abb. 33: Electronic insert with optional HistoROM®/M-DAT memory module

1 optional HistoROM®/M-DAT
2 To copy configuration data from the HistoROM®/M-DAT module to a device or from a device to a HistoROM®/
M-DAT,, the operation must be unlocked DIP-switch 1, Position "off" ,parameter INSERT PIN NO. = 100). Observe
page 44, section 5.9 "Locking/unlocking operation".
On-site operation – on-site display not connected

Copying configuration data from a device to a HistoROM®/M-DAT module:
! Note!
The operation must be unlocked.
1. Disconnect device from supply voltage.
2. Attach the HistoROM®/M-DAT module to the electronic insert.
3. Reestablish supply voltage to the device.
4. Press "E" and "-"-keys (for at least 3 seconds) until the LED on the electronic insert lights up.
5. Wait approx. 20 seconds. Configuration data are loaded from the device to the HistoROM®/
M-DAT. The device is not restarted.
6. Disconnect device from the supply voltage again.
7. Detach memory module.
40 Endress+Hauser
Copying configuration data from a HistoROM®/M-DAT to a device:
! Note!
2. Attach the HistoROM®/M-DAT module to the electronic insert. Configuration data from
another device are stored in the HistoROM®/M-DAT.
4. Press "E" und "+"-keys (for at least 3 seconds) until the LED on the electronic insert lights up.
5. Wait approx. 20 seconds. All parameters except DEVICE SERIAL No, DEVICE DESIGN.,
CUST. TAG NUMBER, LONG TAG NUMBER, DESCRIPTION, BUS ADDRESS and the
parameters in the POSITION ADJUSTMENT and PROCESS CONNECTION group are loaded
into the device by HistoROM®/M-DAT. The device is restarted.
6. Before removing the HistoROM®/M-DAT again from the electronic insert, disconnect the
device from supply voltage.
On-site operation via on-site display (optional) or remote operation

Copying configuration data from a device to a HistoROM®/M-DAT:
! Note!
2. Attach the HistoROM®/M-DAT module to the electronic insert.
4. The DOWNLOAD SELECT. parameter setting has no influence on an upload from the device
into HistoROM.
(Menu path: (GROUP SELECTION →) OPERATING MENU → OPERATION)
5. Using the HistoROM CONTROL parameter select the option "Device → HistoROM" as the
data transfer direction.
(Menu path: GROUPSELECTION → OPERATING MENU → OPERATION)
M-DAT. The device is not restarted.
7. Disconnect device from the supply voltage again.
8. Detach memory module.
Endress+Hauser 41
Copying configuration data from a HistoROM®/M-DAT to a device:
! Note!
2. Attach the HistoROM®/M-DAT module to the electronic insert. Configuration data from
another device are stored in the HistoROM®/M-DAT.
4. Use the DOWNLOAD SELECT parameter to select which parameters are to be overwritten
(Menu path: (GROUPS SELECTION →) OPERATING MENU → OPERATION).
The following parameters are overwritten according to the selection:

– Configuration copy (factory setting):
all parameters except DEVICE SERIAL No., DEVICE DESIGN, CUST. TAG NUMBER,
LONG TAG NUMBER, DESCRIPTION, BUS ADDRESS and the parameters in the
POSITION ADJUSTMENT, PROCESS CONNECTION, CURR. TRIM (SERVICE /SYSTEM
2), SENSOR TRIM and SENSOR DATA group.
– Device replacement:
all parameters except DEVICE SERIAL No., DEVICE DESIGN and the parameters in the
POSITION ADJUSTMENT, PROCESS CONNECTION, CURR. TRIM (SERVICE/SYSTEM
2), SENSOR TRIM and SENSOR DATA group.
– Electronics replace:
all parameters except the parameters in the CURR. TRIM (SERVICE/SYSTEM 2) and
SENSOR DATA group.
Factory setting: Configuration copy
5. Using the HistoROM CONTROL parameter select the option "HistoROM → Device" as the
data transfer direction.
(Menu path: GROUP SELECTION → OPERATING MENU → OPERATION)
M-DAT. The device is restarted.
7. Before removing the HistoROM®/M-DAT again from the electronic insert, disconnect the
device from supply voltage.
42 Endress+Hauser
5.6 Operation via SFX100

Compact, flexible and robust industry handheld terminal for remote parametrization and measured
value inspection via the HART current output (4-20mA).
For details refer to Operating Instructions BA00060S/04/EN.
5.7 FieldCare
FieldCare is an FDT-based system asset management tool from Endress+Hauser. With FieldCare,
you can configure all Endress+Hauser devices as well as devices from other manufacturers that
support the FDT standard. Hardware and software requirements you can find on the internet:
www.endress.com → select your country → Search: FieldCare → FieldCare → Technical Data.
FieldCare supports the following functions:
• Configuration of transmitters in online operation
• Loading and saving device data (upload/download)
• HistoROM®/M-DAT analysis
• Documentation of the measuring point
Connection options:
• HART via Commubox FXA195 and the USB interface of a computer
• HART via Fieldgate FXA520
! Note!
• → ä 26, Section 4.2.6 "Connecting Commubox FXA195".
• Further information on the FieldCare can be found on the Internet (http://www.endress.com,
Download → Search for: FieldCare).
Endress+Hauser 43
5.8 Locking/unlocking operation

Once you have entered all the parameters, you can lock your entries against unauthorised and
undesired access.
You have the following possibilities for locking/unlocking the operation:
• Via a DIP-switch on the electronic insert, locally on the display.
• Via the on-site display (optional)
• Via digital communication.
The -symbol on the on-site display indicates that operation is locked. Parameters which refer to
how the display appears, e.g. LANGUAGE and DISPLAY CONTRAST can still be altered.
! Note!
• If operation is locked by means of the DIP-switch, you can only unlock operation again by means
of the DIP-switch. If operation is locked by means of the on-site display or remote operation e.g.
FieldCare, you can only unlock operation again by means of the on-site display or remote
operation.
The table provides an overview of the locking functions:
Locking via View/read Modify/write via1) Unlocking via

parameter
On-site Remote DIP-switch On-site Remote
display operation display operation
DIP-switch Yes No No Yes No No
On-site display Yes No No No Yes Yes
Remote operation Yes No No No Yes Yes
1) Parameters which refer to how the display appears, e.g. LANGUAGE and DISPLAY CONTRAST can still be altered.
5.8.1 Locking/unlocking operation locally via DIP-switch

Damping [t]
Damping [t]
➀
➁ ➂
on on
1 2
PC
1 2 1 2
off off
R
HART
250002271-–
FIELD COMMUNICATION PROTOCOL
HW-Version: 1
SW-Version: 2
– + E
Fig. 34: DIP-switch position "Hardware locking" on the electronic insert

1 If necessary, remove on-site display (optional)
2 DIP-switch is at "on": operation is locked.
3 DIP-switch is at "off": operation is unlocked (operation possible)
44 Endress+Hauser
5.8.2 Locking/unlocking operation via on-site display or remote

operation
Description
Locking operation 1. Select INSERT PIN NO. parameter,

Menu path: OPERATING MENU → OPERATION → INSERT PIN NO.
2. To lock operation, enter a number for this parameter between 0...9999 that is ≠100.
Unlocking operation 1. Select INSERT PIN NO. parameter.

2. To unlock operation, enter "100" for the parameter.
5.9 Factory setting (reset)

By entering a certain code, you can completely, or partially, reset the entries for the parameters to
the factory settings. (→ For factory settings refer to the Operating Instructions BA00274P "Cerabar
S/Deltabar S/Deltapilot S, Description of device functions". → ä 2, "Overview documentation".)
Enter the code by means of the ENTER RESET CODE parameter (Menu path: (GROUP SELECTION
→) OPERATING MENU → OPERATING).
There are various reset codes for the device. The following table illustrates which parameters are
reset by the particular reset codes. Operation must be unlocked to reset parameters (→ ä 45,
Section 5.9).
! Note!
Any customer-specific configuration carried out by the factory is not affected by a reset (customer-
specific configuration remains). If, after a reset, you wish the parameters to be reset to the factory
settings, please contact Endress+Hauser Service.
Reset code Description and effect

1846 Display reset
– This reset resets all parameters which have to do with how the display appears (DISPLAY
group).
– Any simulation which may be running is ended.
– The device is restarted.
62 PowerUp reset (warm start)

– This reset resets all the parameters in the RAM. Data are read back anew from the
EEPROM (processor is initialised again).
2710 Measuring mode level reset

– Depending on the settings for the LEVEL MODE, LIN MEASURAND,
LINdMEASURAND or COMB. MEASURAND parameters, the parameters needed for
this measuring task will be reset.
Example LEVEL MODE = linear and LIN. MEASURAND = Height
• HEIGHT UNIT = m
• CALIBRATION MODE = wet
• EMPTY CALIB. = 0
• FULL CALIB. = Sensor end value converted to mH2O, e.g. 5.99 mH2O for a 500 mbar
(7,5 psi) sensor
333 User reset

– Affects the following parameters:
– Function group POSITION ADJUSTMENT
– Function group BASIC SETUP, except for the customer-specific units
– Function group EXTENDED SETUP
– Function group TOTALIZER SETUP
– Group OUTPUT
– Function group HART DATA: BUS ADDRESS and PREAMBLE NUMBER
Endress+Hauser 45
Reset code Description and effect
7864 Total reset

– Affects the following parameters:
– Function group POSITION ADJUSTMENT
– Function group BASIC SETUP
– Function group EXTENDED SETUP
– Function group LINEARISATION (an existing linearisation table is erased)
– Function group TOTALIZER SETUP
– Group OUTPUT
– Function group PEAK HOLD INDICATOR
– Function group HART DATA
– All configurable messages ("Error" type) are set to factory setting.
→ ä 63, Section 8.1 "Messages" and page → ä 72, Section 8.2 "Response of outputs
to errors".
– Function group USER LIMITS
– Function group SYSTEM 2
8888 HistoROM reset

The measured value memory and event memory are cleared. During the reset, the
HistoROM must be attached to the electronic insert.
46 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Commissioning
6 Commissioning
# Warning!
• If a pressure smaller than the minimum permitted pressure is present at the device, the messages
"E120 Sensor low pressure" and "E727 Sensor pressure error - overrange" are output in
succession.
• If a pressure greater than the maximum permitted pressure is present at the device, the messages
"E115 Sensor overpressure" and "E727 Sensor pressure error - overrange" are output in
succession.
• Messages E727, E115 and E120 are "Error"-type messages and can be configured as a "Warning"
or an "Alarm". These messages are configured as "Warning" messages at the factory. This setting
prevents the current output from assuming the set alarm current value for applications (e.g.
cascade measurement) where the user is consciously aware of the fact that the sensor range can
be exceeded
• We recommend setting messages E727, E115 and E120 to "Alarm" in the following instances:
– The sensor range does not have to be exceeded for the measuring application.
– Position adjustment has to be carried out that has to correct a large measured error as a result
of the orientation of the device (e.g. devices with a diaphragm seal).
! Note!
The device is configured for the Pressure measuring mode as standard. The measuring range and
the unit in which the measured value is transmitted correspond to the specifications on the
nameplate.
6.1 Function check

Carry out a post-installation and a post-connection check as per the checklist before commissioning
the device.
• "Post-installation check" checklist → see Section 3.4
• "Post-connection check" checklist → see Section 4.5
6.2 Selecting language and measuring mode
6.2.1 On-site operation

The LANGUAGE and MEASURING MODE parameters are located on the top menu level. → See
also → ä 37, Section 5.4.1 "General structure of the operating menu".
The following measuring modes are available:
• Pressure
• Level
• Flow
6.2.2 Digital communication

The MEASURING MODE parameter is displayed in the digital communication in the QUICK
SETUP menus and in the BASIC SETUP function group (OPERATING MENU → SETTINGS →
BASIC SETUP).
The following measuring modes are available:
• Pressure
• Level
• Flow
The LANGUAGE parameter is arranged in the DISPLAY group (OPERATING MENU → DISPLAY).
• Use the LANGUAGE parameter to select the menu language for the on-site display.
• Select the menu language for FieldCare by means of the "Language Button" in the configuration
window. Select the menu language for the FieldCare frame via the "Extra" menu → "Options" →
"Display" → "Language".
Endress+Hauser 47
Commissioning Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
6.3 Position adjustment

Due to the orientation of the device, there may be a shift in the measured value, i.e. when the
container is empty or partly filled, the measured value parameter does not display zero. There are
three options to choose from when performing position adjustment.
(Menu path: (GROUP SELECTION →) OPERATING MENU → SETTINGS → POSITION
ADJUSTMENT)
Parameter name Description
POS. ZERO ADJUST (685) Position adjustment – the pressure difference between zero (set point) and the measured
Entry pressure need not be known.
Example:
– MEASURED VALUE = 2.2 mbar (0,032 psi)
– Correct the MEASURED VALUE via the POS. ZERO ADJUST parameter with the
"Confirm" option. This means that you are assigning the value 0.0 to the pressure
present.
– MEASURED VALUE (after pos. zero adjust) = 0.0 mbar
– The current value is also corrected.
The CALIB. OFFSET parameter displays the resulting pressure difference (offset) by which
the MEASURED VALUE was corrected.
Factory setting:
0.0
POS. INPUT VALUE (563) Position adjustment – the pressure difference between zero (set point) and the measured
Entry pressure need not be known. To correct the pressure difference, you need a reference
measurement value (e. g. from a reference device).
Example:
– For the POS. INPUT VALUE parameter, specify the desired set point for the
MEASURED VALUE, e.g. 2.0 mbar (0,029 psi).
(MEASURED VALUEnew = POS. INPUT VALUE)
– MEASURED VALUE (after entry for POS. INPUT VALUE) = 2.0 mbar (0,029 psi)
– The CALIB. OFFSET parameter displays the resulting pressure difference (offset) by
which the MEASURED VALUE was corrected.
CALIB. OFFSET = MEASURED VALUEold – POS. INPUT VALUE,
here: CALIB. OFFSET = 0.5 mbar (0,0073 psi) – 2.0 mbar (0,029 psi) = – 1.5 mbar
(0,022 psi))
Factory setting:
0.0
CALIB. OFFSET (319) Position adjustment – the pressure difference between zero (set point) and the measured
Entry pressure is known.
Example:
– Via the CALIB. OFFSET parameter, enter the value by which the MEASURED VALUE
should be corrected. To correct the MEASURED VALUE to 0.0 mbar, you must enter
the value 2.2 here.
(MEASURED VALUE new = MEASURED VALUEold – CALIB. OFFSET)
– MEASURED VALUE (after entry for calib. offset) = 0.0 mbar
Factory setting:
0.0
48 Endress+Hauser
6.4 Flow measurement
6.4.1 Preparatory steps
! Note!
• The Deltabar S PMD70 or PMD75 is usually used for flow measurement.
• Before calibrating the Deltabar S, the impulse piping must be cleaned and filled with fluid. → See
the following table.
Valves Meaning Preferred installation
1 Close 3.
2 Fill measuring system with fluid. 6 7

Open A, B, 2, 4. Fluid flows in. I
3 Clean impulse piping if necessary1): + –

– by blowing out with compressed air in the case of gases
II 3
– by rinsing out in the case of liquids.
Close 2 and 4. Block off device. 2 4
Open 1 and 5.1 Blow out/rinse out impulse + –

piping. A B
Close 1 and 5.1 Close valves after cleaning.
4 Vent device.
Open 2 and 4. Introduce fluid.

Close 4. Close negative side.
Open 3. Balance positive and negative

side.
A B
Open 6 and 7 briefly, then Fill device completely with
6 7
close them again. fluid and remove air. + I
5 Carry out pos. zero adjustment if the following conditions are
met. If the conditions are not met, then do not carry out the III III
+ –
pos. zero adjustment until after step 6. → ä 51, II
3
Section 6.4.3 and → ä 48, Section 6.3.
Conditions: 2 4
1 5
– The process cannot be blocked off.
– The tapping points (A and B) are at the same geodetic
height. P01-xMD7xxxx-11-xx-xx-xx-002
6 Set measuring point in operation. Fig. 35: Above: preferred installation for gases
Below: preferred installation for liquids
Close 3. Shut off positive side from
negative side. I Deltabar S, PMD70 or PMD75
II Three-valve manifold
Open 4. Connect negative side. Separator
1, 5 Drain valves
Now
2, 4 Inlet valves
– 11, 3, 51, 6 and 7 are closed.
3 Equalising valve
– 2 and 4 are open.
6, 7 Vent valves on Deltabar S
– A and B open (if present).
A, B Shut-off valves
7 Carry out pos. zero adjustment if the flow can be blocked off.
In this case, step 5 is not applicable.
→ ä 51, Section 6.4.3 and → ä 48, Section 6.3
8 Carry out calibration. → ä 50, Section 6.4.2.
1) for arrangement with 5 valves
Endress+Hauser 49
6.4.2 Information on flow measurement

In the "Flow" measuring mode, the device determines a volume or mass flow value from the
differential pressure measured. The differential pressure is generated by means of primary elements
such as pitot tubes or orifice plates and depends on the volume or mass flow. Four flow measuring
modes are available: volume flow, norm volume flow (European norm conditions), standard volume
flow (American standard conditions) and mass flow.
In addition, the Deltabar S software is equipped with two totalizers as standard. The totalizers add
up the volume or the mass flow. The counting function and the unit can be set separately for both
totalizers. The first totalizer (totalizer 1) can be reset to zero at any time while the second
(totalizer 2) totalises the flow from commissioning onwards and cannot be reset.
! Note!
• There is a Quick Setup menu for each of the measuring modes Pressure, Level and Flow which
guides you through the most important basic functions. With the setting in the MEASURING
MODE parameter, you specify which Quick Setup menu should be displayed. → See also
→ ä 47, Section 6.2 "Selecting language and measuring mode".
• For a detailed description of the parameters see the Operating Instructions BA00274P "Cerabar
S/Deltabar S/Deltapilot S, Description of device functions"
– Table 6, POSITION ADJUSTMENT
– Table 12, BASIC SETUP
– Table 17, EXTENDED SETUP
– Table 20, TOTALIZER SETUP.
→ See also → ä 2, section "Overview documentation".
• For flow measurement, select the "Flow" option by means of the MEASURING MODE parameter.
The operating menu is structured appropriately. → Section 10.1.
50 Endress+Hauser
6.4.3 Quick Setup menu for the Flow measuring mode
Measured value
1)
GROUP SELECTION
1) 1)
2)
MEASURING MODE
Pressure Level Flow
POS. ZERO ADJUST
MAX FLOW
MAX. PRESS. FLOW

1) Display via on-site display only
2) Display via ToF Tool, FieldCare and
HART handheld terminal only DAMPING VALUE
Fig. 36: Quick Setup menu for the Flow measuring mode
On-site operation Digital communication

Measured value display Measured value display
On-site display: Switch from the measured value display Select QUICK SETUP menu.
to GROUP SELECTION with F.
GROUP SELECTION MEASURING MODE

Select MEASURING MODE. Select "Flow" option.
MEASURING MODE
Select "Flow" option.
GROUP SELECTION
Select QUICK SETUP menu.
POS. ZERO ADJUST POS. ZERO ADJUST
Due to orientation of the device, there may be a shift in Due to orientation of the device, there may be a shift in
the measured value. You correct the MEASURED the measured value. You correct the MEASURED
VALUE via the POS. ZERO ADJUST parameter with the VALUE via the POS. ZERO ADJUST parameter with the
"Confirm" option, i. e. you assign the value 0.0 to the "Confirm" option, i. e. you assign the value 0.0 to the
pressure present. pressure present.
MAX. FLOW MAX. FLOW

Enter maximum flow of primary device. (→ See also Enter maximum flow of primary device. (→ See also
layout sheet of primary device). layout sheet of primary device).
MAX. PRESS FLOW MAX. PRESS FLOW

Enter maximum pressure of primary device. Enter maximum pressure of primary device.
(→ See also layout sheet of primary device). (→ See also layout sheet of primary device).
DAMPING TIME DAMPING TIME
Enter damping time (time constant τ). The damping Enter damping time (time constant τ). The damping
affects the speed at which all subsequent elements, such affects the speed at which all subsequent elements, such
as the on-site display, measured value and current as the on-site display, measured value and current
output react to a change in the pressure. output react to a change in the pressure.
! Note!
For on-site operation, → ä 32, Section 5.2.3 "Function of the operating elements – on-site display
connected" and → ä 37, Section 5.4 "On-site operation – on-site display connected".
Endress+Hauser 51
6.5 Level measurement
Open container
! Note!
• The Deltabar S PMD70, PMD75, FMD76 and FMD77 are suitable for level measurement in an
open container.
• FMD76 and FMD77: the device is ready for calibration immediately after opening a shut-off valve
(may or may not be present).
• PMD70 and PMD75: before calibrating the device, the impulse piping must be cleaned and filled
with fluid. → See the following table.
Valves Meaning Installation
1 Fill container to a level above the lower tap.
2 Fill measuring system with fluid.
Open A. Open shut-off valve.
3 Vent device. +
Open 6 briefly, then close it Fill device completely with 6
again. fluid and remove air. II I
4 Set measuring point in operation.

B + – patm
Now
– B and 6 are closed. A
– A is open.
Carry out calibration. → ä 55, Section 6.5.2.

5
Fig. 37: Open container
I Deltabar S, PMD70 or PMD75
II Separator
6 Vent valves on Deltabar S
A Shut-off valve
B Drain valve
52 Endress+Hauser
Closed container
! Note!
• All Deltabar S versions are suitable for level measurement in closed containers.
• FMD76 and FMD77: the device is ready for calibration immediately after opening the shut-off
valves (may or may not be present).
• FMD78: the device is ready for calibration immediately.

B
negative side.
Open A and B. Open shut-off valves. + A

3 Vent positive side (empty negative side if necessary).
Open 2 and 4. Introduce fluid on positive 6 7

side. I
Open 6 and 7 briefly, then Fill positive side completely
close them again. with fluid and remove air. + –
II
4 Set measuring point in operation. III 3 III
Now 2 4
– 3, 6 and 7 are closed.
1 5
– 2, 4, A and B are open.
5 Carry out calibration. → ä 55, Section 6.5.2. P01-xMD7xxxx-11-xx-xx-xx-004
Fig. 38: Closed container

I Deltabar S, PMD70 and PMD75
III Separator
1, 2 Drain valves
2, 4 Inlet valves
3 Equalising valve
6, 7 Vent valve on Deltabar S
A, B Shut-off valve
Endress+Hauser 53
Closed container with superimposed steam
! Note!
• All Deltabar S versions are suitable for level measurement in containers with superimposed steam.
• FMD76 and FMD77: the device is ready for calibration immediately after opening the shut-off
valves (may or may not be present).
Open A and B. Open shut-off valves.
B
Fill the negative impulse piping to the level of the condensate
trap. + A
3 Vent device.
Open 2 and 4. Introduce fluid. 6 7

Close 4. Close negative side. I
Open 3. Balance positive and negative + –

side. II
III 3 III
close them again. fluid and remove air. 2 4
4 Set measuring point in operation. 1 5

negative side.
Fig. 39: Closed container with superimposed
Open 4. Connect negative side. steam
Now I Deltabar S, PMD70 and PMD75
– 3, 6 and 7 are closed. II Three-valve manifold
– 2, 4, A and B are open. III Separator
1, 5 Drain valves
5 Carry out calibration. → ä 55, Section 6.5.2.
2, 4 Inlet valves
3 Equalising valve
A, B Shut-off valves
54 Endress+Hauser
6.5.2 Information on level measurement
! Note!
• The Flow, Level and Pressure operating modes each have a quick setup menu which guides you
through the most important basic functions. → ä 57 for the "Level" quick setup menu.
• Furthermore, the three level modes "Level Easy Pressure", "Level Easy Height" and "Level
Standard" are available to you for level measurement. You can select from the "Linear", "Pressure
linearized" and "Height linearized" level types for the "Level Standard" level mode. The table in
the "Overview of level measurement" section below provides an overview of the various
measuring tasks.
– In the "Level Easy Pressure" and "Level Easy Height" level modes, the values entered are not
tested as extensively as in the "Level Standard" level mode. The values entered for EMPTY
CALIB./FULL CALIB., EMPTY PRESSURE/FULL PRESSURE, EMPTY HEIGHT/FULL
HEIGHT and SET LRV/SET URV must have a minimum interval of 1% for the "Level Easy
Pressure" and "Level Easy Height" level modes. The value will be rejected with a warning
message if the values are too close together. Further limit values are not checked; i.e. the values
entered must be appropriate for the sensor and the measuring task so that the measuring device
can measure correctly.
– The "Level Easy Pressure" and "Level Easy Height" level modes encompass fewer parameters
than the "Level Standard" mode and are used for quick and easy configuration of a level
application.
– Customer-specific units of fill level, volume and mass or a linearization table may only be
entered in the "Level Standard" level mode.
– Where the device is intended for use as a subsystem in a safety function (SIL), a "Device
configuration with enhanced parameter security" (SAFETY CONFIRM.) is only possible for the
"Level" operating mode in the "Level Easy Pressure" level mode. All parameters previously
entered are checked after a password is entered. Once the "Level Easy Height" or "Level
Standard" has been selected, the configuration will first have to be reset to the ex-works setting
using the RESET parameter (menu path: (GROUP SELECTION →) OPERATING MENU →
OPERATION) using the reset code "7864". → For further information see the Deltabar S
(SD00189P) Functional Safety Manual.
• See the Operating Instructions BA00274P "Cerabar S/Deltabar S/Deltapilot S, Description of
device functions". See also → ä 2, "Overview documentation" section.
Endress+Hauser 55
6.5.3 Overview of level measurement
Measuring task LEVEL Measured Description Comment Measured value

SELECTION/ variable options display
LEVEL MODE
The measured variable is LEVEL SELECTION: Via OUTPUT UNIT – Calibration with reference – Incorrect entries are The measured value
in direct proportion to the Level Easy Pressure parameter: %, level, pressure – wet calibration, possible display and the LEVEL
measured pressure. volume or mass see Operating Instructions – SIL mode possible BEFORE LIN parameter
Calibration is performed units. BA00274P. – Customised units are show the measured value.
by entering two pressure- – Calibration without not possible
level value pairs. reference pressure – dry
calibration, see Operating
Instructions BA00274P.
The measured variable is LEVEL SELECTION: Via OUTPUT UNIT – Calibration with reference – Incorrect entries are The measured value
in direct proportion to the Level Easy Height parameter: %, level, pressure – wet calibration, possible display and the LEVEL
measured pressure. volume or mass see Operating Instructions – SIL mode not possible BEFORE LIN parameter
Calibration is performed units. BA00274P. – Customised units are show the measured value.
by entering the density – Calibration without not possible
and two height-level value reference pressure – dry
pairs. calibration, see Operating
The measured variable is LEVEL SELECTION: Via LIN. – Calibration with reference – Incorrect entries are The measured value
in direct proportion to the Level standard/ MEASURAND pressure – wet calibration, rejected by the device display and the LEVEL
measured pressure. LEVEL MODE: parameter: see Operating Instructions – SIL mode not possible BEFORE LIN parameter
Linear – % (level) BA00274P. – Customised level, show the measured value.
– Level – Calibration without volume and mass units
– Volume reference pressure – dry are possible
– Mass calibration, see Operating
The measured variable is LEVEL SELECTION: Via LINd. – Calibration with reference – Incorrect entries are The measured value
not in direct proportion to Level standard/ MEASURAND pressure: semiautomatic rejected by the device display and the
the measured pressure as, LEVEL MODE: parameter: entry of linearisation table, – SIL mode not possible TANK CONTENT
for example, with Pressure linearized – Pressure + % see Operating Instructions – Customised level, parameter show the
containers with a conical – Pressure + volume BA00274P. volume and mass units measured value.
outlet. A linearisation table – Pressure + mass – Calibration without are possible
must be entered for the reference pressure: manual
calibration. entry of linearisation table,
see Operating Instructions
BA00274P.
– Two measured variables LEVEL SELECTION: Via COMB. – Calibration with reference – Incorrect entries are The measured value
are required or Level standard/ MEASURAND pressure: wet calibration rejected by the device display and the
– The container shape is LEVEL MODE: parameter: and semiautomatic entry of – SIL mode not possible TANK CONTENT
given by value pairs, Height linearized – Height + volume linearisation table, see – Customised level, parameter show the 2nd
such as height and – Height + mass Operating Instructions volume and mass units measured value (volume,
volume. – Height + % BA00274P. are possible mass or %).
The 1st measured variable – %-Height + – Calibration without
%-height or height must be volume reference pressure: dry The LEVEL BEFORE LIN
in direct proportion to the – %-Height + mass calibration and manual parameter displays the 1st
measured pressure. The – %-Height + % entry of linearisation table, measured value (%-height
2nd measured variable see Operating Instructions or height).
volume, mass or % need BA00274P.
not to be in direct
proportion to the
measured pressure. A
linearisation table must be
entered for the 2nd
measured variable. The
2nd measured variable is
assigned to the 1st
measured variable by
means of this table.
56 Endress+Hauser
6.5.4 Quick Setup menu for Level measuring mode
! Note!
• Some parameters are only displayed if other parameters are appropriately configured. For
example, the EMPTY CALIB. parameter is only displayed in the following cases:
– LEVEL SELECTION "Level Easy Pressure" and CALIBRATION MODE "Wet"
– LEVEL SELECTION "Level Standard", LEVEL MODE "Linear" and
CALIBRATION MODE "WET"
You can find the LEVEL MODE parameter in the BASIC SETTINGS function group (menu path:
(GROUP SELECTION →) OPERATING MENU → SETTINGS → BASIC SETTINGS).
• The following parameters are set to the following values in the factory:
– LEVEL SELETION: Level Easy Pressure
– CALIBRATION MODE: Wet
– OUTPUT UNIT or LIN. MEASURAND: %
– EMPTY CALIB.: 0.0
– FULL CALIB.: 100.0
– SET LRV (BASIC SETTINGS group): 0.0 (corresponds to 4 mA value)
– SET URV (BASIC SETTINGS group): 100.0 (corresponds to 20 mA value).
• The quick setup is suitable for simple and quick commissioning. If you wish to make more
complex settings, e.g. change the unit from "%" to "m", you will have to calibrate using the BASIC
SETTINGS group. → See Operating Instructions BA00274P or → ä 2, "Overview
documentation" section.
Measured value
1)
GROUP SELECTION
1) 1)
2)
LEVEL SELECTION
MEASURING MODE
Pressure Level Flow
LEVEL SELECTION
POS. ZERO ADJUST

3)
2) Display via FieldCare and
EMPTY CALIB.
HART handheld terminal only
3)
3) – LEVEL SELECTION "Level Easy Pressure" and
FULL CALIB.
CALIBRATION MODE "Wet"
– LEVEL SELECTION = "Level Standard",
LEVEL MODE = "Linear" and
DAMPING VALUE
CALIBRATION MODE = "Wet"
Fig. 40: Quick Setup menu for the Level measuring mode


Select MEASURING MODE. Select "Level" option.
MEASURING MODE
Select "Level" option.
LEVEL SELECTION LEVEL SELECTION
Select level mode. For an overview → ä 56. Select level mode. For an overview → ä 56.
GROUP SELECTION
Endress+Hauser 57

EMPTY CALIB. 1) EMPTY CALIB. 1

Enter level for the lower calibration point. Enter level for the lower calibration point.
For this parameter, enter a level value which is assigned For this parameter, enter a level value which is assigned
to the pressure present at the device. to the pressure present at the device.
FULL CALIB. 1 FULL CALIB. 1

Enter level for the upper calibration point. Enter level for the upper calibration point.
For this parameter, enter a level value which is assigned For this parameter, enter a level value which is assigned
to the pressure present at the device. to the pressure present at the device.

