Instruction Manual

TABLE OF CONTENTS
Table of contents
General
General.......................................................................................................................1
Technical Data
Technical Data............................................................................................................2
Main Diagram
Main Diagram.............................................................................................................3
Electrical System
Electrical System.........................................................................................................4
TFO
TFO...........................................................................................................................5
Burner
Burner........................................................................................................................6
Pumps
Pumps........................................................................................................................7
Expansion Tank & System Pipes

Expansion Tank & System Pipes...................................................................................8
Heat-Exchanger
Heat-Exchanger...........................................................................................................9
Plate Heat-Exchanger.................................................................................................10
Valves
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TABLE OF CONTENTS
Valves......................................................................................................................11
Accessories & Other Equipment

Accessories & Other Equipment..................................................................................12
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TABLE OF CONTENTS
Table of contents
General
.
Description Document ID Page
Operation manual...................................................... 203809........................ 1-2
Selection Of A Heat Transfer Fluid.............................. SD9012_02.................. 1-10
How to safely take a hot water sample.......................... OM9012_02................ 1-19
Water quality guidelines hot water systems................... OM9012_05................ 1-21
Commissioning guideline thermal oil systems............... RTM_OM9012_08....... 1-22
General guarantee information.................................... SD9010_39.................. 1-26
Preface / conditions.................................................... SD9010_40.................. 1-28
Safety precautions..................................................... SD9010_41.................. 1-29
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Operation manual
Thermal oil system 203809 – Rev. A (2019-05-06)
Operation manualTable of Content
1 Important .................................................................................................................................................1
1.1 How to contact Alfa Laval ....................................................................................................................1
2 System Operation ....................................................................................................................................3
2.1 Before start up .......................................................................................................................................3
2.2 Starting the oil-fired heater....................................................................................................................3
2.3 General reset ..........................................................................................................................................4
3 Description of the installation .................................................................................................................5
3.1 Prioritizing consumers ...........................................................................................................................5
3.2 Thermal fluid circulation pumps ...........................................................................................................6
3.3 Oil fired heater with burner ...................................................................................................................6
3.4 Electrical heat exchanger.......................................................................................................................6
3.5 Heat recovery from jacket water cooling system ..................................................................................7
3.6 Maximum pressure control ....................................................................................................................7
3.7 Expansion tank ......................................................................................................................................7
4 General set points ....................................................................................................................................7
5 Alarm list and troubleshooting guidelines. ..............................................................................................8
1 Important
The following chapters of this instruction manual describe the operation of the
thermal fluid installation. It is important to study all the chapters in this manual
thoroughly as well as the individual manuals of the separate components. It is
especially important that the operator of the installation becomes familiar with the
operation instructions of the burner and the control panel.
Important: To ensure a safe and reliable operation of the thermal fluid system,
all operation and/or maintenance of the system should be carried
out only by qualified personnel.
If any unexpected plant behaviour, deterioration or similar event should occur such
as to raise any reasonable doubt as to the continued safety of the plant, the matter
should be reported at once to Alfa Laval for their advice.
Repairs, adjustments, alterations or changes to plant operation not covered by these
instructions should not be effected without reference in writing to Alfa Laval.
For detailed operating instructions please see the separate instruction manuals of the
individual parts
1.1 How to contact Alfa Laval
How to contact Alfa Laval?

Contact details for all countries are continually updated on our web site.
Please visit www.alfalaval.com/marine to access the information directly.
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2 System Operation
The thermal fluid system may only be taken into operation after commissioning,
when the burner and all safeties have been adjusted to the correct settings. If one of
the safety devices is activated, the installation will be switched off and electrically
blocked.
Important: IT IS NEVER ALLOWED TO OVERRULE THE SAFETY

DEVICES!
During commissioning of the thermal fluid system the set point for the correct
supply temperature will be determined. It is possible to adjust the set point
afterwards but it is not recommended. During commissioning the Alfa Laval
commissioning engineer will balance the thermal fluid system, changing set points
might upset this balance and create instability which can result in continues stopping
and starting of the burner.
2.1 Before start up
Before operating the system:

Step A: Check if all valves are in the correct position before operating the system.
See the main flow diagram for correct start-up positions of the valves.
Step B: Check the thermal fluid level in the expansion tank. The level in the tank
must be up to about one third of the tank.
Step C: Turn on the main switches on the control box(es).
2.2 Starting the oil-fired heater
Step A: Start the thermal fluid circulation pump for the oil-fired heater.
Step B: Start a fuel oil pump. The selected fuel should be MDO.
Step C: Check flow over oil fired heater and fuel oil ring-line pressure.
Step D: Reset the system with the reset button.
Step E: Adjust temperature on temperature controller of oil-fired heater.

Temperature controller
The set-point of the temperature controller can be adjusted by pressing the "P"
button; the set point will be shown on the screen and can be changed by using the
"UP" and "DOWN" buttons. (see also instruction book temperature controller).
To switch back to the supply temperature screen press the "P" button again (the
controller will switch back automatically after 60 seconds).
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Step F: Check if light “burner ready to start” is on
Step G: Start burner with burner selector switch, partial load or automatic.
Step H: The burner will always start on partial load, if automatic control is selected
the burner will switch to automatic load control when the thermal fluid flow
is sufficient.
As long as the thermal fluid return temperature is below 80 °C and the flow is below
0.2bar(g) the burner is not able to burn at full load.
The burner will start fully automatic according to the following procedure:
 Air flap (servo) in closed position.
 Burner motor will be started, air flap will go to full load position
 Start of the pre-set purge timer, the purging time is fixed in the burner relay,
during purging the oil-fired heater is ventilated.
 Air flap to start up/low flame position.
 Safety solenoid valves will be opened and fuel oil circulates over the nozzle
head for pre-heating purposes.
 Ignition activated
 Fuel valves will be actuated, 5 seconds safety time will start.
The burner starts in the lowest position, after the 5 seconds safety time a stabile
flame has to be registered by the flame scanner, if no flame is registered, the burner
will give a flame failure, shut off the fuel oil valves and block the installation
electrically.
The temperature controller is provided with two switches. When there is a large heat
demand the second switch will be closed and the burner will operate at full load. If
the heat demand is reduced the burner will automatically switch back to partial load.
In the return line of the oil-fired heater a second Pt 100 sensor is installed, which is
also connected to the temperature controller. By means of a push-button (see the
description of the controller) you are able to read out the inlet temperature of the
thermal fluid into the oil-fired heater. While showing the return temperature, the
controller will maintain the supply temperature at the set point.
2.3 General reset
If one of the safety devices is activated, the burner will be switched off and
electrically blocked. The installation has to be reset by pressing the reset button on
the switch panel and the burner can be started again.
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3 Description of the installation

The hot water system is installed on-board a cable laying vessel and main purpose is
to provide heat to the below mentioned consumers in prioritized order:
1. Sanitary or potable hot water heater 300 kW (Alfa Laval supply).

2. HVAC consumers 313 kW (Yard supply).
3. Freshwater generator 844 kW (Yard supply).
In the thermal fluid system, the following main components are installed:
 Two circulation pumps
 One oil fired heater with a 2-stage burner.
 One electrical heat exchanger 42 kW
 Plate heat exchangers for heat recovery from jacket water cooling system.
 An electric min. flow control - Pressure controlled
 An expansion tank (membrane pressurized tank)
3.1 Prioritizing consumers
First priority hot water heat consumer is the sanitary/potable hot water heater. The
system is designed to ensure a sufficient flow of hot water to this heater at all times.
A manually set constant flow of hot water will pass trough the heater and a manual
3-way valve will allow for by-pass during maintenance.
Second priority hot water heat consumer is the HVAC system. This consumer will
be fed with hot water flow and thereby heat up to max 313kW after the
sanitary/potable hot water heater is supplied.
The flow of the hot water to the HVAC system is regulated by means of an electric
2-way valve (TAG no. 1T452) placed in the supply line to the HVAC consumer and
regulation is based on a minimum hot water temperature in the supply line to the oil-
fired heater using a temperature transmitter (TAG no. 1T286).
Third and thus lowest priority hot water consumer is the fresh water generator.
Flow of hot water through this heat exchanger is controlled by means of a 3-way
control valve (TAG no. 1T551) in the fresh water generator supply line and
regulated based on a minimum hot water temperature in the return line from the
HVAC system using temperature transmitter (TAG no. 1T287). When the hot water
temperature drops below the pre-determined set-point, the controller regulates
modulating towards closed position on the 3-way valve until a temperature equal to
or above the set-point is once again reached.
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3.2 Thermal fluid circulation pumps
There are two circulation pumps installed in the system, one circulation pump will
generate enough flow for the entire system, the second circulation pump is installed
as a stand-by pump. If included in scope, please make sure that the stand still
heating is switched on when the pump is not running/ on stand-by.
Important: Make sure all valves are in the correct position before operating
the pumps
The circulation pumps can be started with a switch on the control box:
 On
 Off
 Stand-by
After a black out the pump will re-start automatically (if the pump was running
before the black out). For more information on the circulation pumps please see the
chapter circulation pumps in this manual.
3.3 Oil fired heater with burner
Temperature controller in the control box receives input from temperature sensors,
in the supply line and in the return line after the oil-fired heater. The required supply
temperature can be entered as a set point in this controller. The temperature
controller commands the oil burner. For more information see chapter “oil fired
heater” in this manual.
The burner is a 2-stage burner.
On the control box the following settings can be chosen:
 0 Off
 1 Partial load
 2 Automatic
For more information see chapter “Burner” in this manual.
3.4 Electrical heat exchanger
An electrical heater type EH20 (TAG no. 1T800) is included in the system.
The heater can add additional 42kW heat-input to the thermal fluid, if required.
The heater operates as stand alone from main control system with its own electrical
cabinet. Based on thermostat settings it will connect/disconnect 4 separate heating
steps.
The heater control can be switched between on/off position manually on the heater
cabinet front.
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3.5 Heat recovery from jacket water cooling system
4 jacket water heat exchangers (heat exchange of up to 250kW each) are installed on
the pressure side of the circulation pumps.
If ship’s engines are in operation, heat will be transferred from engine jacket cooling
system to the hot water system.
Amount of heat energy exchanged depends on jacket water flow and temperature.
3.6 Maximum pressure control
The maximum pressure control consists of a 2-way valve (TAG no.1T270) and a
pressure transmitter (TAG no. 1T284).
In case the HVAC consumers are consuming more than the available heat energy,
the return temperature will be below setpoint (TAG no. 1T286), the supply of HW to
HVAC will be reduced by partly closing the control valve (TAG no. 1T452). Due to
the lower flow, the pressure at pressure transmitter (TAG no. 1T284) will rise and
the control valve (TAG no. 1T270) will be opened to bypass the HVAC.
With the maximum pressure control the pressure in the system will not increase too
much and stable flow rate towards the sanitary heater is maintained.
3.7 Expansion tank
To accommodate for fluid expansion a pressurized membrane type expansion tank

has been installed. For more information please see the chapter expansion tanks and
system pipes in this manual.
4 General set points
General set Final set

point point
Temp.controller oil fired heater (OFH) 96°C °C
Flow switch OFH (T34) Low alarm 0.2 bar(g) bar(g)
Max. Flue gas thermostat OFH (T32) HH alarm 360 °C °C
Max.temp. TF thermostat (T24) HH alarm 230 °C °C
Minimum flow control (T284) 2.5 bar(g) bar(g)
Stand‐by switch circulation pump (T427) 4 bar(g) bar(g)
Safety valve (T1) pre‐set at 10 bar(g) ‐‐
Exp. Tank safety valve (T187) 3 bar(g) bar(g)
System pressure low low (T181) 2 bar(g) bar(g)
System pressure high high (1T46) 4 bar(g) bar(g)
HVAC temp controller set‐point (T286) 76 °C °C
Fresh water generator controller (T287) 60 °C °C
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More set points can be found in the project specific Control and Alarm list that can
be found within the chapter Electrical systems within the manual.
Note: Final set points will be adjusted during commissioning. We advise to

register these final settings in this manual.
We advise you to have the installation checked by one of our service engineers
every year.
5 Alarm list and troubleshooting guidelines.

Note: Pre-alarms are for notification ONLY, no automatic action will follow.
Alarm Automatic action Follow up

Burner trouble:
Common burner alarms: Check: Fuel supply, flame sensor (see burner
Alarm, burner shut down + lock
‐ No feedback instructions)
‐ Flame failure
Burner flange open Alarm, burner shut down + lock Close burner/check switch
Flue gas temp. HH Alarm, burner shut down + lock Check/ clean convection part of heater
T.F Temp. HH‐ OFH Alarm, burner shut down + lock Investigate cause.
Are all valves in correct position?
Flow LL OFH Alarm, burner shut down + lock Are TF circulation pumps running?
Are TF strainers un obstructed?
Alarm; circ. pump 1 stop; when
Find cause for tripping see instruction manual
Circ. Pump 1 trip in standby mode circ. pump 2
circulation pumps
will be activated
Alarm; circ. pump 2 stop; when
Find cause for tripping see instruction manual
Circ. Pump 2 trip in standby mode circ. pump 1
circulation pumps
will be activated
Alarm, burner shutdown + lock,
System pressure low low Investigate cause
circulation pumps stopped
System pressure high high Alarm, burner shutdown + lock Investigate cause

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SELECTION OF A HEAT TRANSFER FLUID
SD9012#02
Selection of a Heat transfer fluid
Selection Of A Heat
TableTransfer
of Content Fluid
1 Introduction .............................................................................................................................................1
2 General demands .....................................................................................................................................2
3 Water .......................................................................................................................................................2
3.1 Heat storage ...........................................................................................................................................2
3.2 Thermal stability....................................................................................................................................2
3.3 Economical conveying ..........................................................................................................................3
3.4 Acquisition costs ...................................................................................................................................3
3.5 Operation risks ......................................................................................................................................3
4 Thermal oil ..............................................................................................................................................4
4.1 Heat storage ...........................................................................................................................................5
4.2 Thermal stability....................................................................................................................................5
4.3 Heat transfer characteristics ..................................................................................................................5
4.4 Economical conveying ..........................................................................................................................6
4.5 Acquisition costs ...................................................................................................................................6
4.6 Operation risks ......................................................................................................................................6
4.7 Minimum thermal oil requirements .......................................................................................................7
4.8 Rejection criteria for mineral oil ...........................................................................................................7
5 Definition of terms ..................................................................................................................................8
1 Introduction
Choosing a heat transfer fluid (also called thermal fluid) can sometimes be a
difficult decision. What makes one better than the other? Why do some last longer?
How do I know which one is best for my application?
Water, mineral oil based or synthetic fluids may be used as the heat transfer medium
in our systems. The medium can be selected from many commercially available
products depending upon the system operating parameters, but mainly depends upon
the system operating temperature.
This document will give some information about the different types of thermal fluids
that can be used in our systems.
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2 General demands
Heat transfer media transport heat from the heat-generators to the heat-consumers.
They carry heat and release it at the heating surface of the consumers. Therefore,
they must fulfil some relevant specifications, in particular:
• Ability to store heat (favourable heat transfer characteristics)
• Capability to handle operating temperature (temperature range)
• Film temperature/ Boundary layer temperature
• Safe operation in specific application (think food grade quality or not)
• Environmental considerations
• Economic operation (price of the fluid/ operating duty)
• Availability
All the above mentioned characteristics are not always fulfilled simultaneously. For
the choice of an adequate heat transfer medium, advantages and disadvantages must
be balanced.
The most essential characteristics for the operator are the minimum operating and
the maximum feed line temperature. The other values are particularly important for
the plant designer and heater manufacturer.
3 Water
Of all the heat transfer media, water is currently the most popular and this will
probably also be true in the future.
Water fulfils a lot of the above mentioned criteria but its operation limits are limited.
High temperature operation leads to high system vapour pressures and it cannot be
used at temperatures below freezing without adding additives
Water is the ideal heat carrier for a temperature range of 0°C to 100°C. When used
at higher temperatures the system pressure should be increased accordingly.
3.1 Heat storage
Water is able to store a lot of heat. The specific heat content (storage capacity)
amounts to 4.181 kJ/kg.K (at an ambient pressure of 1 bar(g) and an ambient
temperature of 20°C)
3.2 Thermal stability
Water is stable under high temperatures. It does not decompose during overheating
and it does not age. It is non-sensitive to oxidation, but it adsorbs gases and minerals
which can change its properties.
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The characteristic of water to freeze at low temperatures and expand in volume is a
slightly unfavourable characteristic (Water is the only medium with this trait). It can
result in breakage of pipelines and equipment, but it is relatively easy to counteract
with additives or with other basic provisions. Of course not all additives are cheap or
compatible to be used at high temperatures as well.
3.3 Economical conveying
Water has a low viscosity and can be easily and economically pumped. The friction
losses in pipelines are low. First limitations are encountered during the design phase
when temperatures above 100°C are needed.
A higher design temperature results in a fast increasing design pressure. Costs for
suitable pipes and fittings quickly become uneconomical. For heating systems, the
pressure rating of PN40 represents the economic limit. Above this rating the fitting
designs become complicated and their prices rise rapidly.
3.4 Acquisition costs
Water is available in any quantities but costs can be incurred for water treatment.
Water in closed loop systems is less of a problem. Effectively, it is self-conditioning.
Problems with the water treatment can lead to damage of the plant and equipment.
3.5 Operation risks
Water is benign to the environment. Leaks are mostly harmless except if they occur
in areas such as electrical rooms or heat consumers where water can do damage.
But risks rise as the temperature increases. The absolute vapour pressure of water
increases approximately with temperature (°C) the power of four!
At 110°C, a pressure of only 0.5 bar is achieved. At 140°C, a pressure of 3 bar is
already experienced, going to 5.5 bar at 160°C, 9.5 bar at 180°C and 15 bar at
200°C. The operation-limit of fittings with a pressure rating of PN 40 is attained at
238°C. Then, a pressure of 32 bar occurs.
The following condition must also be taken into consideration: if a pressure vessel
with liquid under high vapour pressure bursts, a part of the liquid (approx. 15 %)
evaporates rapidly and moves just as rapidly a big volume of air.
This characteristic of water to develop high vapour pressure at practically rather low
temperatures causes unavoidable operating limits and forces the search for
alternatives. An alternative to water is thermal oil.
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4 Thermal oil
The main advantage of heat transfer with thermal oils is that these systems do not
generate a vapour pressure above 1 bar(g), even at very high temperatures. This
means thermal oil systems, with the exception of some exotic installations, form low
pressure heat transfer systems. Our non-pressurized closed-loop thermal fluid
systems are mostly filled with mineral oils, synthetic and organic-based formulas.
Synthetic organic-based fluids will reach the highest temperature ranges, from
approx. -50ºC to +350ºC.
There are several thermal oil classifications:

• Mineral thermal oils (treated distillates from petroleum), characterized by low
price and having the advantage that certain of them are miscible with each other.
• Synthetic thermal oils, these are synthetic organic fluids that are designed for
special applications, mostly used in high temperature applications.
• Silicone oils, these are special synthetic thermal oils with carbon-silicon chains
in the molecular structure that offer a special high temperature thermal stability.
These oils are less frequently used.
Furthermore, there are special oils for example:
• Cleaning oils that dissolve deposits in the pipelines.
• White oils that are non-toxic and that are useful in the food industry.
Most brands of thermal oils are suitable for our heaters, below are some brands that
we recommend. We have mentioned just one type of fluid of various makers, but of
course many other types of fluids and makers can fulfil the demands of the
installation and thermal fluid heater.
Mineral fluids Synthetic fluids

Shell Thermia B Therminol 55
BP Transcal N BP Transcal S
Mobiltherm 605 Monsanto Santotherm 66
Texatherm 32 / Texatherm 46
Gulf Transotherm M
Castrol Perfecto HT5
There are many oil companies and/or makers that can deliver mineral-oil based
fluids and most look alike, they all transfer heat efficiently, some just tend to last
longer than others. We have just mentioned some brands of fluid, so that you can
compare to other fluids.
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4.1 Heat storage
Thermal oils have by volume about half the heat storage ability compared to water
but because of higher temperature application limits, this disadvantage can be
adjusted by higher temperature difference between the feed and return flow. This
results in typically the same pipe size as for a water plant.
The application as vapour is also possible with particular oils at higher temperatures.
While the heat for condensation is considerably lower than for water, the specific
vapour-weight is considerably higher. Even in this case, the dimensions of vapour
pipes are nearly the same as for steam. A changeover of consumers from hot water
or steam operations to thermal oil is often possible while keeping the same
connecting pipes.
4.2 Thermal stability
It is quite possible to destroy thermal oils by over-heating. Low cost mineral oil
based thermal oils have allowable operating temperatures up to approximately
300°C with a lifetime of 10 years and more. High-quality synthetic oils can be used
up to 400°C. For these the lifetimes can be rather low but these oils can be
economically regenerated.
Special precautions are taken in all our thermal fluid systems to make sure that the
oil cannot be overheated in boundary layers in the heater. A minimum flow control
system and high temperature alarms are mandatory in all our systems.
Further, it must be taken into consideration that the permitted feed line temperature
indicated in thermal oil manufacturers’ literature is the temperature at which the oil
is only serviceable for one year. So a certain safety margin must be observed with
this temperature. With each 10°C temperature reduction, the thermal oil lifetime
typically doubles.
4.3 Heat transfer characteristics
Even in this parameter, thermal oils are comparable to water. The transition point
between laminar and turbulent flow occurs a little bit later. This must be taken into
consideration when heating surfaces are designed.
The heat transfer surfaces of heaters must be adapted to the particular oil and to the
design circulation. These parameters do not allow the same heater design to be used
for water and thermal oil systems especially at a lower temperature range.
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4.4 Economical conveying
As previously mentioned, circulating volumes and pipe sizes are comparable with
heat transfer plants using water. From 100°C, most oils are low viscosity so the costs
for circulation are comparable to water.
4.5 Acquisition costs
Thermal oils are more expensive to purchase than water. The thermal oil system
must be leak free. Conditioning & treatment costs for makeup water do not occur in
thermal oil plants. Furthermore, thermal oils effectively protect the pipeline system
against corrosion.
Standard mineral oils are inexpensive to purchase when considered as a proportion

of the cost of a new plant. In contrast, high-quality synthetic oils for use in the high
temperature range are quite expensive. Here it is difficult to find a low-priced
alternative. Heat transfer plants using liquid metals, fused salt or hot gases are only
an economical alternative where very high temperatures are required and their use is
unavoidable.
4.6 Operation risks
Several different possible risks must be kept in mind:

• Leakage:
Leaks absolutely have to be avoided because most thermal oils (with exemption
of “white oils”) are hazardous to the environment. Special precautions and
system design decisions to make leaks very unlikely have to be made, such as
special shaft seals for pumps and fittings, use of fittings with weld ends, design
of collecting oil pans, use of high-quality sealing materials such as Grafoil and
use of special insulation design at flanges.
• Fire Risk:
Thermal oils are flammable but – due to the higher thermal stability – more
difficult to ignite than usual organic oils. A big risk occurs for insulation
material that becomes oil-saturated. This can spontaneously ignite due to the
massive surface area exposed to air.
• Pressure:
In most plants the thermal oil is not under vapour pressure but only under pump
pressure. Elevated expansion tanks have to be designed in such a way that they
can be isolated from the system and/or quickly drained during an emergency.
For plants with thermal oils under higher pressures, the above mentioned
advantages are not fully realized. But in this case the operation pressure and the
subsequent damage risk for pressurized vessels are quite low.
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4.7 Minimum thermal oil requirements
Minimum thermal oil requirements for our standard closed loop systems are:
• Paraffin based oil
• Viscosity index > 100
• High thermal stability
• Good oxidation stability
• Flash point COC > 180°C
• Fire point > 230°C
• Boiling point < 320°C (76 cm Hg)
• Acid number 0.05 mg KOH/g
• Conradson carbon < 0.05 (wght %)
• Viscosity 35 mm2/s - 20 mm2/s by 40°C
• Film temperature ≥ 340°C
• Expansion coefficient approx. 0.00075 (1/°C)
Obviously the demands made of the oil depend largely on the supply (bulk)
temperature. On new plants the oil should be tested three months after
commissioning. After that tests are recommended every six months.
All oil samples submitted for tests should be tested on:

• Viscosity
• Flash point
• Acid number
• Conradson carbon
The recommendations made by the thermal fluid provider are leading
4.8 Rejection criteria for mineral oil
• Viscosity
Most new unused oils have a viscosity of approximately 25 mm2/s at 40°C. The
rejection limit is reached when the viscosity increases by more than 50 mm2/s at
40°C. The viscosity will fall if the oil is overheated (cracked). In general thermal
cracking occurs at temperatures above 340°C.
• COC flash point
Most new unused oils have a flash point of about 220°C. The rejection limit is
reached when the flash point is reduced to about 140°C.
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However, the flash point by itself does not need to be a reason for rejection.
• Acid number
Most new unused oils have an acid number of less than 0.05 mg KOH/g. The
rejection limit is reached when the acid number exceeds 2 mg KOH/g.
• Conradson carbon
Most new unused oils have a Conradson carbon index of less than 0.05 % wght.
The oil has reached the rejection limit when the index rises to 1 % wght.
Generally speaking one rejection limit is unlikely to cause the rejection of a full oil
batch of oil. Similarly the reduction of the flash point or increase of the Conradson
carbon index (which fall and rise quite quickly in a new plant) will not immediately
lead to rejection.
The reason for this is that in a new system the reduction or rise will happen quite
quickly and be followed by stabilisation. After some time the oil will turn black and
develop a penetrating odour. This is also normal. The decision whether or not to
reject the oil can only be taken after the appropriate laboratory tests by the oil
supplier.
5 Definition of terms
• Flash point
The temperature at which the vapours produced from a fluid will ignite (flash
off) with the presence of an ignition source (the fluid will not burn at this point).
While some applications might require a high flashpoint fluid, it is quite
common to operate systems at temperatures above the flash point of the fluid.
• Fire point
The temperature at which the fluid will sustain a fire if ignited by an outside
ignition source. Heat transfer systems are commonly run at temperatures above a
fluid’s fire point as the fluid is contained within the system, far removed from
ignition sources.
• Maximum bulk temperature
The maximum bulk temperature is the thermal oil’s highest average temperature
and will usually take place at the exit of the fluid heater.
As a rule of thumb, the rate of thermal degradation will approximately double
for every 10ºC increase in the bulk fluid temperature. Therefore, the fluid's life
will be cut in half by operating 10ºC above the maximum rate bulk temperature.
Similarly, lowering the temperature 10ºC will cut the rate of degradation in half.
Given that relatively small changes in temperature can have such a large effect
on fluid life at elevated temperatures, it is very important to accurately
determine the maximum average system temperature to select a thermal oil with
a bulk temperature below that temperature to get the best possible fluid life.
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SD9012_02#A.3
SD9012#02
• Film temperature
The film temperature is an approximation to the temperature of a fluid inside a
convection boundary layer, normally it is found adjacent to the tube wall at the
heating surface. It is calculated as the arithmetic mean of the temperature at the
surface of the solid boundary wall and the free-stream temperature
Maximum film temperature is the highest acceptable temperature a fluid may
experiences in the system.
• Boundary layer temperature.
The absolute temperature limit that may not be exceeded in the heater.
• Minimum temperature.
That at which the plant can be filled without any problems. At this temperature,
it must also be possible to start-up the plant meaning an operation with
minimum heater capacity with a reduced flow must be possible.
• Minimum operating temperature
That at which economical operation is possible.
• Maximum feed line temperature
That at which the oil has a specified life of one year (but due to the lower return
line temperature, the oil could still be used two years in the plant before needing
to be changed).
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OM9012_02#A.2
HOW TO SAFELY TAKE A HOT WATER SAMPLE
How to take a hot water sample
How
Takingto safely
a hot water take
samplea hot water sample
The sample should be taken with system running and at normal working temperature at a location with
sufficient flow through the pipes. This way the turbulent flow will ensure that a homogenous mix of water
is sampled. Also any insoluble contaminants will, for the same reason, be more likely to be suspended
within.
Important: Wear adequate protective gear like heat resistant gloves and safety goggles when taking
a hot water sample.
To take a sample:
Step A: Open the valves before and after the sampling pipe (1) and (2) and let the
thermal fluid circulate for at least 5 minutes to ensure a representative
sample of the thermal fluid.
Step B: Then close the valves and let the sampling pipe cool down to a safe
handling temperature.
Step C: Open valve (4 ) and have the sampling container ready- always use a clean
sampling bottle with tight-fitting cap to be tested according to the water
treatment plan.
Step D: Open valve (3). to break the vacuum in the sampling tank.
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OM9012_02#A.2
HOW TO SAFELY TAKE A HOT WATER SAMPLE
How to take a hot water sample
Step E: After taking the sample close all valves.
Open valve (2)and slowly open valve (3) to bleed of air.

Beware the thermal fluid entering the sample pipe is HOT take the necessary safety
measures to prevent scalding.
Step F: After all the air has been vented close valve (3).valves (2) can be left open.
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OM9012_05#A.2
WATER QUALITY GUIDELINES HOT WATER SYSTEMS
Water quality guideline
Closed hot water systems
Water
1
quality guidelines hot water sys-
General
tems
Alfa Laval Aalborg gives some general requirements and recommendations
regarding the conditions of the water in your closed hot water system. These are
guidelines only and as such they may not be sufficient for special regulations e.g. in
food or pharmaceutical industries. The strictest requirement of the individual
application must be complied with.
Note: These guidelines apply to thermal fluid heaters which use water as heat
transfer medium and are heated by combustion of one or more fuels or
by hot gasses.
System water for Hotwater Heater

Parameter Unit System water
Operating pressure MPa Total range
Conductivity at 25°C µS/cm < 1500
pH value at 25°C - 9.0 to 11.5*1
Acid capacity up to pH mmol/l <5
8.2
Silica (SiO2) mg/l -
Phosphate (PO4)*2 mg/l -
Organic substances - -
*1
If non-ferrous materials are present in the system, e.g. aluminium, they may require lower pH value and
conductivity, however, the protection of the heater has priority.
*2
If phosphate is used, considering all other values higher PO4-concentrations are acceptable, for instance with
balanced or co-ordinated phosphate treatment.
• In a closed system, water treatment is only necessary at first start up when filling
the system and when new water is added to make up for losses due to
maintenance and/or repair.
• The water should be tested just after start up and after every fill-up afterwards.
• Any changes in the appearance of the water regarding suspended solids, colour,
or foam indicate that uncontrolled changes have occurred and the water should
be tested immediately and corrective measures must be taken.
For more information on which chemicals to use to treat your system water please
contact your supplier of water treatment chemicals.
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RTM_OM9012_08#A.2
COMMISSIONING GUIDELINE THERMAL OIL SYSTEMS
OM9012#08
Commissioning guideline thermal fluid systems
Commissioning guideline Table of Content thermal oil sys-

tems 1 General ...................................................................................................................1
2 Prior to commissioning ..........................................................................................1
3 Commissioning by Alfa Laval engineer.................................................................2
3.1 Commissioning of the HFO burner ..................................................................4
3.2 Sea trail.............................................................................................................4
3.3 Set points ..........................................................................................................4
1 General
In order to guarantee a faultless functioning of the thermal fluid installation, the
following points are to be observed during the commissioning of these installations.
The yard/builder is expected to have taken care of the correct installation of the
various parts of the installation according to the procedures and recommendations
given to the customer in the approval/working drawings. The various pipe systems
are expected to have been installed according to the agreed (PI) diagrams.
The electrical installation is expected to have been executed according to the

electrical diagrams and according to the rules and requirements of the classification
society and local authorities. It should be noted that signal lines should not be
installed close to power lines or other sources, which may conduct a magnetic field,
which can disturb the normal operation.
The special types of heaters and installations must be observed. The operating staff
should be made familiar with the special piping diagrams, the installation scheme
and operating instructions for heater and auxiliary equipment before the start of the
operation and should be informed about the functioning of the whole plant by using
these instructions. There should be sufficient spare-parts available for maintenance
and repair.
2 Prior to commissioning
The total pipe network and the heat consumers should as far as possible be checked
for leak-tightness with air under low pressure (1.5 - 2 bar).
Our thermal fluid heaters and exhaust gas heat exchangers are already pressure
tested in our factory by the classification. The maximum working pressure of these
parts is 10 bar(g). The pressure test with thermal fluid has been carried out with a
minimum pressure of 15 bar(g) or a pressure in accordance with the classification.
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RTM_OM9012_08#A.2
OM9012#08
Before the leak test, close all the valves to the expansion tank and temporarily install
a blind flange in the de-aerating line to close the system.
Important: Check all measuring and control equipment carefully for their
maximum pressure tolerances and take protective measures to
keep them from damage
When all piping is leak tested, the instrumentation placed and connected, the system
is ready for commissioning by an Alfa Laval commissioning engineer.
It is not advisable to fill the system until the complete installation has been inspected
by the commissioning engineer.
When the commissioning arrives on board the following items have to be

completed/ available on board:
• Total pipe network should be completed, leak tested and ready for filling
Note: Thermal oil systems should be delivered as clean and dry as possible,
vacuum or nitrogen dried.
• All electrical connections should be done, working on switch panel is NOT

allowed during and after the alarms have been checked
• Power supply (correct system voltage if possible) should be available to the
control panel(s)
• Thermal fluid (sufficient amount and type) filled into the storage tank.
• Fuel (MDO) should be available.
Important: Make sure that the area around the installation is safe, sufficiently
clean and lightened for our commissioning engineer to work in.
3 Commissioning by Alfa Laval engineer

Depending on the size of the plant, the systems applications (e.g. heavy fuel oil
burner) and whether or not there are secondary systems to start up there can be one
of more commissioning visits and or a sea trial.
During the commissioning the engineer will perform the following tasks:
• Check of the piping network (heating plant, secondary system(s) and fuel
piping) according Pi diagrams, placement of instrumentation
• Power up the switch panel(s).
• Prepare and start the filling pump, fill the system
Duration depending on size of the system (approx. 1 to 2 m3/h )
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RTM_OM9012_08#A.2
OM9012#08
• Check and adjustment of the alarms and control devices.(performed while filling
the system )
• Prepare the circulation pump(s) for rotation check (fill up the seal chambers
with thermal fluid )
• Start the circulation pump and start deaerating of the system.
• Prepare the fuel oil system
- check the electrical connections
- prime/fill the fuel oil pump(s),
- check rotating direction,
- start the fuel pump deaerate the fuel system,
- adjust the pre-pressure.
• Prepare burner for start-up
- check electrical connections,
- check and adjust settings for flame tube, diffuser plate and ignition electrodes
- check nozzle size/type
- check burner motor rotating direction
- Start and adjust the burner
When the burner is started the commissioning engineer will measure the flue-gasses
and adjust the burner according Alfa Laval specifications
Flue gas measurements are necessary to obtain good and economic operation. The
CO2 content must be as high as possible and the smoke number as favourable as
possible.
There must be no ingress of uncontrolled air into the system. The draught conditions
should be reasonably constant, or a draught regulator should be used if necessary.
For economic operation the flue gas temperature should be limited. It must be noted
that depending on chimney type, height and cross section a minimum temperature is
required to prevent flue gas temperatures falling below dew point.
After the burner is started the system will slowly be heated up to the operating
temperature.
• Start of flushing,
Note: At this point yard or site personnel should prepare for cleaning of the
circulation pump strainers.
Note: For systems filled with thermal oil this is also the moment that the
boiling out procedure is started.
• During, or at the end of commissioning there is normally a presentation / test

made for the owner and/or class.
• Short operating instructions to yard/owner.
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RTM_OM9012_08#A.2
OM9012#08
3.1 Commissioning of the HFO burner
When the system is equipped with a HFO burner there will be a second
commissioning necessary to adjust the burner for HFO
Important: When the system is provided with a heavy fuel burner make sure
that HFO is available, separated and heated (at 80° C) and fuel oil
piping is provided with tracing and insulation when the
commissioning engineer visits.
The commissioning engineer will:

• Start and adjustments of the burner(s) on heavy fuel.
• Filling and commissioning of sec. systems.(if applicable)
• Perform a classification/owners check of the system.
3.2 Sea trail
For plants including exhaust gas heaters (economisers) and other equipment which
can only be tested under sea trial , for example final adjustment at full load
conditions or use under ordinary sea going conditions, adjustments and tests must be
performed under actual or simulated conditions.
Sea trial can be ordered separately or within the contract.
3.3 Set points
It is important to obtain normal expected operation conditions when the plant’s

various controllers are optimised. The set point lists are filled in with actual values,
when the settings are modified to operational conditions
Note: During commissioning of the thermal fluid system the set point for the
correct supply temperature will be determined. It is possible to adjust
the set point afterwards but it is not recommended. During
commissioning the Alfa Laval commissioning engineer will balance the
thermal fluid system, changing set points might upset this balance and
create instability which can result in continues stopping and starting of
the burner.
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Page 32
SD9010_39#F.1
GENERAL GUARANTEE INFORMATION
General guarantee information
1 Guarantee agreement and conditions

The guarantee agreement and conditions for the boiler plant are agreed on the con-
tractual stage, and keep valid as long as the contract is in force. The guarantee agree-
ment can not be transferred to another party without a written agreement with Alfa
Laval.
1.1 Conditions
The guarantee does not cover normal wear and tear on parts, unless this is stated in the
guarantee agreement, or if the plant/items are not operated or handled as intended per
the instruction manuals. Typical parts which are not covered by the guarantee due to
normal wear and tear is, but not limited to, Photo cells, Electrodes, Burner Nozzles,
Mechanical Seals, Bearings, Pump Impellers and Spindles, Gaskets, Water Level
Glasses, Refractory, Filter elements, Diaphragm of Membrane Pumps, and Valves
Stem seals. Typical items which are not covered due to wrong operation conditions
include, but not limited to, are: Valve damages, Pump Impellers and Spindles due to
foreign matters in the fluid. Consumable items is not covered by the guarantee, like
for instance: Test chemicals or batteries.
1.2 Trouble shooting
Normal trouble shooting in order to identify failing items are not covered by the guar-
antee, however guidance by e-mail are available for such when needed.
1.3 Requirement for support
When needed support can be obtained, and if so following should be informed in order
to make the process smooth and fast.
• Order number (is typically mentioned both on the outside of the instruction manual,
and on the first pages with the technical data of the plant
• Short description of the observed trouble
• Which alarms has been activated, and in which burner sequence step
• If the failing item is known, the Tag number or Data Sheet number, and serial
number
• Photo’s which can support the process
• Use English language
1.4 Guarantee claim handling
Claim handling has to follow the contractual flow and condition. This means that a
claim has to be issued to the vendor, including the above mentioned information. This
causes that yard, or other dealers, in between the user and Alfa Laval has to be part of
1-26 / 32 Language UK
SD9010_39#F.1
GENERAL GUARANTEE INFORMATION
a claim flow. This process might slow down the response time and therefore, in emer-
gency matters where prompt action may be needed, Alfa Laval accept to be contacted
directly, provided this takes place as a parallel flow (cc in correspondence) not over-
ruling the normal contractual flow and conditions.
SD9010_40#B.1
PREFACE / CONDITIONS
Preface / conditions
1 Preface / conditions for use of manuals
1.1 Introduction
The present (set of) manual(s) have been produced with the intension of giving the
user the greatest benefit in relation to the scope of supply supplied by Alfa Laval.
However unless the user do read and understand the manual(s) in its full extend, this
may not be the result why it is important to emphasize that this takes place as intended.
1.2 Prequalification / required basic knowledge
The content of the manual(s) has been developed on the basis that the user has both
the necessary engineering qualification, as well as the understanding and knowledge
of the normal design and operations for the complete plant, within the maritime field.
1.3 Content of manual(s)
The content of the manual(s) have been composed by a number of standard documents
as well as scope of supply related documents. The intension is to cover the scope of
supply delivered by Alfa Laval, and as such there might be areas of the total plant
which is not covered by this manual(s). Drawings with dimension for installations,
maintenance space, data sheets, etc. have to be observed with care in order to obtain
the correct result. Many of the instructions contain pictures, sketches and drawings for
information and guide line purpose and should be used as intended only.
1.4 Responsibility
It is the users’ responsibility to use the manuals as intended, and where not found
sufficient to raise the relevant questions.
1.5 Subject to change
The manual has been compiled with great care. However, it may be necessary within
the scope of product care to make changes to the product and its operation without
prior notice which are not contained in this manual. Alfa Laval are not liable for any
costs ensuing for this reason.
1.6 Disclaimer of liability
We have checked the contents of this manual for agreement with the hardware and
software described. Since deviations cannot be precluded entirely, we cannot guarantee
full agreement. However, the documents and data in this manual are reviewed regularly
and any necessary corrections included in subsequent editions. Suggestions for im-
provement are welcomed.
SD9010_41#B.1
SAFETY PRECAUTIONS
Safety precautions
1 Purpose
The purpose of this document is to lay down general guidelines and precautions to the
user of the plant, and its components, in connection with operation and maintenance
of the plant, in order to ensure the safety of personnel as well as of the plant.
It is important to study the instruction manuals carefully and observe the warnings
before installation, operation, service and maintenance. Not following the instructions
can result in serious accidents.
In order to make the information clear and understandable, only foreseeable conditions
have been considered. No warnings are given for situations arising from the unintended
usage of the machine and its tools. The plant and its components shall be used as
intended only.
1.1 Exception
This document does not overrule other precautions given for specific equipment(s)
operations and maintenance instructions.
1.2 Education
The user of the equipment must be in possession of an education relevant for the op-
eration and maintenance of the plant.
Operation and maintenance work must only be carried out by qualified and authorized
personnel.
1.3 Working clothes
Protective clothes must be of tight-fit.

If there is a possibility of your face coming in contact with metal splinters or dust, you
should wear a full face protection mask with protective goggles.
Always wear safety boots if there is a risk of heavy objects turning over, slipping off
or falling down and squashing your feet.
Use heat protective gloves to protect fingers and hands towards hot items.
Use ear protection in noisy environments.
1.4 Tools
As a measure to avoid injuries, only suitable/professional tools and working aids must
be used for maintenance, adjustment and repair work.
1.5 Lifting
Use correct lifting tools and follow lifting instructions.

Do not work under a hanging load.
SD9010_41#B.1
SAFETY PRECAUTIONS
1.6 General maintenance and fault rectification practice
Allow the unit to cool prior to servicing and maintenance work to avoid injury through
high temperatures.
Necessary installation, service and inspection work should be carried out at the speci-
fied time.
Inform relevant staff before beginning any service work.
For all service, inspection and repair work, electrically isolate the equipment and ensure
the mains switch cannot be accidentally switched back on. Cut off the fuel supply.
If, during servicing or testing, seal/joints/packings have to be opened, these have to be
thoroughly cleaned to ensure tight sealing when re-assembling.
Damaged seals/joints/packings must be replaced. Carry out a pressure/leak test!
Flame monitoring devices, limit controls, correcting elements and all other safety de-
vices must be commissioned by, and may only be replaced by, the manufacturer or
authorized personnel.
Screwed connections, which have been loosened, must be re-tightened without cross-
threading.
Following service work, all related safety devices should be tested to ensure they are
functioning correctly.
1.7 Pressurized equipment and items
Always relieve the pressure before starting to work on pressure equipment and/or lines.
Close all shut-off valves. Vent all pressure lines.
Always be extremely careful when checking pressurized lines for leaks.
Pressure test with air/gas is dangerous, use hydraulic pressure test when possible.
Fluids or air escaping under pressure can penetrate clothes and skin.
Be careful when changing pressure hoses; mixing up pressure hoses by mistake may
reverse the function of the equipment.
1.8 Chemicals, cleaning agents, lubricants, etc.
When using/handling chemicals, cleaning agents, and similar articles make sure you
follow the general rules and regulations of protection as well as the suppliers recom-
mendation regarding ventilation, personnel protection etc.
1.9 Electrical equipment
Make sure that the electric power supply is disconnected/switched off in relation to
maintenance. The touching of parts, which are connected to the electric power supply,
can cause immediate loss of life.
Always secure non-insulated and uncovered power lines and connectors against un-
intended touching.
Electric components stored and unused for longer periods of time should be carefully
inspected before use, to ensure that the integrity of any electrical insulation remains
intact.
Always check on wet electric components to determine whether parts that could be
touched are electrically live.
SD9010_41#B.1
SAFETY PRECAUTIONS
When working on high voltage equipment/groups, connect the mains supply cable to
earth after disconnecting/switching the power supply off in order to discharge com-
ponents such as capacitors.
1.10 Hinged equipment
When opening doors or swinging out hinged equipments/parts, these must be fixed in
position during maintenance in order to prevent unintended movement of the item, for
instance due to ships rolling.
1.11 Valves
Shut-off valves may leak due to impurities or wear, whereas it must be ensured that
fluids, air or steam which might leak through, will not cause any dangerous situation
in connection with maintenance.
Do always disconnect actuators both electrically and pneumatically in case of main-
tenance and trouble shooting.
Do never use the fingers to check automatic valves as there might be springs which
may suddenly release their power – always use tools for this purpose.
1.12 Rotating equipment
Rotating equipment must always be disconnected, electrically and/or hydraulically

and/or pneumatically, in connection with maintenance.
Do not touch rotating machines/parts when in operation.
1.13 Hot surfaces/equipment
Depending on the operating conditions many items may reach a temperature which
can harm the human body, for instance the boiler, all pipe lines, valve and actuator,
etc. Always let these items cool down before touching it or wear protective gloves.
1.14 Warning signs
Always follow the instructions given in relation to warning signs attached to parts and
machinery.
1.15 Alterations to the construction of the equipment
No alterations to the equipment are to be made without the approval of the manufac-
turer.
Any parts not in perfect working order should be replaced immediately.
No additional components may be fitted, which have not been tested for use with the
equipment.
Parts from other manufacturers are not guaranteed to be suitable to meet the necessary
operational and safety requirements.
1.16 Spare parts
Use only Alfa Laval genuine spare parts. Parts from other manufacturers are not guar-
anteed to be suitable to meet the necessary operational and safety requirements.
SD9010_41#B.1
SAFETY PRECAUTIONS
1.17 Waste disposal
All materials used should be handled and disposed of correctly, with due regard to the
environment and valid rules/regulations/law.
Note: In case of any doubts please contact Alfa Laval.
TABLE OF CONTENTS
Table of contents
Technical Data
.
Technical data for Aalborg TFO Hot water heater.......... .................................. 2-2
Technical data for oil fired burner................................ .................................. 2-3
Technical data for circulation pumps............................ .................................. 2-4
Technical data for fuel oil pump.................................. .................................. 2-5
Technical data for Heat exchanger 1T800..................... .................................. 2-6
Technical data for Heat exchanger
1T630/2T630/3T630/4T630........................................ .................................. 2-7
Technical data for Heat exchanger 1T650..................... .................................. 2-9
TECHNICAL DATA FOR AALBORG TFO HOT WATER
HEATER
Technical data for Aalborg TFO Hot water

heater
1 General data
• Project No.:................................................................................................203809
• Hull No.:.................................................................................................NC-0243
2 Technical specification each
• Heating media:.......................................................................................Hot water

• Type:.................................................................................................V3-TFO-004
• Capacity:...................................................................................................400 kW
• Quantity:....................................................................................................1 Pc(s).
• Maximum supply temperature:....................................................................299ºC
• Supply temperature:......................................................................................96 ºC
• Return temperature:......................................................................................76 ºC
• Maximum allowable pressure:.................................................................10 bar(g)
• Nominal flow:........................................................................................17.7 m3/h
• Fuel consumption at full load:....................................................................36 kg/h
3 Dimensions execution
• Diameter incl. insulation:........................................................................1090 mm

• Length / Height excl. burner:..................................................................1861 mm
• Length / Height incl. burner:...................................................................2514 mm
• Exhaust gas connection:............................................................................DN 200
• Weight (empty):........................................................................................1100 kg
• Contents:.................................................................................................150 litres
TECHNICAL DATA FOR OIL FIRED BURNER
Technical data for oil fired burner
1 General data
• Project No.:................................................................................................203809
• Hull No.:.................................................................................................NC-0243
2 Design data
• Burner type:.............................................................................Pressure atomizing

• Burner regulation:...............................................................................Modulating
• Model:............................................................................................................L3Z
• Fuel oil pump type:....................................................................................AE97K
• Fuel oil amount, fuel oil, max....................................................................36 kg/h
• Nozzle size 1:.........................................................................................5.00 USG
• Nozzle size 2:.........................................................................................3.00 USG
• Flame Tube:................................................................................................M5/2a
• Diffuser disk:.............................................................................................116x40
• Oil heater:.........................................................................................................No
• Voltage:........................................................................................3X440 V 60 Hz
• Control voltage:............................................................................................230V
• E-Motor:..................................................................................................0.76 kW
• Starting current:.............................................................................................23 A
• Norminel current:..........................................................................................2.3 A
• Color:....................................................................................................RAL 5009
Fuel oil according to ISO8217 (2012).
• DMA (MGO) with a viscosity of 2 to 6 cSt at 40 °C

• DMB (MDO) with a viscosity of 2 to 11 cSt at 40 °C
• DMZ (MGO with a viscosity of 3 to 6 cSt at 40 °C
TECHNICAL DATA FOR CIRCULATION PUMPS
Technical data for circulation pumps
1 General data
• Order No.:..................................................................................................203809
• Hull No.:.................................................................................................NC-0243
2 Data for pump
• Pump type:.............................................................................................CR90-2-1
• Quantity of pumps:.......................................................................................2 pcs.
• Delivery head:...........................................................................................59 m.l.c
• Pump capacity:.......................................................................................92.7 m³/h
• Connection pressure side:...........................................................................DN100
• Connection suction side:............................................................................DN100
3 Data for pump motor
• Motor maker:...............................................................................Makers standard

• Rated output:...............................................................................................22 kW
• Voltage:..................................................................................................3 x 440V
• Frequency:...................................................................................................60 Hz
• Starting current:...........................................................................................314 A
• Nominel current:.........................................................................................35.5 A
• Revolutions:........................................................................................3556 r.p.m.
• Degree of protection:......................................................................................IP55
• Insulation class:...................................................................................................F
• Stand still heating:..............................................................................76 W(2x38)
• Colour:........................................................................................Makers standard
• Size of cable glands:..............................................................................M40 x 1.5
• Number of cable glands:...............................................................................2 pcs.
TECHNICAL DATA FOR FUEL OIL PUMP
Technical data for fuel oil pump
1 General data
• Project No.:................................................................................................203809
• Hull Nos.:...............................................................................................NC-0243
2 Data for fuel oil pumps
• Pump:...................................................................................DS1/240 NE51,1 cSt

• Pump type:.........................................................................................Screw pump
• Delivery head:.............................................................................................5 barg
• Relief valve set point (factory set):..............................................................8 barg
• Oil temperature, maximum:........................................................................150 C
• Pump capacity at 1,1 cSt:............................................................................198 l/h
• Pump capacity at 380 cSt:...........................................................................380 l/h
• NPSH at 1,1 cSt. (including filter):..................................................................5 m
• NPSH at 380 cSt. (including filter):.................................................................2 m
• Weight of fuel oil pump unit:........................................................................40 kg
• Colour of fuel oil pump unit:.................................................................RAL 5017
3 Data for pump motor
• Motor make:.....................................................................................................AC
• Motor type:........................................................................................ACA 71 A-4
• Power supply:..............................................................................3 x 440 V, 60Hz
• Rated output for motor:..............................................................................0,3 kW
• Revolutions:...........................................................................................1596 rpm
• Ambient air temperature:..............................................................................45 °C
• Starting method:..........................................................................................Direct
• Starting current:............................................................................................3,9 A
• Operating current (full load):......................................................................0,75 A
• Power consumption at 1,1 cSt:.................................................................0,09 kW
• Power consumption at 380 cSt:................................................................0.12 kW
• Numbers of cable glands:..............................................................1 pcs. M20x1.5
• Insulation class:...................................................................................................F
• Degree of protection:......................................................................................IP55
TECHNICAL DATA FOR HEAT EXCHANGER 1T800
Technical data for Heat exchanger 1T800
1 General data
• Project No.:................................................................................................203809
• Hull No.:.................................................................................................NC-0243
2 Data for Heat exchanger
• Type of Heater:.....................................................................................EH20 T10

• Type of system application:...................................................................Hot water
• Number of heatexchanger:............................................................................1 pcs.
• Capacity:.................................................................................................... 42 kW
• Weight (dry):.............................................................................................109 kg.
• Colour of heat-exchanger unit:.....................................................Makers standard
• Flow:........................................................................................................1.8 m³/h
• Media:..........................................................................................................Water
• Inlettemperature:...........................................................................................70C
• Outlettemperature:.........................................................................................90C
• Design pressure:......................................................................................16 bar(g)
• Design temperature:.....................................................................................160C
TECHNICAL DATA FOR HEAT EXCHANGER
1T630/2T630/3T630/4T630
Technical data for Heat exchanger

1T630/2T630/3T630/4T630
1 General data
• Project No.:................................................................................................203809
• Hull No.:.................................................................................................NC-0243
• Type of Heater:....................................................................Plate Heat Exchanger

• Type of system application:...................................................................Hot Water
• Number of heat exchanger:...........................................................................4 pcs.
• Capacity:...................................................................................................250 kW
• Weight (dry):..............................................................................................140 kg
3 Hot side
• Flow:......................................................................................................21.5 m³/h
• Media:..........................................................................................................Water
• Inlet temperature:..........................................................................................90C
• Outlet temperature:........................................................................................80C
• Design pressure:........................................................................................5 bar(g)
• Design temperature:.......................................................................................90C
4 Cold side
• Flow:.......................................................................................................23.2m³/h
• Media:..........................................................................................................Water
TECHNICAL DATA FOR HEAT EXCHANGER
1T630/2T630/3T630/4T630
5 Materials
• Plates:....................................................................................ALLOY 316/0.5mm
• No. of plates:..............................................................................................19 pcs.
Technical data for Heat exchanger 1T650
1 General data
• Project No.:................................................................................................203809
• Hull No.:.................................................................................................NC-0243
• Type of Heater:..................................................................Double wall plate type

• Type of system application:...................................................................Hot water
• Number of heat exchanger:...........................................................................1 pcs.
• Capacity:...................................................................................................300 kW
• Weight (dry):..............................................................................................154 kg
3 Hot side
• Flow:......................................................................................................13.4 m³/h
• Media:..........................................................................................................Water
4 Cold side
• Flow:.........................................................................................................6.5m³/h
• Media:..........................................................................................................Water
5 Materials
• Plates:................................................................................ALLOY 316 / 0.75mm

• No. of plates:..............................................................................................23 pcs.
TABLE OF CONTENTS
Table of contents
Main Diagram
.
List Of Symbols........................................................ D86180....................... 3-3
Flow Diagram - Hot Water System.............................. D178403..................... 3-5
Flow Diagram - Fuel oil Diagram................................ D188481..................... 3-7
List of Parts.............................................................. 203809........................ 3-9
TABLE OF CONTENTS
LIST OF SYMBOLS
List Of Symbols
D178403#A.2
FLOW DIAGRAM - HOT WATER SYSTEM
Flow Diagram - Hot Water System
D188481#A.2
FLOW DIAGRAM - FUEL OIL DIAGRAM
Flow Diagram - Fuel oil Diagram
All Tag. no. Indicated with decimal point are sub-components of main items and not necessarily indicated on PiD or have data sheets attached
203809_Project List Of Parts LIST OF PARTS
Rev. C
Item No. Rev Qty Article No. Description Tag No. Module
Oil Fired Heater
07Y:088356 A 1 Oil Fired heater V3-TFO-004, 400 kW 1T Oil fired heater
6040000002 1 Safety valve DN25/40 1T1 Oil fired heater
22046-00050 1 Stop valve Globe Bellow seal Straight DN50 PN16 GGG-40.3 1T2 Oil fired heater
22046-02050 1 Stop valve Globe Bellow seal Straight DN50 PN16 GGG-40.3 Loose disc 1T3 Oil fired heater
22046-01080 A 1 Stop valve Globe Bellow seal Straight DN80 PN16 GGG-40.3 Control disc 1T4 Oil fired heater
Language UK
941071-00001 2 Temperature transmitter -40 → 400 °C, 1x PT 100 3L (single) 1T20-1T21 Oil fired heater
951411-00050 1 Temperature indicator 0-500°C 1T22 Oil fired heater
951221-00001 1 Thermowell black 1T22.1 Oil fired heater
LIST OF PARTS
951167-00215 1 Temperature switch 20-150°C 1T24 Oil fired heater

951165-02050 1 Temperature switch 200-500°C 1T32 Oil fired heater
8040000019 1 Differential pressure switch 0 - 0.6 Bar(g) 1T34 Oil fired heater
951444-00010 2 EO-shut off valve PN250/PN400 1T40-1T41 Oil fired heater
D188430-00200 A 1 Spark arrestor DN200, Length=565 mm - Type SA 1T42 Oil fired heater
8510000027 A 1 Expansion joint, DN 200 1T43 Oil fired heater
941071-00001 1 Temperature transmitter -40 → 400 °C, 1x PT 100 3L (single) 1T44 Oil fired heater
951221-00001 1 Thermowell black 1T44.1 Oil fired heater
List of Parts
6310325 1 Pressure switch KPS35 1T46 Oil fired heater

72406-00001 1 Brass reducing ring 1T46.1 Oil fired heater
72406-00002 1 Pressure gauge sealing washer 1T46.2 Oil fired heater
62053-00002 1 Pressure gauge rings copper 1T46.3 Oil fired heater
2541002 1 Pressure gauge valve 1/2" PN400 1T47 Oil fired heater
2420101 1 Pressure gauge pipe 1T48 Oil fired heater
Control Panel
102X03_088663 C 1 Control Panel 1L1 Control panel
Fuel Oil System

65110030 A, C 1 Burner L3Z 1F Fuel oil system
9656000512 A 1 Fuel oil de-aerator size 1 1F2 Fuel oil system
6000000141 1 Combined ball valve set DN25 PN40 1F3 Fuel oil system
6020000101 1 Check valve DN15 PN40 Disc-spring 1F4 Fuel oil system
6310320 1 Pressure switch KPS33 1F5 Fuel oil system
72406-00001 1 Brass reducing ring 1F5.1 Fuel oil system
72406-00002 1 Pressure gauge sealing washer 1F5.2 Fuel oil system
62053-00002 1 Pressure gauge rings copper 1F5.3 Fuel oil system
2541002 3 Pressure gauge valve 1/2" PN400 1F6-1G4-1G6 Fuel oil system
In burner delivery 1 Fuel oil hose supply L3 1F13 Fuel oil system
In burner delivery 1 Fuel oil hose return L3 1F15 Fuel oil system
9294002152 A 1 Pump KRAL DS1-240 1G1 Fuel oil system
D00800-00015 2 Oil Pressure Controller DN15 1G2-1G14 Fuel oil system
62053-00010 1 Pressure gauge 100.00 0-10 bar 1G3 Fuel oil system
D75015-00060 1 Pressure Transmitter 0-6 Bar(g) 1G5 Fuel oil system
6070000237 B 2 Three-way valve Ball DN25 PN40 1G7-1G7.1-1G7.2-1G8-1G8.1-1G8.2 Fuel oil system
8000000103 B 2 Filter Regulator incl. pressure gauge and bracket 1G7.3-1G8.3 Fuel oil system
941071-00001 2 Temperature transmitter -40 → 400 °C, 1x PT 100 3L (single) 1G11-1G12 Fuel oil system
951221-00001 2 Thermowell Black 1G11.1-1G12.1 Fuel oil system
Yard Supply 1 De-aerating pipe Fuel oil system
Circulating Pumps
5545000048 A 2 Pump GRUNDFOS CR90 1T410-1T430 Circulating pumps
22046-00150 2 Stop valve Globe Bellow seal straight DN150 PN16 GGG-40.3 1T411-1T431 Circulating pumps
22050-00150 2 Strainer DN150 1T412-1T432 Circulating pumps
22046-00015 2 Stop valve Globe Bellow seal straight DN15 PN16 GGG-40.3 1T414-1T434 Circulating pumps
62053-01030 2 Pressure gauge 100.00 -1 +3 bar 1T415-1T435 Circulating pumps
2541002 2 Pressure gauge valve 1/2" PN400 1T416-1T436 Circulating pumps
2420101 2 Pressure gauge pipe 1T417-1T437 Circulating pumps
22046-01015 1 Stop valve Globe Bellow seal straight DN15 PN16 GGG-40.3 Control disc 1T418 Circulating pumps
62053-00016 2 Pressure gauge 100.00 0 - 16 bar 1T420-1T440 Circulating pumps
2541002 2 Pressure gauge valve 1/2" PN400 1T421-1T441 Circulating pumps
2420101 2 Pressure gauge pipe 1T422-1T442 Circulating pumps
22046-02125 2 Stop valve Globe Bellow seal straight DN125 PN16 GGG-40.3 Loose disc 1T423-1T443 Circulating pumps
3-9 / 10
8040000026 1 Differential presssure switch 0-6.0 bar(g) 1T427 Circulating pumps
951444-00010 2 EO-shut off valve PN250/PN400 1T428-1T429 Circulating pumps
Minimum Flow Control
72851-00032 1 Control valve 2-way linear DN32 PN16 ARI 23.441 electric controlled GGG-40.3 1T270 Min. flow control
22046-00040 2 Stop valve Globe Bellow seal Straight DN40 PN16 GGG-40.3 1T271-1T272 Min. flow control
22046-01032 1 Stop valve Globe Bellow seal Straight DN32 PN16 GGG-40.3 Control disc 1T273 Min. flow control
2541002 1 Pressure gauge valve 1/2" PN400 1T275 Min. flow control
3-10 / 10
2420101 1 Pressure gauge pipe 1T276 Min. flow control
D75015-00060 1 Pressure transmitter 0 - 6 Bar(g) 1T284 Min. flow control
Expansion Tank
D75126-00140 1 Expansion Tank SU140.3 1T180 Expansion tank
LIST OF PARTS
6310325 1 Pressure switch KPS35 1T181 Expansion tank

72406-00001 1 Brass reducing ring 1T181.1 Expansion tank
72406-00002 1 Pressure gauge sealing washer 1T181.2 Expansion tank
62053-00002 1 Pressure gauge rings copper 1T181.3 Expansion tank
2541002 2 Pressure gauge valve 1/2" PN400 1T182-1T185 Expansion tank
2420101 2 Pressure gauge pipe 1T183-1T186 Expansion tank
62053-00010 1 Pressure gauge 100.00 0 - 10 bar 1T184 Expansion tank
6040000002 1 Safety valve DN25/40 1T187 Expansion tank
22046-00025 1 Stop valve Globe Bellow seal Straight DN25 PN16 GGG-40.3 1T188 Expansion tank
Hot Water Heater

8677000220 A 1 13K4001 Electric hot water heater EH20 / 42 kW - including terminal box & safety thermostat 1T800 Hot water heater
22046-00032 1 Stop valve Globe Bellow seal Straight DN32 PN16 GGG-40.3 1T802 Hot water heater
22046-02032 1 Stop valve Globe Bellow seal Straight DN32 PN16 GGG-40.3 Loose disc 1T803 Hot water heater
22046-01100 1 Stop valve Globe Bellow seal Straight DN100 PN16 GGG-40.3 Control disc 1T804 Hot water heater
87S0031 A 1 Safety valve 1/2" PN100 67.953 1T806 - Part of Heater delivery Hot water heater
6666106 A 1 Drain valve 1T807 - Part of Heater delivery Hot water heater
6633004 A 1 Temeperature gauge 0-160 °C L=150 1T809 - Part of Heater delivery Hot water heater
2541002 A 1 Manometer valve with test connection 1T810 - Part of Heater delivery Hot water heater
6633120 A 1 Preassure Gauge 63.00 0-16 bar/kg/Mpa 1T811 - Part of Heater delivery Hot water heater
Jacket Water Heater

8669000035 A,C 4 Plate heat exchanger / 250 kW 1T630-2T630-3T630-4T630 Jacket water heater
22046-00065 8 Stop valve Globe Bellow seal Straight DN65 PN16 GGG-40.3 1T631-1T632-2T631-2T632-3T631-3T632-4T631-4T632 Jacket water heater
22046-01050 4 Stop valve Globe Bellow seal Straight DN50 PN16 GGG-40.3 Control disc 1T633-2T633-3T633-4T633 Jacket water heater
Sanitary Water Heater

8669000034 A,C 1 Double wall plate heat exchanger / 300 kW 1T650 Sanitary water heater
6070000243 1 3-Way valve Ball DN50 PN40 1T651 Sanitary water heater
22046-01100 1 Stop valve Globe Bellow seal Straight DN100 PN16 GGG-40.3 Control disc 1T652 Sanitary water heater
22046-00050 1 Stop valve Globe Bellow seal straight DN50 PN16 GGG-40.3 1T654 Sanitary water heater
951411-00016 1 Temperature indicator 0-160°C 1T656 Sanitary water heater
951221-00001 1 Thermowell black 1T656.1 Sanitary water heater
941071-00001 1 Temperature transmitter -40 → 400 °C, 1x PT 100 3L (single) 1T657 Sanitary water heater
951221-00001 1 Thermowell black 1T657.1 Sanitary water heater
951444-00010 2 EO-shut off valve PN250/PN400 1T658-1T659 Sanitary water heater
8040000019 1 Differential pressure switch 0 - 0.6 Bar(g) 1T660 Sanitary water heater
8611000028 A 1 K18:071961 Orifice set DN50 PN40 1T661 Sanitary water heater
Fresh Water Generator

72903-00080 C 1 Control valve 3-way DN80 PN16 ARI 23.451 - Diverting - electric controlled GGG-40.3 1T551 Fresh water generator
951411-00016 1 Temperature indicator 0-160°C 1T556 Fresh water generator
951221-00001 1 Thermowell black 1T556.1 Fresh water generator
941071-00001 1 Temperature transmitter -40 → 400 °C, 1x PT 100 3L (single) 1T557 Fresh water generator
941071-00001 1 Temperature transmitter -40 → 400 °C, 1x PT 100 3L (single) 1T287 Fresh water generator
HVAC Consumers
72851-00040 1 Control valve 2-way linear DN40 PN16 ARI 23.441 electric controlled GGG-40.3 1T452 HVAC consumers
941071-00001 1 Temperature transmitter -40 → 400 °C, 1x PT 100 3L (single) 1T286 HVAC consumers
Language UK
951221-00001 1 Thermowell black 1T286.1 HVAC consumers
951411-00016 1 Temperature indicator 0-160°C 1T288 HVAC consumers
951221-00001 1 Thermowell black 1T288.1 HVAC consumers
TABLE OF CONTENTS
Table of contents
Electrical System
.
Electrical Drawings.................................................... 102X03_088663........... 4-2
EH20T16 L850 42KW
Panel Drawing for Electrical Heater............................. ................................... 4-59
Temperature controllers.............................................. OM8210_43................ 4-68
Alarm module 821A20............................................... RTM_OM8220_01....... 4-85
0 1 2 3 4 5 6 7 8 9
4-2 / 92
Alfa Laval
Gasvaerksvej 21
9000 Aalborg
B
102X03_088663#A.2
ELECTRICAL DRAWINGS
Project/Order Number : 203809-01

Customer/Yard Name : Colombo Dockyard PLC
C
Hull Number : NC-0243

Heater Type : V3-TFO-004
Oil System : NA
Oil Type : DMZ/DMA OR DMB
Electrical Drawings
Burner Type & Size : L3Z

D
Norm / Standards / Class Society : NKK Type Of Enclosure : Control Panel

Compliance : NA Fabrication Year : 2018
Rated Voltage / Frequency : 440 V / 60 Hz Degree Of Protection : IP 54
Rated Power Consumption : 32 kW EMC - Environment : Makers Standard
E
Protection Device : Ship Distribution Panel Max. Ambient Temperature : 45 Degree Celcius
Earth System : PE and IE Panel Dimension(s) H x W x D : 2000 (+100) x 1200x 405mm
Rated Control Voltage : Control Voltage Control Panel Colour : RAL 7035
Rated Short-Circuit Max. : See Enclosure Sign Cables : See Cable Connection Report
Rated Short-Circuit Min. : See Enclosure Sign Control Panel Tag No.: : 1L1
Alfa Laval will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
F
Drawing Revision: Revision 2
This document and its contents is owned by Alfa Laval AB (publ.) or its affiliates and protected by laws governing intellectual property and thereto related rights.
or for any purpose, without the expressed permission of Alfa Laval. Nor may it be used in any other way or for any other purpose than expressly permitted by Alfa Laval.
G
Language UK
Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise),
Page: 1
Master Templates: Title page / cover sheet =
Dkaaabh STU Alfa Laval Aalborg Project Drawing No.:
Revision 2 See Title Page ALA/182 18/5-2018 +
15-08-2018 24-05-2018 Order Template Version:TFO_OT_Rev2 Gasvaerksvej 21
102X03: 088663 Next Page: 2
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Revision No. Rev.Made by/Date Approved by/Date Project Created By Creation Date Master Drawing Number: 102X03:077024 Pages of: 56
0 1 2 3 4 5 6 7 8 9
Table of contents TFO_TableOfContents_Rev2
A Page Page type Page description Date Edited by

&GR/1 Title page / cover sheet Title page / cover sheet 25-05-2018 Dkaaabh
&GR/2 Table of contents Table Of Contents 15-08-2018 Dkaaabh
&GR/3 Table of contents Table Of Contents 15-08-2018 Dkaaabh
&Revision Overview/1 Revision overview Revision overview : =TFO_Primary System+CP&SCH/16 - =TFO_Primary System+CP&SCH/36 15-08-2018 Dkaaabh
Control Panel Information
=TFO_Primary System+CP&SCH/1 Graphic 16-05-2018 Dkaaabh
Language UK
=TFO_Primary System+CP&SCH/2 Graphic Wire Colours 02-11-2016 dkaaabh
B
=TFO_Primary System+CP&SCH/3 Panel layout Panel Layout Front & Side View 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/4 Panel layout Panel Layout Socket Overview 24-05-2018 Dkaaabh
102X03_088663#A.2
=TFO_Primary System+CP&SCH/5 Schematic multi-line MainSwitch_b 25-05-2018 Dkaaabh

=TFO_Primary System+CP&SCH/6 Schematic multi-line Mainpower - Circulation Pump And Burner 25-05-2018 Dkaaabh
ELECTRICAL DRAWINGS
=TFO_Primary System+CP&SCH/7 Schematic multi-line Control Voltage 24-05-2018 Dkaaabh

=TFO_Primary System+CP&SCH/8 Schematic multi-line Pilot Voltage 24-05-2018 Dkaaabh
C =TFO_Primary System+CP&SCH/9 Schematic multi-line Emergency Stop_b 24-05-2018 Dkaaabh

=TFO_Primary System+CP&SCH/10 Schematic multi-line Reset 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/11 Schematic multi-line Stand Still Heating - TFO Pumps_a 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/12 Schematic multi-line Circulation Pumps & Low Pressure_b 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/13 Schematic multi-line Fuel Oil Pumps_a 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/14 Schematic multi-line Fuel Oil Pumps_b 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/15 Schematic multi-line Fuel Oil Pumps_c 15-08-2018 Dkaaabh
D
=TFO_Primary System+CP&SCH/16 Schematic multi-line Fuel_Oil_System_a 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/17 Schematic multi-line Fuel_Oil_System_b 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/18 Schematic multi-line Fuel_Oil_System_c 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/19 Schematic multi-line Fuel_Oil_System_d 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/20 Schematic multi-line Fuel_Oil_System_e 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/21 Schematic multi-line Fuel_Oil_System_f 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/22 Schematic multi-line Fuel_Oil_System_g 15-08-2018 Dkaaabh
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=TFO_Primary System+CP&SCH/23 Schematic multi-line Fuel_Oil_System_h 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/24 Schematic multi-line Fuel_Oil_System_i 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/25 Schematic multi-line Burner Safety_a 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/26 Schematic multi-line Burner Safety_b 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/27 Schematic multi-line Burner Safety_c 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/28 Schematic multi-line Burner Control_a 24-05-2018 Dkaaabh
F =TFO_Primary System+CP&SCH/29 Schematic multi-line Burmer Control_b 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/30 Schematic multi-line San. Water Heater 25-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/31 Schematic multi-line Minimum Flow Controller 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/32 Schematic multi-line HVAC Consumer - Controller 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/33 Schematic multi-line Freshwater Generator - Controller 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/34 Schematic multi-line Potential Free Signals 24-05-2018 Dkaaabh
=TFO_Primary System+CP&SCH/35 Schematic multi-line Status Module 15-08-2018 Dkaaabh
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A Page Page type Page description Date Edited by

=TFO_Primary System+CP&SCH/36 Schematic multi-line Pre-Alarm Module 15-08-2018 Dkaaabh
4-4 / 92
=TFO_Primary System+CP&SCH/37 Schematic multi-line Alarm Module_a 15-08-2018 Dkaaabh
=TFO_Primary System+CP&SCH/38 Schematic multi-line Alarm Module_a 15-08-2018 Dkaaabh
=TFO_Primary System+CP&Cable Connection Diagram/1 Cable-connection diagram Cable-connection diagram =TFO_Primary System+CP-W1 =TFO_Primary System+CP-W2 =TFO_Primary System+CP-W3 15-08-2018 Dkaaabh
=TFO_Primary System+CP&Cable Connection Diagram/1.a Cable-connection diagram Cable-connection diagram =TFO_Primary System+CP-W4 =TFO_Primary System+CP-W5 =TFO_Primary System+CP-W6 15-08-2018 Dkaaabh
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102X03_088663#A.2
ELECTRICAL DRAWINGS
C =TFO_Primary System+CP&Cable Connection Diagram/5.a Cable-connection diagram Cable-connection diagram =TFO_Primary System+CP-W39 =TFO_Primary System+CP-W40 =TFO_Primary System+CP-W41 15-08-2018 Dkaaabh
=TFO_Primary System+CP&Cable Connection Diagram/7.a Cable-connection diagram Cable-connection diagram =TFO_Primary System+CP-W51 =TFO_Primary System+CP-W52 25-05-2018 Dkaaabh
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Language UK
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Page: Overview/1
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0 1 2 3 4 5 6 7 8 9
Revision overview TFO_Revision Form 1_Rev1
Revision name Revision comment Reason for revision change Page name Revision description Creator Date
A
Revision 2 Change from 3 fuels to 2 fuels - DMZ removed =TFO_Primary System+CP&SCH/16 Dkaaabh 15-08-2018
Language UK
B
102X03_088663#A.2
ELECTRICAL DRAWINGS
Revision 1 SysEng - Comments &GR/2 SysEng - Comments Dkaaabh 25-05-2018
Revision 1 SysEng - Comments &GR/3 SysEng - Comments Dkaaabh 25-05-2018

C
Revision 1 SysEng - Comments &Revision Overview/1 SysEng - Comments Dkaaabh 25-05-2018
Revision 1 SysEng - Comments =TFO_Primary System+CP&Cable Connection

SysEng - Comments
Diagram/1 Dkaaabh 25-05-2018

SysEng - Comments
Diagram/1.a Dkaaabh 25-05-2018

SysEng - Comments

SysEng - Comments
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Revision 1 SysEng - Comments &Revision Overview/1 New page created Dkaaabh 25-05-2018
Revision 1 SysEng - Comments &GR/1 Dkaaabh 25-05-2018
Revision 1 SysEng - Comments =TFO_Primary System+CP&SCH/5 Dkaaabh 25-05-2018

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Revision 1 SysEng - Comments =TFO_Primary System+CP&SCH/11 SysEng Comments Dkaaabh 16-05-2018
Revision 1 SysEng - Comments =TFO_Primary System+CP&SCH/36 SysEng Comments Dkaaabh 16-05-2018
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Revision 2 See Title Page ALA/182 18/5-2018 System+CP&SCH/16 - =TFO_Primary +
System+CP&SCH/36 102X03: 088663 =TFO_Primary System+CP&SCH/1
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9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9
A
Control Panel - Common Section
Additional Information
4-6 / 92
Component Type Description
Terminals: A Equipment Group : Amplifier, PLC,...

Panel Connection NB - Off-standard Information:
X0: Communication
X1: 230/115 VAC Internal Distribution 10% Additional DIN Rail Space Required! B Controllers - LOK-16
X2: 24 VDC Internal Distribution Information to Panel Builder.
X3: In Panel C Condensator
B
X3.1: 230/115 VAC External Distribution & Actual Terminal:
102X03_088663#A.2
Terminals w. Static Numbers E Lightning Equipment, Heating Equipment..

