Manual Komplett MT 10-35 ENG

MT 10-35T SRH
CONTENTS
1. Operational manual
2. Drawings
3. Control system
− Drawings
− Program
4. Control system for RO with SA-650SW

− Drawings
− Program
5. Product component data
− Feedwaterpump
− Valves
− Solenoid valves
− Filter
− Pressure indicator
− High pressure pump
− Pressure cut off
− Membrane
− Pressure vessels
− Flow meter
− Conductivity meter
6. Chemicals
− Material Safety data
7. Operational manual Sandfilter

− SA-650
− SA-33 –41
8. Operational manual Deacidificationfilter

− N-40
9. Log sheet
10. Declaration of Conformity

ENGLISH
no. 530564
Operating
Manual
Manual for systems:
MT 10T SRH
MT 15T SRH
MT 20T SRH
MT 25T SRH
MT 35T SRH
ENWA AB
Tel: +46 (0)31-742 92 50
Fax: +46 (0)31-742 92 60
E-post: info@enwa.se
2007-01-03
version 1
ENGLISH
no. 530564
CONTENTS
1. GENERAL SAFETY INSTRUCTIONS ............................................................. 4

2. INTENDED APPLICATION AREAS................................................................. 4
3. TRANSPORT AND HANDLING....................................................................... 5
4. UNPACKING ................................................................................................... 5
5. PLACEMENT ................................................................................................... 5
6. DESCRIPTION OF THE PROCESS................................................................ 6
7. INSTALLATION ............................................................................................... 8
8. INITIAL START .............................................................................................. 10
9. NORMAL START........................................................................................... 12
10. NORMAL STOP ......................................................................................... 13
11. CHEMICAL CLEANING INSTRUCTIONS.................................................. 14
12. CLEANING, STERILIZATION AND PRESERVATION............................... 15
13. ROUTINE SERVICE AND MAINTENANCE............................................... 19
14. TROUBLESHOOTING ............................................................................... 21
15. DIMENSIONS AND TECHNICAL DATA .................................................... 22
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ADDRESS OF NEAREST SERVICE CENTER

For information on your nearest authorized service center, please contact:
ENWA AB
Phone: +46 (0)31-42 92 50
Fax: +46 (0)31-742 92 60
E mail: info@enwa.se
In the event of malfunction or other problem on the system, turn off the system and
consult section, TROUBLESHOOTING. If the problem remains, contact an
authorized service center in accordance with the information above. Insist that only
original spare parts be used. Attempting to correct problems without following the
recommendations in the service and maintenance instructions can endanger the
system’s future operational reliability. Always specify product ID numbers when
contacting a service center.
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INTRODUCTION
Keep these operating instructions in a safe and accessible location close to the
system. Read these instructions in their entirety before starting the system.
Installation of the system, as well as all work that affects it, must be carried out
in accordance with the applicable regulations for electrical equipment and
personal safety.
1. GENERAL SAFETY INSTRUCTIONS

UNDER NO CIRCUMSTANCES MAY THE EQUIPMENT BE UNDER
POWER OR PRESSURE WHEN WORK IS PERFORMED. WORK ON
THE EQUIPMENT, EVEN THAT WHICH IS SEEMINGLY
INSIGNIFICANT, MAY ONLY BE PERFORMED BY QUALIFIED
PERSONNEL.
COMPLIANCE WITH ALL APPLICABLE ELECTRICAL REGULATIONS IS OF

THE GREATEST IMPORTANCE, BOTH IN REGARDS TO PERSONAL
SAFETY AND THE EQUIPMENT’S OPERATIONAL RELIABILITY.
FAULTS THAT MAY OCCUR BECAUSE OF FAILURE TO COMPLY WITH THE
SPECIFIED RECOMMENDATIONS CAN ENTAIL THAT THE
MANUFACTURER AND AGENT’S GUARANTEE COMMITMENTS NO
LONGER APPLY.
THIS EQUIPMENT IS NOT INTENDED FOR PLACEMENT OUTDOORS.

THE SYSTEM COMPLIES WITH EUROPEAN STANDARD EN 292 AND
DIRECTIVE 89/392.
The equipment shall be served and maintained by authorized service staff or

especially qualified and trained personnel. All work on or modifications to the
equipment shall be approved by the manufacturer or dealer for their liabilities and
guarantees to apply
Tampering with the system’s safety equipment can result in non-compliance with
applicable European safety directives.
2. INTENDED APPLICATION AREAS
ENWA’s desalination systems are designed and manufactured to purify water in

normal industrial and household applications. The system may not be used where
there is an obvious risk for fire, for example, adjoining storage of flammable liquids,
gasses or other substances. In applications where after treatment, the water is be
stored in some form of storage tank, suitable equipment shall be installed to ensure
water quality. Consult your dealer in such cases. The equipment may only be used in
applications for which it is originally designed, and in accordance with these
instructions. All other use is inappropriate, and in such cases, the manufacturer and
dealer decline all liability relating to damages and any returns/complaints.
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3. TRANSPORT AND HANDLING
The equipment may only be lifted and transported in accordance with the following
instructions.
− Whenever possible, transport the equipment in the supplied packaging.
4. UNPACKING
DISPOSE OF ALL PACKAGING MATERIAL IN AN ENVIRONMENTALLY CORRECT MANNER.
After unpacking, check that the equipment is intact and that there is no visible
damage.
If in doubt, do not use the equipment before contacting the manufacturer or you
dealer for advice. All packaging materials (plastic sheeting and bags, nails, screws,
wood, metal straps, etc.) shall be considered as hazardous waste, especially in
regards to children, and shall be sorted and disposed of in accordance with
applicable environmental directives.
5. PLACEMENT
Proper placement of the equipment can extend its service life. The room must be
spacious, dry and well ventilated.
− The desalination unit must be bolted horizontally. Use the holes on the rack
− The desalination unit must be bolted horizontally where the location chosen
should:
- The ambient temperature may never exceed 45°C (113°F).
- The temperature of incoming water must be between +5°C (41°F) and +45°C
(113°F).
- There must be sufficient space for operation and maintenance.
Ensure that unanticipated leaks cannot cause damage.
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6. DESCRIPTION OF THE PROCESS

6.1 REVERSE OSMOSIS
RO is the abbreviation for reverse osmosis. Osmosis (from the Greek osmos,
meaning pressure, thrust) is the capability of liquids and liquid soluble substances to
permeate a membrane. Osmosis takes place when two solutions of different
concentrations are on either side of a membrane. The more concentrated solution will
always attract water from the weaker until the same concentration is attained on both
sides of the membrane (under the condition that the water, and not the dissolved
substance, can pass through the membrane). Osmosis continues until the
concentration of the substances that diffuse (diffusion is dispersion through random
movement of atoms, molecules or ions) through the membrane is the same on both
sides. The membrane is permeable for one substance but not the other (semi
permeable/partially penetrable) and can be used to separate different substances.
Osmosis has major significance for living organisms, where cell walls form the
membrane through which nutrients and metabolic products are transported. In
nature, water is purified and transported through osmosis, for example, in the human
body and in plants.
RO involves utilizing osmosis with the help of technology. By raising the pressure of
the “contaminated” liquid, the water is forced through a synthetic, semi permeable
membrane, which separates the smallest particles, molecules and ions, and only
allows clean water to pass. A major advantage of osmosis is that no chemicals are
used in purification
Figure 1 Figure 2 Figure 3

Osmosis Osmotic equilibrium Reverse Osmosis
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The membrane is fitted in a pressurized vessel. This construction is referred to as an

RO-module or just module.
Figure 4. Spiral wounded module
6.2 FUNCTION
Before the water is desalinated in the membrane, the water must be free from
chlorine, iron, aluminum, silica acid, particles, organic and biological contaminants,
etc. It is therefore common that the feed water is pretreated before it passes through
the system. Pretreatment is intended to reduce particles and contaminants that would
otherwise damage the membrane, block piping or damage the high pressure pump.
The water filter requires a certain pressure to be able to clean the water. To achieve
the necessary pressure, a feed water pump is required that raises the pressure of the
feed water before it reaches the filter.
Thereafter, the water flows through a second filter to remove smaller particles, and
then through a high pressure pump. The pump increases the pressure of the feed
water so that it exceeds the osmotic, before the water is desalinated in the
membrane. When the water passes through the high pressure pump, it is important
that the water is at the working pressure the pump requires. Lower pressures can
otherwise result in pump failure. This is why a pressure control valve is installed
before the pump. It automatically stops the flow of water if the pressure is too low.
After the water has passed the RO-module, two flows are produced. One is
desalinated water and the other is salt concentrate (brine). The brine is immediately
discharged.
The treated water from the RO-module passes through a conductivity cell that
measures the conductivity in the product water. If the conductivity is too high, the
water is automatically discharged through a 3-way magnetic valve. If the conductivity
is under the limit value, the product waters goes to a tank.
The product water flow can be seen on a flow instrument.
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7. INSTALLATION
FLUSHWATER Int. 1/2”R (Pipe thread)
OUTLET TO WASTE Int. 1/2”R
PRODUCT TO WASTE Int. 1/2”R
PRODUCT TO TANK Int. 1/2”R
FEEDWATER Int. 1”R
Figur 5. Connections
7.1 PRODUCT WATER TO TANK

(CN-2060)
The product from the unit must be led to the fresh water storage tank.
7.2 DISCHARGED BRINE AND PRODUCT WATER
The product water and brine discharge outlet is to be connected so that neither
seawater nor contaminated water can return when the system is stopped. The water
must be released above the waterline. When the system is stopped, air flows the
back way into the RO-module to prevent vacuums from being created in the system.
NOTE: If a valve has been installed on a product, discharge or brine line, it

must not be closed. If the system is operated with a closed line, the water
pressure will rise until the unions fail
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7.3 FLUSH WATER
When the system is stopped, it is automatically flushed with freshwater to remove

saltwater. Connect a line from the freshwater pressure system (cold water) to the
flush water valve upstream from the flush water filter.
The system is equipped with automatic freshwater flushing and will flush 100 hours
after shutdown, as long as the power is on and the line is connected from the
freshwater pressure system to the flush water valve. Make sure that there is enough
clean water for flushing.
7.4 ELECTRICAL CONNECTIONS
Connect the electrical components as shown on the wiring diagram.
NOTE: Install a ground fault breaker for the system’s electrical circuitry.
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8. INITIAL START
Follow these instructions the first time the desalination system is used, or after an
extended period of non-operation.
OBS! If the unit is combined with a sandfilter, it needs to be backwashed before initial
start. Use the manual for the sandfilter
1. Check the oil level in the high-pressure pump.
Figure 6. Correct oil level
2. Check that the filter cartridges are installed and clean.
3. Check that the following valves are open:
− Feed water valve (HV-2010) Figure 7. HV-2010 open
− Manual flush water valve (HV-2020)

Figure 8. HV 2020 open
− Pressure control valve (PCV-250) shall be turned fully

counter clockwise
Figure 9. PCV-2050 open
− The bottom valve for the feed water inlet (not supplied by ENWA)
− Brine outlet (if fitted)
− Product to discharge (if fitted)
− Tank valve (if fitted)
4. Open the feed water valve (CCV-2055) from the feed water pump as
shown in the figure.
Figure 10. CCV 2055
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5. Start the feed water pump (FP-1010)

− ”SYSTEM” Æ ON
6. Turn off the conductivity meter (1u400)

− ”SALINITY” Æ OFF.
Figure 11. point 5,6,7
7. Start the high pressure pump (HPP-2010)
− ”HP PUMP” ÆAUTO.
After 5-10 minutes
8. Adjust the working pressure

− Check recommended pressure in “DIMENSIONS AND TECHNICAL
DATA”
− turn the dial on the pressure control valve (PCV-2050) clockwise.
Figure 12. Adjusting the
working pressure
Let the system run (product water to discharge) approx 15 minutes. So the
system is flushed from chemicals, etc. At the same time, check that no leaks
occur.
9. Turn on the conductivity meter (1u400)

When the conductivity is under 1200 uS/cm, the product water goes to the tank. Figur 13. punkt 9
10. To stop the system, refer to the instructions under NORMAL STOP.
NOTE: If the buyer of this system has specified certain requirements regarding
surrounding temperature exceeding 45 °C, the unit might be equipped with delay
start up sequence. This means that the system will run the feed water pump (turning
the switch in position “on” and HP switch in position “auto”), alone for a couple of
minuets without starting the HP pump. This is done for cooling the membranes.
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9. NORMAL START
After the system has been started the first time as described in section 8, the system
can be started as follows.
1. Check that the flush water valve (HV-2020) is open
2. Open the feed water valve (HV-2010)
3. Open the feed water valve (CCV 2055) from the feed water pump.
4. Start the feed water pump (FP-1010)

− ”SYSTEM” Æ ON
5. Start the high-pressure pump (HPP-2010).

− ”HP PUMP” ÆAUTO.
6. Adjust the working pressure

− Check recommended pressure in “DIMENSIONS AND TECHNICAL
DATA”
− turn the dial on the pressure control valve (PCV-2050) clockwise.
Figure 14. point 1,2,3,4,5,6
NOTE: If the system has been turned off for more than two days, the system must be
flushed for at least 30 minutes by discharging the produced product water. Turn off
the conductivity meter (1u400) by turning the switch labeled SALINITY to OFF. In this
position, the product water is always automatically discharged since ROV-2060 is
inactive.
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10. NORMAL STOP

Turn off the system as follows.
1. Turn the switch labeled HP PUMP to OFF.
2. Turn the switch labeled SYSTEM to OFF.
The flush water valve (ROV-2020) is automatically opened for about 10–15 minutes
(the flush water valve is turned off automatically). Clean water runs through the
system and is discharged if the line from the freshwater pressure system is
connected.
SYSTEM SHUTDOWN FOR EXTENDED PERIODS

If the system will be off for an extended period (more than one week), or when the
system’s automatic flush system is not in operation, it must be treated to prevent the
growth of bacteria. Follow the instructions in “LONG-TERM PRESERVATION”.
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11. CHEMICAL CLEANING INSTRUCTIONS

Extreme caution must be observed when chemicals are used.
CHEMICALS CAUSE IRRITATION TO THE SKIN, EYES AND THROAT. AVOID

EXTENDED OR REPEATED CONTACT WITH ANY PART OF THE BODY.
MAY NOT BE INHALED!

ENSURE GOOD VENTILATION.
IF THE SOLUTION COMES IN CONTACT WITH THE SKIN OR EYES,
IMMEDIATELY AND THOROUGHLY FLUSH WITH WATER FOR AT LEAST 15
MINUTES. IF THE SOLUTION GETS INTO THE EYES, SEEK MEDICAL CARE
IMMEDIATELY AFTER FLUSHING, AND IF POSSIBLE CONTINUE FLUSHING
EN ROUTE.
READ THESE INSTRUCTIONS ON CHEMICAL CLEANING BEFORE

USING THE CHEMICALS.
When any of the chemicals are used, extreme caution must be observed.
When a chemical cleaning solution is prepared, the chemicals must be dissolved and
thoroughly mixed before the solution enters the RO-module.
During recirculation, the temperature may not exceed 40°C (104°F).
All chemical used for cleaning and treatment must be handled with extreme care. The
chemicals cause irritation to the eyes, nose, throat and skin. Avoid extended or
repeated contact with any part of the body. May not be inhaled. Ensure good
ventilation. If the solution comes in contact with the skin or eyes, immediately and
thoroughly flush with water for at least 15 minutes. If the solution gets into the eyes,
seek medical care immediately after flushing, and if possible continue flushing en
route.
The freshwater used in chemical treatment may not contain chlorine. Normal tap
water must be dechlorinated with a carbon filter. The product water from the system
can be used immediately. Wear protective gloves and goggles.
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12. CLEANING, STERILIZATION AND PRESERVATION

Extreme caution must be observed when chemicals are used.
READ THE CHEMICAL CLEANING INSTRUCTIONS BEFORE USING THE
CHEMICALS.
12.1 CHEMICAL CLEANING WITH MED MT-10 AND MT-20
To ensure that the system is properly cleaned, two cleaning agents are used – MT-10
and MT-20. After cleaning, the feed water filter should be replaced (“SERVICE AND
MAINTENANCE”). Follow the instructions below.
1. Turn off the system as descried under “NORMAL STOP”.
2. Open the valve (CCV-2060) for chemical cleaning as in fig. and

connect a hose from the nozzle to a tank. of 100 liters.
Figure 15. CCV 2050/60
3. Start the system and produce clean water until the tank is almost full.
4. Turn off the conductivity meter (1u400)

5. Mix a batch of MT-10 solution and mix with a clean stick.
6. Turn off the manual flush water valve (HV-2020).
Figure 16. HV-2020 closed
7. open valve CCV 2055 from cleaningtank and connect a

hose from the cleaning tank. From
cleaningtank
Figure 17. CCV 2055

8. Fully open the pressure control valve (PCV-2050). from cleaning tank
Do not start the feed water pump.
Figure 18. PCV 2050 open
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9. Start the high-pressure pump (HPP-2010) in the manual position.

− ”HP PUMP” ÆMAN.
Let the system run until the cleaning tank is almost empty. Stop
10. Open the valve (CCV-2050) for the cleaning tank
11. Start the high-pressure pump in the manual position and let Figur 19. CCV 2050/60
circulate for about 1 min.
NOTE: If the temperature of the solution exceeds 40° C (104F°), the pump must be
stopped so that the solution can cool. The best temperature range for the treatment is
30-35° C (86–95°F); the lowest permitted temperature is 25°C (77°F).
12. Stop the high-pressure pump (HPP-2010).
13. Let the system remain stopped for 5 minutes so that the solution soaks the
equipment.
14. Start the high-pressure pump (HPP-2010) in the manual position.
15. Let the solution circulate until the membranes stop loosing dirt.
16. Stop the high-pressure pump (HPP-2010).
17. Repeat points 12, 13, 14 and 15 until the water stops getting dirtier.
18. To discharge the water in the container, turn the valve CCV-2050 to
discharge
19. Flush the cleaning agent from the system with feed water for at least 15
minutes. Open valve CCV-2055 from the feed water pump.
NOTE: When the system is flushed, the pressure control valve must be Figure 20. CCV 2055
fully open and the product water valve open to discharge.
20. Repeat points 1–19 but use MT-20 as the cleaning agent.
If the system is to be returned to service, it is started in accordance with the section

INITIAL START.
NOTE: If cleaning has no effect, the RO-module can be sent to ENWA for cleaning.
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12.2 STERILIZATION WITH MT-5
Sterilization is performed if the bacteria content becomes too high, which is usually
detected by the water the system produces tasting bad.
Treat the system with MT-10 (section 12.1). Flush for at least 15 minutes.
Follow points 1–10 in the instructions under CHEMICAL CLEANING. Under point 5,
two batches of MT-5 solution are used.
11. Start the high-pressure pump in the manual position and let the solution circulate
for 30 minutes.
NOTE: If the temperature of the solution exceeds 40° C (104°), the pump must be
stopped so that the solution can cool. The best temperature range for the treatment
is 30 35° C (86–95°F); the lowest permitted temperature is 25°C (77°F).
12. Stop the high pressure pump (HPP-2010).
If the system is to be put in service:
13. Flush the cleaning agent from the system with feed water for at
least 15 minutes. The pressure control valve must be fully open feedwater
and the product water valve open to discharge. Open the 3-
way valve from the feed water pump as shown in the figure.
Figure 21. CCV-2055
14. Start the system as described under INITIAL START.
If the system will not be used: Let the MT-5 solution remain in the system. The
system may not be flushed.
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12.3 LONG-TERM PRESERVATION

The RO-module must be preserved with MT-5 solution when extended non-operation
is planned or when it cannot be flushed weekly. The period of preservation is a
maximum of one year. If the system will not be operated for more than one year,
preservation procedures are repeated.
Follow points 1–9 in the instructions under “CHEMICAL CLEANING”. Under point 5,
a batch of MT-5 solution is used.
To discharge the water in the container, turn the valve CCV-2050 to discharge, start
the high pressure pump in manual position.
Do not flush the system after preservation. (The preservation solution would
otherwise be washed away.)
NOTE: When the system is to be restarted, follow the instructions under INITIAL START.
NOTE: The longest permitted length of time that the system may go unused when preserved
with MT-5 solution is one year. If the system will not be operated for more than one
year, preservation procedures must be repeated.
WARNING
Preservation agents containing chlorine may not be used; these agents damage
membranes in such a way that they cannot be repaired.
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13. ROUTINE SERVICE AND MAINTENANCE

14.1 PRESSURES AND FLOWS
Regularly check the following flows and pressures. See DIMENSIONS AND
TECHNICAL DATA, section 16.
− Feed water pressure PI-2011

(after filter)
− Working pressure PI-2050
− Product flow FI-2060
If the values are not correct, see the section TROUBLESHOOTING.
14.2 SALT CONTENT
Be observant of the salt content in the product water. Check at the control cabinet.
14.3 FEED WATER FILTER REPLACEMENT
The feed water filter is changed when it appears very dirty or when the feed water
pressure is less than 0.5 bar. Disassemble the filter housing, replace the filter and
reassemble. If the O-ring leaks, check that it is properly seated. Lubricate the O-ring
with glycerin or silicon.
14.4 REPAIR OF HIGH PRESSURE PUMP
Follow the manufacturer’s instructions included in this manual under the tab
HIGH PRESSURE PUMP.
Figure 22
EVERY 1000 HOUR
14.5 LUBRICATION OF HIGH PRESSURE PUMP
Change the oil in the pump after the first 100 hours of operation.
Thereafter, change the oil after every 1000 hours of operation. Remove
the oil plug and drain the contents of the pump. Refill with SAE 40 motor
oil. Figure 23
14.6 LOW PRESSURE SWITCH
If the pressure goes below 0,5 bar the low-pressure switch shall stop the unit. Check
this function every 1000 hours (when changing oil in the pump), by slowly closing the
inlet valve situated between the charcoal filter house and cartridge filter house.
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EVERY 9000 HOUR
14.7 CHECK OF SAFETY VALVE
Check the opening pressure of the safety valve (PSV-2050) once each
year. The valve should open at about 75 bar. Increase the working
pressure temporarily by turning the pressure control valve to about 75 bar
and adjusting the opening pressure if the valve has not opened at 75 bar. Figure 24. PCV-
2050
NOTE: Return to normal operating pressure directly after the check.
2 TIMES / YEAR
14.8 FLUSH WATER FILTER
This carbon filter is used to dechlorinate the freshwater to the system and should be
replaced once a year.
NOTE: Only use ENWA-approved feed water and flush water filters. An incorrect
choice of filter cartridges can damage the system.
14.9 BELT TENSIONING
Adjust the V-belt to the greatest tension that will allow a belt movement of 1 cm when
pushed lightly at mid-span by the hand with about 2 kg force. To adjust the belt
tension, sufficiently loosen the four base-plate bolts of the motor, and then adjust the
belt tension by turning the two small nuts located at the motor end of the pump base
plate. Then retighten the four motor bolts.
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14. TROUBLESHOOTING
15.1 THE SYSTEM STOPS
If the feed water pressure falls below 0.5 bar, the low pressure control valve will stop
the system. Low feed water pressure can be caused by blockage in the feed water
filter or coarse filter.
− Change the feed water filter.
− Clean the coarse filter in the water inlet.
15.2 THE WORKING PRESSURE SHOWS ZERO IF THE PRESSURE CONTROL
VALVE (PCV-2050) IS NEARLY CLOSED
− Check that the valves in the high-pressure pump are functioning properly.
− Check that the seals around the pistons in the high-pressure pump are
undamaged.
If necessary, correct the problems using the manufacturer’s instructions included in
this manual under the tab HIGH PRESSURE PUMP.
15.3 THE HIGH PRESSURE PUMP DOES NOT START
− Check the power and motor using the manufacturer’s instructions included in
this manual under the tab HIGH PRESSURE PUMP.
15.4 WHEN THE HIGH PRESSURE PUMP STARTS BUT STOPS AFTER 1–30
MINUTES
The motor’s thermal switch may have stopped the pump because of overloading.
− Check the power (generator)
− Check that there is sufficient ventilation around the electric motor.
15.5 THE CAPACITY HAS DECREASED BY MORE THAN 10–15%

If the product flow has declined by 10–15% under the calculated flow, it is time for
chemical cleaning.
− Clean the system as described under CLEANING.
15.6 THE SALT CONTENT IS TOO HIGH

Membrane fouling is a phenomenon that entails that contaminants of various types
have attached to the membrane surface. When a membrane has fouled, the salt
concentration increases on the membrane surface. The conductivity meter shows
higher conductivity. When it has reached an unacceptable level, it is time for
chemical cleaning.
The system is equipped with a conductivity control/alarm, and it triggers at 1200

nS/cm.
− Clean the system as described under CLEANING.
NOTE: It is normal that product water is discharged the first 20 minutes after starting.
This is because the salt content is too high.
IF THE PROBLEM REMAINS, CONTACT ENWA’S SERVICE DEPARTMENT.
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15. DIMENSIONS AND TECHNICAL DATA

16.1 DIMENSIONS
MT 10 MT 15 MT 20 MT 25 MT 35
Length 1400 1400 1400 2300 2300 mm
Width 750 750 750 750 750 mm
Height 870 870 870 870 870 mm
Weight 150 160 170 200 220 kg
16.2 POWER SUPPLY
MT 10 MT 15 MT 20 MT 25 MT 35
Fuse 20 20 20 25 35 A
Fuse controlsys. 6 6 6 6 6 A
HP-pump 5.5/6.3 5.5/6.3 5.5/6.3 7.5/8.6 11.0/12.6 kW
Feed-pump 0.66 0.66 0.66 0.66 0.66 kW
16.3 FEED WATER FLOW
MT 10 MT 15 MT 20 MT 25 MT 35
clean
seawater ca 28 31 36 50 60 liter/min
16.4 FEED WATER TEMPERATURE
Design 25°C (77°F)

Min. 0°C (32°)
Max. 45°C (113°F)
16.5 WATER PRESSURE
Feed water Min. 1.5 bar, max. 4.0 bar

(after filter)
Flush water Min. 2.0 bar, max. 4.0 bar
Product water Max. back-pressure 2.5 bar
16.6 WORKING PRESSURE
Max. 70 bar
Normal 40–70 bar
Depending on the feed water’s salt content and temperature
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16.7 SALT CONTENT
Max. in feed water 42,000 mg/l (4.2%, about 60,000 nS/cm).
If the salt content exceeds 35,000 mg/l, the salt content in the product can exceed
500 mg/l, (WHO's recommendation).
16.8 PRODUCT WATER FLOW
Normal product water flow is dependent on:
− System type
− Feed water temperature
− Salt content in feed water
When the temperature decreases, the flow decreases. When the salt content
increases, the flow decreases. When the product flow decreases without the
temperature or salt content in the feed water changing, the membrane can require
cleaning.
The red values show the capacity at which it decreases by about 15%. It can then be
time for chemical cleaning. See CHEMICAL CLEANING, section 13.
Temp. 25°C (77°F) Temp. 15°C (59°F) Temp. 5°C (41°F)
System Max. flow Normal flow Low flow Normal flow Low flow Normal flow Low flow
MT 10 T 375 375 320 375 320 330 280
MT 15 T 560 560 475 560 475 475 404
MT 20 T 750 750 640 750 640 625 530
MT 25 T 1040 1040 885 1040 885 960 815
MT 35 T 1450 1450 1230 1450 1230 1250 1060
The table is based on a salt content of 30,000 mg/l (3.0%, 45,000 uS/cm) in the feed
water. The flow is shown in liters/hour.
23
Item nr. Part nr Description Beskrivning Manufacturer Type Note
1
2
3 1 13195 Feed pump Råvattenpump Calpeda BNM25/160AE 440,60Hz
5
6 2 14690 Sandfilter Sandfilter ENWA SA-33 x 2-2510
7
8 3 14518 Deacidification filter Avsyrningsfilter ENWA N-40-RO Magnedol
9
10 4 12719 RO unit RO enhet Enwa AB MT 10T SRH 400V 50Hz
20
21 Option
22 12577 Hose connector Slangnippel Ezze AB R20x20
23 12578 Hose connector Slangnippel Ezze AB R25 x 25
24 13653 Cleaning tank Tvättank Örnplast 100 l
25
26
27
28
29
31
32
33
DATUM
partlist
KONSTR. AV: HE Reverse osmosis unit
RITAD AV
NR REVIDERING GODKÄND AV 06-12-28 530565
1
2
5
6 2 10248 Sandflter Seawater Sandfilter, sjövatten Enwa AB SA-650
7
8 3 14518 Deacidification filter Avsyrningsfilter Enwa AB N-40-RO Magnedol
9
10 4 15319 RO unit RO enhet Enwa AB MT 25T SRH 400V 50Hz m. Sandfilter
13
14
15
16 Option
17 12577 Hose connector Slangnippel Ezze AB R20x20
18 12578 Hose connector Slangnippel Ezze AB R25 x 25
19 13653 Cleaning tank Tvättank Örnplast 100 l
20
21
22
23
24
25
26
27
28
29
31
32
33
DATUM
KONSTR. AV: HE Reverse osmosis unit partlist
RITAD AV
NR REVIDERING GODKÄND AV 06-12-28 SA-650 530441
1 13673 Rack Rack ENWA 10-35RO9
2 Cell 13583 Conductivity meter Konduktivitetsmätare Jumo dTrans Lf01
3 Cell 13560 Conductivity sensor Konduktivitetsgivare Jumo 2EL5/1,0/PT100/G1/2A/B
4 CCV 2050-60 14262 cleaning valve kit PP Tvättventil kit PP 25 George Fisher
5 CCV 2055 13361 3-way valve 3 vägsventil PA ventil PA-160-1"-3-väg
6 CV 2010 13401 Check valve Backventil PA ventil PA-409-1"
7 CV 2020 13416 Check valve Backventil OEM 6062 1/4"
8 F 2010 10291 Filter housing Filterhus Fileder Big blue 20 utan avluftning
9 F 2010 10256 Filter cartridge Filterinsats Fileder BB 20 CP5
10 F 2020 10284 Filter housing Filterhus Fileder BF 10" utan avlyftning
11 F 2020 10305 Filter cartridge Filterinsats Fileder Act.Carbon CEP-10
3
12 FI 2060 13536 Flow meter Flödesmätare Kytölä HV 4FC 1,8m
13 HPP 2010 13054 High pressure pump Högtryckspump CAT Pump CAT 1051 MT 10-20T SRH
14 13111 High pressure pump Högtryckspump CAT Pump CAT 2531 MT 25-35T SRH
15 PD 2010 13048 Pulsation damper Vibrationsdämpare CAT Pump 0,35 lit. 1/2"
16 HV 2010 13356 Ball valve Kulvemtil PA ventil PA-163-1"
17 HV 2020 13409 Ball valve Kulvemtil GPA 222200-1/4"
18 PCV 2050 13411 Pressure control valve Reglerventil Swagelok SS 18RF8-RT
19 PI 2010 13518 Pressure gauge Manometer WIKA 2941.63/R1/4"/ 6 bar
20 PI 2011 13512 Pressure gauge Manometer WIKA 2940.63/R1/4"/-1-5 bar
21 PI 2012 13504 Pressure gauge Manometer WIKA 2940.63/R1/4"/100 bar
22 PI 2050 13504 Pressure gauge Manometer WIKA 2940.63R1/4"/100 bar
23 PLCO 2010 13562 Pressure cut off Tryckvakt Stig Wahlström AB PS 41 0.35-2bar
24 PSV 2010 14500 Pressure relief valve Säkerhetsventil Swagelok SS R4M8F8 Spring 177-13K-R4-C
25 PSV 2050 13427 Pressure relief valve Säkerhetsventil Swagelok SS-8CPA2-50
26 PSV 2060 13428 Pressure relief valve Säkerhetsventil Swagelok B-8CPA2-50
27 RO 2030 12957 Membrane element Membran Hydranautics SWC1 4040 MT 10-35T SRH
28 12958 Membrane element Membran Hydranautics SWC2 4040 MT 25-35T SRH
29 RO 2030 12988 Pressure vessel Tryckkapslar Plasticon 2 x704040 MT 10-35T SRH
30 FV 2020 13450 Solenoid valve Magnetventil Bürkert 6013A-3-MS-G1/4/
31 13595 timer timer Bürkert timer 1078, 110-230V for MT with SA-650 SW
32 FV2060 13459 Solenoid 3-way valve 3 vägs magnetventil Bürkert 323-F-15,0-BB-MS-230/50
33
DATUM
KONSTR. AV: HE partlist
RITAD AV
MT 10-35T SRH
34
35 50 Hz
36 13115 Electrical motor elektrisk motor ABB 7,5kW/1420/15.3A/IP55
37 13290 V-belt kilrem Teknikprodukter SPA 1180
38 13226 Vibration damper tassar Teknikprodukter C 75-36B
39 13301 Drive pulleys Drivskivor Teknikprodukter SPA 3-250
40 13282 Drive pulleys Drivskivor Teknikprodukter SPA 3-100
41 13271 Drive bushes Bussning Teknikprodukter 2517-30
43 60 Hz
44 13115 Electrical motor elektrisk motor ABB 8,6kW/1750/15,1A/IP55
47 13301 Drive pulleys Drivskivor Teknikprodukter 3 SPA 250
48 13306 Drive pulleys Drivskivor Teknikprodukter 3 SPA 90
51 MT 35, 50 Hz
52 13121 Electrical motor elektrisk motor ABB 11kw/1450rpm/22A
55 13297 Drive pulleys, pump Drivskivor Teknikprodukter 3 SPA 200
56 13288 Drive pulleys, motor Drivskivor Teknikprodukter 3 SPA 112
57 13271 Drive bushes, pump Bussning Teknikprodukter 2517-30
58 13264 Drive bushes, motor Bussning Teknikprodukter 1610-38
59
60
61
62
63
64
65
66
DATUM
KONSTR. AV: HE partlist
RITAD AV
MT 10 - 35T SRH
Dokumentation
»enwa_1u100FD_rev2_2003_06_22.e40«
Kund: ENWA Företag:

Kund dok.nr.: Konstruktör: OW
Kontrollerad: TL
Order nr.: 401084 Ritnings datum/tid: 11.02.2004 14:00
Fabriks nr.: senaste justering: 13.09.2004 09:16
Ritnings nr.: 1u100FD Utskrifts datum/tid: 13.09.2004 09:19
Device Information
Apparattyp: EASY 619-AC-RC
Ingångsfördröjning: till
P-knapp: till
Remanens: till
Start vilkor: RUN
Loggin: xxxx
Datum: 2004-02-11 Kund: ENWA Order nr.: 401084
Konstruktör: OW Kund dok.nr.: Fabriks nr.:

Kontrollerad: TL Ritnings nr.: 1u100FD
Företag:
1u100FD Rev.2 2003-06-22 Sida: 1
av sida: 8/1
Kretsanslutning A B C D E F G H I Parameters
Parameter Display = On
FP_ON NIVÅVAKT LARM PLCO PULS START Timing Relay Type =Single Pulse
___ Setpoint =1 s . 0 ms
001 I01 I02 M04 TT01
002
PLCO TRYCKV. PULS START BACKSPOLNING PLCO HJÄLPR.

___ ___ ___
003 I06 T01 I05 M01
PLCO HJÄLPR. HP_AUTO FEEDPUMP PLCO DELAY
004 M01 I04 Q01 TT02 Parameter Display = On

Timing Relay Type =On-delay
Setpoint =10 s . 0 ms
PLCO DELAY FP_ON LARM PLCO
005 T02 I01 M04
LARM PLCO
006 M04

Företag:
1u100FD Rev.2 2003-06-22 Sida: 2
av sida: 8/1
007
FP_ON LARM PLCO ALARM ING. STOPP AUTO

___
008 I01 M04 I08 M02
PULS START NIVÅVAKT STOPP AUTO FEEDPUMP
009 T01 I02 M02 Q01
FEEDPUMP
010 Q01
FEEDPUMP HP_AUTO DELAY HP AUT
011 Q01 I04 TT05

Setpoint =0 min : 1 s
012

Företag:
1u100FD Rev.2 2003-06-22 Sida: 3
av sida: 8/1
ALARM ING. BACKSPOLNING STOP BACKSP.

___
013 I08 I05 M05
FEEDPUMP DELAY HP AUT STOP BACKSP. HP PUMP
014 Q01 T05 M05 Q02
HP_MAN ALARM ING.
015 I03 I08
016
KONDUKTIV. HP PUMP HP_AUTO COND.VALVE
017 I07 Q02 I04 M06
COND.VALVE ALARM ING. COND.MEETER VENTIL SALIN
018 M06 I08 I10 Q03

Företag:
1u100FD Rev.2 2003-06-22 Sida: 4
av sida: 8/1
019
ALARM ING. ALARM

___
020 I08 Q04
LARM PLCO
021 M04
HP PUMP HP_AUTO VENTIL SALIN

___
022 Q02 I04 Q03
023
HP PUMP 100H FLUSH 15min FLUSH

___ ___
024 Q02 T04 TT03
Timing Relay Type =Single Pulse

Företag:
1u100FD Rev.2 2003-06-22 Sida: 5
av sida: 8/1
100H FLUSH Timing Relay Type =On-delay
Setpoint =99 h : 50 min
025 TT04
15min FLUSH HP PUMP FLUSH

___
026 T03 Q02 Q05
027
HP PUMP HP_AUTO RUN SIGNAL
028 Q02 I04 Q06
029
HP PUMP 1p/HOUR
030 Q02 TT06
Timing Relay Type =Flashing

Företag:
1u100FD Rev.2 2003-06-22 Sida: 6
av sida: 8/1
1p/HOUR DRIFTID Setpoint =0
031 T06 CC08
DRIFTID DUMMY
032 C08 M07
FÖRD MOTION
033 P01 TT07 Timing Relay Type =Off-delay
FÖRD MOTION DRIFTTID
___
034 T07 D01 RUN TIME
DRIFTTID
C8:Actual Value
HOURS TIMMA
035
036

Företag:
1u100FD Rev.2 2003-06-22 Sida: 7
av sida: 8/1
Operand Kommentar Kretsanslutning
I1 FP_ON 1A, 5C, 8A

I2 NIVÅVAKT 1C, 9C
I3 HP_MAN 15A
I4 HP_AUTO 4C, 11C, 17E, 22C, 28C
I5 BACKSPOLNING 3E, 13C
I6 PLCO TRYCKV. 3A
I7 KONDUKTIV. 17A
I8 ALARM ING. 8E, 13A, 15C, 18C, 20A
I10 COND.MEETER 18E
Q1 FEEDPUMP 4E, 9G, 10A, 11A, 14A
Q2 HP PUMP 14G, 17C, 22A, 24A, 26C, 28A, 30A
Q3 VENTIL SALIN 18G, 22E
Q4 ALARM 20G
Q5 FLUSH 26G
Q6 RUN SIGNAL 28G
P1 33A
M1 PLCO HJÄLPR. 3G, 4A
M2 STOPP AUTO 8G, 9E
M4 LARM PLCO 1E, 5G, 6A, 8C, 21A
M5 STOP BACKSP. 13G, 14E
M6 COND.VALVE 17G, 18A
M7 DUMMY 32G
T1 PULS START 1G, 3C, 9A
T2 PLCO DELAY 4G, 5A
T3 15min FLUSH 24G, 26A
T4 100H FLUSH 24E, 25G
T5 DELAY HP AUT 11G, 14C
T6 1p/HOUR 30G, 31A
T7 FÖRD MOTION 33G, 34A
C8 DRIFTID 31G, 32A
D1 DRIFTTID 34G

Företag:
1u100FD Rev.2 2003-06-22 Sida: 8
av sida: 8/1
Documentation
»enwa_1u100FEB.e40«
Customer: ENWA Author: OW

Customer Doc. No.: Editor: OW
Checked: TL
Order No.: 403070 Creation date and time: 07.03.2005 13:55
Factory No.: Last changed: 07.03.2005 13:58
Document No.: Print date and time: 07.03.2005 14:03
Device Information
Device type: EASY 619-AC-RC
I debounce: on
P buttons: on
Retention: on
Start mode: RUN
Password: xxxx
Date: 2003-09-04 Customer: ENWA Order No.: 403070
Editor: OW Customer Doc. No.: Factory No.:

Checked: TL Document No.:
Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 1
of Sheet: 9/1
Circuit Con. A B C D E F G H I Parameters
FP_ON NIVÅVAKT LARM PLCO PULS START Timing Relay Type =Single Pulse
___ Setpoint =1 s . 0 ms
001 I01 I02 M04 TT01
002
PLCO TRYCKV. PULS START FLUSH SEQ. PLCO HJÄLPR.

___ ___ ___
003 I06 T01 M08 M01
PLCO HJÄLPR. HP_AUTO FEEDPUMP PLCO DELAY
004 M01 I04 Q01 TT02 Parameter Display = On

Setpoint =10 s . 0 ms
PLCO DELAY FP_ON LARM PLCO
005 T02 I01 M04
LARM PLCO
006 M04

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 2
of Sheet: 9/1
007
FP_ON LARM PLCO ALARM ING. STOPP AUTO

___
008 I01 M04 I08 M02
PULS START NIVÅVAKT STOPP AUTO UNIT ON
009 T01 I02 M02 M03
UNIT ON
010 M03
UNIT ON FEEDPUMP
011 M03 Q01
FEEDPUMP HP_AUTO DELAY HP AUT
012 Q01 I04 TT05

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 3
of Sheet: 9/1
013
ALARM ING. FLUSH SEQ. STOP FLUSH

___
014 I08 M08 M05
FEEDPUMP DELAY HP AUT STOP FLUSH HP PUMP
015 Q01 T05 M05 Q02
HP_MAN ALARM ING.
016 I03 I08
017
KONDUKTIV. HP PUMP HP_AUTO COND.VALVE
018 I07 Q02 I04 M06

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 4
of Sheet: 9/1
COND.VALVE ALARM ING. COND.MEETER VENTIL SALIN
019 M06 I08 I10 Q03
020
ALARM ING. ALARM

___
021 I08 Q04
LARM PLCO
022 M04
HP PUMP HP_AUTO VENTIL SALIN

___
023 Q02 I04 Q03
UNIT ON MAN.FLUSH 5min.FLUSH 24H FLUSH

___ ___
024 M03 I05 T08 TT04
Setpoint =24 h : 0 min

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 5
of Sheet: 9/1
24H FLUSH 10min FLUSH Timing Relay Type =On-delay
025 T04 TT03
MAN.FLUSH FP_ON 5min.FLUSH FLUSH SEQ.