1) – LEVEL SELECTION "Level Easy Pressure" and CALIBRATION MODE "Wet"

– LEVEL SELECTION "Level Standard", LEVEL MODE "Linear" and CALIBRATION MODE "Wet"
! Note!
58 Endress+Hauser
6.6 Differential pressure measurement
! Note!
• The Deltabar S PMD70, PMD75 and FMD78 are usually used for differential pressure
measurement.
Valves Meaning Preferred installation
1 Close 3.
2 Fill measuring system with fluid. 6 7

Open A, B, 2, 4. Fluid flows in. I
3 Clean impulse piping if necessary:1) + –

– by blowing out with compressed air in the case of gases
II 3
– by rinsing out in the case of liquids.
Close 2 and 4. Block off device. 2 4
Open 1 and 5.1 Blow out/rinse out impulse + –

piping. A B
Close 1 and 5.1 Close valves after cleaning.
4 Vent device.
Open 2 and 4. Introduce fluid.

Close 4. Close negative side.
Open 3. Balance positive and negative

side.
A B
6 7
close them again. fluid and remove air. + I
5 Set measuring point in operation.
III + – III
II
negative side. 3
Open 4. Connect negative side. 2 4

1 5
Now
– 11, 3, 51, 6 and 7 are closed.
– 2 and 4 are open. P01-xMD7xxxx-11-xx-xx-xx-002
– A and B open (if present). Fig. 41: Above: preferred installation for gases
Below: preferred installation for liquids
6 Carry out calibration if necessary. → ä 60, Section 6.6.2.
I Deltabar S, PMD70 or PMD75
III Separator
1, 5 Drain valves
2, 4 Inlet valves
3 Equalising valve
A, B Shut-off valve
1) for arrangement with 5 valves
Endress+Hauser 59
6.6.2 Information on differential pressure measurement
! Note!
• There is a Quick Setup menu for each of the measuring modes Pressure, Level and Flow which
guides you through the most important basic functions. With the setting in the MEASURING
MODE parameter, you specify which Quick Setup menu should be displayed. → ä 47,
Section 6.2 "Selecting language and measuring mode".
• For a detailed description of the parameters see the Operating Instructions BA00274P "Cerabar
S/Deltabar S/Deltapilot S, Description of device functions"
– Table 6, POSITION ADJUSTMENT
– Table 7, BASIC SETUP
– Table 15, EXTENDED SETUP
• For differential pressure measurement, select the "Pressure" option by means of the MEASURING
MODE parameter. The operating menu is structured appropriately. → See also Section 10.1.
6.6.3 Quick Setup menu for Pressure measuring mode
Measured value
1)
GROUP SELECTION
1) 1)
2)
MEASURING MODE
Pressure Level Flow

POS. ZERO ADJUST
SET LRV
1) Display via on-site display only SET URV

HART handheld terminal only DAMPING VALUE
Fig. 42: Quick Setup menu for Pressure measuring mode


Select MEASURING MODE. Select "Pressure" option.
MEASURING MODE
Select "Pressure" option.
GROUP SELECTION

SET LRV SET LRV

Set the measuring range (enter 4 mA value). Set the measuring range (enter 4 mA value).
Specify a pressure value for the lower current value Specify a pressure value for the lower current value
(4 mA value). A reference pressure does not have to be (4 mA value). A reference pressure does not have to be
present at the device. present at the device.
60 Endress+Hauser
SET URV SET URV

Set the measuring range (enter 20 mA value). Set the measuring range (enter 20 mA value).
The pressure for the upper current value (20 mA value) The pressure for the upper current value (20 mA value)
is present at device. With the "Confirm" option, you is present at device. With the "Confirm" option, you
assign the upper current value to the pressure value assign the upper current value to the pressure value
present. present.

! Note!
Endress+Hauser 61
Maintenance Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
7 Maintenance
Deltabar S requires no maintenance.
7.1 Exterior cleaning

Please note the following points when cleaning the device:
• The cleaning agents used should not attack the surface and the seals.
• Mechanical damage to the process isolating diaphragm, e.g. due to pointed objects, must be
avoided.
• Observe degree of protection. See therefor nameplate if necessary (→ ä 6).
62 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Trouble-shooting
8 Trouble-shooting
8.1 Messages
The following table lists all the possible messages that can occur.
The device differentiates between the error types "Alarm", "Warning" and "Error". You may specify
whether the instrument should react as if for an "Alarm" or "Warning" for "Error" messages.
→ See "Error type/NA 64" column and Section 8.2 "Response of outputs to errors".
In addition, the "Error type/NA 64" column classifies the messages in accordance with NAMUR
Recommendation NA 64:
• Break down: indicated with "B"
• Maintenance need: indicated with "C" (check request)
• Function check: indicated with "I" (in service)
Error message display on the on-site display:
• The measured value display shows the message with the highest priority. → See "Priority"
column.
• The ALARM STATUS parameter shows all the messages present in descending order of priority.
You can scroll through all the messages present with the S-key or O-key.
Message display via digial communication:
• The ALARM STATUS parameter shows the message with the highest priority. → See "Priority"
column.
! Note!
• If the device detects a defect in the on-site display during initialization, special error messages are
generated. → For the error messages, → ä 71, Section 8.1.1 "On-site display error messages".
• For support and further information, please contact Endress+Hauser Service.
• → See also Section 8.4 ff.
Code Error type/ Corresponds Message/description Cause Measure Prio

NA 64 NE 107 rity
101 (A101) Alarm Failure (F) B>Sensor electronic EEPROM – Electromagnetic effects are greater – Wait a few minutes. 17
B error than specifications in the – Restart the device. Perform reset
technical data. (→ See Section 9.) (Code 62).
This message normally only – Block off electromagnetic effects
appears briefly. or eliminate source of
disturbance.
– Sensor defect. – Replace sensor.
102 (W102) Warning Maintenance C>Checksum error in – Main electronics defect. Correct – Replace main electronics. 53
C request (M) EEPROM: peakhold segment measurement can continue as
long as you do not need the peak
hold indicator function.
106 (W106) Warning Funktion C>Downloading - please wait – Downloading. – Wait for download to complete. 52
C check (C)
110 (A110) Alarm Failure (F) B>Checksum error in – The supply voltage is – Reestablish supply voltage. 6
B EEPROM: configuration disconnected when writing. Perform reset (Code 7864) if
segment necessary. Carry out calibration
again.
– Electromagnetic effects are greater – Block off electromagnetic effects

than specifications in the or eliminate sources of
technical data. disturbance.
(→ See Section 9.)
– Main electronics defect. – Replace main electronics.
113 (A113) Alarm Failure (F) B>ROM failure in transmitter – Main electronics defect. – Replace main electronics. 1
B electronic
Endress+Hauser 63
Trouble-shooting Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART

NA 64 NE 107 rity
115 (E115) Error Out of B>Sensor overpressure – Overpressure present. – Reduce pressure until message 29
B specification disappears.
factory (S)
setting:
Warning C
116 (W116) Warning Maintenance C>Download error, repeat – The file is defect. – Use another file. 36
C request (M) download
– During the download, the data are – Check cable connection PC –
not correctly transmitted to the transmitter.
processor, e.g. because of open – Block off electromagnetic effects
cable connections, spikes (ripple) or eliminate sources of
on the supply voltage or disturbance.
electromagnetic effects. – Perform reset (Code 7864) and
carry out calibration again.
– Repeat download.
120 (E120) Error Out of B>Sensor low pressure – Pressure too low. – Increase pressure until message 30
B specification disappears.
factory (S)
setting:
Warning C
121 (A121) Alarm Failure (F) B>Checksum error in factory – Main electronics defect. – Replace main electronics. 5
B segment of EEPROM
122 (A122) Alarm Failure (F) B>Sensor not connected – Cable connection sensor –main – Check cable connection and 13
B electronics disconnected. repair if necessary.
– Electromagnetic effects are greater – Block off electromagnetic effects
than specifications in the or eliminate source of
(→ See Section 9.)

130 (A130) Alarm Failure (F) B>EEPROM is defect. – Main electronics defect. – Replace main electronics. 10
B
131 (A131) Alarm Failure (F) B>Checksum error in – Main electronics defect. – Replace main electronics. 9
B EEPROM: min/max segment
132 (A132) Alarm Failure (F) B>Checksum error in – Main electronics defect. – Replace main electronics. 7
B totalizer EEPROM
133 (A133) Alarm Failure (F) B>Checksum error in History – An error occurred when writing. – Perform reset (Code 7864) and 8
B EEPROM carry out calibration again.
– Main electronics defect. – Replace electronics.
602 (W602) Warning Funktion C>Linearisation curve not – The linearisation table is not – Add to linearisation table or 57
C check (C) monotone monotonic increasing or perform linearisation again.
decreasing.
64 Endress+Hauser

NA 64 NE 107 rity
604 (W604) Warning

C
Funktion
check (C)
C>Linearisation table not
valid. Less than 2 points or
! Note!
From software version "02.10.xx" onwards, there is no min. span for the Y-
58
points too close points.
– The linearisation table consists of – Add to linearisation table. If

less than 2 points. necessary, perform linearisation
again.
– At least 2 points in the – Correct linearisation table and

linearisation table are too close accept again.
together. A minimum gap of 0.5
% of the distance between two
points must be maintained.
Spans for the "Pressure linearized"
option: HYDR. PRESS MAX. –
HYDR. PRESS MIN.; TANK
CONTENT MAX. – TANK
CONTENT MIN.
Spans for the "Height linearized"
option: LEVEL MAX – LEVEL
MIN; TANK CONTENT MAX. –
TANK CONTENT MIN.
613 (W613) Warning Funktion I>Simulation is active – Simulation is switched on, i.e. the – Switch off simulation. 60
I check (C) device is not measuring at
present.
620 (E620) Error Out of C>Current output out of The current is outside the permitted – Check pressure applied, 49
C specification range range 3.8 to 20.5 mA. reconfigure measuring range if
Factory (S) – The pressure applied is outside necessary (→ See also Operating
setting: Instructions BA00274P or these
the set measuring range (but
Warning C Operating Instructions → ä 2.)
within the sensor range).
– Perform reset (Code 7864) and
carry out calibration again.
– Loose connection at sensor cable – Wait a short period of time and

tighten the connection, or avoid
loose connection.
700 (W700) Warning Maintenance C>Last configuration not – An error occurred when writing – Perform reset (Code 7864) and 54
C request (M) stored or reading configuration data or carry out calibration again.
the power supply was
disconnected.

701 (W701) Warning Funktion C>Measuring chain config. – The calibration carried out would – Carry out calibration again. 50
C check (C) exceeds sensor range result in the sensor nominal
operating range being undershot
or overshot.
702 (W702) Warning Maintenance C>HistoROM data not – Data were not written correctly to – Repeat upload. 55
C request (M) consistent. the HistoROM, e.g. if the – Perform reset (Code 7864) and
HistoROM was detached during carry out calibration again.
the writing process.
– HistoROM does not have any – Copy suitable data to the

data. HistoROM. (→ See also → ä 40,
Section 5.5.1 "Copying
configuration data".)
703 (A703) Alarm Failure (F) B>Measurement error – Fault in the main electronics. – Briefly disconnect device from the 22
B power supply.

704 (A704) Alarm Funktion B>Measurement error – Fault in the main electronics. – Briefly disconnect device from the 12
B check (C) power supply.
Endress+Hauser 65

NA 64 NE 107 rity
B power supply.
706 (W706) Warning Maintenance C>Configuration in – Configuration (parameters) in the – Copy data from the device to the 59
C request (M) HistoROM and device not HistoROM and in the device is HistoROM. (→ See also
identical not identical. → ä 40, Section 5.5.1 "Copying
configuration data".)
– Copy data from the HistoROM to
the device. (→ See also → ä 40,
Section 5.5.1 "Copying
configuration data".) The message
remains if the HistoROM and the
device have different software
versions. The message goes out if
you copy the data from the device
to the HistoROM.
– Device reset codes such as 7864
do not have any effect on the
HistoROM. That means that if you
do a reset, the configurations in
the HistoROM and in the device
may not be the same.
707 (A707) Alarm Funktion B>X-VAL. of lin. table out of – At least one X-VALUE in the – Carry out calibration again. (→ 38
B check (C) edit limits. linearisation table is either below See also Operating Instructions
the value for HYDR. PRESS MIN. BA00274P or these Operating
or MIN. LEVEL or above the Instructions → ä 2.)
value for HYDR. PRESS. MAX. or
LEVEL MAX.
710 (W710) Warning Funktion B>Set span too small. Not – Values for calibration (e.g. lower – Adjust calibration to suit sensor. 51
C check (C) allowed. range value and upper range (→ See also Operating
value) are too close together. Instructions BA00274P,
parameter description MINIMUM
SPAN or these Operating
Instructions → ä 2.)
– The sensor was replaced and the – Adjust calibration to suit sensor.
customer-specific configuration – Replace sensor with a suitable
does not suit the sensor. sensor.
– Unsuitable download carried out. – Check configuration and perform

download again.
711 (A711) Alarm Funktion B>LRV or URV out of edit – Lower range value and/or upper – Reconfigure lower range value 37
B check (C) limits range value undershoot or and/or upper range value to suit
overshoot the sensor range limits. the sensor. Pay attention to
position factor.
– The sensor was replaced and the – Reconfigure lower range value
customer-specific configuration and/or upper range value to suit
does not suit the sensor. the sensor. Pay attention to
position factor.
– Replace sensor with a suitable
sensor.

download again.
713 (A713) Alarm Funktion B>100% POINT level out of – The sensor was replaced. – Carry out calibration again. 39
B check (C) edit limits
66 Endress+Hauser

NA 64 NE 107 rity
715 (E715) Error Out of C>Sensor over temperature – The temperature measured in the – Reduce process temperature/ 32
C specification sensor is greater than the upper ambient temperature.
Factory (S) nominal temperature of the
setting: sensor. (→ See also Operating
Warning C Instructions BA00274P,
parameter description Tmax
SENSOR or these Operating

download again.
716 (E716) Error Failure (F) B>process isolating – Sensor defect. – Replace sensor. 24
B diaphragm broken – PMD70, FMD76: Overpressure is – Reduce pressure.
Factory present at minus or plus side of
setting: the device (on-sided overpressure)
Alarm B
717 (E717) Error Out of C>Transmitter over – The temperature measured in the – Reduce ambient temperature. 34
C specification temperature electronics is greater than the
Factory (S) upper nominal temperature of the
setting: electronics (+88 °C (+190 °F)).
Warning
download again.
718 (E718) Error Out of C>Transmitter under – The temperature measured in the – Increase ambient temperature. 35
C specification temperature electronics is smaller than the Insulate device if necessary.
Factory (S) lower nominal temperature of the
setting: electronics (–43 °C (-45 °F)).
Warning C
download again.
719 (A719) Alarm Funktion B>Y-VAL of lin. table out of – At least on Y-VALUE in the – Carry out calibration again. (→ 40
B check (C) edit limits linearisation table is below the See also Operating Instructions
MIN. TANK CONTANT or above BA00274P or these Operating
the MAX. TANK CONTENT. Instruction → ä 2.)
720 (E720) Error Out of C>Sensor under temperature – The temperature measured in the – Increase process temperature/ 33
C specification sensor is smaller than the lower ambient temperature.
Factory (S) nominal temperature of the
setting: sensor. (→ See also Operating
Warning C Instructions BA00274P,
parameter description Tmin
SENSOR or Operating

download again.
loose connection.
721 (A721) Alarm Funktion B>ZERO POSITION level out – LEVEL MIN or LEVEL MAX has – Perform reset (Code 2710) and 41
B check (C) of edit limits been changed. carry out calibration again.
722 (A722) Alarm Funktion B>EMPTY CALIB. or FULL – LEVEL MIN or LEVEL MAX has – Perform reset (Code 2710) and 42
B check (C) CALIB. out of edit limits been changed. carry out calibration again.
723 (A723) Alarm Funktion B>MAX. FLOW out of edit – FLOW-MEAS. TYPE has been – Carry out calibration again. 43
B check (C) limits changed.
Endress+Hauser 67

NA 64 NE 107 rity
725 (A725) Alarm Failure (F) B>Sensor connection error, – Electromagnetic effects are greater – Block off electromagnetic effects 25
B cycle disturbance than specifications in the or eliminate source of
technical data. (→ See Section 9.) disturbance.
– Setscrew loose.
– Retighten setscrew with 1 Nm
(0,74 lbf ft) (see Chap. 3.3.9).
– Sensor or main electronics defect. – Replace sensor or main

electronics.
726 (E726) Error Out of C>Sensor temperature error - – Electromagnetic effects are greater – Block off electromagnetic effects 31
C specification overrange than specifications in the or eliminate source of
Factory (S) technical data. disturbance.
setting: (→ See Section 9.)
Warning C
– Process temperature is outside – Check temperature present,
permitted range. reduce or increase if necessary.
– Sensor defect. – If the process temperature is

within the permitted range,
replace sensor.
727 (E727) Error Out of C>Sensor pressure error - – Electromagnetic effects are greater – Block off electromagnetic effects 28
C specification overrange than specifications in the or eliminate source of
Factory (S) technical data. disturbance.
setting: (→ See Section 9.)
Warning C
– Pressure is outside permitted – Check pressure present, reduce or
range. increase if necessary.
– Sensor defect. – If the pressure is within the

permitted range, replace sensor.
728 (A728) Alarm Failure (F) B>RAM error – Fault in the main electronics. – Briefly disconnect device from the 2
B power supply.
B power supply.
730 (E730) Error Out of C>LRV user limits exceeded – Pressure measured value has – Check system/pressure measured 46
C specification undershot the value specified for value.
Factory (S) the Pmin ALARM WINDOW – Change value for Pmin ALARM
setting: parameter. WINDOW if necessary. (→ See
Warning C also Operating Instructions
BA00274P, parameter description
Pmin ALARM WINDOW or these
Operating Instruction → ä 2.)

loose connection.
731 (E731) Error Out of C>URV user limits exceeded – Pressure measured value has – Check system/pressure measured 45
C specification overshot the value specified for value.
Factory (S) the Pmax ALARM WINDOW – Change value for Pmax ALARM
Pmax ALARM WINDOW or these
Operating Instructions → ä 2.)
68 Endress+Hauser

NA 64 NE 107 rity
732 (E732) Error Out of C>LRV Temp. User limits – Temperature measured value has – Check system/temperature 48
C specification exceeded undershot the value specified for measured value.
Factory (S) the Tmin ALARM WINDOW – Change value for Tmin ALARM
Tmin ALARM WINDOW or these

loose connection.
733 (E733) Error Out of C>URV Temp. User limits – Temperature measured value has – Check system/temperature 47
C specification exceeded overshot the value specified for measured value.
Factory (S) the Tmax ALARM WINDOW – Change value for Tmax ALARM
Tmax ALARM WINDOW or these
B power supply.
B power supply.
B power supply.
B power supply.
740 (E740) Error Maintenance C>Calculation overflow, bad – Level measuring mode: the – Check configuration and carry out 27
C request (M) configuration measured pressure has undershot calibration again if necessary.
Factory the value for HYDR. PRESS. MIN. – Select a device with a suitable
setting: or overshot the value for HYDR. measuring range.
Warning C PRESS MAX.
– Level measuring mode: The – Check configuration and carry out

measured level did not reach the calibration again if necessary.
LEVEL MIN value or exceeded (→ See also Operating
the LEVEL MAX value. Instructions BA00274P,
parameter description LEVEL
MIN. these Operating Instructions
→ ä 2.)
– Flow measuring mode: the – Check configuration and carry out

measured pressure has undershot calibration again if necessary.
the value for MAX. PRESS FLOW. – Select a device with a suitable
measuring range.
741 (A741) Alarm Funktion B>TANK HEIGHT out of edit – LEVEL MIN or LEVEL MAX has – Perform reset (Code 2710) and 44
B check (C) limits been changed. carry out calibration again.
742 (A742) Alarm Failure (F) B>Sensor connection error – Electromagnetic effects are greater – Wait a few minutes. 18
B (upload) than specifications in the – Perform reset (Code 7864) and
technical data. (→ See Section 9.) carry out calibration again.
This message normally only
appears briefly.
– Cable connection sensor –main – Check cable connection and

electronics disconnected. repair if necessary.
Endress+Hauser 69

NA 64 NE 107 rity
743 (E743) Alarm Failure (F) B>Electronic PCB error – This message normally only – Wait a few minutes. 14
B during initialisation appears briefly. – Restart the device. Perform reset
(Code 62).

744 (A744) Alarm Failure (F) B>Main electronic PCB error – Electromagnetic effects are greater – Restart the device. Perform reset 11
B than specifications in the (Code 62).
technical data. – Block off electromagnetic effects
(→ See Section 9.) or eliminate source of
disturbance.

745 (W745) Warning Maintenance C>Sensor data unknown – Sensor does not suit the device – Replace sensor with a suitable 56
C request (M) (electronic sensor nameplate). sensor.
Device continues measuring.
746 (W746) Warning Funktion C>Sensor connection error - – Electromagnetic effects are greater – Wait a few minutes. 26
C check (C) initialising than specifications in the – Restart the device. Perform reset
technical data. (→ See Section 9.) (Code 7864).
This message normally only – Block off electromagnetic effects
appears briefly. or eliminate source of
disturbance.
– Overpressure or low pressure – Reduce or increase pressure.
present.
747 (A747) Alarm Failure (F) B>Sensor software not – Sensor does not suit the device – Replace sensor with a suitable 16
B compatible to electronics (electronic sensor nameplate). sensor.
748 (A748) Alarm Failure (F) B>Memory failure in signal – Electromagnetic effects are greater – Block off electromagnetic effects 15
B processor than specifications in the or eliminate source of
(→See Section 9.)
70 Endress+Hauser
8.1.1 On-site display error messages

If the device detects a defect in the on-site display during initialization, the following error messages
can be displayed:
Message Measure
Initialization, VU Electr. Defect A110 Exchange on-site display.
Initialization, VU Electr. Defect A114
Initialization, VU Electr. Defect A281

Initialization, VU Checksum Err. A110
Endress+Hauser 71
8.2 Response of outputs to errors

The device differentiates between the error types Alarm, Warning and Error.
→ See the following table and → ä 63, Section 8.1 "Messages".
Output A (Alarm) W (Warning) E (Error: Alarm/Warning)
Current output Assumes the value specified via the Device continues measuring. For this error, you can enter whether the
OUTPUT FAIL MODE1), ALT. CURR. device should react as in the event of an
OUTPUT1 and SET MAX. ALARM1 alarm or as in the event of a warning. See
parameter. → See also the following section corresponding "Alarm" or "Warning"
"Configuring current output for an alarm". column. (→ See also Operating Instructions
BA00274P, parameter description SELECT
ALARM TYPE or these Operating
Bargraph The bargraph adopts the value defined by The bargraph adopts the value which → See this table, "Alarm" or "Warning"
(on-site display) the OUTPUT FAIL MODE 1 parameter. corresponds to the current value. column, depending on selection.
On-site display – The measured value and message are – The measured value and message are – The measured value and message are
displayed alternately displayed alternately displayed alternately
– Measured value display: -symbol is – Measured value display: -symbol – Measured value display: see
permanently displayed. flashes. corresponding "Alarm" or "Warning"
column
Message display Message display: Message display:

– 3-digit number such as A122 and – 3-digit number such as W613 and – 3-digit number such as E731 and
description description description
Remote operation In the case of an alarm, the In the case of a warning, the ALARM In the case of an error, the
(digital communication) ALARM STATUS2) parameter displays a 3- STATUS2 parameter displays a 3-digit ALARM STATUS2 parameter displays a 3-
digit number such as 122 for "Sensor not number such as 613 for "Simulation is digit number such as 731 for "URV user
connected". active". limits exceeded".
1) Menu path: (GROUP SELECTION →) OPERATING MENU → OUTPUT

2) Menu path: (GROUP SELECTION →) OPERATING MENU → MESSAGES
72 Endress+Hauser
8.2.1 Configuring current output for an alarm

You can configure the current output for the event of an alarm by means of the OUTPUT FAIL
MODE, ALT. CURR. OUTPUT and SET MAX. ALARM parameters. The parameters are displayed
in the OUTPUT group (menu path: (GROUP SELECTION →) OPERATING MENU → OUTPUT).
In the event of an alarm, the current and the bargraph assume the value entered with the OUTPUT
FAIL MODE parameter.
I
max.
➀ 21...23 mA
min.
➂ 3.6 mA
t
P01-xxxxxxxx-05
Fig. 43: Current output in the event of an alarm

Options:
1 Max. alarm (110%): can be set between 21...23 mA via the SET MAX. ALARM parameter
2 Hold meas. value: last measured value is kept
3 Min. alarm (–10%): 3.6 mA
Factory setting:
• OUTPUT FAIL MODE: Max. Alarm (110%)
• SET MAX. ALARM: 22 mA
Use the ALT. CURR. OUTPUT parameter to set the current output value for the error messages E
120 "Sensor low pressure" and E 115 "Sensor overpressure". You have the following options:
– Normal: the current output assumes the value set via the OUTPUT FAIL MODE and SET MAX.
ALARM parameters.
– NAMUR
– Lower sensor limit undershot (E 120 "Sensor low pressure"): 3.6 mA
– Upper sensor limit overshot (E 115 "Sensor overpressure") overshot: current output assumes
the value set via the SET MAX ALARM parameter.
Factory setting:
• ALT. CURR. OUTPUT: normal
Endress+Hauser 73
8.3 Confirming messages

Depending on the settings for the ALARM DISPL. TIME and ACK. ALARM MODE parameters, the
following measures should be taken to clear a message:
Settings 1) Measures
– ALARM DISPL. TIME = 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = off
– ALARM DISPL. TIME > 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = off – Wait for the alarm display time to elapse.
– ALARM DISPL. TIME = 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = on – Confirm message using ACK. ALARM parameter.
– ALARM DISPL. TIME > 0 s – Rectify cause of the message (see also Section 8.1).
– ACK. ALARM MODE = on – Confirm message using ACK. ALARM parameter.
– Wait for the alarm display time to elapse. If a message appears and the alarm
display time elapses before the message has been acknowledged, the message
will be cleared once it has been acknowledged.
1) Menu path for ALARM DISPL. TIME and ACK. ALARM MODE: (GROUP SELECTION →) OPERATING MENU →
DIAGNOSTICS → MESSAGES
If the on-site display displays a message, you can suppress it with the F-key.
If there are several messages, the on-site display shows the message which has the highest priority
(see also Section 8.1). Once you have suppressed this message using the F-key, the message with
the next highest priority is displayed. You can use the F-key to suppress each message, one after
the other.
The ALARM STATUS parameter continues to display all the messages present.
74 Endress+Hauser
8.4 Repair
The Endress+Hauser repairs concept provides for measuring devices to have a modular design and
also the customer may carry out repairs (→ ä 76, Section 8.6 "Spare Parts").
! Note!
• For certified devices, please consult Chapter "Repair of Ex-certified devices".
• For more information on service and spare parts contact the Endress+Hauser Service. ( → See
www.endress.com/worldwide)
8.5 Repair of Ex-certified devices

# Warning!
When repairing Ex-certified devices, please note the following:
• Only specialist personnel or Endress+Hauser may undertake repairs of certified devices.
• Relevant standards, national hazardous area regulations and Safety Instructions and Certificates
must be observed.
• Only genuine Endress+Hauser spare parts may be used.
• When ordering spare parts, please check the device designation on the nameplate. Identical parts
may only be used as replacements.
• Electronic inserts or sensors already in use in a standard instrument may not be used as spare parts
for a certified device.
• Carry out repairs according to the instructions. After repairs, the device must fulfil the
requirements of the specified individual tests.
• A certified device may only be converted into another certified variant by Endress+Hauser.
• All repairs and modifications must be documented.
Endress+Hauser 75
8.6 Spare Parts

An overview of the spare parts for your device is available in the internet at www.endress.com.
To obtain information on the spare parts, proceed as follows:
1. Go to "www.endress.com" and select your country.
2. Click "Instruments".
3. Enter the product name into the "product name" field.
4. Select the device.

