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VI Instruction manual for boiler plant, volume 1
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Table of contents
System concept (vol. 1)

Technical data 1
Flow diagrams 2
AQ-18 boiler/accessories (vol. 1)

General descriptions 3
Operation and maintenance 4
Feed and boiler water 5
Water level gauge 6
Safety valves 7
Feed water system 8
Regulating feed water valve 9
Feed water pumps 10
Chemical dosing unit 11
Salinity alarm equipment 12
Oil detection equipment 13
Drawings.... 14
Datasheets 15
KBSA burner/accessories (vol. 1)

Descriptions, operation and maintenance 16
Oil flow regulating valve 17
Oil flowmeter 18
Differential pressure transmitter 19
Regulating valves 20
Ignition pump 21
Combustion air fan 22
Fuel oil pump unit 23
Fuel oil heater 24
KBSA burner/accessories (vol. 2)

Drawings 1
Datasheets 2
Language UK Page 1/2

AALBORG
INDUSTRIES
Performance curves 3
Control system/electrical equipment (vol. 2)

Control system 4
Operating instructions for control system 5
Process controller, SIPART DR21 6
Process controller, SIPART DR 24 7
Controller hardware for BMS-system 8
Hand programming unit FTX 117 9
Dual trip amplifier 10
F/I-F/F converter 11
Flame safeguard 12
List of settings for single controllers, SIPART DR 21 13
Configuration list for electronic limit switches 14
List of settings for air/oil combustion controllers, SIPART DR 24 15
PLC documentation 16
Electric drawings for boiler control panel 17
Set points 18
Datasheets 19
Spare parts (vol. 2)

Spare parts for boiler 20
Spare parts for burner 21
Spare parts for control system 22

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Table of contents
Technical data for boiler unit

General data 1
Dimensions for boiler unit 2
Water/steam process data 3
Combustion process data 4
Data for atomising steam 5
Data for electric systems 6
Data for pressure part 7
Data for burner 8
Data for water level operation :. 9
Data for steam pressure operation 10
Manuals 11

•••• •
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INDUSTRIES ^m^mu^m^gQ|m£g|^^ø|gjjyg^||m|
Technical data for boiler unit

1 General data
• ProjectNo.: 736950, 736952

• Hull No.: 03130007,03130008
• Classification society: LRS
• Pressure gauge calibration: MPa
• Thermometer calibration: °C
• Language for signs: UK
2 Dimensions for boiler unit
• Height to top of local control panel incl. retraction of burner: 8,650 mm

• Diameter excl. insulation: 3,050 mm
• Weight of boiler unit excl. water: 26,900 kg
• Weight of boiler unit incl. water: 37,900 kg
3 Water/steam process data
• Steam output: 18,000 kg/h

• Working pressure: 0.7 MPa
• Max. allowable working pressure: 0.9 MPa
• Working temperature: 170°C
• Feed water operation: Modulating
• Feed water temperature, operation: 85-95°C
• Feed water temperature, layout: 60°C
4 Combustion process data
• Min. calorific value of diesel oil: 42200 kJ/kg

• Min./max. viscosity of diesel oil: 6-8 cSt at 50°C
• Density of diesel oil: 890 kg/m3
• Min. calorific value of fuel oil: 40200 kJ/kg

AALBORG
INDUSTRIES
• Max. viscosity of fuel oil: 700 cSt at 50°C

• Density of fuel oil: 980 kg/m3
• Fuel oil temperature before pre-heater: 55°C
• Fuel oil viscosity at burner inlet: 15 cSt
• Fuel oil temperature at burner inlet: 140°C
• Ambient air temperature: 45°C
• Air excess No. at 100% load: 1.15
• Flue gas temperature (clean boiler): 336°C
• Air consumption at 100% load: 20,227 kg/h
• Flue gas flow (approx.): 21,590 kg/h
• Expected back pressure from stack at full load: 15 mmWG
5 Data for atomising steam
• Atomising steam pressure at burner, max.: 0.6 MPa

• Atomising steam consumption, max.: 78 kg/h
• Atomising air pressure at burner, max.: 0.7 MPa
• Atomising air consumption, max.: 138 kg/h
6 Data for electric systems
• Power supply: 3 x 440 V, 60 Hz

• Control voltage: 1 x 220 V, 60 Hz
• Pilot voltage: 24V
• Insulation class: B
• Degree of protection: IP 44
7 Data for pressure part
• Boiler type: Large oil fired boiler

• Model: AQ-18
• Test pressure: 1.35 MPa
• Max. allowable shrink: 0.82 m3
• Max. allowable swell: 0.39 m3

AALBORG flSflSBESHS
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• Burner type: Steam atomising, modulating

8 •Data for
Model: burner KBSA 1550
• Burner capacity on diesel oil, minVmax.: 155 - 1291 kg/h
• Burner capacity on fuel oil, minVmax.: 155 - 1355 kg/h
9 Data for water level operation
• Too high water level alarm: + 200 mm

• High water level warning: + 150 mm
• Normal water level: 0 mm
• Start stand-by feed water pump: not AI supply
• Low water level warning: -120 mm
• Too low water level alarm and burner off: -145 mm
• Too low water level alarm and burner off: -145 mm
10 Data for steam pressure operation
• Safety valve: 0.87 MPa

• High steam pressure alarm and burner off: 0.85 MPa
• Burner start/stop: 0.72 / 0.80 MPa
• Burner operation: 0.7 MPa
• Low steam pressure warning: 0.4 MPa
11 Manuals
• Language for manuals: UK

• Set of approval manuals:..... 12
• Set of working manuals: 8
• Set of instruction manuals: 8/ship
• Document revision date: 19 OCT 2004

•
AALBORG TABLE OF CONTENTS
INDUSTRIES
Table of contents
Flow diagrams—
Steam/water system X01:024262d
List of parts for steam/water flow diagram X01:024262d
Oil system X02:028451d
List of parts for oil system X02:028451d
Burner unit 92X02:028394a
List of parts for burner unit flow diagram 92X02:028394a

Part list updated 041117 HeU Changed according to order 040503 GKa SøK Description Index Date Drawn Appr.
Hull nos 03130011, 03130012, 04130001 & 04130002 added 040625 GKa SøK Revised according to order a 03.10.2003 BUa SøK
/ .QN Service
lOOOl 10001 ^""^ steam LP
Cooling
water
Control air
ax. 10 bar
(ompressed air
from m.e.
starting air
system -ÇD Condensate
Max.85°C
-Çn Make-up
I
Signatures:
Steam
Title: Date
Water Overboard \ 22.11.2002
Chemicals x AQ-1818000 kg/h+1 x AQ-10/16W 3000/1000 kg/h Appr.
ISk
Date
Air NOTE: Customer Guangzhou Shipyard Steam/water system JKP 22.11.2002
Blow down/drain lines
External wiring
- Components specified by item no. are supplied by AI
- Items: see separate list of parts.
Society LRS LRS LRS LRS LRS LRS LRS LRS iiSiii Feed water regulation modulating Weight Scale: Size
03130011 04130001 1:1 A2

Oil - For electrical connections, see actual electrical wiring diagrams. Newb. No. 03130007 03130008 03130009 03130010 03130012 04130002 Flow diagram
Exhaust gas
- * Instrument air
Project No. 736950/51 736952/53 736954/55 736956/57 737633/34 737635/36 737929/30 737931/32 AALBORG Article/Drawing No:
- For connections [x]see burner arr. drawing INPUSTIIES TW9 DRAWING AMD DESIGN SHOWN HEREW IS THE PROPERTY OF AALBORG INDUSTRIES
Boiler No. 13368/69 13370/71 13372/73 13374/75 14116/17 14118/19 14487/88 14489/90 AND MUST NOT BE USED BY OR REPROOUCEO FOR THIRD PARTY X01:024262
AALBORG
INDUSTRIES
List of Parts for Oil Fired Boiler Type AQ-18 Rev:d Class.:
"SteamAVater Flow Diagram", Drawing No.: X01:024262d Date: 17 NOV 2004 LRS
Item Qty Dim. Applications Type Data Sheet
No DN or Drawing
1C l Oil fired boiler 18t/h- 0.8-1.0 MPa 45Y:028399
CI 2 65/100 Safety valve Boiler 261 1174
C2 1 200 Main steam valve Stop valve 6010 000087
C3 2 65 Feed water valve inlet Stop valve 6010 000090
C4 2 65 Feed water valve inlet Stop-check valve 6030 000023
C5 1 40 Scum valve Stop-check valve 6030 000013
C7 2 40 Blow-down valve Stop-check valve 6030 000016
C9 1 1/2" Sample valve 6220 000002
CIO 1 1/2" Air escape valve 6220 000002
Cll 1 1/2" Gauge board valve 6220 000002
**C13 1 20 Atomising valve Stop-check valve 264 1087
*C14 1 200 Main steam check valve 6020 000022
C15 1 25 By-pass steam valve Stop valve 250 1088
*C16 1 80 Stop valve Furnace drain 6010 000042
C17 1 25 Water level gauge left Water level indicator 7010 000151
C18 1 25 Water level gauge right Water level indicator 7010 000150
C23 1 Heating coil
C24 1 25 Stop valve for heating coil 250 1088
C26 1 15 Safety valve for heating coil 261 1358
C27 2 25 Stop valve DP-unit 250 1088
C28 2 25 Stop valve Low water level switch 250 1088
C30 1 Gauge board Boiler
C179 1 1100 Smoke uptake TAO supply
CI 84 2 65/100 Expansion joints for safety valve TAO supply 85Y:013427
•C189 1 High pressure cleaner 8500 000464
(Not shown on flow diagram)
C191 1 Water washing hose 8500 000016
(Not shown on flow diagram)
C196 1 Î4" Stop valve Drain for soot blower 6220 000002
V..-'
C211 1 Counter flanges incl. gasket & bolts K16:004096
C212 set (Slip-on) / \
\.y
C213 Gaskets in steam line: spiral wound
C214
•C227 4 1 Vi" Solenoid valve / " \ / • \
6240 000006.-.
) i •> • \
*L2 Control panel 63X03:028295;

O ,'" X : ' Y
W14 2 High & low water level switch x 8100 000008 x7
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AALBORG
INDUSTRIES
List of Parts for Oil Fired Boiler Type AQ-18 Rev: d Class.:
"SteamAVater Flow Diagram", Drawing No.: X01:024262d Date:17 NOV 2004 LRS
Item Qty Dim. Applications Type Data Sheet
No DN or Drawing
1C l Oil fired boiler 18 t / h - 0.8-1.0 MPa 45Y:028399
W16 l DP-unit Feed water control 70Z:019538
** 31/01-2005 changed to DN 20
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2/6
AALBORG
INDUSTRIES
List of Parts for Oil/Exhaust Gas Fired Boiler Type AQ-10/16W Rev:d Class.:
"Steam/Water Flow Diagram", Drawing No: X01:024262d Date: 17 NOV 2004 LRS
Item <Qty Dim Description Applications Data Sheet
No DN or Drawing
2C 1 Oil / exhaust gas fired boiler 3000/1000 kg/h- 46Y:024242
0.8-1.0 MPa
CI 2 32/50 Safety valve Boiler 261 1171
*C2 1 125 Stop check valve angle Main steam valve 6030 000012
C3 2 32 Stop valve angle Feed water inlet 6010 000129
C4 2 32 Stop check valve Feed water inlet 6030 000011
C5 1 32 Stop check valve Scum valve 6030 000011
C7 2 32 Stop check valve Blow-down 6030 000011
l
C9 1 A" Stop valve Sampling boiler water 6220 000002
CIO 1 W Stop valve Air escape for boiler 6220 000002
Cll 1 Vi" Stop valve Pressure gauge 6220 000002
C12 1 V? Stop valve Max. pressure switch 6220 000002
*C16 1 65 Furnace drain valve 6010 000066
C17 1 25 Water level gauge left Water level indicator 7010 000136
C18 1 25 Water level gauge right Water level indicator 7010 000135
C23 1 Heating coil
C26 1 15 Safety valve for heating coil 261 1358
*C27 2 25 Stop valve 250 1088
*C28 2 25 Stop valve 250 1088
C123 1 50 Pneumatic stop valve with limit switches and Soot blower air flow K.1053
solenoid valve
C124 1 %" Filter regulator with automatic drain 291 5101
C125 1 50 Soot blower
C127 1 3/8" Low pressure switch (interlock) Soot blowing B.3001
C128 1 Pressure gauge 0-40 bar 8050 000027
C129 1 3/8" Low pressure switch (safety) Soot blowing B.3001
1
C135 2 •/i" Instrument stop valve 254 1002
C179 1 Smoke uptake TAO supply Q
C184 2 32/50 Expansion joints for safety valve TAO supply (} 85Y:013421
*C198 1 65 Stop valve Exhaust gas section drain 6010 000066, x
w x y
valve
C211 1 Counter flanges incl gaskets & bolts v J \ J K16:004096 {
C212 se (slip-on) •. y -. y ' .y
C213 t o ( ^ f~"\
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C214 yy r ~\ /'"'N .
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AALBORG
I N D U S T R I E S
L2 Control panel
L5 Control panel for soot blower
*W14 1 25 Low water level switch 8100 000008
W16 1 25 DP-unit Feed water control 70Z:028277
V:\Marine\Order\736xxx\736950,51,52,53,54,55,56,57\1300 Documentation\1310 Flow.diagrams - steam water\RQ020148A.doc 17-11-04 ,

4/6 -
AALBORG
INDUSTRIES
List of Parts Boiler Type AQ-18 & AQ-10/16W Rev:d Class.:

"SteamAVater Flow Diagram", Drawing No.: X01:024262d Date:17 NOV 2004 LRS
Item No Qty Di Description Applications Data Sheet
m. or Drawing
DN
1H2 i Remote steam pressure indication 8000 000034
1K5 i Temperature switch 632 0110
1M4 2 Feed water pump CR 32-5-2
1M7 2 Pressure gauge suction side 663 3118
1M8 2 Pressure gauge 663 3121
1M9 1 Pressure switch 6310340
*1M10 4 Instrument stop valve 666 6006
*1M12 2 Orifice Kl 8:003559
1M23 1 Chemical dosing unit 9296 000002
1M25 1 Sample cooler 875 0005
*1M130 1 Remote start /stop box 8000 000036
1M142 5 Check valve Feed water pumps 6020 000028
1W1 1 40 Feed water control valve 6050 000050
1W32 1 Remote water level indication 8000 000034
1W3 1 Filter regulator with automatic drain 2915101
2H2 1 Remote steam pressure indication 8000 000034
2K5 1 Temperature switch 632 0110
2M4 2 Feed water pump CR 5-13
2M7 2 Pressure gauge suction side 663 3118
2M8 2 Pressure gauge 663 3120
*2M9 1 Pressure switch 6310330
2M11 1 3/8" Instrument stop valve 87D3050
2M12 2 Orifice Kl 8:005874
2M23 1 Chemical dosing unit 9296 0000002
2M25 1 Sample cooler 875 0005
*2M130 1 Remote start /stop box • ' ' x
:8000 000036
2W1 1 15 Feed water control valve '6050 000026
2W3 1 Filter regulator with automatic drain 291 5101 rs
V J
2W32 1 Remote water level indication 8000 00003 V -
C) O ß \ i \ }
M77 1 Water test equipment, 880 0050, / x
AGK 100 with armerzine V .J V J . y '• J V ./
\ / \ / \ / \ ,' \
V / V '' \ / V / \ v' V../
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AALBORG
INDUSTRIES
M82 1 40 Stop valve for steam injection 64Z:027665

M83 40 Strainer for steam injection 64Z:027665
M84 40 Steam injection control valve 64Z:027665
M85 1 Control system 121 with pocket Temperature transmitter 64Z:027665
M86 40 Check valve for steam injection 64Z:027665
M87 Vi" Vacuum breaker for steam injection 64Z:027665
M88 1 Steam injector 64Z:027665
Vi"
M89 1" Steam injector 64Z:027665
N5 1 40 Steam dump control valve with pneumatic 6050 000050

actuator
N6 1 Filter regulator with automatic drain 2915101
M146 1 Salinity alarm equipment 8210 000005
8620 000003
M145 1 Oil detection alarm equipment 8210 000025
8310 000005
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6/6
Tag No./
Item Pes. Designation Dimension Article No.
1F Burner unit, chosen by project 91Y:028380
1F.1 Burner front plate incl. lance
G17 Pressure switch, oil sucsion 631 0340
G18 Instrument stop valve 87D3050
G19 Filter for steam 7040 000042
G20 Temperature control valve 6050 000061
1G22 Fuel oil heater 8640 000119
1G23 Pressure relief valve 87S0041
1G24 Heater drain valve - oil side 87D3062
G28 Temp, transmitter PT100 8060 000007
G38 Temp, gauge HFO from tank 88T0003
G42 Temp, gauge HFO heated 88T0003
G44 Press, gauge HFO from tank 663 3118
G47 Press, gauge HFO heated 663 3122
G51 Three way valve heater bypass 6070 000027
G78 Pressure relief valve DO 87D3059
G99 Pressure transmitter FO press. 663 8234
G99.1 Gasket for G99, not shown 291 1602
G100 Control valve - FO press. 6050 000093
G105 Instrument stop valve 254 1002
G111 Three way ball valve FO return,DN20 87D3178,solval230,663 8652
G114 Air filter/regulator for G111 291 5101
G115 Three way ball valve HFO/DO, DN40 87D3074,BoxM
1G145 Ignition oil pump 71Z:024019
G147 Fuel oil supply pump 5750 000020
1G224 Remote start/stop box 8000 000011
2G224 Remote start/stop box 8000 000011
L2 Boiler power panel
1R Fan unit chosen by project 9220-2286.B
G40 Air vent valve, heater 87N6003
G354 4 Check valve 6020 000028
G355.1 4 Check valve 6020 000028
Title Drawn Date

BiJa 08.10.2003
Flow diagram Appr. Date
1 x steam atomising KBSA 1550
Weight Scale Size
oil system 1:1 A2
Article / Drawing No: Affix
Pagel 17/11-2004
This drawing and design shown herein is the property of Aalborg Industries
and must not be used by or reproduced for third party
X02: 028'151 d
Description Index Date Drawn Appr.
Hull nos 0 3 1 3 0 0 1 1 , 0 3 1 3 0 0 1 2 , 0 4 1 3 0 0 0 1 & 04130002 added 040625 GKa SøK
NOTE:
- Components: see separate list of parts
• For electrical connections, see actual electrical wiring diagrams
- All heavy fuel oil piping to be steam traced piping and Insulated
- Steam tracing to be temperature controlled
• For connections: \x\ - see burner arrangement drawing
Customer Guangzhou Shipyard
Society LRS LRS LRS LRS LRS LRS LRS LRS
Newb. No. 03130007 03130008 03130009 03130010 03130011 03130012 04130001 04130002
Project No. 736950 736952 736954 736956 737633 737635 737929 737931
Signatures:
Boiler No. 13368 13370 13372 13374 14116 14118 14487 14489
Steam Title: Data
Water
1 x KBSA Appr.
BiJa 08.10.2003
Date
Chemicals
Air
Standard STh 08.10.2003
Blow down/drain lines
External wiring
iiiiiiiii Burner unit Weight Scale:
1:1
Size
A3R
Oil AALBORG Flow diagram Article/Drawing No:
Exhaust gas INDUSTRIES THIS DRAWMO AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
AND MUST MOT BE USED BY OR REPRODUCED FOR THIRD PARTY 92X02:028394
Tag No./
C31 Instrument stop valve 87D3050
C33 Pressure gauge 6632998
C35 Pressure switch max. steam 6310330
C48 Pressure transmitter 6638232
C50 Drain valve
F1 Steam atomising burner
F17 Stop valve, ball - oil ign burner 6666006
F18 Solenoid valve - oil ign burner 6638146
F19 Solenoid valve - oil ign burner 6638146
F31 Ignition burner
F33 Flame scanner auto/man 6639045
F36 Temp, switch - fire in windbox 6638211
F41 Stop valve, ball atom, steam 87D3064
F42 Stop valve, ball - atom, steam 87D3064
F43 Water separator atom, steam 6638601
F44 Shut off valve - purge steam 87D3064
F45 Non return valve - purge steam 87D3093
F50 Instrument stop valve 87D3050
F51 Press, transm. atom, steam 8010000006
F56 Solenoid valve, air for F57 6666233
F57 Pneumatic actuator for F42 6638651
F62.1 Manometer 6633015
F62.2 Filter regulator, for F148 6639046
F63.1 Filter regulato, for valve actuator 6639046
F64 Stop valve, ball FO to burner 87D3064
F65 Solenoid valve for F66 6666233
F67 Ball stop valve, FO to burner 87D3064
F68 Pressure gauge FO nozz. pr. 6633121
F69 Instrument stop valve 87D3050
F73 Stop valve 6666006
F74 Position switch, lance in position 6614712
Title Drawn Date
BiJa 08.10.2003
1 x KBSA Appr. Date
Standard
Weight Scale Size
Burner unit 1:1 A3R
Flow diagram Article / Drawing No: Affix
Pagel 17/11-2004
This drawing and design shown herein Is the property of Aalborg Industnes
and must not be used by orreproducedfor third party
92X02 :02)3394 a
Tag No./
F75 Three way valve, FO return 87D3071
F76 D.P. transmitter, airflow 8020000001
F77 Non return valve 6638103
F78 Solenoid valve 6638146
F80 Non return valve 6638103
F85 Micro switch on F67 6638660
F86 Micro switch on F75 6638660
F87 Stop valve, ball 87D3064
F91 Pressure control valve 87A3033
F93 Stop valve, ball 87D3064
F94 Control valve 6635198
F95 l/P converter 6635210
F96.1 Filter regulator 6639046
F97.1 Filter regulator 6639046
F99 Three-way valve 87D3085
F100.1 Flow meter, oil 7060000013
F100.2 Pick-up for flow meter 8310000006
F106 Flame scanner - ign. burner 6639035
F108 Non return valve 87D3093
F135 Pressure gauge 6633120
F148 Actuator 6666109
F149 Position switch 6666110
F152 Throttle valve 6641220
F157 Temperature indicator 88T0003
F166 Transformer for Ignition Burner 6639100
L10 Junction box
Title Drawn Date

BiJa 08.10.2003
1 x KBSA Appr. Date
Standard
Weight Scale Size
Burner unit 1:1 A3R
Flow diagram Article / Drawing No: Affix
Page 2 17/11-2004
This drawing and design shown herein is the property of Aalborg Industries
and must not be used by or reproduced for third party
92X02 :02)3394 a
1
INDUSTRIES ^mn^^g^g^gnmii^^^mg^^^^^mi
Table of contents
Descriptions
AQ-18 boiler general description 1
Water level control 2

AALBORG
INDUSTRIES
Vertical Water -Tube Boiler

TYPEAQ-18
GENERAL DESCRIPTION
Instruction K.7140.0
JOI/30S/gs
21 FEB 94
1
-1 -
BOILER DESCRIPTION
The AQ-18 boiler is an all-welded vertical water tube boiler and consists in the main
of the following components. (Please see figure 1).
From the top the steam/water drum, below this drum the furnace room and in the
bottom the water drum.
STEAM/WATER DRUM
The steam/water drum consists of a circular shell limited by two flat tube plates.
Because of the increased internal pressure, the tube plates are mutually connected by
vertical solid stays.
The main connections to the boiler are located at the steam/water drum which is also
furnished with necessary internals to ensure an even distribution of feed water and
circulating water from the exhaust gas boiler.
Access is obtained by the manhole located at the top plate/shell.
In the centre of the steam/water drum, the vertical positioned central furnace opening
for the steam atomizing burner is located. Accordingly, access to the furnace room is
possible from there.
FURNACE ROOM
The furnace room consists of both internal polygonal shaped membrane walls and of
an outer casing wall of the same shape.
This construction is gas tight and between the walls the generating tube bank is
located. The generating tube bank consists of vertical tubes arranged in a staggered
configuration.
All the tubes and panel walls are welded on to the tube plates in the steam/water drum
and water drum, respectively.
The flue gas leaves the furnace room through the deflected tubes at the bottom and
passes through the generating tube bank before leaving the boiler.
JOI/4710/jbn
20 DEC 93
" - 2-
An effective circulation in the boiler is achieved by the fact that a number of tubes
in the cold area acts as down comers.
Access is also possible through the access door at the bottom side as well as the
access door provided on the smoke outlet box. Further, access to the generating
tubes is possible at the four access doors provided on corners of the casing wall.
The bottom tube plate is first covered with coat of insulating refractory and above
with castable refractory.
WATER DRUM
The water drum is constructed similar to the steam/water drum and is supporting
the boiler.
Inside a heating coil is installed to ensure a quick starting up of the boiler and to
maintain a higher temperature during standstill securing the boiler against corrosion.
Access is obtained by the manhole located at the shell.
For the foundation the boiler is provided with four support feeds, one as fixed food
and the others constructed with possibility of thermal expansions. Counter plates
are provided for welding to deck.
Sketch of AQ18-B0ILER
Steam atomizing burner
Steam/water drum
Smoke outlet
Membrane wails
Generating
tube bank
Furnace room
Water drum
Heating coil
Fig. 1
AALBORG WATER LEVEL CONTROL SD9230#17.1
I N D U S T R I E S
Water level control