___
026 I05 I01 T08 M08
FLUSH SEQ.
027 M08
FLUSH SEQ. 10min FLUSH FLUSH

___
028 M08 T03 Q05
10min FLUSH 5min.FLUSH
029 T03 TT08

5min.FLUSH 10min FLUSH RUN SIGNAL
___
030 T08 T03 Q06

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 6
of Sheet: 9/1
031
HP PUMP 1p/HOUR
Timing Relay Type =Flashing
032 Q02 TT06 Setpoint =30 min : 0 s
1p/HOUR DRIFTID
033 T06 CC08 Setpoint =0
DRIFTID DUMMY
034 C08 M07
FÖRD MOTION
035 P01 TT07

Timing Relay Type =Off-delay
FÖRD MOTION DRIFTTID
___
036 T07 D01
RUN TIME
DRIFTTID
C8:Actual Value
HOURS TIMMA

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 7
of Sheet: 9/1
Operand Comment Circuit Con.
I1 FP_ON 1A, 5C, 8A, 26C

I2 NIVÅVAKT 1C, 9C
I3 HP_MAN 16A
I4 HP_AUTO 4C, 12C, 18E, 23C
I5 MAN.FLUSH 24C, 26A
I6 PLCO TRYCKV. 3A
I7 KONDUKTIV. 18A
I8 ALARM ING. 8E, 14A, 16C, 19C, 21A
I10 COND.MEETER 19E
Q1 FEEDPUMP 4E, 11G, 12A, 15A
Q2 HP PUMP 15G, 18C, 23A, 32A
Q3 VENTIL SALIN 19G, 23E
Q4 ALARM 21G
Q5 FLUSH 28G
Q6 RUN SIGNAL 30G
P1 35A
M1 PLCO HJÄLPR. 3G, 4A
M2 STOPP AUTO 8G, 9E
M3 UNIT ON 9G, 10A, 11A, 24A
M4 LARM PLCO 1E, 5G, 6A, 8C, 22A
M5 STOP FLUSH 14G, 15E
M6 COND.VALVE 18G, 19A
M7 DUMMY 34G
M8 FLUSH SEQ. 3E, 14C, 26G, 27A, 28A
T1 PULS START 1G, 3C, 9A
T2 PLCO DELAY 4G, 5A
T3 10min FLUSH 25G, 28C, 29C, 30E
T4 24H FLUSH 24G, 25A
T5 DELAY HP AUT 12G, 15C
T6 1p/HOUR 32G, 33A
T7 FÖRD MOTION 35G, 36A
T8 5min.FLUSH 24E, 26E, 29G, 30C

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 8
of Sheet: 9/1
Operand Comment Circuit Con.
C8 DRIFTID 33G, 34A

D1 DRIFTTID 36G

Author: OW
1u100FEB Rev.0 2003-09-04 Sheet: 9
of Sheet: 9/1
NM, NMD Close Coupled Centrifugal Pumps
with threaded ports C R E A T I V E T E C H N O L O G Y
Construction
Close-coupled, centrifugal pumps; electric motor with 1
extended shaft directly connected to the pump.
NM: single-impeller
NMD:with two back-to-back impellers (with axial thrust
balancing).
Connections: threaded ports ISO 228/1 (BS 2779).
Applications
- For clean liquids without abrasives, which are non-aggressive
for the pump materials ( solids content up to 0.2%).
- For water supply.
- For heating, air-conditioning, cooling and circulation plants.
- For civil and industrial applications.
- For fire fighting applications.
- For irrigation.
Operating conditions
Liquid temperature from -10 °C to +90 °C.
Ambient temperature up to 40° C.
Total suction lift up to 7 m.
Maximum permissible working pressure up to 10 bar
(16 bar for pumps NMD 25/190; NMD 32/210; NMD 40/180).
Continuous duty.
Motor
2-pole induction motor, 50 Hz (n = 2900 rpm).
Materials NM, NMD: three-phase 230/400 V ± 10% up to 3 kW;
400/690 V ± 10% from 4 to 9,2 kW;
Components NM, NMD B-NM, B-NMD I-NM, I-NMD NMM, NMDM:single-phase 230 V ± 10%, with thermal protector.
Pump casing Cast iron Bronze Insulation class F.
Lantern bracket GJL 200 EN 1561 G-Cu Sn 10 UNI 7013 Protection IP 54.
Impeller Brass P- Cu Zn 40 Pb 2 UNI 5705 Constructed in accordance with IEC 34.
NM 17 Cast iron Bronze Cr Ni Mo steel
GJL 200 EN 1561 G-Cu Sn 10 UNI 7013 AISI 316 Special features on request
Shaft Cr steel AISI 430 - Other voltages.
Cr Ni Mo steel - Frequency 60 Hz (as per 60 Hz data sheet).
Cr Ni steel AISI 303
AISI 316 - Protection IP 55.
1,1 -1,5 - 2,2 kW
- Special mechanical seal
Mechanical seal Carbon - Ceramic - NBR - Higher or lower liquid or ambient temperatures.
Coverage chart n ≈ 2900 rpm

5 U.S. g.p.m. 10 20 30 40 50 100 200 300 400
4 5 Imp. g.p.m. 10 20 30 40 50 100 200 300
130
400
100 NMD 32/210
300
H NMD 25/190
m NMD 40/180
200
NMD 20/140
50
H
NM 3 NM 25/20 NM
40 ft
12
NM 20/160
30 100
NMD 20/110 NM 25/160 NM 11
NM 2
20
NM 1 NM 25/12
50
NM 10
40
NM 17
10
30
20
5
4
1 m 3/h 2 3 4 5 6 7 8 9 10 20 30 40 50 100
Q l/min 30 40 50 100 150 200 300 400 500 1000 1500
72.820.C
7
NM, NMD Close Coupled Centrifugal Pumps
Performance n ≈ 2900 rpm
Q
P2 m3/h 1 1,2 1,5 1,89 2,4 3 3,6 4,2 4,8 5,4 6 6,6 7,5 8,4
NM
kW HP l/min 16 20 25 31,5 40 50 60 70 80 90 100 110 125 140
NM 1/AE ● 0,37 0,5 22 21,5 21 20,5 20 19 17,5 15,5
NM 2/BE ● 0,55 0,75 27 26,5 26 25,5 25 24 23 22 20
NM 2/SE ● 0,55 0,75 31 30,5 30 29 27,5 25,5 23,5 20 16
NM 2/AE ● 0,75 1 H 33,5 33 32,5 32 31,5 30,5 29,5 28,5 27 26 24
NMM 3/CE 1,1 1,5 m 37,5 37,5 37 36,5 36 35 34 32
NM 3/CE 1,1 1,5 37,5 37,5 37 36,5 36 35 34 32 30,5* 28,5*
NMM 3/BE 1,5 2 42 42 41 41,5 40,5 40 39 37 35* 32*
NM 3/BE 1,5 2 47 47 46,5 46 45,5 45 44 43 41,5* 40* 37,5* 33* 26*
NM 3/AE 2,2 3 56 55,5 55,5 55 54,5 53,5 52,5 51,5 50* 48* 46* 42* 36*
B-NM Q
P2 m3/h 1 1,2 1,5 1,89 2,4 3 3,6 4,2 4,8 5,4 6 6,6 7,5 8,4
B-NMD NM
I-NMD NMD kW HP l/min 16 20 25 31,5 40 50 60 70 80 90 100 110 125 140
B-NMD 20/110BE ● NMD 20/110BE ● 0,45 0,6 33 32 31 29 26,5 23 18
B-NMD 20/110ZE ● NMD 20/110ZE ● 0,55 0,75 37 36 35 33 30,5 27,5 23 18*
B-NMD 20/110AE ● NMD 20/110AE ● 0,75 1 43 42 40,5 39 36,5 33 29 25*
I- B-NMDM 20/140BE NMDM 20/140BE 1,1 1,5 H 52 51,5 51 50 48,5 47 45
I- B-NMD 20/140BE NMD 20/140BE 1,1 1,5 m 53 52,5 52 51 50 48 46 43,5 40
I- B-NMDM 20/140AE NMDM 20/140AE 1,5 2 57,5 57 56,5 55,5 54 51,5 49 46 43 40 36
I- B-NMD 20/140AE NMD 20/140AE 1,5 2 67 66,5 66 64,5 63 61,5 59 57 53,5 50 46
B-NM 20/160BE ● NM 20/160BE ● 0,75 1 30,5 30 29,5 28,5 27,5 26,5 25,5 24 22*
B-NM 20/160AE ● NM 20/160AE ● 1,1 1,5 36 35,5 35 34,5 33,5 32 30,5 29 27*
Q
B-NMD, B-NMD NM P2 m3/h 2,4 3 3,6 4,8 6 6,6 7,5 8,4 9,6 10,8 12 13,2 15 16,8
I-NM, I-NMD NMD kW HP l/min 40 50 60 80 100 110 125 140 160 180 200 220 250 280
B-NM 25/125BE ● NM 25/12BE ● 0,55 0,75 20 19,9 19,8 19,3 18,5 18 17,3 16,3 15* 13,2* 11*
B-NM 25/125AE ● NM 25/12AE ● 0,75 1 23,5 23,4 23,3 22,9 22,1 21,7 20,9 20 18,7* 17,1* 15,2*
B-NM 25/160BE ● NM 25/160BE ● 1,1 1,5 31 30,7 30 28,5 28 27 26 23
B-NM 25/160AE ● NM 25/160AE ● 1,5 2 36,5 36,2 35,5 34,5 34 33,5 32,5 31 28,5* 26*
I- B-NM 25/200BE NM 25/20BE 2,2 3 42,5 42 41 40 39,5 38,5 37,5 36 33* 29*
H
I- B-NM 25/200AE NM 25/20AE 3 4 m 50 49,7 49 48 47,5 47 46,5 45,5 44* 42* 39*
I- B-NM 25/200SE NM 25/20SE 4 5,5 59 58,5 58 57,5 57 56,5 55,5 54,5 53 51,5 49* 44,5* 37*
I- B-NMD 25/190CE NMD 25/190CE 2,2 3 62 60,5 59 55,5 51 48,5 44 38*
I- B-NMD 25/190BE NMD 25/190BE 3 4 76 75 74 70 66 64 60 54 46*
I- B-NMD 25/190AE NMD 25/190AE 4 5,5 98 97 96 93,5 90 88 84 79 70*
Q
P2 m3/h 6,6 7,5 8,4 9,6 10,8 12 13,2 15 16,8 18,9 21 24 27 30
NM
kW HP l/min 110 125 140 160 180 200 220 250 280 315 350 400 450 500
NM 10/FE ● 0,55 0,75 12,5 12,5 12 11,5 11 10 9 7,5
NM 10/DE ● 0,75 1 18 18 17,5 17 16,5 16 15,5 14
NM 10/AE ● 1,1 1,5 23 23 22,5 22 21,5 21 20,5 19
NM 10/SE ● 1,5 2 23,5 23,5 23 22,5 22 21,5 21 20,5 19* 18,5* 16,5* 13*
NMM 11/BE 1,5 2 26,5 25,5 25 24 23 22,5 21,5 19,5 17,5
H
NM 11/BE 1,5 2 m 29,5 29,5 29 28,5 27,5 27 26 25* 22,5*
NM 11/AE 2,2 3 35,5 35,5 35 34,5 34 33,5 33 32* 30*
NM 12/DE 2,2 3 38 37,5 37 36 35 33,5 32
NM 12/CE 3 4 45 44,5 44 43,5 42,5 41 40 38 36*
NM 12/AE 4 5,5 57,5 57 56 55,5 55 54,5 53,5 51,5 49*
8
NMD Close Coupled Centrifugal Pumps
Dimensions and weights
NMD 20/140
NMD 20/110 NMD 25/190
f
a l1 l2
325
DN2 DN2
75 93 93
G1 G1
G 1 1/4
h2
132
200
DN1
h3
10
95
g1 h1
4.93.179
4.93.005
36 9.5 17 38
m2 s n3 b
46 130
8.5 188 170 m1 n2
w n1
NMDM NMD B-NMD NMDM NMD B-NMD I-NMD

TYPE TYPE
kg kg kg kg kg kg kg
B- NMD 20/110BE 13 12,1 13,4 I- B- NMD 20/140BE 23,9 22,7 25,2 25

B- NMD 20/110ZE 14 13 14,2 I- B- NMD 20/140AE 25,2 24,8 27,6 29,2
B- NMD 20/110AE 15,1 14,2 17,4 I- B- NMD 25/190CE 39 42,7 40
I- B- NMD 25/190BE 46,7 51 48
I- B- NMD 25/190AE 51 55 52
B-NMD DN1 DN2 mm

NMD
I-NMD ISO 228 a f h1 h2 h3 m1 m2 n1 n2 n3 b s l1 l2 w g1
I-B- NMD 20/140AE-BE NMD 20/140AE-BE G 11/4 G1 80 410 112 150 222 75 55 200 160 37 38 9,5 110 110 256 10
I-B- NMD 25/190CE NMD 25/190CE 447 250 50 274
I-B- NMD 25/190BE NMD 25/190BE G 11/2 G1 97 495 140 180 268 100 70 240 190 49 50 14 133 133 306 13
I-B- NMD 25/190AE NMD 25/190AE 495 268 49 306
NMD 32/210
NMD 40/180
f l
a l1 l2
DN2 DN2
NMD B-NMD I-NMD

h2 TYPE kg kg kg
DN1
h3 B- NMD 32/210DE 60 66
B- NMD 32/210CE 70 76
g1
h1 B- NMD 32/210BE 76,5 82
4.93.077
B- NMD 32/210AE 99 105
I- B- NMD 40/180DE 59 65 61
s b
I- B- NMD 40/180CE 69 75 71
g2
w m2 z n2 I- B- NMD 40/180BE 75,5 81 77
m1 n1 I- B- NMD 40/180AE 97 102 99
B-NMD DN1 DN2 mm

NMD
I - NMD ISO 228 a f h1 h2 h3 m1 m2 n1 n2 z b s l l1 l2 w g1 g2
B- NMD 32/210DE NMD 32/210DE 525 155 283 205 175 194 140 54 10 - 139 - 6
B- NMD 32/210BE-CE NMD 32/210BE-CE G2 G 11/4 110 550 150 215 - 280 250 258 190 15 68 12 170 150 150 108 38 -
B- NMD 32/210AE NMD 32/210AE 625 170 355 298 268 286 216 70 12 - 152 38 -
I- B- NMD 40/180DE NMD 40/180DE 530 155 283 205 175 194 140 54 10 - 133 - 6
I- B- NMD 40/180BE-CE NMD 40/180BE-CE G2 G 11/2 121 555 150 215 - 280 250 258 190 15 68 12 170 145 145 102 38 -
I- B- NMD 40/180AE NMD 40/180AE 630 170 355 298 268 286 216 70 12 - 145 38 -
16
Curve caratteristiche - Characteristic curves n = 2900 1/min
NMD 20/110AE-ZE-BE B-NMD 20/110AE-ZE-BE

NMD NMDM 20/110AE-ZE-BE B-NMDM 20/110AE-ZE-BE
0 U.S. g.p.m. 5 10 15 20
50
A Ø 130-130 NMD 20/110 150
30
40 Z Ø 124-124
35
B Ø 118-118 37
Hm
38
η 38,5% 100
H ft
30
38
37
20
50
10
0 3 1 2 3 4 5
Q m /h
0 l/min 20 30 40 50 60 70 80
0 l/s 0.2 0.4 0.6 0.8 1 1.2

1.0
1.2
0.8 A
1.0
P kW
P HP
Z
0.6 0.8
B
0.6
0.4
0.4
0.2
4
NPSH m
3 10
NPSH ft
2
5
1
0 0
72.001
0 Q m3/h 1 2 3 4 5
1.13
Sezione - Cross section - Schnittzeichnung - Section - Sección - Sektion NMD
NMD 20/110AE-ZE-BE B-NMD 20/110AE-ZE-BE
NMD 20/140AE-BE B-NMD 20/140AE-BE
NMD 20/110AE-ZE-BE 16.12 20.00 36.00 98.00 76.04 94.00 98.04 90.00
16.00 20.04 46.00 76.54 76.00 94.02 82.00 90.04
B-NMD 20/110AE-ZE-BE 76.50
3.94.044
28.04 20.12 28.00 30.00 73.00 92.00 81.00 88.00

16.04 16.20 18.00 28.20 78.00 76.16 82.04
NMD 20/140AE-BE 16.12 20.04 28.20 36.50 98.08 76.04 98.00 90.04 90.00
16.20 20.00 30.00 36.00 98.04 76.54 94.00 82.08
B-NMD 20/140AE-BE
3.94.045
28.04 20.12 28.00 46.00 70.20 78.00 76.16 81.00 82.00

16.04 16.00 18.00 73.00 76.50 76.00 76.20 82.04 88.00
2.01
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Page 1 of 1
TM
SERIES 38 M38.cdr
4/17/2000
3-Way Ball Valve Mx4 K I
Reduced Port, L or T Option MATERIALS LIST
MARS Female Threaded Caps F
NO. PART NAME MATERIAL Q'TY
1000 PSI WOG 1 Body ASTM A351 Gr. CF8M 1

4 (DN8) to 2" (DN50)
1
2 End Cap ASTM A351 Gr. CF8M 3
3 Ball SUS316 1
B
13 4 Stem SUS316 1
2 5 Stem Nut SUS 304 1
B 6 Stem Spacer SUS 304 1
L 7 Handle SUS 304 1

Pressure Vs. Temperature Chart
for Valve 1 4 (DN8) to 2"(DN50) E 8 Seat RPTFE 4
D1
6 12 5 17 14 9 15 16 9 Gland Nut SUS 304 1
10 Stem Packing RPTFE 2

7
10
11 Stem Seal RPTFE 1
4
11 12 Stem Disc SUS 304 1
H
3
PT
2 13 Joint Gasket RPTFE 3

FE
8
14 Cylindrical Spacer SUS 304 1
13 Locking Device
C 15 SUS 304 1
1 16 Handle Sleeve Vinyl 1
17 Stop Bolt SUS 304 1
STEM VIEW DIMENSIONS (mm)

D1
Flow Patterns for L-Port (38-1L) SIZE B B1 B2 C D D1 E F H I K L M ISO5211 Wt.(kg)
D 1
4 34.0 11.0 6.0 11.0 12.0 22 106 9.0 58 42 29.7 68 M5 F04 0.6
F
1 2 1 2 1 2 1 2 8 34.0 11.0 6.0 11.0 12.0 22 106 9.0 58 42 29.7 68 M5 F04 0.6
1
2 37.5 11.0 6.0 12.7 12.0 22 138 9.0 61 42 29.7 75 M5 F04 0.7
3 3 3 3
3
4 43.0 13.0 6.0 16.0 15.0 31 138 11.0 74 50 35.4 86 M6 F05 1.2
B1 1" 51.5 19.0 7.5 20.0 15.0 31 162 11.0 81 50 35.4 103 M6 F05 1.7
Flow Patterns for T-Port (38-1T)
11 4 57.5 23.0 7.5 25.0 15.0 31 162 11.0 88 50 35.4 115 M6 F05 2.4
B2
1 2 1 2 1 2 1 2 11 2 62.5 23.5 8.5 32.0 15.0 31 220 11.0 104 70 49.5 125 M8 F07 3.4
2" 73.0 24.5 8.5 38.1 18.5 34 220 14.0 110 70 49.5 146 M8 F07 5.5
3 3 3 3
Page 1 of 1
TM
SERIES YC-800 YC-800.cdr
9/18/2002
Y-Type Spring Check Valve
800 PSI, Stainless Steel
MARS 1
4 (DN8) to 3" (DN80)
MATERIALS LIST
NO. PART NAME MATERIAL Q'TY
1 Body ASTM A351 Gr. CF8M 1
2 Spring SUS 304 1
3 Gasket PTFE 1
4 Cap ASTM A351 Gr. CF8M 1
5 Bolt SUS 304 1
6 Washer SUS 304 1
7 Seat PTFE 1
8 Piston SUS 316 1
C
H
DIMENSIONS (mm)
4
SIZE C d H L W(kg)
1
2 4 19 11 46 65 0.27
8 19 13 46 65 0.26
3 1
2 19 15 46 65 0.26
3
4 23 20 58 80 0.42
1" 27 25 69 90 0.80
d 1 1 4" 32 32 75 105 1.00
1
1 2" 41 38 85 120 1.50
2" 50 50 98 140 2.20
2 1 2" 58 65 121 170
5 6 7 8 1 3" 58 80 134 200
L
Page 1 of 1
SERIES 20-20
TM
M20-20.cdr
11/06/2002
Economical, Full Port MATERIALS LIST
Two-Piece Ball Valve NO. PART NAME MATERIAL Q'TY
MARS Mounting Pad 1 Body CF8M WCB 1
1000 PSI WOG 2 End Cap CF8M WCB 1
1/4" (DN8) to 3" (DN80) 3 Ball SUS316 1
4 Stem SUS316 1
Top View
Pressure Vs. Temperature Chart 5 Stem Nut SUS 304 1
for Valve 1/4" (DN8) to 3"(DN80)
Top View 1100 76 6 Stem Washer SUS 304 1
W4 1000 69 7 Handle SUS 304 1
900 62
800 55
8 Seat PTFE 2
PRESSURE IN PSIG
PRESSURE IN BAR
W2 Top Mounting 700 48 9 Gland Nut SUS 304 1
F
Location for 21 2" ~ 3" 600 41
10 V-Ring Packing PTFE
PT
500 34
FE
400 28 11 Thrust Washer PTFE 1
Side View
W1 300 21
12 Handle Sleeve Vinyl 1
200 14
Mounting Location for
100 7 13 Joint Gasket PTFE 1
1/4"~ 2" W3 0 0
-30 0 100 200 300 400 500 14 Locking Device SUS 304 1
(-34) (-18) (38) (93) (149) (204) (260)
1 ~ 8 regular 1pc stem packing is used instead
4
TEMPERATURE IN F ( C) 1 ~ 3" 1 set of v-ring packing consists of 2pcs of v-ring
2
Side Mounting Available as an option

E Location for 2 1 2" ~ 3"
6 5 14 12
7 J SIZE B B1 B3 B4 C J E F F1 H L W1 W2 W3 W4 W (kg)
1
4 27.5 23 8 10 11.5 5/16"-18UNC 100 5.0 15 50 55 12.7 28.5 0.23
9 B4 8 27.5 23 8 10 12.5 5/16"-18UNC 100 5.0 15 50 55 12.7 28.5 0.23
B1
10 B3 H 1
2 32.5 25.6 10.1 11.5 15.0 3/8"-24UNF 130 6.5 16 60 65 12.7 28.5 0.38
3
4 37.0 25.6 10.5 11.5 20.0 3/8"-24UNF 130 6.5 17 64 74 22.4 35.0 0.52
11
1" 44.0 30.1 11.5 15 25.0 7/16"-20UNF 165 8.0 20.4 71 88 22.4 35.0 0.92
C 1 4 " 51.0 36.7 12.2
1
15 32.0 7/16"-20UNF 165 8.0 78 102 25.4 38.1 1.32
4 Thread Standard in 22
PT, NPT, PF, etc. 1
1 2 " 55.0 35.1 12.2 15.6 38.0 9/16"-18UNF 190 9.7 22.5 86 110 25.4 38.1 1.90
2
F1+- 0.5 2" 62.5 30.6 9.5 15.6 50.0 9/16"-18UNF 190 9.7 26 95 125 25.4 38.1 3.12
13 8 3 1 2 2 " 81.5
1
51 18.4 24.5 65.0 3/4"-16UNF 250 12.0 31 130 161.5 59 61 6.50
B
L 3" 89.0 48.7 16.4 24.5 80.0 3/4"-16UNF 250 12.0 34 148 178 70 71 9.30
Art. 6062 - Art. 6063
VALVOLE UNIDIREZIONALI
O DI NON RITORNO
Questo tipo di valvole permette il libero

passaggio in un solo senso (quello indi-
cato dalla freccia) e lo impedisce nel
senso contrario.
Azionate direttamente dall’aria che le
attraversa, vengono normalmente
impiegate come dispositivi di sicurezza,
consentendo di mantenere in pressione
una parte del circuito pur mandando a
scarico l’alimentazione.
1 2
Art. 6062 - Art. 6063

UNIDIRECTIONAL VALVES OR NON
RETURN VALVES
This kind of valves allow the free

passage in only one direction, the
one showed with the arrow marked
on the body.
They do not allow the passage on MATERIALI E COMPONENTI / COMPONENT PARTS AND MATERIALS
the opposite way, i.e non return.
They operate directly with the air
that goes through, they are normal- Part. 1 CORPO/BODY OT UNI EN 12164 CW 614N Nichelato/Nickel-plated
ly used as safety device, permitting Part. 2 ATTACCO TERMINALE / VALVE BACK PART OT UNI EN 12164 CW 614N Nichelato/Nickel-plated
to keep pressure in a part of the cir- Part. 3 O-RING NBR 70
cuit, also when the feeding pressure
has been taked off. Part. 4 OTTURATORE / SHUTTER OT UNI EN 12164 CW 614N Nichelato/Nickel-plated
Part. 5 MOLLA DI MANTENIMENTO / KEEP SPRING ACCIAIO/STEEL AISI 302
Part. 6 O-RING NBR 70
TEMPERATURE E PRESSIONI / TEMPERATURES AND PRESSURES
Pressione minima 2 bar Minimun pressure 2 bar

Pressione massima 8 bar Maximum pressure 8 bar
Temperatura minima - 18° C Minimum temperature -18° C

Temperatura massima +70° C Maximum temperature +70° C
FILETTATURE / THREADS FLUIDI COMPATIBILI / FLUIDS

Gas Cilindrica conforme ISO 228. Aria compressa.
Parallel gas in conformity with ISO 228. Compressed air.
ATTENZIONE!
TUBI DI COLLEGAMENTO / CONNECTION TUBES LO SCARICO IN AMBIENTE ESCLUDE L’ UTILIZZO DELLA VALVOLA
CON GAS TOSSICI, CORROSIVI, INFIAMMABILI.
Raccordi vari per impiantistica pneumatica.
Tubi metallici in genere. ATTENTION!
Various types of fittings used on the pneumatic plants and THE FREE EXHAUST TO ATMOSPHERE DO NOT ALLOW TO USE THE
metallic threaded tubes. VALVE WITH TOXICS, CORROSIVES AND INFLAMMABLES GAS.
SU RICHIESTA O-RING IN VITON
CH
L
6062
VALVOLA UNIDIREZIONALE FEMMINA-FEMMINA
IF REQUIRED VITON O-RING
FEMALE-FEMALE NON RETURN VALVE

A
A
Prezzo Conf.
A B L CH
Price Pack.
B B M5 5.5 26.5 8 4.705 10
1/8 8.5 35.5 13 4.475 10
1/4 11 43 17 5.515 10
3/8 12 58 24 12.025 10
1/2 15 63 24 12.355 10
176
CH
L 6063 SU RICHIESTA O-RING IN VITON
IF REQUIRED VITON O-RING
VALVOLA UNIDIREZIONALE MASCHIO-FEMMINA
MALE-FEMALE NON-RETURN VALVE
A
Prezzo Conf.
A B C L CH
Price Pack.
C B M5 5.5 4 34.5 8 4.945 10
1/8 8.5 6 37.5 14 4.700 10
1/4 11 8 46.5 17 5.790 10
3/8 12 9 61 24 12.630 10
1/2 15 10 64 24 12.970 10
Art. 6062 - Art. 6063 Art. 6062 - Art. 6063
CARATTERISTICA DI FLUSSO CARATTERISTICA DI FLUSSO

CON SCARICO IN ARIA LIBERA CON PERDITA DI CARICO DI 1 BAR
FLOW CHARACTERISTIC FLOW CHARACTERISTIC
WITH EXHAUST TO ATMOSPHERE WITH PRESSURE DROP OF 1 BAR
Air rate Q at 0°C and 1013 mbar (Nl/min)
Air rate Q at 0°C and 1013 mbar (Nl/min)
6500 3600
Portata d' aria Q a 0°C e 1013 mbar (Nl/min)
Portata d' aria Q a 0°C e 1013 mbar (Nl/min)
6000 3300
2
1/
5500
3000 /2
8-
- 1
3/
5000 8
2700
3/
4500
2400
4000
2100
3500
1800
3000
1500
2500
1200
2000
1/4 1/4
900
1500
1/8 600 1/8

1000
500 300
M5
M5
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
PRESSIONE A MONTE P1 (bar) PRESSIONE A MONTE P1 (bar)

INLET PRESSURE P1 (bar) INLET PRESSURE P1 (bar)
177
www.swagelok.com
C h e c k Va l v e s
C , C A , C H , C P, a n d C PA S e r i e s
■ Working pressures up to 6000 psig (413 bar)
■ Adjustable and fixed cracking pressures
■ Variety of end connections
■ 316 stainless steel and brass materials

2 Check Valves
Contents
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Testing, Cleaning, and Packaging . . . . . . . . . . . . . . . . . 10
Pressure-Temperature Ratings . . . . . . . . . . . . . . . . . . . . 3 Ordering Information and Dimensions . . . . . . . . . . . . . . 11
Cracking and Reseal Pressures . . . . . . . . . . . . . . . . . . . 4 Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . 14
Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . 5
Features
Fixed Cracking Pressures Adjustable Cracking Pressures
From 1/3 to 25 psi (0.02 to 1.7 bar) From 3 to 600 psi (0.20 to 41.3 bar)
C Series CA Series
Locking screw
maintains settings
O-ring seals Spring Fully contained Adjustable Adjusting screw sets

body halves Poppet O-ring seal spring cracking pressure
CH Series CPA Series
Poppet with Poppet stop

bonded Fully Adjustable Adjusting screw Locking screw
elastomer seal contained spring sets cracking maintains
O-ring seal pressure setting
Compact, one-piece body

O-ring seals body halves Backup ring supports O-ring
CP Series
Fully contained O-ring seal
Compact, one-piece body

Check Valves 3
Technical Data
Cracking pressure—the upstream pressure at which the first For valves not actuated for a period of time, initial
indication of flow occurs. cracking pressure may be higher than the set
Reseal pressure—the pressure at which there is no indication cracking pressure.
of flow.
Maximum Nominal Downstream Pressure

Flow Coefficient Cracking Pressure at 70°F (20°C)
Series (Cv ) psi (bar) psig (bar)
Fixed Cracking Pressure
2C 0.10
1000 (68.9)➀
4C 0.47
1/3, 1, 10 and 25
6C 1.47
(0.02, 0.06, 0.68, and 1.7)
8C 1.68 200 (13.7)
12C, 16C 4.48
CH4 0.67
1/3, 1, 5, 10 and 25 6000 (413)
CH8 1.8 (0.02, 0.06, 0.34
0.68, and 1.7)
CH16 4.7 5000 (344)
4CP 0.35 1/3, 1, 10 and 25
3000 (206)
8CP 1.20 (0.02, 0.06, 0.68, and 1.7)
Adjustable Cracking Pressure

CA 0.37 3 to 50 (0.20 to 3.4)
50 to 150 (3.4 to 10.3)
4CPA 0.35 3000 (206)
150 to 350 (10.3 to 24.1)
8CPA 1.20 350 to 600 (24.1 to 41.3)
➀ For cracking pressure of 25 psi (1.7 bar), downstream pressure is 3000 psig (206 bar).
Pressure-Temperature Ratings
C (2C, 4C, 6C, and 8C), CA, CP, and CPA Series
Ratings based on fluorocarbon FKM O-rings in 316 stainless
steel valves and Buna N in brass valves.
Material 316 SS Brass

Temperature, °F (°C) Working Pressure, psig (bar)
–10 (–23) to 100 (37) 3000 (206) 3000 (206)
200 (93) 2575 (177) 2600 (179)
250 (121) 2450 (168) 2405 (165)
300 (148) 2325 (160) —
375 (190) 2185 (150) —
C Series (12C and 16C) CH Series

Ratings based on fluorocarbon FKM O-rings in 316 stainless Ratings based on fluorocarbon FKM seals.
steel valves and Buna N in brass valves.
Material 316 SS Brass Material 316 SS

Temperature, °F (°C) Working Pressure, psig (bar) Series CH4, CH8 CH16
–10 (–23) to 100 (37) 2000 (137) 1500 (103) Temperature, °F (°C) Working Pressure, psig (bar)
200 (93) 1715 (118) 1300 (89.5) –10 (–23) to 100 (37) 6000 (413) 5000 (344) ➀
250 (121) 1630 (112) 1200 (82.6) 200 (93) 5160 (355) 4290 (295)
300 (148) 1545 (106) — 250 (121) 4910 (338) 4080 (281)
375 (190) 1450 (99.9) — 300 (148) 4660 (321) 3875 (266)
400 (204) 4280 (294) 3560 (245)
For more information about pressure ratings of valves with tube fitting end
connections, see Swagelok ® Tubing Data.
➀ Pressure ratings may be limited by the end connection. See Dimensions,
page 12.
4 Check Valves
Cracking and Reseal Pressures

at 70°F (20°C)
Cracking pressure—the upstream pressure at which the first For valves not actuated for a period of time, initial
indication of flow occurs. cracking pressure may be higher than the set
Reseal pressure—the pressure at which there is no indication cracking pressure.
of flow.
C Series CH Series
Nominal Cracking Nominal Cracking
Cracking Pressure Pressure Range Reseal Pressure Cracking Pressure Pressure Range Reseal Pressure
psi (bar) psi (bar) psi (bar) psi (bar) psi (bar) psi (bar)
Up to 6 (0.41) Up to 6 (0.41)
1/3 (0.02) Up to 3 (0.20) 1/3 (0.02) Up to 3 (0.20)
downstream pressure back pressure
Up to 6 (0.41) Up to 5 (0.34)
1 (0.06) Up to 4 (0.27) 1 (0.06) Up to 4 (0.27)
downstream pressure back pressure
7 to 15 3 (0.20) or more 3 to 9 Up to 2 (0.13)
10 (0.68) 5 (0.34)
(0.48 to 1.0) upstream pressure (0.20 to 0.62) back pressure
20 to 30 17 (1.1) or more 7 to 15 3 (0.20) or more
25 (1.7) 10 (0.68)
(1.3 to 2.0) upstream pressure (0.48 to 1.0) upstream pressure
20 to 30 17 (1.1) or more
25 (1.7)
(1.3 to 2.0) upstream pressure
CP Series CA and CPA Series

Nominal Cracking Reseal Cracking Pressure, bar
Cracking Pressure Pressure Range Pressure 0 4 8 12 16 20 24 28 32 36 40
psi (bar) psi (bar) psi (bar) 600
40
550
6 to 20 (0.41 to 1.3) 500
36
1/3 (0.02) Up to 3 (0.20)
Reseal Pressure, bar

Reseal Pressure, psi
downstream pressure 450

450 32
400 390 28
5 to 20 (0.34 to 1.3)
1 (0.06) Up to 4 (0.27) 350 24
downstream pressure
300 20
7 to 13 3 to 10 (0.20 to 0.68) 250
10 (0.68) 16
(0.48 to 0.89) downstream pressure 200
12
150
21 to 29 5 (0.34) or more 8
25 (1.7) 100
(1.4 to 1.9) upstream pressure 4
50
0 0
–50 –3.4
0 50 100 150 200 250 300 350 400 450 500 550 600
Back Pressure
Cracking Pressure, psi
6 Check Valves
Materials of Construction
CP Series
6
1 2 3 4 5
CPA Series
6
1 2 3 4 5 7 8
Valve Body Materials

Brass
316 SS 4CP 8CP 4CPA 8CPA
Component Material Grade/ASTM Specification
1 Insert lock screw 316 SS/A276 or A479 Brass 485/ Brass 360/ Brass 485/ Brass 360/
2 Insert 316 SS/A479 B21 B16 B21 B16
3 O-ring Fluorocarbon FKM Buna N
4 Poppet 316 SS/A479 Brass 360/B16
5 Spring 302 SS/A313
6 Body 316 SS/A479 Brass 360/B16
7 Adjusting screw (CPA series) 316 SS/ Brass 360 ➀/
316 SS/A276 —
8 Locking screw (CPA series) A276 B16
Silicone-based
(CP series);
Lubricants Silicone-based
PTFE-based
(CPA series)
Wetted components listed in italics.
➀ Adjusting screw in valve with 150 or 350 psi spring is 316 SS.
Check Valves 9
Flow Data at 70°F (20°C)

CA and CPA Series
Nominal Cracking Pressures
3 psi (0.20 bar) 50 psi (3.4 bar) 150 psi (10.3 bar) 350 psi (24.1) bar)
Air Water
CA Series CA Series
Air Flow, std L/min Water Flow, L/min
0 400 800 1200 1600 2000 2400 2800 0 2.0 4.0 6.0
800 600
40
50
700
500
Inlet Pressure, psig
600
Pressure Drop, bar

Pressure Drop, psi
Inlet Pressure, bar
40 30
400
500
30
400 300 20
300 20 200
200 10
10 100
100
0 0 0 0
0 20 40 60 80 100 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
Air Flow, std ft3/min Water Flow, U.S. gal/min
4CPA Series 4CPA Series

0 400 800 1200 1600 2000 2400 2800 0 2.0 4.0 6.0
800 600
40
50
700
500
600
Pressure Drop, bar

Pressure Drop, psi
Inlet Pressure, bar
40 30
400
500
30
400 300 20
300 20
200
200 10
10 100
100
0 0 0 0
0 20 40 60 80 100 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
8CPA Series 8CPA Series

0 400 800 1200 1600 2000 2400 2800 0 4.0 8.0 12 16 20
800 600
40
50
700
500
600
Pressure Drop, bar
Pressure Drop, psi
40
Inlet Pressure, bar
30
400
500
30
400 300 20
300 20
200
200 10
10 100
100
0 0 0 0
0 20 40 60 80 100 0 1.0 2.0 3.0 4.0 5.0 6.0

13 Check Valves
Dimensions
Dimensions, shown with Swagelok tube fitting nuts finger-tight, are for reference only and are subject to change.
CP and CPA Series
A
D flat
Basic Ordering Information

End Connections Dimensions, in. (mm)
Ordering Basic ordering numbers specify
Inlet/Outlet Size Number Series A D
stainless steel material. To order
Fixed Cracking Pressure, CP Series brass, replace SS with B in the basic
1/4 in. SS-4CP4- 4CP 2.41 (61.2) 3/4 ordering number.
Female NPT
1/2 in. SS-8CP4- 8CP 3.71 (94.2) 1 1/16 Example: B-2C-
1/4 in. SS-4CP2- 4CP 1.62 (41.1) 9/16
Male NPT
1/2 in. SS-8CP2- 8CP 2.28 (57.9) 7/8 CP Series
Female/ To order, add a cracking pressure
1/4 in. SS-4CP6- 2.29 (58.2) 3/4
male NPT 4CP designator to the basic ordering
Male/ 1/4 in. SS-4CP5- 1.75 (44.4) 3/4 number.
female NPT 1/2 in. SS-8CP5- 8CP 2.83 (71.9) 1 1/16
Cracking Pressure
Female ISO ➀ 1/4 in. SS-4CP4-RT- 2.54 (64.5) 3/4 psi (bar) Designator
4CP
Male ISO ➀ 1/4 in. SS-4CP2-RT- 1.62 (41.1) 9/16 1/3 (0.02) 1/3
Adjustable Cracking Pressure, CPA Series 1 (0.06) 1
Female NPT 1/4 in. SS-4CPA4- 2.98 (75.7) 3/4 10 (0.68) 10
4CPA
1/4 in. SS-4CPA2- 1.62 (41.1) 9/16 25 (1.7) 25
Male NPT
1/2 in. SS-8CPA2- 8CPA 2.56 (65.0) 7/8
1/4 in. SS-4CPA2-RT- 4CPA 1.62 (41.1) 9/16 Example: B-4CP4-1/3
Male ISO ➀
1/2 in. SS-8CPA2-RT- 8CPA 2.56 (65.0) 7/8
CPA Series
➀ See specifications ISO 7/1, BS21, DIN-2999, and JIS B0203.
To order, add a cracking pressure
range designator to the basic
ordering number.
Cracking Pressure
Range, psi (bar) Designator
3 to 50 (0.20 to 3.4) 3
50 to 150 (3.4 to 10.3) 50
150 to 350 (10.3 to 24.1) 150
350 to 600 (24.1 to 41.3) 350
Example: SS-4CPA4-3
Check valves are designed for

directional flow control only.
Swagelok check valves
should never be used as code
safety relief devices.
Options and Accessories
Seal Materials (All Series) Sour Gas Valves (CH Series)
Fluorocarbon FKM O-rings are standard in 316 stainless steel CH series valves with Swagelok tube fitting end connections
valves; Buna N O-rings are standard in brass valves. Other are available for sour gas service. Materials for wetted
elastomer seals (poppet bonding material and O-ring) are components are selected in accordance with NACE
available. To order, insert the seal material designator into the Specification MR0175 for sulfide stress cracking-resistant
valve ordering number. materials.
Seal Temperature Rating Technical Data

Material Designator °F (°C)
Pressure Rating at 70°F (20°C)
Buna N -BU –10 to 250 (–23 to 121) CH4 and CH8 series: 5000 psig (344 bar)
Ethylene propylene -EP –50 to 300 (–45 to 148) CH16 series: 4700 psig (323 bar)
Fluorocarbon FKM -VI –10 to 375 (–23 to 190) Temperature Rating
Neoprene -NE –40 to 250 (–40 to 121) –50 to 300°F (–45 to 148°C)
PTFE➀ -TR –50 to 350 (–45 to 176) Nominal Cracking Pressures
➀ PTFE requires high back pressure to seal leaktight. PTFE seals not available 1/3, 1, and 5 psi (0.02, 0.06, and 0.34 bar)
for CH series valves. End Connections
1/4, 3/8, 1/2, 3/4, and 1 in. Swagelok tube fittings
Example: B-2C-VI-1/3
Silicone, Buna C, Kalrez® and Aflas® O-rings are available. Body, poppet—alloy R-405/B164
Contact your independent Swagelok sales and service Seals—ethylene propylene
representative for details. Backup ring—PTFE
Spring—alloy X-750/AMS 5699
Special Alloys (All Series) All other materials and lubricant same as standard
Springs of alloy 400 or alloy C-276 are available in some sizes. product. See Materials of Construction, page 5.
Valve bodies of alloy R-405, carbon steel, aluminum, or other
alloys are available in some sizes. Ordering Information
Contact your independent Swagelok representative for more To order, replace SS with M and insert -SG into the ordering
information. number.
Example: M-CHS2-SG-1/3
Special Cleaning and Packaging (SC-11)
Every C, CA, and CH series check valve with VCR® end Deflector Cap (CP and CPA Series)
connections is processed in accordance with Swagelok Special A polyethylene deflector cap is available for CP
Cleaning and Packaging (SC-11) to ensure compliance with and CPA series valves with male NPT end
product cleanliness requirements stated in ASTM G93 Level C. connections. The deflector cap deflects flow
To order special cleaning and packaging for C, CA, and CH from direct contact with personnel and prevents
series check valves with other end connections, add -SC11 to atmospheric contaminants from entering the
the ordering number. valve. The deflector cap screws easily onto the
Example: SS-2C-1/3-SC11 male NPT outlet end of the valve. Maximum
rating is 300 psig at 100°F (20.6 bar at 37°C).
PTFE-Coated Springs To order, insert -DG for a green cap or -DR for
(C, CA, CP, and CPA Series) a red cap into the ordering number.
Springs with PTFE coating are available in some sizes. Example: SS-4CPA2-DR-3
Contact your independent Swagelok representative for more
information. Maintenance Kits
Spring kits and seal kits are available for retrofit or maintenance.
See the Swagelok Check Valve Maintenance Kits catalog.
Oxygen Service
Safe Product Selection For more information about hazards and risks of oxygen-
When selecting a product, the total system design must enriched systems, see the Swagelok Oxygen System Safety
be considered to ensure safe, trouble-free performance. technical report.
Function, material compatibility, adequate ratings,
proper installation, operation, and maintenance are the
responsibilities of the system designer and user. VCR, VCO, Swagelok—TM Swagelok Company
Aflas—TM Asahi Glass Co., Ltd.
Kalrez—TM DuPont
© 2002, 2003 Swagelok Company
Caution: Do not mix or interchange parts with those of Printed in U.S.A., MI
other manufacturers. December 2003, R4
MS-01-176
www.swagelok.com
P ro p o r t i o n a l R e l i e f Va l v e s
R Series
■ Liquid or gas service
■ Set pressures from 10 to 6000 psig (0.68 to 413 bar)
■ 1/4 and 1/2 in. and 6 to 12 mm end connections

2 Proportional Relief Valves
Cap
provides easy external
Spring
set pressure adjustment
adjusts to provide
desired set pressure Label
identifies set
pressure range
Lock nut
maintains cap position, Lock wire capability
ensuring set pressure adjustment secures cap to maintain
set pressure adjustment
Quad seal
eliminates leakage
around stem during
relief mode
O-ring
provides elastomer-to-metal End connections
seal for positive shutoff at seat. include gaugeable Swagelok tube
(Other series use bonded disc. fittings and NPT or ISO pipe threads
See Materials of Construction)
R3A series valve shown.
Features Applications
High-Pressure Valves R series relief valves are proportional relief valves that open
gradually as the pressure increases. Consequently, they do not
■ Service up to 6000 psig (413 bar)
have a capacity rating at a given pressure rise (accumulation),
■ Multiple springs for a selection of set pressure ranges and they are not certified to ASME or any other codes.
■ 1/4 in. and 6 and 8 mm end connections—R3A series
The system designer and user must determine
■ 1/2 in. and 12 mm end connections—R4 series applicable code requirements and whether R series
relief valves are acceptable for use.
Low-Pressure Valves
■ Service up to 300 psig (20.6 bar) Operation
■ One spring for the full set pressure range R series relief valves OPEN when system pressure reaches
■ 1/4 in. and 6 and 8 mm end connections—RL3 series the set pressure and CLOSE when system pressure falls
■ 1/2 in. and 12 mm end connections—RL4 series below the set pressure.
■ High-pressure R3A and R4 series—select and install the
spring that covers the required set pressure; apply the
matching label to the cap.
■ Low-pressure RL3 and RL4 series—the spring is already
installed.
For valves not actuated for a period of time, initial
relief pressure may be higher than the set pressure.
Proportional Relief Valves 3
Technical Data
Pressure-Temperature Ratings
Series R3A R4 RL3 and RL4
Working Pressure at 6000 psig (413 bar);
6000 psig (413 bar) 300 psig (20.6 bar)
70°F (20°C) up to 8000 psig (551 bar) during relief
Set Pressure➀ 50 to 6000 psig (3.4 to 413 bar) 50 to 1500 psig (3.4 to 103 bar) 10 to 225 psig (0.68 to 15.5 bar)
Outlet Pressure➁ 1500 psig (103 bar) 2500 psig (172 bar) 225 psig (15.5 bar)
Fluoro- Ethylene Fluoro- Ethylene Fluoro- Ethylene
carbon Neo- pro- carbon Neo- pro- carbon Neo- pro-
Seal Material FKM Buna N prene pylene FKM Buna N prene pylene FKM Buna N prene pylene
Temperature, °F (°C) Maximum Set Pressure, psig (bar)
–40 (–40) —
— —
–30 (–34) —
—
–10 (–23) — —
—
0 (–17) — — —
10 (–12) 6000
6000 (413)
25 (–4)
6000 (413)
30 (–1) 6000
(413)
50 (10) (413) 225
225 (15.5)
5580 5580 5580 5580 225 (15.5)
150 (65) 225 (15.5)
(384) (384) (384) (384) (15.5)
1500 1500 1500
5160 5160 5160 5160 (103) (103) (103)
200 (93) 1500
(355) (355) (355) (355)
(103)
4910 4910 4910 4910
250 (121)
(338) (338) (338) (338)
275 (135) 4660
— — — — —
300 (148) (321) —
➀ The pressure-temperature ratings are based upon laboratory testing to ensure that the cracking pressure does not deviate by more than 20 % from the initial room
temperature set pressure.
➁ Outlet pressure should not exceed inlet pressure.
Set Pressure and Resealing Pressure Back Pressure

■ Set pressure is the upstream pressure at which the first High-Pressure Valves (R3A and R4 Series)
indication of flow occurs. Set pressure of each valve after
The effect of system back pressure is minimized by the design
initial relief is repeatable within ± 5 % at room temperature.
of these high-pressure valves.
■ Resealing pressure is the upstream pressure at which there
is no indication of flow. Resealing pressure is always lower Low-Pressure Valves (RL3 and RL4 Series)
than set pressure. System back pressure increases the set pressure of the valve.
To compensate, multiply the back pressure by 0.8 and subtract
Testing the result from the desired set pressure. Use the result to pre-set
Every R series proportional relief valve is tested for set and the valve while back pressure is equal to atmospheric pressure.
resealing performance. Example:
Desired set pressure is 120 psig. System back pressure is
Minimum Resealing 40 psig.
Test Set Pressure Pressure as a Percentage
Series psig (bar) of Set Pressure, % Step 1. Multiply back pressure by 0.8.
10 to 20 (0.68 to 1.3) 50 40 psig 0.8 = 32 psig.
RL3, RL4
175 to 225 (12.0 to 15.5) 91 Step 2. Subtract result from desired set pressure.
100 to 200 (6.8 to 13.7) 50 120 psig – 32 psig = 88 psig.
R3A, R4
850 to 1000 (58.5 to 68.9) 84 Step 3. Pre-set proportional relief valve to 88 psig.
Cleaning and Packaging Oxygen Service

