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kupke + wolf gmbh kupke + wolf gmbh
Hägerstr. 22 Werkstraße 226
27321 Thedinghausen / Germany 19061 Schwerin / Germany
D - 27321 Thedinghausen D - 19061 Schwerin
Tel. +49 (0) 4204 9165-0 Tel. +49 (0) 385 640 14-0
Fax +49 (0) 4204 9165 65 Fax +49 (0) 385 640 14-14
Spare parts and other components
Our range of supply for world-wide support
Phone
+49 (385) 64014 - 62
Fax
+49 (385) 64014 - 14
Spares@KuWo.com
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kupke + wolf gmbh kupke + wolf gmbh
Hägerstr. 22 Werkstraße 226
27321 Thedinghausen / Germany 19061 Schwerin / Germany
D - 27321 Thedinghausen D - 19061 Schwerin
Tel. +49 (0) 4204 9165-0 Tel. +49 (0) 385 640 14-0
Fax +49 (0) 4204 9165 65 Fax +49 (0) 385 640 14-14
Spare parts and other components
Our range of supply for world-wide support
Of course Kupke + Wolf is able to supply any required spares
for our modules within shortest time to any destination aroundthe world by sea or by air.
We work together with well-known world-wide courier services
to guarantee a trouble-free operation of our fuel oil systems
at any time and any place of the world.
If requested we are able to store spares for our customers
in our central warehouse to dispatch the goods within 24 hours.
Beside the production of fuel oil modules Kupke + Wolf also
supplies all kinds of components, systems and spares
of well-known manufacturers such as:
- Oily-water separators (HEISHIN-Pump Works)
- Viscosity control systems
- Fuel oil blending units
- bunker control systems
- flowmeters for most fluids
- filtration units (e.g. automatic filters)
- gear pumps, centrifugal pumps, screw pumps
- shut-off valves, ball valves, quick-closing valves
- fittings (e.g. thermometers, manometers)
- steam-, thermal oil- and electrical-operated heaters
We are proud of our wide range of supply which allows usto meet most of our customers requirements.
Just ask us about your demands and we surely can fulfil them.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Documentationfor
fuel oil supply and
booster module
Type: KAH-22-C60-2D-MC
ATTENTION!
Pumps with magnetic coupling are installed on this module.
Persons with pacemakers must not install, maintain and
operate the pumps.
Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Type of vessel: 2700 TEU CV
Hull no.: 8184/17
Com.: 17.283ME
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Contents
A. ............................................................. General technical information.........................................................................................................Technical specification
............................................................................................................General arrangement
........................................................................................................................... P+I diagram
....................................................................................................................................Item list
........................................................................................................................ Spare part list
B. .............................................General danger and safety information
C./D. ................................................................. Start-up/ Commissioning............................................................Start-up for fuel oil supply and booster module
......................................................................Flushing instructions for booster module
E. ................................................................................................. Electricity.........................................................Main control cabinet (Circuit diagram and parts list)
............................................................. Description and allocation of the keypad TD 200
...................................Control cabinet for supply pumps (Circuit diagram and parts list)
.................................Control cabinet for booster pumps (Circuit diagram and parts list)
................................................................Distribution box (Circuit diagram and parts list)
...................................................................Spare part list for supply and booster module
1. .................................................................................... Pumps with drive............Operating instructions screw spindle pumps with magnetic coupling (series K)............................................ Installation and maintenance instructions for electric motors
2. .......................................................................................................... Filter ........... Description and operating instructions for duplex filter 2.04.5 110.260 with DPI.........Description and operating instructions for the back-flushing filter type 6.61 Gr.15
......Description and operating instructions for duplex filter 2.06.5.4.195.250 with DPS
3. ............................................................................................... Flow meter ..................................................................................................................Maintenance VZO
4. ........................................................................................................ Tanks..............................................................................................................................Mixing tank...............................................................................Compensation damping pressure tank
................................................Mounting and operating instructions for float switches SR
..............................................................................................Automatic vent valve EF 8180
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
5. ....................................................................................... Heat exchanger .............................................................................Instructions for shell and tube heater MX
............................................................................Spare parts for shell and tube heater MX
6. ................................................................ Viscosity measuring system.......................................................................................................Viscosimeter series V92
............................................................. Instruction manual for FCX-CII series transmitters
........................................................Operating instructions for industry controller 93KU10
....................................................................................External set point value input 99bwa
.......................................................................................................Remote control units 929
...............................................................................................Additional analog inputs 99ax
.........................................................................................Resistance thermometer PT 100
7. ..................................................................................... Pressure control......................................................................Pressure relief valve SPVF (Technical data).....................................................................Pressure relief valve (Operating instructions)
8. ..................................................................... Instruments and sensors..............................................................................................................Pressure switch 900
...........................................................................................Differential pressure switch 920
.............................................................................Instructions (differential) pressure switch
9. ........................................................................ Heating medium control............Operating and installation instructions for straight through control valve BR 440
....................................................................Operation instruction for linear actuator CS20
..............................................................Operating and installation instructions for strainer
....................Operating and installation instructions for ball float steam traps CONA SC
10. ..................................................................................................... Valves................................................................................................................Change over valve............................................................................................................................. Ball valves
.......................................................................................................................Shut-off valves
..................................................................................................................Non-return valves
.........................................................................................................................Safety valves
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
A. Generaltechnical
information
ATTENTION!
Pumps with magnetic coupling are installed on this module.
Persons with pacemakers must not install, maintain and operate
the pumps.
ATTENTION!
It is not allowed to operate the pumps of fuel oil supply and
booster module, if the viscosity of used fuel is less than 4 mPas.
ATTENTION!
Pay attention at installation and operation of the fuel oil supply
and booster module on board that pressure surges will be
avoided in the fuel oil pipes from/to engine.
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process engineering • fuel oil modules • liquid systems
02.01.2006 ts17281me_e-mail.doc 1/9
D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
TECHNI CAL SPECIF ICATION
FOR FUEL OIL SUPPLY AND BOOSTER MODULE ME:
Shipyard: Stocznia Gdynia S.A.
Hull no.: 8184/16 - 20Type of vessel: 2700 TEU CV Ship Owner: Peter Döhle Schiffahrts-KG
Manufacturer: kupke + wolf gmbh
Project: 17281ME
Module-type: KAH-22-C60-2D-MC
BASIC TECHNICAL DATA:
MAIN DIESEL ENGINE:diesel engines manufacturer: MAN B&W
engine type: 7 S70 MC-C engine max. output: 21,770 kW nominal fuel consumption: 169 g/kWh + 5 % MDO
max. total HFO consumption (100 %): 4,471 l/h (at 0.908 kg/l)
heavy fuel oil type: IF 700 (700 mm²/s at 50 °C)
automatic back flush filter fineness: 10 µm absolute
heating medium: steam, 0.8 MPa absolutetrace heating: steam, 0.8 MPa absolute
voltage: 440 V frequency: 60 Hz
classification: GL
BASIC MODULE DESIGN DATA:
supply | booster part max. fuel oil operating pressure: 1.0 | 1.6 MPa gaugemax. fuel oil operating temperature: 100 | 160 °C
max. design pressure steam: 0.9 MPa absolute
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process engineering • fuel oil modules • liquid systems
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
BASIC MODULE OPERATING DATA:temperature at module outlet: 160 °C
viscosity at module outlet: 9.5 mPa s(equal to 10.5 mm²/s at 0.908 kg/l)
lowest assumed module inlet temp.: 70 °C
calc. mixed temp. in mixing tank: 117 °C assumed thermal loss between inlet
to engine and return to mixing tank: 5.4 °C
SUPPLY PUMP (with magnetic coupling):capacity: 5.6 m³/h
layout differential pressure: 0.5 MPaoperation viscosity approx.: 200 mm²/smin. operating viscosity for MDO service: 4.6 mm²/s
power absorbed at 1,000 mm²/s (cSt): 2.72 kW magnetic coupling: 20 Nm
electric motor: power: 3.6 kW revolution: 1,720 rpm
insulation class: F protection class: IP55
BOOSTER PUMP (with magnetic coupling):
capacity: 10 m³/hlayout differential pressure: 0.6 MPaoperation viscosity approx.: 28 mm²/s
min. operating viscosity for MDO service: 4.6 mm²/s power absorbed at 1,000 mm²/s (cSt): 7.36 kW
magnetic coupling: 20 Nmelectric motor:
power: 8.9 kW
revolution: 3,460 rpm
insulation class: F protection class: IP55
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
HEATER:max. capacity: 250 kW
saturated steam temperature: 170 °C saturated steam pressure: 0.8 MPa absolutemax. steam consumption: 435 kg/h
fuel oil inlet temperature: 117 °C max. fuel oil outlet temperature: 160 °C
capacity of each heater: 100 % fouling of each heater: 15 %
PIPING DIMENSIONS:
HFO into the module DN 50 MDO into the module DN 40 fuel oil out of the module DN 65
fuel oil return from main engine DN 65
steam inlet DN 40condensate outlet DN 25
MODULE DIMENSIONS: L (length): 4,200 mm
B (width): 1,600 mm H (height): 2,100 mm
Hm (height for maintenance of float switch in mixing tank) 2,300 mm
weight: approx. 2,800 kg
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
PRESSURIZED FUEL OIL SUPPLY AND BOOSTER MODULE ME TYPE: KAH-22-C60-2D-MC
P & I DIAGRAM no.: KAH-22000-C60-2D-MC-1/A
MAIN COMPONENTS
1. HFO/MDO - CHANGE OVER VAL VE, POS. 10.1
1 pc. manual operated change over valve, with two end position switches for remoteindication of status.
2. PRIM ARY FI LTER, POS. 2.1
1 pc. Duplex strainer BOLL & KIRCH, as pumps protection strainer. Filtration of 320
µm absolute (~50 mesh).
3. SUPPLY PUMPS, POS. 1.1, 1.2
2 pc. Screw pumps with magnetic coupling, complete with full capacity safety valves.
Each pump is equipped with electric driving motor and piped with non-return valveand closing valve.
One screw pump is working while the other screw pump is in stand-by.
4. PRESSURE CONTROL SYSTEM WI TH RADI ATOR COOLER POS. 7.1
1 pc. Directly spring operated control valve for controlling the pressure of the supply
pumps. Pressure range adjustable 0.2 - 0.5 MPa.Piping of r eli ef valve is equipped with fi n coolers.
The relief valve is equipped with bypass and closing valves.
5. AUTOMATIC BACKFLUSH ING FI NE F I LTER, POS. 2.2
1 pc. Automatic fine filter (10 µm absolute), BOLL & KIRCH. The automatic filter is
equipped with an alarm of filter pollution. Complete with electric switch board onthe module. The filter is heated and equipped with closing valves and with
differential pressure indicator.
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
6. CONSUMPTION MEASURING SYSTEM , POS. 3.1
1 pc. Flow meter with local totalizer for indicating the total fuel oil consumption of all engines. The flow meter is equipped with closing valves and bypass valve.
Suitable for media temperature up to 130 °C.
7. PRESSURE M IXI NG TANK WITH ACCESSORIES, POS. 4.1
1 pc. Pressure mixing tank with automatic degassing equipment:
capacity approx.: 150 litremax. working pressure: 1.0 MPatest pressure: 1.5 MPa
max. working temperature: 160 °C
The pressure mixing tank is equipped with:
1 float switch for low level alarm
1 safety valve, opening pressure 1.0 MPa1 closing valve (manual degassing)1 automatic degassing valve
1 drain valve1 thermometer
1 pressure gauge
with tank heating, insulation and galvanized metal plate covering.
Determined by mixing tank volume of 150 liters changing over is possible at 36 % of
maximum fuel consumption for injection systems with allowed temperature gradient of 2 °C/min at most.
8. BOOSTER PUMPS, POS. 1.3, 1.4
2 pc. Screw pumps with magnetic coupling, complete with full capacity safety valves. Each pump is equipped with electric driving motor and piped with non-return valve
and closing valve.
One screw pump is working while the other screw pump is in stand-by.
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
9. HEATERS, POS. 5.1, 5.2
2 pc. Shell and tube heat exchangers, Aalborg. The heat exchangers are counter flowtype, the heated medium is flowing through the shell and the heating mediumthrough the pipes. The heaters are insulated and equipped with safety valves.
The heaters are equipped with bypass and closing valves.
10. HEATI NG MEDI UM CONTROL VAL VE, POS. 9.1
1 pc. Control valve with built-on positioning drive. The control valve is driven by the
output signal of the viscosity controller and controls the heating medium flow to theheaters.control valve kvs value: 10
The valve is equipped with strainer, bypass and closing valves.
11. VI SCOSITY CONTROL SYSTEM , POS. 6.1, 6.2, 6.3
1 pc. Automatic viscosity and temperature measure and control unit, system VAF - KuWo, complete with:
- sensor (VAF)- temperature sensor PT 100
- controller for viscosity and temperature controlling (including indication)- sensor casing - differential pressure transmitter
- electric driving motor (60 Hz, 230 V)
The sensor, including the differential pressure transmitter is factory calibrated as acommon unit and delivers current output signal, proportional to the measured viscosity (4 - 20 mA).
Viscosity can be set from main control cabinet and from ECR by additional set point device/generator ( loose del ivery ).This additional set point generator is equipped with display for indication of viscosity and temperature.
All scales are: in mm²/s (cSt) for viscosity and °C for temperature.
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
12. INDI CATOR FI LTER, POS. 2.3
1 pc. Duplex filter BOLL & KIRCH, as engine protection strainer. Filtration of 50 µm absolute. The strainer is equipped with a built-on differential pressure indicator for indicating the strainer pollution.
The duplex strainer is heatable and equipped with differential pressure indicator with terminal for remote alarm.
13. COMPENSATION DAMPING PRESSURE TANK, POS. 4.2
1 pc. Compensation damping pressure tank
capacity approx.: 19 litremax. working pressure: 1.6 MPa
test pressure: 2.4 MPamax. working temperature: 160 °C
The compensation damping tank is equipped with 3 ball valves.
The purpose of the compensation damping pressure tank is to avoid the possible pressure peaks and to compensate the quick changes of fuel oil consumption if the fuel oil system is maneuvering and/or when the automatic fine filter is in the back
flushing period.
14. CONTROL AND REGULATI ON OF THE MODULE
The module is controlled automatically with alarms and starters by programable logiccontroller (PLC).
1 pc. Main cabinet with:- automatic change over device for power supply
- main switch
- all required signal lamps- starter viscosity motor - starter viscosity controller - filter controlling
- 3-point-step-controller for viscosity and temperature controlling - ampere-meter for viscosity motor
- alarm outputs on terminal strip (dry contacts):- low level in mixing tank - differential pressure high at automatic filter
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
- viscosity too high / too low- temperature high (sensitive to MDO service)
- common alarm
4 pc. pump cabinets for supply and booster pumps with:
- main switch- all required signal lamps
- selection switch (Auto-Start, Stop, Manual- Start)- connection terminal for Remote-Emergency-Stop- ampere-meter with red marking
- alarm outputs on terminal strip (dry contacts):- supply pump Stand-by Start
- booster pump Stand-by Start
2 pc. distribution boxes
Output signal s:
- fuel temperature (4-20 mA)- fuel viscosity (4-20 mA)
I nput signals: - fuel viscosity set point (4-20 mA)
All control cabinets contain the necessary components, like transformers, relays, fuses etc. .
All casings of control cabinets meet IP 54.
Power distribution of each pump starter cabinet is done via two distribution boxes
connected to different circuits (MSB, ESB) of sufficient power.
All electrical operated components of the module are completely cabled to the terminal strips in the corresponding cabinets, which are installed on the module.
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D-27321 ThedinghausenHägerstraße 22
Phone (04204) 9165-0
Fax (04204) 9165-65
D-19061 SchwerinWerkstraße 226
Phone (0385) 64014-0
Fax (0385) 64014-14
VR Bank eG, Schwerin Account No. 170 976
Swift/BIC: GENO DE F1SN1
IBAN:DE95140914640000170976
Managing Directors:Paul Kupke, Jürgen Wolf
Registered at:
Pinneberg court HRB1380VAT-No. DE 116735004
15. PERFORMANCE AND MATERIAL S
Steel construction : The steel construction is a welded construction of profile steel bars for mounting the main components. The base frame is equipped with a metal oil pan for leakageoil.
Piping: All piping components of the module are connected with each other through thenecessary pipes.
Counter f langes: All the ingoing and outgoing piping of the module are flange connectionswith counter flanges type 11 according to DIN EN 1092-1. The ingoing and outgoing piping of the module for compressed air are provided with pipe fittings.
Valves: The fit in valves have a nominal pressure class of at least 1.6 MPa.
Pipes: The material of the piping is steel according to EN ISO 4200.
Insulation: The hot fuel oil pipes (with T > 60 °C) are equipped with hard-top insulationwhich is covered with aluminium foil and wire-gauze.
Trace heating: The HFO pipes of the module are additionally equipped with trace heating.
Trace heating medium: steam (approx. 170 °C). The heating medium pipes are safety protected against contact where necessary.
Spray protection : All flange connections of the fuel oil pipes are equipped with spray protection.
Coating: The module is painted in standard paint color RAL 6019. The control cabinets are
painted in RAL 7038 (customers request) .
Lettering: With name plates (brass engraved) at all main components and on all the inlets
and outlets of the module in English and German language.
Classification: All material and components are according to the rules and regulations of SOLAS and the desired classification society.
Test/Certification: The module will be tested hydrostatical and functional in the workshopwithout heating under surveillance of the classification society’s representative.
Dimensions and component arrangement reservation
The external module dimensions and flange positions as stated herein are referred to therequirements and performance of this technical specification and the so resulting components and control systems.
Supplementary modifications of the module as requested by the customer and namely
changes in capacity, performance and/or functions may lead to revised dimensions and component arrangements.
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kupke+wolf gmbh * germany * telephone +49 (0)385 64014-0 * fax +49 (0)385 6401414
customer: STOCZNIA GDYNIA S.A
Project: 17283ME
2700 TEU CV, hull no.: 8184/17
ber icht ig t am 02.01.06 OW (bal l and safety valves )
pos. no. pc. title type DN PN
1. Pumps
1.1 1 f.o. pressure screw pump, body KFU, magnetic coupling KF-85.DAA.000711 50 16
1.1.1 1 electr. driving motor for f. o. pressure pump 100 LB 4 pole (3.60 kW)
1.1.2 1 ball valve V3NBC-316-050 50 25
1.1.3 1 ball valve V3NBC-316-050 50 25
1.1.4 1 non-return valve, wafer type SR 20.40 St 50 40
1.2 1 f.o. pressure screw pump, body KFU, magnetic coupling KF-85.DAA.000711 50 16
1.2.1 1 electr. driving motor for f. o. pressure pump 100 LB 4 pole (3.60 kW)
1.2.2 1 ball valve V3NBC-316-050 50 25
1.2.3 1 ball valve V3NBC-316-050 50 25
1.2.4 1 non-return valve, wafer type SR 20.40 St 50 40
1.3 1 f.o. pressure screw pump, body KFU, magnetic coupling KF-74.DBA.000710 50 16
1.3.1 1 electr. driving motor for circulating pump 132M 2 pole (8.9 kW)
1.3.2 1 ball valve V3NBC-316-050 50 25
1.3.3 1 ball valve V3NBC-316-050 50 25
1.3.4 1 non-return valve, wafer type SR 20.40 St 50 40
1.4 1 f.o. pressure screw pump, body KFU, magnetic coupling KF-74.DBA.000710 50 16
1.4.1 1 electr. driving motor for circulating pump 132M 2 pole (8.9 kW)1.4.2 1 ball valve V3NBC-316-050 50 25
1.4.3 1 ball valve V3NBC-316-050 50 25
1.4.4 1 non-return valve, wafer type SR 20.40 St 50 40
2. Filters
2.1 1 duplex filter with DPI (320 µm) 2.04.5.110.260 + 4.36.1 50 16
2.1.3 1 glycerin pressure gauge (d=63,-1/+5 bar) 7122849 1/4" 16
2.1.4 1 pressure gauge valve and test GAUGE11 1/4" 125
2.2 1 autom. self-cleaning filter without control 6.61 Gr.15, 10µm 40 16
2.2.1 1 ball valve V3NBC-316-040 40 25
2.2.2 1 ball valve V3NBC-316-040 40 252.2.3 1 ball valve V3NBC-316-040 40 25
2.5 1 indicating filter 2.06.5.4.195.250 + 4.36.2 50 16
2.5.3 1 ball valve (drain) V1-316-299-015 1/2" 25
2.5.4 1 ball valve (drain) V1-316-299-015 1/2" 25
3. Flowmeter
3.1 1 flowmeter VZO 40 FL 130/25 40 25
3.1.1 1 ball valve V3NBC-316-040 40 25
3.1.2 1 ball valve V3NBC-316-040 40 25
3.1.2 1 ball valve V3NBC-316-040 40 25
3.1.4 1 straight thermometer (0-200 °C) - Tt=63mm 2712201106321 1/2"
4. Tanks
4.1 1 mixing tank nominal volume = 150 ltrs 16
4.1.1 1 float switch, L=350mm, set point 300mm, SR1 AX 350 LA 1A 65
ITEM LIST
pressurized fuel oil supply
and booster module
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kupke+wolf gmbh * germany * telephone +49 (0)385 64014-0 * fax +49 (0)385 6401414
pos. no. pc. title type DN PN
4.1.2 1 safety valve, set point 10 bar SAFE-TCP 1/2" 100
4.1.3 1 ball valve (drain) V3NBC-316-020 20 25
4.1.4 1 ball valve (vent) V3NBC-316-020 20 254.1.5 1 glycerin pressure gauge (d=63, 0-10 bar) 7122865 1/4" 16
4.1.6 1 pressure gauge valve and test GAUGE11 1/4" 125
4.1.7 1 angle thermometer (0-200 °C) - Tt=100mm 2722201110021 1/4"
4.1.8 1 non-return valve, wafer type SR 20.40 St 65 40
4.1.9 1 ball valve V3NBC-316-020 20 25
4.1.10 1 autom. degasing valve EF-8180 20 25
4.2 1 compensation damping tank nominal volume = 19 ltrs 25
4.2.1 1 ball valve V3NBC-316-032 32 25
4.2.2 1 ball valve (drain) V3NBC-316-020 20 25
4.2.3 1 ball valve V3NBC-316-020 20 25
5. Heat exchangers
5.1 1 steam heater MX 25 L=2200 50 16
5.1.1 1 ball valve V3NBC-316-050 50 25
5.1.2 1 ball valve V3NBC-316-050 50 25
5.1.3 1 ball valve V3NBC-316-050 50 25
5.1.4 1 ball valve (vent) V1-316-299-015 1/2" 25
5.1.5 1 ball valve (drain) V1-316-299-015 1/2" 25
5.1.6 1 safety valve, set point 16 bar SAFE-TCP 1/2" 100
5.1.7 1 shut-off valve GGG-40.3 2204600321 32 16
5.1.8 1 shut-off valve GGG-40.3 2204600201 20 16
5.1.9 1 straight thermometer (0-200 °C) - Tt=63mm 2712201106321 1/2"
5.2 1 steam heater MX 25 L=2200 50 165.2.1 1 ball valve V3NBC-316-050 50 25
5.2.2 1 ball valve V3NBC-316-050 50 25
5.2.3 1 ball valve V3NBC-316-050 50 25
5.2.4 1 ball valve (vent) V1-316-299-015 1/2" 25
5.2.5 1 ball valve (drain) V1-316-299-015 1/2" 25
5.2.6 1 safety valve, set point 16 bar SAFE-TCP 1/2" 100
5.2.7 1 shut-off valve GGG-40.3 2204600321 32 16
5.2.8 1 shut-off valve GGG-40.3 2204600201 20 16
6. Viscosimeter
6.1 1 Viscosimeter V92 50
6.1.1 1 gear motor
6.1.2 1 casing
6.1.3 1 ball valve V3NBC-316-050 50 25
6.1.4 1 ball valve V3NBC-316-050 50 25
6.1.5 1 ball valve V3NBC-316-050 50 25
6.1.6 1 straight thermometer (0-200 °C) - Tt=63mm 2712201106321 1/2" 25
6.1.7 1 temperature sensor PT 100, Tt=70 mm W083P310502102 1/2"
6.1.8 1 temperature sensor PT 100, Tt=70 mm W083P310502102 1/2"
6.2 1 dp-transmitter (4-20 mA) FKKX35V4-AKAYY-AA
6.3 1 3-point-step-controller, indication in cST/°C 93KU10-99bwa-ogx2
6.3.1 1 set point generator with actual value remote display;lo92933e-99axe-b1s2-xkuw2
7. Pressure control
7.1 1 pressure control valve SPVF 40 K2F 1A 05 40 16
1 counter flanges for pos. 7.1 SAE/DN 40 40 16
7.1.1 1 ball valve V3NBC-316-040 40 25
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kupke+wolf gmbh * germany * telephone +49 (0)385 64014-0 * fax +49 (0)385 6401414
pos. no. pc. title type DN PN
7.1.2 1 ball valve V3NBC-316-040 40 25
7.1.3 1 ball valve V3NBC-316-040 40 25
8. Instruments and sensors
8.1 1 pressostate, IP 65 (1-10 bar) 900.2378.905 1/4" 20
8.1.1 1 glycerin pressure gauge (d=63, 0-10 bar) 7122865 1/4" 16
8.1.2 1 brass pressure gauge shock absorber 008800090002 1/4"
8.1.3 1 pressure gauge valve and test GAUGE11 1/4" 125
8.2 1 differential pressostate, IP 65, 0-4 bar 920.2376.937 1/4" 20
8.2.1 1 glycerin pressure gauge (d=63, 0-16 bar) 7122793 1/4" 25
8.2.2 1 brass pressure gauge shock absorber 008800090002 1/4"
8.2.3 1 pressure gauge valve and test GAUGE11 1/4" 125
8.2.6 1 brass pressure gauge shock absorber 008800090002 1/4"
8.2.7 1 pressure gauge valve and test GAUGE11 1/4" 125
8.4.1 1 glycerin pressure gauge (d=63, 0-16 bar) 7122793 1/4" 25
8.4.2 1 pressure gauge valve and test GAUGE11 1/4" 125
9. Heating medium
9.1 1 heating medium control valve (2/2-way, kvs=10) BR440 + CS20 32 16
9.1.1 1 shut-off valve GGG-40.3 2204600321 32 16
9.1.2 1 shut-off valve GGG-40.3 2204600321 32 16
9.1.3 1 shut-off valve GGG-40.3 2204600321 32 16
9.1.4 1 y-strainer, GGG-40.3, 250 µm 2305000322 32 16
9.2 1 float steam trap CONA-SC R14 20 16
9.2.1 1 shut-off valve GGG-40.3 2204600201 20 169.2.2 1 shut-off valve GGG-40.3 2204600201 20 16
9.2.3 1 shut-off valve GGG-40.3 2204600201 20 16
9.3 1 float steam trap CONA-SC R14 15 16
9.3.1 1 shut-off valve GGG-40.3 2204600151 15 16
9.3.2 1 shut-off valve GGG-40.3 2204600151 15 16
9.4.1 1 shut-off valve GGG-40.3 2204600151 15 16
10. 3-way valve
10.1 1 3-way ball valve, manual operated 776 50 16
10.1.2 2 endposition switches TINY Ti2
10.1.3 1 non-return valve, wafer type SR 20.40 St 50 40
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kupke+wolf gmbh * germany * telephone 0385 64014-0 * telefax 0385 6401414
client: GTS
project: 17281ME
2700 TEU C/V hull no.: 8184/16-/20
berichtigt am 2.3.05 DW
pos.no. pcs title type DN PN
all spares:
140-0 1 safety valve, set point 16 bar SAFE-TCP 1/2" 100
for back flushing filter (pos. 2.2):
150-0 1 key for dismantling the filter chamber SW10, No.5
150-1 1 key for unscrewing the filter element No. 7
150-2 2 guide bolt
150-3 1 compressed air cleaning gun 5.01, No. 2 500 LG
SPARE PART / TOOL LIST
and booster module
pressurized heavy fuel oil supply
file: spare-17281me.xls , date: 13.12.2005, 13:07 page 1/1
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
B. General danger and safety
information
ATTENTION!
Pumps with magnetic coupling are installed on this module.
Persons with pacemakers must not install, maintain and operate
the pumps.
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kupke+wolf gmbhWerkstraße 226D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-mail: info@kuwo.com Hägerstraße 22D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 13.12.2005
Project: 17.283ME
Revision: ----
Language: English
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 1 of 5
2.1 GENERAL
2.1.1 Introduction
All responsible persons and those who work with KUPKE+WOLF fuel oil supplyand booster modules must read, understand and observe in all points thisinformation.
The complete technical documentation should always be kept in the vicinity
the fuel oil supply and booster module.
This documentation refers to details of particular importance for the deployment of this supply module.
It is very important that all responsible persons acquaint with of the presentdocumentation. Errors on the fuel oil supply and booster module can only beavoided and a trouble-free operation guaranteed by knowledge of thisdocumentation.
We recommend you to read this documentation carefully prior to functioning. Themanufacturer doesn’t take any responsibility for damages or malfunctions resulting
from the non-observance of this documentation!
In case of difficulties, please contact the after sales service and/or spare partsdepartment or one of our representatives. They will be pleased to help you.
For possible changes in illustrations and information included in thisdocumentation, in case of improvement or technical modifications in the fueloil supply and booster module, all rights reserved.
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kupke+wolf gmbhWerkstraße 226D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-mail: info@kuwo.com Hägerstraße 22D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 13.12.2005
Project: 17.283ME
Revision: ----
Language: English
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 2 of 5
2.1.2 Application
Fuel oil supply and booster modules are used among others, for supplying mainengines on board of sea going ships. They are designed as a complete module.
In order to deploy an optimal fuel oil supply and booster module for thecorresponding application, the designs are tuned to the complete system, the fuelsand lubricants as well as the flow rate, temperature and the pressure of themedium.
The fuel oil supply and booster module is only designed for the applicationindicated in the chapter A “General technical information”.
Never use the supply module out of its contractual application (cf. chapter A“General technical information”), without asking the after sales service of KUPKE+WOLF GmbH for advice (the address can be found in the followingchapter). Otherwise the guarantee becomes invalid.
2.1.3 Copyright
The copyright to this documentation remains with KUPKE+WOLF GmbH. Thisdocumentation is intended for the assembly personnel, operators and supervisors.It contains prescriptions and drawings of technical nature that may not be copied,neither completely or in part, nor be distributed or used in an unauthorised manner for competition purposes or be disclosed to third parties.
Kupke+Wolf GmbH
Werkstraße 226D-19061 Schwerin / WüstmarkPhone: +49(0)385-640 14-0Fax: +49(0)385-640 14-14E-mail: info@kuwo.comInternet: www.kuwo.com
Kupke+Wolf GmbH
Hägerstraße 22D-27321 Thedinghausen, GermanyPhone: +49(0)4204-9165-0
Fax: +49(0)4204-9165-65
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kupke+wolf gmbhWerkstraße 226D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-mail: info@kuwo.com Hägerstraße 22D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 13.12.2005
Project: 17.283ME
Revision: ----
Language: English
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 3 of 5
2.2 Safety
2.2.1
2.2.1.1
Symbols and notices
Warning symbol
Hazard to life and limb of persons. Observe these notes andbehave in all cases extreme cautiously.Please forward all notes for the safe system at work to other users as well.Further on, follow the generally applicable safety regulationsand regulations for the prevention of accidents.
2.2.1.2 Important symbol
Special attention! Observe directives, regulations, indications andthe correct sequence of operations to prevent damages anddestruction of the system and/or system components.
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kupke+wolf gmbhWerkstraße 226D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-mail: info@kuwo.com Hägerstraße 22D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 13.12.2005
Project: 17.283ME
Revision: ----
Language: English
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 4 of 5
2.2.2 Notices for the warning symbol
The following notes for work safety are to be observed.
- The fuel oil supply and booster module has been manufactured according tothe actual technical standards and is operationally reliable. However,hazards can emanate from this system if it is used improperly by untrainedpersonnel or not for the intended purpose.
- Each person who is involved in the premises of the user with the assembly,dismantling, disassembly, start-up, operation and servicing (inspection,maintenance, repair) of the fuel oil supply and booster module must haveread and understood the complete documentation and in particular thischapter (2.2). We recommend the user to confirm this in writing form.
- The fuel oil supply and booster module can only be used for the technicalpurpose agreed upon in the contract. Any other use than this one is notconsidered to be normal use. The manufacturer will not be liable for anydamage resulting. It is only risk of the user.
- Normal use also includes observance of the assembly, dismantling anddisassembly, start-up, operating and servicing conditions prescribed by themanufacturer.
- Only authorised, trained and instructed personnel are allowed to operate,maintain and repair the functional module. These personnel must get specialinstruction as regards possible hazards.
- To avoid unnecessary risks, all responsibilities for assembly, dismantlingand disassembly, start-up, operation and servicing must be clearly definedand complied.
- For all work concerning assembly, dismantling and disassembly, start-up,operation, adaptation and servicing, the shut-off procedures have to beobserved.
- Any working method that impairs the safety of the fuel oil supply and booster module is prohibited.
- The operator must ensure that no unauthorised persons work on the system.
- The operator is obliged to report immediately any alterations of the fuel oilsupply and booster module that impair the safety to the responsible safetyengineer.
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kupke+wolf gmbhWerkstraße 226D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-mail: info@kuwo.com Hägerstraße 22D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 13.12.2005
Project: 17.283ME
Revision: ----
Language: English
General danger and safety informationShipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KGHull no.: 8184/17
Page 5 of 5
- The user is obliged to operate the fuel oil supply and booster module only inperfect condition.
- The user must ensure cleanness and clarity of the system throughcorresponding instructions and controls.
- Arbitrary rebuild and modifications that influence the safety of the fuel oilsupply and booster module are not allowed.
- Basically, all work on the supply module may be carried out only when thesystem is turned off.
- Prior to performing any work on the functional module, be sure that thesystem is depressurised. Furthermore, its drives and additional equipmentare to be so protected that they cannot be switched on unintentionally.This is possible means a lockable local switch (not in scope of supply).Extreme caution is required when handling components that are stillwarm.
- After servicing and prior to start-up and following repairs, verify that allprotection devices are fitted.
- Remove protection devices only when the system is turned off.
- The lifting capacity of hoisting gears for installation must be sufficiently rated(cf. chapter A “General technical information”).
- Fasten the fuel oil supply and booster module only to the existing liftingeyelets.
- Whenever having carried out an electric installation or repair of the electricequipment, the protective measures installed have to be checked (e.g.earthing resistance).
- The local safety regulations and regulations for the prevention of accidentsapply in each case to the operation of the fuel oil supply and booster module.
2.2.3 Environmental protection and dangerous substances
For handling the fuel oil supply and booster module, it is absolutelynecessary to comply with the provisions regarding environmentalprotection and dangerous substances!
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
C./D. Start-up/Commissioning
ATTENTION!
Pumps with magnetic coupling are installed on this module.Persons with pacemakers must not install, maintain and operate
the pumps.
ATTENTION!
It is not allowed to operate the pumps of fuel oil supply and
booster module, if the viscosity of used fuel is less than 4 mPas.
ATTENTION!
Pay attention at installation and operation of the fuel oil supply
and booster module on board that pressure surges will be
avoided in the fuel oil pipes from/to engine.
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 1 of 9
Start-up
for
fuel oil supply and booster module
steam heated
ATTENTION!
Pumps with magnetic coupling are installed on this module.Persons with pacemakers must not install, maintain and
operate the pumps.
Take care that no water or moisture penetrates in the module.
Operation data:
Operation pressure: 1.0/1.6 MPa max.
Test pressure: 1.5/2.4 MPa
Operation temperature: 160 °C max.
The fuel supply system is executed and accepted according to the classification society GL.
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 2 of 9
Start-up with gas oil or diesel oil
Always activate cooler when engine is running with gas oil or
diesel oil.
Before switching over to MDO operation turn off trace heating.
1. Open all valves to pressure gauges and pressure switches.
2. Take care that following valves and ball valves are closed: Title Pos. no.
By-pass pressure control valve 7.1.3Inlet automatic filter 2.2.1
Outlet automatic filter 2.2.2
Inlet flow meter 3.1.1
Outlet flow meter 3.1.2
By-pass automatic degassing mixing tank 4.1.4
Drain mixing tank 4.1.3Fuel inlet heater I + II 5.1.1, 5.2.1
Fuel outlet heater I + II 5.1.2, 5.2.2
Vent heater I + II 5.1.4, 5.2.4
Drain heater I + II 5.1.5, 5.2.5
Inlet viscosimeter 6.1.3
Outlet viscosimeter 6.1.4Drain indicating filter 2.5.3, 2.5.4
Steam inlet all
Trace heating inlet 9.4.1
Steam control valve by-pass 9.1.3
Steam trap by-pass 9.2.3Inlet compensation tank 4.2.1 Aerating compensation tank 4.2.3
Drain compensation tank 4.2.2
3. Open following valves and ball valves:
Title Pos. no.
Shut-off automatic degassing 4.1.9
Inlet supply pump I + II 1.1.2, 1.2.2
Outlet supply pump I + II 1.1.3, 1.2.3
Inlet pressure control valve 7.1.1Outlet pressure control valve 7.1.2
By-pass automatic filter 2.2.3
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 3 of 9
By-pass flow meter 3.1.3
Inlet booster pump I + II 1.3.2, 1.4.2
Outlet booster pump I + II 1.3.3, 1.4.3By-pass heater I + II 5.1.3, 5.2.3
By-pass viscosimeter 6.1.5
Outlet condensate 5.1.8, 5.2.8,
9.2.1, 9.2.2,
9.3.1, 9.3.2
Manifold valve at DP-transmitter (viscosimeter) all
4. Open ball valves “Aerating compensation tank”, pos. 4.2.3 and “Drain
compensation tank”, pos. 4.2.2 until compensation tank is empty. Then close
ball valves “Aerating compensation tank” and “Drain compensation tank”.
5. Start-up main control cabinet
Make sure that the pumps, the viscosimeter, the viscosity/temperature controller
and the automatic filter are switched “OFF” before switching on main control
cabinet.
Pumps to be switched off at separate pump control cabinets.
After that switch on the main switch S1 at main control cabinet. Indicationlamps H1 “Voltage 1 ON” and H2 “Voltage 2 ON” light up at the main control
cabinet.
6. Turn 3-way-ball valve pos. 10.1 at FO inlet into position “MDO Service”.
Indication lamp H4 for MDO service lights up at the main control cabinet.
7. Start-up automatic filter, pos. 2.2, in by-pass operation
The ball valves “Inlet automatic filter”, pos. 2.2.1 and “Outlet automatic
filter”, pos. 2.2.2 are closed. Ball valve “By-pass automatic filter”, pos. 2.2.3
is opened.Make sure that supply line of compressed air is opened.
Adjust the compressed air filter regulator of the automatic filter up to 3.5 - 4 bar.
8. Open all valves between diesel oil day tank and module.
9. Vent the duplex filters, pos. 2.1 and pos. 2.5 (see separate instruction manual in
chapter 2 “Filter” of this documentation).
Take care that only one filter chamber of the duplex filters is in operation and
the other filter chamber is in reserve after that.
10. Open the ball valve “Inlet compensation tank”, pos. 4.2.1.
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 4 of 9
11. Start-up pumps, pos. 1.1, 1.2, 1.3, 1.4
ATTENTION!
Pumps with magnetic coupling are installed on this module.
Persons with pacemakers must not install, maintain and
operate the pumps.
Make sure that the selective switches S2 and S4 at the control cabinets for
supply pumps and booster pumps are in position “0” before starting pumps. After that switch on the main switches S1 and S3 at the pump control cabinets.
Observe the rotary direction of the supply pumps and booster pumps
by shortly starting the pumps using selective switches S2 and S4 at the
pump control cabinets.
11.1 Start-up supply pump I, pos. 1.1, manually
Set selective switch S2 at the control cabinet for supply pumps in position
“Man.”.
When the ball valve “Shut-off automatic degassing” is open, mixing tank isautomatically degassed.
Close ball valve “By-pass flow meter”, pos. 3.1.3. Observe the pressure gauge
on pressure side of supply pumps. It must indicate 4 bar. If not, adjust the
pressure control valve, pos. 7.1, to 4 bar.
After that check the relief valve of the pump. For this close the ball valve “Inlet
pressure control valve”. Pressure at pressure gauge should be approx. 7 bar.
If not, adjust relief valve of the pump (see separate description in chapter 1
“Pumps with drive” of this documentation). Open the ball valves “Inlet pressure
control valve” and “By-pass flow meter”.
Stop supply pump I.
Take care that both pumps do not run parallel.
11.2 Start-up supply pump II, pos. 1.2, manually
Set selective switch S4 at the control cabinet for supply pumps in position
“Man.”.
Act according to procedure of the two last sections of pos. 11.1.
Supply pump II keeps on running.
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 5 of 9
11.3 Start-up booster pump I, pos. 1.3, manually
One of supply pumps has to be running before start-up of
booster pumps.
Set selective switch S2 at the control cabinet for booster pumps in position
“Man.”.
The pressure gauge on pressure side of booster pump must indicate a minimum
differential pressure of 1 bar relating to primary pressure. After that check the relief valve of the pump. For this close the ball valve
“By-pass viscosimeter”, pos. 6.1.5. The differential pressure should be
approx. 10 bar. If not, adjust relief valve of the pump (see separate description in
chapter 1 “Pumps with drive” of this documentation). After that open ball valve
“By-pass viscosimeter”.
Stop booster pump I.
Take care that both pumps do not run parallel.
11.4. Start-up booster pump II, pos. 1.4, manually
Set selective switch S4 at the control cabinet for booster pumps in position
“Man.”.
Act according to procedure of the two last sections of pos. 11.3.
Booster pump II keeps on running.
If only start-up of pumps will carried out, all the pumps have to
be switched off after that.
12. Start-up flow meter , pos. 3.1
V e r y s l o w l y a n d i n s u c c e s s i o n open ball valve “Inlet flow meter”,
pos. 3.1.1 and ball valve “Outlet flow meter”, pos. 3.1.2.
Close ball valve “By-pass flow meter”, pos. 3.1.3.
13. Start-up heater
Please no te: In all the 3 operating in stances o f heaters rules:
If one supply pump and one booster pump are running the pressure in the
mixing tank has to be 4 bar and the fuel pressure to main engine 5 b ar or
mo re. However, minim um dif ferent ia l pressure should n ot be less than
1 bar.
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 6 of 9
13.1 Heater I, pos. 5.1, in operation, heater II in stand-by
Open ball valve “Inlet heater 1”, pos. 5.1.1 and “Outlet heater 1”, pos. 5.1.2.
Close ball valve “By-pass heater 1”, pos. 5.1.3. Open ball valve “Outlet
heater 2”, pos. 5.2.2.
Fill up heater 1 with diesel oil and vent the heater using ball valve pos. 5.1.4.
13.2 Heater II, pos. 5.2, in operation, heater I in stand-by
Open ball valve “Inlet heater 2”, pos. 5.2.1 and “Outlet heater 2”, pos. 5.2.2.
Close the ball valve “By-pass heater 2”, pos. 5.2.3 and “Inlet heater 1”,pos. 5.1.1.
Fill up heater 2 with diesel oil and vent the heater using ball valve pos. 5.2.4.
13.3 Both heaters in operation (emergency function)
At first open inlet and outlet ball valves of both heaters. After that close both
by-pass ball valves (pos. 5.1.3 and 5.2.3).
14. Start-up viscosimeter , pos. 6.1
Open the ball valves “Inlet viscosimeter”, pos. 6.1.3 and “Outlet
viscosimeter”, pos. 6.1.4 and close “By-pass viscosimeter”, pos. 6.1.5.Switch on the viscosimeter motor using switch S2 “Visco. motor” at the main
control cabinet. Indication lamp H3, which is integrated in this switch, lights up.
Observe the rotary direction of viscosimeter motor.
For the complete start-up of the viscosimeter see separate instruction manual (in
chapter 6 “Viscosity measuring system” of this documentation).
15. Start-up automatic filter , pos. 2.2
Switch on voltage of automatic filter control using switch S11 “Voltage automatic
filter ON” at main control cabinet. Indication lamp H15, which is integrated in this
switch, lights up.
Open ball valve “Inlet automatic filter”, pos. 2.2.1. Fill up the automatic filter
with diesel oil. After that open ball valve “Outlet automatic filter”, pos. 2.2.2.
Close the ball valve “By-pass automatic filter”, pos. 2.2.3.
Check time settings of the filter control on TD 200-display using key F3:
- Flush time 10 sec
- Blocking time 5 - 8 minutes
- Flushing cycle time 2 hours
For adjustment of time settings see separate instruction manual for TD 200 (inchapter E “Electricity” of this documentation).
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 7 of 9
16. Set pumps in automatic operation
16.1 Set the selective switches S2 and S4 at the control cabinets for supply pumps
and booster pumps in position “Autom.”.
Indication lamp H6 for automatic operation of supply pumps and indication lamp
H11 for automatic operation of booster pumps light up at the main control cabinet
(panel “Pumps controller”).
16.2 Now it is possible to switch on at first the requested supply pump and after
that - with time delay - the requested booster pump using the selective switchesS7 (for supply pump) and S9 (for booster pump) at main control cabinet (panel
“Pumps controller”). Then the other supply resp. booster pump is in stand-by
operation.
If time delay during switching on the booster pump was not long enough, may
be that pumps change to stand-by operation. The alarm message “stand-by
alarm” lights up on the TD 200-display. This alarm message must be signed
(For this see separate instruction manual for TD 200 in chapter E “Electricity” of
this documentation.).
After that a pump reset is to be done. PushbuttonS8 (for reset stand-by supply
pumps) resp. pushbutton S10 (for reset stand-by booster pumps) must pushed for this at the main control cabinet (panel “Pumps controller”). The alarm
message “stand-by alarm” lights down on the TD 200-display and Indication
lamp, which is integrated in before pushed pushbutton for alarm reset, lights
down also.
17. Operating with heavy fuel oil (HFO)
17.1 Set selective switch S4 “Visco. - temp. control” at main control cabinet into
position “Visco.” and selective switch S5 “Local - remote visco. control” at maincontrol cabinet in position “Local”.
Now “Steam control valve”, pos. 9.1 will be controlled depending on
changes of HFO viscosity.
17.2 Switch on the viscosimeter motor and the viscosity/temperature controller at main
control cabinet17.3 Set viscosity/temperature controller into manual operation.
17.4 Make sure that the “Steam control valve”, pos. 9.1 is completely closed. If not,
switch it off manually via viscosity/temperature controller. (See separate
instruction manual for viscosimeter in chapter 6 “Viscosity measuring system” of
this documentation).
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 8 of 9
17.5 Open all “Steam inlet” and “Condensate outlet” valves.
17.6 Make sure that the valves “Inlet trace heating”, pos. 9.4.1 and “By-pass
steam control valve”, pos. 9.1.3 are closed.
17.7 Check the viscosity set-point of the viscosity/temperature controller.
17.8 Close the by-pass valve of the manifold valve at the DP-transmitter.
17.9 Set the viscosity/temperature controller into automatic operation.
17.10 Turn 3-way ball valve pos. 10.1 at FO inlet into position “HFO Service”.
Indication lamp H5 for HFO service lights up at the main control cabinet.
Set MDO cooler into by-pass operation.The system will be filled up automatically with HFO depending on consumption of
the engine(s). The viscosity/temperature controller regulates automatically theviscosity to the adjusted set-point (see separate instruction manual for
viscosimeter in chapter 6 “Viscosity measuring system” of this documentation).
17.11 In case of pure HFO service it is also possible to control the steam control valve
in dependency on temperature. Set the selection switch S4 “Visco. - temp.
control” at main control cabinet into position “Temp.” and selective switch S5
“Local - remote visco. control” at main control cabinet in position “Local”. Now
the “Steam control valve” will be controlled in dependency on temperature of
heavy fuel oil.
Open valve “Inlet trace heating” not until the system is completely
filled with HFO or if required.
In case of back-flushing of automatic filter will released because differential
pressure increased, indication lamp H16 “Back-flushing release by differential
pressure” lights up at the main control cabinet and is lighting as long as a reset is
done. A corresponding alarm message will be indicated also on the
TD 200-display. The alarm message has to be signed at this display using key
F2 (= reset for indication lamp H16 also).The reason for back-flushing release has to be investigated. Insufficient HFO
quality can be a reason for this. In this case change time setting for “flushing cycle
time” to a lower value at TD 200-display using key F3.
The default value of time setting for “flushing cycle time” (see pos. 15 of this
start-up) has to be adjusted as soon as HFO of better quality has been
bunkered.
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kupke+wolf gmbhWerkstraße 226
D-19061 Schwerin/Wüstmark
Phone: +49-385-640 14-0
Fax: +49-385-640 14-14
E-Mail: info@kuwo.com
Hägerstraße 22
D-27321 Thedinghausen
Phone: +49-4204-9165-0
Fax: +49-4204-9165-65
Manufacturer: kuwo
Prepared on: 30.12.2005
Project: 17.283ME
Revision: ---
Language: English
Start-up / Commissioning Shipyard: Stocznia Gdynia S.A.
Ship owner: Peter Döhle Schiffahrts-KG
Hull no.: 8184/17
Page 9 of 9
18. Switching back from HFO operation to MDO operation
Before switching over to MDO operation turn off trace heating.
Turn 3-way ball valve pos. 10.1 at FO inlet into position “MDO Service”.
Indication lamp H4 for MDO service lights up at the main control cabinet.
The inflow of MDO leads to drop down of viscosity. Because of that the
viscosity/temperature controller closes the “Steam control valve”, pos. 9.1
independently.
If the viscosity/temperature controller works in temperature control mode at the
moment of switching over to MDO service, it will be automatically changed over
to viscosity control mode.
If the viscosity drops down below 5 mPas so the MDO cooler
shall be set in operation.