5. Click the "Accessories/Spare parts" tab.
6. Select the required spare parts (You may also use the overview drawing on the right side of the
screen.)
When ordering spare parts, always quote the serial number indicated on the nameplate. As far as
necessary, the spare parts also include replacement instructions.
76 Endress+Hauser
8.7 Return
The measuring device must be returned if repairs or a factory calibration are required, or if the
wrong measuring device has been ordered or delivered. According to legal regulations,
Endress+Hauser, as a ISO-certified company, is required to follow certain procedures when
handling returned products that are in contact with process fluids.
To ensure swift, safe and professional device returns, please read the return procedures and
conditions on the Endress+Hauser website at www.services.endress.com/return-material.
8.8 Disposal
When disposing, separate and recycle the device components based on the materials.
Endress+Hauser 77
8.9 Software history
Date Software version Changes software Documentation
Operating Instructions Description of

Instrument Functions
11.2003 01.00.zz Original software. BA270P/00/EN/10.03 —

52020515
Compatible with:
– ToF Tool Field Tool Package, version 1.04.00 or higher
– Commuwin II version 2.08.-1, Update G or higher
– HART Communicator DXR375 with Device Rev.: 10, DD
Rev.: 1
06.2004 02.00.zz – Number of parameters in the Quick Setup menus has been BA270P/00/EN/05.04 BA274P/00/EN/05.04
reduced. 52022793 52021469
– On-site operation: LANGUAGE and MEASURING MODE
parameters have been moved to the top level.
– New SAFETY CONFIRM. group implemented for SIL.
→ See also SD00189P Safety Manual Deltabar S.
– MEASURING MODE "Level", LEVEL MODE "Linear": AREA
UNIT and TANK SECTION parameters have been replaced
with the TANK VOLUME and TANK HEIGHT parameters.
– Function of the UNIT FLOW parameter has been split across
four parameters.
– Function of the SIMULATED VALUE parameter has been
split across six parameters.
– SENSOR TRIM and CURRENT TRIM groups have been
removed.
– Sensor adapt reset, code 1209 and sensor calibration reset,
code 2509 have been removed.
– Quick Setup menus are available via ToF Tool.
Compatible with:
– ToF Tool Field Tool Package version 2.00.00 or higher
– Commuwin II version 2.08.-1, Update > G
– HART Communicator DXR375 with Device Rev.: 20, DD
Rev.: 1
06.2005 02.01.zz – Operating keys also integrated on the optional on-site display. BA270P/00/EN/06.05 BA274P/00/EN/05.04
– Chinese and Japanese are available as the menu language on 71000109 52021469
request.
BA270P/00/EN/11.05 BA274P/00/EN/05.04
Compatible with: 71009586 52021469
– ToF Tool Field Tool Package version 3.00.00 or higher
– FieldCare version 2.01.00, DTM Library version 2.06.00,
DTM: Deltabar S/MD7x/V02.00 V 1.4.98.74*
– HART Communicator DXR375 with Device Rev.: 20,
DD Rev.: 1*
* Menu languages Chinese and Japanese not selectable
78 Endress+Hauser
Date Software version Changes software Documentation
Operating Instructions Description of

Instrument Functions
06.2006 02.10.zz – New "Level Easy Pressure" and "Level Easy Height" level BA270P/00/en/07.06 BA274P/00/en/07.06
modes implemented. New LEVEL SELECTION parameter 71027244 71027249
implemented.
– OPERATION group with DOWNLOAD SELECT parameter BA270P/00/en/08.06 BA274P/00/en/07.06
71027244 71027249
extended.
– SAFETY CONFIRM group extended for the "Level" operating BA270P/00/en/10.07 BA274P/00/en/07.07
mode in the "Level Easy Pressure" level selection. 71043294 71061021
→ See also SD00189P Safety Manual Deltabar S.
– Factory setting for the "Error" messages redefined. BA270P/00/en/12.07 BA274P/00/en/07.07
– Chinese and Japanese included as menu languages by 71043294 71061021
default.
BA270P/00/en/05.08 BA274P/00/en/05.08
Compatible with: 71071730 71071855
– ToF Tool Field Tool Package version 4.0
BA270P/00/en/08.08 BA274P/00/en/05.08
– FieldCare version 2.02.00
– HART Communicator DXR375 with Device Rev.: 21, DD 71077506 71071855
Rev.: 1 BA270P/00/EN/06.09 BA274P/00/EN/06.09
71095415 71095452
BA270P/00/EN/05.10 BA274P/00/EN/05.10
71114104 71118244
BA00270P/00/EN/13.11 BA00274P/00/EN/13.11
71139762 71139795
BA00270P/00/EN/14.12 BA00274P/00/EN/13.11
71161876 71139795
01.2013 02.11.zz "Russian" is included as a menu language by default. BA00270P/00/EN/15.13 BA00274P/00/EN/14.13

The menu language "Nederlands" is no longer supported. 71204581 71204628
Endress+Hauser 79
Technical data Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
9 Technical data
For technical data, please refer to the Technical Information TI00382P for Deltabar S.
10 Appendix
10.1 Operating menu for on-site display, FieldCare and

HART handheld terminal
! Note!
• The entire menu is depicted on the following pages.
• The menu has a different structure depending on the measuring mode selected. This means that
some function groups are only displayed for one measuring mode, e.g. "LINEARISATION"
function group for the Level measuring mode.
• In addition, there are also parameters that are only displayed if other parameters are appropriately
configured. For example the Customer Unit P parameter is only displayed if the "User unit" option
was selected for the PRESS. ENG. UNIT parameter. These parameters are indicated with a "*".
• For a description of the parameters, please refer to Operating Instructions BA00274P "Description
of device functions". The exact dependency of individual parameters on one another is explained
here. See also → ä 2, section "Overview documentation".
80 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Appendix
Measured value
1)
GROUP SELECTION
1) 1)
1)
Level measuring
LEVEL SELECTION mode only SETTINGS
POSITION ADJUSTMENT
2)
MEASURING MODE
Pressure Level Flow

2)
POS. ZERO ADJUST LEVEL SELECTION POS. ZERO ADJUST POS. ZERO ADJUST
SET LRV POS. ZERO ADJUST MAX. FLOW POS. INPUT VALUE
SET URV EMPTY CALIB.

* MAX PRESS. FLOW CALIB. OFFSET
DAMPING VALUE FULL CALIB.

* DAMPING VALUE
DAMPING VALUE

HART Handheld terminal only
* There are parameters that are only displayed if other parameters are
appropriately configured.
For example the CUSTOMER UNIT P parameter is only displayed
if the "User unit" option was selected for the PRESS. ENG. UNIT parameter.
These parameters are indicated with a "*".
Endress+Hauser 81
Appendix Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART
BASIC SETUP
2)
MEASURING MODE
Pressure Level Flow

2)
PRESS. ENG. UNIT LEVEL SELECTION PRESS. ENG. UNIT
CUSTOMER UNIT P
* CUSTOMER UNIT P
*
Level Easy Pressure Level Easy Height Level Standard
CUST. UNIT FACT. P
* CUST. UNIT FACT. P
*
PRESS. ENG. UNIT PRESS. ENG. UNIT
X
SET LRV
CUSTOMER UNIT P
* CUSTOMER UNIT P
* Continuation,
see the following page
FLOW-MEAS. TYPE
SET URV
CUST. UNIT FACT. P
* CUST. UNIT FACT. P
* A
GET LRV B
OUTPUT UNIT OUTPUT UNIT
GET URV CUSTOMER UNIT F

*
CALIBRATION MODE HEIGHT UNIT
DAMPING VALUE
Dry
CUST. UNIT FACT. F
*
Wet CALIBRATION MODE
EMPTY CALIB. EMPTY CALIB. MAX. FLOW

Wet Dry
FULL CALIB. EMPTY PRESSUE DENSITY UNIT DENSITY UNIT MAX PRESS. FLOW
FULL CALIB. ADJUST DENSITY ADJUST DENSITY DAMPING VALUE
FULL PRESSURE EMPTY CALIB. EMPTY CALIB.
FULL CALIB. EMPTY HEIGHT

SET LRV
FULL CALIB.
SET URV
FULL HEIGHT
DAMPING VALUE
SET LRV
SET URV
DAMPING VALUE
Volume Gas Gas Mass

p. cond. norm cond. std. cond.
UNIT FLOW NORM FLOW UNIT STD. FLOW UNIT MASS FLOW UNIT
B B B B

HART Handheld terminal only
For example the CUSTOMER UNIT P parameter is only displayed
if the "User unit" option was selected for the PRESS. ENG. UNIT parameter.
82 Endress+Hauser
C
Continuation
BASIC SETUP "Level",
X see also the previous page Height Volume Mass %
LEVEL SELECTION = HEIGHT UNIT UNIT VOLUME MASS UNIT

Level Standard
PRESS. ENG. UNIT CUTOMER UNIT H * CUSTOMER UNIT V * CUSTOMER UNIT M *

CUSTOMER UNIT P CUST. UNIT FACT. H * CUST. UNIT FACT. V * CUST. UNIT FACT. M *
CUST. UNIT FACT. P D D D D
LEVEL MODE
Linear
Pressure Height E
Linearized Linearized
LIN. MEASURAND LINd MEASURAND COMB. MEASURAND
% Volume Mass
UNIT VOLUME MASS UNIT

C E G
D F H CUSTOMER UNIT V * CUSTOMER UNIT M *
CALIBRATION MODE HYDR. PRESS MIN.
E CUST. UNIT FACT. V * CUST. UNIT FACT. M *
HYDR. PRESS MAX. F
Wet Dry F F F
EMPTY CALIB. DENSITY UNIT DAMPING VALUE LEVEL MIN
EMPTY PRESSURE ADJUST DENSITY LEVEL MAX

G
FULL CALIB. VOLUME UNIT
* CALIBRATION MODE
Height+... %Height+...
FULL PRESSURE CUSTOMER UNIT V
*
Wet Dry HEIGHT UNIT
ADJUSTED DENSITY * CUST. UNIT FACT. V

* EMPTY CALIB. DENSITY UNIT
*
CUTOMER UNIT H
TANK VOLUME
* EMPTY PRESSURE ADJUST DENSITY
*
CUST. UNIT FACT. H
HEIGHT UNIT
* FULL CALIB. HEIGHT UNIT *
H H
CUSTOMER UNIT H FULL PRESSURE CUSTOMER UNIT H *
CUST. UNIT FACT. H
* ADJUSTED DENSITY * CUST. UNIT FACT. H *
TANK HEIGHT
* 100% POINT *
100% POINT
* ZERO POSITION
ZERO POSITION
DAMPING VALUE
SET LRV
SET URV
DAMPING VALUE * There are parameters that are only displayed if other parameters are
For example the CUST. UNIT FACT. H parameter is only displayed
if the "User unit" option was selected for the HEIGHT UNIT parameter.
Endress+Hauser 83
EXTENDED SETUP LINEARISATION LINEARISATION TOTALIZER SETUP

Level measuring Level measuring Flow measuring
mode only mode only mode only
Display via on-site Display via ToF Tool or

display only HART handheld terminal
only
Pressure Level Flow
TEMP. ENG UNIT TEMP. ENG UNIT TEMP. ENG UNIT TANK CONTENT MIN TANK CONTENT MIN TOTALIZER 1 UNIT
DENSITIY UNIT LOW FLOW CUT-OFF TANK CONTENT MAX TANK CONTENT MAX TOT. 1 USER UNIT
*
ADJUST DENSITIY SET L. FL. CUT-OFF
* TABLE SELECTION TABLE SELECTION FACT. U. U. TOTAL.1
*
PROCESS DENSITY SET LRV Measuring Measuring NEG. FLOW TOT. 1
Editor Table Editor Table
Table Table
SET LRV
* SET URV LIN. EDIT MODE MEASURING TABLE LIN. EDIT MODE LINE-NUMB RESET TOTALIZER 1
SET URV * EDITOR TABLE MEASURING TABLE EDITOR TABLE ACTIVE LIN. TAB. X TOTALIZER 2 UNIT
EDITOR TABLE LINE-NUMB ACTIVE LIN. TAB. Y TOT. 2 USER UNIT

*
EDITOR TABLE X-VAL. FACT. U. U. TOTAL. 2 *
Y-VAL. NEG. FLOW TOT. 2
TANK DESCRIPTION
EDITOR TABLE
TANK DESCRIPTION
For example the TOT. 1 USER UNIT parameter is only displayed
if the "User unit" option was selected for the TOTALIZER 1 UNIT parameter.
84 Endress+Hauser
SAFETY CONFIRM.
** DISPLAY OUTPUT
SAFETY LOCK MENU DESCRIPTOR OUTPUT CURRENT
SAFETY PASSWORD MAIN DATA FORMAT CURR. CHARACT.
DIGIT SETS ALTERNATE DATA OUTPUT FAIL MODE
2)
CURRENT OUTPUT LANGUAGE ALT. CURR. OUTPUT
ACK. ALARM MODE DISPLAY CONTRAST SET MAX. ALARM
CALIB. OFFSET DIGIT SETS SET MIN. CURRENT
3)
MEASURING MODE ASSIGN CURRENT
4)
Pressure Level Flow LINEAR/SQROOT
5)
SET LRV EMPTY PRESSURE MAX. FLOW
SET URV EMPTY CALIB. MAX PRESS FLOW
DAMPING VALUE FULL PRESSURE LOW FLOW CUT-OFF
CONF. PASSWORD FULL CALIB. SET L. FLOW CUT-OFF

*
SET LRV LINEAR/SQROOT
SET URV SET LRV
DAMPING VALUE SET URV
CONF. PASSWORD DAMPING VALUE
CONF. PASSWORD
2) Display via
HART handheld terminal only * There are parameters that are only displayed if other parameters are
3) Level measuring mode only These parameters are indicated with a "*".
4) Flow measuring mode only See Safety Manual SD189P
5) only LEVEL SELECTION = Level Easy Pressure
** for Deltabar S.
Endress+Hauser 85
TRANSMITTER INFO PROCESS INFO
HART DATA TRANSMITTER DATA PROCESS CONNECTION SENSOR DATA PROCESS VALUE PEAK HOLD INDICATOR
Pressure Level Flow
BUS ADDRESS DEVICE SERIAL No Pmax PROC. CONN. SENSOR SER. NO. MEASURED VALUE MEASURED VALUE MEASURED VALUE COUNTER:P > Pmax
DEVICE TYPE ELECTR. SERIAL No PROC. CONN. TYPE PRESS. SENS LOLIM PRESSURE PRESSURE PRESSURE MAX. MEAS. PRESS.
DEVICE REVISION CUST. TAG NUMBER MAT. PROC. CONN. + PRESS. SENS HILIM CORRECTED PRESS. CORRECTED PRESS. CORRECTED PRESS. COUNTER:P < Pmin
2)
BURST MODE LONG TAG NUMBER MAT. PROC. CONN. – MINIMUM SPAN SENSOR PRESSURE SENSOR PRESSURE SENSOR PRESSURE MIN. MEAS. PRESS.
2)
BURST OPTION ADDITIONAL INFO. SEAL TYPE SENSOR MEAS. TYPE SENSOR TEMP. SENSOR TEMP. SENSOR TEMP. COUNTER:T > Tmax
2)
PREAMBLE NUMBER DEVICE DESIGN. BOLTS MATERIAL Pmin SENS. DAMAGE MEAS. VAL. TREND MEAS. VAL. TREND MEAS. VAL. TREND MAX. MEAS. TEMP.
2)
MANUFACTOR ID HARDWARE REV. NUTS MATERIAL Pmax SENS. DAMAGE LEVEL BEFORE LIN
* SUPPRESSED FLOW COUNTER:T< Tmin
2)
HART MESSAGE SOFTWARE VERSION DRAIN VENT MAT. MAT. MEMBRANE TANK CONTENT
* TOTALIZER 1 MIN. MEAS. TEMP.
2)
HART DATE CONFIG RECORDER DRAIN VENT POS. FILLING FLUID TOTAL. 1 OVERFLOW PCB COUNT:T > Tmax
2) 2)
PRIMARY VALUE IS PCB TEMPERATURE THREAD Tmin SENSOR TOTALIZER 2 PCB MAX. TEMP.
2) 2)
PRIMARY VALUE ALLOWED MIN. TEMP MOUNTING THREAD Tmax SENSOR TOTAL. 2 OVERFLOW PCB COUNT: T< Tmin
2) 2)
SECONDARY VAL. IS ALLOWED MAX. TEMP REMOTE SEAL + SENSOR H/WARE REV. PCB MIN. TEMP.
2) 2)
SECONDARY VALUE DIP STATUS REMOTE SEAL – RESET PEAKHOLD
2) 2)
THIRD VALUE IS DIAPHRAGM MAT. +
2) 2)
THIRD VALUE DIAPHRAGM MAT. –
2) 2)
4TH VALUE IS NR OF REMOTE SEAL
2) 2)
4 TH VALUE FILL FLUID
2) Display via FieldCare

HART handheld terminal only
There are parameters that are only displayed if other parameters are
* appropriately configured.
86 Endress+Hauser
OPERATION DIAGNOSTICS SERVICE
SIMULATION MESSAGES USER LIMITS SYSTEM 2
ENTER RESET CODE SIMULATION MODE ALARM STATUS Pmin ALARM WINDOW CURR. TRIM 4mA
OPERATING HOURS LAST DIAG. CODE Pmax ALARM WINDOW CURR. TRIM 20mA
INSERT PIN NO ACK. ALARM MODE Tmin ALARM WINDOW OFFSET 4mA TRIM
HistoROM AVAIL. ACK. ALARM * Tmax ALARM WINDOW OFFSET 20mA TRIM
DOWNLOAD SELECT. * RESET ALL ALARMS
HistoROM CONTROL * ERROR NO.

Display via digital communication
SELECT ALARMTYPE
ALARM DELAY
ALARM DISPL. TIME
none Pressure Flow Level Tank content Current Alarm Warning

SIM. PRESSURE SIM. FLOW VALUE SIM. LEVEL SIM. TANK CONT. SIM. CURRENT SIM. ERROR NO.
There are parameters that are only displayed if other parameters are
* appropriately configured.
Endress+Hauser 87
88 Endress+Hauser
Endress+Hauser 89
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Index
Index
Numerics N
4...20 mA test signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A O
Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 On-site display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operating elements, function . . . . . . . . . . . . . . . . . . . 31–32
C Operating elements, position. . . . . . . . . . . . . . . . . . . . . . . 30
Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operating keys, on-site, Flow measuring mode . . . . . . . . . 36
Commubox FXA195 anschließen . . . . . . . . . . . . . . . . . . . 26 Operating keys, on-site, function. . . . . . . . . . . . . . . . . 31–32
Connecting Commubox FXA291 . . . . . . . . . . . . . . . . . . . 27 Operating keys, on-site, Level measuring mode . . . . . . . . . 34
Connecting ToF Adapter FXA291 . . . . . . . . . . . . . . . . . . . 27 Operating keys, on-site, Pressure measuring mode. . . . . . . 33
Operating keys, position . . . . . . . . . . . . . . . . . . . . . . . . . . 30
D Operating menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 80
Diaphragm seals, installation instructions . . . . . . . . . . . . . 17 Overvoltage protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diaphragm seals, vacuum application . . . . . . . . . . . . . . . . 18
Differential pressure measurement . . . . . . . . . . . . . . . . . . 59 P
Differential pressure measurement, information . . . . . . . . 60 Pipe mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Differential pressure measurement, installation . . . . . . . . . 16 Position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Differential pressure measurement, preparatory steps . . . . 59 Potential matching . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–27
Differential pressure measurement, Quick Setup menu . . . 60 Pressure measurement, Quick Setup menu . . . . . . . . . . . . 60
Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Q
E Quick Setup menu flow . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Quick Setup menu level . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Quick Setup menu pressure . . . . . . . . . . . . . . . . . . . . . . . 60
F R
Factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FieldCare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Repair of Ex-certified devices . . . . . . . . . . . . . . . . . . . . . . 75
Flow measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Flow measurement, installation . . . . . . . . . . . . . . . . . . . . 11 Returning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Flow measurement, Ouick Setup menu . . . . . . . . . . . . . . 51 Rotating the housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Flow measurement, preparatory steps . . . . . . . . . . . . . . . . 49
S
H Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Screening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Heat insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Separate housing, assemble and mount . . . . . . . . . . . . . . . 21
HistoROM/M-Dat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Service Interface FXA291 . . . . . . . . . . . . . . . . . . . . . . . . . 27
SIL3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
I Software history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
L Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Language, selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Level measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 55–56 T
Level measurement, installation . . . . . . . . . . . . . . . . . . . . 12 Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Level measurement, preparatory steps. . . . . . . . . . . . . . . . 52
Level measurement, Quick Setup menu . . . . . . . . . . . . . . 57 U
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Unlocking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Locking operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
W
M Wand mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Measuring layout for flow measurement . . . . . . . . . . . . . . 11 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Measuring layout for level measurement . . . . . . . . . . . . . . 12
Measuring layout for pressure measurement . . . . . . . . . . . 16
Measuring mode, selection . . . . . . . . . . . . . . . . . . . . . . . . 47
90 Endress+Hauser
Deltabar S FMD76/77/78, PMD70/75 with 4...20 mA HART Index
Endress+Hauser 91
www.endress.com/worldwide
BA00270P/00/EN/15.13
71204581
CCS/FM+SGML 9 71204581
PNEUMATIC CONTROL VALVE
( K2C(3C)-DP )

TABLE OF CONTENTS
PAGE
1. TYPE --------------------------- 3
2. MATERIALS --------------------------- 4
3. CONSTRUCTION --------------------------- 5
4. WORKING AIR PRESSURE --------------------------- 7
5. NAME PLATE --------------------------- 7
6. AIR PIPING CONNECTION --------------------------- 8
METHOD OF INSTALLING
7. --------------------------- 9
CONTROL VALVE
8. MAINTENANCE --------------------------- 10
9. TROUBLE SHOOTING --------------------------- 14
10. GENERAL PRECAUTIONS --------------------------- 15
Method of Handling and Maintenance of

11. --------------------------- 17
Gland Packing
2
1. TYPE
The indication of type of cage type control valve is as shown below :
The following sample a full designation of type.
[Example]
K2C(3C) - DP 1 ( R )
┃ ┃ ┃ ┗━━━ Diaphragm Acting Mode
┃ ┃┃ D : Direct action
┃ ┃┃ R : Reverse action
┃ ┃┃ B : Double action
┃ ┃┃
┃ ┃ ┗ Indicates body configuration. (See Table b.)
┃ ┃
┃ ┗━ ACTUATOR TYPE ( DP : Pneumatic Diaphragm)
┃
┗ 2Way(3Way) Control valve series
Table a. STANDARD PRESSURE RATING

MARK 1 2 3 4 5 6
JIS
5ㆍ10 16ㆍ20 30ㆍ40 63 (100) ---
(kgf/cm2)
ANSI
(125ㆍ150) 250ㆍ300 400ㆍ600 900 1500 2500
(Class)
Table b. Body configuration

Symbol Meaning
1 Cage guided type body
2 Single seated and top guided type body
3 Cage guided and angle type body
4 Single seated and suitable flow type body
5 Special body (Other than those mentioned above)
3
2. MATERIALS
2.1 BODY
Optimum materials are selected, depending on type of fluid, pressures,
temperatures and other requirements. (flushing, cavitation, corrosion, etc.)
Cast iron (FC), gunmetal (BC) , ordinary cast steel (SC) and cast stainless
steel (SUS) conform to the requirements specified in JIS and special cast
steel (WC, S5, etc.) conform to the requirements specified in ASTM.
2.2 TRIM
Table shows typical standard trim materials among types herein. The trim
materials for cage type control valves are shown on pertinent drawing.
Standard trim materials for general purpose type control valve (Mark of
materials : JIS)
Service temperature of
Lower Seat
Disc Seat Gland fluids such as water, oil,
Stem Ring
steam, air and gas (℃)
SUS 410
SCS SUS SUS SUS
or
o 220
0 AND U
UNDER
24 316 316 316
SCS 24
4
3. CONSTRUCTION
3.1 Body (See Attached Figs. 1～9.)
Control valves can be largely divided into single seat valve and double seat
valve. Normally single seat valve is used. How ever, for small n bore or
where pressure is relatively low and low leaking is desired single seat valve
is used.
Balance piston valve combines the advantages of both single and double
seat valves. Its leaking is similar to that of single seat valve. It can be used
up to the differential pressure 5 - 6 times that of the single seat valve.
Operation Principle of the balance piston valve is
: When working pressure is applied on diaphragm, the stem is brought
down.
This causes pilot valve to open first. Then the inlet pressure is applied on
the upper side of piston, Since the piston is almost the same in diameter
with the main valve, it balances with the back pressure of the main valve.
Thus the unbalance of the valve is reduced to a fraction.
3.2 Valve disc
a. Single seat : <FIG. 1>
b. Double seat : <FIG. 2>
See Figs. 1 and 2 for the shape of each disc.
<FIG. 1> <FIG. 2>
5
3.3 Bonnet
Standard Fin type bellows extension type

Fin type
type ( for cage seal type
( FOR GENERAL
type )
PURPOSE TYPE )
<Fig.
g 3> Type
yp of bonnet
3.4 Diaphragm Motor
Diaphragm motor includes D (direct action) Type and R (reverse action)
Type. The two types are used either as air to open air to close type
considering from the process condition in the event of interuption of working
air.
Single Action
< Fig. 4> Diaphragm Motor

6
4. WORKING AIR PRESSURE

The range of standard working air pressure is 0.2 to 1.0 kg/cm2 or 0.4 to
2.0kg/cm2. However, in a special case when closing force is specially
required, the range is may be deviated to 0.4～1.2kg/cm2 or 0.6～
2.2kg/cm2.
5. NAME PLATE
5.1 Name Plate for Specification
<Fig. 5>
7
5.2 Indicator Plate for Lift
<Fig. 6>
6. AIR PIPING CONNECTION
6.1 Direct Action Diaphragm
<Fig. 7>
8
6.2 Reverse Action diaphragm
<Fig. 8>
7. METHOD OF INSTALLING CONTROL VALVE