All Swagelok R series relief valves are cleaned and packaged For more information about hazards and risks of oxygen-
in accordance with Swagelok Specification SC-10. enriched systems, see the Swagelok Oxygen System Safety
technical report.
Component Material Grade/ASTM Specification
RL3 and R3A RL4 and R4 RL3, R3A—nickel-plated brass;
1 Plug
RL4, R4—brass
1 1
2 2 Cap 316 SS/A479
2 3 Label Polyester
3 RL3, R3A—316 SS powdered metal;
4 Lock nut
3 RL4, R4—316 SS/A276
4 5 Spring S17700 SS/AMS 5678
6 Sleeve 304 SS/A240
RL3 5
only 4 7 Spring support
RL3, R3A—316 SS powdered metal;
RL4, R4—316 SS/A276
6 8 Bonnet 316 SS/A479
7 5
9 O-ring Fluorocarbon FKM
RL4 10 Quad seal PTFE-coated fluorocarbon FKM

8 only RL3, R3A—316 SS/A666;
11 Retainer
RL4, R4—316 SS/A479
6 12 Stem 316 SS/A479
12a Bonded stem Fluorocarbon FKM-bonded ➀
9 7
13 Bonded disc 316 SS/A479
10 R3A
11 only 14 Seat 316 SS/A479
15 Gasket PTFE-coated 316 SS/A240
12 12 8 16 Seat retainer 316 SS/A479
17 O-ring Fluorocarbon FKM
13 18 Insert 316 SS/A479
16
14 19 Body 316 SS/A182
17
Molybdenum disulfide-based dry film
15 18 9 Lubricants
and paste; silicone-based
10 Wetted components listed in italics.
19 R4
11 ➀ Material Safety Data Sheet for bonding agents available on request.
only
12
12a
13
19
RL3 R3A RL4 R4

Dimensions
Dimensions, in inches (millimeters), are Low-Pressure Valves (RL3 and RL4 Series)
for reference only and are subject to
change. End Connections Dimensions, in. (mm)
Ordering
Inlet/Outlet Size Number A B C D E H
RL3 series: 0.14 in. (3.6 mm) fully open orifice
1/4 in. SS-RL3S4
Swagelok 1.44 4.14
6 mm SS-RL3S6MM
0.06 in. tube fittings (36.6) (105)
(1.5 mm) 8 mm SS-RL3S8MM 1.60
lock wire (40.6)
hole Male NPT/
Swagelok 1/4 in. SS-RL3M4-S4 2.70 0.43 4.09
A (68.6) (10.9) (104)
max tube fitting
0.09 in. Male NPT/ 1.19 3.89
(2.2 mm) 1/4 in. SS-RL3M4-F4 (30.2) (98.8)
lock wire
E female NPT 1.17
max
hole Male ISO/ (29.7)
female ISO➀ 1/4 in. SS-RL3M4F4-RT
RL4 series: 0.25 in. (6.4 mm) fully open orifice

1.72 5.81
1/2 in. SS-RL4S8
Swagelok (43.7) (148)
tube fittings 1.83 5.92
Outlet B 12 mm SS-RL4S12MM
(46.5) (150)
4.09 0.50 5.37
Inlet Male NPT/ (104) (12.7) (136)
1.72
Swagelok 1/2 in. SS-RL4M8S8
1.43 (43.7) 5.52
tube fitting
(36.3) (140)
D C Male NPT/ 1.43
1/2 in. SS-RL4M8F8
female NPT (36.3)
High-Pressure Valves (R3A and R4 Series)

End Connections Dimensions, in. (mm)
Ordering
Inlet/Outlet Size Number A B C D E H
R3A series: 0.14 in. (3.6 mm) fully open orifice
1/4 in. SS-4R3A
Swagelok 1.44 4.14
6 mm SS-6R3A-MM
tube fittings (36.6) (105)
8 mm SS-8R3A-MM 1.60
0.06 in. (40.6)
(1.5 mm) H Male NPT/
lock wire max Swagelok 1/4 in. SS-4R3A1 2.70 0.43 4.09
hole (68.6) (10.9) (104)
tube fitting
Male NPT/ 1.19 3.89
1/4 in. SS-4R3A5 (30.2) (98.8)
female NPT 1.17
0.09 in.
(2.2 mm) Male ISO/ (29.7)
lock wire female ISO➀ 1/4 in. SS-4R3A5-RT
hole
R4 series: 0.25 in. (6.4 mm) fully open orifice
1.72 5.81
1/2 in. SS-R4S8
Swagelok (43.7) (148)
tube fittings 1.83 5.92
12 mm SS-R4S12MM
(46.5) (150)
Outlet
4.09 0.50 5.37
Male NPT/ (104) (12.7) (136)
1.72
Swagelok 1/2 in. SS-R4M8S8
Inlet 1.43 (43.7) 5.52
tube fitting
(36.3) (140)
Male NPT/ 1.43
1/2 in. SS-R4M8F8
Valve with Manual female NPT (36.3)
Override Handle Dimensions shown with Swagelok tube fitting nuts finger-tight.
➀ See specifications ISO 7/1, BS21, DIN-2999, and JIS B0203.
Proportional Relief Valves 7
Ordering Information Options and Accessories

Low-Pressure Valves (RL3 and RL4 Series) Seal Materials Seal Material Designator
Valve contains spring; set pressure must be adjusted. Select Fluorocarbon FKM is the Buna N -BU
a valve ordering number. standard seal material.
Ethylene
Optional seal materials are -EP
Spring Kits propylene
available. To order, add a seal
Spring kits include spring and installation instructions. Select Neoprene -NE
material designator to the
a spring kit ordering number. valve ordering number. -VI for seal kits;
Fluorocarbon
no designator
Example: SS-RL3S4-BU FKM
for valves
Spring Kit Set Pressure Range
Series Ordering Number psig (bar) Seal Kits
RL3 177-13K-RL3 Fluorocarbon FKM, Buna N, ethylene propylene, and
10 to 225 (0.68 to 15.5)
RL4 177-13K-RL4 neoprene seal kits are available. To order, insert a seal
material designator as a prefix (R3A series) or suffix (all
others) to the seal kit basic ordering number.
High-Pressure Valves (R3A and R4 Series)
Examples: BU-R3A-K2
Valve does not contain spring. Select a valve ordering number
SS-3K-RL3-BU
and a spring kit ordering number.
Spring Kits RL3 Series R3A Series RL4 Series R4 Series
Spring kits include spring, label, 302 SS lock wire with seal, Seal kit basic ordering number
spring support, and installation instructions. SS-3K-RL3- -R3A-K2 SS-3K-RL4- SS-3K-R4-
Select a spring kit basic ordering number and add the spring Seal kit contents
designator for the desired set pressure range. O-ring, O-ring,
O-rings (2), O-ring,
Examples: 177-R3A-K1-F quad seal, quad seal,
quad seal, quad seal,
bonded disc, bonded disc,
177-13K-R4-C retainer, bonded stem,
retainer, retainer,
instructions instructions
instructions instructions
Set Pressure Range Spring Spring
psig (bar) Designator Color
R3A series spring kit: basic ordering number 177-R3A-K1- Manual Override
50 to 350 (3.5 to 25) A Blue Handles
350 to 750 (25 to 50) B Yellow
Phenolic
A manual override handle handle
750 to 1500 (50 to 100) C Purple opens the valve without
316 SS
1500 to 2250 (100 to 155) D Orange changing the set pressure.
pull rod
2250 to 3000 (155 to 205) E Brown For use with:
3000 to 4000 (205 to 275) F White ■ RL3 and RL4 series—
4000 to 5000 (275 to 340) G Red standard spring
5000 to 6000 (340 to 410) H Green ■ R3A series—A, B, and C
springs only 316 SS spring
R4 series spring kit: basic ordering number 177-13K-R4-
support
50 to 350 (3.5 to 25) A Blue ■ R4 series—A spring only.
350 to 750 (25 to 50) B Yellow Handle diameter is 1.50 in.

(38.1 mm). Maximum overall
750 to 1500 (50 to 100) C Purple
height of valve with handle
in closed position:
Special Cleaning and Packaging (SC-11) ■ 5.16 in. (131 mm) for R3A
To order R series relief valves processed in accordance with and RL3 series
Swagelok Special Cleaning and Packaging (SC-11) to ensure ■ 6.78 in. (172 mm) for R4
compliance with product cleanliness requirements stated in and RL4 series.
ASTM G93 Level C, add -SC11 to the valve ordering number. To order, add -MO to the valve ordering number.
Example: SS-RL3S4-SC11 Example: SS-RL3S4-MO
Manual Override Manual Override Kit
Handle Kits Series Ordering Number
Kits contain handle, pull rod, RL3, R3A SS-R3A-K5
spring support, and RL4, R4 SS-R4-K5
instructions. To order, select
the desired kit ordering number.
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Compact Solenoid Valve - General Purpose Type 6013
Threaded Port G 1/8" – G 3/8"
2/2-Way; G 1/8" – G 3/8"; PN up to 25 bar Advantages/Benefits
Coil can easily be changed

with valve in place
Coil lockable in 4 x 90 o
positions or freely movable
in between, as required
Medium is only in contact

with the valve internals
and the body
High-quality seal material

FPM (Viton) as standard
High temperature option
Design/Function Applications
The 6013 valves are based on a To simplify ordering, a wide Fluids

modular concept comprising three selection of standard Brass version:
basic elements: Valve body, push- combinations of valve body, Neutral gases and liquids, e.g.
over coil and standard cable plug. push over coil and standard cable compressed air, town gas,
The valve assembly consists of a plug can be ordered with one order natural gas, water, hydraulic oil,
body to which the armature guide number. petrol.
tube containing the plunger, seals Stainless steel version:
and springs is attached. Cable plug options of Type 2508 Difficult and slightly aggressive
The coil is pushed over the guide are available to suit special media
tube and thus isolated from the electrical application requirements. High temperature version:
medium. Steam
The medium is only in contact with – The modular concept provides
Suitable for technical vacuum
the valve internals and body. flexibility to meet application
requirements. Applications
A wide selection of port and orifice • Pneumatic control
sizes is offered. The valve body – The valves are interchangeable • Shut-off, dosing, filling and
material is brass and stainless steel. with Type 211. venting
All valves have high quality viton • Small-scale instruments,
(FPM) seals as standard. laboratory and measuring
technology
• Welding technology
Fluid Control Systems
www.buerkert-contromatic.com Page 1 / 4
Technical Data Type 6013
Circuit function Symbol
A 2/2-way valve,
normally closed
Operating Data (Valve) Operating Data (Actuator)
Pressure range 0-25 bar (see specifications) Operating voltages AC 24, 110, 230 V/50 Hz,
24 V/DC
Port connection Threaded port G 1/8''-G 3/8''
Voltage tolerance ±10 %
Orifice DN 2,0-6,0 mm
Fluid Neutral gases and liquids, Power consumption See ordering chart
e.g. compressed air, town
gas, natural gas, water, Duty cycle 100% continuously rated
hydraulic oil, petrol. Duty cycle for multiple 60% periodic duty (30 min)
Stainless steel version for manifolds or use 5W-version
difficult and slightly (on request)
aggressive media.
High temperature version Cycling rate Up to 1 000 c.p.m.
for steam.
Suitable for techn. vacuum. Rating with
cable plug IP 65
Medium temperature
FPM –10 up to +100 °C Electr. connection Delivery standard:
PTFE / Graphite 0 up to +180 °C Cable plug DIN 43 650 A,
0-250 V. (other versions see
Max. ambient temperature +55 °C
accessories)
Max. viscosity 21 mm2/s
On request • Ex version EEx me II T4
Response times • Analytical version
Opening AC, DC 20 ms • DVGW version
Closing AC, DC 30 ms
Installation As required, but preferably

with solenoid system upright
Materials
1 Valve body: Brass,

14 SS 1.4305 (G1/8")
SS 1.4401 (G1/4")
2 Plunger-seal: FPM (Viton)
8 3 O-rings: FPM (Viton)
13 4 Armature guide tube: 1.4303
7
12 5 Plunger: 1.4105
6
11 6 Spring: 1.4310
5
7 Shading ring: Cu (brass version)
4 Ag (stainless steel version)
3 8 Stopper: 1.4105
9 Flange: Zn3 gl cC (surface)
2
10 Bonnet: Durethan BKV30H
1 11 Coil: PA (Polyamide)
10 12 Flat seal: NBR
9 13 Cable plug: PA (Polyamide)
14 Locknut: 9SMnPb28K (surface
Zn5glcA)
Page 2 / 4
Specifications - Ordering Chart (Other Versions on Request)
Standard version (up to 100 °C); FPM sealing (with standard-cable plug 0-250 V AC/DC)
Circuit Orifice Port Kv-Value Power Pressure Voltage/ Item-No. Item-No.
function connection water 1) consumption range 2) frequency • Brass body • SS body
(coil) • FPM seal • FPM seal
[mm] [inch] [m 3 /h] [W] [bar] [V/Hz]
A 2.0 G 1/8 0.12 8 0 – 12 24/DC 134 237 M 134 233 R
0 – 25 24/50 132 865 R 134 234 J
0 – 25 110/50 134 238 W 134 235 K
0 – 25 230/50 134 239 X 134 236 L
A 2.0 G 1/4 0.12 8 0 – 12 24/DC 137 537 D 137 533 H
0 – 25 24/50 137 538 N 137 534 A
0 – 25 110/50 137 539 P 137 535 B
0 – 25 230/50 137 540 U 137 536 C
A 2.5 G 1/8 0.16 8 0 – 10 24/DC 134 240 C –
0 – 16 24/50 134 241 Z –
0 – 16 110/50 134 242 S –
0 – 16 230/50 134 243 T –
A 2.5 G 1/4 0.16 8 0 – 10 24/DC 137 541 R –
0 – 16 24/50 137 542 J –
0 – 16 110/50 137 543 K –
0 – 16 230/50 137 544 L –
A 3.0 G 1/8 0.23 8 0– 6 24/DC 126 091 F 126 078 Z
0 – 10 24/50 126 092 G 126 079 S
0 – 10 110/50 126 093 H 126 080 Q
0 – 10 230/50 126 094 A 126 081 D
A 3.0 G 1/4 0.23 8 0– 6 24/DC 125 301 V 125 317 L
0 – 10 24/50 125 302 W 126 082 E
0 – 10 110/50 125 303 X 126 083 F
0 – 10 230/50 125 304 Y 126 084 G
A 4.0 G 1/4 0.30 8 0 – 1.5 24/DC 125 306 S 125 318 V
0– 4 24/50 125 307 T 125 319 W
0– 4 110/50 125 308 C 126 085 H
0– 4 230/50 125 309 D 125 320 T
A 6.0 G 1/4 0.55 8 0 – 0.5 24/DC 125 311 N –
0 – 1.5 24/50 125 312 P –
0 – 1.5 110/50 125 313 Q –
0 – 1.5 230/50 125 314 R –
A 3.0 G 3/8 0.23 10 0– 8 24/DC 134 248 G –
0 – 14 24/50 134 249 H –
0 – 14 110/50 134 250 E –
0 – 14 230/50 134 251 T –
A 4.0 G 3/8 0.30 10 0 – 2.5 24/DC 134 252 U –
0– 6 24/50 134 253 V –
0– 6 110/50 134 254 W –
0– 6 230/50 134 255 X –
A 6.0 G 3/8 0.55 10 0 – 0.75 24/DC 134 256 Y –
0 – 2.5 24/50 134 257 Z –
0 – 2.5 110/50 134 258 A –
0 – 2.5 230/50 134 259 B –
High temperature version (up to 180 °C); PTFE/Graphite sealing (with standard-cable plug 0-250 V AC/DC)
Circuit Orifice Port Kv-Value Materials Power Pressure Voltage/ Item-No.
function connection water 1) consumption range 2) frequency • PTFE/Graph.
(coil) seal
[mm] [inch] [m 3 /h] [W] [bar] [V/Hz]
A 2.0 G 1/4 0.12 Brass body 8 0 – 6.00 24/DC 136 015 C
SS seat 0 – 10.00 24/50 136 016 D
0 – 10.00 110/50 136 017 E
0 – 10.00 230/50 136 018 P
A 3.0 G 1/4 0.23 Brass body 10 0 – 6.00 24/DC 136 019 Q
SS seat 0 – 10.00 24/50 136 020 M
0 – 10.00 110/50 136 021 A
0 – 10.00 230/50 136 022 B
A 3.0 G 3/8 0.23 Brass body 10 0 – 6.00 24/DC 136 023 C
SS seat 0 – 10.00 24/50 136 024 D
0 – 10.00 110/50 136 025 E
0 – 10.00 230/50 136 026 F
1)
Measured with 6 bar upstream pressure and 1 bar pressure drop across the valve at +20 ˚C.
2)
All pressures quoted are gauge pressures with respect to the prevailing atmospheric pressure.
Options on request: • Rc and NPT threads

• Other voltages and 60 Hz
• EEx, UL and CSA approvals
• Sub-base
• EPDM seals for -30 up to +120°C
Page 3 / 4
Dimensions [mm]
Threaded port version
29 45 32
41
C
A
M4
4 x 8 depth B
24
32
35
Variable dimensions [mm]

Cable plug DIN 43650, form A,
A B C
(0-250 V AC/DC) delivery standard.
Threaded port G 1/8 32 20.8
Dimensions Accessories [mm] Ordering Chart for Accessories
Device/ Features Item-No.

Accessory
Cable plugs 1) Standard cable plug, 0–250 V AC/DC 008 376 N

Type 2508 (standard-delivery) 1)
with LED, 12–24 V AC/DC 008 360 S
with LED, 100-120 V AC/DC 008 361 P
with LED + varistor, 12–24 V AC/DC 008 367 M
Contact inset with LED + varistor, 100–120 V AC/DC 008 368 W
with LED + varistor, 200–240 V AC/DC 008 369 X
Flat seal
(optional wirings and connection speci-
Cap
fications see data sheet Type 2508)
Cylinder screw
M3 x 30
1)
The standard cable plug (0-250 V AC/DC), Order-No. 008 376 N
Pressure ring is part of the standard delivery.
Ordering of optional cable plugs with separate item number.
Seal ring
A wide selection of further cable plugs is available
Collet (see data sheet type 2508)
Transparent cap, when Union nut
wired with LED.
In case of special requirements We reserve the right to make technical 710-GB/ 3-0046
please consult for advice. changes without notice.
Page 4 / 4
Timer Unit Type 1078-1
Advantages/Benefits
Programming via DIP-

switches and potentiometers
4 functions
Time range from 0.5s - 10h
IP 65 rating
Mains voltage displayed

via LEDs
Simple, space-saving
installation instead of cable
plug to DIN 43 650
Flexible installation; cable

outlet can be oriented in
90°-step intervals
Low installation and wiring

costs
Design/Function Applications
The timer unit Type 1078-1 can be The timer unit is internally program- • Repeated valve timing control
fitted to all valves with the cable mable via DIP-switches and poten- • Irrigation systems
plug standard to DIN 43 650. This tiometers. Four functions can be • Condensate drain of
standard, developed by Bürkert, is programmed. 2 LEDs display the compressors or pipeline
used internationally. mains voltage and valve status. systems
• Repeated timing control of
unsupervised processes
• Cost-effective alternative to
relays or PLC's for repeated
valve operation
Fluid Control Systems

Technical Data
Operating voltages 12 - 24 V/ DC Time setting ranges for t on and t off

24 - 48 V/ 50-60 Hz and DC
48 - 110 V/ 50-60 Hz and DC Any of the time ranges for ton and t off can be selected.
110 - 230 V/ 50-60 Hz Within a selected time range ton and t off are adjustable
± 10 % via a potentiometer:
0,5 - 10 s
Power consumption max. 1.0 W 1,5 - 30 s
5,0 - 100 s
Switching load Imax. = 2 A at supply voltage 0,5 - 10 min
12 - 24 V/ DC 1,5 - 30 min
Imax. = 1.5 A at supply voltage 5,0 - 100 min
24 - 48 V/ 50-60 Hz and DC 12,0 - 240 min
Imax. = 0,5 A at supply voltage 0,5 - 10 h
48 - 110 V/ 50-60 HZ and DC
110 - 230 V/ 50-60 Hz Delivery status ton = 0,5 - 10 s
toff = 0,5 - 10 s
Note
function pulse generator
Terminal voltage and current type must always be
compatible with the solenoid valve.
Version with extended time range
Cable outlet 4x 90°positioning on request: 0,1 - 2s
0,5 - 10 s
Poles 2-pole and earth 5,0 - 100 s
0,5 - 10 min
Outlet connector pin standard to 3,0 - 60 min
DIN 43 650 0,3 - 6h
1,2 - 24 h
Contact spade terminal 5,0 - 100 h
(DIN 46 247/48)
AC voltage timers should always be isolated from the
Connection 3-pole terminal strip in the unit, mains to change the function or time settings
wire diameter max. 1.5 mm2,
PG-cable gland ø 6 to 7 mm
Rating IP 65
air gaps and leakage paths to
VDE 0100
Body material polyamide
Mounting cheesehead screw M 3 x 45 mm
Weight approx. 60 g
Working temperature
range 0 to +60 °C
Influence of temperature
on response time ±5 % of full scale time range
Influence of voltage on
response time ±1 % of full scale time range
Display LED-connected power supply

LED-energized load
Adjustment Function and time range via

DIP-switches, precision adjustment
of response times via potentio-
meters
Functions
EIN
Operating Voltages ON
OFF
Signal: AUS
t
Cycler: starting with “ON”

The connected valve is switched-ton and toff
periodically according to the set times ton and toff.
The “cycler” function starts with ton.
ton toff t
Inverted cycler :
The circuit function of the cycler is reversed i.e.
"Inverted cycler" starts with toff.
Switch-on impulse toff ton t

Once energized, the connected valve is
operated for the pre-set time (ton). Then, the valve
switches t off until it is energized again.
Switch-on delay
Once energized, the connected valve is only
switched ton after the expiration of the preset ton toff ∞ t
time (toff ), for the duration of the supply voltage
being applied.
toff ton ∞ t
Dimensions in mm
Gasket
1.5 thick
Ordering Chart (Other Versions on Request)
Voltage Order-No.
AC 110 - 230 V/ (50-60 Hz) 060 620 N

AC, DC 24 - 48 V/ (50-60 Hz/ =) 060 621 B
AC, DC 48 - 110 V/ (50-60 Hz/ =) 414 900 U
DC 12 - 24 V/ (=) 060 647 M
Version with extended time range

AC, DC 48 - 110 V/ (50-60 Hz/ =) 060 668 S
AC 110 - 230 V/ ( 50-60 Hz) 060 659 Z
Time control for impulse valves on request.
In case of special requirements We reserve the right to make technical 710-GB/ 2-0129
please consult for advice. changes without notice.
STANDARD
FILTER HOUSINGS
#20 Blue MB
#20 Blue
STANDARD FILTER HOUSINGS

• Ideal for a wide range of applications, including residential, commercial
#10 Blue MB #10 Blue
and industrial
• Available in 10" and 20" sizes to meet your needs #10 Clear MB
MB=Mounting Boss Cap
• Optional pressure-relief/bleed button on inlet side of cap
• Thick walls for increased strength
• Leak-proof sealing with top-seated Buna-N O-ring
• Available with clear and blue sumps
Standard filter housings are Standard filter housings are

manufactured of a durable poly- available in both 10" and 20"
propylene or clear Styrene- lengths and will accommodate a
Acrylonitrile (SAN). All are wide range of 21⁄2" to 27⁄8" diameter
equipped with 3/4" NPT inlet and cartridges.
outlet ports.
Reinforced polypropylene housings
have excellent chemical resistance
and are ideal for many residential,
commercial and industrial
applications. Clear sumps are
manufactured from a clear, FDA-
compliant Styrene-Acrylonitrile
(SAN) and offer on-site examination
of the cartridge.
STANDARD
Filter Housings
18
Approximate Net Pressure Drop – psi (bar)
(1.2)
15
(1.0)
12
(0.8)
9
(0.6)
The 150001, 150002, 150067, 150068, 150071, 150072, 150435 and

6
(0.4) 150436 are Tested and Certified by NSF International to NSF/ANSI
Standard 42 for material and structural integrity requirements only.
3
(0.2)
1 3 5 8 10 15 20 25
(4) (11) (19) (30) (38) (57) (76) (95)
Flow Rate – gpm (L/min)
Housing Specifications and Performance Data

Maximum Initial UP (psi)
Model Dimensions @ Flow Rate (gpm)
#10 Blue 12-1/4" x 5-1/8" 1 psi @ 10 gpm

(311 mm x 130 mm) (0.1 bar @ 38 L/min)
#10 Clear 12-5/8" x 5-1/4" 1 psi @ 10 gpm
(321 mm x 133 mm) (0.1 bar @ 38 L/min)
#20 Blue 22-3/8" x 5-1/8" 1 psi @ 10 gpm
(568 mm x 130 mm) (0.1 bar @ 38 L/min)
• Housing Polypropylene (Blue) • O-Ring Buna-N
Styrene Acrylonitrile (Clear) • Maximum Temperature 125˚F (51.7˚C)
• Cap Reinforced Polypropylene • Maximum Pressure 125 psi (8.62 bar)
• Button Assembly 300-series Stainless Steel, EPDM
and Polypropylene
CAUTION: Protect against freezing to prevent cracking of the filter and water leakage.
502 Indiana Avenue • P.O. Box 1047 • Sheboygan, Wisconsin 53082-1047

Customer Service: 800-645-0267 • Fax: 888-203-7361 • supportspecialist@pentekfiltration.com
International: 920-457-9435 • Fax: 920-457-2417 • international@pentekfiltration.com
© 2004 Pentair Water Treatment www.pentekfiltration.com Printed in U.S.A. 01/04 310051
BIG BLUE®
FILTER HOUSINGS
BIG BLUE ® FILTER HOUSINGS #10 Big Blue®
• Large capacity housing suitable for high flow applications
• Available in 10" and 20" sizes to meet your needs #20 Big Blue®
• Optional pressure relief/bleed on inlet side of cap
• Accepts 41⁄2" diameter cartridges
Big Blue® filter housings offer the Big Blue® housings are compatible
versatility to meet all of your large- with a broad range of chemicals and
capacity filtration needs, including are available with or without an
high-flow and heavy-sediment optional pressure relief button. They
applications. The extra large accept a wide variety of 41⁄2"
housing allows for greater cartridge diameter cartridges in either 10" or
capacity, reducing the number of 20" lengths.
vessels required for high flow-rate
applications. Sumps are constructed
of durable reinforced polypropylene
and are available in both 10" and
20" lengths.
The high-flow polypropylene
(HFPP) cap is available with 3/4",
1" or 11⁄2" NPT inlet and outlet
ports. The 11⁄4" internal port allows
a greater volume of liquid to pass
through the HFPP cap more rapidly.
BIG BLUE ®
Filter Housings
18
(1.24)
15
(1.03)
-1"
12
PP
(.83)
HF
UE ®
9
⁄2"
(.62)
-1 1
BL
PP
BIG
The 150233, 150234, 150235, 150236, 150237, 150238, 150239, 150240,

HF
6 150467 and 150469 are Tested and Certified by NSF International to

E®
(.41) NSF/ANSI Standard 42 for material and structural integrity requirements

U
only.
BL
G
3
BI
(.21)
10 20 30 40 50 60 70 80
(38) (76) (114) (151) (189) (227) (265) (303)
Housing Specifications and Performance Data

Maximum Initial UP (psi)
Model Dimensions @ Flow Rate (gpm)
10" BB–3/4" 13-1/8" x 7-1/4" 2 psi @ 15 gpm

(333 mm x 184 mm) (0.1 bar @ 57 L/min)
10" BB–1" 13-1/8" x 7-1/4" 1 psi @ 15 gpm
(333 mm x 184 mm) (0.1 bar @ 57 L/min)
10" BB–1-1/2" 13-5/8" x 7-1/4" 1 psi @ 20 gpm
(346 mm x 184 mm) (0.1 bar @ 76 L/min)
20" BB–3/4" 23-3/8" x 7-1/4" 2 psi @ 15 gpm
(594 mm x 184 mm) (0.1 bar @ 57 L/min)
20" BB–1" 23-3/8" x 7-1/4" 1 psi @ 15 gpm
(594 mm x 184 mm) (0.1 bar @ 57 L/min)
20" BB–1-1/2" 23-7/8" x 7-1/4" 1 psi @ 20 gpm
(606 mm x 184 mm) (0.1 bar @ 76 L/min)
• Housing Polypropylene • O-Ring Buna-N
• Cap Polypropylene (HFPP) • Maximum Temperature 100˚F (37.8˚C)
• Button Assembly 300-series Stainless Steel, EPDM • Maximum Pressure #10BB – 100 psi (6.9 bar)
and Polypropylene #20BB – 90 psi (6.2 bar)
CAUTION: Protect against freezing to prevent cracking of the filter and water leakage.

CARTRIDGE
CEP-10E
CEP-10E
CEP-10E COCONUT BASED CARBON BLOCK CARTRIDGE

• Nominal 5-micron rating*
• Acid-washed coconut-carbon formulation
• Bad taste & odor and chlorine taste & odor reduction*
• Low extractables, minimal pH rise for RO pre- and post-filter applications*
• Enhanced dirt holding capacity*
CEP-10E cartridges are These cartridges are protected by

manufactured from an acid-washed Endurawrap™, a uniquely
coconut-carbon based formulation formulated polyolefin bilaminate
that minimizes the pH rise and prefilter, designed to significantly
produces better tasting water. increase the useful life of the
cartridge by trapping sediment that
Our patented manufacturing process typically plugs carbon block
yields a cartridge with a nominal 5- cartridges.
micron filtration rating, low
extractables and a minimal pH rise * Based on manufacturer’s internal
ideal for RO pre- and post-filter testing.
applications. A thin-wall, high
porosity design helps prevent the
cartridge from plugging before its
adsorption capacity is exhausted,
maximizing the utilization of the
carbon while maintaining low
pressure drop.
CEP-10E
Coconut Based Carbon Block Cartridge
30
(2.1)
99.9

25
(1.7)
99
20
(1.4)
Percent Efficiency
98
95 15
(1.0)
90
10
(0.7)
80
5
70 (0.3)
60 0
1 2 5 10 20 50 100 0 2 4 6 8 10 12
(7.6) (15) (23) (30) (38) (45)
Particle Size (Microns)
Tested and Certified by NSF International to NSF/ANSI Standard 42 for

material requirements only.
Cartridge Specifications and Performance Data

Maximum Micron Rating Initial UP (psi) Chlorine Taste & Odor Reduction*
Model Dimensions (Nominal)* @ Flow Rate (gpm)* @ Flow Rate (gpm)
CEP-10E 2-7/8" x 9-3/4" 5 3.0 psi @ 1 gpm >5,000 gallons @ 1 gpm

(73 mm x 248 mm) (0.2 bar @ 3.8 L/min) (18,900 liters @ 3.8 L/min)
* Based on manufacturer’s internal testing.
• Filter Media Acid-Washed • Gaskets Buna-N
Coconut Based Carbon • Temperature Rating 40˚F to 125˚F (4.4˚C to 51.7˚C)
• End Caps Polypropylene
• Inner/Outer Wraps Polyolefin
• Netting Polyethylene
WARNING: Do not use with water that is microbiologically unsafe or of unknown quality without adequate disinfection before or after the system.
U.S. Patent No. 5,976,432 & 5,823,668

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Pressure Gauge type 2940
Stainless steel with liquid filling
Design Industrial pressure gauge in stainless steel.

Suitable for corrosive environments and
where pulsation or vibration exists.
Case diameter Dim 63, 100 or 160 mm
Case filling Glycerine 99,7%
Accuracy Case dim 63 = kl. 1,6%

Case dim 100 and 160 = kl. 1,0%
Case Stock finish stainless steel
Window Instrument glass
Pressure element Stainless steel 1.4571
Movement Stainless steel 1.4571
Pressure unit Bar/Pascal or Bar
Pressure connection Case dim 63 = G1/4"

Case dim 100 = G3/8" or G1/2"
Pressure entry Radial or back pressure entry
Working Pressure 75% of full scale range by fluctuating pressure.

Case dim 63 By short time pressure, full scale value.
PRESSURE RANGE
Working Pressure 90% of full scale range by fluctuating pressure. PRESSURE

Case dim 100 and 160 Full scale value by steady pressure. 0,6 bar
By short time pressure1,3 x full scale value. 1 bar
1,6 bar
Weather Protection IP 65
2,5 bar
Operating temperature -20+100° C 4 bar
6 bar
10 bar
16 bar
25 bar
40 bar
60 bar
100 bar
160 bar
Type Description 250 bar
400 bar
2940 Radial pressure entry 600 bar
1000 bar
2945 Radial pressure entry with back flange
1600 bar
2949 Radial pressure entry with front flange for panel VACUUM
–1/0 bar
2941 Back pressure entry
–1/+1,5 bar
2947 Back pressure entry with front flange for panel –1/+3 bar
–1/+5 bar
2948 Back pressure entry with triangular bezel for panel
–1/+9 bar
AB Svenska Industri Instrument SINI Visiting Address Telephone Telefax e-mail Internet
Head office Box 8923, SE-402 73 Göteborg Exportgatan 38 D +46 (0) 31-742 56 00 +46 (0) 31-742 56 01 info@sini.se www.sini.se
Branch office Box 1208, SE-751 42 Uppsala Suttungsgränd 3 +46 (0) 18-10 00 33 +46 (0) 18-10 00 44 (utg.01.01) E02.09
Pressure Gauge type 2940
Stainless steel with liquid filling
Radial pressure entry
Back pressure entry
Back pressure entry

case dim 63 mm
Radial pressure entry Back pressure entry
Fig.nr Description Type Description
2940 Standard 2941 Standard
2945 with back flange 2947 with front flange
2949 with front flange 2948 with triangular bezel
Dim Ø a b b1 b2 D1 D2 e f G h±1 SW weight
63 9,5 33 33 60 63 62 11,5 18,5 G 1/4” 53 14 0,1
100 15,5 49,5 49,5 83 101 99 17,5 30 G 3/8” or G 1/2” 87 22 0,6
160 15,5 49,5 1) 49,5 2) 83 2) 161 159 17,5 50 G 3/8” or G 1/2” 118 22 1,1
1) Pressure range 1600 bar b = 65,5 mm

2) From 60 bar b1 = 65,5 mm, b2 = 99 mm
®
15 Frame
Plunger Pump
Standard Brass
Model 10 5 0
Stainless Steel
Model 10 51
FEATURES
Nickel Aluminum
Bronze Model 10 57
Superior Design
● Triplex plunger design gives smoother liquid flow. SPECIFICATIONS U.S. Measure Metric Measure
● V-Packings are completely lubricated and cooled by the liquid STANDARD SPECIFICATIONS
being pumped. Flow ..................................................................10 GPM (38 L/M)
● Inlet and discharge valve assemblies interchange for easier Pressure Range....................................100 to 2200 PSI (7 to 155 BAR)
maintenance. RPM ...............................................................958 RPM (958 RPM)
Inlet Pressure Range .................................– 5 to 60 PSI (– 0.35 to 4 BAR)
● Lubricated Lo-Pressure Seals provide double protection against
Maximum Liquid Temperature .............................160°F (71°C)
external leakage.
● Oil bath crankcase assures optimum lubrication. ALTERNATE SPECIFICATIONS
Flow ...............................................................★ 12 GPM (45 L/M)
● Close tolerance concentricity of the ceramic plunger maximizes Pressure Range ................................★ 100 to 1800 PSI (7 to 125 BAR)
seal life. RPM ..........................................................★ 1150 RPM (1150 RPM)
Quality Materials Inlet Pressure Range - ★ C.A.T. Required ....20 to 60 PSI (1.4 to 4 BAR)
● All stainless steel valves are heat treated and seats are roller Maximum Liquid Temperature ...........................★ 100°F (38°C)
burnished for a positive seal and extended valve life. COMMON SPECIFICATIONS
● Brass, Stainless Steel or Nickel Aluminum Bronze manifolds for Bore......................................................................0.945" (24 mm)
strength and corrosion resistance. Stroke...................................................................1.180" (30 mm)
Crankcase Capacity .............................................42 oz. (1.26 L)
● Special concentric, high density, polished, graphite impregnated, Inlet Ports (2) .................................................3/4" NPTF (3/4” NPTF)
solid ceramic plungers are abrasion resistant and result in Discharge Ports (2)........................................1/2" NPTF (1/2" NPTF)
extended seal life. Pulley Mounting ............................................Either Side (Either Side)
● Specially formulated, CAT PUMP exclusive, V-Packings offers Shaft Diameter .....................................................1.181" (30 mm)
unmatched performance and seal life. Weight..................................................................44 lbs. (19.9 kg)
● Die cast aluminum crankcase provides high strength, minimum Dimensions ....................................16.28 x 12.99 x 6.44" (413.50 x 330 x 163.50 mm)
weight and precision tolerance control.
● Chrome-moly crankshaft gives unmatched strength and surface HORSEPOWER REQUIREMENTS
hardness.
● Oversized crankshaft bearings with greater loading capacity FLOW PRESSURE MOTOR PULLEY SIZE
mean longer bearing life. PSI PSI PSI Using 1725 RPM Motor &
1800 2000 2200 Std. 10" Pump Pulley
Easy Maintenance
● Wet-end is easily serviced without entering crankcase, requiring U.S. BAR BAR BAR RPM Pulley
less time and effort. GPM L/M 125 140 155 O.D.
● Valve assemblies are accessible without disturbing piping, for 12.0 45 14.8 N/A N/A 1150 6.5
quick service. 10.0 38 12.4 13.7 15.1 958 5.4
9.0 34 11.1 12.4 13.6 836 4.9
● Preset packings mean no packing gland adjustment is necessary,
reducing maintenance costs. DETERMINING Rated G.P. M. = “Desired” G.P. M.
THE PUMP R.P.M. Rated R.P. M. “Desired” R.P. M.
CAUTION DETERMINING GPM x PSI = Electric Brake
All systems require both a primary pressure regulating device (i.e., regulator, unloader) THE REQUIRED H.P. 1460 H. P. Required
and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to
DETERMINING Motor Pulley O.D. = Pump Pulley O.D.
install such relief devices could result in personal injury or damage to the pump or to
system components. CAT PUMPS does not assume any liability or responsibility for the MOTOR PULLEY SIZE Pump R.P.M. Motor R.P.M.
operation of a customer’s high pressure system. See complete Drive Packages [Inclds: Pulleys, Belts, Hubs, Key] Tech Bulletin 003.
Refer to pump Service Manual for repair procedure and additional technical information.
“Customer confidence is our greatest asset”

PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY
1050 MATL 1051 MATL 1057 MATL
● 2 30067 STL 30067 STL 30067 STL Key (M8x7.5x25)) 1 ●
5 92519 STZP 92538 S 92538 S Screw, HHC Sems (M6x16) 8
8 43496 AL 43496 AL 43496 AL Cover, Bearing 2
9 43520 FBR 43520 FBR 43520 FBR Shim, Bearing Cover 2/4
45387 S 45387 S 45387 S Shim, Split 2-Pc 0/4
10 11340 NBR 11340 NBR 11340 NBR O-Ring, Bearing Cover 2
11 43495 NBR 43495 NBR 43495 NBR Seal, Oil, Crankshaft 2
15 39060 STL 39060 STL 39060 STL Bearing, Roller 2
20 48600 TNM 48600 TNM 48600 TNM Rod, Connecting Assembly [10/01] 3
25 43494 FCM 43494 FCM 43494 FCM Crankshaft, Dual End 1
31 828710 828710 828710 Protector, Oil Cap 1
32 43211 ABS 43211 ABS 43211 ABS Cap, Oil Filler 1
33 14177 NBR 14177 NBR 14177 NBR O-Ring, Filler Cap - 70D 1
37 92241 92241 92241 Gauge, Oil, Bubble w/Gasket - 80D 1
38 44428 NBR 44428 NBR 44428 NBR Gasket, Flat, Oil Gauge - 80D 1
40 92520 STZP 92542 S 92542 S Screw, HHC Sems (M6x20) 4
48 25625 STCP 25625 STCP 25625 STCP Plug, Drain (1/4"x19BSP) 1
49 23170 NBR 23170 NBR 23170 NBR O-Ring, Drain Plug - 70D 1
50 43491 AL 43491 AL 43491 AL Cover, Rear 1
51 44834 NBR 44834 NBR 44834 NBR O-Ring, Rear Cover - 70D 1
● 53 43488 AL 43488 AL 43488 AL Crankcase w/Guide Pins 1 ●
54 27488 S 27488 S 27488 S Pin, Guide 2
56 44664 POP 44664 POP 44664 POP Pan, Oil, w/Screws 1
64 43507 CM 43507 CM 43507 CM Pin, Crosshead 3
65 43501 SZZ 45258 SSZZ 45258 SSZZ Rod, Plunger 3
69 43504 STZP 43504 STZP 43504 STZP Washer, Oil Seal 3
70 43500 NBR 43500 NBR 43500 NBR Seal, Oil, Crankcase 3
75 43506 S 43506 S 43506 S Slinger, Barrier 3
88 45675 SS 45675 SS 45675 SS Washer, Keyhole 3
89 43553 BB 45879 SS 45879 SS Collar, Spacer 3
90 43552 CC 43552 CC 43552 CC Plunger (M24x77) 3
95 — SS 89651 SS 89651 SS Stud, Plunger Retainer (M6x70) 3
96 43235 PTFE 43235 PTFE 43235 PTFE Back-up-Ring, Plunger Retainer 3
97 17399 NBR 17399 NBR 17399 NBR O-Ring, Plunger Retainer - 80D 3
14160 FPM 14160 FPM 14160 FPM O-Ring, Plunger Retainer - 80D 3
◆ 46204 EPDM ◆ 46204 EPDM ◆ 46204 EPDM O-Ring, Plunger Retainer - 80D 3
98 44041 SS 44041 SS 44041 SS Gasket, Plunger Retainer 3
99 — 44031 SS 44031 SS Retainer, Plunger 3
104360 S — — Retainer w/Stud 3
100 43509 POP 43509 POP 43509 POP Retainer, Seal 3
101 43554 43554 43554 Wick, Long Tab 3
103 44036 S 44036 S 44036 S Ring, Retaining 3
106 44035 NBR 44035 NBR 44035 NBR Seal, LPS w/SS-Spg 3
44388 FPM 44388 FPM 44388 FPM Seal, LPS w/SS-Spg 3
◆ 46208 EPDM ◆ 46208 EPDM ◆ 46208 EPDM Seal, LPS w/SS-Spg 3
120 43555 BB 48464 SSNP 48464 SSNP Case, Seal 3
121 14762 NBR 14762 NBR 14762 NBR O-Ring, Seal Case 3
11737 FPM 11737 FPM 11737 FPM O-Ring, Seal Case - 75D 3
◆ 46205 EPDM ◆ 46205 EPDM ◆ 46205 EPDM O-Ring, Seal Case 3
126 43558 BB 48389 D 48389 D Adapter, Female 3
127 43559 SNG 103692 STG* 103692 STG* V-Packing 6
128 43560 BB 45074 SSL 45074 SSL Adapter, Male 3
139 20326 BBCP 44382 SS 44562 NAB Plug, Inlet (3/4" NPT) 1
162 43248 PTFE 43248 PTFE 43248 PTFE Back-up-Ring, Valve Seat 6
163 43249 NBR 43249 NBR 43249 NBR O-Ring, Seat - 70D 6
44383 FPM 44383 FPM 44383 FPM O-Ring, Seat - 70D 6
◆ 46206 EPDM ◆ 46206 EPDM ◆ 46206 EPDM O-Ring, Seat - 70D 6
164 44718 S 44037 SS 44037 SS Seat 6
166 43721 S 44038 SS 44038 SS Valve 6
167 43751 S 44039 SS 44039 SS Spring, Valve 6
168 44564 PVDF 44564 PVDF 44564 PVDF Retainer, Spring 6
171 — — 44832 S Coil Spring, Valve Plug 6
172 17617 NBR 17617 NBR 17617 NBR O-Ring, Valve Plug - 90D 6
11691 FPM 11691 FPM 11691 FPM O-Ring, Valve Plug - 90D 6
◆ 46207 EPDM ◆ 46207 EPDM ◆ 46207 EPDM O-Ring, Valve Plug - 90D 6
174 43851 BBCP 48463 SSNP 44831 NAB Plug, Valve 6
● 185 46704 BBCP 48726 SS 46706 NAB Head, Manifold [9/00] 1 ●
187 14050 STZP 44005 S 44005 S Stud, Manifold (M10x45) 4
192 12503 STZP 15847 S 15847 S Lockwasher (M10) 4
194 81048 STZP 81258 S 81258 S Nut, Hex (M10) 4
250 30764 NY 30764 NY 30764 NY Protector, Shaft w/2 Screws 1
255 30264 STZP 30264 STZP 30264 STZP Mounting, Direct (Inclds: 12490, 12503, 14050, 81048) 1
260 30613 STZP 30613 STZP 30613 STZP Rail, Angle Assy, A (Inclds: 30635, 30903, 30921, 30912) 1
265 30661 30661 30661 Kit, Complete Mounting, U.S. (Inclds: 30613, 30206, 30059, 30067, 30764) 1
● 269 30206 F 30206 F 30206 F Pulley (10") AB [See Drive Packages, Tech Bulletin 03] 1 ●
● 274 30059 STL 30059 STL 30059 STL Hub,“H”, M30 (Keyway M8) [See Drive Packages, Tech Bulletin 03] 1 ●
EXPLODED VIEW
Models
Standard - 1050
Stainless Steel - 1051
Nickel Aluminum Bronze - 1057
August 2001
● 283 34334 34334 34334 Kit, Oil Drain 1 ●
● 290 — 6104 6104 Gasket, Liquid (1 oz.) 1 ●
● 299 814560 BBCP 816771 SS 815261 NAB Head, Complete [9/00] 1 ●
300 30913 NBR 33916 NBR* 33916 NBR* Kit, Seal (Inclds: 97, 103, 106, 121, 127) 1
30986 FPM* 30986 FPM* 30986 FPM* Kit, Seal (Inclds: 97, 103, 106, 121, 127) 1
◆ 33913 EPDM* ◆ 33913 EPDM* ◆ 33913 EPDM* Kit, Seal (Inclds: 97, 103, 106, 121, 127) 1
310 34920 NBR 34387 NBR 34387 NBR Kit, Valve (Inclds: 162, 163, 164, 166, 167, 168, 172) 2
31256 FPM 30987 FPM 30987 FPM Kit, Valve (Inclds: 162, 163, 164, 166, 167, 168, 172) 2
◆ 31253 EPDM ◆ 31258 EPDM ◆ 31258 EPDM Kit, Valve (Inclds: 162, 163, 164, 166, 167, 168, 172) 2
350 30696 STZP 30696 STZP 30696 STZP Plier, Reverse 1
351 43523 STZP 43523 STZP 43523 STZP Tool, Seal Case Removal 1
— 6565.1 6565.1 6565.1 Service Video 1
● Industrial discount. Bold print part numbers are unique to a particular pump model. Italics are optional items. ◆ Silicone oil/grease required.
[ ] Date of latest production change. *Review material codes for individual items (STG generally may be used as an alternate).
See Tech Bulletins 02, 03, 24, 27, 35, 36, 43, 45, 46, 48, 49, 52, 53, 72, 74, 77, 83, 87 and 89 for additional information.
MATERIAL CODES (Not Part of Part Number): ABS=ABS Plastic AL=Aluminum BB=Brass BBCP=Brass/Chrome Plated CC=Ceramic CM=Chrome-moly D=Delrin ®
EPDM=Ethylene Propylene Diene Monamer F=Cast Iron FBR=Fiber FCM=Forged Chrome-moly FPM=Fluorocarbon (Viton ®)
NAB=Nickel Aluminum Bronze NBR=Medium Nitrile (Buna-N) NY=Nylon POP=Polypropylene PTFE=Pure Teflon ® PVDF=Fluoroplastic (High Strength)
S=304SS SNG=Special Blend (Buna) STG=Special Blend (Teflon®) White SS=316SS SSL=316SS/Low Carbon SSZZ=316SS/Zamak STCP=Steel/Chrome Plated
SSNP=316SS/Nickel Plated STL=Steel STZP=Steel/Zinc Plated SZZ=304SS/Zamak TNM=Special High Strength
12.99 (330) 16.28 (413.50)
12.60 (320)
***5.08 (129) 9.65 (245)
9.59 (243.50)
2 - 1/2" NPTF
2.28
(58)
*1.22 (31)
6.44
(163.50) **1.30 (33)
.315 (8)
3.54
(90) 1.181 (30)
5.28 (134)
.39 (10)
.59 (15) 2X 1.38 (35)
2.18 2 - 3/4" NPTF .78 (20)
4 - M10x1.5 1.95 (50) 4 - ø11
(55.40) .043 (11) 18 DEEP
2.05 (52)
3.46 (88) 2 SLOTS 6.69 (170)
*MODEL 1051 - 1.26 (32)
4.17 (106) **MODEL 1051 - 1.58 (40) 1.07
6.58 (167) (27)
6.06 (154) ***MODEL 1051 - 5.20 (132) 11.81 (300)
Models 1050, 1051, 1057
8
10
1
11 9
2
7 6 5 12 4 3
8 10
1 Die cast aluminum crankcase means 6 The stainless steel slinger provides 9 100% wet seal design adds to service
high strength, lightweight, and excellent back-up protection for the crankcase life by allowing pumped liquids to cool
tolerance control. seal, keeping pumped liquids out of the and lubricate on both sides.
2 Oversized crankshaft bearings provide ex- crankcase. 10 Stainless steel valves, seats and springs
tended bearing life and pump performance. 7 Special concentric, high density, polished, provide corrosion-resistance, positive
3 Chrome-moly crankshaft provides graphite impregnated, solid ceramic seating and long life.
unmatched strength and surface hard- plungers are abrasion resistant and 11 Specially formulated, CAT PUMP exclu-
ness for long life. result in extended seal life. sive, V-Packings offer unmatched
4 Matched oversized high strength con- 8 Manifolds are a high tensile strength forged performance and seal life.
necting rods are noted for superior brass, stainless steel or nickel aluminum 12 Crossheads are 360° supported for
strength and bearing quality. bronze for long term, continuous duty. uncompromising alignment.
5 The plunger rods are high tensile strength
stainless steel with Zamak crossheads.
Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580
World Headquarters CAT PUMPS (U.K.) LTD.