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Ingenieurbüro • Anlagenbau • Vertrieb
02.12.2004 Flushing instructions for booster module_021204-korrigiert.doc 1/1
D-27321 Thedinghausen
Hägerstraße 22
Telefon (0 42 04) 91 65 - 0Telefax (0 42 04) 91 65 - 65
Werkstraße 226
19061 Schwerin
Telefon (0385) 640 14 - 0Telefax (0385) 640 14 - 14
Deutsche Bank Bremen
(BLZ 290 700 50) Kto. 1 007 004Deutsche Bank Holm(BLZ 200 700 00) Kto. 5 924 824VR Bank eG, Schwerin
(BLZ 140 914 64) Kto. 170976
Geschäftsführer
Paul Kupke, Jürgen Wolf
AmtsgerichtPinneberg HRB 1380
Ust.-ID-Nr. DE 116735004
APPENDIX / DEVIATION CONTRACT
->at ten t ion fo r Sh ipyard : F lush ing ins t ruc t i ons fo r boo s te r mo du le =======================================================================================================
All diesel engine manufacturers require a flushing procedure of the fuel oil systembefore the diesel engine is started up (see engine guide -> general flushing
procedures).Your fuel oil system includes a supply and booster module made by kupke+wolf gmbh.
The internal tubes of our modules are sandblasted, cleaned and each module iscarefully flushed with diesel oil on the test bench.To save the guarantee of this module (and its main components) the shipyard has
to pay attention to some additional requirements regarding flushing of the fuel oilsystem including the booster module.
Our instructions:- Flushing of the module must be effected with Marine Diesel Oil (MDO) with
minimal viscosity of 4 mPas (resp. 4.6 cSt).- Make sure that the internal piping is cleaned and pre-flushed.- Open the drain of mixing tank and compensating pressure tank to flush out the
rests of the conservation oil remained after flushing on the test bench.- Flushing of the booster module has to be done from flange A or B (fuel inlet) to
flange C (outlet to engine) using the internal automatic fine filter on the module.- The return stroke from the engine to the mixing tank has to be flushed as well.- In order to ensure that dirt from the external pipe lines (especially from the return
pipe line of the shipyard does not get into the booster module the additionalfilters should be installed before flange A or B (fuel inlet) and before flange D
(return stroke from engine = return inlet to the mixing tank). These filters shouldhave purity rate of min. 25 µm absolute. The filters should have a check bag or
any other possibility to control the cleanness.- Flushing should be provided in two steps: - Step one: Flow meter, heater, viscosimeter and compensating pressure tank have
to be closed and flushing has to be done through the bypass lines of thesecomponents. After four hours of continuous flushing the shipyard representativehas to check the additional filters. Flushing has to continue until the filters are
clean. When the filters are clean proceed to step two.
- Step two: The bypass lines are to be closed and flushing has to be done throughthe flow meter, heater, viscosimeter and compensating pressure tank. After four hour of continuous flushing the shipyard representative has to check the additionalfilters. Flushing has to continue until the filters are clean.
- As experience shows the whole flushing process should continue min. 24 hours.
If you have any further questions regarding these instructions, please don’t hesitate to
contact with us.
kupke+wolf gmbh
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
E. Electricity
ATTENTION!
Pumps with magnetic coupling are installed on this module.
Persons with pacemakers must not install, maintain and operatethe pumps.
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25.09.01
Da.
Description and allocation of the keypad TD 200
The pumps and automatic filter are controlled by a SPS, located in the
main-cabinet.With the key pad TD 200 it is possible to change some necessary adjustments.
The buttons allocation is fixed as follows:
F1 Automatic filter manually flush
Press button F1 to release the flushing
F2 Reset of the lamp - ”backflushing release by differential pressure”
Press button F2 to reset displayed message
F3 Changing the time settings of the filter
Press button F3 to indicate the adjusted flushing time. After pressing the ENTER-button the displayed value starts to flash.With the arrow keys it is now possible to increase or decrease the value.Confirm with ENTER-button to proceed to the next step.*
Afterwards the filling up time (blocking time) is indicated in the display.
By pressing the ENTER-button the value starts to flash and can also bechanged in the same way as described above.Confirm with ENTER-button to proceed.*
At last the display switches to the adjusted flushing cycle time (automaticflushing release) This value can also be changed in the same way as described
above.
F4 Changing the delay time for pumps st.-by start
1. Approach of the st.- by pumps after pressure-drop or breakdown
of operation pump. Range: 3 - 30 sec.Press button F4 to indicate the adjusted delay time.
After pressing the ENTER-button the displayed value starts to flash.With the arrow key this value can be increaded or decreased.
Confirm with ENTER-button.*
*
To prevent that the TD 200 left off in change-mode, all changes of adjustmentshave to be done within 50 sec.Afterward the TD 200 returns to display-mode automatically.
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2. Delayed start of the Supply pumps after black-out
The pumps re-start with different times. Range 1 – 30 sec.
This value can be changed by pressing the arrow keys in the sameprocedure as before described.
3. Delayed start of the Booster pumps after black- out
The pumps re-start with different times. Range 1 – 30 sec.
This value can be changed by pressing the arrow keys in the sameprocedure as before described.
The function “delay start after black out “ can also be carried out,by turning the main switch off and on.
ENTER to confirm each data input / to proceed to next menu
SHIFT This operator level is password protected and containes the delay times
+F4 for the alarms.
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Blbbla-blaTextdisplay
F5F1
F6F2
F7F3
F8F4
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
1. Pumps with drive
ATTENTION!
Pumps with magnetic coupling are installed on this module.
Persons with pacemakers must not install, maintain and operate
the pumps.
Type:
KF-85.DAA.000711 with
magnetic coupling,100LB 4 pole 3.6 kW;
KF-74.DBA.000710 with
magnetic coupling,132M 2 pole 10.6 kW
Pos.: 1.1, 1.1.1, 1.2, 1.2.1;
1.3, 1.3.1, 1.4, 1.4.1
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Operating Instructions
Screw pumps
K Series with magnetic coupling
OIK 09B
02_01/2005 Edition
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Table of contents
OperationStartup
Filling the pump 31
Checking the direction of rotation 32
Commissioning the pump 33
Adjusting the overflow valve 33
Pump shutdown
Switching off the pump 35
Resuming pump operation
Restarting the pump 35
ServicingMaintenance
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Table of Contents
Maintenance requirement 37
General drawing of the pump with magnetic coupling and motor
General drawing 38
Replacing the magnetic coupling
Removing the magnetic coupling 39
Installing the magnetic coupling 43
General drawing of the pump
General drawing 49
Replacing the ball bearing
Removing ball bearings 50
Installing ball bearings 52
Replacing the set of screws
Removing the set of screws 55
Installing the set of screws 57
Assistance with problemsTroubleshooting
Faultfinding reference 61
AppendixGeneral drawings
Exploded view of pump with magnetic coupling and motor 67
Exploded view of pump 68
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Operation
31
O p e r a t i o n
Startup
Filling the pump
There are three possible ways to fill the pump:
• via the shut-off device on the suction side
• via the shut-off device on the pressure side
• via the vent holes
Requirement:
• Pump securely attached
• Pump connection to the piping system is free of mechanical stress
• Pump motor is connected correctly to the electrical power supply
• Piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be cleaned by the
pump
1. Open one of the vent holes on the pump casing.
2. If the pumped medium on the suction side is under inlet pressure, open the shut-off device on
the suction side and fill the pump. Turn the pump shaft or the fan impeller of the motor by handto speed up the filling process.
- or -
If there is already pumped medium available, open the shut-off device on the pressure side and
fill the pump. Turn the pump shaft or the fan impeller of the motor by hand to speed up the
filling process.
- or -
If there is no pumped medium at either the pressure or the suction side flange, fill the pump
via the vent hole. Turn the pump shaft or the fan impeller of the motor by hand to speed up the
filling process.
3. Fill the pump until pumped medium escapes at the vent hole.
4. Close the vent hole
5. Open vent hole of the seal <1> and wait until medium escapes.
6. Close vent hole of the seal.
<1> Suction side vent hole
<2> Pressure side vent hole
Fig. 1 Vent holes
21
0 0 0 0 9 6
WARNING!
Dry-running can damage pump equipment.
Before you start it, make sure that the pump is full.
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Operation
32
Checking the direction of rotation
The direction of rotation and the direction of flow are indicated by arrows on the pump. The
direction of rotation of the motor gives the direction of rotation of the pump. That is to say, the fan
impeller of the motor must rotate in the direction in which the arrow on the pump is pointing to
indicate direction of rotation. Normally the direction of rotation of the pump is to the right
(clockwise), as seen from motor side.
Requirement:
• Pump securely attached
• Pump connection to the piping system is stress free
• Pump motor is connected correctly to the electrical power supply
• Piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be flushed by the
pump
• Pump is full
1. Switch on the power supply and then turn it off again immediately.
2. When the fan impeller of the motor moves slowly after switching off, compare the direction of
rotation of the fan impeller with the arrow indicating direction of rotation on the pump flange.
If the directions do not match, swap over two electrical connection phases. Repeat steps 1 and
2.
<1> Arrow to indicate
direction of rotation
<2> Arrows to indicate
direction of flow
Fig. 2 Identifying direction of rotation and direction of flow
1
2 2
0 0 0 0 9 5
WARNING!
Dry-running can damage pump equipment.
Turn the pump on (for max. 1 sec.) and then off again immediately (checking the direction of
rotation).
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Operation
33
Commissioning the pump
Requirement:
• The ambient conditions correspond to the operating data, see "Operating data", page 4
• The pump is securely attached
• The pump is connected to the piping system without stress or strain
• The pump motor is connected correctly to the electrical power supply
• The piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be cleaned by the
pump
• The pump is full
• If there are shut-off devices in the suction and pressure pipes, they are open
1. Switch on the pump.
The pump will deliver when the pressure on the pressure side of the pump rises or when a flow
indicator, which is available from the factory, responds.
2. If the pump does not deliver after 10–15 seconds of operation, abort commissioning, establish
the cause of the fault and only then continue the startup procedure. Follow the instructions in the
fault diagnosis charts, see "Faultfinding reference", page 61.
3. Run the pump for a few minutes to allow the piping system to vent fully.
The piping system is fully vented when there is a smooth operating noise and a pressure gauge
on the pressure side of the pump shows no more fluctuations.
Adjusting the overflow valve
If the delivery pipe on the pressure side of the pump is blocked, extremely high pressure can build
up which could possibly lead to the parts under pressure rupturing. An overflow valve is integrated
into KRAL pumps of the K series. The overflow valve prevents too high a pressure building up in
the pump. The overflow valve is set to 110 % of nominal pressure at the factory. This opening
pressure must not be exceeded in normal pump operation, otherwise the opening pressure of the
valve will have to be reset.
WARNING!
Dry-running can damage pump equipment.
Before commissioning the pump, take note of these operating instructions.
Before commissioning, make sure that the pump is full. If the pump does not deliver after 10–15 seconds, abort commissioning.
<1> Plugscrew<2> Setscrew
<3> Spring
<4> Valve cone
Fig. 3 Mounting position of the overflow valve
2
1
3 4
0 0 0 0 9 4
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Operation
35
Pump shutdown
Switching off the pump
Requirement:
• Pump in operation
1. Disconnect the motor from the mains.
2. If there is no return valve fitted in the pressure pipe, close the shut-off device on the pressure
side.
Resuming pump operation
Restarting the pump
Requirement:
• A return valve incorporated in the suction pipe, if it is possible to drain the suction pipe when the
pump is at a standstill
• The requirements for commissioning are met, see "Commissioning the pump", page 33
Switch on the pump.
Under the requirements mentioned above, the pump is ready for operation at any time.
WARNING!
Pressurizing the pump while it is at a standstill may damage the pump seals.
Make sure that while the pump is at a standstill, the pressure in the pump does not exceed
the inlet pressure during operation.
WARNING!
Dry-running can damage pump equipment.
Before starting the pump, make sure that the pump is full.
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Operation
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Servicing
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S e r v i c i n g
Maintenance
Maintenance requirement
The service life of the pump is heavily dependent on the pump operating conditions. If the
operational limits are adhered to, see "Operating data", page 4, the pump will last for many years.Symptoms of advanced wear in individual pump components can be detected in accordance with
the following table.
Tab. 1 Chart for testing the maintenance requirement
1. Check the pump regularly every four weeks, both by looking at it and by listening to it.
2. Check for symptoms of premature wear in accordance with the above chart and eliminate the
cause.
Findings Cause Remedy
Running noise increases Onset of bearing damage Replace bearing
Increased leakage Onset of seal damage Replace shaft seal
Abrasive components at the
seal
Non-volatile media Clean seal
Increased shaft coupling play Advanced wear in the
intermediate coupling ring
Replace intermediate ring
Drop in delivery rate and
pressure during constantoperating conditions
Advanced wear of screws and
casing
Replace screws and casing
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Servicing
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General drawing of the pump with
magnetic coupling and motor
General drawing
Fig. 1 Exploded view of a K-pump with magnetic coupling and motor
K1
K9
K8
K7
K6
K5
K4
K3
K2
K10
K14 K13 K12
K11
K15K16
0 0 0 0 7 0
K1 pump K7 socket screws K12 containment can
K2 socket screws K8 motor K13 conical hub connector
K3 pump bracket K9 hexagon screws K14 inner rotor
K4 outer rotor K10 pump pedestal K15 o-ring
K5 hub part K11 socket screws K16 distance sleeve
K6 fixation screw
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Replacing the magnetic coupling
Removing the magnetic coupling
Requirement:
• Pump dismantled, see "Removing the Pump", page 28
1. Before starting to disassemble the aggregate use
suitable covers to protect the pump internals
from dirt and solid bodies.
2. Remove the hexagon screws <K9> which con-
nect motor <K8> and pump bracket <K3>.
3. Carefully lift the pump <K1> with pump bracket
<K3> and containment can <K12>. Use crane for
larger pump units.
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4. Open fixation screw <K6> of the outer magnetic
rotor <K4> on the shaft of the motor <K8>.
5. Push the outer magnetic rotor <K4> off the motor
shaft by means of suitable levers or extractor.
6. To exchange the outer rotor <K4> open the
socket screws <K7> which connect it to the hub
part <K5>.
7. Remove the socket screws <K2> which connect
the pump <K1> to the pump bracket <K3>.
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8. Lift the pump bracket <K3> off the pump <K1>.
9. Remove the socket screws <K11> which connect
containment can <K12> and pump <K1>.
10. Take off the containment can <K12> . If necessa-
ry, apply strokes of a soft hammer.
11. Remove o-ring <K15>.
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12. To exchange the inner rotor <K14> insert two
screws in the void threads of the conical hub con-
nector <K13>to be used as a torque support . Loo-
sen the fixation screws of the conical hub
connector.
13. Remove inner rotor <K14> from the shaft.
14. Take off the distance sleeve <K16> for the inner
rotor <K14>.
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Installing the magnetic coupling
Requirement:
• Replacement coupling available
1. Slide distance sleeve <K16> for inner rotor
<K14> on pump shaft.
2. Insert conical hub connector <K13> into the inner
rotor <K14>.
3. Put inner rotor <K14> onto pump shaft. Prelima-
narily tighten the screws of the conical hub con-
nector <K13>. The position is correct once the
bottom side of the conical hub connector is flush
with the distance sleeve and the up side of the in-
ner rotor is flush with the conical hub connector.
Tighten screws.
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4. Carefully clean the sealing surfaces of contain-
ment can <K12> and o-ring <K15>.
5. Improve sliding properties of the o-ring <K15> by
applying some silicone grease. Insert o-ring.
6. Push containment can <K12> onto the pump flan-
ge until it is flush with the flange surface.
7. Tighten connecting screws <K11> of contain-
ment can <K12> and pump <K1>.
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8. Put the pump bracket <K3> onto the pump <K1>.
9. Tighten connecting screws <K2> of pump <K1>
and pump bracket <K3>.
10. Carefully clean the outer rotor <K4> by means of
compressed air.
11. Tighten connecting screws <K7> of outer rotor
<K4> and hub part <K5>.
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12. Carefully clean shaft end of the motor <K8>.
13. Apply lubricating agent to the motor shaft end.
14. Put hub part <K5> with outer rotor <K4> onto the
shaft end of the motor <K8>.
15. If necessary, drive hub part <K5> onto shaft with
careful strokes of a soft hammer.
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16. Attention: Shaft end must be flush with the face
of the hub part <K5>.
17. Tighten fixation screw <K6> of the outer rotor
<K4> on the shaft of the motor.
18. Align pump preassembly <K1> and outer rotor
<K4> to a proper centering. Carefully move pump
preassembly onto the motor. Do not apply force
and ensure, that the outer rotor does not hit thecontainment can <K12>.
19. Tighten connecting screws <K9> of motor and
pump bracket <K3>.
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20. Remove protective covers only just before con-
necting the pump unit to the pipe system.
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General drawing of the pump
General drawing
Fig. 2 Exploded view of a K-Pump
E12
E19
E18
E17
E16E15
E14
E13
E29E28
E27
E26
E25E24
E23
E22
E21E20
E30
E31
E32
E1
E2
E11
E6
E5
E4E3
E10
E9
E8E7
0 0 0 0 6 9
<E1> plug screw <E12> plug screw <E23> plug screw
<E2> flat gasket <E13> flat gasket <E24> flat gasket
<E3> type plate <E14> plug screw <E25> flat gasket
<E4> socket screws <E15> flat gasket <E26> plug screw
<E5> end cover <E16> socket screws <E27> circlip
<E6> adjusting screw <E17> socket screws <E28> balancing cylinder
<E7> spring <E18> flange cover <E29> main screw
<E8> valve cone <E19> ball bearing <E30> idle screws
<E9> flat gasket <E20> circlip <E31> plug screw
<E10> pump casing <E21> support ring <E32> flat gasket
<E11> flat gasket <E22> circlip
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Replacing the ball bearing
Removing ball bearings
Requirement:
• Pump dismantled, see "Removing the Pump", page 28
1. Unscrew the four socket screws <E17> on the
flange cover <E18>.
2. Loosen the flange cover <E18> with gentle "re-
bound" blows.
3. Take out the withdrawable unit comprising the
main screw <E29>, the bearing <E19>–<E22>
and the flange cover <E18> from the pump
casing <E10>.
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4. Detach the circlip <E22>.
5. Remove the support ring <E21>.
6. Expel the main screw <E29> by gently driving it
out of the bearing <E19> with a soft hammer.
7. Loosen the circlip <E20> in the flange cover
<E18>.
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8. Use an extractor to pull the bearing <E19> out of
the flange cover <E18>.
Installing ball bearings
Requirement:• Replacement bearing available
• New flat gasket available
1. Carefully remove the remains of the flat gasket
<E15> from the flange cover <E18> and pump
casing <E10>.
2. Press-in the ball bearing <E19> into the flange co-
ver <E18>.
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3. To attach the ball bearing <E19> in the flange co-
ver <E18>, fit the circlip <E20>.
4. Press-in the main screw <E29> until it stops in
the ball bearing <E19> in the flange cover <E18>.
5. Slide-on the support ring <E21>.
6. To fix the main screw <E29>, fit the circlip
<E22>.
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7. Place the new flat gasket <E15> onto the pump
casing <E10>. Carefully grease the sealing sur-
faces.
8. Turn the preassembled unit until the vent hole in
the flange cover <E18> is in the same position as
the associated hole in the pump casing <E10>.
Take care of position of straight pin.
9. Push the preassembled unit comprising flange
cover <E18> and the main screw <E29> into the
pump casing <E10>, until the main screw enga-
ges in the idle screws <E30>. Turn the main
screw while doing this.
10. Tighten the four socket screws <E17> on the
flange cover <E18>.
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Replacing the set of screws
Removing the set of screws
Requirement:
• Pump dismantled, see "Removing the Pump", page 28
1. Unscrew the four socket screws <E17> on the
flange cover <E18>.
2. Loosen the flange cover <E18> with gentle "re-
bound" blows.
3. Take out the withdrawable unit comprising main
screw <E29>, the bearing <19>–<22> and the
flange cover <E18> from the pump casing
<E10>.
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4. Detach the circlip <E22>.
5. Remove the support ring <E21>.
6. Expel the main screw <E29> by gently driving it
out of the bearing <E19> with a soft hammer.
7. Remove the idle screws <E30> from the pump
casing <E10>.
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Installing the set of screws
Requirement:
• Replacement set of screws available
• New flat gasket available
1. Carefully remove the remains of the flat gasket
<E15> from the flange cover <E18> and the
pump casing <E10>.
2. Insert the new idle screws <E30> into the pump
casing <E10>.
3. Carefully clean and grease the new main screw
<E29>.
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4. Press-in the main screw <E29> until it stops in
the ball bearing <E19> in the flange cover <E18>.
5. Slide-on the support ring <E21>.
6. To fix the main screw <E29>, fit the circlip
<E22>.
7. Place the new flat gasket <E15> onto the pump
casing <E10>. Carefully grease the sealing sur-
faces.
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8. Turn the preassembled unit until the vent hole in
the flange cover <E18> is in the same position as
the associated hole in the pump casing <E10>.
Take care of position of straight pin.
9. Push the preassembled unit comprising the flan-
ge cover <E18> and the main screw <E29> into
the pump casing <E10>, until the main screw
<E29> engages in the idle screws <E30>. Turn
the main screw while doing this.
10. Tighten the four socket screws <E17> on the
flange cover <E18>.
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A s s i s t a n c e
w i t h p r o b l e m s
Troubleshooting
Faultfinding reference
Malfunctions can have different causes. The following table lists the symptoms of a fault, the
possible causes and measures for elimination.
Findings Cause and remedy
No pump suction Pump suction pipe closed
Check shut-off devices in the suction pipe and open it, if
necessary.
Suction valve or pipe obstructed
Check for clear passage through the suction valve and pipe.
Level of liquid in the intake container too low
Top-up the pumped medium.
Dirty filter
Clean the filter.
Pump intake capacity reduced by inadequate wetting
Fill pump with medium.
Incorrect pump rotation direction
Make the electrical connection such that the direction of pump
rotation matches that of the arrow on the flange cover.
Leaking suction pipe or shaft seal
Check suction pipe or shaft seal for leaks. Pay particular
attention to leakage at valves and connection points. If
necessary, replace parts.
Suction head too high
Reduce difference of level
- or -reduce pipe length
- or -
increase pipe diameter
- or -
heat the medium to reduce viscosity
- or -
fit a suction filter with greater mesh width. Make sure that
the permissible mesh width is not exceeded, see Tab. 1,
page 26.
Pump does not vent
Vent the pressure pipe at the highest point.
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Delivery rate too low Differential pressure at the pump too high
Check the installation and reduce the differential pressure.
Broken-off magnetic coupling
1. Stop pump and re-start it
2. Avoid excessive difference pressures
3. After repeated occurence, check if pump is stuck
Viscosity of the pumped medium too high
Raise the temperature of the medium
- or -
reduce the rotation speed.
Viscosity of the pumped medium too low
Lower the temperature of the medium
- or -
increase the rotation speed
Dirty filter
Clean the filter.
Suction valve or pipe obstructed
Check for clear passage through the suction valve and pipe.
Leaking suction pipe or shaft seal
Check suction pipe or shaft seal for leaks. Pay particular
attention to leakage at valves and connection points. If
necessary, replace parts.
Suction head too high
Reduce difference of level
- or -
reduce pipe length
- or -
increase pipe diameter
- or -
heat the medium to reduce viscosity
- or -
fit a suction filter with greater mesh width. Make sure that
the permissible mesh width is not exceeded, see Tab. 1,
page 26.
Motor running at wrong voltage or frequency
1. Make sure that the motor voltage and frequency match the
operating voltage.
2. Compare the speed of the motor with the pump nameplate. If
the data does not match, adjust the speed of the motor.
Airlock or gas in the medium
1. Test the piping system for air admission and if necessary,
replace parts.
2. Reduce the suction head
- or -
increase the inlet pressure.
Overflow valve opens during normal operation
Set opening pressure above value of operating pressure.
Overflow valve leaking
Clean overflow valve and if necessary, re-seat.
Advanced wear of rotating pump components
Check set of screws and casing and replace if necessary.
Findings Cause and remedy
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Pump runs noisily Dirty filter
Clean the filter.
Broken-off magnetic coupling
1. Stop pump and re-start it
2. Avoid excessive difference pressures
3. After repeated occurence, check if pump is stuck
Suction valve or pipe obstructed
Check for clear passage through the suction valve and pipe.
Leaking suction pipe or shaft seal
Check suction pipe or shaft seal for leaks. Pay particular
attention to leakage at valves and connection points. If
necessary, replace parts.
Suction head too high
Reduce difference of level
- or -
reduce pipe length
- or -
increase pipe diameter
- or -
heat the medium to reduce viscosity
- or -
fit suction filter with greater mesh width. Make sure that the
permissible mesh width is not exceeded, see Tab. 1, page
26.
Viscosity of pumped medium too high
Raise the temperature of the medium
- or -
reduce the rotation speed
Airlock or gas in the medium
1. Test the piping system for air admission and if necessary,
replace parts.
2. Reduce the suction head
- or -
increase the inlet pressure.
Inadequate alignment of shaft coupling
Align the shaft coupling correctly, see "Aligning and checking
the shaft coupling", page 27.
Pump deflected
1. Support the weight of the pipeline.
2. Loosen pipeline connections and assemble stress free, see
"Installing the pump", page 26.
Resonance in the installation
Provide a flexible bearing arrangement for the unit
- or -
make the connections with hoses.
Speed of flow in suction or pressure pipe too high
1. Set the flow speed in the suction pipe so that it does not
exceed 1 m/s.
2. Set the flow speed in the pressure pipe so that it does not
exceed 3 m/s.
Ball bearing damaged
Replace the ball bearing, see "Removing ball bearings", page
50.
Overflow valve opens during normal operation
Set opening pressure above value of operating pressure.
Findings Cause and remedy
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Motor overload Motor running at wrong voltage or frequency
1. Make sure that the motor voltage and frequency match the
operating voltage.
2. Compare the speed of the motor with the pump nameplate. If
the data does not match, adjust the speed of the motor.
Differential pressure too high
Check the installation and reduce the differential pressure.
High viscosity of pumped medium
Raise the temperature of the medium
- or -
reduce the rotation speed.
Lack of lubrication or foreign bodies have caused superficial
damage to rotating pump components
Check the set of screws and the casing and replace if
necessary.
Damaged rolling bearing
Replace the rolling bearing, see "Removing ball bearings", page
50.
Uneven pump capacity Dirty filter
Clean the filter.
Suction valve or pipe obstructed
Check for clear passage through the suction valve and pipe.
Leaking suction pipe or shaft seal
Check suction pipe or shaft seal for leaks. Pay particular
attention to leakage at valves and connection points. If
necessary, replace parts.
Suction head too high
Reduce difference of level
- or -
reduce pipe length
- or -
increase pipe diameter
- or -
heat the medium to reduce viscosity
- or -
fit a suction filter with greater mesh width. Make sure that
the permissible mesh width is not exceeded, see Tab. 1,
page 26.
Viscosity of the pumped medium is too high
Raise the temperature of the medium
- or -
reduce the rotation speed.
Airlock or gas in the medium
1. Test the piping system for air admission and if necessary,
replace parts.
2. Reduce the suction head
- or -
increase the inlet pressure.
Overflow valve opens during normal operation
Set opening pressure above value of operating pressure.
Overflow valve leaks
Clean the overflow valve and if necessary, re-seat.
Findings Cause and remedy
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Tab. 1 Fault diagnosis chart
Leaking shaft seal Dry running has damaged the shaft seal
Replace the shaft seal. When starting up the pump, pay
attention to venting.
Inlet pressure too high
Reduce the inlet pressure at the installation end.
Thermal or chemical loading of elastomer seals exceeded
1. Check the maximum operating temperature.
2. Check the resistance of the elastomer with regard to the
pumped medium.
Cold start when delivering high-viscosity media
Install pump heating.
Seal overload during heating process
To prevent thermal expansion of the media causing a buildup
of pressure, open the pressure or suction side shut-off
devices.
Leaking return valve causes seal overload when pump is at a
standstill
Clean the return valve and if necessary, replace it.
Advanced wear of sealing surfaces
Replace the seal and if necessary, check the pumped medium
for abrasive content.
Pump is stuck Foreign bodies in the pump
Dismantle the pump and clean it.
Smooth the superficial damage to the casing and the rotating
parts with an oilstone and if necessary, replace the set of
screws and/or the casing.
Differential pressure is too high and has overloaded the sleeve
bearing
Dismantle the pump.
Smooth the superficial damage to the casing and the rotating
parts with an oilstone and if necessary, replace the set of
screws and/or the casing.
Reduce the differential pressure.
Viscosity is too low and has overloaded the sleeve bearing
Dismantle the pump.
Smooth the superficial damage to the casing and the rotating
parts with an oilstone and if necessary, replace the set of
screws and/or the casing.
Increase the viscosity, for example by reducing the operating
temperature.
Dry running has damaged the pump
Dismantle the pump.
Smooth the superficial damage to the casing and the rotating
parts with an oilstone and if necessary, replace the set of
screws and/or the casing.
When resuming operation, take action to prevent dry running,
see "Resuming pump operation", page 35.
Findings Cause and remedy
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Assistance with problems
66
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Appendix
67
A p p e n d i x
General drawings
Exploded view of pump with magnetic coupling and motor
Tab. 1 Spare part numbers of magnetic coupling and motor
Fig. 1 Exploded view of a K-pump with magnetic coupling and motor
K1
K9
K8
K7
K6
K5
K4
K3
K2
K10
K14 K13 K12
K11
K15K16
0 0 0 0 7 0
Item no. Part Spare part no. Item no. Part Spare part no.
<K1> pump 1 <K9> hexagon screws 900
<K2> socket screws 915,1 <K10> pump pedestal 225
<K3> pump bracket 180 <K11> socket screws 915,3
<K4> outer rotor 515 <K12> containment can 038
<K5> hub part 052 <K13> conical hub connector 585
<K6> fixation screw <K14> inner rotor 518
<K7> socket screws 915,2 <K15> o-ring 739
<K8> motor 529 <K15> distance sleeve 39
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0 2 8 0 . 1
4 0 0
INSTALLATIONS-OG VEDLIGEHOLDELSESVEJLEDNINGFOR ELEKTRISKE MOTORER
ISTRUZIONI DUSO E MANUTENZIONEPER MOTORI ELETTRICI
INSTRUCTIONS POUR INSTALLATION ETMANUTENTION DE MOTEURS ÉLECTRIQUES
BETRIEBS - UND WARTUNGSANLEITUNGENFÜR ELEKTROMOTOREN
INSTRUCCIONES PARA LA INSTALACIÓN Y MANTENIMIENTO DE MOTORES ELÉCTRICOS
INSTALLATION AND MAINTENANCE INSTRUCTIONSFOR ELECTRIC MOTORS
INSTALLATIONS- OCH UNDERHÅLLSINSTRUKTIONER FÖR ELEK
ENGLISHENGLISHENGLISHENGLISHENGLISH
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READ CAREFULLY THIS MANUAL
BEFORE INSTALLING THE MOTOR
RECEIVING CHECK
Check if any damage has occured duringtransportation.üCheck nameplate data.üRemove shaft locking device (if any) beforeoperating the motor.üTurn the shaft with the hand to make sure it
is turning freely.
HANDLING AND TRANSPORTATION1 - General
MOTORS MUST NOT BE LIFTED BY
THE SHAFT, BUT BY THE EYEBOLTS
Lifting devices, when supplied, aredesigned only to support the motor. If the motorhas two lifting devices then a double chain mustbe used to lift it.
Lifting and lowering must be done gentlywithout any shocks, otherwise the bearings canget damaged.
DURING TRANSPORTATION,
MOTORS FITTED WITH ROLLER OR
ANGULAR CONTACT BEARINGS
ARE PROTECTED AGAINST
BEARING DAMAGES WITH A
SHAFT LOCKING DEVICE.
THIS LOCKING DEVICE MUST BE
USED ON ANY FURTHER MOTOR
TRANSPORTATION, EVEN WHEN THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE.
STORAGE
If motors are not immediately installed,they must be stored in dry places, free ofdust, vibrations, gases, corrosive smokes,
under constant temperature and in normalposition free from other objects.
Motor storage temperature must remainbetween 5ºC to 60ºC, with relative humidity notexceeding 50%.
In case the motors are stored for more thantwo years, the bearings must be replaced or thelubrication grease must be totally removed aftercleaning.
Single phase motors when kept in stockfor 2 years or more must have their capacitorsreplaced (if any).
We recommend to turn the shaft (by hands)at least once a month, and to measure theinsulation resistance before installing it, in casesof motors stored for more than 6 months or whensubject to high humidity areas.
If motor is fitted with space heaters, theseshould be switched on.
Insulation Resistance Check
Measure the insulation resistance beforeoperating the motor and/or when there is anysign of humidity in the winding.
The resistance measured at 25ºC must be:
Ri ≥ (20 x U) / (1000 + 2P) [MΩ](measured with a MEGGER at 500 V d.c.)where U = voltage (V); P = power (kW).
If the insulation resistance is less than 2megaohms, the winding must be driedaccording to the following:
Warm it up inside an oven at a minimumtemperature of 80ºC increasing 5ºC every houruntil 105ºC, remaining under this temperaturefor at least one hour.
Check if the stator insulation resistanceremains constant within the accepted values. Ifnot, stator must be reimpregnated.
INSTALLATION
1 - Safety
All personnel involved with electricalinstallations, either handling, li fting, operationor maintenance must be well informed and
updated concerning safety standards andprinciples that govern the work and carefullyfollow them.
We strongly recommend that these jobsare carried out by qualified personnel.
ENGLISH
E N G L I S H
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MAKE SURE THAT ELECTRIC
MOTORS ARE SWITCHED OFF
BEFORE STARTING ANY
MAINTENANCE SERVICE.
Motors must be protected against acci-dental starts.
When performing any maintenanceservice, disconnect the motor from the powersupply. Make sure all accessories have beenswitched off and disconnected.
In order to prevent from penetrating dustand/or water into the terminal box, cable glandsor threaded pipe in the lead holes must beinstalled.
Do not change the regulation of theprotecting devices to avoid damaging.
2 - Operating Conditions
Electric motors, in general, are designedfor operation at an altitude of 1000m above sealevel for an ambient temperature between 0ºCand 40ºC. Any variation is stated on thenameplate.
COMPARE THE CURRENT, VOLTAGE,
FREQUENCY, SPEED, OUTPUT AND
OTHER VALUES DEMANDED BY THE
APPLICATION WITH THE DATA GIVEN
ON THE NAMEPLATE.
Motors supplied for hazardous locations
must be installed in areas that comply with thatspecified on the motor nameplate.
KEEP AIR INLET AND OUTLET FREE
AND CLEAN. THE AIR BLOWN OUT
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE
INLET OPENING DIAMETER.
3 - Foundation
Motors provided with feet must be installedon solid foundations to avoid excessivevibrations.
The purchaser is fully responsible for the
foundation.Metal parts must be painted to avoid
corrosion.The foundation must be uniform and suf-
ficiently tough to support any schock. It must be
TH E MOTORS ARE DYNAMICALLY
BALANCED WITH HALF KEY, AT NO
LOAD AND UNCOUPLED.
Transmission elements such as pulleys,couplings, etc must be dynamically balanced
with half key before installation.Use always appropriate tools for installation andremoval.
6 - Alignment
ALIGN THE SHAFT ENDS AND
USE FLEXIBLE COUPLING,
WHENEVER POSSIBLE.
Ensure that the motor mounting devices
do not allow modifications on the alignment andfurther damages to the bearings.
When assembling a half-coupling, be sureto use suitable equipment and tools to protectthe bearings.
Suitable assembly of half-coupling:Check that clearance Y is less than
0.05 mm and that the difference X1 to X2 is lessthan 0.05 mm, as well.
Note: Dimension X1 and X2 must be3mm minimum
Figure and alignment tolerances
designed in such a way to stop any vibrationoriginated from resonance.
4 - Drain Holes
Make sure the drains are placed in thelower part of the motor when the mounting
configuration differs from that specified on themotor purchase order.
5 - Balancing
7 - Belt Drive
When using pulley or belt coupling, thefollowing must be observed:
Belts must be tighten just enough to avoidslippage when running, according to the
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WARN I NG : WARN I NG : WARN I NG : WARN I NG : WARN I NG :
Excessive tension on the pulleys willdamage the bearings and lead to a
probable shaft rupture.
8 - Connection
WARNING:
Voltage may be connected at standstillinside the terminal box for heating elements ordirect winding heating.
WARNING:
The capacitor on single-phase motorscan retain a charge which appears across themotor terminals, even when the motor hasreached standstill.
A WRONG CONNECTION CAN
BURN THE MOTOR.
Voltage and connection are indicated on
the nameplate. The acceptable voltagevariation is ± 10%; the acceptable frequency
variation is ± 5% and the total acceptablevariation is ± 10%.
9 - Starting Methods
The motor is rather started through directstarting. In case this is not possible, usecompatible methods to the motor load andvoltage.
The rotation direction is clockwise if themotor is viewed from DE side and if the
phases are connected according to thesequence L1, L2, L3.
To change the rotation direction, inter-change two of the connecting leads.
Make sure to use the correct cabledimension, based on the rated current stampedon the motor nameplate.
BEFORE ENERGIZING THE
TERMINALS, CHECK IF THE
GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIALAGAINST ACCIDENT RISKS.
When the motor is supplied withprotective or monitor temperature device suchas thermostats, thermistors, termal protector, etc,connect their terminals to the correspondingdevices on the control panel.
10 - Start-Up
THE KEY MUST BE FASTENED OR REMOVED BEFORE STARTING THE
MOTOR.
a) The motor must start and operatesmoothly. In case this does not occur, turn it offand check the connections and the mountingbefore starting it again.
b) If there is excessive vibration, check ifthe fastening screws are correctly fastened.Check also if the vibration comes from a
neighbour machine. Periodical vibration checksmust be done.
c) Run the motor under rated load for ashort period of time and compare if the runningcurrent is equal to that stamped on thenameplate.
1 - General Inspection
üCheck the motor periodically.üKeep the motor clean and assure free air flow.üCheck the seals or V Ring and replace them, ifrequired.üCheck the connections as well as supportingscrews.üCheck the bearings and observe: Any excessive
noise, vibration, bearing temperature and greasecondition.üWhen a change, under normal conditions, isdetected, check the motor and replace therequired parts.
WARNING:
SAFETY CHECK LIST
MAINTENANCE
E N G L I S H
specifications stated on the belt supplierrecommendation.
THE CONNECTION TO THE POWER
SUPPLY MUST BE DONE BY
QUALIFIED PERSONNEL AND WITH
FULL ATTENTION TO ASSURE A SAFE
AND PERMANENT CONNECTION.
AFTER CONNECTING THE MOTOR,CHECK FOR ANY STRANGE BODY
INSIDE THE TERMINAL BOX. THE
CABLE INLETS NOT IN USE MUST BE
CLOSED.
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Bearing 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27 NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Bearing 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
Bearing 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
Serie 62
Serie 63
TABLE 1 - BALL BEARINGS - Series 62/63
Relubrication intervals (running hours horizontal position)
FOLLOW THE REGREASING
INTERVALS. THIS IS FUNDAMENTAL
FOR PROPER MOTOR OPERATION.
1 - Machines without Grease Nipples
Motors up to frame 200 are normally fittedwithout grease nipples. In these cases theregreasing shall be done at the preventivemaintenance job observing the followingaspects:
üDisassemble carefully the motors.üTake all the grease out.üWash the bearing with querosene or diesel.üRegrease the bearing immediately.
LUBRICATION
2 - Machines Fitted with Grease Nipples
It is strongly recommended to grease themachine while running. This allows the greaserenewal in the bearing housing. When this isnot possible due to turning parts by the greasedevice (pulleys, bushing, etc) that offer somerisk to the physical integrity of the operator,
proceed as follows:üClean the area near the grease nipple.üPut approximately half of the total grease andrun the motor for 1 minute at full speed.Then turn off the motor and insert the rest of thegrease.üThe injection of all the grease with the motor instandstill can make the grease penetrate into themotor, through the inner seal of the bearinghousing.
RELUBRICATION INTERVALS
The frequency of the inspections dependson the motor type and on the applicationconditions.
FOR LUBRICATION USE ONLY MANUAL GREASE GUN.
TABLE 2 - ROLLER BEARINGS - Series NU 3
Relubrication intervals (running hours horizontal position)
GreaseII pole IV pole VI pole VIII pole X pole XII pole
GreaseII pole IV pole VI pole VIII pole X pole XII pole
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SPARE PARTS
When ordering spare parts, please specifythe full type designation and product code asstated on the motor nameplate. Please alsoinform the motor serial number stated on thenameplate.
MOTORS FOR HAZARDOUSLOCATIONS
Besides the recommendations givenpreviously, these ones must be also followed:
THE SPECIFICATION OF THE MOTOR
INSTALLATION PLACE IS FOR
CUSTOMER’S RESPONSIBIL ITY,
WHO WILL ALSO DETERMINE THE
ENVIRONMENT CHARACTERISTICS.
Motors for hazardous locations aremanufactured according to specific standardsfor such environments and they are certified byworldwide certifying entities.
1 - Installation
The complete installation must followprocedures given by the local legislation in effect.
THE INSTALLATION OF HAZARDOUS
LOCATION MOTORS MUST BE
CARRIED OUT BY SKILLED PEOPLE,
AND THE THERMAL PROTECTION
MUST BE ALWAYS INSTALLED,
EITHER INSIDE OR OUTSIDE THE
MOTOR, OPERATING AT THE RATED
CURRENT.
2 - Maintenance
Maintenance must be carried out by repair
shops authorized by KUWO.Repair shops and people without KUWO’sauthorization who will perform any service onhazardous location motors wil l be ful lyresponsible for such service as well as for anyconsequential damage.
E N G L I S H
N o te :N o te :N o te :N o te :N o te :üThe ZZ bearings from 6201 to 6307 do notrequire relubrication as its life time is about20,000 hours.üTables 1 and 2 are intended for the lubricationperiod under bearing temperature of 70°C (forbearings up to 6312 and NU 312) andtemperature of 85°C (for bearings 6314 and NU314 and larger).
üFor each 15°C of temperature r ise, therelubrication period is reduced by half.üThe relubrication periods given above arefor those cases applying Polyrex ® EM grease.üWhen motors are used on the verticalposition, their relubrication interval is reducedby half if compared to horizontal positionmotors.
N o te s :N o te s :N o te s :N o te s :No tes :üAlthough Polyrex ® EM is compatible with typesof grease given above, we do not recommendedto mix it with any other greases.ü If you intend to use a type of grease differentthan those recommended above , first contact
KUWO.üOn applications (with high or low temperatures,speed variation, etc), the type of grease andrelubrification interval are given on an additionalnameplate attached to the motor.
THE USE OF STANDARD MOTORS
IN SPECIFIC AREAS OR SPECIAL
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE
MANUFACTURER OR KUWO
Compat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rexCompat ib i l i t y o f Po ly rex ® ® ® ® ® EM greaseEM greaseEM greaseEM greaseEM grease
wi th other types of grease:wi th other types of grease:wi th other types of grease:wi th other types of grease:wi th other types of grease:
Containing polyurea thickener and mineral
oil, the Polyrex ® EM grease is compatible withother types of grease that contain:üLithium base or complex of lithium or polyureaand highly refined mineral oil.üInhibitor additive against corrosion, rust andanti-oxidant additive.
WARNING:
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING
RESULTING IN COMPLETE
DAMARGE.
WE RECOMENDED TO USE BALL
BEARINGS FOR MOTORS DIRECTLY
COUPLED TO THE LOAD.
Disassembly and assembly must be doneby qualified personnel using only suitable toolsand appropriated methods.
DISASSEMBLY AND ASSEMBLY
The stator grips must be applied over theside face of the inner ring to be disassembled orover an adjacent part.
It is essential that bearings assembly bedone under cleanning conditions to ensuregood operation and to avoid damages. Newbearings shall only be taken out from their caseswhen assembling them.
Before installing a new bearing it is
required to check the shaft fitting for any sharpedge or strike signals.For bearing assembly warm their inner
parts withsuitable equipment - inductive pocess- or use suitable tools.
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When performing maintenance,installation or relubrication, follow theseinstructions:
üCheck if all components are free of edges,knocks or dirt.üMake sure all parts are in perfect conditions.üLubricate the surfaces of the endshield fittingswith protective oil to make the assembly easier.üUse only rubber hammer to fit the parts.üCheck for correct bolts tightening.üUse clearance calibrator for correct T-box fitting(smaller than 0.05mm).
DO NOT REUSE DAMAGED OR
WORN PARTS. REPLACE THEM BY
NEW ONES SUPPLIED BY THE
FACTORY.
MOTORS DRIVEN BY VFDApplications using VFD´s without filter
can affect motor performance as follows:
IF SUCH RECOMMENDATIONS ARE
NOT FOLLOWED ACCORDINGLY,
MOTOR WARRANTY WILL BE VOID.
2- Inverter Duty Motors:
üCheck power supply voltage of the forcedcooling set.üFilters are not required.
üLower efficiency.üHigher vibration.üHigher noise level.üHigher rated current.üHigher temperature rise.üReduced motor insulation.üReduced bearing life.
1- Standard Motors
üVoltages lower than 440V do not require filter.üVoltages equal or higher than 440V or lowerthan 575V require filter for motor power supplycables longer than 20 meters.üVoltages equal or higher than 575V requirefilter for any size of power supply cables.
WARRANTY TERMSWe warrant our products against defects inworkmanship and materials for twelve (12)
months from the invoice date issued by thefactory, authorized distributor or agent limitedto eighteen (18) months from manufacturing dateindependent of installation date as long as thefollowing items are fulfilled accordingly:
- Proper transportation, handling and storage;- Correct installation based on the specified
ambient conditions and free of corrosivegases;
- Operation under motor capacity limits;- Observation of the periodical maintenance
services;- Repair and/or replacement effected only by
personnel duly authorized in writing by KUWO;- The failed product be available to the supplier
and/or repair shop for a required period todetect the cause of the failure andcorresponding repair;
- Immediate notice by the purchaser aboutfailures accured and that these are acceptedby KUWO as manufacturing defects.
This warranty does not include disassemblyservices at the purchaser facilities,
transportation costs with product, tickets,accomodation and meals for technical personnelwhen requested by the customer.The warranty service will be only carried out atKUWO Authorized Repair Shops or at ourfacilities.
Components whose useful life, under normaluse, is shorter than the warranty period are notcovered by these warranty terms.
The repair and/or replacement of parts orcomponents, when effected by KUWO and/or anyKUWO Authorized Repair Shop, will not givewarranty extension.
This constitutes KUWO’s only warranty inconnection with this sale and the company willhave no obligation or liability whatsoever topeople, third parties, other equipment orinstallations, including without limitation, any
claims for consequential damages or labor costs.
ANY ELECTRICAL OR MECHANICAL
MODIFICATION MADE ON
HAZARDOUS LOCATION MOTORS
WILL VOID THE CERTIFICATION.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
2. Filter
ATTENTION!
Valid for all filter with heating chamber (heating connection):
At the first start up of trace heating the heat transfer cement
connecting the heating chamber to the filter may get splits or
cracks due to extension.
This will not lead to a leakage of heating medium.
Type: 2.04.5.110.260,
6.61 Gr. 15,
2.06.5.4.195.250
Pos.: 2.1, 2.2, 2.5
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DESCRIPTION AND OPERATING INSTRUCTIONS
FOR THE DUPLEX FILTER
Contents:
1. Type sheet
2. Spare parts drawing and spare parts list
3. Description and Operating Instructions for the duplex filter
4. Description and Operating Instructions for the filter element cleaning
5. Data Sheet for the Differential Pressure Indicator (to order)
6. Spare parts drawing for the Differential Pressure Indicator (to order)
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ERSATZTEILLISTE TYP 2.04.5
SPARE PART LIST LISTE DES PIECES DE RECHANGE
Typenschlüssel:2.04.5. =Doppelfilter duplex filter Filtre doubleG . =Gehäusedurchmesser cabin diameter diamètre du corpsQ . = Filtereinsatzlänge length of the filter element longueur du panier DN .= Anschlußflansche connection flanges brides désirées
Pos.
Nr.
BezeichnungDesignationDesignation
DN 25 St. DN 32 St. DN 40 St. DN 50 St. DN 65 St. DN 80 St.
2Verschlußschraubescrew plugvis
2000188 2 2000188 2 2000188 2 2000188 2 2000188 2 2000188 2
3
Dichtung
gasket joint
3270003 2 3270003 2 3270003 2 3270003 2 3270003 2 3270003 2
4Verschlußschraubescrew plugvis
2002885 2 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2
5Dichtunggasket joint
3270002 2 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2
6Verschlußschraubescrew plugvis
2002885 2 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2
7Dichtunggasket joint
3270002 2 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2
10Stiftschraubeboltvis
2000002 6 2000002 6 2000004 6 2000004 6 2000004 6 2000007 6
11Deckelcover couvercle
Z26002 2 Z26002 2 Z25721 2 Z25721 2 Z25721 2 Z31610 2
12O-Ring (Viton)O-RingO-Ring (Perbunan)
3030742
30401022
3030742
30401022
3035046
30423292
3035046
30423292
3035046
30423292
3030367
30401072
13Mutter nutecrou
2100005 6 2100005 6 2100006 6 2100006 6 2100006 6 2100007 8
16Kugelhahnball valve
vannes à boisseauspherique
G 1/4 1 G 1/4 1 G 1/4 1 G 1/4 1 G 3/8 1 G 3/8 1
18Kükencockvanne à boisseau
Z25998 1 Z25998 1 Z25889 1 Z25735 1 Z31309 1 Z31612 1
19O-Ring (Viton)O-RingO-Ring (Perbunan)
3030172
30401582
3030172
30401582
3030466
30405012
3031849
30401172
3030175
30401192
3030075
30401212
19.1O-Ring (Viton)O-RingO-Ring (Perbunan)
------- ------- ------- -------3030174
30401801
3030177
30312771
20Sicherungsringcirclip ringcirclip exterieune
2201921 1 2201921 1 2209026 1 2205389 1 2205119 1 2205119 1
21Hahnschlüsselplug keyclef du robinet
WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1 WN 48.2 1
22Siebeinsatzsiebe elementélément filtrant
Fabr.Nr.Filtertyp
Fabr.No.Filtertype
Fabr.No.Type de
Filtre
Fabr.Nr.Filtertyp
Fabr.No.Filtertype
Fabr.No.Type de
Filtre
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36Dichtunggasket
joint
3380136 2 3380136 2 3382898 2 3380037 2 3380040 2 3380041 2
37Schraubeboltvis
2000002 8 2000002 8 2005659 8 2005659 8 2000511 8 2000511 8
38Mutter nutecrou
2100005 8 2100005 8 2100006 8 2100006 8 2100007 8 2100007 8
65DDADPIIPD
TypDruck
TypePressure
TypePression
TypDruck
TypePressure
TypePression
70Zylinderschraubescrewvis
2000122 2 2000122 2 2000122 2 2000122 2 2000122 2 2000122 2
72
Mutter
nutecrou 2100003 2 2100003 2 2100003 2 2100003 2 2100003 2 2100003 2
73Federringspring washer annneau ressant
2209799 2 2209799 2 2209799 2 2209799 2 2209799 2 2209799 2
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Installation and Operating Instructions for the Duplex Filter
Type 2.04.5
General:
The switchable duplex filter type 2.04.5 comprises two
filter housings which are connected in parallel through
a two-stage change-over housing. The filter housings
are designed to meet current regulations in respect of
pressure rating. The filter elements are adequately
protected to cope with the differential pressures which
occur in the filter, details of which are given on thefilter mounted instruction plates. These pressures are
1,2 bar for star-form elements and 0,8 bar for basket-
type elements.