7.1 Selection of Location
a) Select the place convenient for maintenance and servicing.

(Consider the space to allow vertical disassembly of control valve.)
b) Avoid the place where vibration is produced
produced.
c) Avoid the place of high ambient temperature. (Lese than 60℃)
d) Consider the distance air piping from controller.
(UP ti 50 meters with air operated type)
7.2 Control valve should essentially be installed in vertical position, to

horizontal piping, with the actuator positioned upward on the upper side.
However, if location compels to install the control valve in inclined position,
provide support to the control section.
7.3 Install the control valve with its flow direction conforming to the direction
shown by the arrow mark casted (or engraved) on the body.
9
8. MAINTENANCE
8.1 Disassembly, Assembly and Parts Replacement
8.1.1 Replacing the Diaphragm of direct action Diaphragm

a) Disconnect air piping from diaphragm casing.
b) Remove bolt and nut.
c) Remove diaphragm casing.
d) Replace diaphragm.
e) Reassemble in the reverse order of disassembly.
f) Perform adjustment and checking according to Paras. 8.2. and 8.3.
(Perform the following Paras end just the same procedure
as paras 8.2. and 8.3)
Note.
1. If casing removal is difficult due to sticking of diaphragm, tap a screw
driver or the like into the clearance.
2. It is desirable to use a chain block for handing diaphragm casings of
520J and 645J because of their weight.
3. After replacing the diaphragm, correctly set the mounting holes.
4 Notes 1,
4. 1 2 and 3 air also applied to each of the following paragraphs
paragraphs.
8.1.2 Replacing the diaphragm of reverse Action Diaphragm

a) Loosen adjusting screw to bring it down.
b) remove bolt and nut.
c) Remove diaphragm casing.
d) Slightly loosen bolt.
e) Turn the assembly diaphragm disc, diaphragm stem and diaphragm
counterclockwise and withdraw it upward.
f) Hold the head of diaphragm disc with a vise, apply a wrench on the
square shaft of diaphragm stem and unscrew.
g) replace diaphragm.
h) Reassemble in the reverse order of disassembly.
10
8.1.3 Replacing the spring of direct Action Diaphragm

a) Perform the same operations up to a) - c) of para. 9.1.1.
b) Remove diaphragm.
c) Slightly loosen bolt, turn the top of diaphragm disc to left by hand
and draw out diaphragm stem.
d) Replace spring.
e) Reassemble in the reverse order of disassembly
Note.
1. Diaphragm stem must be screwed down completely to the step of.
2. Fasten firmly bolts after assembly at any occasion.
3. If the valve is fixed with positioner, keep the spring in positioner casing
free before disassembling, after finishing, keep it original performance.
8.1.4 Replacing the Spring of Reverse Action Diaphragm

a) Perform the same operations of a) - e) of para. 9.1.2.
b) Disconnect air piping from diaphragm casing.
c) Remove bolt and remove casing and piece.
d) Replace spring.
e) Reassemble in the reverse order of disassembly.
8.1.5 Valve with Handle

A. For paras. 9.1.1., and 9.1.3. (Direct Action Diaphragm Motor)
Operations are the same.
B. For paras. 9.1.2., 9.1.4.
a) First remove hand wheel and lock nut.
b) Remove bolts and nuts of diaphragm casing.
c) While bringing up the diaphragm casing, screw down the spindle
of the handwheel to let it protrude inward.
11
8.1.6 Valve disc

A. Reverse Valve
a) Loosen the bolt and disassemble in half.
b) Loosen nut and remove lower cover.
c) slightly bring down valve plug and remove indicator and nut.
Then completely draw out the plug downward.
d) Reassemble in the reverse order of disassembly.
Note.
Pay special attention in locking the nut in reassembly, taking care not to
cause uneven tightening. Move the valve stem vertically and see if it moves
smoothly by hand. While checking in this way, lock up the nut evenly.
B. Direct Valve
a) Disconnect air piping from diaphragm casing.
b) Remove bolt and disassemble into half.
c) Loosen round nut and remove it. For diaphragms larger than 410J
(nominal) yoke is bolted to upper cover. In this case, remove bolts nuts.
d) Bring up the assembly above yoke yoke.
e) Remove nut and dismount cover.
f) Draw out the valve plug from cover.
g) Reassemble approximately in the reverse order to disassembly.
First insert the valve plug into body (valve seats). Then, put back bonnet.
Note.
1. Take the same care as that in the note of page. 9.1.6.A when locking
up the Bonnet.
2. When lifting the yoke and its related parts of a large size (diaphragms
larger then 410J) it is desirable to hook a wire rope to the arm of the yoke
or the head after slightly unscrewing the two bolts and then hoist the yoke
with a chain block.
3. While lifting the yoke, care not to bend valve stem or damage the
fitted parts by lifting the yoke diagonally.
4. The same care should be paid when handling the valve plug.
12
8.1.7 Gland Packing (Reference : para 12)

a) Screw down the nuts if tightening allowance is provided.
b) To place additional packing, insert packing only after confirming that
the pressure in the piping is perfectly zero. Remove the nuts, gland
flange bring up gland as high as possible and support them not to be
brought down.
Then, insert one ring of packing, push it by bringing down gland, raise
gland and gland flange and insert another ring and in the way put all
additional packing rings.
c) To replace the whole packing, reference para 12
d) When placing additional packing or replacing packing, do not lock up the
nut tightly from the beginning, but retighten little by little by checking
leakage, with internal pressure being kept applied.
13
9. TROUBLE SHOOTING
Problems and solutions for the cases when the lift of control valve is not
correctly changed against normal working air pressure.
Problems Solutions
Overhaul valve.
1) Sticking of valve guide, stem, etc. Remove engaged particles, scale etc,
if any and clearing
2) Defective diaphragm or leak out Replace with new one or lock
on connection face up the nut tightly
3) Leaking through O-ring seal of

yoke, in case of reverse action Replace with new O-ring
diaphragm motor
4) Leaking through handwheel

gland packing or O-ring in case Retighten or replace with new packing
of valve with handle
5) Sticking of pilot or lever, in case Remove scratches made after

of valve with positioner sticking with fine emery cloth or file.
6) Disconnection of diaphragm
Correct to normal.
stem from positioner
14
10. GENERAL PRECAUTIONS

(1) When disassembling a diaphragm control valve, put match marks to all
joining
faces and reassemble according to these marks.
(2) Perfectly protect the removed parts.
(3) Never allow any foreign matter to enter the body and valve interior when
reassembling.
(4) Do not install valve unnaturally to piping.
(5) Periodical Inspection carry out static test for each individual valve or general
static test of each valve with controller periodically about twice a year
(disassemble and inspect the following) and check if operation is normal.
a) Inspect valve disc and seat in the body twice a year. Overhaul and inspect
the diaphragm, diaphragm sliding parts and o-rings (in case of reverse
action type) of control section once a year.
However, when no trouble is observed, overhaul period may be
successively prolonged, and overhaul and inspection must be carried out
with proper intervals
intervals.
b) If oiler is provided with gland, properly feed oil by determining intervals

depending on the lubricating condition of valve stem.
However, oiler is not provided if teflon packing is used as these do not
require lubrication.
15
< FIG. 12 >
16
11. Instruction on Handling and Maintenance of Gland Packing

To assure high performance of the control valve, due care should be given
to handling and maintenance of gland packing since it is required to meet
severe conditions of sealing and low friction.
11.1 Preparation
11.1.1 Maintenance of Valve
Inner surface of the stuffing box:
Rusting or roughened surface will reduce the tightness. If it is the case, the
clamping force of the gland flange will not reach the bottom of the stuffing
box, resulting in inferior compaction. Clean and smooth the inner surface
with a piece of fine sandpaper. If it is permissible, coat the inner surface of
the stuffing box with a thin coat of grease.
11.1.2 Valve Stem

Check the sliding surface of the valve stem for any harmful scars, bend,
or misalignment against the stuffing box.
11.1.2 Make sure the material and size of the packing are as specified.
17
11.2 Fitting
11.2.1 Fit the formed ring without distorting the forming as much as practicable.
When putting the ring on the stem from the end of the stem, do not disturb
the shape of the ring. When putting the ring from the side of the stem, twist
the ring to open as shown in the diagram. In this way, deformation of the
ring, which is formed to have even density, can be minimized. It should be
avoided to loosen a ring of inappropriate size and repack it into the stuffing
box.
< FIG. 13 >

11.2.2 Distribution of the cuts of the rings over the circumference of the stem
should be by 90 degrees.
< FIG. 14 >
18
The density of the portions near the cut tends to become low, resulting in
leakage. Arrange the rings so that the cuts overlap once every four rings.
11.2.3 Hammer in one ring at a time with a wood hammer or a plastic hammer
and a bush-shaped jig. (The bush is made of aluminium or brass to prevent
damage to the stem or stuffing box. As for the size of the bush, it is
sufficient to have a small clearance when it is inserted in the box.) If
insertion of the first rings is not appropriate, tightening of the gland nuts will
not generate a clamping force which reaches the bottom of the stuffing box;
effective sealing can not be obtained.
It will also result in partial clamping of only one or two rings near the gland
flange. Such partial clamping has the following demerits;
a) Degrading of packing. Lubricant contained in the packing will ooze out.

b) Larger friction resistance and increased hysterics.
c) Valve stem tends to wear or receive damages.
d) Sealing lasts for a shorter time. Retightening of gland nuts has only
temporary effect. The conditions will get worse.
11.3 Tightening of Gland Nuts

The sliding surface of the packing will get to fit the stem through movement
of the stem, resulting in a smaller friction resistance. Accordingly. tighten
the nuts little by little and alternately while constantly moving the stem till
leak stops.
19
11.4 Lubrication
If an oiler is provided on the side of the stuffing box, feed the specified
grease without fail.
11.5 Retightening
11.5.1 The objective of retightening is to recover the initial clamping pressure. The
procedure is the same with 3.
11.5.2 When exposed to high temperature, packing will experience thermal creep
and loss. Retightening the packing after it has been exposed to the possible
to bring the packing back to the normal temperature, it is necessary to
retighten the packing at the service temperature.
11.5.3 Should a leak be detected when the valve is in service, retighten the
packing immediately to prevent the leak from increasing.
11.5.4 If retightening to stop leakage is frequent and the clamping torque is
excessive,
degrading of the packing may be suspected. As it affects the performance
of the control valve, replace the packing with new one.
11.6 Addition of packing rings

Under normal service conditions, it is hardly required to add extra packing
rings.
However, if the packing loose capacity for clamping, add one or two rings.
Before starting work, always make sure that the fluid pressure has been
released to atmosphere and the valve is safe to work on it.
11.7 Replacement with new packing

As explained in 2～3, should the packing be degraded due to improper
fitting, oozing of lubricant, etc., replace it with a new one in accordance with
the procedure described in this manual.
20
CHEMICAL DOSING UNIT
( CONc 1602 )

TABLE OF CONTENTS
PAGE
1. User Information --------------------------- 3
2. Safety Notes --------------------------- 3
3. Product Description --------------------------- 5
4. Installation --------------------------- 8
5. Operationg and Setting --------------------------- 11
6. Maintenance and Repairs

p --------------------------- 12
7. Trouble shooting --------------------------- 14
8. Spare parts --------------------------- 16
2
1. User Information
Thank you for having selected CONCEPT c type electromagnetic metering
pump. This instruction manual deals with the correct handling, operation
procedures and troubleshooting for the pump. Please read this manual
through completely first to ensure this equipment are operated safely and
reliably.
Please familiarize yourself with the following designations and symbols:
WARNING
There is a danger to life or a risk of serious injury if the notes on safety are
not observed!
CAUTION
There is a danger of slight injury and damage to property if the notes on
safety are not observed!
2. Safety Notes
WARNING
ㆍTurn off the power supply.
Disconnect cable from mains power supply before commencing
work on the pump, otherwise may cause an electrical shock.
ㆍArrange grounding!
This pump is supplied with a grounding conductor and grounding-
type attachment plug. To reduce the risk of electric shock, be
certain that it is connected only to a properly grounding-type
socket.
ㆍStop operating!
In emergencies the pump should be switched off immediately!
Disconnect the power cable from the power supply!
ㆍ For specified application only.
It is forbidden to use a pump for any other purpose. The pump
may be used only in compliance with the technical data and
specifications given in the operating instructions.
ㆍNo remodeling!
Do not modify the pump in any way or use parts which have not
been tested and approved by us for assembly of company
metering pumps. This can result in damage to persons and
property for which no liability will be accepted!
ㆍWear protective clothing
Always wear protective clothing (goggles and gloves, etc.) when
handling hazardous or unknown chemicals!
3
CAUTION
ㆍQualified operators only!
The pump must not be operated by untrained and unauthorized
personnel. Pump operators must have a sufficient knowledge of
the pump and its operation.
ㆍSpecified power only.
It may result in damage or fire to use the power supply which
doesn’t correspond to the details device label! Only the specified
power level is to be applied.
ㆍDo not run the pump dry.
Do not run the pump dry（without liquid inside the pump）.
Otherwise heat generated by abrasion between elements inside
the pump may damage the pump.
ㆍVentilate!
Dosing toxic or odorous media may result poisonings. Ensure the
operating site with good ventilation.
ㆍFollow the instruction manual.
Replace the wear parts according to the descriptions in the
instruction manual. Do not disassemble any part which is not
regarded as wear parts
in the spare parts.
ㆍLimited operating site and storage.
Do not install or store the pump in the following places：
Places where a flammable gas or material is used or stored.
Places where the ambient temperature is extremely high（45℃ or
higher）
ㆍDisposal of used pump
For disposal of used or damaged pumps, please observe all
locally applicable directives! (Consult a licensed industrial waste
products disposing company.)
4
3. Product Description
3.1 Functions
It is a microprocessor-controlled short-stroke solenoid-operated diaphragm-
type metering pump for metering liquid, non-combustible media.
Metering is based on a pulsating action. For each pulse coming from the
electronic control, the solenoid energizes and completes a stroke. The
diaphragm, stabilized by a steel core, displaces the medium in the liquid
end, the balls on the intake side are pressed against their seat while the
balls on the delivery side open, thus releasing the medium for metering.
The solenoid is deactivated on completion of the stroke and returned to its
initial position by a spring. In so doing, the valve on the delivery end closes
while the valve on the intake side opens so as to draw medium into the
liquid end. The safety diaphragm protects the leadthrough in the housing
from dust and moisture.
The solenoid-operated, diaphragm-type metering pump covers a capacity
range from approx. 0.7 l/h to 23 l/h (liter specifications at max. stroke length
and max. stroke rate) at a max. back pressure of 1.5 bar to 16 bar. The
recommended stroke length range, which will practically guarantee
metering accuracy, is 30%-100%. The delivery capacity can be adjusted on
the basis of the stroke length by means of a rotary knob and the stroke rate
byy means of a switch. The various operating
p g statuses are indicated byy an
LED for operation and empty/fault signal.
The pump features a connection facility for a single-stage level switch.
3.2 Technical Data

a) General Data
Metering deviations All material versions –5 % to +15 %
Metering reproducibility ±2%(under constant conditions,
stroke length>30%)
Permissible ambient temperature -10°C to +45°C
Electrical connection 220V±10%, 50Hz
1 10V±10%, 50 Hz
Mean power intake Strokes frequencies Power intake
90 strokes/min 12W
120 strokes/min 16W
180 strokes/min 24W
Type of enclosure IP 65
Insulation class F
External contact activation(optional) Necessary contact duration 20 ms
Contact load 5 V; 0.5 mA
External analog activation(optional) 4-20mA
5
b) Device Identification/Identity Code

The type identification plate affixed on the cover page is identical to that of
the supplied pump thus establishing distinct allocation between the
operating instructions and the pump. Please enter the 18 digits identity
code as specified under “Type” on the type identification plate in the gray
box below.
* All options except for NP6 & NP7 are with bleeding valves.
** Frequency 60Hz are available for special requirements.
*** 3 or 6 or 9 is necessary for control types 1 & 2.
Viton® is a registered trademark of DuPont Dow Elastomers.
6
c) Capacity Data
d) Installation dimensions
7
3.3 CONCEPT c Overview/Control

1 Frequency Selector Switch
2 Stroke Length Adjustment Knob
3 Pulse/Operation Indicator
(Green/Red/Orange)
4 Mains Power Connection
5 Connection Socket for Level Switch
6 Connection for External Activation
7 Transparent Cover
8 Housing
9 Head Valve
10 Bleeder Valve
11 Bypass Hose Socket
12 Liquid End
13 End Disc
14 Intake Valve
4. Installation
WARNING
The metering pump can contain water residue in the liquid end as the result
of testing at the factory! If handling media, which must not come in contact
with water, all traces of water must be removed from the liquid end before
start-up! For this purpose, turn the pump through 180°and drain off the
liquid end then flush with a suitable medium from above via the intake
connection.
CAUTION
ㆍPumps must be accessible at all times to facilitate operation and
maintenance.
Access points must not be obstructed or blocked!
ㆍWhen operating the metering pump against a closed shutoff element on
the delivery side, the resulting pressure buildup can reach a multiple of the
maximum permissible backpressure! This can cause the delivery line to
burst! To avoid this, it is advisable to install a ProMinent multifunction valve
which limits the maximum pressure which can be reached!
8
ㆍOnly use the clamping rings and hose sockets intended for the relevant
hose diameter as well as original hoses with the specified hose size and
wall
thickness otherwise the stability and durability of the connection will not be
guaranteed! Avoid reducing hose sizes! The next higher line cross-section
or a pulsation damper should be used for longer lines and high-viscosity
media.
4.1 Pump installation
ㆍMount metering pump on a tank or
support bracket with bolts and U-
washers (Ø5 mm).
ㆍTo ensure efficient operation, the
valves of the liquid
end must always be positioned
vertically.
ㆍShorten intake lines such that the
foot valve hangs approx.10–30mm
(approx. 50mm for heavily soiled
metering solutions) over the bottom
of the tank.
ㆍInstall
Install delivery line and metering
valve, pressure retention valve for
free outlet.
4.2 Hose connections

ㆍFit union nut and clamping ring
over hose line.
ㆍPush the hose end, cut at right
angles, onto socket as far as it will
go.
ㆍSlightly widen hose end if
necessary.
ㆍShorten hose end at right angles
by approx.10mm for connecting
several times.
ㆍPress on hose and firmly tighten
union nut.
9
4.3 Installation of Bypass Bleeder Line

Note: see section 3.3
ㆍThe bleeder valve (10) with bypass (11) is provided on the liquid end.
ㆍFit 4mm inside Ø (max. 6mm) hose on to bypass hose socket (11),
preferably use 6 x 4mm soft PVC.
ㆍIf PE lines are used, secure with a cable tie to prevent slipping.
Insert free end of hose line in metering tank.
ㆍConnect delivery line directly to delivery connection and metering valve.
4.4 Connection of Control Cable and Level Switch
ㆍIf applicable, connect level switch to connection socket (5) on the pump.
ㆍFor control type metering pump, control cable is connected to the pump
(cable length is subject to order by Device Identification Code), please
connect the cable to your control as follows:
External Lock Function provides safer dosing mode for customer: when
External Lock is activated, the metering pump is controlled only by external
control signal,
i.e. if Frequency Selection Switch is switched to 100% or 50% positions, the
metering pump won’t stop, still respond to external control signal. If External
Lock is set inactive, a required operation mode can be selected by
Frequency Selection Switch: When switch to 100%, 50%, the pump will
operate at 100% and 50% of maximum stroke frequency respectively, and
when switch to “contact” or “analog” （External control）, the metering
pump will stop.
4.4 Mains Power Connection

WARNING
ㆍTake particular care to ensure that the mains voltage agrees with ratings
on the type ienfication plate. A separate switching contact, e.g. relay or
contactor should be provided for parallel connection with inductive loads.
ㆍConnect mains power plug in the socket provided.
10
5. Operationg and Setting

5.1 Setting
The stroke length is set by means of the stroke length setting knob (2) and
the stroke rate by means of the frequency switch (1):
Setting 100%, 50% correspond to 100%, 50% of maximum stroke rate
respectively; and setting 25% corresponds to 25% of maximum stroke rate
or 0-100% stroke rate continuously adjustable for control type metering
pump.
CAUTION
ㆍFor control type metering pump, when priming, if External Lock is inactive
and External Lock is not reactivated after priming, then over dosing might
occurs, this would be serious to some applications (such as disinfect
d i ki water
drinking t with
ith di
disinfectant
i f t t containing
t i i chlorine).
hl i )
ㆍThe stroke length should only be set with the pump in operation when the
load on the metering stroke setting pin is relieved temporarily.
5.2 Start-
ㆍIn order to prime the metering pump, as for control type metering pump
and when External Lock is activated, if necessary, make External Lock
Inactivated, set stroke length knob (2) to 100% and stroke rate setting knob
(1) to 100%.
ㆍOpen bleeder valve by approx. 1 turn.
ㆍAllow pump to run until a little of the chemical is visible in the delivery line
or emerges at the bleeder valve.
ㆍOn metering pumps without a bleeder valve, the delivery line must be
released at the liquid end or a multifunction valve should be used.
ㆍAfter priming, close bleeder valve (10) or resecure delivery line at
metering valve.
11
6. Maintenance and Repairs

WARNING
ㆍOnly qualified electricians are permitted to carry out electrical repairs
(safety regu tons of Employer's Liability Insurance Association: VBG 4 and
ZH 1/11)!
ㆍDisconnect power plug or power supply line before opening the pump!
Isolate relay option if applicable! Check to ensure power is disconnected!
Secure pump while carrying out repairs to ensure it cannot be switched on
unintentionally!
ㆍAlways depressurize the delivery line first before carrying out any work on
the pump! Always discharge and flush liquid end! Observe safety date
sheets for metered liquid!
CAUTION
Before carrying out any maintenance and repair work always drain off and
flush out the liquid end first if hazardous or unknown metered media are
used! Observe data sheets of metered liquids!
6.1 Maintenance
Maintenance of the CONCEPT c metering pump is restricted to checking:
ㆍthe liquid end screws (firm fit)
ㆍthe delivery lines (firm fit)
ㆍthe delivery lines (firm fit)
ㆍthe leakage hole at the end disc (moisture can indicate diaphragm failure)
12
6.2 Replacing metering diaphragm

ㆍWith pump in operation, set stroke length to
"0" with rotary knob (2).
ㆍRelease screws (15).
ㆍPull liquid end (12) together with screws out
of end disc (13) and pump housing (8)
(approx.5mm) until the screws no longer offer
any resistance when turning the liquid end.
ㆍHold housing (8) in the left hand and release
diaphragm (13a) with the right hand by lightly
jolting liquid end (12) together with end disc
(13) in counterclockwise direction and release
screws (15) from drive spindle (13b).
ㆍNow pull liquid end together with screws out
of diaphragm and unscrew the entire
assembly from the drive spindle.
ㆍRemove diaphragm (13a) from end disc
(13). Screw on new diaphragm (13a) as far as
it will go on drive spindle (13b) and check
thread movement.
movement
ㆍOnce again remove diaphragm from drive
spindle.
ㆍFit end disc on housing.
ㆍInsert diaphragm in end disc and screw on
by 2 thread turns.
ATTENTION
Turn diaphragm such that the 4
holes in the diaphragm and end disc
are precisely aligned! The outlet in
the end disc must face downward!
13
ㆍFit liquid end (intake connection must face downward!) with screws on to
diaphragm and end disc (once again leave approx. 5mm space between
liquidend and end disc) such that the parts can still be turnded.
ㆍNow slowly turn parts in clockwise direction until diaphragm is firmly fitted
(resistance of return spring can be felt).
ATTENTION
Do not overturn diaphragm, particularly in Type 1601!
ㆍSet stroke length to 100 % with rotary knob (2) and with metering pump
running, slowly turn thecomplete delivery unit in clockwise direction until the
intake connection faces vertically downward.
ㆍStop pump.
ㆍTighten 4 screws (15) crosswise.
ATTENTION
Observe screw tightening torques!
Check the tightening torque of the liquid end screws after 24 hours of
operation! Additionally check the tightening torques on PP pumps every 3
months!
h !
Tightening torque for screws:
M4: 2.5 to 3 Nm
M5: 4.5 to 5 Nm
ㆍSet required stroke length with pump in operation.
7. Trouble shooting
WARNING
Return the me tering pump for repair only in a clean condition with the liquid
end flushed clean. Pumps which are used for metering radioactive media
must not be shipped!
Breakdown assistance
In order to be able to repair a small breakdown at any time, we recommend
to always keep a spare parts kit in stock - consisting of diaphragm, valves,
balls andseals. See chapter 6 for order information.
14
No pump intake despite full stroke movement and venting

Cause
Crystalline deposits caused by valves drying out.
Remed
ㆍRemove intake hose out of metering tank and thoroughly flush out liquid
end.
If this provides no improvement, remove and clean valves.
ㆍThe valve seat in the intake and head valve can be pressed out with a
3mm drift
Warning lamp (3) lights red

Cause
Chemical deficiency.
Remed
ㆍThe fault signal is acknowledged automatically by filling the supply tank.
Warning lamp (3) lights orange

Cause
External Lock is not activated.
Remed
ㆍIf external mode is required, connect external control cable to make
External Lock activiated.
Liquid emerges at head end

Cause
Delivery unit leaking at metering diaphragm
Remed
ㆍscrews in liquid end crosswise.
ㆍIf liquid still leaks out this indicates the diaphragm has failed and must be
replaced.
15
8. Spare parts
In order to repair small breakdowns at any time we recommend to always
keep a spare parts kit in stock. This kit contains the following wearing or
spare parts: 1 Intake valve, complete; 1Discharge valve, complete; 1set of
seals; 1diaphragm; 1set of connection part.
16
Guarantee Form
17
SALINITY METER SYSTEM
SALINITY METER
( MODEL : SI - 30 )

TABLE OF CONTENTS
PAGE
1. The Generals of System
1.1 Instruction --------------------------- 3
1.2 Measuring Principle --------------------------- 3
2. Installation of Salinity Meter

2.1 Controller Installation --------------------------- 4
2.2 The Sensor Installation --------------------------- 5
3. Operating the Salinity Meter --------------------------- 6
4. Technical Specifications of System --------------------------- 7
5. Drawing Inspection --------------------------- 8
6. Troubleshooting Guide --------------------------- 9
2
1. The Generals of System

1.1 Instruction
Salinity Meter is an instrument, which measures the content of natrium
chloride in the evaporated water from a fresh water generator displayed in
PPM (parts per million), and ensures that water containing a higher level of
PPM, than what has been keyed in at the salinity meter, is rerouted back to
the fresh water generator.
1.2 Measuring Principle

Measuring principle is that calculating the conductivity between two
electrodes submerged in evaporated water as means of quantity of current
on condition that constant voltage is supplied. Furthermore, measured
value, that is substantially affected by ambient temperature,is to be
calibrated by additional temperature compensation circuit to acquire reliable
result.
3
2. Installation of Salinity Meter

2.1 Controller Installation
The Salinity Meter is consist of two parts :
A display part where from the connected sensors is shown as well as
installation part whitch is delivered in a plastic module in which power
supply and connection clips are mounted. The display part is delivered in a
cabinet for front installation in the control cabinet and enclosed shape can
be used for the installation. The installation part is fastened. The cable is to
be connected through receptable & plug to the sensor and the sensor must
be connected to the terminal block, as described Fig 1.
( Figure 1. Connection diagram of the control box )
1) The white color cable of the sensor is connected to the terminal 4 (' Sensor + ')
2) The white color cable of the sensor is connected to the terminal 5 (' Sensor - ')
3) The red color cable of the sensor is connected to the terminal 6 (' Temp +')
4) The red color cable of the sensor is connected to the terminal 7 (' TEMP.- ')
4
2.2 The Sensor Installation
INSIDE OUT SIDE INSTALLATION &

TANK TANK DISASSEMBLY METHOD
5
3. Operating the Salinity Meter
1) On the front plate of the display part there are 4 keys