1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet
CAT PUMPS Hampshire GU52 8BF, England
1681 - 94th Lane N.E. Minneapolis, MN 55449 - 4324 Phone Fleet 44 1252-622031 — Fax 44 1252-626655
e-mail: sales@catpumps.co.uk
Phone (763) 780-5440 — FAX (763) 780-2958 N.V. CAT PUMPS INTERNATIONAL S. A.
e-mail: sales@catpumps.com Heiveldekens 6A, 2550 Kontich, Belgium
www.catpumps.com “The World’s Most Dependable Pumps” Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51
e-mail: cpi@catpumps.be www.catpumps.be
International Inquiries CAT PUMPS DEUTSCHLAND GmbH
FAX (763) 785-4329 Buchwiese 2, D-65510 Idstein, Germany
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
e-mail: intlsales@catpumps.com e-mail: catpumps@t-online.de www.catpumps.de
PN 993114 Rev A 7106

5, 7, 15PFR PLUNGER PUMP SERVICE MANUAL
5 FRAME: 310, 340, 350, 311, 341, 351, 317, 347, 357 7 FRAME: 530, 550
5 FRAME OEM: 30, 31, 34, 35, 42HS, 43HS, 45 7 FRAME OEM: 51, 53, 55, 56, 57, 58, 59, 60, 70
15 FRAME: 650, 651, 660, 661,1050, 1051, 1057
INSTALLATION AND START-UP INFORMATION
Optimum performance of the pump is dependent upon the entire liquid system and will be obtained
only with the proper selection, installation of plumbing and operation of the pump and accessories.
SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to
implied that all maximums can be performed simultaneously. If more than one avoid deadhead overpressure condition and severe damage to the pump or system.
maximum is considered, check with your CAT PUMPS supplier to confirm the Install a Pulsation Dampening device on the discharge head or in the discharge line
proper performance and pump selection. Refer to individual pump Data Sheets for as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator)
complete specifications, parts list and exploded view. is properly precharged for the system pressure (see individual Data Sheet).
LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications A reliable Pressure Gauge should be installed near the discharge outlet of the high
[5PFR-18 oz., 7PFR-25 oz., 15PFR-42oz.]. DO NOT RUN PUMP WITHOUT OIL IN pressure manifold. This is extremely important for adjusting pressure regulating
CRANKCASE. Change initial fill after 50 hours running period. Thereafter, change devices and also for proper sizing of the nozzle or restricting orifice. The pump is
oil every 3 months or 500 hour intervals, whichever comes first. rated for a maximum pressure; this is the pressure that is read at the discharge
PUMP ROTATION: Pump was designed for forward rotation to allow optimum manifold of the pump, NOT AT THE GUN OR NOZZLE.
lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil Use PTFE liquid (sparingly) or tape to connect accessories or plumbing. Exercise
level is increased slightly above center dot to assure adequate lubrication. caution not to wrap tape beyond the last thread to avoid tape from becoming
PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow lodged in the pump or accessories. This condition will cause a malfunction of the
from Horsepower Requirement and Pulley Selection Chart (refer to Tech Bulletin pump or system.
003 or individual Data Sheet). PRESSURE REGULATION: All systems require both a primary pressure regulating
DRIVE SELECTION: The motor or engine driving the pump must be of adequate device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e.,
horsepower to maintain full RPM when the pump is under load. Select the electric pop-off valve, safety valve). The primary pressure device must be installed on the
motor from the Horsepower Requirement Chart according to required pump discharge side of the pump. The function of the primary pressure regulating device
discharge flow, maximum pressure at the pump and drive losses of approximately is to protect the pump from over pressurization, which can be caused by a plugged
3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper or closed off discharge line. Over pressurization can severely damage the pump,
engine size. other system components and can cause bodily harm. The secondary safety relief
MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit device must be installed between the primary device and pump. This will ensure
drainage of crankcase oil. An uneven mounting surface will cause extensive damage pressure relief of the system if the primary regulating device fails. Failure to install
to the pump base. To minimize piping stress, use appropriate flexible hose to such a safely device will void the warranty on the pump.
inlet and discharge ports. Use the correct belt; make sure pulleys are aligned. When the high pressure system is left running with the trigger gun off, the by-pass
Excessive belt tension may be harmful to the bearings. Hand rotate pump before liquid can be routed to drain or to the pump inlet. If routed to the pump inlet, the
starting to be certain shaft and bearings are free moving. by-pass liquid can quickly develop excessive heat and result in damage to the
LOCATION: If the pump is used in extremely dirty or humid conditions, it is recom- pump. A THERMO VALVE installed in the by-pass line is recommended to protect
mended pump be enclosed. Do not store or operate in excessively high temperature the pump. An AUTO SHUT-OFF ASSEMBLY may also be used.
areas or without proper ventilation. NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual regulating device to compensate. Replace nozzle and reset regulating device to
before starting system. DO NOT STARVE THE PUMP OR RUN DRY. Temperatures system pressure.
above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over PUMPED LIQUIDS: Some Liquids may require a flush between operations or
130°F. Elastomer or RPM changes may be required. See Tech Bulletin 002 or call before storing. For pumping liquids other than water, contact your CAT PUMPS
CAT PUMPS for recommendations. supplier.
C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in ap- STORING: For extended storing or between use in cold climates, drain all pumped
plications with stressful inlet conditions such as high temperatures, booster pump liquids from pump and flush with antifreeze solution to prevent freezing and
feed, long inlet lines or quick closing valves. damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech
Bulletin 083).
WARNING
All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve).
Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility
for the operation of a customer’s high pressure system.

e-mail: techsupport@catpumps.com Heiveldekens 6A, 2550 Kontich, Belgium
www.catpumps.com The Pumps with Nine Lives Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
PN 30002 Rev K 7311

Removal of Valve Plugs Examination of O-Ring and Back-up-Ring on Valve Plug Removal of Valve Assembly
CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off water supply to
pump. Relieve all discharge line pressure by triggering gun or opening valve in discharge line.
After servicing is completed, turn on water supply to pump, start drive, reset pressure regulating device and secondary valve, read
system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation.
SERVICING THE VALVES

Disassembly Reassembly
NOTE: Usually the valve assembly will remain together 1. Examine Spring Retainers for internal wear or breaks in
while being removed. the structure and replace as needed.
1. Remove the hex Valve Plugs (top discharge, bottom inlet). 2. Examine Springs for fatigue or breaks and replace as needed.
2. Examine the O-Ring under the Valve Plug for cuts or dis- 3. Examine Valves and Seats for grooves, pitting or wear and
tortion and replace if worn. Lubricate new O-Rings before replace as needed.
installing. 4. Examine Seat and Valve Plug O-Rings for cuts or wear
NOTE: On Models 43HS, 45, 56, 57, 59, 60, 70 there is an and replace as needed. Lubricate and install new O-Ring
extended Valve Plug with O-Ring and Back-up-Ring. onto outside diameter of Seat and Valve Plugs.
Install the Back-up-Ring, then the O-Ring into the groove NOTE: Inlet and discharge valve parts are interchangeable.
at the end of the Valve Plug (refer to Tech Bulletin 058). Two Valve Kits are needed for complete valve change.
3. Grasp Spring Retainer by tab at the top with pliers and re- 5. Grasp new Valve Assembly by tab at top with pliers and
move from valve chamber. push into valve chamber. Be certain Valve Assembly is
4. To separate the valve assembly, insert a screwdriver into completely seated in valve chamber.
the side of the Retainer and press on the back side of the NOTE: For certain applications apply liquid gasket to
Valve to begin separation, then between the Retainer and the O-Ring crevices and seal surfaces (refer to Tech
Valve Seat to separate completely. Bulletin 053).
5. If the valve assembly separates during removal, remove NOTE: For Corrosion Resistant Models remember to
the Spring and Valve with a needle nose pliers. install the Coil Spring between the Valve Plug
6. Using a reverse pliers, remove the Valve Seat from the and Retainer (refer to Tech Bulletin 046).
manifold chamber. 6. Apply Loctite 242 to the threads of the Valve Plug, thread
into manifold port and torque per chart.
Y
X
Order of parts in Valve Assembly Removal of Seal Cases from Manifold Head Removal of High Pressure Seals
V-P Models
Y
X
H.P.S. Models
X
Seal and V-Packing Arrangement Installation of Male Adapter Order of Packings [MA, VP, FA]
SERVICING THE SEALS

Disassembly Reassembly
1. Remove the Manifold Head as described in SERVICING V-Packing Models:
THE PLUNGERS section. 1. Lubricate seal chamber in the manifold.
2. Place Manifold Head on work surface with crankcase NOTE: For certain applications apply liquid gasket to
side up. the O-Ring crevices and seal surfaces (refer to Tech
3. On 5PFR and 7PFR plunger pumps prior to May of 1989, Bulletin 053).
remove Snap Ring and Lo-Pressure Seal from each Seal 2. Insert Male Adapter with notches down and “v” side up
Case. Discard Snap Rings (refer to Tech Bulletin 054). and press completely into chamber by hand.
4. On 5PFR and 7PFR plunger pumps after May of 1989, re- 3. Lubricate V-Packings and install one at a time with
move Lo-Pressure Seal from each Seal Case. grooved side down.
5. On 15PFR plunger pumps, remove Snap Ring and 4. Install Female Adapter with grooved side down.
Lo-Pressure Seal from each Seal Case.
5. Examine Seal Case O-Ring and replace if worn. Lubricate
6. Remove Seal Case from each seal chamber. Remove new O-Rings before installing.
O-Ring from outside diameter of Seal Case.
6. Thread Seal Case into manifold and tighten with special
7. Hi-Pressure Seal Models: The Hi-Pressure Seal is gener- seal case tool. Torque per chart.
ally easily removed from the manifold without any tools. If
extremely worn a reverse pliers may be used.
8. V-Packing Models: The Female Adapter, V-Packings and
Male Adapter are easily removed from manifold without
any tools. If extremely worn a reverse pliers may be used.
Separating Manifold Head from Crankcase Removal of Manifold Head from Crankcase Removal of Seal Retainers and Wicks
Ceramic Plunger and Retainer Arrangement Proper Alignment of Ceramic Plungers for reassembly
Hi-Pressure Seal Models: SERVICING THE PLUNGERS

1. Lubricate seal chamber in manifold. Disassembly
NOTE: For certain applications apply liquid gasket to 1. Using an M8 allen wrench on the 5PFR pumps, a M14 hex
the O-Ring crevices and seal surfaces (refer to Tech tool on the 7PFR pumps, or a M17 hex tool on the 15PFR
Bulletin 053). pumps, remove the two (2) Socket Head Screws, and two
2. Carefully square Hi-Pressure Seal into position by hand (2) Lockwashers or four (4) Flanged Nuts.
with the grooved side down (metal back facing out). 2. Rotate Crankshaft by hand to start separation of Manifold
NOTE: When alternate materials, the fit of the head from Crankcase.
special materials may be snug and require gently driv- 3. Insert two flat head screwdrivers on opposite sides to further
ing the LPS into position with a cylinder of the same separate Manifold Head from Crankcase or support the
diameter to assure a square seating and no damage to underside of the Manifold Head and tap lightly with a mallet
the LPS. on the backside of the Manifold Head.
3. Examine Seal Case O-Ring and replace if worn. Lubricate CAUTION: KEEP MANIFOLD PROPERLY ALIGNED
new O-Ring before installing. WITH CERAMIC PLUNGERS WHEN REMOVING TO
4. Secure Hi-Pressure Seal into position by threading Seal AVOID DAMAGE TO EITHER PLUNGERS OR SEALS.
Case into manifold. Tighten Seal Case with special seal 4. Remove Oil Pan and slide out Seal Retainer with Wick.
case tool. Torque per chart.
5. Using an M12 hex tool on the 5, 7 and 15PFR pumps, or
Lo-Pressure Seal - All Models: an M11 hex tool on the OEM 5, and 7PFR pumps, loosen
1. Examine Lo-Pressure Seals for wear or broken springs the Plunger Retainer about three to four turns.
and replace if necessary. 6. Push the Ceramic Plunger back towards the Crankcase to
2. Install Lo-Pressure Seal into each seal case with garter separate it from the Plunger Retainer and proceed with un-
spring down. threading the Plunger Retainer by hand.
3. On 5PFR and 7PFR plunger pumps do not use Snap Ring 7. Remove the Plunger Retainer, O-Ring, Back-up-Ring and
(refer to Tech Bulletin 054). Gasket. Stud may stay on Plunger Rod or come off with
Plunger Retainers.
4. On 15PFR plunger pumps install Snap Ring into each
Seal Case. 8. Remove the Ceramic Plunger, Keyhole Washer and
Barrier Slinger from Plunger Rod.
5. Install the Seal Retainer with new Wick onto each plunger
rod with tab down and wick out. Reassembly
6. Rotate Crankshaft by hand so the two outside plungers 1. Visually inspect Crankcase Oil Seals for deterioration or
are extended equally. leaks. Contact CAT PUMPS for assistance with replace-
ment. See SERVICING THE CRANKCASE section.
7. Lightly lubricate the Ceramic Plunger, then carefully slide
the Manifold Head over the Ceramic Plunger, supporting it 2. Examine Barrier Slingers and Keyhole Washers for dam-
from the underside to avoid damage to the plungers or age. Slide onto Plunger Rod with concave side away
seals. Press the Manifold Head into the Crankcase until from Crankcase.
flush. 3. Examine Ceramic Plunger for scoring, scale build-up, chips
8. Replace two (2) Lockwashers, two (2) Socket Head or cracks and replace as needed.
Screws for (4) Flange Nuts and torque per chart. 4. Slide Ceramic Plunger over each Plunger Rod.
NOTE: Ceramic Plunger can only be installed in one
direction (front to back). Do not force onto rod.
5. Examine O-Ring and Back-up-Ring on Plunger Retainer
and replace if cut or worn. Lubricate O-Rings for ease of
installation and to avoid damage to the O-Rings.
PREVENTATIVE MAINTENANCE CHECK-LIST
Check Daily Weekly 50 hrs. 500 hrs.* 1500 hrs.** 3000 hrs.**
Clean Filters x
Oil Level/Quality x
Oil Leaks x
Water Leaks x
Belts, Pulley x
Plumbing x
Initial Oil Change x
Oil Change x
Seal Change x
Valve Change x
Accessories x
* If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change
cycle should be every 300 hours.
** Each system’s maintenance cycle will be exclusive. If system performance
6. Install new Gasket, then O-Ring, then Back-up-Ring onto decreases, check immediately. If no wear at 1500 hours, check again at
2000 hours and each 500 hours until wear is observed. Valves typically
each Plunger Retainer. require changing every other seal change.
NOTE: OEM models have a longer Plunger Retainer Stud. Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all
effect the life of pump wear parts and service cycle.
7. Apply Loctite 242 to exposed threads of Stud and thread ** Remember to service the regulator/unloader at each seal servicing and check
Plunger Retainer onto Plunger Rod. Torque per chart. all system accessories and connections before resuming operation.
Refer to video for additional assistance.
8. Install the seal Retainer with NEW Wick onto each rod with
tab down and wick out.
NOTE: Do not lubricate wicks at initial start-up. TECHNICAL BULLETIN REFERENCE CHART
Operate for 10 to 15 minutes to allow grease from No. Subject Models
LPS to penetrate the plunger surface, then lubricate 003 Power Unit Drive Packages 3PFR - 68PFR, 10FR - 60FR
as needed.
024 Lubrication of Lo-Pressure Seals All Models
9. Rotate Crankshaft by hand so the two outside plungers 027 Spring Retainer 5PFR, 7PFR, 15PFR
are extended equally. 032 Shaft Extension and Manifold Port 310, 317, 323, 530, 550
10.Lightly lubricate the Ceramic Plungers, then carefully slide 035 Servicing Crankcase Section 7PFR - 60PFR
the Manifold Head over the Ceramic Plungers supporting it 036 Cylinder and Plunger Reference Chart All Models
from the underside to avoid damage to the Ceramic 043 LPS and HPS Servicing All Plunger Models
Plungers or Seals. On the high pressure V-Packing models 045 One-Piece S.S. Plunger Retainer w/Stud 5PFR, 7PFR, 15PFR
or larger manifolds, it may be necessary to gently tap with a 046 Valve Plug with Coil Spring 317, 347, 357, 1057
soft mallet until the manifold is flush with the crankcase. 047 Blind Bearing Shaft Cover Gearbox Plunger Pumps
11.Replace two (2) Lockwashers, two (2) Socket Head 048 Extended Valve Plug 7PFR and 15PFR
Screws or four (4) Flanged Nuts and torque per chart. 049 Stainless Steel Hardware 3PFR7, 5PFR7, 15PFR7
051 M10 Manifold and Crankcase 7PFR and OEM
052 Plunger Rod and Stud 3PFR, 5PFR, 15PFR, 35PFR, 60PFR
SERVICING THE CRANKCASE SECTION 053 Liquid Gasket All Plunger NAB-S.S. Models
054 2 Piece Seal Retainer 5PFR and 7PFR
1. While Manifold, Plungers and Seal Retainers are
058 Forged Manifold and Extended Valve Plugs 56, 57, 59, 60
removed, examine Crankcase Oil Seals for leaking and
060 Baffle Assembly 34170
wear.
061 Installation and Adjustment Procedure 8100
2. Check for any signs of leaking at Bearing Covers, Rear 062 Manifold and Seal Case 650 and 651
Cover, Drain Plug or Bubble Gauge.
064 By-Pass Hose Sizing All Unloaders/Regulators
3. Check oil level and for evidence of water in oil. 067 S.S. Plunger Retainer 3PFR, 5PFR, 7PFR
4. Rotate Crankshaft by hand to feel for smooth bearing 072 Manifold Head and V-Packing 1050, 1051, 1057
movement. 073 Hi-Temp HPS 3PFR, 5PFR, 2SF
074 Torque Chart Piston and Plunger Pumps
5. Examine Crankshaft Oil Seals externally for drying, crack-
077 Oil Drain Kit All Models (except 2SF/4SF)
ing or leaking.
083 Winterizing a Pump All Models
6. Consult CAT PUMPS or your local distributor if crankcase
service is evidenced.
See Section I of the Plunger Pump Service Video for addi-
tional information.
INLET CONDITION CHECK-LIST
TORQUE CHART Review Before Start-Up
Pump Item Torque
Inadequate inlet conditions can cause serious malfunctions in the best designed
Pump Model Thread Tool Size [P/N] in. lbs. ft. lbs. Nm pump. Surprisingly, the simplest of things can cause the most severe problems
or go unnoticed to the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST
PLUNGER RETAINER BEFORE OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so
there can be no ONE best way to set-up a system. All factors must be
OEM Models ....................................M6 M11 Hex [44044] 55 4.4 6 carefully considered.
All Standard Models.........................M6 M12 Hex 55 4.4 6
INLET SUPPLY should exceed the maximum flow being delivered by the pump to
assure proper performance.
MANIFOLD HEAD BOLTS ❏ Open inlet shut-off valve and turn on water supply to avoid starving the pump.
DO NOT RUN PUMP DRY.
5PFR 30, 31, 34, 35....................M10 M8 Allen [25052] 220 18.1 25
❏ Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each
310, 340, 350
degree F over 130°F. Elastomer or RPM changes may be required. See Tech
311, 341, 351 Bulletin 002 or call CAT PUMPS for recommendations.
317, 347, 357 ❏ Avoid closed loop systems especially with high temperature, ultra-high pressure
or large volumes. Conditions vary with regulating/unloader valve.
5PFR 42HS, 43HS, 45................M10 M8 Allen [33046] 220 18.1 25
❏ Low vapor pressure liquids, such as solvents, require a booster pump and C. A.T.
7PFR 510, 530, 550....................M10 M14 Hex [25053] 220 18.1 25 to maintain adequate inlet supply.
❏ Higher viscosity liquids require a positive head and a C. A.T. to assure adequate
56, 57, 58, 59, 60, 70
inlet supply.
15PFR 650, 651, 660, 661............M10 M17 Hex [25083] 220 18.1 25 ❏ Higher temperature liquids tend to vaporize and require positive heads and
1050, 1051, 1057 C. A.T. to assure adequate inlet supply.
❏ When using an inlet supply reservoir, size it to provide adequate liquids to accom-
modate the maximum output of the pump, generally a minimum of 6-10 times the
VALVE PLUGS GPM (however, a combination of system factors can change this requirement);
provide adequate baffling in the tank to eliminate air bubbles and turbulence; install
5PFR 30, 31, 34, 35....................M22 M24 Hex [44046] 870 72.3 98
diffusers on all return lines to the tank.
310, 311, 317
340, 341, 347 INLET LINE SIZE should be adequate to avoid starving the pump.
350, 351, 357 ❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid
42HS tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of
flow restriction and cavitation.
5PFR 43HS, 45...........................M25 M24 Hex [44046] 520 43.4 59 ❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on
SUCTION systems to avoid collapsing.
7PFR 530, 550 ........................3/4" SPT M27 Hex [44045] 870 72.3 98
❏ The simpler the inlet plumbing the less the potential for problems. Keep the
51, 55, 56, 57, 58 length to a minimum, the number of elbows and joints to a minimum (ideally no
59, 60, 70 elbows) and the inlet accessories to a minimum.
❏ Use pipe sealant to assure air-tight, positive sealing pipe joints.
15PFR 650, 651, 660, 661 ........3/4" SPT M27 Hex [44045] 870 72.3 98
1050, 1051, 1057 INLET PRESSURE should fall within the specifications of the pump.
❏ Acceleration loss of liquids may be increased by high RPM, high temperatures,
CRANKCASE COVER / BEARING COVER SCREWS low vapor pressures or high viscosity and may require pressurized inlet and
C. A.T. to maintain adequate inlet supply. DO NOT USE C. A.T. WITH SUCTION
5PFR 30, 31, 34, 35.....................M6 M10 Hex/Phil. [25082] 50 4.0 6 INLET.
310, 340, 350 ❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet
317, 347, 357 pressure and a C. A.T. for certain applications. With adequate inlet plumbing,
311, 341, 351 most pumps will perform with flooded suction. Maximum inlet pressure is 60 PSI
(4 BAR).
5PFR 42HS, 43HS, 45.................M6 M10 Hex/Phil. [25082] 50 4.0 6 ❏ After prolonged storage, pump should be rotated by hand and purged of air to
...........................................M8 M13 Hex [25324] 115 9.4 13 facilitate priming. Disconnect the discharge port and allow liquid to pass through
pump and measure flow.
7PFR 51, 53, 55, 56, 57,..............M6 M10 Hex [25082] 115 9.4 13
59, 60, 70 INLET ACCESSORIES are designed to protect against overpressurization,
control inlet flow, contamination or temperature and provide ease of servicing.
15PFR 650, 1050...........................M6 M10 Hex [25082] 50 4.0 5.7 ❏ A shut-off valve is recommended to facilitate maintenance.
❏ Installation of a C. A.T. is essential in applications with stressful conditions such
SEAL CASE as high temperatures, booster pump feed or long inlet lines. Do not use C. A.T.
with negative inlet pressure.
5PFR 30, 31, 34, 35 ....................N/A 1/2" Soc. Drive [33004] 354 29.5 40 ❏ A stand pipe can be used in some applications to help maintain a positive head
310, 311, 317 at the pump inlet.
340, 341, 347 ❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
❏ A pressure transducer is necessary to accurately read inlet pressure. (Short
350, 351, 357
term, intermittent cavitation will not register on a standard gauge.)
42HS, 43HS, 45 ................N/A 1/2" Soc. Drive [33005] 354 29.5 40
❏ All accessories should be sized to avoid restricting the inlet flow.
7PFR 51, 53, 55, 56, ...................N/A 1/2" Soc. Drive [33005] 354 29.5 40 ❏ All accessories should be compatible with the solution being pumped to
prevent premature failure or malfunction.
57, 58, 59, 60, 70
❏ Optional inlet protection can be achieved by installing a pressure cutoff switch
530, 550
between the inlet filter and the pump to shut off pump when there is no positive
15PFR 650, 651, 660, 661 ............N/A 1/2" Soc. Drive [33006] 346 28.8 39 inlet pressure.
1050, 1051, 1057 ..............N/A 1/2" Soc. Drive [33006] 390 32.5 44
BY-PASS TO INLET Care should be exercised when deciding the method of
by-pass from control valves.
BUBBLE OIL GAUGE ❏ It is recommended the by-pass be directed to a baffled reservoir tank, with at
least one baffle between the by-pass line and the inlet line to the pump.
All Models .......................................M28 Oil Gauge Tool [44050] 45 3.6 5
❏ Although not recommended, by-pass liquid may be returned to the inlet line of
the pump if the system is properly designed to protect your pump. A PRESSURE
MOUNTING BOLTS REDUCING VALVE must be installed on the inlet line (BETWEEN THE
BY-PASS CONNECTION AND THE INLET TO THE PUMP) to avoid excessive
5PFR, 7PFR ....................................M8 M13 Hex [25324] 115 9.4 13 pressure to the inlet of the pump. It is also recommended that a THERMO
15PFR ..........................................M10 M17 Hex [25083] 240 19.7 29 VALVE be used in the by-pass line to monitor the temperature build-up in the
by-pass loop to avoid premature seal failure.
❏ A low-pressure, flexible cloth braid (not metal braid) hose should be used from
the by-pass connection to the inlet of the pump.
❏ Caution should be exercised not to undersize the by-pass hose diameter and
length. Refer to Technical Bulletin 64 for additional information on the size and
length of the by-pass line.
❏ Check the pressure in the by-pass line to avoid overpressurizing the inlet.
❏ The by-pass line should be connected to the pump inlet line at a gentle angle of
45° or less and no closer than 10 times the pump inlet port diameter
e.g. 1-1/2" port size = 15" distance from pump inlet port.
HOSE FRICTION LOSS Handy Formulas to Help You
PRESSURE DROP IN PSI PER 100 FT OF HOSE
WITH TYPICAL WATER FLOW RATES Q. How can I find the RPM needed to get specific GPM
Water* Hose Inside Diameters, Inches
Flow (Gallons Per Minute) I want?
Gal/Min 1/4 5/16 3/8 1/2 5/8 3/4 1"
Rated RPM
0.5 16 5 2 A. Desired RPM = Desired GPM x
1 54 20 7 2 Rated GPM
2 180 60 25 6 2
3 380 120 50 13 4 2 Q. I have to run my pump at a certain RPM. How do I figure
4 220 90 24 7 3 the GPM I’ll get?
5 320 130 34 10 4 Rated GPM
6 220 52 16 7 1 A. Desired GPM = Desired RPM x
8 300 80 25 10 2 Rated RPM
10 450 120 38 14 3
15 900 250 80 30 7 Q. Is there a simple way to find the approximate horsepower
20 1600 400 121 50 12 I’ll need to run the pump?
25 650 200 76 19
30 250 96 24 A. Electric Brake GPM x PSI (Standard 85%
40 410 162 42 =
Horsepower Required 1460 Mech. Efficiency)
50 600 235 62
60 370 93
*At a fixed flow rate with a given size hose, the pressure drop across a given hose length
Q. What size motor pulley should I use?
will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 Pump RPM (Consult
ft. hose. Above values shown are valid at all pressure levels. A. Pump Pulley (Outer Diameter) x Engine Mfr.)
Motor/Engine RPM
Q. How do I calculate the torque for my hydraulic drive
WATER LINE PRESSURE LOSS system?
Water
PRESSURE DROP IN PSI PER 100 FEET
Steel Pipe—Nominal Dia. Brass Pipe—Nominal Dia. Copper Tubing O.D. Type L
A. Torque (ft. lbs.) = 3.6 (
GPM x PSI
RPM
)
GPM 1/4 3/8 1/2 3/4 1 11/4 11/2 1/4 3/8 1/2 3/4 1 11/4 11/2 1/4 3/8 1/2 5/8 3/4 7/8
1
2
8.5 1.9
30 7.0 2.1
6.0 1.6
20 5.6 1.8
120 13 2.9 1.0
400 45 10 3.4 1.3 Avoid Cavitation Damage
3 60 14 4.5 1.1 40 11 3.6 94 20 6.7 2.6
5 150 36 12 2.8 100 28 9.0 2.2 230 50 17 6.1 3.0

8 330 86 28 6.7 1.9 220 62 21 5.2 1.6 500 120 40 15 6.5
10 520 130 43 10 3.0 320 90 30 7.8 2.4 180 56 22 10
15 270 90 21 6.2 1.6 190 62 16 5.0 1.5 120 44 20

25 670 240 56 16 4.2 2.0 470 150 40 12 3.8 1.7 330 110 50
40 66 17 8.0 39 11 5.0 550 200 88
60 37 17 23 11
80 52 29 40 19
100 210 107 48 61 28
RESISTANCE OF VALVES AND FITTINGS One or several of the conditions shown in the chart below may
Nominal Equivalent Length of Standard Pipe in Feet contribute to cavitation in a system resulting in premature wear,
Pipe Inside 180˚ Tee Tee system downtime and unnecessary operating costs.
Size Diameter Gate Globe Angle 45˚ 90˚ Close Thru Thru
Inches Inches Valve Valve Valve Elbow Elbow Ret Run Branch
CONDITION SOLUTION
1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33 Inadequate inlet ● Increase line size to the inlet port or one size
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41 line size larger
1 1.049 0.69 31.2 15.6 1.31 2.81 6.25 1.56 5.62
11/4 1.380 0.90 41.0 20.5 1.73 3.70 8.22 2.06 7.40
Water hammering ● Install C.A.T. Tube
11/2 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63
liquid acceleration/ ● Move pump closer to liquid supply
deacceleration
2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60
2 1/2 2.469 1.62 73.5 36.8 3.09 6.61 14.70 3.68 13.20
Rigid Inlet Plumbing ● Use flexible wire reinforced hose to absorb
3 3.068 2.01 91.5 45.8 3.84 8.23 18.20 4.57 16.40
pulsation and pressure spikes
4 4.026 2.64 120.0 60.0 5.03 10.80 23.90 6.00 21.60 Excessive Elbows in ● Keep elbows to a minimum and less than 90°
Arriving at a total line pressure loss, consideration should then be given to

Inlet Plumbing
pressure loss created by valves, fittings and elevation of lines. Excessive liquid ●Use Thermo Valve in bypass line
If a sufficient number of valves and fittings are incorporated in the system to Temperature ●Do not exceed pump temperature specifications
materially affect the total line loss, add to the total line length, the equivalent ● Substitute closed loop with baffled holding tank
length of line of each valve or fitting. ● Adequately size tank for frequent or high
volume bypass
● Pressure feed high temperature liquids
TYPICAL RESERVOIR TANK ● Properly ventilate cabinets and rooms
RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Air Leaks in Plumbing ● Check all connections
● Use Teflon tape
Supply Line Agitation in Supply ● Size tank according to pump output —

Bypass Line
(from regulator or unloader) Tank Minimum 6-10 times system GPM
→
T (Dia of pipe) ● Baffle tank to purge air from liquid and

Level Sensing
Device X D separate inlet from discharge
→
→
→
High Viscosity Liquids ● Verify viscosity against pump specifications

→
MIN. 4"
before operation
→
1.5 x D (Min.)
● Elevate liquid temperature enough to reduce
→
viscosity
● Lower RPM of pump
Flexible Hose Minimum
to Pump ● Pressure feed pump
Liquid Bypass Line
Level (from regulator or ● Increase inlet line size
FILTER unloader)
→
Clogged Filters ● Perform regular maintenance or use clean

filters to monitor build up
→
● Use adequate mesh size for liquid and pump

Minimum Two Baffles
MIN. 4" Sealed at Bottom specifications
DIAGNOSIS AND MAINTENANCE
One of the most important steps in a high pressure system is to establish a regular maintenance program. This will vary slightly with each
system and is determined by various elements such as the duty cycle, the liquid being pumped, the actual specifications vs rated specifications
of the pump, the ambient conditions, the inlet conditions and the accessories in the system. A careful review of the necessary inlet conditions
and protection devices required before the system is installed will eliminate many potential problems.
CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps. Typically, only common tools are required,
making in-field service convenient, however, there are a few custom tools, special to certain models, that do simplify the process. This service
manual is designed to assist you with the disassembly and reassembly of your pump. The following guide will assist in determining the cause
and remedy to various operating conditions. You can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact
CAT PUMPS directly.
PROBLEM PROBABLE CAUSE SOLUTION
Low pressure •Worn nozzle. •Replace with properly sized nozzle.

•Belt slippage. •Tighten belt(s) or install new belt(s).
•Air leak in inlet plumbing. •Tighten fittings and hoses. Use PTFE liquid or tape.
•Pressure gauge inoperative or not registering accurately. •Check with new gauge. Replace worn or damaged gauge.
•Relief valve stuck, partially plugged or improperly adjusted. •Clean/adjust relief valve. Replace worn seats/valves and o-rings.
•Inlet suction strainer (filter) clogged or improperly sized. •Clean filter. Use adequate size filter. Check more frequently.
•Abrasives in pumped liquid. •Install proper filter.
•Leaky discharge hose. •Replace discharge hose with proper rating for system.
•Inadequate liquid supply. •Pressurize inlet and install C.A.T.
•Severe cavitation. •Check inlet conditions.
•Worn seals. •Install new seal kit. Increase frequency of service.
•Worn or dirty inlet/discharge valves. •Clean inlet/discharge valves or install new valve kit.
Pulsation •Faulty Pulsation Dampener. •Check precharge. If low, recharge, or install a new dampener.
•Foreign material trapped in inlet/discharge valves. •Clean inlet/discharge valves or install new valve kit.
Water leak
•Under the manifold •Worn V-Packings, Hi-Pressure or Lo-Pressure Seals. •Install new seal kit. Increase frequency of service.
•Worn adapter o-rings. •Install new o-rings.
•Into the crankcase •Humid air condensing into water inside the crankcase. •Install oil cap protector. Change oil every 3 months or 500 hours.
•Excessive wear to seals and V-Packings. •Install new seal kit. Increase frequency of service.
Knocking noise
•Inlet supply •Inadequate inlet liquid supply. •Check liquid supply. Increase line size, pressurize or install C.A.T.
•Bearing •Broken or worn bearing. •Replace bearing.
•Pulley •Loose pulley on crankshaft •Check key and tighten set screw.
Oil leak
•Crankcase oil seals. •Worn crankcase oil seals. •Replace crankcase oil seals.
•Crankshaft oil seals and o-rings. •Worn crankshaft oil seals or o-rings on bearing cover. •Remove bearing cover and replace o-rings and/or oil seals.
•Drain plug •Loose drain plug or worn drain plug o-ring. •Tighten drain plug or replace o-ring.
•Bubble gauge •Loose bubble gauge or worn bubble gauge gasket. •Tighten bubble gauge or replace gasket.
•Rear cover •Loose rear cover or worn rear cover o-ring. •Tighten rear cover or replace o-ring.
•Filler cap •Loose filler cap or excessive oil in crankcase. •Tighten filler cap. Fill crankcase to specified capacity.
Pump runs extremely rough

•Inlet conditions •Restricted inlet or air entering the inlet plumbing •Correct inlet size plumbing. Check for air tight seal.
•Pump valves •Stuck inlet/discharge valves. •Clean out foreign material or install new valve kit.
•Pump seals •Leaking V-Packings, Hi-Pressure or Lo-Pressure seals. •Install new seal kit. Increase frequency of service.
Premature seal failure •Scored plungers. •Replace plungers.

•Over pressure to inlet manifold. •Reduce inlet pressure per specifications.
•Abrasive material in the liquid being pumped. •Install proper filtration at pump inlet and clean regularly.
•Excessive pressure and/or temperature of pumped liquid. •Check pressure and inlet liquid temperature.
•Running pump dry. •DO NOT RUN PUMP WITHOUT LIQUID.
•Starving pump of adequate liquid. •Increase hose one size larger than inlet port size. Pressurize and
install C.A.T.
•Eroded manifold. •Replace manifold. Check liquid compatibility.
®
25 Frame
Plunger Pump
Standard Brass
Model 2530
Stainless Steel
Model 2 5 31
FEATURES
Superior Design
Nickel Aluminum
Bronze Model 2537
● Triplex plunger design gives smoother liquid flow.
● Hi-Pressure Seals are completely lubricated and cooled by SPECIFICATIONS U.S. Measure Metric Measure
the liquid being pumped.
● Inlet and discharge valve assemblies interchange for easier
MODELS 2530 AND 2531
Flow........................................................25 GPM (95 L/M)
maintenance. Pressure Range.........................100 to 1000 PSI (7 to 70 BAR)
● Lubricated Lo-Pressure Seals provide double protection against RPM ...................................................1025 RPM (1025 RPM)
external leakage.
MODEL 2537
● Oil bath crankcase assures optimum lubrication. Flow .......................................................21 GPM (80 L/M)
● Close tolerance concentricity of the ceramic plunger maximizes Pressure Range.........................100 to 1200 PSI (7 to 85 BAR)
seal life. RPM ....................................................860 RPM (860 RPM)
Quality Materials COMMON SPECIFICATIONS

Inlet Pressure Range ..............Flooded to 70 PSI (Flooded to 4.9 BAR)
● All stainless steel valves are heat treated and seats are roller Bore...........................................................1.260" (32 mm)
burnished for a positive seal and extended valve life. Stroke........................................................1.516" (38.5 mm)
● Brass, 316 Stainless Steel or Nickel Aluminum Bronze manifolds Crankcase Capacity ..................................84 oz. (2.5 L)
are strong and corrosion resistance. Maximum Liquid Temperature ..................160°F (71°C)
Inlet Ports (2) ...................................1-1/4" NPTF (1-1/4" NPTF)
● Special concentric, high density, polished, graphite impregnated, Discharge Ports (2).............................3/4" NPTF (3/4" NPTF)
solid ceramic plungers are abrasion resistant and result in Pulley Mounting .................................Either Side (Either Side)
extended seal life. Shaft Diameter ..........................................1.181" (30 mm)
● Specially formulated, CAT PUMP exclusive, Hi-Pressure Seal Weight.......................................................82 lbs. (37.1 kg)
offers unmatched performance and seal life. Dimensions..........................19.11 x 15.04 x 7.8" (485.44 x 382 x 198 mm)
● Die cast aluminum crankcase provides high strength, minimum
weight and precision tolerance control. HORSEPOWER REQUIREMENTS
● Chrome-moly crankshaft gives unmatched strength and surface MODEL FLOW PRESSURE RPM
hardness. PSI PSI PSI
800 1000 1200
● Oversized crankshaft bearings with greater loading capacity U.S. BAR BAR BAR
mean longer bearing life. GPM L/M 55 70 85
2530, 2531 25 95 13.7 17.2 N/A 1025
Easy Maintenance 21 80 11.5 14.4 17.3 860
● Wet-end is easily serviced without entering crankcase, requiring 2537 21 80 11.5 14.4 17.3 860
less time and effort. 18 68 9.9 12.3 14.8 738
15 57 8.2 10.3 12.4 615
● Preset packings mean no packing gland adjustment is necessary,
reducing maintenance costs. DETERMINING Rated G.P. M. = “Desired” G.P. M.
THE PUMP R.P.M. Rated R.P. M. “Desired” R.P. M.
DETERMINING GPM x PSI = Electric Brake
WARNING THE REQUIRED H.P. 1460 H. P. Required
All systems require both a primary pressure regulating device (i.e., regulator, unloader) and
a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to DETERMINING Motor Pulley O.D. = Pump Pulley O.D.
install such relief devices could result in personal injury or damage to the pump or to MOTOR PULLEY SIZE Pump R.P.M. Motor R.P.M.
system components. CAT PUMPS does not assume any liability or responsibility for the See complete Drive Packages [Inclds: Pulleys, Belts, Hubs, Key] Tech Bulletin 003.
operation of a customer’s high pressure system. Refer to pump Service Manual for repair procedure and additional technical information.
“Customer confidence is our greatest asset”