X4: On Burner
X5: Emergency Stop F Protection: Circuit Breaker, Fuse,
ELECTRICAL DRAWINGS
X6: Plugs On Burner Therm. Overload Relay

X7: Gaugeboard
Layer 2
G Generator, Power Supply`s, Fan,..
Wire(s) Colour: H Signaling Device,..

Layer 1
C See "Wire Colour Sheet"
K Contactor
Wire(s) Numbering: Text Plates:

Yard Connection K Relay
Potential Numbering: Colour plate: White
Ex.: "FOP1" - Meaning "Fuel Oil Pump 1" Colour letters: Black M Motors
Other wires are numbered: Language: English
Ex.: 051, 052, 053 etc. P Amp. Meter
Number On Page YD :
Q Power Gear:
Page No.
Yard Delivery (& Connection) Load Switch Breaker
D Page no.
Motor Circuit Breaker, ...
R Resistance,Rheostat,...
Cables/Connection: Motors Rotational Direction:
NB. Cables Marked with * or 1W S Electrical Equipment For Control Circuits:
All Motors, Shall Have Correct Rotational Direction*
Are Prewired By ALFA LAVAL AALBORG Switch, Push Button, Limit Switch,...
Change Of Direction Can Be Done According To Below Scheme`s:
Cables to tag no., all cables with screen, T Transformer,...

must be seperate cables as shown in drawings/cable connection Y/D Motors: D.O.L Motors:
Motor Motor U Transducer : Electrical / Electrical Quantity
E
Other cables marked W(and a number 1-?), Terminals U1 V1 W1 U2 V2 W2 Terminals U1 V1 W1 Frequency Controller,Softstarter,Transducer,
yard can chose to collect into multiple multi-core cables. Motor Motor Special Equipment,..
Etc. 12-wire multicore or 18-wire multicore... Rotation Rotation
Right** Right**
V Hourcounter
Cable Routing:
Cable runs shall be installed well clear of substantial heat sources. L1 L2 L3 L2 L3 L1
L1 L2 L3 X Terminal Blocks,Connectors,Socket,...
Power cables and signal cables,
must be held with respect distance to one another
according to applicable standard(s). Y Electrical Controlled Mechanical Device:
Valve,Brake,...
F Motor Motor
Vibration:
Terminals U1 V1 W1 U2 V2 W2 Terminals U1 V1 W1 Component Labeling:
Maximun Vibration Values Motor Motor A1
100 GAL At 10-30 Hz Rotation Rotation In Connection
Left** Left** -K100
1 GAL = 0,01 m/Sek Diagram (Example):
A2
L3 L2 L1 L2 L1 L3
Setpoints: L3 L2 L1
Setpoints For Motor Protection
Shall be Set To Operation Current (In) Component Type
Maximum Setpoint Is 110%
G *To Be Checked/Corrected By Customer
Language UK
Component No.
**Seen At The Shaft Driving End Of The Motor
=+&Revision Overview/1 Page: 1
Master Templates: Control Panel Information = TFO_Primary System
Revision 2 See Title Page ALA/182 18/5-2018 & Off-Standard issues + CP
102X03: 088663 Next Page: 2
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9
A
Common Panel - Additional Information
Wire Colour Wire Code Application mm² Marking Comments
Language UK
440-230V AC and With VFD Always
B Black BK Min. 0,75
24V DC Power Circuits Use Cable With Screen
Green / Yellow GNYE Earth ( PE ) Min. 0,75
102X03_088663#A.2
Light Blue BU N ( 230 VAC ) Min. 0,75

ELECTRICAL DRAWINGS
White WH DC Control Circuits Min. 0,75

C
Red RD AC Control Circuits Min. 0,75

Remember:
Orange OG Foreign Voltage Min. 0,75
Permanent Warning Label(s)
F
NB. Colour identification according to above shall be used
For safety reasons, the colour Green or the colour Yellow may not be used except in the bicolour combination Green and Yellow (PE)
Colour identification combined with clear and durable wire numbering as described on page 1 "Control Panel Information" is to be used!
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Master Templates: Wire Colours = TFO_Primary System
Revision 2 See Title Page ALA/182 18/5-2018 + CP
102X03: 088663 Next Page: 3
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9
PANEL WEIGHT: 375KG (+/-15%)

A TAG NO: 1L1
IP CLASS: 54
COLOUR : RAL7035 405 mm 1200 mm
4-8 / 92
335 mm 1135 mm
m
5m
R1
Q1 Main Switch Power Switch
H1 Control Voltage On Lamp/White

H2 S/S HEATIING SUPPLY ON Lamp/White
B
S1 RESET PUSH BUTTON
102X03_088663#A.2
U7 U8 U5 U6 S3 STAND STILL HEATING T.F. CIRC. PUMP 1 Switch

Alarm Alarm
Status
S3.1 STAND STILL HEATING T.F. CIRC. PUMP 2 Switch
Pre-Alarm S4 BURNER Switch
S14 FUEL SELECTION Switch
ELECTRICAL DRAWINGS
S17 FUEL PUMP 1 Switch

U1 U2 U3 U4 S18 FUEL PUMP 2 Switch
K1 Switch
K2 K1 K1 K1
K3
K4
K2
K3
K2
K3
K2
K3
S23 T.F. CIRC. PUMP 1
K4 K4 K4
BURNER S25 T.F. CIRC. PUMP 2 Switch

MIN. FLOW HVAC FRESH
S27 ACCEPT ALARM PUSH BUTTON
S28 LED TEST PUSH BUTTON
S30 HVAC Switch
C S31 FRESH WATER GENERATOR Switch
V1 T.F. CIRC. PUMP 1 HOUR

V2 T.F. CIRC. PUMP 2 HOUR
V3 BURNER HOUR
V4 BURNER HOUR
V1 P1 P2 P1 T.F. CIRC. PUMP 1 A-METER

V3 V4 V2
A A P2 T.F. CIRC. PUMP 2 A-METER
U1 BURNER CONTROLLER
D
U2 MINIMUM FLOW CONTROLLER
S4 S17 S18 S14 S23 S25 S30 S25 U3 HVAC CONTROLLER
0 0 0 0
0 0 0 0
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
U4 FRESH WATER GENERATOR CONTROLLER
2000 mm
U5 STATUS MODULE
U6 PRE-ALARM MODULE
S3 S3.1 H2
U7 ALARM MODULE
U8 ALARM MODULE
S28 S27 S1
H1
Q1
F
100 mm
G
Language UK
2 Page: 3
Master Templates: Panel Layout Front & Side View = TFO_Primary System
102X03: 088663 Next Page: 4
9100 Aalborg DK
Revision 2
F
E
B
C
A
G
D
3
Dkaaabh
15-08-2018
0
369 mm
335 mm 100 mm
STU
24-05-2018
Revision No. Rev.Made by/Date Approved by/Date
1
Project
See Title Page
ALA/182
Created By
2
1135 mm
1200 mm
1200 mm
18/5-2018
Creation Date
PANEL SOCKET (ALA SUPPLY)
3
Master Templates:
Order Template Version:TFO_OT_Rev2
Master Drawing Number: 102X03:077024
4
14x18 mm
5
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
1135 mm
Top of Panel
Backside of Panel
6
Wall brackets for roof-side wall attactment. (Optional)
100 mm 50 mm
7
Panel Layout Socket Overview

60 mm 100 mm
102X03: 088663
8
Project Drawing No.:

+ CP
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ELECTRICAL DRAWINGS
9
102X03_088663#A.2
= TFO_Primary System
56
5
Page: 4
40 41 42 43 44 45 46 47 48 49
1L1
1L1 / 6.50
1L2
1L2 / 6.50
A 1L3
1L3 / 6.50
4-10 / 92
1L1
1L2
1L3
B
102X03_088663#A.2
ELECTRICAL DRAWINGS
0
1
1 3 5
C -Q1
32A 2 4 6
-Q1
POWER SELECTOR
IMPORTANT:
IN CASE OF REPAIR/MAINTENANCE
ON EQUIPMENT
IT MUST BE ENSURED THAT THE CORRECT
D
MAINSWITCH IS TURNED TO "OFF" POSITION
OR THAT BOTH/ALL MAINSWITCHES
ARE TURNED TO "OFF" POSITION AND LOCKED!
-W1
-PE
1
-PE
E
1 2 3
-U100
NB:
PE Connection Outside Enclosure
If Enclosure Mounting Bolt Are Used
Ensure Firmly & Clean Surface Contact
With PE/Hull
F
Section A Use Correct Materials
To Avoid Galvanic Corrosion
MAIN SUPPLY 1 (MSB A -SECTION)
Un: 3 x 440VAC
32 kW
G
Language UK
4 Page: 5
Master Templates: MainSwitch_b = TFO_Primary System
102X03: 088663 Next Page: 6
9100 Aalborg DK
50 51 52 53 54 55 56 57 58 59
1L1 1L1 1L1 1L1 1L1 1L1 1L1
5.43 / 1L1 1L1 / 7.60

1L2 1L2 1L2 1L2 1L2 1L2
5.43 / 1L2 1L2 / 7.60

A 1L3 1L3 1L3 1L3
5.43 / 1L3 1L3
Language UK
1/L1 3/L2 5/L3 13 23 1/L1 3/L2 5/L3 13 23 1/L1 3/L2 5/L3 13 23 1/L1 3/L2 5/L3 13 23 1/L1 3/L2 5/L3 13 23
-Q2 -Q3 -Q5 -Q7 -Q8
B 14 24 14 24 14 24 14 24 14 24
I> I> I> I> I> I> I> I> I> I> I> I> I> I> I>
2/T1 4/T2 6/T3 2/T1 4/T2 6/T3 2/T1 4/T2 6/T3 2/T1 4/T2 6/T3 2/T1 4/T2 6/T3
/12.111
/37.362
/12.113
/37.363
/27.267
/37.366
/13.122
/38.371
/13.124
/38.372
102X03_088663#A.2
1
1
066 0613
ELECTRICAL DRAWINGS
-T1 -T2
066
066
0613
0613
066 0613
2 4 x1 2 4 x1
C 067 A -P1 0614 A -P2

1 3 1 3
061
063
068
0610
0615
0617
0619
0621
0623
0625
0627
0629
0631
x2 x2
067
067
0614
0614
067 0614
1
1
1/L1 3/L2 5/L3 1/L1 3/L2 5/L3 1/L1 3/L2 5/L3 1/L1 3/L2 5/L3 1/L1 3/L2 5/L3
D -K7 -K9 -K68 -K13 -K14
/12.111 2/T1 4/T2 6/T3 /12.113 2/T1 4/T2 6/T3 /27.267 2/T1 4/T2 6/T3 /13.122 2/T1 4/T2 6/T3 /13.124 2/T1 4/T2 6/T3
062
064
065
069
0611
0612
0616
0618
0620
0622
0624
0626
0628
0630
0632
E -X3 U1 V1 W1 -X3 U1 V2 W2 -X3 U3 V3 W3 -X3 U4 V4 W4 -X3 U5 V5 W5
-W2 -W3 -W4 -W5 -W6
U1 V1 W1 U1 V1 W1 U1 V1 W1 U1 V1 W1 U1 V1 W1
M M M M M
F -1T410 -1T430 -R15 -1G1 -1G1
3 3 3 3 3
T.F. CIRC. PUMP 1 T.F. CIRC. PUMP 2 BURNER MOTOR 1 FUEL PUMP 1 FUEL PUMP 2
U: 440 V U: 440 V U: 440 V U: 440 V U: 440 V
P: 22 kW P: 22 kW P: 0,76 kW P: 0,3 kW P: 0,3 kW
In: 35,5 A In: 35,5 A In: 2,3A In: 0,75 A In: 0,75 A
Ist: 314 A Ist: 314 A Ist: 23 A Ist: 3,9 A Ist: 3,9 A
G
4-11 / 92
5 Page: 6
Master Templates: Mainpower - Circulation Pump And = TFO_Primary System
Revision 2 See Title Page ALA/182 18/5-2018 Burner + CP
102X03: 088663 Next Page: 7
9100 Aalborg DK
Revision 2
F
E
B
C
A
G
D
6
6.59 /
6.59 /
Dkaaabh
1L2
1L1
15-08-2018
60
1,6-2,5A
(2,3 A)
CONT. CURRENT
-Q6
4A C-kar
-F1
1L1
1KVA
-T3
440V/230V
1L2
I>
2
1
3
1
N 072 071 1L1

230VAC
STU
1/L1
2/T1
24-05-2018
I>
073 1L2
3/L2
4/T2

I>
4
3
4
2
L 075 074 073

CONTROL VOLTAGE
5/L3
6/T3
073
073
61
073
Project
See Title Page
L
ALA/182
Created By
62
L
18/5-2018
Creation Date
L
WHITE
-H1
63
x2
x1
ON/OFF LAMP
CTRL VOLTAGE
Master Templates:
64
65
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
L
66
Control Voltage
67
102X03: 088663
68

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N / 8.70
L / 8.70
56
8
Page: 7
Revision 2
F
E
B
C
A
G
D
7
7.69 /
7.69 /
Dkaaabh
L
15-08-2018
70
5A
-V5
L
081
V+
N
STU
24-05-2018
L

N
082
V-
N
71
081
Project
See Title Page
L / 9.80
N / 10.90
082
ALA/182
Created By
081
72
082
18/5-2018
Creation Date
081
73
082
Master Templates:
-F3

74
2
1
E1+ 081
24VDC
4
3
F1- 082
75
E1+
F1-
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
76
Pilot Voltage
F1- / 14.134
E1+ / 14.132
77
102X03: 088663
78

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102X03_088663#A.2
56
9
Page: 8
Revision 2
F
E
B
C
A
G
D
8
8.71 /
Dkaaabh
L
15-08-2018
80
STU
L
24-05-2018
-S3

External
Emg. Stop
+External
-W7
Not ALA Supply

-X5
81
1
2
1
L
Project
NB. YARD SUPPLY
YD
See Title Page

2
L
REMOTE EMERGENCY STOP
ALA/182
Created By
82
18/5-2018
Creation Date
-X5
83
L L
L
4
L L
Master Templates:
84
85
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
86
Emergency Stop_b
87
102X03: 088663
88

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89
102X03_088663#A.2
L / 10.90
56
10
Page: 9
90 91 92 93 94 95 96 97 98 99
L L L L
9.89 / L L / 12.110
3 15
-S1 -K6
4 /10.98 16 18
101
101
Language UK
101
B
102X03_088663#A.2
ELECTRICAL DRAWINGS
101 101 101 101

101
A1 A1 A1 A1 A1 A1
-K1 -K2 -K3 -K4 -K5 -K6
230VAC A2 230VAC A2 230VAC A2 230VAC A2 230VAC A2 230 VAC A2
3sec.
N N N N N N N
F 8.71 / N N / 12.110
14 11 /25.241 14 11 /25.248 14 11 /26.251 14 11 /26.258 14 11 /24.233 18
12 12 12 12 12 16 15
24 21 /26.252 24 21 /27.266 24 21 /24.236 24 21 /14.135 24 21 /15.142 18 15 /10.92
22 22 22 22 22 16
34 31 /25.242 34 31 /35.341 34 31 /30.292 34 31 /14.137 34
32 32 32 32 32 31
44 41 /25.247 44 41 /24.232 44 41 /33.327 44 41 /26.254 44
42 42 42 42 42 41
RESET
4-15 / 92
9 Page: 10
Master Templates: Reset = TFO_Primary System
102X03: 088663 Next Page: 11
9100 Aalborg DK
100 101 102 103 104 105 106 107 108 109
111 113 113 113 113 113
112
111
A
112
113
1 3 1 1
4-16 / 92
-F4 -F5 -F6
2A 2 4 1A 1A
2 2
113
113
117
111
B
102X03_088663#A.2
112
ELECTRICAL DRAWINGS
21 12 14 21 32 34
-K7 -K78 -K9 -K78
/12.111 22 /35.342 11 /12.113 22 /35.342 31
113
116
1110
118
6 7
-K78 -K78
-X3 116 1110
24 21 44 41
115 119
22 42
114
13 /35.342 x2 13 /35.342 x2
-S3 -S3.1
BLUE BLUE
115
119
14 x1 14 x1
D
115
119
115 119
-W8
-X3 8 -X3 10
-W9 -W10
=Heater+ x1 =Heater+ x1 x1
E -1T410.1 -1T430.1 -H2

WHITE
x2 x2 x2
-W9 -W10
114
1 2 -X3 9 -X3 11
-U1
114 114 114 114 114
F
YD
=External+
STAND STILL HEATING STAND STILL HEATING 230V HEATING

G
Language UK
230VAC/50 hZ CIRC. PUMP 1 CIRC. PUMP 2 SUPPLY ON
SUPPLY FOR Tag No.: 1T410 Tag No.: 1T430
STAND STILL HEATING
10 Page: 11
Master Templates: Stand Still Heating - TFO Pumps_a = TFO_Primary System
102X03: 088663 Next Page: 12
9100 Aalborg DK
110 111 112 113 114 115 116 117 118 119
L L
10.99 / L L / 13.120
122 122 122 122
122
32 34 22 24 12 14
-K11 -K11 -K58
/12.115 31 /12.115 21 /25.246 11
STAND BY STAND BY SYSTEM PRESS.
122
LOW LOW
125
DELAYED
125
123
122
125
Language UK
123
122
123
B
1 3 5 1 3 5 7 9 11 7 9 11
-S23 -S25 -S23 -S25

/12.115 /12.116 /12.111 /12.113
2 4 6 2 4 6 8 10 12 8 10 12
102X03_088663#A.2
124
124
1210
1210
1214
124 124 1210 1210 1214 1214 1214 1214 1214
OFF OFF
ST.BY ON ST.BY ON
ELECTRICAL DRAWINGS
1214
-X3 16
-S6 -S7
1214
-W11
C
=Heater+
1214
31 31 12 14 1
-K9 -K7 -K11 -1T427 DP
/12.113 32 /12.111 32 /12.115 11
STAND BY 2
126
1211
-W11
1215
D 13 13 -X3 17
-Q2 -Q3
/6.51 14 /6.53 14 1215
127
1212
-X3 12 -X3 14
16 18
External Stop (Jumper if not used) External Stop (Jumper if not used)
128
1213
-K12
NB. Not Alfa Laval Supply NB. Not Alfa Laval Supply
1215
E 13 15 /12.116 15
-X3 -X3
BUILD UP
121
129
121 121 129 129 PRESSURE
121
129
1216
121
129
x1 x1
-V1 A1 A1 -V2 A1 A1 A1 A1
HOUR h -K7 -K8 HOUR h -K9 -K10 -K11 -K12
COUNTER COUNTER 230VAC
x2 230VAC A2 230VAC A2 x2 230VAC A2 230VAC A2 230VAC A2 A2
3-10 sec.
N N N N N N N N N
F 10.99 / N N / 13.120
1/L1 2/T1 /6.51 14 11 /32.310 1/L1 2/T1 /6.53 14 11 /32.311 14 11 /12.115 18 15 /12.115
3/L2 4/T2 /6.51 12 3/L2 4/T2 /6.53 12 12 16
24 21 /33.320 24 21 /33.321 24 21 /12.113
5/L3 6/T3 /6.51 5/L3 6/T3 /6.53
22 22 22
21 22 /11.104 21 22 /11.106
34 31 /34.331 34 31 /34.332 34 31 /12.111
31 32 /12.113 32 31 32 /12.111 32 32
43 44 /35.341 44 43 44 /35.342 44 44 41 /37.363
53 54 /27.264 42 41 53 54 /27.265 42 41 42
G
CIRC PUMP 1 T.F. CIRC. PUMP 1 CIRC PUMP 2 T.F. CIRC. PUMP 2 T.F. CIRC. PUMP T.F. CIRC. PUMP
RUNNING HOURS RUNNING HOURS ST. BY ACTUATED ST. BY ACTUATED
4-17 / 92
11 Page: 12
Master Templates: Circulation Pumps & Low Pressure_b = TFO_Primary System
102X03: 088663 Next Page: 13
9100 Aalborg DK
120 121 122 123 124 125 126 127 128 129
L L
12.119 / L L / 14.130
131 131 131 131
131
131
32 34 22 24
4-18 / 92
-K15 -K15
/13.126 31 /13.126 21 16 18
STAND BY STAND BY
-K71
134
/28.277 15
134
BURNER OFF
132
STOP FOP
134
1317
132
42 44
132
B -K52
OFF OFF
102X03_088663#A.2
ST.BY ON 1 3 5 ST.BY ON 1 3 5 7 9 11 7 9 11 /24.234 41

DMA TEMP.
-S17 -S18 -S17 -S18 HIGH HIGH
1318
/13.126 /33.329 /13.122 /13.124

2 4 6 2 4 6 8 10 12 8 10 12
-S10 -S12 /13.127
133
133
139
139
1314
ELECTRICAL DRAWINGS
133 133 139 139 1314 1314 1314 1314 1314 42 44

-K53
/24.237 41
DMB TEMP.
1314
21 HIGH HIGH
21 -K13 12 14
1314
/13.122 22
-K14 -K15
C /13.124 22 /13.126 11
STAND BY
1310
135
1320
13 13 21
-Q7 -Q8 -B11 22 24
/6.57 14 /6.58 14 /14.131 22 -K49
/23.225 21
VALVES NOT IN
1315
DMA POSITION
1321
22 24 22 24
D -K50 -K19
136
1311
/23.228 21 /14.138 21
VALVES NOT IN FUEL PRESSURE
1322
1322
1315 DMB POSITION 1322

HIGH HIGH
16 18
-K16
/13.127 15 13 13
BUILD UP
-X3 18 -X3 20 PRESSURE -K13 -K14
EXTERNAL STOP EXTERNAL STOP /13.122 /13.124
14 14
(JUMPER IF NOT USED) (JUMPER IF NOT USED)
137
1312
1315
E
NB. NOT ALFA LAVAL SUPPLY NB. NOT ALFA LAVAL SUPPLY
1323
1323
-X3 19 -X3 21
1316
1323 1323
138
1313
A1 A1 A1 A1 A1
-K13 -K14 -K15 -K16 -K17
230VAC 230VAC 230VAC 230VAC 230VAC
A2 A2 A2 A2 A2
3-10 sec.
N N N N N N
F 12.119 / N N / 14.130
1/L1 2/T1 /6.57 1/L1 2/T1 /6.58 14 11 /13.126 18 15 /13.126 14 11 /14.135
3/L2 4/T2 /6.57 3/L2 4/T2 /6.59 12 16 12
24 21 /13.124 24 21 /14.137
5/L3 6/T3 /6.57 5/L3 6/T3 /6.59
22 22
13 14 /13.128 13 14 /13.129
34 31 /13.121 34
21 22 /13.124 21 22 /13.122 32 32 31
31 32 31 32 44 41 /38.375 44
43 44 /35.345 43 44 /35.346 42 42 41
53 54 /34.336 53 54 /34.337
Language UK
FUEL PUMP 1 FUEL PUMP 2 FUEL PUMPS FUEL PUMPS FUEL PUMP 1 OR
ST.BY ACTIVATED ST.BY ACTIVATED FUEL PUMP 2 RUNNIG
12 Page: 13
Master Templates: Fuel Oil Pumps_a = TFO_Primary System
102X03: 088663 Next Page: 14
9100 Aalborg DK
130 131 132 133 134 135 136 137 138 139
L L L L L
13.129 / L L / 15.140
-B11 -B13
A /13.127 /14.136
/14.138
31 PR4131 + 4501 31 PR4131 + 4501
33 43 42 33 43 42
Language UK
F1-
142
B F1- L L
142
8.76 / F1-
102X03_088663#A.2
E1+ 142 21 23
8.76 / E1+ -B13 -B13
L
L
/14.133 22 /14.133 24
ELECTRICAL DRAWINGS
141
C
12 14 22 24
E1+
-K17 -K17
143
145
/13.128 11 /13.128 21
FUEL PUMP 1 OR FUEL PUMP 1 OR
FUEL PUMP 2 RUNNIG FUEL PUMP 2 RUNNIG
143
145
-X3 22 23 IE
143 145
-W12
22 24 12 14 32 34 12 14
-K4 -K18 -K4 -K19
/10.94 21 /14.136 11 31 /14.138 11
/10.94
144
146
144 146
E
-1G5
-1G5 -1G5
PRESSURE
144
146
TRANSMITTER
=Oil_System+
A1 A1
-K18 -K19
230VAC A2 230VAC A2
N N N N N
F 13.129 / N N / 15.140
14 11 /14.136 14 11 /14.138
12 12
24 21 /36.352 24 21 /13.129
22 22
34 34
32 31 32 31
44 44
42 41 42 41
24 21 /38.375
22
G
FUEL PRESSURE FUEL PRESSURE FUEL PRESSURE
RINGLINE RINGLINE LOW HIGH HIGH
4-19 / 92
13 Page: 14
Master Templates: Fuel Oil Pumps_b = TFO_Primary System
102X03: 088663 Next Page: 15
9100 Aalborg DK
Revision 2
F
E
B
C
A
G
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14.139 /
14.139 /
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L
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140
STU
24-05-2018
141
Project
See Title Page
L
N
=Oil_System+
ALA/182
-1F5
Created By
/10.95
-K5
230VAC
-K20
P
-W13
-W13
42
44
32
34
22
24
12
14
-X3
-X3
142
4
1
152 151
22 24
FUEL
A2
A1
25
24
41
31
LOW LOW
PRESSURE
21 /15.142
-K20
18/5-2018
Creation Date
152
151
21 /38.376
11 /15.142
152 151
11
12 14
-K70
N
143
/27.268
15
16 18
Master Templates:
144
145
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
146
Fuel Oil Pumps_c

147
102X03: 088663
148

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L / 16.150
N / 16.150
56
16
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F
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15.149 /
15.149 /
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150
STU
24-05-2018
151
Project
See Title Page
N
ALA/182
Created By
152
18/5-2018
Creation Date
153
Master Templates:
230VAC
2:DMA
3:DMB
1:DMZ
-K22
-S14

42
44
32
34
22
24
12
14
154
162
DMA
A2
A1
L
41
31
162
2
1
162
L
21 /23.224
11 /21.201
4
3
163 L
N
163
230VAC
-K23
42
44
32
34
22
24
12
14
155
163
A2
A1
DMB
41
31
21 /23.227
11 /22.211
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
156
Fuel_Oil_System_a
N
157
102X03: 088663
158

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L / 17.160
N / 17.160
56
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160 161 162 163 164 165 166 167 168 169
L L L L L L
16.159 / L L / 18.170
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-X3 26 -X3 28 -X3 30 -X3 32 -X3 34 -X3 36
-W16 -W17 -W18 -W19

=Oil_System+ =Oil_System+
+1G7 1 1
+1G8 1 1
B 1G7.1 1G7.2 -1G8.1 1G8.2
102X03_088663#A.2
2 2 2 2
ELECTRICAL DRAWINGS
-W16 -W17 -W18 -W19
-X3 27 -X3 29 -X3 31 -X3 33 -X3 35 -X3 37
173
174
175
176
A1 A1 A1 A1
-K26 -K27 -K28 -K29
230VAC A2 230VAC A2 230VAC A2 230VAC A2
N N N N N
F 16.159 / N N / 18.170
14 11 /19.185 14 14 11 /19.185 14
12 12 11 12 12 11
24 24 21 /19.183 24 24 21 /19.183
22 21 22 22 21 22
34 34 34 34
32 31 32 31 32 31 32 31
44 44 44 44
42 41 42 41 42 41 42 41
Language UK
DMB DMA DMB RETURN
RINGLINE
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9100 Aalborg DK
170 171 172 173 174 175 176 177 178 179
L L L
17.169 / L L / 19.180
16 18 16 18 16 18
-K39 -K45 -K42
/21.202 15 /22.212 15 /21.205 15
PULS TO PULS TO PULS TO
DMA DMB DMB
Language UK
B
185
184
102X03_088663#A.2
ELECTRICAL DRAWINGS
183
184
C
184
-X3 38 -X3 40 42 -X3 44 -X3 46 -X3 48
-W22 -W23 -W24 -W25

x1 x1 x1 x1
E -1G7 -1G7 -1G8 -1G8
/18.175 x2 /18.174 x2 /18.178 x2 /18.177 x2
-W22 -W23 -W24 -W25
-X3 39 -X3 41 43 -X3 45 -X3 47 -X3 49
N N N N N N N
F 17.169 / N N / 19.180
G
DMA DMB RETURN DMB
SUPPLY RINGLINE RETURN
4-23 / 92
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Master Templates: Fuel_Oil_System_c = TFO_Primary System
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9100 Aalborg DK
180 181 182 183 184 185 186 187 188 189
L L L L
18.179 / L L / 20.190
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12 14
B -K26
102X03_088663#A.2
/17.164 11
DMB
194
197
ELECTRICAL DRAWINGS
22 24 12 14
-K27 -K28
/17.165 21 /17.167 11
DMA DMB
195
22 24
C -K29
/17.168 21
RETURN
RINGLINE
198
196
D
196 198
196
198
A1 A1
-K31 -K32
230VAC A2 230VAC A2
N N N
F 18.179 / N N / 20.190
14 11 /23.224 14 11 /23.227
12 12
24 21 /35.346 24 21 /35.347
22 22
34 34
32 31 32 31
44 44
42 41 42 41
Language UK
BURNER IN DMA BURNER IN DMB
OPERATION OPERATION
18 Page: 19
Master Templates: Fuel_Oil_System_d = TFO_Primary System
102X03: 088663 Next Page: 20
9100 Aalborg DK
Revision 2
F
E
B
C
A
G
D
19
19.189 /
19.189 /
Dkaaabh
L
15-08-2018
190
STU
24-05-2018
191
Project
See Title Page
ALA/182
Created By
192
18/5-2018
Creation Date
193
Master Templates:
194
L
195
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
196
Fuel_Oil_System_e
197
102X03: 088663
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198

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200 201 202 203 204 205 206 207 208 209
L L
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12 14
B -K22
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/16.154 11
DMA
ELECTRICAL DRAWINGS
211
C
211 211 211 211 211

211
12 14
D -K43
/21.206 11
16 18
-K41
/21.204 15
212
213
212
E
212
211 212
211
212
A1 Y1 A1 A1 A1 Y1 A1 A1
-K39 -K40 -K41 -K42 -K43 -K44
CT-MFE A2 230VAC A2 CT-ERE A2 CT-MFE A2 230VAC A2 230VAC A2
N N N N N N N
F 20.199 / N N / 22.210
14 14 11 /21.207 14 11 /23.226
12 11 12 12
24 24 24
18 18 15 /21.205 18 22 21 22 21
22 21
16 15 /18.174 16 16 15 /18.177 34 34
34
32 31 32 31 32 31
44 44 44
42 41 42 41 42 41
Language UK
PULS TO FLUSH PULSE TO OVERRULE
DMA TIME DMA VALVE EROR
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Master Templates: Fuel_Oil_System_f = TFO_Primary System
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9100 Aalborg DK
Revision 2
F
E
B
C
A
G
D
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21.209 /
21.209 /
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15-08-2018
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L
24-05-2018
/16.155
DMB
-K23
N
211
221
11
12 14
Project
See Title Page
221
CT-MFE
-K45
ALA/182
Created By
16
18
212
DMB
A2
A1
PULS TO
221
221
Y1
18/5-2018
Creation Date
15 /18.175
N
221
230VAC
-K46
42
44
32
34
22
24
12
14
213
A2
A1
41
31
21
11 /22.215
Master Templates:
N
214
221
/22.213
-K46
230VAC
-K47
42
44
32
34
22
24
12
14
L
215
222 221
11
12 14
A2
A1
41
31
21
OVERRULE
VALVE EROR
11 /23.229
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
216
Fuel_Oil_System_g
N
217
102X03: 088663
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L L L L L
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22 24 12 14 22 24 12 14
B -K22 -K44 -K23 -K47
102X03_088663#A.2
/16.154 21 /21.207 11 /16.155 21 /22.215 11

DMA OVERRULE DMB OVERRULE
VALVE EROR VALVE EROR
ELECTRICAL DRAWINGS
233
235
12 14 12 14
C -K31 -K32
234
236
/19.184 11 /19.186 11
BURNER IN DMA BURNER IN DMB
OPERATION OPERATION
234
236
234 234 236 236
A1 A1
-K49 -K50
230VAC A2 230VAC A2
N N N N
F 22.219 / N N / 24.230
14 11 /38.374 14 11 /38.374
12 12
24 21 /13.128 24 21 /13.128
22 22
34 34
32 31 32 31
44 44
42 41 42 41
Language UK
VALVES NOT IN VALVES NOT IN
DMA POSITION DMB POSITION
22 Page: 23
Master Templates: Fuel_Oil_System_h = TFO_Primary System
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9100 Aalborg DK
230 231 232 233 234 235 236 237 238 239
L L L L L L
23.229 / L L / 25.240
-B6 -B10
A
21 23 21
31 PR4131 + 4501 31 PR4131 + 4501
33 44 43 42 41 33 44 43 42 41
22 24 22
Language UK
241
242
243
248
249
2410
B
-X3 50 51 52 IE -X3 53 54 55 IE
102X03_088663#A.2
-W26 -W27
ELECTRICAL DRAWINGS
244
246
2411
C
1 2 3 1 2 3
-1G11 -1G12
PT100 PT100
244 246 2411
244
246
2411
42 44 12 14 12 14 12 14 22 24 12 14
-K2 -K51 -K5 -K52 -K3 -K53
/10.92 41 /24.233 11 /10.95 11 /24.234 11 /10.93 21 /24.237 11
245
247
2412
245 247 2412
245
247
2412
A1 A1 A1
-K51 -K52 -K53
230VAC A2 230VAC A2 230VAC A2
N N N N N N
F 23.229 / N N / 25.240
14 11 /24.233 14 11 /24.234 14 11 /24.237
12 12 12
24 21 /27.260 24 21 /38.372 24 21 /38.373
22 22 22
34 31 /38.372 34 31 /27.260 34 31 /27.261
32 32 32
44 44 41 /13.128 44 41 /13.128
42 41 42 42
G
DMA TEMP. F.O. TEMP. DMA TEMP. DMB TEMP. DMB TEMP.
LOW LOW HIGH HIGH HIGH HIGH
4-29 / 92
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9100 Aalborg DK
240 241 242 243 244 245 246 247 248 249
L L L L L L L L
24.239 / L L / 26.250
4-30 / 92
-X3 56 -X3 58 -X3 60 -X3 62
-W28 -W29 -W30 -W31

=Heater+ =Heater+ =Heater+
=BURNER+
31 13 16 18 16 18 1 1
B -F224 1T181 P -K55 -K57 1T24 1T46 P
102X03_088663#A.2
14 /25.242 15 /25.245 15 2
32 2
ELECTRICAL DRAWINGS
-W28 -W29 -W30 -W31
-X3 57 -X3 59 -X3 61 -X3 63
251
253
257
2510
255
251 253 257 2510
251
253
257
2510
256
12 14 12 14 32 34 12 14 42 44 12 14 12 14 12 14
D -K1 -K54 -K1 -K56 -K1 -K59 -K2 -K61
/10.91 11 /25.241 11 /10.91 31 /25.244 11 /10.91 41 /25.247 11 /10.92 11 /25.249 11
252
254
258
259
252 254 255 258 259

259
259
252
254
255
258
E
259
A1 A1 Y1 A1 A1 A1 A1 A1 A1
-K54 -K55 -K56 -K57 -K58 -K59 -K60 -K61
230VAC A2 5 SEC A2 230VAC A2 180 SEC. A2 230VAC A2 230VAC A2 230VAC A2 230VAC A2
CT-AHS
N N N N N N N N N
F 24.239 / N N / 26.250
14 11 /25.241 14 11 /25.243 14 11 /12.118 14 11 /25.247 14 11 /32.310 14 11 /25.249
12 12 12 12 12 12
24 21 /27.260 24 21 /27.260 24 21 /32.310 24 21 /27.260 24 21 /33.320 24 21 /37.361
22 18 15 /25.244 22 18 15 /25.246 22 22 22 22
34 31 /37.365 16 34 16 34 31 /33.320 34 31 /37.364 34 34 31 /27.260
32 32 31 32 32 32 31 32
44 44 41 /37.361 44 44 44 44
42 41 42 42 41 42 41 42 41 42 41
Language UK
BURNER FLANGE DELAY SYSTEM PRESS. SYSTEM PRESS. OFH T.F. SYSTEM PRESS.
OPEN WATER PRESSURE LOW LOW LOW LOW TEMP. HIGH HIGH HIGH HIGH
LOW LOW DELAYED
24 Page: 25
Master Templates: Burner Safety_a = TFO_Primary System
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9100 Aalborg DK
250 251 252 253 254 255 256 257 258 259
L L L L L L
25.249 / L L / 27.260
A
-U1
/28.270
-X3 64 -X3 66 -X3 68 Xk5
-W32 -W33 -W34 7 8 9 63 64 62

=Heater+ =Heater+
=BURNER+
Language UK
11 13 33 16 18
B 1T32 1T34 DP -R3 P -K69
267
268
269
14 34 /27.267 15
12
102X03_088663#A.2
-W32 -W33 -W34 70 71 72 IE

-X3
ELECTRICAL DRAWINGS
-X3 65 -X3 67 -X3 69
265
C
-W35
2610
261
263
265
261 263 265
=Heater+
261
263
12 14 12 14 22 24 12 14 42 44 12 14 1 2 3
D
-1T21
-K3 -K62 -K1 -K63 -K4 -K64 PT100
/10.93 11 /26.251 11 /10.91 21 /26.253 11 /10.94 41 /26.254 11
262
264
266
262 264 266
2610
2610
12 14 12 14
-K4 -K65
262
264
266
E /10.94 11 /26.258 11
2611
2611
2611
A1 A1 A1 A1
-K62 -K63 -K64 -K65
230VAC A2 230VAC A2 230VAC A2 230VAC A2
N N N N N
F 25.249 / N N / 27.260
14 11 /26.251 14 11 /26.253 14 11 /26.255 14 11 /26.259
12 12 12 12
24 21 /27.260 24 21 /37.363 24 21 /28.277 24 21 /36.351
22 22 22 22
34 31 /37.364 34 31 /27.260 34 31 /37.366 34
32 32 32 32 31
44 44 44 41 /27.260 44
42 41 42 41 42 42 41
G
OFH FLUE GAS TEMP. OFH T.F FLOW BURNER OFH T.F.
HIGH HIGH LOW LOW AIRPRESSURE TEMP. HIGH
LOW LOW
4-31 / 92
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9100 Aalborg DK
260 261 262 263 264 265 266 267 268 269
L L
26.259 / L L / 28.270
2710
2710
22 24
A 73
-B7
-K56 -X3 /27.265
/25.244 LOK16
21
SYSTEM PRESS. -W36
LOW LOW
+External
271
4-32 / 92
1 2 3 21 7 22 24 6
32 34 11
-K61 -S1 YD
/25.249 31 12
SYSTEM PRESS. OPTIONAL
HIGH HIGH TO BE PLACED
-W36 AS CLOSED AS
272
2715
2716
2718
2720
POSSIBLE TO THE
32 34 BURNER
2711
B -K63 -X3 74 22 24 13
102X03_088663#A.2
/26.253 31 -K2 -Q5

OFH T.F FLOW
/10.92 21 /6.55 14 75 76
LOW LOW -X3 -X3
273
2711
2714
ELECTRICAL DRAWINGS
22 24 2711 2714
-W37
-K59
/25.247 21
OFH T.F.
TEMP. HIGH HIGH
274
2710
22 24
C -K62 53 53 46 47
/26.251 21 -K7 -K9
OFH FLUE GAS TEMP.
2719
/12.111 54 /12.113 54
HIGH HIGH 2719
275
X1 X2
2712
2712
22 24
-K54 2712
/25.241 21
BURNER FLANGE -F32
2717
OPEN
=BURNER+ (Flame sensor cable MUST be
276
a separete cable)
42 44
D -K64
2714
/26.254 41
BURNER
AIRPRESSURE
277
LOW LOW
22 24
-K51
/24.233 21
F.O. TEMP.
LOW LOW
278
32 34 32 34
E -K52 -K53
/24.234 31 /24.237 31 2717 2717
DMA TEMP. DMB TEMP.
HIGH HIGH HIGH HIGH
279
279
12 14
2717
279 -K67
/27.266 11
2713
A1 A1 A1 A1 A1
-K66 -K67 -K68 -K69 -K70
230VAC A2 230VAC A2 A2 A2 A2
N N N N N N N
F 26.259 / N N / 28.270
14 11 /28.278 14 11 /27.264 1/L1 2/T1 /6.55
12 12 3/L2 4/T2 /6.55
24 24 21 /37.365 5/L3 6/T3 /6.55
22 21 22 18 15 /26.255 18 15 /15.143
13 14 /34.333
34 31 /35.342 34 16 16
32 32 31 23 24 /28.277
44 44
42 41 42 41
Language UK
SAFETY CIRCUIT BURNER TROUBLE BURNER MOTOR FLAME SCANNER
26 Page: 27
Master Templates: Burner Safety_c = TFO_Primary System
102X03: 088663 Next Page: 28
9100 Aalborg DK
270 271 272 273 274 275 276 277 278 279
L L
27.269 / L L / 30.290
A
-U1 Controller Type: 93W00a200 -B9
/26.257 27 30100100 Xk5= Water Temp. High /28.276 Burner Relay LOK16
/29.280
Range: 0-400 °C
RELEASE LOAD AIR PRESSURE ON/OFF CONTROL
Xk3 Xk1 Xk2 CONTROL CHECK BURNER
28 1 2 3 4 5 6 29 20 14 12 4 5
57 58 56 51 52 50 54 55 53
Language UK
281
282
283
284
285
286
2811
2813
B 23 12 14
-X3 77 78 79 IE -X3 80 81 82 IE -K68 -K66
/27.267 24 /27.264 11
Safety
287
287a
102X03_088663#A.2
Circuit
2810
2812
-W39 -W40
22 24
ELECTRICAL DRAWINGS
287 -K64
289
E
/26.254 21
BURNER
F
AIRPRESSURE
C 0 2 LOW LOW
1
288
-S4
BURNER 0 1 2 288 288
OFF
PARTIAL
287
1 2 3 1 2 3
-1T44 -1T20
289
AUTO
PT100 PT100
288
288
E E
287
289 E / 29.280
F
D 288 F / 29.280
=Heater+ =Heater+
287
E
288
A1
-K71
5 MIN A2
N N N
F 27.269 / N N / 30.290
18 15 /13.128
16
Supply Return BURNER SERVO MOTOR BURNER OFF
G
ON/OFF CLOSED/OPEN STOP FOP
4-33 / 92
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9100 Aalborg DK
280 281 282 283 284 285 286 287 288 289
A
-B9
/28.276
/28.276 BURNER RELAY LOK 16
4-34 / 92
BURNER IN FEEDBACK SERVOMOTOR IGNITTION
OPERATION OPEN SIGNAL CLOSE IGNITTION POSITION STAGE ONE TRAFFO
19 9 8 11 10 18 16
F
E
B E
102X03_088663#A.2
28.277 / E
292
F
295
296
297
298
28.277 / F
ELECTRICAL DRAWINGS
292
293
292
293
-X3 83 84 85 86 88 89 90 91
C
-W38
12 14
=BURNER+ 12
-K73 6 17 11 14 19 20 3 1
/29.282 11
BURNER IN
FULL LOAD
293
D 7 8 9 2 6 5 3 4 10 11 12
291
T1 1
-F204 I III IV II -F205

Y12 Y14
2
I = AUX. SWITCH STAGE TWO VALVE -F203

R16 II = LIMIT SWITCH PARTIAL LOAD Y11
291 293
E
III = LIMIT SWITCH FULL LOAD
N
IV = LIMIT SWITCH CLOSED
SERVOMOTOR
291
293
294
x1 x1
N N
N N
-V3 -V4
HOUR COUNTER h A1 A1 HOUR COUNTER h
PARTIAL LOAD FULL LOAD -W38
x2 -K72 -K73 x2
230VAC A2 230VAC A2 87 92
N_s1 N_s1 N_s1 N_s1 N_s1 -X3 N_s1 -X3 N_s1
F
29.289 / N_s1 N_s1 / 29.280
BURNER IN BURNER IN T1 = IGNITION TRANSFORMER

PARTIAL LOAD FULL LOAD F203/Y11 = SOLENOID VALVE - STAGE ONE
14 11 /35.342 14 11 /29.281
F204/Y12 = SOLENOID VALVE - STAGE TWO
12 12
24 24 21 /35.343 F205/Y14 = SOLENOID VALVE - OIL SUPPLY VALVE
22 21 22
34 34
32 31 32 31
44 44
42 41 42 41
Language UK
IGNITION
TRAFO
28 Page: 29
Master Templates: Burmer Control_b = TFO_Primary System
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9100 Aalborg DK
Revision 2
F
E
B
C
A
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28.279 /
28.279 /
Dkaaabh
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15-08-2018
290
STU
L
24-05-2018
-B12
33
31
291
Project
See Title Page
44
=Heater+
PT100
-1T657
-W41
-X3
43
301
93
PR4131 + 4501
ALA/182
Created By
San. Water Heater
42
302
94
L
N
/10.93
-K3
41
292
303
95
305 304
31
32 34
18/5-2018
Creation Date
IE
305
304
/30.293
-K74
230VAC
-K74
42
44
32
34
22
24
12
14
21
305 304
11
12 14
A2
A1
22
41
31
SAN. WATER
293
HEATER TEMP. LOW

21 /36.352
11 /30.293
Master Templates:
294
295
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
L
N
296
San. Water Heater

297
102X03: 088663
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Revision 2
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30.299 /
30.299 /
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15-08-2018
300
STU
24-05-2018
-U2
N
27
301
Project
-W42
See Title Page

L
311
51
PE
L
ALA NO.: 30100400
52
-X3
OPEN
ALA/182
312
Created By
96
CONTROL VALVE
-1T270
50
CONTROLLER: 93W01a70E
311
14
PE
-W42
54
302
-X3
OPEN/CLOSE
311
11
97
W1
55
CLOSE
CONTROL VALVE
18/5-2018
Creation Date
313
98
53
-1T284
-W43
-X3
99
314
99
303
10
PRESSURE
315
PRESSURE
100
TRANSMITTER
TRANSMITTER
N
IE
Master Templates:
304
28
29
L
305
Gasvaerksvej 21
9100 Aalborg DK
Alfa Laval Aalborg
306
Minimum Flow Controller

307
102X03: 088663
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310 311 312 313 314 315 316 317 318 319
L L
31.309 / L L / 33.320
A
-U3 CONTROLLER: 93W01a70E
ALA NO.: 30100400
27 1 2 3 28 29
51 52 50 54 55 53
326
L
326
326
3210
3211
3212
Language UK
L L L
B -X3 104 105 106 IE
OPEN
327
CLOSE
329
102X03_088663#A.2
1 2
3
-W45
-S30
OFF ON 4
ELECTRICAL DRAWINGS
321 321 12 14 22 24 32 34
C -K75 -K75 -K75
/32.310 11 /32.310 21 /32.310 31
321
321
325
328
325
12 14 12 14 325
-K8 -K10 1 2 3
/12.112 11 /12.114 11
-1T286
T.F. CIRC. T.F. CIRC. PT100
PUMP 1 PUMP 2
322
322
PE -X3 101 -X3 103
322 322
-W44 =Heater+
22 24
-K58
/25.246 21
SYSTEM PRESS.
LOW LOW
323
DELAYED
14 11
12 14
E -K60
/25.248 11 -1T452
SYSTEM PRESS.
CONTROL VALVE
HIGH HIGH
PE W1
324
-W44
A1
-K75
230VAC A2 102
N N -X3 N N
F 31.309 / N N / 33.320
14 11 /32.312
12
24 21 /32.313
22
34 31 /32.314
32
44 41 /35.348
42
G
HVAC CONSUMERS CONTROL VALVE PRESSURE
OPEN/CLOSE TRANSMITTER
4-37 / 92
31 Page: 32
Master Templates: HVAC Consumer - Controller = TFO_Primary System
102X03: 088663 Next Page: 33
9100 Aalborg DK
320 321 322 323 324 325 326 327 328 329
L L L L
32.319 / L L / 35.340
A
-U4
27 Controller Type: 93W00a701
30100200
4-38 / 92
Xk1 Xk2 Xk5
28 1 2 3 7 8 9 29
51 52 50 54 55 53 63 64 62
L
L L L L
B
102X03_088663#A.2
339
3311
335
336
337
3312
3313
3314
3315
1
ELECTRICAL DRAWINGS
1 2
3
L
OPEN
CLOSE
-S31 -S18
OFF / ON 4 /13.124
2
FRESH WATER /13.127
GENERATOR
3315
331 331 12 14 22 24 32 34 3315
C -K76 -K76 -K76

-X3 107 108 109 IE /33.320 11 /33.320 21 /33.320 31 -X3 113 114 115 IE
331
331
338
3310
338
22 24 22 24 338
-K10
-K8 /12.114
/12.112 21 21
T.F. CIRC. -W46 -W48
T.F. CIRC. PUMP 2
PUMP 1
332
332
PE -X3 110 -X3 112
332 332
3315
-W47
3315
42 44 12 14
32 34 -K3 -K77
/10.93 41 /33.328 11
-K58 1 2 3 1 2 3
/25.246 31
-1T287 -1T557
SYSTEM PRESS. PT100 PT100
3316
LOW LOW 3316
333
DELAYED
14 11
22 24
E -K60
/25.248 21 -1T551
SYSTEM PRESS.
3316
CONTROL VALVE
HIGH HIGH
=Heater+ =Heater+
PE W1
334
A1
-W47
A1 -K77
230VAC A2
-K76
230VAC A2 111
N N N -X3 N N
F 32.319 / N N / 35.340
14 11 /33.328
12
24 21 /36.353
14 11 /33.323 22
12 34
24 21 /33.324 32 31
22 44
34 31 /33.324
42 41
32
44 41 /35.348
42
Language UK
FRESH WATER FRESH WATER
GENERATOR GENERATOR
TEMP. LOW
32 Page: 33
Master Templates: Freshwater Generator - Controller = TFO_Primary System
102X03: 088663 Next Page: 34
9100 Aalborg DK
330 331 332 333 334 335 336 337 338 339
Language UK
B
341 343 345 347 349

102X03_088663#A.2
341
343
345
347
349
ELECTRICAL DRAWINGS
32 34 32 34 13 53 53
-K8 -K10 -K68 -K13 -K14
C /12.112 31 /12.114 31 /27.267 14 /13.122 54 /13.124 54
341
343
345
347
349
342
344
346
348
3410
D -X3 116 117 -X3 118 119 -X3 120 121 -X3 122 123 -X3 124 125 -X3 126 127 -X3 128 129
E
-W49
=AMS+
-U1
1 2 3 4 5 6 7 8 9 10 11 12 13 14
F
T.F. CIRC. PUMP 1 T.F. CIRC. PUMP 2 BURNER FUEL PUMP 1 FUEL PUMP 2
G
IN OPERATION IN OPERATION RUNNING IN OPERATION IN OPERATION
4-39 / 92
33 Page: 34
Master Templates: Potential Free Signals = TFO_Primary System
102X03: 088663 Next Page: 35
9100 Aalborg DK
340 341 342 343 344 345 346 347 348 349
L L L L L L L L L L L L L L
33.329 / L L / 36.350
4-40 / 92
43 43 32 34 12 14 22 24 43 43 22 24 22 24
-K7 K9 -K66 -K72 -K73 -K13 -K14 -K31 -K32 42 44 42 44
/12.111 44 /12.113 44 /27.264 31 /29.281 11 /29.282 21 /13.122 44 /13.124 44 /19.184 21 /19.186 21 -K75 -K76
/32.310 41 /33.320 41
B
102X03_088663#A.2
351
352
353
355
356
357
358
3510
3511
3512
3513
ELECTRICAL DRAWINGS
-U5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C gn gn gn gn gn gn gn gn gn gn gn gn gn gn gn gn
T3A T3 28 29
Module type: 821A21g - ALA No. 30200100
1T3
1T3
1T1
1T1 / 36.350
1T3
1T2
D 1T2 / 36.350
1T1
1T3
1T2
1T3 / 36.350
3 32 34 12 14
-S27 -K2 -K79
4 /10.92 31 /35.343 11
L
L L
E
ACCEPT RESET
ALARM ALARM
3
-S28
4
LED
354
354
TEST
354
A1 A1
-K78 -K79
230VAC A2 230VAC A2
F N N N N
33.329 / N N / 36.350
14 11 /11.105 14 11 /35.342
12 12
24 21 /11.105 24
22 22 21
34 31 /11.107 34
32
32 31
44 41 /11.107 44
42
42 41
Language UK
T.F. CIRC. PUMP 1
T.F. CIRC. PUMP 2
BURNER CONDITIONS
CORRECT
BURNER IN
OPERATION
BURNER IN
FULL LOAD
T.F. CIRC. PUMP 1
T.F. CIRC. PUMP 2
BURNER IN DMA
OPERATION
BURNER IN DMB
OPERATION
HVAC CONSUMERS
FRESH WATER
GENERATOR
34 Page: 35
Master Templates: Status Module = TFO_Primary System
102X03: 088663 Next Page: 36
9100 Aalborg DK
350 351 352 353 354 355 356 357 358 359
L L L L L L L L L L
35.349 / L L / 37.360
A 22 24 22 24 22 24 22 24
-K65 -K18 -K74 -K77
/26.258 21 /14.136 21 /30.293 21 /33.328 21
Language UK
361
362
363
364
B
102X03_088663#A.2
-U6
N1 N2
ELECTRICAL DRAWINGS
27 1 2 3 4 5 6 7 8
ye ye ye ye ye ye ye ye
C
28 28
OUT 1 OUT 2
T1 T2 T3 28 29
51 52 50 54 55 53 Module type: 821A21y - ALA No.: 30200600
365
366
367
368
1T1 1T1
35.343 / 1T1 1T1 / 37.360

D 1T2 1T2 -X6 1 2 -X6 3 4
35.343 / 1T2 1T2 / 37.360
-W50
1T3 1T3
35.343 / 1T3 1T3 / 37.360

+AMS
-U14
7 8 9 10
COMMON COMMON
PRE-ALARM PRE-ALARM
E
ALARM MONITORING SYSTEM (AMS)
NB. USE CORRECT CONECTION POINTS!
N N
35.349 / N N / 37.360
F
G
4-41 / 92
OFH T.F.
TEMP. HIGH
FUEL PRESSURE
RINGLINE LOW
SAN. WATER
HEATER TEMP. LOW
FRESH WATER
GENERATOR
TEMP. LOW
35 Page: 36
Master Templates: Pre-Alarm Module = TFO_Primary System
102X03: 088663 Next Page: 37
9100 Aalborg DK
360 361 362 363 364 365 366 367 368 369
L L L L L L L L L L L L L L L L L L
36.359 / L L / 38.370
4-42 / 92
42 44 22 24 23 23 42 44 22 24 32 34 32 34 32 34 22 24 23 32 34
-K56 -K61 -Q2 -Q3 -K11 -K63 -K59 -K62 -K54 -K67 -Q5 -K64
/25.244 41 /25.249 21 /6.51 24 /6.53 24 /12.115 41 /26.253 21 /25.247 31 /26.251 31 /25.241 31 /27.266 21 /6.55 24 /26.254 31
B
102X03_088663#A.2
371
372
373
374
375
378
3710
3712
3713
3714
3715
3716
ELECTRICAL DRAWINGS
-U7
27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 N1 N2
3723
3724
rd rd rd rd rd rd rd rd rd rd rd rd rd rd rd rd
C
28 28
OUT 1 OUT 2 OUT 3 OUT 4 HORN
T1 T2 T3 28 29
51 52 50 54 55 53 Module type: 821A21rr ALA No. 30200400 57 58 56 60 61 59 63 64 62
376
377
379
3711
3717
3718
3719
3720
3721
3722
1T1 1T1
36.352 / 1T1 1T1 / 38.370

D 1T2 1T2 -X3 130 131 -X3 132 133 -X3 134 135 -X3 136 137 -X3 138 139
36.352 / 1T2 1T2 / 38.370
-W51
1T3 1T3
36.352 / 1T3 1T3 / 38.370
+AMS
-U1
11 12 13 14 15 16 17 18 19 20
COMMON ALARM COMMON ALARM HORN

COMMON ALARM COMMON ALARM
E
N N
36.359 / N N / 38.370
F
G
Language UK
SYSTEM PRESS.
LOW LOW
SYSTEM PRESSURE
HIGH HIGH
T.F. CIRC. PUMP 1
FUSE TRIPPED
T.F. CIRC. PUMP 2
FUSE TRIPPED
T.F. CIRC. PUMP
ST. BY ACTUATED
OFH T.F FLOW
LOW LOW
OFH T.F.
TEMP. HIGH HIGH
OFH FLUE GAS TEMP.
HIGH HIGH
BURNER FLANGE
OPEN
BURNER TROUBLE
BURNER MOTOR
FUSE TRIPPED
BURNER
AIRPRESSURE
LOW LOW
36 Page: 37
Master Templates: Alarm Module_a = TFO_Primary System
102X03: 088663 Next Page: 38
9100 Aalborg DK
370 371 372 373 374 375 376 377 378 379
L L L L L L L L L L L L L L L L L
37.369 / L
23 23 32 34 22 24 22 24 12 14 12 14 42 44 22 24 22 24
-Q7 -Q8 -K51 -K52 -K53 -K49 -K50 -K15 -K19 -K20
L
/6.57 24 /6.58 24 /24.233 31 /24.234 21 /24.237 21 /23.225 11 /23.228 11 /13.126 41 /14.138 21 /15.142 21
Language UK
B
381
382
383
384
385
3810
3812
3813
3814
3815
102X03_088663#A.2
-U8
N1 N2
ELECTRICAL DRAWINGS
27 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
3822
3823
rd rd rd rd rd rd rd rd rd rd rd rd rd rd rd rd
C
28 28
OUT 1 OUT 2 OUT 3 OUT 4 HORN
T1 T2 T3 28 29
51 52 50 54 55 53 Module type: 821A21rr ALA No. 30200400 57 58 56 60 61 59 63 64 62
1T1
386
387
389
3811
3816
3817
3818
3819
3820
3821
1T1
1T2
37.362 / 1T1
1T3
D 1T2 -X3 140 141 -X3 142 143 -X3 144 145 -X3 146 147 -X3 148 149
37.362 / 1T2
-W52
1T3
37.362 / 1T3
+AMS
-U15
11 12 13 14 15 16 17 18 19 20
N
COMMON ALARM COMMON ALARM HORN

COMMON ALARM COMMON ALARM
E
37.369 / N
F
G
FUEL PUMP 1
FUSE TRIPPED
FUEL PUMP 2
FUSE TRIPPED
F.O. TEMP.
LOW LOW
DMA TEMP.
HIGH HIGH
DMB TEMP.
HIGH HIGH
VALVES NOT IN
DMA POSITION
VALVES NOT IN
DMB POSITION
FUEL PUMPS
ST.BY ACTIVATED
FUEL PRESSURE
HIGH HIGH
FUEL
PRESSURE
LOW LOW
4-43 / 92
37 Page: 38
Master Templates: Alarm Module_a = TFO_Primary System
102X03: 088663 &Cable
NextConnection
Page: Diagram/1
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9
Cable-connection diagram Ala_Std_Cable_ConForm_TFO_External_Rev1

15-08-2018Dkaaabh
A
4-44 / 92
V1 W1 V2 W2 V3
1 3 5
B U1 U1 U3
-Q1
-X3
-X3
-X3
2 4 6
102X03_088663#A.2
Internal targets
ELECTRICAL DRAWINGS
2 4 6 1 3 5 U1 V1 W1 U1 V2 W2 U3 V3
=TFO_Primary =TFO_Primary =TFO_Primary =TFO_Primary

System+CP-W1 System+CP-W2 System+CP-W3 System+CP-W4
conductor
conductor
conductor
conductor
MAIN SUPPLY 1 (MSB A T.F. CIRC. PUMP 1 U: 440 V P: T.F. CIRC. PUMP 2 U: 440 V P: BURNER MOTOR 1 U: 440 V P:
D -SECTION) Un: 3 x 440VAC 32 kW 22 kW In: 35,5 A Ist: 314 A 22 kW In: 35,5 A Ist: 314 A 0,76 kW In: 2,3A Ist: 23 A
1 2 3 U1 V1 W1 U1 V1 W1 U1 V1
-U100
-1T410
-1T430
-R15
1 2 3
U1 V1 W1 U1 V1 W1
U1 V1 W1
F M M M
3
External targets
3 3
G
Language UK
&SCH/38 &SCH/5.41 &SCH/6.51 &SCH/6.53 &SCH/6.55 Page: 1
Master Templates: Cable-connection diagram = TFO_Primary System
Revision 2 See Title Page ALA/182 18/5-2018 =TFO_Primary System+CP-W1 + CP
15-08-2018 24-05-2018 Order Template Version: TFO_OT_Rev2 Gasvaerksvej 21
=TFO_Primary System+CP-W2 102X03: 088663 Next Page: 1.a
9100 Aalborg DK
Revision No. Rev.Made by/Date Approved by/Date Project Created By Creation Date Master Drawing Number: 102X03:077024 =TFO_Primary System+CP-W3 Pages of: 56
=TFO_Primary System+CP-W4
0 1 2 3 4 5 6 7 8 9

15-08-2018Dkaaabh
A
W3 V4 W4 V5 W5 1
Language UK
B W3 U4 U5 1
-X3
-X3
-X3
-X5
Internal targets
102X03_088663#A.2
W3 U4 V4 W4 U5 V5 W5 1 2
ELECTRICAL DRAWINGS

conductor
conductor
conductor
conductor
BURNER MOTOR 1 U: 440 V P: FUEL PUMP 1 U: 440 V P: 0,3 kW FUEL PUMP 2 U: 440 V P: 0,3 kW REMOTE EMERGENCY STOP NB.
D 0,76 kW In: 2,3A Ist: 23 A In: 0,75 A Ist: 3,9 A In: 0,75 A Ist: 3,9 A Tag No. 1G1 YARD SUPPLY
W1 U1 V1 W1 U1 V1 W1 2 1
-R15
-1G1
-1G1
+External-S3
U1 V1 W1 U1 V1 W1
U1 V1 W1
2
F M M M
3
External targets
3 3 1
G
4-45 / 92
1 &SCH/6.55 &SCH/6.57 &SCH/6.58 &SCH/9.81 Page: 1.a
=TFO_Primary System+CP-W5 102X03: 088663 Next Page: 2
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9

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6 7 8 9 10 11 16 17 22
B 6 8 10 16 22
-X3
-X3
-X3
-X3
-X3
102X03_088663#A.2
Internal targets
6 7 8 9 10 11 16 17 22
ELECTRICAL DRAWINGS
=TFO_Primary =TFO_Primary =TFO_Primary =TFO_Primary =TFO_Primary

System+CP-W8 System+CP-W9 System+CP-W10 System+CP-W11 System+CP-W12
conductor
conductor
conductor
conductor
conductor
230VAC/50 hZ SUPPLY FOR STAND STILL HEATING CIRC. STAND STILL HEATING CIRC. T.F. CIRC. PUMP ST. BY
FUEL PRESSURE RINGLINE
D STAND STILL HEATING PUMP 1 Tag No.: 1T410 PUMP 2 Tag No.: 1T430 ACTUATED
1 2 x1 x2 x1 x2 1 2
=External-U1
=Heater-1T410.1
=Heater-1T430.1
=Heater-1T427
=Oil_System-1G5
1 2
1;2 1;2
x1 x1 1
F
PRESSURE
TRANSMITTER
External targets
x2 x2 2
YD
G
Language UK
1.a &SCH/11.100 &SCH/11.104 &SCH/11.106 &SCH/12.116 &SCH/14.131
Page: 2
9100 Aalborg DK =TFO_Primary System+CP-W10
0 1 2 3 4 5 6 7 8 9

15-08-2018Dkaaabh
A
23 24 25 30 31 33
Language UK
B 23 24 30 32
-X3
-IE
-X3
-X3
-X3
Internal targets
102X03_088663#A.2
23 24 25 30 31 32 33
ELECTRICAL DRAWINGS

conductor
conductor
conductor
conductor
FUEL PRESSURE RINGLINE FUEL PRESSURE LOW LOW DMB DMA

D
1 4 1 2 1 2
=Oil_System-1G5
=Oil_System-1F5
=Oil_System+1G7-1G7.1
1 1 1
F PRESSURE P
TRANSMITTER
External targets
4 2 2
G
4-47 / 92
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9

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35 36 37 42 44 46
B 34 36 42 44 46
-X3
-X3
-X3
-X3
-X3
102X03_088663#A.2
Internal targets
34 35 36 37 42 43 44 45 46
ELECTRICAL DRAWINGS

conductor
conductor
conductor
conductor
conductor
DMB RETURN RINGLINE DMA DMB RETURN RINGLINE

D
1 2 1 2 x1 x2 x1 x2 x1
=Oil_System-1G7
=Oil_System-1G7
=Oil_System-1G8
1 1 x1 x1 x1
F
External targets
2 2 x2 x2 x2
G
Language UK
Page: 3
0 1 2 3 4 5 6 7 8 9

15-08-2018Dkaaabh
A
49 50 51 52 53 54 55
Language UK
B 47 48 50 53
-X3
-X3
-X3
-IE
-X3
-IE
Internal targets
102X03_088663#A.2
47 48 49 50 51 52 53 54 55
ELECTRICAL DRAWINGS

conductor
conductor
conductor
conductor
RETURN RINGLINE DMB DMA TEMP. DMB TEMP.

D
x2 x1 x2 1 2 3 1 2 3
=Oil_System-1G8
=Oil_System-1G8
=Oil_System-1G11
=Oil_System-1G12
1 2 3 1 2 3
x1 x1
F
External targets
x2 x2
G
4-49 / 92
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9

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56 57 58 59 60 61 63
B 56 58 60 62 64
-X3
-X3
-X3
-X3
-X3
102X03_088663#A.2
Internal targets
56 57 58 59 60 61 62 63 64
ELECTRICAL DRAWINGS

conductor
conductor
conductor
conductor
conductor
DELAY WATER PRESSURE LOW

BURNER FLANGE OPEN OFH T.F. TEMP. HIGH HIGH SYSTEM PRESS. HIGH HIGH OFH FLUE GAS TEMP. HIGH HIGH
D LOW
31 32 13 14 1 2 1 2 11
=BURNER-F224
=Heater-1T181
=Heater-1T24
=Heater-1T46
=Heater-1T32
31 13 1 1 11
F
P P
External targets
32 14 2 2 12
G
Language UK
Page: 4
0 1 2 3 4 5 6 7 8 9

25-05-2018Dkaaabh
A
65 67 68 69 70 71 72
Language UK
B 65 66 68 70
-X3
-X3
-X3
-X3
-IE
Internal targets
102X03_088663#A.2
65 66 67 68 69 70 71 72
ELECTRICAL DRAWINGS

conductor
conductor
conductor
conductor
OFH FLUE GAS TEMP. HIGH HIGH OFH T.F FLOW LOW LOW BURNER AIRPRESSURE LOW LOW BURNER AIRPRESSURE LOW LOW
D
12 13 14 33 34 1 2 3
=Heater-1T32
=Heater-1T34
=BURNER-R3
=Heater-1T21
1 2 3
11 13 33
F P
External targets
12 14 34
G
4-51 / 92
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0 1 2 3 4 5 6 7 8 9

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73 74 75 76 83 84 85 86 87 88 89 90 91 92 77
B 73 75 83 77
-X3
-X3
-X3
-X3
102X03_088663#A.2
Internal targets
ELECTRICAL DRAWINGS
73 74 75 76 83 84 85 86 87 88 89 90 91 92 77

conductor
conductor
conductor
conductor
OPTIONAL BURNER EMERGENCY T.F. SUPPLY TEMP. PT100 TAG

FLAME SENSOR TAG NO.+1F1 CONNECTION TO BURNER
D STOP YD NO.: 1T44
11 12 46 47 6 17 11 14 N 19 20 3 1 N 1
+External-S1
=Heater-1T44
1 2 3
11
F
46 N
External targets
12
G
Language UK
4.a &SCH/27.264 &SCH/27.268 &SCH/29.289 &SCH/28.271
Page: 5
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9

15-08-2018Dkaaabh
A
78 79 80 81 82 93 94 95
Language UK
B 78 80 93
-X3
-IE
-X3
-IE
-X3
-IE
Internal targets
102X03_088663#A.2
78 79 80 81 82 93 94 95
ELECTRICAL DRAWINGS
=TFO_Primary =TFO_Primary =TFO_Primary

System+CP-W39 System+CP-W40 System+CP-W41
conductor
conductor
conductor
T.F. SUPPLY TEMP. PT100 TAG T.F. RETURN TEMP. PT100 TAG
San. Water Heater
D NO.: 1T44 NO.: 1T20
2 3 1 2 3 1 2 3
=Heater-1T44
=Heater-1T20
=Heater-1T657
1 2 3 1 2 3 1 2 3
F
External targets
G
4-53 / 92
5 &SCH/28.271 &SCH/28.272 &SCH/30.292 Page: 5.a
0 1 2 3 4 5 6 7 8 9

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96 98 97 99 100 101 103 102 104 105
B 96 99 101 104
-X3
-X3
-IE
-PE
-X3
-X3
102X03_088663#A.2
Internal targets
ELECTRICAL DRAWINGS
96 98 97 99 100 101 103 102 104 105

conductor
conductor
conductor
conductor
RETURN TEMP. PT100 TAG NO.:

CONTROL VALVE OPEN/CLOSE PRESSURE TRANSMITTER CONTROL VALVE OPEN/CLOSE
D 1T286
14 11 W1 PE + - PE 14 11 W1 1 2
-1T270
-1T284
-1T452
=Heater-1T286
14 11 14 11 1 2 3
+ -
+;- +;-
F
PRESSURE
External targets
TRANSMITTER
PE W1 PE W1
G
Language UK
5.a &SCH/31.302 &SCH/31.303 &SCH/32.313 &SCH/32.314 Page: 6
9100 Aalborg DK
0 1 2 3 4 5 6 7 8 9

24-05-2018Dkaaabh
A
106 107 108 109 110 112 111 113 114 115
Language UK
B 106 107 110 113
-X3
-X3
-X3
-X3
Internal targets
102X03_088663#A.2
106 107 108 109 110 112 111 113 114 115
ELECTRICAL DRAWINGS

conductor
conductor
conductor
conductor
RETURN TEMP. PT100 TAG NO.:

FRESH WATER GENERATOR FRESH WATER GENERATOR FRESH WATER GENERATOR
D 1T286
3 1 2 3 14 11 W1 PE 1 2 3
=Heater-1T286
=Heater-1T287
-1T551
=Heater-1T557
1 2 3 14 11 1 2 3
1 2 3
F
External targets
PE W1
G
4-55 / 92
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116 117 118 119 120 121 126 127 128 129 1 2 3 4 130 131 132
B 116 1 130
-X3
-X6
-X3
102X03_088663#A.2
Internal targets
ELECTRICAL DRAWINGS
116 117 118 119 120 121 122 123 124 125 126 127 128 129 1 2 3 4 130 131 132
=TFO_Primary =TFO_Primary =TFO_Primary

System+CP-W49 System+CP-W50 System+CP-W51
conductor
conductor
conductor
Potential Free Signals See Pre_Alarm Signals See drawings Alarm Signals See drawings for
D drawings for more info for more info more info
1 2 3 4 5 6 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13
=AMS-U1
+AMS-U14
+AMS-U1
F
1 7 11
External targets
G
Language UK
6.a &SCH/34.331 &SCH/36.354 &SCH/37.363 Page: 7
0 1 2 3 4 5 6 7 8 9

25-05-2018Dkaaabh
A
133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149
Language UK
B 133 140
-X3
-X3
Internal targets
102X03_088663#A.2
133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149
ELECTRICAL DRAWINGS
=TFO_Primary =TFO_Primary
System+CP-W51 System+CP-W52
conductor
conductor
Alarm Signals See drawings for Alarm Signals See drawings for
D more info more info
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+AMS-U1
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9100 Aalborg DK
102X03_088663#A.2
ELECTRICAL DRAWINGS
EH20T16 L850 42KW#A.4
PANEL DRAWING FOR ELECTRICAL HEATER
Panel Drawing for Electrical Heater
EH20T16 L850 42KW#A.4
EH20T16 L850 42KW#A.4
EH20T16 L850 42KW#A.4
EH20T16 L850 42KW#A.4
EH20T16 L850 42KW#A.4
EH20T16 L850 42KW#A.4
EH20T16 L850 42KW#A.4
EH20T16 L850 42KW#A.4
OM8210_43#B.1
TEMPERATURE CONTROLLERS
Temperature controllers
1 General
The following chapters of the instruction manual describe the operation.
1.1 Intended use
Please observe the notes in these operating instructions as well as the conditions of use
and permitted data specified on the data sheet of the device in use, in order that the
device will function perfectly and have a long service life.
• On non-observance of these notes and unauthorized interference with the device,

we will refuse all liability and the guarantee on the device and accessories will
become void!
• All necessary settings are described in these Operation Instructions. However, if
any difficulties should still arise during start-up, you are asked not to carry out any
unauthorized manipulations on the unit. This could endanger your rights under the
instrument warranty!
• Any other use or use exceeding the specific scope is considered to be non intended
use. Alfa Laval will not be liable for any damage resulting there from. The risk
will be borne solely by the user.
• Please read these operating instructions before commissioning the instrument.
Keep the manual in a place that is accessible to all users at all times. Please assist
us to improve these operating instructions, where necessary.
Information in this manual is subject to changes without notice and does not represent
a commitment on the part of Alfa Laval. It is not allowed to copy this manual or part
here of for any purpose other than the purchaser’s personal use. Alfa Laval shall not
be held responsible for any damage or losses caused by the use of this manual.
Attention: Alfa Laval does not accept any responsibility for the damage to people
or property when the device we provide is used in any other manner
than intended in our thermal fluid systems and stated in our drawings.
OM8210_43#B.1
2 Instrument identification
Temperature controller
Figure 1 temp_20x4297990en.wmf
The controllers of type 93W0 depend on hardware adjusted in one of up to four possible
preconfigured types: 200, 701 700, 700E.
The adjusted type can be found on the type plate, furthermore at the display by pressing
the P-button longer than 5 seconds if the parameter level is locked.
Types -200 and -701 contain additional analog inputs and switching contacts for full
load lock and expansion tank high alarm. In deviation to the pre-configured types it is
also possible to use all existing hardware with special individual adjustments.
Dual controller type 927030 has an additional contact with a special function for a
switchable common output for 2 control channels (99f1u. E). In deviation to the normal
device (1 output for each control loop) there is only one output for both control loops.
Depending on the switching state of the additional contact (relay 3) the control channel
1 or the control channel 2 is connected to the output.
additional contact switched off: control channel 1 is connected to the output

additional contact switched on: control channel 2 is connected to the output
Besides the switching state of the additional contact (relay 3 ) the LED 3 gives the
additional information of the active control channel. The adjustments and the other
functions of the additional contact are equal to the normal device.
OM8210_43#B.1
2.1 Characteristics
Characteristics
• Adjustment on parameter level, with lock switch, pre adjusted on customer's de-
mand. (parameters depending on sub type:)
• Proportional band Xp: 0,1…999,9 %
• Integral action time Tn: 0,0...999,9 min
• Rate time Tv: 0,0...99,9 min
• Sensitivity of response Xsh: 0,1…1,0 %
• Travel time of the actuator Tm: 6…600 sec
• Switching frequency cy: 2...120 sec
• Function characteristics: direct / inverted
• Switching interval SA (add. contacts): 0…100,0 K
• Switching difference Sd: 0,1...100,0 K
2.2 Additional contact functions
As switching interval above and below set point or independent adjustable with own
set point and measuring input, switching function adjustable (ref. to chapter additional
switching contacts).
OM8210_43#B.1
2.3 Installation dimensions
Installation dimensions
Form 96 x 96: L = 150mm, B = 92mm, H = 92mm

Form 72 x 144: L = 170mm, B = 168mm, H = 139mm
2.4 Other data
• Housing for panel mounting, 96 x 96 mm

• Power supply: 230VAC +/- 10 %, 48 ... 62Hz approx. 14 VA, alternative 115 VAC,
48 VAC, 24 VAC, 24 VDC
• Protective system DIN 40050: IP54 (terminals IP20)
• Permissible ambient temperature: 0 ... 60°C
• Nominal temperature: 20°C
• Climatic category: KUF to DIN 40050
• Relative humidity <= 75 % yearly average, no condensation.
• EMC: refer to EN 50081-2 and EN 50082-2
3 Installation
Before installation inspect the controller for any visible signs of damage caused during
transport Check power supply acc. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind
with the fastening devices supplied.
3.1 Electrical wiring
Plug bar on the back face of the controller; connect up the controller at the rear fol-
lowing the wiring diagram; wire cross section max. 1,5 mm².
• To avoid cross interference all low voltage measuring lines and pilot wires must
be encased in 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.
OM8210_43#B.1
4 Operation and maintenance
4.1 First set up
• Switch on power supply.