Duplex filters are installed in cases where regeneration
of contaminated filter elements must be carried out
without shutting down the equipment or plant.The
change-over housing, which contains a segment-typerotating valve, allows shock pressure-free change
over, because as one chamber is closed theother
chamber is opened the same amount, in otherwords, both filter chambers can be put into operation
at the same time whenever the need arises (see Picture 2 - Valve Position Indicator). The
undesired closing of both chambers is prevented by a stop, i.e.by the constructional design of the
change-over housing.
Installation:
The filter housings must not be over-stressed when tightening the filter assembly onto its base or
mounting. This also applies to the pipe connections. It is also important to make sure that the
direction of liquid flow through the filter is compatible with the filter elements installed in the filter.
The flow direction is marked on the filter assembly, usually on the flanges.
According to the AD Information Sheets, the filter housings are
only rated for internal overpressure. Additional external forces
and moments at the connection flanges of the filter are to be
avoided (possibly support feed lines).
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I. Segment Valve Operation
The segment valve (18) is operated by the lever (21). The lever moves through an
angle of 144ø. The travel stops of the lever are located inside the change-over housing. A cam, which is cast integral with the neck of the segment valve extension, moves over the valve position indicator plate (25) to indicate to the operator the position of thesegment valve (see Picture 2).
1. Changing over filter chambers:1.1 Slacken the air vent plug (4) of the cleaned filter chamber.1.2 Turn the lever (21) to move the position indicator cam from position "1" to position "2"
(see Picture 2). In this position the segment valve opens a port to allow liquid to flow inand fill the cleaned chamber. As soon as the liquid flows free of air bubbles from the ventplugt (4), close the vent plug.
2. Preparing the Filter for Operation2.1 Position the lever (21) in the middle position - both filter chambers in operation.2.2 Open both filter chamber vent plugs.2.3 Start and slowly run the plant or equipment.2.4 As soon as liquid flows from the vent plugs free of air bubbles, close the vent plugs.2.5 Operate the lever to close one of the filter chambers; whilst the other filter chamber
takes over filtration of the liquid, the other (closed) filter chamber remains in reserveuntil, due to contamination, the maximum preset differential pressure is reached. At adifferential pressure of 1,2 bar allowed for starform elements or 0,8 bar allowed for basket-type elements, the reserve or cleaned filter chamber is to be put into operationas follows:
2.6 Momentarily open the vent plug (4) of the reserve chamber and check to make sure thatthis chamber is full.
2.7 Change over the filters as described under paragraph 1.2.8 Open the vent plug (4) of the closed filter chamber to relieve any pressure in this
chamber. It will now be possible to check whether the segment valve (18) has in factclosed the inlet port to this chamber.Note that a complete sealing of a segment type valve is not possible. By opening thesludge discharge plug (2), any liquid that has leaked passed the segment valve duringcleaning can be drained off.
2.9 Remove the filter cover (11) from the closed (shutoff) filter chamber.2.10 Open the sludge discharge plug (2) and drain down the liquid until the liquid level is
below the seat of the element. Remove the filter element from the filter housing.
2.11 Clean the filter element (see the Operating Instructions for cleaning the element).2.12 Replace the cleaned element into the filter housing. Make sure the seal of the element
is not damaged before replacing the element!
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2.13 Replace the filter cover (11). The vent plug isto be left open at this stage. Make sure that thecover seal (12) and its seat are clean and in agood condition, if necessary, renew the seal (12).
2.14 Move the lever (21) from position "1" to position "2" - the cleaned filter chamber will now be refilled and vented of air.
2.15 Close the vent plug - the filter chamber is now in an operational-ready condition.
3. MaintenanceMaintenance of the duplex filter extends to an inspection and eventual replacement of the sealing elements and screens. If the filter assembly shows signs of corrosion, then itshould be reconditioned or renewed as necessary.The filtering of cooling water and other certain types of operating mediums can lead toformation of harmful deposits on the surfaces of the components in the change-over housing, it is therefore advisable to operate the change-over mechanism at regular inter vals to avoid seizure of the segment valve.
Removing and Replacing the Segment valve (18)3.1 Open both filter chamber vent plugs (4) to depressurize the filter chambers.
3.2 Drain both filter chambers.3.3 Using circlip pliers (DIN 5256C - Securing Borings), remove the circlip (20) from the
groove.3.4 By rotating and at the same time lifting the segment valve (18), remove the valve
from the change-over housing.3.5 Detach the O-rings (19).3.6 Thoroughly clean the segment valve and examine the valve for damage. Remove any
traces of scoring by polishing the valve with a suitable, fine carborumdum paste.Examine the valve bore in the change-over housing and if necessary treat in thesame manner.
3.7 Lightly oil the O-rings (19) and then refit them in the grooves of the segment valve. It isrecommended to renew these O-rings as, due to hardening and compression they
loose a certain amount of elasticity.3.8 Carefully insert the segment valve (18) into the top of the change-over housing and, by
pressing down and rotating the valve at the same time, push the valve into the housing.
3.9 Position the indicator cam to point to the centre position on the valve position indica tor plate (see Picture 2).
3.10 Now push the segment valve further down into the bore until the groove for the circlip (20)becomes visible.
3.11 Refit the circlip (29) in the groove.3.12 Check the segment valve for ease of operation.3.13 Prepare the filter assembly for operation as described in paragraph 2.
It is recommended to wet the recess for the O-ring (12) in the Filter housing withVaseline to make it more difficult for theO-ring to move..
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1. Maintenance and Cleaning1.1 Take the filter out of operation. See the
operating instructions for simplex and
duplex filters.
1.2 The filter chamber taken out of operation isdrained, using the discharge screw, until thelevel of the liquid is below the elementsupport. The basket element is thenremoved from the housing. The coarsestdirt particles can now be shaken off. Theelement should then be placed in a suitablecleaning agent, e.g. BOLL CLEAN 2000,and compressed air should carefully be
blown through the element from the outsideto the inside. For obstinate dirt, use of a softbrush which will not damage the mesh isrecommended.
If media containing ferritec particles are tobe filtered out, the basket element is fittedwith a bar magnet (225).
1.3 Structure of the Basket ElementThe basket element is a compoundstructure, consisting of a bottom plate (11),top ring (1), handle (124), support mantle(80) and tie rod (222).
All the elements are held together on the tie rod (222). The thread on the tie rod(222) is glued to the handle (124) so that the element can only be dismantled byundoing the hexagonal nut (221).The wire gauze (100) is welded from inside on to the support mantle (8).The flow is always from the inside to the outside.
1.4 Basket elementThe element is to be inspected and cleaned at regular intervals. The length of theintervals depends on the amount of contamination expected. It is recommended,however, that the initial cleaning should take place immediately after a newsystem is flushed trough.In general, however, the pressure drop across the filter is a good indicator of thecontamination on the filter element. This pressure drop should not exceed 0,8 bar,since otherwise there is a danger of the element fracturing.(Dedicated differential-pressure monitors are available from the our
product range.)
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COVER SECURING DEVICE FOR DOUBLE FILTERS
The function of the cover securingdevice is to prevent the uncontrolled
excape of lubricantes and fuels in the
case of operating errors. The cover plate
(2) covers a minimum number of cover
screws (3), so that the cover (1) cannot
be removed with out actuating the
venting facility (4).
The filter chamber is relieved through
the venting screw (4). With the correct
switching position, the service pressure
of the filter chamber falls immediately
and hardly any fuel excapes. Otherwise,
the venting screw is immediately closed
and the fuel discharge is limited.
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Operation:
1. Establish on the circuit diagram (5)
with chamber is switched off.
2. Unscrew the venting screw of this
chamber (4) to the point where the
cover plate (2) can swivel over the
cover screws (3)
3. Loosen cover screws (3) and remove
cover (1).
4. Assemble in reverse order
5. For sieve cleaning and
commissioning, see Sieve Cleaning
Operating Instructions and Double
Filter Operating Instructions.
Check seals items 6 and 7for damage.
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G1/4
G 1 / 4- +
DIFFERENTIAL PRESSURE INDICATOR TYPE 4.36.1
MATERIAL : GD - ALUMINIUM
RATING : MAX. PRESSURE 100 BARMAX. TEMPERATURE 150°C
RANGES OF PRESSURE DIFFERENTIAL DELTA P = 0 - 0.5 BAR0 - 0.8 BAR0 - 1.2 BAR TO BE SPECIDIED WHEN ORDERING0 - 2.0 BAR0 - 3.0 BAR
DESCRIPTION:
THE PURPOSE OF THE DEVICE IS TO MEASURE AND GIVE A VISUAL INDICATION OF A VARIABLEPRESSURE DIFFERENCE.
METHOD OF OPERATION:
A PISTON WITH DIAPHRAGM SEAL DIVIDES THE SPACE UNDER PRESSURE INTO TWO CHAMBERS.THROUGH THE ACTION OF A SPRING UNDER TENSION THE PISTON IS KEPT IN THE ZERO POSITION WHENDELTA P = 0.
AS THE PRESSURE DIFFERENCE INCREASES (DELTA P > 0), THE PISTON MOVES AGAINST THE SPRING. ATTHE SAME TIME AN INDICATOR DISC IS ROTATED BY MAGNETIC MEANS, THAT IS VIRTUALLY WITHOUTFRICTION. AS A RESULT OF THE MOVEMENT OF THE PISTON, THE RED SEGMENT OF THE DISC BECOMESVISIBLE IN THE REGION EXTENDING FROM APROX 50% TO 100% OF THE DIFFERENTIAL PRESSURERANGE.
01.01.00TYP4.36.1Z45552
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POS.NR. BEZEICHNUNG DESIGNATION DESIGNATION
7
10
11 ROLLMEMBRAN DIAPHRAGM DIAPHRAGME
FEDER
KOLBEN PISTON PISTON
SPRING RESSORT
ERSATZTEILZEICHNUNG
ZUM TYP 4.36.1 UND 4.46.1
SPARE PARTS PLAN DES PIECES
18.01.93
Z21513
DRAWING DE RECHANGE
7
10
11
GEKLEBT
A - B
GEKLEBT
A
B
BEI BESTELLUNG ANGEBEN
AUFTR.NR.:
TYP 4.36.1
TYP4.36.1+4.46.1
CEMENTED
CEMENTED
TO BE MENTIONEDIN CASE OF ORDER
ORDER NO.
COLLE
COLLE
A MENTIONNER LORS DE LA COMMANDE
NO DE COMMANDE
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DESCRIPTION AND OPERATING INSTRUCTIONS FOR THEBACK-FLUSHING FILTER TYPE 6.61
====================================================================
Commission-No.
C O N T E N T S
1. Type Sheet 6.61
2. General Information on the Automatic Filter
3. Filter Installation
Installations diagram Z35095
4. Commissioning
5. Filtration Phase
Filtration Phase diagram Z32326 Bl. 1
6. Back-Flushing Operation
Back-Flushing Operation diagram Z32326 Bl. 2
10. Servicing
11. Servicing Tools
12. Cleaning Agents for Candle Elements
13. Manual Cleaning of Candle Elements
14. Manual operation of the automatic filter
15. Spare Part Drawing for Type 6.6116. Spare Part List for Type 6.61
17. Type Sheet for the Differential Pressure Indicator with Electrical Contact
18. Spare Part Drawing for the Differential Pressure Indicator
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2. General
The fully automatic back-flushing filter is used to filter a variety of fluids, but chiefly
for the filtration of fuels, lubricating oils, caustic solutions and emulsions. The filter
elements semblies are cleaned automatically by compressed air assisted back-
flushing without interrupting the filtration process. One clean chamber is always
held in reserve.
This self-cleaning filter consists basically of the following parts:
The lower housing with connection flange for filter outlet and connection flange for
the removal of flushing fluid (sludge discharge).
The change-over system housing with the filter inlet, on which the filter chambers
containing the candle elements and the automatic vent are set out. In the centre of
the housing is the stop plug with refill bore.
The geared motor.
The air supply with non-return valve, shutt-off valve and pressure regulator.
The safety valve.
The differential pressure indicator ∆p1.
The flushing valve with manual actuation.
The limit switch.
The EL.-control system in its own switch box separate from the filter.
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3. Installation of the Filter
Care must be taken during installation of the filter that the pipelines attached to the
filter inlet and outlet are clean and not under tension.
The pipeline selcted for the sludge discharge is to be no smaller than the size
indicated on the type sheet. To avoid back-pressure arising in the pipe, it is to be
laid on a gradient and vented.
The terminal board on the filter is to be connected to the terminal board in the
switch cabinet by means of the control system cable (see circuit diagram).
When the filter is used in aqueous media, it is imperative to observe the following:
3.1 It must be ensured that the filter does not run dry even after the supply
pump has been switched off (owing to hardening of dirt).
3.2 If this condition cannot be fulfilled, at least the EL.- control must be
designed so that, even when the supply pump is switched off, back-
flushing is initiated every 2 hours by a time relay.
Flushing operations into a completely empty chamber for test
purposes are permitted without any restrictions. Flushing into a
partially filled chamber results in increased loading of the filter
candles. Back-flushing for installation (pipe) or control reasons into
a filter chamber which is only partially filled is therefore
inadmissible.
The filter housings are only designed for internal overpressure in
accordance with the AD Information Sheets. Additional external
forces and moments at the filter connection flanges are to be
avoided (possibly by supporting the supply lines).
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When installing the filters, make sure that any oil or fuel which
leaks due to improper handling cannot result in a fire or injury.
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4. Commissioning
The following requirements must be met for the commissioning of the filter:
4.1 Clean and dry compressed air for the control system at between 4 and
10 bar operating pressure, must be available at the open shut-off valve.
4.2 Switch on the electricity using the "Main Switch" on the switch box. The
"Power" lamp respectively LED-operating display lights up. (Activation of
the main switch initiates a back-flushing cycle.)
4.3 To check the EL.- control system a back-flushing cycle should now beperformed by activating the "Manual" trip on the switch box.
4.4 Open the slide valve at the filter outlet. Slowly open the slide valve at the
filter inlet (avoiding pipe hammer). A further back-flushing cycle is to be
performed using the Manual trip on the switch box. Once the back-
flushing operation is completed, the "Flushing" respectively the display
"SP.1" lamp goes out. If these conditions are met, the filter is in the start
position and is therefore ready for operation.
NOTE: Possible time interval calculation for time-dependent back-flushing
Let the filter run for 24 hours using the differential pressure and establish the
number of back-flushing operations (flushing cycle counter or display).
Calculate the average flushing interval.
Set the flushing interval (shortened by 30%) on the time relay or PA.2.
After completion of a back-flushing cycle, the next backflushing
operation can only be intiated (manually or by means of the
differential pressure indicator) after a time delay.
This time delay corresponds to the time preset on the time relay
"K1A" or the preselected time "PA.5" in the electronic control. It is
needed to guarantee that the cleaned filter chamber is filled.
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5. Filtration Phase
(see Drawing Z 32326 p. 1 or Z 33701 p. 1)
The medium to be filtered flows down into the change-over system housing and
passes from there through the chamber inlet and the connected filter chambers to
the candle elements. The medium flows through the filter elements from the outside
to the inside and the contamination in the medium is retained on the filter mesh of
the candle elements. The cleaned fluid passes to the filter outlet.
In this position the air supply (by means of the solenoid valve) keeps the sludge
discharge closed and compressed air is maintained in the air receiver ready for
the next backflushing cycle.
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6. Back-Flushing Operation
(See Drawing Z32326 p. 2 or Z33701 p. 2)
The contamination retained on the candle elements produces an increasing
pressure differential between the filter inlet and outlet. This difference in pressure is
indicated optcally on the differential pressure indicator when a set value is reached
and an electrical contact triggers the back-flushing.
When the back-flushing cycle is initiated, the geared motor is switched on and the
change-over plug rotates from the chamber held in reserve to the filter chamber to
be cleaned. Connection of the reserve chamber, together with its clean candle
elements, causes an immediate reduction in the pressure differential. When the
stop plug reaches the filter chamber to be cleaned the rotation is stopped by means
of a cam plate and a limit switch.
The solenoid valve (from the sludge discharge) is then switched electrically and air
from the air supply passes to the rear side of the sludge discharge valve shaft. The
sludge discharge valve opens and pressure is released from the chamber now shut
off. (See Note!)
While the sludge discharge valve shaft is opening, the control system air reaches
the attached flushing valve (once the pressure has been released on the filter
chamber). The flushing valve opens and the compressed air from the air receiver
dispatches the clean fluid present and pushes it in the counter current direction
through the mesh of the screw-in candle elements.
This allows the compressed air in the upper region of the plug to
immediately expand and thus creates additional space for the fluid
displaced (by the air) in the backflushing cycle.
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The pressure drop thus generated flushes off the contamination deposited on the
mesh and washes it out of the filter housing via the open sludge discharge valve.
The air flow is continued for a short period (flushing period) before the solenoid
valve is electrically switched over, causing the sludge discharge valve to close. At
the same time the flow of air from the control system to the connected flushing
valve is interrupted and thus also stops the flow of the stored back-flushing air. The
backflushed filter chamber is now refilled with clean medium through the refill bore
until operating pressure is achieved.
Only then is the delay of the electric control cancelled for the next back-flushing
operation.
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10. Servicing
Even automatic filters require inspection and servicing at regular intervals. It is to be
noted in particular that despite regular back-flushing the filter mesh can become
clogged in the course of time, depending on the quality of the medium and the by-
pass cleaning available.
Contamination on the mesh can be removed by cleaning the candle element
manually using an appropriate solvent (see Section 13). An increase in the clogging
on the mesh can be inferred from the progressively shorter intervals between back-
flushing cycles. The number of back-flushing cycles can be seen on the "Flushing
Cycle Counter" respectively display on the switch box.
To maintain trouble-free operation the following points are to be noted:
a) All connections are to be regularly checked for leaks.
b) Candle elements are to be dismantled and inspected initially after
500 flushing cycles, then after 5.000 and later every 10.000 flushing
cycles. If, however, a sharp reduction in the intervals between back-
flushing cycles should occur, inspection and cleaning should be carried
out sooner. If sudden lengthening of the intervals between back-flushing
cycles should occur all candle elements must be inspected without fail for
damage.
Before the cartridge elements are dismantled, the automatic filter
must be completely drained by automatic back-flushing (i.e. all filter
chambers). "Manual" activation on the control box. Care must be
taken to ensure that the liquid level is below the cartridge element
before the element is dismantled.
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10.1 You must close the compressed air supply valve (item 127), then
starting a manual backflushing, before you are allowed to removed
the manometer (item 72). This well ensure that the compressed air
reservoir (item 13) is pressure released.
The candles are subjected to wear through reciprocal loading. It is
therefore recommended that a complete candle filter element, the
number of candle elements depending on the size of the filter, be
kept in stock.
It is expedient to renew all seals when overhauling the filter.
Check the sludge discharge for leaks every 10.000 flushing cycles.
No medium should run from the end of the sludge discharge line
during the filtration phase (except during the flushing cycle).
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11. Servicing Tools
The following special tools are supplied for servicing the filter:
11.1 Special key with SW 10 or 14 for dismantling the filter chamber.
11.2 Special key for unscrewing the candle elements from the candle holder.
11.3 Key for opening the switch box and hand crank for operation during a
power failure.
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12. Candle Element Cleaning Agent "BOLL CLEAN 2000"
The choice of cleaning medium depends on the type of the contamination. With
fuels recipitation of paraffin and asphalt or with lubricating oils mixing of different
types of oil can form solid encrustations on the mesh. Effective cleaning of fine
meshes is achieved by soaking in "BOLL CLEAN 2000" followed by blasting with
compressed air using a cleaning gun.
PRODUCT DESCRIPTION:
BOLL CLEAN 2000 is a fluid cleaning and degreasing agent with a wide range of
application. It can be used for practically all cleaning and degreasing purposes.
BOLL CLEAN 2000 cleans rapidly, thoroughly and extremely economically.
Use of BOLL CLEAN 2000 renders safety precautions superfluous.
BOLL CLEAN 2000 has these outstanding characteristics without exhibiting the
isadvantages of solvent cleaners.
BOLL CLEAN 2000 is non-flammable
does not require special marking
does not have an irritating odour
is not caustic
is physiologically unobjectionable
is biologically degradable
is registered with the Federal Office
for the Environment, Reg.-No. 04860019
BOLL CLEAN 2000 can be undercooled or overheated during storage but remainsfully usable when returned to normal temperature.
MESH CONTAMINATED WITH HEAVY OIL:
Elements contaminated with heavy oil must be soaked in a standard commercial
solvent. After soaking the elements are cleaned in the Type 5.04
Cleaning Device using BOLL CLEAN 2000 and high pressure pump.
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INSTRUCTIONS FOR USE:
Use of BOLL CLEAN 2000 is not restricted to a particular method of cleaning.
Depending on the operating conditions, BOLL CLEAN 2000 can be used in a dip
bath, in a spraying plant, in steam jetting or in manual application using a cloth,
brush or sponge. It can be used warm or cold.
BOLL CLEAN 2000 is miscible with water - even seawater.
Concentration for mesh cleaning: 1 : 2,5
Temperature: up to a maximum of 60 °C
The concentration depends on the type and thickness of the adhesive substance to
be removed. When used in concentration below 1 : 30 rinsing is usually not
required.
No visible film remains on the surface.
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13. Manual Cleaning of the Candle Filter Elements
13.1 Remove the whole filter element assembly. Then soak the filter
element assembly, with the openings of the candle elements facing
down, in a suitable tank filled with solvent. Detached contaminants
can then sink downwards out of the candle.
13.2 The soaking time and the relevant solvents are:
a) In cold BOLL CLEAN 2000 cleaner the maximum soaking time
is 24 hours.
b) In Filterclean (Vecom) the maximum soaking time is 12 hours.
c) In Reiniger B85 (Vecom) the maximum soaking time is 12
hours.
d) In gas oil the maximum soaking time is 48 hours.
13.3 After soaking remove the whole filter element assembly from the tank
and place it on a suitable stand (e.g. perforated sheet metal) with the
candle element opening pointing down and allow the solvent to drain.
13.4 Now with the cleaning gun supplied blow compressed air through the
candles from the inside to the outside.
Before the cartridge elements are dismantled, the automatic filter
must be completely drained by automatic back-flushing (i.e. all filter
chambers). "Manual" activation on the control box. Care must be
taken to ensure that the liquid level is below the cartridge element
before the element is dismantled.
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13.5 After this procedure the complete filter element assembly should be
immersed in fresh cleaner, with the candle element opening down-
wards, and rinsed through with an up and down motion.
13.6 Allow the filter element assembly to drain again and dry it by blowingcompressed air through it again from the inside to the outside.
The manual cleaning procedure described here has produced
adequate results (ca. 60 % clean) in similar applications.
13.7 Almost 100 % cleaning is only possible manually, in our experience,
by using the Type 5.04 High Pressure Cleaning Unit with BOLL
CLEAN 2000.
See the separate description "Filter Cleaning Unit Type 5.04".
The washing procedure described in Section 13.5 should only be
carried out in a separate tank using clean solvent. The solvent can
then be used again for the next soaking procedure.
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14. Manual operation of the automatic Filter
Before operating the filter manually, you have to switch off the main switch on the
control box, in the interests of safety (self turning handle will cause violations).
Attach the crank handle supplied to the free end of the motor sharft. By rotating the
motor (in either direction) the cam disc is rotated to the next changeover point (i.e.
the next filter chamber). The cam and the limit switch must align precisely.
Back flushing is initiated directly by a manual actuation of the flushing valve (with a
screw [60] driver). This manual actuation should last 12 seconds.
You have to wait 2 min. before changing over to the next filter chamber, to give time
to fill up the backflushed filter chamber.
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UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
04 06.09.01 1
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0000 0630321 6.61 GR.15 DN150 AUTOMAT 04 1.000 ST
FULLY AUTOMATIC BACK FLUSHING FILTER
................................................................................
ZUSAMMENSTELLUNG : Z31671
ASSEMBLY DRAWING
MASSBLATT : TYP6.61
DIMENSION PAGE
AUSLEGUNGSUEBERDRUCK: 16 BAR / 140 GRD C
DESIGN PRESSURE
HEIZRAUM : 14 BAR / 200 GRD C
HEATING ROOM
PRUEFUEBERDRUCK GGG : 2 X AUSLEG. UEBERDRUCK
TEST PRESSURE : 2 X CALCULATION PRESS.
********************
................................................................................
0001 5422697 GEH.UNTERT. 1.000 ST
HOUSING LOWER PART
................................................................................
0002 5423823 SCHALTGEHAEUSE 1.000 ST
CHANGE OVER HOUSING
................................................................................
0003 6537759 FILTERTOPF 4.000 ST
FILTER CHAMBER
................................................................................
0003 2000004 STIFTSCHRAUBE 8.000 ST
STUD BOLT
................................................................................0004 5421472 KUEKEN 1.000 ST
COCK
................................................................................
0005 5007947 KERZENHALTER 4.000 ST
CANDLE SUPPORT
................................................................................
0006 STERNKERZE (FILTRA 8.000 ST
................................................................................
0007 5906594 DECKEL 4.000 ST
COVER
................................................................................
0007 5218298 DUESE POS. 1 4.000 ST
NOZZLE
................................................................................0007 6712641 BUEGEL 4.000 ST
BOW
................................................................................
0007 2000266 ZYL.-SCHRAUBE 8.000 ST
SLOTTED CHESSE HEAD
................................................................................
0008 2610023 SCHWIMMERKUGEL 4.000 ST
FLOAT
................................................................................
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UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
04 06.09.01 2
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0008 2611123 STIFT 4.000 STPIN
................................................................................
0008 3530032 DOPPELNIPPEL ENTL. 4.000 ST
DOUBLE NIPPLE
................................................................................
0009 5229254 DECKEL SCHALTGEH. 1.000 ST
COVER
................................................................................
0010 5427288 MOTORFLANSCH 1.000 ST
MOTOR FLANGE
................................................................................
0011 6530357 HEIZKAMMER 2.000 ST
HEATING CHAMBER
................................................................................0012 5000011 GEGENFLANSCH 2.000 ST
COUNTER FLANGE
................................................................................
0013 6533516 LUFTBEHAELTER 1.000 ST
AIR RESERVOIR
................................................................................
0014 5229568 VENTILGEHAEUSE 1.000 ST
HOUSING
................................................................................
0015 5000486 VENTILSTOESSEL 1.000 ST
RAM
................................................................................
0016 5005528 VENTILSITZ 1.000 ST
VALVE SEAT................................................................................
0017 5005609 GEH USE 1.000 ST
HOUSING
................................................................................
0018 5006510 VENTILDECKEL 1.000 ST
COVER
................................................................................
0019 5007512 SCHEIBE 1.000 ST
DISC
................................................................................
0020 5006512 VENTILSTOESSEL 1.000 ST
RAM
................................................................................
0023 5120153 NOCKENSCHEIBE 1.000 STCONTROL DISC
................................................................................
0030 3030729 O-RING 1.000 ST
GASKET
................................................................................
0031 3030661 O-RING 4.000 ST
GASKET
................................................................................
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UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
04 06.09.01 4
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0052 3380199 FLACHDICHTUNG 1.000 STGASKET
................................................................................
0053 3040224 RUNDSCHNURRING 2.000 ST
GASKET
................................................................................
0055 4500100 G.MOTOR 5.5/6.6UPM 1.000 ST
GEAR MOTOR
................................................................................
0058 2708948 ZYL. ROLLENLAGER 1.000 ST
CYLINDRICAL ROLLER B
................................................................................
0059 2307427 DRUCKFEDER 1.000 ST
SPRING
................................................................................0060 2656655 5/2WEGE-VENTIL 1.000 ST
VALVE
................................................................................
0060 4206553 SPULE 1.000 ST
COIL
................................................................................
0060 2614072 SCHALLDAEMPFER 1.000 ST
SOUND ABSORBER
................................................................................
0063 5950196 ANSCHLUSSKASTEN 1.000 ST
CONNECTOR BOX
................................................................................
0064 8450198 DECKEL Z.ANSCHL.K. 1.000 ST
COVER................................................................................
0065 4105616 KLEMME 15.000 ST
BINDER
................................................................................
0065 4105617 KLEMME 6.000 ST
BINDER
................................................................................
0065 4100015 ZWISCHENPLATTE 3.000 ST
DISTANCE PLATE
................................................................................
0066 2000258 ZYL.-SCHRAUBE 2.000 ST
SLOTTED CHEESE HEAD
................................................................................
0067 4105805 HUTSCHIENE 1.000 STASSEMBLY RAIL
................................................................................
0068 4102567 WINKELKABELVERSCHR. 1.000 ST
SCREWING
................................................................................
0068 4102568 REDURING 1.000 ST
ADAPTOR
................................................................................
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UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
04 06.09.01 5
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0069 4100101 KABELVERSCHRAUBUNG 8.000 STCABLE GLAND
................................................................................
0069 4100103 KABELVERSCHRAUBUNG 1.000 ST
CABLE SCREWING
................................................................................
0069 4870016 STOPFEN PG16 1.000 ST
PLUG
................................................................................
0070 2650017 HOCHDRUCKREGLER 1.000 ST
HIGH PRESSURE CONTRO
................................................................................
0071 2660005 SICHERHEITSVENTIL 1.000 ST
SAFETY VALVE
................................................................................0072 2602689 MANOMETER 1.000 ST
MANOMETER
................................................................................
0073 0550001 4.36.2 P = 0.8 DDA 09322 08 1.000 ST
PRESSURE DIFFERENT.CONTACT INDICATOR
................................................................................
0075 2560063 WINKELKUGELHAHN 2.000 ST
ANGLE BALL COCK
................................................................................
0076 4200057 ENDSCHALTER 1.000 ST
LIMIT SWITCH
................................................................................
0078 2002155 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD................................................................................
0080 2000239 STIFTSCHRAUBE 6.000 ST
STUD
................................................................................
0081 2000155 ZYL.-SCHRAUBE 6.000 ST
HEXAGON SOCKET HEAD
................................................................................
0082 2000131 ZYL.-SCHRAUBE 4.000 ST
HEXAGON SOCKET HEAD
................................................................................
0083 2000132 ZYL.-SCHRAUBE 4.000 ST
SOCKET HEAD CAP SCRE
................................................................................
0084 2000158 ZYL.-SCHRAUBE 16.000 STHEXAGON SOCKET HEAD
................................................................................
0085 2100006 SECHSKANTMUTTER 8.000 ST
HEXAGON NUT
................................................................................
0088 2000122 ZYL.-SCHRAUBE 4.000 ST
HEXAGON SOCKET HEAD
................................................................................
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UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
04 06.09.01 6
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0089 2000131 ZYL.-SCHRAUBE 3.000 STHEXAGON SOCKET HEAD
................................................................................
0090 2000156 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0091 2000144 ZYL.-SCHRAUBE 4.000 ST
HEXAGON SOCKET HEAD
................................................................................
0092 2000122 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0093 2000131 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................0094 2000261 ZYL.-SCHRAUBE 2.000 ST
SLOTTED CHEESE HEAD
................................................................................
0095 2000001 STIFTSCHRAUBE 8.000 ST
STUD
................................................................................
0096 2000132 ZYL.-SCHRAUBE 2.000 ST
SOCKET HEAD CAP SCRE
................................................................................
0098 2004354 GEWINDESTIFT 2.000 ST
SET SCREW
................................................................................
0099 2000967 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD................................................................................
0100 2100011 SECHSKANTMUTTER 6.000 ST
HEXAGON NUT
................................................................................
0102 2003587 GEWINDEF.SCHRAUBE 4.000 ST
SCREW
................................................................................
0103 2100004 SECHSKANTMUTTER 8.000 ST
HEXAGON NUT
................................................................................
0104 5002790 WELLENMUTTER 1.000 ST
NUT
................................................................................
0105 2004715 SECHSKANTSCHRAUBE 1.000 STBOLT
................................................................................
0107 2200007 SCHEIBE 1.000 ST
WASHER
................................................................................
0108 2308746 HALBRUNDKERBNAGEL 1.000 ST
GROOVED PINS WITH RO
................................................................................
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UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
04 06.09.01 7
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0110 2001578 SCHAFTSCHRAUBE 1.000 STBOLT
................................................................................
0111 2400109 PASSFEDER 1.000 ST
PARALLEL KEYS
................................................................................
0112 2614171 SCHALLDAEMPFER 3.000 ST
SOUND ABSORBER
................................................................................
0114 2608775 RUECKSCHL.VENT. 1.000 ST
NON RETURN VALVE
................................................................................
0115 2500024 VERSCHRAUB. 3.000 ST
SCREWING
................................................................................0116 2500025 VERSCHRAUB. 9.000 ST
SCREWING
................................................................................
0117 2500028 VERSCHRAUB. 1.000 ST
SCREWING
................................................................................
0118 2500029 VERSCHRAUB. 2.000 ST
SCREWING
................................................................................
0119 2507461 VERSCHRAUB. 1.000 ST
SCREWING
................................................................................
0120 2500258 VERSCHRAUB. 1.000 ST
SCREWING................................................................................
0121 2508115 VERSCHRAUB. 2.000 ST
SCREWING
................................................................................
0123 2505339 VERSCHRAUB. 2.000 ST
SCREWING
................................................................................
0124 2001772 VERSCHLUSSCHRAUBE 1.000 ST
HEXAGON HEAD SCREW P
................................................................................
0124 3275525 DICHTRING 1.000 ST
GASKET SET
................................................................................
0125 2000186 VERSCHLUSSCHRAUBE 1.000 STHEXAGON HEAD SCREW P
................................................................................
0125 3270001 DICHTRING 1.000 ST
SEAL
................................................................................
0126 2500083 EINSCHR.STUTZ. 2.000 ST
NIPPLE
................................................................................
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UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
04 06.09.01 8
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0127 2560356 WINKELKUGELHAHN 1.000 STANGLE BALL COCK
................................................................................
0128 0602658 ROHRLEIT.SATZ 6.61 GR.15 Z34749 1.000 ST
PIPE SET
................................................................................
0130 9401690 TYPENSCHILD 1.000 ST
NAME PLATE
................................................................................
0131 9407569 SCHILD "AUS/OU 1.000 ST
LABEL " OUT "
................................................................................
0131 9400997 SCHILD "EIN/IN 1.000 ST
LABEL " IN "
................................................................................0131 9407396 SCHILD "SCHLAMMAB 1.000 ST
LABEL " MUD DRA
................................................................................
0131 9402898 SCHILD LUFTVERS. DEU 1.000 ST
LABEL AIR RELEASE
................................................................................
0131 9405704 SCHILD "...2 OESEN.. 2.000 ST
LABEL "...2 HOOKS...
................................................................................
0131 9403614 SCHILD "DRUCKLUFTANS 1.000 ST
LABEL "COMPRESSED AI
................................................................................
0131 9404642 SCHILD "DELTA P" 1.000 ST
LABEL " DELTA P................................................................................
0140 STEUERUNG / ELECTRIC 1.000 ST
................................................................................
0150 6705030 SCHLUESSEL 1.000 ST
KEY
................................................................................
0150 6705032 KERZENSCHLUESSEL 7 1.000 ST
KEY FOR UNSCREWING T
................................................................................
0150 2300808 HANDKURBEL 1.000 ST
CRANK HANDLE
................................................................................
0150 5700721 FUEHRUNGSBOLZEN 2.000 ST
GUIDE BOLT................................................................................
0180 3635420 DICHTUNGSSATZ 1.000 ST
GASKET SET
................................................................................
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DESCRIPTION AND OPERATING INSTRUCTIONS
FOR THE DUPLEX FILTER
Contents:
1. Type sheet
2. Spare parts drawing and spare parts list
3. Description and Operating Instructions for the duplex filter
4. Description and Operating Instructions for the filter element cleaning
5. Data Sheet for the Differential Pressure Indicator (to order)
6. Spare parts drawing for the Differential Pressure Indicator (to order)
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S
POS.2
POS.1RE
RS
(ø265)
(ø265)
RE(ø195)
RS(ø195)
SUBJECT TO ALTERATIONS
DUPLEX FILTER
DRAIN
DISMOUNTING OF THE FILTERELEMENT
WORKING PRESSURE, HEATING COMPARTMENT IN BAT AT 200°CEQUALIZATION OF PRESSURE
WORKING PRESSURE, FILTER COMPARTMENT IN BAR AT 120°CCASING CASTED, EN-GJL-250
DIFFERENCE PRESSURE INDICATOR
AIR ESCAPE
TOLERANCE DIN ISO 2768-v
, ON REQUEST
ORDERING EXAMPLE
OUTLET INLET HEATING CONNECTION, FOR TUBE ø21.3
MODIFICATIONS RÉSERVÉES
FILTRE DOUBLE
EXEMPLE DE COMMANDE
VIDANGE
DEMONTAGE DU PANIER
PRESSION DE SERVICE, CHAMBRE DE CHAUFFAGE EN BAR POUR 200°C ÉQUILIBRAGE DE PRESSION
PRESSION DE SERVICE, CHAMBRE DE FILTRATION EN BAR POUR 120°C
INDICATEUR DE DIFF.DE PRESSION
CORPS MOULÉ, EN-GJL-250
DÉSAÉRATION
TOLÉRANCE DIN ISO 2768-v
, SUR DEMANDE
SORTIE ENTRÉE CONNECTION DE CHAUFFAGE, POUR TUBE Ø21,3
2.06.5.4 265 500 80
TYP øG Q DN
195
265
øG
250 65 80 135 425 130 175 195 580 45 520 320 350 480 130 G1/2 85 2x10500 80 100
10155
200695 150 420 210 840 50 550 350 610
160510 150
68 120G1 130 2x17
500 80 100 10 165 270 685 150 420 210 840 65 685 415 600 220 640 150 65 160 G1 195 2x32
Q min. max. PN1 A B C D E F H J L M S a h øk r t RS kg LTR.DN INHALTGEW.
14
14
PN2
TYP2.06.5.423.09.2002
200 45
270 60
m n
GEHÄUSE GEGOSSEN, EN-GJL-250
AUF WUNSCH
RS ENTLEERUNG
S SIEBAUSBAU
PN2 BETRIEBSÜBERDRUCK HEIZRAUM IN BAR BEI 200°CPOS.1 DRUCKAUSGLEICH
PN1 BETRIEBSÜBERDRUCK FILTERRAUM IN BAR BEI 120°C
POS.2 DIFFERENZDRUCKANZEIGER
RE ENTLÜFTUNG G1/4
ALLGEMEINTOLERANZEN DIN ISO 2768-v
ÄNDERUNGEN VORBEHALTEN!
DOPPELFILTER 2.06.5.4
EINTRITTAUSTRITT HEIZANSCHLÜSSE, FÜR ROHR Ø21,3
BESTELLBEISPIEL
60
A
J
q D
J
B
C
OG18O
k Q
2 0
H
t
r
3 0
33n
a m
M
L
h14O
Z45555
S=Q BEI MANTEL- UND RINGSIEBBY MULTIMANTLE AND RING FILTERELEMENTPOUR LES PANIERS À MANTEAUX ET ANNEAUX
D N
N2
N1
WITH RING-ELEMENTS FLOW IN OPOSITE DIRECTIONAVEC DES PANIERS À ANNEAUX LE PASSAGE EST EN SENS CONTRAIRE
BEI RINGSIEB DURCHFLUSS ENTGEGENGESETZT
FÜR KORSIEB NICHT GEEIGNETNOT QUALIFIED FOR BASKET- OR STAR PLEATET ELEMENTS
N'EST PAS POUR PANIERS ÀCORBEILLE OU ÀTRELLIS PLISSÈ
N2 FILTERAUSTRITTN1 FILTEREINTRITTFILTEROUTLETFILTERINLETSORTIE DU FILTREENTRÉE DE FILTRE
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ERSATZTEILLISTE TYP 2.06.5 (.4)
SPARE PART LIST LISTE DES PIECES DE RECHANGE
Typenschlüssel:
2.06.5. = Doppelfilter aus GG25 duplex filter made of GG25 Filtre double en GG25 G . = Gehäusedurchmesser cabin diameter diamètre du corpsQ . = Filtereinsatzlänge length of the filter element longueur du panier DN .= Anschlußflansche connection flanges brides désirées
Pos.Nr.
BezeichnungDesignationDesignation
G 265Q 500DN 80
St. G 195Q 500DN 80
St. G 195Q 250DN 65
St.
3Verschlußschraubescrew plug
vis
2000191 2 2000191 2 2000189 2
4Dichtunggasket joint
3270006 2 3270006 2 3270006 2
5O-Ring (Viton)O-RingO-Ring (Perbunan)
3030183
30401312 ------------ ------------
5Flachdichtunggasket joint
------------ 3380008 2 3380008 2
6
Verschlußschraube
screw plugvis 2000189 2 2002885 2 2002885 2
7Dichtunggasket joint
3270003 2 3270002 2 3270002 2
8Stiftschraubestud boltvis
2009088 6 2009088 4 2009088 4
9Mutter nutécrou
2100007 6 2100007 4 2100007 4
11
Siebeinsatz
filter elementélément filtrant
Fabr.Nr.
Filtertyp
Fabr.No.
Filtertype
Fabr.No.
Type de Filtre
12*)
Anker boltvis
WN 5.1.90 (1)WN 5.1.91 (2) 2
WN 5.1.83 (1)WN 5.1.84 (2) 2
WN 5.1.81 (1)WN 5.1.82 (2) 2
13*)
Mutter nutécrou
2100035 2 2100033 2 2100033 2
14Kükencockrobinet
Z35933 1 Z35933 1 Z35932 1
15 O-Ring (Viton)O-RingO-Ring (Perbunan)
3030075
30401212 3030075
30401212 3030175
30401192
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Pos.Nr.
BezeichnungDesignationDesignation
G 265Q 500DN 80
St. G 195Q 500DN 80
St. G 195Q 250DN 65
St.
16
Sicherungsring
retaining ringanneau de protection 2200002 1 2200002 1 2200001 1
18Druckausgleichkükencock for equalizuation of pressurerobinet d'equilibroge de pression
Z35775 1 Z35775 1 Z35775 1
19O-Ring (Viton)O-RingO-Ring (Perbunan)
3034796
30400942
3034796
30400942
3034796
30400942
20Schraubescrewvis
2007497 2 2007497 2 2007497 2
21
Federring
springressort
2209799 2 2209799 2 2209799 2
23Hahnschlüsselreversing handleclé
WN 48.3SW 27 1
WN 48.3SW 27 1
WN 48.3SW 27 1
24Differenzdruckanzeiger differ. press. indicator indi. de diff. de pressure
TypDruck
TypePressure
TypePression
30Verschlußschraubescrew plugvis
2002885 2 2002885 2 2002885 2
31 Dichtunggasket joint
3270002 4 3270002 4 3270002 4
32Verschlußschraubescrew plugvis
2002885 2 2002885 2 2002885 2
39Mutter Nutecrou
2100003 1 2100003 1 2100003 1
47Dichtunggasket joint
3380041 2 3380041 2 3380040 2
48Dichtunggasket joint
4-18109 1 4-18109 1 4-18109 1
49Stiftschraubestud boldvis
2000001 4 2000001 4 2000001 4
50Mutter Nutecrou
2100004 4 2100004 4 2100004 4
*) Bei Mantelsieb (1) und Kerzeneinsatz (2) zusätzlich.These items are supplementary by multimantle- (1) and filtercandle-element (2)En supplément avec panier á manteaux (1) et cartouches (2) filtrantes.
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INSTALLATION AND OPERATING INSTRUCTIONS FOR
DUPLEX FILTERS
1. Description
Duplex filters which can be changed over consist of two filter housings operated inparallel by a two-stage change-over device. The filter housings are designed tomeet the current regulations for a particular pressure range, the filter elements areprovided with an appropriate safety factor for the differential pressures indicated onthe filter nameplates. The maximum differential pressure for filter meshes is 0.8 bar,for micro-cartridges 2 bar.Duplex filters are used in cases where the contaminated filter elements have to beregenerated without interrupting the filtration process.
The change-over devices, i.e. cylindrical plugs, ball valves or double-stage change-
over valves, permit change-over without pressure shocks. Owing to the design of the change-over device it is not possible for both filter chambers to be switched off at the same time.
2. Installation
When the filter is attached to its foundation, the filter housing must be free fromstrain. The same applies to the connected piping. The connections for the inlet andoutlet depend on the strainer element used (see works standard WN 211). Payattention to the arrow marked on the housing.
Heated filters with shut-off devices:- Special equipment needed for heatable filters -
Heating of the filter serves to offset the heating loss at the filter during the filtration process
or before start-up of the plant to heat the liquid in the filter.
According to the AD Information Sheets, the filter housingsare only rated for internal overpressure. Additional externalforces and moments at the connection flanges of the filter are to be avoided (possibly support feed lines).
a) Steam-heated filters:
Safety valves for the filter chamber set to operate at therelief pressure which is 10 % above the max. admissibleoperating pressure of the filter housing.
b) Electrically heated filters:Thermostats which cut off the power supply to theheating element at a max. admissible temperature of 150 °C in the filter chamber and one safety valve per filter pot.
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3. Start-up
3.1 Pressure filters (> 0.1 bar pressure in the filter)Set the change-over device to the mid-position, both chambers in service, pressureequalising cock open.Open air vents of both chambers (with venting screws only about 1 turn).Start plant up slowly.Close air vents when the air has escaped and the liquid has started to emerge.Isolate one filter chamber by operating the change-over device, leave the pressureequalising cock open; while one of the filter chambers is being used for filtering, theisolated chamber is on stand-by until the admissible differential pressure has built upas a result of clogging. At a differential pressure of 0.8 bar in filter meshes or 2 bar in micro-cartridge filterschange over to the clean filter chamber as follows:
Cleaning
• Check that the pressure equalising cock is open and whether the stand-bychamber is full by briefly opening the air vents.
• Change over.
• Close pressure equalising cock.• Open the air vent on the isolated filter; this releases the liquid pressure and it isthen possible to check whether the change-over device has cut off the flow to thefilter chamber.In contrast to the change-over and ball valve devices, complete sealing is notpossible with the plug-type system; by opening the sludge outlet, liquid leakingduring the cleaning process can be drained off.
• Remove the housing cover from the isolated filter chamber.• Drain liquid down to the strainer base in the case of basket strainers; drain filter
housing completely in the case of mantle strainers, cartridge strainers and micro-cartridges.
• Remove the filter element vertically upwards.
It is imperative for the pressure equalising cock to onlyremain closed in the cleaning phase so that there is noinadmissible pressure build-up through the thermalexpansion of the medium in the isolated chamber.
In smaller duplex filters without pressure compensation theheat expansion of the medium is so low that there is norisk to the components.
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• Clean filter element (see operating instructions "Strainer cleaning"); renewdisposable elements and install them in the filter.
• Before mounting the cover, check that the seal is in perfect condition and seatedproperly.It is imperative to renew seals which have become hardened and deformed.
Screw cover on, the air vent remains open.Open pressure equalising cock or, if not installed, set change-over device to midposition until the air has been vented.
• Close air vent. This filter is now on stand-by.
3.2 Suction filters (< 0.1 bar pressure in filter)
Recommended container filling for suction filters
drain
filling line
• Fill and vent both filter halves.• Isolate one of the filters with the change-over device, close pressure equalising
cock.• Start up the plant. While one filter chamber is being used for filtration, the isolated
chamber is on stand-by. When the differential pressure across the filter reachesthe maximum allowed by the pump suction head, a change-over to the other filter
half must be made.• Open pressure equalising cock.• Change over.• Close pressure equalising cock.• Open air vent on the isolated filter half.
Air may be drawn in if the level drops.
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• Dismantle the housing cover from the isolated filter half.• Drain liquid down to the strainer base.• Remove filter element vertically upwards.• Clean filter element (see operating instructions "Strainer cleaning"). Renew
disposable elements and install in the filter.• Fill filter housing (see Fig.).• Before mounting the cover, check that the seal is in perfect condition and seated
properly.It is imperative to renew seals which have become hardened and deformed.Close air vent.
• The cleaned filter half is ready on stand-by. This procedure is to be repeated fromsection as and when required.
4. Servicing:Servicing of the duplex filter comprises checking and, if necessary, renew theseals and filter elements. If the filter is provided with rust-inhibiting paint, touch up or repaint as and when required.When filtering cooling water or media which may cause sedimentation on thechange-over device, it is advisable to activate the change-over device as often aspossible and at regular intervals in order to prevent clogging.
It is not permitted to fill the filter against theindicated flow direction of the filter elements.
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OPERATING INSTRUCTIONSFOR SEGMENTAL COCK CHANGE-OVER VALVE FOR DUPLEX FILTER TYPE 2.06.5 AND 2.06.7
1. GeneralThe segmental cock valve is used as a change-over element in duplex filters.The flow diagram, Fig. 1, shows the change-over arrangement and the filter chamber in use.
The special design and the limited change-over movement of the segmental cock (2) preventpressure surges and interruptions to the flow.
Ease of movement and pressure-tightness of the
segmental cock (2) are achieved by means of exact fits and small friction surfaces.