( MENU/ACK ,Increase(▲) ,Decrease(▼) ,ENTER ON-OFF ).
2) When the press ON-OFF key during 3 Sec.
after the source ( AC 220V ) is supplied to this controller,
the process value(PPM & TEMP.) will be displayed(Option DC24V).
3) If you want to alter the alarm setting value, press the '▲' + key and ▼' - key
at the same time then the current setting value(PPM) will be displayed while
the ALARM lamp is turned on after that set the alarm setting value
as much as you want.
4) After adjusting, Please make sure of saving the altered value by means
pressing the 'ENTER ' key. (Very Important)
5) When occur the alarm, click the 'MENU/ACK' key once then the alarming
will be stopped but the solenoid valve will be still on working.
6) The Power Fail ,,Alarm and Sol'valve output
p function is free contact.
(NO / COM / NC).
7) To keep the salinity operating accurately all the time,
detach the electrode(cell) and clean the sensor at least once a month.
In cleaning the electrode, carefully wipe off dust and scale from
its surface with soft cloth. Do not use sandpaper or other material
whitch may hurt the surface.
6
4. Specificaion Sheet
SPECIFICATION SHEET
CUSMOMER :
USED FOR :
1.1 SECIFICATION
NO. DESCRIPTION VALVE ENABLE
1 MODEL SI-30
2 MEASURING RANGE 0 ~ 200 PPM
3 ACCURACY ± 2.5 %
4 TEMP. RANGE 0 ℃ ~ 100 ℃ ( ± 2.0% )
5 CELL OPERATIONG PRESSURE 5 kg / ㎠
6 ALARM POINT 80 PPM ( User can be convert)
A. CONTACT FREE CONTACT ( 250V / 5A )
B. ALARM HORN CONTACT FREE CONTACT ( 250V / 5A )
7
C. SORENOID CONTACT FREE CONTACT ( 250V / 5A )
D. S
SIGNAL
G OUTPUT
OU U 4 ~ 20
0 mA OU
OUTPUT
U
8 POWER SOURCE AC 220V, 60Hz (OPTION : AC 110V)
9 CONTROL BOX AL DIECAST ( IP67 )

10 REFERENCE TEMPERATURE 25 ℃ PROGRAMMABLE
1.1 THE SCOPE OF SUPPLY

NO. NAME OF PARTS TYPE Q'TY REMARK
160＊120＊90
1 SALINITY INDICATOR SI-30-CB 1
(W＊H＊D)
SALINITY CELL WITH CABLE SUS316/STD/

2 (OLFLEX-110＊3C＊0.5SQ＊3M)
SI-30-CB 1
POLYACETAL
3 SAFETY VALVE SI-30-CB 1 SUS316/BS
NOTE :
7
5. Drawing Inspection
8
9
6. Troubleshooting Guide
Condition Cause Solution Remark
Check the power cable or ,
Power fail No power or fuse trouble
replace the fuse.
Check the Alarm Setting Value

Alarm Setting Value is higher
(Refer to the OPERATING
than normal state.
MANUAL)
ALARM LED fail
Change the I/O Main-PCB

Caution output signal error
(Contact to the manufacturer)
Check the Alarm Setting Value

Alarm Setting Value is lower
(Refer to the
than normal state
ALARM LED is on OPERATING MANUAL)
continually
Change the I/O Main-PCB
Caution output signal error
(Contact to the manufacturer)
PPM valve is lower

Inferiors on the senser serface Clean the sensor
than
e oso
Inferiors on tthe
e se
senser
se se
serface
ace Clean
C ea tthe
e se
sensor
so
PPM valve is higher
than normal Wire cut or error of Main-PCB Change the I/O Main-PCB
in the control box. (Contact to the manufacturer)
Bad connect between Jack Check the condition of

FND signal board Cable and Control Box Main-PCB Cable Jack tightened
error for the PPM and
Temperature
Wire cut or error of Main-PCB Change the I/O Main-PCB
PPM connect cable(white) is

Check the cable
unconnected or bad
ERR' and Alarm sign
on the PPM signal
Open the safety valve and
board The sensor cell is exposured in
contain water after insert the
the air
sensor
ERR' and Alarm sign TEMP connect cable(Red) is

on the Temp. signal Check the cable
unconnected or bad
board
mA connect cable error Check the positive and
negative of mA connect cable.
Non output
the mA value
Wire cut or error of Main-PCB Change the I/O Main-PCB
10
OIL DETECTOR
OIL DETECTOR
( CLS-112-2 )

OIL DETECTOR
TABLE OF CONTENTS
PAGE
1. INFORMATION --------------------------- 3
2. Features --------------------------- 3
3. Principle of Operationon --------------------------- 3
4. Application --------------------------- 3
5. Specifications --------------------------- 4
6. Adjustment Elements --------------------------- 5
7. Functional Table --------------------------- 5
8. Maintenance --------------------------- 6
9. Repair --------------------------- 6
10. Exchange ofelectronics --------------------------- 6
2
OIL DETECTOR
1. INFORMATION
The Model CLS-112-2 is the versatile Capacitance Type Level switch that
can detect the level of sediments in liquid, interface between two different
liquids as well as the level of high- insulating powders / granules, conductive
liquids / viscous liquids and others. It is one of the highly efficient detectors
whitch Si-Marine Co.,Ltd. has developed to ensure a correct level detection
under such conditions requiring the high technology as varied measuring
materials, complex / harsh products and so on. Through our long-term
experiencrs and achievements, use of quality materials and strict quality
control, we have here provided you with more stable and reliable products.
2. Features
ㆍChemically highly resistant materials.
ㆍHighly sensitive and stable meter .
ㆍMaintenceance - free.
ㆍCan easily detect highly corrosive substance .
ㆍRugged construction.
ㆍInsensitive to buildup.
ㆍCan easily install and adjust .
3. Principle of Operationon
This measures the impedance variation coming out between a main
electrode and a tank-wall or between the main electrode and an earth
electrode. As the level rises, the capacitance value goes up, and it provides
a contact output when the level exceeds the set value.
4. Application
ㆍINTERFACE : Oil and Water mercury in the Water alcohol and Acid,
Sediment in the water liquid and foam.
ㆍPOWDER : Plastic power, Slaked lime, Carbon, Iron oxide, Dust, Soil and
Sand, Surgar, Flour and others.
3
OIL DETECTOR
5. Specifications
▶ Installation Method : Top Mounting , Side Mounting.
▶ Conn. Size : PF 1" Thread , JIS 10K 50A FF Flange Type.
▶ Cable Gland : PG 13.5 * 2
▶ Power Supply : AC 110 / 220 V / 60HZ
▶ Output : Relay(SPDT) Contact , 250VAC 5A
▶ Material : Housing ~ ADC12
Connector ~ SUS 304
Probe ~ SUS316L
▶ Max. Pressure : 10 Kg/Cm2
▶ Max. Temperature : -40 ~+80℃
▶ Frequency : 400KHz
▶ Power Consumption : Max. 1.5W
▶ Protection : IP66
①POWER LAMP
②INDICATOR ALARM LAMP
③TIME DELAY RANGE
④SENSITIVITY ADJUST RANGE
⑤COARSE RANGE
4
OIL DETECTOR
6. Adjustment Elements
ㆍPOWER LAMP
Diode for indication of the switching status (DC or AC power supply).
ㆍINDICATOR LAMP
Diode for indication of the switching status (when any of substances
are contacted on the probe).
ㆍTIME DELAY ADJUST RANGE
Turnning the switch to the clockwise the reponse speed of the contact
signal will be slow then it can prevent the sensing error by the rolling of the
liquid or solid.
ㆍSENSITIVITY ADJUST RANGE
At the Low position, it senses from the top of the probe, when it indicates
60, it senses from the middle of the probe. When it is 80, it senses from the
20mm place from the edge of probe and when it is the High position it
senses from the the edge.
ㆍCOARSE RANGE
The sensing position can be adjusted by turnning the coarse switch to the
colokwise.
7. Functional Table
5
OIL DETECTOR
8. Adjustment Elements
The instrument is maintenance free.
9. Repair
For safety and warranty reasons, any internal work on the instrument, apart
from installation and wiring, must be carried out only by us
10. Exchange ofelectronics

Remove the old electronics and plug in the new oscillator. Carry out an
adjustment. The instruction is given upper “Simulation"(Switch point
adjustment).
6
FUEL OIL FLOWMETER
FUEL OIL FLOWMETER
( VZF 15 ~ 50, VZO 4 ~ 50 )

FUEL OIL FLOWMETER
TABLE OF CONTENTS
PAGE
1. Applications --------------------------- 3
2. Features --------------------------- 3
3. Your benefits --------------------------- 3
4. The right product for every application --------------------------- 4
The world’s most frequently used oil

5. --------------------------- 5
consumption meter
6. Control VZF 15...50 --------------------------- 7
7. Classic VZO 4...50 --------------------------- 12
VZFA/VZOA 15...50, versions for special

8. --------------------------- 22
requirements / applications
9. Accessories --------------------------- 29
10. Meter data --------------------------- 30
11. Selection of the optimal meter --------------------------- 37
12. Fuel oils --------------------------- 39
13. How to obtain an optimal measurement --------------------------- 40
14. Application examples --------------------------- 45
2
FUEL OIL FLOWMETER
1. Applications
• Flow measurement of mineral oils such as heating or propellant fuels
• In burners, on board ships, land vehicles and fixed installations
• Marine and metrological type approvals (optional)
2. Features
• The complete range of products offering the best solutions for the
measurement of oil consumption.
• State-of-the-art design with electronic counter, flow indication, analogue
and digital output signals and limiting value switch.
• Mounting on the pressure or suction side of a pump, with no straight inlets
or outlets required.
• Independent of viscosity and temperature
• High vibration resistance
• Classical version with mechanical display
3. Your benefits
• The reliable solution with everything from a single supplier.
• Reliable monitoring and flexible control of the system. Simplifies burner
settings and optimising consumption.
• Highly flexible mounting with very small space requirements
• Accurate measurements
• Maximum safety in the shipbuilding and automobile industries.
• Cost-effective metering point
4. The right product for every application

VZF 15 … 50 with multifunctional display and parameterisable outputs
Electronic display of
• totaliser, total and resettable volume
• actual flow rate
• other flow parameters
Output signals for
• volume pulses
• limiting values (Qmin, Qmax)
Simple to operate. Interactive parameter input
External power supply
Housing with threaded or flanged connections
Main characteristic data:
• flow range 10 … 30 000 l/h
• temperature ranges 130 and 180° C
• nominal pressure PN 16 and 25 bar (PN 40 on request)
3
FUEL OIL FLOWMETER
VZF 15 … 50 total volume display and remote transmission

Total volume display on roller counter
Option: Reed pulser RE or RV for remote totalisation
Option: Inductive IN pulser for control purposes
• flow range 0.5 … 30.000 l/h
• temperature ranges 60, 130 and 180° C
• nominal pressure PN 16, PN 25 and PN 40 bar
VZFA / VZOA optimal solution for special applications such as:

• differential measurement ((VZFA / VZOA 15...50))
• certification/official verification for commercial
transactions (VZOA 4…50)
• engine test benches (VZFA / VZOA 15…50)
VZFA
Electronic display of
• totaliser, total and resettable volume
• other flow parameters
Output signals for
• volume pulses
• limiting values (Qmin, Qmax)
Simple to operate
Interactive parameter input
External power supply
4
FUEL OIL FLOWMETER
VZOA 4 and 8
• Volume display on roller counter
VZOA 15...50
• Volume display on roller counter
Option: IN inductive pulser for control purposes

Option: RV Reed pulser for remote totalisation, integrated
into the roller counter
• flow range 10 … 30,000 l/h
• temperature ranges 130 and 180° C
• nominal pressure PN 16 and PN 25 bar (PN 40 on
request)
with special pairing for minimum measurement variance.
5. The world’s
world s most frequently used oil consumption meter
Leading manufacturers of oil burners and operators of heating systems,
ships or diesel engines rely on CONTOIL® fuel oil meters - and with good
reasons.
The advantages of CONTOIL® fuel oil meters – your benefits

You can decide which of these many benefits are the most important for
you:
• the optimal solution for every application
• simple burner setting with flow rate display (types VZF)
• simple consumption monitoring with limiting value switch Qmin/Qmax
(types VZF)
• manual dosing feature, with a resettable counter (types VZF)
• can be mounted on the pressure or suction side of a pump
• space-saving installation, because no straight inlet/outlet sections are
needed
• flexible mounting of the meter in horizontal, vertical or inclined positions
• accurate measurement result, since the reading is independent of the
temperature and viscosity of the fluid
• minimum failure costs due to simple function monitoring, rapid fault
analysis and the possibility of simple repairs on site
5
FUEL OIL FLOWMETER
Areas of application
• to measure heating fuel consumption by oil burners (for example, in
heating boilers, industrial furnaces, tar processing plants, ships boilers)
• to measure propellant fuel consumption by motors and engines (such as
diesel locomotives, construction machinery and ships, or in emergency
power units, combined heating and power stations)
• consumption monitoring and optimisation
• flow measurement for mineral oils
• optional remote processing and integration into superior systems
• manual dosing / batching
• flow measurement for machine and motor/engine oils
• engine test benches
Fuel types
• heating fuel extra light / light, medium, heavy
• naphtha
• diesel
• petrol and other lubricating liquids
6
FUEL OIL FLOWMETER
6. Control VZF 15...50

1)
6.1 Technical data
• display of total volume, resettable volume, and flow rate in m3, litres or US
2)
gallons
• user-friendly, interactive parameter input
• fuel oil meter with threaded or flanged connections
• for mounting in horizontal or vertical positions Versions available on
request:
• different flange drillings, such as ANSI, JIS
1) Manufacturer's specification, valid for the reference conditions as specified under

“APPENDIX: Meter data”.
2) 1 US gallon corresponds to 3.785 litres.
3) For burners and engines or motors, the meter must be selected on the basis of the
permanent flow rate. For higher viscosities, or if the meter is installed on the suction side, the
pressure drop and any reduction in the measuring range must be taken into consideration.
4) Weight without couplings.
5) Two freely selectable outputs are available, totally independent of each other.
7
FUEL OIL FLOWMETER
6.2 Electronic display
Display values:
• total volume, resettable volume, flow rate.
• In the information menu, hours of operation and other information can be
Obtained.
Display:
• 8-character LCD with identification of the parameter, height of numbers: 8
mm, flow rate (meter load) using bar indicator
Temperature:
• ambient temperature -25
25 … +70°
+70 C,
C
storage temperature -25 … +85° C
Safety:
• CE, vibration and shock test to DIN IEC 68
Power supply:
• 24 V DC (6...30 V DC)
Data preservation:
• by non-volatile memory (EEPROM)
Protection class:
• IP66 (IEC 60529) against water jets and dust
8
FUEL OIL FLOWMETER
6.3 Outputs
Four different output functions are available:
• Pulser for volume pulses with programmable pulse value (for external
totaliser)
• Analogue current output 4...20 mA corresponding to flow rate
• Frequency output 0...100 Hz corresponding to flow rate
• Switching function (limiting value switch) specified by programmable upper
and lower flow rates
Except for the current output function, any two of the remaining three
functions can always be used simultaneously. This results in two
types of connection:
• 1 potential-free digital output (Rel. 1), parameterisable to one of the three

functions described below.
• 1 passive analogue 4...20 mA output also used for powering the meter.
• 2 potenial-free digital outputs (Rel. 1 + Rel. 2), each parameterisable to
one of the three functions described below.
• the analogue output is not available in this case. The power however, is
suppled over these terminals.
9
FUEL OIL FLOWMETER
6.4 Specification of the outputs

Passive analogue output (1-2)
• Voltage range U: 6...30V DC
• Maximum load RL: (U-5) V / 0.0215A [Ω]
• Resolution: 16 Bit
• Max. error: + 0.2 mA
• Update interval: < 1s
Digital outputs (3-4, 5-6)

• Max. voltage Umax : 48V AC/DC
• Max. current Imax : 50 mA
• Max. output frequency fmax : 100 Hz
• Update interval: < 1s
• ON-resistance R0: <100Ω
• OFF-resistance R∞: >10MΩ
• Insulation voltage: > 100V AC/DC
Volume pulses
Pulse width t: 5, 50, 250, 500 ms
Pulse value: parameterisable
Current signal
• Flow rate at 4 mA Q1 : parameterisable
• Flow rate 20 mA Q2 : parameterisable
• Attenuation: parameterisable
Frequency signal
Output frequency fmax: 100Hz
Pulse ratio: 1:1
Frequency / Flowrate f1/Q1: parameterisable
Frequency / Flowrate f2/Q2: parameterisable
Limiting value switch

Limit Qmin: parameterisable
Limit Qmax: parameterisable
Hysteresis H: parameterisable
10
FUEL OIL FLOWMETER
Dimensions
Type designation key
Ordering specifications
11
FUEL OIL FLOWMETER
7. Classic VZO 4...50

7.1 VZO 4 and 8
Technical data 1)
• oil meter with internal threaded connections located on the bottom plate
• with mechanical roller counter, volume display in litres
• meters in US-Gallons 2)
• for mounting in horizontal, vertical and inclined positions
• VZOA 4 and 8 with EEC legal verification
Option: Reed pulser 48 V

2) 1 US gallon corresponds to 3.785 litres
permanent flow rate. For higher viscosities, or if the meter is installed on the suction side, the
pressure drop and any reduction in the measuring range must also be taken into
consideration.
4) Max. permissible error: VZO 4 Qmin 0.5: 0.5 l/h … 2 l/h = + 1%/– 2%. VZO 4: 1 l/h … 2 l/h =
+ 1%/– 2%.
5) Note: pulses of short duration!
12
FUEL OIL FLOWMETER
1) VZOA 4 and 8 with EEC legal verification D 04/5.232.14
2) Pressure drop curves

See “APPENDIX: Meter data”
3) Dimensions in mm
height = 79 Dial
width = 65
depth = 65
Detailed dimensional drawings

g in “APPENDIX: Meter data”
4) Mouting kit for VZO 8
Order No. 81130: some possible mounting positions
13
FUEL OIL FLOWMETER
5) RE Pulsers
Switching element : • Reed switch with dry contact (inert gas)

Switching voltage : • Max. 48 V AC/DC
Switching current : • Max. 50 mA
Quiescent current : • Open Contact
Switching power : • Max. 3 VA
ON-time
• VZO 4-RE 0.00125 : 65...90 %
• VZO 4-RE 0.01 : 10...30 %
• VZO 4-RE 1 : 30...70 %
• VZO 8-RE 0.00311 : 65...90 %
• VZO 8-RE
8 RE 0.1
01 : 10...30
10 30 %
• VZO 8-RE 1 : 30...70 %
Temperature : • Ambient -10 … +60° C
Protection class : Meters without pulser:
• IP 65 (IEC 60529) against water-jets and dust Meters with pulser RE:
• IP 50 (IEC 60529) against dust deposits
Connections: • On plug supplied with product for cable, 2 0.35 mm2
6) Ordering specifications
7) Special versions with FPM fluoroelastomer gaskets

VZO 4 V Order No. 92487
VZO 4 V - RE 0.01 Order No. 92488
VZO 4 V - RE 0.1 Order No. 92489
14
FUEL OIL FLOWMETER
7.2 VZO 4 and 8 OEM

Technical data 1)
• fuel oil meters for OEMs (original equipment manufacturers), to be
mounted under the burner cover
• meters with lateral internal threaded connections
• with 230V Reed pulser to display measurement values on remote totaliser
or on burner control unit
• for mounting in horizontal, vertical or inclined positions

permanent flow rate. For higher viscosities, or if the meter is installed on the suction
side, the pressure drop and any reduction in the measuring range must also be taken
into consideration.
3) Max. permissible error: VZO 4 OEM: 1 l/h … 2 l/h = + 1%/– 2%.
15
FUEL OIL FLOWMETER
1) Safety precaution
When connecting the Reed pulser to a low-voltage power source (50...250
V AC/DC), the specialist installing the equipment is responsible for ensuring
that all local regulations are observed (e.g. regulations for electrical
installations, personnel safety).

3) Dimensions in mm
16
FUEL OIL FLOWMETER
4) RE Pulsers
Switching element: • Reed switch with dry contact (inert gas)

Switching voltage: • max. 230 V AC/DC
Switching current: • max. 50 mA
Quiescent current: • Open Contact
Switching power: • max. 3 VA
ON-time: • 40 … 55%
Temperature: • Ambient -10 … +60° C
Protection class: • IP 65 (IEC 60529) against water-jets and dust
Connections: • Cable cross section 2 0.5 mm2, length 480 mm
5) Remote totaliser for VZO 4 OEM

Power supply: • 230 V, 50/60 Hz
Pulse value (input): • 0.005 l
Smallest readable
amount: • 0.005 l
Registration capacity: • 10 000 l
Registration:
before return • at Q
to zero 200 h
Panel cut-out: • 27 14.4 – 0/+ 0.2 mm
Installation depth: • 56 mm
17
FUEL OIL FLOWMETER
7.3 VZO 15 … 50
Technical data 1)
• Volume display on roller counter, in litres
• fuel oil meter with threaded or flanged ends
• for horizontal, vertical or inclined mounting
Option: Reed pulser or RV / IN pulser
Versions available on request:
2)
• meters in US gallons (option)

permanent flow rate. For higher viscosities, or if the meter is installed on the suction
side, the pressure drop and any reduction in the measuring range must also be taken
into consideration.
18
FUEL OIL FLOWMETER

2) Dimensions
Detailed dimensional diagrams in “APPENDIX: Meter data”.

3) RV Pulsers
This type of pulser is integrated into the roller counter and thus is
especially appropriate for remote totalisation. For other applications the IN
inductive pulser is preferable.
Switching element: • Reed switch with dry contact (inert gas)

Switching voltage: • max. 48 V AC/DC
Switching current: • max. 50 mA (Ri = 47 Ω/0.5 W)
Quiescent current: • Open Contact
Switching power: • max. 2 W
ON-time: • 50% ± 10%
Temperature: • Ambient -10 … +70° C
Connections: • Cast-in cable, length 3 m
Cable cross section: • 2 x 0.14 mm2
19
FUEL OIL FLOWMETER
4) IN Pulsers
Pulser for industrial applications. Supplied with plug-in pulser sensor.

Switching element: • Inductiv slot initiator according to IEC 60947-5-6
Switching voltage: • 5 …15 V DC
Residual ripple: • max. 5%
Switching current: • > 3 mA at 8 V DC / 1 kΩ
Quiescent current: • < 1 mA at 8 V DC / 1 kΩ
ON-time: • 50% ± 10%
Temperature:
p • Ambient –10 … +70° C
Connections:
• Pulser supplied with special plug. Required cable min.
2 x 0.35 mm2 and 4...6 mm external diameter or the cable is already
mounted if the option “Order No. 80019” is chosen.
Option:
• Cable mounted, 2 x 0.5 mm2, PVC black, length 3 m (Order No. 80019)
5) Type designation key
20
FUEL OIL FLOWMETER
DN 15 only when the plant has a dirt filter with a max. 0.1 mm mesh size.
21
FUEL OIL FLOWMETER
8. VZFA/VZOA 15...50, versions for special requirements / applications

For applications requiring an increased accuracy of ± 0.5 % or better,
such as:
• Measurement of EL heating fuel or diesel in testing facilities
• Differential measurement
• Commercial transactions for which the meters are legally required to have
type approval or official verification.
These products require dirt filters with smaller mesh size.
8.1 Versions for differential measurements

For differential measurements, the flow is measured in the supply and
return pipes. The difference between the two measurements is regarded as
the consumption.
To obtain optimal measurement results, VZFA or VZOA CONTOIL® fuel oil
meters calibrated in pairs should only be used, which are adapted precisely
to the plant/system operating conditions. The flow rate occurring in each
meter, the permissible pressure drop and the viscosity of the fluid must all
be considered during the design phase. The load on the meter is obtained
as follows: flow in supply section less consumption = flow in return section.
When the order is placed, the following information is required:

• application e.g. differential measurement for diesel
engines in an emergency power system
• fuel type e.g. diesel fuel
• temperature e.g. 15 … 40° C
• operating pressure e.g. 4 bar
• flow rate in supply section e.g. fixed pumping rate 200 l/h
• flow rate in return section e.g. 120 … 190 l/h
(for a consumption of 10 … 80 l/h)
The meters are marked “supply” and “return” during calibration and final
testing in the factory. They must then be installed in the correct pipes.
For further information on the subject of differential measurement, see the
sections “How to obtain an optimal measurement” and "Application
examples".
22
FUEL OIL FLOWMETER
8.2 Versions with type approval or official verification

Fuel oil meters are used almost exclusively for the measurement of the
consumption of fuel oil. The metrological standards (such as MID or EC
guideline 71/319/EEC), however, regulate the requirements for meters and
systems used for commercial transactions as well as the procedures for
design approval and official verification. Measuring installations where a
fluid is sold are regarded as transfer points that require official verification.
These include petrol pumps at petrol stations, measuring devices for road
tankers and measuring stations for loading and unloading all types of road
vehicles. As a rule, a metering system must be ready for use and be
checked and sealed by the local office responsible for transfer verification.
Typical of these applications is the narrow range of use with regard to
liquid, flow rate and temperature. Subject to type approval restictions,
CONTOIL® oil meters are also available with metrological type approval or
official verification. The differences in products relate only to the design or
specifications of the meter and not to the quality of the product.
23
FUEL OIL FLOWMETER
Technical data 1)
• Versions for optimal results from differential measurement or for fiscal or
commercial transactions
• VZFA with electronic display of total volume, resettable volume and flow
rate; units of measurement: litres, US gallons 2) or m3.
• VZOA with display of total volume on roller counter; units of measurement:
litres.
Optional versions with counter in US gallons.
• VZOA option: with RV reed or IN inductive pulser
• threaded or flanged connections available
• mounting in horizontal or vertical positions possible (for calibrated meters
horizontally only).
• VZFA: User-friendly, interactive parameter input. Easy integration into
control systems. Further Versions available on request:
24
FUEL OIL FLOWMETER
Note.
1) Manufacturer's specification, valid for the reference conditions as
specified under “APPENDIX: Meter data”.
3) For burners and engines or motors, the meter must be selected on the
basis of the permanent flow rate. For higher viscosities, or if the meter is
installed on the suction side, the pressure drop and any reduction in the
measuring range must also be taken into consideration.
5) Two freely selectable outputs are available, totally independent of each
other.
1) Technical data for VZOA with PTB certification: 5.232 / 04.37 Class 1
2) Technical data for VZOA with EEC legal verification: D 04 / 5.232.14
Two items are required when ordering: the VZOA meter and EEC legal
verification, Order No. 96026.
1)
For burners and engines or motors, the meter must be selected on the
basis of the permanent flow rate. For higher viscosities, or if the meter is
installed on the suction side, the pressure drop and any reduction in the
measuring range must also be taken into consideration.
Electronic display and Outputs VZFA: see page 6

RV Pulsers and IN Pulsers: see page 15
Pressure drop curves: See “APPENDIX: Meter data”
25
FUEL OIL FLOWMETER
3) Dimensions VZFA
4) Dimensions VZOA
5) Type designation key
6) Information required to process orders

When the order is placed, information is required on the plant operating
conditions (as stated at the beginning of this section). For fiscal and
commercial transactions only VZOA type meters may be used.
7) Example for differential measurement:

Application:
Differential measurement diesel, supply 200 l/h, return 120. … 190 l/h
2 Units Order No. 93758 Fuel oil meter, type VZFA 20 RC 130/16
2 Units Order No. 96112 Modification for differential measurement
26
FUEL OIL FLOWMETER
8) Example for fiscal or commercial transactions:

Application: Commercial transactions in Germany, extra light heating oil,
flow rate 200...400 l/h, temperature approximately 20 °C
1 Unit Order No. 92290 Fuel oil meter, type VZOA 20 RC 130/16
1 Unit Order No. 96026 Modification with EC official verification
9) Example for standard applications without options:

Application: Measurement of Diesel fuel on testing facility,
flow rate 200...400 l/h, temperature 20...50 °C
1 Unit Order No. 93758 Fuel oil meter, type VZFA 20 RC 130/16
10) Ordering details for VZFA (meters with electronic counters and
parameterisable outputs)
27
FUEL OIL FLOWMETER
11) Ordering details for VZOA (meter with roller counter)
28
FUEL OIL FLOWMETER
9. Accessories
1) Ordering details for accessories
2) Order details for supplementary equipment
3) Order details for supplementary equipment with mounting kits
29
FUEL OIL FLOWMETER
10. Meter data

10.1 Function
Flow meters work on the volumetric principle of rotary piston meters
(positive displacement meters).
The main features of this measuring principle are large measuring ranges,
high accuracy, suitability for high viscosities and independence from power
supply; flow disturbances do not influence proper operation.
10.2 Construction
Rotary piston, guide roller and drive are the only moving parts in contact
with the liquid. Their movement is transmitted by a magnetic coupling
through a sealing plate. The hydraulic part is completely separated from the
totalising module.
1) VZF/VZFA 15 ... 50
Connections are made radially with two cable entries
underneath the display unit which can be mounted and
rotated through 90° steps.
2) VZO/VZOA 15 … 50
With the exception of the counter with the RV Reed
pulser, the roller counter can be rotated through 360° for
optimum readability.
3) VZO/VZOA 15 … 50
The connections for the inlet and outlet are situated
vertically from below in the base plate. With the OEM
meter version the connections are situated on the side.
30
FUEL OIL FLOWMETER
10.3 Measuring error limits: Reference conditions