• Digital display and control lamps will light up according to the set point after some
seconds. If nothing happens check the fine-wire fuse on the back panel of the
controller and the electrical wiring.
• Adjust set value and check other adjustments.
4.2 Maintenance
All electronic controllers of this type are virtually maintenance-free. Provided that the
controller is correctly installed and put into operation and is protected against me-
chanical damage 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 such as bridge circuits and 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.
5 Error messages and operating status
5.1 Error messages
Err 1 ... 6 Fault on measuring input nr. ...

- check measuring lines for short circuit or breakage
- check measuring input by connecting a RTD
Err 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 section
no further operation possible, remit controller for repair
Err 52 Hardware error in data section
no further operation possible, remit controller for repair
Table 1
OM8210_43#B.1
Error messages during self adaptation:
Err 202 Ambient conditions are not suitable for self adaptation; adjust pa-
rameter manually
Err 205 Routine exceeded the set point, raise set point or lower actual value
and start adaptation again
Table 2
5.2 Operating status
The upper display shows the actual value (channel/measuring input 1), the lower dis-
play shows the attendant unit of measure (°C, °F, %, bar..) (depending on the settings)
types 93W00 200 and 701 only:

Switch over the upper display to the further actual values by pressing the key, the
lower display shows the number of the attendant measuring input ("lst2" = return tem-
perature)
or an abbreviation of the input's name ("EPtH" = expansion tank high).
Return to operating level:
Press key shortly (or automatically after 30 seconds without any key-action).
6 Manual operation
6.1 Set point value setting
Press key shortly (do not hold down).
The upper display shows the abbreviation of the activated set point 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:

Pressing longer causes faster alterations.
6.1.1 Return to operating level
Press key shortly (or automatically after 30 seconds without any key-action).
OM8210_43#B.1
Optional:
Press key shortly again: *SP = set values of further control loops (*=no.) / SP* =
further set values of the control loop / SPE =external set point (display mode only);
flashing display signifies that the function is not active at the moment.
6.2 Manual operation (optional)
Hold down key and press key , then release both keys.
(optional: switch on and off using separate key)
(for multi-channel controllers first enter the channel number*, and press key, then:
The lower display 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.
6.2.1 Return to operating level
Return to operating level only by pressing the key (if present: the key). (no
automatic return from the manual mode).
Optional:
Starting the self adaptation (ref. to chapter optimization):
On manual operation level key >5 sec ;

the lower display indicates "-Ad-".
Cancel: key >5 sec again.
6.3 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).
OM8210_43#B.1
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
6.4 Settings in detail (not available on all types)
6.4.1 Level 1
Invoke: Hold down the key for more than 5 sec until the display changes
Configuration 200:
Factory Notes
settings
Sd1 switching difference for contact no.1 3.0
SA2 switching interval for contact no.2 3.0
Sd2 switching difference for contact no.2 3.0
SP4 set point for independent contact no.4 80.0
Sd4 switching difference for additional contact no.4 3.0
SP5 set point for independent additional contact no.5 80.0
Sd5 switching difference for additional contact no.5 1.0
Table 3
OM8210_43#B.1
Configuration 701:
Factory Notes
settings
P Proportional range Xp (%) (ref. to chapter "Optimiza- 25,0
tion")
I integral action time Tn (min) (ref. to chapter "Optimiza- 7,0
tion")
D rate time Tv (min) (ref. to chapter "Optimization") 0,2
Sh Sensitivity of response Xsh (%) 0,1
SA3 switching interval for contact no.3 8,0
Sd3 switching difference for additional contact no.3 3,0
SP4 set point for independent contact no.4 80,0
SP5 set point for independent additional contact no.5 80,0
Table 4
Configuration 700 /700E:
Factory Notes
settings
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
Table 5
Return to operating status:
Briefly press the key (or automatically after 30 sec.) .
OM8210_43#B.1
6.4.2 Level 2
Invoke: Hold down key and press the key, hold down both keys for more than
5 sec. until display changes.
Factory Notes
settings
Unit switch-over the display unit (°C/°F) for Pt100- C
input only
1bLo/ Start/end of display range for voltage-/current 0 / 0,6
1bHI xinput (only)
nSt modification of decimal point characters 0/2
(0/1/2)
Lo/HI start / end of set point range (°C/°F or value) acc. to
range
dSPL select function for lower display (AUS/SP/ °C/bar
IST2/IST3/°C/°F/%/bar) (AUS=off, SP=set
point, Ist2/3=act. value inp.2/3, °C/°F/%/
bar=text)
Table 6
Return to operating status:
Briefly press the key (or automatically after 30 sec.) .
7 Optimization
7.1 Manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to bal-

ance an appearing deviation as quickly, non-oscillating and exactly as possible, ac-
cording to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be

replaced by this brief information.
The following information is 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 set point is reached very slowly after initial exceeding: Xp too high.
OM8210_43#B.1
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 set point alterations
(adjust only if necessary). Higher values cause higher increase.
7.2 Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjusts the op-
timum 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 set point adequately, if admissible. (faster proce-
dure for slower circuits)
Call manual operation level:

Press key plus key (optional: separate 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 sta-
bilization of 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.
OM8210_43#B.1
After successfully finishing the procedure the controller will return to operating level
automatically.
Unsuccessful adaptation
(Display shows error code, ref. to chapter error messages):
Press key again: Return to manual operation level eliminate the indicated error
start adaptation again: key> 5 sec. or return to operating level: key shortly
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
Note: Changing the configuration will change the controller function.
Enter the code number (password) ... (1 ...9999) : Contact Alfa Laval for the
code and remote trouble shooting.
After entering the code move 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 configured
control function can be changed by pressing the key:

700 = Three point step controller (temperature)
700E= Three point step controller (pressure)
only Type 93W00:
200 = 2 stage controller with additional contacts and advices
701 = Three point step controller (temperature) with additional contacts and advices
OM8210_43#B.1
Return to operating level: briefly press the key

or
move 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 settings
Ain1 type of measuring input no 1, rtd/0/4-20mA/ 0/2 ... 10V (ob- rtd (700E:4- 20mA)
serve different terminal connection I/U)
Ain2/3* status of measuring inputs no 2/3, Aus 1 rtd rtd/rtd
Ist1/2*/3* correction value to change the controller display (+ / -) 0.0
Y’ ‘ travel time of the actuator "6 ... 600" (sec.) 60
out adjusting output characteristics direct 1 inverted "di 1 in" in
Y_S behaviour of the output in case of measuring line fault: relay Rel2(70.),rel1(20.)
position:"reI1 1 rel2 1 AUS"
( AUS = relays off)
reL3* function selection for add. switching contact no 3: select the SoA(701)
corresponding measuring input 1 control circuit Aus(200)
relay condition in case of measuring line fault: "SiE/SiA"(on/ 1st 1
off) Si A
reL4* function selection for add. switching contacts: USA(200/701)
select the corresponding measuring input 1 control circuit
relay condition in case of measuring line fault: "SiE/SiA"(on/ Ist2
off) Si A
reL5* function selection for add. switching contacts: USA(200/701)
select the corresponding measuring input 1 control circuit relay Ist3
condition in case of measuring line fault: "SiE/SiA"(on/off) Si A
Adr bus address (address no.) (for interface equipment only) 5
Table 7
Return to operating level: briefly press the key again.
7.3 Selectable switching functions
Selectable switching functions (depending on version):

For setting please refer to configuration level under "reL... "
OM8210_43#B.1
7.3.1 Switching functions for trailing contacts
LC A Break contact on either side of setpoint

(Limit comparator). Relay drops out as de-
viation increases (Aus = off)
LC E Make contact on either side of setpoint

(Limit comparator). Relay picks up as devi-
ation increases (Ein = on)
Su A Break contact below setpoint. Relay drops

out as actual value decreases (Aus = off)
Su E Make contact below setpoint. Relay picks up

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)
Table 8
7.4 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)
Table 9
Service function:
Ein/Aus contact is constantly switched on (Ein) or off (Aus) respectively
Only for units with program option:

Pr A Relay switched off (aus) during SP program level, otherwise switched on
OM8210_43#B.1
Pr E Relay switched on e(in) 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 ac-
knowledged (P key) (depending on version):
1st./ Y assigned value: actual value no .... or Y (actuating signal)
CH../..SP (only) for trailing contacts: assigned control circuit I channel (no.) or as-
signed 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
8 Wiring diagrams
Note: The wiring diagram valid for each delivered controller is the wiring dia-
gram on its casing only.
8.1 Wiring diagram conf "200"
Example for connecting a 2 stage burner
OM8210_43#B.1
Example for connecting a modulating burner
Example for connecting a control valve in a temperature loop
8.4 Wiring diagram conf "700E"
Example for connecting a control valve in a pressure loop
OM8210_43#B.1
9 Part numbers
Item name Type Item number

Temperature controller 993w00200 30100100
Temperature controller 927 030E/99fu2 30100900
Pressure controller 93w0170e 30100400
Table 10
RTM_OM8220_01#A.3
ALARM MODULE 821A20 ALARM INDICATION MODULE OM8220#01/MAR10
Alarm module 821A20
ALARM INDICATION MODULE
OPERATING INSTRUCTIONS
Language UK Page 1/8
RTM_OM8220_01#A.3
TABLE OF CONTENTS
1 GENERAL...............................................................................................................3
1.1 Intended use ............................................................................................. 3
1.2 General description.................................................................................. 4
1.3 Type Summary......................................................................................... 5
2 FUNCTIONS...........................................................................................................5
3 TECHNICAL DATA..............................................................................................6
3.1 Assembly dimensions .............................................................................. 6
3.2 Technical data.......................................................................................... 6
4 CONNECTION DIAGRAMS (EXAMPLES).....................................................7
5 PARTNUMBERS ...................................................................................................8
RTM_OM8220_01#A.3
1 General
1.1 Intended use
Please observe the notes in these operating instructions as well as the conditions of
use and permitted data specified on the data sheet of the device in use, in order that
the device will function perfectly and have a long service life.
• On non-observance of these notes and unauthorized interference with the device,
we will refuse all liability and the guarantee on the device and accessories will
become void!
• All necessary settings are described in these Operation Instructions. However, if
any difficulties should still arise during start-up, you are asked not to carry out
any unauthorized manipulations on the unit. This could endanger your rights
under the instrument warranty!
• Any other use or use exceeding the specific scope is considered to be non-
intended use. Aalborg-Industries will not be liable for any damage resulting
there from. The risk will be borne solely by the user.
• Please read these operating instructions before commissioning the instrument.
Keep the manual in a place that is accessible to all users at all times. Please
assist us to improve these operating instructions, where necessary.
Information in this manual is subject to changes without notice and does not
represent a commitment on the part of Aalborg Industries. It is not allowed to copy
this manual or part hereof for any purpose other than the purchaser’s personal use.
Aalborg Industries shall not be held responsible for any damage or losses caused by
the use of this manual.
Attention: Aalborg industries does not accept any responsibility for the
damage to people or property when the device we provide is used in
any other manner than intended in our thermal fluid systems and
stated in our drawings
RTM_OM8220_01#A.3
1.2 General description
Compact device in 96x96 mm switch panel format for operating and malfunction
signal indication in control and monitoring equipment.
Figure 1
Alarm indication module – front plate

Red LED's are used to indicate malfunctions, yellow for pre-alarm and green for
operating indications on the front plate (other colours are possible as options).
Operating indications are controlled by contact inputs, and have a pure display
function; pre-alarms and malfunction indications also initiate an internal, self-
latching alarm circuit.
All operating functions are brought out to terminals. Externally connected push
buttons can be used to execute the "Acceptance", "Reset" and "LED Test" functions.
The film on which the text labelling is written is located behind the top membrane,
and is accessible if the front frame is removed.
RTM_OM8220_01#A.3
1.3 Type Summary
821A20g 8 operating indications, input for 1 external pushbutton

821A20gg 16 operating indications, input for 1 external pushbutton
821A20r 8 malfunction indications, each 4 malfunction indications
affecting 1 collective malfunction relay,
1 common horn relay, input for 3 external push buttons
821A20rr 16 malfunction indications, each 4 malfunction indications
1 common horn relay, input for 3 external push buttons
821A20ry 8 malfunction indications, each 4 malfunction indications
8 pre-alarms, each 4 pre-alarms affecting 1 collective relay,
1 common horn relay, input for 3 external pushbuttons
821A20y 8 pre-alarms, each 4 pre-alarms affecting 1 collective relay, inputs
for 3 external pushbuttons
Additional fittings:
8219s. Interface
2 Functions
Note: Operating indications have a pure display function.
Indication is provided by green LED's (other colours optional).
Depending on the version, a group of 4 malfunction signals or 4 pre-alarms are

connected together to provide a collective malfunction signal at relays K1 to K4.
When a malfunction is registered at one of these inputs, the horn relay operates (not
in the case of pre-alarms) and the associated LED flashes.
After an external acceptance pushbutton is pressed, the horn relay is reset, i.e. it
drops out again.
The malfunction indicator LED is now continuously illuminated. After the
malfunction has been corrected, the malfunction indicator LED goes out when the
external reset pushbutton is pressed.
If the external reset pushbutton is pressed while malfunctions are still present, the
horn relay will switch on again.
If another malfunction, in addition to the existing malfunction, occurs, the horn relay
will actuate again and the LED for the malfunction input that has now become active
flashes.
The associated collective malfunction relay is briefly deactivated (approx. 1 sec.).
The "LED Test" input is used to check the LED function.
RTM_OM8220_01#A.3
3 Technical data
3.1 Assembly dimensions
Figure 2
Assembly dimensions L = 150 mm; B = 92 mm; H = 92 mm
3.2 Technical data
Status / (pre-) alarm inputs: 230 V, approx. 2 mA

Pushbutton inputs: 230 V, approx. 2 mA / 16 mA types 821 A20g.
Supply voltage: 230 V, approx. 3.5 VA
Relay outputs: 230 V / max. 2 A
Degr. of protection DIN 40050: IP54 (terminals IP 20)
Permissible ambient temp.: 0 ... 60°C, rated temp. 20°C
Operating orientation: any
Permissible relative humidity: 75 % annual mean (Group F, DIN 40040)
without condensation
RTM_OM8220_01#A.3
4 Connection diagrams (examples)
Figure 3
821A20g/821A20gg
Figure 4
821A20r/821A20y
Figure 5
821A20rr/821A20ry
RTM_OM8220_01#A.3
5 PARTNUMBERS
Item name Type Item number

Status module 8x Green 821A20G 30200100
Status module 16 x Green 821A21GG 30200200
Alarm module 8 x Red 821A21R 30200300
Alarm module 16 x Red 821A21rr 30200400
Alarm module 16 x Red Yellow 821A21RY 30200500
Alarm module 8 x Yellow 821A21Y 30200600
Contact address
Aalborg Industries BV
P.O Box 145
3200 AC Spijkenisse
The Netherlands
Direct tel.: +31 181 650 500
Direct fax: +31 181 650 501
www.aalborg-industries.com
TABLE OF CONTENTS
Table of contents
TFO
.
General Arrangement - V3-TFO-004........................... 07Y_088356................ 5-3
Costumer Option....................................................... 203809........................ 5-5
Spark Arrestor - DN200............................................. D188430-00200........... 5-7
Hot Water Heater....................................................... OM8643_01................ 5-8
Cleaning Instructions................................................. OM8643_03................ 5-16
Minimum Flow Control.............................................. OM9012_06................ 5-17
07Y_088356#A.2
GENERAL ARRANGEMENT - V3-TFO-004
General Arrangement - V3-TFO-004
203809#A.3
COSTUMER OPTION
Costumer Option
COSTUMER OPTION
D188430-00200#A.4
SPARK ARRESTOR - DN200
Spark Arrestor - DN200
HOT WATER HEATER
Oil fired hot water heater

Description & maintenance
Hot Water Heater
Table of Content
1 Oil fired hot water heater.........................................................................................................................2

1.1 Fittings and safeties ...............................................................................................................................3
1.1.1 Safety valves...................................................................................................................................4
1.1.2 Monitoring flow through the heater ...............................................................................................4
1.1.3 Maximum water temperature .........................................................................................................4
1.1.4 Maximum flue gas temperature ......................................................................................................4
1.1.5 Leakage detection device ...............................................................................................................5
1.1.6 Temperature sensors .......................................................................................................................5
1.1.7 Temperature indicators ...................................................................................................................5
1.1.8 Valves in the supply and return line ...............................................................................................5
1.2 Water quality .........................................................................................................................................6
2 Maintenance ............................................................................................................................................6
2.1 Daily operation ......................................................................................................................................6
2.2 Weekly routine checks ..........................................................................................................................6
2.3 Monthly routine checks .........................................................................................................................7
3 Inspection ................................................................................................................................................7
3.1 Inspection of furnace .............................................................................................................................7
3.2 Testing of safety valves .........................................................................................................................7
3.3 Cleaning ................................................................................................................................................7
4 Appendix 1 ..............................................................................................................................................8
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HOT WATER HEATER
1 Oil fired hot water heater

The oil-fired hot water heater is available in a horizontal or vertical execution and is,
depending on the size (capacity) of the heater, constructed with a single or multiple
coil of bare tubes.
For a heater capacity of 100kW up to 2500kW a single coil is sufficient, with
capacities from 3000kW up to 4500kW a double coil is needed. Higher capacities
are also possible but will require more coils and customized calculations, please
contact Alfa Laval Aalborg if you have any special needs or need a heater outside
our standard range.
The heater is designed with a three-pass flue gas configuration which ensures an
optimum heat transfer and results in very high efficiency. The internal space of the
inner coil forms the furnace chamber where the fuel oils are combusted. The flue
gases leave the furnace at the end of the coil and flow between the inner and outer
coil, turn and flow between the outer coil and the shell plate to the flue gas funnel.
The outer coil and the outer side of the inner coils thus form the convection heating
surface of the heater.
In a 3-pass flue gas track the flue gases pass the coils 3 times, see figure 1.
Figure 01
3-pass flue gas configuration

The heater has a removable top or end plate (burner end) which provides access for
inspection and cleaning. The cover can be removed easily without special tools but
be aware of the weight of the cover, for this is provided with refractory lining.
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HOT WATER HEATER

The heavy insulation jacket of the heater is made of thin steel plating material with
insulation material in between the plating and the heater.
Important: Do not stand on the insulation cladding of the heater this can
damage the insulation.
1.1 Fittings and safeties
Important: IT IS NEVER ALLOWED TO OVERRULE THE SAFETY

DEVICES!
Figure 2 shows a horizontal single coil hot water heater. For vertical heaters and
double coil execution please see appendix 1
Figure 02
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HOT WATER HEATER
Tag. No. Description
1T Oil fired heater
1T1 Safety valve
1T1.1 Safety valve (OPTIONAL)
1T2 Stop valve with control disc
1T3 Stop valve with loose disc (non-return)
1T11 Drain valve for coils
1T12 Vent valve for coils
1T20 Temperature transmitter (return)
1T21 Temperature transmitter (supply)
1T22 Temperature indicator (flue gas)
1T23 Temperature transmitter (flue gas)
1T24 Temperature switch (fluid)
1T32 Temperature switch (flue gas)
1T34 Indicating differential pressure switch
1T35 Leakage detection device (OPTIONAL)
1T40 EO shut off valve
1T8 Remote controlled 3-way valve (OPTIONAL, see appendix 1)
1.1.1 Safety valves

Safety valves (1T1 and 1T1.1) are installed to make sure the pressure in the heater
does not rise above the maximum allowable pressure. (Tag no. 1T1 and 1T1.1). If
the pressure rises above the set point the safety (relief) valve will open to vent of the
excess pressure. The amount of safety valves depends on the system temperature
and class requirements.
If the safety (relief) valve has been activated it must be checked (pressure tested)
and the set points of electronic temperature controller and maximum temperature
alarm must be checked and tested on their correct function.
1.1.2 Monitoring flow through the heater
The thermal fluid flow through the heater is monitored with an orifice in
combination with an indicating pressure differential switch (flow switch, 1T34).
This device is installed in the outlet of the thermal fluid heater and measures the
differential pressure over the orifice. The differential pressure is an indication of the
flow. When there is insufficient flow through the heater the burner will be stopped
and electrically blocked and an alarm will be generated.
1.1.3 Maximum water temperature
A temperature switch (1T24) is installed in the supply line to make sure that the
water temperature does not rise above a set value. When this switch is activated the
burner will be stopped and electrically blocked and an alarm will be generated
1.1.4 Maximum flue gas temperature
A temperature switch (1T32) is installed in the flue gas connection of the oil-fired
heater to make sure that the flue gas temperature does not rise above the set value.
When this switch is activated the burner will be stopped and electrically blocked and
an alarm will be generated
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HOT WATER HEATER

We recommend to adjust the set point of the temperature switch approx.10% higher
than the flue gas temperature at full load of the burner. This is best done by setting
the set point just above the measured temperature and then turn it back very slowly
with several time intervals. At a certain moment the burner trips, take the value from
the scale of the temperature switch and increase this value with 10% to set the set
point.
In order to keep the heat transfer area sufficiently clean the boiler is designed with a
high flue gas velocity through the coils and under normal circumstances, with a
correct combustion, fouling will be minimised. However, after long term operation,
e.g. during combustion of poor quality fuel or with reduced combustion quality,
deposits can be formed on the heating surface. When there is a lot of soot on the
coils the flue gas temperature will rise as less heat is transferred to the fluid.
When the maximum flue gas temperature switch is activated the convection side of
the heater must be cleaned.
It is possible that the temperature switch is activated just after the first few weeks of
operation, this does not mean that the heat exchanger is extremely dirty. The
temperature switch has to be adjusted again as mentioned before. Inform Alfa Laval
Aalborg about the temperature rise.
1.1.5 Leakage detection device
A leakage detection device (1T35) can be installed to detect leakage of the heater
coils.
1.1.6 Temperature sensors
The signal of the temperature sensor in the supply line (1T21) is used in
combination with a temperature controller in the control box to control the burner.
The signal of the temperature sensor in the return line (1T20) is used for the display
of temperature on the control box.
The signal of the temperature sensor in the stack of the heater is used for display of
temperature on the control box or as a pre-alarm for high flue gas temperature
depending on class requirements.
1.1.7 Temperature indicators
Temperature indicators (1T22) are installed to read out the temperature. The amount
and position of the temperature indicators depends on class requirements and or
customers preferences.
1.1.8 Valves in the supply and return line
The stop valves in the supply (1T3) and return (1T2) lines are installed to remove
the heater from the circulation flow. When these valves are closed the by-pass valve
(1T4) should be opened
The stop valve in the return line (1T2) is equipped with a control disc and is used for
fine tuning of the flow through the heater during commissioning.
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HOT WATER HEATER
It is also a possibility to have a remote controlled 3-way valve installed to by-pass
the flow through the heater See Appendix 1
1.2 Water quality
The hot water system is a closed system and the water quality must be checked
when first filling the system and every time new water is added.
The water quality should be checked on the following points:
 The electrical conductivity.
 The PH-value.
 Oxygen.
 Alkality.
 Phosphate.
 Possible natriumsulphite.
In order to prevent any damage to the warm water system we advise you to check
the above-mentioned points with your local water chemical supplier.
As a guideline EN 12952-2:2001 (previous EN 12952-12:1998) can be used.
2 Maintenance
Maintenance should always be executed with skill and in accordance with valid
rules and regulations from the authorities, below are given some recommendations
for periodical inspections and maintenance.
2.1 Daily operation
During normal operation of the heater some work and check procedures have to be
considered every day.
 Visual check of the outside, look for any abnormalities
 Check flow over oil fired heater.
 Check the water temperature.
 Check the flue gas temperature, make note of this temperature to keep a
consecutive record to monitor the fouling conditions.
2.2 Weekly routine checks
 Test all stand-by pumps.

 Run burner tests (see burner manual)
 Check the flue gases that are leaving the funnel, they have to be colourless. If
not, the burner has to be adjusted.
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HOT WATER HEATER

2.3 Monthly routine checks
 Run burner tests (see burner manual)

 Check all boiler mountings for damage or leaks and repair/replace if necessary.
 Test the flow alarm; Slowly close the supply valve after the circulation pump
during operation, the burner must stop and the alarm “water flow low low” must
be activated.
 Test hot water temperature alarm; decrease the set point of the temperature
switch (1T24) during operation, the burner must stop and the alarm “warm water
temperature high high” must be activated. Return the set point to its original
position
3 Inspection
3.1 Inspection of furnace
The furnace should be inspected at least twice a year. During this inspection the
following issues should be taken into consideration:
 Check for cracks at the refractory lining and that the furnace is free from
excessive soot deposits.
 Examine carefully the area opposite the burner. Too much soot deposits indicate
that the burner should be adjusted.
3.2 Testing of safety valves
The safety (relief) valves should be pressure tested once a year by a certified
company. It is not possible to pressure test these valves when installed in the hot
water system. For this reason we advise to install these valves as high as possible so
that the system does not have to be (completely) drained when removing the valve.
Also keeping a spare valve will make for an easy exchange without a lot of delay for
the vessel.
3.3 Cleaning
In order to keep the heat transfer area sufficiently clean the boiler is designed with a
high flue gas velocity through the coils and under normal circumstances, with a
correct combustion, fouling will be minimised. However, after long term operation,
e.g. during combustion of poor quality fuel or with reduced combustion quality,
deposits can be formed on the heating surface.
It is best to keep a consecutive record of the flue gas temperature and when a steady
rise is detected it is time to clean the heater. When the maximum flue gas
temperature switch is activated the convection side of the heater must be cleaned
before taking back into operation.
Please see the cleaning instructions for the heater for further information.
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HOT WATER HEATER
4 Appendix 1
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CLEANING INSTRUCTIONS
Cleaning instructions for

Oil-fired thermal fluid heater TFO
Cleaning Instructions
Cleaning the convection side of the oil fired heater.
With an oil-fired heater that burns on MDO, it is hardly ever necessary to clean the
convection side, with an oil-fired heater that burns on HFO the need to clean the
furnace will occur more often. As a rule we advise to clean the convection side once
a year for a heater that runs on MDO and twice a year for a heater that runs on HFO.
Attention: It is recommended to keep a consecutive record of the flue gas

temperature and use these values for comparison with the original
data of a clean heater. In this way it is possible to monitor the
fouling condition of the heater.
When the convection side is dirty it has to be cleaned. The cover can be removed
easily without special tools but be aware of the weight of the cover, for this is
provided with refractory lining. After removing the cover you can clean the
radiation and convection part.
Clean the convection part with a dry brush and remove the combustion residues with
a vacuum cleaner. If the convection chamber is very dirty additional cleaning is
needed and we recommend spraying it with a mild detergent and rinsing it
thoroughly with fresh water afterwards.
On the outside, at the bottom of a vertical heater, two drain connections have to be
opened so that water with removed dirt can be drained. On a horizontally executed
heater there is only one drain connection.
When re-mounting the cover, make sure that the gaskets are in a good condition to
avoid flue gas leakages. We recommend replacing the gaskets if they show any sign
of wear.
We ask your special attention for a good position of the gasket in the cover for
tightening the flue gases between radiation part and third pass.
When the cleaning procedure is over make sure that the drain connections are closed
again.
Important: After cleaning it is necessary to fire the burner as soon as possible

and run the installation up to the operating temperature to avoid
sulphur corrosion.
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OM9012_06#A.2
MINIMUM FLOW CONTROL
Thermal fluid systems
Minimum flow control
Minimum Flow Control

Table of Content
1 General ...................................................................................................................1
2 Dew point control ...................................................................................................2
3 Minimum flow control ...........................................................................................2
3.1 Min. flow control - pressure controlled ............................................................3
3.2 Min. flow control - amount of flow..................................................................3
3.3 Min. flow control – differential pressure..........................................................3
4 Maintenance ...........................................................................................................3
5 Manual control .......................................................................................................4
6 List of parts ............................................................................................................4
7 Appendix 1 –min. flow pressure controlled ...........................................................5
8 Appendix 2 –min. flow, flow controlled ................................................................6
9 Appendix 3 –min. flow, DP controlled ..................................................................7
1 General
For economic and safety reasons, care must be taken to ensure that the flow rate of
thermal fluid through the heaters is always sufficiently high, as uniform as possible,
and is largely independent of the heat required by the users. The amount of flow
needed through your system is carefully calculated to get the optimum heat transfer
by making sure that there is a turbulent fluid flow in the heater and the consumers.
During normal operation (when most of the consumers are open) the minimum flow
valve should be in closed position. In general our thermal fluid systems are
calculated so that the differential pressure over the orifice of the heater is approx.0,4
bar(g) at nominal flow (all consumers open)
The flow control can consist of one manually operated control valve or a complete
flow control set with an automatic control valve with actuator, an electronic
controller in the control box and a flow measuring device in the system.
The type and size of the control valve determines the stability of the control system.
The control valve in your system has been carefully selected to make the resistance
of the valve equal to the resistance of the heat consumers so the valve will have
good control characteristics.
With an automatic minimum flow control set, the set point on the controller is set
just above the set point of the flow alarms for the heaters. This way the heaters will
continue to operate independent of the amount of consumers being switched on or
off.
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2 Dew point control
It is very important to pay attention to the system return temperature and the
temperature of the exhaust and flue gases:
• The temperature of the flue gas of the oil-fired heater and the exhaust gas
temperature of the main- and auxiliary engines may not drop below 180°C.
• Additionally in a thermal oil system the thermal fluid return temperature is not
allowed to drop below 135°C.
If the temperatures drop below these values there is a high risk of dew point
corrosion. This means that some very harmful gases that are present in the
flue\exhaust gas will cool down below their dew point (condensation point) and
form acids like hydrochloric and sulphur acid. These acids can cause serious damage
to both the oil-fired heater and economisers.
Important: The temperature of the flue gas of the oil-fired heater and the
exhaust gas temperature of the main- en auxiliary engines may not
drop below 180°C.
Important: The thermal oil return temperature is not allowed drop to below
135°C
In low temperature systems it is especially important to be aware of the return

temperature when starting up the system from cold conditions. If the fluid is very
cold the minimum flow valve has to be opened fully to create an as small as possible
circulation loop, so that the returning fluid can heat up as fast as possible.
To monitor the return temperature a temperature sensor can be installed in the return
line.(1T284) When the temperature drops below the set point, the minimum flow
valve will open automatically to allow more hot thermal fluid back into the return
line.
3 Minimum flow control

A good minimum flow control will avoid system shut downs due to low flow alarms
over the heaters. During system commissioning an Alfa Laval engineer will adjust
the set point of the controller or PLC to make sure each individual system is
optimally balanced.
There are different ways to measure and control the flow in the thermal fluid system:
• Flow control depending on the (back)pressure
• Flow control depending on the amount of flow (measured over an orifice)
• Flow control depending on the differential pressure between supply and return
line.
The most common set-ups for minimum flow control sets will be explained in this
manual.
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OM9012_06#A.2
3.1 Min. flow control - pressure controlled
A minimum flow control set is installed between the supply and return line of the
thermal fluid systems before the heat consumers. A pressure transmitter (1T284) is
installed in the supply line and this sends a signal to a pressure controller or PLC in
the control box. (see appendix 1)
When the valves to the consumers are opened or closed, the systems back pressure
will change and the control valve will open or close to keep the pressure (= flow)
above the minimum required pressure.
When there is no automatic minimum flow control and only a manual valve is
installed the operator should manually open/ close the valve to keep the flow above
the systems limits.
3.2 Min. flow control - amount of flow
thermal fluid systems before the heat consumers. In the supply line to the consumers
a differential pressure transmitter (1T282) with orifice (1T283) is installed. (See
appendix 2)
The orifice diameter is carefully calculated for the amount of flow and the diameter
of the pipes. The differential pressure is measured over the orifice and a signal is
sent to a pressure controller to a pressure controller or PLC in the control box.
When the valves to the consumers are opened or closed, the differential pressure will
change and the control valve will open or close to keep the differential pressure
within the set point range.
3.3 Min. flow control – differential pressure.
thermal fluid systems before the heat consumers. The differential pressure is
measured over the supply and return line of the thermal fluid systems (see appendix
3)
When the valves to the consumers are opened or closed, the differential pressure will
change and the control valve will open or close to keep the differential pressure
within the set point range.
4 Maintenance
rules and regulations from the authorities. Please consult the separate manuals of the
control valves and actuators for guidance on maintenance and recommendations for
periodical inspections.
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5 Manual control
When the automatic minimum flow control valve is malfunctioning or the controller
in the control panel is out of order, the minimum flow in the system can also be
controlled manually with the minimum flow by-pass valve (1T273). The valve must
be adjusted so that the flow over the orifice of the heaters is at the nominal value of
approx. 0.4 bar(g)
6 List of parts
Tag number Description Appendix

1T270 Minimum flow control valve 1, 2, 3
1T271 Stop valve 1, 2, 3
1T272 Stop valve 1, 2, 3
1T273 Minimum flow by-pass valve 1, 2, 3
1T275 Manometer valve with test connection 1
1T276 Siphon pipe 1
1T278 Air filter reducers 1, 2, 3
1T280 EO valve 2, 3
1T281 EO valve 2, 3
1T282 Differential pressure transmitter 2, 3
1T283 Orifice set 2
1T284 Pressure transmitter 1
1T285 Pocket tube 1, 2, 3
1T286 Temperature transmitter 1, 2, 3
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7 Appendix 1 –min. flow pressure controlled
Controller electric minimum flow
Controller electric-pneumatic minimum flow
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8 Appendix 2 –min. flow, flow controlled
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9 Appendix 3 –min. flow, DP controlled
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Page 23
TABLE OF CONTENTS
Table of contents
Burner
.
Weishaupt Size 1 to 3
Installation and Operating Instructions......................... ................................... 6-2
Weishaupt Size 1 to 3
Spare parts for Weishaupt........................................... ................................... 6-42
Fuel oil de-aerator...................................................... D00799....................... 6-70
Combined ball valve set , DN 25, PN40....................... 6000000141................. 6-71
Pressure Hoses.......................................................... RTM_IN8511_01......... 6-72
Burner sequence control............................................. OM8200_02................ 6-81
Flame safeguard........................................................ OM8200_04................ 6-94
Photo cell................................................................. OM8630_01................ 6-95
Electric oil pre-heater................................................. OM5560_13................ 6-96
Handling fuel oil........................................................ OM9280_02................ 6-98
Viscosity - temperature chart....................................... OM9280_01................ 6-100



Weishaupt Size 1 to 3#A.3
INSTALLATION AND OPERATING INSTRUCTIONS


Installation and Operating Instructions
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   
  
  
   
 

   
   


   
  
 
 

 

 
 
 

 
  
  
  
 
 
 
 
 
 
  

 
 
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
 
 
 
 
 

 
 
  
 
 
 


 
 

 
 

 
 

   

 
 

 

 
 
 


 

 
 

 






 




 







 

  

       
       
       

       

 

 









 
 
 

 
 
 


 
 
 


 
 

  
   
   

 
 


 
 
 
 
 

 

 
 

 
 
 





 
 
 
 
 


 
 



   

   
     

     
     
     
     
     

     



 
   
   
 
 
      
     
  
    



 

 
  
 

     

   
 
  

 
 

 
 

  
 



 
INSTALLATION
 AND OPERATING INSTRUCTIONS 

 
 
 

 
 
 


 
 
 

 
 


 
   
   
 

 
   
  
     
  
   

   
  
     
 




 

  
  
 
 
 
  
   
 
 
 
 
 
 
 
 
 
 
     
 

   



















 




 





       

    
    
     
   
 

    
 
     
   
     
   
 
   
             
   
                   
    

  
  
  
   
 
 
 
 
 
             
                 


 




 




     

  
  
    
   
 
 
 

  
   
    


                       
   

                           
    

  
  
    
   
 
 
 
 
 
                   
                             



 
 
 
 
  
 
 
 


 
 
 

 

  
 
  

  





 
 



  
  





  
  



















 

 


 




 

 


 

  

  


   
  

 
  
 


 
 

  
 
  

 
  
  
  




 

 



 















 
 
 

 
 
 

 


 







  
INSTALLATION
 AND OPERATING
 INSTRUCTIONS

       
        

        
        

        
        

        
  
 
 
 
 



 
 
 
 
 
 
 
 
 

 
 
 




 
 











 

 

























 
 


 

 
 
 

 
 
 


 










 
 
 
INSTALLATION AND OPERATING INSTRUCTIONS 









 
 
  
  
 





INSTALLATION AND OPERATING INSTRUCTIONS 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 
 

 
 
   
  

 



 

 
 
 








   
  
   
   
 
 
   

 
 
 
 
 




 


 





 
 














  
  
 
  
 








 


 
 

 



 



 



 






 


  
 

 

  
   
 
 


 

   

 


   


  


 
 
 

 

  

  

 


 
 




    
 

   
 

   
   


   
 
   
 
 
  
 



  
  
  
 

  

 
  

  
 
 






   
 

 
  

 
 
  

  
 

 





   
 
 
 
   

 
   

 
 




 













 
 
 










 



 



 
 
 
 
 

 


   
  
   
  
   
   
 


 

     
     
    
  



 

 
 
 
 
 
 
 
 

 
 
 

 

 

 

 
  
 
 
 

 
 
 
 
 
 
 
 


 


 

 

 
 

 
 
 
 

 
 
 
 


 
 
 
 
 
 
 
 
 
 
 



 
 
 
 

 
 
 

 
 
 

 
 
 

 
  
 
  
 

  

  

  

  

    
     
      
     
     
     


 
 
INSTALLATION
  AND OPERATING INSTRUCTIONS  
                   
 
 
 
 
 
 
 
 
   
         
   
 
 
 
 
 

 
 

 
 



 






 
   
   
   
   
   
 


















    

    



 
 
















 



 
  
   

 
 


 
 


 



 

 
 







   
  
    
    
    
 
   
    
    
    
    
    
    
    
 
   
 

   
    
    
    

 
     
     
     
    


  
  
     



     

    
   

  
   
 

  

  


  
 
   

 






  

   
   
   
   
   
   
 
 
   
 
 
 
 
 





 
 
 
 
 
 
 
 
 
 
 
 
 
 













  

  
 
 
 
 
 

  
 
 
 

  
 
 
 
 
 
 
 
  
 

  
 
 
 
  
  


  

INSTALLATION AND OPERATING
 INSTRUCTIONS
 
 
  
  

  

 
 
 





  
  

  
 

 

 

 


 
  

















 




































 







Language UK
 6-41 / 101
Mai 2012
Weishaupt Size 1für

Ersatzteile to 3#A.3 Spare parts for Pièces de rechange
Weishaupt
SPARE Brenner
PARTS FOR WEISHAUPT Weishaupt burner pour brûleurs types
Größen 1 und 3 Sizes 1 and 3 Grandeurs 1 et 3
Spare parts for Weishaupt
Gebrauch Instructions for use Utilisation Weitere Baugruppen Seite

Further assemblies Page
Brennertyp und Fabriknummer fest- Determine burner type and serial Chercher le type et le numéro de Eléments de
stellen. Diese Angaben stehen auf number. These data are on the fabrication du brûleur. Ces éléments montage supplementaires Page
dem Typenschild. nameplate. se trouvent sur la plaque signalé-
tique. Luftregelung
Zuordnung des defekten Teiles zu Coordination of the defective part to Air regulation 3
einer der Sachgruppen des Inhalts- one of the subject indexes of the La pièce défectueuse appartient à Régulation d’air
verzeichnisses bestimmen. table of contents. une famille du catalogue.
Ölschläuche
Teil in der entsprechenden Sach- Select part in the appropriate subject Choisir la pièce dans cette famille. Oil lines 9
gruppe der Ersatzteilliste auswählen. index of the spare parts list. Canalisation fuel
Feuerungsautomaten
Burner controls 23
Bitte geben sie in der Bestellung an: Kindly indicate in the order: Indiquer également:
Coffret de sécurité
– Bezeichnung des Ersatzteiles – Designation of the spare part – Désignation de la pièce Ölvorwärmer
– Bestellnummer – Order-No. – No de référence Oil preheater 26
– Brennertyp – Burner type – Type brûleur Réchauffeurs
– Fabriknummer – Serial-No. – No de fabrication
SPARE PARTS FOR WEISHAUPT
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12
1.14 1.16
1.13 1.15 1.17 1.18 1.19 1.20 1.21 1.22 1.24 1.25 1.26 1.27
Bezeichnung
Bild Brenner-Typenreihe Größe Bestell-Nr. Preis EUR Designation Désignation
Pict. Burner serie Size Order-No. (o. MwSt.)
Photo Type brûleur Grand. No de commande
1. Einzelteile für Individual parts for Pièces détachées

Brennergehäuse burner casings pour carcasses de
brûleur
Gehäusedeckel-Set Closing cover Trappe d’inspection
1.1 L, M, G, GL 1 211 153 0116 2
L, RL, M, G, GL, RGL 3 211 353 0111 2
Schwenkflansch Swivel flange Bride à charnière

1.2 Ölbrenner L, RL, M 1 211 153 0104 7 oil fioul
3 211 353 0104 7
1.3 Gasbrenner G, GL, RGL 1 251 103 0112 7 gas gaz
3 251 303 0102 7
Klemmschraube Locking screw Vis de blocage

1.4 G, GL, RGL 1+3 151 316 0105 7
Ausf. NA 1+3 251 103 0111 7
Flammkopfhalter Holder for combustion Support pour tête
1.5 Aufnahme Ø head de combustion
110 mm 1 211 153 0108 7
120 mm 3 211 353 0107 7
140 mm 3 211 353 0108 7
140 mm 3 LN 211 364 0102 7
1.6 Abdeckhaube 1+3 211 153 0106 2 Cover Capot

1.7 Verschlussdeckel für Pumpenflansch 1+3 251 103 0104 7 Closing cover for pump flange Plaque de fermeture pour
fixation pompe
Flanschdichtung Flange sealing Joint de bride

1.8 L, M 185 x 135 1 211 153 0130 7
G, GL 194 x 132 1 251 103 0108 7
L, RL, M 210 x 165 3 211 353 0120 7
G, GL, RGL 210 x 160 3 111 512 0009 7
1.9 Stehbolzen M5 x 136,5 1-3 211 153 0141 7 Stay bolt Goujon
Schwenkbolzen Swivel bolt Axe de charnière
1.10 L, M, G, GL 1 211 153 0120 7
L, RL, M, G, GL, RGL 3 211 353 0114 7
1.11 Endschalter mit Anschlusskabel 1+3 701 251* Limit switch with connection Fin de course avec câble raccor-
cable dement
1.12 Schauglas 1+3 211 153 0115 7 Clear sight glass Verre de visée
1.13 Abdeckblech 1+3 211 153 0116 7 Cover sheet Cache verre de visée
Tülle für Brennergehäuse Transition nipple for burner casing Passe-câble pour carcasse de
1.14 L 1+3 211 153 1302 7 brûleur
RL, M 1+3 111 351 0004 7
1.15 RL, G, GL 1+3 111 351 0005 7
1.16 L, M, RL, GL 1+3 111 351 0006 7
1.17 M (Z), L 1T 1+3 112 351 0010 7
1.18 Ansaugluftführung 50 Hz 1 211 153 0136 7 Inlet nozzle Déflecteur d’air

50 Hz 3 211 353 0129 7
60 Hz 3 211 353 0130 7
1.19 Einlaufdüse 60 Hz 1 211 153 0148 7 Inlet nozzle Couronne aspiration
1.20 Schutzgitter 1+3 211 153 0124 7 Air intake protection Grille de protection
1.21 Verschlussblech 1 211 153 0109 7 Closing sheet Plaque de fermeture

3 211 353 0109 7
1.22 Verschlussstopfen 1+3 211 153 0118 7 Closing plug Bouchon
1.23 Stopfen GPN 700 R 1/8 1 452 859 Plug Bouchon
1.24 Blinddeckel rot 1+3 111 211 0003 7 Cover red Obturateur rouge
schwarz 1+3 251 103 0106 7 black noir
1.26 Tülle 4,7 x 12,5 1+3 794 032 Bushing Douille
1.27 Dichtungstülle 1+3 211 153 0122 7 Sealing sleeve Passe-câble
* ab 05.09.05 bei Gr. 1

ab 19.09.05 bei Gr. 3
2
2.1 2.2 2.3, 2.4 2.5 2.6 2.7 2.8
3.1 3.4 3.5 3.6
Bezeichnung
2. Luftregelung Air regulation Régulation d’air

Luftklappe Air damper Volet d’air
2.1 L, M, G, GL 1 211 153 0214 7
L, RL, M, G, GL, RGL 3 211 353 0203 7
G, Ausf. ZMI 1 251 106 0202 2
G, Ausf. ZMI 3 251 306 0202 2
Luftklappenwelle Air damper shaft Axe volet d’air

2.2 L, G, GL 8 x 144 1 211 153 0220 7
L, RL, G, GL, RGL 8 x 158 3 211 353 0207 7
Einstellknopf, komplett Adjusting knob, complete Bouton de réglage, complet

2.3 L, M (Z) 1+3 211 163 0402 2
2.4 G, GL 1 251 103 0202 2
G, GL, RGL, RL 3 251 306 0203 2
2.5 Buchse 35 x 16 x 12 1+3 211 153 0203 2 Sleeve Coussinet

2.6 Buchse 10 x 7 1+3 211 153 0207 7 Sleeve Coussinet
2.7 Nadelkranz 1+3 460 036 Needle sleeve Douille à aiguille
2.8 Dichtungstülle 1+3 211 153 0203 7 Sealing sleeve Passe-câble
2.9 Auskleidung für Luftregler (ohne Bild) 1 211 153 0217 7 Insulation for air regulator (without Habillage pour régulateur d’air
3 211 353 0205 7 picture) (sans photo)
2.10 Haltegitter (ohne Bild) 1 211 153 0218 7 Support grating (without picture) Grille de support (sans photo)
3 211 353 0204 7
2.11 Klemmscheibe 431 801 Fixing disc Rondelle frein
3. Stellantrieb für Ölbrenner Servomotor for Servomoteur pour

oil burners brûleur fioul
Stellantrieb 1055/23 1+3 Z Servo drive Servomoteur
3.1 110 V 50 Hz 110 500 0009 2
110 V 60 Hz 110 500 0010 2
230 V 50 Hz 110 500 0011 2
230 V 60 Hz 110 500 0012 2
Stellantrieb 1055/80 1+3 T Servomotor Servomoteur

110 V 50-60 Hz 110 500 0013 2
230 V 50-60 Hz 110 500 0014 2
3.2 Abdeckhaube 1055 651 399 Cover Capot 1055/23

Kabel für Stellantrieb (ohne Bild) Cable for Servomotor Câble pour servomoteur
für Brenner (without picture) for burner (sans photo) pour brûleur
3.3 L (M)1Z, L (M)3Z m. LOA 9 x 0,75 111 762 0406 2
3.4 Antriebshebel 1+3 211 163 1523 7 Drive lever Levier d’entraînement
3.5 Leiste L,M 1 211 163 1505 7 Strip Bornier

3 211 363 1507 7
3.6 Flachkopfschraube M6 x 4,5 211 163 1512 7 Screw Vis à tête plate

3
3.31 3.32, 3.33 3.36 3.37 3.38 3.39 3.40 3.41 3.42
3.43 3.45 3.46 3.47 3.48 3.49 3.50 3.51
Bezeichnung
3.30 Stellantrieb Servomotor Servomoteur pour

für Gasbrenner for gas burners brûleurs gaz
ohne Regelgestänge für without regul. rod for sans tringle de réglage
zweistufige Brenner stage burners pour brûleur 2 allures
Stellantrieb Typ 1055/80 Servomotor Servomoteur

3.31 G, GL 230V/50-60Hz 151 101 1504 2
Stellantrieb Typ 1055/80 Servomotor Servomoteur

3.32 110 V 50-60 Hz 1+3 110 500 0013 2
3.33 230 V 50-60 Hz 1+3 110 500 0014 2
3.34 Abdeckhaube 1055/80 ohne Bild 651 399 Cover without picture Capot sans photo
3.36 Reglerscheibe 1+3 151 101 1506 2 Control segment Disque de réglage
3.37 Stahlband 1+3 151 101 1530 7 Steel band Lame d’acier
3.38 Führungsstück 1+3 211 373 1514 7 Guide piece Butée guide
3.39 Befestigungsstück 1+3 151 101 1515 7 Attachement piece Butée de fixation
3.40 Federscheibe 1+3 431 615 Spring plate Clips
3.41 Platte 1+3 151 101 1505 2 Plate Support
3.42 Reglerhebel 1+3 251 303 1504 2 Regulating lever Levier de réglage
3.43 Passcheibe 10 x 16 x 1 1+3 434 005 Distance shim Entretoise
3.44 Sicherungsscheibe S5 490 002 Locking washer Circlips

S6 (ohne Bild) 490 003 (without picture) (sans photo)
S8 490 005
3.45 Sicherungsring A10 x 1 1+3 435 424 Grip screw Circlips
3.46 Welle 8 x 8 x 105 1+3 151 101 1514 7 Shaft Axe

Regelgestänge, Luft Regulating rod, air Tige de réglage, air
3.47 G, GL 1 251 103 1503 2
G, GL 3 251 303 1503 2
Regelgestänge, Gas Regulating rod gas Tige de réglage, gaz

3.48 G, GL 1 255 103 1501 2
G, GL 3 251 303 1502 2
3.49 Gewindestange M6 x 168 1+3 151 316 1506 7 Threaded rod Tige filetée
M6 x 75 3 251 303 1503 7
3.50 Gelenkkopf SFEV6 1+3 499 001 Hinge rod head Rotule d’accouplement
3.51 Distanzrohr 6,2 x 8 x 34 1+3 251 103 1501 7 Distance sleeve Entretoise
6,1 x 10 x 4 1+3 151 101 1520 7

4
3.60 3.61 3.63 3.64 3.65 3.68 3.69/3.70 3.71 3.72 3.73
3.74 3.75 3.76 3.77 3.78 3.79
Bezeichnung
Stellantrieb Typ SQM10 auf Anfrage Servomotor Servomoteur

mit Regelgestänge für gleitend- with regulating rod avec tringle de réglage
zweistufige Brenner for sliding two stage burners pour brûleur 2 allures progressif
(bitte Spannung und Laufzeit angeben) (please stipulate voltage and run (préciser la tension et
time) le temps de course)
ohne Regelgestänge für gleitend- without regulating rod sans tringle de réglage
zweistufige Brenner 230V 42 sek. for sliding two stage pour brûleur 2 allures progressif
3.60 G, GL 1 251 106 1503 2 burners
G, GL 3 251 306 1501 2
RGL 3 256 306 1501 2
G, Ausf. Zweigas 1 250 106 1503 2
G, Ausf. ZMI 1 251 106 1506 2
G, Ausf. ZMI 3 250 306 1501 2
RL 3 211 373 1501 2
Einzelteile vom Stellantrieb für Spare parts for servomotors Pièces de rechange pour
gleitend-zweistufige (ZM) Brenner for sliding two stage (ZM) burners brûleur 2 allures progressif (ZM)
3.61 Stellantrieb Typ SQM10 Servo drive Servomoteur

220-240V/50-60 Hz, Laufzeit 42 Sek. 651 418 Run time 42 secs. tps course 42’
110V/50-60 Hz, Laufzeit 42 Sek. 651 417 Run time 42 secs. tps course 42’
220-240V/50-60 Hz, Laufzeit 20 Sek. 651 422 Run time 20 secs. tps course 20’
110V/50-60 Hz, Laufzeit 20 Sek. 651 423 Run time 20 secs. tps course 20’
3.62 Abdeckhaube SQM 10 651 428 Cover plate Capot
3.63 Grundplatte RL, G, GL, RGL 3 151 327 1538 7 Base plate Plaque de base
3.64 Nabe G, GL 3 151 327 1511 2 Hub Support moyen

3.65 Ölregler RL, RGL 3 211 373 1504 2 Oil regulator Régulateur fioul
Einschraubstutzen Reducing plug Réduction

3.68 G 3/8” x G 1/4” x 20 3 211 373 1512 7
Reglerscheibe Control segment Disque de réglage

3.69 G, GL 1+3 151 327 1506 2
3.70 RL, RGL 3 121 362 2103 2
3.71 Führungsstück, 18 x 20 211 373 1514 7 Guide piece Butée guide

3.72 Sicherungsscheibe, 4 431 601 Locking washer Circlips
Verstellspindel Adjusting spindle Vis de réglage

3.73 50 lang 121 362 2178 7
55 lang 121 362 2179 7
60 lang 121 362 2180 7
65 lang 121 362 2181 7
75 lang 121 362 2182 7
3.74 Führungswinkel 121 362 2196 7 Angular guide piece Equerre de réglage
3.75 Stahlband 16 x 0,8 x 212 110 004 3795 7 Steel band Lame d’acier
3.76 Paßscheibe 121 362 2187 7 Shim Rondelle plate
3.77 Hebel 151 327 1517 7 Lever Levier
3.78 Schraubbolzen 121 464 2114 7 Screwing bolt Boulon
3.79 Kupplungstück 1+3 151 327 1527 7 Coupling piece Accouplement

5
3.80 3.81 3.82, 3.85 3.83 3.84 3.86 3.87 3.88 3.89
3.90 3.91 3.92 3.93 3.94 3.95 3.96 3.99
Bezeichnung
3.80 Welle 66 mm RGL3 156 327 1507 7 Shaft Axe

66 mm 1+3 151 327 1526 7
142 mm 1+3 151 327 1528 7
212 mm RGL3 156 327 1504 7
212 mm G3ZMI 156 327 1504 7
10 X 212 mm G1ZMI 251 106 1505 7
3.81 Scheibenfeder 5 x 6,5 490 151 Woodruff key Clavette bateau
3 x 3,7 490 157
3.82 Buchse 8 x 6 121 464 2112 7 Sleeve Douille
3.83 Gleitlager 499 089 Bearing Coussinet
3.84 Lagerbuchse 151 327 1512 2 Bearing sleeve Palier

3.85 Buchse 156 327 1505 7 Sleeve Manchon
Hebel Lever Levier

3.86 127 mm 156 327 1506 7
3.87 165 mm 151 327 1530 7
3.88 Reglerhebel 211 373 1515 2 Regulating lever Levier de réglage
23.89 Stellring 151 327 1532 7 Adjusting ring Rondelle graduée
3.90 Stehbolzen M8 x 134 151 327 1524 7 Stay bolt Entretoise taraudée
M8 x 204 156 327 1503 7
3.91 Leiste 151 327 1533 7 Strip Barrette de jonction

3.92 Regelgestänge Luft G, GL 1 251 103 1501 2 Regulating rod air Tringle de réglage air
RL, G, GL, RGL 3 251 306 1502 2
3.93 Regelgestänge Gas G, GL 1 251 103 1502 2 Regulating rod gas Tringle de réglage gaz
G, GL 3 251 306 1503 2
RGL, ZMA, ZMI 3 256 306 1504 2
Gewindestange (Luft und Gas) Threaded rod (air and gas) Tige filetée (air et gaz)
3.94 M6 x 75 251 303 1503 7
M6 x 165 111 974 1505 7
3.95 Gelenkkopf SFEV6 499 001 Ball joint Rotule d’accouplement
3.96 Distanzrohr 6,2 x 8 x 14 251 306 1503 7 Distance sleeve Entretoise

12 x 1,5 x 5 251 106 1504 7
6,2 x 8 x 28 151 327 1535 7
3.97 Anschlusskabel 9 x 0,75 x 920 111 762 0406 2 Connection cable Câble raccordement
(ohne Bild) (without picture) (sans photo)
3.98 Anschlusskabel 12 x 0,75 x 830 Connection cable Câble raccordement

(ohne Bild) 151 518 1506 2 (without picture) (sans photo)
Potentiometer (Einbau in SQM) Potentiometer Potentiomètre de recopie

3.99 ASZ8 220 Ohm 651 434
ASZ12 1000 Ohm 651 435

6
4.1 4.2 4.3 4.4 5.1-5.3 5.4
Bezeichnung
4. Brennermotor Burner motor Moteur de brûleur

Bei Bestellung Spannung und When ordering indicate A la commande indiquer
Frequenz angeben voltage and frequency la tension et la fréquence
Brennermotoren 50 Hz Burner motor Moteur de brûleurs

4.1 EC 90/50-2 220-230V 1 111 153 0750 0
EC 90/90-2 220-230V 3 111 353 0750 0
W-D 90/90-2/0 K5 220-240/380-415V 1 251 103 0701 0
W-D90/90-2/1 K0 220-240/380-415V 3 251 303 0701 0
4.2 Scheibenfeder 5 x 6,5 1+3 490 151 Woodruff key

Clavette disque
Kondensator Capacitor
4.3 16µ F zu Motor EC90/50-2 1 713 112 Condensateur
25µ F zu Motor EC90/90-2 3 713 122
4.4 Zwischenring 1 211 153 0137 7 Intermediate ring

3 211 353 0127 7 Bride intermédiaire
4.5 Ventilatorflügel für D 90/EC90 1+3 111 153 0758 7 Baffle
Ventilateur du moteur
4.6 Lüfterhaube für D 90/EC90 1+3 111 153 0756 7 Fan cowl
Capot ventilateur
4.7 Kabelverschraubung M20 x 1,5 1+3 730 602 Cable connector
für Motor D90 + EC 90 Presse-étoupe
5. Gebläse Fan Ventilateur

Gebläserad Fan wheel Turbine
Ømm
5.1 TLR-S 188 x 62, S1 50-60 Hz 1 211 153 0806 1
5.2 TLR-S 217 x 92, S1 50 Hz 3 211 353 0807 1
5.3 TLR 200 x 92, S1 rot (60 Hz) 3 211 353 0808 1 red rouge
5.4 Abziehvorrichtung für Gebläserad 111 111 0001 2 Fan wheel extractor for fan wheel Arrache turbine pour turbine

7
6.1, 6.2 6.6 6.7 6.10 6.15, 6.16 6.17 - 6.20 6.21
6.31 6.41 6.42 6.43 6.44 6.45
Bezeichnung
6. Pumpen Pumps Pompes

Pumpentyp
6.1 L, GL AEV 67 C 1 601 753
6.2 L, GL AEV 97 C 3 601 754
6.6 RL, RGL AJV 4 CE 3 601 750

6.7 M E4 NC 1+3 601 156
Anschlussteile für Pumpe: Connection parts Eléments de raccordement

(ohne Bild) for pump (without picture) pour pompe (sans photo)
6.8 AE67 / AE 97 211 163 0605 2
AJ 4 111 273 0602 2
6.9 E4 212 153 0602 2
6.11 Sieb (ohne Bild) E4 601 067 Filter (without picture) Filtre (sans photo)
6.12 Deckeldichtung (ohne Bild) Sealing (without picture) Joint couvercle (sans photo)
Pumpe E 601 069 for pump pour pompe
6.13 Filtersatz Nr. 1 AE 67, AT 601 107 Filter set Tamis
Nr. 2 AE 97 601 102
Nr. 3 AJ 601 103
Pumpenkupplung Pump coupling Accouplement de pompe

6.15 L, GL 1+3 111 151 0902 2
M 1 111 011 0902 2
6.16 M, RL, RGL 3 111 011 0902 2
Kupplungsmittelstück Coupling center piece Accouplement intermediaire

6.17 M 129 mm 1 212 153 0902 2
6.18 RL, M, RGL 141 mm 3 211 363 0903 2
6.19 L, GL 162 mm 1 211 153 0903 2
6.20 L, GL 173 mm 3 211 363 0904 2
6.21 Kupplungskreuz Coupling cross Croisillon

L, M, RL, GL, RGL 1+3 111 151 0901 7
6.22 Wellendichtung für Pumpe Shaft seal for pump Presse-étoupe pour pompe
AEV 601 764
AJV 601 765
E4 601 059
6.30 Pumpenheizung Pump heating Chauffage de pompe

6.31 Heizpatrone 110V/80W 794 284 Heating cartridge Cartouche chauffante
230V/88W 794 290
6.32 Zwischenstutzen M16 x 1,5 x 25 730 900 Intermadiate nipple Raccord intermédiaire
für Heizpatrone for heating cardridge pour cartouche chauffante
6.40 Magnetkupplung Magnet coupling Accouplement

magnétique
Magnetkupplung Magnet coupling Accouplement
6.41 WMK 10 230 V 218 114 0905 2 magnétique
WMK 10 110 V 218 114 0906 2
6.42 Lagerflansch 256 306 0901 2 Bearing flange Bride avec roulements
6.43 Haltescheibe 155 101 0903 7 Washer Rondelle de maintien

6.44 Distanzscheibe 155 101 0904 7 Distance shim Entretoise
6.45 Pumpenflansch 256 306 0601 7 Pump flange Support de pompe

6.46 Verschlussstopfen für Pumpenflansch 256 306 0602 7 Closing plug for pump flange Bouchon pour support de pompe
6.47 Steckerkabel mit Gleichrichter 250 101 0902 2 Plug cable with rectifier for magnet Câble à fiche avec redresseur pour
für Magnetkupplung coupling accouplement magnétique

8
6.51, 6.52 6.53, 6.54 6.55
Bezeichnung
6.50 Ölschläuche Oil hoses Flexibles fioul

Ölschläuche für Ölpumpe als Oil hoses for oil pump as Flexibles pour pompe
Ansaug- und Rücklaufschlauch suction intake and return hose aspiration et refoulement
Für Heizöl EL bis max. 70°C For fuel oil EL up to max. 70°C Pour fioul FOD max. 70°C
DN Länge G Length mm Connection Longueur mm
mm
6.51 L, RL, GL, RGL 8 1000 3/8” 1+3 491 011

8 1300 3/8” 1+3 491 050
Für Heizöl M bis max. 150°C For fuel oil MS up to max. 150°C Pour fioul FOD max. 150°C
dürfen nicht in Feuerungsanlagen not permitted for combustion plant ne doivent pas être montés sur des
innerhalb der BRD eingebaut werden within the Federal Republic of installations en Allemagne.
6.52 M, 13 1000 1/2” 1+3 491 078 Germany
13 1300 1/2” 1+3 491 079
Schiffsausführung für Heizöl EL Marine execution for fuel Exécution marine pour
und M bis max. 150°C (Edelstahl) oil EL and MS up to fioul FOD et FOL
6.53 8 500 3/8” 491 115 max. 150° C (stainless steel) max. 150°C (inox)
8 700 3/8” 491 116
8 800 3/8” 491 117
8 1000 3/8” 491 107
6.54 12 500 1/2” 491 118

12 700 1/2” 491 119
12 800 1/2” 491 120
12 1000 1/2” 491 093
6.55 Einschraubstutzen External screw part Raccord droit
G 1/2 x G 1/2 x 37, DN 13 111 512 0003 7

9
7.1 * ** 7.6
Bezeichnung
Bild Brenner-Typenreihe Bestell-Nr. Preis EUR Designation Désignation
Pict. Burner serie Order-No. (o. MwSt.)
Photo Type brûleur No de commande
7. Magnetventile für Öl Solenoid valves Vannes magnétiques

for oil pour fioul
Magnetventil Typ 121 Z 2323, 1/8” Solenoid valve Vanne magnétique
mit Spule 3764, 9 Watt with coil avec bobine
stromlos geschlossen normally closed fermée hors tension
7.1 230 V 50 Hz, 240 V 60 Hz 604 480
110 V/50 Hz, 115 V/60 Hz 604 481
220V60Hz 604 482
240V50Hz 604 483
Magnetventil Typ 121 K2423, 1/8” Stufe 2 Solenoid valve stage 2 Vanne magnétique type allure 2
7.2 55 V/60Hz* 604 611
58 V/50 Hz*, 60 V/60 Hz* 604 601
110 V/60Hz* 604 612
115 V/50 Hz*, 120 V/60 Hz* 604 602
220 V/60Hz* 604 613
230 V/50 Hz*, 240 V/60 Hz* 604 603
55 V/60Hz** 604 614
58 V/50 Hz**, 60 V/60 Hz** 604 604
110 V/60Hz** 604 615
115 V/50 Hz**,120 V/60 Hz** 604 605
220 V/60Hz** 604 616
230 V/50 Hz**,240 V/60 Hz** 604 606
120 V/50 Hz* 604 609
120 V/50 Hz* 604 607
240 V50 Hz* 604 608
240 V50 Hz** 604 610
Magnetventil Typ 122 K9321, 1/8” Stufe 1 Solenoid valve stage 1 Vanne magnétique type allure 1
stromlos offen normally open ouverte hors tension
7.3 110 V/60Hz* 604 676
115 V/50 Hz*, 120V/60 Hz* 604 597
220 V/60Hz* 604 677
230 V/50 Hz*, 240V/60 Hz* 604 598
110 V/60Hz** 604 678
115 V/50 Hz**,120V/60 Hz** 604 599
220 V/60Hz** 604 679
230 V/50 Hz**,240V/60 Hz** 604 600
240 V/50 Hz* 604 568
240 V/50 Hz** 604 570
Magnetventil Typ 121 K6220, 1/4” Solenoid valve Vanne magnétique

7.4 55 V/60Hz* 604 630
58 V/50 Hz*, 60V/60 Hz* 604 512
110 V/60Hz* 604 631
115 V/50 Hz*, 120V/60 Hz* 604 513
220 V/60Hz* 604 632
230 V/50 Hz*, 240V/60 Hz* 604 514
120 V/50 Hz* 604 571
240 V/50 Hz* 604 572
Magnetventil Typ 121 K6220, 1/4” Solenoid valve Vanne magnétique

7.5 55 V/60Hz** 604 633
58 V/50 Hz**, 60V/60 Hz** 604 515
110 V/60Hz** 604 634
115 V/50 Hz**,120V/60 Hz** 604 516
220 V/60Hz** 604 635
230 V/50 Hz**, 240V/60 Hz** 604 517
120 V/50 Hz** 604 573
* Spulen-Gehäuse Standard * Coil casing standard * Corps de bobine standard

** Spulen-Gehäuse wasserdicht ** Coil casing waterproof ** Corps de bobine étanche à l´eau
Magnet-Spule für Ventil 121 Z 2323 Solenoid valve coil for valve Bobine de vanne magnétique pour
7.6 Typ 483764, 9 Watt vanne
110V/50 Hz, 115V/60 Hz 604 452
230 V 50 Hz, 240 V 60 Hz 604 453
240V/50Hz 604 458
220V/60Hz 604 471

10
7.7, 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17
7.18, 7.19, 7.25 7.22 7.2 7.25 7.26
Bezeichnung
7.7 Typ 483 824, 55V/60 Hz 604 620

19 Watt 58V/50 Hz, 60V/60 Hz 604 551
110V/60Hz 604 621
115V/50 Hz, 120 V/60 Hz 604 552
220V/60Hz 604 622
230V/50 Hz, 240 V/60 Hz 604 553
120V/50 Hz 604 593
240V/50 Hz 604 594
7.8 Typ 483 541, 55V/60Hz 604 638

20 Watt 58V/50 Hz, 60V/60 Hz 604 554
110V/60Hz 604 639
115V/50 Hz, 120 V/60 Hz 604 555
220V/60Hz 604 640
230V/50 Hz, 240 V/60 Hz 604 556
120V/50 Hz 604 595
7.9 Anschlusskabel mit Stecker Connection cable with Câble de raccordement avec fiche
für Magnetventil 121 Z2323, 850 mm 716 507 plug for solenoid valve avec prise pour vanne
Anschlusskabel für Magnetventil Connection cable Câble de raccordement pour

7.11 121 K2423 u. 122 K9321 2 x 1 x 765 112 151 1307 7 for solenoid valve vanne
7.12 121 K6220 2 x 0,75 x 975 111 764 1302 2
Verteilerstück Distributor piece Répartiteur

7.13 M1Z 212 163 1303 2
7.14 M3 112 564 1301 2
7.15 Thermometer 0-160°C 642 011 Thermometer Thermomètre
7.16 Einschraubstutzen Adapter Raccord droit

M 10 x 1 x G 1/8” x 62 212 153 1307 7
M 10 x 1 x G 1/8” x 102 212 153 1308 7
M 12 x 1 x G 1/8” x 62 212 163 1306 7
M 14 x 1,5 x M 20 x 1,5 212 153 1306 7
7.17 Verschraubung XGE 3/8” 452 277 Screwing Raccord
7.18 Gehäuse SWVE08-LLR 452 619 Casing Corps
7.19 Hohlschraube XHS G 1/8 A 452 877 Hollow screw Vis creuse
7.20 Dichtring A10 x 13,5 x 1 440 027 Sealing ring Joint
7.21 Bundschraube R 1/8” (ohne Bild) 111 574 1309 7 Collar screw (without picture) Ecrou (sans photo)
7.22 Dichtring CU Copper ring Joint cuivre

10, x 14 x 1,5 440 034
13,5 x 17 x 1,5 440 010
16, x 20 x 1,5 440 048
17, x 21 x 1,5 440 003
10 x 13,5 x 1,5 440 027
7.23 Anschlussteile-Verteilerstück (ohne Bild) Connection parts-distributor Eléments de raccordement

M1Z 212 163 1305 2 (without picture) pour répartiteur
M3 212 364 1303 2 (sans photo)
7.24 Heizpatrone 230V, 22 Watt komplett 112 381 1304 2 Heating cartridge Cartouche chauffante
7.25 Heizpatrone 230V, 22 Watt 794 281 Heating cartridge Cartouche chauffante
7.26 Druckwächter Typ DSA 46, 1 - 10 bar 640 096 Pressure monitor Pressostat

11
8.1 8.2 8.3 8.4 8.5 8.6 8.7, 8.8 8.9
Bezeichnung
8. Magnetventile für Gas Solenoid valves Vannes magnétiques

for gas pour gaz
Magnetventile Typ Solenoid valves quality Vannes magnétiques
Baugruppe A mit Mengeneinstellung class A with quantity classe A, réglables
Druckbereich 0 - 500 mbar adjustment Pressure Pression d’utilisation
Typ Rp Spannung Type ID Voltage Type DN Tension/Fréquence
8.1 DMV-D 507/11 1/2-3/4 230V 605 204
DMV-D 512/11 1 230V 605 206
DMV-D 520/11 1 1/2-2 230V 605 208
8.2 DMV-D 5065/11, eco DN65 230V 625 100

DMV-D 5080/11, eco DN80 230V 625 104
DMV-D 5100/11, eco DN100 230V 625 108
8.3 Stecker 4-polig, 250 V, 16 A, schwarz 217 304 2601 2 Plug 4 pole, black Fiche 4 pôles, noir
8.4 Flansch Flange Bride

Rp 3/4” für DMV 507 605 227
Rp 1 für DMV 507 605 233
Rp 1” für DMV 512 605 228
Rp 1 1/2 für DMV 520 605 230
Rp 2 für DMV 520 605 231
8.5 Zündgasflansch für DMV507 - DMV520 605 232 Ignition gas flange Bride ligne d’allumage
8.6 Hydraulikbremse Hydraulic brake Cartouche hydraulique

Set für DMV 507/11 605 237
DMV 5040/11 605 238
DMV 5100/11 605 239
Magnet komplett, für Solenoid, complete for Bobine, complète pour

Typ Nr. Spannung Type No Voltage Type No Tension/Fréquence
8.7 DMV-D 507/11 1111 220-240V 605 941
DMV-D 512/11 1211 220-240V 605 942
DMV-D 520/11 1212 220-240V 605 943
8.8 DMV-D 5065/11, eco 1411/2P 220-240V 625 038

DMV-D 5080/11, eco 1511/2P 220-240V 625 024
DMV-D 5100/11, eco 1611/2P 220-240V 625 026
8.9 O-Ring O-ring Joint O

10,5 x 2,25 Zündgasflansch DMV 507, 512, 520 445 512 Ignition gas flange Bride d’allumage gaz
27 x 1,5 Zündgasflansch DMV 5065 - 5100 445 517 Ignition gas flange Bride d’allumage gaz
57 x 3 Anschlussflansch DMV 507 445 519 Connection flange Bride de raccordement
75 x 3,5 Anschlussflansch DMV 512, 520 445 520 Connection flange Bride de raccordement
8.10 Verschlussschraube flach G1/8 mit O-Ring 409 040 Closing screw flat head Vis de fermeture plate avec
(ohne Bild) (without picture) joint torique (sans photo)
8.11 Leiterplatte (ohne Bild) Conductor plate Circuit imprimé

DMV 507 605 996 (without picture) avec redresseur (sans photo)
DMV 512 + 520 605 997
DMV 5080 + 5100 eco 605 989
8.12 Endschalter K01 605 429 Limit switch Fin de course K01

12
9.1, 9.2 9.3 9.5 9.6 10.1 10.2 10.3 10.4 10.5 10.6
Bezeichnung
9. Druckwächter Pressure monitor Pressostat pour

für Luft und Gas for air and gas air et gaz
Druckwächter Pressure monitor Pressostat
9.1 Typ LGW 50 A2 P 691 373
9.2 Typ GW 50 A6/1 691 381

Typ GW 150 A6/1 691 382
Typ GW 500 A6/1 691 383
Typ GW 50 A5/1 691 378

Typ GW 150 A5/1 691 379
Typ GW 500 A5/1 691 380
9.3 Kappe für LGW 446 011 Cap for LGW Capuchon pour LGW
9.4 Anschlusskabel 3 x 0,75 x 1000 251 103 2401 2 Connection cable Câble de raccordement
für LGW 50 A4 (ohne Bild) (without picture) (sans photo)
Luft
9.5 Einschraubstutzen Luft 251 103 2401 7 External screw part air Raccord droit pour tuyaux air
M10 x G1/4” x 42
9.6 Stecker 4-polig, 250 V, 16 A, grau 217 304 2602 2 Plug 4 pole, grey Fiche 4 pôles, gris
für GW...
9.7 O-Ring 10,5 x 2,25 O Ring Joint torique

für GW... 445 512
10. Gasdrossel Gas throttle Clapet gaz

Gasdrossel, komplett DN Gas throttle, complete Clapet gaz, complet
10.1 G,GL 25 1 151 101 2506 0
G,GL,RGL 40 3 151 327 2506 0
G,GL,RGL 40/25 3 151 327 2507 0
G, Ausf. ZMI25 1 151 101 2507 0

G, Ausf. ZMI40 3 151 327 2508 0
Dichtung für Gasdrossel Sealing ring for gas throttle Joint pour clapet gaz
10.2 G,GL,RGL 115 x 35 x 2 25 1 151 101 0005 7
G,GL,RGL 150 x 45 x 2 40 3 151 327 0012 7
10.3 Abschlussdeckel 1+3 151 907 2505 7 Closing cover Couvercle
10.4 Skala 1+3 151 907 2506 7 Scale Graduation
10.5 Antriebsnabe 1+3 151 101 2504 2 Driving hub Moyeu de mouvement
10.6 Verstellhebel 1+3 161 208 2530 7 Adjusting lever Levier de réglage
10.7 Drehfeder 0,8 x 10 1+3 151 101 2508 7 Spring for gas butterfly Ressort pour clapet

13
11.1, 11.4 11.2 11.5 11.3, 11.6 11.7 11.8, 11.9
Bezeichnung
11. Flammkopf für Combustion head Tête de combustion