1 Description
The water level control is a modulating system at this type of boiler. The system is
illustrated in Figure 1. The safety device system for too low water level shut down
and burner stop consists of a level float switch mounted as an external unit. For
measuring and control of the water level, the boiler is equipped with a dp water level
transmitter unit, which includes external reference and variable legs, and a dp-
transmitter. The continuous 4-20 mA output signal from the dp-transmitter is
processed in the control system, which provides level alarms/shut downs and control
of the regulating feed water valve.
Water level control system

Instrument air
Regulating feed water valve
Reference leg
Variable leg
Valve
manifold
dp-transmitter
Feed water pumps
[p=^<3=Q=iX}=j
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Figure 1 dp_l_mod.cdr

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AALBORG ÆHIiilBBHHIiHI^^^^MI
INDUSTRIES ^•••••••BlMIIIBIIMHHHHHIHi^H
Table of contents
Operation and maintenance

General 1

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INDUSTRIES
3.2 OPERATION DESCRIPTION
3.2.1 Flue gas flov/
The ignition and combustion take place vertically down in the furnace. From
here the flue gas flows through the deflected tubes in bottom of the furnace.
The flue gas is distributed in the height of the convection section in the
cavity at the furnace outlet. In the convection section the flow takes place
horizontally through the convection section.
After passage of the convection section the flue gas flows horizontally out
through the flue gas outlet.
3.2.2 Water-steam flow
The heat input is transferred to the water through the heating surfaces in
the furnace room and the convection section.
The heat transfer in the furnace takes mainly-place by means of radiation,'

while convective heat transfer mainly takes place in the convection part.
The natural circulation in the boiler provides that water flows from the steam
drum and down to the water drum through the tubes least heat effected i.e.
generating bank tubes and casing v/all tubes nearest the flue gas outlet.
From the v/ater drum the water rises through the other tubes (the furnace
membrane walls and the generating bank tubes strongest effected of heat),
where an evaporation takes place on the way up through the tubes.
The v/ater-steam mixture rises to the steam drum. In the steam drum steam
and water are separated, and then the saturated steam leaves the boiler
through the steam dryer to the main steam socket.
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Feed water inlet
Main steam
Steam dryer
Steam drum
Manhole
Furnace
Flueqas outlet
Membrane v/atls
Generating
tube bank
Sockets for
water washing
nspection door
View A-A
users/orrlrp?70/aaia/arochure/tecn;ncsr/sl<3
AALBORG
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3.3 Lighting-up
Before lighting-up of the boiler the whole boiler plant is to be prepared and
tested. The preparations and processes mentioned here are normally only
carried out in connection with the first lighting-up and after large repairs.
3.3.1 Preparation
When the steam plant has been installed it is to be inspected before

lighting-up and start.
The following description and check list are to be considered as inspection

manual. When each single component in this manual has been inspected
and found functional, the plant is ready for lighting-up.
3.3.1.1 Furnace
In the furnace it is to be tested that refractory at the burner and on the

furnace bottom plate is in position and in order. If damage has been noted,
this is to be repaired before lighting-up.
3.3.1.2 Burner
The boiler is equipped with steam atomizing burner intended for firing with
D.O. and H.O.
The burner consists of a windbox with guide vanes and throttle, an ignition
burner, lance with atomizer nozzles, cone and a gas ring.
The arrangement, position and state of these components are to be tested

before lighting-up. Please see burner instructions.
3.3.1.3 Combustion air
The combustion air volume is adjusted by the throttle in the burner air inlet.
Blower rotor and shaft are to be able to turn freely by manual force without
binding or scratching. The direction of rotation is to be as marked on the
blower casing.
C C) O
3.3.1.4 Fuel pipes _ _,
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The diagrams of the fuel pipes in the separate manualjs to "be stildied)
thoroughly for understanding of the structure of the system, pipelines and^
w
flanged connections are to be absolute tight. \ J x-r-/ v c7 ::
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AALBORG
INDUSTRIES
3.3.1.5 Feed water line
It is to be tested that all joinings are tight, the valves are placed correctly
and that the flow direction through them are right.
The feed water regulating valve function is to be tested (please see speciel
instruction).
3.3.1.6 Steam lines
It is to be tested that the valves have been placed correctly and the flow
direction through them are right.
All drain lines on the steam boiler to the blow dov/n tank are to be
inspected. It is to be ensured that no restrictions betv/een boiler and blow
down tank are available.
3.3.1.7 Water level supervision
The safety equipment in connection with alarm and disconnection of the

firing at low water level and feed water regulation is vital for the operation
of the boiler and is therefore to be inspected thoroughly. The water level
supervision equipment is to be tested according to the prescribtions of the
approval authorities.
3.3.1.8 Safety valves
Normally safety valves have been adjusted from the factory. The opening
pressure is to be tested at lighting-up (please see instruction).
•
3.3.2 Drying of refractory
After repair of refractory or other big repair/cleaning it is very important to

secure that the refractory is totally dry before lighting-up.
In order to secure that.the refractory is totally dry and formation of cracks

does not take place, the following procedure is to be used:
1. The boiler is to be filled v/ith water to normal water level with open
air relief valve. ^ ^ --'
C) O C)
2. The burner is lighted-up at minimum load for a^few minutes at a
time and the whole procedure lasts total 8 hours: 3 w ^ .; ^
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INDUSTRIES
Hour no. . 1 2 3 4 5 6 7 8 9
Burner on fire, minutes 2 3 4 5 5 10 10 15 60
Burner out, minutes 8 10 10 10 5 5 5 5
The lighting-up continues after this for 2 hours with gradually

increasing load.
3.3.3 Boiling out

The boiler is to be boiled out to clean the surfaces on the v/ater side. If oil
film or dirt exist on the steel surface the heat transmission to the water side
is reduced, the steel is superheated and tube failure can occur.
The chemicals used for boiling out can be led-in through the manhole in the
upper drum.
NB: A certain caution must be exercised regarding the chemicals used

when boiling out. The operator or the person working with the
chemicals must be dressed to the job, which is going to be made.
Overclothes and a mask are recommended.
1) The v/ater voiume at normal v/ater level is stated in the data para-
graph in this manual. Do not add the chemical solution until
everything is ready for carrying through of the boiling out.
Crystallized trisodium phosphate (NA3POJ is to be used. On the basis of

18.8% 5 kg/m3 water is used. Before addition the chemicals are to be
resolved in hot water.
2) Boiling out procedure
a) The air relief valve is to be opened and the boiler is to be

filled with water to just above lov/ v/ater level.
b) The chemicals are to be added and all'the valves except

the air valve to be closed. o Q Q
c) The boiler safety equipment must be v conn acted" when

boiling out. O Q (J (J O
d) The boiler is to be lighted-up as, described :(n the next

paragraph. O :K'J :\ j l _ / v j •,._
e) When steam comes from the air relief valve it is partly
closed and the pressure is increased in accordance with the
lighting-up procedure.
f) The pressure is to be keept for approx. eight (8) hours by

means of discontinuous firing.
g) After the initial eight hours period the v/ater level is increa-
sed to 75 mm above normal water level.
h) The burner is to be stopped and the water level is blown

down to the lowest point visible in the v/ater level glass by
means of the scum valve and the blow-off valve.
i) Then the air relief valve is to be opened and the boiler to

be drained.
j) The boiler is to be examined inside and might be rinsed

with a high pressure cleaner. All surfaces must be cleaned
for mud and impurities. If the internal surfaces not are
satisfactory, the boiling out procedure is to be repeated.
k) When the boiler has been closed down the valves are to be
adjusted in accordance with the list of valves, and the boiler
is to be filled v/ith fresh treated v/ater up to approx. 50 mm
below the normal operation level, and the boiler is ready for
operation.
Filling of water
The boiler is slowly to be filled v/ith feed water. The v/ater level is to be
approx. 50 mm below normal water level out of regard for the water
expansion during the following heating.
Liqhtinq-up
During lighting-up.
Procedure: Q 3. Q
1) Feed pump is to be started

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INDUSTRIES
2) The water level in the steam drum is to be adjusted
at high level: opening of scum valve

at low level: opening of feed valve
3) The burner is to be started, please see separate instruction and the

firing capacity is to be adjusted, so that the lighting-up curve will be
followed.
4) The air relief valves are to be closed, when clear steam outflow is
observed.
5) When the boiler pressure is near the working pressure the water
gauge fittings are to be blown through.
6) The main relief valve is to be opened and the lighting-up has been
completed.
If the steam line after the main relief valve has no pressure the
valve is to be opened very slowly for heating of the steam line.
7) When the boiler after this supplies steam to the steam system
continuous feeding is established.
n
AALBORG
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LIGHTING-UP CURVE FOR A Q 1 8 - B 0 I L E R
Boiler pressure (barg) Temperature (C° )
#-3 200
h 175
•\- 150
-~j - — I - 125
L_ iOO
h 15
\- 50
-4- 25
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1 i i T n i
45 60 75 90 105 110 135
O
Time (min )
O y.j O
t : Boiler temp, at start.
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AALBORG
INDUSTRIES
3.3.6 Adjustments of valves
The following list shows the adjustment of the valves in various situations
both during lighting-up and operation.
VALVE DRAINING BOILING OUT LIGHTING-UP | OPERATION
Main relief valve - Closed Closed Closed Open

steam
Feed water regualting Closed Closed Open Open
valve
Main feed valve Closed Closed Closed Open
Auxiliary feed valve Closed Closed Closed Closed
Air relief valve (1) Open Open/closed Opea'closed Closed
Safety valve(s) Free Free Free Free

Blowing down Closed Open/closed Closed Closed
Chemical dosing Closed Closed Closed Open

Drain, water level Closed Closed Closed Closed
indicator
Closing valve for Open Open Open Open

manometer (2)
(1) This valve is to be open during filling of water.
(2) Use a test manometer before pressure test.
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AALBORG
INDUSTRIES
3.4 OPERATION
3.4.1 Generel operation manual
3.4.1.1 Levels for HW. LW and LLW
At high water level (HW) an alarm is released and the feed pumps are
stopped. In this way it is secured that the water level will not be so high that
the steam quality is damaged.
At low water level (LW) an alarm is released and the firing is stopped. In
this way damage, due to non-cooling, is avoided.
At low low water level (LLW) an alarm is released and further safety stop
of the lighting-up is made.
3.4.1.2 Feed water
The water level in the boiler is automatically regulated by a feed water

regulator, which is to be adjusted in such a way that the water leve.l is
maintained at normal water level. The same is to be aimed at by manual
operation, if any.
3.4.1.3 Combustion control
The combustion control is to be adjusted according to separate instruction

(please see that instruction), so that optimum combustion is obtained.
3.4.1.4 Temperature
The temperatures, exhaust gas and feed water are to be supervised with
regard to trouble-shooting.
An increasing exhaust gas temperature indicates the demand for boiler

cleaning. Concerning water washing of boilers, please see paragraph 3.6.
3.4.2 Periodical control and maintenance
It is recommended that a thourough maintenance program 4s carried

through. As minimum the following is recommended: 0 ,~,
1. Daily
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a) Test the oil pressure at the burner. Inspect^the jlame,.
pattern through the sight glass in burner, furnace wall and
access door. .
b) Blow the v/ater level glass through.

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c) Blowing down is to be made according to the heat

treatment result.
d) Clean the fuel filters (only when working on heavy fuel oil).
e) Operate soot blowers (only when working on heavy fuel oil).
f) Test water shortage equipment
g) Take tests of the feed water, boiler v/ater and steam con-
densate for supervision of water and steam quality. Please
see description of water quality in paragraph 3.4.4.
Concerning chemical dosing, please see instruction manual

for SRO-plants.
;
2. Weekly
a) Clean the flame scanner.
3. Periodical
a) Clean and inspect the furnace room inside in order to avoid

deterioration of refractory and bad thermal conduction.
b) Make quarterly checks of the v/ater shortage equipment

according to the rules of Arbejdstilsynet.
3.4.3 Boiler blow down
Mud is to be blown out through the blow dov/n valve once a day. Scum
blov/ out by means of the scum valve is made when required. There is to
be blov/n until the outflowing water is clean.
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AALBORG
INDUSTRIES
Units of measurement
Concentrations are usually expressed in "ppm" i.e. parts solute per millio
solution by weight; this is the same as "mg/iitre".
Specific gravity:
As a guidance the following conversion can be used:
1 Be° = 10,000 mg/1 total dissolved solids (TDS)
1 mg/1 total dissolved solids = 2 jiS/cm
1 u.S/cm = 1 micromho
V..' '••.J
AALBORG
INDUSTRIES
•
3.5 CLOSING DOWN
3.5.1 General
It is possible to close the boiler down at any load, without special prepara-
tions, if absolute necessary.
When closing down sudden temperature and pressure drops are to be

avoided, as they can expose accessories, pipe lines and the boiler plant to
inadmissible temperature gradients.
3.5.2 Procedure for closing down

#
When obtaining minimum load regulating circuits (feed water, steam
pressure) are to be disconnected.
The burner is to be stopped.
The v/ater level is to be kept at the centre line of the v/ater level
indicator until the boiler stops producing steam.
The feed pump is to be stopped and valves on the feed water pipe
are to be closed.
The main steam valve and other valves on the pressure system are
to be closed.
When closed down for a long time boiler and economizer are to be
preserved, both from the water and exhaust gas side. Regarding
preservation, please see the next paragraph.
3.5.3 Preservation of boiler during standstill
Steam boilers which are taken out of operation for a short or long time,
should be preserved in order to avoid corrosion damage.
3.5.3.1 Preservation of the flue aas side
The soot deposited on the flue gas side during operation can contain
sulphuric acid and water, which can result in corrosion. Therefore the flue
gas side is to be preserved in the following way: y
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v.../ ^ _-'' V y
Water washing: /"\ r

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The boiler is to be water washed. Then the boiler is slowly to be lighted-up

(please see lighting-up) for boiling out.
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Dry preservation
If the water side of the boiler is preserved by keeping the super pressure,
the boiler temperature will keep the flue gas side dry in the whole standstill
period.
In connection with the other v/ater side preservation methods, the exhaust
gas side is to be closed as tight as possible after boiling out.
3.5.3.2 Preservation of water/steam side
Presence of oxygen may result in corrosion, which shows as "pittings"

inside surfaces.
Preservation can be made in the following ways:
Dry preservation
By this method the boiler is totally to be emptied of v/ater and boiled out.
The boiler is emptied of water by blov/ down of the boiler with a pressure
of 3-5 bar, then the boiler is to be opened and drained for remaining water,
if any.
Boiling out of the boiler can be carried out by circulation of dried air from an
air blower or by placing a bag of silicagel in the boiler drums.
Alternatively some inhibitor can be supplied to the boiler drums after cooling
'down and thorough draining, and then the boiler is totally to be closed.
Wet preservation
Wet preservation is carried out by filling the water totally with treated feed
water added oxygen binding agent in a quantity corresponding to 100-200
ml/m3 hydrazine or sulphite. At the same time the pH-value is to be adjusted
to 10-10.5.
When the boiler is lighted-up again, the water is to be drained off until
normal water level has been established. The boiler can now be lighted-up
in usual way.
Nitrogen preservation Q Q Q
The boiler is to be filled with treated feed v/ater up to normalV/ater level.

The v/ater has been supplied oxygen binding agent as(d,esçfibed m the;
above mentioned point. Steam chamber and superheater, if any, are to be.,
filled with nitrogen, and the pressure is to be kept on 0i2 barg! When
lighting-up the nitrogen supply is to be stopped and the boiler immediately
be lighted-up. " '
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The nitrogen is to be blown down through the air valve, as described in the
paragraph "Lighting-up".
Maintaining super pressure
For short standstill periods the water side of the boiler can be protected by
maintaining the super pressure by means of steam heating coil or electrical
heating element.
3.5.4 Selection of preservation method
Preservation method can be selected as follows:
Out-of-service period Preservation method
> 30-45 days Dry preservation

< 30 days Wet/nitrogen preservation
< 30 days Maintaining steam super pressure
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3.6 Repair and maintenance
3.6.1 Inspection
For inspection on the flue gas side, access to the furnace is possible
through the door at the bottom of the furnace.
For inspection of the flue gas side of the tubes there are several possibili-
ties:
Through the access door mentioned above, at the flue gas outlet from the
flue gas channel, and through the four (4) inspection openings at the bottom
of the tube section, placed at the panel wall corners. From here it is
possible to see, whether the tubes are covered with soot or possible to
locate a damaged tube in the area.
For inspection inside the steam drum and water drum, manholes in both
shells are available, through which access to the internal parts is possible.
Inside the drums it is possible to see all the details and to plug some tubes,
if necessary.
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3.6.2 General maintenance of boiler pressure part
Part Interval Maintenance/check Comments
1. Shell 6 months, Check of Precautions,

maybe 12 months x) Deposits cleaning and repair
x) Damage of damage.
2. Valves Daily Check of tightness In case of leakage

at the spindle the
stuNing box is to be
adjusted. If occasion
should arise, change
the stuffing box at
the next standstill.
3 months Valve spindle is to be According to the

cleaned. instructions of the
• factory.
3. Safety valves 12 months Operation check According to the

instructions of the
factory.
Daily Tightness check.

When leaky there is
to be started corre-
sponding repair ar-
rangements at the
following boiler
,. standstills.
4. Water level Daily Check of damage o! in case of damage

indicator water level indicator exchange is carried
out during operation
(the valve is to be
shut off).
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3.6.3 Water washing
Generally there will be a selfcleaning effect of the generating tube bank due
to a high flue gas velocity.
However, after long term operation, especially during part load, deposits can
be formed on the tubes, which can be removed by means of either soot
blov/ing (with air) or water washing.
During combustion of oil of a poor quality or with a reduced combustion

quality, deposits can be formed, which cannot be removed by means of
normal soot blowing. The heating surface is to be washed with an alkaline
solution (10% soda solution) and/or freshwater.
As most of the deposits mainly consist of non-soluble particles, which are

held together by a water soluble bonding material, water under pressure will
have the following purposes:
a) to dissolve the bonding material

b) to wash the loosened insoluble remainders away.
The AQ-18 boiler is provided with a sufficient number of fixed cleaning

sockets in two levels, facilitating removal of soot deposit, when necessary.
Water washing is carried out with a manually operated lance, which is to be

mounted on a handle for a high pressure washer (see fig. 1).
-By water washing the boiler must be out of operation and max. boiler
temperature is to be 110°C.
By v/ater washing the following procedure is to be used (fig. 2):
1) At bottom of the boiler furnace a drain has been mounted, which is

to be opened and connected to an accumulation tank.
2) On the boiler walls (panel walls) a number of cleaning sockets have

been mounted in different levels. The threaded socket is to be
unscrewed from these and the lance is to be led.through the
cleaning socket. Q
3) The handle is to be activated in order to lead high-pressureCwater

to the lance. ,o ^
4) Lead slowly the lance to full depth and back again. (Rèpeat) thiP
process several times for approx. 2 minutes, in'each' socket, to)
ensure good cleaning.
j
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INDUSTRIES
5) The cleaning is to be repeated for all cleaning sockets and caps to

be mounted after cleaning.
6) After cleaning in all the sockets, soot blowing can also be done
through the inspection doors at the bottom of the tube section. The
doors are removed and the lance is to be inserted between the
convection tubes. Cleaning is done in the same way as described
above. After cleaning the doors are to be mounted again.
7) After water washing the refractory at the furnace bottom must be

cleaned with alkaline water, as the water is very corrosive. It has
to be observed that all washing v/ater and removed deposits are
taken out of the boiler.
If water washing is started, it has to be continued in order to

remove all deposits, as some deposits get hard and difficult to
remove, v/hen they get wet and later dry out.
8) The plant is to be boiled out immediately after the v/ater washing

has been completed in order to avoid damage on refractory and
heating surfaces. The boiler is to be lighted-up and pressure to be
raised, as described in paragraph 3.3 "Lighting-up".
When the water v/ashing has been started it has to be carried through, so
that all deposits are removed, as some types of coatings hardens and get
difficult to remove, when they first have been saturated and then dry out.
The plant is to be boiled out immediately after the v/ater v/ashing has been
completed in order to avoid damage on refractory and heating surfaces. The
boiler is to be lighted-up and pressure to be raised as described in
paragraph 3.3 "Lighting-up".
/' \ /•""'"N / "\.
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Water washing for AQ18 - Boiler Fig 1.
Steam drum
Furnace
16 pes. of sockets
for waterwashing
(4 pes. in L, corners)
Membrane walls
Generating
tube bank
Sockets for
water washing
nspecfion door
View A-A
600
I 00=
Lance for water washing

Supplied by Al
AI supply
Water washing for AQ18 - Boiler Fig 2.
Detail B
Sockets for
waterwashing
Water washing
trough sockets
View D-D
Water washing trough

inspection doors
Detail C
D
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3.6.4 Repair
3.6.4.1 Instruction for plugging of tubes
In case of leakage on a boiler tube, the burner is to be stopped and the

pressure to be removed from the boiler.
If the tube in question cannot be located immediately, the boiler is to be

set on pressure by means of the feed water pump, so that the leakage will
indicate the tube which has been damaged.
The boiler is to be emptied of v/ater and the manhole covers in the steam
drum and the water drum are dismantled.
When a damaged tube has been located, the tube is to be plugged with a
conical tube plug. Before the conical tube plug is mounted, the tube ends
are to be cleaned inside, so that no deposits are present in the tube.
When a tube has been plugged, a new tube should be mounted as soon as
possible. When tubes are plugged, the efficient heating surface is reduced
and the boiler efficiency v/ill go down.
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Plugging of furnace tubes
When a furnace tube has been plugged, the furnace side of the damaged
tube is to be cut vertically along the connections with the fins between the
tubes in the membrane wall (sketch no.1).
Inside the rest of the tube and on the fins next to the damaged tube a
number of anchors of heat resistant or stainless steel are to be welded on.
Hereafter refractory is to be placed against the damaged tube and the

neighbouring fins in the full height in the furnace.
Plugging of convective tubes and outside membrande wall tubes
Sketch no. 2 shows plugging of convection tubes and tubes in outside

membrane walls.
When the tube has been located, it is to be plugged in both ends. After this
operation the boiler can be filled up with water and the normal boiler use
can continue, until the tube can be replaced by a new tube.
3.6.4.2 Repair of refractory
Normally, routine maintenance is carried out of all refractory. In case of

often lighting-ups and closing downs of the plant increased maintenance of
the refractory is required. As the refractory not is elastic, a sudden load can
make it crack.
Peeling can occur, if pieces of the refractory is loosened. Peeling is

acceptable, provided that the material loss does not exceed more than the
half of the thickness of the original casting. Peeling is to be patched with
own refractory at the next closing down of the boiler. Normally, cracks in the
refractory do not need repair, unless the size and extent cause direct fatigue
of the refractory.
Light cracks indicate that the crack is a natural expansion and these are not
to be repaired.
O
Dark cracks are to be repaired, however, it is pointed out that expansion
v
cracks in time get darker.
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Plugging of tubes
Manhole
Steam drum
Fluegas outlet
Furnace tube
Convection
tube
Outer walls
Furnace
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Wbter'drum
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AALBORG
INDUSTRIES
Sketch no. 1
Tube plug
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AALBORG
4fc INDUSTRIES
Sketch no. 2
Tube plug
Convectionom
tubes
Outside mem-
brane walls
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AALBORG
INDUSTRIES
TECHNICAL DATA PLISTIX 14
Type* ' Repair material - also for large thicknesses - for

application by casting or gunning.
Thermal Values:
Operating temperature: 100 - 1420°C
Max. operating temperature: 1470°C
Melting point: SK 33 1730°C
Thermal conductivity
(kcal/in h°C) at S40°C: o,67
at 815°C: o,72
at 1090°C: o,77
Expansion coefficiency: o,St at 1000°C.
Chemical Data:
%
A1203 Si02 F e 2°3 Ti0

2 Ca0 M
2° Na
2° K
2°
48 43 1,2 1,9 4,8 o,2 o,l o,2
Granulating: 6 mm
Physical Data:
Consumption of material: 1,85 t/m
Bulk density at U 0 0 ° C : 1,85 kg/dm-5
Porosity at 1100°C: • 321,
Setting hydraulic
•Temp°C Shrinkage Bending Strength Cold Crushing
after firing Strength
kp/cm psi kp/cm psi
110 o,lo 49,5 700 100 1420
600 o,4o 25,3 360 60 852
1100 o,8o 24,6 350 60 852
1500 o,8o 52,8 750 110 1560
1400 o,5o 52,8 750 110 1560
General Properties: ~~
Water required: +16 - 171
Working time after casting: 10 minutes^
Min. time before heating up: immediately" or later.
Application by gunning: good r, r> r.
Waste: less thin Ï0\
Packing: 20 kgs buckets - or 50 kgs bags. '•--'
Storage time: For 50 kgs bags: 12 months. For 2:0) kgsy buckets: O
f-\ ,/--2 4 months .,•--<
in particular:Follow installation instructions. v ' ' y vy
This material is also very suitable for t'rowelLing v /
moulding balls first by hand, ô ( x- ( \ /' \ ' \ \ N r
-12-
AALBORG
INDUSTRIES
INSTRUCTION FOR REPAIR

w i t h PLISTIX 14
r e f r a c t o r y p l a s t i c s e r v i c e mix
Repair of worn-rdown brickwork.
The part of the brickwork needing repair to be cleaned

of slag,
The existing brickwork must not be moistened with water.
PLISTIX 14 is mixed with water - abt. 3 - 3j litres per
bucket (20 kg) - to e proper consistency and trowelled upon the
worn-down areas without glazing.
2_. R.epair of burned-through brickwork.
The part of brickwork needing repair is cleaned of slag.