Measuring error limits according to technical data of meter in % of actual
value for the whole measuring range.
10.4 Reference conditions
Liquid: Calibration oil similar to extra light heating oil, density at 20°
C = 814 kg/m3 Viscosity = 5.0 mm2/s according to DIN 51757 / ISO 3104
(corresponds to 4.1 mPa.s)
Temperature: 18 … 25°C
Horizontal mounting, readings from counter.
Oil meters are never to be tested with water, otherwise they will get
damaged.
10.5 Pressure drop curves

1) Viscosityy information
Kinematic viscosity : Stokes, Centi-Stokes, mm2/s. St, cSt, mm2/s
Dynamic viscosity : Pascal seconds, millipascal seconds. Pas, mPa.s
Poise, Centipoise (outmoded). P, cP
Conversion : cSt density = mPa.s
Engler degrees °E to mPa.s: only use conversion table
Saybolt units to mPa.s: only use conversion table
Redwood units to mPa.s: only use conversion table
Rule of thumb : 1 cSt ➝ 1mm2/s ➝ 1mPa.s
31
FUEL OIL FLOWMETER
Viscosityy diagrams
g : A = 5 mPa.s C = 100 mPa.s E = 500 mPa.s
B = 50 mPa.s D = 200 mPa.s
For a pressure drop of more than 1 bar, it is recommended to use the next
larger meter size. Maximum permissible pressure drop = 3 bar
32
FUEL OIL FLOWMETER
Viscosityy diagrams
g : A = 5 mPa.s C = 50 mPa.s E = 200 mPa.s
B = 25 mPa.s D = 100 mPa.s F = 500 mPa.s
For a pressure drop of more than 1 bar, it is recommended to use the next
larger meter size. Maximum permissible pressure drop = 3 bar
33
FUEL OIL FLOWMETER
※ Example
Mineral oil, viscosity 450 mPa.s
VZO 25 mounted on pressure side of
pumps
❶ Viscosity curves DN 25
select closest curve
F = 500 mPa.s
❷Assume max. permissible pressure
drop = 1 bar
❸ The intersection of curve F with
the line corresponding
to 1bar gives a flow rate of 2000 l/h.
34
FUEL OIL FLOWMETER
S = Special versions
2) Dimensions in mm
35
FUEL OIL FLOWMETER
3) Dimensions of transducer groups / measurement transducer
4) VZF(A), VZO(A) Dimensional drawings 1 - 7 from table above
36
FUEL OIL FLOWMETER
5) Display / Roller counter
11. Selection of the optimal meter
37
FUEL OIL FLOWMETER
● applicable ❍ on request – not applicable
1) Only in accordance with the maximum mesh size of the dirt filter as per
technical data.
2) Determine conditions of use with supplier (other measured values!).
3)) DN 15 onlyy when the p
plant has a dirt filter with a max. 0.1 mm mesh size.
4) Two freely selectable independent outputs are always available.
※ Application note
For viscosities higher than 5mPa.s or for installations on the suction side of a
pump, pressure drop and possible limitation of flow range
must be taken into consideration.
38
FUEL OIL FLOWMETER
12. Fuel oils

12.1 Characteristics of different fuels
12.2 Indicative values on power for burners and engines Burners
Formula for consumption in litres/hour:

-Example-
Burner power in kW
=
Energy value of fuel in kWh/kg x density in kg/dm3
600 kW
= 62 l/h
11.8 kWh/kg x 0.82 kg/dm3
12.2 Engines
1) For differential measurement the flow meter has to be selected according

to the pump flow rate and the flow in the return pipe.
39
FUEL OIL FLOWMETER
Formula:
1 HP = 0.736 kW 1 kg Diesel at 0.84 kg/dm3 = 1.19 l
1 kW = 1.36 HP
Rule of thumb:
approx. 190 g/kWh correspond to 0.226 l/kWh
approx. 140 g/HP correspond to 0.167 l/HP/h
13. How to obtain an optimal measurement
13.1 Planning
Flow meters are precision measuring instruments.
They achieve optimal results if
• a few important rules are observed during plant design,
• mounting and commissioning are carried out with care,
• the meters are used for their defined purpose only.
13.2 Layout of Pipework

• The quantities consumed by all consumers must be registered by the
meter.
• Rotary piston meters do not require flow conditioners or inlet runs (after
b d T
bends, T-pieces
i or fi
fittings).
i ) Th
They may b
be mounted d iin h
horizontal,
i l vertical
i l or
inclined position, except with the head pointing downwards.
• The layout of piping must ensure that the meter is at all times filled with
liquid and that no inclusions of air or gas may occur. Do not install the
instrument at the highest point of the installation.
• Meter and accessory equipment must be easily accessible.
40
FUEL OIL FLOWMETER
13.3 Selection of the Meter and

To be considered when selecting the meter:
• Operating temperature
• Viscosity of the medium
• Operating pressure
• Flow rate
• Resistance of the material against fuel to be metered and working
conditions
The technical data are valid for the following reference conditions: EL
heating fuel / diesel at 20° C. For higher viscosities or if the meter is
mounted on the suction side of a pump, it is necessary to determine the
pressure drop and the flow rate that can still be attained by using the
pressure loss curves (page 25ff). If the pressure drop is more than 1 bar, it
is advised to use the next larger meter size. Maximum permissible pressure
drop = 3 bar.
13.4 Mounting on pressure side of pump (burners)
13.5 Mounting on suction side of pump (burners)
41
FUEL OIL FLOWMETER
13.6 Impurities in plant or fuel

Should impurities occur in the plant or in the fuel, a dirt filter has to be
installed before the meter. The filter mounted in the meter inlet is only a
safety filter and is too small to act as a dirt filter.
13.7 Stop valves or cocks

In order to avoid backflow and draining, stop valves have to be mounted
after the meter. Backflow and draining cause measuring errors and can
damage the meter.
13.8 Filling/Dosing
13.9 Remote Processing/Ancillaries

Any backflow must be avoided on meters equipped with pulsers for remote
processing. If this cannot be achieved by appropriate plant design,
a non-return valve should be fitted.
42
FUEL OIL FLOWMETER
13.10 Electrical wiring and installations

Electrical wiring and installations are subject to statutory regulations which
must be taken into account when planning the system. For installations in
zones subject to explosion hazards, consult an appropriate expert.
The following factors should be taken into account during plant design:
• ancillaries connected to the meter
• environmental interference
• maximum permissible cable lengths (with or without amplifier)
• junction boxes, cable guides
13.11 Cable lengths on the VZF meter outputs

A cable with wire diameter of 0.5mm is generally suitable up to 25 m and
such of 0.8mm will go up to 100m. In all other cases the limiting factors
should be considered.
a) for the analogue current output: ( 4..20mA)
Limiting factors are supply voltage (U) and resistance of the load (RL). To
ensure the maximum current signal of 21.5 mA with sufficient operating
voltage for the meter the following formula is used to calculate the
maximum
i permissible
i ibl resistance
i (RL) which
hi h consists
i off the
h resistance
i off
the cable plus the resistance of other components within the circuit.
Knowing the resistance of the other components, the maximum permissible
length for the cable can then be calculated.
b) for the semi conductor relay output: (volume pulses, frequency signal,
limit switch)
Limiting factors depend on the input specification of the higher system or
the totalizer. The ability of the input to detect the actual state of the switch is
specified by the system manufacturer.
For the relay switch a maximum of 100Ω at ON-state has to be considered
together with the cable’s resistance. A minimum of 10MΩ at OFF-state has
to be considered together with the cable’s capacity. The maximum
permissible length of the cable depends on the individual properties for
resistance and capacity.
43
FUEL OIL FLOWMETER
13.12 Pulsers IN and RV

a) Power supply
Our range of products includes passive pulsers for the remote processing
of flow data. The pulser generates one pulse per unit of volume and is to be
supplied with power from the pulse processing device.
RV IN
b) Selection of the appropriate pulser
The selection of the most appropriate pulser and pulse value depends on
the application. As a rule, remote totalisation demands rather large pulse
values, whereas analogue signals, dosing control or indication of actual flow
rate tend to need small values. Battery supplied devices can only be used
together with Reed pulsers.
c) Selection of the processing device

The pulse length depends on the flow rate. Continuous contact may occur
at zero flow. The device connected must therefore be able to accept
continuous load; otherwise, protective measures have to be taken. For
remote totalisation, it is recommended to use an electronic pulse counter
with a low power consumption and bounce filter.
d) Correct pulse processing

Interrupted flow may cause hydraulic oscillation of the liquid in certain
plants (hydraulic vibration with minimal backward/forward flow). The pulses
which can occur in such cases may be interpreted as forward flow by the
connected device. Such faulty pulses do not affect the indication of the
actual value since they can only occur at almost zero flow. However, if the
pulser controls a counting device, hydraulic vibration must be avoided by an
appropriate modification or layout of the plant.
44
FUEL OIL FLOWMETER
e) Pulse values
Pulse values depend on type and nominal size of the meter. They are
listed in the technical information of the meter concerned.
f) Pulse period
Pulse period as well as on- and off-times can be calculated with the
following formula:
pulse value in litres 3600
Pulse period in s =
flow Q in l/h
pulse period in s x on-time in % of pulse period
On-time =
100
Off-time = pulse period in s minus on-time
We recommend that this calculation be carried out for the highest and
lowest expected flow rates.
14. Application examples

14.1 Diesel engine
a) Direct consumption measurement
Instead of returning the fuel back into the main tank, an intermediate tank
equipped with a heat exchanger should be installed on the supply side of
the system. The flow measurement is taken in the supply pipe to the
intermediate tank. The load on the meter and the measuring result
correspond precisely to the consumption.
45
FUEL OIL FLOWMETER
b) Differential measurements
For differential measurements, the piping remains unchanged, with
circulation back into the tank. A flowmeter is installed in both supply and
return pipes. The consumption is determined as the difference between the
amount in the supply section and the amount in the return section. The
meter loads therefore correspond to the supply and return flow rates.
c) Reasons for using special meters for differential measurements

Standard meters feature a large measuring range and a max. permissible
error of ±1%. This makes them unsuitable for differential measurements, as
the following
g example
p shows:
For an optimal result, special meters are therefore used for differential
measurements. These are precisely matched to the operating conditions
and are calibrated in pairs. This means that the measurement error can be
significantly reduced (for example: ±0.1% at constant flow rates on the
supply side and ±0.3% with slightly variable flow rates on the return side).
46
FUEL OIL FLOWMETER
14.2 Loads on meters

Example: Engine power 500 hp, vehicle with electric pump
Effective loads on meters Supply constant 180 l/h

Return 100 … 174 l/h
Effective loads on meters Supply 45 …180

180 l/h
Return 39 …100 l/h
14.3 Consumption measurement on ships
On ships, care is usually taken to ensure that the engine can still be
operated at full power even if the filter is heavily contaminated or if the
meter is damaged. When switching over to the bypass, attention may be
drawn to the necessary maintenance via an alarm output, and the engine
can be temporarily operated without measuring the consumption.
47
FUEL OIL FLOWMETER
The magnetic valve opens as soon as the pressure drops below a defined
level.
Float or valve control in the intermediate tank is required. Formation of gas

is to be avoided. The magnetic valve opens as soon as the pressure drops
below a defined level. For measuring the consumption of more than one
engine, each will require a separate installation similar to the one above.
14.4 Installation of meter on suction side of pump
If the flow meter is installed on the suction side of the pump, the pressure
drop at the max. allowed flow rate and highest possible viscosity must be
taken into account. Also to be considered are installed filters.
48
/0%2!4)/. !.$ -!).4%.!.#% -!.5!,
-ARINE BURNERS
41'"
"URNERS 20 - 20 - 20 - 20 - 20 -

Table of contents
1. General
1.1. Forewords................................................................................................................................. 5
1.2. Conventions in this Manual ..................................................................................................... 5
1.3. Type labelling on Oilon burners .............................................................................................. 6
1.4. General information.................................................................................................................. 7
1.5. Inspecting boiler room ............................................................................................................. 8
2. Burner operation
2.1. Burner operation modulating ( M ) burners........................................................................... 10

2.2. Oil circulation in the burner.................................................................................................... 12
2.3. Sequence program, fuel oil ................................................................................................... 14
2.4. Automated functions in a modulating burner, oil fuel ........................................................... 16
2.5. Control Program of the Sequence Switch ............................................................................ 19
2.6. Control Program under Fault Conditions and Lockout Indication ........................................ 20
2.7. Additional heating................................................................................................................... 23
3. Installing the burner
3.1. Burner Installation .................................................................................................................. 27

3.2. Burner hinges......................................................................................................................... 28
3.3. Examplery Oil supply diagram............................................................................................... 29
3.4. Installing hoses ...................................................................................................................... 30
3.5. De-aerator and oil filter .......................................................................................................... 31
3.6. Electric connections ............................................................................................................... 32
4. First start-up and adjusting
4.1. First start-up and adjusting .................................................................................................... 33

4.2. Nozzle capacity charts........................................................................................................... 34
4.3. Adjusting combustion air........................................................................................................ 37
4.4. Adjusting pressure drop in combustion head ....................................................................... 39
4.5. Setting the burner head ......................................................................................................... 40
4.6. Adjusting oil pump ................................................................................................................. 42
4.7. Burning light fuel oil ............................................................................................................... 44
4.8. Preheater................................................................................................................................ 45
4.9. Temperature Controller for Preheater ................................................................................... 46
4.10. Preheater limit thermostat settings...................................................................................... 47
4.11. Compound regulator ............................................................................................................ 48
2 (77) RPMARINES 30820641GB

5. Maintenance
5.1. Burner maintenance............................................................................................................... 49

5.2. Dismounting the Combustion Head ...................................................................................... 50
5.3. Oil Filter .................................................................................................................................. 51
5.4. Changing the burner motor.................................................................................................... 52
5.5. Nozzle Valve RPL-1............................................................................................................... 54
5.6. Adjusting cam......................................................................................................................... 56
5.7. The Oil regulator .................................................................................................................... 58
5.8. Disassembling and assembling and the oil regulator........................................................... 59
5.9. Trouble shooting .................................................................................................................... 63
6. Technical data
6.1. Technical data........................................................................................................................ 69

6.2. Control unit technical Data ................................................................................................... 73
6.3. Control unit LAL 2.25............................................................................................................. 74
6.4. Flame Detector....................................................................................................................... 75
RPMARINES 30820641GB 3 (77)

1. General
1. General
1.1. Forewords
Thank you for using Oilon-products. We hope you are content with the product and our
service. This manual is intented to guide operation and maintenace of the product. We
pursue to improve our products and services. Therefore we readily accept feedback
about on our operation and maintenance manuals. Feedback may be sent to info@oilon.
com
Installation and maintenance of the device must be performed by a certified personnel. If

you need help with maintenance issues, please contact your nearest representative or
Oilon Oy technical support. Contact information can be found on our website at www.
oilon.com
1.2. Conventions in this Manual
1.2.1 Warning symbols in this manual
Read these instructions carefully before installation, commissioning or maintenance of

the burner. The given instructions must be followed.
Symbols used are :
Be careful. The DANGER symbol indicates a possible danger of bodily

harm or lethal injury.
Pay attention. The CAUTION sign indicates a possible danger of

damage to the device, components or surroundings.
Notes indicate tips, hints and other essential information.
KEEP THIS MANUAL ALONG WITH THE INSTALLATION RECORD AND THE
ELECTRICAL SCHEMES AVAILABLE NEAR THE BURNER!

1. General
1.3. Type labelling on Oilon burners
1.3.1 Example of type labelling
GRP-150 M-II
1 2 3 4
Label element 1: Fuel
KP Light fuel oil

RP Heavy fuel oil
GP Gas
GKP Gas + light fuel oil
GRP Gas + heavy fuel oil
Label element 2: burner size categorization
Label element 3: method of control
H Two-stage
T Three-stage
M Modulating
ME Modulating with a separate fan
P High-Low or modulating with an electronic controller
LH High-low with a preheater
On-Off
Label element 4: possible additional code

1. General
1.4. General information
1.4.1 Burner features and general information
BURNER CONTROL
BURNER APPLICATIONS Most heating appliances such as hot water
boilers, steam boilers, air heaters and thermo
fluid boilers
APPLICABLE FUEL . The burners are suitable for use on
heavy fuel oil, with a viscosity of max.
380 mm²/s (cSt) at a temperature of +50
°C and on burners with electric tracing
max. 700 mm²/s (cSt) at a temperature
of +50 °C.
. Temporarily light fuel oil
MINIMUM VISCOSITY FOR IN-LET OIL 1.5 mm²/s (cSt)
IN-LET OIL TEMPERATURE The temperature of oil coming to the burner
should be from 60 to 100 degrees Celsius.
OIL FILTRATION The oil coming to the burner must be filtered
before the oil pump. Maximum filtration
degree is 125 μm.
PREHEATER Oil is preheated in the burner's preheater to
the atomizing temperature. The oil
temperature is controlled by an electronic
regulator.
HEAT CARTRIDGES Oil pump and solenoid valves are equipped
with heat cartridges.
ADDITIONAL HEATING The burner pipes are equipped with trace
heating
HEAVY FUEL OIL ATOMIZING VISCOSITY
LIGHT FUEL OIL ATOMIZING VISCOSITY 1.5 to 12 mm²/s (cSt) at a temperature of +20
°C
OIL ATOMIZING PRESSURE 25 - 30 bar for heavy fuel oil
20 - 25 bar for light fuel oil
OIL PUMP RP 130 M : TA2
RP 140 M : TA2
RP 150 M : TA2
RP 250 M : TA3
RP 280 M : TA3
NUMBER OF NOZZLES 1
NOZZLE CONTROL Nozzle valve piston opens the nozzle. The
nozzle valve is controlled with a solenoid
valve.
BURNER MAX. TURNDOWN RATIO 1:2,5 (100 - 40 %)

1. General
COMBUSTION AIR FAN The fan provides the air needed in the
combustion. It is dimensioned to provide a
sufficiently high and even air pressure for
efficient combustion in modern combustion
chamber.
REQUIRED COMBUSTION AIR QUANTITY 15 m³ of combustion air for each burnt kilo of
oil
SERVOMOTOR AND COMPOUND Controls the burner capacity and the air/fuel
REGULATOR ratio according to the capacity demand.
OPERATING TEMPERATURE 0... + 45 C°
. The burner must be installed firmly. Vibrations may damage burner

or its components.
. Never store any inflammable material in the boiler room.
. Never use a naked flame while checking the burner or the boiler.
. Keep the boiler door closed while starting the burner and during
burner operation.
. Do not touch the oil pipes during burner operation. They may be
hot.
. Do not touch the levers of the compound-regulator or adjusting rod
leading out from the compound-regulator, and do not leave things
lying close to them when burner is operating.
. Wear hearing protectors, if there is noise in the boiler room.
. IN CASE OF FIRE OR OTHER EMERGENCY

. Switch off the main switch.
. Close the main fuel shut-off valve outside the plant.
. Take appropriate actions.
. Local regulations and requirements must be adhered to when ins-

talling or servicing the burner.
. Correct installation and adjustment together with regular servicing
are the most reliable guarantees of trouble-free burner operation.
. The burner has to be installed in such a way that the motor shaft
lies horizontally; however, it is not allowed to install the burner
upside down.
. Use only original spare parts. When ordering spare parts please
give the burner type and serial number indicated on the burner na-
meplate.
1.5. Inspecting boiler room
1.5.1 Take care of the boiler room

. Maintain tidiness in the boiler room and keep the door closed
. Make sure the there is always enough water (pressure) in the heating system.
. Make sure the boiler and the chimney are swept regularly, at least once a year
. Check the correct adjustment of the flue damper and the gate valve regularely.

1. General
. Make sure the burner room combustion air gap (air in-let hole) is open.
. Make sure the shut-off valves on pressure gauges are shut.
. Make sure tightness of the pipeworks, safety appliances of the boiler system,
pipeworks, and the burner are checked regularly according to rules and regulations of
public authorities.
. Check boiler and it's components.
. Making a maintenance contract is recommended.
Never use a naked flame while checking the burner or the boiler.
Never store any inflammable material in the boiler room.
Wear hearing protectors, if there is noise in the boiler room.

2. Burner operation
2. Burner operation
2.1. Burner operation modulating ( M ) burners
2.1.1 Combustion air
Burner device has been provided with a fan that is tailored to produce high and steady air
pressure, that is required to get a flawless ignition and good combustion in a modern
combustion chamber. A servomotor controls the amount of air feeded according to the
amount of fuel combusted.
2.1.2 Pre-ventilation, purging and ignition
Before ignition burner runs through pre-ventilation and purging periods.

During the pre-ventilation period the burner fan is ran with full load settings to exhaust
explosive fumes from the boiler.
Purging period flushes the nozzle valve and the utilisation circuit. The nozzle valve is
preheated and the oil temperature controller ensures adequate temperature has been
reached for fuel atomizing.
During purging period solenoid valve (NC) is closed and solenoid valves (NO) and main
solenoid valves (NC) are open. During this time oil does not flow through the control
circuit, but only to the nozzle valve of the utilisation circuit.
After the end of the purging period servomotor turns to the position of ignition load and
solenoid valve (NC) opens and solenoid valve (NO) closes. The oil pressure begins to
take effect on the nozzle control circuit. Oil flows from the nozzle. Spark between the
ignition electrodes ignites oil spraying from the nozzle.
2.1.3 Atomizing
During burner operation the capacity controller drives the servomotor, which drives the oil
regulator and air dampers between partial load and full load according to the capacity
demand.
If the burner shuts down, solenoid valve (NC) and main solenoid valves close, solenoid
valve (NO) opens. Oil pressure is released from nozzle valve. Nozzle valve springback
closes the needle valve in the nozzle and closes the oil flow in the nozzle.
10 (77) RPMARINES 30820641GB

2. Burner operation
The oil quantity to be burnt (= burner capacity) is regulated by means of the oil regulator
by throttling the oil return flow. At partial load the oil regulator is open and at full load
closed.
To get a sufficient viscosity for the fuel atomizing the oil temperature is raised with a
preheater device. The temperature of the heated oil is controlled electronically.
Atomizing pressure is provided by the burner oil pump.
In-let oil pressure to the pump varies case-specificly; See 'Pump adjustments'.
The nozzle is controlled by the the control circuit pressure (open-close).

For safety reason there is a throttle plug in the control flow line fitted to the connection of
solenoid valve (NC), with an aperture of Ø 1,5 mm. This plug reduces the strong control
flow, which is directed onto the spring-loaded piston.
2.1.4 PI-diagram of M-burner
5 23
19
*17
PS
16
20
PI
6 M
18 RE RE
21
5 7
* 11 15
14
* 12 12
4 PI PS 25
10 TZA
3 2 6
TI
9 9
* TE TIC 13
24 8
1 22 B-552E_2
1. Return to tank
2. Oil to Burner
3. Oil filter
4. Oil pump
5. Pressure gauge
6. Closing valve (normal position closed)
7. Pressure switch
8. Temperature indicator and controller
9. Main solenoid valves, NC (Normal closed)
10. Preheater
11. Limit thermostat preheater
12. Flame detector
13. Temperature indicator
RPMARINES 30820641GB 11 (77)

2. Burner operation
14. Solenoid valve, NC (normal closed) + throttle plug diam. 1,5 mm

15. Solenoid valve, NO (normal open)
16. Oil regulator
17. Pressure switch
18. Nozzle valve
19. servo motor
20. Non-return valve
21. De-aerator
22. Drilled-ball valve (normal position closed)
23. Servo motor
24. Temperature sensor
25. Three way valve
NC = default postion closed

NO = default position open
Components marked with a star symbol may be included or excluded according to

class and customer requirements
The burner has to be connected to the oil circulation system according

to the oil supply diagram.
2.2. Oil circulation in the burner
2.2.1 Oil circulation periods on a modulating burner ( M )
*
PS
* PI
M
M
EL.TR
PS
*
RE RE
*
PI PS
* TZA EL.TR
EL.TR EL.TR
TI
TE TT
EL.TR EL.TR
B-526A_1
Shutdown period
12 (77) RPMARINES 30820641GB

2. Burner operation
*
PS
* PI
M
M
EL.TR
PS
*
RE RE
*
PI PS
* TZA EL.TR
EL.TR EL.TR
TI
TE TT
EL.TR EL.TR
B-526A_1
Purging period
*
PS
* PI
M
M
EL.TR
PS
*
RE RE
*
PI PS
* TZA EL.TR
EL.TR EL.TR
TI
TE TT
EL.TR EL.TR
B-526A_1
Atomizing period
Components marked with a star symbol may be included or excluded according to

class and customer requirements
RPMARINES 30820641GB 13 (77)

2. Burner operation
2.3. Sequence program, fuel oil
2.3.1 Time Sequence Diagram LAL.2.25

4 LAL2.25 5
M B
NO
C NC
p
5
M D
2,5s
2
F
15s
TE H
CC
PT
5s
22.5s
I * 9 10 I
PID
J V V
IV * III IV
ON/OFF
II * II
K
5s
4 7 8
M L
3
1
M
13
5s 35s 15s
1 2 3 4 5 6 7 8 9 10 11 X W 12 13 14
W W
LAL2.25 3 P 7 1 12
p_103154.1
Required input signals to Control signals Permissible input signals to

control unit control unit
14 (77) RPMARINES 30820641GB

2. Burner operation
2.3.2 Time sequence diagram legend
A Control loop
B Fan
C Differential air pressure switch
D Oil pump
E Main solenoid valve, NC
F Ignition transformer
G Control circuit solenoid valves, NC and NO
H Capacity controller
J Air dampers
K Adjustable cam disc, air
L Servomotor
M Oil regulator
N Nozzle valve
O Flame signal
W Sequence switch stopped
X Sequence switch idle steps
* Required start signal to control unit terminal 8
2.3.3 Adjustable switching points on the cam switches of the servomotor
I switching point of full load

II switching point of the ”closed” position after controlled shutdown
III switching point of ignition load
IV switching point of partial load before change over to modulating area
V switching point of partial load at the low limit of the modulating area (V-I)
VI free
VII free
RPMARINES 30820641GB 15 (77)

2. Burner operation
2.4. Automated functions in a modulating burner, oil fuel
2.4.1 Sequence point 1. Prerequisites for start-up

. Failures and interlocks are reset
. Limit switch on burner flange is closed
. Control unit is reset (lockout indicator at symbol ◄)
. Control switch in position 2, 3, 4 or 5 (A) *M*
. Contact of burner switch-on/switch-off level in capacity controller is closed or it is by-
passed with manual operation position 3, 4 or 5 of control switch (A)
. Contact of boiler thermostat or pressurestat closed
. Preheater control switch in position 1 (heating ON)
. Required start signal from the limit switch of the switching point II in the servomotor to
terminal 8 in the control unit
. oil temperature > min. or temperature controller (min.) by-passed (light fuel oil)
. Contact C/NC of differential air pressure switch is closed (differential air pressure <
min.)
. Contacts of the low oil pressure switch connected to the control circuit are closed
. External contacts connected to the control circuit are closed
. Start signal at terminal 12 in control unit.
2.4.2 Sequence point 1.1. Start-up (lockout indicator of the control unit is at symbol ◄)
. Control loop closes

. Control program (sequence switch) of control unit starts.
. Checking of the flame detection circuit is in process
2.4.3 Sequence point 2
. Fan motor starts

. Oil pump motor starts
. Main oil valve opens and purging of nozzle valve with warm oil begins.
. After the differential air pressure switch has changed over its contact to position C/
NO pre-ignition begins (differential air pressure > min.).
2.4.4 Sequence point 3. Lockout indicator of the control unit is at symbol ▲

. Servomotor runs to switching point I (air dampers are open)
. Sequence switch does not operate during the running time.
2.4.5 Sequence point 4. Servomotor has run to switching point I (Air smapers are open)
. Start signal from the limit switch of switching point I to terminal 8 in control unit.
Otherwise the start-up program interrupts and the control unit remains (symbol ▲)
waiting for start signal (no failure).
. Pre-purge (22,5 s) with nominal air quantity begins.
16 (77) RPMARINES 30820641GB

2. Burner operation
2.4.6 Sequence point 5. Lockout indicator of the control unit is at symbol P
. Differential air pressure switch has to have changed its contact over to position C/NO.
2.4.7 Sequence point 6. Lockout indicator of the control unit is at symbol ■

. Control of flame supervision circuit completed
2.4.8 Sequence point 7. Lockout indicator of the control unit is at symbol ▼