Ölbrenner oil burner pour fioul brûleurs
Flammrohr, Flame tube, Tube de combustion,
ohne Stauscheibe without diffuser sans déflecteur
Flammrohrtyp Flame tube type Tube de combustion type
11.1 M 1/5a 1 211 153 1404 7
11.2 M 2/1a 3 111 211 1416 7
11.3 M 5/2a 3 151 327 1402 7
Flammrohr, Flame tube, Tube de combustion,

ohne Stauscheibe without diffuser, sans déflecteur pour la
für höhere Wärmebelastung for higher thermal stress (f.i. fire- puissance calorifique
(z.B.: schamottierte Brenn- clay lined combustion supérieure (par exemple:
kammern) chambers) tête de combustion murée)
11.4 H1 M 1/5a 1 210 153 1402 7
11.5 H1 M 2/1a 3 111 211 1423 7
11.6 H1 M 5/2a 3 111 512 1416 7
Stauscheibe komplett Diffuser complete Déflecteur complet

für FlammrohrØ mm for flame tube pour tube de combustion
11.7 M 1/5a 100K x 33 1 211 153 1403 2
M 1/5a 105K x 33 1 211 153 1404 2
M 1/5a 100x36 1T 211 193 1401 2
M1/5a 105x36 1T 211 193 1402 2
11.8 M 2/1a 116 x 40 3 111 211 1410 2
11.9 M 5/2a 116 x 40 3 111 512 1413 2

14
Bezeichnung
11.20 Flammkopfverlängerung Combustion head Rallonge tête de

extension combustion
Flammkopfverlängerung, komplett Combustion head extension, Rallonge tête de combustion,
Brenner Aufnahme Verl. complete complète
mm mm Burner Adapter Ext. brûleur Raccordement Rallonge
11.21 L (Z) 110 100 1 210 003 2201 2 mm by mm mm mm
L (Z) 110 200 1 210 003 2301 2
L (Z) 110 300 1 210 003 2401 2
11.22 L (Z) 120 100 3 210 000 1902 2

L (Z) 140 100 3 210 000 1903 2
11.23 L (Z) 120 200 3 210 000 2102 2
L (Z) 140 200 3 210 000 2103 2
11.24 RL (M2) 120 100 3 210 000 2301 2

RL (M5) 140 100 3 210 000 2302 2
11.25 RL (M2) 120 200 3 210 000 2501 2
RL (M5) 140 200 3 210 000 2502 2
11.26 M (Z) 110 100 1 210 003 3001 2
11.27 M (Z) 110 200 1 210 003 3101 2
11.28 M (Z) 120 100 3 210 002 2901 2

M (Z) 140 100 3 210 002 2902 2
11.29 M (Z) 120 200 3 210 002 3001 2
M (Z) 140 200 3 210 002 3002 2
Stauscheibe Diffuser Déflecteur

für Flammrohr Ø mm for flame tube pour tube de combustion
11.30 M1/5a 100K x 33 1 210 153 1401 2
M1/5a 105K x 33 1 210 153 1402 2
M2/1a 116 x 40 3 111 211 8301 2

M5/2a 116 x 40 3 210 000 1905 2

15
12.1 12.2 12.3 12.4 12.5 12.6
12.7 12.8 12.10 12.12 12.13 12.14 12.15
12.16 12.17 12.18 12.19 12.20 12.21 12.22 12.23
Bezeichnung
12. Flammkopf für Combustion head Tête de combustion

G/GL/RGL-Brenner for G/GL/RGL- pour brûleurs
burner G/GL/RGL
Mischgehäuse, komplett Mixing chamber, complete Chambre de mélange, complète
12.1 G 1 151 101 1409 2
G-LN 1 251 103 1423 2
G 3 151 327 1421 2
G-LN 3 251 303 1401 2
12.2 GL 1 155 103 1403 2
GL 3 155 327 1411 2
12.3 RGL 3 156 327 1401 2
Mischgehäuse Mixing casing Chambre de mélange

12.4 G,GL 1 151 101 1417 7
G-LN 1 251 103 1423 1
G,GL,RGL 3 151 327 1452 7
G-LN 3 251 303 1401 1
Mischrohr außen Mixing tube outside Tube de mélange extérieur

12.5 G,GL 80 x 95 1 151 101 1431 7
G,GL, RGL 90 x 105 3 151 327 1472 7
Mischrohr innen Mixing tube inside Tube de mélange intérieur

12.6 G,GL 60 x 155 1 151 101 1420 7
G,GL,RGL 60 x 180 3 151 327 1462 7
Stauscheibe Ø mm Air diffuser assemblyt Déflecteur
12.7 G,GL 95K x 40 1 151 101 1413 2
G-LN 105 x 36 1 251 103 1405 7
G,GL,RGL 100K x 40 3 151 327 1426 2
G-LN 120 x 41 3 251 303 1406 7
12.8 G,GL 115 x 80 1 151 101 1405 2

G,GL,RGL 133 x 90 3 151 327 1416 2
12.81 Düseneinsatz (ohne Bild) 45 x 12 1 251 103 1406 7 Nozzle element (without picture) Coupelle gicleur (sans photo)
55,8 x 12 3 251 303 1409 7
12.9 Düsenstern (ohne Bild) 76 x 0,8 x 40 1 151 101 1430 7 Nozzle ring (without picture) Tôle étoile (sans photo)
86 x 0,8 x 40 3 151 327 1471 7
12.10 Düsenring 151 327 1468 7 Nozzle ring Diffuseur gaz
12.11 Elektrodenhalter, komplett Electrode holder, complete Support électrodes, complète

G 1 151 101 1403 2
G 3 151 327 1422 2
12.12 Düsenkopf, komplett Nozzle head, complete Ligne de gicleur, complète

GL 1 155 103 1404 2
GL 3 155 327 1412 2
12.13 RGL 3 156 327 1402 2
12.14 Zündelektroden Ignition electrodes Electrodes d’allumage

G, RGL 1+3 151 327 1433 7
GL links 1+3 151 327 1433 7
rechts 1+3 155 327 1420 7
G-LN 1+3 132 101 1403 7
12.15 Fühlerelektrode Länge mm Sensor electrode Length mm Sonde d’ionisation Longueur mm

G 85/150 1+3 151 327 1434 7
G-LN 1+3 232 100 1420 7
12.16 Scheibe (Elektrodenhalter) G,GL 1+3 151 327 1436 7 Disk (electrode holder) Rondelle (support électrodes)
12.17 Bügel GL 1+3 155 103 1404 7 Bracket Etrier
Klemmstück (Elektrodenhalter) Shim (electrode holder) Etrier pour sonde d’ionisation

12.18 G 1+3 151 327 1437 7 (support électrodes)
G-LN 1+3 251 303 1408 7
12.19 Elektrodenhalter G/GL 1+3 251 103 1401 7 Electrode holder Support électrodes
12.20 Haltering G,GL,RGL 1+3 151 101 1425 7 Guard ring Rondelle support
12.21 Stehbolzen M 6 Länge mm Threaded rod Length mm Goujon Longueur mm

G 88 1 151 101 1426 7
G 122 3 151 327 1467 7
12.22 Düsenkopf GL 1+3 155 103 1405 2 Nozzle tube Ligne de gicleur

16
12.26 12.27 12.28 12.30 12.31, 12.32 12.33
12.51, 12.53, 12.55 12.52, 12.54, 12.56 12.57
Bezeichnung
12.23 Druckschlauch DN 6 x 355 1+3 111 552 0064 2 Pressure hose Flexible HP
12.26 Zündrohr, G,GL,RGL 3 151 327 1458 7 Ignition pipe Tube d’allumage
12.27 Verschlussstopfen Closing plug Bouchon obturateur

G,GL,RGL 3 151 327 1454 7
12.28 Zündkopf Ignition head Tête allumage

G,GL,RGL 3 151 327 1420 2
12.29 Zündkabel (ohne Bild) Ignition line extension Prolongateur pour

G,GL 400 mm lang 1 217 104 1105 2 (without picture) lignes d’allumage
G,GL,RGL 400 mm lang 3 217 104 1105 2 (sans photo)
12.30 Fixierbolzen Arresting bolt Goujon de fixation

G,GL 1 151 101 1432 7
G,GL,RGL 3 151 327 1473 7
12.31 Flammrohr, ohne Stauscheibe Flame tube, without Tube de combustion,

Ø mm air diffuser disk sans deflecteur
G,GL 130 G1/2a 1 151 101 1423 7
G,GL,RGL 160 G3/1a 3 151 327 1439 7
G-LN 1 251 103 1427 2
G-LN 3 251 303 1406 2
12.32 Flammrohr, ohne Stauscheibe Flame tube, without air diffuser Tube de combustion
für höhere Wärmebelastung disk for higher thermal stress sans déflecteur pour la puissance
(z. B.: schamottierte Brennkammern) (f.i. fire-clay lined combustion calorifique supérieure
Ø mm chambers) (par ex.: tête de combustion murée)
G,GL 130 H1G1/2a 1 151 101 1424 7
G,GL,RGL 160 H1G3/1a 3 151 327 1465 7
12.33 Ionisationskabel 200 mm 1 217 105 1456 2 Sensor line Câble d´ionisation
300 mm 3 217 105 1457 2
300 mm 1+3LN 217 105 1450 2
12.50 Flammkopfverlängerung Combustion head Rallonge tête de

extension combustion
Mischgehäuse komplett Mixing head, complete Chambre de mélange, complète
Verlängerung mm Extended by mm Rallonge mm
12.51 G 100 1 150 001 2301 2
G 3 150 001 0702 2
G-LN 1 250 103 1422 2
G-LN 3 250 303 1409 2
12.52 GL 1 150 001 2501 2

GL 3 150 001 1202 2
RGL 3 150 006 2902 2
12.53 G 200 1 150 001 2401 2

G 3 150 001 0802 2
G-LN 1 250 103 1423 2
G-LN 3 250 303 1410 2
12.54 GL 1 150 001 2601 2
GL 3 150 001 1302 2
RGL 3 150 006 3002 2
12.55 G 300 1 150 002 3401 2

G 3 150 002 3602 2
G-LN 1 250 103 1424 2
G-LN 3 250 303 1411 2
12.56 GL 1 150 002 3501 2

GL 3 150 002 3702 2
RGL 3 150 006 3102 2
12.57 Verlängerungsrohr Extension tube Rallonge de tube

G, GL 100 1 250 103 1401 7
G, GL, RGL 3 250 303 1410 7
G, GL 200 1 250 103 1402 7

G, GL, RGL 3 250 303 1411 7
G, GL 300 1 250 103 1401 2

G, GL, RGL 3 250 303 1412 7
Ionisationskabel, komplett (ohne Bild) Sensor line, complete Câble d’ionisation complet
Länge mm (without picture) (sans photo)
12.58 540 für Verlängerung bis 300 mm 1+3 251 103 1408 2 Length mm Longeur mm
600 für Verlängerung bis 300 mm 1+3 LN 217 105 1453 2
17
13.1, 13.2 13.3 13.4 13.5 13.6 13.7 13.10
13.11 13.13 13.14 13.15, 13.16 13.17 13.18 13.19
Bezeichnung
13. Düsenstock Nozzle assembly Ligne de gicleur

Düsenkreuz Nozzle support Croisillon porte ligne gicleur
13.1 L (zweistufig) 1Z 211 163 1001 7 (two stage) (deux allures)
13.2 L,RL 3 211 363 1001 7
13.3 M (zweistufig) 1Z 212 163 1011 7 (two stages) (deux allures)
M (zweistufig) 3Z 212 364 1011 7 (two stages) (deux allures)
Düsenkopf Nozzle head Porte ligne avec ligne de gicleur

13.4 L (zweistufig) mit Zündelektroden 1Z 211 153 1002 2 (two stages) (deux allures) avec électrode d’all.
L (dreistufig) mit Zündelektroden 1T 211 193 1002 2 (three stage) (trois allures) avec électrode d’all.
13.5 L (zweistufig) mit Zündelektroden 3Z 211 363 1001 2 (two stage) (trois allures) avec électrode d’all.
L (dreistufig) mit Zündelektroden 3T 210 393 1001 2 (three stage) (dreistufig) avec électrode d’all.
13.6 RL 3 111 273 1001 2
13.7 M (zweistufig) 1+3Z 212 163 1001 2 (two stage) (deux allures)
13.9 Schneidring D 04-LL 452 808 Cutting ring Olive
13.10 Überwurfmutter M 04-LL 452 806 Union nut Contre écrou

13.11 Düsenabschluss, 2,5 bar Nozzle closure Clapet obturateur
Monarch Düse 1+3 112 261 1016 2 Monarch nozzle Gicleur Monarch
Steinen Düse 1+3 112 261 1017 2 Steinen nozzle Gicleur Steinen
Zündelektroden Ignition electrodes Electrodes d’allumage

13.13 L (Z + T) links 1+3 211 163 1011 7 left gauche
rechts 1+3 211 163 1012 7 right droite
13.14 RL links 3 121 364 1006 7 left gauche

rechts 3 121 364 1007 7 right droite
13.15 M (zweistufig) links 1 212 163 1029 7 (two stage) left (deux allures) gauche
3 212 163 1020 7
13.16 rechts 1 212 163 1030 7 right droite
3 212 163 1021 7
Zündelektroden für Gasbrenner Ignition electrodes for gas Electrodes d’allumage
siehe Seite 16 burners see page 16 pour brûleurs gaz voir page 16
Befestigungsbügel Attachment bracket Etrier de fixation
13.17 für Zündelektroden 111 011 1012 7 for ignition electrode pour electrodes d’allumage
13.18 Heizpatrone 230V, 110 Watt M1+3 112 564 1007 2 Heating cartridge Cartouche chauffante
13.19 NTC-Temperaturfühler 1200 mm M1+3 112 564 1004 2 NTC Sensor Sonde de température NTC
(für Verlängerung) 600 mm M1+3 144 213 1015 2 (for extension) (pour rallonge)

18
14.1
Bezeichnung
14. Düsen Nozzles Gicleurs

14.1 Düsen Fabrikat Monarch Monarch manufacture Fabrication Monarch
Größe in US Gph bei 7 bar Size in US Gph at 7 bar grandeur en US Gph à 7 bar
Typ R - 45° Vollstrahl 0,50 602 293 Solid spray Cône-plein

0,60 602 294
0,65 602 295
0,75 602 296
0,85 602 297
1,00 602 298

1,10 602 316
1,20 602 305
1,25 602 317
1,35 602 306
1,50 602 307
1,65 602 308
1,75 602 309
2,00 602 310
2,25 602 311
Typ R - 45° Vollstrahl 2,50 602 312 Solid spray Cône plein
3,00 602 313
3,50 602 314
Typ R - 60° Vollstrahl 0,50 602 343 Solid spray Cône plein
0,60 602 344
0,65 602 345
0,75 602 346
0,85 602 347
1,00 602 348

1,10 602 355
1,20 602 356
1,25 602 357
1,35 602 358
1,50 602 359

1,65 602 360
1,75 602 361
2,00 602 362
2,25 602 363
2,50 602 364
3,00 602 365
3,50 602 366
Typ PLP - 45° Halbstrahl 2,25 602 011 Semi-solid spray Cône 1/2 plein
2,50 602 012
3,00 602 013
3,50 602 014
4,00 602 015

4,50 602 016
5,00 602 017
5,50 602 018
6,00 602 019

6,50 602 020
7,00 602 021
7,50 602 022
8,50 602 023
9,50 602 024
2,50 602 213
3,00 602 214
3,50 602 215
4,50 602 217
5,00 602 218
5,50 602 219
6,00 602 220

6,50 602 221
7,00 602 222
7,50 602 223
8,50 602 224
9,50 602 225
12,00 602 227

19
14.2
Bezeichnung
Typ HO - 45° Hohlstrahl 2,25 602 600 Hollow spray Cône creux
2,50 602 601
3,00 602 602
3,50 602 603
4,00 602 604
4,50 602 605

5,00 602 606
5,50 602 607
6,00 602 608

6,50 602 609
7,00 602 610
7,50 602 611
8,50 602 612

9,50 602 613
10,50 602 614
12,00 602 615
Typ PLHO - 60° Hohlstrahl 2,25 602 650 Hollow spray Cône creux
2,50 602 651
3,00 602 652
3,50 602 653
4,00 602 654

4,50 602 655
5,00 602 656

5,50 602 657
6,00 602 658
6,50 602 659
7,00 602 660
7,50 602 661
8,50 602 662

9,50 602 663
10,50 602 664
12,00 602 665
14.2 Düsen Fabrikat Steinen Steinen manufacture Fabrication Steinen

Typ S - 45° Vollstrahl 1,50 612 013 Solid spray Cône plein
1,65 612 014
1,75 612 015
2,00 612 017
2,25 612 018

2,50 612 052
2,75 612 019
3,00 612 020
3,50 612 021
4,00 612 022
0,60 612 201
0,65 612 250
0,75 612 203
0,85 612 206

1,00 612 207
1,10 612 208
1,25 612 210
1,35 612 211

1,50 612 212
1,65 612 213
1,75 612 214
2,00 612 216

2,25 612 217
2,50 612 251
2,75 612 218
3,00 612 219
3,50 612 220
4,00 612 221

20
14.2-14.5
Bezeichnung
Typ SS - 45° Halbvollstrahl 4,50 612 023 Semi-solid spray Cône 1/2 creux
5,00 612 024
5,50 612 025
6,00 612 026
6,50 612 027
7,00 612 028

7,50 612 029
8,00 612 030
9,00 612 032
10,00 612 034
11,00 612 035
12,00 612 036
Typ SS - 60° Halbvollstrahl 4,50 612 222 Semi-solid spray Cône 1/2 creux
5,00 612 223
5,50 612 224
6,00 612 225
6,50 612 226
7,00 612 227

7,50 612 228
8,00 612 229
9,00 612 231
10,00 612 233
11,00 612 234
12,00 612 235
0,60 612 401
0,75 612 403
0,85 612 405
1,00 612 407

1,10 612 408
1,25 612 410
1,35 612 411
1,50 612 412

1,65 612 413
1,75 612 414
2,00 612 416
Düsen Fabrikat Fluidics Fluidics manufacture Fabrication Fluidics
14.3 Typ H- 45° Hohlstrahl 2,50 602 685 Hollow spray Cône creux
2,75 602 686
3,0 602 687
3,5 602 688
4,0 602 689
4,5 602 690
5,0 602 692
5,5 602 691
Düsen Fabrikat Fluidics Fluidics manufacture Fabrication Fluidics
14.4 Typ HF- 60° Hohlstrahl 1,00 602 728 Hollow spray Cône creux
14.5 Typ H- 60° Hohlstrahl 1,10 602 729 Hollow spray Cône creux
1,25 602 730
1,35 602 731
1,50 602 732
1,65 602 733
1,75 602 734
2,00 602 735

2,25 602 736
2,50 602 737
2,75 602 738
3,00 602 739
3,50 602 760

4,00 602 761
4,50 602 762
5,00 602 763
5,50 602 764
6,00 602 765

21
14.11
Bezeichnung
14.10 Regeldüsen Regulating nozzles Gicleur à retour

14.11 Typ K3 S2 50°V kg/h
15 602 800
20 602 801
25 602 802
30 602 803
35 602 804
40 602 805
45 602 806
50 602 807
55 602 808
60 602 809
65 602 810
70 602 811
Siebfilter für Regeldüse (ohne Bild) Screen filter for regulating nozzle Filtre à tamis pour gicleur à retour
14.14 110 Maschen bis 70 kg/h, für Typ K3 602 544 (without picture) (sans photo)
14.15 O-Ring 4 x 1,5 aus Viton für Regeldüse K3 445 134 O Ring 4 x 1.5 made of Viton for Joint torique en viton pour gicleur
regulating nozzles

22
15.1 15.2–15.5 15.7 15.8 15.11
15.12 15.13 15.14 15.16 15.17 15.19 15.20
Bezeichnung
15. Feuerungsautomaten Burner controls Coffret de sécurité

Preise für Sonderspannungen auf Anfrage Price for special voltages Prix pour tensions spéciales
on request sur demande
Feuerungsautomat, 220-240V 50-60 Hz Burner control Coffret de sécurité

15.1 LOA 24.171 600 206
LMO 24.011 B2 600 249
LOA 25.173 600 208
LMO 44.255 C2 600 247
15.2 LAL 2.14 600 175

LAL 2.25 600 177
LAL 2.65 600 178
LAL 3.25 600 179
15.3 LFL 1.122 600 161

LFL 1.333 600 255
LFL 1.335 600 172
LFL 1.622 600 165
LFL 1.635 600 174
15.4 LOK 16.250 600 192

LOK 16.650 600 220
15.5 LGK 16.122 600 200

LGK 16.333 600 257
LGK 16.622 600 201
LGK 16.335 600 197
15.6 Steckerkabel AGM19 für QRA55 (ohne Bild) 600 579 Cable (without picture) Câble (sans photo)
15.7 Klemmensockel LOA 600 527 Terminal socket Bornier socle

15.8 LFL 600 516
LAL 600 517
LOK 600 521
LGK 600 523
15.9 Stopfbuchsenhalter AGK65 (ohne Bild) 600 529 Gland support (without picture) Support (sans photo)
15.10 Zwischensockel LOA (ohne Bild) 141 213 1207 7 Intermediate peace Console intermédiaire
(without picture) (sans photo)
Flammenfühler Flame feeler Cellule de détection

15.11 QRB1A (Kabel 800 mm) 111 964 1201 2
15.12 RAR9 210 153 1201 2
15.13 QRA2 (UV-Zelle) 600 501 (UV-Cell) (Cellule UV)
15.14 QRA55 (UV-Zelle) 600 660 (UV-Cell) (Cellule UV)
15.15 UV-Fühler für QRA55 (ohne Bild) 600 587 UV sensor (without picture) Sonde UV (sans photo)
Bride Holder Bride
15.16 für QRB1 600 566
15.17 für QRA und RAR 600 601
Flansch Flange Bride
15.18 für QRB1 (ohne Bild) 241 050 0103 2 (without picture) (sans photo)
15.19 für QRA und RAR 600 602
15.20 Anschlusskabel für QRA 122 464 1001 7 Connect. cable Câble raccordement

23
16.1 16.3
Bezeichnung
16. Zündgerät Ignition unit Transformateur

230V/50-60 Hz d’allumage
Zündgerät, W-ZG 02 Ignition unit Transformateur d’allumage
16.1 W-ZG 02 230V 110 VA 1+3 603 203
W-ZG 02 110V 110 VA 1+3 603 204
16.2 Zündkabel (ohne Bild) Ignition cables (without picture) Câbles d’allumage (sans photo)
1000 mm, Silikon, schwarz 603 156
16.3 Steckerkupplung 716 501 Plug coupling Fiche embrochable
16.4 Dichtring 44 x 18 x 4 für Zündgerät 211 163 1102 7 Sealing ring for Ignition unit Joint passe-câble pour allumeur

24
17.1 17.3 17.4 17.5 17.6 17.7 17.8, 17.9 17.10
Bezeichnung
17. Einbauklemmleisten – auf Anfrage Terminals Commande incor-

Einbauschaltteile incorporation box – porée et bornier
switching equipment de raccordement
Abdeckhaube Cover Capot
17.1 L, M (Z) 1 211 153 1708 2
G, GL 1 251 103 1708 2
L, M, G, GL, RGL Einbauklemmleiste 3 211 353 1704 2 Inbuild terminal rail commande incorporée
L, M (mit LAL) Einbauschaltteil 3 211 363 2201 2 Inbuilt swithcgear commande incorporée
G, GL (mit LFL) Einbauschaltteil 3 211 363 2201 2 Inbuilt swithcgear commande incorporée
RL 3 211 353 1703 2
17.2 Klemmleiste (ohne Bild) Terminal strip (without picture) Bornier (sans photo)
22 polig, L 1 211 153 2204 2
L 3 211 363 2208 2
12 polig, RL, G, GL, RGL 3 211 373 1703 2
25 polig, RL, G, GL, RGL 3 211 373 1705 2
33 polig, RL, M, G, GL, RGL 3 211 373 1702 2
28 polig, M (Z), G, GL 1 251 103 1703 2
G, GL, RGL 3 251 303 1702 2
30 polig, M (Z) 1 212 153 2204 2
32 polig, M (Z) 3 212 364 2209 2
17.3 Einbauklemmleiste Inbuilt terminal rail Bornier incorporé

G Ausf. ZD+ZMD 1 251 104 1704 2
GL Ausf. ZM 1 255 107 1703 2
G Ausf. ZD/ ZMD 3 251 304 1704 2
GL Ausf. ZD 3 211 364 1706 2
17.4 Erdungsschiene 1+3 211 153 2205 2 Earth bar Barre de terre
Leistungsschütz Contactor Contacteur

220/240V, 50-60 HzTyp Type Type
17.5 A12-30-10 702 755
17.6 A 9-30-10 702 751
17.7 Überstromrelais auf Anfrage Overload relay Relais thermique

Bei Bestellung Brennertype, When ordering indicate burner Préciser le type du brûleur, le
Motortype, Stromstärke und type, motor type, amperage moteur, intensité et tension.
Spannung angeben. and voltage.
Schalter Switch Interrupteur

17.8 GS 1302 - Ziffer 2 1+3 700 916
GS1302CBN-AS-B5 1-2 1+3 700 918
17.9 GS 1300 - Ziffer 1 1+3 700 914
GS 1312 - B5 1-2 gelb 1T 700 932
17.10 Temperaturregler ROB 1+3 691 120 Temperature regulator ROB Régulateur de temperature ROB
220-240 V, 50-60 Hz
17.11 Zeitzähler Typ 604, 10-2 (ohne Bild) Hours counter (without picture) Compteur horaire (sans photo)
230V 50 Hz 1+3 709 586
230V 60 Hz 1+3 709 587

25
18.1-18.4 18.5 18.6 18.7 18.8 18.9, 18.10 18.11, 18.12 18.13
Bezeichnung
18. Ölvorwärmer EV2A Oil preheater EV2A Réchauffeurs EV2A

und EV2B and EV2B et EV2B
Bei Bestellung Spannung angeben When ordering indicate voltage à la commande indiquer
la tension
Ölvorwärmer komplett, Oil preheater complete, Réchauffeur complète,

jedoch ohne Ölabgang however without oil outlet sans départ fuel
Typ Temperaturbereich Type Temperature range Type Plage
18.1 EV2A/01 bis 160°C 220-230V 511 210 0101 0
18.2 EV2B/01 bis160°C 380/400V 511 220 0101 0

Ölvorwärmer in Schiffsausführung Oil preheater marine execution Réchauffeur exécution marine
18.3 Typ Type Type
EV2A/01 220-230V 511 215 0101 0
EV2A/01 240V 511 215 3101 0
EV2A/01 254V 511 215 4101 0
EV2A/01 380-400V 511 215 6101 0
18.4 EV2B/01 380/400V 511 225 0101 0

EV2B/01 240/415V 511 225 3101 0
EV2B/01 254/440V 511 225 4101 0
Temperaturregler Temperature regulator Régulateur de température

18.5 EMF-f-23 691 119
Temperaturschalter für Brennerfreigabe Temperature switch for burner Thermostat pour marche brûleur
18.6 55° F 55-17 690 166 release
Rondelle
18.7 Scheibe 533 001 006 7 Disk
Temperaturbegrenzer Temperature limiter Limiteur de température

18.8 EMf-5 u 691 115
18.9 Haube Cover Capot

EV2A/01 051 121 0011 7
EV2B/01 051 122 0003 2
18.20 Haube für Vorw. in Schiffsausführung Cover for preheater in Capot pour réchauffeur
EV2A/01 051 121 0003 2 marine execution en exécution marine
EV2B/01 051 122 0002 2
18.11 Heizeinsätze Heating elements Cartouches chauffantes

230V, 2200W EV2A/01 051 121 0113 2
240V, 2200W EV2A/01 051 121 0114 2

254V, 2200W EV2A/01 051 122 0102 2
290V, 2200W EV2A/01 051 122 0103 2
190V, 2200W EV2A/01 051 121 0111 2
440V, 2200W EV2A/01 051 121 0104 2
230V, 1500W EV2B 051 123 0102 2
240V, 1500W EV2B 051 122 0107 2
254V, 1500W EV2B 051 122 0105 2

290V, 1500W EV2B 051 122 0104 2
18.12 Heizeinsätze für Schiffsausführung Heating elements Eléments chauffants

EV2A/01 for ship’s execution pour exécution marine
230V/2200W 051 121 0120 2
240V/2200W 051 121 0122 2
254V/2200W 051 121 0119 2
EV2B
230V/1500W 051 122 0108 2
240V/1500W 051 122 0110 2
254V/1500W 051 122 0109 2
18.13 Ölwendel komplett Oil coil complete Serpentin complète

EV2A/01 051 121 0123 2
EV2B/01 051 122 0111 2

26
Notizen/Notes/Notes

Max Weishaupt GmbH
D-88475 Schwendi
SPARE PARTS FOR WEISHAUPT Weishaupt in Ihrer Nähe?
Adressen, Telefonnummern usw.
finden sie unter www.weishaupt.de
Druck-Nr. 83022301, Mai 2012

Änderungen aller Art vorbehalten.
Nachdruck verboten.
Produkt Beschreibung Leistung
W-Brenner Die millionenfach bewährte Kompakt-Baureihe: Sparsam, bis 570 kW

zuverlässig, vollautomatisch. Öl-, Gas- und Zweistoff-
brenner für Ein- und Mehrfamilienhäuser sowie Gewerbe-
betriebe. Als purflam Brenner wird Öl nahezu rußfrei
verbrannt und NOx-Emissionen nachhaltig reduziert.
monarch® und Der legendäre Industriebrenner: Bewährt, langlebig, bis 10.900 kW
Industriebrenner übersichtlich. Öl-, Gas- und Zweistoffbrenner für
zentrale Wärmeversorgungsanlagen.
multiflam® Brenner Innovative Weishaupt-Technologie für Großbrenner: bis 12.000 kW

Minimale Emissionswerte besonders bei Leistungen
über ein Megawatt. Öl-, Gas- und Zweistoffbrenner mit
patentierter Brennstoffaufteilung.
WK-Industriebrenner Kraftpakete im Baukastensystem: Anpassungsfähig, bis 18.000 kW

robust, leistungsstark. Öl-, Gas- und Zweistoffbrenner
für Industrieanlagen.
Thermo Unit Die Heizsysteme Thermo Unit aus Guss oder Stahl: bis 55 kW
Modern, wirtschaftlich, zuverlässig. Für die umwelt-
schonende Beheizung von Ein- und Mehrfamilienhäusern.
Brennstoff: Wahlweise Gas oder Öl.
Thermo Condens Die innovativen Gas-Brennwertgeräte mit SCOT-System: bis 1.200 kW

Effizient, schadstoffarm, vielseitig. Ideal für Wohnungen,
Ein- und Mehrfamilienhäuser. Und für den großen
Wärmebedarf als bodenstehende Gas-Brennwertkessel
mit bis zu 1200 kW Leistung (Kaskade).
Wärmepumpen Das Wärmepumpenprogramm bietet Lösungen für die bis 130 kW
Nutzung von Wärme aus der Luft, der Erde oder dem
Grundwasser. Die Systeme sind geeignet für Sanierung
oder Neubau.
Solar-Systeme Gratisenergie von der Sonne: Perfekt abgestimmte

Komponenten, innovativ, bewährt. Formschöne
Flachdachkollektoren zur Heizungsunterstützung und
Trinkwassererwärmung.
Wassererwärmer / Das attraktive Programm zur Trinkwassererwärmung

Energiespeicher umfasst klassische Wassererwärmer, die über ein Heiz-
system versorgt werden und Energiespeicher, die über
Solarsysteme gespeist werden können.
MSR-Technik / Vom Schaltschrank bis zur Komplettsteuerung von

Gebäudeautomation Gebäudetechnik – bei Weishaupt finden Sie das
gesamte Spektrum moderner MSR Technik.
Zukunftsorientiert, wirtschaftlich und flexibel.
D00799#A.2
FUEL OIL DE-AERATOR
Fuel oil de-aerator

DATA SHEET
Tag No(s):
Type:
• Combined ball valve set 12 13
• Full bore, fire safe 11
Size: 10
8
• DN 25 6
7 5
Pressure range:
• Pressure nominal: PN 40 4 Antistatic
device
Connection type:
• Connection type: Flange according to
DIN 9
Application:
• For oil flow
1 2
Material: 3
• 1. Body: ASTM- A-105

• 2. End Connection: ASTM-A105 Dimension:
• 3. Ball: A182-F304 • L: 160
• 4. Thrust washer: P.T.F.E. • L1: 20
• 5. O-ring: FKM (Viton) • H: 190
• 6. Packing gland: Carbon steel • W: 46
• 7. O-ring: FKM (Viton) • O.D.: Ø 110
• 8. Stem seat: P.T.F.E. Vergine • I.D.: Ø 25
• 9. Ball seat: Metal core P.T.F.E. • P.D.C.: Ø 85
• 10. 90º stop: AISI 430 • t: 6
• 11. Spring washer: Carbon steel • N x M: 4 x M12
• 12. Nut: Carbon steel
• 13. Stem: A182-F316 L1
Technical data:
• Working temperature, min.: - 20ºC
• Working temperature, max.: 160°
• Weight: 6 kg
H
NxM I.D.
P.D.C
O.D.
L W
Type No.: 6010

Version: B.1 Combined ball valve set , DN 25, PN40 6000000141

RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
Pressure Hoses Table of Content
1 General ....................................................................................................................................................1
2 Application Possibilities ..........................................................................................................................2
2.1 Bending movement along the axis ........................................................................................................2
2.2 Lifting Movements ................................................................................................................................3
2.3 Instructions on Application and Installation..........................................................................................6
3 Specifications and technical data.............................................................................................................7
3.1 Oil hoses in oil supply installations (flow and return)...........................................................................7
3.2 Pressure hoses (between pump and nozzle) ..........................................................................................7
4 Part numbers ............................................................................................................................................9
1 General
The oil and pressure hoses are corrugated high grade steel with a high grade steel
woven wire sleeve cover.
With adherence to the following application rules, the oil hoses and pressure hoses
are extremely well qualified for residual oil applications. The stability, against
chemical and temperature effects of fuel oil, is designed for long term service.
The TRD 411 , 7/81 edition recommends metal hoses for residual oil plants.
The oil and pressure hoses should be protected from external mechanical damage.
When fitting, care must be taken to ensure the hose is not twisted. It must not during
fitting, or during later movement, receive torsional strain, it is important that both
hose ends and movement lie in one plane.
To guarantee a strain-free assembly, the hose should first be installed loosely at each
end, and then moved through the required hose movements two or three times so
that the hose can align without distortion and then tighten.
A spanner should be used to counter hold when tightening. Particular care should be
taken that hoses do not foul each other, or other equipment (burner, oil lines or
boiler).
During installation, sufficient curve radii and minimum hose lengths should be
allowed. For horizontal fitting the hose should, in most cases, be supported.
6-72 Language
UK 1/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
Figure 1_Example connect hoses without twisting
2 Application Possibilities
2.1 Bending movement along the axis
For angular movement ability, fit hose with sufficient tension free ends. Take into
consideration the required curve radius. Calculation of nominal length and
installation distances follows according to the formula for angular movement.
Figure 2_Example bending movement along the axis
Angular movement and hose curves must lie in one plane. Damaging torsional strain
is thus avoided.
Language UK
Language UK 6-73
Page/ 101
2/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
Figure 3_Example damaging torsional strain
By ensuring tension free hose ends, the angular movement can be enlarged
accordingly. The simultaneous extension of the nominal i.e. installed length should
be noted. It is not permitted to bend the hose excessively.
Figure 4_Example tension free hose ends
2.2 Lifting Movements
Fit an 180º curve with sufficient tension free hose ends The length is determined
according to the formula for an 180º. Determine the distance for fitting according to
the required curve radius.
6-74 Language
UK 3/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
Figure 5_Example distance for fitting according to the required curve radius.
By installing rigid pipes, avoid inadmissible bending directly behind the hose
connections. The minimum curve radius must not be exceeded.
Figure 6_Example inadmissible bending
Movement direction and hose axis must lie in on plane. Damaging torsional strain is
thus avoided.
Figure 7_ Example damaging torsional strain
Language UK
Language UK 6-75
Page/ 101
4/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
By installing rigid pipes, there is no varying curve strain and no very sharp bends
directly behind the hose connections.
Figure 8_ Example varying curve strain
Direction of movement and hose curve must lie in one plane. Damaging torsional
strain is thus avoided.
Figure 9_ Example direction of movement/hose curve in one plane
Arrange the hose in a loosely hanging curve so that even on extended movements it
does not come in contact with the wall, floor or other objects.
6-76 Language
UK 5/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
Figure 10_ Example loosely hanging curve
2.3 Instructions on Application and Installation
If external mechanical strain (e.g. pulling on the ground) cannot be avoided, the hose
should be protected from damage either by an external round wire coil or a guard
hose, according to the degree of strain.
Figure 11_ Example external round wire coil or a guard hose
During manual use, protect hose ends from undue curve strain with rigid pipes.
Language UK
Language UK 6-77
Page/ 101
6/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
Figure 12_ Example protect hose ends
3 Specifications and technical data
3.1 Oil hoses in oil supply installations (flow and return)
The hoses on residual oil plants should be designed for a working pressure of 10
bar(g) and a temperature (medium) of 150ºC.
With consideration of the temperature factor for high-grade steel, the following is
stipulated for these hoses:
Nominal pressure PN = 16 bar
Test pressure PP = 21 bar
Working pressure PB = 10 bar
Working temperature TB = 150ºC
Note: For the installation of oil hoses in flow and return (between pump and
rigid pipe installation), please observe the installation diagrams relating
to the product:
3.2 Pressure hoses (between pump and nozzle)
For this application, the pressure hose is designed for a working pressure of 30
bar(g)and 150ºC temperature.
With consideration of the temperature factor, the following is stipulated for these
hoses:
Nominal pressure PN = 64 bar
Test pressure PP = 82 bar
Working pressure PB = 30 bar
Working temperature TB = 150ºC
The minimum curve radius is dependent on the nominal clearance, the application,
the material, and on the type of manufacture.
6-78 Language
UK 7/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
The hose application on our products is agreed with the manufacturer using the
original equipment.
For free use i.e. installation, with regard to the fitting assembly instructions, the
following minimum radii must be maintained:
r = minimum curve
DN
radius
6 70
8 100
10 110
12 110
16 210
20 240
25 250
The length of hose chosen must be sufficiently long.

On each hose end, a Z section must be allowed for. This length must stay straight,
i.e. the curve radius may not start until after this straight section.
Figure 13_Z section
DN Z = length
6 80
8 85
10 90
12 100
16 125
20 130
25 135
After assembly is complete, the maintenance of minimum radii should be checked in

the most adverse position and if need be, a fixed mechanical stop must be made to
limit the movement.
Language UK
Language UK 6-79
Page/ 101
8/9
RTM_IN8511_01#A.2
PRESSURE HOSES
Pressure hoses
IN8511#01
4 Part numbers
Fuel oil hoses for burners with burner pump on the burner.
Item name Item number

65030100 Fuel oil hose L1 - L3 (L=1000 mm)
65032100 Fuel oil hose MS-RMS 7-10 (L=1000 mm)
65032130 Fuel oil hose MS-RMS 7-10 (L=1300 mm)
65033100 Fuel oil hose RMS 11 (L=1000 mm)
65033130 Fuel oil hose RMS 11 (L=1300 mm)
6-80 Language
UK 9/9
OM8200_02#B.1
BURNER SEQUENCE CONTROL
Burner sequence control
1 General
The burner sequence control unit “LOK 16...” is designed for control and supervision
of the oil burner in automatic operation. It is used for both two-stage and modulating
oil burners. A motor driven cam shaft activates electric switches which control burner
servo motor, burner motor, ignition and solenoid valves.
The control unit is connected to one or more photo cells, and in normal operation it
controls the flame supervision circuit.
Note: The burner sequence control unit has no function when the oil burner is
running in manual mode.
During start-up the control unit operates the oil burner in a pre-fixed start-up sequence.
In the event of fault during start-up or in normal operation, the fuel supply is instan-
taneously interrupted, and the sequence control unit stops the oil burner. The lock-out
indication which is placed in the viewing window of the control unit shows where the
fault has occurred in the sequence. Furthermore, the fault signal lamp and the reset
button are located in the window.
1.1 Features
The control unit is provided with the following additional features which result in a
higher level of safety:

OM8200_02#B.1
• The control unit features a self-checking flame supervision circuit. This circuit
initiates the required safety actions for any kind of failure on the flame detector.
• The signal delivered by the flame detector is handled dynamically. To achieve this,
the flame detector signal is converted into a sequence of control pulses and then
delivered to the flame relay circuit. The latter is designed so that the flame relay
can be energised only when a dynamic flame signal is present. If the pulse changes
due to a faulty detector or faulty detector leads, the relay is de-energised, and the
control unit will initiate a lock-out.
• If the mains voltage drops to a level at which the safe operation of the burner is no
longer ensured, burner operation is automatically interrupted. When the mains
voltage returns to the normal level, the control unit repeats the start-up sequence.
However, if the detector signals are only slightly above the minimum levels, such
mains voltage fluctuations may also cause the burner to initiate lock-out.
• Detector and extraneous light test is restarted immediately after the tolerated after-
burn time. This means that open or not fully closed fuel valves initiate a lock-out
immediately after this time has elapsed. The test ends only on completion of the
pre-purge time of the next burner start-up.
• The correct functioning of the flame supervision circuit is automatically checked
during each burner start-up sequence.
• The unit permits burner operation with or without post-purge.
• The control contacts for fuel release are checked for welding during the post-purge
time.
• A built-in unit fuse protects the control contacts against overload.
• Fan motors with a power consumption of up to 4 A can be directly connected.
• Separate control outputs for:
- Pre-ignition from start command, post-ignition until shortly before completion of
the burner start-up programme and short pre-ignition with post-ignition until the
end of the safety time.
- OPEN, CLOSE and MIN. of the air damper actuator.
• Checked air damper operation to ensure pre-purge with the nominal amount of air.
• Checked positions for CLOSED or MIN. (low flame position) at the start, OPEN
at the beginning and MIN. on completion of the pre-purge time. If the actuator
does not drive the air damper in the required position, the burner start-up sequence
will be interrupted.
• Two control outputs for release of the second output stage or the burner load con-
trol.
• When load control is enabled, the control outputs for the air damper actuator are
galvanically separated from the control section of the unit.
• Connection facilities for remote lock-out warning device, remote reset and remote
emergency shut-down.
• Possibility of air pressure supervision with functional test of air pressure monitor
at the start-up.
• Connection of different detectors. Detector and extraneous light tests are carried
out automatically during the burner off periods and the pre-purge time.
2 Connection diagrams
Figure 1 and Figure 2 show the connection diagrams for the control unit. Table 1
describes the abbreviations in Figure 1 and Figure 2.
Warning: The burner sequence control unit is a safety device. It is therefore not
permitted to open, interfere with or modify the unit.

OM8200_02#B.1
Attention: Check the wiring before the control unit is set into operation.
Connection diagram of the burner sequence control unit
Figure 1 om8200_02_lok_01x0058040en.wmf

OM8200_02#B.1
Connection diagram of the burner sequence control unit

OM8200_02#B.1
Description of the abbreviations in Figure 1 and Figure 2

Change-over limit switch for OPEN position of the NTC NTC-resistor
a
air damper R Control thermostat or pressurestat
Remote lock-out warning devise (alarm) RAR Selenium photo cell detector
AR Main relay (load relay) with contacts ar... RV Continuously adjustable fuel valve
AS Unit fuse S Fuse
Wire link (on the plug section of the control unit) SA Air damper actuator
B
SB Safety limiter (temperature, pressure, etc.)
BR Lock-out relay with contacts br... SM Synchronous motor of the sequence mechanism
BV Fuel valve In the actuator: auxiliary change-over switch for the
EK... Lock-out reset button v release of fuel according to air damper position
FR Flame relay with contacts fr...
FS Flame signal amplifier V Flame signal amplifier
H Mains isolator W Limit thermostat or pressurestat
L Fault signal lamp In the actuator: limit switch for the CLOSED position
z
LK Air damper of the air damper
LP Air pressure monitor Z Ignition transformer
LR Load controller A Start-up
Auxiliary switch for the MIN. position of the air B Operating position
m
damper C Controlled shut-down
M... Fan or burner motor D End of control programme
Table 1
2.1 Comments on the connection diagrams
The terminal numbers found in this section refer to the connection diagrams in Fig-
ure 1 and Figure 2.
• Phase and neutral may not be reversed.

• Max. permissible input current: 5 A continuously, peaks of max. 20 A.
• Safety limit thermostats (manual reset, e.g. STB) are normally connected in the
line.
• When button EK2 is connected to terminal 3, only remote reset is possible. When
it is connected to terminal 1, emergency shut-down is also possible.
• Required switching capacity:
- of switching devices between terminal 12 and LP is 1 A.
- of air pressure monitor LP is 5 A.
- of switching devices between terminals 4 and 5 is 1 A.
• Control contacts of other devices in the burner installation must be connected in
series as follows:
- To terminal 12: Contacts which must be closed only during start-up (otherwise no
start).
- To terminal 4 or 5: Contacts which must be closed from start-up to the controlled
shutdown (otherwise no start or controlled shut-down).
- To terminal 14: Contacts which must be closed at the latest at the beginning of the
pre-ignition time and which must remain closed until the controlled shut-down
occurs (otherwise lock-out). This is valid for both a long and a short pre-ignition.

OM8200_02#B.1
• Maximum loading of the control terminals 3, 6, 7, 9, 10, 11, 15 to 20: 4 A each

terminal, total 5 A max. (e.g. starting current of M1 or M2).
• Z connected to terminal 15 (long pre-ignition t3’ and post-ignition t3n). Post-ig-
nition is only permitted if the burner has an oil throughput of no more than 30 kg/
h.
• In case of burners without air damper or with an air damper not controlled and
supervised by the control unit, terminal 8 must be connected to terminal 6.
• Wire link B:
- Connected: The control unit go into lock-out if flame failure occurs during oper-
ation.
3 Mode of operation
The diagrams in Figure 1 and Figure 2 show the connection circuit and the control
programme of the permissible or required input signals to the control section of the
control unit and the flame supervision circuit. If the required input signals are not
present, the control unit interrupts the start-up sequence at the points marked in Fig-
ure 1 by the symbols (A, B, C and D) and initiates lock-out where this is required by
the safety regulations. The symbols used are identical to those at the lock-out indicator
of the control unit.
A:
- Start command (e.g. given by the pressure switch R of the installation).
A-B:
- Start-up sequence.
B-C:
- Burner operation (according to the control commands of the load controller LR).
C:
- Controlled shut-down through R.
C-D:
- Sequence mechanism runs into start position A, post-purge.
Note: During burner off periods the flame supervision circuit is under voltage,
in order to carry out the detector and extraneous light test.
3.1 Prerequisites for burner start-up
• Control unit is reset and in start position (terminals 11 and 12 under voltage).
• Air damper closed. The limit switch “z” for the CLOSED position must supply
voltage from terminal 11 to terminal 8.
• All check contacts between terminals 12 and 5 (limit thermostat, pressure switch,
etc.) must be closed.

OM8200_02#B.1
3.2 Start-up sequence
3.2.1 A: start
Step A: When “R” closes, the control unit sequence switch starts running. At the
same time the fan motor receives voltage via terminal 6 (only pre-purge).
After "t7" has elapsed, the fan motor or the flue gas fan also receives voltage
via terminal 7 (pre-purge and post-purge).
Step B: On completion of "t16" the control command to open the air damper is given
via terminal 9. During the running time of the motor, the sequence switch
does not operate as terminal 8 is not under voltage during that period of time.
The sequence switch starts again only after the air damper is fully open, and
limit switch “a” has changed over to feed voltage to terminal 8.
t1: pre-purge time with air damper fully open:
Step A: Shortly after the pre-purge time begins, the air pressure monitor “LP” must
change over, thus interrupting the current path between terminal 4 and ter-
minal 13. Otherwise the control unit initiates lock-out (start of air pressure
check). At the same time, terminal 14 must be under voltage as the current
path is used to power the ignition transformer and the fuel valves.
t3’: long pre-ignition time:
Step A: For long pre-ignition time the ignition transformer must be connected to
terminal 15). If there is no “LP”, the ignition transformer receives voltage
already with the start command.
Step B: After completion of the pre-purge time the control unit drives the air damper
via terminal 10 into the low flame position which is determined by the
change over point of auxiliary switch “m”. During the positioning time the
sequence switch stops until terminal 8 receives voltage via “m”.
t3: short pre-ignition time:
Step A: Short pre-ignition time is possible provided that the fuel release is connected
via terminal 18.
t2: safety time:
Step A: No later than at the end of the safety time, a flame signal must be present at
the input of the flame signal amplifier. Otherwise the control unit initiates
lock-out.
t3n: post-ignition time:
Step A: Post-ignition time, provided the ignition transformer is connected to termi-
nal 15.
t4: interval:
Step A: Interval until the fuel valve at terminal 19 is enabled.
t5: interval:
Step A: After "t5" has elapsed, terminal 20 receives voltage. At the same time control
outputs 9 to 11 and the input 8 are galvanically separated from the control
section of the control unit. This causes that the latter is protected against
reverse voltages from the load control circuit.
Step B: The start-up sequence of the control unit ends with the enabling of the load
controller “LR” at terminal 20. The sequence switch switches itself auto-
matically off, either immediately or after a few so-called idle steps, i.e. steps
without change of the contact positions - depending on the time variant used.

OM8200_02#B.1
3.2.2 B: operating position of the burner

B-C: burner operation
Step A: During burner operation the load controller drives the air damper into nom-
inal load or low flame position, depending on the demand of heat. The release
of the nominal load is carried out by the auxiliary switch “v” in the air damper
actuator.
3.2.3 C: controlled shut-down
Step A: During controlled shut-down the fuel valves are closed immediately. At the
same time the sequence switch starts again.
t6: post-purge time:
Step A: Shortly after the start of the post-purge time terminal 10 receives voltage so
that the air damper is driven into the MIN. position.
Step B: The completion closing of the damper starts only shortly before the post-
purge time has elapsed. This is initiated by the control signal at terminal 11,
which also remains under voltage during the following burner-off period.
3.2.4 D - A: end of control program
Step A: When the sequence switch has reset the control contacts to their start position
on completion of “t6" thereby switched itself off, the detector and flame
simulation test is started again. However, during the burner-off period, lock-
out can only occur if the faulty flame signal lasts a few seconds. Hence, short
ignition pulses of the UV detector caused by cosmic radiation do not initiate
lock-out.
3.3 Lock-out indication
In the event of fault conditions, the fuel supply is always interrupted. At the same time,
the sequence switch stops and with it the lock-out indicator. An illustration of the lock-
out indicator is shown in Figure 3. The symbol above the reading mark of the indicator
gives the type of disturbances:
Illustration of the lock-out indicator

OM8200_02#B.1
◄:
- No start, because one of the contacts is not closed or lock-out during or after com-
pletion of the control programme due to extraneous light (e.g. flame not extin-
guished, leaking fuel valves, faulty in flame supervision circuit, etc.).
▲:
- Abortion of the start-up sequence because the OPEN signal has not been delivered
to terminal 8 by limit switch “a”. Terminal 6, 7, 14 and 15 remain under voltage
until the fault is corrected.
P:
- Lock-out because the air pressure signal has not been received at the start of the
air pressure check. Every air pressure failure after this time leads to a lock-out,
too.
■:
- Lock-out due to a fault in the flame supervision circuit.

▼:
- Abortion of start-up sequence because the position signal for the low flame position
has not been delivered to terminal 8 by auxiliary switch “m”. Terminals 6, 7, 14
and 15 remain under voltage until the fault has been corrected.
1:
- Lock-out because no flame signal is present after completion of the safety time.
l:
- Lock-out because the flame signal has been lost during burner operation, or air
pressure failure has occurred.
The control unit can be reset immediately after a lock-out has occurred. After resetting,
after correction of a fault which resulted in a controlled shut-down, or after a mains
failure, the sequence switch always returns to its start position. This means that only
terminals 7, 9, 10 and 11 receive voltage in accordance with the control programme.
At this time the control unit begins with a new burner start-up.
Note: Do not press the lock-out reset button for more than 10 seconds.
4 Connection examples
This section shows connection examples for the control unit. The actual connection of
the control unit to a specified burner plant can be found in the chapter containing the
electric diagrams. Figure 4 shows the connection of the control unit to a two-stage oil
burner. The air damper is closed during burner off periods.

OM8200_02#B.1
Connection example for a two-stage oil burner
Figure 4 om8200_02_lal_04x0058020en.wmf
Figure 5 shows the connection of the control unit to a modulating oil burner. The air
damper is closed during burner off periods.

OM8200_02#B.1
Connection example for a modulating oil burner
Figure 5 om8200_02_lal_05x0058030en.wmf
Figure 6 shows the wiring required for operation without air pressure supervision. If
an auxiliary contact of the fan contactor is included in the circuit as shown in Fig-
ure 6, ignition and fuel release are only possible when the contact is closed.
Connection example for operation without air pressure supervision

OM8200_02#B.1
5 Sequence diagram
Switching times are given in seconds. In the sequence of the burner start-up the times
are valid for a frequency of 50 Hz. The times are reduced by approximately 20% for
burner plants with a frequency of 60 Hz. Figure 7 shows a sequence diagram for the
control unit and Table 2 a description of the switching times.
Sequence diagram

OM8200_02#B.1
Description of switching times

Time Time Time
No. Description
LOK16.140 LOK16.250 LOK16.650
t1 Pre-pure time with open air damper 10 22.5 22.5
t2 Safety time 4 5 5
t3 Pre-ignition time, short (ignition transformer on terminal 16) 2 2.5 2.5
t3’ Pre-ignition time, long (ignition transformer on terminal 15) From start* From start* From start*
t3n Post-ignition time (ignition transformer on terminal 15) 10 10 15
t4 Interval between voltage at terminals 18 - 19, BV1 - BV2 8 7.5 7.5
t5 Interval between voltage at terminals 19 - 20, BV2-load controller 4 7.5 7.5
t6 Post-purge time (identical with t13) 10 15 15
t7 Switch-on delay for fan motor M2 2 2.5 2.5
t8 Duration of start-up sequence (without t11 and t12) 30 47.5 47.5
t10 Interval from start-up to beginning of air pressure check 6 10 10
t11 Running time of air damper into OPEN position Optional Optional Optional
t12 Running time of air damper into low flame position (MIN.) Optional Optional Optional
t13 Permissible after-burn time 10 15 15
t16 Interval until OPEN command for the air damper 4 5 5
t20 Interval until self-shutdown of the switch 35
* With air pressure monitor: with the presence of the air pressure signal.
Table 2

OM8200_04#B.1
FLAME SAFEGUARD
Flame safeguard
1 Description
The flame safeguard LAE10 is designed for the supervision of the oil flame in con-
nection with a photo cell when the burner is running in manual mode. It comprises a
power section, a flame signal amplifier, a flame relay and a combined flame-present
indicator lamp and reset button.
Note: The flame safeguard has no function when the burner is running in auto-
matic mode.
In the event of non-ignition of the flame or loss of flame during burner operation, the
supply of fuel is always interrupted instantaneously. The unit can be reset by pushing
the reset button on the flame safeguard. Any flame signal - in normal operation or a
faulty flame signal - is signalled by the indicator lamp. The switching function needed
to enter the flame signal to the control circuit of the burner system is provided by the
flame relay “FR” of the flame safeguard. Figure 1 shows an illustration of the con-
nection diagram for the flame safeguard. The connection of the terminals can be found
in the chapter containing the electric diagrams.
Connection diagram
Figure 1 om8200_04_lae10x0058160en.wmf
The current generated in the path will normally be in the range 10-20 microamperes.
Below 10 microamperes the control box may become unstable, and below 8 micro-
ampere the control box will not recognise the signal as sufficient. Typically low current
are caused by a normal wear/aging of the RAR photocell.

OM8630_01#C.1
PHOTO CELL
Photo cell
1 Description
The RAR detector is used for supervision of yellow burning oil flames. If the photo
cell detects a missing flame, the burner stops instantaneously. It is not possible to start
the burner before the control system has been reset.
With this type of detector, the radiation of the oil flame in the visible band of the light
spectrum is used to generate a flame signal. The light-sensitive element is a photo cell.
When illuminated, it generates DC voltage which causes a current to flow to the input
of the flame signal amplifier in the control unit. Hence, the photo cell is an active
detector.
The cell is insensitive to infrared radiation. If the burner is started with an illuminated
combustion chamber, the start sequence of the burner breaks, and an alarm for flame
failure will be indicated.
The number of photo cells for automatic operation and emergency operation depend
on the classification society.
1.1 Commissioning
The intensity of the light radiation can be checked by measuring the detector current
by means of a DC ampere meter (internal resistance 5000 ohm). Figure 1 shows the
measuring circuit.
Note: If the wiring of the photo cell is connected incorrectly, it is not possible to
start the oil burner.
Measuring circuit
-22 24 LAL2.../LAL3...
22 24 LOK16...
9 10 LAE10...
M - + 14 13 LAE1...
A
-
RAR
+
Figure 1 photcircax0460930en.wmf

OM5560_13#B.1
ELECTRIC OIL PRE-HEATER
Electric oil pre-heater
1 Electric oil pre-heater

The electric oil pre-heater, illustrated in Figure 1, is placed on the burner housing and
is used for preheating the fuel oil.
The pre-heater is provided with electric heating elements. The produced heat is con-
ducted to the oil pipes on both sides of the elements via a copper plate. No liquid
medium is used for the heat transfer.
The pre-heater has a large heat exchange surface and contains a relatively small amount
of fuel oil. Therefore, it is possible to heat the fuel oil to the necessary atomizing
temperature very quickly. The quick heat transfer equalizes the temperatures and
therefore prevents local overheating, i.e. the fuel oil does not carbonize.
Fluctuations in oil temperature are minimised by thermostat sensors placed directly on

the heating plate.
The pre-heater can handle HFO with viscosity up to 380 cSt. at 50°C. The maximum
obtainable oil temperature is approx. 150°C. Please note that this temperature depends
on the throughput and the supply temperature of the fuel oil.
Illustration of the electric oil pre-heater
Figure 1 om5560_13_evheatx0055270en.wmf
1.1 Setting the pre-heater set point
An adjustment of the temperature set point of the pre-heater unit is simple, as only the
regulating thermostat has to be adjusted. Please note that the thermostat has to be set
10 - 15°C higher than the desired preheating temperature on account of the heat loss
between the oil pre-heater and the nozzle head.

OM5560_13#B.1
ELECTRIC OIL PRE-HEATER
1.2 Safety thermostats
The pre-heater is equipped with safety thermostats with a fixed temperature setting
which is higher than the maximum temperature of the regulating thermostat. If the oil
temperature becomes too high, the safety thermostats shuts down the burner and ac-
tuates an alarm, e.g. if the regulating thermostat has failed.
A signal lamp on the control panel “High oil temperature” indicates this situation.
In case of failure the fault has to be repaired. Before the pre-heater can be taken into
service again, the reset button on the safety thermostat must be activated.
1.3 Release thermostat
The release thermostat or “low temperature thermostat” contacts close and allow the
burner to start when the fixed minimum temperature setting is reached. The pre-purge
then commences. When starting from cold condition, the release thermostat will op-
erate several times before the conducted heat will enable the release thermostat to
respond.
A signal lamp on the control panel “Low oil temperature” indicates that the release
thermostat has not yet reached the fixed temperature.
If the oil temperature becomes too low during operation, e.g. if the regulating thermo-
stat fails to respond or if the heater elements are faulty, the release thermostat shuts
down the burner and actuates an alarm.
1.4 Test of the functions
The function of the safety thermostat can be tested by short-circuiting the terminals to
the regulating thermostat. The oil temperature will rise and when the limit of the safety
thermostat is reached, the burner shuts down.
The function of the release thermostat can be tested by removing the fuses for the pre-
heater. When the oil temperature drops below the limit of the release thermostat, the
burner shuts down.

OM9280_02#G.1
HANDLING FUEL OIL
Handling fuel oil
1 Precautions to be taken with fuel oil

Marine gas oil MGO and marine diesel oil MDO are distillates of crude oil. Heavy fuel
HFO is the residual of the crude oil after the removal of distillates.
Liquid oil is very difficult to ignite in bulk and not capable of spontaneous combustion.
However both the distillates and the residuals are capable of forming vapours which
are explosive when mixed with air. As the vapours can be heavier that air, it tends to
accumulate in low levels such as bilges and bottoms of tanks where it may remain
undiscovered until ignited by a naked light or spark. It is always present in a partly
filled oil tank or in a tank which has contained fuel oil and is given off through the
vents from tanks in the process of being filled.
If allowed to continue, a leak in any part of the oil burning system may result in an
accumulation of this explosive vapour.
Ignition of the vapour can be caused by an open light, electric spark, smoking, spark
caused by striking metal, heat from the filament of a broken electric lamp, sparks from
funnel or can be communicated from galley or fires under boilers.
Note: An oil fire cannot be extinguished by water, but may be extinguished by

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

prevention of accident than adherence to any set of rules that may be pre-described.

OM9280_02#G.1
HANDLING FUEL OIL
However, the following detailed precautions should be rigidly enforced:
• When oil is being received, no naked light or electric apparatus liable to spark
should be permitted within 20 meters of the oil hose, tank or compartment, con-
taining the tank or the vent from the tank, except when special arrangements are
carried out.
• While receiving fuel oil, the storage tank must be closely watched for leaks, and
care must be taken that all outlets from the tank, except the vents, are closed.
• No naked lights or electric apparatus liable to spark should be permitted at any
time in a compartment containing a fuel oil tank. Electric lamps used in such com-
partments should have a wire protector around the bulb or be of a type that will
ensure the breaking of a circuit through the lamp in the event of the lamp being
broken.
• No one should be allowed to enter a fuel oil tank until it has been gas-freed, and
any person then entering the tank must have a properly tended life-line around his
body in order to be hauled out if overcome by gas.
• Electric fuses and switches, unless the enclosed type, should not be permitted in
compartments containing fuel oil pumps or piping.
• Care must be taken that the wire-gauze protectors in vent pipes from fuel oil tanks
are intact at all times.
• Dampers, where fitted in the uptakes of the boilers, must be kept fully open while
burning oil. Otherwise, this may result in dangerous accumulation of gas in the
furnace with a resultant blowing out into the boiler or engine room.
• The valves on glass gauges in fuel oil storage or service tanks should be kept
habitually shut. When a reading of the gauge is desired, the valves may be opened,
but must be shut again at once.
• In each boiler or engine room fitted for oil burning there should be fire extin-
guishing apparatus in accordance with the requirements/rules from the authorities
and classification societies in question such as, e.g.: Fire hose, permanently cou-
pled and of sufficient length to reach all parts of the boiler or engine room, and
either:
- (a) a box containing at least 85 litres (2 cubic ft) of dry sand with a large scoop
- (b) a chemical fire extinguisher of the tank type
• When the fuel oil system has not been in use for a long period, or after joints in
the piping have been re-made, the system should be tested “cold” under a pressure
at least equal to the working pressure before fires are ignited. During the test a
careful inspection for leaks should be carried out.
• Fuel oil should not be habitually heated above 60°C for marine gas oil / diesel oil
and 120°C for heavy oils and never above its flash point in any part of the system
except in the burners.
• Care must be taken to prevent accumulation of oil or vapour in any place outside
the system and in ships particularly in bilges under the furnace. This can be ac-
complished by rigid cleanliness.

OM9280_01#E.1
VISCOSITY - TEMPERATURE CHART
Viscosity - temperature chart
1 Description
The preheating temperature can be determined by means of the viscosity - temperature
chart shown in Figure 1. In order to use the chart, the viscosity of the fuel oil must be
known at a reference temperature.
It should be noted that the preheating temperature should be set somewhat higher than
the temperature shown in the chart due to the heat loss between pre-heater and nozzle/
cup.
1.1 Example
The example is based on a pressure atomizing burner type MS or RMS.
Known:
Oil viscosity: 380 cSt. at 50°C
Required:
Preheating temperature in °C
Procedure to be followed:
Step A: Follow the reference temperature line at 50°C vertically down to the inter-
section with the 380 cSt. viscosity line.
Step B: From this point move parallel down with the nearest fuel grade line.
Step C: When the line meets the recommended nozzle viscosity line, go vertically
up to the temperature axis.
Step D: At this point read the desired preheating temperature of 150°C.

OM9280_01#E.1
VISCOSITY - TEMPERATURE CHART
Viscosity - temperature chart

Redwood
1 sec.
cSt.
cSt.
o o
Centigrade TEMPERATURE C
40,000 -15 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
10,000 10,000
9,000 9,000
8,000 8,000
30,000
7,000 7,000
6,000 Viscosity - temperature chart 6,000
20,000 5,000 5,000
4,500 4,500
15,000 4,000 4,000
3,500 3,500
3,000 3,000
10,000 2,500 2,500
8,000 2,000 2,000
1,500 1,500
5,000
4,000 1,000 1,000
900 900
3,000 800 800
700 700
600 600
2,000 500 500
450 450
400 400
1,500 350 350
300 300
1,000 250 250
KINEMATIC, CENTISTOKES
KINEMATIC, CENTISTOKES
800 200 200

REDWOOD, 1 SECOND
600 150 150

500
400 100 100
90 90
300 80 80
70 70
60 60
200 50 1 50
45 45
150 40 40
35 35
30 30
100 25 25
90
80 20 20
2
70
15 15
4
60
10 10
50 9 3 9
8 8
7 7
40 6 6
5 5
4 4
3 3
2 2
28.5 1 1
5 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350
o o
Fahrenheit TEMPERATURE F
1 Recommended cup viscosity for rotary cup burners 45-60 cSt.

2 Recommended nozzle viscosity for steam atomizing burners 15-20 cSt.
3 Recommended nozzle viscosity for pressure atomizing burners type MS, RMS and Aalborg KBP 8-10 cSt.
4 Recommended nozzle viscosity for pressure atomizing burners type KBM and KBO 14-16 cSt.
Figure 1 visc1ex3264790en.wmf

TABLE OF CONTENTS
Table of contents
Pumps
.
Circulation pump CR 90-2-1....................................... 5545000048................. 7-2
Fuel oil supply unit, with filter, size 240....................... 9294002152................. 7-5
Pumps, type CR, CRN................................................ OM5540_20................ 7-8
DL - DS - DCL - DCS
Kral Operating Instruction.......................................... ................................... 7-19
Circulation pumps in TF system.................................. OM5542_01................ 7-50
5545000048#A.2 Company name:
CIRCULATION PUMP CR 90-2-1 Created by:
Phone:
Date: 07/05/2018
H CR 90-2-1, 3*440 V, 60Hz eta
Description Value [m] [%]
General information:
Circulation pump CR 90-2-1

Product name:
Product No:
EAN number:
CR 90-2-1 A-F-A-E-HQQE
96124149
5700396704531
90
80
Technical:
Speed for pump data: 3556 rpm
70
Rated flow: 108 m³/h
Rated head: 52.2 m 60
Stages: 2
Impellers: 2 50 100
Number of reduced-diameter 1
40 80
impellers:
Low NPSH: N
Pump orientation: Vertical 30 60
Shaft seal arrangement: Single

20 40
Code for shaft seal: HQQE
Approvals on nameplate: CE, EAC,ACS
10 20
Curve tolerance: ISO9906:2012 3B
Pump version: A 0 0
Model: B 0 20 40 60 80 100 120 Q [m³/h]
P NPSH
Materials: [kW] [m]
Base: Cast iron 25 P1 25
EN 1563 EN-GJS-500-7 P2
ASTM A536 80-55-06 20 20
Impeller: Stainless steel

15 15
EN 1.4301
AISI 304 10 10
Material code: A
Code for rubber: E 5 5
Bearing: SIC
Support bearing: Graflon 0 0
Installation:
Maximum ambient temperature: 60 °C
Maximum operating pressure: 16 bar
Max pressure at stated temp: 16 bar / 120 °C
16 bar / -30 °C
Type of connection: DIN
Connect code: F
Size of inlet connection: DN 100
Size of outlet connection: DN 100
Pressure rating for pipe connection: PN 16
Flange size for motor: FF300
Liquid:
Pumped liquid: Water
Liquid temperature range: -30 .. 120 °C
Liquid temperature during operation: 20 °C
Density: 998.2 kg/m³
Electrical data:
Motor standard: IEC
Motor type: 180MB
IE Efficiency class: NEMA Premium / IE3 60Hz
Rated power - P2: 22 kW
Power (P2) required by pump: 22 kW
Mains frequency: 60 Hz
Rated voltage: 3 x 220-277D/380-480Y V
Rated current: 69,5-56,5/40,0-32,5 A
Starting current: 650-1040 %
Cos phi - power factor: 0,91-0,91
7-2 / from
Printed 60 Grundfos Product Centre [2018.02.043] Language UK 4/6

Phone:
Date: 07/05/2018
Description Value
Rated speed: 3520-3560 rpm
Efficiency: IE3 91,7%
Motor efficiency at full load: 91.7 %
Motor efficiency at 3/4 load: 93.7 %
Motor efficiency at 1/2 load: 94.4 %
Number of poles: 2
Enclosure class (IEC 34-5): 55 Dust/Jetting
Insulation class (IEC 85): F
Motor protec: PTC
Motor No: 85U07530
Controls:
Frequency converter: NONE
Others:
Minimum efficiency index, MEI ≥: 0.7
Net weight: 207 kg
Gross weight: 240 kg
Shipping volume: 0.495 m³
Language
Printed from UK Product Centre [2018.02.043]
Grundfos 7-3 / 605/6

Phone:
Date: 07/05/2018
96124149 CR 90-2-1 60 Hz
081
022
54
041
145 377
Note! All units are in [mm] unless others are stated.

Disclaimer: This simplified dimensional drawing does not show all details.
7-4 / from
Printed 60 Grundfos Product Centre [2018.02.043] Language UK 6/6

DATA SHEET
Tag No(s):
Type: Electrical specification:

• Fuel oil supply pump unit, with filter • Rated output for motor: 0.25 kW
Size: • Starting method: Direct
• Pump: NE 5 • Starting current: 3.5 A
• Operating current (full load): 0.91 A
Connection type:
• Revolution: 1410 r.p.m.
• Connection inlet and outlet, pipe size in- • Heating element motor: Not included
side / outside diameter: 25/ 34
• Power supply: 3 x 400V
• Connection type: Flange according to • Frequency: 50 Hz
SAE, hole pattern 3.000PSI
• Cable connection: M 20 x 1.5 • Insulation class: F
• Degree of protection: IP55
Application:
• For handling Fuel oils - DMA, DMB,
DMZ and RMx according. to ISO 8217
Material:
Materiale for
• Station block, casing: EN-GJS-400-15
• Pump, casing: Silafont
• Pump, screw set: Steel 1.0726
Technical data:
• Ambient air temperature: 50°C
• Pressure, max. supply: 5.0 barg
• Pressure, relief design: 8 barg
• Pressure, discharge outlet: 5 barg
• Temperature max. fuel oil: 150°C
• Foundation bolts: M12
• Oil viscosity min.: 1.1 cSt
• Oil viscosity max.: 380 cSt
• Oil viscosity: 1.1 cSt
Oil capacity: 102 l/h
NPSH: 5.0 mWC
• Viscosity: 2.0 cSt
NPSH: 2.0 mWC
• Viscosity at 380 cSt:
NPSH: 2.0 mWC
• Filtration: 500µ
• Weight motor: 6 kg
• Weight: 40 kg
Type No.: 9294

Version: F.1 Fuel oil supply unit, with filter, size 240 9294002152
DATA SHEET
Tag No(s):
H1
H
H2
H1
H3
L2 I.D.2
L3
L1
L L4
I.D.1, SAE 3000 PSI

cable gland
cable gland
W5
W4
W1
W
W3
W2
I.D., SAE 3000 PSI
Dimension: Dimension:
• L: 400 • H: 441
• L1: 310 • H1: 114
• L2: 280 • H2: 153
• L3: 400 • H3: 50
• L4: 423 • I.D.: 25
• W: 414 • I.D.1: 25
• W1: 266 • I.D.2: 10.5
• W2: 66
• W3: 91
• W4: 80
• W5: 95
Type No.: 9294

DATA SHEET
Tag No(s):
Installation:
• The pump/motor assemblies are of a ver-
tical design and are delivered with
mounting feet and oil sump. For safety
purposes, the arrangement with “motor
downwards” is not admissible
Connections / flanges:
• Counter flanges according to SAE. Bolts
and gaskets will be included in the sup-
ply.
Connection diagram:
2 4
5
1 6
1 Reversing valve
2 Filter
3 Suction side - Pressure gauge
4 Pump
5 Non return valve
6 Safety valve
7 Pressure side - Pressure gauge
Type No.: 9294

OM5540_20#C.1
PUMPS, TYPE CR, CRN
Pumps, type CR, CRN
1 General
The multistage in-line centrifugal pumps are used as condensate, make-up, and feed
water pumps in boiler plants. To have a proper functioning of the centrifugal pumps it
is essential that the pumped liquid does not contain any steam, air, solid particles or
fibres. Furthermore the liquid must not attack the pump material chemically.
1.1 Technical data
• Electrical data: see motor nameplate.