The area which has to be filled out with service mix is
formed like a dovetail in order to prevent the mix from falling
out.
The existing anchorage to be renewed if necessa.ry.
PLISTIX 14 is mixed with water - abt. 3-31 litres per
bucket (20 kg) - to a proper consistency.
The existing brickwork must not be moistened with water
In case of a larger repair work abt-. 1 square meter is
cast at the time and expansion material - 1 - 2 mm cardboard or
equal - is installed between the sections.
$_. Heating-up.
O
The heating up of the- b o i l e r can take place a l r e a d y

50 m i n u t e s a f t e r the r e p a i r work i s f i n i s h e d . (} ( ) Q
The r i s e of t e m p e r a t u r e - 50-60°C per hour - as dependent
upon the t h i c k n e s s of the i n s t a l l e d m a t e r i a l . / , r\ > %, >
I N D U S T R I E S
Water level control

1 Description

Instrument air
Reference leg
Variable leg
Valve
manifold
dp-transmitter

AALBORG gsgiaaaaagnasHS^^^^^M
^••••••^••••••••^HIIH^HlHi^^H
Table of contents
Feed and boiler water

General 1
Layout of the treatment system 2
Feed and boiler water characteristics 3
Feed and boiler water maintenance 4
Treatment systems / injection points 5

AALBORG FEED AND BOILER WATER OM9210#99.2
INDUSTRIES
Feed and boiler water

1 General
Note: The recommended feed and boiler water characteristics are only valid
for boilers with a working pressure below 20 barg.
There is a number of ways to produce good quality feed water for boiler plants.
Methods such as e.g. reverse osmosis plants or ion exchange plants produce good
quality distillate. Also evaporators generally produce good distillate. The important
thing is that the distillate used should be clean and without foreign salt
contamination.
In practice most distillates used contain minor parts of various salt combinations
which can and must be chemically treated away. Furthermore, the distillate may
contain dissolved gases like for example oxygen (O2) and carbon dioxide (CO2)
which may lead to corrosion in the boiler, steam, and condensate system.
Important: Boiler and feed water must be chemically treated in order to avoid
corrosion and scaling in the boiler.
Layout of the treatment system

The condition of the feed and boiler water is an essential part of the boiler operation
and operation philosophy. The design and construction of the treatment system
should therefore be considered carefully during layout of the plant. Aalborg
Industries gives some general requirements and recommendations regarding the
conditions of the feed and boiler water. However, there is several ways to obtain this
results, or similar, by using different treatment systems. The following should
therefore be considered already at the layout stage:
— Choose the treatment system that should be used.
— Present the condensate and feed water system to the supplier of the treatment
system and inform about the operation philosophy of the plant.
— Let the supplier indicate where the injection points should be located and also
inform if special equipment is required.
— Let the supplier inform about which test facilities is needed.
— Purchase the recommended equipment and install it in the correct way.
— Use the treatment system as soon as the boiler is taken into operation.

INDUSTRIES
Feed and boiler water characteristics

The following text regarding feed and boiler water treatment is the normal
recommendations given by Aalborg Industries. These recommendations should be
followed strictly in order to have the best working conditions for the boiler plant and
to extend the working life of the plant. The requirements/recommendations of the
various values for feed and boiler water are listed in Table 1 below.
"-"",, Requirements for feed and boiler water

Unit Feed water Boiler water
Appearance - Clear and free of mud Clear and free of mud
Hardness ppm CaC0 3 0-5 -
Chloride content ppm Cl" <15 <100
"P" alkalinity ppm CaC0 3 - 100-150
Total (T) alkalinity ppm CaC0 3 - <2 x "P" - Alkalinity
PH-valueat25°C - 8.5-9.5 10.5-11.5
Hydrazine excess ppm N2rL, - 0.1-0.2
Phosphate excess ppm PO4 - 20-50
Specific density at 20°C Kg/m3 - <1.003
Conductivity at 25°C (xS/cm - <2000
Oil content - NIL NIL
Table 1
If hydrazine (N2H4) is not used, sodium sulphate (Na2S04) can be used instead, and
the excess should be 30 - 60 ppm.
In cases where other kinds of oxygen binding agents are used, it is recommended
that an excess of oxygen binding agents can be measured and indicates that no
oxygen has been dissolved in the boiler water.
If it is requested to measure the content of dissolved oxygen directly, it is
recommended to keep the value < 0.02 ppm.
In addition to the above values, the various water treatment companies will add
further demands, depending on the method used for treatment of feed and boiler
• water.
However, the most important point is that the above values or their equivalents are
observed and that a regular (daily) test of feed and boiler water is carried out.
3.1 Units of measurement
Concentrations are usually expressed in "ppm" i.e. parts solute per million.
Concentrations for parts solution by weight are the same as "mg/litre".
3.1.1 Specific gravity
As guidance the following conversion can be used:
• 1 Be° = 10.000 mg/1 total dissolved solids (TDS)
• 1 mg/1 total dissolved solids = 2 u,S/cm
• 1 nS/cm = 1 (xmho

INDUSTRIES
Feed and boiler water maintenance

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

INDUSTRIES
Treatment systems / injection points

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

recommended to seek assistance by the chemical manufacturer/supplier.

INDUSTRIES
Chemical injection points

I Table No. 1
Manufacturer / supplier: Ashland Chemical / Drew Marine Division
Product name / method: Standard with Drewplex OX

Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No.
Adjunct B 3, 3a, 3b X 1
GC 3, 3a, 3b X 1
1,2,3
SLCC-A 3, 3a, 3b X 1
Drewplex OX 2, 2a, 2b X 1,3,4
I Table No. 2
Ashland Chemical / Drew Marine Division
Product name / method: Standard with Amerzine

Adjunct B 3, 3a, 3b X 1
GC 3, 3a, 3b X 1
1,2,3
SLCC-A 3, 3a, 3b X 1
Amerzine 2, 2a, 2b X 1,3,4
Table No. 3

Adjunct B 3 X
GC 3 X
1
SLCC-A 3 X
Amerzine 1 X 2,3,4
I Table No. 4

Adjunct B 3a, 3b X
GC 3a, 3b X
2,3
SLCC-A 3a, 3b X
Amerzine 1 X 2, 3, 4, 5
Table No. 5
Product name / method: Drewplex AT / OX

Drewplex AT 3, 3a, 3b X 1
Drewplex OX 2, 2a, 2b X 1,3,4
1,2,3

INDUSTRIES
Chemical injection points (continued)

I Table No. 6
Product name / method: Drewplex AT/OX

Drewplex AT 2, 2a, 2b X 2,3,4
Drewplex OX 2, 2a, 2b X 3,4
1,2,3
Table No. 7
Product name / method: Drewplex AT with Amerzine

1,2,3
I Table No. 8

Amerzine 2, 2a, 2b X 3,4
1,2,3
I Table No. 9

Amerzine 1 X 2, 3, 4, 5
1,2,3
Manufacturer / supplier: I Table No. 10

Product name / method: AGK-100 with Amerzine

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

INDUSTRIES

I Table No. 11

AGK-100 2, 2a, 2b X 3,4
Amerzine 1 X 2, 3, 4, 5
1,2,3
'
I Table No. 12

AGK-100 1 X 2, 3, 4, 5
Amerzine 1 X 2, 3, 4, 5
1,2,3
I Table No. 13
Manufacturer / supplier: Marichem
Product name / method: Standard

Alkalinity control 3, 3a, 3b X 1,3,4
Phosphate 3, 3a, 3b X 1,3,4
1,2,3
Oxycontrol 2, 2a, 2b X 1,3,4
Marichem CCI 2, 2a, 2b X 1,3,4
Table No. 14
Product name / method: Standard

Alkalinity control 1 X 2,3,4
Phosphate 1 X 2,3,4
1
Oxycontrol 2 X 3,4
Marichem CCI 2 X 3,4
I Table No. 15
Product name / method: BWT new formula

B.W.T. new formula 2, 2a, 2b X 1,3,4
Marichem CCI 2, 2a, 2b X 1,3,4
1,2,3

INDUSTRIES

I Table No. 16
Product name / method: BWT new formula

B.W.T. new formula 1 X 2, 3, 4, 5
Manchem CCI 2, 2a, 2b X 3,4
1,2,3
I Table No. 17
Product name / method: BWT

B.W.T. powder 2, 2a, 2b X 1,3,4
Manchem CCI 2, 2a, 2b X 1,3,4
1,2,3
•
Table No. 18
Product name / method: BWT

B.W.T. powder 1 X 2, 3, 4, 5
Manchem CCI 2, 2a, 2b X 3,4
1,2,3
Table No. 19
Manufacturer / supplier: Unitor Chemicals
Product name / method: I

Hardness control 3, 3a, 3b X 1
Alkalinity control 3, 3a, 3b X 1
1,2,3
Oxygen control 2, 2a, 2b , X 1,3,4
Condensate control 2, 2a, 2b X 1,3,4
Table No. 20

Hardness control 1 X 2
Alkalinity control 1 X 2
1
Oxygen control 2 X 3,4
Condensate control 2 X 3,4

INDUSTRIES

| Table No. 21
Product name / method: II

1,2,3
Cat sulphite L (CSL) 2, 2a, 2b X 1,3,4
Table No. 22

1
Cat sulphite L (CSL) 2 X 3,4
Table No. 23
Product name / method: Liquitreat

Liquitreat 3, 3a, 3b X 1
1,2,3
(Oxygen control) 2, 2a, 2b X 1,3,4
Table No. 24
Product name / method: Liquitreat

Liquitreat 1 X 2
Condensate control 2, 2a, 2b X 3,4
1
(Oxygen control) 2, 2a, 2b X 3,4
I Table No. 25
Product name / method: Combitreat

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

INDUSTRIES

I Table No. 26
Product name / method: Combitreat

Combitreat 1 X 2
1
; 1- Table No. 27

1,2,3
Hydrazine 2, 2a, 2b X 1,3,4
I Table No. 28

1
Hydrazine 2 X 3,4
Table No. 29

1,2,3
Oxygen control 2, 2a, 2b X 1,3,4
| Table No. 30

1

Ull:
AALBORG
'NDUSTRiEs
Language UK
Page 11/14
INDUSTRIES
Flow diagram No.: 1
OZJ Condensate
Single boiler operation with or without

forced circulation exhaust gas boiler
Figure 1 flowdiag_l.cdr

INDUSTRIES
Flow diagram No.: 2
<^p Condensate
Double boiler operation with separate feed water pumps

with or without forced circulation exhaust gas boiler
Figure 2 flowdiag_2.cdr

INDUSTRIES
Flow diagram No.: 3
Double boiler operation with common feed water pumps

with or without forced circulation exhaust gas boiler
Figure 3 flowdiag_3.cdr

;
INDUSTRIES ^••••••••••••••^^^•••••ilH
Table of contents
Water level gauge

Maintenance and service instructions 1

AALBORG WATER LEVEL GAUGE OM7010#01.1
INDUSTRIES
Water level gauge

1 Maintenance and service instructions
This section describes the maintenance and service instructions for the water level
gauge.
Illustration of the water level gauge
Nut
Box heads
Joint rings
Box heads
Tubes
Screws
Screws
8 - Cock plug
D - Drain cocks
G - Gauge body
S - Cocks
W - Cocks
Figure 1 kli Ole.cdr
1.1 Maintenance
The item nos. mentioned in the following maintenance instructions refer to Figure 1.
When out of service with the gauge body in cool and depressurised condition the
hexagon screws (6) can be re-tightened.

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

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

INDUSTRIES
1.3 Dismantling
The following dismantling instructions refer to Figure 1 and Figure 2.
Sectional view of the water level gauge
6 - Screws
9 - Wedge piece
10-Centre piece
11 - Reflex
12-Sealing gasket
13-Cushion gasket
14 - Cover plate
Figure 2 kli 05e.cdr
Step A: Shut the cocks S and W.
Step B: The drain cock D to be opened until the glass is completely emptied.
Step C: Remove nuts (1) and lift off stuffing box heads (2) together with the gauge
body from the cocks S and W.
Step D: Slacken the union nuts (4) and pull off the stuffing box head (2).
Step E: Place the gauge body (G) horizontally with the screws (6) turning upwards
and loosen the screws.
Step F: Move the wedge piece (9) length wise and lift upwards.
Step G: Lift off centre piece (10) reflex glass (11) and gaskets (12 and 13).
Step H: Clean sealing surface of cover plate (14) and centre piece (10) and examine
for through going scars.
1.4 Assembling
The following assembling instructions refer to Figure 2.

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

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

The following assembling instructions refer to Figure 3.
Detail drawing of the straight-through cock
15-Screw
16-Split ring
17- Packing sleeve
18-Plug
19- Bottom screw
Figure 3 kli 06e.cdr
The cylindrical plug (18) is sealed with a resilient packing sleeve (17).
Should leakage arise during service the packing sleeve must be further compressed
by tightening the bottom screw (19) until the leakage is stopped. This must only be
done with the cock in open position.
1.5.2 Dismantling
Step A: Remove bottom screw (19).
Step B: Remove screw (15), washer and handle.
Step C: Knock the plug (18) together with split ring (16) and packing sleeve (3) out
of the cock body by means of a soft mandrel.
Step D: Remove split ring and knock plug out of the packing sleeve.
Step E: Clean all sealing surfaces carefully and lubricate threads with a high
temperature grease before installation.

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

AALBORG ggfliaaaaswnang^^^^^M
INDUSTRIES ^HHÉJi^felHMÉÉlIlIlBflH^H^^^^H^H
Table of contents
Safety valves
General 1
Maintenance and start-up of boiler 2
Adjustment and dismantling 3
Temporary locking of a safety valve

General 1

AALBORG SAFETY VALVES OM6040#01.0
INDUSTRIES
Safety valves
1 General
In the following the measures required to achieve a safe and reliable maintenance of
the safety valves will be described, together with adjustment and dismantling
instructions.
An example of an installation of the safety valve is shown in Figure 1.
Mounting of safety valves, example
Waste steam pipe
Drip pan
Drain
Figure 1 safe Ola.cdr
Maintenance and start-up of boiler

A regular inspection of the safety valve is recommended at least once a year. Some
media and appliances require a more frequent inspection, this is according to the
experience of the supplier.
Warning: Before handling and dismantling of the safety valve ensure that the
system is NOT pressurised!
Before lighting-up the boiler the pipe connections must be thoroughly cleaned for
dirt and foreign bodies.

INDUSTRIES
If the valve is not completely tight, which often happens after starting up the plant,
this is usually caused by impurities between the seat and the cone. In order to
remove these impurities the valve must be heavily blown out by means of the lifting
device. If the valve is not tight after several blows, it may be due to the fact that a
hard foreign body has got stuck between the cone and the seat, and it will then be
necessary to dismount the valve for overhaul.
Warning: In case of a leaking safety valve the valve must be inspected and
over-hauled at earliest possible opportunity. It must be ensured that
the boiler is totally depressurised before dismounting the valve.
Note: Before dismantling the safety valve in the workshop the position of the
adjusting screw must be measured and noted which will facilitate the
adjustment later when the valve is to be adjusted when in service.
If the facings between the cone and the seat have been damaged, they must be
grinded.
Step A: The cone can be grinded against a cast iron plate, using a fine grained
carborundom stirred in kerosene.
Step B: The seat in the valve body can be grinded in the same way by using a cast
iron punch of suitable size.
Note: Never use the cone itself when grinding the seat.
Warning: The spindle and the valve cone must always be secured against
turning as the seat and the cone may thus be damaged.
Step C: Before assembly the valve must be thoroughly cleaned, and all traces of
grinding material and impurities must be removed.
When the valve has been mounted the boiler is commissioned, and the valve is then
checked for leakage and adjusted to the set pressure.
Step D: The adjustment screw is secured by means of its lock nut, and the valve is
sealed.
2.2 Routine check
The following should be regarded as recommendations of routine checks on the

safety valves, in order to keep a proper functioning.

INDUSTRIES
Yearly
Step A: The safety valve should be tested in operation by raising the boiler pressure.
Step B: Expansion and exhaust pipe should be examined at the same time.
Monthly
Step A: Examine the safety valves for any leaking, such as:
• Is water seeping from the drain plug at the valve body?

• Is the escape pipe hot due to seeping steam from the valve seat?
Step B: Examine the drain and expansion device at the escape pipe.
Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts.
Adjustment and dismantling

Safety valves are delivered with the required spring setting and sealed against
unauthorised adjustment.
Adjustments are only allowed in the spring margins. Outside the margin a new
spring is required. The pressure in a system should not exceed 90% of the set
pressure.
All item nos. mentioned in the following sections refer to Figure 2.
3.1 Dismantling of lifting device
Safety valve with open cap

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

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

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

AALBORG TEMPORARY LOCKING OF A SAFETY VALVE OM6040#02.0
INDUSTRIES
Figure 1 safe 06.cdr

AALBORG cBsfläsggssnajRg^^^^^H
INDUSTRIES ^HHÉBHÉBÉMHIIIIHH^^^^HH^^^H
Table of contents
Feed water system

Water level control 1
Dp water level transmitter unit 1
Level float switch 1

INDUSTRIES
Water level control

1 Description

Instrument air
Reference leg
Variable leg
Valve
manifold
dp-transmitter
Feed water pumps

AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1
INDUSTRIES
dp water level transmitter unit

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

Shut-off valves
Filling plug
Reference leg
Drain valve
Equalising valve
dp-transmitter—
Figure 1 dpunit.cdr
The differential pressure transmitter is installed with the process connections upward
to prevent trapping of air. The pipes are mounted with continuous fall (at least 5°)
from the boiler connections to the transmitter also to prevent trapping of air.
The reference impulse leg (upper connection point) is connected to the high pressure
connection (+), and the variable impulse leg (lower connection point) to the low
pressure connection (-).
Note: The dp water level transmitter unit or any part of it must not be
insulated to ensure the correct function.

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

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

INDUSTRIES
2.2.1 Blind calibration

Blind calibration of the differential pressure transmitter can be performed if no
pressure source is available. This means when the boiler cannot be operated at
normal working pressure and the water level cannot be increased/decreased. The
"start of scale" and "full scale" differential pressures are calibrated on the basis of
calculated values. The start of scale value should be calibrated to obtain a 4 mA
output signal from the transmitter when the water level is at the lower connection
point and the full scale value to obtain a 20 mA output signal when the water level is
at the upper connection point. To ensure an accurate calibration it is necessary to
take the density difference between the water in the reference leg and in the boiler
into consideration when calculating the differential pressure values.
4 mA output signal from the differential pressure transmitter:
— When the water level in the boiler is at the lower connection point the pressure
difference over the transmitter is equal to the height between the connection
points (column of water) corrected with the density of the water in the reference
leg. The value must be specified and entered in engineering unit, e.g. in mm
H 2 0.
20 mA output signal from the differential pressure transmitter:
— When the water level in the boiler is at the upper connection point the pressure
difference over the transmitter is equal to the height between the connection
points corrected with the density difference between the water in the reference
leg and in the boiler. The value must be specified and entered in engineering
unit, e.g. in mm H 2 0.
Figure 2 indicates the calculation procedures of the differential pressures. As
standard it is assumed that the temperature in the reference leg (condensate receiver)
is 40°C. Table 1 shows the calculated values for some standard heights between the
connection points. If the actual boiler plant does not fit any of the standard
calculations the specified calculated values can be entered in the table for calibration
record purpose.
If the boiler plant is intended to operate at different set points (high/low pressure
mode) the differential pressure transmitter must be calibrated so that the minimum
indicated "Too low water level" on the control system not is lower than the actual
"Too low water level" mark. Because of the density difference in the boiler water at
different working pressures/temperatures the indicated water levels will not be
identical. This means that the differential pressures for start of scale and full scale
should be calculated using the parameters from operation in high pressure mode.
When the differential pressures corresponding to the "start of scale" and "full scale"
have been calculated carry out the following work steps (please also see the specific
instruction for the differential pressure transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential
pressure transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys T and i are used to change the mode
value.

INDUSTRIES
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select e.g. "mm H20" as engineering units.
Step D: Select mode 5 using the "M" key.
Step E: Use the t or i key to set the start of scale in the selected engineering unit. If
mm H2O is selected as engineering units, then set the start of scale to the
calculated value in mm H2O (differential pressure at 4 mA).
Step F: Press both the t and -l keys simultaneously for about 2 seconds, and the
start of scale is set to zero (in the selected engineering unit).
Step G: Select mode 6 using the "M" key.
Step H: Use the T or 4 key to set the full scale in the selected engineering unit. If
mm H20 is selected as engineering units, then set the full scale to the
calculated value in mm H2O (differential pressure at 20 mA).
Step I: Press both the t and X keys simultaneously for about 2 seconds, and the full
scale is set to the upper limit (in the selected engineering unit).
Step J: Mount the protective cover of the differential pressure transmitter again.
Calibration of differential pressure transmitter '

Height between Working pressure Transmitter output, Differential pressure
Connection point
connection [mm] [barg - kg/cm2] fmAl calibration [mm H 2 0|
Calculations for standard heights, working pressures, and ambient temperature (40 XI)
Lower connection 4 521
7.0
Upper connection 20 50
525
16.0
7.0
700
16.0
7.0
800
16.0
Calculation records for other heights, working pressures, and/or ambient temperatures
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Table 1

INDUSTRIES
Calculation of the differential pressures
^ = 40°C, density: 992.2 kg/m3
t, = not existing
/
Differential pressure
between connections: Height between
525 X 0.9922 = connections, e.g.:
525 mm
521 mmH,0(at4mA)
,, Water level
\
t3=170°Cat7barg,
204°Cat16barg
t2 = 40°C, density: 992.2 kg/m3 t, = not existing
Water level
between connections
(at 7 barg):
525 x (0.9922 - 0.8970) =
Height between
50.0 mm H 2 0 (at 20 mA) connections, e.g.:
525 mm
between connections
(at 16 barg):
525 X (0.9922 - 0.8596) =
69.6 mm H,0 (at 20 mA)
t , = 170°Cat7barg,
density 897.0 kg/m3
204°Cat16barg,
density 859.6 kg/m3
Figure 2 dpunit_calil.cdr
2.2.2 Live calibration

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

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

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

INDUSTRIES
from the differential pressure transmitter is at 4 mA or the start of scale

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

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

INDUSTRIES
Step H: After performing the blow-through check that the dp water level transmitter
unit and feed water control valve are fully operational.
In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through
procedure of the impulse legs must be done more often.
3.1.2 Blow-through procedure of the connection pipes
The blow-through procedure should be performed as describe below when the boiler
plant is stopped, but still pressurised. The procedure should be carried out at least
once each year.
Step A: Open the venting facilities located on the valve manifold for the impulse
legs. The transmitter connection valves must remain open and the
equalising valve closed during the blow-through procedure.
Step B: Close the venting facilities on the valve manifold when only clean water
escapes.
Step C: Close the shut-off valve for the reference leg.
Step D: Slowly open the drain valve of the reference leg.
Step E: Close the drain valve again when the reference leg is completely
depressurised.
Step F: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step G: Screw on the filling plug and slowly open the shut-off valve for the
reference leg.
procedure of the connection pipes must be done more often.
3.1.3 Function test of the dp water level transmitter unit
During normal operation of the boiler plant a function test of dp water level
transmitter unit should be carried out at least once each month. The purpose of the
function test is to check that the connected alarms/shut downs and control functions
are operational. The boiler should be operated at normal working pressure during the
test to provide for correct indications. When the boiler is at normal water level and
the burner is in operation, carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
the control system, (if provided).