2. Operation
Change-over The segmental cock (2) is moved through 120°by turning the valve lever (6) to the left or right.The pin "A" in Fig. 1 points towards the ap-propriate symbol indicating which chamber themedium is flowing through.The pressure equalisation knob (3) is closed byturning the knurled screw (5) clockwise until
screwed in full. This covers a bore located atright angles to the cock axis.The relevant filter chamber is filled through thisopen transverse bore.The isolated filter chamber is pressure-relievedby loosening the venting screw and can then becleaned (see Operating Instructions for DuplexFilters and Operating Instructions for Strainer Cleaning).
In the operating mode the pressureequalisation knob must always be open,i.e. both filter chambers are under operating pressure.
When the filter chambers are operated in parallel, the pin „A“ in Fig. 1 isin the central position pointing towards the relevant symbol.In this position both filter chambers are in operation.The illustration in Fig. 2 shows the parallel-operation position of thesegmental cock.
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CLEANING THE MULTI-MANTLE FILTER ELEMENTS
1. The multi-mantle filters consist of up to 6 nested filter elements.Fields of application are filter meshes < 200 µm.In order to prevent flow short-circuits, the joins of the individual components are sealed with O-rings.
2. The admissible differential pressures depend on the multi-mantle filter diameter:
Filter Ø (mm) ∆p max. adm. (bar) ∆p max. oper. (bar)
86 - 230 8 1,2
290 5 0,8
356 - 434 3,5 0,8
3. Accessories of the filter element
The following items can be
supplied as accessories: • magnetic primary filter (19)• magnetic secondary filter (20)
4. Maintenance
4.1 Clean and inspect multi-mantle filter elements at regular intervals. The length of these intervalsdepends on the amount of dirt that has accumulated.
4.2 Carry out the first cleaning operation immediately after the installation has been flushed. A risingpressure loss is a sign of increasing dirt accumulation.The differential pressure is not to exceed 0.8 or 1.2 bar (suitable monitoring appliances are availablefrom BOLL & KIRCH).
5. Cleaning
5.1 Shut off single filter or change over duplex filter. Release pressure from the filter housing by undoingthe venting screw and remove the housing cover. Open the drain screw in the filter base and draincontents completely. Slacken the self-locking nut (4) on the central tie rod (5) and lift out the inner filter with the lifting eye (18). Lift the remaining filter elements out individually by gripping the inside of the filter ring.
5.2 Place the individual filter elements into containers with cleaning agent and brush off with not too harda brush (e.g. nylon brush).
5.3 Now blow compressed air at about 4 bar through the filter element cleaned in the above manner from the clean side. To this end insert the cleaning gun type 5.02 (22) into the openings located inthe upper filter ring and blow through the filter surface from the inside with up and down motions.
5.4 In the case of persistent dirt or paint encrustation, place the filter into a container (e.g. as shown indrawing No. 3-23700) with cleaning agent (to sheet KV 349) and allow to soak for up to 4 hours.Make sure that the filter is not completely immersed but that the upper ring remains free. Thisprevents dirt from reaching the clean side.
5.5 Remove filter and continue to treat as described under points 5.2 and 5.3.5.6 If necessary, repeat points 5.4 and 5.5.5.7 For final cleaning, rinse the filter in clean cleaning fluid (e.g. petroleum ether, paraffin, hot water or
similar) and blow through again. Then check fabric for cleanness and damage. Assess cleaningeffect by holding the filter element against the light. Use a torch for finer fabrics. If the light
penetrates evenly, the fabric has been cleaned well.5.8 Check all seals including cover seals. Seals which have become hard and deformed must berenewed without fail.
Before you open the filter chambers, observe the operating instructions for
single and duplex filters.
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6. Cleaning appliances
6.1 2 cleaning containers to drawing No. 3-23700.6.2 Cleaning gun, type 5.02.6.3 10 mm spanner.
6.4 Compressed air connection, max. 6 bar.For particularly convenient and thorough filter cleaning we recommend our cleaning trolley type 5.04with cartridge filter, pump and cleaning gun.
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COVER SECURING DEVICE FOR DOUBLE FILTERS
The function of the cover securingdevice is to prevent the uncontrolled
excape of lubricantes and fuels in the
case of operating errors. The cover plate
(2) covers a minimum number of cover
screws (3), so that the cover (1) cannot
be removed with out actuating the
venting facility (4).
The filter chamber is relieved through
the venting screw (4). With the correct
switching position, the service pressure
of the filter chamber falls immediately
and hardly any fuel excapes. Otherwise,
the venting screw is immediately closed
and the fuel discharge is limited.
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Operation:
1. Establish on the circuit diagram (5)
with chamber is switched off.
2. Unscrew the venting screw of this
chamber (4) to the point where the
cover plate (2) can swivel over the
cover screws (3)
3. Loosen cover screws (3) and remove
cover (1).
4. Assemble in reverse order
5. For sieve cleaning and
commissioning, see Sieve Cleaning
Operating Instructions and Double
Filter Operating Instructions.
Check seals items 6 and 7for damage.
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01.01.00TYP4.36.2
PG13.5
G1/4
G 1 / 4
- +
1
2
1a
3a 3
P1 P2
CIRCUIT DIAGRAM
DIFFERENTIAL PRESSURE CONTACT INDICATOR TYPE 4.36.2
DESCRIPTION:THE PURPOSE OF THIS DEVICE IS THE MEASUREMENT, AND VISUAL INDICATION OF THE DIFFERENCE INPRESSURE BETWEEN TWO POINTS, AND THE ESTABLISHMENT OF AN ELECTRICAL CONTACT WHEN THEPRESSURE DIFFERENTIAL ATTAINS A SPECIFIED FIGURE.
METHOD OF OPERATION:A PLUNGER SEALED BY A DIAPHRAGM SEPARATES THE SPACE UNDER PRESSURE INTO TWO CHAMBERS.A PRE-LOADED SPRING CAUSES THE PLUNGER TO TAKE UP ITS ZERO POSITION WHEN THE PRESSUREDIFFERENCE DELTA P IS ZERO. AS THE PRESSURE DIFFERENCE INCREASES (DELTA P > 0), THE PLUNGERIS FORCED TO MOVE AGAINST THE SPRING. AT THE SAME TIME, AN INDICATOR DISC IS MOVEDMAGNETICALLY, AND THEREFORE VIRTUALLY WITHOUT FRICTION, AND THE TWO REED CONTACTS AREACTUATED.
THE RED SEGMENT OF THE INDICATOR DISC IS VISIBLE OVER A PRESSURE RANGE EQUAL TOAPROX.50-100% DELTA P . THE FIRST REED CONTACT IS ACTUATED AT 75% DELTA P1, AND THE SECONDAT 100% DELTA P2.
SPECIFICATION:PROTECTION CLASS: IP 65
ELECTR. DATA: SWITCHING VOLTAGE V= MAX.= 250 220
FREQUENCY HZ MAX.= 0-60 0-60SWITCHING CURRENT A MAX.= 1 0.8MAKING AND/OR BREAKING CAPACITY
W/VA MAX.= 60/60 40/60MATERIAL : GD - ALUMINIUMRATING : MAX. PRESSURE 100 BAR
MAX. TEMPERATURE 150°C
RANGES OF PRESSURE DIFFERENTIAL: DELTA P = 0 - 0.5 BAR0 - 0.8 BAR0 - 1.2 BAR TO BE SPECIFIED WHEN ORDERING0 - 2.0 BAR0 - 3.0 BAR
Z45550
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POS.NR. BEZEICHNUNG DESIGNATION DESIGNATION
37
1011 ROLLMEMBRAN DIAPHRAGM DIAPHRAGME
FEDER
KOLBEN
DICHTUNG GASKET JOINT
PISTON PISTON
SPRING RESSORT
ERSATZTEILZEICHNUNGZUM TYP 4.36.2 UND 4.46.2
SPARE PARTS PLAN DES PIECES
11.02.94
Z21434
DRAWING DE RECHANGE
3
7
11
GEKLEBT11a233aA
B
A - B
10
TYP 4.36.2
TYP4.36.2+4.46.2
TO BE MENTIONED IN CASE OF ORDER
ORDER NO.
BEI BESTELLUNG ANGEBEN
AUFTR.NR.:
CEMENTEDCOLLE
A MENTIONNER LORS DE LA COMMANDE
NO DE COMMANDE
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
3. Flow meter
Type: VZO 40 FL 130/25
Pos.: 3.1
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Unterhalt VD 4-413 DFE 11.00
Maintenance
Maintenance
CONTOIL â VZE / VZO 15...50
KuWo GmbH Werkstraße 226 D-19061 Schwerin Tel.: +49 385-640-14-0, Fax: +49 385-640-14-14
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VD 4-413 DFE 11.00 2 KuWo GmbH
VZE / VZO / VZEA / VZOA Messaufnehmer / Mesureurs / Flow sensors
12
10
11
8
9
5
7
6
2
4
3
1
Pos. 12: Schrauben-AnzugsdrehmomentePos. 12: Serrage des visPos. 12: Screw Torque
Zähler Compteur
Flow meter
SchraubenVis
Screws
DrehmomentSerrageTorque
DN 15, 20 M 6 6 Nm
DN 25 M 8 16 NmDN 40 M 12 47 Nm
DN 50 M 16 100 Nm
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KuWo GmbH 3 VD 4-413 DFE 11.00
VZE / VZEA
Aufbaugruppe
Dispositifs complémentaires
Modules
VZO / VZOA
Aufbaugruppe
Dispositifs complémentaires
Modules
16
17
13
20
18
22
Aufb-VZE
13
15
16
14
18
17
20
19
22
Aufb-VZO
PRM/RZE 15.11 .00 / 4-413def-02.doc
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VD 4-413 DFE 11.00 4 KuWo GmbH
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
VZE / VZO / VZEA / VZOA Messaufnehmer / Mesureurs / Flow sensors
1 Gehäuse 1 auf Anfrage
Corps sur demandeHousing on request
Überwurfmutter für Ausführung USA 2 37470 2961 2887Ecrou pour version USACap nuts for version USA
2 Filtersieb 1 12968 19021 12969 12970 12971Filtre d'embout Inlet filter
3 Messkammerdeckel PN 16,25 1 12856 19008 12861 12859 12860Couvercle de la chambre de mesure PN 40 1 12857 19389 12862 12864 12866
Cover of the measuring chamber
4,5 Dichtung FPM 1 13002 13002 12985 12985 12985Joint 1 13003 19020 16028 12994 13004
Gasket
6 Mitnehmer max. 130 °C 1 19154 19155 19156 19157 19383Galet d'entraînement max 180 °C 1 19095 19045 13160 13161 13162
Driver
7 Ringkolben 1 12790 19022 12881 12882 12883Piston rotatif Rotary piston
8 Trennwand max. 130 °C 1 13024 -- 12963 12965 12967Paroi de séparation max. 180 °C 1 13025 13033 13026 13027 13028
Separating plate
9 Führungsrolle VZE / VZO max. 130 °C 1 19167 19025 19168 19169 19170Galet de guidage VZE / VZO max. 180 °C 1 19163 19025 19164 19165 19166
Guide roller VZE / VZO
Führungsrolle VZEA / VZOA max. 130 °C 1 12972 19391 12973 12974 12975Galet de guidage VZEA / VZOA max. 180 °C 1 13146 19391 13147 13148 13149
Guide roller VZEA / VZOA
10 Messkammer PN 16 1 -- 19007 -- -- --Chambre de mesure PN 25 1 12841 19032 12851 19551 19506Measuring chamber PN 40 1 12842 19387 12844 19550 19507
Beim Austausch einer einteiligen Messkammer (DN 15, 25, 40 oder 50) gegen eine neue, zweiteiligewerden zusätzlich Pos. 11 (Flansch) und Pos. 12 (Schrauben) benötigt. Siehe Hinweis auf Seite 7.
Lorsqu'une chambre de mesure monopièce (DN 15, 25, 40 ou 50) doit être remplacée par une neuve,comportant 2 pièces, il faut, en plus, pos. 11 (bride de la chambre de mesure) et pos. 12 (vis). Voir remarque page 7.
If a measuring chamber in DN 15, 25, 40 or 50, consisting of one part, has to be replaced by a new one(consisting of two parts), pos. 11 and 12 (flange and screws) are needed additionally. See remark onpage 7.
Korrektur Führungsrolle VZE/VZO 180°C am 28.03.01
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KuWo GmbH 5 VD 4-413 DFE 11.00
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
11 Messkammmerflansch PN 16 1 12874Bride de la chambre de mesure PN 25/40 12877Flange of measuring chamber PN 16...40 1 -- -- 12978 19547 19508
12 Schraube M 6 x 16 PN 16 4 12958Vis M 6 x 16 PN 25/40 6 12958Screw M 6 x 12 PN 16 4 19035
M 6 x 16 PN 25/40 6 12958M 8 x 25 6 13101M 12 x 40 8 19548M 16 x 50 10 19549
VZE / VZEA Zähler mit elektronischem Zählwerk / Compteur avec totalisateur électronique /
Meter with electronic register Zur Bedienung des elektron. Zählwerkes sicher stellen, dass Gebrauchsanleitung des Zählers, Art. Nr. 11601,vorhanden ist. Umbausätze VZO in VZE oder komplette Aufbaugruppen auf Seite 11.
Le totalisateur électronique doit être adapté au compteur; la marche à suivre figure dans le mode d'emploi ducompteur, document no. 11601. Veuillez vous assurer que ce document est à disposition. Kit de conversion VZO enVZE ou dispositifs complémentaires voir page 11.
In order to operate the electronic register assure that the manual of the flow meter, PN 11601, is at hand.Conversion kits VZO to VZE or complete modules see page 11.
VZE / VZEA
13 Kupplungsstück max. 70 °C 1 13221 13221 13222 19740 19741
Adaptateur 130 / 180 °C 1 19742 19743 19744 19745 19746 Adapting piece
17 Elektron. Zählwerk, Liter oder US-Gallonen 1 19757 19757 19757 19757 19757Totalisateur électronique, litres ou gallons
Electronic register, Litres or US gallons
18 Abschlussring RW 1 12903 12903 12903 12903 12903Bague de fermeture RW Head ring RW
20 Schrauben M 6 x 16 max. 70 °C 4 12958 12958 12958 12958 12958Vis M 6 x 93 130 / 180 °C 4 13167 13167 13167 13167 13167
Screws
22 Deckel 1 13423 13423 13423 13423 13423Couvercle
Cover
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VD 4-413 DFE 11.00 6 KuWo GmbH
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
VZE / VZEA mit Impulsgeber INA / avec émetteur d'impulsions INA / with pulser INA
13 Impulsgebermodul INA, ohne Sonde max. 70 °C 1 19747 19748 19749 19750 19751Emetteur d'impulsions INA, sans sonde max. 180 °C 1 19752 19753 19754 19755 19756
Pulser module without detector
16 Abtastsonde INA 1 13240 13240 13240 13240 13240Sonde de détection INA
Plug-in detector INA
In Plasticbeutel enthalten / contenus dans un sachet / Included in plastic bag:
Kontaktstift 4 5560 5560 5560 5560 5560BrocheContact pin
und / et / and
Steckergehäuse 1 13243 13243 13243 13243 13243Corps de prisePlug body
17 Elektron. Zählwerk, Liter oder US-Gallonen 1 19757 19757 19757 19757 19757Totalisateur électronique, litres ou gallonsElectronic register, Litres or US gallons
18 Abschlussring RW 1 12903 12903 12903 12903 12903Bague de fermeture RW Head ring RW
20 Schrauben M 6 x 55 max. 70 °C 4 12959 12959 12959 12959 12959
Vis M 6 x 93 max. 180 °C 4 13167 13167 13167 13167 13167 Screws
22 Deckel 1 13423 13423 13423 13423 13423Couvercle
Cover
VZO / VZOA Aufbaugruppen / Dispositifs comprlémentaires / Modules
VZO max. 130 °C
Zähler mit Rollenzählwerk / Compteur avec totalisateur à rouleaux / Meter with roller register
13 Kupplungsstück 1 13221 13221 13222 Adaptateur Adapting piece
oder / ou / or
Reguliergetriebe Liter 1 12943 12888Mouvement à réglage progressif, litres
Adjustment gear, litres
oder / ou / or
Reguliergetriebe US-Gallonen 1 19451 19452
Mouvement à réglage progressif, gallons Adjustment gear, US gallons
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KoWo GmbH 7 VD 4-413 DFE 11.00
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
17 Rollenzählwerk, Liter 1 19216 19219 19221 12871 12873Totalisateur à rouleaux, litres
Roller counter, litres
oder / ou / or
Rollenzählwerk, US-Gallonen 1 19440 19441 19442 19445 19445Totalisateur à rouleaux, gallonsRoller counter, US gallons
18 Abschlussring RW 1 12903 12903 12903 12903 12903Bague de fermeture RW Head ring RW
20 Schrauben M 6 x 16 4 12958 12958 12958Vis M 6 x 55 4 12959 12959
Screws
22 Deckel 1 13423 13423 13423 13423 13423Couvercle
Cover
VZO max. 130 °C
Zähler mit Impulsgeber RV /Compteur avec émetteur d'impulsions RV /Meter with pulser RV
13 Kupplungsstück 1 13221 13221 13222 -- -- Adaptateur Adapting piece
oder / ou / or Reguliergetriebe Liter 1 12943 12888Mouvement à réglage progressif, litres
Adjustment gear, litres
oder / ou / or
Reguliergetriebe US-Gallonen 1 19451 19452Mouvement à réglage progressif, gallons
Adjustment gear, US gallons
17 Rollenzählwerk Liter RV 0.1 l 1 19217Totalisateur à rouleaux, litres RV 1 l 1 19218 19220 19222 13064
Roller counter, litres RV 10 l 1 13065 13066RV 100 l 1 13067
oder / ou / or
Rollenzählwerk, US-Gallonen RV 10ppg 1 19446 19447Totalisateur à rouleaux, gallons RV 1ppg 1 19448Roller counter, US gallons RV 0.1ppg 1 19458 19458
18 Abschlussring RV, ohne Schauglas 1 13070 13070 13070 13070 13070Bague de fermeture RV, sans verre
Head ring RV, without sight glass
19 Schauglas 1 13558 13558 13558 13558 13558Verre
Sight glass
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VD 4-413 DFE 11.00 8 KuWo GmbH
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
20 Schrauben M 6 x 16 4 12958 12958 12958Vis M 6 x 55 4 12959 12959
Screws
22 Deckel 1 13423 13423 13423 13423 13423Couvercle
Cover
VZO / VZOA max. 180 °C
Zähler mit Rollenzählwerk / Compteur avec totalisateur à rouleaux / Meter with roller
register
13 Reguliergetriebe Liter 1 12889 12944 12942 12943 12888Mouvement à réglage progressif, litres
Adjustment gear, litres
17 Rollenzählwerk, Liter 1 12870 19028 12871 12871 12873Totalisateur à rouleaux, litres
Roller counter, litres
18 Abschlussring RW 1 12903 12903 12903 12903 12903Bague de fermeture RW Head ring RW
20 Schrauben M 6 x 55 4 12959 12959 12959 12959 12959Vis
Screws
22 Deckel 1 13423 13423 13423 13423 13423Couvercle
Cover
VZO / VZOA max. 180 °C
Zähler mit Impulsgeber RV /Compteur avec émetteur d'impulsions RV /Meter with pulser RV
13 Reguliergetriebe Liter 1 12889 12944 12942 12943 12888Mouvement à réglage progressif, litres
Adjustment gear, litres
oder / ou / or
Reguliergetriebe US-Gallonen 1 19449 19075 19450 19451 19452Mouvement à réglage progressif, gallons
Adjustment gear, US gallons
17 Rollenzählwerk Liter RV 0.1 l 1 13062Totalisateur à rouleaux, litres RV 1 l 1 13063 19030 13064 13064Roller counter, litres RV 10 l 1 19031 13065 13065 13066
RV 100 l 1 13067
oder / ou / or
Rollenzählwerk, US-Gallonen RV 10ppg 1 -- --Totalisateur à rouleaux, gallons RV 1ppg 1 --Roller counter, US gallons RV 0.1ppg 1 19458 19458
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KuWo GmbH 9 VD 4-413 DFE 11.00
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
18 Abschlussring RV, ohne Schauglas 1 13070 13070 13070 13070 13070Bague de fermeture RV, sans verre
Head ring RV, without sight glass
19 Schauglas 1 13558 13558 13558 13558 13558VerreSight glass
20 Schrauben M 6 x 55 4 12959 12959 12959 12959 12959Vis
Screws
22 Deckel 1 13423 13423 13423 13423 13423Couvercle
Cover
VZO / VZOA Zähler mit Impulsgeber IN / Compteur avec émetteur d'impulsions IN /
Meter with pulser IN
13 Reguliergetriebe Liter 1 12889 12944 12942 12943 12888Mouvement à réglage progressif, litres
Adjustment gear, litres
oder / ou / or
Reguliergetriebe US-Gallonen 1 19449 19075 19450 19451 19452Mouvement à réglage progressif, gallons
Adjustment gear, US gallons
Nur für Ausführungen / seulement pour exécutions / only for versions 180°C
14 Isolierstück (inkl. Pos 20 und 21) 1 13172 13172 13172 13172 13172Isolateur thermique (pos 20 et 21 inclus) Isolating piece (pos. 20 and 21 included)
15 Impulsgebermodul ohne Sonde IN 0,01 l 1 13261 13261Emetteur d'impulsions, sans sonde IN 0,1 l 1 13261 13261
Pulser module without detector IN 1 l 1 13261
oder / ou / or
Impulsgeber IN IN 1000ppg 1 13261Emetteur d'impulsions IN 100ppg 1 13261 13261
Pulser IN 10ppg 1 13261 13261
16 Abtastsonde IN 1 13240 13240 13240 13240 13240Sonde de détection
Plug-in detector
In Plasticbeutel enthalten / contenus dans un sachet / Included in plastic bag:
Kontaktstift 4 5560 5560 5560 5560 5560BrocheContact pin
und / et / and
Steckergehäuse 1 13243 13243 13243 13243 13243
Corps de prisePlug body
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VD 4-413 DFE 11.00 10 KuWo GmbH
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
17 Rollenzählwerk, Liter 1 12870 19028 12871 12871 12873Totalisateur à rouleaux, litres
Roller counter, litres
oder / ou / or
Rollenzählwerk, US-Gallonen 1 19443 19444 19444 19445 19445Totalisateur à rouleaux, gallonsRoller counter, US gallons
18 Abschlussring RW 1 12903 12903 12903 12903 12903Bague de fermeture RW Head ring RW
20 Schrauben M 6 x 93 4 13167 13167 13167 13167 13167Vis
Screws
Nur für Ausführungen / seulement pour exécutions / only for versions 180°C
21 Verlängerung 4 13166 13166 13166 13166 13166Rallonge
Extension
22 Deckel 1 13423 13423 13423 13423 13423Couvercle
Cover
Gebrauchsanleitung / Mode d'emploi / User manual VZE / VZO / VZEA / VZOA 15...50
Montage und Bedienungsanleitung VD 4-419 DEF 1 11601Instruction de montage et mode d'emploi Mounting and operating instructions
Umbausätze / Kit de conversion / Conversion kits VZE 15...50
VZE .... 70°C VZE .... 70°C - INA VZE .... 130 / 180°C VZE .... 130 / 180°C - INA
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KuWo GmbH 11 VD 4-413 DFE 11.00
Wichtig ! Important ! Important !
Beim Umbau eines Ölzählers VZOzu einem VZE muss die ganze
Aufbaugruppe ersetzt werden. Dieneuen Teile werden mit der Kalibrierung zum Defaultwert undZählerständen NULL ausgeliefert.
Die ausführende Stelle ist für dieZähleridentifikation nach demUmbau verantwortlich. Wir empfehlen, das Typenschild mit denZählerdaten zu ergänzen.
Lors de la modification d’un VZO enVZE, l’ensemble du dispositif complémentaire doit être changé.Les pièces de remplacement seront livrées avec des valeurs decalibration standard, et le nouveau
compteur sera mis à zéro.
Pour celui ou celle qui entreprend lamodification, celle-ci reste sous sonentière responsabilité. Nour recommandons de complèter la plaque d'identification avec laspécification du compteur.
During the modification from theVZO into a VZE, the completeancillaries related to the VZO mustbe dismantled. The exchanged itemswill be delivered with standardcalibration values, and the counter will be set to zero.
The modification remains under theresponsibility of the party who makesthat modification. We recommend tocomplete the name plate with themeter data.
Fotos/Conversion.tif
Pos. Bezeichnung Menge Artikel-Nr.Pos. Description Quantité No. d'articlePos. Description Quantity Part number
DN 15 DN 20 DN 25 DN 40 DN 50
Umbausatz VZE .... 70°C 19776 19777 19778 19779 --Kit de transformation VZE .... 70 °C Conversion kit VZE .... 70°C
Umbausatz VZE .... 70°C - INA 19785 19786 19787 19788 --Kit de transformation VZE .... 70 °C - INAConversion kit VZE .... 70°C - INA
Umbausatz VZE .... 130 / 180°C 19780 19781 19782 19783 19784Kit de transformation VZE .... 130 / 180 °C Conversion kit VZE .... 130 / 180°C
Umbausatz VZE .... 130 / 180°C - INA 19789 19790 19791 19792 19793Kit de transformation VZE .... 130 / 180 °C - INAConversion kit VZE .... 130 / 180°C - INA
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KuWo GmbH 13 VD 4-413 DFE 11.00
Repair instructions and fault finding
This is a measuring instrument to be handled with care.
Note on safety
· When removing from pipe, observe safety instructions in the operating manual.· When using inflammable cleaning substances, inflammable objects and liquids are to be removed from the
working area. Room to be well ventilated.· Prior to disassembly, the measuring instrument must be free from residues that could represent a danger to
persons or test equipment. Flush thoroughly with care.
Repair instructions for measuring sensors
Replacement of filter
When removing the filter, small splinters can be formed, and these must not be allowed to enter the measuring unit.It is therefore recommended to separate the housing from the measuring unit.
1. Remove measuring chamber screws (Item 12).
2. Remove housing (Item 1).3. Extract filter (Item 2) with screwdriver and replace.4. Remove deposits from housing surface and seating using fine emery-cloth (Fig. 1).5. Clean housing connections with a cloth.6. Fit new filter (Item 2) in housing connection. Press the metal ring into position using a round bar.
è Do not press on the filter bottom!7. Wash housing and remove any splinters with cloth.8. Locate the inlet and outlet space of the housing (Item 1) opposite the openings in the cover of the measuring
chamber (Fig. 6) and place housing on measuring chamber (Item 3).9. Insert measuring chamber screws (Item 12) and tighten. Correct torque see page 2.
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VD 4-413 DFE 11.00 14 KuWo GmbH
Cleaning or repair of measuring unit
1. Remove measuring chamber screws (Item 12).2. Remove housing (Item 1).3. Remove cover of measuring chamber (Item 3).4. Remove driver (Item 6), rotary piston (Item 7), separating plate (Item 8), and guide roller (Item 9).5. Replace worn parts and clean all remaining parts.
è For cleaning purposes it is recommended to use non-fraying cloths and kerosene or solvents.6. Remove deposits from housing surface and seating using fine emery-cloth (Fig. 1).
7. Replace guide roller (Item 9) on pin at bottom of measuring chamber (Item 10).8. Insert separating plate (Item 8).9. Insert rotary piston (Item 7) with guide pin facing downwards.
è The guide pin has a larger diameter than the driver pin and is located at the center of the rotarypiston.
10. The rotary piston (Item 7) has very little clearance but can easily be rotated.11. Rotate the rotary piston (Item 7) to the starting position (Fig. 2).
è The driver pin of the rotary piston lies on the axis of the separating plate.12. Place the driver (Item 6) on the pin of the cover of measuring chamber (Item 3).
è Locate the long, deep, groove of the driver opposite the groove for the separating plate (fig. 3).13. Place cover of measuring chamber (Item 3) with driver (Item 6) on the measuring chamber and press down
firmly avoiding tilting (Fig. 4).è The cover of the measuring chamber and the measuring chamber now form a continuous surface.
When the measuring chamber is shaked in a circle, the rotary piston can move freely.14. Treat new gaskets (Items 4 and 5) with lubricant (silicon grease) and mount on cover of measuring chamber (Item 3) (Fig. 5).
15. Locate the inlet and outlet space of the housing (Item 1) opposite the openings in the cover of the measuringchamber (Fig. 6) and join.
16. Align boring mark or cast mark on the measuring chamber base (Item 10) in a right angle to the housing axle.17. Insert measuring chamber screws (Item 12) and tighten. Correct torque see page 2.
Flow meters with rotary pistons in metal must only be tested and operated using fluids having a
lubricating effect!
Repair instructions for modules
è The individual modules are not screwed together. Be careful to ensure that these do not fall apart whenremoving from meter housing.
1. Note the position of the cover opening and the pulser connection in relation to the housing axle.2. Remove Allen screws (Item 20).3. Remove head ring (Item 18) with cover (Item 22).4. Remove counter with clamping ring.5. Replace worn or damaged modules.6. Reassemble in reverse order.
Fault finding
Fault Identification Possible cause Procedure 1)
· Meter not working· No reading on counter · No or very little flow· Quantity shown is too small
· Flow rate below Qmin or aboveQmax of meter
· Check flow rate· If flow rate too high, reduce flow
or fit larger meter · If flow rate too low, increase flow
or fit smaller meter · Dirt trap filter heavily soiled · Clean dirt trap or replace filter · Safety filter in meter inlet clogged · Fit correct filter mesh in dirt trap
· Replace safety filter in meter · Measuring unit jammed · Remove and clean measurement
chamber, replace damaged partsand assemble
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KuWo GmbH 15 VD 4-413 DFE 11.00
· Quantity shown is too large · Gas or air bubbles atmeasurement position
· Meter positioned at highest pointof plant
· Check operating conditions andmeter positioning
· Thoroughly and carefully de-aerate pipes
· Pointers of roller counter do notrotate regularly
· This is normal at high flow ratesand has no effect on accuracy of measurement
· No action necessary
· High pressure drop at meter exit · Dirt trap filter heavily soiled · Clean dirt trap or replace filter · Meter runs backwards · Meter mounted in wrong direction · Mount meter with arrow in
direction of flow· No pulse output signal · No flow · Check flow using counter
· Pulser sensor defective · Replace sensor · Pulser module defective · Remove sensor and check
whether pulser disk rotates under flow
· Pulser disk does not rotate · Remove pulser module, placeroller counter on first module, andcheck flow using roller counter
· If the roller counter gives areading, the pulser module must
be replaced
Fault Identification Primary cause Recommended measures 1)
· Separating plate broken · Pressure shock due to air in pipe· Meter mounted in unsuitable
position· Gas bubbles at measuring point
· Check operating conditions andmeter positioning
· Thoroughly de-aerate pipes andthen slowly refill
1) Consult operating instructions
PRM/RZE 17.10.2000 - 4-413def-01.doc Art. Nr. 11723ersetzt 14-419A.doc vom 10.01.00
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
4. Tanks
Type:
mixing tank 150 litres,
compensation damping
tank 19 litres
float switch
SR1 AX 350 LA 1 A,
automatic degassingvalve EF-8180
Pos.: 4.1, 4.2, 4.1.1, 4.1.10
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kupke + wolf gmbh kupke + wolf gmbh
Hägerstr. 22 Werkstraße 226
D-27321 Thedinghausen D-19061 Schwerin
D - 27321 Thedinghausen D-19061 Schwerin
Telefon 04204-91 65-0 Telefon 0385-64 014-0
MIXING TANK
General Explanation:
Purpose of the mixing tank is to mix the warm return-flow fuel from the engine with the coldfuel flow as provided from the daily tank. In this way the injection pumps are protected againstquick temperature shocks by switching from HFO operation to MDO operation.The mentioned switching should not be performed during higher engine load situation (pleasesee engine’s operation manual). The mixing tank is equipped with a level monitoring device(float switch, pos. 1).
Technical data:Nominal volume: 150 litresMaximum operation pressure: 1.0 MPaTest pressure: 1.5 MPaMaximum operation temperature: 160 °C
Operation note:To secure a faultless operation it is recommended to drain water daily.
1 Float switch 7 Thermometer
2 Safety valve 8 Non-return valve
3 Drain valve (secured against incidental operation) 9 Shut-off valve
4 Bypass valve automatic degassing 10 Automatic degassing
5 Pressure gauge valve
6 Pressure gauge valve and test
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kupke + wolf gmbh kupke + wolf gmbh
Hägerstr. 22 Werkstraße 226
D-27321 Thedinghausen D-19061 Schwerin
D - 27321 Thedinghausen D-19061 Schwerin
Telefon 04204-91 65-0 Telefon 0385-64 014-0
Compensation Damping Pressure Tank
General description:
The purpose of the compensation damping pressure tank is to avoid possible pressurepeaks and to compensate the quick changes of fuel oil consumption if the fuel oil systemis manoeuvering and / or when the automatic filter is in the back flushing period.
Technical data:
Capacity: 19 litres
Maximum working pressure: 1.6 MPaTest pressure: 2.4 MPaMaximum working temperature: 160 °C
Equipped with:
1. Inlet valve2. Outlet valve3. Aerating valve
Maintenance:
To ensure perfect operation it is recommended to let out the fuel in intervals of about14 days so that the air cushion can be build up again to 100 per cent.
This measure can be carried on during operation.
In order to do so take the following steps:
1.) Close the fuel inlet valve of the compensation tank.
2.) Slowly open the outlet and the aerating valve.
When no more fuel is running out close the outlet and the aerating valve. Afterwardsopen fuel inlet slowly.
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Float Switch in stainless steel 1.4571 with connecting box
Float type Dimensions Max. operating Max. operating Medium Material
Ø D(mm) Ø d (mm) H (mm) pressure (MPa) temperature (°C) density kg/m3
SE1 Cylindrical float 44 15 52 1,6 150 > 750 1.4571
SE2 Spherical float 52 15 52 4,0 150 > 750 1.4571
Technical data
Switch power capacity Opener / Closer: Authorisation Germanischer Lloyd
230 V AC; 100 VA; 1 A AC Temperature -30°C to +150°C
230 V DC; 50 W; 0,5 A DC Medium density ≥ 500 kg/m³
Switcher: Max. pressure 4.0 MPa
230 V AC; 40 VA; 1 A AC Installation position vertical, ± 30°
230 V DC; 20 W; 0,5 A DC Max. tube length L 1500 mm,Switch funktion Opener / Closer / Switcher attached to the bottom
with a rising liquid level of the tank: < 3000 mm
Switching points max. 4 switching points Process connection Standard: G 1½“, G2“,
Connecting box Aluminium 75 x 80 x 57 mm flange DN50 PN16
Aluminium 64 x 58 x 36 mm other types on request
Protection IP66
Dimensions
Connecting box
Process connectionG1½“, G2“, flange
Tube Ø 12 mm
Cylindrical or spherical float
S 1
t o m a x .
S 4
L
T = 4 5
SR 1-0-GL
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Product overview /
Order table Connecting box
A Aluminium case 75 x 80 x 57 mm, IP66B Aluminium case 64 x 58 x 36 mm, IP66
Process connections (installation: vertical, ± 30°)A Fixing screw thread G 1
1/2", 1.4571
B Fixing screw thread G 2", 1.4571C Flange DIN 2527, form B, DN 50 PN 16, 1.4571X other types on request
Tube length L (see dimensioned diagram)Tube length from sealing face of process connection L< 1500mm, resp. < 3000mmDimensions in mm (see page 1)
Float types
K SE1 (cylindrical float44 in 1.4571)
L SE2 (spherical float52 in 1.4571)X other types on request
Temperature range A -30° to +150 °CB -30° to +80 °C
SR 1-0
SR 1-0-GL
Switch point number (see dimensioned diagram)max. 4 switching points
S1
S2
S4
Switch function on rising liquid levelO Opener S Closer
U Switcher
Switch positionswitch position from sealing face of process connection in mm
-GL
S WI T C H 1 S WI T C H 2
S W I T C H 3
S W I T C H 4
W1 W2 W 3 W4 W 5 W 6
W 1 2
W 1 1
W 1 0
W 9
W 8
W 7
I M B
R P 0 0 1
Electrical connectionOpener / Closer
SWITCH 1 SWITCH 2
W1 W4
W2 W5
SWITCH 3 SWITCH 4
W7 W10
W8 W11
Switcher
SWITCH 1 SWITCH 2
1 W4
2 W5
3 W6
SWITCH 3 SWITCH 4
7 W10
8 W11
9 W12
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
5. Heat exchanger
Type:MX 25 L=2200
Pos.: 5.1, 5.2
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INSTRUCTIONS FOR SHELL & TUBE HEATER
Instruction Manualfor VESTATM MXTable of contents for instruction manual
1.
General Description........................................................................................ 12. Installation Space Requirements .................................................................... 2
3. Storage............................................................................................................ 3
4. Mounting and Installation............................................................................... 2
5. Connecting the Heat Exchanger ..................................................................... 3
6. Operation........................................................................................................ 3
7. Conservation during shut down periods ......................................................... 4
8. Maintenance and Cleaning ............................................................................. 4
9.
Dismantling and reassembling of the tube section ......................................... 510. Spare Parts...................................................................................................... 5
Appendix:
- Spare Parts Drawing
1. General DescriptionVesta MX heat exchangers are of the shell and tube type with u-tubes.
The Vesta MX heaters range from 0,5 m² to 60 m² heating surface with design pressures 16 or 30 BAR.
Other capacities may be manufactured at request.
All heaters may be delivered as immersion or outflow heaters for insertion intanks.
Vesta MX heat exchangers are primarily used as fuel oil, lubrication oil, or water heaters (JCW).
The heating media used is either steam, hot water or thermal oil.
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2 / 5
INSTRUCTIONS FOR SHELL & TUBE HEATER
Safety valve, thermometer, and pressure gauge may be mounted on a standard
outlet tube (optional).
Regulating equipment for either oil, steam or water is optional.
All heaters have been hydrostatic pressure tested before delivery.
Vesta MX heat exchangers have been type approved by all major classificationsocieties.
2. Installation Space Requirements
2.1. Space allowance
When mounting the heater sufficient space must be allowed for withdrawal of
the tube insert for cleaning, inspection, or replacement purposes.
Please refer to dimensional drawing for withdrawal space requirements.
2.2. Installation surface
The heater must be placed on a level and stable surface.
3. Storage
3.1. Damp and humidity
Store the heater only in a dry storage room before installation. If the room isdamp the heater must be isolated with bags of silica gel. To avoid damage it isrecommended the heater be stored in the original packaging.
3.2. Hydrostatic testing
All heat exchangers have undergone hydrostatic pressuretesting before delivery. The testing fluid used contains a certain amount of corro-sion protection (Castrol Rustilo Aqua 2); hence no further actions regarding stor-age are required before installation.
3.3. Extended storage
When heat exchangers are to be kept in storage for an extended period of timewe recommend Castrol Rustilo Aqua 2 be used as protection against corrosion.
4. Mounting and InstallationThe heat exchanger is designed for vertical or horizontal installations.
In case of horizontal installation, the inlet pipe and media outlet pipe must faceupwards.
If the heater is placed vertically the inlet and outlet tubes as well as the mediainlet must be at the bottom and the heater must be equipped with an air escape
screw at the top end.
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3 / 5
INSTRUCTIONS FOR SHELL & TUBE HEATER
The steam regulator (optional) must always be placed horizontally.
The steam trap (optional) should be mounted as close to the condensate outlet as
possible and somewhat lower. The steam trap is always to be placed horizon-
tally.
Place the heater on the surface and drill the holes for the foundation bolts. Placethe bolts into the holes and tighten up.
5. Connecting the Heat Exchanger
5.1. Preparation and pipe connection of the heat exchanger
Remove all plugs and cover flanges before connecting the heater. Make suresand and other impurities are removed from all connections. Set up the pipe con-nections and make sure that no forces are transferred to the heat exchanger.
6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securelytightened.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.
6.2. Initial adjustments
The safety valve must be adjusted to maximum design pressure or lower.
6.3. Initial start-up
IMPORTANT: Fluid flow through the heat exchanger must be established be-fore the heating medium is applied.
Tighten all main flange bolts according to below schedule. Operate the heater for one hour, stop, and retighten all bolts according to schedule.
Heater main flange bolts tightening schedule (dry values) – T16 types
No bolts Size Torque [Nm] Tightening schedule
MX10 8 M16 50 1 4 7 2 5 8 3 6
MX15 8 M20 83 1 4 7 2 5 8 3 6
MX20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8
MX30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
MX40 16 M27 245 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2
Always use a torque wrench when tightening the flange bolts.
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4 / 5
INSTRUCTIONS FOR SHELL & TUBE HEATER
Both sides of the heater must be carefully vented and the circuits carefully in-spected for leakage during the whole start-up period.
6.4. OutputThe output of the heater is subject to the supply of heating media at the inletsteam valve. The steam pressure/heating media temperature applied, is to be ac-cording to heater size calculation.
The output is furthermore subject to correct type of steam trap being used. Cor-rect layout of the condensate system avoids negative effect of counter pressure.
7. Conservation during shut down periodsCorrosion occurrences in shut down periods are mainly caused by oxygen. Thecorrosion occurs if non-distilled or alkaline water remains in the heat exchanger.
However, even when fully emptied, heaters are exposed to corrosion caused bywater residues or condensation. Hence, heaters out of service should be protectedagainst corrosion.
If the heater is out of service for an extended period of time – in particular duringwinter seasons with frost – it must be carefully emptied. Open the air escapevalve and check for clogging.
8. Maintenance and Cleaning
8.1. Regular cleaning periods
The heater should be cleaned regularly every six months by removing the tubeinsert or at any time there is a decrease in output not related to other causes.
Note: The heat exchanger must be emptied before removing the tube section.
Check if any deposits have collected on the tubes.
8.2. Cleaning of tubes
Cleaning of the tube system from the outside is carried out after removing thetube insert using a sharp liquid jet (citric acid or water).
Cleaning of the tube system from the inside is carried out after removing the
cover by flushing the tubes with e.g. citric acid.
8.3. Heavy contamination
If the heater is heavily contaminated with carbon deposits Aalborg Industriesrecommends the heater chemically cleaned with a carbon remover.
After cleaning has been completed the heater must be flushed carefully withfresh water and allowed to dry afterwards.
8.4. Checking the safety valves
Once every year the safety valve must be checked for correct set point.
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5 / 5
INSTRUCTIONS FOR SHELL & TUBE HEATER
9. Dismantling and reassembling of the tubesectionThe tube section is inserted into the heater and fastened tightly between the shellflange and the end flange. The back end of the tube section is not fixed.
The primary connection for heating media must be dismantled before disman-tling the tube section for inspection, cleaning, etc. The tube flange has threadedholes for dismantling screws and for mounting eyebolts for lifting devices.
Gasket surfaces are to be cleaned and protected against damage. New gaskets areto be fitted every time the flange connection has been dismantled.
IMPORTANT: Fluid flow through the heat exchanger must be established be-fore the heating medium is applied.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.
Heater main flange bolts tightening schedule (dry values) – T16 types
No bolts Size Torque [Nm] Tightening schedule
MX10 8 M16 50 1 4 7 2 5 8 3 6
MX15 8 M20 83 1 4 7 2 5 8 3 6
MX20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8
MX30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
MX40 16 M27 245 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2
Always use a torque wrench when tightening the flange bolts.
A pressure test should be carried out to prove tight joints.
Note: Pressure testing to be carried out only with insert mounted in shell.
Both sides of the heater must be carefully vented and the circuits carefully in-spected for leakage during the whole start-up period.
10. Spare partsWhen ordering spare parts please state the serial number of the heat exchanger (located on the nameplate).
For spare parts and further information please contact KuWo GmbH.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/WüstmarkTelefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
6. Viscositymeasuring system
Type:viscosimeter V92;
FKKX35V4-AKAYY-AA;93KU10-99bwa-ogx2;set-point generator
92933e-99axe-b1s2-xkuw2(loose delivery);
temperature sensor PT100W083P310502102
Pos.: 6.1; 6.2; 6.3; 6.3.1 (loose
delivery); 6.1.7, 6.1.8
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kupke + wolf gmbh kupke + wolf gmbhHägerstr. 22 Werkstraße 226
27321 Thedinghausen / Germany 19061 Schwerin / Germany
D - 27321 Thedinghausen D - 19061 Schwerin
Tel. +49 (0) 4204 9165-0 Tel. +49 (0) 385 640 14-0
Fax +49 (0) 4204 9165 65 Fax +49 (0) 385 640 14-14
1
Viscosimeter
Series V92
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kupke + wolf gmbh kupke + wolf gmbhHägerstr. 22 Werkstraße 226
27321 Thedinghausen / Germany 19061 Schwerin / Germany
D - 27321 Thedinghausen D - 19061 Schwerin
Tel. +49 (0) 4204 9165-0 Tel. +49 (0) 385 640 14-0
Fax +49 (0) 4204 9165 65 Fax +49 (0) 385 640 14-14
2
Contents
Page
1. System configuration 3
2. System description 5
2.1 Principle of operation 5
2.2 Differential pressure transmitter 6
2.3 Valve manifold 6
2.4 Heater control cabinet (only with electrically operated heat exchangers) 72.5 Control valve (only with steam operated resp. thermal oil operated
heat exchangers) 7
3. Operating instructions 8
3.1 First start-up or commissioning with Diesel oil 8
3.2 Change over from Diesel oil operation to heavy fuel oil (HFO) operation 93.3 Change over from heavy fuel oil operation to Diesel oil operation 9
3.4 Decommissioning with Diesel oil 10
4. Maintenance 10
4.1 Maintenance plan „A“ 104.2 Maintenance plan „B“ 10
4.3 Maintenance plan „C“ 11
4.4 Maintenance of the differential pressure transmitter 11
4.5 Cleaning of the reduction gear 12
5. Troubleshooting 12
5.1 Viscosity signal is too low 12
5.2 Viscosity signal is too high 135.3 Viscosity signal remains at maximum value 13
5.4 No viscosity signal 14
6. Repair instructions 15
6.1 Cleaning of the capillary tube 15
7. Spare parts list 16
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2.4 Heater control cabinet (only with electrically operated heat
exchangers)
The heater control cabinet makes for control of heating steps of the electrical heaters. A
typical example for a system with a 6-ary heater is shown in fig. 1 on page 3.
The control cabinet contains the following components:- sequential circuit or PLC (in the quoted example: with 6 steps) for control of
the heating rods- fuses- transformer - main switch- terminal strips- (in the quoted example: 2 x 6) contactors for switching “on” resp. “off” the
heating steps- auxiliary contactors for locking and for alarm
Mounted in the control cabinet door:- lamps for: voltage supply ON
indication heating steps ON
alarm- switches for: switching over from manual operation to automatic
operation
switch “on” resp. “off” the heating steps manually
switch “on” resp. “off” voltage supply (main switch)lamp’s test (optionally)
Functional principle:
The impulse outlet of the viscosity controller sends to the sequential circuit (in the quoted
example: with 6 steps) for control of the heater. The circuit of the sequential circuit is
factory preset.
2.5 Control valve (only with steam operated resp. thermal oiloperated heat exchangers)
The control valve makes for control the flow rate of the heating medium. It consists of a
valve body with adjusting plug (2/2-way resp. 3/2-way) and an actuator.
Fig. 2 (see page 4) shows a steam control valve as example. The viscosity controller directly controls the actuator of the control valve.
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3.2 Change over from Diesel oil operation to heavy fuel oil (HFO)
operation
1. The system has been started up with Diesel oil already. Supply pumps and
booster pumps are running.
2. The shut-off valves (D and E, see fig. 5) at valve manifold of the transmitter
have to be opened; the counterbalance valve (F) has to be closed.
3. Check adjusted viscosity set point at controller and set the controller inautomatic operation.
4. a) with electrically operated heat exchangers (automatic operation)
Set selective switch on heater control cabinet „Man. – 0 – Auto“ in position
„Auto“. Be sure that all heating steps are turned off. If not, switch off theheating steps using the keypad of the viscosity controller. Switch “on” the main
switch at heater control cabinet.b) with electrically operated heat exchangers (manual operation)
Set selective switch on heater control cabinet „Man. – 0 – Auto“ in position„Man.“. Switch on the needed heating steps by using the toggle switches for
heating steps.
c) with steam operated resp. thermal oil operated heat exchangers
Be sure, that the heating medium control valve is completely closed. If not,switch it off manually via viscosity controller.
5. Change over the plant from Diesel oil operation to heavy fuel oil operation.
6. The system will be filled up automatically with HFO depending on
consumption of engine. Now the viscosity controller regulates automaticallythe viscosity to the adjusted set point.
3.3 Change over from heavy fuel oil operation to Diesel oil
operation
1. Switch over the plant to Diesel oil operation.
2. The inflow of Diesel oil leads to dropping of viscosity. In consequence of the
nominal value default the controller switches off all heating steps automatically(with electrically operated heat exchangers) resp. closes the heating medium
control valve (with steam operated resp. thermal oil operated heat
exchangers).
3. When the system is completely filled with Diesel oil, you should stop
viscosimeter and set controller to manual operation in order to avoid
unnecessary abrasion.
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3.4 Decommissioning with Diesel oil
1. Change over the plant from heavy fuel oil operation to Diesel oil operation.
2. Turn off trace heating. The system will be filled up slowly with Diesel oil,that brings about a dropping of viscosity. In consequence of the nominal
value default the controller switches off all heating steps automatically (with
electrically operated heat exchangers) resp. closes the heating medium
control valve (with steam operated resp. thermal oil operated heat
exchangers). This brings about a dropping of temperature.3. When the system is filled with Diesel oil, viscosimeter motor shall be
turned off.
4. Open counterbalance valve (F) at valve manifold.
5. Set controller to manual operation.
6. Close steam inlet resp. thermal oil inlet before control valve (only withsteam operated resp. thermal oil operated heat exchangers).
4. Maintenance
4.1 Maintenance plan „A“
Following checks should be carried out by capable personnel:
Time slice Check
Monthly Zero adjustment of the differential
pressure transmitter
4.2 Maintenance plan „B“
Following checks/maintenance procedures should carried out every 2 years:
Denomination of the part Check/Maintenance procedure
Differential pressure transmitter Zero adjust
Complete system Commissioning for checking the fullefficiency of the system
Note:
Checks according to maintenance plan „B“ as well as fault repairs, inspections and
part exchange of the viscosity sensor and associated parts must be carried out only
by a service engineer from Kupke + Wolf GmbH. Kupke + Wolf GmbH will give neither
liability nor guarantee for damages which result from the third party.