PARTS LIST
ITEM PART NUMBER DESCRIPTION QTY

● 2 990036 STL 990036 STL 990036 STL Key (M8x7x40) [2/00] 1 ●
5 92508 STZP 118824 S 118824 S Screw, Sems HHC (M8x25) 8
8 27773 AL 27773 AL 27773 AL Cover, Bearing 2
10 27772 NBR 27772 NBR 27772 NBR O-Ring, Oil Seal Case - 70D 2
11 27771 NBR 27771 NBR 27771 NBR Seal, Oil, Crankshaft - 70D 2
15 26512 STL 26512 STL 26512 STL Bearing, Ball 2
20 48613 TNM 48613 TNM 48613 TNM Rod, Connecting 3
21 48533 STZP 48533 STZP 48533 STZP Washer, Tab 3
25 48704 FCM 48704 FCM 48704 FCM Crankshaft - Dual End [2/00] 1
31 828710 828710 828710 Protector, Oil Cap 1
32 43211 ABS 43211 ABS 43211 ABS Cap, Oil Filler 1
33 14177 NBR 14177 NBR 14177 NBR O-Ring, Oil Filler Cap -70D 1
38 11338 NBR 11338 NBR 11338 NBR O-Ring, Dipstick - 70D 1
39 27769 ABS 27769 ABS 27769 ABS Dipstick 1
48 25625 STCP 25625 STCP 25625 STCP Plug, Drain (1/4"x19BSP) 1
49 23170 NBR 23170 NBR 23170 NBR O-Ring, Drain Plug - 70D 1
50 27768 AL 27768 AL 27768 AL Cover, Rear 1
51 27767 NBR 27767 NBR 27767 NBR O-Ring, Rear Cover - 70D 1
● 53 27762 AL 27762 AL 27762 AL Crankcase w/Guide Pins 1 ●
54 27488 S 27488 S 27488 S Pin, Guide 2
56 27790 PE 27790 PE 27790 PE Pan, Oil 1
64 27784 CM 27784 CM 27784 CM Pin, Crosshead 3
65 ✝ 48592 SSHS ✝ 48592 SSHS ✝ 48592 SSHS Rod, Plunger 3
70 27785 NBR 27785 NBR 27785 NBR Seal, Crankcase Oil -70D 3
75 110669 S 110669 S 110669 S Slinger, Barrier 3
88 110670 S 110670 S 110670 S Washer, Keyhole 3
90 45749 CC 45749 CC 45749 CC Plunger (M32x93) 3
95 ✝ 89835 SSL ✝ 89835 SSL ✝ 89835 SSL Stud, Retainer (M7x71) 3
96 20184 PTFE 20184 PTFE 20184 PTFE Back-up-Ring, Plunger Retainer 3
97 14190 NBR 14190 NBR 14190 NBR O-Ring, Plunger Retainer - 70D 3
14161 FPM 14161 FPM 14161 FPM O-Ring, Plunger Retainer 3
◆ 48239 EPDM ◆ 48239 EPDM ◆ 48239 EPDM O-Ring, Plunger Retainer 3
98 44069 SSL 44069 SSL 44069 SSL Gasket, Plunger Retainer 3
99 44068 SSL 44068 SSL 44068 SSL Retainer, Plunger [7/02] 3
100 110672 NY 110672 NY 110672 NY Retainer, LPS, Front 3
111116 NY 111116 NY 111116 NY Retainer, LPS, Rear 3
101 110796 110796 110796 Wick, Long Tab (M32) 3
106 ✝ 44098 NBR ✝ 44098 NBR ✝ 44098 NBR Seal, LPS w/SS-Spg 3
44827 FPM 44827 FPM 44827 FPM Seal, LPS w/SS-Spg 3
◆ 48244 EPDM ◆ 48244 EPDM ◆ 48244 EPDM Seal, LPS w/SS-Spg 3
● 110 45750 BB 48583 SSL 45830 NAB Manifold, Inlet 1 ●
116 30908 STZP 19085 S 19085 S Lockwasher, Split 4
117 89822 STZP 88398 S 88398 S Screw, HSH (M12x40) 4
125 ✝ 45832 SNG ✝ 45832 SNG ✝ 45832 SNG Seal, HPS w/SS 3
48220 STG* 48220 STG* 48220 STG* Seal, HPS w/SS 3
143 14203 NBR 14203 NBR 14203 NBR O-Ring, I.V. Adapter-Rear 3
11731 FPM 11731 FPM 11731 FPM O-Ring, I.V. Adapter-Rear 3
◆ 48241 EPDM ◆ 48241 EPDM ◆ 48241 EPDM O-Ring, I.V. Adapter-Rear 3
150 45752 BB 45835 SSL 45835 SSL Adapter, Inlet Valve 3
154 18690 NBR 18690 NBR 18690 NBR O-Ring, I.V. Adapter-Front 3
11744 FPM 11744 FPM 11744 FPM O-Ring, I.V. Adapter-Front 3
◆ 48242 EPDM ◆ 48242 EPDM ◆ 48242 EPDM O-Ring, I.V. Adapter-Front 3
155 14520 NBR 14520 NBR 14520 NBR O-Ring, D.V. Spacer 6
11745 FPM 11745 FPM 11745 FPM O-Ring, D.V. Spacer 6
◆ 28240 EPDM ◆ 28240 EPDM ◆ 28240 EPDM O-Ring, D.V. Spacer 6
157 45751 BB 45834 SS 45834 SS Spacer, Discharge Valve 3
164 ✝ 46857 SSL ✝ 46857 SSL ✝ 46857 SSL Seat [1/96] 6
165 14014 NBR 14014 NBR 14014 NBR O-Ring, Seat 6
48238 FPM 48238 FPM 48238 FPM O-Ring, Seat 6
◆ 48243 EPDM ◆ 48243 EPDM ◆ 48243 EPDM O-Ring, Seat 6
166 45839 SSL 45839 SSL 45839 SSL Valve 6
167 ✝ 45840 SS ✝ 45840 SS ✝ 45840 SS Spring 6
168 110682 PVDF 110682 PVDF 110682 PVDF Retainer, Spring 6
● 185 45753 BBCP 48585 SSL 45836 NAB Manifold, Discharge 1 ●
186 30908 STZP 19085 S 19085 S Lockwasher, Split 8
188 89573 STCP 89628 S 89628 S Screw, HSH (M12x65) 8
250 26516 STCP 26516 STCP 26516 STCP Protector, Shaft 1
260 30614 STZP 30614 STZP 30614 STZP Rail, Angle Assy (Inclds: 27808, 30902, 30930, 30908, 30911) 1
● 269 30206 F 30206 F 30206 F Pulley (10") [See Drive Packages, Tech Bulletin 003] 1 ●
● 270 30059 STL 30059 STL 30059 STL Hub, “H”, M30 (Keyway M8) [See Drive Packages, Tech Bulletin 003] [2/00] 1 ●
● 279 30278 STZP 30278 STZP 30278 STZP Oilers (1 oz.) 3 ●
281 30967 30967 30967 Glass, Oiler 3
282 10069 NBR 10069 NBR 10069 NBR Gasket, Oiler 3
● 283 34334 34334 34334 Kit, Oil Drain 1 ●
EXPLODED VIEW
Models
Standard - 2530

Stainless Steel - 2531

Nickel Aluminum Bronze - 2537
July 2002
● 290 6104 6104 6104 Gasket, Liquid (1 oz.) 1 ●
● 299 814838 BB 816735 SS 816538 NAB Head, Complete 1 ●
300 30952 NBR 30952 NBR 30952 NBR Kit, Seal (Inclds: 97,106,125,143,154,155) 1
33607 FPM* 33607 FPM* 33607 FPM* Kit, Seal (Inclds: 97,106,125,143,154,155) 1
33608 EPDM* 33608 EPDM* 33608 EPDM* Kit, Seal (Inclds: 97,106,125,143,154,155) 1
310 33952 NBR 33952 NBR 33952 NBR Kit, Valve (Inclds: 143,154,155,164,166,167,168,165) [Prior to 11/95 6 Req.] [1/96] 2
31267 FPM 31267 FPM 31267 FPM Kit, Valve (Inclds: 143,154,155,164,166,167,168,165) [Prior to 11/95 6 Req.] [1/96] 2
31268 EPDM 31268 EPDM 31268 EPDM Kit, Valve (Inclds: 143,154,155,164,166,167,168,165) [Prior to 11/95 6 Req.] [1/96] 2
● — 714500 SS 714500 SS 714500 SS C.A.T. (For R.O. or Industrial Applications) 1 ●
● — 714505 SS 714505 SS 714505 SS Adapter (2 per C.A.T.) (See Data Sheet for complete selection) 2 ●
— 6565.2 6565.2 6565.2 Plunger Pump Service Video 1
— 6100 6100 6100 Oil, Case (12 Bottles) ISO 68 Multi-viscosity Hydraulic 1
(Fill to specified crankcase capacity prior to start-up)
Industrial discount. Bold print part numbers are unique to a particular pump model. Italics are optional items. Silicone oil/grease required.
[ ] Date of latest production change. *Review material codes for individual items (STG generally may be used as alternate).
See Tech Bulletins 002, 003, 024, 036, 043, 053, 074, 076, 077, 083 and 085 for additional information. ✝ Production parts are different than service parts.
MATERIAL CODES (Not Part of Part Number): ABS=ABS Plastic AL=Aluminum BB=Brass BBCP=Brass/Chrome Plated CM=Chrome-moly
EPDM=Ethylene Propylene Diene Moname F=Cast Iron FCM=Forged Chrome-moly FPM=Fluorocarbon (Viton ®) HS=High Strength
NAB=Nickel Aluminum Bronze NBR=Medium Nitrile (Buna-N) NY=Nylon PE=Polyethylene PTFE=Pure Teflon ® PVDF=Fluoroplastic (High Strength)
S=304SS SS=316SS SNG=Special Blend (Buna) Black SSL=316SS/Low Carbon STG=Special Blend (Teflon ®) White STL=Steel SSHS=316SS/High Strength
STCP=Steel/Chrome Plated STZP=Steel/Zinc Plated TNM=Special High Strength
15.04 (382) 19.11 (485.44)
8.42 (214) 14.86 (377.40) 4.25 (108)
7.48 (190) 13.91 (353.40)

7.52 (191)
(2) 3/4" NPTF DISCHARGE
.39 (10) 1.18 (30)

.31 (8)
7.80 (198)
2.68 (68)
4.33 (110)
.39 (10)
2.21 (56.17) 0.59 (15)

0.59 (15)
2.36 (60)
2.09
4 -.51 (13)
(53)
4.92 (125) (2) 1-1/4" NPTF INLET
6.89 (175)
6.89 (175) .98 (25)
7.87 (200)
8.66 (220)
10.61 (269.50)
Models 2530, 2531, 2537

2
13 10 12
3 9
6 7 8 11
5
4
11
1 Die cast aluminum crankcase means 6 Special stainless steel plunger rods with 10 100% wet seal design adds to service life
high strength, light weight, and excellent high tensile strength crossheads for long life. by allowing pumped liquids to cool and
tolerance control. 7 The stainless steel slinger provides back- lubricate on both sides.
2 Dipstick offers top access for easy oil up protection for the crankcase seal, keep- 11 Stainless steel valves, seats and springs
level check. ing pumped liquids out of the crankcase. provide corrosion-resistance, positive
3 Oversized crankshaft bearings provide ex- 8 Special concentric, high density, polished, seating and long life.
tended bearing life and pump performance. graphite impregnated, solid ceramic 12 Specially formulated, CAT PUMP exclu-
4 Chrome-moly crankshaft provides plungers are abrasion resistant and result sive, Hi-Pressure Seals offer unmatched
unmatched strength and surface hardness in extended seal life. performance and seal life.
for long life. 9 Manifolds are a high tensile strength brass, 13 Crosshead is 360° supported for uncom-
5 Matched oversized high strength connect- 316 stainless steel or nickel aluminum bronze promising alignment.
ing rods are noted for superior strength and for long term, continuous duty.
bearing quality.

e-mail: sales@catpumps.com Heiveldekens 6A, 2550 Kontich, Belgium
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
PN 993117 Rev A 7203

25PFR PLUNGER PUMP SERVICE MANUAL
25 FRAME SPLIT MANIFOLD: 2530, 2531, 2537
INSTALLATION AND START-UP INFORMATION

Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only
with the proper selection, installation of plumbing, and operation of the pump and accessories.
SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to
implied that all maximums can be performed simultaneously. If more than one avoid deadhead overpressure condition and severe damage to the pump or system.
maximum is considered, check with your CAT PUMPS supplier to confirm the Install a Pulsation Dampening device on the discharge head or in the discharge line
proper performance and pump selection. Refer to individual pump Data Sheets for as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is
complete specifications, parts list and exploded view. properly precharged for the system pressure (see individual Data Sheet.)
LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications A reliable Pressure Gauge should be installed near the discharge outlet of the high
[84 oz., 2.5 L]. DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change pressure manifold. This is extremely important for adjusting pressure regulating
initial fill after 50 hours running period. Thereafter, change oil every 3 months or devices and also for proper sizing of the nozzle or restricting orifice. The pump is
500 hour intervals. Oiler adjustment is vertical to start feed, horizontal to stop rated for a maximum pressure; this is the pressure which would be read at the
feed, dial to adjust flow rate. Additional lubrication may be required with increased discharge manifold of the pump, NOT AT THE GUN OR NOZZLE.
hours of operation and temperature.
Use PTFE liquid (sparingly) or tape to connect accessories or plumbing. Exercise
PUMP ROTATION: Pump was designed for forward rotation to allow optimum caution not to wrap tape beyond the last thread to avoid tape from becoming
lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil lodged in the pump or accessories. This condition will cause a malfunction of the
level is increased slightly above center dot to assure adequate lubrication. pump or system.
PULLEY SELECTION: Select size of motor pulley required to deliver the desired PRESSURE REGULATION: All systems require both a primary pressure regulating
flow from Horsepower Requirement and Pulley Selection Chart (refer to Tech device (i.e., regulator, unloader) and a secondary pressure safety relief device
Bulletin 003 or individual Data Sheet). (i.e., pop-off valve, safety valve). The primary pressure device must be installed on
MOTOR SELECTION: The motor or engine driving the pump must be of adequate the discharge side of the pump. The function of the primary pressure regulating
horsepower to maintain full RPM when the pump is under load. Select the electric device is to protect the pump from over pressurization, which can be caused by a
motor from the Horsepower Requirement Chart according to required pump plugged or closed off discharge line. Over pressurization can severely damage the
discharge flow, maximum pressure at the pump and drive losses of approximately pump, other system components and can cause bodily harm. The secondary safety
3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper relief device must be installed between the primary device and pump. This will
engine size. ensure pressure relief of the system if the primary regulating device fails. Failure to
MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit install such a safely device will void the warranty on the pump.
drainage of crankcase oil. An uneven mounting surface will cause extensive If a large portion of the pumped liquid is by-passed (not used) when the high
damage to the pump base. To minimize piping stress, use appropriate flexible pressure system is running, this by-pass liquid should be routed to an adequately
hose to inlet and discharge ports. Use the correct belt; make sure pulleys are sized, baffled supply tank or to drain. If routed to the pump inlet, the by-pass liquid
aligned. Excessive belt tension may be harmful to the bearings. Hand rotate pump can quickly develop excessive heat and result in damage to the pump. A
before starting to be certain shaft and bearings are free moving. temperature control device to shut the system down within the pump limits or multiple
LOCATION: If the pump is used in extremely dirty or humid conditions, it is THERMO VALVES must be installed in the by-pass line to protect the pump.
recommended pump be enclosed. Do not store or operate in excessively high NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure
temperature areas or without proper ventilation. regulating device to compensate. Replace nozzle and reset regulating device to
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual system pressure.
before starting system. DO NOT STARVE THE PUMP OR RUN DRY . PUMPED LIQUIDS: Some liquids may require a flush between operations or before
Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each storing. For pumping liquids other than water, contact your CAT PUMPS supplier.
degree F over 130°F. Elastomer or RPM changes may be required. See Tech STORING: For extended storing or between use in cold climates, drain all pumped
Bulletin 002 or call CAT PUMPS for recommendations. liquids from pump and flush with antifreeze solution to prevent freezing and
C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech
applications with stressful inlet conditions such as high temperatures, booster pump Bulletin 083).
feed, long inlet lines or quick closing valves.
WARNING
All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve).
Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility
for the operation of a customer’s high pressure system.

Phone (763) 780-5440 — FAX (763) 780-2958 ®
N.V. CAT PUMPS INTERNATIONAL S. A.
e-mail: techsupport@catpumps.com Heiveldekens 6A, 2550 Kontich, Belgium
Phone 49 6126-9303 0 — Fax 49 6126-9303 33
PN 30053 Rev G 5343

Removal of Discharge Socket Head Screws Separation of Discharge Manifold from Inlet Manifold Discharge Manifold with both Inlet Valve Adapters and
Discharge Valve Spacers.
SERVICING THE VALVES

Disassembly 6. Both the Inlet and Discharge use the same Valve
Assembly. With a flat head screwdriver, carefully pry the
1. To service the Valves, the Discharge Manifold must be re- Seat, O-Ring, Valve, Spring and Retainer from the mani-
moved. Using a M10 allen wrench remove the eight fold chamber.
Socket Head Screws.
CAUTION: Exercise caution to avoid scoring the mani-
2. Support the underside of the Discharge Manifold and fold chamber wall.
lightly tap the top back of the manifold with a soft mallet.
Two screwdrivers may be needed to further separate the NOTE: This Valve Assembly does not snap together.
Discharge Manifold from the Inlet Manifold. Reassembly
3. Remove the Discharge Manifold and place it crankcase NOTE: For certain applications apply liquid gasket to
side up. the O-Ring crevices and seal surfaces. See Tech
NOTE: The Discharge Valve Assembly is secured in Bulletin 053 for model identification.
the upper chambers by the Discharge Valve Spacer, NOTE: EPDM elastomers require a silicone-base
while the Inlet Valve Assembly is secured in the lower lubricant.
chambers by the Inlet Valve Adapter.
1. Inspect the Spring Retainer for any scale buildup or wear
4. The Discharge Valve Spacers will remain in either the and replace as needed. Place the Spring Retainer into the
Inlet Manifold or the Discharge Manifold. To remove the valve chamber.
Spacer from the manifold, insert two screwdrivers on op-
posite sides under the machined lip on the outside of the 2. Examine the Spring for fatigue or breaks and replace as
Spacer and pry out. needed. Place the Spring into the Retainer.
5. Use a reverse pliers to remove the Inlet Valve Adapters 3. Examine the Valve for pitting or grooves and replace as
from the Discharge Manifold or insert two screwdrivers needed. Set the Valve onto the Spring with the concave
into the secondary groove on opposite sides of the side down.
adapter and pry from valve chamber.
Removal of Disharge Valve Spacers Removal of Inlet Valve Adapters Discharge Valve Assembly
Inlet Valve Assembly Removal of I.M. Socket Head Screws Rotate Crankshaft to position plungers
4. Place the Seat into the valve chamber with the concave 10. Fit the new O-Rings into the groove on the outside of the
side down. Then apply liquid gasket to the O-Ring and Discharge Valve Spacer. Apply liquid gasket into the
press squarely into the lip on the Spring Retainer. O-Ring crevice and carefully press the Spacer completely
into the Discharge Manifold chamber with the smaller
NOTE: Effective with 6-95 mfg date, the O-Ring was
diameter side down.
moved to the back side of the Seat with the O-Ring in-
stalled first, onto the lip in the manifold chamber, then 11. Replace Discharge Manifold over the Plunger Rods with
the Seat with the machined O-Ring groove down. Discharge Valve Spacers to the top and Inlet Adapters to
the bottom. Tap with a soft mallet until completely seated
NOTE: Effective with 11-95 mfg date, the Seat was
in chambers.
modified to a new thicker style, still with the O-Ring
installed first, onto the lip in the manifold chamber, 12. Reinstall the eight Socket Head Screws and torque in
then the Seat with the machined O-Ring groove down. sequence to specifications in torque chart.
5. Examine the Seat for any grooves, pitting or wear and re- IMPORTANT: Follow the torque sequence to assure
place. Place the new Seat onto the the O-Ring with the the proper alignment.
concave side down.
6. Look for wear or damage to both the inner and outer
O-Rings on the Inlet Adapter and replace.
7. Fit the O-Rings into both the outer groove and face
groove of the Inlet Adapter and apply liquid gasket into the
O-Ring crevice.
8. Press the Inlet Adapter into the lower manifold chamber.
9. Remove and examine both O-Rings on the Discharge
Valve Spacer for wear or cuts and replace as needed.
Removal of Inlet Manifold Removal of Hi-Pressure Seals Removal of Lo-Pressure Seals

Plunger Arrangement
SERVICING THE SEALS SERVICING THE PLUNGERS

Disassembly Disassembly
1. Remove the Discharge Manifold as described in SERVIC- NOTE: The Ceramic Plungers and the Plunger
ING THE VALVES section. Retainers should be examined on the same schedule
as servicing the seals.
2. To service the seals the Inlet Manifold must be removed,
use a M10 allen wrench to remove the 4 Socket Head 1. To service the Ceramic Plungers, first remove the Seal
Screws. Retainers.
3. Support the Inlet Manifold and lightly tap the top back side 2. Loosen the Plunger Retainer about three or four turns
with a soft mallet. Remove the Inlet Manifold and place it using a M14 hex tool.
crankcase side down.
3. Grasp the Ceramic Plunger and push toward the
4. Use a reverse pliers to remove the Hi-Pressure Seals. Crankcase until it separates from the Plunger Retainer.
5. The Lo-Pressure Seals may stay on the Plungers or in the 4. Unthread the Plunger Retainer with Gasket, O-Ring,
Inlet Manifold. Back-up-Ring and Ceramic Plunger. Remove the Keyhole
Washer and Barrier Slinger from the Plunger Rod.
6. Invert the Inlet Manifold with the crankcase side up.
Reassembly
7. Remove the Lo-Pressure Seal using a reverse pliers or
slide it off the Plunger by hand. 1. Examine the Barrier Slinger for any wear or damage and
place on the Plunger Rod with the concave side facing
Reassembly
out.
NOTE: Replace Seals and O-Rings with the same
2. Examine the Keyhole Washer and place on the Plunger
material called out by your pump model number (i.e.,
Rod with the slot down.
.0110 for FPM [Viton®], .0220 for EPDM).
3. Examine the O-Ring and Back-up-Ring on the Plunger
NOTE: For certain applications apply liquid gasket to
Retainer and replace if worn or damaged. First install
the O-Ring crevices and seal surfaces. See Tech
the Gasket, then the O-Ring and Back-up-Ring. Lubricate
Bulletin 053 for model identification.
the Plunger Retainer O-Ring to avoid cutting during
NOTE: EPDM elastomers require a silicone-base installation.
lubricant.
4. If the Plunger Retainer unthreads from the stud during re-
1. Examine the Lo-Pressure Seal for wear or spring fatigue moval, thread the stud into the retainer.
and replace. Apply liquid gasket to the outside of the new
5. Examine the Ceramic Plunger for scoring, cracks or scale
Lo-Pressure Seal and carefully press it into the Inlet
and replace if needed. The Ceramic Plunger can be
Manifold chamber with the spring down.
cleaned with a scotchbrite pad. Slide the Ceramic Plunger
NOTE: When using alternate materials, the fit of the onto the retainer and stud assembly with the shallower
special materials may be snug and require gently counterbore away from the retainer.
driving the LPS into position with a cylinder of the
NOTE: Plunger can only be installed one direction. Do
same diameter to assure a square seating and no
not force into Plunger Rod.
damage to the LPS.
2. Invert the Inlet Manifold and place the crankcase side 6. Apply locktite 242 to the threads of the Plunger Retainer
down. Examine the Hi-Pressure Seal for deformity or Stud and thread onto the Plunger Rod. Then torque to
wear and replace. Apply liquid gasket to the outside of the specifications in chart.
new Hi-Pressure Seal and carefully press it into the Inlet
Manifold chamber with the metal side down.
7. Reinstall the Seal Retainers with the slots to the top and SERVICING THE CRANKCASE SECTION
bottom.
1. While Inlet Manifold, Plungers and Seal Retainers are re-
8. Rotate the Crankshaft to line up the outside Plungers. moved, examine crankcase seals for wear.
Then lightly lubricate the Plungers with oil.
2. Check for any signs of leaking at Rear Cover or Dipstick.
9. Carefully slide the Inlet Manifold over the Ceramic
Plungers and press until flush with the Crankcase. 3. Check oil level and for evidence of water in oil.
10. Reinstall the four Inlet Socket Head Screws and torque to 4. Rotate Crankshaft by hand to feel for smooth bearing
specifications in chart. movement.
11. The Hi-Pressure Seals may shift while installing the Inlet 5. Examine Crankshaft Oil Seals externally for drying, crack-
Manifold. Use one of the Discharge Valve Spacers to ing or leaking.
press the Seals back into position. 6. Consult CAT PUMPS or your local distributor if Crankcase
12. Carefully press the Discharge Manifold into the Inlet service is required. See also Tech Bulletin 035.
Manifold. Use a soft mallet to tap into place and reinstall See Section II of the Plunger Pump Service Video for
the eight Socket Head Screws. Torque in sequence to additional information.
specifications in torque chart.
TORQUE SEQUENCE
5 1 3 7
8 4 2 6
INLET CONDITION CHECK-LIST
PREVENTATIVE MAINTENANCE CHECK-LIST Review Before Start-Up
Inadequate inlet conditions can cause serious malfunctions in the best designed
Check Daily Weekly 50 hrs. 500 hrs.* 1500 hrs.** 3000 hrs.**
pump. Surprisingly, the simplest of things can cause the most severe problems or go
Clean Filters x unnoticed to the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST BEFORE
OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so there can
Oil Level/Quality x be no ONE best way to set-up a system. All factors must be carefully considered.
Oil Leaks x
INLET SUPPLY should exceed the maximum flow being delivered by the pump to
Water Leaks x assure proper performance.
Belts, Pulley x ❏ Open inlet shut-off valve and turn on water supply to avoid starving pump. DO
NOT RUN PUMP DRY.
Plumbing x ❏ Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each
degree F over 130°F. Elastomer or RPM changes may be required. See Tech
Initial Oil Change x
Bulletin 002 or call CAT PUMPS for recommendations.
Oil Change x ❏ Avoid closed loop systems especially with high temperature, ultra-high pressure
or large volumes. Conditions vary with regulating/unloader valve.
Seal Change x ❏ Low vapor pressure liquids, such as solvents, require a booster pump and C. A.T.
Valve Change x to maintain adequate inlet supply (where compatible).
❏ Higher viscosity liquids require a positive head and a C. A.T. to assure adequate
Accessories x inlet supply.
❏ Higher temperature liquids tend to vaporize and require positive heads and
* If other than CAT PUMPS special multi-viscosity ISO68 oil is used, C. A.T. to assure adequate inlet supply.
change cycle should be every 300 hours. ❏ When using an inlet supply reservoir, size it to provide adequate liquid to
accommodate the maximum output of the pump, generally a minimum of 6-10
** Each system’s maintenance cycle will be exclusive. If system per-
times the GPM (however, a combination of system factors can change this
formance decreases, check immediately. If no wear at 1500 hours, requirement); provide adequate baffling in the tank to eliminate air bubbles and
check again at 2000 hours and each 500 hours until wear is ob- turbulence; install diffusers on all return lines to the tank.
served. Valves typically require changing every other seal change.
Duty cycle, temperature, quality of pumped liquid and inlet feed INLET LINE SIZE should be adequate to avoid starving the pump.
conditions all effect the life of pump wear parts and service cycle. ❏ Line size must be a minimum of one size larger than the pump inlet fitting. Avoid
tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of
** Remember to service the regulator/unloader at each seal servicing
flow restriction and cavitation.
and check all system accessories and connections before resuming ❏ The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION
operation. systems to avoid collapsing.
Refer to video for additional assistance. ❏ The simpler the inlet plumbing the less the potential for problems. Keep the
length to a minimum, the number of elbows and joints to a minimum (ideally no
elbows) and the inlet accessories to a minimum.
❏ Use pipe sealant to assure air-tight, positive sealing pipe joints.
TORQUE CHART INLET PRESSURE should fall within the specifications of the pump.
❏ Acceleration loss of liquids may be increased by high RPM, high temperatures,
Tool Size Torque low vapor pressures or high viscosity and may require pressurized inlet
Pump Item Thread [Part No.] in. lbs. ft. lbs. Nm and C. A.T. to maintain adequate inlet supply. DO NOT USE C.A.T. WITH
SUCTION INLET.
Plunger Retainer M7 M14 Hex 108 9.0 12 ❏ Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure
[25053] and a C. A.T. for certain applications. With adequate inlet plumbing, most pumps
will perform with flooded suction. Maximum inlet pressure is 70 PSI (4.9 BAR).
Inlet Manifold Screws M12 M10 Allen 355 29.6 40 ❏ After prolonged storage, pump should be rotated by hand and purged of air to
[33047] facilitate priming. Disconnect the discharge port and allow liquid to pass through
pump and measure flow.
Discharge Manifold Screws M12 M10 Allen 355 29.6 40
[33047] INLET ACCESSORIES are offered to protect against over pressurization,
contamination or temperature and control flow.
Crankcase Cover/ M8 M13 Hex 115 9.6 13 ❏ A shut-off valve is recommended to facilitate maintenance.
Bearing Cover Screws [25324] ❏ Installation of a C. A.T. is essential in applications with stressful conditions such
as high temperatures, booster pump feed or long inlet lines. Do not use C. A.T.
Connecting Rod Screws M8 M13 Hex 216 18.0 24 with negative inlet pressure.
[25324] ❏ A stand pipe can be used in some applications to help maintain a positive head
at the pump inlet line.
Bubble Oil Gauge M28 Oil Gauge Tool 45 3.6 5 ❏ Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
[44050] ❏ A pressure transducer is necessary to accurately read inlet pressure. Short
term, intermittent cavitation will not register on a standard gauge.
Mounting Bolts M12 M19 Hex 355 29.6 40 ❏ All accessories should be sized to avoid restricting the inlet flow.
❏ All accessories should be compatible with the solution being pumped to prevent
premature failure or malfunction.
❏ Optional inlet protection can be achieved by installing a pressure cut off switch
between the inlet filter and the pump to shut off pump when there is no positive
TECHNICAL BULLETIN REFERENCE CHART inlet pressure.
No. Subject Models BY-PASS TO INLET Care should be exercised when deciding the method of by-pass
002 Inlet Pressure VS Liquid Temperature All Models from control valves.
❏ It is recommended the by-pass be directed to a baffled reservoir tank, with at
003 Power Unit Drive Packages 3PFR - 68PFR, 10FR - 60FR
least one baffle between the by-pass line and the inlet line to the pump.
024 Lubrication of Lo-Pressure Seals All Models ❏ Although not recommended, by-pass liquid may be returned to the inlet line
035 Servicing Crankcase Section 7PFR - 60PFR of the pump if the system is properly designed to protect your pump. When a
pulsation dampener is used, a PRESSURE REDUCING VALVE must be
036 Cylinder and Plunger Reference Chart All Models
installed on the inlet line (BETWEEN THE BY-PASS CONNECTION AND THE
043 LPS and HPS Servicing All Plunger Models INLET TO THE PUMP) to avoid excessive pressure to the inlet of the pump. It is
053 Liquid Gasket All Plunger NAB-S.S. Models also recommended that a THERMO VALVE be used in the by-pass line to moni-
tor the temperature build-up in the by-pass loop to avoid premature seal failure.
064 By-Pass Hose Sizing All Unloaders/Regulators
❏ A low-pressure, flexible cloth braid (not metal braid) hose should be used from
074 Torque Chart Piston and Plunger Pumps the by-pass connection to the inlet of the pump.
076 Valve Seat and O-Ring 2530 and 2537 ❏ Caution should be exercised not to undersize the by-pass hose diameter and
length. Refer to Technical Bulletin 064 for additional information on the size and
077 Oil Drain Kit All Models (except 2SF/4SF)
length of the by-pass line.
081 Seal Case and Wick 2530 and 2537 ❏ Check the pressure in the by-pass line to avoid over pressurizing the inlet.
083 Winterizing a Pump All Models ❏ The by-pass line should be connected to the pump inlet line at a gentle angle of
45° or less and no closer than 10 times the pump inlet port diameter e.g. 1-1/2"
085 M8 Keyway 25FR, 25PFR, 28PFR
port size = 15" distance from pump inlet port.
HOSE FRICTION LOSS Handy Formulas to Help You
PRESSURE DROP IN PSI PER 100 FT OF HOSE
WITH TYPICAL WATER FLOW RATES Q. How can I find the RPM needed to get specific GPM
Water* Hose Inside Diameters, Inches
Flow (Gallons Per Minute) I want?
Gal/Min 1/4 5/16 3/8 1/2 5/8 3/4 1"
Rated RPM
0.5 16 5 2 A. Desired RPM = Desired GPM x
1 54 20 7 2 Rated GPM
2 180 60 25 6 2
3 380 120 50 13 4 2 Q. I have to run my pump at a certain RPM. How do I figure
4 220 90 24 7 3 the GPM I’ll get?
5 320 130 34 10 4 Rated GPM
6 220 52 16 7 1 A. Desired GPM = Desired RPM x
8 300 80 25 10 2 Rated RPM
10 450 120 38 14 3
15 900 250 80 30 7 Q. Is there a simple way to find the approximate horsepower
20 1600 400 121 50 12 I’ll need to run the pump?
25 650 200 76 19
30 250 96 24 A. Electric Brake GPM x PSI (Standard 85%
40 410 162 42 =
Horsepower Required 1460 Mech. Efficiency)
50 600 235 62
60 370 93
*At a fixed flow rate with a given size hose, the pressure drop across a given hose length
Q. What size motor pulley should I use?
will be directly proportional. A 50 ft. hose will exhibit one-half the pressure drop of a 100 Pump RPM (Consult
ft. hose. Above values shown are valid at all pressure levels. A. Pump Pulley (Outer Diameter) x Engine Mfr.)
Motor/Engine RPM
Q. How do I calculate the torque for my hydraulic drive
WATER LINE PRESSURE LOSS system?
Water
PRESSURE DROP IN PSI PER 100 FEET
Steel Pipe—Nominal Dia. Brass Pipe—Nominal Dia. Copper Tubing O.D. Type L
A. Torque (ft. lbs.) = 3.6 (
GPM x PSI
RPM
)
GPM 1/4 3/8 1/2 3/4 1 11/4 11/2 1/4 3/8 1/2 3/4 1 11/4 11/2 1/4 3/8 1/2 5/8 3/4 7/8
1
2
8.5 1.9
30 7.0 2.1
6.0 1.6
20 5.6 1.8
120 13 2.9 1.0
400 45 10 3.4 1.3 Avoid Cavitation Damage
3 60 14 4.5 1.1 40 11 3.6 94 20 6.7 2.6
5 150 36 12 2.8 100 28 9.0 2.2 230 50 17 6.1 3.0

8 330 86 28 6.7 1.9 220 62 21 5.2 1.6 500 120 40 15 6.5
10 520 130 43 10 3.0 320 90 30 7.8 2.4 180 56 22 10
15 270 90 21 6.2 1.6 190 62 16 5.0 1.5 120 44 20

25 670 240 56 16 4.2 2.0 470 150 40 12 3.8 1.7 330 110 50
40 66 17 8.0 39 11 5.0 550 200 88
60 37 17 23 11
80 52 29 40 19
100 210 107 48 61 28
RESISTANCE OF VALVES AND FITTINGS One or several of the conditions shown in the chart below may
Nominal Equivalent Length of Standard Pipe in Feet contribute to cavitation in a system resulting in premature wear,
Pipe Inside 180˚ Tee Tee system downtime and unnecessary operating costs.
Size Diameter Gate Globe Angle 45˚ 90˚ Close Thru Thru
Inches Inches Valve Valve Valve Elbow Elbow Ret Run Branch
CONDITION SOLUTION
1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33 Inadequate inlet ● Increase line size to the inlet port or one size
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41 line size larger
1 1.049 0.69 31.2 15.6 1.31 2.81 6.25 1.56 5.62
11/4 1.380 0.90 41.0 20.5 1.73 3.70 8.22 2.06 7.40
Water hammering ● Install C.A.T. Tube
11/2 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63
liquid acceleration/ ● Move pump closer to liquid supply
deacceleration
2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60
2 1/2 2.469 1.62 73.5 36.8 3.09 6.61 14.70 3.68 13.20
Rigid Inlet Plumbing ● Use flexible wire reinforced hose to absorb
3 3.068 2.01 91.5 45.8 3.84 8.23 18.20 4.57 16.40
pulsation and pressure spikes
4 4.026 2.64 120.0 60.0 5.03 10.80 23.90 6.00 21.60 Excessive Elbows in ● Keep elbows to a minimum and less than 90°
Arriving at a total line pressure loss, consideration should then be given to

Inlet Plumbing
pressure loss created by valves, fittings and elevation of lines. Excessive Liquid ●Use Thermo Valve in bypass line
If a sufficient number of valves and fittings are incorporated in the system to Temperature ●Do not exceed pump temperature specifications
materially affect the total line loss, add to the total line length, the equivalent ● Substitute closed loop with baffled holding tank
length of line of each valve or fitting. ● Adequately size tank for frequent or high
volume bypass
● Pressure feed high temperature liquids
TYPICAL RESERVOIR TANK ● Properly ventilate cabinets and rooms
RECOMMENDED 6 TO 10 TIMES SYSTEM CAPACITY Air Leaks in Plumbing ● Check all connections
● Use Teflon tape
Supply Line Agitation in Supply ● Size tank according to pump output —

Bypass Line
(from regulator or unloader) Tank Minimum 6-10 times system GPM
→
T (Dia of pipe) ● Baffle tank to purge air from liquid and

Level Sensing
Device X D separate inlet from discharge
→
→
→
High Viscosity Liquids ● Verify viscosity against pump specifications

→
MIN. 4"
before operation
→
1.5 x D (Min.)
● Elevate liquid temperature enough to reduce
→
viscosity
● Lower RPM of pump
Flexible Hose Minimum
to Pump ● Pressure feed pump
Liquid Bypass Line
Level (from regulator or ● Increase inlet line size
FILTER unloader)
→
Clogged Filters ● Perform regular maintenance or use clean

filters to monitor build up
→
● Use adequate mesh size for liquid and pump

Minimum Two Baffles
MIN. 4" Sealed at Bottom specifications
DIAGNOSIS AND MAINTENANCE
One of the most important steps in a high pressure system is to establish a regular maintenance program. This will vary slightly with each
system and is determined by various elements such as the duty cycle, the liquid being pumped, the actual specifications vs rated specifications
of the pump, the ambient conditions, the inlet conditions and the accessories in the system. A careful review of the necessary inlet conditions
and protection devices required before the system is installed will eliminate many potential problems.
CAT PUMPS are very easy pumps to service and require far less frequent service than most pumps. Typically, only common tools are required,
making in-field service convenient, however, there are a few custom tools, special to certain models, that do simplify the process. This service
manual is designed to assist you with the disassembly and reassembly of your pump. The following guide will assist in determining the cause
and remedy to various operating conditions. You can also review our FAQ or SERVICE sections on our WEB SITE for more facts or contact
CAT PUMPS directly.
PROBLEM PROBABLE CAUSE SOLUTION
Low pressure •Worn nozzle. •Replace with properly sized nozzle.

•Belt slippage. •Tighten belt(s) or install new belt(s).
•Air leak in inlet plumbing. •Tighten fittings and hoses. Use PTFE liquid or tape.
•Pressure gauge inoperative or not registering accurately. •Check with new gauge. Replace worn or damaged gauge.
•Relief valve stuck, partially plugged or improperly adjusted. •Clean/adjust relief valve. Replace worn seats/valves and o-rings.
•Inlet suction strainer (filter) clogged or improperly sized. •Clean filter. Use adequate size filter. Check more frequently.
•Abrasives in pumped liquid. •Install proper filter.
•Leaky discharge hose. •Replace discharge hose with proper rating for system.
•Inadequate liquid supply. •Pressurize inlet and install C.A.T.
•Severe cavitation. •Check inlet conditions.
•Worn seals. •Install new seal kit. Increase frequency of service.
•Worn or dirty inlet/discharge valves. •Clean inlet/discharge valves or install new valve kit.
Pulsation •Faulty Pulsation Dampener. •Check precharge. If low, recharge, or install a new dampener.
•Foreign material trapped in inlet/discharge valves. •Clean inlet/discharge valves or install new valve kit.
Water leak
•Under the manifold •Worn High Pressure or Lo-Pressure Seals. •Install new seal kit. Increase frequency of service.
•Worn adapter o-rings. •Install new o-rings.
•Into the crankcase •Humid air condensing into water inside the crankcase. •Install oil cap protector. Change oil every 3 months or 500 hours.
•Excessive wear to seals and V-Packings. •Install new seal kit. Increase frequency of service.
Knocking noise
•Inlet supply •Inadequate inlet liquid supply. •Check liquid supply. Increase line size, pressurize or install C.A.T.
•Bearing •Broken or worn bearing. •Replace bearing.
•Pulley •Loose pulley on crankshaft •Check key and tighten set screw.
Oil leak
•Crankcase oil seals. •Worn crankcase oil seals. •Replace crankcase oil seals.
•Crankshaft oil seals and o-rings. •Worn crankshaft oil seals or o-rings on bearing cover. •Remove bearing cover and replace o-rings and/or oil seals.
•Drain plug •Loose drain plug or worn drain plug o-ring. •Tighten drain plug or replace o-ring.
•Bubble gauge •Loose bubble gauge or worn bubble gauge gasket. •Tighten bubble gauge or replace gasket.
•Rear cover •Loose rear cover or worn rear cover o-ring. •Tighten rear cover or replace o-ring.
•Filler cap •Loose filler cap or excessive oil in crankcase. •Tighten filler cap. Fill crankcase to specified capacity.
Pump runs extremely rough

•Inlet conditions •Restricted inlet or air entering the inlet plumbing •Correct inlet size plumbing. Check for air tight seal.
•Pump valves •Stuck inlet/discharge valves. •Clean out foreign material or install new valve kit.
•Pump seals •Leaking High Pressure or Lo-Pressure seals. •Install new seal kit. Increase frequency of service.
Premature seal failure •Scored plungers. •Replace plungers.