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

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

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

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

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

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

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

pressurised.

•
«a,
AALBORG gsaigRHggffnasns^^^^^M
INDUSTRIES ^••••••••••••^•^^•i
Table of contents
Control valves, type 470/471
General 1
Operation 2
Maintenance 3
Pneumatic actuator, type DP
General 1
Reversal of the actuator action 2
Manual operation device 3
Maintenance 4
Positioner, SIPART PS2 6DR5000
General 1
Mechanic connection of the positioner 2
Electric connection of the positioner 3
Pneumatic connection 4
Commissioning 5
Diagnosis 6
Service and maintenance 7

AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0
INDUSTRIES
1 General
This type of control valve is suited to regulate fluids, gases and steams. The valve
plug is normally a parabolic plug, but can also be supplied in a perforated design.
Both types of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always against the closing direction.
However, with perforated plugs for steam and gases, it is in the closing direction. If
a valve with a perforated plug is operated by means of a pneumatic actuator with the
flow in the closing direction, the pneumatic actuator should have a stronger thrust
force. This is necessary to prevent thumping near to the closing position.
All control valves can be fitted alternately with manual-, pneumatic-, electric- or
hydraulic operation devices.
Illustration of control valves type 470 and 471
Control valve, type 470 Control valve, type 471
Figure 1 val47x.tif

INDUSTRIES
Table of position numbers in Figure 1

Part Designation Part Designation Part Designation
1 Body 7 Gland flange 15.1 Studs
2 Seat ring 7.1 Screw joint 17 Hexagon nuts
3 Mounting bonnet 8 Spindle guiding 17.1 Hexagon nuts
3.1 Mounting bonnet 10 Stuffing box 19 Spring-type straight pin
4 Guiding bush 10.1 Stuffing-box packing 21 Set-pin
5 Plug 14 Gasket 25 Bellow housing
6 Spindle 14.1 Gasket 26 Bellow unit
6.1 Spindle 15 Studs
Table 1
Operation
2.1 Fitting instructions
The valve should be inserted so that the spindle has a vertical position together with
the actuator. The valve can also be tilted to a maximum horizontal position if the
installation point does not allow any better condition.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length (min. two times the pipe
diameter by inlet and six times by outlet). The piping should be rinsed to clear out
any pollution, welding beads, rust, etc. before inserting the control valves. A strainer
should be fitted in front of the control valve to catch the remaining particles. Bolts
should be tightened after taking into operation.
The flow direction is signalled by an arrow on the valve body. The valves should be
insulated against high temperatures to guard the actuator.
2.2 Actuator assembly
The control valves are normally delivered with actuators already fitted. For
alternations or maintenance of actuator, the assembly should occur in accordance
with the operation instructions for the actuator.
2.3 Setting into operation
When the piping system is filled, the spindle sealing should be checked for leakage
and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as
the spring tension maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter
than it is necessary for the sealing. Flange connection bolts should never be loosened
or tightened when the valve is under temperature or pressure even if a leakage may
arise.
For actuators please see to the appropriate actuator operation instructions.

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

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

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

INDUSTRIES
Note: Special care should be given to the spindle surface. Rough surfaces wear
the sealing lips enormously and can be due to failure of the packing unit.
3.3 Exchange of the bellow unit
Step B: Unscrew the screw joint (7.1).
Step C : Unscrew the hexagon nuts (17) and remove the bellow housing (25).
Dismantle the plug as described in the next section.
Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1).
Step E: The bellow unit (26) is removed from the bellow housing (25).
Step F: Replace the two gaskets (14.1) and the gasket (14).
Step G: When the bellow unit (26) is replaced, the proper position of the anti-
twisting device must be observed.
Step H: The set pins (21) have to drive within the slots of the anti-twisting device.
Check for friction-free movement.
Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1)
crosswise.
3.4 Exchange of the plug-spindle unit
Step B: Unscrew the gland flange (7).
3.4.2 Control valve type 470
Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).
Step B: Pull out the plug with the spindle and exchange this unit.
Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6).
Step D: Replace the old parts and assemble it.
Step E: Drill a hole through the plug shaft and insert a new pin.
Step F: Replace the gasket (14) and assemble the mounting bonnet (3).
Step G: Tighten the nuts (17) evenly, crosswise.

INDUSTRIES
Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with
plug (5).
Step B: Drive the spindle in the bottom position and remove the spring-type straight
pin (19).
Step C: Unscrew the plug.
Step D: Screw a new plug at the spindle and drill through the shaft. Drive the
spring-type straight pin (19) into the hole.
Step E: Replace the gasket (14).
Step F: Assemble the bellow housing (25) with plug (5) together with the body (1)
and fix it by screwing the hexagon nuts (17) crosswise.
The spindle can only be completely replaced together with the bellow.
3.5 Changing the seat ring

The seat ring is screwed into the valve body. The seat ring can be obtained after
removing the bonnet and can then be refinished or replaced as required.
Step A: Clean and lubricate the thread and conical sealing surface before insertion.

AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0
INDUSTRIES
Pneumatic actuator, type dp

1 General
The pneumatic linear actuator is designed to be mounted directly on a control valve.
The pneumatic actuator converts positioning command signals into stem thrust
forces. The required back setting force is produced by the spring arrangement inside
the actuator. The rolling-diaphragm produces linear spindle movements over the
complete stroke.
The preferred mounting position is with the actuator and valve spindle in vertical
position.
The mode of operation for the actuator depends on how the springs are inserted
when the actuator is assembled. Even when the actuator is fitted in a piping system,
the mode of operation can be changed.
The pneumatic actuator can be operated as:
• Spring opens valve/air closes valve operation mode
• Air opens valve/spring closes valve operation mode
Illustration of a pneumatic actuator
Operation mode:
Spring opens - Air closes Air opens - Spring closes
Figure 1 dpactuat.tif

INDUSTRIES
Table 1 below shows a list of the position numbers in Figure 1 and Figure 2.

Part Denomination Part Denomination
1 Rolling diaphragm 15 Stroke indicator
2 Diaphragm housing 16 Hexagon nut
3 Diaphragm lid 17 Mounting rod
4 Diaphragm plate 18 Bellow
5 Spindle 19 Collar nut
7 Spring 21 O-ring (spindle)
10 Coupling flange 22 O-ring (bushing)
11 Guide flange 26 Slotted guide bearing
12 Rotation guard 27 Spindle guide
13 Socket screw 30 Hexagon nut
14 Threaded bushing 31 Hexagon nut
Table 1
1.1 Pneumatic connection
The air supply should be dry and at a low service temperature. A heat-guard should
be installed to prevent high service temperature.
The pneumatic supply tube must be connected to the diaphragm housing (2) by
operation mode "spring closes" and to the diaphragm lid (3) by operation mode
"spring opens".
By air failure the stem automatically returns into the original position caused by the
inserted springs.
Warning: The actuator diaphragm may only be pressure loaded on the side
opposite of the springs. The vent hole in the other connection must
remain open.
1.2 Assembly of the actuator on the valve
The assembling of the actuator on the valve is shown in Figure 2. For both "spring
closes" and "spring opens" operation modes the following assembling procedure
should be followed:
Step A: If the actuator and the valve are separated, press the plug and spindle unit
(5) into the closed position for operation mode "spring closes" or into the
open position for operation mode "spring opens".
Warning: Make sure that the plug does not turn while pressing on the seat
during assembly.
Step B: Loosen the socket screws (13), remove the rotation guard (12) and the guide
flange (11). The threaded bushing (14) is now free.

INDUSTRIES
Step C: Turn the locking hexagon nut (30) onto the valve spindle. Place the rotation
guard (12) and the guide flange (11) over the valve spindle and then turn
the threaded bushing (14) onto the valve spindle.
Step D: Check the actuator for proper operation mode and connect the pneumatic
supply to the connection piece in the diaphragm housing (2) for operation
mode "spring closes" or in the diaphragm lid (3) for operation mode "spring
opens".
Step E: Drive the actuator into approximately mid-stroke position over the air
supply and mount it onto the valve (read the value from the pressure gauge
- middle of the spring range).
Step F: Tighten the hexagon nuts (31).
Assembly of the actuator on the valve
Operation mode: Spring closes valve - Air opens valve Operation mode: Spring opens valve - Air closes valve
Pneumatic connection
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Figure 2 dpactspr.tif

INDUSTRIES
1.3 Adjustment of the starting pressure signal
Step A: Drive the actuator to the required spring-starting point over the air supply.
Step B: Turn the threaded bushing (14) up against the coupling flange (10) so that
the collar enters into the flange and presses against it. Make sure that the
plug is lying on the valve seat.
Attention: Note that sufficient thread of the valve spindle is inside the threaded
bushing (14). If not, turn the coupling flange (10) downwards from
the actuator spindle and pull the threaded bushing (14) against it.
Step C: For operation mode: "spring closes":
— Attach the guide flange (11) and the rotation guard (12) with the socket screws
(13) to the coupling flange (10).
— Check that the plug lifts off the seat at the required spring starting point.
Step D: For operation mode: "spring opens":
— Check that the plug leaves the end position at the required spring starting point,
and finishes the valve stroke at the spring-range end value.
— The plug must then also press on the valve seat.
Step E: After the test operation set the stroke indicators (15) into the end positions.
Step F: Lock the hexagon nuts (16 + 30) at the valve mid-stroke.
Step G: Do not turn the plug on the seat when it is under force.
Reversal of the actuator action

The actuator action can be reversed even when the valve is installed in a piping
system. The position numbers mentioned in this section refer to Figure 1 and Figure
2.
Step A: Drive the actuator into approximately mid-stroke position with the air
supply.
StepB: Loosen and remove the socket screws (13) from the coupling flange (10)
and drop the rotation guard (12) over the valve spindle.
Step C: Remove the hexagon nuts (31) from the actuator and lift off the valve.
Step D: Reduce the air supply until the chamber is pressure free.

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

INDUSTRIES
Place the diaphragm lid (3) on the top, and screw it together. Make sure that the
springs (7) stay properly arranged.
— Turn the hexagon nut (16) and the coupling flange (10) onto the spindle (5).
— Mount the actuator as described previously, and connect the air supply tube to
the diaphragm housing (2).
Manual operation device

Some actuators are fitted with a manual operation device. The device is connected to
the actuator by means of a new diaphragm lid, a spindle extension with a USIT-ring
and a spindle sealing unit.
The manual operation device is equipped with stroke indicators. The stroke
indicators of both the actuator and the manual operation device must be in the same
end positions when the actuator is pressure free.
The manual operation device must be set into neutral position when the actuator is
running automatically.
The locking device of the manual operation device must be unlocked before
operating.
The locking device prevents an unwanted disarrangement of the setting during
operation, e.g. due to vibration, etc.
Maintenance
The pneumatic actuator is maintenance free. To maintain a disturbance free
operation, the air should be supplied by an air-supply station.
The diaphragm, spindle sealing unit and springs are wear parts and should be
replaced when necessary.
4.1 Exchange of spindle sealing
When the spindle sealing is changed, the slotted PTFE-guide bearing and the 0-ring
should be replaced. The spindle surface must be clean and undamaged. Before the
actuator is assembled, the spindle unit and the spindle must be greased.

AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.0
INDUSTRIES
1 General
The following instruction is a general description of SIPART positioners and covers
the complete range in the PS2 6DR5000 series.
The electronic pneumatic positioner is used as the final control element of a
pneumatic linear actuator or a part-turn actuator (rotary movements). The positioner
converts a current output signal (4 to 20 mA) from a process controller or control
system to a set point value and into a corresponding movement. The positioner
changes the pressure in a pneumatic actuator chamber or cylinder until the position
corresponds to the set point value.
The positioner can be set up either as a single-action positioner or a double-action
positioner. The single-action positioner is mainly used together with a control valve.
The opposite movement for the control valve is supplied by means of springs. The
double-action positioner is mainly used to control an air damper via a pneumatic
cylinder (actuator). All movements of the pneumatic cylinder are supplied by the
positioner. An illustration of the function diagram for the positioner is shown in
Figure 1. The function diagram is shown with option modules.
1.1 Mode of operation
Comparison of the set point and the actual value takes^place electronically in a micro
controller. If the micro controller detects a deviation, it uses a 5-way switch
procedure to control the piezoelectric valves, which in turn regulate the flow of air
into the actuating chambers. When connected in a two-wire system, the SIPART
PS2 draws its power exclusively from the 4 to 20 mA set point signal.
The piezoelectric valve converts the command into a pneumatic positional
increment. The positioner outputs a continuous signal in the area where there is a
large control deviation (high-speed zone). In areas of moderate control deviation
(slow-speed zone) it outputs a sequence of pulses. No positioning signals are output
in the case of a small control deviation (adaptive or variable dead zone).
Commissioning (initialisation) is carried out automatically to a large extend. During
initialisation, the micro controller automatically determines the zero, full-scale
value, direction of action, and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, thus optimising the control.
The positioner can also be operated manually by the pushbuttons and the LCD of the
SIPART PS2.
The installation of the positioner must be carried out in the following order:
• Mechanic connection
• Electric connection
• Pneumatic connection
• Commissioning

„m.
INDUSTRIES
Illustration of a function diagram
Supply air
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1 Motherboard with microcontroller and input circuit

2 Control panel with LC-display and momentary action switch
3 Rezo-vatve unit, always built-in
4 Valve unit with double action positioner always built-in
5 ly-modutetorpositioner SIPART PS2
6 Alarm moduletorthree alarm outputs and one digital input
7 SIA-modu)e(Slotlnitiator-Alarm-module)
& Spring-loaded pneumatic actuator (single action)
9 Spring-loaded pneumatic actuator (double action)
Figure 1 sips2_5a.tif
Mechanic connection of the positioner

Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the
installation guide lines below.
2.1 Mechanic connection to an actuator
Figure 2 shows the mechanic connection of the positioner to an actuator for a control
valve.
Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and
lock washers (16) on the actuator spindle.
Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly.
Set the necessary length and tighten the screws so that the pick-up bracket
can still be shifted.

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

I N D U S T R I E S
Mechanic connection of the positioner (linear actuator)
2) 4
3)
Mounting on yoke Mounting on yoke

with plane surface
11 with ledge
Mounting on yoke
with columns
As required
Figure 2 sips2_5b.tif

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

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

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

INDUSTRIES
Mechanic connection of the positioner (rotary actuator)
Figure 3 sips2_5c.tif

INDUSTRIES
Electric connection of the positioner

When the positioner is connected in a two-wire system, the positioner draws its
power exclusivelyfromthe 4 to 20 mA set point signal. Figure 4 indicates the input
circuits for the positioner.
View of the controls and connections
14
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61 6.2
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11 ..10
1 Input: Supply air 7 Silencer

2 Output: Actuating pressure Y i 8 Transmission ratio selector
3 Display 9 Adjusting wheel slip clutch
4 Oulput: Actuating pressure Y2 *) 10 Terminals options modules
S Operating keys 12 Dummy plug
6 Restrictor 13 Screw-type cable gland
6.1 Restrictor Yl 14 Terminal plate on cover
6.2 Restrictor Y2 "> 15 Purging air switch
Figure 4 sips2_5d.tif
Ensure that the air quality is suitable. Grease-free instrumental air with a solid
content < 30 um and a pressure dew point 20 K below the lowest ambient
temperature must be supplied.
Warning: For reasons of safety, pneumatic power may only be supplied after
assembly when the positioner is switched to operating level "P
manual" operation with electrical signal applied.
4.1.1 Selection of P manual mode

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

INDUSTRIES
4.1.2 Pneumatic connections

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

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

For a single-action actuator is Yl deaerated. For a double-action actuator is Yl
equal to the supply air pressure and Y2 is deaerated.
4.1.4 Restrictors
To increase the positioning times for fast actuators when necessary, the airflowcan
be reduced with the restrictors Yl and Y2 (only for double-action valves). Turning
the restrictors in the clockwise direction reduces the air flow until it is shut off. To
set the restrictors it is recommended to first close them and then open them again
slowly (see initialisation process RUN 3).
4.1.5 Purging air switchover
The purging, air changeover switch located above the pneumatic terminal block on
the valve manifold can be accessed when the housing is open. When the switch is in
position "IN" the interior of me housing is purged with very small quantities of
clean and dry instrument air. In position "OUT" the purging air is led directly out of
the instrument.
Commissioning
initialisation, the micro controller automatically determines the zero value, full-scale
value, direction of action and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, hereby optimising the control.
SIPART PS2.
The commissioning of the positioner can be divided into the following steps:
• Preparation for initialisation
Start the automatic initialisation procedure

INDUSTRIES
• Set additional parameters if required

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

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

INDUSTRIES
Step I: During the initialisation phase "RUNl" to "RUN5" appear one after another
in the bottom of the display. Please note that the initialisation process may
last up to 15 minutes depending on the actuator.
Note: The ongoing initialisation can be aborted at any time by pressing the
hand symbol key. The previous settings are retained. All the parameters
are reset to the factory setting only after performing a preset
"55.PRST".
Step J: If problems occur, carry out the measures as described in the table "Possible
messages" shown in Figure 7.
Step K: The initialisation is completed when "FINSH" appears in the bottom of the
display.
Step L: When pressing the hand symbol key briefly the menu item line "4.INITA"
is displayed.
Step M: To exit the configuration operating mode, press the hand symbol key for
longer than 5 seconds. The software version is displayed after about 5
seconds. The instrument is in manual operation after releasing the key.
Step N: The positioner can be changed to automatic mode by pressing the " j " key
once as indicated in Figure 5.
Step O: The automatic mode is the normal mode. In this mode the positioner
compares the set point current with the current position and moves the
actuator until the control deviation reaches the dead zone.
Operation in the configuration mode
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Figure 6 sips2_5f.tif

INDUSTRIES
Initialisation process
Automatic initial sort-up (starting with factory setting) Possible messages
Step Meaning Display Meaning Measures
Acknowledge message
Partium turn 90° using the hand syrrod key
actuator 1 YFCT 2 YAGL P 324 Actuator does
RUN 1 not move Check restrictor (6) and open
Linear WAY 33° St rt if necessary
actuator 1 YFCT 2 YAGL 3 YVÄY P 324 Drive actuator to working range
ERROR using the up and down keys
Press tte up key tor > 5 sec.
Strt Restart initialisation
4 INTA Remaining steps are carried out automatical/
Change gearing (7)
P 324 Continue using up key

3.) Diiecticn of action is determined
D RUN 1
Or adjust sliding clutch up
P 884 Down tolerance
todsplay
S d i u IU band violated
P 924 Checking of travel and adjustment of P 6.4
4) S diOIU
Q RUN 2 zero andstroke(from stop to stop)
Détermination and display of positioning time Then only

5.) P 824 down(dxx.x), up (uxxx). Stop with the down key Con time ushg the down key
r, RUN 3
Pressing t he up key inllates leakage measurement Linearactuator. set pick-up
Once the slipp Ing lever h to ID montai position
6.)
D
P 324
RUN 4
Determination of mhimum here ment length
SB
3
MIDDL
dutch has been
adjusted
using the up and down keys
Continue ushg hand symbol key
7)
P 524 Optimisation of transient response Acknowledge message
D RUN 5 using the hand symbol key
P 98.3 Up tot era nee band
Inl'alisaion terminated successfuly h UP > violated Set the next highest travel
value on the lever
«-> 324 (travel in m mfor linear actuators)
FIN3H (angleofrotatlon for part-turn ætuators)
Restart iri« alisäbn
Ccntinueushg hand symbol ley
Additionally possible with rotary
actuators:
Adjust using up and down keys
up to dspla y:
923
80 95
Continue u shg hand symbol key
Acknowledge message
using the hand symbol key
P 19.8 Up/down span
Set the nect lowest travel
<i U-d < violated
value on the lever
Restart inüdisatbn
Adjust positioning time ushg

1.3 Actuator does resrictcrfs)
NOZZL not move.
Positioning Continue ushg the
time Is possibl e up or down key
1.8 to adjust
NOZZL
Figure 7 sips2_5g.cdr
5.3 Parameters
After the initialisation process, the positioner can be configured to meet the
requirements of a specified task. The factory settings correspond to the requirements
for a typical application. This means that normally only a few parameters will need
to be changed.
Table 1 shows the parameter list for the positioner. The parameter name is written in
plain text in the "menu line" column. The function of the parameter is described
briefly in the "Function column". In addition, the possible parameter values, the
physical unit and the factory setting of the parameters are shown.

INDUSTRIES
•ti- *- \V 'Parameter-list \J -;, x ' *''* v ":. • "-.'"'

Customer
Menu line Function Parameter values Unit Factory setting
setting
turn (part-turn actuator)
WAY (linear actuator)
LWAY (linear actuator
without sine correction)
l.YFCT Type of actuator WAY
ncSt (part-turn actuator
withNCS)
-ncSt (part-turn actuator
with NCS, inverted)
Rated angle of rotation for feedback 90°
2.YAGL 0 Degrees 33°
(must correspond to gear ratio) 33°
Stroke range (optional setting) OFF
5,10,15,20
When used, the value must correspond with
(short lever 33°)
the set of the leverage ratio on the actuator
3.YWAY2» 25 , 3 0 , 35 mm OFF
Driver pin must be set to the value of the (short lever 90°)
actuator travel or, if this value is not scaled, 40, 50 , 60, 70,
to the next lager scale value 90,110,130
(long lever 90°)
4.INITA Initialisation (automatically) noini/no/###.#/Strt no
5.INITM Initialisation (manually) noini/###.#/Strt no
„ . . . . 0 to 20 mA 0MA
6.SCUR Current range ofe set point . ^ „„ . 4MA
° 4 to 20 mA 4MA
riSE
7.SDIR Set point direction fir riSE
FALL
8.SPRA Set point for start of split range 0.0 to 100.0 % 0.0
9.SPRE Set point for end of split range 0.0 to 100.0 % 0.0
Auto
10.TSUP Set point ramp up s 0
0 to 400
ll.TSDO Set point ramp down 0 to 400 s 0
Set point function
Linear Lin
12.SFCT Equal-percentage 1:25,1:33, 1:50 1-25 ,1-33 ,1-50 Lin
Inverse equal-percentage 1:25,1:33,1:50 nl-25 , nl-33 , nl-50
Freely adjustable FrEE
13.SL03) Set point turning point at 0% 0.0
14.SL1 5% 5.0
to to 0.0 to 100.0 % to
32.SL19 95% 95.0
33.SL20 100% 100.0
Auto
34.DEBA Dead zone of controller % Auto
0.1 to 10.0
35.YA Start of manipulated variable limiting 0.0 to 100.0 % 0.0
36.YE End of manipulated variable limiting 0.0 to 100.0 % 100.0
Standardisation of To mech. travel MPOS
37.YNRM MPOS
manipulated variable To flow FLOW
Direction of manipulated Rising riSE
38.YDIR riSE
variable for display Falling FALL
Without no
Tight closing with Top only UP
39.YCLS no
manipulated variable Bottom only do
Top and bottom uPdo
40.YCDO Value for tight closing, bottom 0.0 to 100.0 % 0.5
41.YCUP Value for tight closing, top 0.0 to 100.0 % 99.5

INDUSTRIES
Parameter list continued

Customer
setting
Function of B I 1 :
None OFF
Only message (NO/NC contact) on / -on
Block configuring (NO contact) bLocl
42.BIN14) OFF
Block configuring and manual (NO contact) bLoc2
Drive valve to pos. up (NO/NC contact) uP/-uP
Drive valve to pos. down (NO/NC contact) doWn/-doWn
Block movement (NO/NC contact) StoP / - StoP
Function of BI 2:
None OFF
4) Only message (NO/NC contact) on / -on
43.BIN2 OFF
Drive valve to pos. up (NO/NC contact) uP/-uP
Drive valve to pos. down (NO/NC contact) doWn/-doWn
Block movement (NO/NC contact) StoP / -StoP
Without oFF
.. „ Al=min. A2=max. N,NA
44.AFCT5) Alarm function .. ,„ OFF
Al=min. A2=min. N,N
Al=max. A2=max. NA.NA
45.A1 Response threshold of alarm 1 0.0 to 100.0 % 10.0
Function of alarm output
On fault h -
47.4FCT 6) Fault + not automatic SnA h
Fault + not automatic + BI SnAb
("+" means logical OR operation)
Monitoring time for fault message Auto
48. STIM s Auto
"control deviation" 0 to 100
Response threshold for fault message Auto
49. h LIM % Auto
"control deviation" 0.0 to 100.0
OFF
50.SSTRK Limit for stroke integral OFF
1 to 1.00E9
OFF
51-SDCHG Limit for direction change OFF
1 to 1.00E9
OFF
52. h ZERO Limit for end stop monitoring, bottom % OFF
0.0 to 100.0
OFF
53. h OPEN Limit for end stop monitoring, top % OFF
0.0 to 100.0
OFF
54. S DEB A Limit for dead zone monitoring % OFF
0.0 to 100.0
Preset (factory setting)
"no" nothing activated no
"Strt" start of factory setting after pressing
55.PRST key for 5 sec. Strt
"oCAY" display following successful
factory setting oCAY
CAUTION: preset results in "NO INIT"
Table 1
!)
If turn is selected it is not possible to set 33°.
2)
Parameter does not appear if 1 .YFCT = turn has been selected.
3)
Turning points only appear with selection 12.SFCT = FrEE.
4)
Alternatively "no" if initialisation has not yet been carried out
5)
NC contact means; action with opened switch or low level. NO contact means;
action with closed switch or high level.
6)
Normal means: high level without fault. Inverted means: low level without fault.