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4.3 Maintenance plan „C“
A complete overhauling of the system is advisable every 4 - 6 years. This overhauling
shall be carried out by a service engineer from Kupke + Wolf GmbH or by other qualifiedservice personnel provided that required spare parts are originals from
Kupke + Wolf GmbH.
Kupke + Wolf GmbH will give no liability for maintenance work carried out by the thirdparty.
Checks according to maintenance plan “C” are:
- checks which be considered accordingly maintenance plan “A” and “B”
- complete inspection and cleaning of all instruments- substitution of worn and faulty parts- fresh factory calibration of the viscosity sensor - reassembly of the overhauled equipment and test run accomplishment
If possible the maintenance work will be carried out on the spot. But calibration of
viscosity sensor must be effected on the calibration stand in our factory. If repair on the
spot is not possible, the corresponding part and/or other system components must be
overhauled in the factory or nearest service representative.
For service work aboard a ship the service engineer must be provided with allnecessary labour, equipment, tools, and appliances (fuel, oil, current, air pressure etc.).
Guarantee terms of Kupke + Wolf GmbH apply for maintenance work which is carried
out by our authorized service engineer.
4.4 Maintenance of the differential pressure transmitter
The differential pressure transmitter requires minimum of maintenance under normaloperating conditions.
Zero check is to be carried out monthly as follows:
Note: It is possible only to carry out this check only when the viscosimeter system is
in operation and voltage supply is switched “on”.
1. Switch over the system to manual operation.2. Open counterbalance valve (F, see fig. 5 on page 8) at valve manifold of the
differential pressure transmitter and turn off viscosimeter motor.
3. When output signal of the differential pressure transmitter is correct (4 mA),the controller display indicates „0.0“. If not, adjust zero at differential pressure
transmitter.4. Turn on viscosimeter motor and close counterbalance valve (F) at valve
manifold.
5. Set viscosity controller to automatic operation.
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4.5 Cleaning of the reduction gear
The reduction gear is already filled with gear oil at manufacturer’s side. The gear
requires no maintenance under normal operating conditions apart from exchanging thegear oil after 10,000 hours of operation resp. 2 years of operation.
Clean reduction gear as follows:
1. Dismantle reduction gear and electric motor from viscosity sensor.
2. Disassemble electric motor from gear.
3. Remove side cover of gear after dismantling the four socket head screws.4. Clean gear with a solvent and dry with clean air pressure.
5. Assemble electric motor on gear.
6. Fill gear with 200 ml gear oil (Shell Tivela, Shell Omala 220 or similar).
7. Mount side cover and reattach gear motor at measuring flange of theviscosimeter.
5. Troubleshooting
5.1 Viscosity signal is too low
Possible cause Corrective action
Sensing lines between viscosimeter
and transmitter (plus side) leaking.
Tighten couplings.
Repair leaks.
Air entrapped in sensing lines
between viscosimeter and transmitter. Vent sensing lines.
Incorrect zero adjustment. Adjust zero.
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5.2 Viscosity signal is too high
Possible cause Corrective action
Sensing lines between viscosimeter and transmitter (minus side) leaking.
Tighten couplings.Repair leaks.
Incorrect zero adjustment. Adjust zero.
Measuring capillary clogged.Clean measuring capillary
(see section 6.1 of this description).
5.3 Viscosity signal remains at maximum value
Possible cause Corrective action
Fuel to cold before start-up. Start system in accordance withsection 3.2 or heat sensing lines.
Fuel to cold during normal system
operation.
Check control connection between
controller and control unit (control valve
resp. heater control cabinet).
Check control valve (if existing).
Differential pressure transmitter
malfunctioning.
Contact Kupke + Wolf GmbH.
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5.4 No viscosity signal
Possible cause Corrective action
Viscosimeter is not running. Check motor protecting switch.If motor switch „on“, check electricity.
Motor rotates in wrong direction. Reserve 2 of the 3 leads at terminal strip
of motor.
Sensing lines between viscosimeter
and transmitter leaking.
Tighten couplings.
Repair leaks.
Air entrapped in sensing lines after
repair.
Vent sensing lines.
Shut-off valves at valve manifold are
closed or counterbalance valve is
open.
Ensure that shut-off valves are open
resp. counterbalance valve is closed.
No electrical supply at differential
pressure transmitter.
Check integrity of electrical connections.
Check fuses.
Differential pressure transmitter malfunctioning.
Contact Kupke + Wolf GmbH.
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6. Repair instructions
6.1 Cleaning of the capillary tube
Denomination of parts see fig. 6 in chapter 7.
1. Turn off viscosimeter motor.
2. Open by-pass valve (L, see fig. 5 on page 8).3. Remove gear motor (pos. 10). Dismantle screw (pos. 7).
4. Remove measuring flange. Remove screw (pos. 30).
5. Remove damping capillary (pos. 36) after removing the screws (pos. 37).
6. Soak damping capillary in cleaning-fluid and clear it by blowing through it
with air pressure.
7. Remove measuring capillary (pos. 35) by unscrewing anticlockwise viascrew-wrench.
8. Soak measuring capillary in cleaning-fluid and clean it with a soft fitting
wire.
9. Clear the measuring capillary by blowing through it with air pressure.
10. Reassemble the measuring flange last in - first out.
Take care that the capillary tube is sealed well.
11. Install measuring flange.
12. Reattach gear motor.
13. Turn on viscosimeter motor.
14. Vent the differential pressure pipes.
15. Close by-pass valve (L).
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7. Spare parts list
Pos. no.
(fig. 6) Quantity Denomination
Part no.
(LG-No.) Material/Size
1 1 housing VN006 Cast steel GS 52
4 1 ring VN084 OD 116 x ID 92 x 2 mm
5 1 drive console VN024
6 3 spring washer VN161 M12, spring steel
7 3 hexagon head screw VN162 M12 x 40; steel 8.8
8 1 assy magnet outside VN023
9 2 safety screw VN163 M6 x 6; steel 45 H
10 1 electric motor and gear VN034
11 1 pin V12 (long) VN010 steel
12 * 1 gear pump VN012 stainless steel13 1 O-ring seal VN008 Viton, ID 12.00 x 1.00 mm
14 1 plate, gear pump VN043 steel
15 1 pin V12 (short) VN011 steel
16 4 O-ring seal VN007 Viton, ID 4.00 x 1.00 mm
17 2 screw connection VN165 1/4“ NPT x 10 mm
19 4 hexagon head bolt VN167 M6 x 70 mm
20 4 spring washer VN168 M6, spring steel
21 1 plate, gear pump VN169 steel
22 4 spacer VN170 steel
23 1 drive shaft VN02524 2 ball bearing VN026 10 x 19 x 5 mm
25 1 O-ring seal VN020 Viton, ID 67.95 x 2.62 mm
26 1 ring nut VN140
27 1 snap ring VN027
28 1 assy magnet inside VN022
29 1 magnet cap VN021
30 4 socket head screw VN171 M12 x 50 mm
31 4 spring washer VN172 M12, spring steel
32 4 spring washer VN173 M6, spring steel
33 4 hexagon head screw VN174 M6 x 20 mm
35 * 1 measuring capillary 0 – 50 mPas VN157
36 1 damping capillary 25 – 50 mPas VN031
37 4 screw VN175 M4 x 16, steel
38 4 spring washer VN176 M4, spring steel
39 1 O-ring seal VN008 Viton, ID 12.00 x 1.00 mm
-------- 1 measuring flange VISCS1
* = No individual order possible because this is an integral part of measuring flange. Measuring flange
requires factory calibration.
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Instruction Manual
FCX-CII SERIES TRANSMITTERS
Differentiel pressure Transmitter (FKK ...4)
Pressure Transmitter (FKP...4)
Pressure Transmitter with remote seal (FKP, H ...E)
Absolute Pressure Transmitter (FKH...4)
INF-TN3FCXC2b-E
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CONTENTS
INTRODUCTION.......................................................................................i
CAUTION ON SAFETY.............................................................................ii
CAUTION ON USE……………………………………………………… iv
CONFIRMATION OF YOUR SPECIFICATION……………………….. iv
OUTLINE………………………………………………………….. 1
OPERATING PARTS AND THEIR FUNCTIONS………………. 2
OPERATION AND SHUTDOWN………………………………... 43.1. Preparation for operation…………………………………….. 4
3.2. Operation…………………………………………………….. 63.3. Shutdown…………………………………………………….. 7
MAINTENANCE…………………………………………………… 9
4.1. Periodique inspection………………………………………… 9
4.2. Troubleshooting……………………………………………… 104.3. Replacement of parts…………………………………………. 11
SPARE PARTS………………………………………………………14
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i
INTRODUCTION
Thank you very much for your purchase of the Fuji FCX-CII Series Transmitter.
This instruction manual covers the FCX-CII series transmitter and contains information about the
installation, piping, wiring, operation and maintenance of the FCX-CII series (FKK...4 • FKP...4 •FKP...E).
The product conforms to the requirements of the
Electromagnetic compatibility Directive 89/336/EEC as
detailed within the technical construction file number
TN513035. The applicable standards used to demonstrate
compliance are :-
EN 50081-2 :-1993 Conducted and Radiated emissions
EN 50082-2 :-1995 Radiated immunity, ESD and FBT
• First read this instruction manual carefully until an adequate understanding is required, and then
proceed to installation, operation and maintenance of the FCX-CII Series transmitter.
• The specifications of the transmitter will be changed without prior notice for further product
improvement.
• Modification of the transmitter without permission is strictly prohibited. Fuji will not bear any
responsibility for a trouble caused by such a modification.
• This instruction manual should be kept by a person who is actually using the transmitter.
• After reading this manual, keep it at a place easier to access.
• This manual should be delivered to the end user without fail.
• For detail specifications and outline diagrams, refer to the specifications furnished separately.
INTRODUCTION
Type: Described in nameplate on main frame (see Page iv)
Date of manufacture: Described in nameplate on main frame
Product nationality: France
Request
• Transcription of a part or the whole of this manual without per-
mission is prohibited.
• The contents of this manual are subject to change without prior
notice.
Issued in February, 2002
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ii
CAUTION
DANGER
INDICATION
PROHIBITION
DANGER
CAUTION
Installation and Piping
• Non-explosion-proof transmitter must not be used in a place with explosive gases to prevent
serious accidents such as explosion, fire, etc.
• The transmitter is heavy. Be careful when handling it.
• The transmitter should be installed in a place that meets the operating conditions shown in DS
sheet or this instruction manual.
• Install the transmitter according to the instruction manual. Improper installation may lead to the
cause of fall, trouble or incorrect operation.
• When installing, make sure that the transmitter interior is free from cable chips and other foreign
objects to prevent fire, trouble, or incorrect operation.
• When power is ON, do not change the position of the field indicator in an explosion-proof area.
• When power is ON, do not change the position of the transmission unit in an explosion-proof area.
• When power is ON, do not change the angle of the indicator.
• Main valve used for piping should be selected with the maximum pressure of the process taken
into account (piping parts such as main valve, etc. should be furnished by user). If the main valve
and other parts do not meet the rating, it may result in leakage of gas or liquid which could lead to
hazard.
• Pressure pipes to be used must meet the temperature/pressure rating.
• The cautionary descriptions listed here contain important information about safety, so they should be
observed without fail. Those safety precautions are classified into ranks “DANGER” and “CAUTION”.
Wrong handling may cause a dangerous situation, in which there is a
risk of death or heavy injury.
Wrong handling may invite a dangerous situation, in which there is a
possibility of medium-level trouble or slight injury or only physical
damage is predictable.
On items listed under “ CAUTION ”, they may also lead to serious accidents depending on circum-
stances, and must be fully observed.
• The signs of prohibition and indication are explained in the following.
General items which pertain to prohibition (DO NOT)
General items which pertain to user’s action
CAUTION ON SAFETY
First of all, read this “Caution on Safety” to ensure correct operation of the
transmitter.
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iii
DANGER
CAUTION
DANGER
DANGER
Wiring
• On explosion-proof type transmitter, its wiring work must be performed according to the required
laws and regulations. Incorrect wiring may cause explosion, fire or other serious accidents.
• Before making wiring work, be sure to turn OFF the main power to prevent electric shocks.
• Use wiring materials of correct rating to prevent fire accidents.
• Connect a power source of correct rating to prevent fire accidents.
• The transmitter should be grounded as specified to prevent electric shocks or incorrect operation.
• After installing the transmitter, firmly close the covers of the transmission unit and terminal box.
If not, rain water enter the transmitter which may result in trouble or incorrect operation.
Adjustment of Smart Type
• When using a flame-proof transmitter, do not connect HHC to the transmitter terminals and junc-tion terminals.
Replacement of Maintenance Parts
• When removing an explosion-proof transmitter, turn OFF the main power, then disconnect the
piping and wiring. Do not remove it when the power is ON to prevent serious accident such asexplosion, fire, etc.
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iv
Storage for a long period
Store the transmitter in a dry room at normal temperature and humidity.
Keep protection caps in place at the conduit connection and process connection.
For installation, select an appropriate place
Site at location with minimal vibration, dust and corrosive gas
At a place allowing an adequate space for checkup
Site at location large enough to allow maintenance and checking.
Mounting angle
Mount to a pipe horizontally or vertically.
Attention to overload
Do not apply a pressure outside the specified range.
Other
Besides the above, be sure to observe the cautions given in this manual.
The instrument nameplate as shown below is attached at the transmission unit of this transmitter. Before
use, make sure the contents of the nameplate agree exactly with your specifications.
CONFIRMATION OF YOUR SPECIFICATION
SeriesTag No.
Fuji Electric Co., Ltd. Made in Japan
TypeRange
Power Supply
Output 4 ... 20mADC
M.W.P.
Ser.No.
Mfd.
Be sure to observe the following Instructions
CAUTION ON USE
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1
OUTLINE
The FCX-CII series transmitter detects the differential pressure or pressure of various
fluids, converts it into a current signal of 4 to 20 mA DC and transmits it.
All the adjustment functions are incorporated in the transmission unit for making
adjustments easily and exactly.Transmitter settings (such as range and damping time constant, etc.) can be changed from
an HHC (Hand Held Communicator).
Principle
The operating principle of the FCX-CII series transmitter is shown in the block
diagram below.
The input pressure is changed into an electrostatic capacitance in the detecting unit.
The change proportional to the pressure undergoes conditioning and amplification in
the transmission unit, and is then output as a current of 4 to 20mA DC.
Displacement
Sensor
Input
differential
pressure
Detecting unit
Transmission unit
Operationalamplificationcircuit
Output
current
Diaphragm
Measuring
circuit
Capacitance
change
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2
Terminal unit
Zero/span
adjustmentscrew
Transmission unit
Conduitconnection
Terminal unit
Vent/drain
plug
Detecting unit
Process connection
C K
+
C K
–
+
–
FCX-CII Series transmitter
Description of FCX-CII Series transmitter
Part name Description
Detecting unit Detects pressure, differential pressure or level of fluid.
Transmission unit Converts the detected signal into an output signal.
Vent/drain plug Used for gas discharge or draining. (Attention should be paid
under a high pressure.)
Process connection Connects impulse pipes from the process.
Conduit connection Connects the output cable.
Zero adjustment screw Adjusts zero. (For analog type, refer to Section 7.)
Terminals
Symbol Description
+, - Connects the output cable.
CK+, CK- Used for checking the output or connecting an indicator.
An external terminal used for grounding
OPERATING PARTS AND THEIR FUNCTIONS
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4
OPERATION AND SHUTDOWN
(2) Check the signal wiring according to the “Terminal block connection diagram” shown in 4.1
(Page 16).
(3) Vent gas from the transmitter.
Preparation procedure
(4) Perform zero point adjustment.
When the plant requires chemical cleaning at the start of operation, be sure to
close the valve of the transmitter to prevent entry of cleaning liquid into thepressure receiving unit.
Important
3.1 Preparation for operation
Before operating the transmitter, be sure to perform the following checks and procedures. Note
that adjustment is required in a non-hazardous area for zero point check of intrinsically safe
explosionproof and flameproof transmitters, do not open terminal cover and do not use HHC.
Use the transmitter indicator and the external adjustment screw.
(1) Check for liquid or gas leakagefrom the process
connection, etc. by applying soapy water or thelike.
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5
1. After adjustment of the transmitter, it should be kept energized for about 10
seconds to write the adjustment result into memory.
2. Use a blade-edge screwdriver for adjusting the zero/span adjustment screw.
Important
Decrease
Increase
When all the checks and preparatory operations are finished, tighten the cover securely. (Tighten-
ing torque 20 N•m 2 kgf•m <14ft-lb>)
Zero point check
Turn on the power to the transmitter.
Check the output signal of the transmitter by connecting a DC ammeter across CK+ and CK– of
the terminal block.After ten minutes or longer, adjust the transmitter output current to 4 mA (zero adjustment). (See
below.)
(1) Zero adjustment
Zero point of the transmitter is adjustable by the zero screw on the electronics housing with
the zero adjustment screw.
• If the transmitter is locked (see section
“Operating procedure”, Lock of adjustment
function), it is not possible to adjust with the
external adjustment screw.
• When a digital indicator is attached to the
transmitter, make sure that the LCD lamp
“ZERO” is ON.
(2) Adjustment by HHC
Refer “zero adjustment” explained in section 7.1.
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6
3.2 Operation
(1) Operation of pressure(FKP) and absolute (FKH) transmitter
Open the valve slowly to apply a pressure. When a pressure is applied, the transmitter is set
in the operating status.
(2) Operation of differential pressure transmitter (FKK)
Set the operating status by manipulating the manifold valve.
Make sure the equalizing valve is open.
Open the stop valve on the high pressure side slowly.
Close the equalizing valve.
Open
Open
Open
Close
Stop valve
on the low
pressure side
Stop valve
on the highpressure sideEqualizing
valve
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7
Use a field indicator, receiving instrument or HHC to check the operating status.
3.3 Shutdown
(1) Shutdown of pressure (FKP) and absolute (FKH) transmitter
Close the valve slowly to stop applying a pressure. The transmitter is set in the measurement
stop status.
Close
Check of operating status
Finally, open the stop valve on the low pressure side
slowly.
Open
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8
(2) Shutdown of differential pressure transmitter
Set the shutdown status by manipulating the manifold valve.
Turn off power supply.
Close the stop valve on the high pressure side (H side)
slowly.
Open the equalizing valve.
Close the stop valve on the low pressure side (L side)
slowly.
Close
Open
Close
Before a long shutdown, discharge the process fluid and drain completely from
the transmitter.
This is to protect the transmitter from freezing, corrosion, etc.
Important
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MAINTENANCE
4.1 Periodic inspection
In order to ensure the measurement accuracy and long life of the transmitter, it is
essential to inspect the transmitter periodically according to the operating conditions.
Visual inspection
Visually inspect each part of the transmitter for damage, corrosion, etc.
If you detect any material which may cause corrosion, it should be cleaned off.
Check of cover and O-ring
The transmitter has a water and dust-proof construction.
Make sure the O-ring of the case cover is not damaged or deteriorated.
Carefully prevent foreign materials from sticking to threads.
Piping leakage check
Using soapy water or the like, check the all process connections for leakage of
process fluid. If necessary, drain the moisture which has accumulated in
the transmitter and process pipe.
9
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10
4.2 Troubleshooting
If an abnormality occurred in the process or transmitter, action should be taken with reference to the
table below.
If remedy is impossible, contact Fuji Electric’s service department.
(1) The manifold valve doesnot open/close normally.
(2) Pressure leak is occurring.(3) Process piping is improper.(4) Process pipe is clogged.(5) Power supply voltage
and/or load resistance isimproper.
(6) Voltage between the
external connectionterminals of transmissionunit is wrong.
(7) Zero and span are notadjusted.
(8) Electronics unit is faulty.
(1) Same as (1) to (4) above(2) Power supply polarity is
wrong.(3) Power supply voltage and/
or load resistance isimproper.
(4) Voltage between theexternal connectionterminals is wrong.
(5) Electronics unit is faulty.
(1) Process piping is improper.(2) Gas or solution is mixed in.(3) Liquid density changes.(4) Ambient temperature
changes widely.
(5) Zero or span has deviated.(6) Electronics unit is faulty.
Repair the valve so that it opens/closes normally.
Repair a leak.Make correct piping.Eliminate the cause of clogging.Make arrangement to obtain proper values.(For power supply voltage and load resistance,refer to “7.2” (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Check for faulty cable, insulation, etc. and repair
as needed.(For power supply voltage and load resistance,refer to “7.2” (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Readjust according to sections 4 (page 9).
Replace the electronics unit according to 5.3 (page32).
Correct wiring (according to 7.1 (page 48)).
Make arrangement to obtain proper values.(For power supply voltage and load resistance,refer to “7.2” (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Check for faulty cable, insulation, etc. and repairas needed.(For power supply voltage and load resistance,refer to "7.2" (page 50).)(For intrinsically safe installations, the powersupply voltage should be 10.5 to 26V DC forsmart type.)Replace the electronics unit according to 5.3 (page32).
Correct the piping.Vent or drain the transmitter.Perform density compensation.Minimize the temperature change.
Readjust zero or span.Replace the electronics unit according to 5.3 (page32).
No output
current (less
than 3.8 mA).
Output
current
overshoots
scale
(exceeds
20mA).
Symptom Cause Remedy
Output current
error
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11
4.3 Replacement of parts
If the transmitter requires a replacement part, drain process fluid from the transmitter,
disconnect it from the process and carry out replacement in an instrument room.
Replace the transmission unit with a spare one in order to determine whether it is the
detecting unit or transmission unit which is faulty.
When the faulty unit is identified, it should be replaced with a new one.
Indicator
Connection at rear of electronics unit
Electronics unit
Replacing procedure
(1) Turn off the power supply.
(2) Remove the indicator.
(3) Remove the electronics unit.
Unplug each connector.
(4) Remove the stud bolts which fastens
the indicator.
(5) Replace the electronics unit with a
new one and assemble it by
reversing the above procedure from
(4) to (1).
When installing the electronics unit, make sure that thezero adjust screw and the volume control are posi-
tioned as shown the right.
Important
Zero/spanadjustment screw
Volume control
DANGER
When removing an explosion-proof transmitter, turn OFF the main power, then dis-connect the piping and wiring. Do not remove it when the power is ON to prevent
serious accident such as explosion, fire, etc.
To identify faulty part
Replacement of electronics unit
Important The electronics unit should be removed carefully so as not to damage the internal
wiring.
(6) After completion of replacement, perform zero and span adjustments.
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13
In case of differential transmitter (code symbol : FKK/FDK) :
Bolt
Measurementchamberdetecting cover
O-ring
Nut
Seal diaphragm
Seal tape
Seal tape
(6) After assembly, carry out a pressure test. Apply a pressure equal to 150% of the maximum
working pressure to both high pressure (H) and low pressure (L) measurement chambers of
the transmitter simultaneously for 15 minutes, and make sure there is no leakage.
Replacing procedure
(1) Remove four hexagon socket head bolts with a torque wrench, etc..
(2) Disassembly gives access to the casing covers, O-rings, hexagon socket head bolts and nuts.
(3) After disassembly, replace the faulty part with a new one.
(4) Before reassembly, clean the O-ring face of casing cover with the soft cloth immersed in
water, alcohol, or similar detergent.(5) Reassemble the detecting unit by reversing the disassembling procedure. The casing covers
should be assembled so as to be symmetrical with each other in the left-right direction and
carefully so as not to damage the seal diaphragm. Tightening torque should follow the table
below.
Replacement of the internal parts of detecting unit
Tightening Maximum working
torque pressure
Bolt size Bolt material [N•m] [MPa] Application
(kgf•m) bar
<ft-lb> <psi>
50 42M10 Cr-Mo steel (5) 420 Working pressure 42 MPa 420 bar <6000 psi> or less
<36> <6000>
SUS304 30 10
M10 ASTMB7M (3) 100 Working pressure 10MPa 100 bar <1400 psi> or less
ASTML7M <22> <1400>
50 42
M10 SUS630 (5) 420 Working pressure 42 MPa 420 bar <6000 psi> or less
<36> <6000>
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14
SPARE PARTS
B - 1
6 A
- 3
A - 5
A - 5
A - 2
0 A
A - 1
1 A
A - 1
A - 2
A - 1
3 A
A - 6
A - 3
1 A
C - 1
7
B - 1
6 C 1
~ 4
B - 1
4
B - 9
B - 8
B 1
~ 5
A - 2
4 A
A - 5
A
B - 1
2
C - 7
B - 1
7
A - 1
0
A - 3
9
A - 4
0
1 2
2 8
A - 1
2 A
A - 1
2
A - 4
0 A
- 4 1
This diagram shows main parts of the differential pressure transmitter, pressure transmitter.
For details, contact our office.
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15
No. Parts No. Part Name Q’ty Material Remarks
A-1 * ZZPFCX4-A010 Cover 1 Aluminium alloy Blue
ADC12
A-2 * ZZPFCX4-A020 Cover 1 Aluminium alloy Blue
ADC12
A-3 * ZZPFCX4-A030 Cover ass'y 1 Aluminium alloy With indicator
ADC12
A-5 * ZZPFCX4-A050 Indicator 1 Analog, 0 to 100% linear
* ZZPFCX4-A051 Indicator 1 Analog, 0 to 100% square-root
* ZZPFCX4-A052 Indicator 1 Analog, dual scale
* ZZPFCX4-A053 Indicator 1 Analog, actual scale
* ZZPFCX4-A054 Indicator 1 LCD Meter
* ZZPFCX4-A054A Indicator kit 1
A-5A * ZZPFCX4-A05A Unit name plate 1 LCD Indicator type
A-6 * ZZPFCX4-A061 Amplifier unit 1
A-9 * ZZPFCX1-A091 Switch over plug 1 Normal/Reverse action switch over plug.
A-10 * ZZPFKK1-A101 Electronics housing 1 Aluminium alloy With Pg13.5 connection
ADC12
* ZZPFKK1-A102 Electronics housing 1 Aluminium alloy With NPT1/2 connection
ADC12
* ZZPFKK1-A103 Electronics housing 1 Aluminium alloy With M20 x 1.5 connection
ADC12
A-12A * ZZPFCX4-A121A Plug kit 1 Plug for Pg13.5 connection.
* ZZPFCX4-A123A Plug 1 Plug for M20 x 1.5 connection.
A-12 * ZZPFCX1-A122 Plug 1 Stainless steel Plug for NPT1/2 connection.
* ZZPFCX4-A121 Plug 1 Aluminium alloy Plug for Pg13.5 connection.
ADC12
* ZZPFCX4-A123 Plug 1 Aluminium alloy Plug for M20 x 1.5 connection.
ADC12
A-13A * ZZPFCX4-A132 Terminal block unit 1 Round washer type.
* ZZPFCX4-A133 Terminal block unit 1 Wire retaining washer type.
* ZZPFCX4-A134 Terminal block unit 1 Round washer type with arrester.
* ZZPFCX4-A135 Terminal block unit 1 Wire retaining washer type with arrester.
A-20A * ZZPFCX1-A200A Cable gland kit 1
A-24A * ZZPFKK1-A240A Fastener kit 1
A-31A * ZZPFCX1-A310A Hex. socket screw kit 2 Minimum order q’ty 10 pcs.
A-39 * ZZPFCX2-A390 Blank name plate 1 Standard (Minimum order q’ty 5 pcs.)
A-40 * ZZPFCX1-A400 Rivet 4 Minimum order q’ty 50 pcs.
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16
No. Parts No. Part Name Q’ty Material Remarks
B-1~5 –––––––– Detecting unit 1 Contact our office for inquiry
(Differential pressure and Flow)
B-8 * ZZPFCX4-B080 O-ring 2 Viton
* ZZPFCX4-B081 Square section gasket 2 Teflon
B-9 * ZZPFCX4-B091 Cover 2 SCS14
* ZZPFCX4-B093 Cover 2 SCS14
* ZZPFCX4-B095 Cover 2 SCS14
B-12A * ZZPFHC1-B122 Vent/drain kit 2 NPT1/4
B-14 * ZZPFHC1-B143 Bolt/Nut kit 4 C.S.
* ZZPFHC1-B144 Bolt/Nut kit 4 Stainless steel Up to 10MPa 100kgf/cm2
* ZZPFHC1-B145 Bolt/Nut kit 4 Stainless steel Up to 14MPa 140kgf/cm2
B-16 * ZZPFHC1-B160 O-ring 1 Chloroprene Minimum order q’ty 10 pcs.B-17 * ZZPFHK1-B171 Mounting bracket kit 1 Stainless steel
C-1~4 –––––––– Detecting unit 1 Contact our office for inquiry
(Pressure)
C-7 * ZZPFHP1-C071 Adapter 1 Stainless steel Rc1/2
* ZZPFHP1-C072 Adapter 1 Stainless steel NPT1/4
C-17 * ZZPFHP1-C171 Mounting bracket kit 1 Stainless steel
Minimum order q’ty 10 pcs.
4th digit of type code
S
T,X
V,W
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Industry controller type Kuwo 93KU10 B 93KU10 E Operating instructions - page 1 -
data subjects to alteration 93KU10e1.doc / 0110809
cSt
°CK4
K3
K2
K1
Viscosity Alarm
Controloutput
Temp. Alarm
3
1
2
4 5
6
1 Digital display actual value 1 (viscosity)2 Digital display actual value 2 (temperature)3 LED-display relay function4 Key for setpoint and parameter mode
5 Setpoint adjustment
6 Parameter mode lock switch (back face)
Brief description:
The 93KU10 industrial controller is a two-channel, three-point step controller for viscosity andtemperature control. Each control channel has a dedicated measurement input, a dedicatedactual value indicator as well as separate control parameters available to it.
The switch state of a binary input determines whether the viscosity or the temperature controlcircuit is switched through to the output relays K1 and K2. The corresponding green LED’s showthe switch state.
Each control circuit has one accessory alarm contact assigned to it (K3 and K4). When theallowable deviation from the actual value is exceeded, the corresponding relay opens and thecorresponding red LED lights.
The viscosity can be displayed either in mPas, as well as in cSt after entering the density.Sheets with appropriate inscriptions are enclosed with the device.
A signal output makes actual value 1 (viscosity) available at the terminals for further processing.
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data subjects to alteration 9_E2.DOC /0010803
Installation:
Before installation inspect the controller for any visible signs of damage caused during transportCheck power supply acc. to name plate.Push the housing from the front into the DIN- panel cut-out and secure from behind with thefastening devices supplied.
Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following thewiring diagram; wire cross section max. 1,5 mm2
- To avoid cross interference all low voltage measuring lines and pilot wires must be encasedin a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally to protect the output relays. - Phase wire and neutral wire must not be transposed.
Putting into operation:
Switch on power supply. Digital display and control lamps will light up according tothe setpoint after some seconds. If nothing happens check the fine-wire fuse on the back panelof the controller and the electrical wiring. Adjust set value and check other adjustments.
Maintenance: All electronic controllers in the Kuwo range are virtually maintenance-free. Provided that thecontroller is correctly installed and put into operation and is protected against mechanicaldamage and inadmissible operating conditions, it should give years of trouble-free service.In case of faults repair work by the customer should be restricted to the externally accessible
leads and connections and components the customer is expressly permitted to deal with himself(bridge circuits, fuses).
All further work, especially on internal components will terminate warranty, makes subsequent inspection and fault repair more difficult and can cause considerable damage to the circuitry.
For repair remittance remove plug board with connected leads on the rear side,loosen fastening devices and remove controller from the panel.
In case of remittance please give precise details of the fault to reduce time and cost of repair.
Error messages:
Err 1...6 Fault on measuring input nr. ...check measuring lines for short circuit or breakage
check measuring input by connecting a RTDErr 55 Fault on loading the parameter;
press any key, the controller starts in emergency operation mode,configuration of the parameters has to be checked
Err 50 Hardware error in program sectionErr 52 Hardware error in data section
no further operation possible, remit controller for repair
Error messages during self adaptation:
Err 202 Ambient conditions are not suitable for self adaptation;adjust parameter manually
Err 205 routine exceeded the setpointraise setpoint or lower actual value and start adaptation again
Err 206 Fault on measuring input during adaptation;check the wiring and start adaptation again
Industry controller type Kuwo 9...Installation and connection
B 9... Epage -2-
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Industry controller type Kuwo 93KU10 B 9... EOperation - page 3 -
data subjects to alteration 93KU10e3.doc / 0110809
Operating status:
The upper display shows the actual value of measuring input 1 (viscosity)
The lower display shows the actual value of measuring input 2 (temperature)
Setpoint value setting:
press - key shortly (do not hold down) each
The upper display shows the abbreviation ofthe activated setpoint adjustment mode,the lower display shows the adjusted value.
The indicated value can now be changed by the (lower) and (higher) -keys.
Each variation of the set value is immediately active, without any more operating steps. The arrow keys have a built-in accelerator mode:longer pressing causes faster alterations.
1SP viscosity set point
2SP temperature set point
d15 density at 15°C
Return to operating level:
Press - key shortly
(or automatically after 30 seconds without any key-action)
Manual operation: (optional)
Hold down - key and press - key, then release both keys.
The lower diplay shows "H *" and - if activated - the output position.The upper display still shows the actual value. The automatic control is interrupted.
Manual control is now possible using the ... - keys.
Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)
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Industry controller type Kuwo 93KU10 B 93.. EParameter level - page 4 -
data subjects to alteration 93KU10E4.DOC / 0110809
Access from operating level.
Unlock the access first:
Turn the switch on the rear panel of the controller to position "U" = unlocked
(Lock access after the adjustments: Switch position to "L" = locked).
After the parameter level (refer to the instructions to each level ) has been invoked,the first setting is shown and can be modified.
It is not possible to invoke the parameter level when the switch is locked .
In this case the display shows the abbreviation of the configured controller type.
Confirm the entry and / or move on to next parameter:
press the -key briefly
Settings in detail:(not available on all types)
Level 1: Invoke: Hold down the - key for more than 5 sec.until the display changes factory setting: notes:
CH channel selection (no.*) 1 = viscosity , 2 = temperature
* P proportional range Xp (%) (ref. to chapter "Optimization") 25,0 ___
*I integral action time Tn (min) (ref. to chapter "Optimization") 7,0 ___
*d rate time Tv (min) (ref. to chapter "Optimization") 0,2 ___
*Sh sensitivity of response Xsh (%) 0,1 ___( * = channel no.)
SA3 switching interval (absolut value) for following (additional) contact no.3 2,5 ___Sd3 switching difference for additional contact no.3 0,1 ___
SA4 switching interval (absolut value) for following (additional) contact no.4 10,0 ___Sd4 switching difference for additional contact no.4 1,0 ___
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
Level 2: Invoke: Hold down - key and press - key,hold down both keys for more than 5 sec. until display changes.
Unit switch-over of the display unit (cSt/cP (cP=mPas)) cSt ___1bLo/1bHI start / end of display range for voltage- / current -input (only) 0/50 ___1SLo/1SHI start / end of range for signal output (only), referring to signal 0/50 ___
1/2nSt modification of decimal point characters (0 / 1 / 2) 1/0 ___1Lo / 1HI start / end of viscosity setpoint range 0/50 ___2Lo / 2HI start / end of temperature setpoint range 0/200 ___dSPL select display function for lower display (AUS / IST2) ISt2 ___
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
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Industry controller type Kuwo 9.. B 9... EOptimization - page 5 –
data subjects to alteration 9_E5.DOC / 0110813
1. manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to balance
an appearing deviation as quickly, non-oscillating and exactly as possible,
according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replacedby this brief information.The following informations are for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):lower value= shorter impulse gaps, faster balancing
higher value= longer impulse gaps, slower balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):increases the controller reaction in case of fast actual value or setpoint alterations(adjust only if necessary). Higher values cause higher increase.
2. Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjuststhe optimum control parameters Xp, Tn and Tv.
Operation, if contained in supply schedule: (Parameter-safety-switch on the rear panel of the controller has to be unlocked: position "u")
Check starting assumptions:Actual value at least 20% below the adjusted set value,(e.g.:heating phase), otherwise first:Lower actual value adequately by manual operation (position of final control element) (quick circuits)or increase setpoint adequately, if admissible. (faster procedure for slower circuits)
Call manual operation level: Press - key plus - key (optional: seperate key).Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down - key for more than 5 sec. on manual operation level.During operation the lower display shows: "-Ad-",the upper display still shows permanently the actual value.
Information about computer operation: First the self-adaptation program waits for stabilizationof the actual value according to the given controller output (actual value alteration < 0,1% / min),then it increases the output signal about 10% or, in case of three- point- step controller operation,it triggers an output impulse with about 10% of the adjusted regulating time.The optimum parameters are computed according to the unit- step response.
Cancel: Press - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
to operating level.
Unsuccessful adaptation ( Display shows error code, ref.to chapter error messages):
Press - key again: Return to manual operation leveleliminate the indicated error
start adaptation again: - key > 5 sec.
or return to operating level: - key shortly
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Industry controller type Kuwo 93KU10 B 93.. EConfiguration - page 6 -
data subjects to alteration 93KU10E6.DOC / 0110809
Access from the operating level.Unlock the access first: Turn the switch on the rear panel of the controller to position "U"
(= unlocked). It is not possible to configure the controller with locked switch.
(Lock access after the adjustments: Switch position to "L"= locked)
Hold down the - key and press the - key,hold down both keys for more than 5 sec. until the display changes
Enter the code number (password) ... (1...9999), factory setting: 1move on to next input: briefly press - key
Alternatively: Hold down key after entering code for more than 10 sec.Possibility to modify code number (optional)
Select control function (type dependent): the displayed ID number for the configuredcontrol function can be changed by pressing the - key.(Example Type 930K31: choose (92..) 200, 201, 700, 701)
Return to operating level: briefly press the - key
ormove on to following adjustments: hold down - key for more than 5 sec.Note: when switching is continued after a function has been changed, the display will first flash for several seconds, only then will the controller return to the selected level.
Configurations are displayed in succession (type and design dependent)and can be changed: ...
(move on to next input: press - key shortly)
factory setting Ist1/2 correction value to change the controller display (+ / -) 0.0/0.0 Ain1 type of DC signal for input No.*:rtd/ 0/4-20mA/ 0/2...10V 4...20 mA
(observe different terminal connection I/U)Y' ' travel time of the actuator "6...600" (sec.) 60 sec. 1out adjusting output characteristics direct/inverted "di/in" CH1 di 2out adjusting output characteristics direct/inverted "di/in" CH2 in Sout adjusting type of information signal "0..20/4..20(mA)/0..10/2..10(V)" 4...20 mA
1Y_S behaviour of the output in case of measuring line fault CH1:
relay position:"rel1 / rel2 / AUS" ( AUS = relays off) rel2 2Y_S behaviour of the output in case of measuring line fault CH2:
relay position:"rel1 / rel2 / AUS" ( AUS = relays off) rel2 reL3 function selection for add. switching contact K3 : LCA
select the corresponding measuring input ISt1 select the corresponding control circuit 1SP relay condition in case of measuring line fault: "SiE/SiA"(on/off) Si A
reL4 function selection for add. switching contact K4 : LCA
select the corresponding measuring input Ist2 select the corresponding control circuit 2SP
Adr bus adress (adress no.) (for interface equipment only) 5
relay condition in case of measuring line fault: "SiE/SiA"(on/off) Si A
Return to operating level: briefly press the - key again
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Industrial controller type Kuwo 9.. B 9... EFacilities for Setting Supplementary Contacts - page 7 -
_______________________________________________________________________
Subject to technical changes 9_E7.DOC / 0010623
Selectable switching functions (depending on version):
For setting please refer to configuration level under „reL...“
Switching functions for trailing contacts:
LC A Break contact on either side of setpoint
(Limit comparator). Relay drops out asdeviation increases (Aus = off)
LC E Make contact on either side of setpoint
(Limit comparator). Relay picks up asdeviation increases (Ein = on)
Su A Break contact below setpoint. Relay dropsout as actual value decreases (Aus = off)
Su E Make contact below setpoint. Relay picksup as actual value decreases (Ein = on)
So A Break contact above setpoint. Relay drops
out as actual value increases (Aus = off)
So E Make contact above setpoint. Relay picks
up as actual value increases (Ein = on)
St A Heating stage below setpoint. Relay
drops out actual value increases (Aus =off)
Switching functions for independent contacts:
US A Relay drops out with increasing actual
value (Aus = off)
US E Relay picks up with increasing actual
value (Ein = on)
Service function:
Ein/Aus contact is constantly switched on (Ein) or
off (Aus) respectively
on
off
SASd
SASd
on
of f
on
of f
on
of f
onof f
SASd
SASd
Sd
Sd
SASd
SP(setpoint)
actual value
SA
SA
SdSA
on
of f
on
of f Sd
SA
on
Sd
on
of f Sd
SP
Switching point
of f
actual value
Only for units with program option
Pr A Relay switched off (aus) during SP program level, otherwise switched on
Pr E Relay switched on (ein) during SP program level, otherwise switched off
Special function: SF6 as SoA but switching point at setpoint, control output around SA below
In each case additional settings follow under "rEL." after the selection is acknowledged (P key)
(depending on version):
Ist./ Y assigned value: actual value no. ... or Y (actuating signal)
CH../.SP.(only) for trailing contacts: assigned control circuit / channel (no.) or
assigned setpoint (1SP., rSP, SP.1, ..)for independent contacts: assignment of parameter input (channel no..)
"Safety" shut down (in case of measuring line fault):SI E Relay for "Safety" behaviour in event of measuring circuit error: relay on
SI A Relay for "Safety" behaviour in event of measuring circuit error: relay off
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Industry controller type Kuwo 93KU10 B 93.. ETechnical data - page 8 -
data subjects to alteration 93KU10e8.doc / 0110809
Characteristics:Adjustment on parameter level, with lock switch,pre adjusted on customer´s demand.(parameters depending on sub type:)Proportional band Xp: 0,1...999,9 %
Integral action time Tn: 0,0...999,9 minRate time Tv: 0,0...99,9 minSensitivity of response Xsh: 0,1...1,0 %Travel time of the actuator Tm: 6...600 secFunction characteristics: direct / invertedSwitching interval SA (add. contacts): 0..100,0 KSwitching difference Sd: 0,1...100,0 K
Installation dimensions:
three- point- step- controller (inverted)
on
off actual value
Additional contact functions:
As switching interval above and below setpoint orindependent adjustable with own setpoint andmeasuring input, switching function adjustable(ref. to chapter additional switching contacts)
Other data:
Housing for panel mounting, 96 x 96 mm (type 92..,93..) or 72 x 144 mm (type 94)
Power supply: 230VAC +/- 10 %, 48...62Hzalternative 115 VAC, 48 VAC, 24 VAC, 24 VDCPower consumption: approx. 14 VAProtective system DIN 40050: IP54 (terminals IP20)Permissible ambient temperature: 0...60°CNominal temperature: 20°CClimatic category: KUF to DIN 40050Relative humidity <= 75 % yearly average,no condensationEMC: refer to EN 50081-2 and EN 50082-2
Wiring diagram: (Example, depending on sub type some details can be missedvalid for each delivered controller is the wiring diagram on its casing only)
L
B +0,8
H +0,8
For m 96 x9 6: L= 150 mm , B = 9 2m m H= 92m mForm 72x144: L= 170mm, B=168mm H=139mm
Sh
K2(-)K1(+)
SP l92-d4990419
digitalinput
Fuse:
24V:T0,5A
115V:T0,2A
230V:T0,1A
Ist 1 Ist 2 Rel 1
signal-output
Sout 1 Rel 2 Rel 3 Rel 4dig 1
analog inputs powersupply
relay outputs
controller electronics
(+) (-)
A93KU10e10110607
18V / 40mA
50 51 52 53 54 55 56 57 58 59 60 6127 28 291 2 3 4 5 6 40 31
+
19 20
(protect relay outputs by external fuse 2A)L(L+)
N(L-)
99
U+
channel1active+ -4...20mA
channel2active
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This function expansion makes it possible to switch over control units of series 92/93/94/95 from the internalequipment set point value to an externally specified set point value, as desired.
The analog input for processing the external set point value signal is identified on the connection terminalswith the designation SPE, as well as the optional connection type of voltage (U) or direct current (I).
The voltage or current range may be configured to 0 or 2...10 V or 0 or 4...20 mA. Furthermore, the set pointrange allocated to the signal range is freely adjustable. The function of the value is selectable by menu asabsolute (abs) adding (add) or subtracting (sub).
Depending on type, switch-over from the internal to the external set point value takes place through a binarycontrol input (potential free normally open contact), alternative: voltage 5V...24V (type extension ..u") or is toselect by menu adjustment in the set point level (F-SP: choice SP = intern or SPE = extern setpoint. (typeextension "..u")
In the operating level, the incoming external set point value signal is displayed under the designation “SPE”after the set point value “SP”, once the P key is actuated again. In addition, it can be recognized whether thisis currently effective, depending on the switch setting: The respective active value SP or SPE appears in the
normal display, the inactive value only flashing.
Providing the set point value in the operating level is displayed in the bottom display, this displayautomatically switches over to the external set point value, i.e. as soon as it has been activated it displays thecurrent effective set point value.
Types List No.
Control input for potential free normally open contact 99bwaControl input 0V / 5...24V 99bwauto activate with menu function 99bwam
Order text: Accessory equipment:Function expansion for external set point valuewith additional analog input 0/4...20mA o. 0/2...10Vcontrol input.. / to activate.. List No.....
Additional connection terminals:
* Terminal No. depending on the number of available or required inputs:
1. binary input: terminal 19 (+Us) / 20 (^)
2. binary input: terminal 21 (+Us) / 22 (^)
1513 14
I U T
SPE
*
internal setpoint is active*
external setpoint is active*(*=only 99bwa)
*
Us = 0V : internal setpoint is active
Us = 5...24V : external setpoint is active
UsT
Li.No. 99bwa + 99bwamPotential free normally open contact
Li.No. 99bwauSwitch-over with external voltage Us
1513 14
I U T
SPE
I=0/4-20mAU=0/2-10V
I=0/4-20mAU=0/2-10V
l 9 9 a w 1 z E 9 6 1 0 2 2 2
99bwa E
Page 1 of 2
Accessory equipment series 9..
External set point value input
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Kuwo 929 Remote Control Units 929 EPage 1 of 2
929-e1 doc / 0110313
40
31
1
3
13
15
40
31
Geber9293..
Regler92..-99bwa..
l 9 2 9 0 1 1 0 2 0 5
1 Digital display actual value(depending on type)
2 Digital display setpoint
3 Key for setpoint and parameter mode
4 Setpoint adjustment
5 Parameter mode lock switch (back face)
3
1
2
3 4
5
General:
The units in 96 x 96 panel mounting format are based on the Kuwo 92 industrial control unit series and allowexternal setting of one to three setpoints or continuous control outputs and up to 4 three-level signals. Upper
and lower limits can be assigned to the setting ranges.
The unit has a dual display. In operating mode, the target value or control output is displayed in the lowerrow. The upper row can optionally be used for the remote display of the actual value.
Accessories from the Kuwo 92 product range are available as an option.
Types: Type
Setpoint generator 9293.Setpoint generator with actual value remote display (Pt100 / standardised signal) 9293.0 / e
Actuator (three-point step) 9297.Actuator (continuous) 9298.Actuator (continuous, 2 outputs) 9299.
See data sheet 9200 for device variants and accessories
Assembly dimensions:
L
B + 0 , 8
H + 0 , 8
F o r m 9 6 x 9 6 : L = 1 5 0 m m , W = 9 2 m m H = 9 2 m m F o r m 7 2 x 1 4 4 : L = 1 7 0 m m , W = 1 6 8 m m H = 1 3 9 m m
Wiring:
Example:Connections between remote control unit 92930e and controller 92..-99bwa-ogx-..)
open printversion
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Accessory equipment, series 9..
additional analog inputs
A ES
- +
thermocouple
feedback device
UI T
standard signal
l 9 9 a x e 9 6 1 0 4 1 2
Controllers of series 9.. may be equipped with up to 4 analog inputs per unit in addition to the measuringinputs available as standard. They may be used to display additional measuring values or as reference
value for installed additional contacts.
The display is continuously switched over to additional inputs by actuating the key. In addition, thebottom display shows the brief designation of the attendant measuring input. The display automatically
switches back to the standard operating condition 5 seconds after the last key was pressed.Furthermore, input 2 may be configured as a second display in addition to the controller actual value.
For temperature sensor inputs, °C or °F may be selected as display unit, for standard signal inputs, a
scaling between -999 and +4000 may be infinitely set..
Measuring input: List-No.: Measuring/display range
Resistance thermometer:
Pt100 DIN 99ax 0...400 °C
(0...100,0 °C)*(0....600 °C)*
Thermal elements: NiCrNi (Typ K) 99axn 0...1200 °CFeCuNi (Typ J) 99axf 0...900 °C
PtRhPt (Typ S) 99axp 0..1700 °C
Standard signal: 0(4)...20 mA or 0(2)...10 VDC 99axe adjustable
4...20 mA incl voltage supply 99axi adjustable
Rheostatic teletransmitter: 0...100 to 0...1000 Ω 99axw 0...100.0 %
*(Alternative range, according to the order data)
Order text: Accessory equipment:additional analog input for ......
Range: ......Li-No.: 99a ..
additional connection terminals:
*Terminal No. according to number of existing,
or required analog inputs:
second input: terminal 4/5/6
third input: terminal 7/8/9fourth input: terminal 10/11/12
alternative:
99ax E
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
7. Pressure control
Type: SPVF 40 K2F 1A 05
Pos.: 7.1
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Pressure Relief ValvesSPV, SPVF
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Construction of the Pressure Relief Valves SPV, SPVF
1 Housing
2 Sliding Piston
3 Compression Spring
4 Set Screw
5 Bleeding Screw
6 Protective Cap
Description
The direct spring, slidingpiston Pressure Relief Valve
SPV/SPVF is intended for
inline mounting and is
suitable to safeguard low
pressure hydraulic circuits
up to 20 (30) bars. The pipe
connection is to be effected
either by SAE-Mounting
Surfaces (3000 psi) or by
Whitworth Pipe Threads ”G“.