•Over pressure to inlet manifold. •Reduce inlet pressure per specifications.
•Abrasive material in the liquid being pumped. •Install proper filtration at pump inlet and clean regularly.
•Excessive pressure and/or temperature of pumped liquid. •Check pressure and inlet liquid temperature.
•Running pump dry. •DO NOT RUN PUMP WITHOUT LIQUID.
•Starving pump of adequate liquid. •Increase hose one size larger than inlet port size. Pressurize and
install C.A.T.
•Eroded manifold. •Replace manifold. Check liquid compatibility.
WARRANTY:
We guarantee this instrument against faulty workmanship and mate- Pressure Switches - Adjustable
rials for a period of one year from date of delivery. The Company will
undertake to repair, free of charge, ex-works any instrument found to Instruction Bulletin No. 174180
be defective within the specified period; providing the instrument has
been used within the specifications, in accordance with these in-
structions, and has not been misused in any way.
Detailed notice of such defects and satisfactory proof thereof must INSTALLATION
be given to the Company immediately after the discovery. The goods To install the switches, use a suitable wrench on the port and plumb into place
are to be returned free of charge to the Company, packed and ac- with the proper sealant. For electrical wiring, refer to wiring codes on page 3
companied by a detailed failure report.
and to the specification sheet for the switch ratings. All switches are main-
RETURN TO FACTORY: tenance-free.
To comply with health and safety requirements, the instrument must LOCATING AND ACCESSING THE ADJUSTER
be clean and safe to handle and accompanied by a formal statement
to that effect; duly signed by an authorized officer of the Company. PMLA, PMHA, PMVA, PDAM, PNAP, PIAP, PDDA, PS-J, PS-JL:
Any instrument returned without certification will be quarantined and The slotted adjustment screw is located on top
no action will occur until cleared. It may ultimately be returned to of the unit.
you, subject to a transportation charge.
PJDA, PS-D: The 5/64” Allen head screw is located inside
Gems Sensors Ltd. Gems Sensors Inc. the low pressure port.
Lennox Road 1 Cowles Road
Basingstoke Plainville,CT 06062-1198
Hampshire RG22 4A W U.S.A. CFIS, PS-K: Remove the front cover to reveal a hex adjuster
United Kingdom Tel: (1) 860-747-3000 nut, locking nut and the electrical switch
Tel: (44) 1256-320244 Fax: (1) 860-747-4244 deadband thumbwheel.
Fax: (44) 1256-810929
Gems Sensors Gems Sensors Sr.I. PDCA, PDN, PHDA, PDCM, PFCM, PDMM, PS-FA:
ZI des Mardelles Via Oglio NR 1 Remove the plastic cover to reveal a 1/8” Allen
94-106, rue Blaise Pascal 20139 Milano head screw.
B.P.71 Italy
93602 Aulnay sous Bois, Tel: (39)0256816100
Cedex, F Fax: (39)0256816102 All Other Models with HC or HN Option:
France Remove the screw in the center of the DIN
Tel: (33) (0) 1 48 19 99 70 adaptor. Remove the DIN adapter.
Fax: (33) (0) 1 48 199979 Gems Sensors Inc.
246 MacPherson Road
Gems Sensors GrnbH #08-01, Betirne Bldg. All Other Models without HC or HN Option:
Vogelsbergstrasse 47 Singapore 348578 Remove the 1/8” Allen head set screw at the
D-63674 Altenstadt, Tel: (00) 65745-9265 top of the unit which serves as a cover for the
Germany Fax: (00)65746-1791 actual 1/8” Allen head adjustment screw.
Tel: (49) 6047-9611-0
Fax: (49)6047-9611-10
Document No. 174180, Rev. E

Date: 6/03
4 1
ADJUSTING THE SET POINT REASSEMBLY (IF APPLICABLE)
All adjustments except for the PJDA and PS-D are performed while applying a CFIS, PS-K: Install the front cover by tightening the four
known pressure (or vacuum) and monitoring the electrical contacts. The PJDA slotted screws.
and PS-D must be removed from the system for adjustment and reinstalled to
verify the setpoint. PDCA, PDN, PHDA, PDCM, PFCM, PDMM, PS-FA:
Snap the plastic cover onto the electrical
PMLA, PMHA, PS-J, PS-JL housing.
Using a flat bladed screwdriver, turn the screw clockwise to increase the setpoint
and counterclockwise to decrease the setpoint. All Other Models with HC or HN Option:
Install the DIN adapter. Install and tighten the
PMVA screw.
Using a flat bladed screwdriver, turn the screw clockwise to decrease the
vacuum setpoint and counterclockwise to increase the vacuum setpoint. All Other Models without HC or HN Option:
Install the 1/8” Allen adjustment screw cap at
PJDA, PS-D: the top of the unit.
Using a 5/64” Allen key, turn the screw clockwise to increase the differential
setpoint and counterclockwise to decrease the differential setpoint.
How To Wire a DIN
CFIS, PS-K
Pressure Adjustment: Using a 3/4” open-ended wrench, loosen the locknut.
Wiring Code
Using a 5/8” open-ended wrench, turn the adjuster clockwise to increase the
setpoint and counterclockwise to decrease the setpoint. Once the desired
setting is obtained tighten the locknut with the 3/4” open-ended wrench while Lead Color DIN Pin # Electrical Terminal
holding the adjuster with the 5/8” open-ended wrench. Black #1 Common
Green #2 Normally closed
Deadband Adjustment: Turn the thumbwheel clockwise to increase the
Red #3 Normally open
deadband and counterclockwise to decrease the deadband. Deadband is the
difference in pressure between the increasing pressure setpoint and decreasing
pressure setpoint.
VDMA
Using a 1/8” Allen key, turn the screw clockwise to decrease the vacuum
setpoint and counterclockwise to increase the vacuum setpoint.
PRESSURE EQUIPMENT DIRECTIVE
All Other Models
Using a 1/8” Allen key, turn the screw clockwise to increase the setpoint and The pressure switch is designed and manfactured in accordance
counterclockwise to decrease the setpoint. with Sound Engineering Practice as defined by the Pressure
Equipment Directive 97/23/EC. This pressure switch must not be
VERIFICATION OF SETPOINT used as a “safety accessory” as defined by the Pressure
Equipment, Article 1, Paragraph 2.1.3.
Verify the new setpoint by slowly increasing and decreasing the pressure (or
vacuum) while monitoring the electrical contacts. Repeat the adjustment
The CE Mark on the unit does not relate to the Pressure Equipment
procedure if necessary to obtain the desired setpoint.
Directive.
2 3
Membrane Element SWC1-4040
3
Performance: Permeate Flow: 1,200 gpd (4.5 m /d)
Salt Rejection:
Minimum 99.5 %
Type Configuration: Spiral Wound

Membrane Polymer: Composite Polyamide
2
Nominal Membrane Area: 70 ft
Application Data Maximum Applied Pressure: 1000 psig (6.9 MPa)

Maximum Chlorine Concentration: < 0.1 PPM
Maximum Operating Temperature: 113 °F (45 °C)
Feedwater pH Range: 3.0 - 10.0
Maximum Feedwater Turbidity: 1.0 NTU
Maximum Feedwater SDI (15 mins): 5.0
3
Maximum Feed Flow: 16 GPM (3.6 m /h)
Minimum Recovery for any Element: 10 %
Maximum Pressure Drop for Each Element: 10 psi
For operation outside these conditions, please contact Hydranautics.
Test Conditions
The stated performance is initial (data taken after 30 minutes of operation), based on the following conditions:
32,000 ppm NaCl

800 psi (5.5 MPa) Applied Pressure
77 °F (25 °C) Operating Temperature
10% Permeate Recovery
6.5 - 7.0 pH Range
A
C
B PERMEATE
FEED
CONCENTRATE
A, inches (mm) B, inches (mm) C, inches (mm) Weight, lbs. (kg)

40.00 (1016) 3.95 (100.3) 0.75 (19.1) 8 (3.6)
Core tube extension = 1.05" (26.7 mm)
Notice: Permeate flow for individual elements may vary + or - 15 percent. All membrane elements are supplied with a brine seal, interconnector, and o-rings. Elements
are vacuum-sealed in a polyethylene bag containing less than 1.0% sodium meta-bisulfite solution, and then packaged in a cardboard box.
Hydranautics believes the information and data contained herein to be accurate and useful. The information and data are offered in good faith, but without guarantee, as
conditions and methods of use of our products are beyond our control. Hydranautics assumes no liability for results obtained or damages incurred through the application of the
presented information and data. It is the user's responsibility to determine the appropriateness of Hydranautics' products for the user's specific end uses. 03/16/01
Membrane Element SWC2-4040
3
Performance: Permeate Flow: 1,500 gpd (5.7 m /d)
Salt Rejection:
Minimum 99.0 %
Type Configuration: Spiral Wound

Membrane Polymer: Composite Polyamide
2
Nominal Membrane Area: 70 ft
Application Data Maximum Applied Pressure: 1000 psig (6.9 MPa)

Maximum Chlorine Concentration: < 0.1 PPM
Maximum Operating Temperature: 113 °F (45 °C)
Feedwater pH Range: 3.0 - 10.0
Maximum Feedwater Turbidity: 1.0 NTU
Maximum Feedwater SDI (15 mins): 5.0
3
Maximum Feed Flow: 16 GPM (3.6 m /h)
Minimum Recovery for any Element: 10 %
Maximum Pressure Drop for Each Element: 10 psi
For operation outside these conditions, please contact Hydranautics.
Test Conditions
The stated performance is initial (data taken after 30 minutes of operation), based on the following conditions:
32,000 ppm NaCl

800 psi (5.5 MPa) Applied Pressure
77 °F (25 °C) Operating Temperature
10% Permeate Recovery
6.5 - 7.0 pH Range
A
C
B PERMEATE
FEED
CONCENTRATE
A, inches (mm) B, inches (mm) C, inches (mm) Weight, lbs. (kg)

40.00 (1016) 3.95 (100.3) 0.75 (19.1) 8 (3.6)
Core tube extension = 1.05" (26.7 mm)
Notice: Permeate flow for individual elements may vary + 27 or - 15 percent. All membrane elements are supplied with a brine seal, interconnector, and o-rings.
Elements are vacuum sealed in a polyethylene bag containing less than 1.0% sodium meta-bisulfite solution, and then packaged in a cardboard box.
Hydranautics believes the information and data contained herein to be accurate and useful. The information and data are offered in good faith, but without guarantee, as
conditions and methods of use of our products are beyond our control. Hydranautics assumes no liability for results obtained or damages incurred through the application of the
presented information and data. It is the user's responsibility to determine the appropriateness of Hydranautics' products for the user's specific end uses. 03/16/01
Technical data HV
Connection size
Weight
BSP/NPT 1/2" or 20 mm
120 g
HV
Max. pressure 10 bar / 20 °C (* 10 bar / 80 °C)
Max. temperature 50 °C / 2 bar (* 120 °C / 2 bar)
Flow tube Grilamid (PA-12) (* PES)
Connectors PVC (* AISI 316, PVDF)
Float AISI 329 or AISI 329/PTFE
(depending on range)
Seals Nitrile (* Viton®, EPDM)
*) Special construction on request Accuracy ± 5 % F.S. (H2O, +20 °C)
H V- -
Special feature
V PES flowtube
W PES flowtube, Viton® -seals
X Viton® -seals
ø 27 ø 27
Scale ø 20
BSP 1/2
C H2O (m3/h) at +20˚C
15
S Air (Nm3/min) at +20˚C / 101,3 kPa
ø 43
Flow range
H2O Air
6H 0,02 - 0,11 m3/h 0,015 - 0,07 Nm3/min

150
180
3H 0,04 - 0,2 m3/h 0,03 - 0,13 Nm3/min
210
3K 0,075 - 0,3 m3/h 0,04 - 0,18 Nm3/min
3L 0,15 - 0,5 m3/h 0,06 - 0,28 Nm3/min
3M 0,15 - 0,6 m3/h 0,075 - 0,3 Nm3/min
4D 0,2 - 1,0 m3/h 0,1 - 0,5 Nm3/min
4E 0,2 - 1,3 m3/h 0,1 - 0,65 Nm3/min
4F 0,3 - 1,8 m3/h 0,2 - 0,9 Nm3/min ø 20

ø 27 BSP1/2
Connections ø 27
Without PVC connectors
H Socket type connections, Ø20mm HHV HRV

N NPT1/2" connections
R BSP1/2" connections
MANUFACTURER
REPRESENTATIVE
KYTOLA OY • Olli Kytolan tie 1

LOCAL
P.O. Box 5 • FI-40951 MUURAME • FINLAND

Phone +358 14 339 0600 • Fax +358 14 631 419
E-mail sales@kytola.com • www.kytola.com
Type 202540
µP transmitter / controller
for
electrolytic conductivity
B 20.2540.0.1
Operating Instructions
01.03/00401714
Contents
1 General ____________________________________________ 4
1.1 Preface _____________________________________________________ 4
2 Typographical conventions __________________________ 5

2.1 Warning signs _______________________________________________ 5
2.2 Note signs __________________________________________________ 5
3 Application _________________________________________ 6
3.1 Type 202540 ________________________________________________ 6
3.2 Operating Instructions B 20.2540.0.1 __________________________ 6
4 Instrument identification _____________________________ 7

4.1 Type designation ____________________________________________ 8
5 Instrument description ______________________________ 9

5.1 Technical data ______________________________________________ 9
5.2 Dimensions ________________________________________________ 13
5.3 Optional accessories _______________________________________ 13
6 Assembly __________________________________________ 15
6.1 Location ___________________________________________________ 15
6.2 Fitting _____________________________________________________ 15
6.3 Removing the controller module _____________________________ 16
6.4 Cleaning the front panel ____________________________________ 16
7 Installation ________________________________________ 17
7.1 Electrical connection _______________________________________ 17
7.2 Connection diagram ________________________________________ 18
8 Commissioning ____________________________________ 21
8.1 Self-test ___________________________________________________ 21
9 Operation _________________________________________ 22
9.1 Basics _____________________________________________________ 22
9.2 Principle of operation _______________________________________ 23
9.3 Operation within levels _____________________________________ 24
9.4 General ____________________________________________________ 25
9.5 Programming ______________________________________________ 26
Contents
10 Controller _________________________________________ 27
10.1 Configuration ______________________________________________ 27
10.2 Controller optimization _____________________________________ 29
11 Conductivity measurement _________________________ 30

11.1 Select cell constant and measurement range _________________ 30
11.2 Measurement with manual temperature compensation _______ 31
11.3 Manual temperature entry __________________________________ 31
11.4 Measurement with automatic temperature compensation _____ 32
11.5 Compensation of falsified measurements ____________________ 32
12 Calibration ________________________________________ 34
12.1 Preparation ________________________________________________ 34
12.2 Relative cell constant _______________________________________ 36
12.3 Determination of the temperature coefficient _________________ 38
13 Operating level ____________________________________ 41

13.1 Settings ___________________________________________________ 41
14 Parameter level ____________________________________ 42

14.1 Settings ___________________________________________________ 42
15 Configuration level _________________________________ 44

15.1 General ____________________________________________________ 44
15.2 Analog inputs - C111 _______________________________________ 44
15.3 Logic inputs... - C112 _______________________________________ 45
15.4 Serial interface... - C113 ____________________________________ 46
15.5 Controller options - C211 ___________________________________ 47
15.6 Controller outputs - C212 ___________________________________ 48
15.7 Other outputs I - C213 ______________________________________ 49
15.8 Other outputs II - C214 _____________________________________ 50
15.9 Response for HOLD / Overrange - C215 ______________________ 52
15.10 Process value output for conductivity - C311 _________________ 52
15.11 SoL - SoH - SPL - SPH - rAnG - CELL - ALPH - LOFF - OFFS __ 53
16 Manual operation __________________________________ 56

16.1 Manual operation for outputs K1, K2 or K3 ___________________ 56
16.2 Simulated process value output _____________________________ 57
Contents
17 Hold ______________________________________________ 58
17.1 Hold controller _____________________________________________ 58
18 Version ____________________________________________ 59
18.1 Display software version and temperature unit _______________ 59
19 Logic inputs _______________________________________ 60

19.1 Functions __________________________________________________ 60
20 Interface __________________________________________ 61
20.1 MODbus /Jbus _____________________________________________ 61
20.2 Profibus-DP ________________________________________________ 62
21 Glossary ___________________________________________ 63
22 Warnings – Errors __________________________________ 70

22.1 Messages _________________________________________________ 70
23 Appendix __________________________________________ 72
23.1 Programming the controller _________________________________ 72
1 General
1.1 Preface
Please read these Operating Instructions before commissioning the
instrument. Keep the manual in a place that is accessible to all users at all
times.
Please assist us to improve these operating instructions, where necessary.
Your suggestions will be welcome.

Phone +49 661 6003-0
Fax +49 661 6003-607
All necessary settings are described in this manual. However, if any

difficulties should still arise during start-up, please do not carry out
any unauthorized manipulations on the instrument. You could
endanger your rights under the instrument warranty!
Please contact the nearest subsidiary or the main factory in such a
case.
When returning modules, assemblies or components, the rules of

EN 100 015 “Protection of electrostatically sensitive components”
must be observed. Use only the appropriate ESD packaging for
transport.
Please note that we cannot accept any liability for damage caused
by ESD (electrostatic discharge).
4
2 Typographical conventions
2.1 Warning signs
Danger
This symbol is used when there may be danger to personnel if the
instructions are ignored or not followed correctly!
Caution
This symbol is used when there may be damage to equipment or data if the
instructions are ignored or not followed correctly!
2.2 Note signs

Note
This symbol is used when your special attention is drawn to a remark.
see abcd Reference

The cursive (italic) text refers to further information in other chapters or
sections.
abc1 Footnote
Footnotes are remarks that refer to specific points in the text. Footnotes
consist of two parts:
A marker in the text, and the footnote text.
The markers in the text are arranged as continuous superscript numbers.
✱ Action
This symbol indicates that an action to be performed is described.
The individual steps are marked by this asterisk.
Example:
✱ Remove crosspoint screws.
✱ Press the key.
Key combinations
EXIT + PGM
If key symbols are shown connected by a plus sign, this means: first press
and hold down the key, and then press the next key.
EXIT
5
3 Application
3.1 Type 202540
Description The compact microprocessor transmitter/controller, with 96mm x 48mm
bezel and plug-in controller module, measures and controls the conductivity of
aqueous solutions.
Inputs The transmitter has two analog and two logic inputs. The first analog input is
suitable for connecting conductivity electrodes with cell constants of 0.01; 0.1;
1.0; 3.0 and 10.0 [1/cm]. The second analog input can be used to connect
Pt1000 or Pt1000 resistance thermometers.
Display The instrument features two 4-digit 7-segment displays for indicating the
conductivity (red) and the temperature (green). During programming, the
displays provide comments on the inputs.
Outputs The instrument has a maximum of 5 outputs

Out- Stan- Description / configurable Output
put dard
K1 yes Controller / controller off, limit controller, pulse Relay, make
width controller, pulse frequency controller,
modulating controller with P, PI, PD or PID
action
K2 yes Controller / controller off, limit controller, pulse Relay, make
width controller, pulse frequency controller,
modulating controller with P, PI, PD or PID
action
K3 Option Analog output / proportional controller -- / analog
K3 Option Limit comparator Relay,
changeover
contact
K4 yes Logic output 0/5 V
0/12V
K5 Option Analog output / proportional controller -- / analog
K5 Option Limit comparator Relay,
changeover
contact
K5 Option Serial interface / Profibus-DP or MODbus/ RS422 / RS485
Jbus
3.2 Operating Instructions B 20.2540.0.1

These operating instructions provide full instructions on the installation,
electrical connection, commissioning, operation, parameter setting and
configuration of the microprocessor transmitter/controller for electrolytic
conductivity, Type 202540.0.1.
6
4 Instrument identification
Check for You should have received at least the following:

completeness - transmitter/controller for conductivity, Type 202540
- 2 mounting brackets
- seal (housing/panel)
- Operating Instructions B 20.2540.0.1
Nameplate The nameplate is glued to the housing.

(1)
Made in Germany
Typ 202540/00-888,000-23-00/000
0...0,5S/cm...0...200mS/cm K=0,01...10,01/cm
Pt100 / Pt1000: -50,0...250,0C
K1 / K2: Relais 3A; AC 250V; ohm. Last (2)
K4: Binärausgang DC 0 / 5V
AC 48 - 63 Hz,110...240 V +10/-15%, 8 VA
VARTN 20/00000000 FÐNr 000000000009848 0000
Explanation of the type designation (1)

➩ Chapter 4.1 “Type designation”, page 8.
The type designation (1) contains all the factory settings, such as the controller
function, the measurement inputs and extra codes. The extra codes are listed
in sequence and separated by commas.
The supply voltage must correspond to the voltage given on the

nameplate (2).
7
4 Instrument identification
4.1 Type designation
(1) Basic type
202540 Microprocessor transmitter/controller for electrolytic
conductivity
(2) Basic type extensions
00 controller off1
10 limit controller1
21 pulse width controller1
31 pulse frequency controller1
(3) Output I
000 no output
310 relay, changeover contact
888 process value output, freely configurable
(4) Output II
000 no output
310 relay, changeover contact2
888 process value output, freely configurable2
(5) Supply voltage
22 20 — 53 V AC/DC ±0%, 48 — 63/0 Hz
23 110 — 240 V AC +10%/-15%, 48 — 63 Hz
(6) Interface2
00 no interface
54 serial interface RS422/RS485, MODbus/Jbus protocol2
64 Profibus-DP2
(7) Extra codes
000 none
015 logic output 0/12 V DC,
instead of standard 0/5 V DC
Order example
(1) (2) (3) (4)2 (5) (6)2 (7)
202540/ .. - ... , ... - .. - .. / ...
1 Generally, the following configurations can be freely selected by the

user on all instruments of Type 202540:
controller off / limit controller / pulse width controller with P, PI, PD, PID
control action / pulse frequency controller with P, PI, PD, PID control
action / modulating controller.
The variations listed in the type designation are simply factory default
settings!
2 If output II (4) = “310” or “888”, then the interface option (6) “54” or “64”
is not possible (or the other way round).
8
5 Instrument description
5.1 Technical data
Analog Electrode cell for conductivity measurement, with cell constant K of 0.01; 0.1;
input 1 1.0; 3.0 or 10.0 1/cm.
Deviation from characteristic: ≤ 0.5% of the measurement range.
Analog Pt100 or Pt1000 resistance thermometer, in 2-wire or 3-wire circuit, -50 to

input 2 +250°C
Measurement display in °C or °F (option)
Deviation from characteristic: ≤ 0.25% of the measurement range.
Ambient temperature error: ≤ 0.1% per 10 °C
Lead The lead resistance can be compensated in software by a correction of the

compensation, process value. This is not required if the resistance thermometer is connected
analog input 2 in a 3-wire circuit.
Alternatively, when a resistance thermometer is connected in a 2-wire circuit,
lead compensation can be provided by using an external compensation
resistor.
Logic The following functions can be assigned as selected:

input 1
Key inhibit, setpoint switching, alarm stop, alarm time reset, hold, reverse
hold, freeze measurement, range expansion (x10), no function for logic input 1.
Logic As for logic input 1.

input 2
Measurement
and control Cell Display with configured
Measurement Range
range constants measurement (C111)
range (rAng)
K µS mS
0.01 0 — 0.500 µS/cm 0.500 – –1 1
0.01 0 — 2.000 µS/cm 2.000 – –1 2
0.01 0 — 10.00 µS/cm 10.00 – –1 3
0.1 0 — 5.00 µS/cm 5.000 – –1 4
0.1 0 — 20.00 µS/cm 20.00 – –1 5
0.1 0 — 100.0 µS/cm 100.0 – –1 6
0.1 0 — 1.00 mS/cm 1000 1.00 7
0.1 0 — 5.00 mS/cm 5000 5.00 8
1.0 0 — 50.00 µS/cm 50.00 – –1 9
1.0 0 — 100.0 µS/cm 100.0 – –1 10
1.0 0 — 1.00 mS/cm 1000 1.00 11
1.0 0 — 5.00 mS/cm 5000 5.00 12
1.0 0 — 20.00 mS/cm – –1 20.00 13
1.0 0 — 100.0 mS/cm –– 1 100.0 14
3.0 0 — 1.00 mS/cm 1000 1.00 15
3.0 0 — 5.00 mS/cm 5000 5.00 16
3.0 0 — 30.00 mS/cm – –1 30.00 17
9
10.0 0 — 30.00 mS/cm – –1 30.00 18
10.0 0 — 200.0 mS/cm – –1 200.0 19
1 These settings are not permissible – they would cause an incorrect display
Reference 25°C
temperature
Temperature -50 to +250°C (option °F)

display
Deviation from ≤ 0.25% of the measurement range

characteristic
Outputs 5 outputs are available:
Output 1 / 2 Make contact (n.o., can also be configured as n.c. break contact)
relay Contact rating: 3A, 250V AC, with resistive load
(standard) Contact life: > 5x105 operations at rated load
Status indication: relay K1 => LED K1; relay K2 => LED K2
Output 4 0/5V (standard) Rload ≥ 250Ω

logic output 0/12V (option) Rload ≥ 650Ω
(standard) Status indication: LED K4
Output 3 or Can be used as analog process value output or as proportional controller.

output 5 0(2) — 10V Rload ≥ 500Ω
process value 0(4) — 20mA Rload ≤ 500Ω
output electrically isolated from the inputs:
(option) ∆u ≤ 30V AC
∆u ≤ 50V DC
Output 3 or (changeover contact)

output 5 Contact rating: 3A, 250V AC, with resistive load
relay Contact life: > 5x105 operations at rated load
(option) Status indication: K3 => LED K3; K5 => no visible indication
Output 5, electrically isolated;

interface baud rate: 4800 / 9600bps;
RS422 / RS485 Protocol: MODbus/Jbus or Profibus-DP
(option)
10
5.1.1 General controller data
A/D converter resolution > 15 bit
Controller type Output 1 and output 2:

limit controller and/or pulse width or pulse frequency controller, freely
configurable and selectable.
K3 / K5:
Proportional controller
Control action P, PI, PID or PD, freely configurable and selectable
Sampling time 210msec
Meas. circuit Input 1: out-of-range, sensor monitoring

monitoring Input 2: out-of-range, probe short-circuit, probe break
The outputs move to a defined (configurable) status.
Data backup EEPROM
Supply 110 — 240 V AC +10%/-15%, 48 — 63 Hz or

voltage 20 — 53 V AC/DC ±0%, 48 — 63/0 Hz
Power approx. 8VA

consumption
Electrical via gold-plated faston connectors to DIN 46 244/A; 4.8mm x 0.8mm

connection
Permissible 0 to +50°C
ambient
temperature
Permissible -10 to +55°C

ambient temp.
limits
Permissible -40 to +70°C

storage temp.
Climatic rel. humidity ≤ 75%, no condensation

conditions
Enclosure to EN 60 529, front IP65 / back IP20

protection
Electrical safety to EN 61 010, clearance and creepage distances for

- overvoltage category II
- pollution degree 2
11
Electro- to EN 61 326
magnetic
compatibility
(EMC)
Housing panel-mounting housing in conductive plastic to DIN 43 700, base material

ABS, with plug-in controller module
Operating unrestricted
position
Weight approx. 320g
12
5.2 Dimensions
Type 202540/...
5.3 Optional accessories

Additional housing, no door at front, enclosure IP65, Type 2FGE-125-2/125
Restricted external temperature range!

The ambient temperature for the surface-mounting housing must not exceed 45°C.
13
Additional housing, door at front, enclosure IP65, Type 2FGE-150-2/185
Restricted external temperature range!

The ambient temperature for the surface-mounting housing must not exceed 45°C.
14
6 Assembly
6.1 Location
Conditions The location should be as free from vibration as possible. Electromagnetic
fields, e. g. from motors, transformers etc. should be avoided. The ambient
temperature at the location can be from 0 to 50 °C, with a relative humidity of
not more than 75 %.
Panel cut-out
for close
mounting
6.2 Fitting
(1)
✱ Fit the seal (1) that is supplied onto the body of the instrument.
✱ Insert the controller from the front into the panel cut-out.
✱ From behind the panel, slide the mounting brackets into the guides on the
sides of the housing. The flat faces of the mounting brackets must lie
against the housing.
✱ Push the mounting brackets up to the back of the panel, and tighten them
evenly with a screwdriver.
15
6 Assembly
6.3 Removing the controller module
The controller module can be removed from its housing for servicing.
✱ Press together the ribbed surfaces at right and left
and pull the controller module out of the housing.
6.4 Cleaning the front panel

The front panel can be cleaned with normal commercial washing, rinsing and
cleaning agents.
It has a limited resistance to organic solvents (e.g. methylated spirits, white
spirit, P1, xylol etc.).
Do not use high-pressure cleaning equipment!
16
7 Installation
7.1 Electrical connection
The electrical connection must only be carried out
by properly qualified personnel
❏ The choice of cable, the installation and the electrical connection must conform
to the requirements of VDE 0100 “Regulations on the Installation of Power
Circuits with Nominal Voltages below 1000 V” or the appropriate local
regulations.
❏ The electrical connection must only be carried out by properly qualified
personnel.
❏ The instrument must be completely disconnected from the electrical supply if
contact with live parts is possible.
❏ A current-limiting resistor interrupts the supply circuit in the event of a short-
circuit. Any additional external fusing of the supply should not be rated below
1A (slow).
❏ The load must be fused for the maximum relay current, in order to prevent the
contacts of the output relay becoming welded in the event of a short-circuit.
❏ The level of electromagnetic compatibility conforms to EN 61 326.
❏ Run input, output and supply cables separately and not parallel to one another.
❏ Sensor and interface cables should be shielded cables with twisted
conductors. Do not run them close to current-carrying components or cables.
Ground shielding at one end, to the TE terminal on the instrument.
❏ The TE terminal on the instrument must be earthed. This lead must have at least
the same conductor cross-section as used for the supply cables. Grounding
and earthing leads must be wired in a star configuration to a common earth
point that is connected to the protective earth of the electrical supply. Do not
loop earth or ground connections, i.e. do not run them from one instrument to
another.
❏ Do not connect any additional loads to the supply terminals of the instrument.
❏ The instrument is not suitable for use in areas with an explosion hazard
(Ex areas).
❏ In addition to faulty installation, incorrect settings on the controller (set-point,
data of the parameter and configuration levels, internal alterations) can also
interfere with the correct operation of dependent processes, or even cause
damage. The setpoint that is reached should therefore be monitored for
stability. Safety devices should always be provided that are independent of the
controller (such as overpressure valves or temperature monitors/limiters) and
only capable of adjustment by specialist personnel. Please observe the relevant
safety regulations for such matters.
❏ The measurement inputs of the controller must not exceed a maximum
potential of 30 V AC or 50 V DC against TE.
❏ Sensor leads should only be implemented as uninterrupted cables (not routed
through terminal strips etc.).
❏ If frequent relay switching is expected (> 5/min), the system must be fitted with
appropriate suppressor devices against switching interference.
17
7 Installation
After the supply voltage has been applied, the instrument will
operate according to the factory-set parameters (unless the
instrument was ordered with “controller off”).
It is therefore advisable to program the instrument as required
before connecting the actuators.
➩ Chapter 9 “Operation”, page 22 ff.
7.2 Connection diagram

N
L1 (L-)
17 19 20 22
18 21 23 (L+) TE
16 1
15 2
14 3
13 11 9 7 5
12 10 8 6 4
Outputs K Terminal assignments Symbol

Relay 1 1 23 common 23 22
(K1) 22 make (n.o.)
Status indication P S
LED K1
Relay 2 2 21 common 21 20
(K2) 20 make (n.o.)
Status indication P S
LED K2
Relay 3 3 16 break (n.c.) 16 15 14

(K3) 15 common
Status indication
LED K3 14 make (n.o.) Ö
P
S
or
15 – 14 15
process value output
14 +
+ -
18
7 Installation
Outputs K Terminal assignments Symbol
Logic output 1 4 19 – 17 19
(K4)
17 +
Status indication
LED K4 + -
Relay 4 5 3 break (n.c.) 3 2 1

(K5) 2 common
no status indication P
1 make (n.o.) O S
or
process value output 2 – 1 2
1 +
+ -
Inputs Terminal assignments Symbol

Conductivity cell 6 outer electrode 6 7
7 inner electrode
Resistance 9 9 11 10
thermometer
10
in 3-wire circuit ϑ
11
Resistance 10
thermometer
9
in 2-wire curcuit
11
Inputs/outputs Terminal assignments Symbol

Serial interface RS422 RxD 5 RxD + Receive Data 5 4 2 1 3
(option)
4 RxD –
TxD 2 TxD + Transmit Data
1 TxD –
GND 3 GND
Serial interface RS485 + 2 TxD/RxD + 2 1 3
(option)
- 1 TxD/RxD –
GND 3 GND
19
7 Installation
Inputs/outputs Terminal assignments Symbol
Serial interface VP 4 supply voltage plus, (P5V) 2 1 3 4
Profibus-DP RxD/TxD-P 1 receive/transmit data positive,
(option) B conductor
RxD/TxD-N 2 receive/transmit data
negative,
A conductor
DGND 3 ground for data transmission
Logic input 1 13 13 19
19
Logic input 2 12 12 19
19
Supply voltage AC/ AC: DC: L1 N

see nameplate L+ L- TE
DC L1 phase L+
N neutral L–
TE technical
earth
Connection for
conductivity cell JUMO conductivity cell
Type 202540
Plug-in head Fixed cable
Outer electrode white 6
Inner electrode 2 brown 7

Temperature 1 yellow 9
compensation 3 green 11
Link 10
+
9
20
8 Commissioning
8.1 Self-test
After the supply voltage has been applied, the instrument will
operate according to the factory-set parameters.
(unless the instrument was ordered with “controller off”)
It is therefore advisable to program the instrument as required
before connecting the actuators.
➩ Chapter 9 “Operation”, page 22.
After the supply the instrument performs a self-test, during which all displays will light up.
voltage has
been applied
OK If the self-test was OK, then the instrument switches over to the measurement
mode in about 10 seconds.
The measured conductivity is displayed, as is the measured temperature (if the
temperature sensor has been connected and configured); the controller
operates according to the factory-set parameters!
In measurement mode, manual operation, hold, and calibration can be
activated, as well as the display of the software revision level and the unit (°C /
°F) for the temperature input.
Error If an error code (e.g. F010) or “Err” is displayed,

➩ Chapter 22 “Warnings – Errors”, page 70 ff.
21
9 Operation
9.1 Basics
Displays and
keys
(1) (2)
(8)
µS mS
cm
K1 K2 K3 K4
cm (3)
(4)
°C
(7) (5)
PGM EXIT
(6)
(1) Display: Instrument configuration changed (6) PGM key for selection of parameters and
from “µS/cm” to “mS/cm” confirmation or entries, or
for manual operation of relay K3.
(2) Status indicators (yellow)1 (7) 4-digit temperature display
for outputs 1 to 4 (LED, green, 8mm high)
LED “K1” => relay K1
LED “K2” => relay K2
LED “K3” => optional relay K3
LED “K4” => logic output K4
(3) Increment key for altering parameters (8) 4-digit process value indication
or manual operation of relay K2 (LED, red, 13mm high)
(4) Decrement key for altering parameters (4) “CAL”: initiate calibration (cell constant or
or manual operation of relay K1 + temperature coefficient)
(6)
(5) EXIT key to leave (3) Initiate manual operation or hold
the levels +
(5)
1 LED K3 has no function if the instrument was ordered with process

value output (output “888”).
22
9 Operation
9.2 Principle of operation
Operating
modes and Measurement mode The process value and temperature are displayed.
states (normal operation)
Self-test All indicators light up;
(after power-on) the temperature display blinks.
Manual operation The process value display continually switches
between the process value and the text “HAnd”, the
temperature is displayed.
Hold operation The process value display continually switches
between the process value and the text “HoLd”, the
temperature is displayed.
Operation, The temperature display shows the parameters from
parameters, the various levels; the process value display shows
configuration the corresponding values and codes.
Error The temperature display continually switches
between the temperature and the error code
(e.g. F010),
➩ Chapter 22 “Warnings – Errors”, page 70 ff.
Levels The instrument functions are arranged in four levels (see diagram on next
page):
- Measurement mode
- Operating level
- Parameter level
- Configuration level
Measurement The measurements are displayed at this level. Manual operation, hold and
mode1 calibration can be activated.
(normal
operation)
Operating Setpoints, alarm tolerance, alarm delay and the limits for the limit comparators
level1 are entered and displayed at this level.
Parameter Controller parameters and other settings are programmed here.

level1 The display of the individual parameters depends on the type of controller
action.
Configuration The basic functions of the instrument are configured at this level.
level1
1 Entries can only be made after the correct code word has been entered.
➩ “Unlocking the levels”, page 26.
23
9 Operation
9.3 Operation within levels
1 A change of level can only take place after stepping through all the
parameters of the level concerned.
24
9 Operation
9.4 General
Level protection
Changes at the operating level, parameter level and configuration
level can only be made after entering a code word,
➩ “Unlocking the levels”, page 26.
The code word has been entered correctly if the decimal point in
the temperature display starts to blink when a parameter has been
selected for modification.
Within a level, you can step on to the next parameter by pressing
the PGM key.
Cancel
You can change back to the measurement mode at any time, by
pressing the key. For parameters that have been altered, but
EXIT
not confirmed by , the changes will not be accepted.

PGM
Time-out
The controller will automatically return to the measurement mode if
no operations are performed for about 50 seconds.
For parameters that have been altered, but not confirmed by ,PGM
the changes will not be accepted.

Exception: Time-out does not apply during calibration!
Parameter The entry and alteration of parameters and setpoints is made continously. The
entry value changes at a faster rate if the key is kept pressed for a longer time.
✱ Increase the value with
✱ Decrease the value with
The value is only altered within the permissible range of values.
✱ Accept the entry with – the upper display “winks” to confirm it (the
PGM
display switches off briefly)

or
✱ cancel with EXIT
Entering a ✱ Select the digit with (digit blinks).

configuration
✱ Alter the code, with
parameter
or code word ✱ Accept the change with – the upper display “winks” to confirm it
PGM
entry (the display switches off briefly)

or
✱ cancel with EXIT
25
9 Operation
9.5 Programming
Procedure The following procedure is recommended to avoid a “Time-out” (50 seconds
without an action) while entering data:
✱ Fold out the last page of these operating instructions
➩ Chapter 23.1 “Programming the controller”, page 72 ff.
✱ Enter all the changed parameter values and codes in the table
✱ Unlock all the affected levels, see below
✱ Program all the settings right through from top to bottom, in one session
✱ Inhibit all the levels, see below
Depending on the type of controller action that is configured, some

parameters cannot be set and will therefore not be displayed.
After changing the controller type (C211), the controller parameters
must be checked.
➩ Chapter 14.1 “Settings”, page 42 ff.
Unlocking the Initial condition: the instrument is in the measurement mode.

levels ✱ Press the PGM briefly and repeatedly, until “CodE” appears in the lower
display.
✱ Use the and keys to set the required code.
Function Code word1
Enable operating level, CAL, and manual activation of 0110
“hold”
Enable operating and parameter levels 0020
Enable all levels 0300
Activate edit protection xxxx2
✱ Press the PGM key (confirmation) – “0000” appears in the display

The code word has been entered correctly if the decimal point in the
temperature display starts to blink when a parameter has been selected for
modification.
1 Code word 0020 includes 0110; code word 0300 includes

0020 and 0110.
2 The relevant levels remain enabled until the edit protection is
reactivated, either by entering a “wrong” code word (other
than 0000) or the supply voltage to the instrument is
switched off and then on again.
26
10 Controller
10.1 Configuration
For an explanation of the terminology used,
➩ Chapter 21 “Glossary”, page 63 ff.
Possible The control functions of outputs 1 and 2 can be freely combined1:

combinations
- Controller off
- Limit controller
- Pulse width controller
- Pulse frequency controller
1 Exception: When using a modulating controller, outputs 1 und 2 must

have the same configuration.
The controller functions are determined by the following parameters:

Configuration level1 Parameter level2 Operating level3
C211 C212 C212 C213 C214
Controller off –– –– –– –– –– ––
Limit MIN / MAX make/break –– –– Switching differential HYS Setpoint SP(r)
controller contact contact Pull-in delay Ond
Drop-out delay Ofd
Pulse width MIN / MAX make/break –– –– Proportional band Pb Setpoint SP(r)
controller contact contact Derivative time dt
Reset time rt
Minimum ON time tr
Pulse period CY
Output level limit Y1 or Y2
Pulse frequency MIN / MAX make/break –– –– Proportional band Pb Setpoint SP(r)
Reset time rt
Minimum pulse length tr
Maximum pulse frequency Fr
Modulating MIN / MAX make/break –– –– Proportional band Pb Setpoint SP(r)
Reset time rt
Minimum ON time tr
Pulse period CY
Actuator time tt
Proportional MIN / MAX make/break Proportional Proportional Proportional band Pb Setpoint SP(r)
controller contact contact controller 1 controller 2 Derivative time dt
Reset time rt
1 ➩ Chapter 15.5 “Controller options - C211”, page 47 or

➩ Chapter 15.6 “Controller outputs - C212”, page 48 or
➩ Chapter 15.7 “Other outputs I - C213”, page 49 or
➩ Chapter 15.8 “Other outputs II - C214”, page 50.
2 ➩ Chapter 14 “Parameter level”, page 42 ff.
3 ➩ Chapter 13 “Operating level”, page 41 ff.
27
10 Controller
Example
break/make
contact
Process value
Range I Range II Range III
w2
w1
Range I Range II Range III

LED contact LED contact LED contact
MIN make contact on 1 off 0 off 0
break contact on 0 off 1 off 1
MAX make contact off 0 off 0 on 1
break contact off 1 off 1 on 0
Configuration Both outputs (K1 / K2) can be configured as pulse width or pulse frequency
notes outputs (or as a combination).
Switching action Setpoints
K1 / K2 w1 / w2
min / min w1 < w2
min / max w1 < w2
max / max w1 > w2
max / min w1 > w2
28
10 Controller
10.2 Controller optimization
Optimum The optimum adaptation of the controller to the control loop can be tested by
adjustment recording the starting phase.
The following diagrams (referred to the PID action) indicate where the
adjustments may be incorrect, and how they can be rectified.
It can be seen that a slower control action with higher stability can be achieved
by increasing either the proportional band Pb or the reset time rt.
A smaller proportional band Pb and/or a shorter reset time rt will result in a
control action with less damping.
optimum
rt, dt too small rt, dt too large
Pb too small Pb too large
29
11 Conductivity measurement
11.1 Select cell constant and measurement range
Initial The configuration level is unlocked,
condition ➩ “Unlocking the levels”, page 26 (code word 0300)
The instrument is in the measurement mode.
➩ “Operating modes and states”, page 23.
Procedure ✱ Press the key twice, for more than 2 seconds, to access the
PGM
configuration level.
The lower display shows “C111”.
Use and keys to set the configuration code for the measurement unit:
Unit 0 X X X
µS/cm 0
mS/cm 1
✱ Press the PGM key (confirmation)

✱ Press PGM briefly and repeatedly, until “rAnG” appears in the lower display
✱ Use the and keys to set the range number for the
desired combination of cell constant and measurement range
Cell Display with configured

Measurement measurement (C111) Range
constants
range (rAng)
K µS mS
0.01 0 — 0.500 µS/cm 0.500 – –1 1
0.01 0 — 2.000 µS/cm 2.000 – –1 2
0.01 0 — 10.00 µS/cm 10.00 – –1 3
0.1 0 — 5.00 µS/cm 5.000 – –1 4
0.1 0 — 20.00 µS/cm 20.00 – –1 5
0.1 0 — 100.0 µS/cm 100.0 – –1 6
0.1 0 — 1.00 mS/cm 1000 1.00 7
0.1 0 — 5.00 mS/cm 5000 5.00 8
1.0 0 — 50.00 µS/cm 50.00 – –1 9
1.0 0 — 100.0 µS/cm 100.0 – –1 10
1.0 0 — 1.00 mS/cm 1000 1.00 11
1.0 0 — 5.00 mS/cm 5000 5.00 12
1.0 0 — 20.00 mS/cm –– 1 20.00 13
1.0 0 — 100.0 mS/cm – –1 100.02 14
3.0 0 — 1.00 mS/cm 1000 1.00 15
3.0 0 — 5.00 mS/cm 5000 5.00 16
3.0 0 — 30.00 mS/cm –– 1 30.00 17
10.0 0 — 30.00 mS/cm – –1 30.00 18
10.0 0 — 200.0 mS/cm –– 1 200.0 19
1 These settings are not permissible – they would cause an incorrect display.
2 The polarization effect could cause a sizeable error in the measurement with this
combination of measurement range and cell constant.
30
✱ Press the PGM key (confirmation).
✱ Press the EXIT key (return to the measurement mode).
For several seconds, both displays will indicate “bUSY” (upper display blinks).
Afterwards, the upper display shows the measured conductivity (if a cell with
an appropriate medium for measurement is connected). If the measurement
unit is configured as mS/cm, the LED for “mS/cm” lights up.
The lower display shows the temperature measured for the medium, or the
manually set compensation temperature.
If an error number appears,
➩ Chapter 22 “Warnings – Errors”, page 70.
11.2 Measurement with manual temperature compensation

Initial condition A conductivity cell is attached to the Type 202540 transmitter,
➩ Chapter 7.1 “Electrical connection”, page 17.
The temperature acquisition is configured as “Manual temperature
compensation”,
➩ Chapter 15.2 “Analog inputs - C111”, page 44.
Procedure The upper display shows the compensated conductivity value of the solution
being measured.
The indicated value for the conductivity depends on the manual temperature
setting, see Temperature setting, below,
and the set (or automatically acquired) temperature coefficient (TC),
➩ Chapter 12.3.1 “Automatic determination of the temperature coefficient,
using manual temperature entry”, page 38.
The lower display shows the manually entered temperature setting.
11.3 Manual temperature entry

Initial condition The temperature acquisition is configured as “Manual temperature
compensation”,
The operating level is unlocked,
➩ “Unlocking the levels”, page 26, (code word 0110)
Procedure ✱ Press PGM briefly and repeatedly, until “InP2” is displayed.

Use the and keys to set the temperature that is shown
31
✱ Press the EXIT key (to return to measurement mode) or cancel the entry
11.4 Measurement with automatic temperature compensation

Initial condition The temperature acquisition has been configured as “automatic temperature
compensation with Pt100 or Pt1000”,
Procedure The temperature measurement for the medium cannot be altered manually.
11.5 Compensation of falsified measurements

11.5.1 Temperature
Deviations of the indicated temperature from the actual medium temperature

can be compensated by the “OFFS” setting,
➩ Chapter 15.11 “SoL - SoH - SPL - SPH - rAnG - CELL - ALPH - LOFF -
OFFS”, page 53.
11.5.2 Conductivity
The lead resistance of the connecting cable to the cell results in an indication
that is too low for liquids with a high conductivity. In general, this error is not
serious, but it can be compensated, if required, by the “LOFF” setting over the
range 0 — 99.99 Ω ,
➩ Chapter 15.11 “SoL - SoH - SPL - SPH - rAnG - CELL - ALPH - LOFF -
OFFS”, page 53.
Example The following example will help you to decide whether the “LOFF” setting
should be used or not.
- Measurement range 0 to 100 mS/cm
- Cell constant K = 1.0 1/cm
- Connecting cable length 10 meters
With a full-scale value of 100 mS/cm, the cell has a resistance of 10 Ω..
1.0 1/cm (cell constant K)

R (cell resistance) = = 10 Ω.
100 mS/cm (full-scale value)
E.g. the conductivity cable has a specific resistance of roughly 0.06 Ω/m. The
lead resistance (out and return) of the cable in this example amounts to about
1.2 Ω.
The transmitter “sees” a total resistance of
cell + cable = 11.2 Ω.
32
Applying the formula
1.0 1/cm (cell constant K)

Conductivity = = 89 mS/cm
11.2 Ω (cell resistance)
results in an apparent conductivity of approx. 89 mS/cm.

This corresponds to an error of about 11% of the full-scale value.
- Please use the specific resistance value of your particular conductivity
cable for your calculation.
33
12 Calibration
12.1 Preparation
General The cell constants of conductivity cells vary somewhat from one example to
another, and also drift with use (because of deposits and wear). This results in
a change of the output signal from the cell. It is therefore necessary that the
user is able to compensate for the deviations of the cell constant from the
nominal value, either by manual input or an automatic calibration of the relative
cell constant Krel,
➩ Chapter 12.2 “Relative cell constant”, page 36.
The time intervals between calibration depend on the conditions in which the
cell is used.
The conductivity of a solution varies with the temperature, so both the
temperature and the temperature coefficient of the solution being measured
must be known. The temperature can either be measured automatically, with a
Pt100 or Pt1000 temperature probe, or set manually by the user. The
temperature coefficient can be determined automatically by the conductivity
transmitter, or entered manually.
➩ Chapter 12.3 “Determination of the temperature coefficient”, page 38.
Cancel Pressing the EXIT key at any time changes back to the measurement mode.
Preparation for Before the first calibration, it is necessary to select the method of temperature
calibration acquisition (automatic or manual) to be used during calibration.
.
If subsequent calibrations are carried out with the same settings,

then it will not be necessary to set the temperature acquisition
again.
Select The instrument is in the measurement mode.

temperature ✱ Unlock the configuration level, if necessary,
acquisition ➩ “Unlocking the levels”, page 26. (code word 0300).
method
✱ Press the key twice, for more than 2 seconds, to access the
PGM
Use the and keys to set the configuration parameter:
Method of temperature acquisition X X X 0
Manual temperature compensation 0
Automatic temperature compensation with Pt100 1

34
12 Calibration
Calibration “Freezing” the process value output means that, during calibration, the output
with/without signal is held at the value that was produced immediately before calibration
“frozen process started. This is to avoid an uncontrolled reaction from any PLC that may be
value output” connected to the output of the transmitter.
While the process value output is frozen, the lower display shows “donE” after
the last calibration step, and the upper display shows the latest measurement.
The process value output remains unchanged!
After the conductivity cell has been installed once more, the key must be
PGM
pressed. The process value output is now coupled to the display again.
The factory setting is: “Calibration without frozen process value
output”.
Select ✱ The instrument is in the measurement mode.

calibration
✱ Unlock the configuration level, if necessary,
procedure
➩ “Unlocking the levels”, page 26 (code word 0300).
✱ Press the key twice, for more than 2 seconds (but less than 4 seconds),
PGM
to access the configuration level.

✱ Press the PGM key repeatedly, until “C211” appears in the lower display.
Use the and keys to set the configuration parameter:
Calibration procedure X X 0 X
Calibration of the cell constant, process value output not frozen 0
Calibration of the cell constant, process value output frozen 1
Determination of the temperature coefficient, process value 2
output not frozen
Determination of the temperature coefficient, process value 3
output frozen

35
12 Calibration
12.2 Relative cell constant
General The relative cell constant Krel can be used to compensate for the deviation of
the real cell constant over the range from 80 to 120% of the nominal cell
constant.
Manual If the deviation of the cell constant from the nominal value is known, then the
entry relative cell constant Krel can be entered manually:
Initial The operating level is unlocked,

condition ➩ “Unlocking the levels”, page 26.
PGM
✱ Press the PGM key repeatedly, until “CELL” appears in the lower display.
✱ Use the and keys to set Krel (in %).
12.2.1 Automatic determination of the relative cell constant with a

calibration solution
If the cell constant is not known, it can be determined and automatically
stored:
You will need - A calibration solution, with a known conductivity at the prevailing
temperature.
- A thermometer, if you want to use manual compensation.
- A Pt100 or Pt1000 temperature probe (not necessary if the conductivity cell
is equipped with a integrated temperature sensor), if you want to use
automatic temperature compensation.
Initial condition A conductivity cell is attached to the Type 202540 transmitter, as well as a
Pt100 or Pt1000 temperature probe (if required),
➩ Chapter 7.1 “Electrical connection”, page 17 ff.
The calibration procedure has been configured to “Calibration of the cell
constant, process value output ...” – frozen or not frozen,
➩ Chapter 15.5 “Controller options - C211”, page 47.
The instrument is in the measurement mode, see
36
12 Calibration
Procedure ✱ Unlock the instrument for calibration,

✱ Immerse the sensitive portions of the cell and the temperature probe or
thermometer in the calibration solution
– wait until the temperature and conductivity measurements have
stabilized.
✱ Press the PGMand keys – “CAL.1” appears in the lower display,
alternating with the measured or manually set temperature.
✱ Use the and keys to set the indicated conductivity to the real
conductivity of the calibration solution at the temperature now prevailing.
✱ Press the key (saves the new cell constant and returns to the
PGM
measurement mode).
12.2.2 Automatic determination of the relative cell constant with a

reference instrument
If the deviation of the cell constant from its nominal value is not known, then it
can be automatically determined.
You will need A conductivity measuring instrument to serve as a reference.