. Pre-purge (22,5 s) completed
. Servomotor runs to switching point III (ignition load)
. Sequence switch is stopped during the running time.
2.4.9 Sequence point 8. Servomotor has run to switching point III (ignition load)
. Required start signal from the limit switch of switching point III to terminal 8 in control
unit. Otherwise the start-up program interrupts and the control unit remains (symbol
▼) waiting for start signal (no failure).
2.4.10 Sequence point 9. Safety time (5 s) begins
. Contact of return oil pressure switch (max.) must have been closed (C/NC)
. in control circuit of nozzle valve solenoid valve NC opens and solenoid valve NO
closes
. Oil pressure is released to control circuit of the nozzle valve. Nozzle valve needle
moves back and opens the nozzle valve.
. Fuel atomizing from the nozzle begins with pressure set for ignition phase.
. Oil spraying through the nozzle is ignited by the electric arc
2.4.11 Sequence point 10. Ohjelmareleen ohjelmaosoitin on symbolin 1 kohdalla
. Safety time ends (5s)

. Flame burns at set ignition load.
2.4.12 Sequence point 11. Lockout indicator of the control unit is at symbol | (operating)
. Ignition stops (electric arc)

. Sequence switch stops for the running time
. Control signal from terminal 20 on the control unit for the running time
. Servomotor runs to switching point IV (< V) before switching over to modulating area
(between switching points V and I
. When the load is high and the burner is turned on all the time, capacity controller
(PID, 3-step control) adjust the burner capacity on the modulating area (I - V) to
correspond to the load. With signal ”increase” or ”decrease” from the capacity
controller or from the control switch in manual operation, the servomotor of air
dampers and oil regulator is regulated to the direction ”open” or ”closed” according to
the capacity demand.
RPMARINES 30820641GB 17 (77)

2. Burner operation
. Burner operates thus supervised by control unit and controlled by capacity controller
according to set controller parameters and functions (see documentation of
controller)
. Burner shuts down when the load is small and the process value exceeds the burner
switch-off level set on the controller or controlled by the boiler thermostat/
pressurestat. In manual operation the burner shuts down controlled by the boiler
thermostat/ pressurestat only.
. If the oil temperature rises above the set limit on the preheater limit thermostat- the
burner shuts down. (thermostat lockup)
. stop and restart if the flame signal is lost during operation (wire link B has been cut
away from the from the plug section of the control unit)
. Stop and restart if the return oil pressure rises too high
Wire link B has been cut away at the factory.
2.4.13 Sequence point 12. Controlled shuttdown (control loop opens)

. Sequence switch starts and begins to program the permissible post-purge time (15 s)
. Oil pump motor stops
. Main oil valve closes
. Solenoid valve NC closes and NO opens in the control circuit
. Nozzle valve closes when the oil pressure in the control circuit disappears
. Flame extinguishes
. With control signal from terminals 10 and 11 of the control unit servomotor runs to
switching point II (air dampers to position ”closed” and oil regulator to position
”open”).
2.4.14 Sequence point 13. Lockout indicator of the control unit is at symbol ◄
. Permissible after-burn time (15 s) ends
. Flame simulation tests initiate in control unit.
. Sequence switch stops
. Fan motor stops
Re-start possible, if the prerequisites for start-up are fulfilled (see Sequence point 1.)
18 (77) RPMARINES 30820641GB

2. Burner operation
2.5. Control Program of the Sequence Switch
2.5.1 Control program diagram

t11 t1 t12 t6
a
4 12
I b
t7 t4 7
II a 19
b
16
III ab 10
t3 9
IV
t3n
15
t3" 9
V ab
t16 t5 11
VI 20
VII ab 8
t20
VIII ab 17
IX
t2
X ab 18
XI ab
XII ab
t10 t13
XIII ab
XIV ab
t8 p_101472.20
LAL2.25 P 1
a p_101472.4 b b' a
Lockout indication
. a - b = start-up sequence
. b - b' = idle steps (operation)
. b(b') - a = post-purge sequence (reset of control unit)
Numbers 4...20 are the control output contacts from the sequence switch relay
2.5.2 Switching times (in seconds) of the control program of the sequence mechanism
t1 Pre-purge time with air dampers open 22,5

t2 Safety time 5
t3 Pre-ignition time ”SHORT” (transformer connected to terminal 16) 2,5
t3” Pre-ignition time ”LONG” (transformer connected to terminal 15) from start
command
t3n Post-ignition time (transformer connected to terminal 15) 15
RPMARINES 30820641GB 19 (77)

2. Burner operation
t4 Interval between beginning of t2 and release of voltage at terminal 7,5

19
t5 Interval between end of t4 and release of voltage at terminal 20 7,5
t6 Post-purge time 15
t7 Interval between start-up command and release of voltage at 2,5
terminal 7
t8 Duration of start-up (without t11 and t12) 47,5
t11 Running time for air dampers to OPEN position (air dampers optional
position control)
t12 Running time for air dampers to IGNITION position (air dampers optional
position control)
t13 Permissible after-burn time 15
t16 Interval from start-up to OPEN command for air dampers 5
t20 Interval up to the self-shutdown of the sequence mechanism (idle 35
steps)
Switching times in seconds in the sequence of the burner start-up are valid for frequency
of 50 Hz. For 60 Hz frequency, switching times are reduced by approx. 20 %.
2.6. Control Program under Fault Conditions and Lockout Indication
2.6.1 Principle
In case of any fault fuel injection is stopped immediatly. The sequence mechanism stops
along with the lockout indicator. The symbol above the reading mark of the indicator gives
the type of fault.
20 (77) RPMARINES 30820641GB

2. Burner operation
2.6.2 Fault indications on a modulating burner
SYMBOL FAULT CAUSE Note

◄ Lockout the CLOSE signal
has not been
delivered to terminal
8 from air damper
servomotor or
contact have not
been closed between
terminals 12 and 4 or
4 and 5.
◄ Lockout Extraneous light (e.g.
non-extinguished
flame, leaking fuel
valves, defect flame
supervision circuit,
etc.).
▲ Interruption of start- the OPEN signal has Terminals 6, 7 and
up sequence not been delivered to 15 remain under
terminal 8 from the voltage until the fault
air damper is corrected!
servomotor.
P Lockout Lockout because the From this point on till
air pressure signal controlled shut down
has not been every air pressure
received at the start failure triggers a
of the air pressure lockout. Too little
control. difference in air
pressure (<min.)
triggers a lockout
when differential air
pressure switch
connector (C/NC)
engages a control
signal to control unit
terminal 13.
■ Lockout Fault in the flame
detection circuit
▼ Interruption of start- The ignition position Terminals 6, 7 and
up sequence signal has not been 15 remain under
delivered to terminal voltage until the fault
8 from air damper is corrected!
servomotor
RPMARINES 30820641GB 21 (77)

2. Burner operation
1 Lockout Flame signal has not Every flame signal

been received during failure after safety
safety time. time sequence leads
to a lockout
1 Lockout Return line pressure Pressure switch is
switch (max) optional component.
triggering stops fuel May not be included
injection. to delivery.
| Lockout The flame signal has If the wire link B has
been lost during been cut from the
burner operation plug section of the
control unit, repetition
of startup sequence
follows
| Lockout Air pressure signal
lost during operation
2.6.3 Restart
The control unit can be reset immediately after a lockout has occurred. After resetting (as
well as after correction of a fault, which resulted in a controlled shutdown, or after each
mains failure) the sequence switch always returns to its start position, whereby only
terminals 7, 9, 10 and 11 receive voltage in accordance with the control program. It is only
then that the control unit begins with a new burner start-up.
Do not keep the reset button pressed for more than 10 seconds.
22 (77) RPMARINES 30820641GB

2. Burner operation
2.6.4 Control unit LAL 2.25
1. Reset button
2. Program indicator
3. Fuses
. Control unit is a safety device. It is NOT allowed to open nor make altera-
tions or adjustments to it.
. The control unit must be completely separated from supply voltage before
carrying out any procedures to it.
. All safety functions must always be tested when using for the first time
and after changing the fuse.
. The control unit must be kept safe from water drops and sprays at all
times
2.7. Additional heating
2.7.1 Description
Additional heating keeps the burner ready for use. Additional heater devices ensure oil
fluency by keeping oil viscosity adequately low.
Keep heating on at all times. If the heaters are turned off they must be turned ON AT
LEAST 2 HOURS BEFORE starting the burner.
RPMARINES 30820641GB 23 (77)

2. Burner operation
If the oil viscosity is too high :
. ignition does not happen or it is difficult

. the oil pump and sealing components are overstressed which may lead to premature
degrading.
2.7.2 Heating cartridges on pumps
Pump Suntec
2.7.3 Heating cartridges on solenoid valves
Solenoid valves
24 (77) RPMARINES 30820641GB

2. Burner operation
2.7.4 Heating cartridges on nozzle valve
Press the cartridge in to the opening.
Top view of the nozzle valve
2.7.5 Heating the pipes and hoses with heating cables
The heating cables must run in direct contact

with the pipe surface. Loose cable does not
conduct heat into the pipings.
RPMARINES 30820641GB 25 (77)

2. Burner operation
2.7.6 Technical data
Heating cartridge capacity 40 W/230 V

Heating cartridge dimensions 10 x 50 mm
Heating cartridge electric cable 2500 mm
Heating cable Self adjusting - capasity decreases as the
pipe temperature rises.
Heating cable capacity 230 V 45 W/m in +10 C°
Heating cartridge case may be hot
26 (77) RPMARINES 30820641GB

3.1. Burner Installation
3.1.1 Mounting dimensions
2
D3 L2
60 °
D1 D2 L2
L1
1. Gasket
2. Mounting plate
3. Ceramic wool or similar
4. Refractory
Burner Dimensions in mm
D1 D2 D3 D4 L1 L2
RP130 200 240 M16 215 200 275
RP140 240 280 M16 255 220 275
RP150 270 310 M16 285 230 275
RP250 270 310 M16 290 300 365
RP280 300 340 M16 320 312 365
3.1.2 Burner mounting

The boiler front plate must be prepared in accordance with the given dimensions.
The threads of the bolts must be coated with graphite-bearing grease prior to fitting
The burner has to be installed in such a way that the motor shaft lies horizontally;
however, it is not allowed to install the burner upside down.
RPMARINES 30820641GB 27 (77)

Remove the transportation bracket after the burner is attached to the boiler
Make sure there is enough free space on the side to allow the burner to swing fully open
The burner must be installed firmly. Vibrations may damage burner or its
components.
3.2. Burner hinges
3.2.1 Standard composition
As standard the burner can be hinged to the left. The burner can be changed to be hinged
to the right by changing the position of the hinge pins.
Switch off the electric power from your burner before burner swing-out.
28 (77) RPMARINES 30820641GB

3.3. Examplery Oil supply diagram
3.3.1 Oil supply diagram

25
ZA
C PI
PS PS TI
PI PI
A
M
B-552E_1
25 - double closing valve (accessory)
A - Oil from tank

B - Return line to tank
C - Oil from pumping unit

D - Pressure regulating valve
The oil throughput from the pumping unit must be at least 1,2 x quantity of oil to be burned
kg/h + 150 kg/h
Example
If Then
burner capacity is 200kg/h throughput must be
1,2 x 200 kg/h + 150 kg/h = 390 kg/h
Pay attention to instructions from the pump manufacturer when

dimensioning the pipeworks.
RPMARINES 30820641GB 29 (77)

3.4. Installing hoses
3.4.1 Avoid torsion stress on hoses
Leave neutral
hose ends long
enough
Use rigid pipe

pends when
necessary
3.4.2 Minimum bend radius
Hose diameter Minimum bend radius ( r )

Ø 12 130 mm
Ø 15 130 mm
Ø 22 170 mm
30 (77) RPMARINES 30820641GB

3.5. De-aerator and oil filter
B-440J
A = Oil from tank

B = Oil to tank
Connection for oil line from filter to de-aerator

is marked with ONE line ( I )
Connect for oil line from de-aerator to tank is
marked with TWO lines ( II )
The accumulated gas must be able to vent from the deaerator. Always install the
degassing unit upright.
In case the de-aerator is installed separate from the pump, the connecting line has to be
trace heated and the pump has to be equipped with a heating cartridge.
RPMARINES 30820641GB 31 (77)

3.6. Electric connections
3.6.1 Connections
The burner must be connected according to the electrical diagrams delivered together
with the burner. General and local standards and regulations as well as requirements of
electrical equipment on electrical connections must be adhered to. Burner instru-
mentation has to be configured with a switch that allows it to be disconnected from the
low-voltage supply mains.
32 (77) RPMARINES 30820641GB

4.1. First start-up and adjusting
Keep the boiler doors closed during ignition and operation.
4.1.1 Prepatory to first start up
. Check the boiler and it's components are in proper working order
. Check the pipings are installed correctly and the joints are tight and have no leaks
. Check there is sufficiently water in the heating system
. Check there is adequate air inlet to the boiler room for the burner to have sufficiently
air for combustion
. Check there is fuel in the oil tank
. Check electrical connection points (inputs/outputs) are correct
Prior to first start-up the oil pump must be vented. The pump must not operate
without oil. See chapter ”Oil Pump".
4.1.2 First startup with heavy fuel oil

1. Connect main voltage.
2. Switch ON additional heaters at least 2 hours before start-up.
3. Check the installation of the drilled ball valve on the return line. Check that the valve
is CLOSED.
4. Check oil supply pressure and temperature. See further instructions from 'adjusting
the pump'.
5. Check there is oil in the pump.
6. Check direction of rotation of the burner motor. ( The electric connections are made
correctly ) Check direction of rotation of fan motor and pump motor. ( The electric
connections are made correctly )
7. Check atomizing temperature is correct. See further instructions from 'nozzle capacity
charts'.
8. Move the adjustment ring on burner head to middle position.
9. Check the condition and correct settings of ignition electrodes and cables.
10. Check the correct size and type of the nozzle.
11. Check the cam positions on air damper servomotor.
12. Switch the burner ON to minimum capacity.
13. Check the atomizing pressure is correct.
14. Check the return pressure for ignition phase.
RPMARINES 30820641GB 33 (77)

15. Use an oil flow meter to check minimum capacity. ( Minimum capacity preadjusted at
the factory )
16. increase capacity step-by-step by adjusting the screws.
17. Use a gas analyzer to adjust optimum values for the combustion.
18. Use an oil flow meter to check maximum capacity. ( Maximum capacity preadjusted
at the factory )
19. Test the safety equipments on the burner.
Never use a naked flame while checking the burner or the boiler. Never
store any inflammable material in the boiler room.
Wear hearing protectors, if there is noise in the boiler room.
4.2. Nozzle capacity charts
4.2.1 Nozzle capacity charts Fluidics 12 W1

Charts applicable when atomizing viscosity15 mm²/s (cSt)
34 (77) RPMARINES 30820641GB

340 W1-250 880 W1-650

860
320 840
820
W1-225 W1-600
300 800
780
280 760
W1-200
740 W1-550
260 720
700
W1-180
680 W1-500
240 660
640
220 620
W1-160
W1-450
600
200 580
W1-140 560
180 540 W1-400
W1-125
520
160 500
W1-112
480 W1-360
460
140
W1-100 440 W1-330
420
120 W1-90
400 W1-300
W1-80 380
W1-275
100 360
W1-70
340
80 320
25 26 27 28 29 30 25 26 27 28 29 30
4.2.2 Nozzle capacity charts Fluidics 12 W2
Charts applicable when atomizing viscosity15 mm²/s (cSt)
RPMARINES 30820641GB 35 (77)

W 2 NOZZL E CA PAC ITY W 2 NOZZL E CA PAC ITY
340 880
W2-275 860
320 840 W2-700
820
300 W2-250 800
780 W2-650
280 760
W2-225
740
720 W2-600
260
700
680
240 W2-200
660 W2-550
640
220 W2-180 620
600 W2-500
200 580
W2-160
560
180 540 W2-450
W2-145
520
160 500
W2-130
480 W2-400
460
140 W2-115
440 W2-360
420
120 W2-100
400 W2-330
W2-90 380
100 W2-80 360 W2-300
340
80 320
25 26 27 28 29 30 25 26 27 28 29 30
ATOM IZING PRESSURE bar
FOR EXAMPLE
Oil viscosity Atomizing temperature

180 mm2/s at 50 °C 110...115 °C
380 mm2/s at 50 °C 125...130 °C
700 mm2/s at 50 °C 135...140 °C
4.2.3 Fuel consumption by boiler capacity
P = boiler capacity kW
μ = boiler efficiency, 0,80-0,95
q = P/μ *Q Q =heat value, kWh/kg
q = fuel demand, kg/h (Note! all nozzles)
Heat value for light fuel oil approx. 11,86 kWh/kg and for heavy fuel oil approx. 11,22
kWh/kg. Check exact values from supplier.
36 (77) RPMARINES 30820641GB

4.3. Adjusting combustion air
4.3.1 Servomotor SQM 50. cam switches
The diagram shows the basic positions of the cam discs.
Cam switches (limit switches) are set at the factory during testing as follows:
II burner shutdown
III ignition load
IV load, when changing over from ignition load to partial load
V partial load, when changing over from full load to partial load
I full load
RPMARINES 30820641GB 37 (77)

. A - adjusting key (under cover)

. B - release lever
. C - adjusted at the factory, DO NOT RELEASE THE SWITCH!
. D - scale indicates only the turning angle of servomotor shaft
. With the release lever B the cam shaft can be disengaged. This makes it possible to
turn the cam discs manually.
Difference between switches IV and V must be approx. 3 - 5° The black

scale is in use. Cam switches VI, VII, and VIII are free ASZ
(potentiometer) in use when necessary
Do a flue gas analyzis to verify adjustments
Do not release the switch C. Change in position of cam discs will

damage servomotor and change burner adjustments.
38 (77) RPMARINES 30820641GB

4.4. Adjusting pressure drop in combustion head
4.4.1 Combustion head components

1 2 3 4
A-492V
5
1. Flame tube
2. Adjustment ring
3. Diffuser disc
4. Combustion head extension
5. Locking of adjustment ring
4.4.2 Effect of the adjustmen ring

Position of the adjustment ring effects on the pressure drop in the combustion head.
Pressure drop is adjusted by moving the adjustment ring back and fort thus altering the
gap between the adjustment ring and the diffuser plate. With a small load the adjustment
ring is positioned to the front and with a full load in the rear.
If... Then... And...

the adjustment ring is not there is too much pressure the igniton is poor OR
positioned rear enough with drop in the combustion head improper burning due to
a fuller load inadequate amount of air
(high CO-content) OR
flame tear-off from the
diffuser disc when switching
to fuller load
the adjusment ring is too rear there is not enough pressure deficcient combustio (O₂-
with a lesser load drop values too high)
Combustion head pressure drop minimum
RPMARINES 30820641GB 39 (77)

. with gas 2 mbar

. with heavy fuel oil 4 mbar
. with light fuel oil 3 mbar
4.4.3 Note!
If the position of the adjustment ring has to be altered in relation to the diffuser disc, the air
velocity and quantity in the combustion head will change. Check the combustion values by
flue gas analysis and, if necessary, adjust the combustion air quantity to be adequate.
4.4.4 Adjusting the combustion air

Combustion air volume is adjusted with the adjusting cam.
1. Check the surplus oxygen level from the gas flue after every adjustment with a flue
gas analysator.
2. Set the combustion air levels within the operation range of the servomotor
Guideline values
CAPACITY FUEL O2-LEVEL %

Ignition, minimum- and part Heavy fuel oil 4,5 - 6
power
Full power Heavy fuel oil 3 - 4,5
Ignition, minimum- and part Light fuel oil 3,5 - 4,5
power
Full power Light fuel oil 3-4
4.5. Setting the burner head
4.5.1 Setting the ignition electrodes

Check and set the ignition electrode spark gap and the distance of the nozzle to the
ignition electrodes and diffuser disc as show on the drawing
40 (77) RPMARINES 30820641GB

4.5.2 Ignition electrodes drawing
A-459Z
L
P
N M
H 17 mm
K 3,5 mm
L 6 mm
M 8 mm
N 12 mm
P 4 mm
RPMARINES 30820641GB 41 (77)

4.6. Adjusting oil pump
4.6.1 Oil pump connections
TA
6 7
1 2
4
A-212Z
8
3
1. Suction line connection

2. Oil to nozzle
3. Return line connection
4. Pressure adjustment
5. Protective cap
6. Oil inlet pressure gauge port
7. Oil pressure gauge port (to nozzle) / air venting
8. By-pass plug
Pump body includes a drilling to accept an electric preheater.
Note! By-pass plug must be FITTED in when installing to M-burners
4.6.2 Pump values

The pump has a built-in pressure control system
TECHNICAL DATA PUMP TA

Viscosity limits for incoming fuel: Light fuel oil 1.5 - 12 mm²/s (cSt)
Max. oil inlet pressure to burner 5 bar
42 (77) RPMARINES 30820641GB

Min. oil inlet pressure to burner 2.5 bar or higher depending on oil
temperature at the pump. See illustration.
In-let oil temperature range: Heavy fuel oil 60 - 100 C°
Pump operating pressure (=atomizing 25 - 30 bar
pressure) for heavy fuel oil
Pump operating pressure (=atomizing 20 - 25 bar
pressure) for light fuel oil
. Note! 1 bar = 100 kPa.
4.6.3 Adjusting the supply oil pressure
The diagram shows the required oil inlet pressure to the burner.
Check the inlet pressure to the burner from the the pressure gauge fitted to the filter
cover.
P max. 5
3
P min.
A B
C)
50 100 150
T min. T max.
Recommended operating zone illustrated in gray

Temperature curve = Oil temperature at the pump
Example A :
Oil temperature at the pump In-let oil pressure to burner Status

102 C° 2,9 bar OK
Example B :
Oil temperature at the pump In-let oil pressure to burner Status

120 C° 2,9 bar LOW PRESSURE !
Pressure must be lifted over
3,8 bar
RPMARINES 30820641GB 43 (77)

4.6.4 Pump pressure adjustment
Use the pressure adjustment screw. Turn the screw clockwise to increase the pressure.
Install a pressure gauge/valve -assembly if necessary.
4.6.5 Venting the oil pump

1. Loosen the plug of the pressure gauge port. Note! Do NOT remove the plug.
2. Let the burner operate for a while. Bubbles of air come out of the opening
3. Retighten the plug when no more bubbles appear
The pump is self-priming. The pump is intended for use in two-pipe

system (=ring main system).
4.7. Burning light fuel oil
Burner is suitable for temporary use of light fuel oil
Pay attention to following:
. Turn OFF preheater when burning light fuel oil

. Decrease the atomizing pressure
Turn OFF preheater when using light fuel oil
44 (77) RPMARINES 30820641GB

4.8. Preheater
4.8.1 Preheater components
B-348M
1 2 3
8 7
100 C
C
100 125 4 5 200 C
75
150
50
2 1
1. Heater
2. Temperature sensor of limit thermostat
3. Controller sensor
4. Temperature controller
5. Limit thermostat
6. Limit set point - Low
7. Signal lamp, temperature low
8. Signal lamp, control
The burners have electrical preheaters which consists of one or several heating units.
The heating units have one common regulator, and individual thermostats.
The connectors in the control box are under voltage. The safety cover is
allowed to be opened only by authorized staff.
4.8.2 Temperature regulation

Oil atomizing temperature is adjusted with the controller.
Check the oil atomizing temperature on the thermometer.
RPMARINES 30820641GB 45 (77)

4.9. Temperature Controller for Preheater
4.9.1 CAL 8000
CAL 8000 C
A
B C
D E
100
150
F
G 50
90
H p_101739.10
I
A Removable top fascia of potentiometers (manual reset and low limit).

Remove sliding the fascia parallel with the display panel.
B Manual reset potentiometer for correction of deviation. With this
adjustment the position of P-range with respect to the set point can be
altered. Adjust anti-clockwise, if the average temperature of oil stabilises
above the set temperature during burner operation. Adjust clockwise, if
the average temperature of oil stabilises below the set temperature
during burner operation.
C Setting of oil temperature low limit. Adjust the low limit point 20 to 30 °C
below set point by means of the potentiometer. Rotate the definition
scale (G) until the LED (F) lights up. Rotate the definition scale 20 to 30
°C above the operation set point. After this rotate the potentiometer (C)
first completely anti-clockwise and then clockwise until the LED (E) just
lights. Rotate the definition scale back to the right set point (atomising
temperature).
D D LED is lit, when the outlet of control channel is switched on (heating).
E E LED is lit, when the relay of alarm channel is energised (oil
temperature low).
F Set point indication and together with two adjacent LED's indication of
deviation.
G Definition scale
H Hinged fascia on scale lock
I Scale lock. Rotate clockwise or anti-clockwise to unlock. Check after
setting and locking the indication of set point.
46 (77) RPMARINES 30820641GB

4.9.2 Temperature deviation indicator
Controller has three LED's, that operate in five steps and indicate the deviation of the
actual value from the set point. Each step operates for 2 % (4 °C) of full scale (0...200 ºC).
SIGNAL MEANING
more than 6 °C below set value
6 - 2 °C below set value
Set value ± 2°C
2 - 6 °C above set value
more than 6 °C above set value
It is possible to modulate the temperature controller for 110 V voltage.

Contact Oilon technical support for further assistance.
4.10. Preheater limit thermostat settings
4.10.1 Limit thermostat setting
The limit thermostat is adjusted at the factory and sealed with paint. Set value is +180°C .
The limit thermostat has a reset button. Use the reset when the limit thermostat is not
energized.
Do not open the sealed locking screw. Breaking the seal voids warranty
RPMARINES 30820641GB 47 (77)

4.11. Compound regulator
The oil quantity to be burned is determined by nozzle size and oil pump pressure. The oil
regulator controlled by the servomotor regulates the return oil flow according to the
capacity demand.
At partial load the oil regulator is open so that the oil throughput in the valve is at
maximum and return flow pressure and nozzle capacity are adequate.
At full load the oil regulator is closed whereupon the oil throughput is at minimum and the
pressure at maximum. The air quantity is matched to the oil quantity to be burnt by means
of the spring band on the adjustable cam disc (see ”Adjustable Cam Disc”).
The burner is preadjusted at the factory. Accurate adjustments to be made with a flow
meter at site
Do a flue gas analyzis to verify adjustments
48 (77) RPMARINES 30820641GB

5. Maintenance
5. Maintenance
5.1. Burner maintenance
Cut off electric current from the burner and close manual shut-off valves
always before any maintenance work. Cutting power is adequate when
just inspecting the device.
5.1.1 To maintain flawless operation it is recommended to do the following at least once a year:
1. Check the burner head extension and change if necessary.

2. Check the diffuser disc and change if necessary.
3. Clean the ignition electrodes and check their setting.
4. Change the oil nozzle if it is worn or damaged.
5. Check the position, condition and cleanness of the flame detector.
6. Clean filters. Filters may have to be cleaned more often depending on circumstantial
conditions.
7. Check the air dampers lock screws and the servomotor axle lock. Retighten if
necessary.
8. Check and lubricate the joints on adjustment rods.
9. Check the oil pump capacity.
10. Clean your burner from dust and moisture.
11. Check regularly the combustion characteristics by flue gas measurements (after
refilling of the storage tank or at least once a year).
12. Check if the oil tank needs to be cleaned. The oil tank must be cleaned at least every
4-5 years.
Correct installation and adjustments and regular maintenance ensure correct operation of
the burner.
. Service the burner annually

. Use only original spare parts. When ordering spare parts please give the burner type
and serial number indicated on the burner nameplate or manufacturing card
5.1.2 Note!
The burner contains electric and electronic components. Adhere to rules and regulations
from local authorities when disposing.
RPMARINES 30820641GB 49 (77)

5. Maintenance
5.2. Dismounting the Combustion Head
5.2.1 Components
. Unscrew fixing screws of the combustion head and withdraw the combustion head.
The combustion head extension is fixed with rivets to the combustion head guide.
. Reassemble in reverse order
1 2 3 4 7 5 6
B-389P
1. Burner body
2. Fixing screw for combustion head
3. Combustion head guide
4. Adjustment ring
5. Diffuser disc
6. Combustion head extension
7. Nozzle
50 (77) RPMARINES 30820641GB

5. Maintenance
5.3. Oil Filter
5.3.1 Oil Filter components
2 3 4 5 6 7 8 9 1. Mantle
2. Cover
3. O-ring
10
4. Gasket
11 5. Hexagon head plug
1 B
6. Hexagonal screw
7. Gasket
12 8. Spring
9. Filter element
10. Washer
11. O-ring
A-525G
12. Label
13. Plug
14. Nut
A - Oil to filter
A B - Oil to burner
14
13
5.3.2 Note!!
Before cleaning of the filter make sure, that oil does not flow to the filter.
5.3.3 Cleaning
. Remove the plug by loosening the nut.
. Loosen the hexagonal screw and open the filter cover and remove the element. A
suitable solvent and a soft brush, which does not damage the screen, can be used for
cleaning of the element.
. If there is some dirt in the filter, it can be removed by for ex. vacuuming. Check the
condition of O-rings as well as the condition of the washer.
. Lock the plug with nut.
. Place the filter element into the filter and then the cover.
. Fasten the fastening screw on the cover with a torque of 25 - 30 Nm.
RPMARINES 30820641GB 51 (77)

5. Maintenance
5.4. Changing the burner motor
Switch off the electric power from the burner and ensure the motor is not
under voltage. Remove motor fuses if necessary.
5.4.1 Components
1-2 mm
A-429L
1. Motor
2. Fan wheel
3. Oil pump
4. Intermediate shaft
5. Coupling head
6. Wedge
7. Intermediate bushing
8. Fixing screw for fan wheel
9. Base bushing
10. Air dampers
11. Fixing screw for mounting flange
5.4.2 Dismounting the fan wheel
. Switch off the electric power from the burner.