• Ambient temperature: Max. 45°C.
• Minimum inlet pressure: see section 2.
• Maximum inlet pressure: see Table 1. However, the actual inlet pressure + pressure
when the pump is running against a closed valve must always be lower than the
“maximum permissible operating pressure".
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Maximum inlet pressure

50 Hz 60 Hz
CR, CRN 1
CR, CRN 1s-2 → CR, CRN 1s-36 10 bar CR, CRN 1s-2 → CR, CRN 1s-27 10 bar
CR, CRN 1-2 → CR, CRN 1-36 10 bar CR, CRN 1-2 → CR, CRN 1-25 10 bar
CR, CRN 1-27 15 bar
CR, CRN 3
CR, CRN 5
CR, CRN 10
CR, CRN 15
CR, CRN 20
CR, CRN 20-1 → CR, CRN 20-3 8 bar CR, CRN 20-1 8 bar
CR, CRN 32
CR, CRN 32-1-1 → CR, CRN 32-4 4 bar CR, CRN 32-1-1 → CR, CRN 32-2 4 bar
CR, CRN 32-11-2 → CR, CRN 32-14 15 bar CR,CRN 32-7-2 → CR,CRN 15 bar
32-10-2
CR, CRN 45
CR,CRN 45-6-2 → CR,CRN 45-13-2 15 bar CR, CRN 45-4-2 → CR, CRN 45-7 15 bar
CR, CRN 64
CR, CRN 64-1-1 → CR, CRN 64-2-2 4 bar CR, CRN 64-1-1 4 bar
CR, CRN 64-2-1 → CR, CRN 64-4-2 10 bar CR, CRN 64-1 → CR, CRN 64-2-1 10 bar
CR, CRN 64-4-1 → CR, CRN 64-8-1 15 bar CR, CRN 64-2 → CR, CRN 64-5-2 15 bar
CR, CRN 90
CR, CRN 90-1-1 → CR, CRN 90-1 4 bar CR, CRN 90-1-1 → CR, CRN 90-2-1 10 bar
CR, CRN 90-2-2 → CR, CRN 90-3-2 10 bar CR, CRN 90-2-2 → CR, CRN 90-4-2 15 bar
CR, CRN 90-3 → CR, CRN 90-6 15 bar
Table 1
OM5540_20#C.1
PUMPS, TYPE CR, CRN
• Maximum permissible operating pressure: see Table 2.
Maximum permissible operating pressure

Frequency Pump type Temperature range Operating pressure
CR, CRN 1s, 1 25 bar
CR, CRN 3 25 bar
CR, CRN 5 25 bar
CR, CRN 10-1 → CR, CRN 10-22 25 bar
CR, CRN 15-1 → CR, CRN 15-17 25 bar
CR, CRN 20-1 → CR, CRN 20-17 25 bar
CR, CRN 32-1-1 → CR, CRN 32-7 16 bar
CR, CRN 32-8-2 → CR, CRN 32-12 25 bar
50 Hz -20°C to +120°C
CR, CRN 32-13-2 → CR, CRN 32-14 30 bar
CR, CRN 45-1-1 → CR, CRN 45-5 16 bar
CR, CRN 45-6-2 → CR, CRN 45-9 25 bar
CR, CRN 45-10-2 → CR, CRN 45-10 33 bar
CR, CRN 64-1-1 → CR, CRN 64-5 16 bar
CR, CRN 64-6-2 → CR, CRN 64-7-1 25 bar
CR, CRN 90-1-1 → CR, CRN 90-4 16 bar
CR, CRN 90-5-2 → CR, CRN 90-6 25 bar
CR, CRN 1s, 1 25 bar
CR, CRN 3 25 bar
CR, CRN 5 25 bar
CR, CRN 10-1 → CR, CRN 10-17 25 bar
CR, CRN 15-1 → CR, CRN 15-12 25 bar
CR, CRN 20-8 → CR, CRN 20-10 25 bar
CR, CRN 32-1-1 → CR, CRN 32-5 16 bar
60 Hz CR, CRN 32-6-2 → CR, CRN 32-8 -20°C to +120°C 25 bar
CR, CRN 32-9-2 → CR, CRN 32-10-2 40 bar
CR, CRN 45-1-1 → CR, CRN 45-4 16 bar
CR, CRN 45-5-2 → CR, CRN 45-6 25 bar
CR, CRN 64-1-1 → CR, CRN 64-3 16 bar
CR, CRN 64-4-2 → CR, CRN 64-4-1 25 bar
CR, CRN 90-1-1 → CR, CRN 90-3 16 bar
CR, CRN 90-4-2 25 bar
Table 2
OM5540_20#C.1
PUMPS, TYPE CR, CRN
• Minimum flow rates: See Table 3.
Minimum flow rates

Liquid temperature
Pump type
Up to + 80ºC + 80ºC to + 120ºC
CR, CRN 1s 0.1 m3/h 0.2 m3/h
CR, CRN 1 0.1 m3/h 0.3 m3/h
CR, CRN 3 0.4 m3/h 0.8 m3/h
CR, CRN 5 0.6 m3/h 1.3 m3/h
CR, CRN 10 1.2 m3/h 2.6 m3/h
CR, CRN 15 1.8 m3/h 3.8 m3/h
CR, CRN 20
2.4 m3/h 5.0 m3/h
CR, CRN 32 3.8 m3/h 7.6 m3/h
CR, CRN 45 5.4 m3/h 11.0 m3/h
CR, CRN 64 7.7 m3/h 16.0 m3/h
CR, CRN 90 11.0 m3/h 24.0 m3/h
Table 3
• Liquid temperature: -20°C to 120°C. See also Table 2 which indicates the rela-
tionship between liquid temperature and maximum permissible operating pressure.
Note: In condensate and feed water systems where an open hot-well is used it is
recommended to keep a temperature in the hot-well of 85-95ºC.
• Further technical data can be found on the data sheet related to the pumps.
2 Calculation of minimum inlet pressure

The minimum inlet pressure "H" in metres head required to avoid cavitation in the
pump is calculated as follows:
H = pb x 10.2 - NPSH - Hf - Hv - Hs
• pb = barometric pressure in bar (barometric pressure can be set to 1.0 bar). In closed
systems pb indicates the system pressure in bar.
• NPSH = net positive suction head in metres head (to be read from the NPSH curves
in Figure 2and Figure 3at the highest flow the pump will be delivering).
• Hf = friction loss in suction pipe in metres head at the highest flow.
• Hv = vapour pressure in metres head, see Figure 1. Tm = liquid temperature
• Hs = safety margin = 0.5 metres head.
If the calculated “H” is positive, the pump can operate at a suction lift of maximum
“H” metres head. If the calculated “H” is negative, an inlet pressure of minimum “H”
metres head is required. There must be a pressure equal to the calculated “H” during
operation.
Example:
Pump type = CR 20 - 60 Hz, flow rate = 24 m3/h, pb = 1.0 bar.
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Hf = 3.0 metres head, liquid temperature = + 90ºC.
Hv (from Figure 1) = 7.5 metres head.
NPSH (from Figure 2) = 2.5 metres head.
H = pb x 10.2 - NPSH - Hf - Hv - Hs
H = 1 x 10.2 - 2.5 - 3.0 - 7.5 - 0.5 = -3.3 metres head.
This means that an inlet pressure of minimum 3.3 metres head is required.
Relationship between Hv and Tm
Figure 1 om5540_20_cr02ax0054100en.wmf
OM5540_20#C.1
PUMPS, TYPE CR, CRN
NPSH curves
Figure 2 om5540_20_cr03bx0054110en.wmf
OM5540_20#C.1
PUMPS, TYPE CR, CRN
NPSH curves, continued
Figure 3 om5540_20_cr07ax0054130en.wmf
3 Start-up
Note: The pump is not allowed to run against a closed discharge valve as this will
cause an increase in temperature/formation of steam in the pump which
may cause damage to the pump.
If there is any danger of the pump running against a closed discharge valve, a minimum
liquid flow through the pump should be ensured by connecting a by-pass / drain to the
discharge pipe. The drain can for instance be connected to a hot-well / tank.
Warning: Do not start the pump until it is filled with liquid and has been primed
and vented.
3.1 Priming
Note: The following does only apply to systems where the liquid level is above
the pump inlet
Step A: Close the discharge isolating valve and loosen the vent screw in the pump
head, see Figure 4.
Note: Pay attention to the direction of the vent hole and take care to ensure that
the escaping water does not cause injury to persons or damage to the motor
or other components. In hot water installations, special attention should
be paid to the risk of injury caused by scalding hot water.
Step B: Slowly open the isolating valve in the suction pipe until a steady stream of
liquid runs out the vent hole.
Step C: Tighten the vent screw and completely open the isolating valve(s).
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Illustration of the centrifugal pumps
Figure 4 om5540_20_cr06x0054120en.wmf
3.2 Checking direction of rotation
Do not start the pump to check direction of rotation until it has been filled with liquid.
Note: The direction of rotation should not be checked with the motor alone, as
an adjustment of the shaft position is required when the coupling has been
removed.
The correct direction of rotation is shown by arrows on the pump head and/or on the
motor fan cover. When seen from the fan, the pump should rotate counter-clockwise.
3.3 Starting
Before starting the pump:
Step A: Open the isolating valve completely on the suction side of the pump and
leave the discharge isolating valve almost closed.
Step B: Start the pump.
Step C: Vent the pump during starting by loosening the vent screw in the pump head
until a steady stream of liquid runs out the vent hole, see Figure 4.
Warning: Pay attention to the direction of the vent hole and take care to ensure
that the escaping water does not cause injury to persons or damage to
the motor or other components. In hot water installations, special at-
tention should be paid to the risk of injury caused by scalding hot
water.
When the piping system has been filled with liquid:
Step D: Slowly open the discharge isolating valve until it is completely open.When
pumping liquids containing air, it is advisable to vent the pump regularly.
To vent the pump:
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Step E: Loosen the vent screw in the pump head during operation.
3.4 Frequency of starts and stops
Motors smaller than 4 kW should not start more than 100 times per hour.
Other motors should not start more than 20 times per hour.
4 Maintenance
Caution: Before starting work on the pump, make sure that no power is supplied
to the pump and that it cannot be accidentally switched on. Before re-
moving the cover of the electrical terminal box and before any removal/
dismantling of the pump, make sure that the electricity supply has been
switched off.
Pump bearings and shaft seal are maintenance-free.
If the pump is to be drained for a long period of inactivity then:
Step A: Remove one of the coupling guards to inject a few drops of silicone oil on
the shaft between the pump head and the coupling.
This will prevent the shaft seal faces from sticking. When fitting the coupling guards,
make sure that they are centred vertically in the recesses in the pump head.
4.1 Motor bearings
Motors which are not fitted with grease nipples are maintenance-free.
Motors fitted with grease nipples should be lubricated with a high-temperature lithium-
based grease.
In the case of seasonal operation (motor is idle for more than 6 months of the year), it
is recommended to grease the motor when the pump is taken out of operation.
5 Frost protection
Pumps which are not used during periods of frost should be drained to avoid damage.
Step A: Drain the pump by loosening the vent screw in the pump head and by re-
moving the drain plug from the base.
Warning: Care must be taken to ensure that the escaping water does not cause
injury to persons or damage to the motor or other components. In hot
water installations, special attention should be paid to the risk of injury
caused by scalding hot water.
OM5540_20#C.1
PUMPS, TYPE CR, CRN
Do not tighten the vent screw and replace the drain plug until the pump is to be used
again.
Step B: Before replacing the drain plug in the base, screw the by-pass valve out
against the stop, see Figure 4.
Step C: Fit the drain plug by tightening the large union nut followed by the bypass
valve.
OM5540_20#C.1
PUMPS, TYPE CR, CRN
6 Fault finding chart

Before removing the terminal box cover and before any removal/dismantling of the
pump, make sure that the electricity supply has been switched off.
Fault finding chart

Fault Cause Remedy
1. Motor does not run when a) Supply failure. Connect the electrical supply.
started. b) Fuses blown. Replace fuse.
c) Motor starter overload has tripped out. Reactivate the motor protection.
d) Main contacts in motor starter are not making contact
or the coil is faulty. Replace contacts or magnetic coil.
e) Control circuit fuses are defective. Repair the control circuit.
f) Motor is defective. Replace the motor.
2. Motor starter overload trips a) One fuse is blown/automatic circuit breaker is blown. Cut the fuse.
out immediately when supply is b) Contacts in motor starter overload are faulty. Replace motor starter contacts.
switched on. c) Cable connection is loose or faulty. Fasten/replace the cable connection.
d) Motor winding is defective. Replace the motor.
e) Pump mechanically blocked. Remove blocking of the pump.
f) Overload setting too low. Set the motor starter correctly.
3. Motor starter overload trips a) Overload setting too low. Set the motor starter correctly.
out occasionally. b) Low voltage at peak times. Check the electrical supply.
4. Motor starter has not tripped
a) Check 1 a), b), d) and e). -
out but the pump does not run.
5. Pump capacity not constant. a) Pump inlet pressure is too low (cavitation). Check the suction conditions.
b) Suction pipe/pump partly blocked by impurities. Clean the pump or suction side.
c) Pump draws in air. Check the suction conditions.
6. Pump runs but gives no wa- a) Suction pipe/pump blocked by impurities. Clean the pump or suction side.
ter. b) Foot or non-return valve blocked in closed position. Repair the foot or non-return valve.
c) Leakage in suction pipe. Repair the suction pipe.
d) Air in suction pipe or pump. Check the suction conditions.
e) Motor rotates in the wrong direction. Change the direction of rotation of
the motor.
7. Pump runs backwards when a) Leakage in suction pipe. Repair the suction pipe.
switched off. b) Foot or non-return valve defective. Repair the foot or non-return valve.
8. Leakage in shaft seal. a) Shaft seal is defective. Replace the shaft seal.
9. Noise. a) Cavitation occurs in the pump. Check the suction conditions.
b) Pump does not rotate freely (frictional resistance) be-
cause of incorrect pump shaft position. Adjust the pump shaft.
Table 4
DL - DS - DCL - DCS#A.2
KRAL OPERATING INSTRUCTION
Kral Operating Instruction
OPERATING INSTRUCTIONS OID 01en

11/2008 Edition
KRAL Pump Stations

Series DL / DS / DCL / DCS
KRAL OPERATING INSTRUCTION Betriebsanleitung
Ausgabe: 11/2008
OID 01de
TABLE OF CONTENTS
ABOUT THIS DOCUMENT.......................................................................................................................................................5

GENERAL INFORMATION ..........................................................................................................................................5
TARGET GROUPS ....................................................................................................................................................5
FURTHER APPLICABLE DOCUMENTS .........................................................................................................................5
GENERAL SAFETY INSTRUCTIONS ............................................................................................................................5
LABELING................................................................................................................................................................................6
TYPE CODE ............................................................................................................................................................6
RATING PLATE ........................................................................................................................................................6
TECHNICAL DATA...................................................................................................................................................................7
PROPER USE ..........................................................................................................................................................7
IMPROPER USE .......................................................................................................................................................7
OPERATIONAL LIMITS / PERFORMANCE DATA ............................................................................................................7
REQUIRED NPSH VALUES .......................................................................................................................................7
HEATING SYSTEM ..................................................................................................................................................................8
ELECTRIC HEATING SYSTEM ....................................................................................................................................8
FLUID HEATING SYSTEM ..........................................................................................................................................8
FUNCTION DESCRIPTION ....................................................................................................................................................10
STRUCTURE AND DESIGN ......................................................................................................................................10
HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................10
ASSIGNMENT: INSERT PUMPS – STATIONS .............................................................................................................10
INLET PRESSURE / SUCTION BEHAVIOR ...................................................................................................................11
OVERFLOW VALVE ................................................................................................................................................11
PROTECTION OF THE STATION AGAINST SOILING .....................................................................................................11
TRANSPORTATION, STORAGE AND DISPOSAL ...............................................................................................................12
UNPACKING AND CHECKING THE STATE OF DELIVERY ..............................................................................................12
TRANSPORTATION ................................................................................................................................................12
BEARING ..............................................................................................................................................................12
PRESERVATION ....................................................................................................................................................12
Preserving the internal surfaces of the station ................................................................................................................12
Preserving the external surfaces of the station................................................................................................................12
Removing the preservative...............................................................................................................................................12
DISPOSAL.............................................................................................................................................................12
Safety instructions for disposal........................................................................................................................................12
Disposing of the station ...................................................................................................................................................12
INSTALLATION, REMOVAL AND CONNECTION ................................................................................................................13
INSTALLATION .......................................................................................................................................................13
Installation position / Flow directions.............................................................................................................................13
PIPING CONNECTION .............................................................................................................................................13
FOOT-ACTUATED VALVE ........................................................................................................................................13
ELECTRICAL CONNECTION .....................................................................................................................................13
OPERATION...........................................................................................................................................................................14
START-UP ............................................................................................................................................................14
Filling the station ............................................................................................................................................................14
Cleaning the piping network ...........................................................................................................................................14
Checking the direction of rotation...................................................................................................................................14
Start .................................................................................................................................................................................14
Adjusting the overflow valve............................................................................................................................................15
PRESSURE DISPLAY ..............................................................................................................................................16
KRAL OPERATING INSTRUCTION Operating Instructions
Edition: 11/2008
OID 01en
REPAIRS ................................................................................................................................................................................17
MAINTENANCE AND CHECKS ..................................................................................................................................17
Checking the reserve pump..............................................................................................................................................17
CLEANING THE STRAINER ......................................................................................................................................17
INSTALLATION / REMOVAL OF THE INSERT PUMP ......................................................................................................17
Removing the pump .........................................................................................................................................................17
Installing the pump ..........................................................................................................................................................17
CONVERTING TO OUTSIDE BEARINGS .....................................................................................................................18
TROUBLESHOOTING............................................................................................................................................................19
POSSIBLE FAULTS .................................................................................................................................................19
TROUBLESHOOTING ..............................................................................................................................................19
APPENDIX..............................................................................................................................................................................20
EXPLODED VIEWS .................................................................................................................................................20
Insert pump FE 5 .............................................................................................................................................................20
Insert pump NE 5 – 13.....................................................................................................................................................21
Insert pump NE 15 – 57...................................................................................................................................................21
Insert pump CLDR 15 – 42..............................................................................................................................................22
Outside bearing ...............................................................................................................................................................22
Insert pump CLDR 55 – 118............................................................................................................................................23
Outside bearing CLDGA 55 – 118 ..................................................................................................................................23
SECTION VIEWS / SPARE PARTS ............................................................................................................................24
Station DL2 / 150–240 ....................................................................................................................................................24
Station DL2 / 320 – 1300 ...............................................................................................................................................24
Station DS1......................................................................................................................................................................25
Control block...................................................................................................................................................................25
Station DL3, DL4, DS3, DS4...........................................................................................................................................26
Control block...................................................................................................................................................................26
Station DL7, DS7, DCL7, DCS7......................................................................................................................................27
Insert pumps ....................................................................................................................................................................28
TABLE OF TIGHTENING TORQUES ...........................................................................................................................30
NOTES....................................................................................................................................................................................31
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Edition: 11/2008
OID 01en
ABOUT THIS DOCUMENT
GENERAL INFORMATION
The operating instructions form part of the pump or pump station. The operating instructions have to be kept for future use
and reference. Furthermore observe the operating instructions of the drive motor.
TARGET GROUPS
Target group Tasks

Operator-owner Keep these instructions available at the plant's site of use, also for future use
Ensure that employees read and observe these instructions and the associated
documents, in particular the safety instructions and warnings.
Observe additional plant-specific directives and regulations.
Specialist personnel, Read, observe and follow these instructions and the associated documents, in particular
fitters the safety instructions and warnings.
FURTHER APPLICABLE DOCUMENTS

Corresponding operating instructions of the drive motor
Manufacturer's declaration to EU Directive 98/37/EC and 97/23/EC
Declaration of conformity as per EU Directive 94/9/EC
GENERAL SAFETY INSTRUCTIONS
No liability is accepted for damage arising through non-observance of the operating instructions.
Read the operating instructions carefully and observe them.
The operator-owner is responsible for the observance of the operating instructions.
Installation, removal and installation work may only be carried out by specialist personnel.
Do not use KRAL pumps outside the operational limits specified on the rating plate and in the "Technical data" section.
In the case of operating data that do not agree with the specifications on the rating plate, contact the manufacturer.
In order for the warranty to remain valid, corrective maintenance during the warranty period require the express
permission of the manufacturer.
Observe the general regulations for the prevention of accidents as well as the local safety and operating instructions.
Observe the valid national and international standards and specifications of the installation location.
In case of systems with an increased potential of danger to humans and/or machines the failure of a pump may not lead
to injuries or damage to property.
Always equip systems with an increased potential of danger with alarm equipment.
Maintain and check the protective/alarm equipment regularly.
The pumped fluids can be dangerous (for example hot, poisonous, combustible). Observe the safety regulations for
handling dangerous materials.
Pumped fluids can be subject to high pressure and can cause material and/or personal damage if leaks occur.
-5-
Edition: 11/2008
OID 01en
LABELING
TYPE CODE
3 5
1 Model
DS1-1000.AAA.0001 2
3
Size
Seal type
4 Bearing
5 Heating type
1 2 4 6 6 Version index
Item Designation Type

1 Model DS1 Delivery of heavy oil up to a max. of 1,300 l/h, ∆pmax = 6 bar
DL2 Delivery of light oil up to a max. of 1,300 l/h, ∆pmax = 6 bar
DL3 / DS3 Delivery of light/heavy oil up to a max. of 2,900 l/h, ∆pmax = 6 bar
DL4 / DS4 Delivery of light/heavy oil up to a max. of 6 000 l/h, ∆pmax = 6 bar
DL7 / DS7 Delivery of light/heavy oil up to a max. of 9 000 l/h, ∆pmax = 6 bar
DCL / DCS Delivery of light/heavy oil up to a max. of 9 000 l/h, ∆pmax = 40 bar
2 Size corresponds to flow rate in [l/min] at motor speed
3 Seal type A Radial seal ring
B Standard mechanical seal
C Mechanical seal of mechanically resistant material
4 Bearing A Standard, inner bearing
B Outside bearing
5 Heating type A Standard, without heating system
B with heating system
6 Version index for internal administration
RATING PLATE
4 6
1 Nominal delivery rate
3 2 Nominal pressure
3 Operating temperature
4 Serial number
7 5 Type
2 6 Construction year
7 Nominal viscosity
1 8 8 Rotation speed
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Edition: 11/2008
OID 01en
TECHNICAL DATA
PROPER USE
KRAL pump stations of the DL / DS / DCL / DCS series are designed solely to deliver lubricating fluids that are chemically
neutral and do not contain any gas or solids content. The stations may only be used within the operational limits described
within this chapter.
IMPROPER USE
The pump stations are not suitable for delivering gases or media containing solids. Operating data that deviate from the
values on the rating plate and the operational limits can cause damage to the pump station. If there is any doubt whether
deviating operating data can cause damage, inform the manufacturer.
OPERATIONAL LIMITS / PERFORMANCE DATA

The specified values relate to pumped liquid that lubricate well.
Light oil Heavy oil

DL2 DL2 DL3 DL4 DL7 DCL7 DS1 DS3 DS4 DS7 DCS7
Pump stations
150 to
240 1300
Pressure [bar] 6 6 6 6 6 40 6 6 6 6 40
Temperature min. [°C] -10 -10 -10 -10 -10 -10 -10 -10 -10 -10 -10
Temperature max. [°C] 50 50 50 50 50 50 150 150 150 150 150
2
Viscosity min. [mm /s] 2 2 2 2 2 2 10 10 10 10 10
2
Viscosity max. [mm /s] 37 37 37 37 37 37 1000 1000 1000 1000 1000
Suction head refer to NPSH characteristic curves
Inlet pressure [bar]
- with radial seal ring 0,5
- with mechanical seal 5
* above 130 °C to 150 °C a mechanical of mechanical ly resistant material is required Other values on request
REQUIRED NPSH VALUES

The NPSH values do not take into consideration whether the pumped liquid already degasses at a slight low pressure (e.g.
at heating oil EL and diesel oil max. 4 m water column).
Viscosity [mm2/s]
Insert 6* 37 152 380
pump Rotating speed [1/min]
1450 1750 2900 3500 1450 1750 2900 3500 1450 1750 2900 3500 1450 1750 2900 3500
NPSH required [m water column]
FE 5 / NE 5 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3,1
NE 7,5 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3,3 3,5
NE 10 3 3 3 3 3 3 3 3 3 3 3 3,3 3 3,1 3,6 4
NE 13 3 3 3 3,3 3 3 3 3,3 3 3 3,6 4,1 3,2 3,4 4,4 5,1
NE 15 3 3 3 3 3 3 3 3 3 3 3 3,2 3 3 3,6 3,9
NE 20 3 3 3 3,1 3 3 3 3,1 3 3 3,4 3,8 3,1 3,3 4,1 4,7
NE 26 3 3 3,2 3,7 3 3 3,2 3,7 3 3 3,9 4,5 3,3 3,6 4,9 5,8
NE 32 3 3 3 3 3 3 3 3 3 3 3,3 3,7 3 3,2 4 4,5
NE 42 3 3 3,2 3,7 3 3 3,2 3,7 3 3 3,9 4,5 3,3 3,6 4,9 5,8
NE 54 3 3 3,5 4,2 3 3 4 4,9 3,1 3,4 5 6,2 3,8 4,2 6,4 —
CLD 55 3 3 3 3,3 3 3 3 3,3 3 3 3,6 4,1 3,2 3,4 4,9 5,6
CLD 74 3 3 3,5 4,1 3 3 3,5 4,1 3 3,1 4,3 — 3,5 3,8 5,9 —
CLD 85 3 3 3,8 4,5 3 3 3,8 4,5 3 3,3 4,7 — 3,6 4 6,5 —
CLD 118 3 3 — — 3 3 — — 3,2 3,5 — — 3,9 4,3 — —
* For heating oil EL we recommend a max. suction head of 4 m water column, measured at the station suction flange.
-7-
Edition: 11/2008
OID 01en
HEATING SYSTEM
A pump heating is required for high-viscosity fluids. Cold starts are to be avoided (take the heating-up times into account).
Cavitation and shaft seal damage can result.
Open the non-return valves before or after the station because of the thermal expansion.
ELECTRIC HEATING SYSTEM

Electrical heating systems are dimensioned through a limited heating output so that overheating is not possible.
Operating data:
Voltage: 230 V
Frequency: 50 / 60 Hz
2
Wire cross-section: 2 x 1 mm
Heating output:
- DS 1: 180 W
- DS3/DS4: 250 W
- DS7/DCS7/DCL7: 400 W
Other values on request.
FLUID HEATING SYSTEM

Observe the heating-up temperatures in the pump and sealing chamber:
a) Radial seal ring: max. 80 °C
b) Mechanical seal: max. 100 °C
Steam heating:
a) Temperature: max. 180 °C
b) Pressure: max. 18 bar DS1
max. 6 bar DS3, DS4
The max. heating temperature of 100 °C may not be e xceeded.
Heating-up times:
a) b) a) c) a)
Electrical ∆t [min] Steam p t Steam amount ∆t (min)
20 °C 50 °C [bar] [° C] [kg/h] 20 °C 50 °C
DS1 (180 W) 60 180 DS1 15 180 5 30 100
DS4 (250 W) 120 240 DS4 15 180 5 40 120
DS7 (400 W) 180 420 DS7 5 150 5 60 240
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Edition: 11/2008
OID 01en
DS1 DS3, DS4 DS7, DCS7

Standard design with built-in fluid heating system
Pumpe
R 1/2“
165
system connection
R 1/2“
Fluid heating
35
16
30
915.4
48
915.4
161
161
165
Electric heating system
070.1
914.1
070.1
914.1
Filler/vent screw
493
484
481
493
484
481
481
908.3
730.5
Fluid heating system
908.2
908.2
730.2
242
242
The heating is screwed in at the side

in case of subsequent installation.
Open the filler/vent screw and fill
with thermal oil: Approx. 65 mm from
the top edge of the filler opening up
R 3/8“
to the oil level (corresponding to

approx. 1.4 l oil).
R 1/2“
070.1 End cover *730.2 Flat gasket

161 Heat conducting plate *730.5 Flat gasket
242 Heating block 908.2 Screw plug
*481 Heating element 908.3 Screw plug
484 Terminal strip 914.1 Socket screw
493 Screwed gland 915.4 Socket screw
* recommended spare parts
-9-
Edition: 11/2008
OID 01en
FUNCTION DESCRIPTION
STRUCTURE AND DESIGN

Flow direction and direction of rotation indication of the pump
7 8
6 9 1 Oil pan
2 Oil pan
5 3 Pump
10 4 Pressure chamber
5 Coupling
4 11 6 Pump bracket
7 Non-return valve
12 8 Motor
3 9 Pressure gauge
10 Overflow valve
13 11 Strainer cover
2
12 Switching lever
14 13 Reversing valve
1
14 Vacuum gauge
15 15 Strainer
HYDRAULIC CIRCUIT DIAGRAM

DL2 series DL3. DL4, DS1, DS3, DS4 series DL7, DS7, DCL7, DCS7 series
4 5 8 4 3 5 A B C D
M M M
M M M
2 6 7 2 6 7 8 1 2 4 3 5 6 7 8
1 Thermometer 5 Motor-driven pump
2 Reversing valve each A/B + C/D 6 Overflow valve
3 Shut-off pressure and vacuum gauge 7 Non-return valve
4 Strainer 8 Shut-off pressure gauge
ASSIGNMENT: INSERT PUMPS – STATIONS

Insert Station Insert Station Insert Station
pump pump pump
FE 5 DL2/ 150 NE 20 DL3/2300 DS3/1100 NE 42 DL4/4000 DS4/2000
DL2/ 240 DL7/1100 DS3/2300 DL7/4000 DS4/4000
NE 5 DS1/ 150 DL7/2300 DS7/1100 DS7/2000
DS1/ 240 NE 26 DL3/2900 DS3/1500 DS7/4000
NE 7,5 DL2/ 400 DS1/ 400 DL3/1500 DS3/2900 NE 54 DL4/6000 DS4/6000
DL2/ 750 DS1/ 750 DL3/2900 DS7/1500 CLD 55 DL7/6000 DS7/2800 DCS7/3000
NE 10 DL2/ 320 DS1/ 320 DS7/2900 DCL7/6500 DS7/6000 DCS7/6500
DL2/ 500 DS1/ 500 NE 32 DL4/3200 DS4/1600 CLD 74 DL7/8500 DS7/3500 DCS7/4100
DL2/ 1000 DS1/ 1000 DL7/3200 DS4/3200 DCL7/7500 DS7/8500 DCS7/7500
NE 13 DL2/ 1300 DS1/ 1300 DS7/1600 CLD 85 DL7/9000 DS7/3800 DCS7/4500
NE 15 DL3/1800 DS3/900 DS7/3200 DCL7/9000 DS7/9000 DCS7/9000
DL7/900 DS3/1800 CLD118 DS7/7000
DL7/1800 DS7/900
- 10 -
Edition: 11/2008
OID 01en
INLET PRESSURE / SUCTION BEHAVIOR

The water contained in the "S" heating oil evaporates at high temperatures and inlet pressure that is too low. The diagram
shows the minimum inlet pressure at the suction connection of the pump. This values are to be observed in order to ensure
trouble-free operation (max. temperature 150 °C).
7
6
5
Inlet pressure [bar]
4
3
2
1
0
-1
70 80 90 100 110 120 130 140 150
Temperature °C
Water evaporation temperature

Recommended inlet pressure
OVERFLOW VALVE
The overflow valve is used to protect the pump / pump station against impermissible overpressure, a result of which can be
leaking or even bursting of the pump parts under pressure. Longer overflowing can result in damage to the valve or to the
pump / pump station. The overflow valve may not be used as a control or regulating valve.
■ The opening pressure is set in the factory to approx. 10% above the operating pressure (however not under 3 bars).
PROTECTION OF THE STATION AGAINST SOILING

The station is equipped in the factory by default with strainers. The strainers are designed to separate coarse soiling that is
normally not contained in the pumped liquid. Due to their small size the strainers cannot separate larger amounts of soiling
occurring regularly, nor abrasive fine particles. If such operating conditions occur, the station has to be protected
additionally by a correspondingly dimensioned operating filter, refer to "Cleaning the piping system", Page 14.
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Edition: 11/2008
OID 01en
TRANSPORTATION, STORAGE AND DISPOSAL
UNPACKING AND CHECKING THE STATE OF DELIVERY

► On delivery unpack the pump station and check for damage during transportation.
► Report damage during transportation immediately to the manufacturer.
► Dispose of packing material in accordance with the locally applicable regulations.
TRANSPORTATION
► Use intact and correctly dimensioned hoisting equipment.
► In case of heavy motors secure them additionally against tilting.
► Do not stand under raised loads.
BEARING
During the test run, the internal components of the station are wetted with test oil, which has a preservative effect. The pipe
connections are fitted with protective caps. Unless otherwise specified, the external components of the station are
preserved with a single-coat PU-based two-component paint. The preservative applied at the factory will protect the station
for about six weeks, if it is stored in a dry and clean location. Adverse ambient conditions, such as high humidity, salty air,
etc., will noticeably reduce the possible storage time. If storage over longer periods and in adverse storage conditions is
necessary, the station will have to be preserved.
PRESERVATION
Preserving the internal surfaces of the station
► Close the pipe connections with cover plates.
► Open the strainer cover.
► Fill the station block with non-corrosive, resin-free oil up to 1 cm under the edge of the strainer housing.
While doing so, turn the pump slowly in accordance with the arrow for the direction of rotation.
► Close the strainer cover.
► After about 6 months storage check the oil level and if necessary top up oil.
Preserving the external surfaces of the station

Aids:
■ Castrol Rustilo DWX 33 or other preservative offering comparable protection
► Paint or spray the preservative onto all plain and unpainted parts.
► At intervals of 6 months check the preservation and if necessary repeat.
Removing the preservative

Aids:
■ Solvents such as diesel fuel, alcohol, industrial cleaner or steam-jet cleaning device with wax-dissolving additives
► Clean the outside of the station with solvents, if necessary using a steam-jet cleaning device.
► Open the strainer cover.
► Drain the station, collecting the preservative oil in a suitable vessel.
► To remove the residual oil, rinse the station with the pumped fluid.
DISPOSAL
Safety instructions for disposal
► Wear protective clothing during all the work on the station.
► Before disposing of the station, collect the discharging pumped fluid and oil or grease and dispose of it in
accordance with the locally applicable regulations.
► Before disposing of the station, neutralize the residues of the pumped fluid.
Disposing of the station
► Disassemble the station.
► Clean residues of the pumped medium from the individual parts.
► Separate sealing elements made of elastomers from the station and dispose of them in the residual waste.
► Recycle iron parts.
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Edition: 11/2008
OID 01en
INSTALLATION, REMOVAL AND CONNECTION
INSTALLATION
When selecting the location take the limitations of use, NPSH values and ambient conditions into account.
The function, safety and service life may not be impaired by humidity, temperature influences or explosive
atmospheres.
During installation ensure that all the parts of the pump are easily accessible and that maintenance is easily possible.
Installation position / Flow directions
Motor circuit diagram for

DL2/150, DL2/240
ON
OFF
MP
(220V)
u 1 3
R
v
S
w M
T
PIPING CONNECTION
Avoid pipe tensions.
The stations may not be used as the fastening point of the connected piping. Any forces and moments (such as
stresses, expansion of the piping through temperature influences, reaction and bearing forces) are to be avoided.
It is advisable to install expansion joints if heat expansion of the piping is possible.

.
The suction line is to be dimensioned so that the speed of flow lies between 0.5 to a max. of 1.3 m/sec. and the pressure
line between 2 and 3 m/sec. The suction line has to be laid airtight and rising. The pipe system and pump have to be free of
impurities, refer to "Cleaning the piping system", Page 14. Observe the maximum permissible inlet pressure of the shaft
seal ring when checking the piping system for leaks.
FOOT-ACTUATED VALVE
A foot-actuated valve with suction strainer is to be installed in case of suction operation. The suction process is facilitated,
coarse soiling is kept away and emptying of the suction line is prevented.
ELECTRICAL CONNECTION
Connect the motor overload-protected in accordance with the local regulations and in accordance with the motor rating
plate. Compare the existing supply voltage with the motor rating plate. Observe the circuit diagram in the motor terminal
box.
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Edition: 11/2008
OID 01en
OPERATION
START-UP
Filling the station
Pumps may not run dry since pump parts can be destroyed.
Fill the pumps as well as suction line with fluid and vent them.
Filling process:
DL2 DL3, DL4, DL7, DS1, DS3, DS4, DS7, DCL7, DCS7
908.2
076
► Remove the screw plug 908.2. ► Remove both strainer covers 076.
► Lever to the left – fill in oil. ► Fill the station with oil.
► Lever to the right – fill in oil.
► Venting: Open vent valve 423, refer to "Section views / Spare parts", Page 24.
► Turn the pump by hand in the direction of the arrow for the direction of rotation and check whether it runs easily and
smoothly.
Cleaning the piping network

The complete piping network has to be cleaned before commissioning in order to protect the station.
If this is to be done by means of the screw pumps, an additional commissioning filter has to be installed before the
station. The strainer supplied by KRAL by default is not able to separate large amounts of soiling and abrasive fine
particles.
Recommended filter mesh widths of the additional commissioning filter:

Pump size to 275 Light fuel oil 〈 Mesh width 0.025 mm
Heavy fuel oil 〈 Mesh width 0,050 mm
above 370 Light fuel oil 〈 Mesh width 0,035 mm
Heavy fuel oil 〈 Mesh width 0,070 mm
Recommended rinsing duration with commissioning filter: 50 to 100 hours

The pump intake of the screw pump may not be overstrained by the additional pressure loss in the commissioning filter.
► Calculate the flow resistance and determine the remaining pump intake.
► Check and clean the commissioning filter regularly.
A commissioning strainer to be purchased from KRAL can also be used as an alternative to the commissioning filter.
Checking the direction of rotation
The direction of rotation of the motor has to agree with the arrow for the direction of rotation of the pump. In order to check
the direction of rotation the motor can be switched on briefly with the suction and pressure valves opened. If the direction of
rotation is incorrect, the pump does not suck - thus causing damage to the pump. Longer checks of the direction of rotation
have to be carried out without the pump.
Start
Before starting up, open the valves on the suction and pressure sides. Vent the pump/station during the starting up process.
Extreme temperature shocks can destroy the pump/station. Take into account the lever position at the block units and the
position of the non-return valves at the single and dual stations.
- 14 -
Edition: 11/2008
OID 01en
DL2
DL3, DL4,
DS1, DS3, DS4
Lever right: only Lever left: only Lever in center

right pump is left pump is ready position: both pumps
ready to operate to operate are ready to operate
DL7, DS7,
DCL7, DCS7 1 2
Left pump and left Right pump and right Left pump and right Right pump and left
strainer ready to strainer ready to strainer ready to strainer ready to
operate operate operate operate
1: both pumps and left strainer ready to operate

2: both pumps and right strainer ready to operate
Adjusting the overflow valve

The overflow valve is used to protect the pump / pump station against impermissible overpressure, a result of which can be
leaking or even bursting of the pump parts under pressure. Longer overflowing can result in damage to the valve or to the
pump / pump station. The overflow valve may not be used as a control or regulating valve.
The opening pressure is set in the factory to approx. 10% above the operating pressure (however not under 3 bars).
Checking the set bypass pressure:

Close the pressure-side non-return valve slowly. The pressure gauge indicates the bypass pressure.
Caution: Excessive duration of the fluid circulation within the pump can cause heating up, resulting in mechanical damage.
Valve adjustment:
Increase the opening pressure: turn clockwise
Reduce the opening pressure: turn anticlockwise
- 15 -
Edition: 11/2008
OID 01en
Note: For the DL7/DS7/DCL7/DCS7 models loosen the fastening screw 1 before adjusting the valve.
DL2 DL3, DL4, DS1, DS3, DS4 DL7, DS7, DCL7, DCS7
1 Fastening screw
PRESSURE DISPLAY
Stopcocks at pressure and vacuum gauges are always closed. Only open for checking purposes!
open closed
- 16 -
Edition: 11/2008
OID 01en
REPAIRS
MAINTENANCE AND CHECKS

■ Visual and noise checks as well as leak monitoring should be carried out every day.
■ The operator-owner has to prevent possible damage caused by possible leaks at the pump by installing warning
devices.
Checking the reserve pump
The reserve pump should be checked once a week. We furthermore recommend that you check whether the switching lever
moves easily. Soiling can cause the non-return valves to leak. Soiling can be loosened by switching several times between
Pump 1 and Pump 2 as well as to mutual pump operation. If this is not successful, contact KRAL.
CLEANING THE STRAINER

The frequency of cleaning the strainer depends on the degree of impurity of the pumped liquid. The attached vacuum gauge
is used to indicate the degree of soiling.
Maximum permissible vacuum for

Heating oil EL max. 0,5 bar
Heavy heating oil max. 0,7 bar
When the strainers are too soiled, cavitation (strong noise generation) occurs. The strainers may not be cleaned when the
switching lever is in the center position. First switch to the reserve pump and then turn the switching lever to the running
pump, see "Start", Page 14.
INSTALLATION / REMOVAL OF THE INSERT PUMP

Removing the pump
► Disconnect the station from the power supply.
► Close the switching lever or the suction and pressure valves.
► Drain the pumps (draining plug)
► When installing again, check the flat gaskets and o-rings for damage.
An insert pump can be removed without interrupting operation. Carry out the switching process as described under
"Cleaning the strainer". Remove the motor and pump bracket. Loosen the insert pump carefully using two screwdrivers and
check whether any oil leaks through leaky non-return valves. If this is not the case, lift out the insert pump.
Installing the pump
Before carrying out installation, ensure that the max. level of the oil in the station housing amounts to 5 cm, since oil
displacement otherwise makes the installation more difficult. Check the o-rings of the insert pump for damage and grease
them slightly. Push the insert pump into the station housing with slight pressure, mount the pump bracket and motor and set
the switching lever to the center position.
- 17 -
Edition: 11/2008
OID 01en
CONVERTING TO OUTSIDE BEARINGS

Converting the DCL and DCS stations to outside bearings
1 Motor
2 Coupling
3 Nuts
1 4 Insert pump
5 Pump bracket
6 Flat gasket
7 Stud screws
3
Required new parts:
■ Coupling
■ Insert pump with o-ring
■ Pump bracket
■ Flat gasket
4 ■ Long stud screws
► Dismantle the insert pump.

► Rethread and clean the thread of the stud
screws 7.
► Bond in long stud screws 7, e.g. using
Loctite 270.
► Clean and debur the sealing surface.
► Insert the flat gasket 6.
► Place on the new pump bracket 5.
► Slide in the new insert pump 4.
► Tighten the nuts 3 crosswise.
► Mount the motor 1.
5
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Edition: 11/2008
OID 01en
TROUBLESHOOTING
POSSIBLE FAULTS
Malfunction Possible cause
No pump suction 1, 2, 3, 4, 5, 12
Pump does not provide the full performance 3, 4, 5, 8, 9, 10, 11, 17, 18
Pump runs noisily 3, 4, 5, 6, 7, 10, 11, 13, 17
Motor gets too hot 9, 10, 13
Uneven delivery 3, 5, 8, 10, 11, 18
Leaking shaft seal 7, 10, 14, 15, 16, 18
TROUBLESHOOTING
No. Cause Remedy
1 Pump is dry ► Fill pump with fluid.

2 Incorrect pump rotation direction ► Set rotation direction in accordance with arrow
for rotation direction.
3 Strainer, suction valve or pipe obstructed ► Check and clean parts.
4 Suction pipe or shaft seal leaks ► Check the suction line (connecting points,
valves).
► Check the shaft seal.
5 Suction head too high ► Reduce the suction head (level difference).
► Reduce pipe length.
► Increase pipe diameter.
► Reduce viscosity of the medium (heat up).
► Install a larger suction filter.
6 Axis fault pump – coupling – motor ► Align the shaft end more exactly.
► Balance the coupling.
7 Vibrations and pulsation in the system ► Provide a flexible bearing arrangement for the
unit.
► Make the connections with hoses.
8 Overpressure valve jammed or set too low ► Check or adjust the valve.
9 Incorrect voltage or frequency ► Check the speed and power consumption
of the motor.
► Compare the voltage and frequency with the
rating plate.
10 Fluid viscous ► Increase the fluid temperature.
► Reduce the rotation speed.
11 Airlock or gas in the fluid ► Remove the airlocks.
► Reduce the suction head or increase the inlet
pressure.
12 Pump does not vent ► Vent the pressure pipe at the highest point.
13 Motor bearing damaged ► Redo the motor bearing.
14 Shaft seal damaged ► Replace the shaft seal.
15 Inset pressure too high or too low ► Reduce the inlet pressure at the installation.
► Install a non-return valve at the pressure end.
16 Cold start when pumping heavy oil ► Install a pump heating.
17 Overflow valve flutters ► Increase the opening pressure by turning the
adjusting screw clockwise.
18 Leaking non-return valves ► Clean the non-return valves.
- 19 -
Edition: 11/2008
OID 01en
APPENDIX
EXPLODED VIEWS
Insert pump FE 5
- 20 -
Edition: 11/2008
OID 01en
Insert pump NE 5 – 13
al
anic al se
g/ mech
un
ring dicht
Gleit
aft seal
ial sh
/ rad
ht ring
aldic
Radi
Insert pump NE 15 – 57
g
earin
utsi de b
run g/o
nlage
Auße
al
anic al se
/ mech
ung
ringdicht
Gleit
al
l sh aft se
radia
ng /
ald ichtri
Radi
- 21 -
Edition: 11/2008
OID 01en
Insert pump CLDR 15 – 42
l
l sea
echanica
n g/m
ichtu
ringd
Gleit
al
haft se
dial s
tring / ra
ldich
Radia
Outside bearing
1) CLDGA 15 – 26
2) CLDGA 32 – 42
- 42
GA 32
D(E)
2) CL
- 26
DG A 15
1) CL
- 22 -
Edition: 11/2008
OID 01en
Insert pump CLDR 55 – 118
eal
anical s
g/ mech
gdic htun
Gleitrin
seal
dial shaft
tring / ra
ldich
Radia
Outside bearing CLDGA 55 – 118
- 23 -
Edition: 11/2008
OID 01en
SECTION VIEWS / SPARE PARTS

Station DL2 / 150–240
894. 2 908. 2 739. 2

529 2
900. 4 606. 2 704.1
894. 2 155.1 739. 1
052 870. 1 915. 2
901 055.1
180 885
735. 1 040 915. 3
060
304 908. 1 704. 2
119
222. 1 137 166 739. 3
501
809.1 300
001 751.1 859
900. 3
894.1
908. 2 222. 2
241 900. 2
Station DL2 / 320 – 1300
894.2 908.2 739.2

529
900.4 606.2 704.1
894.2 155.1 739.1
052 870.1 915.2
901 055.1
180 885
735.1 040 915.3
060
304 908.1 704.2
119
222.1 137 166 739.3
501
809.1 300
001 751.1 859
900.3
894.1
908.2 222.2
241 900.2
*001 Insert pump 304 Control plug *870.1 Circlip

040 Sleeve *501 Spring 885 Set screw
*052 Coupling 529 Motor 894.1 Hexagonal nut
*055.1 Seal ring *606.1 Shut-off pressure gauge 894.2 Hexagonal nut
060 Washer *606.2 Shut-off pressure gauge 900.1 Hexagon screw
119 Pressure housing 704.1 Flange 900.2 Hexagon screw
137 Valve casing 704.2 Flange 900.3 Hexagon screw
155.1 Pipe *735.1 Copper seal 900.4 Hexagon screw
166 Adjusting screw *739.1 O-ring 901 Stud screw
180 Pump bracket 739.2 O-ring 908.1 Screw plug
*222.1 Flat gasket 739.3 O-ring 908.2 Screw plug
*222.2 Flat gasket *751.1 Spring 915.1 Screw plug
241 Oil pan *809.1 Ball 915.2 Socket screw
300 Switching lever 859 Adapter sleeve 915.3 Socket screw
- 24 -
Edition: 11/2008
OID 01en
Station DS1
A
Detail: Z
900.3
Sectional view: A-B 894.1
904.2
739.2
529 180
894.2
052 894.2
076
900.2 901.2
735.1 155.1 893
900.1 901.1
423 739.1
116.1 116.2 001 501
*675 222 606.1
894.2 901.3 908.1 055.1
904.1 160 241 018
B Z
001 Insert pump 241 Oil pan 894.2 Hexagonal nut

*018 Strainer 423 Vent valve 900.1 Hexagon screw
052 Coupling 501 Conical spring 900.2 Hexagon screw
*055.1 Seal ring 529 Motor 900.3 Hexagon screw
076 Strainer cover *606.1 Shut-off vacuum gauge 901.1 Stud screw
116.1 Main housing left *735.1 Copper seal 901.2 Stud screw
116.2 Main housing right *739.1 O-ring 901.3 Stud screw
155.1 Pipe 739.2 O-ring 904.1 Washer
160 Angle 893 Cap nut 904.2 Washer
180 Pump bracket 894.1 Hexagonal nut 908.1 Screw plug
*222 Flat gasket
Control block
915.4
*055.1 Seal ring

055.1
606.2
165.2
869.1
13 7
88 6
30 0
86 8
137 Valve casing

165.1 Screw plug
165.2 Screw plug
165.3 Screw plug
165.3 166 Adjusting screw
298 Valve insert
299 Valve insert
300 Switching lever
*304.1 Valve cone
*304.2 Valve cone
312 Adjusting spindle
407 Control ball
*456 Molded gasket
*606.2 Shut-off pressure gauge
704 Flange
166
407
312
704
751.1
165.1
809.1
739.5
739.8
*739.3 O-ring
*739.4 O-ring
*739.5 O-ring
739.3
751.3
304.2
739.4
739.8 O-ring
298
765
456
*751.1 Spring
*751.2 Spring
*751.3 Spring
*765 Disk spring
*809.1 Ball
868 Support ring
*869.1 Circlip
886 Set screw
915.4 Socket screw
299
751.2
304.1
739.3
- 25 -
Edition: 11/2008
OID 01en
Station DL3, DL4, DS3, DS4

900. 3
Detail: Z 894. 1
529 904. 2
894. 2 739. 2
052
180 894. 2
900. 2
155. 1 076
*675 901.1
901. 2 739.1
116. 1 893 423 501
900.1
904. 1 018
735.1 001
894. 2
901. 3 116.2 606.1
160 241 908. 1
001 Insert pump 423 Vent valve 900.1 Hexagon screw

*018 Strainer 501 Conical spring 900.2 Hexagon screw
052 Coupling 529 Motor 900.3 Hexagon screw
076 Strainer cover *606.1 Shut-off vacuum gauge 901.1 Stud screw
116.1 Main housing left *735.1 Copper seal 901.2 Stud screw
116.2 Main housing right *739.1 O-ring 901.3 Stud screw
155.1 Pipe 739.2 O-ring 904.1 Washer
160 Angle 893 Cap nut 904.2 Washer
180 Pump bracket 894.1 Hexagonal nut 908.1 Screw plug
241 Oil pan 894.2 Hexagonal nut
Control block
*055.2 Seal ring
111.2
606.2
055.2
908.2
869.1
739.5
111.1 Welding neck flange

886
868
300
111.2 Welding neck flange

A 137 Valve casing
166 Adjusting screw
C *222 Flat gasket
298 Valve insert
299 Valve insert
300 Switching lever
*304.1 Valve cone
*304.2 Valve cone
312 Adjusting spindle
407 Control ball
*456 Molded gasket
*606.2 Shut-off pressure gauge
729.1 Flat gasket
B D 729.2 Flat gasket
*739.3 O-ring
900.4
729.2
751.1
809.1
729.1
900.4
111.1
*739.4 O-ring
166
407
137
312
*739.5 O-ring
*751.1 Spring
304.2
739.3
304.1
*751.2 Spring
298
*751.3 Spring
*765 Disk spring
*809.1 Ball
868 Support ring
*869.1 Circlip
Sectional view: A-B Sectional view: C-D 886 Set screw
900.4 Hexagon screw
908.2 Screw plug

222
765
456
299
739.4
739.3
751.3
751.2
- 26 -
Edition: 11/2008
OID 01en
Station DL7, DS7, DCL7, DCS7
052 870. 2
222 300 Detail: Z
076 423
893 111. 2 908. 3
901.1 *611
501.1 116 111.1 894.1
739.1 001 *304.2 900.1
739. 3
915. 2 739.2
018 304.1
908.1
915.1 739. 6
164. 2 121
908. 2
*Item 304. 2 *Item 611

894. 3 529 870.1
900. 3 884.1 884. 2

180 739.4 164. 1
606. 2 739. 7
894. 2 809. 1
901. 2 751. 2
312 066
900. 2 304. 3 870. 3
606. 1
739. 5 501. 2
301
717 241 751. 1
304. 2 057
859 306 137

854
Z
001 Insert pump *306 Adjusting nut *870.1 Circlip

*018 Strainer 312 Adjusting spindle *870.2 Circlip
052 Coupling 423 Vent valve *870.3 Circlip
057 Threaded ring 501.1 Conical spring 854 Split pin
066 Sealing washer *501.2 Spring 859 Adapter sleeve
076 Strainer cover 529 Motor 884.1 Set screw
111.1 Welding neck flange 606.1 Shut-off vacuum gauge 884.2 Set screw
111.2 Welding neck flange 606.2 Shut-off pressure gauge 893 Cap nut
116 Aggregate casing *611 Non-return valve 894.1 Hexagonal nut
121 Strainer housing *717 Thermometer 894.2 Hexagonal nut
137 Valve casing *739.1 O-ring 894.3 Hexagonal nut
164.1 Adjusting screw *739.2 O-ring 900.1 Hexagon screw
164.2 Adjusting screw *739.3 O-ring 900.2 Hexagon screw
180 Pump bracket *739.4 O-ring 900.3 Hexagon screw
*222 Flat gasket *739.5 O-ring 901.1 Stud screw
241 Oil pan *739.6 O-ring 901.2 Stud screw
300 Switching lever *739.7 O-ring 908.1 Screw plug
301 Disk spring *751.1 Spring 908.2 Screw plug
304.1 Control plug suction end *751.2 Spring 915.1 Socket screw
304.2 Control plug pressure end *809.1 Ball 915.2 Socket screw
*304.3 Valve cone
- 27 -
Edition: 11/2008
OID 01en
Insert pumps
FE 5 NE 5 – 13 866 NEG 5 – 13
870 457
866 915.1
915.1 063 735 155
735 080 869 074
870 062
080
063 739.2 745 739.2
745
809
131 056 817
739.2
879 042
751
739.3 739.3 669 739.3
417 042
669
070 070
131 131 669
915.2
915.2 417 915.2 417
070
NE 15 – 57 NEG 15 – 57 NEGA 15 – 57
866
052
866 745 457
063 870 058 870
870 915.1
059 739.1 039 739.1 817

127
739.2 739.2
861 861
056 056
739.3 739.3
869 869
042 042
669
131 669 131
070
915.2 070 915.2
039 Distance sleeve 127 Bearing housing 751 Spring

*042 Balancing cylinder *131 Casing 809 Ball
052 Coupling 155 Pipe *817 Ball bearing
056 Spacer ring *417 Cylinder strainer 861 Straight grooved pin
058 Mounting ring *457 Mechanical seal 866 Key
059 Mounting ring *669 Screw set *869 Circlip
062 Spacer *735 Copper seal *870 Circlip
063 Support ring *739.1 O-ring 879 Straight pin
070 End cover *739.2 O-ring 915.1 Socket screw
074 Flange cover *739.3 O-ring 915.2 Socket screw
080 Bearing cover *745 Radial seal ring
- 28 -
Edition: 11/2008
OID 01en
CLDR 15 – 42 CLDG 15 – 20 CLDR 55 – 118 CLDG 55 – 118
063 859 866 859 457

457
866 884.1 869.1
868 134 063 884.1 041
868
745 915.1 041 745 915. 2
134 809
869.1 817
134 222. 2 454
222. 2 809 222.1
751 868
817 751
222.1
074 074 056
739.1 739.1
915.1
454
131 042
739. 2 1037
1037
739. 2 661
661
131
CLDGA 32 – 118
074.1 222 859 817 074.1 859 062.1 464 817 057 661.1
868
041
869
915.1 041 134 135 870 661.1 915.4 872 127 074.2 915.3
041 Distance sleeve *222.1 Flat gasket *817 Ball bearing

*042 Balancing cylinder *222.2 Flat gasket 859 Adapter sleeve
056 Spacer, from Size CL 55 454 Edge seal 866 Key
057 Threaded ring *457 Mechanical seal 868 Support ring
062.1 Spacer 464 Nilos ring 869 Circlip
063 Support ring 661 Screw set 870 Circlip
074 Flange cover 661.1 Screw set 884.1 Set screw
074.1 Flange cover *739.1 O-ring 915.1 Socket screw
074.2 Flange cover *739.2 O-ring 915.2 Socket screw
127 Bearing housing *745 Radial seal ring 915.3 Socket screw
*131 Casing 751 Spring 915.4 Socket screw
134 Seal casing 809 Ball 1037 Bearing bush set
- 29 -
Edition: 11/2008
OID 01en
TABLE OF TIGHTENING TORQUES
Tighten all the screws with the torque according to the following table.
Thread Tightening torque [Nm] for

screws with metric threads and head contact surfaces
(DIN 931, 934, 912)
Material quality
8.8 8.8 + aluminum
M3 1,5 1,2
M4 2,9 2,3
M5 6,0 4,8
M6 9,5 7,6
M8 23,1 18,4
M 10 46 36,8
M 12 80 64
M 14 127 101
M 16 194 155
M 18 280 224
M 20 392 313
M 24 675 540
- 30 -
Edition: 11/2008
OID 01en
NOTES
- 31 -
KRAL OPERATING INSTRUCTION
KRAL AG, Bildgasse 40, Industrie Nord, 6890 Lustenau, Austria, Tel.: +43 / 55 77 / 8 66 44-0
Fax: +43 / 55 77 / 8 84 33, www.kral.at, E-Mail: kral@kral.at
OM5542_01#A.2
CIRCULATION PUMPS IN TF SYSTEM
Circulation pumps
in a thermal fluid system
Circulation pumps in TF system
Table of Content
1 General ...................................................................................................................2
2 Centrifugal pumps ..................................................................................................2
2.1 Prevent cavitation .............................................................................................3
2.2 Priming .............................................................................................................3
3 Pump motor ............................................................................................................3
3.1 Motor protection...............................................................................................3
3.2 Standstill heating ..............................................................................................4
4 Explanation of parts of the pump set ......................................................................4
4.1 Compensators ...................................................................................................4
4.2 Flexible coupling ..............................................................................................5
4.3 Mechanical seals ..............................................................................................5
4.4 Strainers............................................................................................................6
4.5 Recirculation line for stand-by pump ...............................................................6
4.6 Non return valve ...............................................................................................6
4.7 Drain valve .......................................................................................................6
4.8 Stand-by function .............................................................................................6
5 Maintenance ...........................................................................................................7
5.1 Cleaning the strainers .......................................................................................7
6 Appendix 1 .............................................................................................................8
7-50 Language
/ 60 UK LanguagePage
UK 1/11
OM5542_01#A.2
Circulation pumps
1 General
This document describes the function of the components and the most common
variations in set-up of circulation pump-sets in our thermal fluid systems.
For specific installation, operation and maintenance instructions please find the
specific product documentation in your project manual.
Depending on the size and requirement of your thermal fluid system there can be
one or several circulation pumps installed (see appendix 1).
All circulation pumps in our thermal fluid system are standardised centrifugal
pumps according to DIN 24255 (EN733). We do not advise to change the type or
capacity of the circulation pumps without consulting Alfa Laval first about possible
consequences to the system
The function of circulation pumps in a thermal fluid system is to transport the heat
generated in the heaters to the consumers by providing fluid circulation. The flow
rate in the system is carefully calculated to ensure the most optimum heat transfer.
During system operation there should always be at least one circulation pump in
operation to avoid damage to the system due to local over heating.
Important: Circuit fluid flow must not be stopped during operation
2 Centrifugal pumps
The circulation pumps used in our thermal fluid system are high quality centrifugal
pumps. This type of pump is best suited because:
• They can work on high temperatures and no additional cooling is required
• No heat transfer to the motor—the pump chamber is separated from the motor
by an air gap; this provides a thermal barrier.
• They are provided with heavy duty groove ball bearings which are virtually
maintenance free and can absorb more radial forces and temperature changes.
• They are provided with a flexible coupling which is installed to compensate for
the temperature growth of the pump during operation.
• Easy maintenance - Back pull out design allows bearing housing and rotating
element removal without disturbing discharge and suction piping.
• They have quiet operation and a long service life
Language UK
Language UK 7-51 2/11
Page / 60
OM5542_01#A.2
Circulation pumps
2.1 Prevent cavitation
The pumps should be placed in the lowest part of the return line to have the lowest
temperature of thermal fluid (lower risk of cavitation) and to ensure that the pressure
present at the pressure maintaining point (connection of the expansion line to the
circuit system) is optimal.
The dimension of the suction line is calculated so that the pressure drop is as low as
possible to keep the cavitation in the suction socket to a minimum
2.2 Priming
The centrifugal pumps are not self-priming and the pump casing must be filled with
liquid before the pump is started, or the pump will not be able to function. If the
pump casing becomes filled with vapors or gases, the pump impeller becomes gas-
bound and incapable of pumping.
To ensure that the pump remains primed and does not become gas-bound, the pump
set is installed below the expansion tank to provide static pressure or a pressurized
expansion vessel is fitted. To make the pressure maintaining point optimal the
pumps should always be placed as low as possible in the return line.
3 Pump motor
Electrical motors are energy transformers. They take in electrical energy and
transform it into mechanical energy. This process causes energy losses, which takes
the form of heat. The motors are designed to comply with degree of protection IP55
(degree of protection is indicated on rating plate).
3.1 Motor protection
All electric motors in our system are equipped with a thermal overload protection in
the control panel. The motor protection device allows full use and efficient operation
of the motor. It will react quickly in case of an overload/ short circuit before any
damage occurs to the motor.
Please be aware of temperature within the control panel as the protection device is
equipped with a bimetal part that has a limited temperature range that will be
influenced by the ambient temperature. Please check the specific data sheets/ project
information for details on temperature limits.
Most breakdowns are caused by an overload. Insulation faults leading to earth faults,
turn-to-turn or winding short circuits are caused by excess voltage or contamination
by dampness, oil, grease, dust or chemicals. Below table shows the most frequent
breakdown causes for motors, their extent and the possible damage caused.
7-52 Language
UK 3/11
OM5542_01#A.2
Circulation pumps
Cause Effect Possible damage
Thermal overload : overcurrent and soldered joint damage

• extreme starting conditions thus unacceptable rotor cage
• locked rotor heating-up of burnt windings
• high overload windings stator windings
• under voltage
• intermittent operation
Cooling problems :
• restricted cooling unacceptable burnt windings
• ambient temperature too high heating-up stator windings
Electical causes :
• single phase conditions unbalanced individual windings or
• unbalanced voltage overcurrent of parts burnt
• earth fault windings heating-up
• shorted turns depending on motor
• winding short circuit size and bearing
damage load
Mechanical causes :
• imbalance uneven wear of bearing damage
• mis-alignment bearings
• improperly installed drive
3.2 Standstill heating
Motors above 5.5kW are equipped with anti-condensation/ stand still heating to add
protection against corrosion damage in a humid environment. The heating should be
switched on as soon as the pump is switched off.
Important: Do not switch on the anti-condensation heating during operation.
4 Explanation of parts of the pump set

Depending on the amount of pumps (one or more) that are fitted the following
equipment can be installed:
4.1 Compensators
Depending on Class requirements stainless steel double braided compensators are

fitted to compensate for lateral movement and absorb vibrations resulting from
temperature changes and vessel operation.
This type of compensators is designed to take straight movement only and may
therefore never be installed between piping that does not align.
Language UK
Page / 60
OM5542_01#A.2
Circulation pumps
4.2 Flexible coupling
The purpose of the flexible coupling is to compensate for temperature changes in the
couplings and shafts, and to permit axial movement of the shafts without
interference with each other while power is transmitted from the driver to the pump.
Important: The flexible coupling should never be used to compensate for

misalignment of the pump and driver shaft.
4.3 Mechanical seals
The function of the mechanical seal is to prevent liquid under pressure from leaking
out of the pump. Since the seal must function as a slider or friction bearing, the seal
has an unpredictable life span. The seal of a centrifugal pump is usually replaced
many times during the life of the pump.
Some operational conditions that can cause extra wear or break down a mechanical
seal are:
• Operating the pump without liquid, even for a very short period of time. Dry
running occurs when there is no liquid around the seal, either due to the absence
of pumped medium in the pump or poor venting, resulting in the formation of air
around the seal.
The absence of lubricating film causes the friction between the seal faces to
increase. Consequently, the temperature rises dramatically and the seal faces
become very hot. The excessive heat can damage the primary ring and/or the o-
ring.
• Abrasive particles in the liquid being pumped. These abrasive particles infiltrate
with the liquid between the seal faces and grind away the carbon primary ring.
The normal shiny face of the primary ring and mating ring can become rough
and uneven and the sealing gap opens correspondingly The result is a leaking
shaft seal. The leakage is small at the beginning, accelerating as more liquid
passes the sealing gap.
• Misalignment e.g shaft misalignment, seats not mounted perpendicular to the
shaft, axially moving shaft etc. The misalignment will cause extra stress on the
pump shaft, bearings and mechanical seal.
• Mechanical vibrations; these can be generated from friction between seal faces,
worn bearings or operational vibration in the vessel itself. Vibration results in
higher forces on each part of a mechanical shaft seal. The result is extended
wear on all parts, chipped seal rings and possibly opening of the sealing gap.
Note: Mechanical seals are classified as “wear& tear” parts and as such
excluded from our warranty.
7-54 Language
UK 5/11
OM5542_01#A.2
Circulation pumps
4.4 Strainers
Solid particles in the thermal fluid can be problematic and they can damage the
pump housing or impellor. To safeguard the pumps from damage by solid particles
strainers have been fitted in the supply line to the pump(s).
We also provide fine mesh inserts to be used during commissioning. These inserts
strain out even smaller particles than the regular strainer baskets. Due to the extra
resistance they can only be used during commissioning and they have to be removed
when normal operation is started.
4.5 Recirculation line for stand-by pump
When two or more pumps are fitted for which one is used as a stand-by pump a
recirculation line is installed between the pumps. In the recirculation line a manual
control valve is fitted for flow regulation.
During operation this valve is opened slightly to keep a hot thermal fluid flow over
the stand-by pump to keep the stand-by pump on operating temperature.
4.6 Non return valve
Non return valves are installed on the pressure side to prevent reverse flow through
the pump that is not running (on stand-by).
4.7 Drain valve
Each pump is provided with a drain valve that can be connected to the drain storage
tank and or the suction line of the filling pump.
4.8 Stand-by function
We use two variations of stand-by functions:

• For an “open” system”, fitted with an expansion tank open to atmosphere. This
is based on the system pressure with a pressure switch in the supply line after
the pumps. When the system pressure drops below the set value, the stand-by
pump will start.
• For a “closed” system, fitted with a pressurized expansion vessel. This is based
on the differential pressure over the pump set. A differential pressure switch is
installed over the complete pump set and when the differential pressure drops
below the set value the standby-pump will start.
Language UK
Page / 60
OM5542_01#A.2
Circulation pumps
5 Maintenance
rules and regulations from the authorities. Please consult the product specific manual
of the pumps and motors for guidance on maintenance and recommendations for
periodical inspections.
Caution!: pump and connecting pipework may be hot.
5.1 Cleaning the strainers
a. Turn off pump and secure the pump.

b. Close control valve in recirculation line.
c. Close suction valve
d. Close valve in supply line
e. Open drain valve to drain the fluid.
f. Vent from manometer connection
g. Carefully open strainer housing and take out strainer basket.
h. Clean strainer with compressed air
i. Return the clean basket and close the housing.
7-56 Language
UK 7/11
OM5542_01#A.2
Circulation pumps
6 Appendix 1
Typical diagrams of circulation pumps for one or two heaters, stand-by with pressure switch.
Language UK
Page / 60
OM5542_01#A.2
Circulation pumps
Typical diagrams of circulation pumps for one or two heaters, stand-by with differential pressure switch.
7-58 Language
UK 9/11
OM5542_01#A.2
Circulation pumps
Tag number Description

1T400 Centrifugal pump with E-motor
1T411 Stop valve, Bellow seal
1T412 Strainer
1T413 Bellow with double braiding and flanges
1T415 Pressure gauge
1T416 Manometer valve with test connection
1T417 Syphon pipe
1T418 Stop valve, Bellow seal with Control disc
1T422 Syphon pipe
1T424 Stop valve, Bellow seal with loose disc
1T425 Pressure switch
1T427 Syphon pipe
1T428 Differential pressure switch
1T432 Strainer
1T437 Syphon pipe
1T442 Syphon pipe
1T447 Syphon pipe
1T448 Differential pressure switch
1T452 Strainer
Language UK
Language UK 7-5910/11
Page / 60
OM5542_01#A.2
Circulation pumps
1T457 Syphon pipe
1T462 Syphon pipe
7-60 Language
/ 60 UK Language UK11/11
Page
TABLE OF CONTENTS
Table of contents
Expansion Tank & System Pipes

.
Expansion Tank......................................................... D75126-00140............. 8-2
Expansion vessel hot water with bladder diaphragm....... OM9600_01................ 8-3
Language UK 8-1 / 6
DATA SHEET
Tag No(s):
Type
• Hot water, pressurized expansion tank.
H2
Application B
60
• Containment of water for maintaining of
°
L1
Front
system pressure.
Technical data B
L
• Max pressure: 3 bar
• Pre-pressure: 1.5 bar I.D.
• Volume: 140 L
• Weight: 42 kg
H1
Dimension
• L: 196
• L1: 40
• L2: 151
• H: 1275
• H1: 210
• H2: 96
H
• H3: 142
• H4: 27
• H5: 185
• H6: 20
• I.D.: 840
• I.D.1: M8
30°
Front
A
L2
20° 5°
H4
G3/4'' X
H5
H3
R3/4''
H6
I.D.1
A-A B-B X
Type No.: 9600

Version: B.2 Expansion Tank D75126-00140
8-2 / 6 Language UK
OM9600_01#A.3
EXPANSION VESSEL HOT WATER WITH BLADDER DIA-
Expansion vessel hot water
PHRAGM
with bladder diaphragm
Expansion vessel hot water with bladder

Table of Content
diaphragm
1 General ...................................................................................................................1
1.1 storage ..............................................................................................................1
1.2 Observing the parameters .................................................................................1
2 installation ..............................................................................................................1
3 Commissioning ......................................................................................................3
3.1 Setting the pre-set pressure: .............................................................................3
3.2 Filling pressure .................................................................................................4
4 Maintenance ...........................................................................................................4
1 General
These instructions are intended for qualified personnel. They must be read before
commencing installation work and stored in a safe place by the operator. Personnel
must possess the appropriate skills and training.
1.1 storage
Store dry and protected from the elements in original packing. Only install in secure
well ventilated rooms free of frost.
1.2 Observing the parameters
Please refer to the label and the technical specifications for details regarding the
manufacturer, year of construction, production number etc. It is important that
admissible temperatures and pressures are not exceeded. In case of deviations from
the admissible internal bag temperature (TB) a temperature blocking pipe is to be
installed in the expansion line.
2 installation
Prior to the assembly a visual inspection of the vessel is to be performed. In case of
serious damage the vessel must not be used.
Important: Welding to the vessel is not allowed and will invalidate the
warranty.
Protection against accidental contact in case of excessive high temperatures.