The temperature coefficient of the reference instrument must be set
to “0” ! If this is not possible, then the solution being measured must
be tempered to the reference temperature for the reference
instrument.

The calibration procedure has been configured to “Calibration of the cell
constant, process value output ...” – frozen or not frozen,

✱ Immerse the sensitive portions of both cells in the calibration solution
– wait until the measurements for both instruments have stabilized.
✱ Press the and
PGM keys on the instrument – “CAL.1” appears in the
lower display, alternating with the measured or manually set temperature.
✱ Use the and keys to set the indicated conductivity to match the
value shown on the reference instrument.
✱ Press the key (saves the new cell constant and returns to the
PGM
measurement mode).
37
12 Calibration
Manual If the temperature coefficient of the solution being measured is known, then it
entry of the can be entered manually.
temperature
coefficient
Initial The configuration level is unlocked,

condition ➩ “Unlocking the levels”, page 26, (code word 0300)
The calibration procedure has been configured to “Determination of the
temperature coefficent, process value output ...” – frozen or not frozen,
➩ “Controller options - C211”, page 47.
PGM
✱ Press the PGM key repeatedly, until “ALPH” appears in the lower display.
✱ Use the and keys to set the temperature coefficient (in % per °C).
12.3 Determination of the temperature coefficient

12.3.1 Automatic determination of the temperature coefficient, using
manual temperature entry
The instrument uses non-temperature compensated measurements (TC = 0) at
two different temperatures (the reference temperature of 25°C and a second
temperature, usually that which will be used for later measurements) to
determine the temperature coefficient of the solution being measured.
You will need - A sample of the medium to be measured

- A tempering setup
- A thermometer

The temperature acquisition is configured as “Manual temperature
compensation”,
38
12 Calibration

✱ Immerse the sensitive portions of the cell and the thermometer in the
solution to be measured.
✱ Temper the solution to 25°C.
✱ Press the and
PGM (CAL) keys.
The upper display shows the uncompensated conductivity value for
the measured solution at 25°C, alternating with “CAL1”; the lower display
shows the temperature that was set manually.
✱ Use the and keys to set 25.0 (°C).
✱ Press the key.
PGM

the measured solution at the present temperature, alternating with “CAL2”.
✱ Temper the solution to the future working temperature.
✱ Use the and keys to set the future working temperature (°C).
✱ Press the key.
PGM
The upper display shows the conductivity value (compensated for 25°C) for
the measurement solution at the present temperature. The lower display
shows the temperature that was set before the start of calibration.
12.3.2 Automatic determination of the temperature coefficient, using

automatic temperature entry
The instrument uses non-temperature compensated measurements (TC = 0) at
two different temperatures (the reference temperature of 25°C and a second
temperature, usually that which will be used for later measurements) to
determine the temperature coefficient of the solution being measured.
You will need - A sample of the medium to be measured

- A tempering setup
- A Pt100 or Pt1000 temperature probe (not necessary if the conductivity cell
is equipped with an integrated temperature sensor).
Initial condition A conductivity cell is attached to the Type 202540 transmitter, as well as a
Pt100 or Pt1000 temperature probe (if required),
➩ “Electrical connection”, page 17ff.
The temperature acquisition is configured as “Automatic temperature
compensation”,
39
12 Calibration

✱ Immerse the sensitive portions of the cell and the temperature probe in the
solution to be measured.
✱ Temper the solution to 25°C.
✱ Press the and
PGM (CAL) keys.
the measured solution at 25°C, alternating with “CAL1”; the lower display
shows the temperature measured by the probe.
✱ Press the key.
PGM

the measured solution at the present temperature, alternating with “CAL2”.
The lower display shows the temperature measured by the probe.
✱ Temper the solution to the future working temperature.
✱ When the temperature display has stabilized, press the key.
PGM
The upper display shows the conductivity value (compensated for 25°C) for
the measurement solution at the present temperature. The lower display
shows the temperature measured by the probe.
40
13 Operating level
13.1 Settings
Preconditions How to access the operating level, or leave this level,
➩ Chapter 9.2 “Principle of operation”, page 23ff.
The operating level must be unlocked,
➩ “Unlocking the levels”, page 26, (code word 0110).
It is possible that not all of the following parameters are needed or
displayed, depending on the configuration of the controller
functions.

How to configure controllers,
➩ Chapter 10.1 “Configuration”, page 27 ff.
see
Parameter Factory displayed if ... is Configura-
Designation Value range
(display) setting configured tion
parameter
Setpoint 1 SP(r)1 0.00 K1
0 — 0.5µS C211
Setpoint 2 SP(r)2 1.00 K2
to
Setpoint 3 SP(r)3 -0.00
0 — 200mS1 Setpoint changeover C112
Setpoint 4 SP(r)4 1.00
Code word CodE 4-digit 0000
Limit LK A (K1) SP A corresponds to K1
C214
Limit LK b (K2) SP b “rAnG” K2
Limit LK C (K3) SP C ➩ “rAnG”, page 54 -1.00 K3
C213
Limit LK d (K4) SP d or K4
Limit LK E (K5) SP E -50.0 to 250.0°C K5 C114
Process value
input 2 InP2 (°C) 25 C111
(temperature)
corresponds to
Alarm tolerance AL1 “rAnG” 0 Controller alarm C211 or
➩ “rAnG”, page 54 messages C213
Alarm delay AL2 0 to 9999 sec 300
1 depending on the configured measurement range, ➩ “SoL - SoH - SPL -
SPH - rAnG - CELL - ALPH - LOFF - OFFS”, page 53.
41
14 Parameter level
14.1 Settings
If it is necessary to reconfigure a number of instrument
parameters,
Preconditions How to access the parameter level, or leave this level,

➩ Chapter 9.2 “Principle of operation”, page 23 ff.
The parameter level must be unlocked,
It is possible that not all of the following parameters are needed or
displayed, depending on the configuration of the controller
functions.

Parameter Display Value Factory displayed if ... is configured

range setting
Relay 1, pulse frequency or
Proportional band 1 Pb1
50% of full pulse width in C211
mS or µS
scale Relay 2, pulse frequency or
Proportional band 2 Pb2
pulse width in C211
Derivative time 1 dt1
pulse width in C211
0 sec
Derivative time 2 dt2
0 to pulse width in C211
Reset time 1 9999 sec Relay 1, pulse frequency or
rt1
(Reset time) pulse width in C211
0 sec
Reset time 2 Relay 2, pulse frequency or
rt2
(Reset time) pulse width in C211
Minimum ON time 1 Controller 1, pulse width in C211
(for limit controller or
pulse width controller)
or tr1
minimum pulse width 1
(for pulse frequency
controller) 0.2 to pulse frequency in C211
0.2
Minimum ON time 2 999.9 sec
Relay 2, pulse width in C211
(for pulse width
controller)
or tr2
minimum pulse width 2
(for pulse frequency
pulse frequency in C211
controller)
42
14 Parameter level
Parameter Display Value Factory displayed if ... is configured
range setting
Switching differential,
HYS1 Relay 1, limit value in C211
controller 1
Switching differential,
controller 2
Switching differential, 0001 to 2% of full
controller 3 9999 scale
Switching differential, Relay 4, limit value in C213
HYS4
controller 4
Switching differential, Relay 5, limit value in C214
HYS5
controller 5
Pull-in delay 1 Ond1 Relay 1, limit value in C211
Pull-in delay 3 Ond3 1.0 Relay 3, limit value in C213
Pull-in delay 5 Ond5 0.00 to Relay 5, limit value in C214
Drop-out delay 1 Ofd1 999.9 sec Relay 1, limit value in C211
Drop-out delay 2 Ofd2 Relay 2, limit value in C211
Drop-out delay 3 Ofd3 0.2 sec Relay 3, limit value in C213
Maximum pulse
Fr1 Relay 1, pulse frequency in C211
frequency 1 0 to 150
100
Maximum pulse pulse/min
Fr2 Relay 2, pulse frequency in C211
frequency 2
Pulse period 1 CY1 1.0 to Relay 1, pulse width in C211
20.0
Pulse period 2 CY2 999.9 sec Relay 2, pulse width in C211
Output level limit Relay 1, pulse frequency or
Y1
Relay 1 pulse length in C211
0 to 100% 100
Output level limit Relay 2, pulse frequency or
Y2
Relay 2 pulse length in C211
0 to 100
Filter constant dF 0.6
sec
15 to 3000
Actuator time tt 60 Modulating controller in C211
sec
43
15 Configuration level
15.1 General
The basic functions of the instrument can be displayed and/or altered at the
If it is necessary to reconfigure a number of instrument
parameters,

Preconditions How to access the configuration level, or leave this level,

➩ Chapter 9.2 “Principle of operation”, page 23 ff.
The configuration level is unlocked,
15.2 Analog inputs - C111

C111* 1 0 0 0
Unit I I I I
µS/cm 0 I I I
mS/cm 1 I I I
I I I
Not used I I I
0 I I
I I
Not used I I
0 I
I
Method of temperature acquisition I
Manual temperature compensation 0
*The factory-set parameters are shown in the position boxes.
44
15.3 Logic inputs... - C112
C112* 0 0 0 0
Function of logic input 11 I I I I
No function 0 I I I
Key inhibit 1 I I I
Alarm stop 2 I I I
Hold 3 I I I
Freeze measurement 4 I I I
Setpoint changeover 5 I I I
Range expansion (x10) 6 I I I
HOLD reversed 7 I I I
Reset alarm time 8 I I I
I I I
Function of logic input 21 I I I
No function 0 I I
Key inhibit 1 I I
Alarm stop 2 I I
Hold 3 I I
Freeze measurement 4 I I
Setpoint changeover 5 I I
Range expansion (x10) 6 I I
HOLD reversed 7 I I
Reset alarm time 8 I I
I I
Probe break detection I I
No 0 I
Yes (process value < 2% of measurement range) 1 I
I
I component of the controller I
The I component of the controller is active between the two setpoints 0
The I component of the controller is not active between the two setpoints 1
1 Function description ➩ Chapter 19.1 “Functions”, page 60.
45
15.4 Serial interface... - C113
C113* 0 1 0 0
Device address I I I I
Address 0 0 0 I I
Address 1 0 1 I I
... I I
Address 99 9 9 I I
I I
Serial interface I I
MODbus / Jbus, 9600 bps, no parity 0 I
MODbus / Jbus, 9600 bps, odd parity 1 I
MODbus / Jbus, 9600 bps, even parity 2 I
MODbus / Jbus, 4800 bps, no parity 3 I
MODbus / Jbus, 4800 bps, odd parity 4 I
MODbus / Jbus, 4800 bps, even parity 5 I
I
Response of the process value output to out-of-range I
or off-scale
Underrange Overrange I
0% 100% 0
0% 110% 1
approx. -10% 1 100% 2
approx. -10% 1 110% 3
1 For 0 — 10V and 0 — 20mA output signals, output is approx. -4% for underrange.
46
15.5 Controller options - C211
a b
C211* 1 1 2 0
Function K11 I I I I
off 0 I I I
Limit controller 1 I I I
Pulse width controller 2 I I I
Pulse frequency controller 3 I I I
Modulating controller5 4 I I I
Proportional controller 5 I I I
I I I
Function K21 I I I
off 0 I I
Limit controller 1 I I
Pulse width controller 2 I I
Pulse frequency controller 3 I I
Modulating controller5 4 I I
Proportional controller 5 I I
I I
Calibration procedure2 I I
Calibration of the cell constant, process value output not frozen 0 I
Calibration of the cell constant, process value output frozen 1 I
Determination of the temperature coefficient, process value output not 2 I
frozen
Determination of the temperature coefficient, process value output frozen 3 I
I
Manual operation3 I
Manual operation off 0
Manual operation enabled, switched4 1
Manual operation enabled, only while the key is pressed 2
Simulated process value output 1 3
Simulated process value output 2 4
1 Only effective if “1” was configured in C214c and/or “1” > Controller 2 or Controller 1
was configured in C214d.
2 Function description, ➩ Chapter 12 “Calibration”, page 34ff.
3 Function description, ➩ Chapter 16 “Manual operation”, page 56.
4 Not possible if limit comparators have been configured.
5 If the function “K1 Modulating controller” is selected, then the function “K2 Modulating
controller” must also be selected (and the other way round).
47
15.6 Controller outputs - C212
C212* 0 0 1 0
Signal K1 for overrange / hold I I I I
Output level 0% 0 I I I
Output level 100% 1 I I I
Output level 50% (not for limit controllers) 2 I I I
Output accepted 3 I I I
I I I
Signal K2 for overrange / hold I I I
Output level 0% 0 I I
Output level 100% 1 I I
Output level 50% (not for limit controllers) 2 I I
Output accepted 3 I I
I I
MIN / MAX contact for K1 / K2 I I
K1 K2 I
MIN MIN 0 I
MIN MAX 1 I
MAX MIN 2 I
MAX MAX 3 I
I
Make / break contact I
K1 K2
make make 0
make break 1
break make 2
break break 3
48
15.7 Other outputs I - C213
a b c d
C213* 8 0 3 0
Function of output 3 (relay 3 or proportional output) I I I I
No function 0 I I I
Hold (relay only) 1 I I I
Alarm pulse contact (relay only) 2 I I I
Alarm steady contact (relay only) 3 I I I
MAX temperature limit comparator (relay only) 4 I I I
MIN temperature limit comparator (relay only) 5 I I I
MAX conductivity limit comparator (relay only) 6 I I I
MIN conductivity limit comparator (relay only) 7 I I I
Process value conductivity (analog output only) 8 I I I
Process value temperature (analog output only) 9 I I I
Proportional controller 1 (only with analog output)1 A I I I
Proportional controller 2 (only with analog output)1 b I I I
I I I
Signal for output 3 (analog output only)2 I I I
0 — 20 mA 0 I I
4 — 20 mA 1 I I
0 — 10 V 2 I I
2 — 10 V 3 I I
20 — 0 mA 4 I I
20 — 4 mA 5 I I
10 — 0 V 6 I I
10 — 2 V 7 I I
I I
Function of output 4 (logic output) I I
No function 0 I
Hold 1 I
Alarm pulse contact 2 I
Alarm steady contact 3 I
MAX temperature limit comparator 4 I
MIN temperature limit comparator 5 I
MAX conductivity limit comparator 6 I
MIN conductivity limit comparator 7 I
I
Alarm monitoring of relays K1 and K2 3 I
K1 / K2
monitored monitored 0
monitored not monitored 1
not monitored monitored 2
not monitored not monitored 3
49
1 The corresponding settings must be made in C211 (5xxx or x5xx), and also: SoL1/2 = 0
and SoH1/2 = 100.
2 Only effective if configuration in C213a is “8”, “9”, “A” or “b”.
3 A monitored relay contact (K1 /K2) triggers an alarm if the alarm tolerance + alarm delay
time is exceeded,
15.8 Other outputs II - C214

a b c d
C214* 0 0 1 1
Function of output 5 (relay 4 or analog output) I I I I
No function 0 I I I
Hold (relay only)2 1 I I I
Alarm pulse contact (relay only)2 2 I I I
Alarm steady contact (relay only)2 3 I I I
MAX temperature limit comparator (relay only)2 4 I I I
MIN temperature limit comparator (relay only)2 5 I I I
MAX conductivity limit comparator (relay only)2 6 I I I
MIN conductivity limit comparator (relay only)2 7 I I I
Process value conductivity (analog output only) 8 I I I
Process value temperature (analog output only) 9 I I I
Proportional controller 1 (only with analog output)3 A I I I
Proportional controller 2 (only with analog output)3 B I I I
I I I
Signal for output 51 I I I
0 — 20 mA 0 I I
4 — 20 mA 1 I I
0 — 10 V 2 I I
2 — 10 V 3 I I
20 — 0 mA 4 I I
20 — 4 mA 5 I I
10 — 0 V 6 I I
10 — 2 V 7 I I
I I
Function of output 2 I I
No function 0 I
Controller 24 1 I
Alarm pulse contact5 2 I
Alarm steady contact5 3 I
MAX temperature limit comparator5 4 I
MIN temperature limit comparator5 5 I
MAX conductivity limit comparator5 6 I
MIN conductivity limit comparator5 7 I
50
I
Function of output 1 I
No function 0
Controller 16 1
Alarm pulse contact7 2
Alarm steady contact7 3
MAX temperature limit comparator7 4
MIN temperature limit comparator7 5
MAX conductivity limit comparator7 6
MIN conductivity limit comparator7 7
1 Only effective if configuration in C214a is “8”, “9”, “A” or “b”.

2 No optical status indication.
3 The corresponding settings must be made in C211 (5xxx or x5xx), and also: SoL1/2 = 0
and SoH1/2 = 100.
4 Enter the desired controller function in C211a.
5 The corresponding setting must be made in C211 (x0xx).
6 Enter the desired controller function in C211b.
7 The corresponding setting must be made in C211 (0xxx).
51
15.9 Response for HOLD / Overrange - C215
C215* 0 0 0 0
No function I I I I
0 I I I
I I I
K5 I I I
Inactive 0 I I
Active 1 I I
I I
K4 I I
Inactive 0 I
Active 1 I
I
K3 I
Inactive 0
Active 1
15.10 Process value output for conductivity - C311

C311* 5 0
Bilinear characteristic I I I I
0% 0 0
1% 0 1
...
99% 9 9
52
15.11 SoL - SoH - SPL - SPH - rAnG - CELL - ALPH - LOFF - OFFS
SoL Standard signal scaling of the analog process value output.
Start value of the range for standard signals of the process value output.
SoL1 -> Output K3
SoL2 -> Output K5
Value range
depending on configuration 0 — 0.5µS to 0 — 200mS1-50.0 to +250.0°C
Factory setting: 0.00
1depending on the configured measurement range
Example 1:
0 — 20 mA should correspond to 10 — 150 mS
-> SoL = 10.00 / SoH = 150.0
Example 2:
0— 20 mA should correspond to -10 to +40°C
-> SoL = -10.00 / SoH = 40.00
Example 3:
0 — 100% of the controller output should correspond to 0 — 8 V of the output
signal (but the standard output signal of the controller is 0 — 10 V)
-> SoL = 0 / SoH = 120
120%
100%
0
8V 10V
SoH Standard signal scaling of the analog process value output.

End value of the range for standard signals of the process value output.
SoH1 -> Output K3
SoH2 -> Output K5
For value ranges and factory settings, see “SoL” above.
SPL Setpoint limiting for controller setpoints.

This parameter is used to define the lower limit setting for the controller
setpoints SPr1/2/3/4.
SPH Setpoint limiting for controller setpoints.

This parameter is used to define the upper limit setting for the controller
setpoints SPr1/2/3/4.
53
rAnG Range number, derived from the combination of cell constant and desired
measurement range.
Cell Display with configured
Measurement Range
constant measurement (C111)
range (rAng)
K µS mS
0.01 0 — 0.500 µS/cm 0.500 – –1 1
0.01 0 — 2.000 µS/cm 2.000 – –1 2
0.01 0 — 10.00 µS/cm 10.00 – –1 3
0.1 0 — 5.00 µS/cm 5.000 – –1 4
0.1 0 — 20.00 µS/cm 20.00 – –1 5
0.1 0 — 100.0 µS/cm 100.0 – –1 6
0.1 0 — 1.00 mS/cm 1000 1.00 7
0.1 0 — 5.00 mS/cm 5000 5.002 8
1.0 0 — 50.00 µS/cm 50.00 – –1 9
1.0 0 — 100.0 µS/cm 100.0 – –1 10
1.0 0 — 1.00 mS/cm 1000 1.00 11
1.0 0 — 5.00 mS/cm 5000 5.00 12
1.0 0 — 20.00 mS/cm – –1 20.00 13
1.0 0 — 100.0 mS/cm – –1 100.02 14
3.0 0 — 1.00 mS/cm 1000 1.00 15
3.0 0 — 5.00 mS/cm 5000 5.00 16
3.0 0 — 30.00 mS/cm – –1 30.00 17
10.0 0 — 30.00 mS/cm – –1 30.00 18
10.0 0 — 200.0 mS/cm –– 1 200.0 19
1 These settings are not permissible – they would cause an incorrect display
2 The polarization effect could cause a sizeable error in the measurement with this
combination of measurement range and cell constant.
CELL The relative cell constant Krel [%] can be used to compensate for the deviation
of the cell constant from the nominal value (0.01; 0.1; 1.0; 3.0; 10.0) over the
range from 80 to 120%.
ALPH Temperature coefficient [% per °C] of the measured solution.

Value range 0.00 — 5.50% per °C
The conductivity of a solution varies with the temperature, so for correct
measurement both the temperature and the temperature coefficient of the
solution being measured must be known.
The temperature coefficient can be determined automatically by the
conductivity transmitter, or entered manually.
➩ “Determination of the temperature coefficient”, page 38.
54
LOFF Compensation of the lead resistance

Value range 0.00 — 99.99 Ω.
The lead resistance of the connecting cable to the cell can result in an
incorrect indication for liquids with a high conductivity.
This error can be compensated by the setting for “LOFF”.
✱ Detach the connecting cable from the conductivity cell and the instrument.
✱ Measure the loop resistance of the connecting cable (out and return leads
=> short it at one end).
✱ Enter the measured resistance [Ω] in “LOFF”.
➩ Chapter 11.5 “Compensation of falsified measurements”, page

32.
OFFS Process value correction for temperature

The process value correction can be used to correct the measured value of the
temperature input, either upwards or downwards.
Value range -199.9 to +199.9°C or °F
Factory setting: 0°C
Example:
Measured Offset Displayed
value value
34.7°C +0.3°C 35.0°C
35.3°C -0.3°C 35.0°C
If the process value correction is made via the parameter “OFFS”,

then no compensation resistance is needed
➩ Chapter 7 “Installation”, page 17 ff.
55
16 Manual operation
Description In manual operation, outputs K1, K2 and K3 can be operated by hand,

independently of the controller.
Manual operation is only possible if it has been configured first.

The output level limiting is effective during manual operation
(except for limit controllers).
Initial The instrument is in the measurement mode.

condition
16.1 Manual operation for outputs K1, K2 or K3

Activate In manual operation, outputs K1, K2 and K3 can be operated by hand.
EXIT + ≤1s
EXIT
✱ Press keys + for less than 1 second – this starts “Manual operation
EXIT
1”. The upper LED display switches between the momentary value and the
text “HAnd”, the lower display shows the present temperature.
✱ Activate or deactivate a particular output, see table
Key Output
K11
K21
PGM K32
✱ Return to measurement mode, with EXIT
1 Output level will be 0 / 100% for a proportional controller.

2 Only while the key is pressed. Only if the third relay is fitted
(“Output 310”, ➩ Chapter 4.1 “Type designation”, page 8).
56
16 Manual operation
16.2 Simulated process value output
Setting When “Simulated process value output” has been configured,
➩ Chapter 15.5 “Controller options - C211”, page 47,
the upper display shows “HAnd” alternately with 50.0 (%).
✱ Use to reduce the signal at the process value output in 10% steps,
use to increase the signal at the process value output in 10% steps,
Example: Output signal 0 — 20 mA,
intended simulated output signal 8 mA
=> Setting 40%
57
17 Hold
17.1 Hold controller
Description When “Hold” is activated, the relay outputs take up the status defined in the
configuration parameters “Controller outputs” – C212 and “Response to
HOLD / Overrange” – C215,
➩ Chapter 15.6 “Controller outputs - C212”, page 48.
➩ Chapter 15.9 “Response for HOLD / Overrange - C215”, page 52.
Any alarm delay time that may be running is set to “0”, but no alarm is
produced.
Initial The operating level is unlocked,

condition ➩ “Unlocking the levels”, page 26. (0110).
Activate “Hold”
(manual)
EXIT + >2s
EXIT + >2s
✱ Press + EXIT for longer than 2 seconds (but less than 4 seconds)
The upper LED display shows “HoLd” alternately with the momentary
measurement
✱ Return to measurement mode by pressing + EXIT for longer than 2
seconds (but less than 4 seconds)
The controller outputs K1, K2 and K3 (depending on the

instrument version and configuration) are set according to the
configuration of C212.
The output level limiting is effective during “Hold” (except for limit
controllers).
After configuration as limit comparator(s), outputs K1, K2, K3, K4
and K5 (depending on the instrument version and configuration)
are set according to the configuration of C212 and C215.
58
18 Version
18.1 Display software version and temperature unit
+ PGM
✱ Display the software version and unit for temperature

with + PGM
The software version is shown in the upper display.

The unit (lower display can be either °C or °F, (standard is °C; a conversion to
°F can only be carried out at the factory).
59
19 Logic inputs
19.1 Functions
Setting the functions of the logic inputs,
see “Configuration level / logic inputs...– C112”, page 36.
Status of the
logic input
Key The transmitter/controller can be The transmitter/controller can not be

inhibit operated from the keys on the front operated from the keys on the front
panel. panel.
Alarm stop Alarm signals are generated at the The alarm contact is deactivated –
configured output. the LED for the configured alarm
output blinks.
Reset alarm time Alarm signals are generated at the The alarm contact is deactivated.
configured output. Any alarm delay that has started to
run will be set to zero and held.
Hold Controller active Hold,
➩ Chapter 17 “Hold”, page 58.
Hold inverse Hold, Controller active
Measurement The measured process value for the The measured process value for the
freeze first measurement variable is first measurement variable is frozen.
displayed. ➩ Chapter 12 “Calibration”, page 34
ff.
Setpoint Setpoint pair 1 (SP1 and SP 2) is Setpoint pair 2 (SP3 and
changeover active. SP 4) is active.
Display at operating level: Display at operating level:
SPr1 SP 1
SPr2 SP 2
SP 3 SPr3
SP 4 SPr4
Range expansion Process value output is linear Process value 0 — 10% of full scale
(x10) between SoL and SoH is scaled up to 0 — 100% of the
process value output.
60
20 Interface
20.1 MODbus /Jbus
This interface can be used to integrate the controller into a data network. The
following applications, for instance, can be implemented:
- Process visualization
- Plant/system control
- Recording / data logging
K1 K2 K3 K4 K1 K2 K3 K4 K1 K2 K3 K4
mV pH mS
°C CAL °C CAL °C CAL
PGM EXIT PGM EXIT PGM EXIT
The bus system is designed around the master-slave concept. A master

computer can communicate with up to 31 controllers or other devices (slaves).
The interface is a serial interface using the RS422 or RS485 standards.
The following data protocols may be used:
- MODbus /Jbus protocol
This interface can only be retrofitted at the factory.
61
20 Interface
20.2 Profibus-DP
Fieldbus The Profibus-DP interface can be used to integrate the controller into a
fieldbus system operating according to the Profibus-DP standard. This
Profibus version is especially designed for communication between
automation systems and decentral peripheral devices at the field level, and
optimized for speed.
Data The data transmission is made serially, using the RS485 standard.
transmission
GSD generator GSD generator, the project-planning tool that is supplied with the package
(GSD = Gerätestammdaten, i.e. basic device data), is used to make a selection
of device characteristics for the controller to create a standardized GSD file
that is used to integrate the controller into the fieldbus system.
For a detailed description, see the PROFIBUS-DP Interface

Description B70.3560.2.1
62
21 Glossary
Parameters which apply to both output K1 and K2 (e.g tAb1 or

tAb2) are only explained once.
Term Parameter Explanation

Actuator time tt The value for this parameter must be taken from the specific
data for the actuator device (e.g. an actuator valve).
Alarm contact With limit control, the active time of the outputs K1 or K2 can be
monitored (dosing monitoring). If the active time exceeds an
adjustable value (Alarm delay AL2), then the alarm contact is
activated. With pulse width or pulse frequency control, the size
of the control deviation is monitored. If the control deviation
exceeds the adjustable Alarm tolerance AL1, and remains
outside this tolerance for longer than the Alarm delay AL2,
then the alarm contact is activated.
Alarm delay AL2 If the control deviation exceeds the adjustable Alarm tolerance
AL1, and remains outside this tolerance for longer than the
adjustable Alarm delay AL2, then the alarm contact is activated.
Alarm tolerance AL1 If the process value goes above or below the value of setpoint
plus or minus alarm tolerance (x > SPr..+AL1 or x < SPr..-AL1)
and remains outside these limits for longer than the Alarm
delay AL2, then the alarm contact is activated.
The alarm tolerance is only active if pulse width or pulse
frequency control has been configured,
➩ Chapter 15.5 “Controller options - C211”, Page 47.
If limit control is configured, then the values for the
alarm tolerance will be ignored.
Bilinear C311 This function has the effect that a small or large input signal
output produces a disproportionate analog process value output
signal. The knee-point of the characteristic can be shifted along
the dotted 50% (output) line. The factory setting of 50% (input)
produces a straight-line characteristic.
63
21 Glossary
Break contact / C212 Break contact: As long as the switching condition is not
make contact fulfilled, the corresponding output is active (closed).
Make contact: As long as the switching condition is fulfilled, the
corresponding output is active (closed).
Cell constant C-Ab This shows the value that the attached conductivity cell should
have. The value is derived from the selected rAnG number
(combination of cell constant and measurement range).
Code word CodE After the supply voltage has been applied, all levels are
protected against accidental or unauthorized editing. If
parameter settings have to be altered, the levels must be
unlocked by entering a code word. A code word is also required
to be able to calibrate the electrode.
It is not necessary to remove the protection against editing if
you just want the check the settings.
Derivative time dt This determines the differential component of the controller
output signal. If the derivative time is set to “0”, then the control
response has no differential component.
Dosing C213 Defines whether the output K1 and / or K2 is/are monitored by
monitoring the alarm contact (see also under “Alarm contact”).
Drop-out delay OFd The time required for the corresponding relay contact to return
to the inactive status when the switching condition is no longer
fulfilled. Brief excursions above or below the setpoint will be
ignored by the controller.
Filter constant df The setting of this parameter is used to filter out interference or
input signals which would provoke undesirable reaction in the
controller. The filter is a 2nd order digital filter.
Hysteresis HYS see Switching differential
64
21 Glossary
Limit controller C211 A single-setpoint controller with pull-in and/or drop-out delay.
Logic input 1 / 2 C112 see “Logic inputs”, page 45.

Make contact / C212 Make contact: As long as the switching condition is fulfilled, the
break contact corresponding output is active (closed).
Break contact: As long as the switching condition is not
fulfilled, the corresponding output is active (closed).
MAX limit C211 SP A ... E defines the switching point.
comparator SP A Function: The output has the “active” status when the process
SP b value is above the limit value.
SP C
1°C/1°F
SP d ON
SP E Ein
X sd
AL x
SP A ... E are only visible at the operating level, when at least
one limit comparator has been configured.
Assignment:
SP A is affected by: HYS1, Ond1 and OfD1
SP b is affected by: HYS2, Ond2 and OfD2
SP C is affected by: HYS3, Ond3 and OfD3
SP d is affected by: HYS4, Ond4 and OfD4
SP E is affected by: HYS5, Ond5 and OfD5
MIN / MAX C212 MIN contact: The controller output is active if the process value
contact is below the setpoint.
MAX contact: The controller output is active if the process value
is above the setpoint.
For further explanation,
➩ Chapter 10 “Controller”, Page 27ff.
Minimum ON time tr With a limit controller, pulse width controller, or modulating
controller.
The value selected is determined by the technical requirements
of the equipment operated by the controller (solenoid valves,
dosing pumps etc.).
65
21 Glossary
MIN temperature C211 SP A ... E defines the switching point.
limit comparator SP A ... E Function: The output has the “active” status when the process
value is below the limit value.
For explanation, see “Max limit comparator”.
Modulating C211 A modulating controller can move a motor actuator in steps to
controller any position from 0 — 100% of the actuator range.
A modulating controller can, for instance, be used to operate
actuator valves.
Output level limit Y1 Defines the maximum output level that can be produced by the
Y2 corresponding relay, for a pulse width or pulse frequency
controller
Proportional Pb The range over which the output signal from a pulse width or
band pulse frequency controller is proportional to the control
deviation. Beyond the proportional band, the controller will
output the signal defined by the output level limit Y1 or Y2 .
Proportional C211 In a proportional controller there is a continuous signal (i.e. a
controller C213 current or voltage) on the output. This signal can take on any
C214 intermediate value between a start value and an end value.
Depending on the configuration of the instrument, this
proportional signal can be in the range 0 — 10 V, 0 — 20 mA or
4 — 20 mA.
Proportional controllers are used, for example, to control
actuator valves.
Process value x The signal that is fed to the controller from the conductivity cell.
Process value C111 With automatic temperature acquisition (using a Pt100 or
input 2 Pt1000 temperature probe), the measured temperature is
(temperature) shown in the lower display.
Pull-in Ond The time required for the corresponding relay contact to be
delay activated when the switching condition is fulfilled. Brief
excursions above or below the setpoint will be ignored by the
controller.
Pulse contact / C213 The behavior of an alarm contact.
steady contact Pulse contact:
The alarm output remains active for approx. 1 second, even if
the switching condition (cause) of the alarm remains present for
a longer time.
The LED (for the output that was defined as the alarm output)
blinks until the switching condition (the cause) of the alarm is no
longer present.
Steady contact:
The alarm output remains active until the switching condition
(the cause) of the alarm is no longer present.
The LED blinks for the output that was defined as the alarm
output.
66
21 Glossary
Pulse frequency Fr Maximum pulse frequency (only for a pulse frequency
controller)
The value selected is determined by the technical requirements
of the equipment operated by the controller (solenoid valves,
dosing pumps etc.).
The value is limited by the minimum pulse width:
Pulse frequency [1/min]< (60 / minimum ON time [sec])
Pulse frequency C211 The repetition rate of the pulses depends on the output level
controller and the controller parameters: proportional band Pb,
derivative time dt, reset time rt, pulse frequency Fr and
output level limits Y1 or Y2 .
The output signal from a pulse frequency controller can, for
instance, be used to operate magnetic dosing pumps.
trt (constant)
(konstant)
r
t
T ( ≥ 1/Fr)
(depends on output level)
(stellgradabhängig)
Pulse period CY This value is the period within which the pulse width modulation
occurs (only for a pulse width or modulating controller).
The value is limited by the minimum ON time, see above:
Pulse period [sec]> minimum ON time [sec])
Pulse width tr For pulse frequency control, otherwise as minimum ON time
Pulse width C211 The width of the pulses depends on the output level and the
controller controller parameters: proportional band Pb, derivative time
dt, reset time rt, pulse period CY and output level limits Y1
or Y2.
The output signal from a pulse width controller can, for
instance, be used to operate solenoid valves.
tt ON(stellgradunabhängig
(independent of output
≥t)
level > tr)
ein r
t
CY
(constant)
(konstant)
67
21 Glossary
Reset time rt Integral time constant – controller parameter in a PI or PID
(Reset time) controller. The value determines the speed with which the
control deviation is integrated. If the reset time is set to “0”,
then the control response has no integral component.
Setpoint 1 SP(r)1 The given value that should be achieved by the control loop
(referring to output K1).
The setpoint pair that is fed to the controller is identified in the
parameter display by (r). See also Setpoint changeover
Example
for the active setpoint pair 1 => SPr1, SPr2 and SP 3, SP 4.
for the active setpoint pair 2 => SP 1, SP 2 and SPr3, SPr4.
Setpoint 2 SP(r)2 As for setpoint 1, referring to output K2
Setpoint 3 SP(r)3 Refers to output K1. For explanation see setpoint 1.
Only with activated setpoint changeover
Setpoint 4 SP(r)4 Refers to output K2. For explanation see setpoint 1.

Only with activated setpoint changeover
Setpoint C112 If setpoint changeover is configured for one of the logic inputs,
changeover then setpoint pair 1 is active if the logic input is inactive, i.e. the
controller uses the setpoints 1 and 2 (SPr1 and SPr2) for
operation.
If the logic input is active, then setpoint pair 2 is active, i.e. the
controller uses the setpoints 3 and 4 (SPr3 and SPr4) for
operation.
Active setpoints are identified by an “r” in the parameter name
(SPr1 and SPr2 as well as SP3 and SP4 if setpoint pair 1 is
active).
Setpoint limiting SPH Setpoint limiting for controller setpoints.
This parameter is used to define the upper limit setting for the
controller setpoints SPr1/2/3/4.
Setpoint limiting SPL Setpoint limiting for controller setpoints.
This parameter is used to define the lower limit setting for the
controller setpoints SPr1/2/3/4.
68
21 Glossary
Steady contact / C213 The behavior of an alarm contact.
pulse contact Steady contact:
The alarm output remains active until the switching condition
(the cause) of the alarm is no longer present. The LED blinks for
the output that was defined as the alarm output.
Pulse contact:
The alarm output remains active for approx. 1 second, even if
the switching condition (cause) of the alarm remains present for
a longer time.
The LED (for the output that was defined as the alarm output)
blinks until the switching condition (the cause) of the alarm is no
longer present.
Switching The process value goes above or below the setpoint. The
condition switching condition is also dependent on the settings “Break
contact / make contact” and “MIN / MAX contact.
Switching HYS In a limit controller, this is the deviation of the process value
differential from the setpoint that is required to trigger the switching of the
(also hysteresis) control contact in response to a falling or rising process value.
Limit controller Limit controller

MAX contact MIN contact
make contact make contact
HYS HYS
SPr...
SPr.. xx SPr...
SPr.. x x
setpoint
Sollwert process value
Istwert setpoint
Sollwert proc. val.
Istwert
69
22 Warnings – Errors
22.1 Messages
.
Warning / Cause / behavior / action
Error
F010 Alarm tolerance overrun/underrun and alarm delay time for the controller has
elapsed.
Relays K1 / K2 behave as defined by the configuration C212,
Check process value. Check controller parameters.
F022 Underrange.
Controller goes to “Hold”,
Check configured setpoints,
➩ Chapter 13.1 “Settings”, page 41.
Check electrode / cable / connector.
F023 Overrange.
Check configured setpoints,
➩ Chapter 13.1 “Settings”, page 41.
F024 With automatic temperature acquisition, a temperature was measured
below -50°C or above +250°C.
Check the connection to the resistance thermometer,
➩ Chapter 7.1 “Electrical connection”, page 17ff.
F030 Process value output (SoL) went below the minimum value (only if output 3 and / or
5 were configured as the process value output (C213 or C214)).
Check the setting,
➩ Chapter 15.11 “SoL - SoH - SPL - SPH - rAnG - CELL - ALPH - LOFF - OFFS”,
page 53.
F031 Process value output (SoL) went above the maximum value (only if output 3 and /
or 5 were configured as the process value output (C213 or C214)).
Check the setting,
page 53.
F050 Parameter limits swapped for process value output: SoL is higher than SoH (only if
output 3 and / or 5 were configured as the process value output (C213 or C214)).
Check the setting,
page 53.
70
22 Warnings – Errors
Warning / Cause / behavior / action
Error
F053 Incorrect setpoint combination.
Precondition: Both controllers must be configured as pulse width or pulse
frequency controllers. The controller contacts must be configured as MIN/MIN or
MAX/MAX,
Cause: With MIN/MIN there will be an error message if w1 > w2. There is no error
message if w1 < w2.
With MAX/MAX there will be an error message if w1 < w2. There is no error
message if w1 > w2.
This also applies to the second pair of setpoints, if setpoint changeover is
configured.
F060 Minimum ON time (tr1) is longer than the pulse period 1 (CY1) (only if controller 1 is
configured as a pulse width controller), or
Minimum ON time (tr1) is longer than 1/60 of the pulse frequency 1 (Fr1) (only if
controller 1 is configured as a pulse frequency controller),
➩ Chapter 14.1 “Settings”, page 42ff.
F061 Minimum ON time 2 (tr2) is longer than the pulse period 2 (CY2) (only if controller 2
is configured as a pulse width controller), or
Minimum ON time (tr2) is longer than 1/60 of the pulse frequency 2 (Fr2) (only if
controller 2 is configured as a pulse frequency controller),
➩ Chapter 14.1 “Settings”, page 42ff.
Err The calibration of the relative cell constant or the determination of the temperature
coefficient for the medium being measured was terminated with an error. The old
data are retained.
Cause:
The relative cell constant (either as set or as determined during the calibration) is
outside the permissible range (80 — 120%), or
The temperature coefficient for the medium being measured (either as set or as
determined during the calibration) is outside the permissible range. (0 — 5.5% per
°C)
Corrective action:
A fresh, correct calibration,
➩ Chapter 12 “Calibration”, page 34ff or
Enter the relative cell constant or temperature coefficient for the medium being
measured, using the keys to alter a digit up and down, and then confirming with
the PGMkey,
➩ Chapter 12.2 “Relative cell constant”, page 36 or ➩ Chapter 12.2.2 “Automatic
determination of the relative cell constant with a reference instrument”, page 37.
Errors F010 to F031 and “Err” trigger an alarm; the configured alarm output will switch
and the corresponding LED will blink.
With errors F022 to F024 and “Err”, the controller also goes to the “HoLd” condition, ➩
Chapter 17 “Hold”, page 58.
The alarm relay does not switch as a result of one of the warnings F050 to F061, but the
corresponding LED will blink.
71
23 Appendix
23.1 Programming the controller
Configuration If a number of instrument parameters have to be modified in the instrument,
then it is advisable to note them in the table below, and then modify these
parameters in the sequence given.
The following list shows the maximum number of parameters that
can be altered.
Depending on the type and configuration, your instrument may not
show some of the listed parameters.
Code words to unlock the individual levels,
➩ "Unlocking the levels”, page 26.
Para- Explanation Factory New see page

meter setting setting
Configuration level
C111 Analog inputs 1000 44
C112 Logic inputs / probe / supply 0000 45
C113 Serial interface 0100 46
C211 Controller options 1120 47
C212 Controller outputs 0010 48
C213 Other outputs I 8030 49
C214 Other outputs II 0011 50
C215 Response for HOLD / Overrange 0000 52
C311 Process value output Lf 5000 53
SoL1 Scaling of the standard signal – start value K3 0.00 53
SoL2 Scaling of the standard signal – start value K5 0.00 53
SoH1 Scaling of the standard signal – end value K3 1.00 53
SoH2 Scaling of the standard signal – end value K5 1.00 53
SPL Lower setpoint limit for controller setpoints – SP(r)1 0.00 53
SPH Upper setpoint limit for controller setpoints – SP(r)1 1.00 53
rAnG Range number 54
CELL Relative cell constant 100.0 54
ALPH Temperature coefficient 2.30 54
OFFS Process value correction for temperature 0.0 55
Parameter level
Pb1 Proportional band 1 0.50 42
Pb2 Proportional band 2 0.50 42
dt1 Derivative time 1 [s] 0 42
dt2 Derivative time 2 [s] 0 42
rt1 Reset time 1 [s] 0 42
rt2 Reset time 2 [s] 0 42
tr1 Minimum ON time 1 [s] 0.2 42
tr2 Minimum ON time 2 [s] 0.2 42
HYS1 Switching differential 1 0.30 43
72
23 Appendix
Para- Explanation Factory New see page
meter setting setting
HYS5 Switching differential 5 0,30 43
Ond1 Pull-in delay 1 [s] 1.0 43
OFd1 Drop-out delay 1 [s] 0.2 43
Fr1 Maximum pulse frequency 1 [imp/min] 100 43
Fr2 Maximum pulse frequency 2 [imp/min] 100 43
CY1 Pulse period 1 [s] 20 43
CY2 Pulse period 2 [s] 20 43
Y1 Output level limit for K1 [%] 100 43
Y2 Output level limit for K2 [%] 100 43
dF Filter constant [s] 0.6 43
tt Actuator time [s] 60 43
Operating level
SP(r)1 1st Setpoint for contact K1 0.00 41
SP(r)2 1st Setpoint for contact K2 1.00 41
SP(r)3 2nd Setpoint for contact K1 0.00 41
SP(r)4 2nd Setpoint for contact K2 1.00 41
CodE Code word to unlock the levels s. p. 26 41
SP A Limit SP A (K1) -50 41
SP b Limit SP b (K2) -50 41
SP C Limit SP C (K3) -50 41
SP d Limit SP d (K4) -50 41
SP E Limit SP E (K5) -50 41
InP2 Temperature display for compensation (°C) 25.0 41
AL1 Alarm tolerance 0.00 41
AL2 Alarm delay (sec) 300 41
73
JUMO GmbH & Co. KG JUMO Instrument Co. Ltd. Vorläufig
JUMO PROCESS CONTROL INC. V
Delivery address:Mackenrodtstraße 14, JUMO House 885 Fox Chase, Suite 103
36039 Fulda, Germany Temple Bank, Riverway Coatesville PA 19320, USA
Postal address: 36035 Fulda, Germany Harlow, Essex CM 20 2TT, UK Phone: 610-380-8002
Phone: +49 661 6003-0 Phone: +44 1279 635533 1-800-554-JUMO
Fax: +49 661 6003-607 Fax: +44 1279 635262 Fax: 610-380-8009
e-mail: mail@jumo.net e-mail: sales@jumo.co.uk e-mail: info@JumoUSA.com
Internet: www.jumo.net Internet: www.jumo.co.uk Internet: www.JumoUSA.com
Data Sheet 20.2923 Page 1/4
JUMO ecoLine Lf-PVC