. Disconnect the electric cable of the motor.
. Remove pressure pipe from the oil pump.
. Remove air dampers. Do not let the air dampers hang on servomotor cable!
. Unscrew screws of oil pump.
. Support with hand the intermediate shaft and withdraw the oil pump.
. Unscrew screws in the mounting flange of the motor and remove the motor (note the
weight of the motor).
52 (77) RPMARINES 30820641GB

5. Maintenance
. Unscrew the fixing screw of the fan wheel.

. Remove intermediate bushing and coupling head.
. Withdraw the fan wheel from the motor shaft using an extractor.
. Loosen the wedge and the base bushing.
5.4.3 Mounting the fan wheel

. Place the base bushing.
. Set the wedge into the shaft slot.
. Pull the fan wheel to its place using a binder plug. The fan wheel lies against the base
bushing.
. Place the coupling head and the intermediate bushing.
. Fasten the fan wheel with fixing screws to the motor shaft.
. Place the motor and fasten the screws.
. Support with hand the intermediate shaft and install the oil pump. Fix the pump with
locking screws.
. Check the axial gap of the coupling heads (1-2 mm). Adjust, if necessary.
. Place the air dampers.
. Fix the pressure pipe of the oil pump (remember to vent the oil pump).
. Connect the electrical cable to the motor.
. Fix the fuses and connect the burner to the mains (check direction of rotation in the
motor).
RPMARINES 30820641GB 53 (77)

5. Maintenance
5.5. Nozzle Valve RPL-1
5.5.1 RPL-1 Components

L
C R S B-384E
4 3 5 6 7 8 1 2 12 9
10
11
L1 L1
1. Body
2. Break spring
3. Rear cover
4. Hexagonal socket screw
5. O-ring for cover 18,72 x 2,62 Viton
6. O-ring for piston 12 x 2 Viton
7. O-ring for bottom plate 18,72 x 2,62 Viton
8. O-ring for spindle 6 x 2 Viton
9. Oil nozzle
10. Cylinder
11. Piston
12. Spindle
C Control circuit
R Return from nozzle
S Outlet to nozzle
L Nominal size of nozzle valve
L1 Nozzle open position (chacking the spindle movement )
54 (77) RPMARINES 30820641GB

5. Maintenance
5.5.2 RPL-1 Operation principle

The opening of the nozzle valve is controlled by solenoid valves and oil pressure. The
force of the oil pressure on the piston must exceed the force of the spring. The pressure of
the spring closes the nozzle valve, when the oil pressure stops having effect on the
nozzle valve. The needle valve of the nozzle closes. The needle in the nozzle valve is
complete withdrawn when the oil pressure in the control circuit is approx. 1800 kPa
(approx. 18 bar).
5.5.3 When to change nozzle
If the nozzle seems to be functioning improperly, you may clean the nozzle with diesel oil.
If cleaning does not fix the problem, the properties of the nozzle have got worse and the
nozzle has to be changed. The new nozzle has to be of same type as the original.
If there is an oil leak from the hole in the rear cover , change the nozzle or install a repair
kit.
RPMARINES 30820641GB 55 (77)

5. Maintenance
5.6. Adjusting cam
5.6.1 Adjusting cam components

5 2 9 10 4 1
3
7
11
6
12
B-391U
1. Adjusting cam body

2. Adjusting guide
3. Adjusting screw
4. Cup spring
5. Spring band
6. Locking screw of spring band
7. Spring band guide
8. Fixing screw of guide
9. Locking plate
10. Hexagon socket-head screws (5 pcs)
11. Hexagon socket grub screw
12. Hexagon socket-head screw
5.6.2 Adjusting cam function

The adjusting cam regulates the air flow into the burner relative to the quantity of
atomized fuel.
Profile of the spring band sets the dampers positions at any point within the adjusting
range. The profile of the band can be shaped with the adjusting guide and the adjusting
screws.
The air dampers are connected to the adjusting cam with the adjusting lever. The
adjusting lever moves according to the profile of the spring band. Combustion values
have to be verified by doing a flue gas analysis with every adjusting cam indvidually.
56 (77) RPMARINES 30820641GB

5. Maintenance
5.6.3 Adjusting the spring band

1. Loosen the locking screws (10) max. ¼ of a turn
2. Adjust the spring band by turning the adjusting screws (3)
3. Retighten the locking screws (10)
The edges of the spring band are sharp. Unwary handling may cause
slashes
5.6.4 Changing the spring band

1. Remove the servomotor along with its locking plate from the compound-regulator.
2. Release the first adjusting lever from compound-regulator
3. Release the adjusting flange
4. Release the locking screw of the spring band and the spring band guide.
5. Replace the damaged spring band
6. Reassemble the components by following these instructions in reverse order
RPMARINES 30820641GB 57 (77)

5. Maintenance
5.7. The Oil regulator
5.7.1 Oil regulator components

1
10 11
14
B-393U
2
3
4
13 9
12 8
5
15
17
18 16
B C
1. Body
2. Dosing shaft
3. Dosing nozzle
4. O-ring 9,3 x 2,4 Viton
5. Fitting
6. Compression spring
7. Thrust washer
8. Roller bearing
9. Spring cotter
10. Front flange
11. Hexagonal socket screw
12. O-ring 45 x 2 Viton
13. X-ring 10,2 x 2,62 Viton
14. Ball bearing
15. Non-return valve
16. Coupling
17. Washer
18. Retaining ring
B Oil to valve
C Oil from valve
58 (77) RPMARINES 30820641GB

5. Maintenance
5.7.2 Oil regulator function
When the in indicator for swing angel is in position 0º, the dosing shaft is in open position.
The return flow is at maximum and the return pressure at minimum. When the in indicator
for swing angel is in position approx. 160º, the dosing shaft is in closed position. The
return flow is at minimum and the return pressure at maximum.
The pressure gauge on the regulator shows the return pressure. There is a number on the
dosing shaft and on the indicator which shows the size of the groove on the shaft.
5.8. Disassembling and assembling and the oil regulator
5.8.1 Detaching the oil regulator
These instructions illustrate detaching the oil regulator (B309Y10...Y30) from the body of
heavy fuel oil burner for maintenance. Photographs are of a model RP 280 M-burner.
Details may vary depending on the burner model. Spare parts may be found from the
spare parts catalog.
CUT OFF ELECTRICITY from the burner main switch and CLOSE OIL
IN-LET to burner prior to dissassembly.
1. Needed tools 2. The oil regulator valve is located between

servomotor and the burner body. See arrow.
RPMARINES 30820641GB 59 (77)

5. Maintenance
3. Remove the locking pin and detach the 4. Release the servomotor shaft by pressing
swivels/adjusting rod from the adjusting lever. the release switch. Turn the adjusting lever
so that your able to loosen the shaft locking
screws.
5. Unscrew the screws holding the 6. Loosen the locking screws on the oil
servomotor mounting plate. Pull out the regulator shaft.
servomotor. Place and fasten the servomotor
so that there is no streching strain on the
cables.
60 (77) RPMARINES 30820641GB

5. Maintenance
7. Pull out the adjusting lever (A). Detach the 8. Open pipe nipples and detach the oil pipes
adjustable cam disc (B). Notice the wedge on from the oil regulator.
the shaft.
9. Dismount the valve from

burner by detaching the
mounting plate from the body.
5.8.2 Disassembling
These instructions illustrate the disassemblying of the oil regulator valve (B309Y10...
Y30). Spare parts may be found from the spare parts catalog, group 16.
RPMARINES 30820641GB 61 (77)

5. Maintenance
Uncover the components in numbered order Be careful not to damage the brass coating
on the dozing nozzle.
Regulator groove is marked on the shaft.
5.8.3 Assembling
Maintain tidiness during assembling. Use lubrication oil on components.
1. Assemble and screw down the valve shaft (3) and attach the screws (2)
2. Assemble the dozing nozzle (4). Note! There is opening in the nozzle for allignment.
3. Attach the washers and the plate needle bearing.
4. Attach the spring and the tube connector.
5. Check the shaft rotation. The saft should roll 360° steady and smooth.
5.8.4 Attaching
1. Mount the assembly plate and the valve to burner body.

2. Attach the oil pipes.
3. Attach the adjustable cam disc and check that the locking screws are tightened
4. Attach the servomotor
5. Attach the adjusting levers
6. Release the servomotor by pressing the release switch and check that the air
dampers move freely as the cam disc turns.
62 (77) RPMARINES 30820641GB

5. Maintenance
5.9. Trouble shooting
5.9.1 Basic checks

In the event of fault conditions the basic requirements for correct operation must be first
examined:
1. Check the electric supply (control and supply voltages).

2. Check the fuse on the control unit by pressing the control unit reset button. If the fuse
is intackt this should cause a fault condition lockup.
3. Check that all regulating and control devices are correctly set.
4. Check that all the safety devices are in normal operating condition
5. Check is the burner getting fuel, are the valves in fuel line open, is there oil in the tank
6. Check is there sufficiently water in the heating system?
7. Check that the direction of motor rotation is correct
When it is established, that the fault is not due to above mentioned, the individual burner
functions must be checked. Reset the burner control unit if it is in lockout position (signal
lamp lights). Burner starts, when the sequence switch has run to its start position and
other prerequisites for start are fulfilled (see chapter Burner Automation; Operation”).
Observe the burner functions.TheThe symbol appearing above the reading mark indicates
the possible kind of fault (see chapter ”Control Program under Fault Conditions and
Lockout Indication”). Measuring instruments can be used for finding of the fault.
RPMARINES 30820641GB 63 (77)

5. Maintenance
5.9.2 Start failure
CONDITON POSSIBLE CAUSE ACTION

Control loop closed, signal Faulty control unit Change the control unit
lamp for start limit is on,
burner or the start-up
program of the control unit
does not start. The lockout
indicator remains at symbol
Control loop closed, burner The control unit (connector 8) 1. Clear the break
or the start-up program of the is not receiving required start 2. Change the servomotor
control unit does not start. signal from servomotor (limit 3. Change the control unit
The lockout indicator remains switch II) 4. Release the dampers,
at symbol ◄ lubricate
1. A break in control circuit
2. Faulty servomotor
3. Faulty control unit
4. Air dampers are stuck
Burner motor starts, program Servomotor does not reach 1. Change the servomotor
remains at pre- purge period the position of full load of air 2. Change the limit switch
▲ dampers (limit switch I) 3. Change control unit
4. Release the dampers,
1. faulty servomotor lubricate
2. faulty limit switch in ser- 5. Correct the settings
vomotor
4. jammed air dampers
5. incorrect setting on cam
switch
Burner motor starts, program Servomotor does not reach 1. Change the servomotor
remains at pre- purge period the position of ignition load of 2. Change the limit switch
▼. air dampers(limit switch III) 3. Change control unit
4. Release the dampers,
1. faulty servomotor lubricate
2. faulty limit switch in ser- 5. Correct the settings
vomotor
4. jammed air dampers
5. incorrect setting on cam
switch
64 (77) RPMARINES 30820641GB

5. Maintenance
5.9.3 Motor failure
CONDITON POSSIBLE CAUSE ACTION

Burner motor does not start. 1. Break in main circuit 1. Repair break
Lockout occurs. Symbol 1 2. Motor overload relay trig- 2. Check relay trigger level
gered , reset or change
3. Fuse triggered 3. reset or change fuse
4. Faulty motor contactor 4. change
5. Faulty motor 5. change
6. Break in the motor 6. Repair break
control circuit 7. Change control unit
7. Faulty control unit 8. Examine, isolate fault
8. Return pressure too high 9. change the switch
(pressure switch trig-
gered)
9. Faulty pressure switch
max.
5.9.4 Ignition failure
CONDITION POSSIBLE CAUSE ACTION

Burner motor starts, control 1. Dirty or worn ignition 1. Clean or change
voltage from control unit to electrodes, insulator 2. Adjust according to inst-
ignition transformer IS cracked ructions
switched on, ignition does 2. Ignition electrodes too 3. Change the cables
not happen and after a short far apart 4. Change the tarnsformer
time lockout occurs. Symbol1 1 3. Ignition cable damaged
4. Faulty ignition trans-
former
Burner motor starts, control 1. Faulty control unit 1. Change control unit
voltage from control unit to 2. Connection joint of ig- 2. Attach properly or
ignition transformer IS NOT nition transformer is change the joint
switched on, ignition does loose or damaged
not happen and after a short
time lockout occurs. Symbol1 1
RPMARINES 30820641GB 65 (77)

5. Maintenance
5.9.5 No flame establishment

Burner motor starts, ignition 1. Solenoid valve does not 1. Change the valve
is operational, after a short function 2. change the coil
period of time a lockout 2. faulty coil on solenoid 3. Change the cable
occurs. Symbol 1 valve 4. Change the control unit
3. damaged cable
4. faulty control unit
Nozzle valve does not open 1. nozzle needle does not 1. Change the nozzle
open 2. Change the piston or the
2. Nozzle valve piston is O-ring
stuck 3. Clean the plug
3. Clogged throttle plug
No spray from nozzle Oil atomizing pressure is See 'pump adjustments'.
inadequate Cahnge the O-ring
The nozzle O-ring is
faultySuuttimen O-rengas on
viallinen
Main solenoid valve does not 1. Return oil pressure is 1. Examine, isolate fault,
open too high repair
2. Faulty return oil pressure 2. Change the pressure
switch (max.) switch
5.9.6 Oil pump failure

Supplies no oil or atomizing 1. Dirty filter 1. Clean or change filter
pressure is too low 2. Leaking suction line of 2. Fix the leaks
transfer pump 3. Change the pump
3. Pump capacity dec-
reased / pump is worn or
faulty
Loud mechanical noise 1. Pump is cavitating / in- 1. Tighten joints, Clean the
sufficent in-let pressure filter, check and adjust
to the burner pressure
2. In-let oil temperatur too 2. Raise in-let oil tempe-
low rature
3. In-let oil pipings con- 3. Check joints
nected incorrectly
66 (77) RPMARINES 30820641GB

5. Maintenance
5.9.7 Lock out after flame establishment

Flame forms. When burner 1. Incorrect burner ad- 1. Correct adjustments
runs to full load, flame justment 2. Clean filters
extinguishes, shutdown 2. Dirty filters 3. Change the nozzle
occurs and then re-start (wire 3. Clogged nozzle
link B cut away from the plug
section of the control unit).
Flame establishes. Shutdown Oil temperature is too low 1. Repair or change the
occurs and then re-start. preheater
1. oil preheater is faulty o 2. Check and adjust the in-
2. oil preheater's capacity is let oil temperature
inadequate
3. incorrect setting on low
limit of oil temperature
5.9.8 Oil flows into the combustion chamber

Oil flows into the combustion Nozzle valve and main oil Clean, repair or replace
chamber during burning valve or nozzle valve and
period non-return valve do not close
properly
Oil leaks to the boiler during valves are leaking Clean, repair or replace
purging period
Constant oil leak from the A leak in non-return valve or Change the valve
nozzle valve when the nozzle main solenoid valve
is closed
RPMARINES 30820641GB 67 (77)

5. Maintenance
5.9.9 Flame monitoring fault (=lockout)

Burner motor starts, flame 1. Incorrect position of 1. Fix position
establishes, and then a flame detector 2. Clean the flame detector
lockout 2. Flame detector is 3. Check burner adjust-
unclean ments
3. The flame is too weak 4. Change the flame de-
(not bright enough) tector
4. Faulty flame detector 5. Change control unit
(due to damage or age) 6. Prevent extraneous light
5. Faulty control unit from reaching the flame
6. Incorrect flame signal detector
due to extraneous light
Lockout during pre-purge 1. Faulty flame detector 1. Change the flame de-
2. Faulty control unit tector
3. Incorrect flame signal 2. Change control unit
due to extraneous light 3. Prevent extraneous light
from reaching the flame
detector
Lockout during shutdown 1. Faulty flame detector 1. Change the flame de-
Symbol ◄ (due to damage or age) tector
2. Faulty control unit 2. Change control unit
3. Incorrect flame signal 3. Prevent extraneous light
due to extraneous light from reaching the flame
4. Oil or carbon deposits detector
burn in combustion head 4. See section ”Combustion
5. Valves don not close head”
5. Clean, repair or replace
5.9.10 Damage in burner head

Diffuser disc burned-out Change diffuser disc
Burner head extension Change burner head
damaged extension
Inside of the burner head is 1. Distance between dif- 1. Correct the adjustments
oily or has heavy carbon fuser disc and nozzle in- 2. Correct the adjustments
deposits correct 3. Enhance air supply
2. Combustion air settings 4. Replace with an appro-
are not correct priate nozzle type of
3. Not enough supply air correct size
for constant combustion 5. Change the nozzle
4. Nozzle incorrectly sized
or of wrong type
5. Nozzle is worn
68 (77) RPMARINES 30820641GB

6. Technical data
6. Technical data
6.1. Technical data
6.1.1 Burner technical data
Weight RP-130 M : 140 kg

RP-140 M : 139 kg
RP-150 M : 167 kg
RP-250 M : 195 kg
RP-280 M : 196 kg
Capacity kW RP-130 M : 390 - 1370
RP-140 M : 560 - 2040
RP-150 M : 680 - 2700
RP-250 M : 650 - 3200
RP-280 M : 900 - 3500
Capacity kg/h RP-130 M : 34 - 121
RP-140 M : 50 - 180
RP-150 M : 60 - 240
RP-250 M : 58 - 282
RP-280 M : 80 - 308
Control unit LAL 2.25 / LOK16 / PLC
Oil pump RP-130 M : TA2
RP-140 M : TA2
RP-150 M : TA2
RP-250 M : TA3
RP-280 M : TA3
Oilhose connection (suction) R ½"
Oilhose connection (return) R ½"
Degree of protection IP44
Control voltage 230 V (-15%... +10%), 50 Hz, 1-phase
Control voltage *on request* 230 V, 60 Hz, 1-phase
Supply voltage 380...420 V, 50 Hz, 3-phase
Supply voltage *on request* 440 V, 60 Hz, 3-phase
Supply voltage *on request* 690 V, 50Hz Hz, 3-phase
Supply voltage *on request* 690 V, 60Hz Hz, 3-phase
RPMARINES 30820641GB 69 (77)

6. Technical data
6.1.2 Suply voltage option 380 V 50 Hz
Burner motor output kW RP-130 M : 3,2

RP-140 M : 4
RP-150 M : 5,5
RP-250 M : 7,5
RP-280 M : 7,5
Burner motor current IN [ A ] RP-130 M : 6,3
RP-140 M : 7,9
RP-150 M : 10,5
RP-250 M : 14,7
RP-280 M : 14,7
Burner motor efficiency [ % ] RP-130 M : 86
RP-140 M : 83,9
RP-150 M : 87,6
RP-250 M : 85,1
RP-280 M : 85,1
Burner motor speed r/min RP-130 M : 2880
RP-140 M : 2840
RP-150 M : 2855
RP-250 M : 2915
RP-280 M : 2915
Preheater capacity kW RP-130 M : 6

RP-140 M : 6
RP-150 M : 12
RP-250 M : 12
RP-280 M : 12
Preheater current A RP-130 M : 8,7
RP-140 M : 8,7
RP-150 M : 17,4
RP-250 M : 17,4
RP-280 M : 17,4
70 (77) RPMARINES 30820641GB

6. Technical data
Burner motor capacity kW RP-130 M : 3,7

RP-140 M : 4,6
RP-150 M : 6,4
RP-250 M : 8,6
RP-280 M : 8,6
Burner motor current A RP-130 M : 6,3
RP-140 M : 7,6
RP-150 M : 10,4
RP-250 M : 14,6
RP-280 M : 14,6
RP-140 M : 3440
RP-150 M : 3445
RP-250 M : 3430
RP-280 M : 3430
Burner motor efficiency % RP-130 M : 86
RP-140 M : 85,8
RP-150 M : 87,6
RP-250 M : 86,5
RP-280 M : 86,5
Preheater capacity kW RP-130 M : 7,2

RP-140 M : 7,2
RP-150 M : 14,4
RP-250 M : 14,4
RP-280 M : 14,4
Preheater current A RP-130 M : 9,6
RP-140 M : 9,6
RP-150 M : 19,2
RP-250 M : 19,2
RP-280 M : 19,2
RPMARINES 30820641GB 71 (77)

6. Technical data
Burner motor output kW RP-130 M : 3,2

RP-140 M : 4
RP-150 M : 5,5
RP-250 M : 7,5
RP-280 M : 7,5
RP-140 M : 4,3
RP-150 M : 5,7
RP-250 M : 8,1
RP-280 M : 8,1
RP-140 M : 2850
RP-150 M : 2855
RP-250 M : 2855
RP-280 M : 2855
Burner motor efficiency % RP-130 M : 85,5
RP-140 M : 86
RP-150 M : 86,5
RP-250 M : 87
RP-280 M : 87

RP-140 M : 6
RP-150 M : 12
RP-250 M : 12
RP-280 M : 12
Preheater current A RP-130 M : 5
RP-140 M : 5
RP-150 M : 10
RP-250 M : 10
RP-280 M : 10
72 (77) RPMARINES 30820641GB

6. Technical data
Burner motor capacity kW RP-130 M : 3,5

RP-140 M : 4,6
RP-150 M : 6,4
RP-250 M : 8,6
RP-280 M : 8,6
RP-140 M : 4,9
RP-150 M : 6,6
RP-250 M : 9,1
RP-280 M : 9,1
RP-140 M : 3450
RP-150 M : 3455
RP-250 M : 3455
RP-280 M : 3455
Burner motor efficiency % RP-130 M : 86
RP-140 M : 87,4
RP-150 M : 87,5
RP-250 M : 85,6
RP-280 M : 85,6

RP-140 M : 6
RP-150 M : 12
RP-250 M : 12
RP-280 M : 12
Preheater current A RP-130 M : 5
RP-140 M : 5
RP-150 M : 10
RP-250 M : 10
RP-280 M : 10
6.2. Control unit technical Data
6.2.1 Technical data (LAL 1.25 and 2.25)
Mains voltage 230 VAC -15 / +10%

Mains frequency 50 – 6%...60 Hz +6%
Power consumption 3,5 VA
Fuse, built-in T6,3H250V, IEC 127
Fuse, external max 10 A
Electromagnetic compatibility EMC 89/336
Permissible inlet current to terminal 1 5 A continuous; instantaneous max. 20 A
RPMARINES 30820641GB 73 (77)

6. Technical data
Permissible load of control terminals 4 A continuous; instantaneous max. 20 A, in total

max 5 A
Required switching capacity of switching 1 A between terminals 4 and 5
devices
Degree of protection IP 40
Permissible ambient temperature -20...+60 °C
6.3. Control unit LAL 2.25
6.3.1 Internal Circuitry LAL2.25

E
K
1 L
H
pic_101472.10_MODIFIED_TRu
1
LAL2.25 AS
br1
a b
I
b
a
ar2
ar1
4 12 6 7
RAR
22 23 24
5 13 14
V
FR
fr1 fr2
a b
IX (1) (2)
XI b a
XIII NTC
a a b
a b XII
b IV
AR XIV
a b
VII
a b
br2
ar3
L1 E M
BR II X VIII V VI III
A a b a b a b
IV b a a b
SM
3 21 2 15 16 18 17 19 9 20 11 10 8
74 (77) RPMARINES 30820641GB

6. Technical data
6.3.2 Diagram legend LAL 2.25
AR Main relay (load relay) with contacts ”ar”

AS Control unit fuse
B Wire link (on the plug section of the control unit) *)
BR Lockout relay with contacts ”br”
EK Lockout reset button
FR Flame relay with contacts ”fr”
H Main switch
L Lockout warning lamp
RAR Flame detector
SM Motor of sequence switch
V Flame signal amplifier
NTC NTC-thermistor
*) The wire link B has been cut away at the factory. This allows an automatic repetition of
start-up sequence, if the flame extinguishes during burner operation. If the wire link B has
not been cut away, lockout occurs, if the flame is extinguished during burner operation.
6.4. Flame Detector
6.4.1 Technical data
TYPE RAR...
Min. required detector current with 230 VAC 6,5 μA
Max. permissible detector current without —
flame
Max. possible detector current 25 μA
Instrument's +pole to terminal 22
Cable run to detector in the same cable as not perm.
control lines
Cable run to detector with a separate cable RAR7: 30 m
in cable duct
Shielded cable (insulated shielding) RAR8: 100 m
Shielding to terminal
RPMARINES 30820641GB 75 (77)

6. Technical data
22 23 LAL2...
RAR...
76 (77) RPMARINES 30820641GB

Oilon Oy
Metsä-Pietilänkatu 1
PL 5
15801 LAHTI
Finland
+358 (03) 85 761
+358 (03) 857 6239
info@oilon.com
www.oilon.com

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Customer : Hyundai Heavy Industries Co.

5. F.O SYSTEM WITH ACCESSORIES

7. SPARE PARTS AND TOOLS

0 14.05.30 FOR FINAL D.Y.BYUN K.J.AHN B.J.KIM

KANGRIM HEAVY INDUSTRIES CO., LTD.

KANGRIM HEAVY INDUSTRIES CO., LTD.

LIST OF DESIGN DATA

NO DRAWING NO. TITLE REV. REMARK

2 MB-TE-01 Design data

- Information table of insturments 0

- proposal water level 0

- Proposal drum pressure setting point 0

- Thermal expansion of boiler 0

5 MB-MN-05 Soda boiling procedure 0

6 MB-BIO-001 Burner lnstallation Guide 0

KANGRIM HEAVY INDUSTRIES CO., LTD.

2. Oil Fired section data

KANGRIM HEAVY INDUSTRIES CO., LTD.

PA type boiler lay out.(Only reference)

KANGRIM HEAVY INDUSTRIES CO., LTD.

Information table of instruments

Diff.pressure transmitter 400 ~

High water level - - - +250 - - ●

Normal water level - - - 0 - - -

Low low water level - - - 220 - ● -

Water level switch

11 Burner swing out - - - - ● ● Burner

12 Flame failure - - - - ● ● Burner

13 Quick closing valve closed - - - - ● ● F.O. Pipe

Burner motor failure Control

15 Low comb. air press. mbar 0~50 - (15) ● ● - Burner

*NOTE : ( ) ~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.

KANGRIM HEAVY INDUSTRIES CO., LTD.

Meas. Item Set Burner Alarm limit

16 Low oil pressure in burner kg/㎠.G 2~40 - 20 ● ● - Burner

18 High oil content in feed water - - W04 - - - ● F.W. Tank

*NOTE : ( ) ~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.

KANGRIM HEAVY INDUSTRIES CO., LTD.

Proposal water level

High Water Level (17.6 mA)

Low Water Level (7.5 mA)

Low Low Water Level (6.9 mA)

KANGRIM HEAVY INDUSTRIES CO., LTD.

Proposal drum pressure setting point

☞ 8.0 Safety valve open / Design pressure

☞ 7.5 High steam pressure

☞ 6.6 Dumping v/v open

☞ 6.0 Boiler working pressure

☞ 5.5 Burner start

☞ 4.5 Low steam pressure

PRESSURE UNIT : kg/㎠.G

KANGRIM HEAVY INDUSTRIES CO., LTD.

Thermal expansion of boiler

KANGRIM HEAVY INDUSTRIES CO., LTD.

KANGRIM HEAVY INDUSTRIES CO., LTD.

NO DRAWING NO. TITLE REV. REMARK

1 - Part list of steam / water piping system 0

135 1$% ."5&3$0%& %&4$3150/ ."5&3*"- ."/6'"$563&3 1$4 . 3&."3,4

135 1$% ."5&3$0%& %&4$3150/ ."5&3*"- ."/6'"$563&3 1$4 . 3&."3,4