Symbol Valve Construction
The SIiding Piston 2 ispressed against the Annu-
Iated Area a by the
Compression Spring 3 and
separates the Pump Connec-
tion P from the Reservoir
Connection R sealing the
Bore d. As soon as the
operating pressure p
adjusted by the Set Screw 4,
is reached the SIiding Piston
2 releases the oil flow to the
reservoir. The Spring
Chamber b is pressure
compensated by the Bore c.
During starting-up the valve
the Spring Chamber b must
be bleeded by the Bleeding
Screw 5, (Hex. Socket
Width: 4). The valve should
preferably be installed in
vertical fitting position with
the pressure setting
arrangement down.The pressure relief valves
are available in four different
pressure setting ranges
because, due to their
springrates, each of the
compression springs can
only cover a limited
pressure setting range.
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Hydraulic Characteristics
Nom. Size: 10 25 40 50 80Pressure SettingRanges: pv min 0,5 0,5 0,5 0,5 0,5 bars
pv max 30 20 20 20 20 bars
Fluid TemperatureRange: ϑm min = – 20 °C
ϑm max = + 80 °C
Viscosity Range: νmin = 6 mm2 /s νmax = 600 mm2 /s
∆p-Q-Characteristics: Page 5
Hydraulic Fluids: Hydraulic Oils acc. to DIN 51 524/25
Other Fluids on request
Type Setting
mechanical Set Screw
Knob
Accessories
Welding Flange
SAE (3000 psi)
Characteristics
Characteristics acc. to VDI 3267
Pressure Relief Valvedirectly spring operated
Nom. Size: 10 25 40 50 80
Max. Flow Capacity: 40 90 450 550 800 l/min
Nom. OperatingPressure: 30 20 20 20 20 bars
General Characteristics
Construction: Sliding Piston Relief Valve
Mounting: Inline
Pipe Connection: SAE-Flange (3000 psi)
Whitworth Pipe Thread ”G“
Dimensions: Pages 7, 9, 10
Weight: Pages 7, 9, 10
Fitting Position: Set Screw down
Perm. Ambient Temp.: ϑu min = – 20 °C
ϑu max = + 60 °C
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Characteristic Curves
Characteristic Curves pE – Q Viscosity = 34 mm2 /s
02
12
02
12
02
12
02
12
0212
05
30
05
20
05
20
05
20
0520
SPV 10Pressure Setting Ranges
SPVF 25Pressure Setting Ranges
SPVF 40Pressure Setting Ranges
SPVF 50Pressure Setting Ranges
SPVF 80Pressure Setting Ranges
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Dimensions
Ordering Code SPVF . A 2F 1 A . Ordering Code SPVF . A 1G 1 A .
Ordering Code SPVF . B 2F 1 A . Ordering Code SPVF . B 1G 1 A .
Nom. SAE Thread Wrench Size or Weight
Size Flange R Hex. Socket Width kg
A B C D E F G H K1 K2 L1 L2 M SW1 SW2 SW3 SW4
25 1˝ G 1 52,4 26,2 M 10 59 70 24 20 50 160 167 210 217 55 17 5 46 17 3,0
40 11 ⁄ 2˝ G 11 ⁄ 2 69,9 35,7 M 12 83 94 38 20 65 170 172 235 237 65 17 5 46 17 6,0
50 2˝ G 2 77,8 42,9 M 12 97 102 50,5 20 75 192 209 267 284 75 19 6 46 19 8,2
80 3˝ G 3 106,4 61,9 M 16 131 135 79 25 110 190 207 300 317 110 19 6 – 19 18,5
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Ordering SAEO-Ring Weight
Code Flange
A B C D F G H I L M kg
CFS 102-ST 1˝ 34,5 25 38 18 14 M 10 71 52,4 53 26,2 4131 0,6
CFS 106-ST 11 ⁄ 2˝ 48,6 38 44 25 18 M 12 94 70,0 77 35,7 4187 1,2
CFS 108-ST 2˝ 61,0 50 45 25 18 M 12 103 77,8 89 42,9 4225 1,5
CFS 112-ST 3˝ 89,0 73 50 27 23 M 16 135 106,4 124 62,0 4337 2,7
Accessories
Welding Flange SAE (3000 psi)
Ordering Code SPVF 40 B 2F 1 A 20 + 2 x CFS 106-ST
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Pressure Limiting Valve
O p e r a t i n g I n s t r u c t i o n s
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Contents
Safety 1
Identification of safety instructions 1
General Safety Instructions 1
Address off Manufacturer 1
The Documentation 2
Description of Operation 2
Installation of the Pressure Limiting Valve 2
Constructions and Spares 3
Commissioning 3
Adjustment 3
Venting 3
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BSPV-006-01.98-E 1
Safety
Identification of safety instructions
The safety instructions contained in these operating instructions are identified by thefollowing attention symbol:
If these instructions are not observed, danger to personnel and equipment can result.
General Safety Instructions
The operating safety of the equipment supplied is only guaranteed under theprescribed conditions of use (see „Description of Equipment“). The stated limitingvalues (see also „Technical Data“) must not be exceeded under any circumstances.
Personnel who are responsible for the installation, operation and the repair of the
pressure limiting valve, must possess an appropriate qualification; this can have beenobtained through training or relevant instruction. Such personnel must be acquaintedwith the contents of this instruction.
During all work, the prevailing national regulations relating to accident prevention andsafety in the work place and, where appropriate, internal regulations of the operator,must be adhered to, even where these are not named in this introduction.
During all work and prior to installation, the connecting pipelines must be de-pressurised!
The operator must ensure that these operating instructions are accessible to thepersonnel concerned at all times.
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2 BSPV-006-01.98-E
The DocumentationThese operating instructions describe the adjustment and venting of the SPVF pressurelimiting valve. The valve is manufactured in various versions.The designated version of a particular valve is given on the type reference plate.
Description of Operation
The directly controlled pressure limiting valves are used to protect low pressure circuits, upto a maximum pressure of 20 bar (SPVF 10, p max 30 bar).In a cast hydraulic housing 10, a valve spool 30 seals the pressure chamber P from thereservoir connection T, when acted on by the the pressure spring 70. When the set pressureis reached, the valve spool 30 opens to create a connection between P and T. As thepressure in P falls below the set pressure value, the valve closes.
Installation of the Pressure Limiting ValveThe valve should preferably be installed in a vertical attitude, with the adjustment screwunderneath.Before installing the pressure limiting valve, the pipe work system must be cleaned to
eliminate dirt, scale, sand, swarf, etc. Welded tube, in particular, must be scoured orscavenged. Cotton rags must not be used in the cleaning operation. The pipelines must beconnected to the valve in an absolutely stress-free condition.The pipes and connections used must be those appropriate for the operating pressurerange. The pipe manufacturers specifications should be consulted!On installation, care should be taken that no sealing material finds its way into the pipeline.Sealing materials such as hemp and mastic are not permissible, since they can lead tosoiling and hence impair the function of the valve.
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BSPV-006-01.98-E 3
Constructions and Spares
Item Description Item Description Item Description
10 Housing 50 Protecting cap 100 Vent (bleed)
20 Plug 70 Pressure cap 110 Flat seal
30 Valve spool 80 Threaded rod 120 O-Ring
40 Spring guide 90 Hexagonal nut
Commissioning
Adjustment
The pressure limiting valve is set to the pressure required by the customer. It may benecessary to carry out a check on the pressure setting during commissioning, since differentflow rates, oil viscosities and pipe lengths can affect the response value. In such cases a
manometer should be connected directly to the valve oil pressure connection. Theircharacteristics are such, that each of the four pressure springs available is only suitable for alimited range of setting pressures.These pressure ranges are specified in the Spare Parts List 58 601/4.The pressure setting adjustment is made by removing the protecting cap 50 and looseningthe hexagonal headed nut 90 on the threaded rod 80, by means of an internal hexagon ringspanner.Rotation to the right increases the pressure setting, rotation to the left decreases thepressure. On achieving the desired pressure setting, the hexagon headed nut 90 must betightened and the cap 50
Venting
Pressure limiting valves only operate correctly when all the voids within the valve are filledwith hydraulic fluid. If the installed attitude is incorrect, air may collect in the spring chambersand lead to hydraulic shock. In these circumstances the valve must be ventilated (bled). Thisis achieved by unscrewing the vent screw 100 through one turn. Venting should occur at lowpressure and is complete when oil is discharged free of air bubbles. After venting, the ventscrew is tightened again.
.
Servicing and adjustments to the pressure limiting valve which require it to be dismantled,are only to be carried out by trained and appropriately qualified personnel.When dismantling the pressure limiting valve, the components must be directly protectedfrom damage and soiling.Fluids emerging from the valve must be collected and disposed of in such a way that there is
no danger to personnel or to the environment. The currently applicable regulations must beobserved.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
8. Instruments andsensors
Type:
pressure switch
900.2378.905,
differential pressure
switch 920.2376.937
Pos.: 8.1, 8.2
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ÄNDERUNGEN VORBEHALTEN - SOU S RÉS ERVE DE MODIFICATIO NS - SUBJECT TO CHANGE
FILE: H72252c DATE: 11/2003 PAGE: 1 (5) DATASHEET: 2.1.1.1
APPLICATIONS APPLICATIONS ANWENDUNGEN
900/904/912PRESSOSTAT P/PS
Fühler: BalgMessbereich: -0.9...1.5 bis 0...100 bar Ausgang: potentialfreier Umschaltkontakt Schaltdifferenz: nicht einstellbar Reproduzierbarbeit: ± 1.0 % d.S. typ.Skalengenauigkeit: ± 2.0 % d.S. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Capteur: soufflet Plage de mesure: -0.9...1.5 à 0...100 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableReproductibilité: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Sensor: bellowsMeasuring range: -0.9...1.5 to 0...100 bar Output: floating change-over contact Switching differential: not adjustableRepeatability: ± 1.0 % FS typ.Scale accuracy: ± 2.0 % FS typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
VORTEILE AVANTAGES PRINCIPAUX MAIN FEATURES
HAUPTMERKMALE CARACTÈRES DISTINCTIFS MAIN CHARACTERISTICS
Schiffbau Construction navale Shipbuilding ABS, BV, DNV, GL, KRS, ABS, BV, DNV, GL, KRS, ABS, BV, DNV, GL, KRS,LRS, PRS, RINA LRS, PRS, RINA LRS, PRS, RINA
Motorenbau Constr. de moteurs Engine manufacturingSchienenfahrzeuge Véhicules sur rail RailwaysMaschinenbau Machines-outils Machine toolsHydraulik Hydraulique HydraulicsHLK CVC HVACKältetechnik Réfrigération RefrigerationProzess Techn. Techn. de procédés Process technology
Wasseraufbereitung Traitement de l'eaux Water treatment Autoindustrie Industrie automobile Automotive industry Prüfstände Banc d'essai à frein Test benches
Ex Ex Ex Lebensmittelindustrie Industrie alimentaire Food Industry Autoklaven Autoclavage Autoclaves
Rugged aluminium housingProtection IP 65 Any mounting position possible
Robustes Alu-GehäuseSchutzart IP 65Beliebige Einbaulage
Boîtier robuste en aluminiumProtection IP 65Montage toutes positions
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ÄNDERUNGEN VORBEHALTEN - SO US RÉS ERVE D E MOD IFICATIONS - SU BJECT TO C HANGE
FILE: H72252c DATE: 11/2003 PAGE: 2 (5) DATASHEET: 2.1.1.1
Andere Varianten auf Anfrage/ Autres variantes sur demande/ Other variations on request
BESTELLINFORMATION / INFORMATION POUR LA COMMANDE / ORDERING INFORMATION
900/904/912PRESSOSTAT P/PS
Dämpfungselemente und Snubber/ Eléments d'amortissement et Snubber/ Damping elements and Snubber:siehe Datenblatt/ voir spécification /see specification sheet H72258
Lager Code (kurze Lieferzeit)/ Codification stock (delai de livraison bref)/ Code for stock products (short delivery time): P/PS (z.B./ Ex./e.g: P16)
(((((siehe Katalog/ voir catalogue/ see catalogue: „Standard Products“
Varianten Code/ Codification de variantes/ Custom build code XXX.XXXX.XXX.XX.XX...
Mit Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 900 With display; with adjusting screw Ohne Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 904
Without display; with adjusting screw Mit Anzeige; mit Verstell-Knopf/ Avec affichage; réglage par mollette/ 912
With display; with adjusting knob
Mikroschalter1) Grosse Schaltdifferenz/ Interrupteur à grand différentiel/ Big switching differential 06Microrupteur Kleine Schaltdifferenz/ Interrupteur à petit différentiel/ Small switching differential 10Microswitch Mittlere Schaltdifferenz/ Interrupteur à moyen différentiel/ Average switching differential 11
Erhöhte Vibrationsbeständigkeit/ Résistance de vibration élevée/ Improved vibration resistance 23Hohe Vibrationsfestigkeit/ Résistance de vibration forte/ High vibration resistance 26Mit vergoldeten Kontakten/ Avec contacts dorés/ With gold plated contacts 21
1) Schaltdifferenz/ Différentiel de l'interrupteur/ Switching differential: nicht einstellbar/ non ajustable/ Not adjustable
Bereich -
0.9... 1.5 Überdruck 10 Berstdruck 13 72Plage 0.2... 1.6 Surpression 10 Pression destruction 13 73Range 0.2... 2.5 Overpressure 10 Burst pressure 13 75
0.0... 4.0 12 26 76[bar] 0.0... 6.0 [bar] 12 [bar] 26 77
1.0... 10.0 24 36 781.0... 16.0 24 36 792.0... 25.0 40 75 804.0... 40.0 40 75 816.0... 60.0 100 160 82
10.0... 100.0 100 160 83
FühlerCapteurSensor
Material/ matière/ material
Gewinde/ filet/ thread G1/4"f 2) G1/2"m3) G1/4"f 2) G1/2"m3) G1/4"f 2) G1/2"m3)
Bereich 72 900 909 950 959 800 809Plage 73, 75 901 902 951 952 801 802Range 76, 77 903 904 953 954 803 804
78, 79 905 906 955 956 805 80680, 81 907 908 957 958 807 80882, 83 9404) 9414) 840 841
2) innen/ femelle/ female 3) aussen/ mâle/ male 4) Balg/ Soufflet/ Bellows: 1.4435
Befestigung Direkt am Fühler oder Gehäuse/ Directement à capteur ou boîtier/ Direct on sensor or housing 00Fixation Mit Montagebügel/ Avec platine murale/ By mounting bracket 31Mounting
Zubehör Plombierung (Schutz vor Manipulation)/ Plombage (protection contre manipulations/ 16 Accessoires Lead seal (mani-pulation protection) Accessories Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland PG 16 32
Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland M 24 x 1.5 (DIN8280) 27Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland M 18 x 1.5 (DIN8280) 40Ohne Kabelverschraubung/ Sans passe-câble à vis/ Without screwed cable gland 33Bahnsichere Ausführung / Exécution pour ferroviaire/ Railway-safety execution 28
B a
l g : B r o n z e
G e
h ä u s e : M e s s i n g
S o u
f f l e t : b r o n z e
B o î t i e r :
l a i t o n
B e
l l o w s :
b r o n z e
H o u s i n g :
b r a s s
B a
l g : B r o n z e
G e
h ä u s e : M e s s i n g c
h e m . v e r n .
S o u
f f l e t : b r o n z e
B o î t i e r :
l a i t o n c
h i m . n i c k e
l é
B e
l l o w s :
b r o n z e
H o u s . :
b r a s s c
h e m .
n i c k e
l p
l a t .
B a
l g : 1 . 4
4 3 5
M e
d i e n
b e r ü
h r e n
d e
T e i l e : 1 . 4
4 3 5
G e
h ä u s e : M S v e r n i
c k e
l t
S o u
f f l e t : 1 . 4
4 3 5
M a t é r i e
l c o n t a c t . a v e c m é d i a s :
1 . 4
4 3 5
B o î t i e r :
l a i t o n n i c k e
l é
B e
l l o w s : 1 . 4
4 3 5
M e
d i u m
c o n t a c t . p a r t s : 1 . 4
4 3 5
H o u s i n g :
b r a s s , n i c
k e
l p
l a t .
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FILE: H72252c DATE: 11/2003 PAGE: 3 (5) DATASHEET: 2.1.1.1
900/904/912PRESSOSTAT P/PS
SPECIFICATIONS
MAIN CHARACTERISTICS
Sensor: bellow Measuring range: -0.9...1.5 to 10...100 bar Output: floating change-over contact Switching differential: not adjustableEN60730-1/ EN60730-2-9: Typ 2.B.H
ACCURACY (@ 20°C)
Repeatability sensor: ± 1.0 % FS typ.Scale accuracy: ± 2.0 % FS typ.Switiching differential: see table
MICROSWITCHRating: see tableResistance of insulation: > 2 MΩDielectric strength: 1.25 kV terminal groundLife time (mechanical)
Microswitch 06: 10 Mio. cyclesMicroswitch 10/11: 20 Mio. cyclesMicroswitch 21: 0.5 Mio. cycles
Microswitch 23/26: 0.3 Mio. cyclesELECTRICAL CONNECTION
Screwed cable gland: see accessoriesTerminal screw: 3 x 1.5...4 mm2
ENVIRONMENTAL CONDITIONS
Operating temperature: --20...+70°CMedia temperature -40...+150°CStorage temperature: -25...+85°CProtection: IP65Humidity: max.95 % relative
Vibration:5...25 Hz: ±1.6 mm25...100 Hz: 4g
Ranges 72, 73, 755...50 Hz: 20 mm/sec.Shock: 50g/ 11 ms
MECHANICAL DATA
MaterialSensor: see ordering informationHousing: AlSi10Mg/ Epoxy coatedSeal: NBRScrewed cable gland: brass nickel plated
Mounting torque: max. 25 NmInstallation: any position
Weight: ~ 710 g
SPEZIFIKATIONEN
HAUPTMERKMALE
Fühler: BalgMessbereich: -0.9...1.5 bis 10...100 bar
Ausgang: potentialfreier Umschaltkontakt Schaltdifferenz: nicht einstellbar EN60730-1/ EN60730-2-9: Typ 2.B.H
GENAUIGKEIT (@ 20°C)
Reproduzierbarkeit Fühler: ± 1.0 % d.S. typ.Skalengenauigkeit: ± 2.0 % d.S. typ.Schaltdifferenz : siehe Tabelle
MIKROSCHALTER Schaltleistung: siehe TabelleIsolationswiderstand: > 2 MΩSpannungsfestigkeit: 1.25 kV gegenüber MasseLebensdauer (mechanisch)
Mikroschalter 06: 10 Mio. LastspieleMikroschalter 10/11: 20 Mio. LastspieleMikroschalter 21: 0.5 Mio. Lastspiele
Mikroschalter 23/26: 0.3 Mio. LastspieleELEKTRISCHER ANSCHLUSS
Kabelverschraubung: siehe Zubehör Schraubenklemmen: 3 x 1.5...4 mm2
UMGEBUNGSBEDINGUNGEN
Betriebstemperatur: -20...+70°CMedientemperatur: -40...+150°CLagertemperatur: -25...+85°CSchutzart: IP65Feuchtigkeit: max. 95 % relativ
Vibration:5...25 Hz: ±1.6 mm25...100 Hz: 4g
Bereiche 72, 73, 755...50 Hz: 20 mm/Sek.Schock: 50g/ 11ms
MECHANISCHE DATEN
MaterialFühler: siehe BestellinformationGehäuse: AlSi10Mg/ Epoxy beschichtet Dichtung: NBRKabelverschraubung: Messing vernickelt
Anziehdrehmoment: max. 25 NmEinbaulage: beliebigGewicht: ~ 710 g
SPÉCIFICATIONS
CARACTÈRES DISTINCTIFS
Capteur: soufflet Plage de mesure: -0.9...1.5 à 10...100 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableEN60730-1/ EN60730-2-9: Typ 2.B.H
PRÉCISION (@ 20°C)
Reproductibilité capteur: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.Différentiel de l'interrupteur: voir tableau
MICRORUPTEUR Pouvoir de coupure: voir tableauRésistive d'isolation: > 2 MΩRigidité diélectrique: 1.25 kV contre la masseDurée de vie (mécanique)
Microrupteur 06: 10 Mio. cyclesMicrorupteur 10/11: 20 Mio. cyclesMicrorupteur 21: 0.5 Mio. cycles
Microrupteur 23/26: 0.3 Mio. cyclesCONNECTION ÉLECTRIQUE
Passe-câble à vis: voir accessoiresBorne à vis: 3 x 1.5...4 mm2
CONDITIONS D'ENVIRONNEMENT
Température de service: --20...+70°CTempérature de médias: -40...+150°CTemp. de stockage: -25...+85°CProtection: IP65Humidité: max. 95 % relatif
Vibration:5...25 Hz: ±1.6 mm25...100 Hz: 4g
Plages 72, 73, 755...50 Hz: 20 mm/sec.Choc: 50g/ 11 ms
SPÉCIFICATIONS MÉCANIQUES
MatiéreCapteur: voir information pour la commandeBoîtier: AlSi10Mg/ Vernis avec époxy
Joint: NBRPasse-câble à vis: laiton nickelé
Couple de serrage: max. 25 NmMontage: toute positionPoids: ~ 710 g
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FILE: H72252c DATE: 11/2003 PAGE: 4 (5) DATASHEET: 2.1.1.1
ELEKTRISCHE DATEN SCHALTER / SPÉCIFICATIONS ÉLECTRIQUES DE L'INTERRUPTEUR / ELECTRICAL DATA SWITCH
2...25
4...400.51.02.06.040
1...10
1...160.20.40.82.424
0...4
0...60.080.20.31.212
Bereich/ Plage/ Range [bar]
Mikroschalter/ Microrupteur/ Microswitch
BalgfühlerCapteur soufflet Bellows sensor
1011/21/23
2606
-0.9...1.5
0.2...1.60.2...2.50.030.10.1
0.3510
6...60
10...1001.53.05.018
100Schaltdifferenz [bar]: fester Wert, nicht einstellbar Différentiel de l’interrupteur [bar]: valeur fixe, non ajustableSwitching differential [bar]: fixed value, not adjustable
P max.
Schalter/ Interrupteur/ Switch 21/26Schalter/ Interrupteur/ Switch 06/10/11/23
900/904/912PRESSOSTAT P/PS
Typ Merkmale Schaltleistung 5)
Type Caractéristiques Pouvoir de coupureType Features Rating
AC DC
06 Grosse Schaltdifferenz 380 V 20 (4) A 220 V 0.6 (0.4) A Interrupteur à grand différentiel 110 V 0.7 (0.5) A large switching differential 24 V 20 (15) A
12 V 20 (15) A
10 Kleine Schaltdifferenz 125 V 10 (1.5) A 250 V 0.2 (0.02) A Interrupteur à petit différentiel 250 V 10 (1.25) A 125 V 0.4 (0.03) A
Small switching differential 30 V 2 (1) A 14 V 15 (2.5) A
11 Mittlere SchaltdifferenzInterrupteur à moyen différentiel
Average switching differential
23 Erhöhte Vibrationsfestigkeit; mittlere Schaltdifferenz 125 V 15 (1.5) A 250 V0.25(0.03) A Résistance de vibration élevée; interrupteur à moyen différentiel 250 V 15 (1.5) A 125 V 0.5(0.05) A Improved vibration resistance; average switching differential 500 V 10 (1.5) A 30 V 6 (1.5) A
26 Hohe Vibrationsfest igkeit; mitt lere Schaltdifferenz 14 V 15 (2.5) A
Résistance de vibration forte; interrupteur à moyen différentielHigh vibration resistance; average switching differential
21 Mit Goldkontakten, geeignet für eigensichere Schaltkreise 24 V 0.01(0.01)A 24 V0.01(0.01)A Avec contacts dorés, approprié aux circuits de côntrole à sécurité intrinsèque 12 V 1 (1.0) A 12 V 1.0 (1.0) A Gold plated contacts, suitable for intrinsically safe control circuits 5 V 2 (2.0) A 5 V 2.0 (2.0) A
5) Ohmsche Last ( Induktive Last)Charge ohmique (Charge inductive)Resist ive Load (Inductive Load)
SCHALTDIFFERENZ (typ.) / DIFFÉRENTIEL DE L’INTERRUPTEUR (typ.) / SWITCHING DIFFERENTIAL (typ.)
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FILE: H72252c DATE: 11/2003 PAGE: 5 (5) DATASHEET: 2.1.1.1
900/904/912PRESSOSTAT P/PS
MASSBILDER / COTES D'ENCOMBREMENT / DIMENSIONS
ZUBEHÖR / ACCESSOIRES / ACCESSORIES
900.XX.XX.XXX.XX.XX 904.XX.XX.XXX.XX.XX 912.XX.XX.XXX.XX.XX
s i e h e
D a t e n
b l a t t
X
v o i r s p é c i f i c a t i o n
2 . 1 . 2
0 . 1
s e e
d a t a
s h e e t
G1/2"aussen/mâle/male
G1/4"innen/femelle/female
XXX.XX.XX.XXX.XX.32PG16
XXX.XX.XX.XXX.XX.27 M24x1.5
XXX.XX.XX.XXX.XX.40M18x1.5
BEFESTIGUNG / FIXATION / MOUNTING
XXX.XX.XX.XXX.31.XX
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FILE: H72253d DATE: 11/2003 PAGE: 1 (5) DATASHEET: 2.1.1.5
APPLICATIONS APPLICATIONS ANWENDUNGEN
920/924/932DIFFERENTIAL PRESSURE PRESSOSTAT PD
Fühler: BalgMessbereich: -1...6 bis -1...18 bar Druckdifferenz: -0.6...3.4 bis 1...16 bar Ausgang: potentialfreier Umschaltkontakt Schaltdifferenz: nicht einstellbar Reproduzierbarbeit: ± 1.0 % d.S. typ.Skalengenauigkeit: ± 2.0 % d.S. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Capteur: soufflet Plage de mesure: -1...6 à -1...18 bar Press. différentielle: -0.6...3.4 à 1...16 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableReproductibilité: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
Sensor: bellowsMeasuring range: -1...6 à -1...18 bar Differential pressure: -0.6...3.4 to1...16 bar Output: floating change-over contact Switching differential: not adjustableRepeatability: ± 1.0 % FS typ.Scale accuracy: ± 2.0 % FS typ.EN60730-1/ EN60730-2-9: Typ 2.B.H
VORTEILE AVANTAGES PRINCIPAUX MAIN FEATURES
HAUPTMERKMALE CARACTÈRES DISTINCTIFS MAIN CHARACTERISTICS
Schiffbau Construction navale Shipbuilding ABS, BV, DNV, GL, KRS, ABS, BV, DNV, GL, KRS, ABS, BV, DNV, GL, KRS,LRS, PRS, RINA LRS, PRS, RINA LRS, PRS, RINA
Motorenbau Constr. de moteurs Engine manufacturingSchienenfahrzeuge Véhicules sur rail RailwaysMaschinenbau Machines-outils Machine toolsHydraulik Hydraulique HydraulicsHLK CVC HVACKältetechnik Réfrigération RefrigerationProzess Techn. Techn. de procédés Process technology
Wasseraufbereitung Traitement de l'eaux Water treatment Autoindustrie Industrie automobile Automotive industry Prüfstände Banc d'essai à frein Test benches
Ex Ex Ex Lebensmittelindustrie Industrie alimentaire Food Industry Autoklaven Autoclavage Autoclaves
Rugged aluminium housingProtection IP 65 Any mounting position possible
Robustes Alu-GehäuseSchutzart IP 65Beliebige Einbaulage
Boîtier robuste en aluminiumProtection IP 65Montage toutes positions
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FILE: H72253d DATE: 11/2003 PAGE: 2 (5) DATASHEET: 2.1.1.5
Andere Varianten auf Anfrage/ Autres variantes sur demande/ Other variations on request
Dämpfungselemente und Snubber/ Eléments d'amortissement et Snubber/ Damping elements and Snubber:siehe Datenblatt/ voir spécification /see specification sheet H72258
BESTELLINFORMATION / INFORMATION POUR LA COMMANDE / ORDERING INFORMATION
920/924/932DIFFERENTIAL PRESSURE PRESSOSTAT PD
Lager Code (kurze Lieferzeit)/ Codification stock (delai de livraison bref)/ Code for stock products (short delivery time): PD (z.B./ Ex./e.g: PD6)
(((((siehe Katalog/ voir catalogue/ see catalogue: „Standard Products“
Varianten Code/ Codification de variantes/ Custom build code XXX.XXXX.XXX.XX.XX...
Mit Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 920 With display; with adjusting screw Ohne Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 924
Without display; with adjusting screw Mit Anzeige; mit Verstell-Knopf/ Avec affichage; réglage par mollette/ 932
With display; with adjusting knob
Mikroschalter1)
Microrupteur Kleine Schaltdifferenz/ Interrupteur à petit différentiel/ Small switching differential 10Microswitch Mittlere Schaltdifferenz/ Interrupteur à moyen différentiel/ Average switching differential 11
Erhöhte Vibrationsbeständigkeit/ Résistance de vibration élevée/ Improved vibration resistance 23Hohe Vibrationsfestigkeit/ Résistance de vibration forte/ High vibration resistance 26Mit vergoldeten Kontakten/ Avec contacts dorés/ With gold plated contacts 21
1) Schaltdifferenz/ Différentiel de l'interrupteur/ Switching differential: nicht einstellbar/ non ajustable/ Not adjustable
Bereich -1. .. 6 Druckdifferenz -0.6... 3.4 Überdruck 12 Berstduck 26 74Plage -1. .. 6 Pressure différentielle 0... 4 Surpression 12 Pression destruction 26 76Range -1. .. 8 Differential pressure 0... 6 Overpressure 12 Burst pressure 26 77
-1...12 1... 10 24 36 78[bar] -1...18 [bar] 1... 16 [bar] 24 [bar] 36 79
FühlerCapteurSensor
MaterialMatière
MaterialGewinde/ filet/ thread G1/8"f 2) G1/4"f 2) G1/2"m3) G1/8"f 2) G1/4"f 2) G1/2"m3) G1/8"f 2) G1/4"f 2) G1/2"m3)
Bereich 74 931 930 932 981 980 982 831 830 832Plage 76, 77 933 937 934 983 987 984 833 837 834Range 78, 79 935 938 936 985 988 986 835 838 8362) innen/ femelle/ female 3) aussen/ mâle/ male
Befestigung Direkt am Fühler oder Gehäuse/ Directement à capteur ou boîtier/ Direct on sensor or housing 00Fixation Mit Montagebügel/ Avec platine murale/ By mounting bracket 31Mounting
Zubehör Plombierung (Schutz vor Manipulation)/ Plombage (protection contre manipulations / Lead seal (mani- 16 Accessoires pulation protection) Accessories Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland PG 16 32
Kabelverschraubung/ Passe-câble à vis / Screwed cable gland M 24 x 1.5 (DIN8280) 27Kabelverschraubung/ Passe-câble à vis / Screwed cable gland M 18 x 1.5 (DIN8280) 40
Adapter/ Adapteur/ Adapter G1/8" aussen/ mâle/ male - G1/2" aussen/ mâle/ maleMessing/ Laiton/ Brass A6Messing vernickelt/ Laiton nickelé/ Brass nickel plated B6Rostfreier Stahl 1.4435/ Acier inox 1.4435/ Stainless steel 1.4435 D6
Adapter/ Adapteur/ Adapter G1/8" aussen/mâle/male - G1/4" innen/femelle/femaleMessing/ Laiton/ Brass A5Messing vernickelt/ Laiton nickelé/ Brass nickel plated B5Rostfreier Stahl 1.4435/ Acier inox 1.4435/ Stainless steel 1.4435 D5
B a l g : B r o n z e
G e
h ä u s e : M e s s i n g
S o u
f f l e t : b r o n z e
B o î t i e r :
l a i t o n
B e l l o w s :
b r o n z e
H o u s i n g :
b r a s s
B a l g : B r o n z e
G e
h ä u s e : M e s s i n g c h e m . v e r n .
S o u
f f l e t : b r o n z e
B o î t i e r :
l a i t o n c
h i m . n i c k e
l é
B e l l o w s :
b r o n z e
H o u s . :
b r a s s c
h e m . n i c k e
l p
l a t .
B a l g : 1 . 4
4 3 5
M e
d i e n
b e r ü
h r e n
d e T e i l e : 1 . 4
4 3 5
G e
h ä u s e : M S v e r n i c k e
l t
S o u
f f l e t : 1 . 4
4 3 5
M a
t é r i e
l c o n t a c t . a v e c m é d i a s :
1 . 4
4 3 5
B o î t i e r :
l a i t o n n i c k e
l é
B e l l o w s : 1 . 4
4 3 5
M e
d i u m
c o n t a c t . p a r t s : 1 . 4
4 3 5
H o u s i n g :
b r a s s , n i c k e
l p
l a t .
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ÄNDERUNGEN VORBEHALTEN - SO US RÉS ERVE D E MOD IFICATIONS - SU BJECT TO C HANGE
FILE: H72253d DATE: 11/2003 PAGE: 3 (5) DATASHEET: 2.1.1.5
920/924/932DIFFERENTIAL PRESSURE PRESSOSTAT PD
SPECIFICATIONS
MAIN CHARACTERISTICS
Sensor: bellow Measuring range: -1...6 to -1...18 bar Differential pressure: -0.6...3.4 to1...16 bar Output: floating change-over contact Switching differential: not adjustableEN60730-1/ EN60730-2-9: Typ 2.B.H
ACCURACY (@ 20°C)
Repeatability sensor: ± 1.0 % FS typ.Scale accuracy: ± 2.0 % FS typ.Switiching differential: see table
MICROSWITCH
Rating: see tableResistance of insulation: > 2 MΩDielectric strength: 1.25 kV terminal groundLife time (mechanical)
Microswitch 10/11: 20 Mio. cyclesMicroswitch 21: 0.5 Mio. cycles
Microswitch 23/26: 0.3 Mio. cyclesELECTRICAL CONNECTION
Screwed cable gland: see accessoriesTerminal screw: 3 x 1.5...4 mm2
ENVIRONMENTAL CONDITIONS
Operating temperature: --20...+70°CMedia temperature -40...+150°CStorage temperature: -25...+85°CProtection: IP65Humidity: max.95 % relative
Vibration:5...25 Hz: ±1.6 mm25...100 Hz: 4g
Shock: 50g/ 11 msMECHANICAL DATA
MaterialSensor: see ordering informationHousing: AlSi10Mg/ Epoxy coatedSeal: NBRScrewed cable gland: brass nickel plated
Mounting torque: max. 25 NmInstallation: any position
Weight: ~ 610 g
SPEZIFIKATIONEN
HAUPTMERKMALE
Fühler: BalgMessbereich: -1...6 bis -1...18 bar Druckdifferenz: -0.6...3.4 bis 1...16 bar
Ausgang: potentialfreier Umschaltkontakt Schaltdifferenz: nicht einstellbar EN60730-1/ EN60730-2-9: Typ 2.B.H
GENAUIGKEIT (@ 20°C)
Reproduzierbarkeit Fühler: ± 1.0 % d.S. typ.Skalengenauigkeit: ± 2.0 % d.S. typ.Schaltdifferenz : siehe Tabelle
MIKROSCHALTER
Schaltleistung: siehe TabelleIsolationswiderstand: > 2 MΩSpannungsfestigkeit: 1.25 kV gegenüber MasseLebensdauer (mechanisch)
Mikroschalter 10/11: 20 Mio. LastspieleMikroschalter 21: 0.5 Mio. Lastspiele
Mikroschalter 23/26: 0.3 Mio. LastspieleELEKTRISCHER ANSCHLUSS
Kabelverschraubung: siehe Zubehör Schraubenklemmen: 3 x 1.5...4 mm2
UMGEBUNGSBEDINGUNGEN
Betriebstemperatur: -20...+70°CMedientemperatur: -40...+150°CLagertemperatur: -25...+85°CSchutzart: IP65Feuchtigkeit: max. 95 % relativ
Vibration:5...25 Hz: ±1.6 mm25...100 Hz: 4g
Schock: 50g/ 11msMECHANISCHE DATEN
MaterialFühler: siehe BestellinformationGehäuse: AlSi10Mg/ Epoxy beschichtet Dichtung: NBRKabelverschraubung: Messing vernickelt
Anziehdrehmoment: max. 25 NmEinbaulage: beliebigGewicht: ~ 610 g
SPÉCIFICATIONS
CARACTÈRES DISTINCTIFS
Capteur: soufflet Plage de mesure: -1...6 à -1...18 bar Press. différentielle: -0.6...3.4 à 1...16 bar Sortie: inverseur libre de potentielDifférentiel de l'interrupteur: non ajustableEN60730-1/ EN60730-2-9: Typ 2.B.H
PRÉCISION (@ 20°C)
Reproductibilité capteur: ± 1.0 % E.M. typ.Précision de l'échelle: ± 2.0 % E.M. typ.Différentiel de l'interrupteur: voir tableau
MICRORUPTEUR
Pouvoir de coupure: voir tableauRésistive d'isolation: > 2 MΩRigidité diélectrique: 1.25 kV contre la masseDurée de vie (mécanique)
Microrupteur 10/11: 20 Mio. cyclesMicrorupteur 21: 0.5 Mio. cycles
Microrupteur 23/26: 0.3 Mio. cyclesCONNECTION ÉLECTRIQUE
Passe-câble à vis: voir accessoiresBorne à vis: 3 x 1.5...4 mm2
CONDITIONS D'ENVIRONNEMENT
Température de service: --20...+70°CTempérature de médias: -40...+150°CTemp. de stockage: -25...+85°CProtection: IP65Humidité: max. 95 % relatif
Vibration:5...25 Hz: ±1.6 mm25...100 Hz: 4g
Choc: 50g/ 11 msSPÉCIFICATIONS MÉCANIQUES
MatiéreCapteur: voir information pour la commandeBoîtier: AlSi10Mg/ Vernis avec époxy
Joint: NBRPasse-câble à vis: laiton nickelé
Couple de serrage: max. 25 NmMontage: toute positionPoids: ~ 610 g
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FILE: H72253d DATE: 11/2003 PAGE: 4 (5) DATASHEET: 2.1.1.5
ELEKTRISCHE DATEN SCHALTER / SPÉCIFICATIONS ÉLECTRIQUES DE L'INTERRUPTEUR / ELECTRICAL DATA SWITCH
920/924/932DIFFERENTIAL PRESSURE PRESSOSTAT PD
-1...12
-1...18
0.20.40.524
Bereich/ Plage/ Range [bar]
Mikroschalter/ Microrupteur/ Microswitch
BalgfühlerCapteur soufflet
Bellows sensor
1011/21/23
26
-1...6
-1...8
0.080.160.2512
Schaltdifferenz [bar]: fester Wert, nicht einstellbar Différentiel de l’interrupteur [bar]: valeur fixe, non ajustableSwitching differential [bar]: fixed value, not adjustable
P max.
Schalter/ Interrupteur/ Switch 21/26Schalter/ Interrupteur/ Switch 10/11/23
Typ Merkmale Schaltleistung 4)
Type Caractéristiques Pouvoir de coupureType Features Rating
AC DC
10 Kleine Schaltdifferenz 125 V 10 (1.5) A 250 V 0.2 (0.02) A Interrupteur à petit différentiel 250 V 10 (1.25) A 125 V 0.4 (0.03) A Small switching differential 30 V 2 (1) A
14 V 15 (2.5) A
11 Mittlere SchaltdifferenzInterrupteur à moyen différentiel
Average switching differential
23 Erhöhte Vibrationsfestigkeit; mittlere Schaltdifferenz 125 V 15 (1.5) A 250 V0.25(0.03) A Résistance de vibration élevée; interrupteur à moyen différentiel 250 V 15 (1.5) A 125 V 0.5(0.05) A
Improved vibration resistance; average switching differential 500 V 10 (1.5) A 30 V 6 (1.5) A 26 Hohe Vibrationsfest igkeit; mitt lere Schaltdifferenz 14 V 15 (2.5) A
Résistance de vibration forte; interrupteur à moyen différentielHigh vibration resistance; average switching differential
21 Mit Goldkontakten, geeignet für eigensichere Schaltkreise 24 V 0.01(0.01)A 24 V0.01(0.01)A Avec contacts dorés, approprié aux circuits de côntrole à sécurité intrinsèque 12 V 1 (1.0) A 12 V 1.0 (1.0) A Gold plated contacts, suitable for intrinsically safe control circuits 5 V 2 (2.0) A 5 V 2.0 (2.0) A
4) Ohmsche Last ( Induktive Last)Charge ohmique (Charge inductive)Resist ive Load (Inductive Load)
SCHALTDIFFERENZ (typ.) / DIFFÉRENTIEL DE L’INTERRUPTEUR (typ.) / SWITCHING DIFFERENTIAL (typ.)
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ÄNDERUNGEN VORBEHALTEN - SOU S RÉS ERVE DE MODIFICATIO NS - SUBJECT TO CHANGE
FILE: H72253d DATE: 11/2003 PAGE: 5 (5) DATASHEET: 2.1.1.5
920/924/932DIFFERENTIAL PRESSURE PRESSOSTAT PD
MASSBILDER / COTES D'ENCOMBREMENT / DIMENSIONS
ZUBEHÖR / ACCESSOIRES / ACCESSORIES
XXX.XX.XX.XXX.XX.32PG16
XXX.XX.XX.XXX.XX.27M24x1.5
XXX.XX.XX.XXX.XX.40M18x1.5
BEFESTIGUNG / FIXATION / MOUNTING
XXX.XX.XX.XXX.31.XXTyp / Type 920 Typ / Type 924 Typ / Type 932
s i e h e D a t e n
b l a t t
X
v o i r s p é c i f i c a t i o n
2 . 1 . 2
0 . 1
s e e
d a t a s h e e t
A5/B5/D5 A6/B6/D6
G1/2"aussenmâlemale
G1/8"innen
femellefemale
G1/4"innen
femellefemale
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
9. Heating mediumcontrol
Type:
heating medium controlvalve (2/2-way) BR440
with drive CS20;
Y-strainer 2305000322;
float steam trap
CONA SC R14
Pos.: 9.1; 9.1.4; 9.2, 9.3
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Rev. 0040301000 3504 englisch
1.0 General information on operating
instructions ..................................................... 2
2.0 Notes on possible dangers............................ 2
2.1 Significance of symbols ..........................................2
2.2 Explanatory notes on safety information.................23.0 Storage and transport ................................... 2
4.0 Description...................................................... 3
4.1 Scope of applications..............................................3
4.2 Operating principles ................................................3
4.3 Diagram ..................................................................44.3.1 Plug design ........................................................5
4.4 Technical data .........................................................6
4.5 Marking ...................................................................6
5.0 Installation....................................................... 7
5.1 General notes on installation...................................7
5.2 Requirements at the place of installation ................85.3 Installation instructions concerning actuators .........8
6.0 Putting the valve into operation.................... 9
7.0 Care and maintenance................................... 9
7.1 Replacement of stem sealings ............................... 97.1.1 PTFE V-ring unit design..................................... 97.1.2 Stuffing box packing design ............................. 107.1.3 Bellows seal design .......................................... 11
7.2 Replacement of internal parts .............................. 127.2.1 Replacement of plug and stem ....................... 127.2.2 Replacement of seals of
pressure balanced plugs................................. 137.2.3 Replacement of the seat ring ........................... 13
7.3 Tightening torques................................................ 147.3.1 Tightening torques for .................................... 147.3.2 Tightening torques for seat rings ................... 14
8.0 Troubleshooting........................................... 14
9.0 Troubleshooting table ................................ 15
10.0 Dismantling the valve or the top part ...... 16
11.0 Warranty / Guarantee................................. 16
Contents
Operating and installation instructionsStraight through control valves - STEVI ® 440 / 441, 445 / 446
Series 440, 445 Series 441, 446
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1.0 General information on operating instructions
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.Information marked with the above symbol and “ ATTENTION ! ” describe practices, afailure to comply with which can result in serious injury or danger of death for users or thirdparties or in material damage to the system or the environment. It is vital to comply withthese practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damageto property.
3.0 Storage and transport
- At -20°C to +65°C.- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
ATTENTION !
. . . Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See catalog sheet for weights.
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4.0 Description
4.1 Scope of applicationsValves are used for „controlling the flow of liquids, gases and vapours in chemical and other processing plants and for plant engineering“.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
ARI control valves are especially suitable for actuation by pneumatic or electrical actuators.
Four plug types are available to suit the various applications:parabolic plug (standard)
perforated plugV-port plugpressure balanced plug
The flow through control valves is always against the closing direction.
In the case of control valves with perforated plugs, gases and vapours flow against theclosing directions, but liquids flow through in the closing direction. If a pneumatic actuator isto be used on a straight-way valve with a perforated plug with the fluid moving in the closingdirection, a higher closing force will be needed. This is to prevent vibration as the plugapproaches the closed position.
If the forces generated by the actuators are too low, arrangements should be made to
relieve the pressure as far as this is compatible with service conditions.
ATTENTION ! - Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from grey cast iron are not authorised for use in systems subject to TRD 110.
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4.3 Diagram
Fig. 1: Series 440 DN15-100 Fig. 2: Series 441 DN15-100
Fig. 3: Series 440 DN125-150
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4.3.1 Plug design
Fig. 4: Series 445 DN15-100(only stainless steel)
Fig. 5: Series 446 DN15-100(only stainless steel)
Fig. 6: Design with perforated plug Fig. 7: Design with V-port plug
(Design with pressure balanced plug refer to Fig. 16)
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5.0 Installation
5.1 General notes on installation
The following items should be taken into account besides the general principles governinginstallation work:
Planners / construction companies or operators are responsible for positioning and
installing products.
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces areavoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.Refer to data sheet for weights.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Strainers or filters should be installed before the valves.
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5.2 Requirements at the place of installation
The place of installation should be easily accessible and provide ample space for maintenance and removing the actuator. Stop valves should be installed before and after the control valve to enable maintenance working without draining the piping system. Thevalve should preferably installed vertically with the actuator at the top. Inclined or horizontal
installation without supports is permissible only with light actuators.For this installation position, the two distance columns (or joke) have to be above eachother in the vertical plane.
Permissible actuator weights for valves with unsupported horizontal stems:
20 kg for DN 15 - 3225 kg for DN 40 - 6535 kg for DN 80-100
The pipes must be lagged to protect the actuators from excessive heat. Sufficient spacemust be left for the maintenance of the stem packing.
To ensure that the control valves function correctly, the pipe run should be straight for atleast 2 x n.d. upstream and 6 x n.d. downstream of the valve.
5.3 Installation instructions concerning actuators
Normally, control valves are supplied complete with actuator fitted.It is not permitted to mantle / dismantle actuators with valves operating and serviceconditions (temperature and pressure). The actuators must be assemble as describe in theoperating instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seating at closing pressure.
When retrofitting actuators, the maximum permissible force for valve actuation must betaken into account:
Fig. 9: Pipeline vertically Fig. 10: Pipeline horizontally
ATTENTION !
Care must be taken with the bellow type valves when actuators are mounted or
removed. (Hold the valve-stem against turning with an open-end wrench!)
Series 440 / 445 Series 441 / 446
12kN for DN 15- 50 18kN for DN 15-100
29kN for DN 65-100
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6.0 Putting the valve into operation
7.0 Care and maintenance
Maintenance and maintenance intervals have to be defined by the operator according tothe service conditions.
7.1 Replacement of stem sealings
7.1.1 PTFE V-ring unit design
PTFE V-ring unit (pos. 12) consisting of:1 backing ring4 sealing rings1 cover ring
Owing to the installed compression spring (pos. 15), thisstem packing is self-adjusting. If the stem starts leaking,the ring pack is worn out and must be replaced.
Replacement of PTFE V-ring units:
- Remove actuator.(Refer to operating instructions for actuator!)
- When replacing PTFE V-ring unit (pos. 12), make surethat the parts are installed in the correct order andpositions (refer to Fig. 11).
- Gasket (pos. 17) must be replaced.
Damaged stems must also be replaced (refer to item 7.2for instructions) since a new ring pack will soon startleaking again if the stem is damaged.
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
ATTENTION !
Refer to item 10.0 and 11.0 beforedismantling the valve.
Fig. 11:
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7.1.2 Stuffing box packing design
- The stuffing box packing (pos. 23) requires maintenance.
- If leaks develop, immediately tighten the screw joint (pos. 25) gradually until the packing(pos. 23) stops leaking.
- The service life of stuffing box packings (pos. 23) can be increased by checking regularlyleakage.
- If leaks can no longer be stopped by tightening the screw joint (pos. 25), a new packingring (pos. 23) must be inserted into the gland.
Replacement of stuffing box packings:
- Remove actuator. (Refer to operating instructions for actuator!)
- Insert new packing ring as shown in Fig. 12 - Fig. 13.
Damaged stems must also be replaced (refer to item 7.2 for instructions) since a new ringpack will soon start leaking again if the stem is damaged.
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
Fig. 12: Stuffing box packing
Fig. 13: Split packing ring
If a split packing ring is used, cut with a chamfer as shown in Fig. 13.
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7.1.3 Bellows seal design
If the stem leaks, the bellows seal (pos. 20.3) is defective. The leak can initially be stoppedby tightening the screw joint (pos. 20.17).
Stem and bellows (pos. 20.3) can only be replaced together.
Replacement of bellows seals:
- Remove actuator.(Refer to operating instructions for actuator!)
- Loose nuts (pos. 11).
- Detach bellows assembly (pos. 20).
- Slacken screw joint (pos. 20.17) by about one turn.
- Press stem/bellows unit (pos. 20.3) down.
- Drive pin (pos. 4) out with a drift.
- Unscrew plug (pos. 3).
- Loose nuts (pos. 20.8).
- Detach mounting bonnet (pos. 20.2).
- Extract stem/bellows unit (pos. 20.3) from thebellows housing (pos. 20.1).
- Bolt new parts together and drill them.
- Replace 2 gaskets (pos. 20.6) and 1 gasket (pos. 9).- Assemble in reverse order.
- Secure with nuts (pos. 10 u. 20.8) and tighten themcrosswise.(For tightening torques refer to item 7.3.1)
- Tighten screw joint (pos. 20.17) gradually up totightness of the stuffing box packing (pos. 20.10).
ATTENTION !