INDUSTRIES
Diagnosis
In the diagnostic mode the current operating data (such as number of strokes,
number of changes in direction, number of fault messages, etc.) can be displayed.
From the automatic or manual modes the diagnostic mode can be reached by
simultaneously pressing all three keys for at least 2 seconds.
Table 2 shows an overview of the displayable values. The diagnostic display has a
similar structure as the parameter menu displays. The respective next diagnostic
value can be selected with the hand symbol key. Certain values can be set to zero by
pressing the "Î" key for at least 5 seconds. These are menu item line "1,2, 3, and.4".
Some diagnostic values may be greater than 99999. In this case the display switches
to exponential display.
Diagnostic list
No.: Abbreviation Meaning Displayable Unit
value
1 STRKS Number of strokes 0 to 4.29E9 -
2 CHDIR Changes of direction 0 to 4.29E9 -
3 hCNT Fault counter 0 to 4.29E9 -
4 A1CNT Alarm counter 1 0 to 4.29E9 -
5 A2CNT Alarm counter 2 0 to 4.29E9
6 HOURS Operating hours 0 to 4.29E9 Hours
7 WAY Determined actuating path 0 to 130 mm or 0
8 TUP Travel time up 0 to 1000 s
9 TDOWN Travel time down 0 to 1000 s
10 LEAK Leakage 0.0 to 100.0 %
11 P0 Potentiometer value below stop (0%) 0.0 to 100.0 %
12 P100 Potentiometer value bottom stop (100%) 0.0 to 100.0 %
13 IMPUP Impulse length up 2 to 100 ms
14 IMPDN Impulse length down 2 to 100 ms
15 DBOP Dead zone up 0.1 to 100.0 %
16 DBDN Dead zone down 0.1 to 100.0 %
17 SSUP Short step zone up 0.1 to 100.0 %
18 SSDN Short step zone down 0.1 to 100.0 %
19 TEMP Current temperature -45 to 85 °C
20 TMIN Minimum temperature -45 to 85 °C
21 TMAX Maximum temperature -45 to 85 °C
22 Tl Number of operating hours in Temperature range 1 0 to 4.29E9 Hours
23 T2 Number of operating hours in Temperature range 2 0 to 4.29E9 Hours
31 VENT1 Number of cycles pre-control valve 1 0 to 4.29E9 -
Store current values as "last maintenance"
33 STORE - -
Press the up key for at least 5 seconds (store)
Table 2

INDUSTRIES
Service and maintenance

The positioner is largely maintenance-free. The positioner is fitted with filters in the
pneumatic connection as protection against coarse particles of dirt. If the pneumatic
energy supply contains particles of dirt, the filters may be clog and impair the
function of the positioner. In this case thefilterscan be cleaned as follows:
Step A: Switch off the pneumatic power supply and remove the pipes.
Step B: Unscrew the cover.
Step C: Remove the three screws from the pneumatic connector strip.
Step D: Remove the filters and O-rings behind the connector strip.
Step E: Clean the filters (e.g. with compressed air).

Step F: After cleaning first insert the filters in the recesses in the housing and then
place the O-rings on the filters.
Step G: Align the pneumatic connector strip on the two lugs and screw tight with
the three self-tapping screws.
Note: Make sure that the same thread is used. To do this, turn the screws anti-
clockwise until they snap into the thread audibly. Only then should the
screws be tightened.

•••••
•iiiiiii. ^ ^ ^ ^ _ ^ ^ ^ ^
AALBORG ÛBIUIlBiBBMHI^BMiM
INDUSTRIES ^ÊÊÈÊÊÊÈ^ÊÊÊÈÊÊÈÈÊÈÈÈÈÈ^ÊÊE^^K^^ÊÊÊi
Table of contents
Feed water pumps
Technical data for feed water pumps
General data 1
Data for feed water pumps 2
Data for pump motor 3
Pumps, type CR, CRN
General 1
Calculation of minimum inlet pressure 2
Start-up 3
Maintenance 4
Frost protection 5
Fault finding chart 6
Spare parts
Spare parts 1

AALBORG TECHNICAL DATA FOR FEED WATER PUMPS SD9010#23.0
INDUSTRIES
Technical data for feed water pumps

1 General data
Project No.: 736950, 736952

Project name: 03130007,03130008
Classification society/local authority: LRS
Pressure gauge calibration: MPa
Thermometer calibration: °C
Language for signs: UK
Data for feed water pumps
Pump: Vertical multistage centrifugal pump

Pump type: CR 32-5-2
Delivery head: 120 m
Pump capacity: 24m3/h
NPSH: 1.8 m
Feed water temperature, operation: 60°C
Feed water temperature, maximum: 120°C
Data for pump motor
Motor make: Grundfos

Power supply: 3 x 440 , 60Hz
Rated output for motor: 15 kW
Rated current: 26 A
Starting method:
Starting current: 202 A
Revolutions: 3500r.p.m.
Ambient air temperature: 40°C
Insulation class: F
Degree of protection: IP55

AALBORG PUMPS, TYPE CR, CRN OM5540#20.3
INDUSTRIES
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. 40°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".
Maximum inlet pressure

50 Hz 60 Hz
CR, CRN 1
CR, CRN ls-2 -> CR, CRN ls-36 10 bar CR, CRN ls-2 -» CR, CRN ls-27 lObar
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 3-2 — CR, CRN 3-29 10 bar CR, CRN 3-2 -> CR, CRN 3-15 10 bar
CR, CRN 3-31 -> CR, CRN 3-36 15 bar CR, CRN 3-17 -* CR, CRN 3-25 15 bar
CR, CRN 5
CR, CRN 5-2 -> CR, CRN 5-16 10 bar CR, CRN 5-2 ->• CR, CRN 5-9 lObar
CR, CRN 5-18 -» CR, CRN 5-36 15 bar CR, CRN 5-10 ->• CR, CRN 5-24 15 bar
CR, CRN 10
CR, CRN 10-1 -> CR, CRN 10-6 8 bar CR, CRN 10-1 -* CR, CRN 10-5 8 bar
CR, CRN 10-7 -* CR, CRN 10-22 10 bar CR, CRN 10-6 - • CR, CRN 10-17 lObar
CR, CRN 15
CR, CRN 15-1 ->• CR, CRN 15-3 8 bar CR, CRN 15-1 -» CR, CRN 15-2 8 bar
CR, CRN 15-4 -* CR, CRN 15-17 10 bar CR, CRN 15-3 -* CR, CRN 15-12 10 bar
CR, CRN 20
CR, CRN 20-1 -»• CR, CRN 20-3 8 bar CR, CRN 20-1 8 bar
CR, CRN 20-4 ->• CR, CRN 20-17 10 bar CR, CRN 20-2 -* CR, CRN 20-10 10 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 32-5-2 -» CR, CRN 32-10 lObar CR, CRN 32-3-2 -» CR, CRN 32-6 lObar
CR, CRN 32-11-2 -* CR, CRN 32-14 15 bar CR.CRN 32-7-2 - • CR.CRN 32-10-2 15 bar

INDUSTRIES
Maximum inlet pressure, continued

SO Hz 60 Hz
CR, CRN 45
CR, CRN 45-1-1 - • CR, CRN 45-2 4 bar CR, CRN 45-1-1 • • CR, CRN 45-1 4 bar
CR, CRN 45-3-2 -» CR, CRN 45-5 10 bar CR, CRN 45-2-2 • • CR, CRN 45-3 10 bar
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
• Maximum permissible operating pressure: see Table 2.
L-
r •
Maximum permissible operating pressure
Frequency Pump type Temperature range Operating pressure
CR,CRNls, 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 lobar
CR, CRN 64-6-2 -+ CR, CRN 64-7-1 25 bar
CR, CRN 90-1-1 -+ CR, CRN 90-4 lobar
CR, CRN 90-5-2 -» CR, CRN 90-6 25 bar
CR, CRN ls, 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 lobar
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 lobar
CR, CRN 45-5-2 -+ CR, CRN 45-6 25 bar
CR, CRN 64-4-2 -» CR, CRN 64-4-1 25 bar
CR, CRN 90-4-2 25 bar
Table 2

•••#•••

INDUSTRIES
Minimum flow rates: See Table 3.
Minimum flow rates
Liquid temperature
Pump type
Up to + 80oC + 80°C to + 120-C
3
CR,CRNls 0.1 m /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 1.3m3/h
CR, CRN 10 1.2m3/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 mJ/h 7.6 m3/h
?CR,CRN45 5.4 m3/h 11.0m3/h
CR, CRN 64 7.7 m3/h 16.0 m3/h
CR, CRN 90 11.0m3/h 24.0 m3/h
Table 3
• Liquid temperature: -20°C to 120°C. See also Table 2 which indicates the
relationship 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 85-95°C.
• Further technical data can be found on the data sheet related to the pumps.
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 = p b 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 2 and Figure 3 at 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.

I N D U S T R I E S
Example:
Pump type = CR 20 - 60 Hz, flow rate = 24 m3/h, pb = 1.0 bar.
Hf = 3.0 metres head, liquid temperature = + 90°C.
Hv (from Figure 1) = 7.5 metres head.
NPSH (from Figure 2) = 2.5 metres head.
H = p b xl0.2-NPSH-H f -H v -H s
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

Ml Hv
PC)
m-
H O - -35
•30
130
•25
120'I- .20
110- •«
•12
100< -10
•8,0
SO-
-40
80--W
K0
70 •3fi
80' •2»
80'
1.0
40 •0,8
•0,8
30' •OA
•0,3
20'
•0,2
10'
•0,1
0'
Figure 1 cr02a.tif

I N D U S T R I E S
NPSH curves
H OR 15, CR115, CRN 15
[«••I M CR1s.CRI1s.CRN1» W ; 1
w. 60 Hz
- i !
50 Hz 60 Hz 50 Hz
,
/ y 32-
„-*• 3
£l 16-
^
l 0-
0.0
•
02 <U
'
0.6 OJ
'
1.0 1.2
' Q[n«iJ
1 1 n
0 2 4 e S tO 12 14 tO t«
' P I22 124 rn î
Q[n«li]
| I I I I | I I I I | I I I I [ I I I I | I I
'I1'"!""!1
o.o 0.1 02 ta 0[B>]
< r otrt]
H CR 20, CRI20, CRN 20

»
Itfal .". CR 1. CRU. CRN 1
B1™ [W* w. 50Hz 60Hz
'
I OHz
u
z /
J
r
60 < /
Si-
y f
te- SS! tr
^^ ^>
=s= =* -a*
0-
"iao HA o.« \a i.» u> M
1 1 ' 1 \ ' 28
\ •
0 4 6 12 16 20 24 Q[n*H]
l l | I l I | l l I | I I I |
1 ' ' ' I '
4 6 6 0[WJ
t*M a i l M CR 3, CRI 3, CRN 3 tu*) ("4 CR 32. CRN 32
50 Hz
7/
50Hz i à '
/ /
' /
y& A
10
o-
1-6
é
4-
4-
"1
ao H» 24 U U U QlmWi] \s is « 1
IJI o » • u n n o t a a i 44 atom]
I 1 1 1 1 V T 1 T I 1 1 1 1 1 1 T
OLO 02 0.« OA M 1.0 u 14 a (ni 0 2 4 8 0 10 18 Opta]
P H
«Ml M CR 45, CRN 45
Hz—
ao 1.0 2 0 3.0 4.0 5.0 6.0 7.0 6.0 8.0 1&0Q[«m]

H
-r i 1
aim
r
op»l
0.8
C R I o,<:RI 10, CRN 10 p

H gm H CR 64, CRN 64
iw«: W' I
reo Hz t
' • bU H] >
'« /
* •
50 Hz /-,
• /
J" •
10 J 1JO-J iË
0- 1 1 1
0 1 i 3 4 5 6 7 S 9 10 11 12 13 Q[mWl] n" 0 10 2 0 S 0 4 0 B O a 0 7 0 B O S O Q{nffll|
T I—I—I—I—I— T—r
00 0.5 1.0 M 20 2S 30 36 a 0*1
Figure 2 cr03b.tif

INDUSTRIES
NPSH curves, continued

p H
{kp*l W CR 90, CRN 90
l '
" 60 Hz
*
* 50 H z , y
*
in *
20 a-
0 20 «0 60 80 tt» 120 Qlnrthl

I 1 1 1 1 1
Figure 3 cr07a.tif
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 liquidflowthrough 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.

INDUSTRIES
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).
Illustration of the centrifugal pumps
Vent Screw/
Priming Plug
J^^T,
Vent Screw/
Drain Plug/ Priming Plug
Bypass Valve iW
_ \ a Drain Plug
Figure 4 cr06.tif
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.

AALBORG PUMPS, TYPE CR, CRN OM5540#20,3
INDUSTRIES
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 attention should be paid to the risk of injury
caused by scalding hot water.
When the piping system has beenfilledwith 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:
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.
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 removing 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.
4.2 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.

INDUSTRIES
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
removing the drain plugfromthe 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.
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.

INDUSTRIES
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 a) Suction pipe/pump blocked by impurities. Clean the pump or suction side.
water. 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-retum 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)
because of incorrect pump shaft position. Adjust the pump shaft.
Table 4

50/60 Hz
CR(N) 32
SHAFT SEAL KIT

9641658 9641658 9641658 9641658 9641658 9641658 9644002 9644003
Kit no.: 96417021 96417022
2 3 4 5 6 7 9 0
Pos. Description EUHE EUHV EUBE EUBV EUUE EUUV HUBE HUBV EQQE EQQV
105 Shaft seal 1 1 1 1 1 1 1 1 1 1
GASKET KIT BOTTOM BEARING KIT
Kit no.: 96416597 96416598 Kit no.: 96416580
Pos. Description EPDM FKM Pos. Description 1-14
37 O-ring 2 2 6g Bearing ring (stationary) 1
38 O-ring 4 4 31 Hex. soc. head screw 1
60 Spring (rubber) 4 4 32 Washer 1
100 O-ring 2 2 47b Bearing ring (rotating) 1
109 O-ring 1 1 66 Washer 1
110 O-ring 1 1 66b Lock washer 1
Distance tool (shaft seal) 1 1 67 Hex. soc. head screw 1
D+E Puller compl. 1
WEAR PARTS KIT
BEARING KIT
Kit no.: 96416728 96416729 96416730 96416731
9641657
Pos. Description 1-2 3-7 8-11 12-14 kit no.: 96416574
6
45 Neck ring 2 7 11 14
Pos. Description 3-7 8-14
47 Bearing (PTFE) 1 2 2
47a Bearing 1 2
47 Bearing bron. 1 2 2
Distance tool 1 1
47c Sleeve 2 6 9 11
47d Lock ring 2 7 11 14
49c Wear ring 2 7 11 14
65 Seal carrier 2 7 11 14
Distance tool 1 1 1 1
COUPLING COMPLETE
Kit no.: 96416589 96416590 96416591 96416592 96416593 96416594 96475477 | 96475478
For shafts with key
and keyway
D shaft Motor/Pump: 24/22 28/22 38/22 42/22 48/22 55/22 42/22 48/22
Pos. Description
10a Coupling half 2 2 2 2 2 2 2 2
9 Hex. soc. head screw 4 4 4 4 4 4 4 4
•-i
9a Hex. soc. head screw 1
9b washer 1 1
Distance tool 1 1 1 1 1 1 1 1
COUPLING COMPLETE NEMA

Kit no.: 96417000 96417001 96417004 96417020
D shaft Motor/Pump: 28.6/22 34.9/22 41.2/22 47.6/22
Pos. Description
10a Coupling half 2 2 2 2
9 Hex. soc. head screw 4 4 4 4
Distance tool 1 1 1 1
ROTATING UNIT COMPLETE (pump stack)

Kit no. CRN 32: 96416290 96416291 96416918 96416292 96416293 96416919 96416294 96416920 96416295
Kit no. CR 32: 96416273 96416274 96416905 96416275 96416276 96416906 96416277 96416907 96416278
Pump type 32-1-1 32-1 32-2-2 32-2-1 32-2 32-3-2 32-3 32-4-2 32-4
Rotating unît 1 1 1 1 1 1 1 1 1
Krt no. CRN"32": 96416921 96416296 96416922 96416297 96416923 96416298 96416924 96416299 96416925
Kit no. CR 32: 96416908 96416279 9 6 4 1 6 9 0 9 96416280 96416910 96416281 96416911 96416282 96416912
Pump type 32-5-2 32-5 32-6-2 32-6 32-7-2 32-7 32-8-2 32-8 32-9-2
Rotating unit 1 1 1 1 1 1 1 1 1
Kit no. CRN 32: 96416300 96416926 96416301 96416927 96416302 96416928 96416303 96416929 96416304
Kit no. CR 32: 96416283 96416913 96416284 96416914 96416285 96416915 96416286 96416916 96416287
Pump t y p e 32-9 32-10-2 32-10 32-11-2 32-11 32-12-2 32-12 32-13-2 32-13
Rotating unit 1 1 1 1 1 1 1 1 1
Kit no. CRN 32: 96416930 96416305
Kit no. CR 32: 96416917 96416288
Pump type 32-14-2 32-14
Rotating unit 1 1
SO/60 Hz
CR(N) 32
49d/49e
h6b
203 201
60 Hz
CR 32
RECOMMENDED SPARE PARTS FOR 2 AND 5 YEARS' OPERATING TIME
for 5 years' operating

for 2 years' operating -^- 3-phase motors H
Wear Intermediate Shaft seal Bottom Chamber Motor bearings

Type Casket kit Motor make
part kit bearing kit kit bearing kit stack ND-side DE-side
CR 32-1-1 96416728 Table 1 Table2 96416580 96416273 ID9990 ID9989 Grundfos
CR 32-1 96416728 - - 96416580 96416274 ID9990 ID9988 -
CR 32-2-2 96416728 - - 96416580 96416905 ID7920 ID7044 -
CR 32-2-1 96416728 - - 96416580 96416275 ID7920 ID7044 -
CR 32-2 96416728 - - 96416580 96416276 ID7920 ID7044 -
CR 32-3-2 96416729 96416574 - - 96416580 96416906 ID3139 ID0583 -
CR 32-3 96416729 96416574 - - 96416580 96416277 ID3139 ID0583 -
CR 32-4-2 96416729 96416574 - - 96416580 96416907 ID3139 ID0583 -
CR 32-4 96416729 96416574 - - 96416580 96416278 ID6705 ID0583 Siemens
CR 32-5-2 96416729 96416574 - - 96416580 96416908 ID670S ID0583 -
CR 32-5 96416729 96416574 - - 96416580 96416279 ID6705 ID0583 -
CR 32-6-2 96416729 96416574 - - 96416580 96416909 ID6705 ID0583 -
CR 32-6 96416729 96416574 - - 96416580 96416280 ID6705 ID0583 -
CR 32-7-2 96416729 96416574 - - 96416580 96416910 ID6705 ID0583 -
CR 32-7 96416729 96416574 - - 96416580 96416281 ID6705 ID0583 -
CR 32-8-2 96416730 96416576 - - 96416580 96416911 ID6719 ID0375 -
CR 32-8 96416730 96416576 - - 96416580 96416282 ID6719 ID0375 -
CR 32-9-2 96416730 96416576 - - 96416580 96416912 ID6719 ID0375 -
CR 32-9 96416730 96416576 - - 96416580 96416283 ID6719 ID0375 -
CR 32-10-2 96416730 96416576 - - 96416580 96416913 ID6719 ID0375 -
CR 32-10 96416730 96416576 - - 96416580 96416284 ID6719 ID0375 -
CR 32-11-2 96416730 96416576 " - 96416580 96416914 ID6719 ID0375 -
Table 1 Shaft seal type EUHE EUHV EUBE EUBV EUUE EUUV HUBE HUBV EQQE EQQV
Part number 96416582 96416583 96416584 96416585 96416586 96416587 96417021 96417022 9 6 4 4 0 0 2 9 9 6 4 4 0 0 3 0
Table 2 Casket kit type EPDM FKM

Part number 96416597 96416598
Recommended spare parts for tenders.