Insulation measures are typically limited to the expansion lines and intermediate
vessels in heating systems. Do not insulate the expansion vessel.
Language UK
Language UK 8-3 1/4
Page /6
OM9600_01#A.3
PHRAGM

The expansion vessel is installed in a standing position. The intended location
should have a level surface and a connection to drainage. The ambient temperature
must not be below 0°C. The connection pipe to the system must not be narrower
than the nominal diameter of the vessel connection. The vessel is connected to the
return line of the installation. The vessel is safeguarded against excess pressure by a
safety valve (1T187).
Figure 1
Tag number Description

1T180 HW Expansion vessel
1T183 Syphon pipe
1T186 Syphon pipe
1T187 Safety valve
1T188 Stop valve
HW Expansion vessel
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OM9600_01#A.3
PHRAGM

3 Commissioning
The expansion vessel is fitted with a gastight rubber bag (bladder diaphragm) inside
dividing the vessel hermetically into a gas space and a water space. The expansion
water is inside the bag, while the gas space is between the bag and the vessel wall.
The water connection to the installation and the gas filling valve are located at the
bottom.
The expansion vessel is provided with a pre-set gas pressure at the factory. On
account of transport regulations this is a low pressure. Depending on the systems
requirements the factory set pre-set pressure needs to be raised before installation.
To find the right pre-set pressure for your system please see the technical
specification sheet (first chapter of operation manual). The pre-set pressure (P0), the
initial pressure (pa) and end pressure (pe) can also be found on the type plate on the
expansion vessel.
Figure 2
Schematic pressure and temperature
3.1 Setting the pre-set pressure:
• Correct gauging of the pre-pressure is only possible when the water bladder is
empty so make sure the vessel is empty on the water side.
• remove the air valve cover at the bottom or top of the vessel
• set the pressure at the gas filling valve. This can be done with regular air
pressure. Set the pre-pressure at the correct value as shown on the specification
sheet. Do not over pressurize!
• tightly close the valve cover.
Important: Set the pre-pressure at the value indicated on the specification

sheet or type plate. Do not exceed this value!
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OM9600_01#A.3
PHRAGM

Important: Parallel connected vessels must be the same size and have the same
pre-set pressure
3.2 Filling pressure
With the installation completely filled and well de-aerated, the filling pressure =
initial pressure (pa) is set a little higher than the pre-set pressure of the empty vessel.
In this way correct pressurization is assured.
As the temperature of the system water rises ,its volume increases. This additional
volume (expansion) causes the pressure to rise in the expansion vessel, because the
gas cushion is the only compressible volume in the system. When the system water
cools its volume diminishes. Consequently the pressure in the system becomes lower
than that in the vessel, and the gas cushion forces water back into the system.
4 Maintenance
rules and regulations from the authorities.
Caution!: Expansion vessel and connecting pipework may be hot.
Prior to maintenance work, inspections and dismantling the vessel must be

unpressurized and cooled down.
• Shut off and evacuate on the water side.
• Depressurize at the gas filling valve on the gas side.
This type of expansion vessels is virtually maintenance-free. In general, it is

sufficient to control the initial pressure (pa) once a year and the pre-pressure (P0)
every 5 years. These maintenance intervals apply to installations with leakage rates
3 litre or 0.5% of the installation volume. Installations with higher leakage rates may
require shorter service intervals.
The difference between the original pre-pressure and the service reading should be
no more than -0.2 bar(g).
P0: Maintenance interval ≤ 5 years: ∆P0 ≤ − 0.2 bar(g)
pa: Maintenance interval ≤ 1 year: ∆pa ≤ − 0.2 bar(g)
Automatic water make up systems must set the filling pressure (pa) and must
replenish when pressure falls by − 0.2 bar(g).
Internal checks can be done on the endoscopic opening on the bigger vessels, the
smaller sizes only have partial sized openings. The corrosion allowance is 0.5mm.
For the bigger sizes it is possible to exchange the rubber bag inside when this is
damaged, with smaller sized vessels the entire vessel is exchanged.
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TABLE OF CONTENTS
Table of contents
Heat-Exchanger
.
Electrical Heater - EH20............................................. 13K4001..................... 9-3
Electrical Heater Hot Water System............................. OM8642_02................ 9-4
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TABLE OF CONTENTS
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13K4001#A.3
ELECTRICAL HEATER - EH20
Electrical Heater - EH20
Language UK 9-3 / 9
OM8642_02#A.3
ELECTRICAL HEATER HOT WATER SYSTEM
Electrical heater hot water system
Description & maintanance
Electrical Heater Table

Hot ofWater
ContentSystem
1 Electrical heater ......................................................................................................1

1.1 Intended use......................................................................................................1
1.2 Safety valve ......................................................................................................2
1.3 Monitoring flow through the heater .................................................................2
1.4 Maximum water temperature ...........................................................................2
1.5 Temperature sensors.........................................................................................2
1.6 Temperature indicators .....................................................................................3
1.7 Valves in the supply and return line .................................................................3
2 Main components of heating element ....................................................................3
3 Safety notes for operation & maintenance .............................................................4
4 Maintenance ...........................................................................................................4
4.1 Daily operation .................................................................................................4
4.2 Monthly routine checks ....................................................................................5
5 Replacing a heater element ....................................................................................5
6 Water quality ..........................................................................................................6
1 Electrical heater
1.1 Intended use
The electrical heater is intended exclusively for heating thermal fluid according to
the specifications of the commissioning and operating manuals for the thermal fluid
system.
Figure 01
Schematic view electrical heater
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OM8642_02#A.3
Tag. No. Description

1T Electrical heater
1T1 Safety valve
1T3 Stop valve with loose disc (non-return)
1T7 Drain valve
1T8 Remote controlled 3-way valve (OPTIONAL)
1T9 Vent valve
1T20 Temperature transmitter (return)
1T21 Temperature transmitter (supply)
1T24 Temperature switch (fluid)
1T34 Indicating differential pressure switch
1.2 Safety valve
Safety valve (1T1) is installed to make sure the pressure in the heater does not rise
above the maximum allowable pressure. If the pressure rises above the set point the
safety (relief) valve will open to vent of the excess pressure. The amount of safety
valves depends on the system temperature and class requirements.
If the safety (relief) valve has been activated it must be checked (pressure tested)
and the set points of electronic temperature controller and maximum temperature
alarm must be checked and tested on their correct function.
1.3 Monitoring flow through the heater
The fluid flow through the heater is monitored with an orifice in combination with
an indicating pressure differential switch (flow switch, 1T34). This device is
installed in the outlet of the thermal fluid heater and measures the differential
pressure over the orifice. The differential pressure is an indication of the flow. When
there is insufficient flow through the heater it will be stopped, electrically blocked
and an alarm will be generated.
1.4 Maximum water temperature
A temperature switch (1T24) is installed in the supply line to make sure that the
water temperature does not rise above a set value. When this switch is activated the
heater will be stopped, electrically blocked and an alarm will be generated.
1.5 Temperature sensors
The signal of the temperature sensor in the supply line (1T21) is used in
combination with a temperature controller in the control box to control the heater
elements.
The signal of the temperature sensor in the return line (1T20) is used for the display
of temperature on the control box.
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OM8642_02#A.3
1.6 Temperature indicators
Temperature indicators can be installed to read out the temperature. The amount and
position of the temperature indicators depends on class requirements and or
customers preferences.
1.7 Valves in the supply and return line
The stop valves in the supply (1T3) and return (1T2) lines are installed to remove
the heater from the circulation flow. When these valves are closed the by-pass valve
(1T4) should be opened
The stop valve in the return line (1T2) is equipped with a control disc and is used for
fine tuning of the flow through the heater during commissioning.
It is also a possibility to have a remote controlled 3-way valve installed to by-pass

the flow through the heater.
2 Main components of heating element
Figure 1 Heating element

1. Spacer plate/ flow labyrinth
Holds the heating rods and stabilises the heating rod bundle
2. Heating rods
Transfer the energy to the medium; their thermal surface load is adapted to the
medium to be heated.
3. Flange plate
Seals the vessel towards the medium, its dimensions result from nominal width and
operating pressure
4. Cooling section
Ensures lower temperatures in the connecting housing than in the medium, it must
therefore not be thermally insulated.
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OM8642_02#A.3
Important: Do not insulate the cooling section
5. Connecting housing
Houses the terminals
6. Screwed cable glands
Seal the cables towards the housing and act as a strain relief
3 Safety notes for operation & maintenance
• Hot parts may be dangerous. Such parts must be secure against contact and
danger warnings must be affixed to them.
• Any protection against contact with hot parts may only be removed when the
electrical heater is switched off and the temperatures are below 40ºC
• It is strictly forbidden to walk on the heating elements of the electrical heater
• Before performing any form of maintenance or work on the heater, the heater
must be: switched of, electrically blocked and secured against resetting and
cooled down sufficiently. The applicable safety regulations must be observed.
Immediately upon completion of the work, all safety, shut-off and protective
devices must be reset and/ or switched on again.
4 Maintenance
A trouble free and safe operation requires regular maintenance. However an
electrical heater for thermal fluid requires almost no maintenance. Maintenance
should always be executed with skill and in accordance with valid rules and
regulations from the authorities, below are given some recommendations for
periodical inspections and maintenance.
4.1 Daily operation
During normal operation of the heater some work and check procedures have to be
considered every day.
• Visual check of the outside, look for any abnormalities
• Check flow over the heater.
• Check the water temperature.
• Cooling surfaces and ventilation slots must be kept free from dust and must not
be covered or obstructed.
• If there is a drop in the output which is not related to other causes it could be
that the electrical heating elements are dirty. The electrical elements may only
be cleaned by a professional, certified company. For further information please
contact Alva Laval.
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OM8642_02#A.3
Caution: Never clean the heating elements mechanically
4.2 Monthly routine checks
• Test the flow alarm; Slowly close the supply valve after the circulation pump
during operation, the heater must stop and the alarm “water flow low low” must
be activated.
• Test hot water temperature alarm; decrease the set point of the temperature
switch (1T24) during operation, the heater must stop and the alarm “warm water
temperature high high” must be activated. Return the set point to its original
position
• After one month of operation under nominal voltage the terminals must be
retightened.
• The dirt traps must be checked for contamination regularly and as required.
• Air filters in the control cabinet must be checked and cleaned regularly and
replaced if required.
• After each start-up of the system, but at least once a month the system must be
checked for leaks in the visible areas.
5 Replacing a heater element

If one of the heating elements is malfunctioning it must be replaced and the
following order of work must be observed:
• Switch off the electrical heater and allow it to cool down
Lock “switch off”, block electrically and secure against resetting
• Disconnect all poles from the heating element (qualified personnel only)
• When the electrical heater is cooled down sufficiently (<40ºC) drain the thermal
fluid.
When exchanging the heater element care must be taken that thermal fluid does not
drip onto any connection head of heating elements lying underneath, into thermal
insulation or onto other components, therefore for instance put a collecting tray
underneath.
Important: If any thermal fluid should leak into the insulation, the insulation
should be removed completely and replaced with new insulation
before starting the electrical heater. Otherwise there is a serious
risk of fire
When taking out the heating element check if the heating element shows any signs
of overheating in the cladding tube or on the flange, this can be seen from bent
cladding tubes or heating elements. Also check if the heating element shows signs of
corrosion or dirt deposits.
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OM8642_02#A.3
• Check the rating and voltage as per type plate on the new heating element.
• Replace the seal
• Replace the heating element
• Tighten the bolts with the correct torque
• Reconnect the electrical heating element (qualified personnel only)
• Fill the electrical heater with thermal fluid, heat up, check for leaks and after the
first cooling down retighten the seal on the heating element
• Put the thermal insulation back in place.
Important: Always contact Alfa Laval in the event of replacing a heater

element. We will provide you with the specific information you
need.
6 Water quality
The hot water system is a closed system and the water quality must be checked
when first filling the system and every time new water is added.
The water quality should be checked on the following points:
• The electrical conductivity.
• The PH-value.
• Oxygen.
• Alkality.
• Phosphate.
• Possible natriumsulphite.
In order to prevent any damage to the warm water system we advise you to check
the above-mentioned points with your local water chemical supplier.
As a guideline EN 12952-2:2001 (previous EN 12952-12:1998) can be used.
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TABLE OF CONTENTS
Table of contents
Plate Heat-Exchanger
.
Orifice Assembly - DN 25 - DN 350 - PN 40................ K18_071961.............. 10-3
Plate Heat Exchanger................................................. M6-MDFG................ 10-5
Plate Heat Exchanger................................................. M6-MFG................... 10-7
Instruction Manual - Plate Heat Exchangers.................. RTM......................... 10-8
TABLE OF CONTENTS
K18_071961#A.3
ORIFICE ASSEMBLY - DN 25 - DN 350 - PN 40
Orifice Assembly - DN 25 - DN 350 - PN 40
K18_071961#A.3
ORIFICE ASSEMBLY - DN 25 - DN 350 - PN 40
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M6-MDFG#A.4
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PLATE HEAT EXCHANGER
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Plate Heat Exchanger
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M6-MDFG#A.4
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10-7 / 36
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TABLE OF CONTENTS
Table of contents
Valves
.
Stop valve, bellow seal, straight, DN 15, PN 16............. 22046-00015.............. 11-3
Stop valve, bellow seal, straight, DN 150, PN 16........... 22046-00150.............. 11-9
Stop valve, bellow seal, straight, control disc DN 15, PN
16............................................................................ 22046-01015.............. 11-10
16............................................................................ 22046-01032.............. 11-11
16............................................................................ 22046-01040.............. 11-12
16............................................................................ 22046-01050.............. 11-13
16............................................................................ 22046-01080.............. 11-14
16............................................................................ 22046-01100.............. 11-15
Stop valve, bellow seal, straight, non return, DN 32, PN
16............................................................................ 22046-02032.............. 11-16
16............................................................................ 22046-02050.............. 11-17
16............................................................................ 22046-02125.............. 11-18
Strainer, DN 150, PN 16............................................. 22050-00150.............. 11-19
Combined ball valve set , DN 25, PN40....................... 6000000141............... 11-20
Check valve, DN 15, PN 40........................................ 6020000101............... 11-21
Safety valve, DN 25/40, PN 40/16............................... 6040000002............... 11-22
Three-way valve, ball DN 25, PN 40, build together with
actuator, solenoid valve and switch box........................ 6070000237............... 11-23
Three-way valve, ball DN 50, PN 40, build together with
actuator, solenoid valve and switch box........................ 6070000243............... 11-26
Stop valve, ball straight, DN 15, PN 40........................ 6666106.................... 11-29
Control valve 2-way linear electric actuator PR............. 72851-00................... 11-30
Control valve 3-way diverting with electrical actuator
................................................................................ 72903-00................... 11-31
Safety valve, DN 15, PN 100...................................... 87S0031.................... 11-32
ARI - FABA - Plus.................................................... RTM......................... 11-33
Operating and Installation Instructions - FABA long life /
FABA-LA................................................................ RTM......................... 11-47
Stobu Stop Valve Gland Seal...................................... RTM......................... 11-60
Straight Way Control Valve Fig 440-446...................... RTM......................... 11-73
Premio thrust actuator................................................ RTM......................... 11-86
Safety valve.............................................................. RTM......................... 11-140

TABLE OF CONTENTS
Electrical actuator, type Premio................................... OM5510_04............... 11-158

Strainer.................................................................... OM7040_01............... 11-182
Oil detection and hot-well tank.................................... OM9430_02............... 11-186

DATA SHEET
Tag No(s):
Type: Dimension [mm]:

• Stop valve with bellow seal, straight • L: 130
Size: • H: 205
• Nominal diameter: DN 15 • O.D.: 95
• O.D.1.: 125
Application:
• P.D.C.: 65
• For steam • I.D.: 15
• For thermal fluid • I.D.1.: 14
Material: • N: 4
• Body: EN-GJS-400-18U-LT Installation:
DIN -Material No. EN-JS1049,
• Seat: X20 Cr13 + QT Positions allowed Position not allowed
DIN -Material No. 1.4021 + QT
• Disc: X20 Cr13 + QT
DIN Material No. 1.4021 + QT
Technical data:
• Nominal pressure: PN 16
• Kvs: 5.3 m³/h
• Weight: 3.7 kg
• Flanges according to DIN
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010

Version: A.6 Stop valve, bellow seal, straight, DN 15, PN 16 22046-00015

DATA SHEET
Tag No(s):

Size: • H: 210
• O.D.1.: 125
Application:
• P.D.C.: 85
Material: • N: 4
Technical data:
• Kvs: 12 m³/h
• Weight: 5.6 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010


DATA SHEET
Tag No(s):

Size: • H: 210
• O.D.1.: 125
Application:
• P.D.C.: 100
Material: • N: 4
Technical data:
• Kvs: 16 m³/h
• Weight: 6.9 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010


DATA SHEET
Tag No(s):

Size: • H: 225
• O.D.1.: 150
Application:
• P.D.C.: 110
Material: • N: 4
Technical data:
• Kvs: 28.5 m³/h
• Weight: 8.9 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010


DATA SHEET
Tag No(s):

Size: • H: 230
• O.D.1.: 150
Application:
• P.D.C.: 125
Material: • N: 4
Technical data:
• Kvs: 43 m³/h
• Weight: 11 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010


DATA SHEET
Tag No(s):

Size: • H: 245
• O.D.1.: 175
Application:
• P.D.C.: 145
Material: • N: 4
Technical data:
• Kvs: 75 m³/h
• Weight: 15.3 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010


DATA SHEET
Tag No(s):

Size: • H: 430
• O.D.1.: 400
Application:
• P.D.C.: 240
Material: • N: 8
Technical data:
• Kvs: 405 m³/h
• Weight: 74 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010


DATA SHEET
Tag No(s):

• Stop valve with bellow seal, control disc, • L: 130
straight • H: 205
Size: • H1: Max. 55
Application: • O.D.1: 125
• P.D.C.: 65
Material: • N: 4
DIN -Material No. EN-JL1049
Technical data:
• Kvs: 5.3 m³/h
• Weight: 3.7 kg
O.D.1
H1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6010 Stop valve, bellow seal, straight, control disc DN
Version: A.11 22046-01015
15, PN 16

DATA SHEET
Tag No(s):

straight • H: 210
• P.D.C.: 100
Material: • N: 4
Technical data:
• Kvs: 16 m³/h
• Weight: 6.9 kg
O.D.1
H1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Version: A.1 22046-01032
32, PN 16

DATA SHEET
Tag No(s):

straight • H: 225
• P.D.C.: 110
Material: • N: 4
Technical data:
• Kvs: 28.5 m³/h
• Weight: 8.9 kg
O.D.1
H1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Version: A.1 22046-01040
40, PN 16

DATA SHEET
Tag No(s):

straight • H: 230
• P.D.C.: 125
Material: • N: 4
Technical data:
• Kvs: 43 m³/h
• Weight: 11 kg
O.D.1
H1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Version: A.1 22046-01050
50, PN 16

DATA SHEET
Tag No(s):

straight • H: 265
• P.D.C.: 160
Material: • N: 8
Technical data:
• Kvs: 105 m³/h
• Weight: 21.1 kg
O.D.1
H1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Version: A.1 22046-01080
80, PN 16

DATA SHEET
Tag No(s):

straight • H: 365
• P.D.C.: 180
Material: • N: 8
Technical data:
• Kvs: 170 m³/h
• Weight: 32.4 kg
O.D.1
H1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Version: A.1 22046-01100
100, PN 16

DATA SHEET
Tag No(s):
Type: Dimension [mm]

• Stop valve with bellow seal, non return, • L: 180
straight • H: 210
Size • O.D: 140
• Nominal diameter: DN 32 • O.D.1.: 125
Application: • P.D.C.: 100
• I.D.: 32
• For steam • I.D.1.: 18
• For thermal fluid • N: 4
Material: Installation:
• Body: EN-GJS-400-18U-LT
DIN -Material No. EN-JL1049 Positions allowed Position not allowed
• Seat: X20 Cr13 + QT
Technical data:
• Kvs: 16 m³/h
• Weight: 6.9 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Type No.: 6030 Stop valve, bellow seal, straight, non return, DN
Version: A.1 22046-02032
32, PN 16

DATA SHEET
Tag No(s):

straight • H: 230
Size • O.D: 165
• I.D.: 50
Technical data:
• Kvs: 43 m³/h
• Weight: 11 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Version: A.1 22046-02050
50, PN 16

DATA SHEET
Tag No(s):

straight • H: 395
Size • O.D: 250
• I.D.: 125
Technical data:
• Kvs: 270 m³/h
• Weight: 51.6 kg
O.D.1
H
Disc
P.D.C. / N x I.D.1
Seat
O.D.
I.D.
Body
Version: A.1 22046-02125
125, PN 16

DATA SHEET
Tag No(s):
Type Dimension: [mm]

• Strainer • H: 305
Size: • H1: 480
• Nominal diameter: DN 150 • L: 480
• L1: 50
Application
• L2: 224
• For mechanical cleaning of different me- • O.D: 285
dia in tube systems before control valves,
reduction valves, pumps, steam traps and • O.D.1.: 160
flow meters • P.D.C: 240
Material:
• I.D: 150
• I.D.1: 22
• Body: EN-GJS-400-18U-LT • N: 8
Din-Material No. EN-JS1049
Installation:
• Cover: P265 GH
Din-Material No. 1.0425
• Screen: X5 CrNi 18-10 Positions allowed
Din-Material No. 1.4301
Technical data:
• Supporting basket including standard Positions not allowed
screen: 1.6 mm
• Fine screen insert (loose): 0.25 mm
• Kvs: 405 m³/h
• Flange according to DIN
• Weight: 58 kg
L L1
Body
P.D.C. / N x I.D.1
Screen
O.D.
I.D.
Cover
L2
H
H1
.
.1
.D
O
Type No.: 7040

Version: A.1 Strainer, DN 150, PN 16 22050-00150

DATA SHEET
Tag No(s):
Type:
• Combined ball valve set 12 13
• Full bore, fire safe 11
Size: 10
8
• DN 25 6
7 5
Pressure range:
• Pressure nominal: PN 40 4 Antistatic
device
Connection type:
• Connection type: Flange according to
DIN 9
Application:
• For oil flow
1 2
Material: 3
• 1. Body: ASTM- A-105

• 2. End Connection: ASTM-A105 Dimension:
• 3. Ball: A182-F304 • L: 160
• 4. Thrust washer: P.T.F.E. • L1: 20
• 5. O-ring: FKM (Viton) • H: 190
• 6. Packing gland: Carbon steel • W: 46
• 7. O-ring: FKM (Viton) • O.D.: Ø 110
• 8. Stem seat: P.T.F.E. Vergine • I.D.: Ø 25
• 9. Ball seat: Metal core P.T.F.E. • P.D.C.: Ø 85
• 10. 90º stop: AISI 430 • t: 6
• 11. Spring washer: Carbon steel • N x M: 4 x M12
• 12. Nut: Carbon steel
• 13. Stem: A182-F316 L1
Technical data:
• Working temperature, min.: - 20ºC
• Working temperature, max.: 160°
• Weight: 6 kg
H
NxM I.D.
P.D.C
O.D.
L W
Type No.: 6010

Version: B.1 Combined ball valve set , DN 25, PN40 6000000141

DATA SHEET
Tag No(s):
Type:
• Check valve
• Disc-spring
Size:
• Connection nominal: DN 15
Pressure rating:
• Pressure nominal: PN 40
Application:
• The check valves are designed to be
sandwiched between flanges. They are
suitable for use on a wide range of fluids Technical data:
for applications in process lines, hot wa-
ter systems, steam and condensate sys- • Weight: 0.14 kg
tems etc. • Kvs-value: 4.4 m³/h
Material:
• Set pressure: 0.02 bar(g)
Installation:
• Body: GX5CrNiMo19-11-2
DIN material No. 1.4408 • The Check valves must be fitted in ac-
• Spring: X10CrNi18-8 cordance with the direction of flow arrow
DIN material No. 1.4310 indicating correct fluid flow direction.
• Valve plate: X6CrNiMoTi17-12-2 • The Check valves can be installed in any
DIN material No. 1.4571 position, except upside down.
• Spring plate: X6CrNiMoTi17-12-2 • The ”cam” design of the body allows the
DIN material No. 1.4571 various flange types to be accommoda-
ted. The body is rotated to touch the
• Retaining ring: X39CrMo17-1+QT flange joint bolts ensuring that the valve
DIN material No. 1.4122+QT is centred in the pipeline.
• Disc check valves are not suitable for use
Retaining ring where heavily pulsating flow exists, such
Valve plate Spring plate as close to a compressor.
Dimension:
• I.D. = 13
• O.D. = 45
• O.D.1 = 95
• W = 16
O.D.
I.D.
Spring
Preparation for
eart connection
Type No.: 6020

Version: A.3 Check valve, DN 15, PN 40 6020000101

DATA SHEET
Tag No(s):
Type: Installation:
• Safety valve, full lift • Before installation one must ensure that
Size: all lines and valves are free from any pol-
lution, welding beads etc.
• Nominal diameter: DN 25/40 • All safety valves are class certified and
Application: sealed, if activated, valve should be
cleaned and set point pressure tested
• For steam: To blow off saturated steam,
air or water
• For Thermal fluid: Safety relief valve, Position allowed Position not allowed
will be opened in case of overpressure in
thermal fluid system
Material:
DIN-Material No.: EN-JS1049
• Seat: X6 Cr Ni Mo Ti 17-12-2
DIN-Material No.: 1.4571
• Disc: X39 Cr Mo 17-1 + QT
H1
DIN-Material No.: 1.4122 + QT

Technical data:
• Nominal pressure: PN 40/16
• Weight: 10 kg
• Flanges according to DIN Seal
• Inlet: DN 25, PN40

• Outlet: DN 40, PN16
Dimension [mm]:
H
• L: 100
• L1: 105
• H: 280
• H1: Min.150
• O.D.: 150
• O.D.1.: 115
• P.D.C.: 110
P.D.C. / N x I.D.2
• P.D.C.1.: 85
O.D.
I.D.
• I.D.: 40 Disc
• I.D.1.: 25 I.D.4
• I.D.2.: 18 Seat
L1
• I.D.3.: 14
• I.D.4.: 22.5 Body
• N: 4
• N.1.: 4 I.D.1.
P.D.C.1. / N.1. x I.D.3
O.D.1.
Type No.: 6040

Version: B.1 Safety valve, DN 25/40, PN 40/16 6040000002

DATA SHEET
Tag No(s):
Type: Dimension:
• Three-way ball valve (reduced L-bore) • L: 210
with actuator, solenoid valve and switch • L1: 105
Size: • L2: 88
• Connection nominal: DN 25 • L3: 135
• Cable connection, switch box: 2 x • L4: 23
M20 x 1.5 for cable diameter 8 - 13 mm • L5: 94
• Cable connection, solenoid valve: M16, • L6: 22
for cable diameter 5 - 6 mm • L7: 46
• Pipe connection, solenoid valve: 1/4" • H: 369
Connection type: • H1: 181
• Connection type: Flange, compact, ac- • H2: 134
cording to DIN, PN 40 • H3: 95.5
Application: • H4: 40
• H5: 110
• For oil flow • O.D.: Ø 115
L L3
L4
Cable gland
H1
L5
Switch
Solenoid valve
H5
2 x Flow reducers
H
L6
H2
Actuator
H4
O.D.
Valve
H3
L1 L2
L7
Type No.: 6070 Three-way valve, ball DN 25, PN 40, build together
Version: D.1 6070000237
with actuator, solenoid valve and switch box

DATA SHEET
Tag No(s):
Material, three-way valve: Detail, three-way valve:

• Body: ASTM A105
Material, actuator:
• Body: Anodized aluminium
Material, solenoid valve:
• Body: Aluminium eloxieret
Technical data, valve:
• Temperature, working min.: - 20°C
• Temperature, working max.: + 160°C
Technical data, actuator:
• Actuator: Double acting (DA)
• Air supply pressure min.: 5 bar(g)
• Air supply pressure max.: 8 bar(g)
• Temperature, min. operating: -20°C Dimension:
• Temperature, max. operating: +80°C
Technical data, solenoid valve:
• L2: 46
• N x I.D.1: 4 x M12
• Type: Bistable solenoid valve with 5/2- • P.D.C.: Ø 85
way function
• OD: Ø 115
• Flow: 1250 l/min
• Flow reduction: 2 x flow reducers
• Manual override function: Fitted
• Protection class: IP65
• Power consumption: 3.1 VA
Technical data, switch box:
• Temperature min., ambient: - 20°C
• Temperature max., ambient: + 80°C
• Switches: 2 pcs. SPDT
Technical data, unit:
• Weight approx.: 17.5 kg
Electrical data:
• Power supply: 230 V
• Frequency: 50 / 60Hz
Version: D.1 6070000237

DATA SHEET
Tag No(s):
Installation:
L-Bore
Port 1 Port 2
Port 3
Port 1 Port 2
Port 3
Solenoid valve:
Switch connection:
Version: D.1 6070000237

DATA SHEET
Tag No(s):
Type: Dimension:
• Three-way ball valve (reduced L-bore) • L: 210
with actuator, solenoid valve and switch • L1: 105
Size: • L2: 115
• Connection nominal: DN 50 • L3: 135
• Cable connection, switch box: 2 x • L4: 23
M20 x 1.5 for cable diameter 8 - 13 mm • L5: 94
• Cable connection, solenoid valve: M16, • L6: 22
for cable diameter 5 - 6 mm • L7: 82
• Pipe connection, solenoid valve: 1/4" • H: 419
Connection type: • H1: 134
• Connection type: Flange, compact, ac- • H2: 225
cording to DIN, PN 40 • H3: 145
Application: • H4: 40
• H5: 100
• For oil flow • O.D.: Ø 165
L L3
L4
Cable gland
H1
L5
Switch
Solenoid valve
H5
2 x Flow reducers
H
L6
H2
Air connection Actuator

H4
O.D.
H3
Valve
L1 L2 L7
Version: A.1 6070000243

DATA SHEET
Tag No(s):
Material, three-way valve: Detail, three-way valve:

• Body: ASTM A105
Material, actuator:
• Body: Aluminium eloxieret
Material, solenoid valve:
• Body: Reinforced polyamide
Technical data, valve:
Technical data, actuator:
• Actuator: Double acting (DA)
• Air supply pressure min.: 5 bar(g)
• Air supply pressure max.: 8 bar(g)
• Temperature, min. operating: -20°C
• Temperature, max. operating: +80°C Dimension:
Technical data, solenoid valve: • L2: 82
• Type: Bistable solenoid valve with 5/2- • N x I.D.1: 4 x M16
way function • P.D.C.: Ø 125
• Temperature, working min.: - 20°C • OD: Ø 165
• Flow: 1250 l/min
• Flow reduction: 2 x flow reducers
• Manual override function: Fitted
• Protection class: IP65
• Power consumption: 3.1VA
Technical data, switch box:
• Temperature min., ambient: - 20°C
• Temperature max., ambient: + 80°C
• Switches: 2 pcs. SPDT
Technical data, unit:
• Weight approx.: 25 kg
Electrical data:
• Power supply: 230 V
• Frequency: 50 / 60Hz
Version: A.1 6070000243

DATA SHEET
Tag No(s):
Installation:
L-Bore
Port 1 Port 2
Port 3
Port 1 Port 2
Port 3
Solenoid valve:
Switch connection:
Version: A.1 6070000243

DATA SHEET
Tag No(s):
Type: Technical data:

• Stop valve, ball straight • Max. workingpressure at 80°C: 32 bar
Size: • Max. working pressure at 150°C: 10 bar
• DN 15 • Weight: 0.18 kg
Application:
• For water, compressed air and oil
Material:
• Body: Nickel-plated brass (MS 58)
• Ball: Hard chromium plating brass
(MS 58)
• Stem: Brass (MS 58)
• Stem nut: Galvanized steel
• Seat rings: Teflon (PTFE)
• Stem gasket: Teflon (PTFE)
85
44
½”BSP
31
60
Type No.: 6010

Version: A.2 Stop valve, ball straight, DN 15, PN 40 6666106

72851-00#A.2
CONTROL VALVE 2-WAY LINEAR ELECTRIC ACTUATOR
PR
Control valve 2-way linear electric actua-

tor PR

72903-00#A.2
CONTROL VALVE 3-WAY DIVERTING WITH ELECTRICAL
ACTUATOR
Control valve 3-way diverting with electri-

cal actuator

DATA SHEET
Tag No(s):
Type:
• Safety valve
100
Size:
• Nominal diameter: DN 15
Application:
• To blow off steam, neutral gases, va-
pours and liquids
Material:
• Body: GGG 40.3
• DIN-material No.: 1.4581
Technical data:
187
• Thread: DIN ISO 228 part 1
• Set point:16 bar
• Weight: 1.2 kg
1/2”
34
15
ø 12
1/2”
42
Type No.: 6040

Version: C.1 Safety valve, DN 15, PN 100 87S0031

RTM#A.2
ARI - FABA - PLUS
ARI - FABA - Plus

ARI-FABA®-Plus
Fig. 046
RTM#A.2
Stop valve - straight through with flanges and bellows seal (Grey cast iron, SG iron, Cast steel)
ARI - FABA - PLUS
Figure-No. Nominal pressure Material Nominal diameter
12.046 PN16 EN-JL1040 DN15-300
PN16 EN-JS1049 DN15-350
22.046
Test: • DIN DVGW-Reg. DG-4313AO 0772
23.046 PN25 EN-JS1049 DN15-150
PN25 1.0619+N DN200-400
34.046
PN40 1.0619+N DN15-250
35.046
Test: • TA - Luft TÜV-Test-No. 973-10183778
Plug with marginal seat standard
At high differential pressures a balancing plug is necessary! (refer to page 12)
Selection of possible applications
Industry, Powerstations, Flue gas purification plant, processing technology, gas supply,
vapour facilities, recycling facilities, vacuum facilities, hot water, heating technology,
district heating, thermal oil applications, general plant manufacturing, etc.
(other applications on request)
Selection of possible flow media
Steam, gases, hot water, thermal fluids, hot oil, process water, vacuum facilities,
ammonia etc.
(other flow media on request)
Parts
Pos. Description Fig. 12.046 Fig. 22. / 23.046 Fig. 34. / 35. 046
1 Body EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT GP240GH+N, 1.0619+N
1.2 Seat ring X20Cr13+QT, 1.4021+QT
: G19 9 NbSi, 1.4551
2 Bonnet EN-JS1049, EN-GJS-400-18U-LT GP240GH+N, 1.0619+N
3 Plug *
4.1 Bellows seal X6CrNiMoTi17 12 2, 1.4571
4.2 Stem X20Cr13+QT, 1.4021+QT
5 Handwheel *
6 Packing ring Pure graphite
7 Hexagon bolt 5.6 --
7 Stud -- 25CrMo4, 1.7218
8 Hexagon nut -- C35E, 1.1181
9 Gasket * Pure graphite (CrNi laminated with graphite)
* Spare part
Information / restriction of technical rules need to be observed!
Operating instructions can be ordered by phone +49 (0)5207 / 994-0 or fax +49 (0)5207 / 994-158 or -159.
ARI-Valves of EN-JL1040 are not allowed to be operated in systems acc. to TRD 110.
A production allowance acc. to TRB 801 No. 45 exists (acc. to TRB 801 No. 45 EN-JL1040 is not allowed.)
The engineer, designing a system or a plant, is responsible for the selection of the correct valve.
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850 980 1100
H1 (mm) 205 205 210 210 225 230 245 265 365 395 430 550 720 775 975 1015
ØC (PN16) (mm) 125 125 125 125 150 150 175 175 225 300 400 520 520 520 640 640
ØC (PN25) (mm) 125 125 125 125 150 150 175 175 300 300 400 520 520 520 640 640
ØC (PN40) (mm) 125 125 125 125 150 150 175 225 300 300 400 520 520 -- -- --
Travel (mm) 6 6 8 8 13 13 16 20 25 32 40 50 70 80 90 100
Kvs-value (m3/h) 5,3 7,2 12 16 28,5 43 75 105 170 270 405 675 1090 1460 2010 2640
Zeta-value -- 2,9 4,9 4,3 6,5 5 5,4 5,1 5,9 5,5 5,3 4,9 5,6 5,2 6,1 5,9 5,9
Zeta-value ... range of tolerance for Kvs-values acc. to VDI/VDE 2173 Standard-flange dimensions refer to page 14
Face-to-face dimension FTF Grundreihe 1 acc. to DIN EN 558
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
12. / 22. / 23.046 (kg) 3,7 4,5 5,6 6,9 8,9 11 15,3 21,1 32,4 51,6 74 147 247 404 524 --
34.046 (kg) -- -- -- -- -- -- -- -- -- -- -- 168 268 395 629 865
35.046 11-34 / 190 (kg) 4,1 5,1 6,2 7,3 10,6 12,6 19,1 26,1 35 60,3 88 225 310 -- Language
-- UK
--
2 Edition 01/11 - Data subject to alteration

ARI-FABA®-Plus
Fig. 046
RTM#A.2
Stop valve - straight through with flanges and bellows seal (Stainless steel)
ARI - FABA - PLUS
52.046 PN16 1.4408 DN15-250
PN16 1.4408 Body / DN15-250
62.046
1.0619+N Cover
54.046 PN25 1.4408 DN200-250
PN25 1.4408 Body / DN200-250
64.046
1.0619+N Cover
55.046 PN40 1.4408 DN15-150
PN40 1.4408 Body / DN15-150
65.046
1.0619+N Cover
Recycling facilities, chemical industry, hospital technology, process water installations,
installations with aggressive media
Process water, aggressive media, etc.
Parts
Pos. Description Fig. 52. / 54. / 55.046 Fig. 62. / 64. / 65.046
1 Body GX5CrNiMo19-11-2, 1.4408
2 Bonnet GX5CrNiMo19-11-2, 1.4408 GP240GH+N, 1.0619+N
3 Plug * X6CrNiMoTi17 12 2, 1.4571
4.2 Stem X6CrNiMoTi17 12 2, 1.4571
5 Handwheel *
7 Hexagon bolt --
7 Stud A4-70 25CrMo4, 1.7218
8 Hexagon nut A4 C35E, 1.1181
* Spare part
A production allowance acc. to TRB 801 No. 45 exists
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730
H1 (mm) 200 200 210 210 225 230 245 265 365 395 430 550 720
ØC (PN16) (mm) 125 125 125 125 150 150 175 175 225 300 400 520 520
ØC (PN25) (mm) 125 125 125 125 150 150 175 175 300 300 400 520 520
ØC (PN40) (mm) 125 125 125 125 150 150 175 225 300 300 400 520 520
Travel (mm) 6 6 8 8 13 13 16 20 25 32 40 50 70
Kvs-value (m3/h) 5,3 7,2 12 16 28,5 43 75 105 170 270 405 675 1090
Zeta-value -- 2,9 4,9 4,3 6,5 5 5,4 5,1 5,9 5,5 5,3 4,9 5,6 5,2
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250
52. / 54. / 62. / 55. / (kg)
64. / Language UK 11-35
4,3 4,8 6,3 7,3 10,3 12,6 19 25 33 53 71 187 / 190
272
65.046
Edition 01/11 - Data subject to alteration 3

ARI-FABA®-Plus
Fig. 046
RTM#A.2
Stop valve - straight through with flanges and bellows seal (Forged steel)
ARI - FABA - PLUS
PN40 1.0460 DN15-50
45.046
DN >50 refer to Fig. 35.046 (1.0619+N)

ammonia etc.
DN40-50
DN15-32
Parts
Pos. Description Fig. 45.046
1 Body P250 GH, 1.0460
1.2 Seat G19 9 NbSi, 1.4551
2 Bonnet GP240GH+N, 1.0619+N
3 Plug * X20Cr13+QT, 1.4021+QT (hardened)
4.2 Stem X20Cr13+QT, 1.4021+QT
5 Handwheel * Fe P01, 1.0330 (cataphoretic coating)
7 Stud 25CrMo4, 1.7218
8 Hexagon nut C35E, 1.1181
* Spare part
A production allowance acc. to TRB 801 No. 45 exists.
Dimensions
DN 15 20 25 32 40 50
L (mm) 130 150 160 180 200 230
H1 (mm) 215 215 225 230 230 230
ØC (PN40) (mm) 125 125 125 125 150 150
Travel (mm) 6 6 8 8 13 13
Kvs-value (m3/h) 3,6 6,3 10 13 24 36
Zeta-value -- 6,2 6,4 6,2 9,9 7,1 7,7
Weights
Figure-No. DN 15 20 25 32 40 50
45.046 11-36 / 190 (kg) 3,8 4,8 5,5 7 10 Language UK
12

ARI-FABA®-Plus
Fig. 040
RTM#A.2
StopARI
valve - straight
- FABA through with butt weld ends and bellows seal (Forged steel)
- PLUS
PN40 1.0460 DN15-50
45.040
DN >50 refer to Fig. 35.040 (1.0619+N)
Butt weld ends according to DIN EN 12627 - 4 (refer to page 11)

ammonia etc.
Parts
Pos. Description Fig. 45.040
1 Body P250 GH, 1.0460
1.2 Seat G19 9 NbSi, 1.4551
3 Plug * X20Cr13+QT, 1.4021+QT (hardened)
4.2 Stem X20Cr13+QT, 1.4021+QT
5 Handwheel * Fe P01, 1.0330 (cataphoretic coating)
7 Stud 25CrMo4, 1.7218
* Spare part
Dimensions
DN 15 20 25 32 40 50
L (mm) 130 150 160 180 200 230
H1 (mm) 215 215 225 230 250 255
ØC (PN40) (mm) 125 125 125 125 150 150
Travel (mm) 6 6 8 8 13 13
Kvs-value (m3/h) 3,6 3,6 10 13 21 32
Zeta-value -- 6,2 6,4 6,2 9,9 9,3 9,7
Zeta-value ... range of tolerance for Kvs-values acc. to VDI/VDE 2173
Face-to-face dimension ETE series 1 according to DIN EN 12982
Weights
Figure-No. DN 15 20 25 32 40 50
Language UK(kg)
45.040 2,6 2,8 3,8 4,2 5,8 11-37 / 190
8,2

ARI-FABA®-Plus
Fig. 040
RTM#A.2
Stop valve - straight through with butt weld ends and bellows seal (Cast steel)
ARI - FABA - PLUS
34.040 PN25 1.0619+N DN200-300
35.040 PN40 1.0619+N DN65-250
alternative: DN 65-200 with shoed ends of P235GH
• DIN DVGW-Reg. DG-4314AO 0777/0778
DN65-150: Plug with marginal seat standard

ammonia etc.
alternative
Parts
Pos. Description Fig. 34.040 / 35.040
1 Body GP240GH+N, 1.0619+N
1.2 Seat G19 9 NbSi, 1.4551
3 Plug *
4.2 Stem X20Cr13+QT, 1.4021+QT
5 Handwheel *
7 Stud 25CrMo4, 1.7218
* Spare part
Dimensions
DN 65 80 100 125 150 200 250 300
L (mm) 290 310 350 400 480 600 730 850
H1 (mm) 245 265 365 395 430 550 720 775
ØC (PN25) (mm) -- -- -- -- -- 520 520 520
ØC (PN40) (mm) 175 225 300 300 400 520 520 --
Travel (mm) 16 20 25 32 40 50 70 80
Kvs-value (m3/h) 75 105 170 270 405 675 1090 1460
Zeta-value -- 5,1 5,9 5,5 5,3 4,9 5,6 5,2 6,1
Weights
Figure-No. DN 65 80 100 125 150 200 250 300
34.040 (kg) -- -- -- -- -- 160 242 370
35.040 11-38 / 190
(kg) 12 16,8 23,6 40 56 166 251 Language
-- UK

ARI-FABA®-Plus
Fig. 069
RTM#A.2
Stop valve - Y-pattern with flanges and bellows seal (Stainless steel)
ARI - FABA - PLUS
52.069 PN16 1.4408 DN15-200
PN16 1.4408 Body / DN15-200
62.069
1.0619+N Cover
54.069 PN25 1.4408 DN200
PN25 1.4408 Body / DN200
64.069
1.0619+N Cover
55.069 PN40 1.4408 DN15-150
PN40 1.4408 Body / DN15-150
65.069
1.0619+N Cover
Recycling facilities, chemical industry, hospital technology, process water installations,
installations with aggressive media
Parts
Pos. Description Fig. 52.069 / Fig. 54.069 / Fig. 55.069 Fig. 62.069 / Fig. 64.069 / Fig. 65.069
1 Body GX5CrNiMo19-11-2, 1.4408
2 Bonnet GX5CrNiMo19-11-2, 1.4408 GP240GH+N, 1.0619+N
3 Plug * X6CrNiMoTi17 12 2, 1.4571
4.2 Stem X6CrNiMoTi17 12 2, 1.4571
5 Handwheel *
7 Stud A4-70 25CrMo4, 1.7218
8 Hexagon nut A4 C35E, 1.1181
* Spare part
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600
H2 (mm) 195 195 205 205 235 235 265 295 380 415 480 615
ØC (PN16) (mm) 125 125 125 125 150 150 175 175 225 300 400 520
ØC (PN25) (mm) 125 125 125 125 150 150 175 175 300 300 400 520
ØC (PN40) (mm) 125 125 125 125 150 150 175 225 300 300 400 520
B (mm) 95 70 70 55 65 35 15 50 120 100 90 140
Travel (mm) 6 6 8 8 13 13 16 20 25 32 40 50
Kvs-value (m3/h) 6,4 9,5 14,5 19,5 36 54 92 127 205 324 485 810
Zeta-value -- 2 2,8 3 4,4 3,2 3,4 3,4 4,1 3,8 3,7 3,4 3,9
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200
52. / 54. / 62.069 (kg) 4 4,5 5,4 6,5 8,5 11,7 16 21,7 31,1 43,5 62 180
55. / Language
64. / 65.069 UK (kg) 4 4,5 5,4 6,5 8,5 11,7 16 21,7 31,1 43,5 11-39 / 190
62 186

ARI-FABA®-Plus
Fig. 066
RTM#A.2
Stop valve - Y-pattern with butt weld ends and bellows seal (Cast steel)
ARI - FABA - PLUS
PN25 1.0619+N DN200-300
34.066
PN40 1.0619+N DN15-250
35.066

ammonia etc. (other flow media on request)
Parts
Pos. Description Fig. 34./35.066
1 Body GP240GH+N, 1.0619+N
1.2 Seat ring
3 Plug *
4.2 Stem X20Cr13+QT, 1.4021+QT
5 Handwheel *
7 Stud 25CrMo4, 1.7218
* Spare part
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850
H2 (mm) 195 195 205 205 235 235 265 295 380 415 480 615 740 795
B (mm) 85 65 65 50 60 35 10 45 90 60 50 110 100 45
ØC (PN25) (mm) -- -- -- -- -- -- -- -- -- -- -- 520 520 520
ØC (PN40) (mm) 125 125 125 125 150 150 175 225 300 300 400 520 520 --
Travel (mm) 6 6 8 8 13 13 16 20 25 32 40 50 70 80
Kvs-value (m3/h) 6,4 9,5 14,5 19,5 36 54 92 127 205 324 485 810 1310 1752
Zeta-value -- 2 2,8 3 4,4 3,2 3,4 3,4 4,1 3,8 3,7 3,4 3,9 3,6 4,2
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300
34.066 (kg) -- -- -- -- -- -- -- -- -- -- -- 138 230 317
35.066 11-40 / 190 (kg) 2,8 3 3,4 3,6 4,5 7,3 9 11,4 30 42 62 144 Language
239 UK
--

ARI-FABA®-Plus
Fig. 066
RTM#A.2
Stop valve - Y-pattern with butt weld ends and bellows seal (Stainless steel)
ARI - FABA - PLUS
54.066 PN25 1.4581 DN200
55.066 PN40 1.4581 DN15-150

Stainless steel: Recycling facilities, chemical industry, hospital technology, process
water installations, installations with aggressive media
Parts
Pos. Description Fig. 54./55.066
1 Body GX5CrNiMoN19-11-2, 1.4581
2 Bonnet GX5CrNiMo19-11-2, 1.4408
3 Plug * X6CrNiMoTi17 12 2, 1.4571
4.2 Stem X6CrNiMoTi17 12 2, 1.4571
5 Handwheel *
7 Stud A2-70
8 Hexagon nut A2
* Spare part
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600
H2 (mm) 195 195 205 205 235 235 265 295 380 415 480 615
B (mm) 85 65 65 50 60 35 10 45 90 60 50 110
ØC (PN25) (mm) -- -- -- -- -- -- -- -- -- -- -- 520
ØC (PN40) (mm) 125 125 125 125 150 150 175 225 300 300 400 520
Travel (mm) 6 6 8 8 13 13 16 20 25 32 40 50
Kvs-value (m3/h) 6,4 9,5 14,5 19,5 36 54 92 127 205 324 485 789
Zeta-value -- 2 2,8 3 4,4 3,2 3,4 3,4 4,1 3,8 3,7 3,4 4,1
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200
Language UK (kg)
55.066 3,2 3,6 4 4,8 6,8 8,5 10 13,8 32 45 11-41 / 190
66 157

ARI-FABA®-Plus
Fig. 047
RTM#A.2
Stop valve - angle pattern with flanges and bellows seal (Grey cast iron, SG iron, Cast steel)
ARI - FABA - PLUS
12.047 PN16 EN-JL1040 DN15-300
PN16 EN-JS1049 DN15-300
22.047
PN25 1.0619+N DN200-300
34.047
PN40 1.0619+N DN15-150
35.047

ammonia etc. (other flow media on request)
Parts
Pos. Description Fig. 12.047 Fig. 22.047 Fig. 34.047 / Fig. 35.047
1 Body EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT GP240GH+N, 1.0619+N
1.2 Seat ring X20Cr13+QT, 1.4021+QT X20Cr13+QT, 1.4021+QT
2 Bonnet EN-JS1049, EN-GJS-400-18U-LT EN-JS1049, EN-GJS-400-18U-LT GP240GH+N, 1.0619+N

3 Plug *
4.2 Stem X20Cr13+QT, 1.4021+QT
5 Handwheel *
7 Hexagon bolt 5.6 --
7 Stud -- 25CrMo4, 1.7218
8 Hexagon nut -- C35E, 1.1181
* Spare part
ARI-Valves of EN-JL1040 are not allowed to be operated in systems acc. to TRD 110.
A production allowance acc. to TRB 801 No. 45 exists (acc. to TRB 801 No. 45 EN-JL1040 is not allowed.)
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300
l (mm) 90 95 100 105 115 125 145 155 175 200 225 275 325 375
H3 (mm) 190 190 195 195 210 210 220 235 325 345 370 485 615 665
ØC (PN16) (mm) 125 125 125 125 150 150 175 175 225 300 400 520 520 520
ØC (PN25) (mm) 125 125 125 125 150 150 175 175 300 300 400 520 520 520
ØC (PN40) (mm) 125 125 125 125 150 150 175 225 300 300 400 520 -- --
Travel (mm) 6 6 8 8 13 13 16 20 25 32 40 50 70 80
Kvs-value (m3/h) 6 9 14 19 35 53 94 143 245 390 590 845 1360 1825
Zeta-value -- 2,2 3,2 3,2 4,6 3,3 3,6 3,2 3,2 2,7 2,6 2,3 3,6 3,4 3,9
Face-to-face dimension CTF Grundreihe 8 acc. to DIN EN 558
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300
12. / 22.047 (kg) 3,7 4,4 5,1 6,5 8,3 11,2 14,6 19,4 29,4 44 58 145 221 298
34.047 (kg) -- -- -- -- -- -- -- -- -- -- -- 155 273 309
35.047 11-42 / 190 (kg) 4,6 6,4 6,7 7,5 10,1 12,7 17,5 22 34 49 60 -- Language
-- UK
--

ARI-FABA®-Plus
Valves with butt weld ends
RTM#A.2
ARI - FABA
L = Face-to-face - PLUS
dimension
Edge shaping acc. to DIN EN ISO 5817
Butt weld ends according to DIN EN 12627 - 4

DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850 980 1100
ØA (mm) 22 28 35 44 50 62 77 91 117 144 172 223 278 329 362 413
ØB (mm) 17,3 22,3 28,5 37,2 43,1 53,9 68,9 80,9 104,3 130,7 157,1 204,9 257, 307,9 338, 384,4
Ødi (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250 300 330 375
R (mm) 3 3 3 3 3 3 3 3 3 3 3 5 5 5 5 5
L1 (mm) 10 10 10 10 10 10 10 12 14 18 20 20 25 33 45 45
Ød3 (mm) 21,3 26,9 33,7 42,4 48,3 60,3 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4
s1 (mm) 2 2,3 2,6 2,6 2,6 3,2 3,6 4 5 4,5 5,6 7,1 8 8 8,8 11
Shoed ends of P235GH (Pipe connection =^ welding neck flanges)

DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
Ød (mm) -- -- -- -- -- -- 76,1 88,9 114,3 139,7 168,3 219,1 -- -- -- --
Øs (mm) -- -- -- -- -- -- 2,9 3,2 3,6 4 4,5 6,3 -- -- -- --
Face-to-face dimension ETE series 1 according to DIN EN 12982.
Butt weld ends according to DIN EN 12627 - 4.
Weld joint according to DIN EN 29692 code numer 1.3.3.
The material used for ARI valves with butt weld ends are:
GP240GH+N, 1.0619+N acc. to DIN EN 10213-2,
P250GH, 1.0460 acc. to DIN EN 10222-2.
The material used for ARI valves with shoed ends (DN 65-200) P235GH according to DIN EN 10216-2.
Based on our experience we recommend electric welding process for connecting valves or strainers with tubes or with each other
Lime based electrodes with an appropriate composite material should be used as filler material for welding.
Gas welding should be avoided.
Due to the different material composition and material thickness of valves and tubes, gas welding is more susceptible to produce faults than electric welding (hardness cracks,
coarse-grained structure).

ARI-FABA®-Plus
Plug - design
RTM#A.2
ARI - FABA - PLUS
Plug with soft seal PTFE + 25% carbon, Max. operating Screw down non-return plug with re-setting spring
Isolation plug with marginal seat; stellited seat and plug temperature 200°C at PTFE + 25% carbon (Set pressure refer to: Flow diagram)
Regulating plug with marginal seat and soft seal PTFE Screw down non-return regulating plug
+ 25% carbon, Max. operating temperature 200°C at with marginal seat
Regulating plug with marginal seat PTFE + 25% carbon
Flow diagram)
Flow direction
Valves with balancing plugs have to be installed with medium flowing over the plug (3) as indicated by flow direction arrow on valve body and the stem is vertically upright.
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 and equalizes the pressure of the medium under the plug (3). After the pressures have been equalized within the values
stated in the table, the valve can be opened by turning the valve further with normal manual force.
Balancing plugs are fully effective only in closed systems.
The pressures of the medium on either side of the plug can not be equalized if the medium is discharged into open air.
A bypass line or some other arrangement is necessary if too much time is required for pressure equalization owing to the volume in the piping system.
ARI-stop valves with differential pressures exceeding the following pressures, have to be fitted with pressure balancing plugs
DN 125 150 200 250 300 350 400 500
(bar) 25 21 14 9 6 4,5 3,5 1,5

ARI-FABA®-Plus
Functions / special design / accessories
RTM#A.2
ARI - FABA - PLUS
Size DN ØC ØC1
(mm) (mm) (mm)
I 15-50 125 170
II 65-80 150 190
III 100-150 225 330
Hood valve acc.to DIN EN 12828
Limit switch (tamper-proof handwheel cover) Handwheel-Ø from DN 65 reduced!
DN ØC2 Weight
(mm) (mm) (kg)
15-32 180 2,5
40-80 220 7
100-150 260 8,9
Chain wheel 200-400 300 11 Stem extension (please specify height in your order)
Accessories: Travel limiter
Lubricating nipple
Travel limiter
(Accessories are not included !)
DN Hexagon bolt
(mm) (mm x mm)
15-80 M8 x 55
Locking device 100 M12 x 70
125-150 M12 x 80
200 M12 x 100
250-300 M12 x 120
Lubricating nipple / Locking device / Travel limiter 350-400 M16 x 160

ARI-FABA®-Plus
Flange dimensions / Pressure-temperature-ratings
RTM#A.2
Standard-flange dimensions Flanges acc. to DIN EN 1092-1/-2 (Flangeholes / -thickness tol. acc. To DIN 2533/2544/2545)
ARI - FABA - PLUS
DN (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
PN6 ØD (mm) 80 90 100 120 130 140 160 190 210 240 265 320 -- -- -- -- --
PN6 ØK (mm) 55 65 75 90 100 110 130 150 170 200 225 280 -- -- -- -- --
PN6 n x Ød (mm) 4x11 4x11 4x11 4x14 4x14 4x14 4x14 4x18 4x18 8x18 8x18 8x18 -- -- -- -- --
PN16 ØD (mm) 95 105 115 140 150 165 185 200 220 250 285 340 405 460 520 580 715
PN16 ØK (mm) 65 75 85 100 110 125 145 160 180 210 240 295 355 410 470 525 650
PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 12x22 12x26 12x26 16x26 16x30 20x33
PN25 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 360 425 485 555 620 730
PN25 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 310 370 430 490 550 660
PN40 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 375 450 515 580 660 755
PN40 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 320 385 450 510 585 670
Pressure-temperature-ratings acc. to DIN EN 1092-2

Material -60°C to <-10°C* -10°C to 120°C 150°C 200°C 250°C 300°C 350°C 400°C 450°C
EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6 -- -- --
EN-JS1049 16 (bar) on request 16 15,5 14,7 13,9 12,8 11,2 -- --
EN-JS1049 25 (bar) on request 25 24,3 23 21,8 20 17,5 -- --
EN-JS1049 40 (bar) on request 40 38,8 36,8 34,8 32 28 -- --
Pressure-temperature-ratings acc. to manufacturers standard

1.0619+N 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 8,2
1.0619+N 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 13,1
1.0460 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 10
1.0460 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 16
Pressure-temperature-ratings acc. to DIN EN 1092-1

1.4408 16 (bar) 16 16 14,5 13,4 12,7 11,8 11,4 10,9 --
1.4408 25 (bar) 25 25 22,7 21 19,8 18,5 17,8 17,1 --
1.4408 40 (bar) 40 40 36,3 33,7 31,8 29,7 28,5 27,4 --
1.4581 16 (bar) 8 16 15,6 14,9 14,1 13,3 12,8 12,4 --
1.4581 25 (bar) 12,5 25 24,5 23,3 22,1 20,8 20,1 19,5 --
1.4581 40 (bar) 20 40 39,2 37,3 35,4 33,3 32,1 31,2 --
Intermediate values for max. permissible operational pressures can be determined by linear interpolation of the given temperature / pressure chart.
* Studs and nuts made of A4-70 (at temperatures below -10°C)
Please indicate when ordering

- Figure-No.
- Nominal pressure
Dimensions in mm
- Nominal diameter
Weights in kg
- Special design / accessories
1 bar =^ 105 Pa =^ 0,1 MPa
Example:
Kvs in m3/h
Figure 35.046; nominal pressure PN40; nominal diameter DN100.
Technology for the Future.

GERMAN QUALITY VALVES
11-46 / 190 ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock, Language UK
Tel. +49 52 07 / 994-0, Telefax +49 52 07 / 994-158 or 159 Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com

RTM#A.2
OPERATING AND INSTALLATION INSTRUCTIONS - FABA
Operating and installation instructions
LONG LIFE / FABA-LA
Stop valve with bellows seal maintenance-free
FABA®Long Life / FABA®-LA
Operating and Installation Instructions -

FABA long life / FABA-LA
Contents
1.0 General information on operating 5.3 Installing valves with pressure balancing plugs...... 6
instructions .................................................... 2 5.4 Installation data on valves with loose plugs ........... 7
2.0 Notes on possible dangers........................... 2 5.5 Installing valves with limit switches ........................ 7
2.1 Significance of symbols ..........................................2 6.0 Putting the valve into operation .................. 7
2.2 Explanatory notes on safety information .................2 7.0 Care and maintenance.................................. 8
3.0 Storage and transport .................................. 2 8.0 Troubleshooting .......................................... 10
4.0 Description..................................................... 3 9.0 Troubleshooting table .................................11
4.1 Scope of applications ..............................................3 10.0 Dismantling the valve or the top part ..... 12
4.2 Operating principles ................................................3 11.0 Warranty / Guarantee ................................ 12
4.3 Diagram...................................................................4 12.0 EC declaration of conformity ................... 13
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
Rev. 0040103000 5104 englisch
RTM#A.2 FABA®Long Life / FABA®-LA
1.0 LIFE
LONG General
/ FABA-LAinformation 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 be
solved 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 be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking 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
ATTENTION !
... Warning of general danger.
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 failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and 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 fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
3.0 Storage and transport

ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- 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 as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- 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.
11-48
Page/ 190
2 Rev. 0040103000 5104 Language UK
4.0LONG
Description
LIFE / FABA-LA
4.1 Scope of applications

Valves are used for “shut-off and/or throttling of media”.
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.
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).
ATTENTION !
Do not use tools to increase the torque on the hand wheel.
The valve stem is sealed by a bellow and an outer safety stuffing box.
Tighten the safety stuffing box if required.
Language UK Rev. 0040103000 5104 11-49

Page / 190
3
4.3 LIFE
LONG Diagram
/ FABA-LA
rotated
view
rotated
view
fig. 1: FABA®Long Life - straight through fig. 2: FABA®-LA - straight through
rotated rotated
view view
fig. 3: FABA®Long Life - fig. 4: FABA®Long Life -

Y pattern with butt weld ends straight through with shoed butt weld ends
Refer to the data sheet for information about materials with designations and figure numbers.
11-50
Page/ 190
4 Rev. 0040103000 5104 Language UK
4.4LONG
Technical data - remarks
LIFE / FABA-LA
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:
CE-marking
0525 Notified body
Manufacturer Address of manufacturer:
refer to item 11.0 Warranty / Guarantee
Typ Type
Bj. Year of manufacture
According to the Pressure Equipment Directive table 6, annex II, valves without safety
function are only allowed to bear the CE-marking DN32 onwards.
5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governing
installation work:
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 are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
See data sheet for weights.
- Valves can be installed with the stem pointing in any direction, but the prefered
stem position is vertical.
- Valves should be installed upside down only, if the medium being handled is
clean.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Planners / construction companies or operators are responsible for positioning and
installing products.
- Mounting position FABA®-LA:
Bellow seal out of media flow path. Especially for pulsating, turbulent flow directly behind
pumps, elbows, junctions etc.
Language UK Rev. 0040103000 5104 11-51
Page / 190
5
5.2 LIFE
LONG Installing
/ FABA-LAvalves with butt weld ends
Please note that only qualified persons using appropriate equipment and working in
accordance 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.
The valves must be welded in closed position.
5.3 Installing valves with pressure balancing plugs
ATTENTION !
ARI stop valves must be equipped with pressure balancing plugs if the
differential 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 (pos. 3) and the stem is vertically upright.
ATTENTION !
Note direction of flow.
Fig. 5
Valves with pressure balancing plugs have to be installed with medium flowing over the
plug (pos. 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 (pos.
3.1) off the larger balancing plug (pos. 3). This allows the medium to pass through the plug
and equalizes the pressure of the medium under the plug (pos. 3). After the pressures have
been equalized within the values stated in the table below, the valve can be opened by
turning the valve further.
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
- 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 medium
is 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).
11-52
Page/ 190
6 Rev. 0040103000 5104 Language UK
5.4LONG
Installation data on valves with loose plugs
LIFE / FABA-LA
The data given in point 5.3 applies to the maximum differential pressure. The set pressure
is 0,05 bar. The valve should only be installed in horizontal lines in an upright position.
5.5 Installing valves with limit switches

The valves with limit switches must be connected up as shown in the plans of the plant on
the basis of their working principles.
6.0 Putting the valve into operation
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and 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) media
temperatures 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.
Language UK Rev. 0040103000 5104 11-53

Page / 190
7
7.0 LIFE
LONG Care and maintenance
/ FABA-LA
Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
fig. 6: Pattern with hinged bolts fig. 7: Pattern with gland screw
- Observe safety instructions!
- Keep the stem well greased!
- 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.
ATTENTION !
Pay attention, that the lubricant is suitable for the media.
- FABA®LA: - If the stem (pos. 4.2) starts leaking and a safety stuffing box is used,
gradually tighten the stuffing box seal (pos. 6) evenly in increments by
means of the hex. nuts (pos. 3.1) until leaking stops (Fig. 6). Replace
bonnet at earliest opportunity!
®
- FABA Long Life: - If the stem (pos. 4.2) starts leaking, tighten the bolted gland (pos. 12)
until leaking stops (Fig. 7). Replace bonnet at earliest opportunity!
11-54
Page/ 190
8 Rev. 0040103000 5104 Language UK
LONG LIFE / FABA-LA
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 when
depressurised.
- Refer to point 10.0 and 11.0 before dismantling the valve.
- Replace stuffing box packings only after the system has cooled down and the pressure in
the plant has been relieved.
In the case of corrosive or aggressive mediums, drain and ventilate the valve before
replacing the packing.
- When cutting the new packing from the roll,

make sure that the ends are cut with a slant
fig. 8: Split packing ring

Mounting of the bonnet:
- Before reassembling the unit, remember that the bearing surface must be cleaned and 2
new gaskets (pos. 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:
DN hexagon nuts / Torque

hexagon screws (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
Language UK Rev. 0040103000 5104 11-55

Page / 190
9
LONG LIFE / FABA-LA
Application of lubricating nipple
1. Lubrication
(Lubricating nipple not screwed in
up to the stop, handwheel is not Standard:
clamped.) Lubricating nipple
Locking screw
2. Locking screw
(Locking the handwheel by turning
the lubricating nipple clockwise.) Special version:
3. Lubrication and locking without lubricating nipple
(threaded hole closed with
(Lubrication is possible with the protective cap).
handwheel locked.)
fig. 9
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-
If malfunctions cannot be eliminate with the help of the following table

“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
11-56
Page/ 190
10 Rev. 0040103000 5104 Language UK
9.0LONG
Troubleshooting
LIFE / FABA-LA 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 Remove flange covers
(pos. 32; fig.1-2) (pos. 32; fig.1-2)
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 Stem (pos. 4.2) dry (fig. 6; page 8) Grease stem (pos. 4.2) (fig. 6)
cannot be opened (Lubricant: refer to page 8)
Wrong direction of rotation Turn in correct direction
(anticlockwise to open valve)
Lubricating nipple / locking screw Loosen lubricating nipple / locking
tightened screw
Valve stem leaking Bellows seal damaged Replace top of bellows seal at earliest
opportunity!
Gland screw (pos. 12) slack Tighten gland screw (pos. 12) until leak-
age stops; Replace bonnet at earliest
opportunity!
Stuffing box gland (pos. 27) slack Tighten stuffing box gland (pos. 27)
(fig. 1-4) until leakage stops
-Hex. nut (fig. 1-4).
Replace bonnet at earliest opportunity!
If necessary, renew packing in stuffing
box seal (pos. 6); Observe warnings
(Fig. 6 and 7)!
Leakage across valve seat Valve not properly closed. Pull hand wheel tight without tools
Seat (pos. 1.2) / plug (pos. 3) damaged Replaced valve or rework sealing
by foreign particles (fig. 1-4; page 4) surfaces
Pressure difference too high. Use a valve with pressure balancing
plug (refer to point 5.3)
Medium contaminated Clean valve;
(suspended solids). Install a strainer upstream of valve
Valve with throttling plug + Lubricating nipple / locking screw has Release lubricating nipple / locking
stroke limiter + locking been tightened. screw
screw cannot be opened Stroke limiter is countered Loosen counter nut, screw the stroke
limiter higher
Flange broken between Bolts tightened unevenly; Re-align piping and fit new valve!
valve and piping Mating flanges not properly aligned
Language UK Rev. 0040103000 5104 11-57

Page/ 11
190
10.0LIFEDismantling
LONG / FABA-LA the valve or the top part
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.
11.0 Warranty / Guarantee

The extent and period of warranty cover are specified in the "Standard Terms and
Conditions 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 the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or 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 specialist
appointed 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, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.

ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com
11-58
Page/ 190
12 Rev. 0040103000 5104 Language UK
12.0
LONGEC
LIFEdeclaration
/ FABA-LA of conformity
ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock
EC declaration of conformity
as defined by
the Pressure Equipment Directive 97/23/EC
Herewith we declare,
that according to the above mentioned Pressure Equipment Directive (PED) the below
listed products comply and have been approved according to table 6, annex II, module H
through LLOYD´S REGISTER QUALITY ASSURANCE (BS-Nr. 0525), Mönckebergstr. 27,
D-20095 Hamburg.
Certificate-No: 50003/1
Stop valves with stainless steel bellows

FABA® LongLife
Type 031, 040, 041, 044, 046, 047, 049, 066, 067, 068, 069
Applied standards:
DIN 3230
DIN 3840
AD 2000 leaflet A4
- Cast iron with spheroidal graphite
- Cast steel
- Forged steel
Schloß Holte-Stukenbrock, 20.08.2002
...................................................
(Brechmann, Managing director)
Language UK Rev. 0040103000 5104 11-59

Page/ 13
190
RTM#A.2
STOBU STOP VALVE GLAND SEAL
Stop valve with gland seal
STOBU®
Stobu Stop Valve Gland Seal
Contents
1.0 General information on operating 5.4 Installing valves with limit switches ...................... 21
instructions .................................................. 16 6.0 Putting the valve into operation ................ 22
2.0 Notes on possible dangers......................... 16 7.0 Care and maintenance................................ 22
2.1 Significance of symbols ........................................16 8.0 Troubleshooting .......................................... 24
2.2 Explanatory notes on safety information ...............16 9.0 Troubleshooting table ................................ 25
3.0 Storage and transport ................................ 16 10.0 Dismantling the valve or the top part ..... 26
4.0 Description................................................... 17 11.0 Warranty / Guarantee ................................ 26
4.1 Scope of applications ............................................17 12.0 EC declaration of conformity ................... 27
4.2 Operating principles ..............................................17
4.3 Diagram.................................................................18
4.4 Technical data - remarks .......................................19
4.5 Marking .................................................................19
5.0 Installation.................................................... 19
5.1 General notes on installation.................................19
5.2 Installing valves with butt weld ends .....................20
5.3 Installing valves with balancing plugs .................21
Rev. 0040102000 2103 page 1
RTM#A.2 STOBU®
1.0 General information on operating instructions
and repair.
ATTENTION ! Warning of general danger.
...

Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
to property.

ATTENTION !
- At -20°C to +65°C.
Language
Page 2 UK Rev. 0040102000 2103 11-61 / 190
RTM#A.2 STOBU®
4.0 Description
Valves are used for „shut-off and/or throttling of media“.
ATTENTION !
state the higher requirements when ordering.
- Valves made from GG-25 are not authorised for use in systems subject to TRD
110.

The valve is closed by turning the hand wheel clockwise (valve plug/seating function).
ATTENTION !
Do not use tools to increase the torque on the hand wheel.
The valve spindle is sealed by a bellow and an outer safety stuffing box.
Tighten the stuffing box if required.
11-62 / 190 Rev. 0040102000 2103 LanguagePage

UK 3
RTM#A.2 STOBU®
4.3 Diagram
rotated
view
rotated
view
rotated
rotated view
view
fig. 1: STOBU straight through 1.0619+N fig. 2: STOBU angle pattern 1.0619+N
rotated
view
rotated view
rotated
view
fig. 3: STOBU straight through fig. 4: STOBU-straight through

GG-25/GGG-40.3 butt weld ends 1.0619+N
Refer to the data sheet for information about materials with designations and figure
numbers.
Language
Page 4 UK Rev. 0040102000 2103 11-63 / 190
RTM#A.2 STOBU®
4.4 Technical data - remarks
for
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Manufacturer Address of manufacturer:
Typ Type refer to item 11.0 Warranty / Guarantee
Bj. Year of manufacture

According to the Pressure Equipment Directive 6 valves without
safety function are only allowed to bear the CE-marking DN32 onwards.
5.0 Installation
installation work:
ATTENTION !
- The interior of valve and pipeline must be free from foreign particles.
- Steam line systems should be designed to prevent water accumulation.
avoided.
- 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 is
clean.
- Keep the thread and shaft of the spindle free from paint.
- Centre gaskets between the flanges.

UK 5
RTM#A.2 STOBU®
- 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 pipelines
in 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 pressure
surges 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.
5.2 Installing valves with butt weld ends

Please note that only qualified persons using appropriate equipment and working in
accordance 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.
Language
Page 6 UK Rev. 0040102000 2103 11-65 / 190
RTM#A.2 STOBU®
5.3 Installing valves with balancing plugs
ATTENTION !
ARI stop valves must be equipped with pressure balancing plugs if the
differential 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).
ATTENTION !
Note direction of flow.
fig. 5
Valves with pressure balancing plugs have to be installed with medium flowing over the
plug (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 and
equalizes the pressure of the medium under the plug (3). After the pressures have been
equalized within the values stated in the table below, the valve can be opened by turning
the valve further.
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
- 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 medium
is 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 switches

The valves with limit switches must be connected up as shown in the plans of the plant on
the basis of their working principles.

UK 7
RTM#A.2 STOBU®
ATTENTION !
7.0 Care and maintenance

Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
fig. 6: Pattern with hinged bolts

- Observe safety instructions!
- Keep the spindle well greased!
Language
Page 8 UK Rev. 0040102000 2103 11-67 / 190
RTM#A.2 STOBU®
- 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.
ATTENTION !
Pay attention, that the lubricant is suitable for the media.
- If the valve spindle (4) leaks, gradually tighten the stuffing box seal (6) evenly in
increments by means of the hex. nuts (19) until leaking stops.
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 when
depressurised.
- Refer to point 10.0 and 11.0 before dismantling the valve.
- Replace stuffing box packings only after the system has cooled down and the pressure in
the plant has been relieved.
In the case of corrosive or aggressive mediums, drain and ventilate the valve before
replacing the packing.
- Valve service life can be improved by leakage checks.
- When cutting the new packing from the roll,

make sure that the ends are cut with a slant
fig. 7: Split packing ring

Mounting of the bonnet:
- Before reassembling the unit, remember that the bearing surface must be cleaned and 2
new 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:
DN hexagon nuts / Torque

hexagon screws (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

UK 9
RTM#A.2 STOBU®
8.0 Troubleshooting
Instructions.
ATTENTION !
-
It is essential that the safety regulations are observed when identifying faults.

“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
Language
Page 10 UK Rev. 0040102000 2103 11-69 / 190
RTM#A.2 STOBU®
9.0 Troubleshooting table
ATTENTION !

No flow Valve closed. Open valve.
Flange covers not removed. Remove flange covers.
(25; fig.1-2; page 4) (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 Spindle (4) dry (fig. 6; page 8) Grease spindle (4) (fig. 6; page 8)
cannot be opened (Lubricant: see page 9)
Stuffing box too tight (6; fig. 1-4; page Slacken hex. nuts of stuffing box gland
4) (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 Tighten stuffing box gland (15) until
(fig. 1-4; page 4). leakage stops.
-Hex. nut (fig. 1-4; page 4).
If necessary, renew packing in stuffing
box seal (6). Observe warnings (Fig. 6;
page )!
Leakage across valve Valve not properly closed. Pull hand wheel tight without tools.
seat. Seat (1.2) / plug (3) damaged by for- Replaced valve, consult supplier/man-
eign particles. ufacturer.
(fig. 1-4; page 4).
Pressure difference too high. Use a valve with balancing plug
(see point 5.3).
Medium contaminated (suspended sol- Clean valve.
ids). Install dirt screen upstream of valve.
Valve with throttling plug + Locking device has been tightened. Release locking device.
position indicator + lock-
ing device cannot be
opened.
Rattling / banging Nominal diameter of the valve in com- Choose smaller nominal diameter
of the plug design with pliance to the flow rate is to big Use a plug damper execution: see
„loose plug“ medium
- high flow turbulences; Alter the system
- the valve with loose plug is mounted Use a plug damper execution: see
directly by a centrifuged pump; medium
- 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
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
valve and piping. Mating flanges not properly aligned.
11-70 / 190 Rev. 0040102000 2103 Language UK 11

Page
RTM#A.2 STOBU®
10.0 Dismantling the valve or the top part
ATTENTION !
media.

appointed by us.

Language
Page 12 UK Rev. 0040102000 2103 11-71 / 190
RTM#A.2 STOBU®
12.0 EC declaration of conformity
Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock
as defined by
that according to the above mentioned Pressure Equipment Directive (PED) the below
listed products comply and have been approved according Module H through
REGISTER QUALITY ASSURANCE (BS-Nr. 0525), Mönckebergstr. 27,


Stop valves with gland seal

STOBU®
Type 005, 006, 007, 009, 017, 306, 307
Applied standards:
DIN 3230
DIN 3840
AD 2000 leaflet A4
- Cast iron with spheroidal graphite
- Cast steel
- Forged steel
...................................................
11-72 / 190 Rev. 0040102000 2103 Language UK 13

Page
RTM#A.2

STRAIGHT WAY CONTROL VALVE FIG 440-446

Straight Way Control Valve Fig 440-446
  

 
 
 
 
 
 

    
  
     
    
    
   
      
     
     
    
     
    
    
  
 
 
  
  




RTM#A.2

              




























             








 


RTM#A.2





















 

 
   

 



 
  






                
                






 


RTM#A.2




 

 
 

 


RTM#A.2


 

 

 
  
 
 






                   



                   



 





 
            




 
 




                  




 


RTM#A.2












 
 


 
                

              
                 
















 


RTM#A.2








  


 














 


RTM#A.2







                 


 


 



 


RTM#A.2

















 


 










 


RTM#A.2
STRAIGHT WAY CONTROL VALVE FIG 440-446









  






   
  
  
  
  
  


 


RTM#A.2
 
 




            









 
 
 
 










               


 


RTM#A.2

  
  
 
  
 

 
 
  
 
        
 
  
  

 
 
  

             
 

       

  
 
 


 
 
 

 
 
 

 


 


RTM#A.2
STRAIGHT WAY CONTROL VALVE FIG 440-446














                  
            








 
              






Language UK  11-85 / 190

RTM#A.2
PREMIO THRUST ACTUATOR
Operating and Installation Instructions

Thrust actuator ARI-PREMIO
Premio thrust actuator
Contents
1.0 General information on operating instructions...................................................................................... 3
2.0 Notes on possible dangers ...................................................................................................................... 3
2.1 Significance of symbols ......................................................................................................................... 3
2.2 Explanatory notes on safety information ................................................................................................. 4
3.0 Storage and transport............................................................................................................................... 4
4.0 Description ................................................................................................................................................ 5
4.1 Field of application .................................................................................................................................. 5
4.2 Method of functioning.............................................................................................................................. 5
4.3 Diagram .................................................................................................................................................. 6
4.3.1 ARI-PREMIO 2,2 - 5 kN........................................................................................................................ 6
4.3.2 ARI-PREMIO 12 - 15 kN....................................................................................................................... 7
4.3.3 Parts list................................................................................................................................................ 8
4.4 Technical data ......................................................................................................................................... 9
4.5 Dimensions ............................................................................................................................................11
5.0 Installation .............................................................................................................................................. 12
5.1 General installation data ....................................................................................................................... 12
5.2 Manual operation .................................................................................................................................. 14
5.2.1 ARI-PREMIO 2.2 - 5 kN ..................................................................................................................... 14
5.2.2 ARI-PREMIO 12 - 15 kN .................................................................................................................... 15
11-86 / 190
Rev. 0040501000 4706 englisch Language UK
RTM#A.2
PREMIO
5.3 THRUST
Installation ACTUATOR
instructions for mounting to valves...................................................................................... 16
5.3.1 Mounting for valve-lift up to 30 mm (yoke version)............................................................................. 16
5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version) .......................................................... 18
5.4 Electrical connection ............................................................................................................................. 20
5.4.1 Wiring diagram ARI-PREMIO 2.2 - 5 kN ............................................................................................ 20
5.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN ........................................................................................... 21
5.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor............................................................. 21
5.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor.................................................................. 22
5.4.3 Connection ........................................................................................................................................ 23
5.5 Settings ................................................................................................................................................ 24
5.5.1 Torque and travel switches - standard feature.................................................................................... 24
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN) ................................................................................... 24
5.5.3 Travel switch....................................................................................................................................... 25
5.5.3.1 Installation of additional travel switches......................................................................................................... 25
5.5.3.2 Setting of standard travel switch (S3) ............................................................................................................ 27
5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25).......................................................................... 28
5.5.4 Potentiometers ................................................................................................................................... 29
5.5.4.1 Installing the potentiometer............................................................................................................................ 29
5.5.4.2 Setting the potentiometer............................................................................................................................... 31
5.5.5 Error-proof potentiometer for single-channel, error-proof position feedback..................................... 32
5.5.5.1 Setting the potentiometer on conductive plastic basis................................................................................... 32
5.5.6 Heating ............................................................................................................................................... 34
5.5.6.1 Installation of heating..................................................................................................................................... 34
5.5.7 Electronic position indicator RI21 ....................................................................................................... 35
5.5.8 Electronic position controller ES11 ..................................................................................................... 35
5.5.9 Electronic position indicator (RI21) and position controller (ES11) together in the actuator............... 36
5.5.10 Integrated temperature controller dTRON 316 ................................................................................. 37
5.5.10.1 Installation of the dTRON 316 ..................................................................................................................... 37
5.5.11 Integrated reversing contactor .......................................................................................................... 38
5.5.11.1 Installing the reversing contactor ................................................................................................................. 38
5.5.11.2 Electrical connection with ES11 or dTRON 316........................................................................................... 38
5.5.12 Phase control relay........................................................................................................................... 39
5.5.12.1 Installing the phase control relay ................................................................................................................. 39
5.5.13 DC-MODULE.................................................................................................................................... 40
5.5.13.1 Fitting the DC MODULE to ARI-PREMIO .................................................................................................... 40
5.5.13.2 Technical data - DC-Module ........................................................................................................................ 42
5.5.13.3 Wiring diagram ARI-PREMIO 2.2 - 5 kN + 3-step DC module ................................................................... 43
5.5.13.4 Wiring diagram ARI-PREMIO 2.2 - 5 kN + DC module .............................................................................. 44
5.5.14 Electronic position indicator RI32 ..................................................................................................... 45
5.5.14.1 Useful range of the linear motion potentiometer ......................................................................................... 45
5.5.14.2 Installing the R132 electronic position indicator in the PREMIO.................................................................. 45
5.5.14.3 Electronic position indicator (RI32) and position controller (ES11) together in the actuator........................ 46
5.5.14.4 Technical data - Position indicator RI32....................................................................................................... 47
5.5.14.5 Potentiometer installation ........................................................................................................................... 47
5.5.14.6 Wiring diagram ............................................................................................................................................ 48
5.5.14.7 Connection conditions ................................................................................................................................. 48
5.5.14.8 Setting zero point and slope span ............................................................................................................... 49
6.0 Putting the actuator into operation ...................................................................................................... 50
7.0 Care and maintenance............................................................................................................................ 50
8.0 Troubleshooting ...................................................................................................................................... 50
9.0 Troubleshooting table ............................................................................................................................ 51
10.0 Dismantlement of thrust actuator ....................................................................................................... 52
11.0 Warranty / Guarantee ............................................................................................................................ 52
12.0 EC declaration of conformity ............................................................................................................... 53

RTM#A.2 Thrust actuator ARI-PREMIO
and repair.
ATTENTION !
ATTENTION !
... Warning of dangerous voltage.
Exposed to injury!
Don’t touch the turning handwheel when the motor is running.
Exposed to injury!
Don’t put your hand into the up or downwards moving
appliance.
Danger when not observing the operating and installation

instructions!
Before installing, operating, maintenance or dismantling read
and observe the instructions.
Danger though voltage!

Before dismantling the hood, switch of the electrical source
and secure against turning on again.

0040501000 4706 Page 3
Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
to property.

ATTENTION !
- Valve mountings such as drives, handwheels, hoods must not be used to take
external forces, e.g. they are not designed for use as climbing aids, or as
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
See “4.4 Technical data” for weights.
- At -20° to +70°C dry, free from dirt.