Refer to item 10.0 and 11.0 beforedismantling the valve.
Fig. 14: Series 441/446
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7.2 Replacement of internal parts
7.2.1 Replacement of plug and stem
- Remove actuator.(Refer to operating instructions for actuator!)
Series 440/445:
- Loose nuts (pos. 11).- Detach mounting bonnet (pos. 7).
- Slacken screw joint (pos. 19 or 25) by about 1 turn.
- DN15-100: Extract plug/stem assembly (pos. 3).
- DN125-150: Extract plug (pos. 3) and stem (pos. 5).
- DN125-150: Drive pin (pos. 4) out with a drift.
- DN125-150: Unscrew plug (pos. 3).
- DN125-150: Bolt new parts together, drill and pin them.
- Replace gasket (pos. 9).
- Assemble in reverse order.
- Secure with nuts (pos. 11) and tighten them crosswise.(For tightening torques refer to item 7.3.1.)
Series 441/446:
For replacement of plug and stem with bellows sealing (Series 441/446) refer to item 7.1.3.
ATTENTION !
Refer to item 10.0 and 11.0 before
dismantling the valve.
Fig. 15: Series 440 / 445DN15-100
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7.2.2 Replacement of seals of pressure balanced plugs
- Remove actuator.
(Refer to operating instructions for actuator!)- Remove plug as described in item 7.2.
- Prise worn piston seal (pos. 32) out of groove inplug with suitable tool (e.g. screwdriver).
- Insert new piston seal (pos. 32), taking care thatit is in the correct position (refer to Fig. 16).
- Replace guide ring (pos. 31).- Clean sliding surface of guide bush (pos. 30);
smooth with fine abrasive if necessary.
- Replace 2 gaskets (pos. 9).- Assemble in reverse order.
- Secure with nuts (pos. 11) and tighten themcrosswise.(For tightening torques refer to item 7.3.1.)
7.2.3 Replacement of the seat ring
Only with control valves series 445 / 446 the seat ring is screwed in.
- Remove actuator. (Refer to operating instruction for actuator!)
- Loose nuts (pos. 11).
- Detach valve top part.
- Unscrew seat ring (pos. 2) with a special wrench (can be obtained from the manufacturer).
- Clean thread and sealing taper in body (pos. 1) and apply with suitable lubricant.
- Replace respectively recondition seat ring (pos. 2).
- Install seat ring (pos. 2). (For tightening torques refer to item 7.3.2.)
- Replace gasket (pos. 9).
- Assemble valve top part.
- Secure with nuts (pos. 11) and tighten them crosswise.(For tightening torques refer to item 7.3.1.)
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
Fig. 16: Pressure balanced plug
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7.3 Tightening torques
7.3.1 Tightening torques for
7.3.2 Tightening torques for seat rings
! Refer to operating instructions for actuator concerned for
installing actuators !
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
M 10 = 15 - 30 Nm
M 12 = 35 - 50 Nm
M 16 = 80 - 120 Nm
DN 15/ 20 = 100 NmDN 25/ 32 = 150 NmDN 40/ 50 = 350 NmDN 65 = 480 NmDN 80 = 660 NmDN100 = 980 Nm
-
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
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9.0 Troubleshooting table
ATTENTION !
- read item 10.0 and 11.0 prior to dismantling and repair work! - read item 6.0 before restarting the plant !
Fault Possible cause Corrective measures
No flow Valve closed. Open valve (using actuator).
Flange covers not removed. Remove flange covers.
Little flow Valve not sufficiently open. Open valve (using actuator).
Dirt sieve clogged. Clean / replace sieve.
Piping system clogged. Check piping system.
Kvs value of valve unsuitable. Fit valve with higher Kvs value.
Valve stem moves in jerks. Stuffing box sealing too tight
(for valves with graphite packings).
Slacken screw joint (pos. 25/20.17)
slightly. Valve must nor start leaking!Valve plug slightly seized owing tosolid dirt particles.
Clean internals, smooth rough spots.
Valve stem or plug cannot bemoved.
Seating and plug clogged with dirt;especially with V-port and perforatedplugs.
Clean seating and plug with suitablesolvent.
Valve plug seized in seating or guideowing to deposits or dirt in medium.
Replace plug and seating; use partsmade from different material if neces-sary.
Valve stem leaking. PTFE V-ring unit damaged or worn. Replace ring pack (pos. 12);refer to item 7.1.1
Stuffing box gland too slack in valveswith stuffing box packings.
Tighten screw joint (pos. 25);refer to item 7.1.2.
Bellows defective in valves with bellowseal.
Replace bellows unit;refer to item 7.1.3
Leakage too high whenvalve is closed.
Sealing surfaces of plug eroded or worn.
Replace plug;refer to item 7.2.1.
Sealing edge of seating damages or worn.
Replace seating(only at Series 445/446); refer to item7.2.3, fit strainer if necessary.
Piston sealing ring worn (pressure-
relieved valves).
Replace sealing ring;
refer to item 7.2.2Seating and/or plug dirty. Clean internals of valve;
fit dirt sieve if necessary.
Pneumatic actuator not completelyvented; spring force not fully effective.
Vent actuator air chamber completely.
Actuator not powerful enough. Install more powerful actuator.Check service data.
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10.0 Dismantling the valve or the top part
11.0 Warranty / Guarantee
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.The warranty shall not cover maintenance work, installation of external parts, designmodifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
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Rev. 0040101000 2103 englisch
1.0 General information on operating
instructions ...................................................22.0 Notes on possible dangers.......................... 2
2.1 Significance of symbols ........................................2
2.2 Explanatory notes on safety information...............2
3.0 Storage and transport ................................. 2
4.0 Description.................................................... 34.1 Scope of applications............................................3
4.2 Operating principles ..............................................3
4.3 Diagram.................................................................4
4.4 Technical data - remarks.......................................4
4.5 Marking .................................................................5
5.0 Installation..................................................... 65.1 General notes on installation.................................6
5.2 Installing valves with butt weld ends .....................6
6.0 Putting the valve into operation ..................7
7.0 Care and maintenance..................................78.0 Troubleshooting............................................8
9.0 Troubleshooting table ..................................8
10.0 Dismantling the valve or the top part .......9
11.0 Warranty / Guarantee ..................................9
Operating and installation instructionsStrainer
Contents
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Strainer
1.0 General information on operating instructions
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ ATTENTION !” describe practices, a failureto comply with which can result in serious injury or danger of death for users or third partiesor in material damage to the system or the environment. It is vital to comply with thesepractices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damageto property.
3.0 Storage and transport
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Donot damage paint protection.
ATTENTION !
. . . Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See catalog sheet for weights.
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Strainer
4.0 Description
4.1 Scope of applications
Strainers are used for "cleanin flowing mediums“.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
The medium flows through the strainer screen in the direction shown on the strainer and isthereby cleaned.
ATTENTION ! - Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD110.
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4.3 Diagram
Refer to the data sheet for information about materials with designations and figurenumbers.
4.4 Technical data - remarks
for
- Principal dimensions
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
fig. 1: Strainer - Y fig. 2: Strainer - Y SE
fig. 3: Strainer - Y (1.4408)
rotatedview
rotatedview
rotated
view
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4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Manufacturer
Typ Type
Bj. Year of manufacture
According to the Pressure Equipment Directive appendix 2 diagram 6 valves withoutsafety function are only allowed to bear the CE-marking DN32 onwards.
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5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governinginstallation work:
- Planners / construction companies or operators are responsible for positioning andinstalling products.
5.2 Installing valves with butt weld ends
Please note that only qualified persons using appropriate equipment and working inaccordance with technical rules are allowed to install fittings by welding.The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces areavoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See data sheet for weights.
- Leave sufficient space to remove the screen basket during installation in pipelines.
- Make sure that the trap is installed to suit the direction of flow.
- Installation position:
a) The screen basket should never be at the top, otherwise the dirt will fall back into the pipe.
b) If water hammer is possible due to condensation in steam lines,never install the trap with the screen basket at the bottom, but install it so that it is horizontal.
- Centre gaskets between the flanges.
- Install compensators to compensate for thermal expansion of the piping.
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6.0 Putting the valve into operation
7.0 Care and maintenance
Maintenance and maintenance-intervals have to be defined by the operator according tothe requirements.
- If necessary, the strainer can be fitted with an additional start-up filter (e.g. filter withsupporting cage) to start up the system.Depending on the degree of dirt accumulation in the system, the filter must be cleanedafter a system-specific number of service hours.
- Flush the plant thoroughly before starting it.
- The strainer requires little maintenance.
- Strainers must be cleaned when clogging becomes apparent.General rules concerning cleaning intervals cannot be given because plants varyconsiderably in their characteristics.
- Before reassembling the unit, remember that the bearing surface must be cleaned and anew gasket (6) must be inserted.
- Set the strainer cover in place.
- Tighten the cover bolts evenly crosswise.
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
ATTENTION !
Refer to point 11.0 before dismantling the valve.
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Tightening torque‘s for hexagon nuts / bolts:
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
9.0 Troubleshooting table
DNhexagon nuts /
boltsTorque(Nm)
15- 32 M 10 20-35
40 M 12 20-35
50- 65 M 12 60-80
80-150 M 16 100-125
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
-
ATTENTION !
It is essential that the safety regulations are observed when identifying faults.
ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work! - read point 6.0 before restarting the plant !
Fault Possible cause Corrective measures
No flow Flange covers have not been removed
(7, Fig. 3, page 4)
Remove flange covers
(7, Fig. 3, page 4)
Flow too low strainer clogged. Clean/replace screen.
Piping clogged. Check piping system.
Flange broken between
unit and pipingBolts tightened unevenly.Mating flanges not properly aligned.
Re-align piping and fit new valve!
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10.0 Dismantling the valve or the top part
11.0 Warranty / Guarantee
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.The warranty shall not cover maintenance work, installation of external parts, designmodifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
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1.0 General information on operatinginstructions.................................................... 2
2.0 Notes on possible dangers............................ 2
2.1 Significance of symbols ..........................................22.2 Explanatory notes on safety information .................2
3.0 Storage and transport ................................... 2
4.0 Description...................................................... 3
4.1 Scope of applications..............................................3
4.2 Operating principles ................................................3
4.3 Diagram...................................................................4
4.4 Technical data - remarks .........................................5
4.5 Marking ...................................................................5
5.0 Installation....................................................... 5
5.1 General notes on installation...................................5
5.2 Installation instructions for welding .........................6
5.3 Controller adjustment ..............................................6
5.4 Steam trap testing through ultrasonic
measurement...........................................................6
5.5 Installation position..................................................6
5.5.1 Possible installation positions .................. 7
6.0 Putting the valve into operation ................... 7
7.0 Care and maintenance................................... 8
7.1 Cleaning/replacing controller assembly.................. 87.2 Changing the installation position........................... 9
7.3 Options ................................................................. 10
7.4 Function testing of diaphragm capsule................. 10
7.5 Tightening torques.................................................11
8.0 Troubleshooting............................................11
9.0 Troubleshooting table ................................. 12
10.0 Dismantling the valve or the body ........... 13
11.0 Warranty / Guarantee................................. 13
Operating and installation instructionsBall float steam traps
CONA®SC (PN16 - 25)
Contents
with capsule for rapid system start-up
PN16 / PN25- with flanges (series 634....1)
- with screwed sockets (series 634....2)
- with socket weld ends (series 634....3)
- with butt weld ends (series 634....4)
for drainage of water from compressed air and gas systems
PN16 / PN25- with flanges (series 636....1)
- with screwed sockets (series 636....2)
- with socket weld ends (series 636....3)
- with butt weld ends (series 636....4)
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CONA ® SC - Ball float steam traps
1.0 General information on operating instructions
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these operating and installation instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ ATTENTION ! ” describe practices, afailure to comply with which can result in serious injury or danger of death for users or thirdparties or in material damage to the system or the environment. It is vital to comply withthese practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damageto property.
3.0 Storage and transport
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage.Do not damage paint protection.
ATTENTION !
. . . Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valves must not be used to take external forces, e.g. they are not designed for use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See catalog sheet for weights.
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CONA ® SC - Ball float steam traps
4.0 Description
4.1 Scope of applications
Series 634: Float-type steam traps with level- and thermal control are used for the drainageof steam facilities.
Series 636: Float-type steam traps with level control are used for the drainage of systems f
with compressed air or aqueous gases.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
(refer to Fig. 4 page 9)
The steam trap is controlled by a swivel-mounted ball float (Pos. 24.16).If condensate is flowing towards the steam trap, the ball float (Pos. 24.16) rises and opensthe discharge valve using the lever mechanism.
In series 634 only (version with diaphragm capsule): An intercoupled diaphragm capsule (Pos. 24.17) ensures automatic start-up air ventingwhen cold.
If the amount of condensate decreases or if there is no condensate, the float ball(Pos. 24.16) falls and shuts the discharge valve.
The compact float ball (Pos. 24.16) exerts level-dependent control on the valve ball
(Pos. 24.4) by means of a lever mechanism. As the level of condensate rises, the valve ball(Pos. 24.4) is rolled off the valve bore by the lever mechanism, thus opening the valve. Thecondensate can now drain away.If the amount of inflowing condensate is less than the possible valve output or if there is nocondensate flow, the ball float (Pos. 24.16) falls and the valve ball (Pos. 24.4) rolls backonto the valve bore. The valve is now closed.
If the steam trap is only acted upon by gas, the float ball (Pos. 24.16) remains in equilibrium,the valve stays shut.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD110.
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CONA ® SC - Ball float steam traps
4.3 Diagram
Refer to the data sheet for information about materials with designations and figure numbers.
Fig. 1: CONA ® SC - series 634 PN16-25DN15-25
Fig. 2: CONA ® SC - series 636 PN16-25DN15-25
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4.4 Technical data - remarks
for
- Principal dimensions,
- Pressure-temperature-ratings, operating limits,
- Valves with different types of connection , etc.refer to datasheet.
4.5 Marking
5.0 Installation5.1 General notes on installation
The following points should be taken into account besides the general principles governinginstallation work:
- Planners / construction companies or operators are responsible for positioning andinstalling products.
Manufacturer
Typ Type
Bj. Year of manufacture
According to the Pressure Equipment Directive appendix 2 diagram 7 valves acc. to article1 paragraph 2.1.2 (pipes) only show the CE-marking from DN40 onwards.
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- The ball float steam trap may be installed for vertical or horizontal flow. Noteinstallation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valves must not be used to take external forces, e.g. they are not designed for use as climbing aids, or as connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See data sheet for weights.
- Centre gaskets between the flanges.- Precautions against freezing should be taken as a matter of course in any facilities susceptible to frost. If a system not in operation is in a positionsusceptible to freezing, we recommend that the drain plug (Pos. 50) on theunpressurised steam trap be unscrewed, the residual condensate drained off,the seal faces cleaned and the plug screwed down again.The sealing ring (Pos. 49) should be replaced if necessary.(see Fig. 2 page 4 and item 7.3).
AWH
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5.2 Installation instructions for welding
(refer to Fig. 1 page 4)
Please note that only qualified persons using appropriate equipment and working inaccordance with technical rules are allowed to install fittings by welding.The responsibility for this lies with the system owner.
Please refer to the catalogue sheet for information on type and instructions relating towelding socket weld ends/butt weld ends.
When welding products to the pipeline system they should be adequately cooled to preventany adverse effect on the complete controller assembly (Pos. 24) or the flat gasket(Pos. 17). The heat-affected zone should be restricted to the immediate weld seam area!Note pre- and post-welding heat treatment in accordance with Material Fact SheetDIN EN 10222.
If there are plans to acid clean the facility before putting it into operation, the controllers(Pos. 24) should be dismantled completely, replaced by acid cleaning inserts, and reassembledafter
acid cleaning (refer to 7.1). In such an event please contact the manufacturer.
5.3 Controller adjustment
The controller is manufactured in 3 pressure stages and is not adjustable.
5.4 Steam trap testing through ultrasonic measurement
Testing the operation of the steam trap in the installed state is straightforward with the“SONACON” function tester.
Refer to data sheet „CONA further components / accessories “.
5.5 Installation position
(refer to Fig. 3 page 7 and Fig. 4 - Fig. 5 page 9)
The float steam trap can be installed for vertical or horizontal flow. This should be statedwhen ordering.If the installation position is not stated it will be supplied for vertical flow (L->R).
It is possible to change the installation position at a later stage (see 7.2).
However, the controller (Pos. 24) must always be installed so that the ball float (Pos. 24.16)operates in a vertical plane.
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CONA ® SC - Ball float steam traps
5.5.1 Possible installation positions
6.0 Putting the valve into operation
Fig. 3
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
Horizontal installation:
Horizontal installation:Vertical installation (standard):Inlet from the top
Inlet from the left side (ZL)
Inlet from the right side (ZR)
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7.0 Care and maintenance
Maintanance and maintenance-intervals have to be defined by the operator according tothe requirements.
7.1 Cleaning / replacing controller assembly
(refer to Fig. 1 - Fig. 2 page 4 and Fig. 4 - Fig. 5 page 9)
- Dismantle hood (Pos. 16) by slackening cheese-head screw (Pos. 27).
- Remove dirt from body (Pos. 1) and hood (Pos. 16); tiny dirt particles can be removed byflushing out the ducts and rinsing the body (Pos. 1).
- If necessary dismantle the float controller (Pos. 24) and clean separately or change floatcontroller.
- Unscrew the hollow-core screw (Pos. 24.10) of the float controller (Pos. 24) from the body(Pos. 1).
- Pull complete float controller (Pos. 24) out to remove, taking care with the sealing ring(Pos. 11).
- Check lifting force of ball float (Pos. 24.16) by immersing the whole controller (Pos. 24) ina water bath. When immersed in the water bath the ball float (Pos. 24.16) must float to the
top. If the ball float (Pos. 24.16) sinks (i.e. goes under) the complete controller (Pos 24)should be replaced!
Series 634 version with diaphragm capsule only:
- Pull spring clip (Pos. 24.18) off radially and remove diaphragm capsule (Pos. 24.17) fromseat (Pos. 24.19).
- Clean and inspect diaphragm capsule (Pos. 24.17) (see 7.4).
- Form-fit diaphragm capsule (Pos. 24.17) to seat (Pos. 24.19) and push the spring clip(Pos. 24.18) radially into slot of seat (Pos. 24.19), at the same time pushing the twoangled ends of the spring clip legs (Pos. 24.18) onto the diaphragm capsule (Pos. 24.17).
- Replace the sealing rings (Pos. 17 and Pos. 11).
- Assemble in reverse order (see 7.5).
ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work! - refer to item 6.0 before restarting the plant!
Prior to installation, threads and seal faces should be coated with temperature-stable lubricant (e.g. “OKS Anti-Seize Paste” white/metal-free for PN16-40 or “Rivolta” lubricant and parting agent silver for PN63 onwards).
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7.2 Changing the installation position
(see Fig. 1 page 4 - Fig. 2 page 4 and Fig. 3 page 7)
- Position body (Pos. 1) as desired, bearing in mind the direction of flow.
- Remove hood (Pos 16), then slacken hollow-core screw (Pos. 24.10) approximately1/2 turn.
- Rotate controller (Pos. 24) 90° in the direction required.
- Always fit controller (Pos. 24) so that the ball float (Pos. 24.16) can work in the verticalplane.
- Tighten hollow-core screw (Pos. 24.10).
- Inspect and if necessary replace body seal (Pos. 17).
- Put on hood (Pos. 16) with drain plug (Pos. 50) pointing down.
- Fit hexagon nuts (Pos. 28) (see 7.5) and tighten crosswise.
Fig. 4: Controller series 634, cpl. Fig. 5: Controller series 636, cpl.
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7.3 Options
(refer to Fig. 2 page 4 and Fig. 6 page 10)
7.4 Function testing of diaphragm capsule
With a dry, cold diaphragm capsule the diaphragm surface with the circular bead must restagainst the top part of the wall (with 3 knobs), capsule is open (see Fig. 7).
If it rests against the bottom part of the wall, this is a sign that it is defective and must bereplaced with a new diaphragm capsule (see Fig. 8).It should also be replaced if there are visible deformations on the surface.
ATTENTION !
Escape of hot medium under pressure!
Observe item 2.2!
Accumulated inert gases can be discharged to theenvironment with the manual air vent valve (Pos. 51) byopening the pressure screw (Pos 51.1).
It is possible to return the accumulating gases to the system byconnecting a pressure compensation line to the union(Pos. 52).
In Series 634 the residual condensate can be drained by wayof the drain plug (Pos. 50) (see 5.1) (standard in Series 636).
Accumulated dirt and condensate can also be removed fromthe hood (Pos. 16) using a ball valve (Pos. 56).
During operation it is imperative to observe general workingsafety conditions and possibly fit devices to guard againstscalding/injury.
Note section 7.5 when installing and operating the option.
Fig. 6
Fig. 7: Capsule OPEN Fig. 8: Capsule CLOSED
top part of wall
bottom part of walldiaphragm surface
capsule type
top part of wall
bottom part of walldiaphragm surface
capsule type
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7.5 Tightening torques
(refer to Fig. 1 page 4 - Fig. 6 page 10)
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
Pos. CONA SC PN16-25Torque (Nm)
DN15-25
24 Controller 6027 Cheese head screw M10 15
47 Plug 50
50 Plug 50
51 Manual ari vent valve 50
51.1 Pressure screw 30
52 Union for pressur compension line 50
56 Ball valve for blow down valve 50
-
ATTENTION !
It is essential that the safety regulations are observed when identifying faults.
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Page 12 Rev. 0040805003 2404
Operating and installation instructions
CONA ® SC - Ball float steam traps
9.0 Troubleshooting table
ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work! - refer to item 6.0 before restarting the plant!
Fault Possible cause Corrective measures
No flow Installed in wrong flow direction Fit valve in direction of flow arrow.
Note installation position
Check lifting force; refer to item 5.5.1!
Flange covers not removed Remove flange covers
Ball float (Pos. 24.16) defective Note installation position;
refer to item 7.1
Reduced flow Wrong installation position Note installation position;
refer to item 5.5.1
Correct installation position;
refer to item 7.2Strainer clogged (Pos. 2) Clean strainer; refer to item 7.1
Piping system clogged Check piping system
Excessive amount of inert gases in
system
Use pressure compensation line option;
refer to item 7.3
No closure, or internal
leakage
Controller clogged Clean strainer and controller; refer to
item 7.1
Controller worn out Change controller; refer to item 7.1
Controller incorrectly screwed into body Check seal face between body and
controller, tighten controller correctly;
refer to item 7.5
Controller operated above safe operatingpressure
Observe operating limits as per datasheet, i.e. possibly select different
controller
External leakage Hood (Pos. 16) not properly tightened
with cheese-head screw (Pos. 27)
Tighten; refer to item 7.5
Flat gasket (Pos. 17) defective Replace sealing;
refer to item 7.1
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Rev. 0040805003 2404 Page 13
Operating and installation instructions
CONA ® SC - Ball float steam traps
10.0 Dismantling the valve or the body
11.0 Warranty / Guarantee
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacementdelivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.- Plant must be drained.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
10. Valves
Change over valve,
ball valves,shut-off valves,
non-return valves,
safety valves
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Change over valve
Type: 776, manualoperated
Pos.: 10.1
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-1-
Documentation
-Englisch-
Date: 04.06.2004
List of contents
Destignation Page
Data sheet 3-way compact ball valve type 776St 2
Assembly drawing 3-way compact ball valve with limit switch 3
Data sheets limit switch type tiny 4 - 5
General maintenance for compact ball valve 6
Operating instructions for ball valves 7 - 9
Pressure-Temperature Rating for ball valves serie 7xx 10
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3-way compact ball valve
steel with L-bore Art. 776St
Technical data
Connection: DIN-flangeDiameters size: DN15 up to DN100
Pressure range: PN16Temperature range: -20°C up to +160°C
(depending from working pressure)Application: Chemical-Refinery-Shipbuilding-Plant factory
for media: Water, Oils, Fuels, etc.
Design features:
y TA-Luft certificated y Reduced bore
y 2 ball seats y ISO-bore for automation T-bore (optional)
e More information on your inquiry!
Dimensions in mm
Pos. Benennung Description Materials Piece
1 Gehäuse Body ASTM A105 1
2 Ring End connection ASTM A105 1
3 Kugel Ball INOX AISI 304 1
4 Kugeldichtung Ball seat PTFE (Teflon) 2
5 O-Ring O-ring FKM (Viton) 1
6 Spindelscheibe Thrust washer PTFE (Teflon) 1
7 O-Ring O-ring FKM (Viton) 1
8 Spindichtung Stem seat PTFE (Teflon) 1
9 Vorspannring Packing gland AVP-9SMNPb36 110 Anschlagscheibe End stop INOX AISI 430 (DN15-50) UNI 7070(DN65-100) 2 1
11 Tellerfeder Spring washer UNI 3545 2
12 Mutter Nut UNI 5771 2
13 Spindel Stem INOX AISI 304 1
14 Handhebel Handle UNI 7070 1
15 Flansch Flange ASTM A105 1
DN X Y Z I L R P A C T G M D S E F N B PN Kg
15 89 65 4xM12 20 40 131,5 64,5 47 15,5 9 95 4xØ14 10 76 10 7 32 4xM5 16 2,23
20 99 75 4xM12 20 40 131,5 67 49,5 13,5 9 105 4xØ14 15 82 10 7 32 4xM5 16 2,86
25 109 85 4xM12 23 46 174,5 79 59 18 12,5 115 4xØ14 20 86 12 8 42 4xM5 16 3,89
32 130 100 4xM16 29 58 174,5 84 64 15,5 11,5 140 4xØ18 25 100 12 8 42 4xM5 16 6,21
40 140 110 4xM16 35,5 71 250,5 102,5 78 24,5 13 150 4xØ18 32 105 16 10 50 4xM6 16 8,50
50 160 125 4xM16 41 82 250,5 109 85 25 13,5 165 4xØ18 40 115 16 10 50 4xM6 16 12,27
65 180 145 4xM16 53 106 321,5 128 104,5 28 18 185 4xØ18 50,2 125 20 14 70 4xM8 16 19,10
80 200 160 8xM16 61 122 321,5 136,5 113 28 18 200 8xØ18 64 150 20 14 70 4xM8 16 24,34
100 220 180 8xM16 76 152 381,5 155,5 136 34,5 22 220 8xØ18 76 159 24 18 102 4xM10 16 38,45
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Plastic-bodiedcompact limit switches
Tiny Ti2
Compact designProtection class IP 65Mounting measurements according toDIN EN 50047Hinged snap lid
l Compact switches for safety or controlapplications in protection class IP 65
l 3 different contact configurationsavailable as slow-action or snap-actiondevices
l Positive break pl Two channel safety monitoring possiblel Galvanically isolated terminals, type Zbl Approvals UL, CSA, BGl Cable entries M 16 x 1.5l 4 screw terminals M3.5 with self-lifting
clampsl PBT enclosure, fiberglass reinforced, self-
extinguishing UL 94-V0l Lid, PA 6.6 UL 94-V0l 2 mm contact opening of slow-action
system according to EN 81-1 for lift con-
structionl Actuator mounting in 4 x 90°
M4
M5
(0.91")23
(0.87")22
( 0 .
2 2 " )
5 .
5
( 0
. 0 8 " )
2
(
0 . 1
6 " )
4
Mountinga) adjustable mounting with two M4
screws (22 mm centres)
b) fixed positioning with two M5 screws(23 mm centres) for safety applications
The switching system for C2 and Ti2l Small hysteresis on the snap-action
systeml Large variety of contact functionsl Optimized size utilising proven terminal
technologyl Snap-action type prevents undefined
status even with very slow actuation
Slow-action device
Snap-action device
q
Contact configuration
Switching element Switch function Switch contact Designation Voltage Continuous current
Slow-action changeover 1NC/1NO U1Z 250 V 10 ASnap-action changeover 1NC/1NO SU1Z 250 V 10 A
Slow-action normally-closed 2NC A2Z 250 V 10 A
Snap-action normally-closed 2NC SA2Z 250 V 10 A
Slow-action normally-open 2NO E2 250 V 10 A
Snap-action normally-open 2NO SE2 250 V 10 A
-4-
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Ti2-U1Z w
p Zb
l /–
w
250 V AC
10 A
l
100/min.
3 x 106
–30 °C/+80 °C
–22 °F/+176 °F
UL, CSA
BG
0.04 kg
l /–
Ti2-SU1Z w
p Zb
–/ l
w
250 V AC
10 A
l
100/min.
3 x 106
–30 °C/+80 °C
–22 °F/+176 °F
UL, CSA
BG
0.04 kg
l /–
23 24
11 12 13 14
21 22
Ti2-A2Z w
p Zb
l /–
w
250 V AC
10 A
l
100/min.
3 x 106
–30 °C/+80 °C
–22 °F/+176 °F
UL, CSA
BG
0.04 kg
l /–
Ti2-U1Z Riw
p Zb
l /–
iw
250 V AC
10 A
l
100/min.
3 x 106
–30 °C/+80 °C
–22 °F/+176 °F
UL, CSA
BG
0.05 kg
l /–
Ti2-SU1Z Riw
p Zb
–/ l
iw
250 V AC
10 A
l
100/min.
3 x 106
–30 °C/+80 °C
–22 °F/+176 °F
UL, CSA
BG
0.05 kg
l /–
Ti2-A2Z Riw
p Zb
l /–
iw
250 V AC
10 A
l
100/min.
3 x 106
–30 °C/+80 °C
–22 °F/+176 °F
UL, CSA
BG
0.05 kg
l /–
11 12
21 22 23 24
11 12 13 14
21 22
11 12
21 22
11 12
21 22 23 24
13 14
23 24
13 14
Plastic-bodiedcompact limit switches
Tiny Ti2
Compact designProtection class IP 65Mounting measurements according toDIN EN 50047Hinged snap lid
Dimensions
All dimensions in mm
Designation
Switching diagram
p positive break according toIEC 947-5-1 Chap. 3
Za: changeover contact is not galvanically isolated
Zb: changeover contact is galvanically isolated
Slow-action contact/snap-action contact
Gasket inside (iw)/outside (w)
Voltage max.
Continuous current max.
Making current, acc. to IEC 947-5-1 AC 15/DC 13
Switching frequency max.
Mech. operational life – number of switching cycles
Ambient temperature min./max.
Approvals
Weight
Delivery: ex-stock/built to order
Contact travel mmTol. ± 0.25 mm
Switching angledegree
Tol. ± 3.5°
Actuating torque NcmTol. ± 10%
Actuating force NTol. ± 10%
In Out
Further switching functions
SA2 E2 SE2
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W O R K S
H E E T
P O S . D E S C R
I P T I O N
G e n e r a l m
a i n t e n a n c e f o r v a l v e s W A F E R
1
B o d y
O p e r a t i o n
1 : L o o s e n t h e n u t ( d e t a i l 2 )
2
E n d c o n
n e c t i o n
O p e r a t i o n
2 : T a k e f u l l y o f f t h e b a l l ( d e t a
i l 3 )
3
B a l l
O p e r a t i o n
3 : T a k e t h e n u t s o f f ( d e t a i l 1 2
) s o a s
4
B a l l s e a
t
T o p u l l t h e s t e m
o u t
5
O - r i n g
O p e r a t i o n
4 : P r o c e e d t o t h e s u b s t i t u t i o n
o f t h e
6
T h r u s t w
a s h e r
F o l l o w i n g d e t a i l s : 4 - 5 - 6 - 7 - 8
7
O - r i n g
O p e r a t i o n
5 : C l e a n t h e b o d y ,
t h e b a l l , t h e s t e m
a n d
8
S t e m s e
a t
T h e e n d c o n n e c t i o n ( d e t a i l s 1 - 3 - 1 3 - 2 )
9
P a k i n g g l a n d
B e f o r e r e a s s e m b l i n g t h e v a
l v e
1 0
E n d s t o p
O p e r a t i o n
6 : A s s e m b l e t h e t h r u s t w a s h e r ( d e t a i l 6 )
1 1
S p r i n g w a s h e r
A n d t h e r i n g ( d e t a i l 7 ) i n t h
e s t e m
1 2
N u t
( d e t a i l 1 3 )
1 3
S t e m
O p e r a t i o n
7 : A s s e m b l e t h e s t e m
( d e t a i l 1
3 ) i n s i d e
1 4
H a n d l e
T h e b o d y ( d e t a i l 1 ) a n d t h e n a s s e m b l e
T h e d e t a i l s 8 - 9 - 1 0 - 1 1 - 1 2 - 1 4
O p e r a t i o n
8 : A s s e m b l e t h e b a l l a n d t h e b
a l l s e a t
( d e t a i l s 3 - 4 ) i n s i d e t h e a s s e
m b l e d b o d y
O p e r a t i o n
9 : P u t t h e o - r i n g ( d e t a i l 5 ) o n
t h e e n d
C o n n e c t i o n ( d e t a i l 2 ) a n d t h e b a l l s e a t
( d e t a i l 4 ) i n t h e e n d c o n n e c
t i o n ( d e t a i l 2 )
O p e r a t i o n
1 0 : A s s e m b l e t h e e n d c o n n e c t i o n ( d e t a i l 2 )
I n t h e b o d y ( d e t a i l 1 ) a n d
s c r e w i t o n
U n t i l i t s t o p s m e t a l t o m e t
a l
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Operating, Montage and Maintenance
Recommendation for Ball Valves TA 7
1. General:
y When making inquiries or spare part orders please always quote our order no. and, if possible, the ball
valve type and year of manufacture.
y We assume no liability in cases of disregard of operating or safety instructions or of faulty installation
or maintenance.
y Please refer to all data on further automation equipment such as drives, actuators, electrovalves, limit
switches etc.
y Unfortunately, we are unable to take back customer-specific valves.
2. Safety instructions:
y Maintenance, assembly and repair work may only be carried out by duly authorised and qualified
personnel.
y The manufacturer assumes no liability for damages or any other occurrences resulting from
changes made without consulting the manufacturer or use of parts other than original parts.
y These operating instructions do not replace any national accident prevention regulations or local
safety regulations; they are invariably subordinate to these.
y Observe the following before carrying out any repair or maintenance work:
e always turn off the power supply of the drives before carrying out repair or maintenance work
(danger of bruising!)
e make sure that no-one puts the plant into operation
e evacuate the pipe, prevent pressure build-up or retention
e inform yourself on possible dangers emanating from residues of operating material; wear safety
gloves and goggles etc. as necessary
e let valves cool off if necessary
e ensure that limit values relating to pressure, temperature and the operating material are
not exceeded
3. Transport:
y Valves should be transported to the building site in a firm packing .
y Do not attach cranes or elevators to the handle or to any mounted drive to prevent damage .
y Check valves for any transport damage immediately upon delivery and report as necessary.
We assume no liability for transport damages that have not been.
4. Storage:
y Ball valves must always be stored either completely opened or completely closed. We advise storing
them completely opened to prevent damage to the ball surface.
y Valves that are not needed immediately should be fitted with a protective cap and stored in a well-aired,
dry room.
-7-
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Operating, Montage and Maintenance
Recommendation for Ball Valves TA 7
5. Functioning:
y Ball valves serve as shut-off devices in plants, where they are screwed or welded into the pipe system.
y Ball valves are OPEN/CLOSE devices which are generally opened and closed by rotation through 90°.
The closing direction according to DIN standards is achieved by rotating the handele clockwise.
They are not intended for throttling or regulating the flow of medium, and intermediate positions are
therefore not permissible.
6. Installation:
y The piplines must be cleaned or flushed before installation, so that any residues and foreign bodies do not
get into the ball valves.
y Should the valves be dirty or contaminated, then set the ball previously to 45° and blow the interior clean
with oil-free comressed air. Then clean the housing.
y Lead the piplines free of stress up to valve to be installed.
y Ensure that the ball valves are in their open position .
y Place the fitting between the pipes using a crane or elevator if necessary. Tighten the flange screws in
opposite directions with the appropriate torque.
y Protect the interior parts of the valve before carrying out any welding (observe maximum tolerable
temperature of gasket!).
7. Initial operation:
y Read and ensure compliance with all operating instructions and check that operating conditions are as
required and the valves has been installed correctly.
y Flush the piping with valves fully opened before testing their function.
y After completing the installation and before putting the valve into operation, check that it works properly
by opening and closing it several times.
y Make sure that the valve works perfectly and that it turns in the right direction.
8. Maintenance:
y The ball valves are designed so that when used as intended no maintenance work at all is required over a
period of 3 years.
y To test the function, the valves should be moved open and closed according to loading every 6 or 12
months thus to confirm safe and leak-free operation.
y It is advisable to check the flange and selector shaft packing for leakage after prolonged operation.
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Operating, Montage and Maintenance
Recommendation for Ball Valves TA 7
9. Troubleshooting:
e Leakage at the selector shaft
This work can be done in the built-in condition and with the line under pressure.
However, it is prossible to do this work only under increased safety precautions. It should
also be observed that this work may be done under no circumstances at very high or very low
temperatures, with combustible media or with aggressive substances.
e Leakage at the ball
For this work the ball valve must be dismantled from the pipeline and only trained skilled personnel
should be entrusted with this work.
Please turn to us if you have any questions or before attempting repair in the event of
operating trouble!
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Druck-Temperatur-Diagramm für Kugelhähne Serie 7xx
Pressure-Temperature Rating for ball valves serie 7xx TA 5
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Ball valves
Type: V3NBC-316-…,
V1-316-299-015
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KUWO GmbH
Hägerstrasse 22, D-27321 Thedinghausen
Werkstrasse 226, D-19061 Schwer in
Operating, installation and maintenance recommendation
for ball valves
Index: Page
1. General 2
2. Safety instructions 2
3. Transport 2
4. Storage 3
5. Functioning 3
6. Installation 3
7. Initial operation 4
8. Maintenance 4
9. Troubleshooting 4
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KUWO GmbH
Hägerstrasse 22, D-27321 Thedinghausen
Werkstrasse 226, D-19061 Schwerin
1. General:
- When making inquiries or spare part orders please always quote our order no. and, if
possible, the ball valve type and year of manufacture.
- We assume no liability in cases of disregard of operating or safety instructions or of faulty
installation or maintenance.
- Please refer to all data on further automation equipment such as drives, actuators,
solenoid valves, limit switches etc.
- Unfortunately, we are unable to take back customer-specific valves.
2. Safety instructions:
- Maintenance, assembly and repair work may only be carried out by duly authorised and
qualified personnel.
- The manufacturer assumes no liability for damages or any other occurrences resulting from
changes made without consulting the manufacturer or use of parts other than original parts.
- These operating instructions do not replace any national accident prevention regulations or
local safety regulations; they are invariably subordinate to these.
- Observe the following before carrying out any repair or maintenance work:
® Always turn off the power supply of the drives before carrying out repair or
maintenance work (danger of bruising!).
® Make sure that no-one puts the plant into operation.
® Evacuate the pipe, prevent pressure build-up or retention.
® Inform yourself on possible dangers emanating from residues of operating material;
wear safety gloves and goggles etc. as necessary.
® Let valves cool off if necessary.
® Ensure that limit values relating to pressure, temperature and the operating material arenot exceeded.
3. Transport:
- Valves should be transported to the building site in a firm packing.
- Do not attach cranes or elevators to the handle or to any mounted drive to prevent damage.
- Check valves for any transport damage immediately upon delivery and report as necessary.
We assume no liability for transport damages that have not been duly reported.
- 2 -
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KUWO GmbH
Hägerstrasse 22, D-27321 Thedinghausen
Werkstrasse 226, D-19061 Schwerin
4. Storage:
- Ball valves must always be stored either completely opened or completely closed. We
advise storing them completely opened to prevent damage to the ball surface.
- Valves that are not needed immediately should be fitted with a protective cap and stored in a
well-aired, dry room.
5. Functioning:
- Ball valves serve as shut-off devices in plants, where they are screwed or welded into the
pipe system.
- Ball valves are OPEN/CLOSE devices which are generally opened and closed by rotation
through 90°. The closing direction according to DIN standards is achieved by rotating thehandle clockwise. They are not intended for throttling or regulating the flow of medium,
and intermediate positions are therefore not permissible.
6. Installation:
- The piplines must be cleaned or flushed before installation, so that any residues and foreign
bodies do not get into the ball valves.
- Should the valves be dirty or contaminated, then set the ball previously to 45° and blow the
interior clean with oil-free com pressed air. Then clean the housing.
- Lead the piplines free of stress up to valve to be installed.
- Ensure that the ball valves are in their open position.- Place the fitting between the pipes using a crane or elevator if necessary. Tighten the flange
screws in opposite directions with the appropriate torque.
- Protect the interior parts of the valve before carrying out any welding (observe maximum
tolerable temperature of gasket!).
- 3 -
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KUWO GmbH
Hägerstrasse 22, D-27321 Thedinghausen
Werkstrasse 226, D-19061 Schwerin
7. Initial operation:
- Read and ensure compliance with all operating instructions and check that operating
conditions are as required and the valves has been installed correctly.
- Flush the piping with valves fully opened before testing their function.
- After completing the installation and before putting the valve into operation, check that it
works properly by opening and closing it several times.
- Make sure that the valve works perfectly and that it turns in the right direction.
8. Maintenance:
- The ball valves are designed so that when used as intended no maintenance work at all is
required over a period of 3 years.
- To test the function, the valves should be moved open and closed according to loading every
6 or 12 months thus to confirm safe and leak-free operation.
- It is advisable to check the flange and selector shaft packing for leakage after prolonged
operation.
- In the event of rough operating conditions flush the ball valve via the provided borings if
necessary.
9. Troubleshooting:
® Leakage at the selector shaft
This work can be done in the built-in condition and with the line under pressure.
However, it is possible to do this work only under increased safety precautions. It should
also be observed that this work may be done under no circumstances at very high or very
low temperatures, with combustible media or with aggressive substances.
® Leakage at the ball
For this work the ball valve must be dismantled from the pipeline and only trained skilled
personnel should be entrusted with this work.
Please turn to us if you have any questions or before attempting repair in the event of
operating trouble.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Shut-off valves
Type: 2204600…
Pos .: 5.1.7, 5.1.8, 5.2.7, 5.2.8,
9.1.1, 9.1.2, 9.1.3, 9.2.1, 9.2.2,
9.2.3, 9.3.1, 9.3.2, 9.4.1
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Rev. 0040102000 2103 page 1
1.0 General information on operating
instructions..................................................22.0 Notes on possible dangers......................... 2
2.1 Significance of symbols ........................................2
2.2 Explanatory notes on safety information...............2
3.0 Storage and transport ................................2
4.0 Description...................................................3
4.1 Scope of applications............................................3
4.2 Operating principles ..............................................3
4.3 Diagram.................................................................4
4.4 Technical data - remarks.......................................5
4.5 Marking .................................................................5
5.0 Installation....................................................5
5.1 General notes on installation.................................5
5.2 Installing valves with butt weld ends .....................6
5.3 Installing valves with balancing plugs .................7
5.4 Installing valves with limit switches ...................... 7
6.0 Putting the valve into operation ................ 8
7.0 Care and maintenance................................ 8
8.0 Troubleshooting.......................................... 10
9.0 Troubleshooting table ................................ 11
10.0 Dismantling the valve or the top part ..... 12
11.0 Warranty / Guarantee................................ 12
Contents
Operating and installation instructionsStop valve with gland seal
STOBU®
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1.0 General information on operating instructions
These operating instructions provide information on mounting and maintaining the fittings.Please contact the supplier or the manufacturer in case of problems which cannot besolved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenanceand repair.The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must besupervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and tomonitor the personnel.
- In addition, current regional safety requirements must be applied and observed whentaking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
2.2 Explanatory notes on safety information
In these Operating and Installation Instructions dangers, risks and items of safetyinformation are highlighted to attract special attention.
Information marked with the above symbol and “ ATTENTION !” describe practices, a failureto comply with which can result in serious injury or danger of death for users or third partiesor in material damage to the system or the environment. It is vital to comply with thesepractices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operatingand maintenance instructions as well as technical data (in the operating instructions,product documentation and on the device itself) must also be complied with to the fullestextent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
3.0 Storage and transport
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Donot damage paint protection.
ATTENTION !
. . .
Warning of general danger.
ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used totake external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
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Rev. 0040102000 2103 Page 3
4.0 Description
4.1 Scope of applicationsValves are used for „shut-off and/or throttling of media“.
The information complies to the Pressure Equipment Directive 97/23/EC.It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
The valve is closed by turning the hand wheel clockwise (valve plug/seating function).
The valve spindle is sealed by a bellow and an outer safety stuffing box.Tighten the stuffing box if required.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed these requirements, e.g. aggressive or abrasive media, the operator should state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD110.
ATTENTION !
Do not use tools to increase the torque on the hand wheel.
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4.3 Diagram
Refer to the data sheet for information about materials with designations and figure
numbers.
fig. 1: STOBU straight through 1.0619+N fig. 2: STOBU angle pattern 1.0619+N
fig. 3: STOBU straight throughGG-25/GGG-40.3
fig. 4: STOBU-straight throughshoed butt weld ends 1.0619+N
rotatedview
rotatedview
rotatedview
rotatedview
rotatedview
rotatedview
rotated
view
rotated
view
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Rev. 0040102000 2103 Page 5
4.4 Technical data - remarks
for
- Principal dimensions
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
4.5 Marking
Details of the CE-marking on the valve:
5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governinginstallation work:
CE-marking
0525 Notified body
Manufacturer
Typ Type
Bj. Year of manufacture
According to the Pressure Equipment Directive appendix 2 diagram 6 valves withoutsafety function are only allowed to bear the CE-marking DN32 onwards.
ATTENTION !
- Remove flange covers if present.- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces areavoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or asconnecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.See data sheet for weights.
- Valves can be installed with the spindle pointing in any direction, but the prefered spindle position is vertical.
- Valves should be installed upside down only, if the medium being handled isclean.
- Keep the thread and shaft of the spindle free from paint.
- Centre gaskets between the flanges.
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- Planners / construction companies or operators are responsible for positioning andinstalling products.
5.2 Installing valves with butt weld ends
Please note that only qualified persons using appropriate equipment and working inaccordance with technical rules are allowed to install fittings by welding.The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
- Lockable stop valves must be installed in such a way that the spindle is vertical and the flow agent enters under the taper. If the valves are installed in pipelinesin positions other than specified, they must be fitted with a closing spring.
- Design with loose plug A plug damper should be used in critical applications, immediately downstream
of pumps, compressors, etc., where severe turbulence and pulsating pressuresurges may occur.Through the damper function of the loose plug, the negative influence of pressure shocks and high turbulences, are not transferred onto the valve.
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5.3 Installing valves with balancing plugs
Valves with pressure balancing plugs have to be installed with medium flowing over theplug (3) as indicated by flow direction arrow on valve body.Working principles:When the valve is closed, anticlockwise rotation of the hand wheel lifts the pilot plug (3.1)off the larger balancing plug (3). This allows the medium to pass through the plug andequalizes the pressure of the medium under the plug (3). After the pressures have beenequalized within the values stated in the table below, the valve can be opened by turningthe valve further.
- Pressure balancing plugs are fully effective only in closed line section.
- The pressures of the medium on either side of the plug cannot be equalized if the mediumis discharged into “open air”.
- If adequate pressure equalisation cannot be achieved using a pressure balancing plug,other design solutions must be used instead (e.g. a bypass line).
5.4 Installing valves with limit switchesThe valves with limit switches must be connected up as shown in the plans of the plant onthe basis of their working principles.
ATTENTION !
ARI stop valves must be equipped with pressure balancing plugs if thedifferential pressures listed in the table below are exceeded in the closed state.
Valves with pressure balancing plugs should be installed so that the pressure of the medium acts on the plug ( 3).
fig. 5
Balancing plug DN 125 150 200 250 300 350 400 500
Pressure difference ∆P 25 bar 21 bar 14 bar 9 bar 6 bar 4,5 bar 3,5 bar 1,5 bar
ATTENTION ! Note direction of flow.
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6.0 Putting the valve into operation
7.0 Care and maintenance
Maintanance and maintenance-intervals have to be defined by the operator according tothe requirements.
- Observe safety instructions!
- Keep the spindle well greased!
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperatureand direction of flow.
- Regional safety instructions must be adhered to.- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) mediatemperatures can cause injury. Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
fig. 6: Pattern with hinged bolts
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- Lubricant: e.g. Klüberpaste HEL 46-450 (at valves for oxygen: Oxigenoex FF 250)to order at: Klüber Lubrication München KG, Postfach 701047, D-81310 München
or a lubricant wich is suitable for the application.
- If the valve spindle (4) leaks, gradually tighten the stuffing box seal (6) evenly inincrements by means of the hex. nuts (19) until leaking stops.
- Replace stuffing box packings only after the system has cooled down and the pressure inthe plant has been relieved.In the case of corrosive or aggressive mediums, drain and ventilate the valve beforereplacing the packing.
- Valve service life can be improved by leakage checks.
Mounting of the bonnet:
- Before reassembling the unit, remember that the bearing surface must be cleaned and 2new gaskets (9) must be inserted.
- Set the cover in place
- Tighten the hexagon nuts (hexagon screws for valves of cast iron) evenly crosswise.
- Tightening torque‘s for hexagon nuts / screws:
ATTENTION !
Pay attention, that the lubricant is suitable for the media.
ATTENTION !
- Retighten the stuffing box packing if required and re-pack it in good time.
- For safety reasons we recommend that valves only be repacked whendepressurised.
- Refer to point 10.0 and 11.0 before dismantling the valve.
fig. 7: Split packing ring
- When cutting the new packing from the roll,make sure that the ends are cut with a slant
DN hexagon nuts /hexagon screws
Torque(Nm)
15- 32 M 10 15-30
40- 65 M 12 35-50
80-100 M 16 75-100
125-150 M 16 80-120
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
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8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation andadjustment work has been carried out and completed in accordance with these OperatingInstructions.
If malfunctions cannot be eliminate with the help of the following table“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
-
ATTENTION ! It is essential that the safety regulations are observed when identifying faults.
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Rev. 0040102000 2103 Page 11
9.0 Troubleshooting table
ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work! - read point 6.0 before restarting the plant !
Fault Possible cause Corrective measures
No flow Valve closed. Open valve.
Flange covers not removed.
(25; fig.1-2; page 4)
Remove flange covers.
(25; fig.1-2; page 4)
Little flow Valve not sufficiently open. Open valve.