Number of Wear part Intermediate Shaft seal Bottom Motor bearing
Casket kit Chamber stack
pumps kit bearing kit kit bearing kit ND-side DE-side
1 1 1 1 1 1 1 1 1
2 1 1 1 1 1 1 2 2
3 2 2 2 2 2 2 3 3
4 2 2 2 2 2 2 4 4
5 2 2 2 2 2 2 5 5
6 3 3 3 3 3 3 6 6
7 3 3 3 3 3 3 7 7
8 3 3 3 3 3 3 8 8
9 3 3 3 3 3 3 9 9
10 3 3 3 3 3 3 10 10
Example: Spare parts for 4 units CR 32-6 with EUBE shaft seal and EPDM gaskets
2 years of operating: 5 years of operating:
2 off wear part kits: 96416729 2 off shaft seal kits: 96416584
2 off intermediate bearing kits: 96416574 2 off gasket kits: 96416597
2 off shaft seal kits: 96416584 2 off bottom bearing kit: 96416580
2 off gasket kits: 96416597 2 off chamber stacks: 96416280
4 off ND motor bearings: ID6705
4 off DE motor bearings: ID0583
•iiiiüi.
AALBORG düBIlillBiBflBHSMW^^M
Table of contents
Chemical dosing pump

General 1
Installation 2
Operation and maintenance 3
Fault location procedures 4

SUMMARY
I GENERAL Page
1.1 Introduction G1.1
1.2 Operating principle G1.1
1.3 Technical characteristics G1.2
II INSTALLATION
2.1 Unpacking and storage G2.1
2.2 Recommendations for installing the pump G2.1
2.3 Electrical installation G2.2
2.4 Hydraulic system G2.2
2.5 Installation sketches G2.3
2.6 Installation of accessories G2.5
2.7 Calculations for installation G2.6
III OPERATION AND MAINTENANCE

3.1 Checking before switching on G3.1
3.2 Start up G3.1
3.3 Routine checks G3.1
3.4 Preventive maintenance G3.1
3.5 Ordering spare parts G3.2
3.6 Product identification G3.2
3.7 Servicing and maintenance of the liquid end G3.3
3.8 Servicing and maintenance of mechanical assembly G3.8
3.9 Lubrication G3.14
IV FAULT LOCATION PROCEDURES G4.1

Ä DOSAPRO
w MILTON ROY
INSTRUCTION MANUAL
FOR INSTALLATION,
OPERATING,
AND MAINTENANCE.
Ci
Dosing pump
mROY A & B
This manual should be made available to the person responsible for installation,
operating and maintenance.
Date : 12/99 O / Ref : T.160.0401.001.Rev. E

«t
I GENERALITES
1.1 -INTRODUCTION
The mRoy pump is a dosing pump with incorporated hydraulic diaphragm, oil-lubricated with sealed housing,
with a variable swept-volume adjustment which can be set when stopped or running. It is designed for
continuous service in industrial operation.
1.2 - OPERATING PRINCIPLE
- Worm (052A) / tangent wheel (052) pair drives connecting rod (214) through means of the
eccentric of wheel (052).
- Connecting rod (214) gives piston (012) a reciprocating motion with constant stroke.
- Through means of oil contained in chamber (D), the piston drives diaphragm (298A) held fast
between 2 contour plates (298).
- Relief valve (212A) protects the pump.
Suction phase:
Piston (012) draws back and sucks in the oil (H) behind diaphragm (298A). The differential pressure which is
created is transmitted by flexible diaphragm (298A) enabling the pumped fluid to be drawn in with perfect
separation between the pump mechanical parts and the pumped fluid. When adjusting sleeve (E) linked
mechanically to piston (012) opens orifice (B) of oil bypass (C), the additional oil is supplied by housing (081).
Discharge phase:
Piston (012) moves forward and forces the oil back to housing (081) through by-pass (C) and orifice (B) until
this orifice is blocked by adjustment sleeve (E). The oil then pushes diaphragm (298A) which moues forward
proportionally to the fraction of remaining swept-volume, after blocking orifice (B). The dosed liquid is pushed
back by the diaphragm through the discharge check-valves.
Flowrate adjustment:
The discharge flowrate is adjustable when running, from 0 to 100%, by turning adjustment knob (255) which
displaces, in the oil bath, and thus without any effort, adjustable liner (012A) and thus the position of orifice
(B).
Fig.1
A = stroke. I = backward
G1.1
GB
1.3 - TECHNICAL CHARACTERISTICS
The nominal pump flow depends on the piston diameter and the actual pumping stroke speed. The influence
of pressure is low, on the order of -2% per section of 10 bars.
1.3.1 Technical characteristics for mRoy A
Type of pump mRoy A
piston diameter _ 0 11.1 15.9 27
(1) (2) Maximum discharge pressure in bars relative 123 123 46 59 21
(4) Maximum suction pressure in bars (Pa) 35 17.5 6
(3) Maximum flow in U H (Q): at pressure of 10 b 2.6 10 5.5 22 66
at maximum pressure 1.95 7.8 4.1 19.8 64.5
Speed in strokes / min 29 112 29 112 112
Motor power in kW 0.25
Motor speed in rpm 1440
Motor mounting: Flange F130
Shaft 14x30
(5) Maximum height of suction in mce (Ha) 2
Volume of pulsation dampener in suction 0.13 L
Volume of pulsation dampener in discharge 0.13 L
Pre-expansion of pulsation dampener in discharge 60% of service pressure
Noise level: Acoustic pressure < 70 dB (A)
Simplex pump weight 25
Duplex pump weight 40
1.3.2 Technical characteristics for mRoy B with 0 1 5 piston
Type of pump mRoy B
piston diameter 0 15
(1) (2) Maximum discharge pressure in bars relative 105
(4) Maximum suction pressure in bars (Pa) 35
(3) Maximum flow In L/H (Q): at pressure of 10 b 14 21 34 53
at maximum pressure 11 17 27 42
Speed in strokes / min 36 56 90 140
Motor power in kW 0.55 0.75 0.55 0.75
Motor speed in rpm 900 1440 900 1440
Shaft 19x40
(5) Maximum height of suction in mce (Ha) 1.5
Volume of pulsation dampener in suction 0.13
G1.2
1.3.3 Technical characteristics for mRoy B with a 0 22.2 piston
Type of pump mRoy B
piston diameter 0 22.2
(1) (2) Maximum discharge pressure in bars relative 49 70 49 70 49 70 49 70
(4) Maximum suction pressure in bars (Pa) 17.5
(3)Maximum fiowrate in U H (Q):at pressure of 10b 30 30 46 46 74 74 114 114
at maximum pressure 27 26 42 40 68 65 105 100
Motor power in kW 0.55 0.75 0.55 0.75 0.55 0.75 0.75 1.1
Motor speed in rpm 900 1440 900 1440
Shaft 19x40 24x50 19x40 19x40 19x40 24x50 19x40 24x50
1.3.4 Technical characteristics for mRoy B with a 0 36.5 piston
Type of pump mRoy B
piston diameter 0 36.5
(1) (2) Maximum discharge pressure in bars relative 14 28 14 28 14 28 14 28
(4) Maximum suction pressure in bars (Pa) 6
(3)Maximum fiowrate in L/H (Q):at pressure of 10b 80 80 124 124 200 200 310 310
at maximum pressure 79 77 123 119 198 192 307 298
Motor power in kW 0.55 0.75 0.55 0.75 0.55 0.75 0.75 1.5
Motor speed in rpm 91)0 1400 900 1400
Shaft 19x40 19x40 19x40 19x40 19x40 24x50 19x40 19x50
(1) Contact us for higher oressures

(2) 10 bars for the "P" versions
(3) Flow obtained on standard configuration, with water
(4) 6 Bars for "P" versions
(5) mce = Water column meter
II. INSTALLATION
2.1 - UNPACKING AND STORAGE
The packing must be carefully examined at reception in order to ensure that the contents have not suffered
any obvious damage. Open the packing carefully; one should be careful not to damage certain accessories
which may be fastened to the inside of the packing. Examine the contents and check them against the
delivery slip.
The packing contains:
- One pump.
- Oil, depending on versions (see chapter 3.9)
- A list of wear-and-tear parts, accompanied by section drawings and space-requirement drawings.
- An instruction manual for pump installation, upkeep and maintenance
Storage precautions
For storage less than 6 months:
Storage is to be carried out preferably in the original packing and protected from inclement weather
conditions.
For storage longer than 6 months:
Preserve the original packing. Also provide packing under plastic heat-sealing wrapping and dehydrating
bags. Store the pump in protected, covered premises with full oil charge.
2.2 - RECOMMENDATION FOR INSTALLING THE PUMP
2.2.1 Manutention
Put the sling under the motor terminal box and under
the motor flange.
Cross the two ends of the sling and close the loop
(see diagrams).
Before attempting to move it, check that the entire
unit is well balanced.
Nota: As soon as the pump is in position, fasten it

down.
2.2.2 - Installing the pump

- Fasten the pump to a horizontal support using its fastening holes. Arrange enough free space around the
pump so as to be able to have easy access, and to ensure the upkeep and adjustments (accessibility to the
liquid end, filling, and housing oil draining).
- Connect the priming drain of the liquid end to a drip-collecting tank
- If the service pressure is greater than 3.5 bars, remove the spring located in the discharge check-valve box.
CAUTION: Pumps installed outdoors must be protected from the elements.
2.2.3 Oil filling (Fig. 1A).
- Unscrew the oil filler plug located on top of
the pump. Oil filler plug.
- Unscrew the level indicator located on the Oil level indicator
side of the pump.
- Pour the oil in until it reaches the threading
Drain plug
of the level indicator.
- Screw the level indicator back in. Fig.lA
- Fill up with oil to the middle of the level
indicator.
- Screw the oil filler plug back on.
2.3 - ELECTRICAL INSTALLATION
Verify the motor data against your available mains supply for the plant before carrying out connections.
Connect the motor according to the indications given in the terminal box.
For 230 V delta connection
O O P
For 400 V star connection 0 0 0
Before operating the pump, check the direction of rotation of the motor which must be
according to the arrow stamped on the motor (Counter-clockwise direction when seen
from top). To reverse the direction of rotation, just reverse A and B or A and C.
c=>
CAUTION : DO NOT FORGET TO CONNECT THE PUMP TO EARTH
Electric protection of the motor (thermic protection or by means of fuses) is to correspond to the rated
current indicated on the motor data plate.
2.4 - HYDRAULIC SYSTEM

Pipework - Generalities
As far as possible, avoid exerting stresses due to incorrect alignments between rigid pipes and the centreline
of valve boxes. Provide facilities for disassembly (union-pieces, and so forth...). Clean piping before
assembly.
2.4.1 Suction pipings

The pump is to be located as close as possible to the suction point and the piping is to be as short and as
direct as possible. If possible, have the suction point located slightly above the pump; in the event of long
period of rest, the pump will not unprime.
The diameter of the piping must be bigger or equal to the connection diameter of the liquid end. The suction
piping is to be ABSOLUTELY AIR TIGHT (check after assembly). When it is not possible to avoid long
suction pipework, use a RESERVOIR tank or a balancing column located as close as possible to the suction
aperture of the pump.
2.4.2 Delivery pipework

The diameter of the piping is to be bigger or equal to the connection diameter to the liquid end. Be sure that
the piping and accessories fitted on the delivery line are sufficiently strong to withstand the delivery pressure.
2.5 - INSTALLATION SKETCHES
2.5.1 Installation on suction side
2.5.1.1 Recommended installations
a
a
Ha
Fig.4
Fig.2 Fig.3
Fig.2: The pump in suction placed above the tank(Ha = maximum 2.5 m water column) is equipped with a
foot valve fitted at the suction end (F). Vertical suction.
Fig.3: Long sized pipework (L) requires the installation of a damper which is to be placed as close as
possible to the pump. L1 = Maximum 10 metres water column.
Fig. 4: The pump "in suction" offset in relation to the tank (Height [Ha] see chapter 1.3), is equipped with a
foot valve (F).
2.5.1.2 Installations to be avoided
Fig.5 Fig.6 Fig.7

Inclined suction pipe, risk of Suction piping long. Suction
height too great. Accumulation of gas (goose
un-priming (See Fig. 4, Chap.
neck) and risk of unpriming.
2.5.1.1)
2.5.1.3 Special installation

Degassing liquids.
1 : Max level
2: Min level
V: Valves
G: Vent
R:degassing vessel
Fig.8
Fig. 8: Setting up a degassing vessel (Chap. 2.6.3.) at the pump suction (one thus avoids frequent un-
priming). Connection between the pump and the inclined degassing vessel in order to facilitate degassing.
reëi
2.5.2 Installations on delivery line
2.5.2.1 Recommended installation
//
c-/ fft (
1
V
•*
-:--:":;Y-.:ti; Fig.10
Fig.9
Fig. 9: Long pipe lengths and delivery in a pressurized conduit (P): Install an injection pipe (E), a buffer tank
(D) and a safety valve (C).
Fig. 10: Long pipe lengths and delivery in a non-pressurized conduit: Install a nonreturn valve (B) or check
valve (A) and a buffer tank (D).
For short lengths of discharge pipe (L), the buffer tank (D) can be dispensed with although it increases the
service life of the metering pump and of the installation.
If the delivery pressure is less than 2 bars, an injection pipe or nonreturn valve should be used.
2.5.2.2 Installations to be avoided

D
/ s.
[V
\; f-'-.
Fig.11 Fig.12 Fig. 13
Pulsation dampener (D) not very Pulsation dampener (D) inefficient. Siphoning.
efficient, (pulsation dampener (D) (nonreturn valve installed before
too far from the liquid end) pulsation dampener (D)).
G2.4
2.6 - INSTALLATION OF ACCESSORIES
Proper functioning of the pump depends on whether certain accessories available from DOSAPRO MILTON
ROY are fitted or not. The salesman is at your disposal to determine the accessories which are best adapted
to your plant.
2.6.1 Non return valve (F)

Necessary when the pump is fitted above the suction point. Thus minimizing the risk of unpriming; it is fitted
with a filter.
2.6.2 Filter
It is very CAUTION when there is gravity feed; it avoids accumulation of solid particles in the valve
assemblies and guarantees precision and pump life.
2.6.3 Safety valve (C)

The safety valve is to be vertically installed just above the liquid end, after the damper and before any other
accessory. The return line of the valve should be connected to the drainage tank or to the sump. The safety
valve protects the metering pump, the piping and accessories in the event of accidental overpressure (e.g.
shutting off of valve). This accessory contributes to safety for users by eliminating risks of the bursting or
rupture of components under pressure. It is recommended that a safety valve should be fitted on all
installations.
2.6.4 Damper (D)

Compressible gas-reserve device; this dampens the flow and pressure pulsations caused naturally by the
dosing pump. It is absolutely essential that the pulsation dampener be installed vertically on the discharge
and/or suction piping of the dosing pump, as near as possible to the latter, before any other accessory and
for it to be placed in the flow. For the volume and the pre-expansion of the dampener, see chapter 1.3.
CAUTION: Dampener construction materials must be compatible with the liquid to be pumped and with the
pumping pressure.
2.6.5 Non return valve (A)

The non-retum valve is to be installed in line on the delivery piping. Its operation may be improved by
installing a dampener located upwards on the line.
2.6.6 Injection nozzle (E)

Fitted at the injection point, it acts as a non-return valve. It isolates the processed fluid from the main fluid
(often water).
1 1 2.6.7 Insulation Valve (F)

When the pump is not running, it is essential to insulate it from the pressure circuit with a manual or automatic
valve, to prevent any return pressure in the liquid end, which could damage the pressure plate of the oil-
actuated diaphragm.
2.7 - INSTALLATION CALCULATIONS
2.7.1 General
Sizing of the plant suction line corresponds to the NPSH calculation (Net Positive Suction Head) and it aims
to avoid any risk of cavitation. Very often when processing non viscous liquids (typically less than 50 cp), the
NPSH calculation is needed to verify the following condition:
W d1
with
W- Liquid density.
Pa = Suction pressure (bars absolute).
Tv = Vapour pressure (in bars).
Ha = Suction height (in m). (Ha is negative with the pump placed above the suction point; it is positive when
gravity fed).
L = Length of the piping (in m).
Q = Max flowrate of the pump (in l/h).
N = No of pump strokes (in strVmin).
d = Inside diameter of the piping (in mm).
2.7.2 Example
Calculation carried out to deliver a flow of 200 L/H.
W 1 L 1
Pa 1 Q 560
Tv 0.025 N 144
Ha :1 d :12.5
10.2 1x144x560
This condition shows: (1-0.025)+
v 1> 2 + 0.016
1 ' 12.52
thus: 10.945 > 4.064
The condition is met and the pump will not give rise to cavitation.
When the NPSH condition is not obtained, the installation conditions must be improved by making or
envisaging the following modifications:
- Place the pump under load: Ha increases
- Place the pump near the tank : L decreases
- Increase the diameter of the piping: d increases (the most effective solution)
- Place an pulsation dampener at the suction (see chapter 1.3)
Do not hesitate to consult your usual DMR representative for complete calculations.
I I I OPERATION AND MAINTENANCE
3 . 1 - C H E C K I N G BEFOR S W I T C H I N G O N
- Check that the pump is properly mounted on its base
- Check the oil level.
- Check that the pump is set at 0%
- Check that all the isolating valves on the suction and discharge circuits are open.
- Check that the pump is properly supplied with liquid.
- If hot cold machine parts lead to a potential danger,
check that the these parts are protected against accidental constact at site.
3.2 - STARTUP
- Tun the pump ON
- Place the vernier on the 50% position, for 10 minutes.
- Untighten by around 1/4 turn, drain plug (B) located on the liquid end (Fig. 19) and (Fig.
20). Thus, the air trapped in the suction piping and the pump head can escape via the drain. Wait
until the liquid comes up to the evacuation level of this drain.
Let it flow for a few seconds in order to degas it completely, then retighten the drain plug.
3.3 - R O U T I N E CHECKS
Periodically, it is necessary to check:
- The level and cleanliness of the oil.
- Leaks or unusual noises.
3.4 - PREVENTIVE MAINTENANCE

Before any servicing operation on the pump, it is necessary to turn the motor power supply OFF.
3.4.1 Servicing-intervention principles for preventive maintenance*:
Intervention Fréquence * *
- Renewal of check-valve boxes (Chap. 3.7.1. to Chap. 3.7.3). 8000 h
- Renewal of diaphragm(s) (Chap. 3.7.4 and Chap. 3.7.5). 8000 h
- Renewal of safety valve assembly (Chap. 3.8.1 and Chap. 3.8.2). 8000 h
- Renewal of worm bearings (Chap. 3.8.10). 20000 h
- Renewal of worm and wheel (Chap. 3.8.11). 20000 h
- Renewal of sleeve liner O-rings (Chap. 3.8.3). 16000 h
* See list of wear parts for the ordering of the various parts.
* * Approximate no of hours when operating under max performance and normal conditions of
use.
3.5 - ORDERING OF SPARE PARTS
To simplify your order and ensure the best delivery times of spare parts, we recommend giving
our services the correct code of your pump and its DOSAPRO MILTON ROY serial no. This
information is shown on the Nameplate fixed on the side of the pump.
Pump code —-—~__^^

( MiDOSAPRO
' M I L T O N ROY
PONT ST PIERRE
Z7360 FRANCE
^
TYPE A 1 1 2 F 3 H21 1
1
Dmax lll/hll MGPHIII/h I
Pmax Nborll IIPSI llutafl
DOSAPRO MILTON ROY — ^ ^ ^ Date 1

N* 92.01.100A.01.01 1
serial no
Item 1
^N'serie ' ,
3 . 6 - PRODUCT I D E N T I F I C A T I O N
Our product identification tells us precisely the kind of equipment involved and gives us details on
each item comprising it.
Code : | A | 112 | F | 3 | H I 21
Zone : 1 2 3 4 5 6
The makeup of a standard mRoy pump is divided up into 6 zones:

Zone 1 : Type of pump (A: mRoy A; B: mRoy B)
Zone 2 : Stroke rate of the pump in spm
Zone 3 : Motor power
Zone 4 : Piston diameter
Zone 5 : Type of liquid end
Zone 6 : Service pressure
and, where applicable, a seventh zone which will be "DX" for a duplex pump.
3.7 - SERVICING AND MAINTENANCE OF LIQUID END
Before carrying out any servicing operation on the metering unit or pipes, take the necessary
A steps to ensure that the harmful liquid they contain cannot escape or come irto contact with
personnel. Suitable protective equipment must be provided. Check that there is no pressure
before proceeding with dismantling.
3.7.1 Renewal of check-valve boxes - General

Before any other servicing operation on the check-valve boxes place the vernier on the 0% position, check
that the isolating valves are closed, then disconnect the piping. When putting the check-valve boxes back
in place, systematically replace all the seals.
3.7.2 Renewal of seals / balls / valves _ metallic version
Fig.14
Discharge check väve assembly Fig. 15
Suction check valve assembly
Suction check valve assembly Discharge check valve assembly

Disassembly Disassembly
- Unscrew counternut (209) by one-quarter - Unscrew cap (013) of the check-valve
of a turn, box by one-quarter of a turn
- Completely unscrew the cartridge of - Completely unscrew the cartridge of
check-valve box (021A), check-valve box (021B).
- Remove circlips (080) and balls (437A) - Completely unscrew cap (013) from the
(437) check-valve box.
- Clean the box completely. - Remove spring (080A), ball guide (003),
balls (437), seat (024).
- Clean the check-valve box completely.
Reassembly Reassembly
- Fit ball (437), then ball (437A) and - Fit O-ring (438) on seat (024)
circlips (080) - Fit balls (437), seat (024), ball guide
- Position spiral seal (408) in the sink of (003), spring (080A).
counternut (209) - Fit O-ring (438A) on cap (013)
- Fit O-ring (438B) against spiral seal (408). - Hand-tighten cap (013) on the check-
- Screw the box cartridge in the liquid end valve box.
so as to align it with the piping. - Fit O-ring (438B), screw the check-valve
- Screw on counternut (209).* box on the liquid end.
- Tighten the cap on the check-valve box*
- Connect the piping making sure of perfect
watertightness.
Note: O-rings (438B) and spiral seals (408) of the check-valve bo>es must be replaced with new seals
each time they are removed.
* For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7.*
3.7.3 Renewal of check-valve boxes _ plastic version
Fig. 18
_. . „ Suction check valve assembly
Fig.16
Plastic liquid end
Disassembly
- Unscrew both nuts (435) located on pressure plate (004).
- Remove pressure plate (004) with both washers (434)
- Remove the Discharge check valve assembly.
- Pull on strap bolt (032) to release the suction check valve assembly
- Remove box cap (013), spring (080), ball guide (003), seal (438), ball (407).
Reassembly
- Fit spring (080), ball guide (003) and seal (438) on box cap (013), and mount ball (407) on its
seat (A).
- Fit seals (438B) and (438A) on the check-valve boxes.
- Fit the check-valve boxes onthe liquid end.
- Fit the pressure plate on strap bolt (032) with two washers (434).
- Hand-tighten screws (435) by pressing on the pressure plate.
- Orient the suction check valve assembly, then tighten two nuts (435).*
Connect the piping making sure of perfect watertightness.
Note: The items comprising the suction check valve assembly cannot be taken apart; this is also the case
for ball (B) and seat (A) of the Discharge check väve assembly.
* For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7.
3.7.4 Diaphragm Renewal
Before carrying out any operations, place the vernier on the 0% position, check that all the isolating valves
are closed, then disconnect the piping.
Disassembly Reassembly
- Drain the pump (Chapter 3.9.2). - Mount contour plate (298B). It is CAUTION for
- Lay the pump on the side opposite one of holes in the contour plate to be placed at
the liquid end the highest point (see detail C).
- Remove suction check valve
assembly (A) (Chapter 3.7.2 or CAUTION: For metallic versions, contour plate (298B) on
Chap. 3.7.3) the mechanical side is made of steel and contour plate
- Remove screws (405A) (Fig. 19) or (298) on liquid end side is made of stainless steel.
(405) (Fig. 20) from the liquid end. - Fit diaphragm (298A).
- Remove diaphragm (298A) and - Fit contour plate (298). It is CAUTION for one
pressure plates (298), (298B) using a of the holes in the contour plate to be placed at
pointed object. the highest point (see C detail)
- Clean all the parts. - Fit the liquid end and tighten screws (405A) or
(405) in star-pattern (Fig. 22).*
- Refit the suction check valve assembly
(Chap. 3.7.2 or Chap. 3.7.3).
- Fill up with oil (Chap. 3.9.2).
- Put into serviœ (Chap. 3.1, Chap. 3.2)
405
Fig. 19 Fig.20
Metallic version Plastic version
A In order to prime the pump, it is necessary to purge the liquid end (to release air) by opening
purge nozzle (B). For toxic liquids, it is recommended to collect this fluid to safe drain point during
this operation.
* For information concerning tightening torque as well as which spanners to use, see Chap. 3.7.7.
3.7.5 Renewal of double diaphragm, "C" type
Before carrying out any operation, place the vernier on the 0% position, check that all the isolating valves
are closed, then disconnect the piping.
Disassembly
- Drain the pump (Chap. 3.9.2).
- Untighten ring pipe fitting (432A) by 1/2 turn.
- Lay the pump on the side opposite the liquid end
- Remove suction check valve assembly (A) Chap. 3.7.2 or Chap. 3.7.3)
- Unscrew the tightening screws from liquid end (405A), beginning with those in support lug (050A).
- Remove the two diaphragms (298) and the 2 contour plates (098).
- Clean all of the parts.
Reassembly
- Fit contour plate (098) on the mechanical side.
- Centre diaphragm (298) on contour plate (098).
- Fit double-diaphragm body (050) on diaphragm (298).
- Centre second diaphragm (298) on double diaphragm body (050).
- Centre second pressure plate (098) on double diaphragm body assembly (050)
- Fit the liquid end and hand-tighten 2 tightening screws (405A) diametrically opposite.
- Fit support lug (050A) and its detection.
- Connect the detection pipe of double-diaphragm body (050) to ring connection (432A).
- Hand-tighten the connection and tighten by 1/4 to 1/2 turn.
- Pre-screw in star-pattern (Fig. 22) tightening screws (405A) of the liquid end
(torque: 2 Nm)
- Tighten tightening screws (405A)of the liquid end in star-pattern. *
- Refit the suction check valve assembly (Chap. 3.7.2 or Chap. 3.7.3).
- Fill up with oil (See Chapter 3.9.2).
- Put into service (Chap. 3.1, Chap. 3,2)
- Degas the double diaphragm (Chap. 3.7.6)
oso
298
Fig.21
Type "C" double diaphragm, metallic version
For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7.
3.7.6 Degassing of double-diaphragm
body, "C"type
- Remove the detection (A)