Electrolytic Conductivity Cells
202923 Series (former 2EL5... Series)
k 2-electrode principle
k proven versions for industrial application
k measuring ranges: 0 — 1 mS/cm (K=0.1) or 0.01 — 15 mS/cm (K=1.0)
k temperature range up to 55°C, maximum pressure: 6 bar at 20°C
Brief description
Conductivity cells in the 202923 series are used, for instance, in general water engineering, air
conditioning and refrigeration, drinking and bathing water, and in industrial rinsing and process
water circulation. The PVC body material restricts their application to media temperatures up to
55°C. Two variants with the cell constants K=0.1 or 1.0 can be supplied.
Versions with the popular thread sizes G3/4" or G1" as well as a pluggable style are available
for installation. The pluggable version is appropriate for use, for instance, with suitable PVC tees
in the nominal sizes DN25, 32 and 40. It enables fast de-installation of the sensor for cleaning
and maintenance. According to choice, the electrical connection is made either by a detachable
connector or an attached cable.
The overall construction and the wetted components are physiologically harmless. Stainless
steel (K=0.1) or special graphite (K=1.0) is used as the electrode material. The temperature
probe, which can optionally be integrated, simultaneously acquires the temperature of the
medium, for temperature compensation in connected instrumentation amplifiers.
Stainless steel variant K=0.1: The cell features 3 metallic pin electrodes. The two outer pins
are electrically connected and form one pole of the 2-electrode cell. The stainless steel pin in
the middle is the counter electrode. This arrangement ensures highly accurate measurement
with narrow stray fields. A temperature probe can be integrated into the middle pin.
Graphite variant K=1.0: Physical requirements necessitate using a special graphite as
electrode material for high conductance measurement. The two graphite electrodes are
completely integrated in the electrode shaft. The optional temperature probe is housed in a
stainless steel sleeve that is immersed in the solution under test.
Principle of operation
The 20.2923 series measuring cells are 2-electrode cells. An a.c. voltage is applied by means of a transmitter. The current flowing through
the liquid and the electrodes is determined by the conductivity of the liquid.
Technical data
Cell constant1 K = 0.1 or K = 1.0
Typical measuring ranges20 — 1.0 mS/cm (with K = 0.1)
0.01 — 15 mS/cm (with K = 1.0)
Temperature compensation optionally with Pt100
Process connection screw-in thread G3/4A; G1A; union nut DN25; 11/2" for PVC tees
Body material PVC
Cell material stainless steel 1.4571 (with K=0.1)
graphite (with K=1.0)
Operating temperature up to +55°C
Maximum pressure 6 bar at 20°C
Electrical connection instrument connector (Hirschmann) to DIN 43 650, IP65 protection or
5 m attached cable, other cable lengths on request.
1 Any deviation of the cell constant can be adjusted on the transmitter.
2 The measuring ranges also depend on the transmitter that is used.
When used for wider ranges than the “typical” ones, measurement errors caused by polarization may occur.
07.04/00421317
JUMO GmbH & Co. KG • 36035 Fulda, Germany Data Sheet 20.2923 Page 2/4
Dimensions / installation options
Attached cable, gray,

6 mm dia.
2
0.34 mm core cross-section
Instrument connector
4-core
DIN 43 650
(Hirschmann) Cable gland
Pg7
32 a/f 36 a/f
Stainless steel electrode
Pt100 (option)
G
G
Type 202923/0010-1003-xxx-37-86-26/000
cell constant K = 0.1
Type 202923/0010-1003-xxx-17-86-26/000
cell constant K = 0.1
Process connection G L
-105 G3/4 16
-106 G1 18
Attached cable, gray,

6 mm dia.
2
0.34 mm core cross-section
Instrument connector 4-core
DIN 43 650 Cable gland
(Hirschmann) Pg7
36 a/f 36 a/f
L
L
Graphite electrode
Pt100 (option)
G G
Type 202923/0100-1003-xxx-37-86-88/000 Type 202923/0100-1003-xxx-17-86-88/000

cell constant K = 1.0 cell constant K = 1.0
07.04/00421317
Pluggable version
~50
~37
45
19
ø41
93
ø44.5
68
10
ø25
Type 202923/0010-1003-687-37-86-26/000 Type 202923/0100-1003-687-37-86-26/000

cell constant K = 0.1 cell constant K = 1.0
Note: supplied without union nut! Note: supplied without union nut!
Accessories for pluggable version
tee DN25
tee DN32
tee DN40
07.04/00421317
Order details
(1) Basic type
202923 JUMO ecoLine Lf-PVC, electrolytic conductivity cells
(2) Cell constant
0010 K = 0.1 (measuring range 0 — 1.0 mS/cm)
0100 K = 1.0 (measuring range 0.01 — 15 mS/cm)
(3) Temperature sensor

o o 0000 none
x x 1003 Pt100
(4) Process connection
o o 687 stepped seat PVC ø32 / DN25 (supplied without union nut)
x x 105 screw-in thread G 3/4" A
o o 106 screw-in thread G 1" A
(5) Electrical connection
o o 17 by attached cable with Pg gland, cable length 5 m
x x 37 by instrument connector to DIN 43 650 (Hirschmann connector)
(6) Body material
x x 86 PVC
(7) Cell material
x - 26 stainless steel 1.4571
- x 84 graphite
(8) Extra codes
o o 000 none
x = combination is standard
o = combination is optional
– = combination cannot be supplied
Additional versions on request!
(1) (2) (3) (4) (5) (6) (7) (8)

Order code 202923 / - - - - 86 - /
Order example 202923 / 0010 - 1003 - 196 - 17 - 86 - 26 / 000
Stock items
Sales No. Type Brief description
20/00303793 202923/0010-1003-105-37-86-26/000 K = 0.1; Pt100; G3/4A
20/00319402 202923/0010-1003-105-17-86-26/000 K = 0.1; Pt100; G3/4A; 5 m attached cable
Non-stock items
Sales No. Type Brief description
20/00089411 202923/0010-1003-106-37-86-26/000 K = 0.1 / Pt100 / G1A
20/00402638 202923/0010-1003-106-17-86-26/000 K = 0.1 / Pt100 / G1A / 5 m attached cable
20/00437032 202923/0100-1003-105-37-86-84/000 K = 1,0 / Pt100 / G3/4A
20/00409610 202923/0100-1003-106-37-86-84/000 K = 1,0 / Pt100 / G1A
20/00437034 202923/0100-1003-687-17-86-84/000 K = 1,0 / Pt100 / stepped seat PVC / 5 m attached cable
Accessories (for pluggable version)

Sales No. Brief description
20/00437035 PVC tee DN25 (incl. union nut, O-ring and glued socket for pluggable version)
20/00303681 Connecting cable 25 m (4-core + screen)
20/00304181 Connecting cable 50 m (4-core + screen)
07.04/00421317
MATERIAL SAFETY DATA
MT 5
1. Name of product and company
Commercial name Biosperse 250 ( MT 5 )

Application Biocide
Supplier ENWA AB
Backa Strandgata 8, SE-422 46 Hisings Backa
Tel: +46(0)31 – 742 92 50
Fax: +46(0)31 – 742 92 60
2. Composition
Chemical name Cas.no. Contents
Magnesium Nitrate 10377-60 1,7 %

Chloro-2-Methyl-4-Isothia zolin-3-one 26172-55-4 1,15 %
2-Methyl-4-isothiazolin-3-one 4 26282-20 0.35
Water 7732-18-5 Balance
3. Hazards Identification
Corrosive
4. First-Aid measures
Eye contact Immediately flush eyes with water for at least 15 minutes. Get medical attention.
Skin contact Promptly wash with lots of water and get medical attention. Take off splashed clothes.
Inhalation Fresh air and rest. Seek medical assistance when continuous trouble.
Swallowing Get medical assistance immediately. Do not induce vomiting.
5. Fire-Fighting measures
Fire extinguishing materials Dry chemical, carbon dioxide, foam or water.
Flammable limits > 100° C.
Special fire-fighting
procedures: Structural fire fighters must wear self-contained Breathing Apparatus
and full protective equipment.
6. Accidental release measures

Proper protective equipment should be used. In case of a spill, clear the affected area, protect people.
Decontaminate the area thoroughly with a soap solution followed by a water rinse. Place all spill
residue in an appropriate container and seal. Dispose of in accordance with Federal, State and local
hazardous waste disposal regulations.
7. Storage and handling

Handling Avoid breathing vapours or mists generated by this product. Use in a well-ventilated
location. Open containers slowly, on a stable surface.
Storage Store containers in a cool, dry location, away from direct sunlight, sources of intense
heat, or where freezing is possible. Store away from incompatible materials. Keep
container tightly closed when not in use.
MT 5, MT 10, MT 20 versiondatum 05-05-10 Sida 1 / 8

8. Exposure control / personal protection
Ventilation protection Use adequate ventilation. Ensure eyewash/safety shower stations are
available.
Respiratory protection Use NIOSH approved respirators if ventilation is inadequate to control
vapours or mists.
Hand protection Wear chemically impervious gloves.
Eye protection Splash goggles or safety glasses.
Body protection Use body protection appropriate for task.
9. Physical and chemical properties

Appearance liquid
Colour green-yellow
Odour aromatic
pH 3,5
Melting point -2,2° C
Flammable point >100 ° C
Relative density 1,03
Solubility in water 100 %
10. Stability and reactivity

Stability Stable.
Decomposition products Oxides of sulphur, oxides of nitrogen and hydrogen chloride.
Materials with which sub-
stance is incompatible This product is not compatible with strong bases, strong acids, reducing
agents and strong oxidisers.
Hazardous Polymerisation Will not occur.
Conditions to avoid Avoid contact with incompatible chemicals.
11. Toxicological information

Health-endangering characteristics
Eye contact May cause severe corrosive damages.

Skin contact May cause severe corrosive damages.
Inhalation Inhalation of dust may cause irritation.
Chronically effects Prolonged or repeated exposure may cause destruction of tissue.
12. Ecological information

Due to corrosive nature of the material, it is anticipated that this product can be harmful to
animal and aquatic life. The product breaks slowly down organic compounds.
AQUATIC TEST DATA
Rainbow trout LC50:8,7 mg/l

96 h static acute bioassay NOEL: 6,5 mg/l
Bluegill sunfish LC50:12,1 mg/l
96h static acute bioassay NOEL: 6,5 mg/l
13. Disposal considerations

Will be handled as per local regulations, e.g. neutralisation.

14. Transport information
ADR/RID (land transport) Class 8.40 (b)
UN No 3265
Proper shipping name Corrosive Liquid, n.o.s (5-Chloro-2-Methyl-4-isothiazolin-3-one, 2-
Methyl-4-Isothiazolin-3-one.
IMDG (ship transport) Class 8
EMS No 8-15
Packaging group II
MFAG table No 760
Label 8
ICAO/IATA 8
15. Regulatory information

Classification
Symbol C
Product contains 5-Chloro-2-Methyl-4-isothiazolin-3-one (CAS 26172-55-4), 2-Methyl-4-
Isothiazolin-3-one (CAS 2682-20-4)
Risk and safety phrases
R34 Corrosive.
R43 May cause allergy when skin contact
S26 When sprinkling in eyes, immediately flush with plenty of water for at
least 15 minutes and get medical attention.
S27 Take off splashed clothes immediately.
S28 When skin contact, wash immediately with plenty of water.
S37/39 Wear gloves and goggles when using the product.
S45 Get medical attention when feeling sick or in an accident. Show if
possible
the label.
16. Other information

To the best of our knowledge, the information contained herein is accurate.

MT 10
Commercial name P3-ultrasil 10 ( MT 10 )
Application Cleaning Fluid
Supplier ENWA AB
Tel: +46(0)31 – 742 92 50
Fax: +46(0)31 – 742 92 60
2. Composition
Chemical name Cas.no. Contents Symbols
Sodium hydroxide 1310-73-2 15-30% C, R35

Phosphate - 5-15% -
Gluconat 527-07-1 5-15% -
EDTA 64-02-8 15-30% Xi, R36
Alkyl benzene sulfonate 68081-81-2 <5% Xi, R36/38
Corrosive
Skin contact Promptly wash with lots of water and get medical attention. Take off splashed clothes.
Inhalation Fresh air and rest. Seek medical assistance when continuous trouble.
Swallowing Give large quantities of milk or water for thinning. Seek medical assistance
immediately.
Remove the product if possibly. Others, according to general fire fighting equipment.

Contain all spilled material. Small quantities can be flushed by water. Contact rescue services at
larger quantities. At larger wastage into water,contact water works alt. purifying plant.

Handling Avoid getting this product to skin and eyes. Avoid breathing of dust. Do not mix with
acid products. When dissolved the product will be added slowly into cold water.
Storage Keep away from children in a closed original packing. Do not keep together with
victuals or pharmaceutical. Keep away from acid products.

− Use safety gloves and safety glasses or face mask.
− Use breathing protection with dust filter when dusty
− Ensure there is water available.

Appearance Powder with pearls
Colour White
Odour Neutral
pH concentrate -
pH value >13 in 1% solution
Density 0,900 - 1,100 kg/l

Will generate heat in contact with acids.

Eye contact May cause severe corrosive damages.

Skin contact May cause severe corrosive damages.
Inhalation Inhalation of dust may cause irritation.
Swallowing May cause severe corrosive damages.

The product contains EDTA, which is a substance that forms heavy alloys. There is a risk of mobility in
water environment.

Will be handled as per local regulations, e.g. neutralisation.

ADR/RID (land transport) Class 8.41 (b)
UN No 1823
Faro No 80
IMDG (ship transport) Class 8, page 8225
EMS No 8-06
Packaging group II
MFAG table No 705
Label 8

Classification
Symbol C
Product contains Sodium hydroxide
R35 May cause severe corrosive damages.
S22 Avoid breathing dust.
S26 When sprinkling in eyes, immediately flush with plenty of water for at
least 15 minutes and get medical attention.
S37/39 Wear gloves and goggles when using the product.
S45 Get medical attention when feeling sick or in an accident. Show if
possible the label.

To the best of our knowledge, the information contained herein is accurate.

MT 20
Commercial name Sulphamic Acid ( MT 20 )

Application Cleaning Fluid
Supplier ENWA AB
Tel: +46(0)31 – 742 92 50
Fax: +46(0)31 – 742 92 60
2. Composition
Chemical name Cas.no. Contents Symbols
Sulphamic Acid 5329-14-6 min 99.5 % Xi; R36 / 38
Irritant for eyes and skin
Inhalation Fresh air, warmth, rest, possibly breathing help. Seek medical assistance.
Skin contact Promptly wash with lots of water. Take off splashed clothes. Corrosive action shall be
treated by medical assistance.
.
Swallowing Give large quantities of milk or water. Do not induce vomiting. Seek medical
assistance immediately.
Non-combustible.
Note: Wear breathing apparatus against sulphur oxide when burning.

Contain all spilled material. Small quantities can be flushed by water.
Contac rescue services at larger quantities. At larger wastage into water,
contact water works alt. purifying plant.

Handling See to good ventilation. Possibility to eye flush and emergency shower.
Storage Store in a cool dry area.

Use safety gloves and safety glasses or face mask.
Use breathing protection with dust filter when insufficient ventilation

Appearance Powder
Colour White
Odour Odourless
Density kg/m3 2120
Boiling point(°C) Dissolved
Melting point(°C) 205
Solubility in water 213 g/l at 20°C
470 g/l at 80°C
Solubility in org.sol. e.g.. alcohols
Flammability point (°C) -
pH-value 1.1 - 1.3 in 1 % solution

When heating, poisoning gases as sulphur dioxide and sulphur trioxide can be formed. Can cause
corrosion on metals, textiles and ordinary structural material.

Inhalation Can cause irritation of the nose, throat and respiratory system.
Skin contact May cause skin irritation, even caustic on wet skin.
Eye contact Can cause severe irritation when sprinkled in eyes. Risk of lasting eye damage.
Swallowing Can cause corrosive damage with vomiting and stomach pains. Even risk of
shock and damage of kidney.
LDLo (rat, oral) 1600 mg / kg
LD50 (rat, oral) 2065 mg / kg

Sulphamic acid will be dissolved in water and form a strong, sour solution. A 1 % solution has appr.
pH 1.2.

Absorb spillage or other absorbent material and dispose of as solid waste as per local regulations.
E.g. incineration.

ADR/RID (land transport)
UN No 2967
Proper ship name Sulphamic acid
Class / division 8, 63 (c)
Faro No 80
ADR-label 8
TK-id 2155
IMDG (ship transport)

Class / division 8
EMS No 8-08
UN-No 2967
Packaging group III
MFAG No 700
Marine pollutant -
DGR (air transport)

Class / division 8
UN-No 2967

Classification
Health-endangering chemical product

Symbol Andreas cross
Faro character Irritating
Biological dangerous chemical product

Symbol No marking obligation
Inflammable chemical product

Symbol No marking obligation
Product contains
Sulphamic acid

R36/38 Irritate eyes and skin
S26 In case of contact with eyes, rinse immediately with plenty of water and
seek
medical advice.
S28 In case of contact with skin, wash immediately with plenty of water.
Other information on the label

EU-label J
EU-No 200-001-8
Label version A

The main supplier is associated to the REPA-register for all kinds of material. Information can be
obtained from
REPA, Telephone No: +46(0)200-880310.

OPERATION AND MAINTENANCE
SA 650
ENGLISH
Nr. 530257
CONTENTS
1. SAFETY REGULATIONS:........................................................................................ 4
2. GENERAL PROPERTIES ........................................................................................ 4
3. INTENDED RANGE OF APPLICATION................................................................... 4
4. TRANSPORT AND HANDLING ............................................................................... 5
5. UNPACKING ............................................................................................................ 5
6. LOCATION OF WATER FILTER .............................................................................. 5
6.1. FRAME ............................................................................................................... 5
6.2. VENTILATION..................................................................................................... 5
7. INSTALLATION........................................................................................................ 6
7.2. PNEUMATIC CONNECTION .............................................................................. 7
7.3. CONNECTION TO THE WATER NETWORK..................................................... 7
7.4. CONNECTION TO THE RO-UNIT ...................................................................... 7
8. FUNCTION............................................................................................................... 8
8.1. FILTRATION POSITION, Normal position .......................................................... 8
8.2. BACK WASH POSITION .................................................................................... 8
8.3. RINSE POSITION ............................................................................................... 8
9. FILLING INSTRUCTION .......................................................................................... 9
10. START UP .......................................................................................................... 10
10.1. START OF ADDITIONAL RINSE ...................................................................... 10
11. DIMENSIONS AND TECHNICAL DATA............................................................. 11
12. ROUTINE SERVICE MEASURES ...................................................................... 11
12.1. MAINTENANCE SCHEDULE ........................................................................... 11
13. SCRAP OF WATER FILTERS ............................................................................ 11
14. TROUBLE SHOOTING AND MEASURES AT CLOSING DOWN ...................... 11
15. DECOMPRESSION ............................................................................................ 12
16. FLOW DIAGRAM................................................................................................ 12
17. SPARE PART LIST............................................................................................. 13
2/13
ENGLISH
Nr. 530257
MACHINE TYPE PLATE
ADRESS TO NEAREST SERVICE CENTER

For information regarding nearest authorized service agent, please contact:
ENWA AB
Tel.: +46 (0)31-742 92 50
Fax: +46 (0)31-742 92 60
e-mail: service@enwa.se
In event of failure or breakdown of the filter, shutdown the filter and contact a service
agent. Insist on original spare parts only. Attempt to rectify faults without above mention
recommendations could jeopardize future reliability of equipment.
Always give the ID-number of Your filter when contacting a service agent
3/13
ENGLISH
Nr. 530257
INTRODUCTION
Keep this instruction safe and within reach in connection with the filter. Read this
instruction entirely before the start of the filter. The installation of the filter and
also all engagement that will occur must be done according to current rules for
electric equipment and personal safety.
1. SAFETY REGULATIONS
BEFORE ENGAGEMENT IN THE WATER FILTER SEE TO THAT IT IS WITHOUT

PRESSURE. AUTHORIZED PERSONNEL MUST DO ENGAGEMENT IN THE UNIT,
EVEN MINOR.
THIS UNIT IS NOT INTENDED FOR USE OUTDOOR. THE FILTER WILL FULFILL
THE SAFETY REGULATIONS ACCORDING TO EUROPEAN STANDARD EN 292
AND DIRECTIVE 89/392.
The unit must be handled and conducted by authorized service or for this purpose any
other qualified and educated personnel. The producer or the retailer must approve every
operation or change in the unit so that his or her responsibility and guarantees can be
valid. Any operation in the safety equipment of the unit can imply that existing European
safety regulations will be neglected.
2. GENERAL PROPERTIES
In ENWA’s water purification filters the water flows through a tank that is filled with filter
material adjusted to the quality of the incoming water. The filter unit can be adjusted so it
filtrates contaminants as humus, iron, manganese, particles etc. The water that will be
purified pass through the water filter where the contaminants remains. The filter material
in the water filter will collect the contaminants. A backpressure valve will then wash the
filter material automatically. The contaminants will then flush to an existing outlet.
3. INTENDED RANGE OF APPLICATION
ENWA’s water purification filters are constructed and made for purification of water in
normal industrial and domestic applications. The water filters must not be used in rooms
where risk of fire is obvious. e.g. storage of inflammable liquids, gases or other
substances. In applications where the water will be stored in a tank after the purification
in the water filter, suitable equipment must be mounted after the tank to secure the water
quality. Contact the suppliers in this matter. The water filter may only be used in
applications that it is originally designed for and according to this instruction. All other is
wrong use and the producer as well as the supplier will not take on the responsibility for
damages or reclaims.
4/13
ENGLISH
Nr. 530257
The unit shall only be lifted and transported according to below instructions.
− Transport the unit with the delivered packing.

− Protect the thermoplastic surface on the filter tank in all transports.
5. UNPACKING
DEPOSIT ALL PACKING IN AN ENVIRONMENTAL WAY
After unpacking, check for damages. If you feel uncertain, don’t use the unit until you
have contacted the producer or your retailer. All packing material (cling film, plastic
bags, nails, screws, wood, metal sting, etc.) shall be treated as dangerous goods,
especially for children, and must be assorted and deposited according to existing
environmental directions.
6. LOCATION OF WATER FILTER

6.1. FRAME
After unpacking the unit and preparation of the room, please see to following:
− Have adequate Space around for operation and maintenance.
− The frames for the storage of the water filter must be on a plain surface and
manage the total weight of the water filter.
MAKE SURE THAT THE UNIT IS PLACED SO THAT IT CAN BE USED IN A SAFE WAY AND EASILY
MAINTAINED AND INSPECTED.
6.2. VENTILATION
The right placing of the water filter can extend the length of life; the room must be
spacious, dry and well ventilated. The following surrounding conditions must be fulfilled:
Surrounding temperature in the room: +5 - +45 °C
Temperature for incoming water: +4 - +45 °C
Max. pressure: 6 bar
5/13
ENGLISH
Nr. 530257
7. INSTALLATION
Refilling
Filling
Control media.
Automatic
Valve 1
Automatic valve.
1.Service position
Water in 2.Back washing.
3.Rinse position.
Control media:
Air alt. water. 3-4 bar.
2 inlet Pressure: max 6 bar.
Temp: 1°C-40°C
outlet Required pumpcapacity : 180 l/min.
Water out Control valves.

controled by R.O.
unit PLC.
Filter Drain flow restriction

Tank
drain
To waste Emptying
Figure 1Seafilter
6/13
ENGLISH
Nr. 530257
7.1. PNEUMATIC CONNECTION

− Connect to pilot valves on the RO-unit.
− Max pressure on incoming pressure air is 4 bar.
7.2. CONNECTION TO THE WATER NETWORK
Mount shut off valves in incoming and outgoing water pipes so that the water filter can
be isolated when maintenance and service is needed. Rinsing water is conducted out of
the water filter to waste. IMPORTANT! The back wash outlet cannot be mounted directly
to waste. An air-break of at least 50 mm is needed.
FAULTS THAT ARISE FROM NEGLIGENCE TO FOLLOW SPECIFIED RECOMMENDATIONS COULD

LEAD TO SUSPENSION OF THE GUARANTEE FROM FACTORY AND AGENT.
7.3. CONNECTION TO THE RO-UNIT
The electrical connections of the solenoid valves are connected to terminals in the
control cabinet
Connect the treated outgoing water from the backwash valve to the inlet of the RO-unit.
Connect compressed air to the filter rate controller
7/13
ENGLISH
Nr. 530257
8. FUNCTION
8.1. FILTRATION POSITION, Normal position
The water from the incoming pipe will pass through the water filter by an inlet valve and
will be treated by the filter material in the filter tank and pass out through the water filter
by an outlet valve. The water filter works automatically, specially made for the specific
flow and the quality of the water. Therefore should any manual adjustment of the
automatic valve not be done.
8.2. BACK WASH POSITION
The water from incoming pipe will pass through the water filter by the inlet valve and
then pass upwards through the filter material in the filter tank and will then pass out
through the water filter by the back wash outlet to waste. When the filter material is back
washed it raises and accumulated contaminants will flush to waste. Necessary pump
capacity: 180 liters/min.
8.3. RINSE POSITION
pass through the filter material in the filter tank and will then pass out downwards
through the back wash outlet to waste.
8/13
ENGLISH
Nr. 530257
9. FILLING INSTRUCTION
Refilling of filter material
− Close the valve for incoming and outgoing lead.

− Make sure that the filter is without pressure.
− Open the refilling cap and fill the filter tank with app. 40 liters of water.
− Fill the filter material according to Figure 1.
− Fill the filter tank completely with water.
− Mount the refilling cap. Tighten all the screws a little bit at first and then
harder.
Always use washers under screws.
150 liters (3 sacks) Anthracite N2
204 liters (12 sacks) 0,8-1,2 mm filtersand
68 liters (4 sacks) 3-5 mm filtergravel
34 liters (2 sacks) 5-10 mm filtergravel
Pre-fill with 40 liters of water before filling

Figure 2 Filling instructions filter media to protect the distribution
system.
9/13
ENGLISH
Nr. 530257
10. START UP
Check that the installation is in accordance with the instructions:
Before start of the water filter, Check:
− That the connections to the water filter are correct.

− That the connection for the drain of rinse water is correct.
− That the filter is connected correctly to the RO-unit.
Keep the valves for incoming and outgoing lead closed.
1. Switch on the power on the RO-units circuit breaker.

2. Set the switch marked “System “ in position ON.
3. Activate a backwashing cycle by pushing the button marked “Manual backwash”
4. Open the valve for incoming water slowly and fill the filter tank with water until
water flows out through the drainpipe. It is very important to fill the filter tank
slowly, or there will be a risk for filter media to accompany water into the
automatic valve.
5. Open the valve fully and rinse the filter, repeat until the water in the drain outlet is
clear.
6. Open the valve for water outlet.
The back wash cycle program on the filter has been factory preset to be back washed
10 minutes every 4:th day. The rinse has been set to 5 minutes. However the timers
may be lengthen or shorted in time to suit local condition. The timers for the back wash
cycle are changed in the control system located in the electrical cabinet of the RO-unit.
Change timer settings in the control unit.

T3 backwash
1. On the front panel of the control unit, press the OK button. T4 day
2. Press arrow down until PARAMETER flashes. T8 rinse
3. Press OK, PARAMETER T1, will flash.
4. Press arrow up unlit chosen timer T3, T4 resp. T8
5. To change timer setting press arrow left and change the time with the arrow key.
6. When the timer is changed, press OK twice and then ESC to return to normal
operation.
When the sandfilter is controlled by the electrical cabinet of the RO-unit, the button
“SYSTEM” must be turned to ON. Then the feedwaterpump starts and the valves on the
filter become alive. After the filter material has been washed, the button “SYSTEM” must
be turned back to OFF. (For more instructions read the manual for the RO-unit)
10.1. START OF ADDITIONAL RINSE
Press the button marked ”Manuel backwash”
10/13
ENGLISH
Nr. 530257
Type Height Inlet connection Outlet connection Weight Air

SA 650 1800 mm R 2” R 2” 930 kg Max 6 bar
12. ROUTINE SERVICE MEASURES

STOP THE UNIT BEFORE EACH SERVICE OPERATION, DECOMPRESS AND CUT OFF THE
CURRENT.
12.1. MAINTENANCE SCHEDULE

Below maintenance schedule is recommended.
Each Month
Check that the water is clean at the end of the back washing. Adjust the back washing
times if needed.
13. SCRAP OF WATER FILTERS
If the water filter needs to be scrapped, a dismounting of the unit is necessary and
assortment of the different materials according to environmental rules.
14. TROUBLE SHOOTING AND MEASURES AT CLOSING DOWN

CURRENT. MAKE SURE THAT THE WATER FILTER IS SEPARATED FROM THE DISTRIBUTION
NET.
PROBLEM / POSSIBLE REASON / MEASURES
The feed water pump will not give any water.

The leads are frozen.
− Surrounding temperature is too low and the lead is full of ice.
The water filter does not work correctly.

The water filter gives poor quality on outgoing water.
− Back wash the filter
− Control the function of the automatic valve
− Control the function of the timer
− Control the water flow through the filter
11/13
ENGLISH
Nr. 530257
15. DECOMPRESSION
Do as follows:
− Close the inlet and outlet valve.
− Relief the pressure in the unit.
− Shut of the power supply.
16. FLOW DIAGRAM

1
2
3
4
1 3
1
2
3
3
1
Figure 3 Flow diagram of the water filter
12/13
ENGLISH
Nr. 530257
17. SPARE PART LIST
NR DESCRIPTION PART NR
1 Pneumatic solenoid valve 5420 56-700
3 DLFC 20-60711
4 Siata valve 350F 22-SIV350F
5 Piston kit washer 22-350-106/05 Figure 4

6 Spare kit principal 22-350-102/05 Figure 4
Figure 4 siata valve kit
13/13
SA -33 -41 /2510 duplex for RO
ENGLISH
nr. 530487

CONTENTS
1. SAFETY REGULATIONS ..................................................................................... 4

2. GENERAL PROPERTIES..................................................................................... 4
3. INTENDED RANGE OF APPLICATION ............................................................... 4
4. TRANSPORT AND HANDLING............................................................................ 5
5. UNPACKING ........................................................................................................ 5
6. LOCATION OF WATER FILTER .......................................................................... 5
6.1. FRAME ................................................................................................................. 5
6.2. VENTILATION ...................................................................................................... 5
7. INSTALLATION .................................................................................................... 6
7.1. CONNECTION TO THE WATER NETWORK ...................................................... 6
7.2. THE ELECTRICAL CONNECTIONS .................................................................... 7
8. FUNCTION ........................................................................................................... 7
8.1. FILTRATION POSITION, Normal position ............................................................ 7
8.2. BACK WASH POSITION ...................................................................................... 7
8.3. RINSE POSITION................................................................................................. 7
9. FILLING INSTRUCTION....................................................................................... 8
10. START UP ............................................................................................................ 9
11. FUNCTIONS AND SETTINGS ........................................................................... 10
11.1. RINSING FREQUENCY ..................................................................................... 10
11.2. CLOCK ............................................................................................................... 10
11.3. START OF ADDITIONAL RINSE........................................................................ 10
11.4. THE BACKWASH CYCLE PROGRAM............................................................... 10
12. DIMENSIONS AND TECHNICAL DATA............................................................. 11
13. ROUTINE SERVICE MEASURES ...................................................................... 11
13.1. MAINTENANCE SCHEDULE ............................................................................. 11
14. SCRAP OF WATER FILTERS ............................................................................ 11
15. DECOMPRESSION ............................................................................................ 12
16. SPARE PART LIST............................................................................................. 12
2/13
ENGLISH
nr. 530487
WATER FILTER SA -33, -41/2510 duplex
MACHINE TYPE PLATE

ENWA AB
Backa Strandgata 8
SE-422 46 Hisings Backa
SWEDEN
Tel.: +46 (0)31-742 92 50
Fax: +46 (0)31-742 92 60
3/13
ENGLISH
nr. 530487
INTRODUCTION

EVEN MINOR.
in the water filter, suitable equipment must be mounted after the tank to secure the water
quality. Contact the suppliers in this matter. The water filter may only be used in
damages or reclaims.
4/13
ENGLISH
nr. 530487

5. UNPACKING

6.1. FRAME
− The frames for the storage of the water filter must be on a plain surface and
manage the total weight of the water filter.
6.2. VENTILATION
5/13
ENGLISH
nr. 530487
7. INSTALLATION
7.1. CONNECTION TO THE WATER NETWORK
Mount shut off valves in incoming and outgoing water pipes so that the water filter can
be isolated when maintenance and service is needed. Rinsing water is conducted out of
the water filter to waste.
IMPORTANT! The back wash outlet cannot be mounted directly to waste. An air-break
of at least 50 mm is needed.
FAULTS THAT ARISE FROM NEGLIGENCE TO FOLLOW SPECIFIED RECOMMENDATIONS COULD

LEAD TO SUSPENSION OF THE GUARANTEE FROM FACTORY AND AGENT.
Figure 1 installation
6/13
ENGLISH
nr. 530487
7.2. THE ELECTRICAL CONNECTIONS
The transformer is integrated in the control unit for the RO. The transformer is then
connected according to the electrical drawings in the instructions for the RO.
8. FUNCTION
8.1. FILTRATION POSITION, Normal position
The water from the incoming pipe will pass through the water filter by an inlet valve and
will be treated by the filter material in the filter tank and pass out through the water filter
by an outlet valve. The water filter works automatically, specially made for the specific
flow and the quality of the water. Therefore should any manual adjustment of the
automatic valve not be done.
8.2. BACK WASH POSITION
then pass upwards through the filter material in the filter tank and will then pass out
through the water filter by the back wash outlet to waste. When the filter material is back
washed it raises and accumulated contaminants will flush to waste. When the filter is in
the backwash position it will block the RO unit automatic. The feedwaterpump will still be
working.
8.3. RINSE POSITION
pass through the filter material in the filter tank and will then pass out downwards
through the back wash outlet to waste.
OBS! The water that comes out during backwash and rinse positions is not filtrated.
7/13
ENGLISH
nr. 530487
9. FILLING INSTRUCTION
Refilling of filter material
− Close the valve for incoming and outgoing lead.

− Make sure that the filter is without pressure. (17.0)
− Dismount the control valve.
− Empty the tank by placing it horizontal. Use a water hose and flush out the
filtermaterial.
− Make sure that the central pipe hasn’t been defected. Cover the top of the
pipe while filling the filter. Fill the filter material according to Figure 4 .
− Fill the filter tank completely with water.
− Mount the control valve.
Amount of filter medium (litres)
SA-33 SA-41
Antrazite 21 48
ø 1-2 mm sand 21 48
ø 3-5 mm gravel 9 17
ø 5-10 mm gravel 5 11
Fill with litres of antrazite

Fill with Ø 1-2 mm filtersand
Fill with Ø 3-5 mm filtergravel
Fill with Ø 5-10 mm filtergravel
Pre fill with 10 litres of water before filling

filter media to protect the distribution system
Figure 2 Filling instructions
8/13
ENGLISH
nr. 530487
10. START UP
Check that the installation is in accordance with the instructions:
Before start of the water filter, Check:
− That the connections to the water filter are correct.

− That the connection for the drain of rinse water is correct.
− That the filter is connected correctly to the RO-unit.
Keep the valves for incoming and outgoing lead closed.
1. Filter 1 is when delivered programmed to start backwash. If not, activate a

backwashing cycle by following instructions 11.3.
The filters will start by automatic when the RO is started. Follow the instructions in the
manual for the RO.
2. Open the valve for incoming water slowly and fill the filter tank with water until
water flows out through the drainpipe. It is very important to fill the filter tank
slowly, or there will be a risk for filter media to accompany water into the
automatic valve.
3. Open the valve fully and rinse the filter, repeat until the water in the drain outlet is
clear.
4. Open the valve for water outlet.
5. Repeat 1-4 on filter 2
9/13
ENGLISH
nr. 530487
11. FUNCTIONS AND SETTINGS
11.1. RINSING FREQUENCY
The filter is set to backwash after 24 hours of running of the RO.

All of the tabs are slide out. The red pointer is marking today.
If the rinsing frequence needs to be changed, set the days that

regeneration is to occur by sliding tabs on the skipper wheel
outward to expose trip fingers.
11.2. CLOCK
The time showing has no importance since the timer only works Figure 3 rinsing frequence
when the RO calls for water.
11.3. START OF ADDITIONAL RINSE

Turn the manual regeneration knob clockwise. This slight
movement of the manual regeneration knob engages the program
wheel and starts the regeneration program.
The black center knob will make one revolution in the following
approximately three hours. Even thought it takes three hours for
this center knob to complete one revolution, the regeneration
cycle of your unit might be set only one half of this time. In any
event, conditioned water may be drawn after rinse water stops
flowing from the water conditioner drain line.
11.4. THE BACKWASH CYCLE PROGRAM Figure 4 timer

The backwash cycle program on your water conditioner has been factory preset,
however, portions of the cycle or program may be lengthened or shortened in time to
suit local conditions.
To expose cycle program wheel, grasp timer in upper left-hand corner and pull,
releasing snap retainer and swinging timer to the right. To change the regeneration cycle
program, the program wheel must be removed. Grasp program wheel and squeeze
protruding lugs toward center, lift program wheel off timer. (Switch arms may require
movement to facilitate removal.)
10/13
ENGLISH
nr. 530487
To change the length of backwash time, add or remove pins

as required. The number of pins times two equals the
backwash time in minutes.
The Brine And Rinse Time and Rapid Rinse time are changed
in the same way.
Your filter has been programmed as the table shows

SA-33. SA-41
(pins) Backwash 8 10
(pins) Rapid rinse 8 8 Figure 5 Program
(pins) Finishing 4 4
Type Inlet connection Outlet connection Drain connection Pressure

SA -33 G½” G½” G 1/2 ” Max 10 bar
SA -41 G½” G½” G 1/2 ” Max 10 bar

CURRENT.
13.1. MAINTENANCE SCHEDULE
Each Month:
Check that the water is clean at the end of the back washing. Adjust the back washing
times if needed.
Check that the motor for the timer is working.
11/13
ENGLISH
nr. 530487
15. DECOMPRESSION
Do as follows:
− Close the inlet and outlet valve.
− Relief the pressure in the unit by making an additional rinse.
− Shut of the power supply.
16. SPARE PART LIST
Figure 6 Control valve
12/13
ENGLISH
nr. 530487
Figure 7 Partslist
13/13
N 40-RO
English
nr. 530247
CONTENTS
1. SAFETY REGULATIONS .................................................................................... 4

2. GENERAL PROPERTIES ................................................................................... 4
3. INTENDED RANGE OF APPLICATION ................................................ 4
4. TRANSPORT AND HANDLING .................................................................... 5
5. UNPACKING ................................................................................................................... 5
6. LOCATION OF WATER FILTER .................................................................. 5
7. INSTALLATION ............................................................................................................ 6
8. FUNCTION ....................................................................................................................... 6
9. START UP ......................................................................................................................... 7
10. DIMENSIONS AND TECHNICAL DATA ............................................... 7
11. ROUTINE SERVICE MEASURES .............................................................. 7
12. SCRAP OF WATER FILTERS ........................................................................ 7
N-40-RO-Eng 2/8
English
nr. 530247
MACHINE TYPE PLATE

ENWA AB
tel.: +46 (0)31-742 92 50
fax: +46 (0)31-742 92 60
N-40-RO-Eng 3/8
English
nr. 530247
INTRODUCTION

EVEN MINOR.
in the water filter, suitable equipment must be mounted after the tank to secure the
water quality. Contact the suppliers in this matter. The water filter may only be used in
damages or reclaims
N-40-RO-Eng 4/8
English
nr. 530247

5. UNPACKING

FRAME
The frames for the storage of the water filter must be on a plain surface and manage the
total weight of the water filter.
VENTILATION
N-40-RO-Eng 5/8
English
nr. 530247
7. INSTALLATION
The filter is connected after the RO-unit.

Two valves should be mounted in incoming water pipe that makes it possible to shut off
the water from the RO and to connect flush water.
It should also be mounted two valves in out coming water pipe so the water can be
connected to waste.
8. FUNCTION
FILTRATION POSITION, Normal position
The water from the incoming pipe will pass through the water filter from below and will
be treated by the filter material in the filter tank and pass out through the water filter by
an outlet valve.
FLUSH POSITION
The filter should be flushed on regular basis with a higher pressure than the RO-unit has
the capacity of (app.20 liters/min) to remove captured contamination and media fines.
Flush the filter with clean water and let the out coming water go to waste for about three
minutes or until the out coming water is clear.
N-40-RO-Eng 6/8
English
nr. 530247
9. START UP
Before starting up the filter it should be flushed. (Use the instructions 8.2)
Now the filter can be connected so the water flows from the RO-unit, through the filter
and into the store tank. Then the filter is in filtration position.
Type Height Inlet connection Outlet connection Weight Air

N 40-RO 1100 mm G 1” G 1” 70 kg Max 6 bar
STOP THE RO-UNIT BEFORE EACH SERVICE OPERATION
FLUSH
Depending on how much water the RO the produce the frequency of the flushing can
vary. But it should be flushed about once/month. (Use instructions 8.2)
CONTROL AND REFILLING OF FILTER MATERIAL

The level of filter material should be controlled about 3 times/year. Compare the level
with the mark outside the tank. If it’s necessary, refill with material MD.
N-40-RO-Eng 7/8
English
nr. 530247
ENWA
N-40-RO-Eng 8/8
Log sheet
Unit ID nr: Date:
Type of unit: Installed by:
DATE FEED WATER- WATER PRESSURE BRINE PRODUCKT- Conductivity CHANGE OF MEMBRANE NOT. SIGN.
PRESSURE PRESSURE AFTER PUMP PRESSSURE FLOW FILTER CLEANING/
AFTER FILTER After menbrane CARTRIDGE CONSERVATI
ON.
PI 2010 PI 2011 PI 2012 PI 2050 FI 2060 µS
www.enwa.se - info@enwa.se
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE/TILLVERKARDEKLARATION
DECLARATION OF CONFORMITY
ENWA AB
Backa Strandgata 8
SE-422 46 HISINGS BACKA
intygar i enlighet med vårt ansvar att produkten

declare under our sole responsibility that the product
Alla ENWA AB avsaltningsanläggningar av typ MT

All ENWA AB desalination units, type MT.
till vilken denna försäkran relaterar överensstämmer med nedanstående

standard(er) eller andra normgivande dokument och (om tillämpligt) följer
villkoren i följande direktiv
to which this declaration relates is in conformity with the following standard(s) or other
normative document(s) and (if applicable) following the provisions of the following directives
Maskindirektivet (89/392/EU)
Lågspänningsdirektivet (73/235/EU)
EMC-direktivet (89/336/EU)
Direktivet för tryck bärande anordningar (PED) (97/23/EU)
Machine Directive (89/392/EU)
Low Voltage Directive (73/235/EU)
EMC Directive (89/336/EU)
PED Directive (97/23/EU)
Tillämpade standarder: EN 292-1, EN 292-2

Applicable standards EN 60 204-1
EN 50 081-1, EN 50 081-2, EN 50 082-1, EN 50 082-2
EN 13 445
Vi försäkrar att angiven materiel uppfyller ovan angivna krav samt genomgått och godkänts vid
provkörning på fabrik hos ENWA AB
We declare that the equipment in question complies with the requirements stated above and that it has passed the
factory acceptance test at ENWA AB
2006-08-30
Datum Date Underskrift Signature VD Managing Director
Befattning Position
Peter Malmer
Namnförtydligande Clarification
Enwa AB, Head Office Enwa AB Enwa AB

Backa Strandgata 8 Kantarellvägen 60 Lärjungevägen 4
SE-422 46 Hisings Backa Box 268 – SE-863 02 Sundsbruk SE-136 69 Haninge
Sweden Sweden Sweden
Tel:+46 (0)31 742 92 50 Tel: +46 (0)60 537170 Tel: +46 (0)8 7763323
Fax:+46 (0)31 742 92 60 Fax: +46 (0)60 537066 Fax: +46 (0)8 7761601
www.enwa.se - info@enwa.se

Manual Komplett MT 10-35 ENG

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MT 10-35T SRH

4. Control system for RO with SA-650SW

5. Product component data

7. Operational manual Sandfilter

8. Operational manual Deacidificationfilter

10. Declaration of Conformity

1. GENERAL SAFETY INSTRUCTIONS ............................................................. 4

ADDRESS OF NEAREST SERVICE CENTER

1. GENERAL SAFETY INSTRUCTIONS

COMPLIANCE WITH ALL APPLICABLE ELECTRICAL REGULATIONS IS OF

THIS EQUIPMENT IS NOT INTENDED FOR PLACEMENT OUTDOORS.

The equipment shall be served and maintained by authorized service staff or

2. INTENDED APPLICATION AREAS

ENWA’s desalination systems are designed and manufactured to purify water in

3. TRANSPORT AND HANDLING

− Whenever possible, transport the equipment in the supplied packaging.

- The ambient temperature may never exceed 45°C (113°F).

- There must be sufficient space for operation and maintenance.

Ensure that unanticipated leaks cannot cause damage.

6. DESCRIPTION OF THE PROCESS

Figure 1 Figure 2 Figure 3

The membrane is fitted in a pressurized vessel. This construction is referred to as an

Figure 4. Spiral wounded module

The product water flow can be seen on a flow instrument.

FLUSHWATER Int. 1/2”R (Pipe thread)

OUTLET TO WASTE Int. 1/2”R

PRODUCT TO WASTE Int. 1/2”R

PRODUCT TO TANK Int. 1/2”R

FEEDWATER Int. 1”R

7.1 PRODUCT WATER TO TANK

7.2 DISCHARGED BRINE AND PRODUCT WATER

NOTE: If a valve has been installed on a product, discharge or brine line, it

7.3 FLUSH WATER

When the system is stopped, it is automatically flushed with freshwater to remove

7.4 ELECTRICAL CONNECTIONS

Connect the electrical components as shown on the wiring diagram.

1. Check the oil level in the high-pressure pump.

Figure 6. Correct oil level

2. Check that the filter cartridges are installed and clean.

3. Check that the following valves are open:

− Feed water valve (HV-2010) Figure 7. HV-2010 open

− Manual flush water valve (HV-2020)

− Pressure control valve (PCV-250) shall be turned fully

Figure 9. PCV-2050 open

5. Start the feed water pump (FP-1010)

6. Turn off the conductivity meter (1u400)

After 5-10 minutes

8. Adjust the working pressure

9. Turn on the conductivity meter (1u400)

1. Check that the flush water valve (HV-2020) is open

2. Open the feed water valve (HV-2010)

4. Start the feed water pump (FP-1010)

5. Start the high-pressure pump (HPP-2010).

6. Adjust the working pressure

Figure 14. point 1,2,3,4,5,6

10. NORMAL STOP

1. Turn the switch labeled HP PUMP to OFF.

2. Turn the switch labeled SYSTEM to OFF.

SYSTEM SHUTDOWN FOR EXTENDED PERIODS

11. CHEMICAL CLEANING INSTRUCTIONS

CHEMICALS CAUSE IRRITATION TO THE SKIN, EYES AND THROAT. AVOID

MAY NOT BE INHALED!

READ THESE INSTRUCTIONS ON CHEMICAL CLEANING BEFORE