Dirt sieve clogged. Clean / replace sieve.
Piping system clogged. Check piping system.
Valve difficult to move or
cannot be opened
Spindle (4) dry (fig. 6; page 8) Grease spindle (4) (fig. 6; page 8)
(Lubricant: see page 9)
Stuffing box too tight (6; fig. 1-4; page
4)
Slacken hex. nuts of stuffing box gland
(15) slightly, but not sufficiently to
cause leakage (fig. 1-4; page 4)
Wrong direction of rotation Turn in correct direction (anticlockwise
to open valve).
Valve spindle leaking Stuffing box gland (15) slack
(fig. 1-4; page 4).
Tighten stuffing box gland (15) until
leakage stops.
-Hex. nut (fig. 1-4; page 4).
If necessary, renew packing in stuffing
box seal (6). Observe warnings (Fig. 6;
page 8)!
Leakage across valve
seat.
Valve not properly closed. Pull hand wheel tight without tools.
Seat (1.2) / plug (3) damaged by for-
eign particles.
(fig. 1-4; page 4).
Replaced valve, consult supplier/man-
ufacturer.
Pressure difference too high. Use a valve with balancing plug
(see point 5.3).
Medium contaminated (suspended sol-
ids).
Clean valve.
Install dirt screen upstream of valve.
Valve with throttling plug +
position indicator + lock-
ing device cannot be
opened.
Locking device has been tightened. Release locking device.
Rattling / bangingof the plug design with
„loose plug“
Nominal diameter of the valve in com-pliance to the flow rate is to big
Choose smaller nominal diameter Use a plug damper execution: see
medium
- high flow turbulences;
- the valve with loose plug is mounted
directly by a centrifuged pump;
- behind pressure reduction stations;
- behind pipe elbows;
- in compact plants;
- expansion joints are missing;
- the pump is not mounted on a
damper;
- there is no flow stabilizing pipe length;- there is no start-up bypass line
Alter the system
Use a plug damper execution: see
medium
Flange broken between
valve and piping.
Bolts tightened unevenly.
Mating flanges not properly aligned.
Re-align piping and fit new valve!
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10.0 Dismantling the valve or the top part
11.0 Warranty / Guarantee
The extent and period of warranty cover are specified in the "Standard Terms andConditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and theconfirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handlingor disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialistappointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.The warranty shall not cover maintenance work, installation of external parts, designmodifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to thecompetent cargo-handling depot, the railway company or carrier company immediately or else claims for replacements from these companies will be invalidated.
ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Non-return valves
Type: SR 20.40 St
Pos .: 1.1.4, 1.2.4, 1.3.4, 1.4.4,
4.1.8, 10.1.3
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1
Instruction Manual
Wafer Type Check Valves
SR / HSR...ZRK / ZRL...
ZRD...
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Content
1. Declaration of Conformity in acc. to PED 97/23/EC 31.1 Declaration of Conformity SR/HSR, ZRK/ZRL 31.2 Declaration of Conformity ZRD 4
2. General Notes 5
3. Intended Use 5
4. Safety Instructions 5
4.1 General safety instructions 54.2 Qualification of personnel 54.3 Safety instructions for the operator 54.4 Special dangers 6
5. Transport and Storage 6
6. Categorisation in acc. to PED 97/23/EC 7
7. Specification 87.1 Marking 87.2 Drawings and parts lists 8
7.3 Functionality 10
8. Installation 108.1 General information 108.2 Operational characteristics 108.3 Range of applications 118.4 Installation instructions 12
9. Initial Operation, Shut down, Maintenance, Elimination of Failures 139.1 Initial operation 139.2 Shut-down 139.3 Maintenance 139.4 Elimination of failures 14
10. Spare Parts 14
11. Further Information 14
This instruction manual contains important safety instructions. Please read carefully before installation and initialoperation. It is hardly recommended to keep this manual within the operation area.
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1.1 Declaration of Conformityin acc. to Pressure Equipment Directive 97/23/EC
Description of the Pressure Equipment
Type DN PN Module Type DN PN Module Type DN PN Module Type DN PN Module
SR10.16 125-200 6-16 A SR12.16 65-200 6-16 A ZRK4 65-200 6-16 A ZRL4 65-200 6-16 A
SR60.06 32-100 6 A SR70.16 65-100 6-16 A ZRK1 50-100 10-40 A1 ZRL1 50-100 10-40 A1
SR61.06 32-100 6 A ZRK1S 50-100 10-40 A1 ZRL1S 50-100 10-40 A1
SR20.40 32-100 6-40 A1 SR33.40 32-100 6-40 A1 ZRK2 50-100 10-40 A1 ZRL2 50-100 10-40 A1
SR20.40St 32-100 6-40 A1 SR34.40 32-100 6-40 A1 ZRK3 50-100 10-40 A1 ZRL3 50-100 10-40 A1
SR22.40 32-100 6-40 A1 SR35.40 32-100 6-40 A1 ZRK4 250,300 6-16 A1 ZRL4 250,300 6-16 A1
SR30.40 32-100 6-40 A1 SR55.40 32-100 6-40 A1 ZRK5 50-100 10-40 A1 ZRL5 50-100 10-40 A1
Sr31.40 32-100 6-40 A1 HSR20.160 32-100 63-160 A1
SR32.40 32-100 6-40 A1 HSR30.160 32-100 63-160 A1 ZRK1 125-600 10-40 H ZRL1 125-600 10-40 H
SR40.40 32-100 6-40 A1 SR50.40 32-100 6-40 A1 ZRK1S 125-600 10-40 H ZRL1S 125-600 10-40 H
SR20.40 125-200 6-40 H SR30.40 125-200 6-40 H ZRK2 125-600 10-40 H ZRL2 125-600 10-40 H
SR20.40ST 125-200 6-40 H SR34.40 125-200 6-40 H ZRK3 125-600 10-40 H ZRL3 125-600 10-40 H
SR22.40 125-200 6-40 H SR35.40 125-200 6-40 H ZRK4 350-600 6-16 H ZRL4 350-600 6-16 H
SR25.40St 250-350 6-40 H SR55.40 125-200 6-40 H ZRK5 125-600 10-40 H ZRL5 125-600 10-40 H
All valves in size DN £25 comply with article 3, paragraph 3 and are not permitted to be markedneither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH HamburgMönckebergstrasse 27
20095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
No harmonized standards available at present
Other Applied Standards and Technical Rules
AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
22.01.2002 Herfried Schrader
Date Authorized Subscriber
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1.2 Declaration of Conformityin acc. to Pressure Equipment Directive 97/23/EC
Description of the Pressure Equipment
Type DN PN Module Type DN PN Module
ZRD G/K3 65 - 200 6 - 16 A ZRD G/API594 21/2" - 6" Class125, 150 A
ZRD G4/K3 65 - 200 6 - 16 A ZRD G4/API594 21/2" - 6" Class125, 150 A
ZRD 4/K3 65 - 200 6 - 16 A ZRD 4/API594 21/2" - 6" Class125, 150 A
ZRD 6/K3 65 - 200 6 - 16 A ZRD 6/API594 21/2" - 6" Class125, 150 A
ZRD G/K3 250, 300 6 - 16 A1 ZRD G/API594 8", 10" Class125, 150 A1
ZRD G4/K3 250, 300 6 - 16 A1 ZRD G4/API594 8", 10" Class125, 150 A1
ZRD 4/K3 250, 300 6 - 16 A1 ZRD 4/API594 8", 10" Class125, 150 A1
ZRD 6/K3 250, 300 6 - 16 A1 ZRD 6/API594 8", 10" Class125, 150 A1
ZRD 1/K3 50 - 100 6 - 40 A1 ZRD 1/API594 2" - 4" Class150, 300 A1
ZRD 2/K3 50 - 100 6 - 40 A1 ZRD 2/API594 2" - 4" Class150, 300 A1
ZRD 3/K3 50 - 100 6 - 40 A1 ZRD 3/API594 2" - 4" Class150, 300 A1
ZRD G/K3 350 - 600 6 - 16 H ZRD G/API594 12" - 24" Class125, 150 H
ZRD G4/K3 350 - 600 6 - 16 H ZRD G4/API594 12" - 24" Class125, 150 H
ZRD 4/K3 350 - 600 6 - 16 H ZRD 4/API594 12" - 24" Class125, 150 H
ZRD 6/K3 350 - 600 6 - 16 H ZRD 6/API594 12" - 24" Class125, 150 H
ZRD 1/K3 125 - 600 6 - 40 H ZRD 1/API594 5" - 24" Class150, 300 H
ZRD 2/K3 125 - 600 6 - 40 H ZRD 2/API594 5" - 24" Class150, 300 H
ZRD 3/K3 125 - 600 6 - 40 H ZRD 3/API594 5" - 24" Class150, 300 H
All valves in size DN £25 comply with article 3, paragraph 3 and are not permitted to be markedneither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH Hamburg
Mönckebergstrasse 2720095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
No harmonized standards available at present
Other Applied Standards and Technical Rules
AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
22.01.2002 Herfried Schrader Date Authorized Subscriber
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2. General Notes
This instruction manual applies to the above mentioned valves which are subject tothe Quality Management System Standard acc. to DIN/ISO9001 in both the manner of manufacturing as well as testing and which do meet the basic safety requirementsof Annex I of the Pressure Equipment Directive 97/23/EC. This instruction manual isintended to support the user of above mentioned valves in installation, operation and
maintenance.
Attention
Disregarding the following caution advices could evokedangerous situations which entail an inefficacy of the manufacturers’warranty.For any questions, please contact the manufacturer and also seechapter 11.
3. Intended Use
Wafer type check valves are solely destined for installation within a pipeline systemin consideration of the admitted pressure and temperature limits to avoid a backflowof the media.It is the operators’ responsibility to examine the chemical resistance in relation to thespecified operation data. All valid operation data are indicated in chapter 8 respectively in the technical datasheets of the relevant types.
4. Safety Instructions
4.1 General Safety Instructions
Those safety regulations applying to the pipeline system apply to the valves itself accordingly, i. e. any national or international rules for accident prevention as well aspossibly existing operators’ working-, production- and safety regulations have to beconsidered. This instruction manual only points to those safety instructions whichhave to be considered additionally.
4.2 Qualification of Personnel
Only qualified staff is permitted to install and maintain the valves. The operator isobliged to coordinate the competencies, the responsibilities and the surveillance of his staff. Should the staff not have the necessary knowledge, the operator mustprovide adequate additional training. The operator has to ensure that the content of this instruction manual is comprehended in all its particulars.
4.3 Safety Instructions for the Operator
Due to the fact that the following points are not in the responsibility of the valvemanufacturer the operator has to ensure when using the valves that
· the valves are solely used in the way described in chapter 3
· the pipeline system is installed in a professional manner. The wall thickness of the valve body is designed in a way that tensions which do exist within thepipeline system are considered in a usual order of magnitude.
· the valves are properly installed between the flanges.
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· an usual flow rate within the pipeline system is not exceeded during acontinuous operation. For abnormal service conditions, e. g. oscillation, water shock, cavitation or a medium that contains larger solid particles, pleasecontact RITAG for clarification.
· the valves are protected against touch when working at a temperature<0°C respectively >40°C.
Danger
Prevention from misusing the valves:It has to be particularly ensured that the selected body materials andinner parts of the valve are suited for the medium that is used. Themanufacturer assumes no liability for any damages caused byaggressive media.Disregarding this precaution may evoke dangerous situations for the operating personnel or cause damages to the pipeline system.
4.4 Special Dangers
Danger toLife
Before disassembling the valve the pipeline has to be depressurized,the pipe has to be totally drained and released. Afterwards the flangescrew connections can be unscrewed and the valve can bedismantled.Misusing this precaution means danger to the life of theoperating personnel.
5. Transport and Storage
The valves are provided ready for installation. They need to be treated, conveyed
and stored carefully.· Those valves that are delivered with a protecting packing need to be storedwithin this packing up to the moment of installation.
· In case of a direct storage at the installation location the valve has to be storedin a closed room and has to be protected against any damaging impacts.
· It is recommended to use up any stock items first in order to achieve shortstorage periods.
· Those valves that are equipped with a soft sealing need to be protectedagainst sunlight that might hit this soft sealing or any other UV-radiation inorder to avoid ageing.
· Lifting tools for transport are only to be fastened on the valve body. Inner parts
may not be misused as „carrying devices“.
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6 Categorisation in acc. to PED 97/23/EC article 9
Wafer Type Lift Check Valves Type SR / HSRCE-marking in conjunction with declaration of conformity in acc. to PED 97/23/EC
Nominal Diameter
Valve type PN Fluid group 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350
SR10.16 16 2 * * * * * * CE CE CE * * *
SR12.16 16 2 no CE no CE no CE CE CE CE CE CE CE * * *
SR70.06K 6 2 no CE no CE no CE no CE no CE no CE * * * * * *
SR70.16 16 2 no CE no CE no CE CE CE CE * * * * * *
SR60.06 6 1 u. 2 CE CE CE CE CE CE * * * * * *
SR20.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR20.40St 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR25.40 40 1 u. 2 * * * * * * * * * CE CE CE
SR22.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR30.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR31.40 40 1 u. 2 no CE CE CE CE CE CE CE CE CE CE * * *
SR32.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR33.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR34.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR35.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR40.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR50.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
SR55.40 40 1 u. 2 CE CE CE CE CE CE CE CE CE * * *
HSR20.160 160 1 u. 2 CE CE CE CE CE CE * * * * * *
HSR30.160 160 1 u. 2 CE CE CE CE CE CE * * * * * *
* not available in this size
Wafer Type Swing Check Valves Type ZRK / ZRLCE-marking in conjunction with declaration of conformity in acc. to PED 97/23/EC
Nominal Diameter
Valve type PN Fluid group 50 65 80 100 125 150 200 250 300 350 400 450 500 600
ZRK1, ZRL1, ZRK5 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
25 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
40 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRK1-S, ZRL1-S 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
25 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
40 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRK2, ZRK3 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE25 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
40 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRK4 10 2 no CE no CE no CE keinCE CE CE CE CE CE CE CE CE CE CE
16 2 no CE CE CE CE CE CE CE CE CE CE CE CE CE CE
Wafer Type Duo Check Valves Type ZRDCE-marking in conjunction with declaration of conformity in acc. to PED 97/23/EC
Nominal Diameter
Valve type PN Fluid group 50 65 80 100 125 150 200 250 300 350 400 450 500 600
ZRD1/K3,ZRD2/K3, 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD3/K3 16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
25 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
40 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD1/API594, 10 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD2/API594, 16 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD3/API594 25 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
40 1 u. 2 CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD G/K3,ZRD G4/K3 6 2 no CE no CE no CE no CE no CE no CE CE CE CE CE CE CE CE CE
ZRD4/K3, ZRD6/K3 10 2 no CE no CE no CE no CE CE CE CE CE CE CE CE CE CE CE
16 2 no CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD G/API594, 6 2 no CE no CE no CE no CE no CE no CE CE CE CE CE CE CE CE CE
ZRD G4/API594, 10 2 no CE no CE no CE no CE CE CE CE CE CE CE CE CE CE CE
ZRD 4/API594, 16 2 no CE CE CE CE CE CE CE CE CE CE CE CE CE CE
ZRD 6/API594
The conformity in acc. to PED 97/23/EC is documented by the CE-marking on thevalve body.
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7 Specification
The sectional drawings shown in this chapter do exemplary illustrate the basic designof the valves. Detailed information can be found in the technical data sheet of thespecific valve type.
7.1 Marking
All valves are marked in acc. to PED 97/23/EC, TRB 801 No. 45 or EN19.
General Marking
Manufacturer RITAGValve type ...Nominal diameter DN...Nominal pressure PN..Material ...Batch no. (retraceability of the material) ...
Year of manufacture (month, year, e.g. 5.02) ... Arrow of flow direction - CE-marking (starting from category I, see chapter 1 u. 6) CECode of the Notified Body (Module A1 und H) 0525 Stamp of inspector ...
Further special markings, e. g. plant identification code or project name could beadditionally affixed on request.
7.2 Drawings and Parts Lists
Lift Check Valves
SR35.40,SR40.40, SR50.40, SR55.40, SR20.40, SR20.40St, SR22.40, SR70.06, SR70.16,HSR20.160, HSR30.160 SR30.40, SR31.40, SR32.40
SR33.40, SR34.40, SR12.16
Item no. Denomination Item no. Denomination1 Body 2 Plate/disc3 Sealing (spare part) 4 Guide plate5 Spring (spare part ) 6 Guide screw7 Centering ring
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Swing Check Valve
No spring illustrated
1 Body 7 Hinge (left)3 Plate 8 Screw4 Sealing (spare part) 9 Ring5 Hinge pin 10 Eye screw6 Hinge (right) Spring (spare part)
Duo Check Valve
1 Body 8 Pin retainer 2 Plate 9 Ring3 Shaft 10 Stop pin4 Sealing (spare part) 11 Eye bolt5 Spring (spare part) 12 Set screw6 Packing (spare part)7 Ring
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7.3 Functionality
Wafer type non-return valves are valves which are controlled by the backflow of themedium. The obturator (disc, cone, plate) is first lifted and then opened by the flow.In the event of an incipient backflow (e. g. failure of a pump) the obturator closes self-controlled by its dead weight. This closing process can optionally be supported by
using a spring.
8 Installation
8.1 General Information
Positioning within the isometry of the pipeline as well as a proper installation of thevalves is basically the responsibility of the engineer or the operator. Any faults inengineering or installation could cause misfunction of the valves and constitute asignificant danger.For the installation of the valves the same safety regulations are to be considered as
for connecting pipelines and its components.
Attention
Pipelines have to be laid in such a manner that shearing strain andbending stress are not able to affect the valve body. The flangefacings have to be in a parallel position to each other. The facingsneed to be clean and undamaged.
Danger
Valve bodies in material cast iron EN-JL1040, EN-JS1030 must notbe treated by sudden pressure (e. g. hammer blow) becausecomponents may be destroyed.Valves working at temperatures <0°C respectively >40°C need to beprotected against touch.
8.2 Operational Characteristics
Wafer Type Lift Check Valves Type SR/HSROperating data for SR - valves
permissible working temperature (°C) 20 100 150 200 250 300 350 400 450 500
Type Material P/T group EN1092-1, -2 PN permiss ible working pressure (bar)
SR10.16 EN-JL1040 16 16 16 14,4 12,8 11,2 9,6
SR60.06 PTFE 6 6 6 5 4
SR12.16 CC483K 16 16 16 15 14 13
SR70.16 2.0401 16 16 16 15 14 13
SR20.40 1.4021 40 40 40 37,5 35 32,5 30 27,5 25
SR20.40St bis DN100 1.0570 1E1 40 40 40 36 33 29 24
SR20.40St DN125 bis 200 1.0421 40 40 40 36 33 29 24
SR25.40 1.0421 40 40 40 36 33 29 24
SR22.40 1.0460 40 40 40 36 33 29 24 20 16
SR30.40 1.4571 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
SR31.40 3.7035 40 40 40 34 28 22 16
SR32.40 2.4617 40 40 40 38 36 34 32 30 28
SR40.40 1.0460 40 40 40 37 35 31,5 29 27 26 23
SR33.40 2.4610 40 40 40 38 36 34 32 30 28
SR34.40 1.4301 11EO 40 34,7 27,9 25,2 22,6 21 19,6 18,5 17,4 16,9 16,4
SR35.40 1.0460 40 40 40 37 35 31,5 29 27 26 23
SR55.40 1.4571 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
HSR20.160 1.0460 160 160 160 145 130 125 100 84 68 53
HSR30.160 1.4571 15EO 160 160 154 148 142 136 130 124 118 110 102
SR50.40 1.4571 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
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Wafer Type Swing Check Valves Type ZRK/ZRLOperating data for ZRK / ZRL - valves
admissible working temperatu re ( °C) 20 100 150 200 250 300 350 400 450 500
Type Material P/T group EN1092-1, -2 PN admiss ible work ing pressure (bar)
ZRK1, ZRL1,ZRK1-S, ZRL1-S 1.0570 1E1 10 10 10 9 8 7 6
1E1 16 16 16 14,4 12,8 11,2 9,6
1E1 25 25 25 22,5 20 17,4 15
1E1 40 40 40 36 33 29 24
ZRK2, ZRL2 1.4301 11EO 10 8,7 7 6,3 5,6 5,2 4,9 4,6 4,4 4,2 4,1
11EO 16 13,9 11,2 10,1 9 8,4 7,8 7,4 7 6,8 6,511EO 25 21,7 17,4 15,8 14,1 13,1 12,2 11,6 10,9 10,6 10,2
11EO 40 34,7 27,9 25,2 22,6 21 19,6 18,5 17,4 16,9 16,4
ZRK3, ZRL3 1.4571 15EO 10 9,3 8,2 7,9 7,4 7 6,4 6,2 6 5,8 5,7
15EO 16 14,9 13,2 12,6 11,9 11,2 10,3 10 9,6 9,3 9,2
15EO 25 23,3 20,6 19,7 18,6 17,4 16 ,1 15,6 15 14,6 14,3
15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
ZRK4, ZRL4 CC483K 10 16 16 15 14 13
16 16 16 15 14 13
ZRK5, ZRL5 1.0425 3EO 10 10 10 9,8 9,5 9 8 7 5,5
3EO 16 16 116 15,7 15,2 14,4 12,8 11,2 8,8
3EO 25 25 25 24,5 23,8 22,5 20 17,5 13,8
3EO 40 40 40 39 38 36 32 28 22
Lowest working temperature: ZRK1, ZRL1, ZRK4, ZRL4, ZRK5, ZRL5 minus 10°C; ZRK2, ZRL2, ZRK3, ZRL3 minus 200°C
Wafer Type Duo Check Valves Type ZRDOperating data for ZRK / ZRL - valves
permissible working tempera ture (°C) 20 100 150 200 250 300 350 400 450 500
Type Material P/T group EN1092-1, -2 PN permissible working pressure (bar)
ZRD G/K3, ZRD G4/K3 EN-JL1040 * 6 6 6 5,4 4 ,8 4,2 3 ,6
ZRD 6/K3 EN-JL1040 * 10 10 10 9 8 7 6
EN-JL1040 * 16 16 16 14,4 12,8 11,2 9,6
ZRD 4/K3 CC483K 6 6 6 5 4 3
CC483K 10 10 10 9 8 7
CC483K 16 16 16 15 14 13
ZRD 1 /K3 1.0619 3EO 10 10 10 9,8 9 ,5 9 8 7 5 ,5
1.0619 3EO 16 16 116 15,7 15,2 14,4 12,8 11,2 8,8
1.0619 3EO 25 25 25 24,5 23,8 22,5 20 17,5 13,8
1.0619 3EO 40 40 40 39 38 36 32 28 22
ZRD 2/K3 1.4308 11EO 10 8,7 7 6,3 5,6 5,2 4,9 4,6 4,4 4,2 4,1
1.4308 11EO 16 13,9 11,2 10,1 9 8,4 7,8 7,4 7 6,8 6,51.4308 11EO 25 21,7 17,4 15,8 14,1 13,1 12,2 11,6 10,9 10,6 10,2
1.4308 11EO 40 34,7 27,9 25,2 22,6 21 19,6 18,5 17,4 16,9 16,4
ZRD 3/K3 1.4581 15EO 10 9,3 8,2 7,9 7,4 7 6,4 6,2 6 5,8 5,7
1.4581 15EO 16 14,9 13,2 12,6 11,9 11,2 10,3 10 9,6 9,3 9,2
1.4581 15EO 25 23,3 20,6 19,7 18,6 17,4 16,1 15,6 15 14,6 14,3
1.4581 15EO 40 37 33 31,5 29,7 27,9 25,8 24,9 24 23,3 22,9
ZRD G/API594, ZRD G4/API594 EN-JL1040 Class125 16 16 14,4 12,8 11,2 9,6
ZRD 6/API594 EN-JL1040 Class150 20 20 18,5 16,5 14,5 12,3
ZRD 4/API594 CC483K Class125 16 16 15 14 13
CC483K Class150 20 20 18 17 16
ZRD 1/API594 1.0619 3EO Class150 20 20 20 19,5 18,5 16,5 14,4 11,3
1.0619 3EO Class300 50 50 49,5 48,5 46 41 35,9 28,3
ZRD 2/API594 1.4308 11EO Class150 20 20 13 11,6 10,7 10 9,5 8,9 8,7 8,35
1.4308 11EO Class300 50 50 32,5 29 26,9 25,3 23,8 22,6 21,7 16,4
ZRD 3/API594 1.4581 15EO Class150 20 20 16,2 15,3 14,3 13,2 12,8 12,3 11,9 11,8
1.4581 15EO Class300 50 50 40,7 38,2 36 33 32 31 29,9 29,2
* EN1092 Teil2 Tabelle17
Lowest working temperature: ZRD G, ZRD G4, ZRD1, ZRD3, ZRD4, ZRD6 minus 10°C; ZRD2 minus 200°C
8.3 Range of Applications
Industrial plants, heating systems, fluids, gases and vapour (see also fluid groups intable of article 6), hot water heating systems DIN4751 / DIN4752, heat transmissionplants DIN4754, steam boiler plants TRD110, pressure vessel plants TRB801No. 45. Potential restrictions by any technical body of legislation are to beconsidered. The materials of the valves have to be applicative for the medium.
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Opening Pressures pö (mbar)- depending on flow direction -
SR / HSR ZRK / ZRL ZRD
DN « ¯ - - nospring
« « with spring - - with spring « - - withspring
15 20 16 24 420 20 16 24 4
25 20 16 24 432 20 16 24 440 20 15,5 24,5 4,550 20 15 25 5 ~0 15 8 23 15 25 1065 20 14,5 25,5 5,5 ~0 15 8 23 15 25 1080 20 13,5 26,5 6,5 ~0 15 8 23 15 30 15100 20 13,5 26,5 6,5 ~0 15 8 23 15 30 15125 20 - 34 14 ~0 10 8 18 15 35 20150 20 - 33 13 ~0 10 8 18 15 35 20200 20 - 32 12 ~0 10 12 22 15 35 20250 20 - 32 12 ~0 10 12 22 15 35 20300 20 - 32 12 ~0 10 12 22 15 45 30350 20 - 32 12 ~0 10 15 25 15 45 30400 20 - - - ~0 10 16 26 15 45 30450 20 - - - ~0 10 16 26 15 55 40
500 20 - - - ~0 10 22 32 15 55 40600 20 - - - ~0 10 24 34 15 75 60
8.4 Installation Instructions
The arrow indicating the flow direction and the flow direction itself need to run in thesame direction.For the valve to open a minimum dynamic pressure is required. Valves without springcan only be installed in vertical lines with upward flow.
Installation in
horizontal vertical pipeline
Eye bolt indicates
top position of
the valve
5 x D N
Pump
5 x D N
Eye bolt
DN
5xDN
2 x D N
Eye bolt
D N
Eye bolt
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Attention
Wafer type non-return valves are designed for installation betweentwo pipeline flanges including appropriate flange sealings. The outer diameter of the valve centres itself by the flange bolts. The fastenersrequire a technical applicability in accordance to the serviceconditions. They have to comply with the regulations and have to betightened with the permissible torque. Screws, nuts or flange sealingsare not covered by the valve manufacturers’ scope of supply.
9 Initial Operation, Shut-down, Maintenance
9.1 Initial Operation
General information
Materials and service conditions have to be compared with the pipeline system databefore pressure test and initial operation in order to check resistance and load.For new plants or repairs the pipeline system has to be thoroughly rinsed in order to
clean it from potential welding residues or any other damaging solid particles.
Pressure tests of pipeline sections
Since non-return valves are always in a closed position within a filled pipeline sectiona testing overpressure value of 1,1 x PS must not be exceeded (PS = NP = max.permissible working pressure).
Throughout the pressure test process the valve and the flange connections have tobe examined regarding any leaks. Leakages have to be immediately sealed byretightening all fasteners.
9.2 Shut-down
If the system is out of operation for a lasting period all media which might change itscondition (i. e. polymerisation, crystallisation, solidification) have to be drained off thepiping system. Rinse the system if necessary.
9.3 Maintenance
The valves are maintenance-free. For safety reasons and in order to avoid
unnecessary periods of interruption the operator is advised to examine functionalityand reliability of the valves within reasonable and regular intervals (periods to bedefined by the operator).Safety instructions in chapter 4 are to be considered.
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9.4 Elimination of Failures
Failure definition Potential reasons Remedy
High leakage rate · Contaminated seat facings ð Clean the seat facings, regrindif necessary
· Deformation of disc/cone/plate by hammer blow
ð Replace disc/cone/plate
· Damaged seat ring ð Replace seat ring
· Disc/cone/plate does notclose, cone is hanging, highactivity rate causes a seizingdue to friction
ð Recheck operating data,reengineer all parts
Inappropriate noises Insufficient flow rate,turbulent flow, deceleratedstarting of the pump
ð Select reduced sizesð Recheck the distance betweenpipe bend and pump (5-7xDN)ð Use lighter plates or springswith reduced opening pressureð Extend the period of running upthe pump
Leaks of stuffing box (ZRL-HG,ZRD)
Stuffing box is inadequatelypreloaded
ð Retighten stuffing boxð Replace stuffing box packings
if necessaryNo flow Valve is installed in the
wrong wayð Arrow of flow direction has torun in the same direction as theflow itself.
Leaks of flange sealings Connection flanges are notwired
ð Retighten fasteners
10 Spare Parts
Attention
For repair work any valve parts must only be replaced by spare parts
from the original supplier. Unauthorised conversion as well as spareparts production cause an expiry of the declaration of conformity andmay also invalidate any warranty claims.
Any springs or o-rings (relevant for valves equipped with a soft sealing) can beordered as spare parts. The full marking of the valve body has to be specified in thepurchase order.
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Kupke + Wolf GmbH Kupke + Wolf GmbHHägerstr. 22 Werkstraße 226D-27321 Thedinghausen D-19061 Schwerin/Wüstmark
D-27321 Thedinghausen D-19061 Schwerin/Wüstmark Telefon: 04204/9165-0 Telefon: 0385/640 14-0Telefax: 04204/9165-65 Telefax: 0385/640 14-14
Safety valves
Type: SAFE-TCP
Pos.: 4.1.2, 5.1.6, 5.2.6
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1.0 General information on
operating instructions .............................................2
2.0 Notes on possible dangers .......................................22.1 Significance of symbols ................................................ 2
2.2 Safety-related definitions .............................................. 2
2.3 Qualified personnel....................................................... 2
3.0 Handling ...................................................................3
3.1 Storage .......................................................................... 3
3.2 Transport ....................................................................... 3
3.3 Handling before installation.......................................... 3
4.0 Specification .............................................................3
4.1 Applications.................................................................. 3
4.2 Technical specification.................................................. 34.3 Technical data ............................................................... 4
4.4 Diagram......................................................................... 5
4.5 Parts list......................................................................... 6
4.6 Marking......................................................................... 7
5.0 Installation................................................................7
5.1 Safety note .....................................................................8
6.0 Notes on dangers during installation, operationand maintenance......................................................8
7.0 Putting the valve into operation .............................9
7.1 Potential hazards............................................................9
8.0 Care and maintenance.............................................9
8.1 Setting instructions .....................................................108.1.1 Removing the cap ................................................................ 118.1.2 Changing the set pressure “without” spring change ............ 118.1.3 Changing the set pressure “with” spring change ................. 11
9.0 Troubleshooting .....................................................12
10.0 Troubleshooting table ..........................................13
11.0 Dismantling the valve ..........................................15
12.0 Warranty ..............................................................15
Contents
Operating and installation instructionsSafety valves
SAFE SAFE-P
(Series 900) (Series 920)
SAFE-TC
(Series 940)SAFE-TCP/TCS
(Series 960/950)
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Operating and installation instructions
Safety valves
1.0 General information on operating instructions
These operating instructions contain information necessary to install and operate the valve both safelyand effectively.If problems arise which cannot be solved with the aid of these operating instructions, please contact thesupplier/manufacturer for further information. These operating instructions comply with applicable EN
safety standards as well as regulations and codes of practice applicable in the Federal Republic of Germany. If the valve is used outside the Federal Republic of Germany, the operator or the personresponsible for the system design must ensure that valid national codes of practice are complied with.The manufacturer reserves all rights to implement technical modifications and improvements at anytime.The use of these operating instructions assumes the user is qualified as described under Section 2.3"Qualified Personnel".The operating personnel must be instructed in accordance with the operating instructions.
2.0 Notes on possible dangers
2.1 Significance of symbols
Warning of general danger
Non-compliance with operating instructions is dangerous!Read the operating instructions before installation, operation, maintenance ordisassembly and adhere to them strictly.
2.2 Safety-related definitions
The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / orconsiderable damage to property can occur.
WARNING means that if the relevant information is disregarded, there is a danger of serious injury and / or damage to property can occur.
CAUTION means that if the relevant information is disregarded, there is a danger of injury and / ordamage to property can occur.
NOTE means that particular attention must be paid to certain technical aspects.
All other information not specifically emphasised such as transport, installation, operating andmaintenance instructions as well as technical data (in the operating instructions, product documentationand on the device itself) must also be complied with to the fullest extent in order to avoid faults which inturn can cause serious injury to persons or damage to property.
2.3 Qualified personnel
The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-up and operation of the product and have the qualifications corresponding to their responsibilities suchas:Instruction and obligation to comply with all operational, regional and in-company regulations andrequirements;Training or instruction in accordance with safety technology standards with regard to the upkeep and useof appropriate safety and work protection equipment;First aid training, etc.
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Operating and installation instructions
Safety valves
3.0 Handling
3.1 Storage
- Storage temperature -20˚ to +65˚C dry, free of dirt
- The painting is only a primer, intending to guard against rust during stock or transportation. Don‘tdamage the paintwork.
- A desiccant or heating to prevent condensation is necessary in damp rooms.
3.2 Transport
- Transport temperature -20˚ to +65˚C.
- Protect against external force (impact, vibration etc.).
- Don‘t damage the paintwork.
3.3 Handling before installation
- If flange covers are fitted, remove shortly before installation!
- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.
4.0 Specification
4.1 Applications
Safety valves are safety devices designed to prevent the pressure in any pressurised system fromexceeding the maximum permissible pressure by more than the permissible tolerance of, usually +10%.The engineer planning a plant is responsible for selecting the correct valve for a given application.The special features of the valve concerned must be taken into account.
- Valves for oxygen application (O2) have a fixed plate.
- Valves for Ammonia (NH 3) acc. to TRD 451-452 must be free from nonferrous metalswith flanges DIN 2512 form N.
- ARI-Valves of GG-25 are not allowed in systems acc. to TRD 110.
- Valves for inflammable, aggressive or toxic media, must be off tensile material.
- With applications for media that demand special criteria, please consult.
- -marking for applications acc. to Pressure Equipment Directive on request.
4.2 Technical specification
Terms as defined in DIN 3320 T1, TRD 421, TRD 721, AD-A2, *ASME Code Section VIII-Devision 1
Direct loaded safety valve
A direct loaded safety valve is a valve, in which the opening force underneath the valve disc is opposedby a closing force such as a spring or a weight.
*Standard safety valve
A standard safety valve is a valve which, following opening, reaches the degree of lift necessary for themass flow to be discharged within a pressure rise of not more than 10%. No further requirements aremade for the opening characteristics.
Full lift safety valve
A full lift safety valve is a valve which, after commencement of lift, opens rapidly within a 5% pressure
rise up to the full lift as limited by the design. The amount of lift up to the rapid opening (proportionalrange) shall not be more than 20% of the total lift.
Oil and grease freefor oxygen application
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Operating and installation instructions
Safety valves
4.3 Technical data
Series 900 : DN 20/32 - DN 150/250, 1“x2“ - 6“x10“Cast iron grades GG-25, GGG-40.3;cast steel grade 1.0619+N (GS-C25N), 1.4408, SA 216 WCBPN 16/16, PN 40/16, ANSI 150/150, ASME 300/150
Approved under:
Figure 901, 902, 911, 912 - VdTÜV Notice 100, AD-A2 and TRD 421.Application letter D/G and F- ASME Code Section VIII Division 1 (UV-Stamp)
Figure 903, 904, 990 - VdTÜV Notice 100, -100/4, TRD 721, DIN 4751 T1 and 2.Application letter D/G/H and D (for figures 904, 990)
Series 920 : DN 20 - DN 100
Cast iron grade GG-25; cast steel grade 1.0619+N (GS-C25N), 1.4408PN 16, PN 40
Approved under:
Figures 921-924 - VdTÜV Notice 100, AD-A2 and TRD 421.Application letter D/G and F
Series 940 : DN 15 - DN 25Cast iron grade GGG-40.3; cast steel grade 1.4408PN 40
Approved under:
Figure 941-943 - VdTÜV Notice 100, AD-A2 and TRD 421.Application letter D/G and F
Figure 945-946 - VdTÜV Notice 100, -100/4, TRD 721, DIN 4751 T1 and 2.Application letter D/G/H and D
Series 950/960 : DN 15 - DN 25 (G 1/2 - G 1)GGG-40.3, 1.4571PN 100
Approved under:
Figure 951-953 - VdTÜV Notice 100, AD-A2.Figure 961-963 Application letter D/G and F
Accessories: Stainless steel bellow for back-pressure compensation; Elastomer bellow;Soft sealing disc; Lock bush; Proximity switch; Heating jacket; Test gag;Rupture disc; Support tongues; Removable lifting aid
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Operating and installation instructions
Safety valves
4.4 Diagram
fig. 1
fig. 2
Fig. 901 Fig. 941 Fig. 961
Fig. 902 / 912 / 903 / 904 / 922 / 924 / 945 / 946
WEDI Bellow
Disc series 950 Bellow series 940Lever
Fig. 951/952; 961/962
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Operating and installation instructions
Safety valves
4.5 Parts listPos Description Pos Description
1 Body 31 Ring
2 Seat 32 Hex. nut
2a Screwed seat 33 Lift bolt
3 Stud 34 Screw4 Spindle guide 35 Lift fork
7 Gasket 36 Lifting lever
8 Hex. nut 37 Spring
9 Lift limitation ring 38 Screw
10 Spindle ring 39 Bolt
11 Bonnet, closed 40 Split pin
12 Disc unit 41 Lever open
13 Lifting aid 42 Bonnet, open14 Spindle 43 Bellow
15 Gasket 44 Ring
16 Spring type straight pin 45 Ring
17 Adjusting screw 47 Ball
18 Ball 48 Retaining ring
19 Spindle cap 55 Bellow unit
20 Parallel pin 59 Protective rim
21 Lock nut 60 Spacer
22 Hex. head screw 61 Coupling
23 Lead seal 62 Weight
25 Snap ring 63 Guide bush
26 Spring plate 65 Coupling
27 Gasket 66 O-Ring
28 Cap, closed 67 Lift button
29 Cap open 68 Spring type straight pin
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Operating and installation instructions
Safety valves
4.6 Marking
fig. 3: Type test plate
fig. 4: Body
Series with thread connections are marked on the body.
5.0 Installation
The following points should be taken into account besides the general principles governing
installation work:
- See appropriate TRD 421, AD-A2, DIN, ASME Code rules for piping and installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before installation.
- Safety valves shall be installed with vertical spindle.
- Safety valves shall be installed with upright spindle, not series 950 when marked, „Installation onlyhorizontal“, then they must be installed horizontally.
- No static, dynamic or thermal loads shall be transferred to the valve.
- Flange gaskets shall be fitted concentrically and not restrict the flow cross section.
- Dirt and foreign bodies shall not be permitted to enter the safety valve.
- Blow-off lines shall be laid with gradient.
Safety valve (TÜV)
Safety valve (ASME)
d0 αd CE-marking
Set pressure
Set pressureCapacity
NB-stamp UV-stamp CE-markingSize (inch)
Units: SCFM = airLB/HR = steamGAL/MIN = water
MechanicNo.Year
ARI Set pressure (bar / psig)
Serial-No. BA/BQ
disc
E = EPDM up to +150°CV = Viton up to +180°CN = Neoprene up to +125°C
Approval(e.g. UDT, SZU)
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Operating and installation instructions
Safety valves
- Water shall be drained from the safety valve and blow-off line via the blow-off line (drainage pointsalways at the lowest point).
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- All drainage systems shall be laid with gradient to a visible discharge.
- The arrangements shall permit the discharge of condensate without danger at all times
fig. 5
- The blow-off line shall be sufficiently large to ensure that the internal back-pressure while blowing-off does not exceed 15% of the set pressure.(Exception: safety valves with metallic bellow for back-pressure compensation).
- The safety valve shall be equipped with a metallic bellow for back-pressure compensation if the back-pressure exceeds 15% of the set pressure.
- The ratio pao/po shall be taken into account when dimensioning the system.
- The inspection connection on the bonnet of safety valves with metallic bellow is for checking the state
of the bellow as damage to the bellow leads to failure of the safety valve (in this case the bellow wouldhave no back-pressure compensating effect and the safety valve would not function as required).
- The state of the bellow is checked by connecting a pressure gauge to the inspection connection so thatthe back-pressure can be seen in the event of damage.
- Caution: No piping or screws shall project through the inspection connection into the bonnet!Danger of jamming !
- Safety valves shall be equipped with support tongues to absorb high reaction forces.
- Pressure losses in the line to the safety valve shall not exceed 3%.
- Any blocking screws shall be removed.
5.1 Safety noteFailure to observe the instructions in point 5 may endanger personnel, the plant and other
objects.
6.0 Notes on dangers during installation, operation and maintenance
DANGER !
Operation can be completely safe only if the valve is properly installed, put into operation andmaintained by trained personnel (cf. point 2.3 “Qualified personnel”) paying full attention to thewarnings in these operating instructions. In addition, the general installation and safety rules for pipingand plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict
attention must be paid to the operating instructions during all work on the valve and when handling it.Injury or damage can be caused by ignoring them.
Support
Drip pan
Drainage
Bellow
Drainage at lowest point
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Operating and installation instructions
Safety valves
7.0 Putting the valve into operation
- Check that the data of the valve are correct for the plant (see Typ test plate).
- Remove protective caps and lever lock before putting the valve into service.
- Clean and flush the plant before it is put into operation as dirty media can cause leaks in safety valves.(See point 5 “Installation”.)
DANGER !
Before putting a new plant into operation or restarting a plant after repairs or modification, always makesure that:- all installation and assembly work has been completed!- only trained personnel (see point 2.3) are employed to start the plant!- existing guards have been attached and in good order.
7.1 Potential hazards
- Always make sure that the safety valve cannot freeze or become clogged or blocked(see point 5 “Installation”.)
- The surface temperature of the casing can become very high during operations with high mediatemperatures. Danger of burns!
- If no blow-off line is provided, medium may suddenly emerge from the valve outlet. Danger of scalding, explosion or injury!
- Loud noises may be generated when blowing off.
- Hot media may emerge from the inspection opening of the spring bonnet.
- with open bonnet hot media may escape.
8.0 Care and maintenance
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due to particlesbetween the seat and disc.
- If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been damaged.This can only be rectified at our works or by an authorised contractor.
- The safety valve must be lifted from time to time in line with current regulations to ensure that thevalve works correctly.(The intervals at which this must be done depends on various factors so that no generally applicableinterval can be specified).Note: Too frequent lifting for test purposes can increase wear of the sealing surfaces.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be returned to theoriginal position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- Our setting instructions (point 8.1) must be strictly adhered to when changing the set pressure orchanging the set pressure and the spring.It is best to have these operations done at our works (Schloss Holte- Stukenbrock).
- The manufacturer accepts guarantee liabilities only if tampering by third parties is prevented.
Caution:
Safety valves acc. to ASME Code Section VIII Division 1 are only allowed to be required, altered andreset by ARI!
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Operating and installation instructions
Safety valves
8.1 Setting instructions
fig. 6
C
l o s e d c a p
O p e n c a p
B e l l o w
S A F E - T C
S A F E - T C S
S A F E - T C P
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Operating and installation instructions
Safety valves
8.1.1 Removing the cap
Open caps
- Remove pin (39/40).
- Extract lifting lever (41).
- Remove screw (38).
- Unscrew cap (29).
Closed caps
- Press lifting lever (36) towards bonnet (11) and against stop.
- Unscrew cap (28).
Closed cap series 960/950
- Remove spring type straight pin (68)
- Remove lift button (67) / lifting lever (36)
- Unscrew cap (28)
8.1.2 Changing the set pressure “without” spring change
- Check the spring range.
- Spindle (14) must be held fast by all alterations.
- Loosen lock nut (21).
- Turn adjusting screw (17) clockwise to increase and anticlockwise to reduce the set pressure.
- Secure spring setting by tightening lock nut (21).
- Assemble lifting device.
8.1.3 Changing the set pressure “with” spring change
- Spindle (14) must be held fast by all alterations.
- Extract parallel pin (20) and lift off the spindle cap (19).
- Slacken locknut (21) and relieve spring (37) by turning adjusting screw (17) anticlockwise.
- Unscrew nuts (8) at flange connection and remove bonnet (11/42).Fig. 940: loosen coupling (61)Fig. 950/960: loosen bonnet (11)
Note: With higher set pressures, the two nuts (8) on the longer studs (3) must be removed last andsimultaneously!
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Operating and installation instructions
Safety valves
- Remove top spring-plate (26) and spring (37).
- Extract spindle (14) with disc (12/12a), guide plate (4/4a) and bottom spring-plate (26).
- Clean seat (2) and disc (12/12a).
- Insert spindle (14) with disc (12/12a), guide plate (4/4a), spring-plate (26) and different spring (37).
- Fit bonnet (11/42) and reset the set pressure; make sure spring setting range is appropriate.
- Secure spring setting by means of lock nut (21).
- Assemble lifting device.
- If necessary, replace both spring plates (26) and use longer studs (3) when fitting a spring for a higherset pressure.
- Further information obtainable from the manufacturer.
Only for the 900 series.When changing the set pressure and fitting a new spring, note that safety valves with set pressuresbetween 0.2 and 1.5 bar have a greater lift.Therefore:
Caution:Safety valves acc. to ASME Code Section VIII Division 1 are not allowed to be delivered with a liftlimitation!
Only for the 950 series
Caution:
Safety valves for horizontal application, must also to be set in a horizontal position.
9.0 Troubleshooting
In the event of failures or malfunctions, check that the valve was assembled and installed as described inthese instructions.
Compare the DN, opening pressure, blowing-off power, back pressure, operating pressure andtemperature with the information given in the plans of the piping system. Check also that the serviceconditions correspond to VDTÜV, AD, TRD, ASME Code and the data given on the Type test plate andthe technical data.
Danger!
It is essential that the safety regulations are observed when identifying faults!
If malfunctions cannot be eliminate with the help of the following „ troubleshooting table“, the supplieror manufacturer should be consulted.
Set pressure in the range Spring change only inthe range
0.2 to 1.5 bar 0.2 to 1.5 bar
> 1.5 bar > 1.5 bar
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Operating and installation instructions
Safety valves
10.0 Troubleshooting table
Fault Possible cause Corrective measures
Safety valve does not respond,no flow
Flange covers not removed. Remove flange covers.Relieve pressure first!
Observe points 7.0 and 11.0!
Test gag still in place. Remove test gag.
Spring blocked. Remove pipe or screw projecting into bonnetthrough inspection connection.
Set pressure too high. Reset (point 8.1) or replace the safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
Stainless steel bellow defective,no back-pressure compensation.
Replace the safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
Back-pressure not taken into account. Reset (point 8.1) or, if necessary, replace thesafety valve.Relieve pressure first!
Observe points 7.0 and 11.0!The use of a stainless steel bellow tocompensate for back-pressure should beconsidered.
Medium viscous or sticky Use bellow / heating jacket. Insert rupturedisc upstream if necessary.Relieve pressure first!
Observe points 7.0 and 11.0!
The valves and piping must be protectedagainst freezing and solidifying media.
Heating !
Stem cannot be lifted. Pressure less than 85% of set pressure. It must be possible to lift the spindle at over85% of the set pressure.
Safety valve seat leaking. Working pressure higher than 90% of setpressure.
Working pressure must be less than 90% of the set pressure.
At low pressures: lever not in neutral positionwith closed cap.
Press lever into neutral position (towardsbonnet).
Safety valve flattering. See separate point “Flattering”.
Medium contaminated; foreign body betweenseat and disc.
Raise spindle briefly or, if necessary, replacesafety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
Use of a soft sealing disc should beconsidered.
Flange broken. Damage during transport. Replace safety valve.Flange bolts not evenly tightened. Replace safety valve.
Relieve pressure first!
Observe points 7.0 and 11.0!
Pressure surges. Safety valve not installed at highest point. Install safety valve at highest point.Relieve pressure first!
Observe points 7.0 and 11.0!
Valve drainage inadequate or not fitted. Install drainage system a required byregulations.Relieve pressure first!
Observe points 7.0 and 11.0!
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Operating and installation instructions
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Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screwabove cap, Figure 990).
Spring corroded by medium and broken. Replace safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
In the case of vapour, select open cap orbonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. liquids)emerging from valve.
Replace safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
Select design with closed bonnet and cap.Install a guard if necessary.
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or radiusin connection socket. Select larger line if necessary.Relieve pressure first!
Observe points 7.0 and 11.0!
Poor welding (root pass), gaskets at inlet andoutlet flanges too small or not concentric. Change conditions.Relieve pressure first!
Observe points 7.0 and 11.0!
Safety valve capacity too high. Install smaller safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
Burner capacity too low. Install smaller safety valve.Relieve pressure first!
Observe points 7.0 and 11.0!
Blow-off line too long or diameter too small. Use larger diameter or back-pressurecompensation by stainless steel bellow.Relieve pressure first!
Observe points 7.0 and 11.0!
Inlet and/or outlet socket too small. Install with dimensions larger than DN of inlet and outlet lines.Relieve pressure first!
Observe points 7.0 and 11.0!
Back-pressure higher than 15%. Install stainless steel bellow for pressurecompensation.Relieve pressure first!
Observe points 7.0 and 11.0!
Capacity too low. Safety valves not applied unsuitable for plantconditions.
Select and install suitable safety valves.Relieve pressure first!
Observe points 7.0 and 11.0!Safety valve not applied in line with currentDIN, AD, TRD, etc. rules.
Adjust conditions.Relieve pressure first!
Fault Possible cause Corrective measures
Recommended