- Do not unpack thrust drive or setting equipment assembly prior to installation.
- Protect against external force (impact, vibration etc.).
- Do not soil or damage type identification plate and wiring diagram on the controller.

Page 4 0040501000 4706
4.0 Description
4.1 Field of application
ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves
requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN.
The thrust actuators are set to the thrust forces specified in the technical data. If supplied
with the valve, the lift of the thrust actuator will be set to the stroke distance of the valve.
Selection of the proper actuator version in alignment with the corresponding fitting as well
as use of the thrust actuator in accordance with the specified technical data is the
responsibility of the systems engineer.
See data sheet for areas of application, application limits and potential.
Any use of the thrust actuator beyond the specified technical data or improper use of the
actuator is deemed to be not for the intended purpose.
The ambient conditions have to be conform to the actual electromagnetic compatibility
directives. Additional the compatibility to this directives has to be maintained in case of
expansion or other changing of the ambient conditions.
4.2 Method of functioning

The thrust actuator, fitted with a yoke or columns, is mounted to the valve.
Transfer of force is effected via a coupling safeguarded against torsion.
The torsion safeguarding feature also serves as a lift indicator.
The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear
clamps mounted to the column.
The electrical components are accommodated separately from the gearbox underneath a
sealed hood, thus being protected against operating and environmental effects.
Following removal of the hood, easy access is provided to the switchgear and indicating
feature.
The rotary motion of the motor is transmitted to the spindle nut by means of spur gear.
The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut
and thus performs a pull or push motion depending on the sense of rotation.
In the final positions of the valve, the spindle nut is pressed against a set of springs so as to
produce closing force.
The motor is switched off by means of two load-dependent switches and one stroke-
dependent switch. The load-dependent switches will also switch off the motor if foreign
bodies have lodged themselves between the valve seat and cone.
The load-dependent switches serve to protect the valve and thrust actuator against
damage.

0040501000 4706 Page 5
4.3 Diagram
4.3.1 ARI-PREMIO 2,2 - 5 kN
Yoke Version Column Version
Fig. 1

Page 6 0040501000 4706
4.3.2 ARI-PREMIO 12 - 15 kN
Fig. 2

0040501000 4706 Page 7
4.3.3 Parts list
Pos. Designation Pos. Designation

50.1 Gearbox 50.35 Grub screw DIN ISO 4766 - M6
50.1.1 Gearbox cover plate 50.36 Set collar
Cable gland 50.37 Grub screw DIN 913-M3x5
2.2 - 5kN: 2 x M16x1,5 50.38 Guide spindle
50.2
12 - 15kN: 2 x M16x1,5 /
1 x M20x1,5 50.39 Hexagon nut DIN EN ISO 4034 - M5
50.4 Sealing plug 1 x M16x1,5 50.40 Synchronous motor, complete
50.6 Hood 50.40.3 Motor capacitor
50.7 Hood seal 50.41 Head cap screw
DIN EN ISO 4762-M4 - 18
50.8 Counter-sunk screw DIN EN ISO 50.42 Board support
10642 - M5x20
50.9 Sealing washer DIN EN ISO 7089 50.43 Standard board
50.10 Column 50.43.1 Directional switch (valve – up) S3
50.11 Conical spring washer 50.43.2 Torque switch
50.12 Handwheel 50.45 Shift lever
50.12.1 Turning handle of handwheel 50.46 Washer
50.14 Yoke 50.47 Wiring diagram sticker, standard
50.15 Flange 50.48 Connector, 3-pole (standard)
50.16 Spring washer DIN 128-A10 50.50 Trip slide
50.17 Hexagon head screw 50.51 Setting spindle for switch S3
DIN EN ISO 4017 - M10x30
50.18 Hexagon head screw 50.52 Setting spindle for switch S4
DIN EN 24017-M10x45
50.19 T-head bolt DIN 261-M12x40 50.53 Setting spindle for switch S5
50.20 Washer DIN EN ISO 7089 50.54 Trip cam
50.21 Spring washer DIN 128-A12 50.56 Spring PREMIO for trip slide
50.22 Hexagon nut DIN EN ISO 4032 - M12 50.57 Head cap screw
50.23 Lift dial 50.58 Protective conductor terminal
50.24 Distance column 50.59 Head cap screw
50.25 Hexagon nut DIN 980-V-M16 50.87 Threaded bush
50.26 2-ear clamp (stroke indicator) 50.96 O-ring DIN 3771 – 4 x 1.8
50.27 Coupling 50.101 Connector, 8-pole
50.30 Driving spindle 50.110 Gear cap
50.31 Spindle safety feature 50.115 O-ring DIN 3771 - 52x2.5
50.32 Torsion safety feature 50.119 Fan wheel
50.34 Bellow

Page 8 0040501000 4706
4.4 Technical data
Type ARI-PREMIO
Thrust force kN 2,2 5,0 12,0 15,0
Stroke distance max. mm 50 80
Duty classification in accordance S1 - 100 % ED; S3 - 80% ED 1200 c/h S1 - 100% ED;
with EN 60034-1/A11 S3 - 50% ED 1200 c/h
Control speed mm/sec. 0.25 0.38 0.38 1,0 0.79 0.38
Motor voltage 230V - 50Hz / 60Hz * 230V - 50Hz
Power consumptionW 10.3 11.7 25.3 52.9 109 96
Torque switch 2 pcs., permanently wired, 2 pcs., permanently
switching capacity 10A, 250V~ wired
switching capacity
16A, 250V~
Travel switch 1 pcs., permanently wired, 1 pcs.,
switching capacity 10A, 250V~ permanently wired
switching capacity
16A, 250V~
Enclosure IEC 60529 IP 65
Max. permissible ambient -20 °C ... +70 °C
temperature
Handwheel Yes (rotating during operation) Yes (engageable)
Mounting position Any. Exception: motor must not be suspended downwards
Gear lubricant Molyduval
Klüber Isoflex Topas NB152
Valenzia H2
Weight kg 5.4 6 6.5 10.5
* Control speed and power consumption are 20% higher at frequency of 60 Hz

0040501000 4706 Page 9
Accessories
Type ARI-PREMIO
Thrust force kN 2,2 5,0 12,0 15,0
2 additional travel switches, zero potential,
Additional travel switches
Switching capacity 10A, 250V ~
2 additional travel switches, zero potential, with gold contacts,
Additional travel switches for
for low switching capacities and at aggressive atmosphere,
low-voltage / electronic system
switching capacity max. 0.1A, 4-30V
Potentiometer max. 2 only Ohmage optional: 100, 200, 500, 1000, 1000 Ohm; 1,5 Watt
max. 2 only - Ohmage 5000
or optional

Not compatible for use with the

0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possible
Electronic position indicator
Using the temperature controller, installation is only possible in the control
RI 21
cabinet
Electronic position indicator RI32 2... 10V; 4... 20 mA Only 1 potentiometer possible.
Electronic position controller 0(2) ... 10V . 0(4) ...20mA, Only 1 potentiometer possible
ES 11 Not compatible for use with the temperature controller.
Heating resistor (with automatic switching) 230V-50Hz, 115V-50Hz, 24V-50Hz, 15 Watt

24V - 50Hz 
24V - 60Hz* 
24V - 50 / 60Hz *
Additional voltages / frequencies 115V - 50Hz 
115V - 50 / 60Hz *
115V - 60Hz* 
230V - 60Hz* 

Standard-voltage connection 2 torque switches and 1 travel switch, zero Possible
board, PA potential, for free wiring, with standard
Switching capacity10A, 250V ~ version
Low-voltage connection board 2 torque switches and 1 travel switch,
(electronic system), NA for free wiring, with gold contacts,
for low switching capacities and at aggressive atmosphere.
Switching capacity max. 01A, 4-30V
Integrated temperature-controller Three-step temperature-controller in microprocessor-technology.
dTRON 316 Control range: -200°C to 850°C (resistance thermometer)
Voltage: 24V, 115V or 230V 50/60Hz
Compatible with resistance thermometers and thermocouples
(provided by customer), or standardized active current or voltage signals.
Not compatible for use with the ES11!
Actuator with 400V-
50Hz and 440V-60Hz
Integrated reversing contactor --
Only 1 electronic mod-
ule possible!
Only in addition with
Phase control relay -- integrated
reversing contactor!
To control ARI-PREMIO 230V-50Hz with 24VDC.
DC-Modul e
Not compatible for use with the --
3-step converter
temperature controller!
* Control speed and power consumption are 20% higher at frequency of 60 Hz

Page 10 0040501000 4706
Fig. 3
RTM#A.2
11-96 / 190
Clearance required for
removal of hood
4.5 Dimensions

removal of hood
removal of hood
0040501000 4706
X L h
236 633 max. 30 mm
256 653 max. 50 mm
271 668 max. 65 mm
286 683 max. 80 mm
Language UK
ARI-PREMIO 2.2 - 5 kN ARI-PREMIO 2.2 - 5 kN ARI-PREMIO 12 - 15 kN
Nominal stroke max. 30 mm Nominal stroke > 30 mm - 50 mm Nominal stroke max. 80 mm
Page 11
5.0 Installation
ATTENTION !
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supervision of a
qualified electrician in compliance with regional electrical safety requirements
and regulations.
- Valve mountings such as drives, handwheels, hoods must not be used to take
external forces, e.g. they are not designed for use as climbing aids, or as
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
- Actuator components which rotate or move during operation are coloured red.
Crushing and injury hazard!
5.1 General installation data

- In addition to general installation guidelines, the following points are required to be
observed:
- Planners / construction firms and operators are responsible for positioning and installing
the products.
ATTENTION !
- A voltage is induced in the thrust actuator motor. This induction voltage may be
higher than the operating voltage.
- For this reason relays and electronic load relays for thrust actuator control
require a protective circuit. The contacts of unprotected relays may stick after a
while.
- This may result in reversed directions of rotation or defective switch-off
Recommended safety circuit for relays and electronic load relays:

Connect a varistor or RC module parallel to each relay point.
Varistor S10K385 to S10K460
RC module 100 Ohm / 100nF
Where relay points and electronic load relays are particularly sensitive a coil should be
connected in series additionally to each relay point.
Recommended coil:
Toroidal coil 2mH / 2A
- Contactors of 16A and upwards do not need a safety circuit.
- Check thrust actuator for damage prior to fitting.
Damaged parts must be replaced by original spares.
- Existing operating instructions for valve.
- Complete valve with crossarm.
- Valve cone approximately in mid lift position - on no account supported inside a seat!
- Electrical installation in accordance with current regional regulations.
- Conductor cross-section selected to correspond to the given drive power and existing line
length.
Page 12 0040501000 4706
- Mains fuse rating max. 6A.
- Circuit breakers in the plant to cut off the mains supply to the actuator.
- Conformity of technical data on thrust actuator with field conditions.
- Mains voltage in accordance with data specified on rating plate of thrust actuator.
- Thrust actuator complete with yoke or distance columns and coupling parts intended for
mounting to the corresponding valve.
- Ease of access to installation site.
- Adequate clearance space above the thrust actuator for removing the hood
(refer to point 4.5 Dimensions).
- Install where there is protection against high-energy heat radiation.

- The ambient temperature must be between -20°C and +70°C.
If installed outdoors, the thrust actuator must be provided with an additional cover to protect
against
- rain,
- direct insulation,
- dust.
In case of widely fluctuating ambient temperatures, high atmospheric humidity and
temperatures below the freezing point, your are recommended to install a heating resistor
to minimise condensation buildup in the actuator.
- Thrust actuator mountable in any position except in downward suspended position.
If installed with a horizontal connecting rod, the thrust actuator must be mounted so both
yoke legs or columns are on top of one another in the vertical plane (see Fig. 4 ).
Correct Incorrect
Fig. 4

0040501000 4706 Page 13
5.2 Manual operation
5.2.1 ARI-PREMIO 2.2 - 5 kN
ATTENTION !
- The handwheel always rotates during motor-driven operation (running
indicator). Never activate manual operation while the motor is running.
Injury hazard!
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator! Since the
handwheel always follows during motor-driven operation (running indication),
never operate by hand while the motor is running - potential injury hazards!
With the motor in the stationary state, the thrust actuator can be run in the retracted and
extended state with the handwheel firmly meshed with the gear.
Proceed as follows:
- Swing out lever (pos. 50.12.1) from handwheel (pos. 50.12).
- Turning in clockwise direction --> extending spindle.
- Turning in counter-clockwise direction --> retracting spindle.
retracting spindle extending spindle
Fig. 5

Page 14 0040501000 4706
5.2.2 ARI-PREMIO 12 - 15 kN
ATTENTION !
- Do not attempt to engage manual operation until the motor has stopped.
Switching over while the motor is running may damage the thrust actuator.
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator!
With the motor in the stationary state, the thrust actuator can be run in the retracted and
extended state with the engageable handwheel.
Proceed as follows:
- Fold the turning handle out of the handwheel (A)
- Turn the handwheel slightly and push in the engaging button for manual mode (B)
--> the button engages
- Turning in clockwise direction --> extending spindle
- Turning in counter-clockwise direction --> retracting spindle
The motor is no longer in mesh when the handwheel is engaged. The handwheel is
automatically disengaged when the motor starts and the motor is once more in mesh.
Engaging button
for manual mode
retracting
extending
Fig. 6
ATTENTION !
When changing the motor, it’s necessary to
observe for a correct function of the manual
operating device, that the head-cap screw
M4x18 is screwed in the right place.

0040501000 4706 Page 15
5.3 Installation instructions for mounting to valves
5.3.1 Mounting for valve-lift up to 30 mm (yoke version)
turn
Hexagon nut Hexagon nut

Valve spindle Valve spindle
Fig. 7
To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed
as follows:
- Screw coupling (pos. 50.27) out of torsion safety feature (pos. 50.32) of thrust
actuator (not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A: - Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (pos. 50.27) over valve spindle.
- Screw threaded bush (pos. 50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
ATTENTION !
Setting dimension (Y) and fitting-projection (X) are measured with
inserted valve spindle. This means for
- 2-way valves at closed valve,
- 3-way valves with mixing plug at closed way B,
- 3-way valves with diverting plug at closed way A
After measuring put the valve plug back in the mid lift position!
- Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.
Fig. C: - Place thrust actuator (pos. 50) on valve.
- Mount thrust actuator (pos. 50) on fitting with two T-head bolts (pos. 50.19), two
washers (pos. 50.20), two spring washers (pos. 50.21), two hexagon nuts
(pos. 50.22).
Fig. D/E: - Swing out handwheel lever (pos. 50.12.1) and use it to move out the thrust
actuator until the driving spindle (pos. 50.30) comes to rest on the threaded
bush (pos. 50.87).

Page 16 0040501000 4706
Fig. F: - Screw the coupling (pos. 50.27) firmly into the torsion safety feature
(pos. 50.32) and secure in place using grub screw M6 (pos. 50.35).
- Run valve to lowest position.
- Clip lift dial (pos. 50.23) onto yoke in such a way that top edge of torsion safety
feature is in alignment with tip of arrow mark on lift dial.
- Run valve to both final positions and check to ensure that these are safely
reached
- Carry out electrical connection (see point 5.4).
- Set travel switch S3 (see point 5.5.3.2).

0040501000 4706 Page 17
5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version)
turn
Hexagon nut Hexagon nut

Valve spindle
Valve spindle
Fig. 8
To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm,
proceed as follows:
- Screw coupling (pos. 50.27) out of torsion safety feature (pos. 50.32) of thrust
actuator
(not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A: - Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (pos. 50.27) over valve spindle.
- Screw threaded bush (pos. 50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
ATTENTION !
Setting dimension (Y) and fitting-projection (X) are measured with
inserted valve spindle. This means for
- 2-way valves at closed valve,
- 3-way valves with mixing plug at closed way B,
- 3-way valves with diverting plug at closed way A
After measuring put the valve plug back in the mid lift position!
- Setting dimension (Y) for fitting-projection (X) 83mm = 102mm.
- Setting dimension (Y) for fitting-projection (X) 98mm = 116mm.

Page 18 0040501000 4706
Fig. C: - Slip 2-ear clamp (pos. 50.26) onto a distance column (pos. 50.24) press on
very lightly.
- Screw distance column with 2-ear clamps on opposite side of handwheel into
the flange in such a way that one of the 2-ear clamps is situated above the
torsion safety feature (pos. 50.32) and the other below.
- Screw the other distance column into the flange likewise.
- Place thrust actuator (pos. 50) with distance columns onto valve and fix into
position with two self-locking hexagon nuts (pos. 50.25).
Fig. D/E: - Fold out turning handle of handwheel (pos. 50.12.1), slightly turn the
handwheel and press in the engaging button for manual mode (only 12 - 15 kN)
(button engages). Having done this, move out the thrust actuator until driving
spindle (pos. 50.30) comes into contact with threaded bush (pos. 50.87).
Fig. F: - Screw coupling (pos. 50.27) firmly into torsion safety feature (pos. 50.32) and
secure using grub screw M6 (pos. 50.35).
- Move the valve to the lowest position.
- Press 2-ear clamps (pos. 50.26) into position according to the stroke so they
cannot slip, with the bottom clamp in the lowest valve position located directly
below torsion safety feature (pos. 50.32) and the top clamp in the highest valve
position located directly above the torsion safety feature.
- Move the valve to both travel positions and check that it reaches them reliably.
- Fold turning handle of handwheel (pos. 50.12.1) back in.
- Make the electrical connection (see point “5.4 Electrical connection”). The
engaging button for manual mode (only 12 - 15 kN) disengages when the
motor starts up.
- Set standard travel switch S3 (see point 5.5.3.2).

0040501000 4706 Page 19
Page
standard accessories
Fig. 9
20
RTM#A.2
Language UK
Tele- Thermo- Current Voltage
Input resistance thermometer
transmitter element 0(4)...20mA 0(2)...10V
Binary input Binary output Logic 12V

alternativ to
binary inputs
bin1 and bin2
5.4 Electrical connection
power
supply
230V/3A Binary output (Out1)
230V/3A Binary outpu t (Out2)

5.4.1 Wiring diagram ARI-PREMIO 2.2 - 5 kN
Output to the actuator

Voltage and power
0040501000 4706
supply voltage are equal
Wire connections of the different valve types HZ Heating resistor

3-way valve 3-way valve
Straight through valve with mixing plug with diverting plug DE Torque switch
WE Travel switch for traveling the stroke distance
closed
(S3) in retracting direction
open
RI 21 Electronic position indicator
Option NA: ES 11 Electronic position controller

same design but no RC circuit NA Low-voltage connection board, zero potential
and switches with gold contacts
PA Standard-voltage connection board,
(Switching capacity 0.1A, 4-30VDC) zero potential
POT Potentiometer
WE Travel switch, zero potential
TTR Electronic temperature-controller dTRON 316
11-105 / 190
Standard Accessories
Fig. 10
RTM#A.2
Thermo- Current Voltage
11-106 / 190
Input resistance thermometer Tele-
transmitter element 0(4)...20mA 0(2)...10V
Binary input Binary output Logic 12V

alternativ to
binary inputs
bin1 and bin2
power
supply
230V/3A Binary output (Out1)
230V/3A Binary outpu t (Out2)
Option NA
same design as Standard but no RC
circuit and switches with gold contacts
(Switching capacity 0.1A, 4-30V) Output to the actuator
Wire connections of the different valve types Voltage and power
3-way valve 3-way valve supply voltage are equal
Straight through valve with mixing plug with diverting plug
5.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN
Standard
closed A-AB open
0040501000 4706
open B-AB open HZ Heating resistor
DE Torque switch
WE Travel switch for traveling the travel
(S3) distance in retracting direction
RI 21 Electronic position indicator
External reversing contactor: ES 11 Electronic position controller
L1, L2, L3 - actuator spindle drives in
L3, L2, L1 - actuator spindle drives out Low-voltage connection board,
NA
In all external reversing circuits the torque zero potential
switches S1 and S2 have to be used to POT Potentiometer
switch off the actuator motor.
WE Travel switch, zero potential
5.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor
external TTR Temperature-controller dTRON 316

reversing Please check the operating direction
contactor of the actuator ! WS Reversing contactor
PR Phase control relay
Language UK
TR Temperature switch motor
Page 21
Page
Accessories WS + PR
Fig. 11
22
RTM#A.2
Language UK
Wire connections of the different valve types

3-way valve 3-way valve
Straight through valve with mixing plug with diverting plug
3-step input signal Connect 3 phases L1, L2, L3 only here
closed A-AB open AB-B open
Accessories WS
open B-AB open AB-A open
0040501000 4706
5.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor
3-step input signal Connect 3 phases L1, L2, L3 only here
Please check the operating direction

of the actuator !
11-107 / 190
5.4.3 Connection
ATTENTION !
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supervision of a
qualified electrician in compliance with regional electrical requirement and
regulations.
- When connecting the thrust actuator the supply line must be disconnected from
the mains (not live) during connection work. It must be impossible to switch the
power on unintentionally while the mains are disconnected in this way. Failure
to comply may result in death, serious injury or substantial damage to property.
To connect the thrust actuator up to the electrical power supply, proceed as follows:
- Run the thrust actuator a few mm out of the lower final position applying the manual mode.
- Loosen countersunk screw in hood, carefully remove hood in upward direction.
- Remove blind plug fom the cable connection.
- Insert the connection line through this cable inlet until sufficient conductor length is
available up to the corresponding terminals; then tighten the cable connection until the
connecting cable is clamped in place inside it.
- Strip connecting cable approx. 1-1.5 cm above cable inlet.
- Strip the individual conductors approx. 5mm away from the end and fit with conductor end
sleeves.
- Connect protective conductor of connecting cable up to protective conductor terminal of
thrust actuator.
- Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator
terminal strip.
- Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator
terminal strip.
- Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal
strip.
- Place hood on carefully from above and mount firmly onto thrust actuator with
countersunk screw and rubber gasket.
- Connect supply line to mains and run thrust actuator to each of the final positions so as to
check whether the final-position travel switches effect switching off, also checking to see
whether the direction of movement on the thrust actuator corresponds to the desired
direction.
- If the directions of movement are contrary to those desired, the pulse lines governing the
move-in and move-out connecting rod will need to be exchanged.

0040501000 4706 Page 23
5.5 Settings
ATTENTION !
- The thrust actuator may only be operated for a short time without the hood for
unavoidable setting operations to the potentiometers, travel switches and the
electrical options. While these operations are in progress, the thrust actuator
has hazardous, live, uninsulated parts exposed as well as moving and rotating
parts.
- Improper execution of the setting operations or lack of care may cause death,
grievous bodily injury or substantial property damage.
- Operation of the thrust actuator without the hood for any purpose other than
that described above is strictly prohibited.
5.5.1 Torque and travel switches - standard feature

As standard, thrust actuators are equipped with a load-dependent travel switch for the
extending direction (S1), a load-dependent travel switch for the retracting direction (S2) and
a stroke-dependent travel switch for the retracting direction (S3).
The load-dependent travel switches (S1, S2) switch off the motor as soon as the factory-set
thrust force is attained.
ATTENTION !
- The settings of the load-dependent travel switches must on no account
whatsoever be changed!
The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke
is attained. If the thrust actuator is supplied on a straight through valve, the stroke-
dependent travel switch S3 is set in such a way that the motor of the thrust actuator is
switched off as soon as the maximum valve-lift is attained.
If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel
switch S3 is set in the retracting direction in the trip slide to such a downward extent that the
upper final position of the valve is attained prior to travel switch S3 being reached, thus
causing the load-dependent travel switch S2 to switch off the motor.
For this function, all three switches reveal interlock-controlled circuitry on the board.
If the standard travel switches are to be integrated directly into the facility control system,
the standard board can be replaced by optional boards PA or NA (only 2.2 - 5 kN).
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN)

On connection boards PA or NA, the standard travel switches S11/S21, S12/S22 and S13/
S23 do not reveal interlock-controlled circuitry and can be integrated individually into the
facility control system.
The 3 contacts on each of the switches S11/S21, S12/S22 and S13/S23, designed as
double-throw contacts, are - in the case of these boards - brought out on terminals 40-48
and can be freely connected.
The switches on the PA optional board (standard-voltage connection board) are designed
for switching capacities of up to 10A, 250V AC.
The switches on the NA optional board (low-voltage connection board) are designed for
switching capacities of up to 0.1A, 4-30V (gold contacts).

Page 24 0040501000 4706
The optional boards may only be installed at the factory due to the switching points of the
load-dependent switches having to be reset following installation of these boards!
ATTENTION !
- When using optional boards PA or NA, it must be warranted - due to the
operator’s individual circuitry- that, when switching the load-dependent travel
switches S11/21, S12/S22 and S13/S23 the motor of the thrust actuator comes
to a standstill without delay.
This function is not provided for on the optional boards PA and NA in the
supplied state!
5.5.3 Travel switch

The thrust actuators can be equipped with an additional stroke-switch board containing two
travel switches (double-throw contact S4 and S5).
These switches can be set on infinitely variable lines over the entire stroke distance in both
lift directions and integrated at will into the facility control system (no interlock-controlled
circuitry).
The maximum switching capacity of the switches (see point “4.4 Technical data”) must not
be exceeded.
For low voltage (see point “4.4 Technical data”), the additional travel switches are supplied
with gold contacts (option: low-voltage travel switch).
5.5.3.1 Installation of additional travel switches
To install additional travel switches, proceed as follows.
- Switch off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen countersunk screw in hood, carefully remove hood.
- Disconnect motor plug and mains connection plug from board.
- Carefully ease open the lock washer (pos. 50.56) (open ends) with a screw driver while
pulling the trip slide (pos. 50.50) upwards from the board support.
- Remove trip slide (pos. 50.50) from board support by pulling upwards.
- Loosen head cap screws (pos. 50.57) on board support and remove this from gearbox
(only necessary on 5kN thrust actuator).
- Insert stroke-switch board (pos. 50.61) in board support (pos. 50.42) and fix in place using
the supplied screws (pos. 50.44).
- Mount board support loosely on gearbox cover plate with two head cap screws (pos.
50.57) (only necessary on 5kN).
- Push trip slide (pos. 50.50) back into board support (pos. 50.42) from above and onto the
guide spindle (pos. 50.38).
- Align board support (pos. 50.42) on gearbox cover plate in such a way that the guide
spindle (pos. 50.38) is centrally situated in the borehole of the board support (pos. 50.42);
then screw down tightly on gearbox cover plate (only necessary on 5kN).
- Mount the trip slide (pos. 50.50) so that the spring (pos. 50.56) clips into the groove of the
guide spindle (pos. 50.38).
- Insert 6-pole connector (pos. 50.62) in jack strip of stroke-switch board.

0040501000 4706 Page 25
- Proceed to strip the connecting cable that has been led in through the cable inlet and
fastened, and connect the individual conductors to the terminal strip in accordance with
the desired circuitry and the wiring diagram.
- Set switch points on travel switches in accordance with section 5.5.3.3 Setting the
additional travel switches (S4/S5 and S24/S25)
- Insert motor connection plug in jack strip (pos. 50.43.4) provided for the purpose.
- Insert mains connection plug in jack strip (pos. 50.43.3) provided for the purpose.
- Carefully place hood onto gearbox and mount firmly on thrust actuator with rubber gasket
and countersunk screw.
Fig. 12 Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

50.38 Guide spindle 50.52 Setting spindle for switch S4
50.42 Board support 50.53 Setting spindle for switch S5
50.43.3 Jack strip for mains connection 50.54 Trip cam
50.43.4 Jack strip for motor connection 50.56 Spring
50.44 Self-tapping screw 50.57 Head cap screws DIN EN ISO 4762 -
M4x10
50.50 Trip slide 50.61 Stroke-switch board
50.51 Setting spindle for switch S3 50.62 Connector, 6-pole
(option: travel switch)

Page 26 0040501000 4706
5.5.3.2 Setting of standard travel switch (S3)
On delivery of the thrust actuator, the standard travel switch (S3) is already set to the
existing valve-lift and the setting spindle for the travel switch S3 (pos. 50.51) is sealed with
screw glyptal.
This setting needs no changing for normal operation.
If reinstalling the thrust actuator on a straight through valve, the travel switch S3 needs to
be set as follows:
- Move valve out of the lowest position so as to run valve-lift to up position.
- Using a screw driver, proceed to turn setting spindle for switch S3 (pos. 50.51) until the trip
cam (pos. 50.54) arriving from below trips the switch (audible click).
- Run thrust actuator briefly in extending direction and then in retracting direction once
more, checking to see whether the thrust actuator is switched off at the desired point
(nominal lift).
- If need be, correct the setting as described.
If reinstalling the thrust actuator on a three-way valve, the travel switch S3 needs to be set
as follows:
- Run valve in both final positions and check in each final position whether the valve
switches off via the load-dependent switch.
- Carry out a check in the top final position the see whether, after switching off the thrust
actuator, the trip cam (pos. 50.54) of the travel switch S3 is situated below switch S3 and
has not tripped the latter. If the trip cam (pos. 50.54) is situated above the travel switch S3
or trips the same, the setting spindle governing the travel switch S3 (pos. 50.51) needs to
be turned until the trip cam is situated below travel switch S3 without tripping it.
- Run the thrust actuator in both final positions once more and check whether thrust
actuator switches off in both final positions via the load-dependent switches.
- If need be, correct the setting as described above.

0040501000 4706 Page 27
5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25)
The two additional travel switches can be freely set in both lift directions for indicating
certain valve positions.
To do this, proceed as follows:
- Run valve to desired position due to be indicated by the corresponding switch.
- Proceed to turn the setting spindle belonging to the appurtenant switch until the switch is
tripped (audible click).
- Run thrust actuator briefly in both directions, checking and, if need be, correcting the
setting.
The actuating feature on the travel switches is designed in such a way that both travel
switches can be overrun in both directions.
Standard design:
For that reason, care should be taken on additional travel switches to see that the actuating
state of the switches remains active only for a short time while the thrust actuator continues
to run and that switching back takes place afterwards.
The actuating state of the travel switches remains in force over a lift of 4 mm.
Special design:
At additional travel switches with extended switch levers, the actuating state of the travel
switches remains in force over a lift of 49 mm.

Page 28 0040501000 4706
5.5.4 Potentiometers
The potentiometers are used for electrical position acknowledgement on the facility control
system or for the options - electronic position controller ES11 or electronic position indicator
RI21
A maximum of 2 potentiometers can be installed (= 1 double potentiometer).
The potentiometers can be supplied with different resistance values
(see point „4.4 Technical data“).
For the electronic position controller ES11 and the electronic position indicator RI21 use
must be made solely of 1000 ohm potentiometers.
Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by
means of transmission determined in respect of each valve-lift between the toothed rack on
the trip slide and the pinion on the potentiometer shaft.
Use must only be made of the pinion specified for the valve-lift.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer
is assembled and set ready for operation.
To achieve optimal electromagnetic compatibility it is recommended to use shielded cables
for connecting potentiometers or standardized active current or voltage signals.
5.5.4.1 Installing the potentiometer
If retrofitting the potentiometer, proceed as follows:
accidentally.
- Plug in the flat connectors on grey potentiometer cables onto the middle connector pins,
those of the red cables onto the upper connector pins and those of the yellow cables onto
the lower connector pins of the potentiometer (Fig. 13 ).
- Insert the potentiometer into the guide in the way that the pinion (pos. 50.73) of the
potentiometer meshes with the gear stick of the trip slide.
- With a valve lift up to 30 mm, hook spiral spring (pos. 50.70) into the left-hand window of
board support (pos. 50.42) above the potentiometer guide, insert into the guide between
the slide block and the potentiometer guide and hook into the cut-out below the
potentiometer.
With a valve lift between 30 mm and 50mm, hook spiral spring (pos. 50.70) into the right-
hand window (for 12 - 15kN middle window) above the potentiometer guide, insert into the
guide between the slide block and the potentiometer guide and hook into the cut-out
below the potentiometer.
With a valve lift between 50 mm and 65 mm, hook spiral spring (pos. 50.70) into the
middle window in board support (pos. 50.42) above the potentiometer guide, insert into
the guide between the slide block and the potentiometer guide and hook into the cut-out
below the potentiometer.
- Check to see whether pinion (pos. 50.73) is pressed into toothed rack by spiral spring
(pos. 50.70) and is positioned free from backlash.
- If this is not the case, remove spiral spring (pos. 50.70), readjust by bending a little, and
place back in position again.
- Screw jack strip of connecting cable (pos. 50.68) to board support (pos. 50.42) with two
self-tapping screws (pos. 50.69) (single potentiometer connectors 25-27).
- Insert additional 3-pole connector (pos. 50.74) in jack strip of connecting cable
(pos. 50.68).

0040501000 4706 Page 29
- Set potentiometer (see point 5.5.4.2).
- Place hood carefully onto thrust actuator and fasten it on the actuator with rubber gasket
and countersunk screw.
red grey
red
grey
yellow
yellow
Fig. 13
Fig. 14: Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

50.42 Board support 50.68 Connecting cable for option:
potentiometer
50.46 Washer 50.69 Self-tapping screw
50.47 Circuit-diagram sticker 50.70 Spiral spring (option:
potentiometer)
50.67.1 Hexagon nut 50.71 Slide block (option: potentiometer)
50.67.2 Tooth lock washer 50.73 Pinion (selection depends on
valve-lift 20, 30, 50, 65 or 80 mm)
50.67.3 Potentiometer 50.74 Connector, 3-pole
(option: potentiometer)

Page 30 0040501000 4706
5.5.4.2 Setting the potentiometer
To set the potentiometer, proceed as follows:
- Move thrust actuator to extended position.
accidentally.
- Turn potentiometer shaft in counter-clockwise direction until reaching the travel stop.
This places the potentiometer in the initial position (approx. 0 ohm).
- For checking purposes, the resistance of the potentiometer needs to be measured using
an ohmmeter.
- Measure resistance on potentiometer 1 between terminals 25 and 26.
- In this position of the actuator, the measured value should be approx. 0 ohm.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.
- The resistance values thus measured need to be taken into account for the settings to the

0040501000 4706 Page 31
5.5.5 Error-proof potentiometer for single-channel, error-proof position feedback
The TÜV certified potentiometer on conductive plastic basis is used for single-channel,
error-proof position feedback in connection with error-proof, electronic group monitoring
systems for the regulation of fuel -, air and exhaust gas streams.
A maximum of 2 potentiometers can be installed (=1 double potentiometer).
The potentiometers can be supplied with different resistance values (see point „4.4
Technical data“).
For the electronic position controller ES11 use must be made solely with 1000 ohm
potentiometers
The conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by
the transmission between the toothed rack on the trip slide and the pinion on the
potentiometer shaft.
The pinion and the potentiometer shaft are firmly connected.
An additional installation of the option „Error-proof potentiometer“ is not permitted for
safety reasons.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer
is assembled and set ready for operation.
The potentiometer is with the options „Heating“ and “position indicator RI21“ not
combinably.
To use for the electromagnetic compatibility, shielded lines are recommended for
potentiometers and electrical unit signals.
Don`t lay signal lines parallel to the main line!




5.5.5.1 Setting the potentiometer on conductive plastic basis

- Move thrust actuator to extended position.
accidentally.
- For checking purposes, the resistance of the potentiometer needs to be measured using
an ohmmeter.
- Loose the potentiometer by unscrewing the 2 screws and remove it incl. pinion from the
toothed rack.
- Turn potentiometer shaft (angle of rotation mech. 360°, electr. 320° without stop) and by
means of ohmmeter bring the potentiometer in initial position (approx. 0 Ohm).
- Bring the potentiomter and the pinion back in contact with the toothed rack and fasten the
screws.
- Subsequently, the screws are to be provided again with locking lacquer.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.

Page 32 0040501000 4706
- The resistance values thus measured need to be taken into account for the settings to the
Fig. 15: Error-proof potentiometer ARI-PREMIO 2,2 - 5 kN

 Designation  Designation
 Guide spindle  Head cap screw
   
 Board support  Metal sheet
 Trip slide  
   
 Slide block (option: potentiometer)  
 Pinion  self-locking
 3-pole connector  self-locking nut
option: potentiometer

0040501000 4706 Page 33
5.5.6 Heating
A heating resistor should be fitted as a means of protection against the formation of
condensation water in cases involving widely varying ambient temperatures, high
atmospheric humidity (outdoor use) and temperatures below the freezing point. The heating
resistor is self-regulating so that a continuous supply of current merely needs to be
connected up.
5.5.6.1 Installation of heating
On principle, the heating can be combined with all options. It is completely mounted on a
holding bracket.
If electronic system ES11 or RI21 is already installed, unscrew the electronic system from
the holding bracket, remove it, install the heating and attach the electronic system to the
holding bracket for the heating.
To install the heating proceed as follows:
accidentally.
- Using the supplied screws, mount complete heating (on holding bracket) at the point on
the gearbox cover plate provided for the purpose. (Fig. 17).
- Lead continuous-current cable (mains voltage = rated voltage of heating) through cable
inlet into thrust actuator and fix in place with inlet.
- Strip continuous-current cable approx. 1-1,5 cm above cable inlet.
- Strip individual conductors approx. 5mm away from the end and provide with conductor
end sleeves.
- Lay the individual conductors in such a way that they do not come into contact with
moving parts.
- Connect the individual conductors up to the connection terminal block in accordance with
the wiring diagram.
Mounting thread M3 Mounting thread M3

for heating resistor for thermal circuit breaker
Mounting thread M4
for options ES11 and RI21
Mounting thread M3
for jack strip
Fig. 16: Heating installation ARI-PREMIO 2.2-15 kN

50.83.1 Holding bracket 50.83.4 Jack strip
(Option: heating)
50.83.2 Head cap screw DIN 84-M3x8 50.83.6 Connector, 2-pole
50.83.3 Thermal circuit breaker 50.83.10 Heating resistor

Page 34 0040501000 4706
5.5.7 Electronic position indicator RI21
The electronic position indicator RI21 converts the resistance of the 1000 ohm
potentiometer corresponding to the lift into an optional output control signal 0 (2) ...10V DC
or 0 (4) ...20mA DC. For installing and setting the electronic position indicator RI21 the
operating instructions applicable to this unit must be observed in the appropriate valid
version. The corresponding operating instructions are supplied with each unit.
5.5.8 Electronic position controller ES11
The electronic position controller ES11 converts continuous input control signals 0 (2)
...10V DC or 0 (4) ...20mA into a 3-point output signal for the motor, in which case
interrogation of the valve position takes place via a 1000 ohm potentiometer. For installing
and setting the electronic position controller ES11 the operating instructions applicable to
this unit must be observed in the appropriate valid version. The corresponding operating
instructions are supplied with each unit.
Fig. 17: Installing RI21 / ES11 / heating ARI-PREMIO 2.2 - 5 kN

50.78/79 Option ES11 or RI21 50.81 Head cap screw
50.80 Holding bracket 50.82 Head cap screw

0040501000 4706 Page 35
5.5.9 Electronic position indicator (RI21) and position controller (ES11) together in
the actuator
Except or the 5 kN, 12 kN and 15 kN type in 24V version, the electronic position indicator
RI21 and the electronic position controller ES11 can be build-in together in the ARI-
PREMIO.
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI21 and ES11 proceed as follows:
accidentally.
- Loosen counter-sunk screw in hood, carefully remove hood.
- Mount RI21 and ES11 with mounting kit according to Fig. 18.
Fig. 18: Installing R121 / ES11 at the same time as ARI-PREMIO 2.2 – 5 kN

50.67 Potentiometer 50.82 Head cap screw
50.78/79 Option ES11 or RI21 50.106 Metal sheet ES11 and RI21
50.81 Head cap screw 50.108 Distance bold

Page 36 0040501000 4706
5.5.10 Integrated temperature controller dTRON 316
The integrated temperature controller controls temperatures, which are measured by input-
connected temperature sensors, to a manual given setpoint by means of a three-step
output connected with the actuator.
5.5.10.1 Installation of the dTRON 316

The dTRON 316 can be mounted in the ARI-PREMIO as a complete unit with a mounting
kit.
It cannot be combined with ES11.
To install the dTRON 316 proceed as follows:
In addition to “5.4.3 Connection”, the electrical connection of the dTRON 316 has to be
done in the following way:
- Mount the temperature controller on the gear plate by using the specific installation kit
(Fig. 19).
- Plug in the connector X2 of the dTRON 316 to the plug-in connector X1 (1/N, 11, 14) of the
actuator terminal.
- Connect the signal input and the individual wanted additional functions according the
wiring diagram to the dTRON 316.
- Connect the power supply L1 and N to the dTRON 316.
- For changing the working direction to heating signal = extending driving spindle, just
change the wires on the connectors 11 and 14.
Pos. Designation
50.81 Head cap screw
50.97 Temperature controller dTRON 316
50.98 Fixing bracket (option dTRON)
50.99 Holding bracket (option dTRON)
50.100 Self-locking nut (option dTRON)
Fig. 19: Installing dTRON 316 ARI-PREMIO 2.2 – 5 kN

0040501000 4706 Page 37
5.5.11 Integrated reversing contactor
The integrated reversing contactor is actuated using a 3-step input signal.
The reversing contactor swaps over phases L1, L2 and L3 to achieve the desired direction
of rotation of the three-phase motor.
5.5.11.1 Installing the reversing contactor

The reversing contactor can be mounted in the ARI-PREMIO as a complete unit using a
mounting kit.
The reversing contactor can only be combined with one of the ES11, RI21 or temperature
controller options. It is also possible to install the heating and the phase control relay.
Proceed as follows to install the reversing contactor:
Switch off the mains voltage and take measures to prevent it being switched back on
inadvertently.
ATTENTION !
- When the reversing contactor is installed without a phase control relay, the
thrust actuator may be damaged if phases L1, L2 and L3 are wrongly
connected!
The electrical connection procedure as described in 6.4.3 Connection is supplemented by

the following steps:
- Use the mounting kit to attach the reversing contactor to the gear plate (fig. 19).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in
fig. 11.
- Wire up as shown in the table in fig. 10 if you are connecting the reversing contactor
without a phase control relay.
- Refer to “5.5.12 Phase control relay” regarding connecting with a phase control relay.
5.5.11.2 Electrical connection with ES11 or dTRON 316
Modify the 3P output cable of the ES11 or the dTRON 316 as follows:
- Remove plug X25.
- Strip off the outer cable insulation down to about 18 cm.
- Connect the individual conductors as follows:
Black (L ) - S2/14
Brown (L ) - S1/11
Blue (1/N) - K1/A2, K2/A2

Page 38 0040501000 4706
5.5.12 Phase control relay
The phase control relay monitors phases L1, L2 and L3 in the mains input supply. The
reversing contactor is only activated by the phase control relay providing phases L1, L2 and
L3 are connected correctly. This protects the thrust actuator.
5.5.12.1 Installing the phase control relay

The phase control relay is installed in the ARI-PREMIO next to the reversing contactor. It is
only possible to use the phase control relay in conjunction with the reversing contactor. It
cannot be combined with the dTRON 316 temperature controller in the actuator.
Proceed as follows to install the phase control relay:
Switch off the mains voltage and take measures to prevent it being switched back on
inadvertently.
The electrical connection procedure as described in „5.4.3 Connection“ and „5.5.11
Integrated reversing contactor“ is supplemented by the following steps:
- Attach the phase control relay next to the reversing contactor (Fig. 19).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in
Fig. 10.
Pos. Designation
50.57 Head cap screw
DIN EN ISO 4762 - M4 x 10
50.59 Head cap screw DIN EN ISO 4762 - M4 x 6
50.81 Head cap screw DIN EN ISO 4762 - M4 x 8
50.102 Reversing contactor
50.103 Fixing plate (option reversing contactor)
50.105 Phase control relay
50.107 Bracket (option phase control relay)
Fig. 20: Installing reversing contactor and phase control relay ARI-PREMIO 12 – 15 kN

0040501000 4706 Page 39
5.5.13 DC-MODULE
Three-step converter for control of electric thrust actuator ARI-PREMIO 230V 50Hz 2.2 to 5
kN, with 24V DC voltage.
The DC MODULE converts a 24V input DC voltage into a 230V 50Hz 3-step output signal
depending on polarity.
Characteristics
- 3-step converter, for conversion of a 24V input DC voltage into a 230V 50Hz 3-step output
control signal, for OPEN – STOP – SHUT functions
- Fitted to the ARI-PREMIO, or wall-mounted
- Simple 2-wire control
- Direction of rotation changed simply by reversing polarity
- Electronics installed in a strong protective housing
- Position controller ES11 and position indicators RI21 and RI32 can be used as optional
extras
- Can be retrofitted to the ARI-PREMIO 2.2 – 5kN 230V 50Hz thrust actuator
5.5.13.1 Fitting the DC MODULE to ARI-PREMIO
The DC MODULE is mounted to the outside of the ARI-PREMIO.
- Release screws (pos. 50.120.6) and remove cover (pos. 50.120.5) from body
(pos. 50.120.4).
- Fasten body (pos. 50.120.4) to retaining plate (pos. 50.120.1) with screws (pos. 50.120.3).
- Unscrew 2 x hexagon bolts (pos. 50.120.2) with lock washers (pos. 50.16) on connection
side of ARI-PREMIO.
- Fasten retaining plate (pos. 50.120.1) with the 2 x hexagon bolts (pos. 50.120.2) and
secure lock washers (pos. 50.16).
- Connect DC MODULE in accordance with wiring diagram.
- The cable from the DC module must be taken through the cable glands on the drive and
screwed.
- Once connection is complete, screw the cover (pos. 50.120.5) back on to the body (pos.
50.120.4).
ATTENTION !
- High voltages are induced in the DC MODULE and ARI-PREMIO.
- Even with only 24V in the input, voltages can reach over 230V.
- For a safe connection it is vital to isolate the 24V in the input.
(Isolation means that the voltage to a system is switched off at all poles)

Page 40 0040501000 4706
Fig. 21: DC Module Option ARI-PREMIO 2,2 - 5 kN

50.16 Lock washers 50.120.3 Head cap screw M4 x 12
50.120 DC module complete 50.120.4 Body
50.120.1 Retaining plate 50.120.5 Cover
50.120.2 Hexagon bolt M10 x 45 50.120.6 Head cap screw M4 x 20/7

0040501000 4706 Page 41
5.5.13.2 Technical data - DC-Module
Type DC-Module
Supply voltage V 24V DC voltage, +10%/-20% (smoothed)
Current consumption A 1 - 5 A (5 A at full load), approx. 0.5 A at no-load
Operating mode EN 60034-1/ S1 – 100% ED
A11
Output voltage V 230V (at no-load above 230V AC)
Output frequency Hz 50Hz
Power output VA 65VA
Protection type EN 60529 IP 65
max. ambient temperature °C -20°C...+70°C
Weight kg 2
Dimensions DC MODULE mm BxHxT 160x100x83
(without retaining plate and screw fittings)
Connection / installation DC-Module

Electrical connection using screw terminals max 2,5mm2
Ensure suitable conductor cross-section, as a high voltage drop
occurs in long conductors!
Add-on to thrust drive ARI- PREMIO 230V 50Hz 2,2 - 5kN (max. 65VA)
PREMIO
ARI-PREMIO with with ES11 230V (option)
Position controller ES11
ARI-PREMIO with mit RI21 230V (option)
Position indicator RI21 only possible in conjunction with ES11 (option)
ARI-PREMIO with mit RI32 (option)
Position indicator RI32 only possible as two-wire connection in current loop
Not possible in combination with dTRON temperature regulator

Page 42 0040501000 4706
Fig. 22
RTM#A.2
11-128 / 190
ARI-PREMIO 2,2-5kN, with DC-MODULE Accessorie
or Potentiometer connection optionally

with R1 or R2 potentiometers
from 100 Ohm to 20 kOhm
0040501000 4706
Two-wire connection
Polarity for extending (current loop)
PREMIO stem 4...20mA
24V DC
Polarity for retracting
PREMIO stem
Four-wire connection
4...20mA
24V DC and AC
Input
5.5.13.3 Wiring diagram ARI-PREMIO 2.2 - 5 kN + 3-step DC module
2...10V
24V DC and AC
Language UK
Page 43
5.5.13.4 Wiring diagram ARI-PREMIO 2.2 - 5 kN + DC module
Accessorie
or
MODULE
from DC-
or
MODULE
from DC-
to ES11
to RI21





Fig. 23

Page 44 0040501000 4706
5.5.14 Electronic position indicator RI32
The R132 electronic indicator transforms a resistance change into a 4...20mA or 2...10V
standardised control signal.
The R132 position indicator can be operated by 24V DC voltage or 24V AC voltage.
It is possible to link into a current loop without an additional power supply.
5.5.14.1 Useful range of the linear motion
potentiometer
Linear motion potentiometers R1 or R2 are
connected in a three-conductor connection.
Here the RI32 position indicator is also suitable
for conductive plastic potentiometers.
adjustable
The diagram on the right will help when zero point setting range
adjusting the RI32 position indicator to the
stroke distance of the linear motion
potentiometer.
It is important that the mechanical stroke
distance of the control actuator is smaller than adjustable
slope span setting range
the stroke distance of the linear motion
potentiometer.
Fig. 24: Linear motion potentiometer
5.5.14.2 Installing the R132 electronic position indicator in the PREMIO
- The RI32 position indicator is fitted to the ARI-PREMIO as illustrated.
- Screw fixing bracket (pos. 50.98) to gearbox cover plate with head cap screw (pos. 50.81).
- Then fit position indicator (pos. 50.121) to fixing bracket (pos. 50.98) with the head cap
screws (pos. 50.59) and washers (pos. 50.122).
Fig. 25: Option RI32 ARI-PREMIO 2,2 - 5 kN

50.59 Head cap screw M4 x 6 50.98 Fixing bracket
50.67 Potentiometer 50.121 Position indicator RI32
50.81 Head cap screw 50.122 Washer 4.3

0040501000 4706 Page 45
5.5.14.3 Electronic position indicator (RI32) and position controller (ES11)
together in the actuator
The electronic position indicator RI32 and the electronic position controller ES11 can be
build-in together in the ARI-PREMIO.
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI32 and ES11 proceed as follows:
accidentally.
- Mount RI32 and ES11 with mounting kit according to Fig. 26.
Fig. 26: Installing RI32 / ES11 at the same time as ARI-PREMIO 2.2 – 5 kN

50.67 Potentiometer 50.82 Head cap screw
50.78 Option ES11 or RI21 50.121 Option RI32

Page 46 0040501000 4706
5.5.14.4 Technical data - Position indicator RI32
Type RI 32 Position indicator
Supply voltage V 24V DC / AC 50...60Hz
Potentiometer input 1 kOhm ... 10 kOhm three-conductor connection, suitable for
conductive plastic potentiometer
Control signal output, V 2...10 V DC with (control signal output with supply voltage
voltage internal electrical connection)
Control signal output, mA 4...20 mA DC (load max. 500 W)
current (control output signal with supply voltage internal electrical
connection)
Measuring current at A max. 800 A
potentiometer arm
Linearity error % ± 0,2 % measurement range
Temperature coefficient %/K 0,04 %/K
Auxiliary energy inflow %/V 0,02 %/V
Protection type EN 60529 IP40 (terminals IP20)
Max. ambient temperature °C -40 °C...+85 °C
Humidity % 95 % r.F., no dewing
Weight g ca. 35 g
Dimensions mm Ø x depth 44 x 38
Connection / installation RI 32 Position indicator

Electrical connection using screw terminals max 2,5 mm2
Built into thrust actuator in ARI-PREMIO all versions
5.5.14.5 Potentiometer installation
ATTENTION !
When installing the potentiometer please note point „5.5.4 Potentiometer“ in
these Operating Instructions.
Plug Ra, Rb, Rc connector from potentiometer cable of R132 position indicator into
pin strip 25, 26, 27 or 28, 29, 30 of the ARI-PREMIO.

0040501000 4706 Page 47
5.5.14.6 Wiring diagram
Control signal selection

The required control signal is adju-
sted using microswitches SA and
SB
or Potentiometer connection optionally

with R1 or R2 potentiometers
from 100 Ohm to 20 kOhm
Two-wire connection
(current loop)
4...20mA
24V DC
4...20mA
24V DC and AC
2...10V
24V DC and AC
Fig. 27
5.5.14.7 Connection conditions
The electrical connections are joined to position indicator R132 by series disconnect
terminals. The connection to the potentiometer is made by a cable.
Position indicator R132 is connected by a potentiometer (R1 or R2) built into the ARI-
PREMIO.
When the valve is shut approx. 0 ohm are applied between Rb and Rc.
Appropriate conductor cross-sections for terminal connections are 0.2 to 2.5 mm2.
To achieve electromagnetic compatibility is recommended that shielded conductors be
used for longer routings.
Please request technical information direct from ARI-Armaturen.

Page 48 0040501000 4706
5.5.14.8 Setting zero point and slope span
The 4...20mA or 2...10V output control signal is adjusted to the potentiometer stroke by
miniature potentiometers S (slope) and N (zero).
Zero point setting

- The zero point setting is always made before the slope span setting.
- Potentiometer must be at approximately 0 .
- Before measuring resistance, isolate the potentiometer from the RI32 position indicator
and reconnect after measuring.
- Resistance measurement at the potentiometer cable between Rb and Rc.
- Make the connection in accordance with the wiring diagram.
- Zero point setting is made at the zero point setscrew marked N.
- Adjust zero point setscrew N so that the desired minimum control signal value is applied to
the meter.
- Rotate zero point setscrew N to the right to increase the output signal, rotate to the left
to reduce it (a slip clutch engages after 12 rotations)
For example:
- Current output ........minimum value ......... = 4 mA
- Voltage output ........minimum value ......... = 2 V
Slope span setting

The slope span setting is made after the zero point setting.
- Before measuring resistance, isolate the potentiometer from the RI32 position indicator
and reconnect after measuring.
- Resistance measurement at potentiometer cable between Rb and Rc.
- Adjustment of resistance range to control signal output range is set at the slope span
setscrew marked S.
- The meter from the zero point setting stays in the same measurement range for the slope
span setting.
- Adjust the slope span setscrew S so that the desired maximum control signal value is
applied to the meter.
- Rotate slope span setscrew S to the right to increase the output signal, rotate to the left
to reduce it (a slip clutch engages after 12 rotations).
For example:
- Current output ........maximum value ........= 20 mA
- Voltage output ........maximum value ........= 10 V

0040501000 4706 Page 49
6.0 Putting the actuator into operation
ATTENTION !
- Actuator components which rotate or move during operation are coloured red.
Crushing or injury hazard!
- all works has been completed!
- Regional safety instructions must be observed as a matter of policy.
- hood of thrust actuator assembled.
When placing into service proceed as follows:
- Using the handwheel, run the thrust actuator to approximately mid lift position.
- Apply brief pulses to the thrust actuator for each direction of movement and check
whether the directions of movement correspond to those desired. If this is not the case,
the pulse lines governing the retracting and extending action must be exchanged on the
thrust actuator.
- Run thrust actuator to the final position in each direction of movement and check whether
it switches off automatically and whether all externally moving parts are able to move
freely.
- If failing to function properly, check all installation and setting work previously carried out,
correcting if necessary, and afterwards place into service once again.
The thrust actuator requires very little maintenance. Accordingly maintenance in specified
intervals is not necessary.
Depending on the conditions governing use, the maintenance and maintenance-intervals
have to be defined by the operator.
The thrust actuator must not be cleaned with high-pressure equipment or aggressive
solvents or detergents injurious to health or highly inflammable.
During and after cleaning, an inspection should be carried out of the sealing points on the
thrust actuator.
If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements
must be repaired.
8.0 Troubleshooting
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-

“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.

Page 50 0040501000 4706
ATTENTION !
Fault Possible Causes Remedy

Thrust actuator fails to move Power failure Ascertain and eliminate cause
Fuse has blown Replace fuse
Thrust actuator not properly Rectify connection on thrust
connected actuator in accordance with wiring
diagram
Short circuit due to: Ascertain exact cause,
- moisture - Dry the thrust actuator and
eliminate leakage
- wrong connection - Rectify connection on thrust
actuator in accordance with
wiring diagram
- motor has burned out - Check whether the mains voltage
agrees with the voltage specified
on the rating plate. Have motor
changed.
Connector contacts not plugged in/ Insert connector firmly in jack strip
not properly plugged into jack strip thus affected
(Only for 12 - 15 kN) Unscrew the motor mounting
Handwheel is still engaged and screw closest to the cable feed-
does not disengage when the through. (Manual release of the
motor starts up handwheel disengagement
mechanism.)
Thrust actuator alternates Motor operating capacitor Have motor operating capacitor
between clockwise and defective replaced
counter-clockwise rotation
Thrust actuator fails to run to Load-dependent travel switches Remove thrust actuator and send
final positions and also out of to factory for repair
produces chatter
/ defective
Voltage drop due to excessively Lay connecting cables in
long connecting cables or accordance with requisite output
inadequate conductor cross-
section
Mains fluctuations beyond Arrange for "clean" mains system
permissible tolerance travels within requisite tolerances
System pressure too high Reduce system pressure
Periodic failure on thrust Loose connection on feedline Tighten connections on terminal
actuator strips
Thrust actuator is switched off Travel switch S3 not set Set travel switch S3 in accordance
in retracting direction prior to corresponding to use with operating instructions
load-dependent switch (three-
way valve)

0040501000 4706 Page 51
10.0 Dismantlement of thrust actuator
ATTENTION !
- The supply line for connecting up the thrust actuator must be in the dead state
i.e. disconnected while dismantlement work is being carried out. After being
disconnected, the mains power must be prevented from being switched back
on again accidentally.
- The system must be run down (depressurised state) as the valve cone is not
held without the thrust actuator and would thus be conducted by the system
pressure.
- Valve plug approximately in mid lift position - on no account supported inside a
seat!
To dismantle the thrust actuator proceed as follows:
- Disconnect all cables led into thrust actuator from outside and remove from thrust
actuator.
- Place hood on carefully from above and fix in place with counter-sunk screw and rubber
gasket.
- Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety
feature.
- Loosen clamping bolts connecting the thrust actuator to the fitting.
- Remove thrust actuator from valve.
appointed by us.



Page 52 0040501000 4706
12.0 EC declaration of conformity
as defined by
Directive about electromagnetic compatibility 89/336/EEC and the
EG-Low voltage directive 73/23/EEC
Declaration of the manufacturer

as defined by
the Machinery Directive 98/37/EC

that the supplied model of
electric thrust actuator ARI-PREMIO
in the delivered version complies with the following regulations:
- Directive about electromagnetic compatibility 89/336/EEC

(amended by 92/31/EEC and 93/68/EEC)
Applied harmonized standards:
EN 55011; EN 50081-1; EN 50082-2
- EG-Low voltage directive 73/23/EEC
(amended by 93/68/EEC)
EN 60204-1, EN 60335-1, EN 60730-1
- EG-Machinery Directive 98/37/EC
EN 292-1; EN 292-2; EN 294; EN 349; EN 60204-1
The supplied model is intended to be incorporated into machinery or assembled with other
machinery to constitute machinery covered by this directive and must be put into service
until the machinery into which it is be incorporated has been declared in conformity with the
provisions of the directive as amended by 98/37/EC.


0040501000 4706 Page 53

0040501000 4706 Page 54
RTM#A.3
SAFETY VALVE
Safety valves SAFE
Safety valve
SAFE SAFE-P
(Series 900) (Series 920)
SAFE-TC SAFE-TCP/TCS
(Series 940) (Series 960/950)
Contents
1.0 General information on operating 7.0 Care and maintenance.................................11
instructions .................................................... 2 7.1 Setting instructions ................................................11
2.0 Notes on possible dangers........................... 2 7.1.1 Removing the cap ........................................11
2.1 Significance of symbols ..........................................2 7.1.2 Changing the set pressure “without”
2.2 Explanatory notes on safety information .................2 spring change ............................................. 12
7.1.3 Changing the set pressure “with”
3.0 Storage and transport .................................. 3 spring change ............................................. 12
4.0 Description..................................................... 3 7.2 Representation .................................................... 14
4.1 Scope of applications ..............................................3
8.0 Troubleshooting .......................................... 15
4.2 Operating principles ................................................3
9.0 Troubleshooting table ............................... 15
4.3 Diagram...................................................................4
4.3.1 Parts list ..........................................................5
10.0 Dismantling the valve or the top part ..... 17
4.4 Technical data - remarks .........................................6
11.0 Warranty / Guarantee ................................ 17
4.5 Marking .................................................................7
12.0 EC declaration of conformity /
Manufacturers declaration........................ 18
5.0 Installation...................................................... 8
5.1 General notes on installation...................................8
6.0 Putting the valve into operation................. 10

Rev. 0040401000 2704
RTM#A.3 SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS
SAFETY VALVE
and repair.
ATTENTION !
Non-compliance with operating instructions is dangerous!

Read the operating instructions before installation, operation,
maintenance or disassembly and adhere to them strictly.

Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
to property.

Page 2 Rev. 0040401000 2704
SAFETY VALVE
ATTENTION !
- At -20°C to +65°C.
4.0 Description
Safety valves are used to protect pressurised systems.
ATTENTION !
state the higher requirements when ordering
- Valves made from grey cast iron are not authorised for use in systems subject
to TRD 110.
- When media in Fluid Group 1 are used, seal exteriors must be designed so that
they pose no danger to humans or the environment.
- Open safety valves (open bonnet / open cap) are not permissible for fluids,
dusty atmospheres, open air use or for any Group 1 fluids in accordance with
Pressure Equipment Directive 97/23/EC.
Safety valves are safety devices designed to prevent the pressure in any pressurised
system from exceeding the maximum permissible pressure by more than the permissible
tolerance of, usually +10%.

Rev. 0040401000 2704 Page 3
SAFETY VALVE
4.3 Diagram
Fig. 901 Fig. 941 Fig. 961
fig. 1
Fig. 902 / 912 / 903 / 904 / 922 / 924 / 945 / 946
WEDI Bellow
Lever Disc series 950 Bellow series 940

Fig. 951/952; 961/962
fig. 2

Page 4 Rev. 0040401000 2704
SAFETY VALVE
4.3.1 Parts list
Pos. Description Pos. Description

1 Body 32 Hex. nut
2 Seat (not changeable) 33 Lift bolt
2 Screwed seat (SAFE-TC) 34 Screw
3 Stud 35 Lift fork
4 Spindle guide 36 Lifting lever
7 Gasket 37 Spring
8 Hex. nut 38 Screw
9 Lift limitation ring 39 Bolt
10 Spindle ring 40 Split pin
11 Bonnet, closed 41 Lever open
12 Disc unit 42 Bonnet, open
13 Lifting aid 43 Bellow
14 Spindle 44 Ring
15 Gasket 45 Ring
16 Spring type straight pin 47 Ball
17 Adjusting screw 48 Retaining ring
18 Ball 55 Bellow unit
19 Spindle cap 59 Protective rim
20 Parallel pin 60 Spacer
21 Lock nut 61 Coupling
22 Hex. head screw 62 Weight
23 Lead seal 63 Guide bush
25 Snap ring 65 Coupling
26 Spring plate 66 O-Ring
27 Gasket 67 Lift button
28 Cap, closed 68 Spring type straight pin
29 Cap open 70 Balanced piston
31 Ring
Refer to the data sheet for information about materials.

Rev. 0040401000 2704 Page 5
SAFETY VALVE
4.4 Technical data - remarks
for
- Pressure-temperature-ratings etc. refer to datasheet.
Series 900: DN 20/32 - DN 150/250, 1”x2“ - 6”x10”

EN-JL1040, EN-JS1049, 1.0619+N, 1.4408, SA 216 WCB
PN 16/16, PN 40/16, ANSI 150/150, ANSI 300/150
Approval acc. to:
Figure 901, 902, 911, - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
912 TRD 421.
Application letter D/G and F
- ASME Code Section VIII-Division 1 (UV-Stamp)
Figure 903, 904, 990 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D (for Figure 904, 990)
Series 920: DN 20 - DN 100

EN-JL1040, 1.0619+N, 1.4408
PN 16, PN 40
Approval acc. to:
Figure 921-924 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Series 940: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4408
PN 40
Approval acc. to:
Figure 941-943 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Figure 945-946 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D
Series 950/960: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4581
PN 100
Approval acc. to:
Figure 951-953 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-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

Page 6 Rev. 0040401000 2704
SAFETY VALVE
4.5 Marking
Fig.-Nr./Type
Manufacturer
Safety valve (TÜV) Type-test d0 Kdr
approved No.
CE-marking
Notified
body
Set pressure
Safety valve (ASME) NB-stamp
Size (inch) Manufacturer
UV-stamp CE-marking
Notified
body
Fig. 3: Capacity
Fig.-No./Type Units: SCFM = air Set pressure
Type test plates lb/hr = steam
gal/min = water
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
Serial-No. BA/BQ Mechanic

Year
No.
ARI Set pressure (bar / psig)

disc
Approval
E = EPDM -35°C up to 150°C
(e.g. UDT, SZU)
V = Viton -25°C up to 180°C
N = Neoprene -30°C up to 125°C
Fig. 4: Body (outlet)
Series with thread connections are marked on the body.

Rev. 0040401000 2704 Page 7
SAFETY VALVE
5.0 Installation
installation work:
ATTENTION !
- The interior of valve and pipeline must be free from foreign particles
- Steam line systems should be designed to prevent water accumulation
avoided.
- Valve mountings such as actuators, handwheels, bonnets must not be used to
- The blow-off line shall be sufficiently large to ensure that the internal back-
pressure while blowing-off does not exceed 10% (on reqest max. 15%) of the
set pressure. (Exception: safety valves with metallic bellow for back-pressure
compensation).
- If back pressure exceeds 10% (on request max. 15%) of set pressure, the
safety valve must be fitted with a metallic bellow seal for back pressure
compensation. The maximum back pressure must be specified by the
manufacturer. If necessary a leak detector should be provided to monitor the
back pressure compensating metallic bellow seal, but the leak detector must
not block ventilation.
- The ventilation hole in the bonnet of safety valves with a metallic bellow seal
must remain open as a matter of principle, although in the case of Group I fluids
(PED 97/23/EC) a non-isolatable pipeline must be connected to remove the
medium safely (without back pressure if the bellow seal is damaged. Ventilation
must not be blocked by any leak detector used.
- No pipe sections or screws must protrude into the spring bonnet through the
inspection connection. Blockage hazard!
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow with or without a
rupture disk.
- Safety valves shall be installed with upright spindle, not series 950 when
marked, “Einbau nur horizontal (Installation only horizontal)”, then they must be
installed horizontally.
- Flange gaskets shall be fitted concentrically and not restrict the flow cross
section.
- Keep the shaft of the spindle-unit free from paint (open bonnet / cap).
- Blow-off lines shall be laid with gradient.
Page 8 Rev. 0040401000 2704
SAFETY VALVE
- The ratio pao/po shall be taken into account when dimensioning the system.
- 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%.
- Ensure that adequate drip pans are used if setting media in Fluid Group
pursuant to PED 97/23/EC.
- Refer to appropriate TRD 421, AD2000-A2, DIN, ASME Code rules for piping and
installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before
installation.
- Water shall be drained from the safety valve and blow-off line via the blow-off line
(drainage points always at the lowest point).
Support
Bellow
Drip pan
Drainage Drainage at lowest point
fig. 5

Rev. 0040401000 2704 Page 9
SAFETY VALVE
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature,
direction of flow and also check that the data of the valve are correct for the
plant
(refer to type test plate)
- Remove any test gag from cap and close opening with stopper.
- Remove protective caps and lever lock before putting the valve into operation
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow without a rupture
disk. (Note point 5 “Installation”).
- When operating without a blow-off line, medium may spurt from the valve outlet.
Injury hazard!
- Blowing off may generate loud flow noise.
- Medium may be discharged from the ventilation or inspection hole in the spring
bonnet (safety valves with stainless steel bellows and heating valves)
Injury hazard!
- Hot vapour may be discharged if the spring bonnet is open.

Page 10 Rev. 0040401000 2704
SAFETY VALVE
Maintenance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- Too frequent lifting for test purposes can increase wear of the sealing surfaces!
- The safety valve must be lifted from time to time in line with current regulations
to ensure that the valve works correctly.
(The intervals at which this must be done depends on various factors so that no
generally applicable interval can be specified)
- Original parts only should be fitted as spares as a matter of policy.
- In safety valves with an open spring bonnet there is a danger of being crushed
between the spring windings during lifting and setting.
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due
to particles between 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.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be
returned to the original position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- The manufacturer accepts guarantee liabilities only if tampering by third parties is
prevented.
7.1 Setting instructions
ATTENTION !
The following work must only be carried out by authorised specialist workshops
or at the operator’s own responsibility with monitoring by an independent agency
(e.g. TÜV).
7.1.1 Removing the cap
ATTENTION !
If there is back pressure or during setting/lifting, medium may be discharged from
the open bonnet, or into the adjusting screw area if the bonnet is closed.
Open caps
- Remove slit pin (pos. 40), bolt (pos. 39).
- Extract lifting lever (pos. 41).
- Remove screw (pos. 38).
- Unscrew cap (pos. 29).
Closed caps
- Press lifting lever (pos. 36) towards bonnet (pos. 11) and against stop.
- Unscrew cap (pos. 28).
Closed cap series 960/950
- Remove spring type straight pin (pos. 68)
- Remove lift button (pos. 67) or lifting lever (pos. 36)
- Unscrew cap (pos. 28)
Rev. 0040401000 2704 Page 11
SAFETY VALVE
7.1.2 Changing the set pressure “without” spring change
ATTENTION !
- When changing the set pressure in a pressurised system bear in mind vapour
discharge if bonnet is open, in adjusting screw area if bonnet is closed.
- Note spring setting range.
- Check the spring range.
- Spindle (pos. 14) must be held fast by all alterations.
- Loosen lock nut (pos. 21).
- Turn adjusting screw (pos. 17) clockwise to increase and anticlockwise to reduce the set
pressure.
- Secure spring setting by tightening lock nut (pos. 21).
- Assemble lifting device.
7.1.3 Changing the set pressure “with” spring change
ATTENTION !
- Depressurise the system before dismantling or opening the safety valve.
- For removing the cap refer to 7.1.1.

- Extract parallel pin (pos. 20) and lift off the spindle cap (pos. 19).
- Slacken locknut (pos. 21) and relieve spring (pos. 37) by turning adjusting screw (pos. 17)
anticlockwise.
- Unscrew nuts (pos. 8) at flange connection and remove bonnet (pos. 11/42).
Fig. 940: loosen coupling (pos. 61)
Fig. 950/960: loosen bonnet (pos. 11)
ATTENTION !
- With higher set pressures, the two nuts (pos. 8) on the longer studs (pos. 3)
must be removed last and simultaneously!
- Remove top spring-plate (pos. 26) and spring (pos. 37).
- Extract spindle (pos. 14) with disc (pos. 12/12a), guide plate (pos. 4/4a) and bottom
spring-plate (pos. 26).
- Clean seat (pos. 2) and disc (pos. 12).
- Insert spindle (pos. 14) with disc (pos. 12), guide plate (pos. 4), spring-plate (pos. 26) and
different spring (pos. 37).

Page 12 Rev. 0040401000 2704
SAFETY VALVE
- when carrying out any adjustment work hold the spindle (pos. 14) firm to prevent it
twisting.
ATTENTION !
- Torques must be observed:
M10 16-25 Nm screw joint BR940 100 Nm
M12 30-40 Nm screwed seat BR940 180 Nm
M16 70-90 Nm bonnet BR950/960 60 Nm
M20 150-175 Nm
- Check spring marking in accordance with manufacturer’s data.

- Note spring setting range.
- Change seals.
- Fit bonnet (pos. 11/42) and reset the set pressure; make sure spring setting range is
appropriate.
- Secure spring setting by means of lock nut (pos. 21).
- Assemble lifting device.
- If necessary, replace both spring plates (pos. 26) and use longer studs (pos. 3) when
fitting a spring for a higher set pressure.
- Further information obtainable from the manufacturer.
Only for series 900

ATTENTION !
When changing the set pressure and fitting a new spring, note that safety valves
with set pressures between 0.2 and 1.5 bar have a greater lift.
Therefore:
Set pressure in the range Spring change only in
the range
0.2 to 1.5 bar 0.2 to 1.5 bar
> 1.5 bar > 1.5 bar
Only for series 950:

ATTENTION !
Safety valves for horizontal application, must also to be set in a
horizontal position ( 4.9 bar).

Rev. 0040401000 2704 Page 13
SAFETY VALVE
7.2 Representation
SAFE-TCS
SAFE-TCP
SAFE-TC
Bellow
Closed cap
Open cap
fig. 6
Page 14 Rev. 0040401000 2704
SAFETY VALVE
8.0 Troubleshooting
Instructions.
ATTENTION !
-
It is essential that the safety regulations are observed when identifying faults.

“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.

ATTENTION !

Safety valve does not Flange covers not removed. Remove flange covers.
respond,
Test gag still in place. Remove test gag.
no flow
Spring blocked. Remove pipe or screw projecting into
bonnet through inspection connection.
Set pressure too high. Reset (point 8.1) or replace the safety
valve.
Stainless steel bellow defective, Replace the safety valve.
no back-pressure compensation.
Back-pressure not taken into account. Reset (point 8.1) or, if necessary,
replace the safety valve.
The use of a stainless steel bellow to
compensate for back-pressure should
be considered.
Medium viscous or sticky Use bellow / heating jacket. Insert
rupture disc upstream if necessary.
The valves and piping must be Heating !

protected against freezing and
solidifying media.
Stem cannot be lifted. Pressure less than 85% of set It must be possible to lift the spindle at
pressure. over 85% of the set pressure.
Safety valve seat leaking. Working pressure higher than 90% of Working pressure must be less than
set pressure. 90% of the set pressure.
At low pressures: lever not in neutral Press lever into neutral position
position with closed cap. (towards bonnet).
Safety valve flattering. Refer to separate point “Flattering”.
Medium contaminated; foreign body Raise spindle briefly or, if necessary,
between seat and disc. replace safety valve.
Use of a soft sealing disc should be
considered.

Rev. 0040401000 2704 Page 15
SAFETY VALVE
Flange broken. Damage during transport. Replace safety valve.
Flange bolts not evenly tightened. Replace safety valve.
Transfer of forces such as bending or Install free of tension.
torsional forces.
Pressure surges. Safety valve not installed at highest Install safety valve at highest point.
point.
Valve drainage inadequate or not fitted. Install drainage system a required by
regulations.
Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screw
above cap, Figure 990).
Spring corroded by medium and Replace safety valve.
broken. In the case of vapour, select open cap
or bonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. Replace safety valve.
liquids) emerging from valve. Select design with closed bonnet and
cap.
Install a guard if necessary.
Injury from vapour discharge Install a guard if necessary
(open bonnet / cap)
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or
radius in connection socket. Select
larger line if necessary.
Poor welding (root pass), gaskets at Change conditions.
inlet and outlet flanges too small or not
concentric.
Safety valve capacity too high. Install smaller safety valve.
Burner capacity too low. Install smaller safety valve.
Blow-off line too long or diameter too Use larger diameter or back-pressure
small. compensation by stainless steel
bellow.
Inlet and/or outlet socket too small. Install with dimensions larger than DN
of inlet and outlet lines.
Back-pressure higher than 10%. Install stainless steel bellow for
pressure compensation.
Capacity too low. Safety valves not applied unsuitable for Select and install suitable safety
plant conditions. valves.
Safety valve not applied in line with Adjust conditions.
current DIN, AD, TRD, etc. rules.

Page 16 Rev. 0040401000 2704
SAFETY VALVE
10.0 Dismantling the valve or the top part
ATTENTION !
media.

appointed by us.
The manufacturer will accept warranty liability only if there has been no third party
tampering.



Rev. 0040401000 2704 Page 17
SAFETY VALVE
12.0 EC declaration of conformity / Manufacturers declaration
as defined by
that according to the above mentioned Pressure Equipment Directive (PED) the below listed
products comply and have been approved according to Module H1 and also EC type test according
to module B+D through LLOYD'S REGISTER QUALITY ASSURANCE (NB-No. 0525),
Mönckebergstr. 27, 20095 Hamburg.
Certificate-No: 50003/2
Safety valves Safety valves

SAFE series 900 SAFE-P series 920
Type 901,911,912,902,903,904,990 Type 921,922,923,924
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
AD 2000 Code of Practice A2 AD 2000 Code of Practice A2
- Cast iron with spher. graphite - Cast steel
- Cast steel TRD 421, TRD 721
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
ASME Code Section VIII-Div. 1
Safety valves Safety valves
SAFE-TC series 940 SAFE-TCP/TCS series 950/960
Type 941,942,943,945,946 Type 951,952,953,961,962,963
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
- Cast iron with spher. graphite - Cast iron with spher. graphite
- Cast steel - Cast steel
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
Manufacturers declaration
as defined by
the Machinery Directive 98/37/EC
that the listed products as supplied are intended for installation in a machine or system and that the
machine / system must not be started up until it has been established that the machine / system
complies with the provisions of the EC Machinery Directive 98/37/EC.
...................................................