- Remove the retaining ring (092)
- Remove the ball (437)
- Put a little oil in the body of nonreturn valve
(432).
èr-^^®
- Set the adjustment knob on 10%, then start
the pump up
- Allow to run for 10 minutes
- Fit the ball (437)
- Fit the retaining ring (092)
- Fit the detection (A) on the nonreturn valve
(432)
Fig.21A
B detail of Fig. 21
If the degassing can not be done by the above procedure there some possibility to perform this operation
with a syringe. This syringe is available on request at the Spare rart Departement
Degassing with syringe
- Fit the syringe (1+2) on the nonreturn valve

(432)
- Inject and pump 4 or 5 time slowly the
degassing liquid
- Remove the syringe and fit the ball (437) and
the retaining ring (092)
- Fit the syringe (1) witout his plunger
- Put the pump into service and adjust the
capacity until 100%
- Remove the syringe (1) with the degassing
liquid
- Fit the detection (A) on the nonreturn valve
(432)
3.7.7 Tightening torque table
Tiqhteninq torque (Nm) Spanner used
m Roy A m Roy B m Rov A m Rov B
Screw / N u t HP BP HP BP HP&BP HP BP
H head screw of liquid end for metallic versions 20 20 40 60 13 16 18
H head screw ( l / 3 / 5 / 7 / 6 / 8 ) o f liquid end for plastic versions 15 15 15 15 13 16 18
H head screw (2/4) of liquid end for plastic versions 15 15 15 15 13 16 18
Check-valve box nut, metallic version 50 50 32 41
Check-valve box, metallic version 50 50 32 38
Strap bolt nut for liquid ends, plastic version 10 13
H head screw of lantern 7 8
He head-screw of relief valve 3/16" 3/16"
He head-screw of connectinq rod shaft 3 3
He head-screw pointed end of connectinq rod shaft / 2
Nut for He screw of connectinq rod shaft / 7
He screw (402) of duplex housing (Flq. 27) / 10
Fig.22
Tightening in star-pattern-shape
3.8 - SERVICING AND MAINTENANCE OF THE MECHANICAL ASSEMBLY
3.8.1 Relief valve

CAUTION: Set in the plant, it must in no case be put out of adjustment, since it protects your pump.
3.8.2 Renewal of relief valve (Fig. 23)
Disassembly
- Place the vernier on the 0% position
- Clean the threaded hole of screw (023) to make it appear
- Note dimension H
- Completely unscrew and remove screw (023) with the hexagonal spanner
(Chap. 3.7.7).
- Remove spring (080) and its valve (212A).
Reassembly
- Cause new valve (212A) to adhere to spring (080) using a little grease.
- Lower the assembly into its housing.
- Screw in tightening screw (023) to the H measurement with the hexagonal spanner
(Chap. 3.7.7).
-023
Fig.23
Disassembly of the relief valve
3.8.3 Renewal of adjustment liner 0-rings(Fig. 24, Fig. 25, Fig. 26)
Disassembly
- Remove the lantern (Chap. 3.8.8)
- Remove circlips (434) (Fig. 25).
- Completely unscrew adjustment knob (255).
- Unscrew screw (256).
- Pull liner (012A) of housing toward you. (Fig. 26)
- Remove 3 O-rings (438B) located on liner (012A) (Fig. 24).
- Remove sleeve (E) from drive pin (214A) (Fig. 26)
- Clean the housing as well as the liner / sleeve assembly
Reassembly
- Refit the 3 O-rings (438B) using the tool (011) (Fig. 24):
- Reference 0110031071 for the mRoy A.
-Reference 0110032071 for the mRoy B.
- Coat the 3 O-rings (438B) with tallow.
- Fit sleeve (E) on drive pin (214A) (Fig. 26).
- Insert liner (012A) very slowly in the housing, turning it whilst holding sleeve (E) in the axis of liner
(012A).
- Screw in screw (256).
- Screw in adjustment knob (255) (Fig. 25)
- Fit circlips (434).
- Fit lantern (Chap. 3.8.8)
- Fill up with oil (see Chap. 3.9.2).
-438B
Fig.24
Liner / sleeve
Adjustment knob
3.8.4 Renewal of eccentric shaft seals (Fig. 26).
For disassembly and reassembly of the eccentric shaft, the pump adjustment knob must be opposite you.
Disassembly
- Remove the 2 circlips (434A) from eccentric shaft (068)
- Drive out eccentric shaft (068) to the right to release seal (438A).
- Remove seal (438A)
- Drive out eccentric shaft (068) to the left to release seal (438A)
- Remove the other seal (438A)
Reassembly
Before reassembly, degrease all parts
- Fit an O-ring (438A) on eccentric shaft (068)
- Put glue (loctite 638) on the end of eccentric shaft (068) until it exceeds the other side of the housing by
one centimetre.
- Fit the other O-ring (438A) on eccentric shaft (068); put glue (loctite 638) on the end of eccentric
shaft (068)
- Position eccentric shaft (068) in the centre of the housing (see Fig. 26)
- Fit circlips (434A) on each end of eccentric shaft (068)
- Allow the glue to harden for 30 minutes
- Fill up with oil (see chap. 3.9.2).
Fig.27
Duplex pump
3.8.5 Renewal of connecting rod and shaft for mRoy A, simplex and duplex (Fig. 26, Fig. 28).
Disassembly
- Remove eccentric shaft (068) (Chap. 3.8.4)
- Unscrew screws (435) and remove drive pin (214A) (Fig. 26)*
- Remove plunger assembly (012) / connecting rod (214) / wheel (052) from the housing, by lifting
wheel (052)
- Drive out connecting rod shaft (011)
- Clean the housing and the parts removed
Reassembly
- Refit piston (012) / connecting rod shaft (011) / connecting rod (214) assembly by gluing the end of
connecting rod shaft (011) with loctite glue 556 and being careful to position the lubricating groove (detail: A)
of connecting rod (214) opposite the threaded holes of the piston (Fig. 28)
- Insert piston / connecting rod assembly in housing
- Fit wheel (052) with connecting rod (214) (Fig.26)
- Fit concentric shaft (068) (Chap. 3.8.4)
- Fit drive pin (214A), then screw in and glue (loctite 221) the two screws (435)
- Refit the lantern (Chap. 3.8.8).
- Put into service (Chap. 3.1, Chap. 3.2)
012
011
Fig.28
Piston / connecting rod assembly
* Fur information concerning which spanners are to be used, see Chapter 3.7.7.
3.8.6 Renewal of connecting rod and shaft for mRoy B, simplex (Fig. 26, Fig. 28).
- Drain the pump (Chap. 3.9.2). - Refit piston (012) / connecting rod shaft (011) /
- Remove the lantern (Chap. 3.8.8) connecting rod (214) assembly, being careful to
- Unscrew nut (435F) and screws position the lubricating groove (detail: A) of
(435), (435E) Fig. 26)*. connecting rod (214) opposite the threaded holes of
- Remove eccentric shaft (068) the piston. (Fig. 28)
(Chap. 3.8.4) - Screw in and glue (loctite 566), locking screw (435E)
- Remove drive pin (214A) on the side where the groove of connecting rod shaft
- Remove plunger assembly (012) / (011) is located
connecting rod (214)/wheel (052) - Insert piston / connecting rod assembly in housing
from the housing, by lifting wheel - Fit wheel (052) with connecting rod (214) (Fig.26)
(052) - Fit eccentric shaft (068) (Chap. 3.8.4)
- Drive out connecting rod shaft (011) - Fit drive pin (214A), then screw in and glue
(Fig. 28) (loctite 221) screw (435) and nut (435F)
- Clean the housing and the parts - Refit lantern (chap. 3.8.8)
removed. - Allow glue to harden 30 minutes
- Carry out startup and operating procedures
(Chap. 3.1, Chap. 3.2).
3.8.7 Renewal of connecting rod and shaft for mRoy B, duplex

(Fig. 26, Fig. 27, Fig. 28).
- Drain the pump (Chap. 3.9.2). - Place plunger (012) in the housing tapped holes up
- Remove the lantern (Chap. 3.8.8) ward
- Unscrew 2 screws (402) (Fig. 27) - Assemble connecting rods (214) with wheel (052)
- Unscrew nut (435F) and screws being careful to position the lubricating groove
(435), (435E) (Fig. 26). (detail: A) of connecting rod (214) downwards
- Remove drive pin (214A) (Fig. 26) (Fig. 28)
- Drive out the 2 shafts of connecting - Place excentric wheel (052) / connecting rod (214)
rod shaft (011) by the threaded holes assembly in the housing
of screws (402) - Fit eccentric shaft (068) (Chap. 3.8.4)
- Remove eccentric shaft (068) - Fit the 2 shafts of connecting rod shaft (011) by the
(chap. 3.8.4) threaded holes of screws (402) (Fig. 27)
- Remove excentric wheel (052) / - Screw in and glue (loctite 566) locking screws
connecting rod (214) assembly in the (435E) of the side where the groove of connecting
housing rod shaft (011) is located
- Remove plunger assembly (012) / - Fit drive pin (214A) then screw in and glue
connecting rod (214)/wheel (052) (loctite 221) screw (435) and nut (435F) (Fig. 26)*
- Remove plunger (012) off the housing - Refit the lantern (Chap. 3.8.8).
- Clean the housing and the parts - Screw in and glue screws (402) with loctite glue 221
removed. (Fig. 27).
- Allow the glue to harden 30 minutes.
- Carry out startup and operating procedures
(Chap. 3.1, Chap. 3.2).
* For information concerning which spanners are to be used, see Chapter 3.7.7.
3.8.8 Disassembly of the lantern (Fig. 26, Fig. 29)
Disassembly *
- Disconnect the power supply cables from the motor
- Unscrew 4 screws (435A), (434C) from lantern (072) and turn while pulling up the
lantern vertically with the motor
Reassembly
- Put sealing compound on side B (Fig. 26)
- Fit lantern (072) being careful not to bump drive pin (214A) with the worm shaft
- Screw in screws (435A) (434C)
- Connect the motor power supply cables
3.8.9 Renewal of the worm shaft (Fig. 29).
Disassembly
- Unscrew screw (435B) from coupling (052D).
- Remove the 2 washers (280) and washer (219) being careful not to separate them.
- Remove the worm.
Reassembly
- Fit washers (280) / washer (219)
- Fit coupling (052D) on the screw whilst adhering to measurement H (H = 5 mm for the mRoy B, or fit
coupling (052D) in mechanical thrust block for the mRoy A)
- Screw in screw (435B)
- Fit the lantern (Chap. 3.8.8)
- Mount the motor
3.8.10 Renewal of worm bearing.
Same procedure as for the Renewal of the worm shaft (Chap. 3.8.9), but by replacing bearings (409A) and
(409).
3.8.11 Renewal of the wheel / worm.
Same procedure as for Renewal of the connecting rod and shaft (Chap. 3.8.5 to Chap. 3.8.7), but without
removing connecting rod shaft (011) (Fig. 28) for the mRoy A
435D/434B/435C
072
Fig.29
Motor lantern
For information concerning which spanners are to be used, see chapter 3.7.7.
G3.6
3.9 - LUBRICATION
The oil level must be checked every month. Fill the housing up to the middle of the level indicator. Use the oil
supplied with the pump or an equivalent oil (see table below). The oil must be changed every 2500 hours of
operation or every six months. The pump must be placed in a zone where the ambient temperature is
between -5°C and 50°C.
3.9.1 Table of oils

ISO.VG 150 oil. Pure mineral oil
QUANTITY:
mROYA mROYB
Simplex 1L 3L
Duplex 2L 4L
TABLE OF CHARACTERISTICS
Viscosity to 40°C 151 Cst
Viscosity to 100° 15Cst
Viscosity Index 100
ISOVG 150
Density to 15° C 0.897 k/l
Flash-point 244°C
Pour-point -12°C
EQUIVALENCY TABLE
Make Type
COFRAN MECANEP 150
B.P. GRXP150
CASTROL ALPHA SP 150
ELF REDUCTELFSP150
FINA GIRAN 150
IGOL DYNAM SP 150
MOBIL OIL MOBILGEAR 629
SHELL OMALA 150
TOTAL CARTER EP 150
ESSO SPARTAN EP 150
3.9.2 Draining the pump

To drain the pump, unscrew the filler plug and the drain plug completely (Fig. 1 A).
To fill up with oil, screw the drain plug back on with Teflon strip to ensure proper impermeability, and see
Chapter 2.2.2.
Note: For information concerning how much oil to use, see the table in Chapter 3.9.1.
IV FAULT LOCATION PROCEDURES
If, during the initial startup, the pump does not work properly, check the pump installation (SECTION:
INSTALLATION II).
4.1 - THE PUMP DOES NOT DELIVER:
CAUSE REMEDY
A - Motor stopped A-
- The thermal relay has been overloaded and has tripped. - Reset the thermal relay (Check the
reason for the overload)
B - No more product to pump.
B - Check the product level
C - Piping clogged up.
C - Unclog the piping
D - Filter blocked.
D - Clean the filter
E - Suction piping valve closed.
E - Open the valve
F - Diaphragm pierced.
F - Change the diaphragm
4.2 -THE PUMP DOES NOT DELIVER AT THE SPECIFIED FLOWRATE:

CAUSE REMEDY
A - The pump flow is improperly adjusted A - Set the vernier on the right percentage
B - Poor impermeability in the suction piping B - Change the piping seals

- Pumped liquid level too low (air intake)
C - suction piping dirty
C - Clean the piping
D - Filter dirty
D - Clean the filter
E - Check-valve box seat dirty or worn
E - Clean or change the check-valve box
F - Operating-pressure too high
F - Use the pump at the pressure specified on the
data-plate
Connecting diagram for
chemical dosing pump unit.
012
Dosing line not A I supply.
The distances between the dosing pump and feedwater line max. 4 mtrs. Fitting
Dosing line ø12 x 1.5mm. Standless steel or (steel).
J A I supply.
Shutdown valve 3/8"BSP.
4 pes of fittings 3/8'BSP / ø12 as sketch.
ti \if!./
-txX- y" "s
Controlvalve boiler feed water
I
Oil fired boiler Hotwell Feed water pump
AALBORG ggiaiaaagggngffns^^^^^M
INDUSTRIES ^migg^g^^gnimi^^mii^^mi^^^m
Table of contents
Salinity alarm e q u i p m e n t
Conductive electrode, ERL 16 1

Conductivity limit switch, LRS l-5b 1

AALBORG CONDUCTIVITY ELECTRODE, ERL 16 OM8620#02.0
INDUSTRIES
Conductivity electrode, ERL 16

1 Description
The conductivity electrode, type ERL 16 is used for monitoring the conductivity of
the feed/boiler water and can be installed in the condensate system, feed water
system, or directly into the boiler. The conductivity of the water produces a
proportional current when the measuring surface and voltage supply remain
constant.
The conductivity electrode is provided with an electrode rod completely insulated by
a PTFE tubing with the exception of the measuring surface. A pressure-tight sealing
between the electrode rod and body is ensured by means of a Teflon tube. An
illustration of the conductivity electrode is shown in Figure 1 together with an
installation example.
The electrode can be used in connection with a salinity monitoring system or a
continuous blow down system. When used in a salinity monitoring system the
electrode is connected to a conductivity limit switch type LRS l-5b or a salinity
controller type LRR l-5b, which continuously monitors the conductivity of the
water and give alarm if the set limit value is exceeded. When used in a continuous
blow down system the electrode is connected to a salinity controller type LRR l-5b
and a continuous blow down valve type BAE. The system provides fully automatic
control of the blow down wastage. Automatic closing of the blow down line is
ensured during boiler shut down.
Illustration of the conductivity electrode, type ERL 16
Pg 11
-*• Flow direction
3/4" BSP
Measuring pot Conductivity
electrode, ERL 16
- Electrode tip
Figure 1 erll6a.cdr

AALBORG CONDUCTIVITY ELECTRODE, ERL 16 OM8620#02.0
I N D U S T R I E S
1.1 Installation
The conductivity electrode may be installed vertically, horizontally, or radial

inclined. However, it is recommended that the electrode is installed in a measuring
pot as illustrated in Figure 1. The electrode tip must be constantly submerged by
approximately 100 mm.
Wiring
The electrical connection is carried out by means of a four-pole connector with
screw terminals, cable strain relief, and cable gland Pg 11. The maximum
permissible ambient temperature at terminal box is 60°C. Figure 2 illustrates the
wiring diagram.
Wiring diagram
Terminals
rr\ rr\ rt\ rt\
Measuring tip
Figure 2 erll6b.cdr
1.2 Maintenance
The electrode does not require any particular maintenance. It is, however,
recommended to check the electrode tip every six months. Cleaning is possible by
carefully grinding the measuring surface.

AALBORG CONDUCTIVITY LIMIT SWITCH, LRS 1-5B OM8210#30.0
INDUSTRIES
Conductivity limit switch, LRS 1-5b
1 Description
The conductivity limit switch, type LRS l-5b is used to amplify and transform
signals from a conductivity electrode, type ERL 16 or LRG 16-4, for continuous
monitoring of the conductivity in feed and boiler water. An illustration of the front
panel can be seen in Figure 1.
The conductivity limit switch is provided with two LEDs. The green LED (lb)
indicates a < limit value and the red LED (la) indicates a > limit value. By means
of the switch (3) the measuring range can be selected between 0-10000 |o,S/cm and
0-1000 |uS/cm. The limit value is continuously adjustable on the switch point
adjuster (2) within the ranges of 400-10000 uS/cm or 40-1000 uS/cm. The switching
hysteresis of the limit switch is 1%. The temperature influences can be compensated
on the adjuster (4) up to max 250°C. Basic adjustment applies to 25°C.
Illustration of the conductivity limit switch LRS l-5b
1a. Red LED

1b. Green LED
2. Switch point adjuster
3. Measuring range switch
4. Adjuster for temperature compensation
5. Screw to fasten the cover base
Figure 1 lrsl 5bl.cdr
1.1 Wiring
The wiring should be carried out in accordance with the wiring diagram shown in
Figure 2. The mains voltage is indicated on the name plate. The maximum
permissible ambient temperature for the limit switch is 55°C. For wiring to the
electrode screened cable is required, and the length and properties of the cable stated
in Table 1 must be observed. The screen should only be connected to terminal 12 of
the LRS l-5b limit switch, and not at the electrode. The screen must not have
contact with any metal part of the plant.

INDUSTRIES
Wiring diagram
LRS 1-5b
T
10 11 12
Alarm
L N
Mains
m/ti/t\ß
Conductivity electrode,
ERL16orLRG16-4
Figure 2 lrsl_5b2.cdr
LRS 1-5b
Nominal measuring range 400 -10000 uS/cm 40 - 1000 uS/cm
Linear in the range 0 -10000 uS/cm 0-1000nS/cm
Cable length - 50 m
Cable capacity <100nF <10nF
Line resistance per conductor <30Q -
Table 1
1.2 Commissioning
When the conductivity limit switch is commissioned or re-calibrated carry out the
following work steps:
Step A: Take sample of the liquid that should be monitored via a sample cooler and
determine the conductivity with a conductivity meter.
Step B: Select the measuring range by means of the switch (3) provided on the front
panel, see Figure 1. The possible selection ranges are 0-10000 uS/cm or 0-
1000 u.S/cm.
Step C: Turn the adjuster (4) onto scale division "7".
Step D: Adjust the switch point adjuster (2) to the conductivity level found.
Step E: When reaching the service temperature of the boiler, turn the adjuster (4)
slowly to the left until the red LED (la) extinguishes and the green LED
(lb) lights up. The temperature is thus compensated.

INDUSTRIES
Note: Gases dissolved in water, such as carbon dioxide or ammonia, increase

the conductivity and simulate a higher salt content (TDS) of the boiler
water.
1.3 Performance test
The conductivity limit switch can be tested performing the following work
procedures:
Step A: Short-circuit terminals 3 and earth of the electrode. The red LED (la,
Figure 1) on the conductivity limit switch should light up independently of
the position of the switch point adjuster (2).
StepB: Short-circuit terminals 9 and 12 of the conductivity limit switch. The red
LED (la) should light up independently of the position of the switch point
adjuster (2).
Step C: Unplug the terminal box of the electrode. The green LED (lb) should light
up independently of the position of the switch point adjuster (2).
1.4 Maintenance
Deposits on the electrode tip produce an error in the measurement. If the electrode is
used in fluids prone to form deposits, it is recommended to clean the electrode tip
every six months.
1.5 Faultfinding
Performance test error

If the performance test is negative check for the correct wiring of the conductivity
limit switch and electrode according to the wiring diagram shown in Figure 2.
Record error
If the conductivity limit switch does not record the adjusted conductivity limit value
then re-calibrate it. Clean the measuring surface of the conductivity electrode.

AALBORG m-.njtiJtsmrasns^^^^^M
INDUSTRIES ^HHBHIBHIIIHIIHHII^^H^^^^^^Î
Table of contents
Oil detection equipment

General 1
Sensor installation 2
Control unit installation 3
Applications 4
Spares and fault finding 5

AALBORG OIL DETECTION EQUIPMENT OM9410#01.0
INDUSTRIES
Oil detection equipment

1 General
This chapter contains installation, operation, and maintenance instructions for the
ultrasonic interface detection system, type 402 SD, using control unit type MCU200.
Each Mobrey ultrasonic control system requires a sensor to suit the specific
application, plus a control unit. These instructions cover the control units in the
MCU200 series.
Sensor installation
2.1 General description
The ultrasonic sensor contains two piezoelectric crystals. A high frequency signal
(3.7 MHz) generated by the control unit is transmitted to one piezoelectric crystal by
coaxial cable. This crystal converts the electrical signal into an ultrasonic oscillation.
The sensor design allows the ultrasonic oscillation to pass from the transmitter
crystal to the receiver piezoelectric crystal. The sensors of type 402 are "gap" type
sensors, where the two piezoelectric crystals are separated by a gap. When the gap is
in liquid the signal reaches the receiver, because of the low ultrasonic attenuation of
the liquid. When the gap is filled with air, no ultrasonic signal can pass from
transmitter to receiver. See Figure 1.
Working principle of the oil detection equipment
Sensor Cap Wet

Control u - .
Unit *'ReU)'
The ultrasonic beam
teaches receiver crystal
^dual
k co-axial
cable
Transmitter Receiver
Crystal Crystal
Control ^ Relay
7
Unit
The ultrasonic beam will
not reach receiver crystal
Figure 1 mobrey01.tif

INDUSTRIES
When the gap is filled with liquid, the piezoelectric receiver crystal converts the
ultrasonic wave into an electrical signal, which is transmitted back to the control unit
using a second coaxial cable. Usually the two coaxial cables to the sensor are in one
overall sheath. The control unit circuitry is a feedback amplifier, which oscillates
when the sensor is wet, and is quiescent for the sensor dry. The "oscillating" or
"non-oscillating" sensor states dictate the output relay states of the MCU200.
For interface detection the sensor "oscillates" in a clear liquid, and is "non-
oscillating" at the interface.
2.2 Switching levels and orientation
The gap sensors should normally be mounted with the gap vertical, to avoid build up
of solids on the sensor faces on either side of the gap. In this condition the switching
level will be halfway up the face: if the sensor is mounted from the side of the tank
this is normally on the centreline of the cylindrical body.
Occasionally such sensors are mounted with the sensor faces horizontal, either to
avoid air bubbles passing through the gap or for convenience of installation. In this
case the switching level will be at the sensor face at the top of the gap.
2.3 Installation of sensor
The sensor must be handled with care - it is a measuring instrument. Before

installation, check that sensor, cable and control unit have not been damaged in
transit. Drill and tap a hole with a suitable thread. It is advisable to use a boss or
similar on thin walls. The sensor has a tapered thread. Use Ptfe tape or similar to
seal the thread. Mark the sensor hexagon to identify the gap orientation of the
sensor, if appropriate. Take care not to damage the sensor cable during tightening.
The cable should be laid on cable trays and separated from any high voltage or
mains cables. The normal cable termination is a plastic gland (to fit the MCU200
control box drilled hole) and crimped terminal pins to suit the MCU200 terminals.
2.4 Extensions cables
Extension cables up to 50 metres long can be fitted to most Mobrey ultrasonic

sensors in the factory to special order but a better site arrangement is to have a
separate extension cable. Table 1 shows a list of suitable extension cables.
Suitable extension cables

SO m 50 -100 m Above 100 m
RG174 URM76
Consult Aalborg Industries
RG178 RG58
Table 1
When double coaxial cable needs to be extended, two sets of coaxial plugs and
sockets will be needed, one set for transmit and one receive. Care must be taken that
the connectors are not connected to earth or shorted together in any way, to prevent
cross-talk or pick-up. The coaxial connections must be made in a waterproof
junction box. Terminal blocks should not be used.