Page 18 Rev. 0040401000 2704
OM5510_04#D.1
ELECTRICAL ACTUATOR, TYPE PREMIO
Electrical actuator, type Premio
1 General
These operating instructions contain information necessary to install and operate the
thrust actuator both safely and effectively. If problems arise which cannot be solved
with the aid of this operating instruction, please contact Alfa Laval for further infor-
mation.
1.1 Qualified personnel
This refers to personnel possessing corresponding qualifications and familiar with the
processes of installing and assembling the product as well as with putting the product
into service and operating the same, e.g.
- Training, instruction, or authorisation to switch on and off electric circuits and

equipment/systems and to disconnect, ground, and identify the same in accordance
with VDE 0100, the regulations stipulated by the local electricity generating boards
as well as technical safety standards.
- Instruction and obligation to comply with all regulations and requirements per-
taining to use as well as regional and in-house regulations and requirements.
- Training or instruction in accordance with technical safety standards in the use and
maintenance of pertinent safety equipment including job-safety equipment.
1.2 Handling
Storage
• Storage temperature: -20ºC to +70ºC dry, free of dirt.
• Do not damage packing.
• A desiccant or heating to prevent condensation is necessary in damp rooms.
Transport
• Transport temperature: -20ºC to +70ºC.
• Protect against external force (impact, vibration, etc.).
• Do not damage packing.
Handling before installation
• Protect against atmospheric conditions e.g. wetness.
• Correct handling protects against damage.
• Do not soil or damage type identification plate and wiring diagram on the con-
troller.

OM5510_04#D.1
2 Description
2.1 Field of application
The PREMIO linear thrust actuators are employed to actuate control or shut-off valves
requiring anominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15
kN. The thrust actuators are set to the thrust forces specified in the technical data. If
supplied with the valve, the lift of the thrust actuator will be set to the stroke distance
of the valve. Selection of the proper actuator version in alignment with the corre-
sponding fitting as well as use of the thrust actuator in accordance with the specified
technical data is the responsibility of the systems engineer.
Attention: Any use of the thrust actuator beyond the specified technical data or
improper use of the actuator is deemed to be not for the intended
purpose.
The ambient conditions have to be conformed to the actual electromagnetic compati-

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

OM5510_04#D.1
2.3 Technical data
The technical date for the thrust actuators is appears from Table 1 and Table 2. Actuator
diagrams are illustrated in Figure 1 and Figure 2 and the part list is shown in Table 3.
Finally a dimension drawing can be found in Figure 3.
Technical data for Premio actuators

Type Actuator type
Thrust force [kN] 2.2 5.0 12.0 15.0
Travel distance max. [mm] 50 80
Duty classification according to
S3 80% 1200 c/h S3 – 50% 1200 c/h
EN 60034-1/A11
Control speed [mm/sec.] 0.38 0.38 1.0 0.79 0.38
Motor voltage 230 V – 50 Hz / 60 Hz 1) 230 V – 50 Hz
Power consumption [W] 11.7 25.3 52.9 109 96
Torque switch 2 pcs., permanently 2 pcs., permanently wired
wired, switching capacity 10A, 250V~ switching capacity 16 A, 250 V~
Travel switch 1 pcs., permanently wired, 1 pcs., permanently wired
switching capacity10 A, 250 V~ switching capacity 16 A, 250 V~
Enclosure IEC 60529 IP65
Max. permissible ambient temperature -20°C to +70°C
Hand wheel Yes (rotating during operation) Yes (engageable)
Mounting position Any. Exception: motor must not be suspended downwards
Gear lubricant Klüber Isoflex Topas NB 152 Molyduval Valenzia H2
Weight [kg] 5.4 6 6.5 10.5
1) Control speed and power consumption are 20% higher at frequency of 60 Hz
Table 1

OM5510_04#D.1
Accessories
Type Actuator type
Thrust force [kN] 2.2 5.0 12.0 15.0
Trip slide for travel switch S3 for actuating travel switch S3 / retracting spindle
(the travel switch S3 exists in the standard version)
Additional travel switches S4, S52) 2 additional travel switches, zero potential, switching capacity 10 A, 250 V~
Additional intermediate position 2 additional intermediate position switches, zero potential, with gold contacts for low
switches for low-voltage / electronic switching capacities and at aggressive atmosphere,
system S4, S5 2) switching capacity max. 0.1 A, 4-30 V
Potentiometer 2) Max. 2 only. Ohmage optional: 100, 200, 500, 1000, 1000 ohm; 1.5 W;
TÜV-approved potentiometer2) max. 2 only - Ohmage 5000
or optional: 100, 200, 500, 1000 Ohm; 1.5 W
Not compatible for use with the heating resistor or RI21!
No retrofitting possible!
Electronic position indicator RI 212) 0 (2) -10 V, 0 (4) – 20 mA – only 1 potentiometer possible.
Using the temperature controller, installation is only possible in the control cabinet.
Electronic position indicator RI322) 2... 10V; 4... 20 mA Only 1 potentiometer possible.
Electronic position controller ES 11 2) 0 (2) -10 V, 0 (4) – 20 mA – only 1 potentiometer possible.
Not compatible for use with the temperature controller.
Heating resistor (with automatic switching) 230 V – 50 Hz, 115 V – 50 Hz, 24 V – 50 Hz, 15 W
Additional voltages / frequencies 24 V - 50/60 Hz 1) 24V,50Hz 24 V – 50/601) Hz
1) 1)
24V, 60 Hz 1)
115 V - 50/60 Hz 115 V – 50/601) Hz
115V, 50 Hz 230V - 601) Hz
115V, 60 Hz 1)
3~400 V – 50 Hz
230V, 60 Hz 1) 3~400 V – 601) Hz
Standard-voltage connection board PA 2 torque switches and 1 travel switch, zero Possible with standard version
potential, for free wiring,
switching capacity 10 A, 250 V ~
Low-voltage connection board (elec- 2 torque switches and 1 travel switch, for free wiring, with gold contacts, for low
tronic system), NA switching capacities and at aggressive atmosphere.
Switching capacity max. 01A, 4-30V
Integrated temperature-controller Three-step temperature-controller in microprocessor-technology.
dTRON 316 Control range: -200°C to 850°C (resistance thermometer)
Voltage: 24V, 115V or 230V 50/60Hz
Compatible with resistance thermometers and thermocouples (provided by customer),
or standardized active current or voltage signals.
Not compatible for use with the ES11!
Integrated reversing contactor -- Actuator with 400 V – 50 Hz and
440 V – 60 Hz.
Only 1 electronic module possible.
Phase control relay -- Only in addition with integrated revers-
ing contactor
DC-Module To control PREMIO 230V-50Hz with
3-step converter 24VDC. Not compatible for use with the
temperature controller!
1)Control speed and power consumption are 20% higher at frequency of 60 Hz
2) Option trip slide necessary
Table 2

OM5510_04#D.1
Diagram for actuators 2.2 - 5.0
Figure 1 om5510_04_1x0609320en.jpg

OM5510_04#D.1
Diagram for actuators type 12.0 - 15.0 kN
Figure 2 om5510_04_2x0609330en.jpg

OM5510_04#D.1
Part list
Pos. Designation Pos. Designation Pos. Designation
Head cap screw DIN EN ISO
50.1 Gearbox Hexagon head screw DIN EN 50.41
50.18 4762-M4 - 18
24017-M10x55
50.1.1 Gearbox cover plate 50.42 Board support
50.19 T-head bolt DIN 261-M12x40 50.43 Standard board
Cable conduit fitting
50.43. Directional switch (valve – up)
2.2–5.0 kN: 2 x M16 x 1.5 50.20 Washer DIN EN ISO 7089
50.2 1 S3
12–15 kN: 2 x M16 x 1.5 /
50.43.
1 x M20 x 1.5 50.21 Spring washer DIN 128-A12 Torque switch
2
Hexagon nut DIN EN ISO
50.4 Sealing plug 1 x M16 x 1.5 50.22 50.45 Shift lever
4032-M12
50.6 Hood 50.23 Lift dial 50.46 Washer
50.7 Hood seal 50.24 Distance column 50.47 Wiring diagram sticker, std.
Counter-sunk screw DIN EN
50.8 50.25 Hexagon nut DIN 980-V-M16 50.48 Connector, 3-pole (standard)
ISO 10642 - M5x20
Sealing washer DIN EN ISO 50.26 2-ear clamp (stroke indicator) 50.57
50.9 4762-M4x10
7089
50.27 Coupling 50.58 Protective conductor terminal
50.10 Column 50.30 Driving spindle 50.59
4762-M4x6
50.11 Conical spring washer 50.31 Spindle safety feature 50.87 Threaded bush
50.12 Hand wheel 50.32 Torsion safety feature 50.96 O-ring DIN 3771 – 4 x 1.8
50.12. 50.10
Turning handle of hand wheel 50.34 Bellow Connector, 8-pole
1 1
50.14 Yoke 50.35 Grub screw DIN ISO 4766 - M6 50.11
Gear cap
50.15 Flange 50.36 Set collar 0
50.11
50.16 Spring washer DIN 128-A10 50.37 Grub screw DIN 913-M3x5 O-ring DIN 3771 - 52x2.5
5
50.11
50.40 Synchronous motor, complete Fan wheel
Hexagon head screw DIN EN 9
50.17
ISO 4017-M10x40 50.40.
Motor capacitor
3
Table 3

OM5510_04#D.1
Dimensions diagram
Figure 3 om5510_04_3x0729030en.wmf
3 Installation
Note: Safe operation of the actuator is only ensured if it is installed, put into
operation, and maintained by qualified personnel. In addition, care must
be taken to ensure that the general equipment and safety regulations for
electrical lines and installations are complied with and that tools and pro-
tection devices are used professionally. The operating instructions for the
electronic actuator must be observed when carrying out all work on and
when handling the electronic actuator. Disregard of these instructions can
result in injury to persons or damage to property.
3.1 General installation data
In addition to general installation guidelines, the following points are required to be

observed:

OM5510_04#D.1
- Existing operating instructions for valve.

- Complete valve with cross-arm.
- Valve cone approximately in mid lift position -on no account supported inside a
seat.
- Electrical installation in accordance with current regional regulations.
- Conductor cross-section selected to correspond to the given drive power and ex-
isting line length.
- Mains fuse rating max. 6 A.
- Circuit breakers to cut off the mains supply to the actuator.
- Conformity of technical data on thrust actuator with field conditions.
- Mains voltage in accordance with data specified on rating plate of thrust actuator.
- Thrust actuator complete with yoke or distance columns and coupling parts inten-
ded for mounting to the corresponding valve.
- Qualified personnel possessing knowledge of the regulations pertaining to the
erection of power installations.
- Ease of access to installation site and adequate clearance space above the thrust
actuator for removing the hood – refer to dimensions diagram, Fig. 3.
- Install where there is protection against high-energy heat radiation.
- The ambient temperature must be between -20°C and +70ºC.
- In case of widely fluctuating ambient temperatures and high atmospheric humidity,
user is recommended to install a heating resistor to minimise condensation build-
up in the actuator.
- Thrust actuator mountable in any position except in downward suspended position.
- If installed with a horizontal connecting rod, the thrust actuator must be mounted
so that both legs of the yoke or columns are on top of one another in the vertical
plane.
Illustration of actuator mounting
Figure 4 premio_14x4434990en.wmf
3.2 Manual operation
For actuators type 2.2 -5.0 kN

With the motor in the stationary state, the thrust actuator can be run in the open and
closed state with the handwheel firmly meshed with the gear. Proceed as follows:
Step A: Swing out lever (50.12.1) from handwheel (50.12), see Figure 5.
- Turning in clockwise direction --> closes valve.
- Turning in counter-clockwise direction --> opens valve.

OM5510_04#D.1
Hand wheel operation (actuator type 2.2 - 5.0 kN)
Figure 5 om5510_04_premiox0053410en.wmf
In the manual operating mode pay careful attention in the final positions that the hand-
wheel is only turned to the point where the torque switch trips (audible click) as oth-
erwise damage will be caused to the thrust actuator. Since the handwheel always fol-
lows during motor-driven operation (running indication), never operate by hand while
the motor is running –potential injury hazards.
For actuators type 12.0 -15.0 kN

With the motor in the stationary state, the thrust actuator can be run in the open and
closed state with the engage able hand wheel. Proceed as follows:
Step A: Fold the turning handle out of the hand wheel (A), see Figure 6.
Step B: Turn the hand wheel slightly and push in the engaging button for manual
mode (B) --> the button engages.
- Turning in clockwise direction --> closes valve.
- Turning in counter-clockwise direction --> opens valve.
The motor is no longer in mesh when the hand wheel is engaged. The hand wheel is
automatically disengaged when the motor starts and the hand wheel is once more in
mesh.
Hand wheel operation (actuator type 12.0 - 15.0 kN)
Figure 6 om5510_04_5x0729040en.wmf
In the manual operating mode pay careful attention in the final positions that the hand
wheel is only turned to the point where the torque switch trips (audible click) as oth-
erwise damage will be caused to the thrust actuator.

OM5510_04#D.1
3.3 Installation instructions for mounting to valves
3.3.1 Mounting for valve-lift up to 30 mm (yoke version)

To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed
as follows (Fig. and position numbers refer to Figure 7):
Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actua-
tor(not illustrated).
Step B: Set valve cone position to approximately mid lift position.
Step C: Turn flat hexagon nut if not present on valve spindle (Figure 7 A).
Step D: Slip coupling (50.27) over valve spindle (Figure 7 A-B).
Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut. Setting
dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.
Step F: Place thrust actuator (50) on valve (Figure 7 C).Mount thrust actuator on
fitting with two T-head bolts (50.19), two washers(50.20), two spring wash-
ers (50.21), and two hexagon nuts (50.22).
Step G: Swing out handwheel lever (50.12.1) and use it to move out the thrust ac-
tuator until the driving spindle (50.30) comes to rest on the threaded bush
(50.87), (Figure 7 D-E).
Step H: Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and
secure in-place using grub screw M6 (50.35), (Figure 7 F).
Step I: Run valve to lowest position.
Step J: Clip lift dial (50.23) onto yoke in such a way that top edge of torsion safety
feature is in alignment with tip of arrow mark on lift dial.
Step K: Run valve to both final positions and check to ensure that these are safely
reached.
Step L: Carry out electrical connection (see section 3.4) and set optional travel
switch S3 (see section 4.3).
Mounting for valve-lift up to 30 mm (yoke version)

OM5510_04#D.1
3.3.2 Mounting for valve-lift over 30 mm to 80 mm (column version)

To mount the thrust actuator to a valve having a nominal lift of over 30mm to 80 mm,
proceed as follows (Fig. and position numbers refer to Figure 8):
Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust actuator
(not illustrated).
Step B: Set valve cone position to approximately mid lift position.
Step C: Turn flat hexagon nut if not present on valve spindle (Figure 8 A).
Step D: Slip coupling (50.27) over valve spindle (Figure 8 A-B).
Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut. Setting
dimension (Y) for fitting-projection (X) 83mm = 102mm or fitting- projec-
tion (X) 98 mm = 116 mm.
Step F: Slip 2-ear clamp (50.26) onto a distance column (50.24) press on very lightly
(Figure 8 C).
Step G: Screw distance column with 2-ear clamps on opposite side of handwheel
into the flange in such a way that one of the 2-ear clamps is situated above
the torsion safety feature(50.32) and the other below.
Step H: Screw the other distance column into the flange likewise.
Step I: Place thrust actuator (50) with distance columns onto valve and fix into
position with two self-locking hexagon nuts (50.25).
Step J: Fold out turning handle of handwheel (50.12.1), slightly turn the handwheel
and press in the engaging button for manual mode (only 12- 15 kN) (button
engages). Having done this, move out the thrust actuator until driving spindle
(50.30) comes into contact with threaded bush (50.87), (Figure 8 D-E).
Step K: Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure
using grubscrew M6 (50.35), (Figure 8 F).
Step L: Move the valve to the lowest position.
Step M: Press 2-ear clamps (50.26) into position according to the stroke so they can-
not slip, with the bottom clamp in the lowest valve position located directly
below torsion safety feature (50.32) and the top clamp in the highest valve
position located directly above the torsion safety feature.
Step N: Move the valve to both travel positions and check that it reaches them reli-
ably. Fold turning handle of handwheel (50.12.1) back in.
Step O: Make the electrical connection (see section 3.4). The engaging button for
manual mode (only 12- 15 kN) disengages when the motor starts up.
Step P: Set optional travel switch S3 (see section 4.3).

OM5510_04#D.1
Mounting for valve-lift over 30 mm to 80 mm (column version)
Figure 9 and Figure 10 illustrate the wiring diagrams for actuators type 2.2 – 5.0 kN
and actuators type 12.0 – 15.0 kN respectively. To connect the thrust actuator up to
the electrical power supply, proceed as follows:
Step A: Run the thrust actuator a few mm out of the lower final position applying
the manual mode.
Step B: Loosen countersunk screw in hood, carefully remove hood in upward di-
rection.
Step C: Remove blind plug from the cable gland.
Step D: Insert the connection cable through this cable gland until sufficient conduc-
tor length is available up to the corresponding terminals. Then tighten the
cable gland until the connecting cable is clamped in place inside it.
Step E: Strip connecting cable approx. 1 – 1.5 cm above cable inlet.
Step F: Strip the individual conductors approx. 5 mm away from the end and fit with
terminal lugs.
Step G: Connect protective conductor of connecting cable up to protective conductor
terminal of thrust actuator.
Step H: Connect neutral N/MP conductor of connecting cable up to terminal 1/N of
thrust -actuator terminal strip.
Step I: Connect pulse line for move-out connecting rod up to terminal 11 of thrust-
actuator terminal strip.
Step J: Connect pulse line for move-in connecting rod up to terminal 14 of thrust-
actuator terminal strip.
Step K: Place hood on carefully from above and mount firmly onto thrust actuator
with countersunk screw and rubber gasket.

OM5510_04#D.1
Step L: Connect supply line to mains and run thrust actuator to each of the final
positions, also checking to see whether the direction of movement on the
thrust actuator corresponds to the desired direction.
Step M: If the directions of movement are contrary to those desired, the pulse lines
governing the move-in and move-out connecting rod will need to be swob-
bed.

OM5510_04#D.1
Wiring diagram for actuators type 2.2 - 5.0 kN
Trip sllide optional
Figure 9 om5510_04_8x0609340en.1.wmf

OM5510_04#D.1
Wiring diagram for actuators type 12.0 - 15.0 kN
Trip sllide optional
Figure 10 om5510_04_92x0729720en.wmf

OM5510_04#D.1
4 Settings
4.1 Torque switches -standard feature
Thrust actuators are as standard equipped with a load-dependent travel switch for the
closing direction (S1), and a load-dependent travel switch for the opening direction
(S2). The load-dependent travel switches (S1, S2) switch off the motor as soon as the
factory-set thrust force is attained.
Note: The settings of the load-dependent travel switches must on no account

whatsoever be changed.
4.2 Setting of optional travel switch (S3)
4.2.1 2-way valve

The stroke-dependent travel switch (S3) is activated by an optional trip slide. It
switches off the motor as soon as the lift or stroke is attained. If the thrust actuator is
supplied on a straight-way valve, the stroke-dependent travel switch S3 is set in such
a way that the motor of the thrust actuator is switched off as soon as the maximum
valve-lift is attained. If the thrust actuator is supplied on a three-way valve, the trip
cam belonging to travel switch S3 is set in the opening direction in the optional trip
slide to such a downward extent that the upper final position of the valve is attained
prior to travel switch S3 being reached, thus causing the load-dependent travel switch
S2 to switch off the motor. For this function, all three switches reveal interlock-con-
trolled circuitry on the board. If the standard travel switches are to be integrated directly
into the facility control system, the standard board can be replaced by optional boards
PA or NA (only 2.2 – 5.0 kN)
On delivery of the thrust actuator, the optional travel switch (S3) is already set to the
existing valve-lift and the setting spindle for the travel switch (S3) is sealed with screw
glyptic. This setting needs no changing for normal operation.
If reinstalling the thrust actuator on a straight-way valve, the travel switch (S3) needs
to be set as follows:
Step A: Move valve out of the lowest position so as to run valve-lift to up position.
Step B: Using a screw driver, proceed to turn setting spindle for switch (S3) until
the trip cam arriving from below trips the switch (audible click).
Step C: Run thrust actuator briefly in closing direction and then in opening direction
once more, checking to see whether the thrust actuator is switched off at the
desired point (nominal lift).
Step D: If needed, correct the setting as described.

OM5510_04#D.1
4.2.2 3-way valve

• Step A: If reinstalling the thrust actuator on a three-way valve, the travel switch
(S3) needs to be set as follows:
Step B: Run valve in both final positions and check in each final position wheth-
er the valve switches off via the load-dependent switches.
Step C: Carry out a check in the top final position the see whether, after switch-
ing off the thrust actuator, the trip cam of the travel switch (S3) is situated
below switch (S3) and has not tripped the latter. If the trip cam is situated
above the travel switch (S3) or trips the same, the setting spindle gov-
erning the travel switch (S3) needs to be turned until the trip cam is
situated below travel switch (S3) without tripping it.
Step D: Run the thrust actuator in both final positions once more and check
whether thrust actuator switches off in both final positions via the load-
dependent switches.
Step E: f needed, correct the setting as described above.
4.3 Potentiometers
An optional trip slide is required to install potentiometers.
The potentiometers are used for electrical position acknowledgement on the facility
control system or for the options, electronic position controller ES11 or electronic
position indicator RI21. A maximum of 2 potentiometers can be installed (= 1 double
potentiometer). The potentiometers can be supplied with different resistance values.
For the electronic position controller ES11 and the electronic position indicator RI21
use must be made solely of 1000 ohm potentiometers. Conversion of the relevant valve-
lift to the potentiometer angle of rotation is effected by means of transmission deter-
mined in respect of each valve-lift between the toothed rack on the trip slide and the
pinion on the potentiometer shaft. Use must only be made of the pinion specified for
the valve-lift.
If the thrust actuator is supplied with the valve and built-in potentiometer, the poten-
tiometer is assembled and set ready for operation. To achieve optimal electromagnetic
compatibility it is recommended to use shielded cables for connecting potentiometers
or standardized active current or voltage signals.
4.3.1 Installing the potentiometer

If retrofitting the potentiometer, proceed as follows:
Step A: Switch off mains voltage and safeguard to prevent it from being switched
back on again accidentally.
Step B: Loosen countersunk screw in hood, carefully remove hood.
Step C: Plug in the flat connectors on grey potentiometer cables onto the middle
connector pins, those of the red cables onto the upper connector pins and
those of the yellow cables onto the lower connector pins of the potentiometer
(see Figure 11, Figure 12, and Table 4).
Step D: Insert the potentiometer into the guide in the way that the pinion (50.73) of
the potentiometer meshes with the gear stick of the trip slide.

OM5510_04#D.1
Step E: With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand
window of board support (50.42) above the potentiometer guide, insert into
the guide between the slide block and the potentiometer guide and hook into
the cut-out below the potentiometer.
Step F: With a valve lift between 30 mm and 50mm, hook spiral spring (50.70) into
the right-hand window (for 12.0 – 15.0 kN middle window) above the po-
tentiometer guide, insert into the guide between the slide block and the po-
tentiometer guide and hook into the cut-out below the potentiometer.
Step G: With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70) into
the middle window in board support (50.42) above the potentiometer guide,
insert into the guide between the slide block and the potentiometer guide
and hook into the cut-out below the potentiometer.
Step H: Check to see whether pinion (50.73) is pressed into toothed rack by spiral
spring (50.70) and is positioned free from backlash.
Step I: If this is not the case, remove spiral spring (50.70), readjust by bending a
little, and place back in position again.
Step J: Screw jack strip of connecting cable (50.68) to board support (50.42) with
two self-tapping screws (50.69), (single potentiometer connectors 25-27).
Step K: Insert additional 3-pole connector (50.74) in jack strip of connecting cable
(50.68).
Step L: Set potentiometer.
Step M: Place hood carefully onto thrust actuator and fasten it on the actuator with
rubber gasket and countersunk screw.
Installation of potentiometer
Figure 11 om5510_04_10x0621140en.jpg

OM5510_04#D.1
Potentiometer connection cable
Figure 12 premio_11x0291060en.tif
Part list for potentiometer PREMIO 2.2 - 5.0 kN

Pos. Designation Pos. Designation Pos. Designation
50.4 Board support 50.6 Potentiometer 50.71 Slide block (potenti-
2 7.3 ometer)
50.4 Washer
6
50.4 Circuit-diagram sticker Connecting cable for Pinion (selection de-
50.6
7 option: pends on
8
potentiometer 50.73 valve lift 20, 30, 50, 65,
50.6 Hexagon nut 50.6 Self-tapping screw 80)
7.1 9
50.6 Tooth lock washer 50.7 Spiral spring (option: Connector, 3-pole
50.74
7.2 0 potentiometer) (option: potentiometer)
Table 4
4.3.2 Setting the potentiometer

Step A: Move thrust actuator to closing position.

Step B: Switch off mains voltage and safeguard to prevent it from being switched
back on again accidentally.
Step C: Using a screw driver, turn slotted potentiometer shaft in counter-clockwise
direction until reaching the travel stop. This places the potentiometer in the
initial position (approx. 0 ohm).
Step D: For checking purposes, the resistance of the potentiometer needs to be
measured using an ohmmeter.
Step E: Measure the resistance on potentiometer 1 between terminals 25 and 26.
Step F: Measure the resistance on potentiometer 2 between terminals 28 and 29.
Step G: In this position of the actuator, the measured value should be approx. 0 ohm.
Step H: Run thrust actuator to upper final position and read corresponding resistance
value on ohmmeter.
Step I: The resistance values thus measured need to be taken into account for the
settings to the facility control system.

OM5510_04#D.1
4.4 Electronic position controller ES11 (option)
The electronic position controller ES11 converts continuous input control signals
0(2) .. 10 VDC or 0(4) .. 20 mA into a 3-point output signal for the motor, in which
case interrogation of the valve takes place via a 1000 ohm potentiometer. For installing
and setting the electronic position controller ES11 the operating instructions applicable
to this unit must be observed in the appropriate valid version. The corresponding op-
erating instructions are supplied with each unit.
Installing RI21 / ES11 / heating 2.2 - 5 kN
Figure 13 om5510_04_11x0621150en.jpg
Part list for position controller

50.78/79 Option ES11 50.81 Head cap screw DIN EN ISO 4762 - M4x8
50.80 Holding bracket 50.82 Head cap screw DIN EN ISO 4762 - M4x12
Table 5

OM5510_04#D.1
5 Starting up
Check the following before starting up a new system or restarting a system after repairs
or conversion:
• Correct completion of all installation/assembly work.

• Circuits of the system in accordance with DIN VDE regulations and regulations
of the relevant power supply company as well as compliance with all safety reg-
ulations.
• Hood of thrust actuator assembled.
• Start up only by qualified personnel.
Warning: While in operation, the thrust actuator has moving and rotating parts
as well as being integrated in an electrical network system. Improper
handling or failure to observe the operating instructions or the valid
regulations may lead to death, grievous bodily injury or substantial
property damage
When placing into service proceed as follows:
Step A: Use the handwheel, to run the thrust actuator to approximately mid lift po-
sition.
Step B: Apply brief pulses to the thrust actuator for each direction of movement and
check whether the directions of movement correspond to those desired. If
this is not the case, the pulse lines governing the opening and closing action
must be swopped on the thrust actuator.
Step C: Run thrust actuator to the final position in each direction of movement and
check whether it switches off automatically and whether all externally mov-
ing parts are able to move freely.
Step D: If failing to function properly, check all installation and setting work previ-
ously carried out, correcting if necessary, and afterwards place into service
once again.
6 Care and maintenance

The thrust actuator requires very little maintenance. Accordingly maintenance in
specified intervals is not necessary. The thrust actuator must not be cleaned with high-
pressure equipment or aggressive solvents or detergents injurious to health or highly
inflammable. During and after cleaning, an inspection should be carried out of the
sealing points on the thrust actuator. If there is any sign of lubricant escaping or dirt
having accumulated, the sealing elements must be repaired.
7 Dismantlement of the thrust actuator

In addition to general installation guidelines, the following points are required to be
observed:

OM5510_04#D.1
• Dismantlement of the thrust actuator from the fitting must only to be carried out
by suitably qualified personnel.
• The supply line for connecting up the thrust actuator must be in the dead state i.e.
disconnected while dismantlement work is being carried out. After being discon-
nected, the mains power must be prevented from being switched back on again
accidentally.
• The system must be run down (depressurised state) as the valve cone is not held
without the thrust actuator and would thus be conducted by the system pressure.
• Valve cone approximately in mid lift position -on no account supported inside a
seat.
To dismantle the thrust actuator proceeds as follows:
Step A: Loosen counter-sunk screw in hood, carefully remove hood.

Step B: Disconnect all cables led into thrust actuator from outside and remove from
thrust actuator.
Step C: Place hood on carefully from above and fix in place with counter-sunk screw
and rubber gasket.
Step D: Loosen grub screw inside torsion safety feature; screw coupling out of tor-
sion safety feature.
Step E: Loosen clamping bolts connecting the thrust actuator to the fitting.
Step F: Remove thrust actuator from valve.
8 Troubleshooting
In the event of malfunctions or disturbances in operation, first check whether the in-
stallation and adjustment work has been carried out and concluded in accordance with
these operating instructions. Compare the data referring to operating voltage, actuating
signal and temperature to the data specified on the layout drawing of the control system.
Also check whether the given operating conditions correspond to those specified on
the type identification plate.
Warning: All relevant safety regulations must be observed when carrying out the
troubleshooting procedure.
Contact Alfa Laval faults cannot be rectified on the basis of the following trouble-
shooting table:

OM5510_04#D.1
Troubleshooting table
Fault Possible causes Remedy
Power failure Ascertain and eliminate cause
Fuse has blown Replace fuse
Rectify connection on thrust actuator in
Thrust actuator not properly connected
accordance with wiring diagram
Short circuit due to: Ascertain exact cause,
-moisture Dry the thrust actuator and eliminate leak-
age
-wrong connection Rectify connection on thrust actuator in
accordance with wiring diagram
Thrust actuator fails to move
-motor has burned out Check whether the mains voltage agrees
with the voltage specified on the rating
plate. Have motor changed.
Connector contacts not plugged in/ not Insert connector firmly in jack strip thus
properly plugged into jack strip affected
Unscrew the motor mounting screw clos-
(Only for 12.0 – 15.0 kN)
est to the cable feed-through. (Manual re-
Hand wheel is still engaged and does not
lease of the hand wheel disengagement
disengage when the motor starts up
mechanism)
Thrust actuator alternates between clock-
Motor operating capacitor defective Have motor operating capacitor replaced
wise and counter-clockwise rotation
Load-dependent travel switches out of ad- Remove thrust actuator and send to for
justment / defective repair
Voltage drop due to excessively long con-
Lay connecting cables in accordance with
Thrust actuator fails to run to final posi- necting cables or inadequate conductor
requisite output
tions and also produces chatter cross-section
Mains fluctuations beyond permissible Arrange for "clean" mains system within
tolerance travels requisite tolerances
System pressure too high Reduce system pressure
Periodic failure on thrust actuator Loose connection on feed line Tighten connections on terminal strips
Thrust actuator is switched off in opening
Travel switch (S3) not set corresponding Set travel switch (S3) in accordance with
direction prior to load-dependent switch
to use operating instructions
(three-way valve)
Table 6

OM7040_01#A.3
STRAINER
Strainer
1 General
Please observe the notes in these instructions as well as the conditions of use and
permitted data specified on the data sheet of the device in use, in order that the device
will function perfectly and have a long service life.
Note: Alfa Laval does not accept any responsibility for the damage to people or
property when the device we provide is used in any other manner than
intended in our thermal fluid systems and stated in our drawings and in-
struction manuals.
Strainers are used for cleaning flowing mediums. The medium flows through the
strainer screen in the direction shown on the strainer and is thereby cleaned.
1.2 Diagram
Strainer
1 Body
2 Cover
3 Screeb 1
4 Stud
5 Nut
6 Gasket
rotated
view
4
5
Figure 1 strain01ax4441540en.wmf
Strainer Refer to the data sheet for information about materials with designations and
figure numbers.

OM7040_01#A.3
STRAINER
2 Installation
The following points should be taken into account besides the general principles gov-
erning installation work:
• Remove flange covers if present.

• The interior of strainer and pipeline must be free from foreign particles.
• Note installation position with reference to flow, see mark on strainer.
• Steam line systems should be designed to prevent water accumulation.
• Lay pipelines so that damaging transverse, bending and torsional forces are avoi-
ded.
• Connection flanges must mate exactly.
• 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.
• 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.
2.2 Taking the valve into operation
Before taking the strainer into operation, check material, pressure, temperature and
direction of flow.
• Regional safety instructions must be adhered to.

• Touching the strainer when it is operating at high (> 50°C) or low (<0°C) media
• Affix warning notice or protective insulation as appropriate!
• Before putting a new plant into operation or restarting a plant after repairs or mod-
ification, always make sure that:
- All work has been completed!
- The strainer is in the correct position for its function.
3 Care and maintenance

The strainer screens must be cleaned regularly. Maintenance and maintenance-inter-
vals are defined in the instructions of the plant and depends on the degree of dirt ac-
cumulation in the system.
• In most systems the strainer is fitted with an additional start-up filter (e.g. filter
with supporting basket) to start up the system. The insert can be removed after
commissioning.
• The strainer requires little maintenance.

OM7040_01#A.3
STRAINER
Attention: Refer to section 5 before opening the strainer.
Attention: Contaminated strainers in suction-lines will result cavitation and

damage the pumps.
• Before reassembling the unit, remember that the bearing surface must be cleaned
and a new gasket (pos. 6) must be inserted.
• Set the strainer cover (pos. 2) in place.
• Tighten the hexagon nuts (pos. 4) evenly crosswise.
DN Hexagon nuts/bolts Torque (Nm)

15-32 M10 20-35
40 M12 20-35
50-65 M12 60-80
80-150 M16 100-125
200 M20 150-200
250-400 M24 340-410
500 M27 340-410 4
Table 1
4 Troubleshooting
Note: In the event of malfunction or faulty operating performance check that the
installation and adjustment work has been carried out and completed in
accordance with these Operating Instructions.
Important: It is essential that the safety regulations are observed when identify-
ing faults.
If malfunctions cannot be eliminate with the help of the following table "troubleshoot-
ing table", Alfa Laval should be consulted.

No flow Flange covers have not been removed Remove flange covers (see Fig-
(see Figure 1 pos. 7) ure 1 pos. 7)
Flow too low Strainer clogged Clean/replace screen
Piping clogged Check piping system
Flange broken be- Bolts tightened unevenly. Mating flang- Re-align piping and fit new strain-
tween unit and piping es not properly aligned er!
Table 2

OM7040_01#A.3
STRAINER
5 Dismantling the strainer or the top part

Before dismantling the strainer the following points must be observed:
• Make sure that the strainer is blocked out and there is no medium flow through the
strainer.
• Let the medium and strainer cool down sufficiently before handling.
• Make sure that there is no pressure on the strainer before opening.
• Loosen the bolts/ nuts carefully and gradually
Note: Always check the gasket and replace it if necessary ton avoid leakage
6 Partnumbers
Item name Application Item number

Strainer (hot) Water 12050
Strainer Thermal fluid 22050
Table 3
When ordering a strainer please state the DN size and the PN value and which type of
screen is required.
We supply two types of strainer inserts for our thermal fluid systems ( hot water and
thermal oil )systems:
• Standard screen with a mesh width of 1 – 1.6 mm depending on the DN size

• Fine screen with a mesh with of 0.25 mm

OM9430_02#C.1
OIL DETECTION AND HOT-WELL TANK
Oil detection and hot-well tank
1 General description
The main purposes of the oil detection and hot-well tank are:
• Collection of condensate which might be polluted with oil, separation of such oil
to prevent it from entering the feed water system/boiler as well as providing oil
warning alarm (if needed) for manual closing down of the leaking component.
• Collection of low pressure condensate
• Preheating of make-up water
1.1 Oil separation/detection
The hot-well tank receives condensate from two categories of heat consumers:
• “Dirty condensate" from consumers where there is a risk of pollution with oil.
• “Clean condensate" from consumer of steam dump condenser.
The main arrangement is shown in Figure 1. The system consists of a hot-well tank
with a filter and two inspection hatches located at the top.
The clean condensate enters the hot-well tank (1) directly, whereas the dirty condensate
must initially pass a series of oil detection tanks (2) cascades, and a filter tank (3) with
a filter basket (6) containing Loofah sponges. This prevents oil leaks from polluting
the hot-well tank and subsequently protects the condensate and feed water system and
boilers, where it can cause fatal overheating/damage.
The oil detection tank (2) are illuminated and equipped with sight glasses (4) and scum
funnels (5) to enable draining off the accumulated oil through the scum valves (7).
A detection electrode (8) using the ultrasonic reflection principle can be mounted in
the first observation tank for detection of oil accumulations. This is connected to a
control box, which will give an oil warning alarm when oil is collected in the tank.
The tank is provided with service and access hatches on the hot-well tank and also on
the oil detection tank with inspection hatch.

OM9430_02#C.1
Oil separation / detection

Clean condensate
Dirty condensate
8
2 4
1 - Hot well tank

6
2 - Oil detection tank
3 - Filter tank
4 - Sight glass
5 - Scum funnel
5
6 - Filter basket
7 - Scum valve
8 - Possible connection of
oil detection equipment 3
7 7
Figure 1 om9430_02_hotwelx0547460en.wmf
1.2 Water level controls
The various water/condensate connections to the hot-well tank are shown in Figure 2.
The level in the observation and hot-well tank will fall when the boilers calls for more
condensate than returned from the consumers to the hot-well tank. A make-up pump
(2) will be started at a certain low level and stopped again when the water level is at a
certain high level.
The make-up pumps can be multi-stage centrifugal type in vertical execution with one
mechanical shaft seal.
The start/stop signals for make-up pumps can be provided from the magnetic level
gauge (1).
The safety shut off of the feed water pumps is also provided by magnetic level gauge
(1).

OM9430_02#C.1
Level controls
Condensate from consumers
1 - Magnetic level gauge

2 - Make-up pumps
Overflow to
bottom-tank Hot-well tank
Bottom feedwater tank (overflow tank)

Make-up pumps
2 2
Figure 2 hotwell7x0565650en.wmf
1.3 Temperature controls
In order to reduce the dissolved oxygen by means of thermal deaeration before the
water is pumped to the boilers a high temperature (90-95°C) must be maintained in the
hot-well tank.
The oxygen is primarily imported with the cold make-up water. Therefore the heating
requirements will be greater when make-up water is supplied to the hot-well tank.
An example of a heating arrangement is shown inFigure 3.
Heating is achieved by direct injection of live steam through injector pipes into the
hot-well.

OM9430_02#C.1
Temperature controls
4 5 6 7
1 1 Steam injector
2 Temperature sensor
3 Vacuum breaker
4 Check valve
5 Control valve
6 Filter
7 Stop valve
Figure 3 om9430_02_hotwelx0547450en.wmf
2 Operation
2.1 Filling
The bottom feed water tanks must contain pure distilled water (e.g. from the fresh water
generators) prior to filling the hot-well tank (and subsequently the feed water system
and boilers).
Step A: Adjust the level switches in the hot-well tank to the desired level span.
Step B: Check proper alignments between make-up pumps and motors.
Step C: Fill the feed water make-up pump with water to obtain the self-priming
properties of these pumps, and start one of the pumps according to the man-
ufacturer’s instructions.
Step D: Engage the automatic operation of the pump.
Step E: Check that the pump stops when the level in the tank has reached the stop
magnetic switch.
Step F: Check that the make-up pump is automatically started at the level of the start
magnetic switch.
Step G: Readjust the level switches in the hot-well tank if necessary.
Step H: Fill the oil detection tank and the filter tank manually with distilled water.
Step I: Connect the temperature control system (steam injection) when steam is
available. Check that the desired temperature is reached and properly main-
tained.

OM9430_02#C.1
2.2 Automatic operation
When the oil detection and hot-well has been filled and the automatic operation of
pumps and steam injection has been engaged, the equipment requires only little at-
tendance. The routine maintenance and checks are described in section 3.
2.3 Draining
Operation of the pumps must be stopped before the tank is drained. The oil detection
and hot-well tank can be drained directly by opening of the drain valve.
3 Maintenance
3.1 Regular maintenance
3.1.1 Daily routine maintenance

Daily routine maintenance should include the following:
Step A: Check for oil accumulation in the oil detection tank by looking through the
sight glasses. Drain-off existing oil through the scum valves. Locate the oil
leakage source (from the oil is coming) and stop it. If oil has appeared in the
oil detection tank also check the filter. Clean the sponges as necessary.
Step B: Check that the make-up pumps are running smoothly without vibration or
noise.
Step C: Check that the temperature in the tank is at normal high level. Check that
the temperature control equipment is working properly.
3.1.2 Weekly routine maintenance
Weekly routine maintenance should include the following:
Step A: Check the functions of the level switches by filling and draining-off the
water level in the hot-well tank.
3.2 Cleaning
Note: The conditions of the interior parts of the tank should be checked at least
once a year.
The tank must be cleaned manually if oil or other solid or liquid substancesare accu-
mulated in the tank.
The tank can be drained as described in section 2.3 and access to the internal parts is
achieved through the various hatches.
The tank must be thoroughly rinsed before is filled again (see section 2.1) and brought
back into service.

TABLE OF CONTENTS
Table of contents
Accessories & Other Equipment

.
Pressure gauge pipe, form B........................................ 2420101.................... 12-2
Needle valve, straight, 1/2" x 1/2", PN 400................... 2541002.................... 12-3
Pressure gauge, ø 100................................................. 62053-00010.............. 12-4
Pressure gauge, ø 100................................................. 62053-00016.............. 12-5
Pressure gauge, ø 100................................................. 62053-01030.............. 12-6
Pressure switch, KPS 33............................................. 6310320.................... 12-7
Pressure switch KPS 35.............................................. 6310325.................... 12-8
Thermometer, straight................................................ 6633004.................... 12-9
Pressure gauge, ø 63 Type P1116................................ 6633120.................... 12-10
Filter regulator with automatic drain............................ 8000000103............... 12-11
Differential pressure switch........................................ 8040000019............... 12-12
Differential pressure switch........................................ 8040000026............... 12-14
Expansion joint, DN 200............................................ 8510000027............... 12-16
Temperature transmitter............................................. 941071-00001............ 12-17
Temperature switch 200-500C..................................... 951165...................... 12-18
Temperature Switch 20-300C...................................... 951167...................... 12-19
Weld in pocket.......................................................... 951221-00001............ 12-20
Thermometer............................................................ 951411...................... 12-21
EO shut off valve....................................................... 951444...................... 12-22
Oil pressure controller................................................ D00800..................... 12-23
Installation pressure transmitter................................... D75015..................... 12-24
Orifice assembly, DN 25 - DN 350, PN 40................... K18_071961.............. 12-25
Indicating Diff Pressure Switch................................... RTM_OM8040-01...... 12-26
Thermostat................................................................ RTM_OM8070_1....... 12-35
DATA SHEET
Tag No(s):
Type Material:
• Pressure gauge pipe form B, incl. union • Tube: Steel 35.8, DIN 16282
Size: Technical data:
• Inlet: BW 20 x 2.6 • Operating pressure at 120°C: 160 bar(g)
• Outlet: ½" with union • Operating pressure at 400°C: 104 bar(g)
Application:
• For horizontal tapping point
Type No.: 2000

Version: A.2 Pressure gauge pipe, form B 2420101
DATA SHEET
Tag No(s):
Type:
• Pressure gauge valve needle straight.
Size:
• 1/2” x 1/2”
Application:
• For instrument connections
Material:
• Body: C22.8
• DIN-material No. 1.0460
Technical data:
• Test connection: M20 x 1.5 mm threaded
male
• Weight: 0.4 kg
Type No.: 6210

Version: D.2 Needle valve, straight, 1/2" x 1/2", PN 400 2541002
DATA SHEET
Tag No(s):

• Pressure gauge • Measuring unit: bar(g)
Size: • Measuring range: 0 - 10 bar(g)
• ø 100 • Connection down: G 1/2" B
• Accuracy class: 1.0
Application:
• Operating temperature:
• For gaseous and liquid media that are not Ambient : -20 to +60°C
highly viscous or crystallising and will Medium: Max +60ºC
not attack copper alloy parts • Ingress protection: IP65 (EN 60529 /
Material: IEC529)
• Case: Stainless steel
• Socket: Cu-alloy
• Liquid filling: Glycerine
48
8
ø 107
87
G 1/2" B
Type No.: 8050

Version: A.5 Pressure gauge, ø 100 62053-00010
DATA SHEET
Tag No(s):

Size: • Measuring range: 0 - 16 bar(g)
Application:
Material: IEC529)
48
8
ø 107
87
G 1/2" B
Type No.: 8050

DATA SHEET
Tag No(s):

Size: • Measuring range: -1 to +3 bar(g)
Application:
Material: IEC529)
48
8
ø 107
87
G 1/2" B
Type No.: 8050

DATA SHEET
Tag No(s):
Type:
• Pressure switch
• KPS 33
Application:
• The units are pressure-controlled
switches.
• The pressure controls are suitable for use
in alarm and regulation system.
Enclosure:
• IP 67 to IEC 529 and DIN 40050.
• The pressure control housing is enamel-
led pressure die cast aluminium (GD-AI-
Si 12). The cover is fastened by four
screws which are anchored to prevent
loss.
The enclosure can be sealed with fuse
wire.
Adjustment:
• When the pressure control cover is re-
moved, and the locking screw (5) is loos-
ened, the range can be set with the spin-
dle (1) while at the same time the scale
(2) is being read. In units having an ad-
justable differential, the spindle (3) must
be used to make the adjustment. The dif-
ferential obtained can be read direct on
the scales (4).
• To ensure that the plant functions prop-
erly, a suitable differential pressure is
necessary. Too small a differential will
give rise to short running periods with a
risk of hunting. Too high a differential
will result in large pressure oscillations.
Technical data:
• Operating pressure:0 –3.5 bar
• Differential:0.2 bar
• Test pressure:10 bar
• Pressure connection:G 3/8 -m
• Cable entry:Pg 13.5 for cable diameters
5 to 14 mm.
• Weight:1 kg
Type No.: 8030

Version: A.2 Pressure switch, KPS 33 6310320
DATA SHEET
Tag No(s):
Type:
• Pressure switch 116
• KPS 35 90
68 6
Application:
• The units are pressure-controlled
switches.
Ø3
• The pressure controls are suitable for use
in alarm and regulation system.
120
103
79
Enclosure:
• IP 67 to IEC 529 and DIN 40050.
• The pressure control housing is enamel-
40
led pressure die cast aluminium (GD-AI- 29
Si 12). The cover is fastened by four 41 35
screws which are anchored to prevent 44
loss. 81 68
The enclosure can be sealed with fuse
wire.
Adjustment:
• When the pressure control cover is re-
moved, and the locking screw (5) is loos-
ened, the range can be set with the spin-
dle (1) while at the same time the scale
(2) is being read. In units having an ad-
justable differential, the spindle (3) must
be used to make the adjustment. The dif-
ferential obtained can be read direct on
the scales (4).
• To ensure that the plant functions prop-
erly, a suitable differential pressure is 1 Range spindle
necessary. Too small a differential will 2 Range scale
give rise to short running periods with a 3 Differential spindle
risk of hunting. Too high a differential 4 Differential scale
will result in large pressure oscillations. 5 Locking screw
Technical data:
• Operating pressure: 0 - 8 bar
• Differential: 0.4 - 1.5 bar
• Test pressure: 12 bar
• Pressure connection: G 3/8 -m
• Cable entry: Pg 13.5 for cable
• Diameters 5 to 14 mm.
• Weight: 1 kg
Type No.: 8030

Version: C.2 Pressure switch KPS 35 6310325
DATA SHEET
Tag No(s):
Type:
• Thermometer, straight
Size:
• DN150 C
Application:
• For liquid
Material:
• Case material: Aluminium, gold col-
oured anodized
• Numerals: Black figures
150
• Glass inserts: Solid glass
• Capillary fluid: Blue fluid
• Immersion tubes: Brass
Technical data:
• Connection: G 1/2”BSP
• Range: 0 – 160°C
• Accuracy: Class 1,6
G ½”-m
63
Type No.: 8080

Version: A.2 Thermometer, straight 6633004
DATA SHEET
Tag No(s):

• Pressure gauge, type P1116 • Connection: G 1/4”-m (1/4 BSP)
Size: • Measuring unit: bar - Mpa, - kg/cm²
• ø 63 • Measuring range: 0 – 16 / 1.6 / 16
• Pressure utilisation:
Application: Static pressure: 75% of Pmax.
• For all gaseous and liquid media Dynamic pressure: 66% of Pmax.
Material: • Operating temperature: -20 to +80°C
• Case: Stainless steel • Accuracy: EN 837 Class 1,6
32
6.5
ø 68
0 bar 16
MPa=bar x 0.1
0 kg/cm² 16
G 1/4" A
Type No.: 8050

Version: B.1 Pressure gauge, ø 63 Type P1116 6633120
DATA SHEET
Tag No(s):
Type:
• Filter regulator with automatic drain
Size:
• Connections ports 1/4” BSPP
• Gauge ports 1/8” BSPP
Application:
• Instrument air for regulating pressure
Technical data:
• Medium: instrument air only
• Max. inlet pressure: 17 bar
• Operating temp.: 0°C to + 80°C
• Filter element: 5 m
• Recommend pressure regulating range:
0.14 - 8.0 bar
• Pressure gauge: 0 – 12 bar
• Weight: 0.4 kg
Material: Pressure gauge (1 pcs.)
• Body: Zinc 43
• Bowl: Zinc
• Handle: Plastic
ø43 G 1/8 -m
Filter regulator (1 pcs.)
160 10
0 psi
bar
0 12
41
Handle 40 Bracket (1 pcs.)
Body 25
60
13
34
5
61
14 6
Bowl 31
46
158
13
23
96
16
11
Distance required
41 to remove all bowls
regardless of
drain option
Type No.: 8000

Version: A.1 Filter regulator with automatic drain 8000000103
DATA SHEET
Tag No(s):
Type: • Contact hysteresis: max.5 % of full scale

range
• Differential pressure switch with gauge • Load data at AC voltage:
and 2 micro switches
U max.= 250 V
Size: Imax. = 5 A
• ø100 Pmax. = 250 VA
Application: • Load data at DC voltage:
U max.= 30 V
• The differential pressure switch is a com- Imax. = 0.4 A
bination of the indicating and switching Pmax. = 10W
instrument for differential pressure • Switching point adjustment: from the
measurements outside at assistant scale by means of
Material: adjustment screw(s)
• Case: EN AC-Al Si9Cu3(Fe), Black • Setting range: from 10% to 100% of full
lacquered scale value
• Window: Plastic • Switching point repeatabillity accuracy
≤ 1.6%
Technical data: • Pressure connection: G1/4" female, cut-
• Ranges: 0 – 0.6 bar(g) ting ring connection for 10 mm steel tube
• Max. static pressure: 25 bar(g) • Electrical connection: Angular
• Ambient temperature: -10° to +70°C connector, 180° rotatable, cable diameter
• Media temperature: -10° to +90°C 7 to 13 mm
• Protection: IP65 according to EN 60529 / • Weight: approx. 1.4 kg
IEC 60529
96
4.4
17
4 -1
11
Ø
ø 100
74
30°
M20 x 1.5
ø10 15 26
Dimension in mm
Type No.: 8040

Version: C.1 Differential pressure switch 8040000019
DATA SHEET
Tag No(s):
Installation:
• Mounting: Vertical, connection
downwards
• Mounting according to affixed symbols:
High pressure
Low pressure
Electrical connection details
5 6
4
2nd contact 3
1
2
1st contact
Terminal box
Type No.: 8040

Version: C.1 Differential pressure switch 8040000019
DATA SHEET
Tag No(s):
Type: • Contact hysteresis: max.5 % of full scale

range
• Differential pressure switch with gauge • Load data at AC voltage:
and 2 micro switches
U max.= 250 V
Size: Imax. = 5 A
• ø100 Pmax. = 250 VA
Application: • Load data at DC voltage:
U max.= 30 V
• The differential pressure switch is a com- Imax. = 0.4 A
bination of the indicating and switching Pmax. = 10W
instrument for differential pressure • Switching point adjustment: from the
measurements outside at assistant scale by means of
Material: adjustment screw(s)
• Case: EN AC-Al Si9Cu3(Fe), Black • Setting range: from 10% to 100% of full
lacquered scale value
• Window: Plastic • Switching point repeatabillity accuracy
≤ 1.6%
Technical data: • Pressure connection: G1/4" female, cut-
• Ranges: 0 – 6 bar(g) ting ring connection for 10 mm steel tube
• Max. static pressure: 25 bar(g) • Electrical connection: Angular connec-
• Ambient temperature: -10° to +70°C tor, 180° rotatable, cable diameter
• Media temperature: -10° to +90°C 7 to 13 mm
• Protection: IP65 according to EN 60529 / • Weight: approx. 1.4 kg
IEC 60529
96
4.4
17
4 -1
11
Ø
ø 100
74
30°
M20 x 1.5
ø10 15 26
Dimensions in mm
Type No.: 8040

Version: B.1 Differential pressure switch 8040000026
DATA SHEET
Tag No(s):
Installation:
• Mounting: Vertical, connection
downwards
• Mounting according to affixed symbols:
High pressure
Low pressure
Electrical connection details
5 6
4
2nd contact 3
1
2
1st contact
Terminal box
Type No.: 8040

Version: B.1 Differential pressure switch 8040000026
DATA SHEET
Tag No(s):
Type:
• Expansion joint with loose flanges 120
• US1FI.0200.1 16
Size: 8 x ø 18
• DN 200
Application:
• For flue gas outlet / exhaust gas inlet/
outlet
Connection type:
• Connection type: Flanges according to
DIN 86044
Material:
• Bellows: W.nr. 1.4541
• Flanges: R.St.37-2
Ø 201
Ø 280
Ø 320
Technical data:
• Design pressure: 2.5 bar
• Design temperature: 550C
• Movements, max. axial: ± dz24 mm
• Movements, max. lateral ± dy: 3 mm
• Spring rates axial: 154 N/mm
• Spring rates lateral: 610 N/mm
• Weight: 12 kg
Type No.:8510
Version: A.2 Expansion joint, DN 200 8510000027
DATA SHEET
Tag No(s):
Type:
• Temperature transmitter 50
Size:
• Connection nominal: G 3/4" Cable gland
• Cable gland: M20 x 1.5
Application:
75
• For measuring temperatures in gases,
vapour and fluids House
Material:
• Terminal head: Die-cast aluminium
• Extension tube and process connection:
45
Stainless steel 1.4571 SW 32
Technical data:
• Measuring range: -40°C to 400°C
• Housing: form B DIN 43729 G 3/4"
• Weight: 0.367 kg
• Dimensions in mm
Electrical specification: Sensor tube
• Degree of protection: IP65
• Internal wiring: 3 wire sensor
220
Electrical connection:
Type No.: 8060

Version: A.3 Temperature transmitter 941071-00001
951165#A.2
TEMPERATURE SWITCH 200-500C
Temperature switch 200-500C
951167#A.2
TEMPERATURE SWITCH 20-300C
Temperature Switch 20-300C
DATA SHEET
Tag No(s):
Type:
• Weld in pocket ø30
Size: G 3/4"
• Connection nominal: G 3/4"
Application:
Connector
• Pocket for thermometers and sensors
15
• For measuring temperatures in gases,
24
vapour and fluids
Material:
• Tube: St. 35.8 ø16
a3
• Connector: 15 Mo 3
Dimensions: Tube
• Dimensions in mm
• Insert length:
L: min. 25 for PT100 sensors
L: min. 25 for Thermometers
L: min. 50 for Capillary thermostats
Pipe 3/4"
Yard supply
200
a3
L
ø6.5
ø8
Type No.: 8500

Version: A.2 Weld in pocket 951221-00001
951411#A.2
THERMOMETER
Thermometer
951444#A.2
EO SHUT OFF VALVE
EO shut off valve
D00800#A.2
OIL PRESSURE CONTROLLER
Oil pressure controller
D75015#A.2
INSTALLATION PRESSURE TRANSMITTER
Installation pressure transmitter
Description Index Date Drawn Appr.
Internal revision a MoS HeJ
Thickness of orifice changed to always be 3mm b HeJ HBe
c HeJ HBe
Material for item 2 has been changed to S235JR - EN10025-2 d 11JUN14 HBe HeJ
Language UK
Tag No(s):
DATA SHEET
FLAT 35x2.5
Version: A.6
1 2
7 6 5
+ -
EO 10mm
3
NOTE:
7
8 Size and qty of item 8 & 9 depends on DN size
3
Size of item 1 & 2 see applicable purchase order
DN
2
2 Nut ISO 898-2
Sharp Sharp
9 1 5
DIN934
Piping is
Stud ISO 898-1
yard supply 8 1 5.6
DIN938
Double cutting ring PSR10L
7 4
Union nut M10LL
6 2
Piping is L+3
0 M10
yard supply 8 9 Union G10LL
5 2
Gasket DIN2690
4 DNxx, t=1.5 2 Klinger/Graphite
4 Tube EN 10305-4
3 2
Orifice assembly, DN 25 - DN 350, PN 40

E235N
Orifice EN10025-2
2 1 S235JR
or Flange EN10222-2
1 DN PN40, EN1092-2 2 P245GH
Designation Material code Article No.
Item Pcs. Cert.
Dimension Material type Detail drawing No.
Title: Drawn Date
Orifice assembly MoS

Appr. Date
HeJ
Type of drawing: Scale: Size
K18_071961
1:1 A3
12-25 / 46
Article/Drawing No:
K18 : 071961 d
RTM_OM8040-01#A.3
INDICATING DIFF PRESSURE SWITCH
INDICATING DIFF. PRESSURE SWITCH OM8040#01
Indicating Diff Pressure Switch

Indicating differential pressure switch
1 General
This differential pressure switch is particularly intended for flow safeguarding in
heat transfer oil plants according to DIN 32 727 and in hot-water apparatus
according to VdTÜV note of instructions “flow 100”. This gauge has been designed
for connection to standard throttling devices (e.g. orifice gauges, nozzles or similar)
that operate according to the differential and are interconnected via differential
pressure lines and shut-off devices.
permitted data specified on the data sheet of the device in use, in order that the
Note: Aalborg industries does not accept any responsibility for the damage to
people or property when the device we provide is used in any other
manner than intended in our thermal fluid systems and stated in our
drawings and instruction manuals.
1.1 Safety instructions
The appropriate national safety regulations (e.g. 0100 /EN60 079-14/ EN837-2)
must be observed when installing, commissioning and operating these instruments.
Important: All installation/operation and maintenance work must be done by

qualified personnel only!
Important: Serious injuries and/or damage can occur should the appropriate
regulations not be observed
Important: Do not work on the device while under voltage!
12-26Language
/ 46 UK Language UK
Page 1/9
RTM_OM8040-01#A.3
2 Operating principle
Pressure p1 and p2 are given in + and – measuring medium chambers separated by
an elastic diaphragm (1).
The differential pressure (∆p=p1 – p2) causes axial movement (measuring travel) of
the diaphragm against the measuring range spring (2).
The transmission of the differential pressure proportional to the measuring travel to

the movement (4) within the indicating case and to the plungers of the micro-
switches(5) and is carried out pressure sealed and with little friction by means of a
connecting rod (3).
The overpressure protection is provided by contoured metal bolsters for the elastic
diaphragm (6).
The adjustment of the switch point is made by setpoint screws accessible from the
front (7). The assistant scales (8) enable a relatively accurate adjustment of the
switch-points over 270º and indicate the setpoint that is momentarily adjusted.
Figure 1
Language UK
Language UK 12-27
Page/ 2/9
46
RTM_OM8040-01#A.3
3 Installation instructions
Installation of the indicating differential pressure switch should follow the
installation recommendations according to EN 837-2/7.
For technical data see datasheet D00776.
• Pressure connections 2 x G ¼female, bottom, in –line, axle base 26mm,

mounting position NL 90 scc. To DIN 16 257 (means dial upright), thread
connection male preferably acc. To EN 837-3(chapter 7.3.2)
• Prior to the installation of the pressure gauge, the pipes should be thoroughly
cleaned by tapping, blowing or rinsing.
Important: The pressure gauge should be protected against contamination and

high temperature fluctuations.
Important: The permissible maximum media / ambient temperature must not

be exceeded
The pressure gauge should be installed and operated such as to avoid exposure to
vibration. If the line to the pressure gauge is not robust enough to prevent vibration
it should be secured by means of brackets for wall mounting. The use of vibration
rubber is recommended.
3.1 Wall mounting.
Installation / fastening by means of three cast-on mounting brackets.
Figure 2
12-28Language
/ 46 UK Language UK
Page 3/9
RTM_OM8040-01#A.3
3.2 Measuring arrangements
The differential pressure lines must be made of metal. Their inside diameter must
not exceed 4mm and the minimum effective length between valve manifold and
differential pressure gauge must be 500 mm.
Figure 3 – recommended set-up
Language UK
Language UK 12-29
Page/ 4/9
46
RTM_OM8040-01#A.3
Figure 4
3.3 Mounting of the pressure connection
The pressure entries are indicated with (+) for high pressure and (-) for low pressure
Figure 5
12-30Language
/ 46 UK Language UK
Page 5/9
RTM_OM8040-01#A.3
3.4 Wiring details
Attention: The electrical connections should be made by qualified electricians.
Attention: Only permanently laid cables and wiring may be inserted.
Attention: The operator must provide suitable stress relief
Attention: The inserted break-off seal must be matched to the diameter of the
cable or wire.
• Connection details and switch functions are given on the instrument type plate.
Connection terminals (1…6) and ground terminal are appropriately marked.
Figure 6
The mains connection lines to be provided must be suitable for maximum instrument
power consumption and comply with IEC 227 or IEC 245
The instruments are to be included in the equipotential bonding of the plant.
Language UK
Language UK 12-31
Page/ 6/9
46
RTM_OM8040-01#A.3
3.4.1 Power ratings micro switch

See datasheet.
Load data : umax 250 V
Imax 1.4 A
Setting range; from 10% to 100% or full scale value
Contact hysteresis: max.5% of full scale value
Switch point repeatability: ≤1.6%
4 Commissioning
4.1 Setting the switch point
The switch points are set at the factory when the desired values are given. The
adjustment of the switch point is made by setpoint screws accessible from the front.
The assistant scales enable a relatively accurate adjustment of the switch points over
270° and indicate the setpoint that is momentarily adjusted.
The blanking plugs should be removed from the snap-fit window for contact re-
adjustment. The desired switch point can be set by turning the contact adjustment
screws with a screw diver.
If a more accurate switch point adjustment is desired, a test variable should be used.
Afterwards the blanking plugs are to be fitted in the snap-fit window again.
After setting and checking of the switch point in the system the instrument is to be
lead sealed and the set value is to be marked at the instrument.
4.2 Zero point correction
When there is no flow in the system there is no differential pressure and the
differential pressure pointer must move into the range of the zero point tolerance
bar.
When there is a deviation beyond the tolerance bar, a zero point correction must be
done via the standard integrated adjustment pointer.
Lift of the snap-fit window using a screw driver at the recess in the circumference.
The zero point is corrected by turning the slotted screw at the adjustment pointer.
12-32Language
/ 46 UK Language UK
Page 7/9
RTM_OM8040-01#A.3
Figure 7: Adjustment pointer
After the correction is made the snap-fit window must be fitted to the case again.
5 Storage
Before installation, in order to prevent damage to the device the following points
must be observed:
The pressure gauge should remain in its original packing until installation.
• After taking out the device (e.g, for tests) re-use the original packing material
• The storage temperature should not exceed -20°C or +60°C
• The instrument must be protected against dust and humidity.
6 Maintenance and servicing / cleaning

These indicating differential pressure switches require no maintenance or servicing
and will have a very long service life when handled and operated properly.
The instrument should be cleaned with a damp cloth (moistened with soap solution).
When removing/handling a used pressure gauge please take into account that there
will still be some thermal fluid inside and leakage should be cleaned appropriately.
7 Repairs
Repairs are only to be carried out by the manufacturer or appropriately trained
personnel.
Please contact Aalborg Industries.
Language UK
Language UK 12-33
Page/ 8/9
46
RTM_OM8040-01#A.3
8 Disposal
Dispose of the instrument components and packaging materials in accordance with
the respected waste-treatment and disposal regulations of the region or country to
which the instrument is supplied.
9 Part numbers
Item name Range Item number

Indicating differential pressure switch 0 - 0.6 bar(g) D00776-00006
Indicating differential pressure switch 0 - 1.6 bar(g) D00776-00016
Indicating differential pressure switch 0 – 6.0 bar(g) D00776-00060
Contact address
P.O Box 145
3200 AC Spijkenisse
The Netherlands
Direct tel.: +31 181 650 500
Direct fax: +31 181 650 501
12-34Language
/ 46 UK Language UK
Page 9/9
RTM_OM8070_1#A.2
THERMOSTAT THERMOSTATS OM8070#1/1110
Thermostat
THERMOSTATS
INSTALLATION & OPERATING INSTRUCTIONS
RTM_OM8070_1#A.2
TABLE OF CONTENTS
1 GENERAL...............................................................................................................3
1.1 Safety notes...................................................................................................... 3
1.2 Regulations and notes for electrical connection............................................... 3
2 DESCRIPTION AND TECHNICAL DATA.......................................................4
2.1 Protection ......................................................................................................... 4
2.2 Self-monitoring ................................................................................................ 4
2.2.1 Response to a fracture of the measuring system........................................ 4
2.2.2 Response to low temperature..................................................................... 4
3 INSTALLATION....................................................................................................5
3.1 Capillary / temperature probe / pocket............................................................. 5
3.2 Fixing the thermostat ....................................................................................... 5
3.3 Electrical connection........................................................................................ 6
3.4 Opening the housing ........................................................................................ 7
3.5 Electrical connection........................................................................................ 7
3.6 Closing the housing (see figure 6) ................................................................... 9
3.7 Connecting the cable (see figure 7)................................................................ 10
4 COMMISSIONING..............................................................................................10
4.1 Setting the limit value .................................................................................... 10
5 MAINTENANCE AND SERVICING / CLEANING.......................................11
6 STORAGE .............................................................................................................11
7 DISPOSAL.............................................................................................................12
8 PART NUMBERS.................................................................................................12
RTM_OM8070_1#A.2
1 General
permitted data specified on the data sheet of the device in use, in order that the
Note: All necessary settings and, where appropriate, alterations inside the
instrument are described in these instructions. If, however, any
difficulties should arise during commissioning, you are asked not to
carry out any unauthorized manipulations on the unit. You could
endanger your rights under the instruments warranty! Please contact
Aalborg Industries in such a case.
1.1 Safety notes
In the event of a fracture of the measuring system, the filling liquid can escape. At
present there is no restrictive statement from the health authorities concerning any
danger to health over short periods of time and low concentrations, e.g. after fracture
of the measuring system.
Table 1 Physical and toxicological properties of substances which may escape in
the event of a fracture:
Fire/explosion hazard Toxicological data

End of scale Dangerous Water
Ignition Explosion Danger to
(range) reaction contamination Irritant Toxic
temperature ºC limit%v/v health
Liquid-filled
<+200ºC no 355ºC 0.6 - 8 yes yes yes no
≥+ 200ºC ≤
no +490ºC -- yes yes yes no
+350ºC
Gas-filled
≥+400ºC
≤+500ºC no
1.2 Regulations and notes for electrical connection
• The electrical connection must only be carried out by qualified personnel.

• The choice of cable, the installation and the electrical connection must conform
tot the requirements of the Classification Society.
• If contact with live parts is possible while working on the unit, it must be
completely disconnected from the supply
• Earth the instrument at the PE terminal to the protective conductor. This cable
must have a cross-section that is at least as large as the supply cables. Earth
cables must be run in a star configuration to a common earth point which is
connected to the protective earth of the supply. Do not loop earth cables. i.e. do
not run them from one instrument to another.
RTM_OM8070_1#A.2
• Apart from faulty installation, incorrect settings on the thermostat can affect the
proper functioning of the following process or lead to damage. Setting up must
be therefore restricted to qualified personnel. Please observe the appropriate
safety regulations in this respect.
2 Description and technical data

Surface-mounting thermostats work on the principle of liquid expansion with a
micro switch acting as the electrical switching device.
These surface-mounting thermostats with micro switch comply with VDE 0631 and
are approved as:
• Safety temperature monitors STW (STB) with change over contact
Type examination as per:

• DIN EN 14597
• Pressure Equipment Directive 97/23/EC
Caution: Cutting through or kinking the capillary of the surface-mounting

thermostats will lead to permanent failure of the instrument!
2.1 Protection
IP54 to EN 60 529; operation under normal conditions.
2.2 Self-monitoring
2.2.1 Response to a fracture of the measuring system

The circuit stays open permanently in the event of a fracture of the measuring
system (leakage). The micro switch will be locked out.
2.2.2 Response to low temperature

If the probe temperature falls below the minimum value of -10ºC, the circuit is
opened. When the temperature rises again the thermostat will reset itself
automatically.
RTM_OM8070_1#A.2
3 Installation
3.1 Capillary / temperature probe / pocket
• Cutting through or kinking the capillary of the thermostats will lead to

permanent instrument failure!
• Minimum permissible bending radius of the capillary is 5mm.
• The temperature probe must be mounted in the special pocket (thermowell)
provided; otherwise the approval of the surface-mounting thermostat becomes
invalid.
• The temperature probe must be completely immersed in the medium to be
measured.
• To unsure their overall accuracy, the thermostats must only be used together
with the pockets supplied by the factory (diameter D = 8, 10mm)
• Pockets with diameter D = 10mm may only be fitted with probes with diameter
d = 8 mm.
3.2 Fixing the thermostat
Operating position: unrestricted
Figure 1 (Thermostat with rigid stem)
RTM_OM8070_1#A.2
Figure 2
Note: The temperature probe (1) must be immersed in the medium for its
entire length; otherwise there will be appreciable deviations from the
switching point.
Attention: The electrical connections should be made by qualified electricians.
Attention: Only permanently laid cables and wiring may be inserted.
Attention: The operator must provide suitable stress relief
Attention: The inserted break-off seal must be matched to the diameter of the
cable or wire.
RTM_OM8070_1#A.2
3.4 Opening the housing
Step A: Unscrew the two cover screws
Step B: Remove the housing top
Figure 3
Important: Make sure that the seal is seated correctly when reassembling!
Step C: Pass the connection cable (cable dia. 10 to 16.5 mm) through the
compression gland (1). Attachment type X (no special tools), screw
connection up to 2.5mm² conductor cross-section.
Step D: Take off the protective cover (4)
Step E: Make the connection to the terminal (1) in accordance with the
appropriate connection diagram (affixed to the housing cover).
Step F: Connect the protective conductor to terminal PE (2).
Step G: Put protective cover (4) back on and snap it onto the guide lug (5)
• The thermostat conforms to Protection Class I.

• The connection is suitable for fixed wiring.
• Cable entry is without fixed strain relief
RTM_OM8070_1#A.2
Figure 4
RTM_OM8070_1#A.2
Figure 5
3.6 Closing the housing (see figure 6)
Step A: Make sure that the plastic seal in the housing base (2) is seated correctly
Step B: Position the housing cover in such a way as to ensure that the reinforcing
ridge (7) on the inside of the cover meets up with the lip (6) on the
housing base (2)
Step C: Place the housing top (1) on the housing base (2)
Step D: Tighten the two lead-sealable cheese-head screws (5)
Figure 6
RTM_OM8070_1#A.2
3.7 Connecting the cable (see figure 7)
Turn the compression gland (1) clockwise until the cable entry is sealed and the
cable is secured against pulling out. The cable has to be protected against vibration
overload by leaving sufficient extra cable length (2).
Figure 7
4 Commissioning
4.1 Setting the limit value
Step A: Open the case
Step B: Set the limit value on the set point marker (5) using a screwdriver.
Step C: Close the case.
RTM_OM8070_1#A.2
Figure 8
5 Maintenance and servicing / cleaning

The thermostats require no maintenance or servicing and will have a very long
service life when handled and operated properly.
The instrument should be cleaned with a damp cloth (moistened with soap solution).
6 Storage
Before installation, in order to prevent damage to the device the following points
must be observed:
• The thermostat should remain in its original packing until installation.
• After taking out the device (e.g, for tests) re-use the original packing material
• Permissible storage temperature: maximum +50°C, -50°C
• The instrument must be protected against dust and humidity.
RTM_OM8070_1#A.2
7 Disposal
Dispose of the instrument components and packaging materials in accordance with
the respected waste-treatment and disposal regulations of the region or country to
which the instrument is supplied.
8 Part numbers
Item name Application Item number

Thermostat 20-150°C (hot) Water 951167-00215
Thermostat 150-300°C Thermal fluid 951167-01530
Thermostat 200-500°C Flue gas 951165-02050
Thermowell black with 3/4" connection 951221-00001
Contact address
P.O Box 145
3200 AC Spijkenisse
The Netherlands
Direct tel.: +31 181 650 500
Direct fax: +31 181 650 501

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TABLE OF CONTENTS

Expansion Tank & System Pipes

Accessories & Other Equipment

Operation manualTable of Content

1.1 How to contact Alfa Laval

How to contact Alfa Laval?

Important: IT IS NEVER ALLOWED TO OVERRULE THE SAFETY

2.1 Before start up

Before operating the system:

Step C: Turn on the main switches on the control box(es).

2.2 Starting the oil-fired heater

Step D: Reset the system with the reset button.

Step E: Adjust temperature on temperature controller of oil-fired heater.

Step F: Check if light “burner ready to start” is on

2.3 General reset

3 Description of the installation

1. Sanitary or potable hot water heater 300 kW (Alfa Laval supply).

3.1 Prioritizing consumers

3.2 Thermal fluid circulation pumps

3.3 Oil fired heater with burner

For more information see chapter “Burner” in this manual.

3.4 Electrical heat exchanger

3.5 Heat recovery from jacket water cooling system

3.6 Maximum pressure control

3.7 Expansion tank

To accommodate for fluid expansion a pressurized membrane type expansion tank

4 General set points

General set Final set

Note: Final set points will be adjusted during commissioning. We advise to

5 Alarm list and troubleshooting guidelines.

Alarm Automatic action Follow up

3.1 Heat storage

3.2 Thermal stability

3.3 Economical conveying

3.4 Acquisition costs

3.5 Operation risks

There are several thermal oil classifications:

Mineral fluids Synthetic fluids

4.2 Thermal stability

4.3 Heat transfer characteristics

4.5 Acquisition costs

Standard mineral oils are inexpensive to purchase when considered as a proportion

4.6 Operation risks

Several different possible risks must be kept in mind:

All oil samples submitted for tests should be tested on:

4.8 Rejection criteria for mineral oil

Step E: After taking the sample close all valves.

Open valve (2)and slowly open valve (3) to bleed of air.

System water for Hotwater Heater

Commissioning guideline Table of Content thermal oil sys-

The electrical installation is expected to have been executed according to the

When the commissioning arrives on board the following items have to be

• All electrical connections should be done, working on switch panel is NOT

3 Commissioning by Alfa Laval engineer

• During, or at the end of commissioning there is normally a presentation / test

3.1 Commissioning of the HFO burner

The commissioning engineer will:

3.2 Sea trail

Sea trial can be ordered separately or within the contract.

3.3 Set points

It is important to obtain normal expected operation conditions when the plant’s

General guarantee information

1 Guarantee agreement and conditions

1.2 Trouble shooting