•••••••

INDUSTRIES
The extension cable needs to be of 50 Ohm characteristic impedance. Suitable dual

coaxial extension cables can be purchased from Aalborg Industries. For extensions
over 50 metres it is recommended two runs of single coaxial low loss cable is used,
with the transmit and return cable runs separated by 0.15 metres to minimise cross-
talk.
If several sensor cables are being run together then all the transmit cables (those
connected to E2) should be grouped together and all receive cables (those connected
to IE) grouped together maintaining the separation specified above.
Two cables are required per sensor. The RG178 should be used where the cable
itself is subject to temperatures exceeding 74°C.
Control unit installation
3.1 Mechanical
The control unit is supplied with three holes drilled in the bottom (longer) side of the
box. Two glands are supplied for the power input cable and relay output cable. The
sensor is normally supplied fitted with a suitable gland on the cable. Two further
holes can be drilled in the bottom side of the box should these be needed: it is
recommended that the circuit board is removed whilst drilling extra gland holes.
Figure 2 shows the dimensions of the MCU200 housing box.
MCU200 Housing dimensions
Mounting
Holes
All cable connections are made to the terminal blocks along the bottom edge of the
pcb, see Figure 3. Release the terminal screw before inserting the wire.

INDUSTRIES
MCU201 PC board
Output
Logic Switches • LED
Indicators
Cain
Controls
ILLI H I II I is
Frequency
'mi <f DANGER LIVE TERMINALS
é * 9 *
Selection
AUX.
IW»UT
a a__ .
i c i ci M » « e
____ -
a «2
„ _
• a
N tisvaaov r Mounting
Cable Check Screws (4)
Selection
' SEE INSUX L I D FOR
SWITCH AND COMCCTION DETAILS
3.2 External connections
3.2.1 AC mains
AC mains is connected between the "N" terminal for neutral and one of the "115V"
or "230V" terminals depending on the voltage supply available - BEWARE - the
terminal not connected externally will be "live" once the transformer is powered via
the other terminals.
3.2.2 Mains earth

Mains earth should be connected to the terminal marked "E". This provides an earth
contact for the pcb mounting pints.
3.2.3 The relay
The relay output connections are labelled:
• NC - Normally closed (relay de-energised)
• C - Common
• NO - Normally open (relay de-energised)
There are also two sets of contacts for DPCO relay, labelled 1 & 2.
3.2.4 The sensor
The sensor connections are labelled "1", "E" for the receiver crystal and "2", "E" for
the coax cable to the transmitter crystal. The screens of these coax cables are
connected to the terminals marked "E".

INDUSTRIES
3.2.5 The auxiliary input

The auxiliary input is a terminal which can be connected to a "push to reset" button
to achieve a latching alarm, or to another Mobrey Control unit, to give a pump
control from the MCU200 unit relay output. If a short circuit is connected between
terminals 3 & 4, the MCU200 relay, once de-energised, is held de-energised. Even if
the sensor attached to the MCU200 changes state, to that which should energise the
output relay, this relay will not energise until the link between terminals 3 & 4 is
broken in the circuit external to the MCU200.
3.3 Switch settings in MCU200 series
3.3.1 Gain switch and potentiometer

See section 4.
3.3.2 Frequency selection
This slide switch is labelled "FREQ" and is located between the sensor terminal
block E2, and the Aux. input terminals. This selects the operating frequency of the
MCU200 oscillator, which for the present installation must be set to 3.7 MHz
(switch in the "up" position). The setting required is dictated by the sensor type
connected to the control unit.
3.3.3 Cable check option selection

This slide switch is located directly above the sensor terminal block E2. It is labelled
"Cable Check" and the ex factory setting is "OUT" with the slide switch to the right.
By sliding this switch to the left, the cable check circuitry is brought into action.
This circuitry monitors the continuity of the screens of the two coaxial cables
attached to the sensors: normally these are linked at the sensor to the metal body of
the fitting (or to each other in the case of non metallic sensors). If this continuity is
broken, the "FAULT" LED" will illuminate giving an indication that the sensor
cable is damaged, and the MCU200 will give the "ALARM" output relay state (see
Figure 4).
3.3.4 Relay output and LED logic selection

The bank of six slide switches towards the top of the pcb sets the relay output state
logic relative to the sensor state, associated time delays and the LEDs. These are
slide switches, best adjusted with a pencil, and the ex factory wetting is with all
switches to the right.
Each switch is colour coded as shown in Figure 4, and the PC board labels give brief
function information.

INDUSTRIES
Relay output and LED logic switch
Colour Code No.

/
Brown 1
30s
Red 2
Orange 3 \
E = Red
Yellow 4
Delay to E
Green 5
OSC = NE
Blue 6
Note: At Figure 4 OSC means sensor oscillating. £ means relay energised, NE

means de-energised.
Set the switches in the following order, starting at the bottom and working upwards:
BLUE:
If the MCU200 relay is to be energised (E) when the sensor is oscillating (OSC)
then set the No 6 blue switch to the right (OSC=E). This is the preferred setting, to
give a de-energised relay in the ALARM state for a gap sensor as a low level alarm.
GREEN:
This selects the relay change which is subject to the time delay selected on the top
switches. When the No.5 green switch is set to the right, the delay occurs between
the sensor changing state and the relay de-energising or becoming "not energised"
(NE). This time delay is a minimum of 0.15 seconds, (achieved by switching the top
BROWN switch to the right) and is used to prevent relay chatter at the changeover
point. Longer time delays are selected on the top three slide switches as shown in
Figure 5.
The relay change in the opposite direction is immediate (within 50 milliseconds).

•#•••#•

INDUSTRIES
The top three slide switches
Colour Code No. Hk Hh -*•> i
Brown 1 .j_ HH ^ 2
Red 2
HK -i- Hh 3
Orange 3
2 seconds* 8 seconds' 30 seconds*
YELLOW:
Only one of the GREEN or RED LEDs will be illuminated at any one time. These
LEDs show the state of the MCU200 output relay. The RED LED is labelled
"ALARM" and the GREEN LED is labelled "NORMAL". The yellow slide switch
(Number 4) determines which LED will be illuminated when the relay is energised
(E). It is usual to have the GREEN/NORMAL condition occur with the relay
energised, i.e. with switch Number 4 to the right (E=GREEN).
Applications
4.1 Gain adjustment
Correct adjustment of the gain (HI/LO switch and potentiometer) is essential for
proper operation of any ultrasonic sensor system. This adjusts the gain of the
feedback amplifier in the control unit, which produces oscillation of the sensor when
the coupling between the ultrasonic crystals is sufficient. Therefore the higher the
gain setting, the lower the coupling needed to produce an oscillating sensor.
The universal control unit of the MCU200 operates with many sensors, so the
correct setting for the particular sensor and application should be found on site by
experiment, if possible. This will take account of particular site conditions like RF
coupling between extension cables, which can affect the maximum allowed gain.
Other liquid characteristics, such as presence of suspended solids, or air bubbles, can
mean that for reliable operation the MCU200 gain must be set as high as possible, to
overcome future solids build up, but at least one potentiometer division below the
maximum allowed level, to ensure temperature and component ageing stability.
The particular procedures outlined below for gain adjustments give the mid point
gain settings, which may need to be adjusted to meet specific site/sensor future
requirements as indicated above.

INDUSTRIES
4.2 Interface detection
4.2.1 Interface detection between two dissimilar liquids

Viscous liquids, emulsions and liquids containing solid particles have a greater
ultrasonic attenuation than clear liquids. This technique is used to detect which
liquid is present at the sensor, for example for the separation of oil and water. For
this duty Mobrey 402 sensors are used, operating at 3.7 MHz to produce the
maximum ultrasonic difference between two liquids monitored.
The gain is adjusted so that the sensor oscillates only in the liquid with the lower
ultrasonic attenuation: this is usually the clearer liquid (water in the example of
Figure 6). Note that the signal when oil is present in the sensor gap will be the same
as that for air in the gasp, and that emulsion layers give a very high attenuation.
Mobrey 402 Sensor as oil/water interface
/ / /
OIL • it 111 tu i il
Receiver Transmitter
Crystal Crystal
Sensor in Oil. The ultrasonic beam

is attenuated and will not reach
receiver crystal.
WATER^ I if iiiimmimimm
— -Receiver Transmitter
a
Crystal Crystal
Figure 6 mobreyl5.tif
Step A: Reduce the gain potentiometer with the sensor immersed in one of the
liquids until a "false dry" indication is obtained. Note the position of the
pot.
Step B: Repeat for the sensor immersed in the other liquid.
Step C: Set the potentiometer half way between these two values. Correct
performance requires a total difference between the two set points of at
least 3 divisions.

INDUSTRIES
Interface detection between two immiscible similar liquids

When liquids are ultrasonically very similar - as happens for example with paraffin
or oil and water - the procedure in section 4.2.1. produces very little difference
between the two "false dry" points. In this case the "reflection" method of interface
detection is used. An illustration of this method is shown in Figure 7.
Note: The Mobrey 402 sensor in the hot well tank is installed as shown in
Figure 7.
If an ultrasonic beam is transmitted from one liquid to another at a suitable angle

(10%) it is split at the interface into a reflected and a refracted beam, so that it does
not reach the receiver crystal. If there is no interference in the gap, but only one
liquid, the beam is received and the sensor oscillates.
Interface detector by reflection method
Paraffin
=.*L*JQL
Water
Sensor at interface level. The

ultrasonic beam is reflected/refracted
and will not reach receiver crystal.
Paraffi
Transmitter
Crystal
i Receiver
Crystal
Figure 7 mobreyl6.tif
The gain adjustment is made so that the gain is 3 divisions higher than the highest
false dry position obtained, as in section 4.2.1. Performance at the interface should
then be checked.
Note: That the non oscillating state of the sensor, at the interface, also occurs
throughout any emulsion layer at the interface, and also when the sensor
is in air.

*•••••*

INDUSTRIES
Spares and fault finding
5.1 Spares
The following parts are suitable for replacements on the MCU201 :

• Main pcb complete: K2641
• LED indicator pcb: K2643
• LED pcb spacers: K2623
• LED pcb connector: K2624/50
• Box assembly: K2662
• Gland Assembly: K746/K747/K748
There are no consumable items such as fuses.
5.2 Fault finding
Step A: At least one LED should be illuminated. If not check the power supply to
the unit.
Step B: If the "Fault" LED is on, check the coax cable to the sensor for incorrect
wiring or damage. Particularly check continuity of extension cables,
connection of crimped connectors on cable ends. The pcb board can be
checked by linking the two terminals labelled E on the sensor terminals -
this should cancel the fault indication LED.
Step C: If the sensor is giving incorrect indications check the gain adjustment (see
section 4.0").
Check for correct sensor operation whenever the gain is adjusted away from the
normal set point. Assume an overlap of 2 divisions between the "LO" and "HI" gain
ranges.
Step D: Check that the incorrect operation has not been produced by incorrect
setting of the frequency selection switch, or an external short circuit on the
Auxiliary input terminals.
Step E: The circuit board can be checked by linking the sensor terminals 1 and 2
with a wire, to simulate an oscillating sensor.

AALBORG dSzSSSSSäfiSfi^^^^^^M
INDUSTRIES ^migg^g^^giiigii^^g^^g^^^^m
Table of contents
Drawings
Arrangement of sockets 45Y:028399d
DP water level control unit 70Z:019538b

Atonjlon Affi* tao Drawn Appr.
031030 KJN PSO
Forward ship
OuOøtbQK ttWKIQßd,
•
b 0403Û8 PSO
4 po. ol I M 31 add«* wni tan 30 rnoMd. c 0405(2 rea
d 0408» PSG TCO
F * foot
ViewC-C ViewE-E
D M OOP) DIN 86044
Outletbox supplied loose

To be welded by yard
mm I pta_:
m
001
HahctBWn X"40mm
Feed m b r L - F u i t kngh
S a m IsFuBiengBi
CtaJdeninM/auJM LaFidtenotfi
SIZE •01 •02
2 Î
0N15
Socket for atomizing «
OW32 DN20
ümo
DN50
Alrrtng lootbkNW
Internal ecvnptpi
Internai *baamapnbr~~
Fixing Iron/uiengkron
31,5 ta
Measuring tockettor öumer
Socket tor drain of «moka o

DN SO PN 20
Fixing tran / letting iron
Manhoto
420x320x150
Socket* ^'aeéttfawina™
Atxaia door / mpecoon
Socket f. nesting c o i dudaT~

ON 25
3öc£iiitf. heeling c o l He*
socket tor i ^ water regulator

DN25
m
Socket tor water tevoi regutator
PN 25
SockeTtor air"
X * BSP leftwnd
socket tor sampling cooler varva "
Socket tor water a m i gauge

ON 25
AQ18
Guangzhou Shipyard Vertical water tut» boler
View A-A Sodoty LRS LRS 1S0rMKg/h 0,9 MPs »3050
03130009
Afiangement of sockets
Project No, AALfiOM»
iHawtiaiie
45Y: 028399
Description Index Date^BBraw Appr.
Item 3 changed BZ
+ and - side reversed )30327f JA BZ
Allen screw 3000000009

M10x55 A2
Washer 3090000004
M10 A 2-70
Gasket 3520000013
018.64x3.53 Rubber/viton
Diff. pressure transmitter 8020000001
2.5-250 mBar
Tube for upper level tube DIN 1629 4000000390
012 L=1446 St.37.4
Lower level tube DIN 17175 70Z:012095
DN25 3.1 C
St.35.8 I
Upper level tube DIN 17175 70K02:012084
3.1C
DN25 St.35.8 I
Designation Material code Article No.
Cert.
Dimension Material type Detail drawing No.
Title:
DP water level control unit JA 020117
Appr.
Note! - side to be connected to lower level tube Socket distance: BZ 020117

Size
ifjjjjiji Weight Scale:

+ side to be connected to upper level tube 525-1300
1:5 A3
* - Drain connection: ø12 tube Assembly drawing
AALBORG Article/Drawing No:
INDUSTRIES THIS ORAWtNQ AND DESIGN SHOWN HEREIN a THE PROPERTY OF AALBORQ INOUSTRJES
AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 70Z:019538
c=3
AALBORG gggiaaigasngsHS^^^^^^^^^^^^^^B
INDUSTRIES ^••••HiflMllllSIIMii^H^^H^^^^HIil^H^^^HBH^HIIH
Table of contents
Data sheets for boiler and steam/water system

Safety valve, DN 65/100, PN 40/16 261 1174
Stop valve, angle, DN 200, PN 25 6010 000087
Stop valve, angle, DN 65, PN 40 6010 000090
Stop valve straight, non return DN 65, PN 40 6030 000023
Stop valve, angle, non return, DN 40, PN 40 6030 000013
Stop valve, straight, non return, DN 40, PN 40 6030 000016
Stop valve, straight, DN 8, PN 160 6220 000002
Stop valve, straight, non return, DN 20, PN 25 264 1087
Check valve, DN 200, PN 25 6020 000022
Water level gauge, left, model 28, DN 25, PN 25 7010 000151
Water level gauge, right, model 28, DN 25, PN 25 7010 000150
Safety valve, DN 15, PN 40 261 1358
Expansion joint for safety valve 85Y:013427a
Water washing hose with nozzle 8500 000016
Counter flange K16:004096
Solenoid valve (C227) data sheet
Level float switch RBA 24, DN 25, PN 40 8100 000008
Temperature switch ATHs-20/a 632 0110
Feed water pumps (1M4) data sheet
Pressure gauge, ø 63 , 663 3118
Pressure gauge, ø 63, Type PI 116 663 3121
Pressure switch, KPS 45 631 0340
Full bore ball valve, EURO-SFER, 1720 666 6006
Needle valve, straight, V2" x '/a", PN 400 ...254 1002
Orifice K18:003559
Chemical dosing unit 9296 000002
Sample cooler 875 0005
Check valve (1M142) 6020 000028
Pneumatic control valve, DN 40, PN 25 w/DP actuator + I/P positioner.6050 000050
Filter regulator with automatic drain 291 5101
Water testing equipment. 880 0050
Steam injection system 64Z:027665a
Stop valve, DN 40, PN 16 6010 000043

•iiiüii.
AALBORG
INDUSTRIES
^BBHHlBBBBBM^M^BI^MBI^^^^fc
^ m g g ^ ø ^ ^ ø u m u ^ g ^ ^ ^ ^ ^ ^ j ^ ^ ^ ^ g ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^
Cast iron strainer, DN 40, PN 16 7040 000016

Control valve, DN 40, PN 16 6000 000042
Temperature switch, 40-105°C 8070 000010
Wafer check valve, DN 40, PN 40 6020 000006
Vacuum breaker, BSP YT 6000 000010
Steam injector, BSP VA" 7000 000014
Steam injector, BSP 1" 7000 000020
Control device, LRS l-5b 8210 000005
Conductive electrode, ERL 16-1 8620 000003
Control unit for oil detection equipment 8210 000025
Ultrasonic sensor for oil detection equipment 8310 000005
Differential pressure transmitter 8020 000001

AALBORG DATASHEET
INDUSTRIES
Type:
• Safety valve, full lift
• 25.912
Size:
• Nominal diameter: DN 65/100
Application:
• To blow off saturated steam, air or water
Material:
• Body: GGG 40.3
DIN-Material No.: 0.7043
• Seat: X6 Cr Ni Mo Ti 17122
DIN-Material No.: 1.4571
• Disc: X35 Cr Mo 17
DIN-Material No.: 1.4122.05
Technical data:
• Nominal pressure: PN 40/16
• Weight: 40 kg
• Flanges according to DIN
• Inlet: DN 65, PN40
• Outlet: DN 100, PN 16
Type No.: 6040

Version: A Safety valve, DN 65/100, PN 40/16 261 1174

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop globe valve, angle • Body:GS-C25N
• 34.007 with stellited seat and cone Din-Material No. 1.0619.1
• Seat: X5CrNiNb 19 9 with stellite
Size: Din-Material No. 1.4551
• Nominal diameter: DN 200 • Disc:X20Crl3
Application: DIN-Material No. 1.4021.05
• For steam and/or water flow Technical data:
• Nominal pressure: PN 25
• Weight: 138 kg
400
Disc
Seat
Body
Type No.: 6010

Version: B Stop valve, angle DN 200, PN 25 6010 000087

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop globe valve, angle • Body:GS-C25N
• 35.007 with stellited seat and cone DIN -Material No. 1.0619.01
• Seat: X5CrNiNb 19 9 with stellite
Size: DIN-Material No. 1.4551
• Nominal diameter: DN 65 • Disc:X20Crl3
Application: DIN-Material No. 1.4021.05
• For steam and/or water flow Technical data:
• Weight: 20 kg
Disc
Seat
Body
Type No.: 6010

Version: A Stop valve, angle, DN 65, PN 40 6010 000090

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop check globe valve, screw down non • Body:GS-C25N
return, straight DIN-Material No. 1.0619.01
• 35.006 R with stellited seat and cone • Seat: X5CrNiNb 19 9 with stellite
DIN-Material No. 1.4551
Size: • Disc:X20Crl3
• Nominal diameter: DN 65 DIN -Material No. 1.4021.05
Application: Technical data:
• For steam and/or water flow • Nominal pressure: PN 40
• Weight: 23.5 kg
0 180
Body
Type No.: 6030 Stop valve, straight, non return

Version: A 6030 000023
DN 65, PN 40

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
return, angle DIN-Material No. 1.0619.01
• 35.007 R with stellited seat and cone • Seat: X5CrNiNbl9 9 with stellited
Size:
• Disc:X20Crl3
• Weight: 12.4 kg
0 160
CM
L • i
^~^4J-i /^
f
f
200
U
~7~~Zî>
fej Disc
Sfeat
|?
115
. Bady
/
'Z^Z / / / '/,
^.0 40
0 1 1 0 / 4 x 0 18
0 150
U 115
Type No.: 6030 S top valve, angle, non return, 6030 000013
Version: A DN 40, PN 40
I J
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
return DIN -Material No. 1.0619.01
• 35.006 R with stellited seat and cone • Seat: X5CrNiNb 19 9 with stellited
• Weight: 11.5 kg
0 160
Body
Type No.: 6030 Stop valve, straight, non return

Version: A 6030 000016
DN 40, PN 40

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Instrument stop cone valve, straight • Body: C 22.8
Size: • Seat:X20Crl3
• G'/ 2 "xøl2 DIN-Material No. 1.4021
• Nominal diameter: DN 8 • Needletip:X35CrMol7
Application: DIN-Material No. 1.4122
• For steam, water and/or air Technical data:
• Inlet: G W male DIN
19207, form R
• Outlet: For steel tube ø 12
• Weight: 0.8 kg
0 80
Type No.: 6220

Version: D Stop valve, straight, DN 8, PN 160 6220 000002

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop check globe valve, screw down non • Body: GGG 40.3
return, straight DIN -Material No. 0.7043
• 23.006 R • Seat:X20Crl3
DIN -Material No. 1.4021.05
• Nominal diameter: DN 25 DIN-Material No. 1.4021.05
• Weight: 5.4 kg
0 140
Body
Type No.: 6030 Stop valve, straight, non return,

Version: A 2641088
DN 25, PN 25

AALBORG DATA SHEET
INDUSTRIES
Type: • Opening pressure at horizontal flow (60°

• Wafer check valve, type WCV 6100 open): 19 mbar
Application: • Opening pressure at vertical flow
upwards: 22 mbar
• For steam and liquid media • Standard Kv value: 1205 m3/h
Design: • Operating temperature max.: 250°C
• The wafer check valve is designed to be • Operating temperature min.: -10°C
sandwiched between welding neck • Weight: 7.5 kg
flanges or slip-on flanges, with Installation:
horizontal flow or vertical flow • The check valve can be installed
upwards. The disc is eccentrically sandwiched between welding neck
placed in relation to the body to obtain a flanges or slip-on flanges
self-centring effect at installation • Determine the correct installation
Size: situation and the direction of flow. It
• Nominal diameter: DN 200 must be installed either in a horizontal
flow or where the flow is vertically
Connection requirements: upwards
• Min. inline diameter of connection • The valve is self-centring. However, it
pipe/flange: 206.5 mm must always be ensured that it is
• Length of required min. inline diameter: completely centred in relation to the
160 mm connection pipe/flange. Use the body
rim (external) diameter for this purpose
Material: • The check valve can be installed directly
• Body: carbon steel on a valve, but a distance of 2-3 times
• Waferdisc:AISI316L the pipe diameter is preferable.
• Disc seating: metallic • In case of a steam system with vertical
installed check valve a steam trap should
Technical data: be installed for drainage of condensate
• Operating pressure max: 25 bar
• Max. cold hydraulic test pressure: 37.5
bar
Type No.: 6020

Version: B Check valve, DN 200, PN 25 6020 000022

AALBORG DATA SHEET
INDUSTRIES
Installation examples:
Welding neck flange Welding neck flange

installation installation with
recessed pipe
Slip-on flange Slip-on flange

installation i
!
i
f
fl[ installation with
recessed pipe
1
J
| ! •
Mln. 0206.5
il
i
Mi
1
V
1
i
i : ,: •
fi-1 IL P ,
60
tj - 1 a
m
Type No.: 6020

Version: B Check valve, DN 200, PN 25 6020 000022

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop check globe valve, screw down non • Body: GGG 40.3
return, straight DIN -Material No. 0.7043
• 23.006 R • Seat:X20Crl3
• Nominal diameter: DN 20 DIN-Material No. 1.4021.05
• Weight: 4.3 kg
0 120
Body
Type No.: 6030 Stop valve, straight, non return, 264 1087
Version: A
DN 20, PN 25

AALBORG DATA SHEET
INDUSTRIES
Type:
• Stop valve, gate straight
Size:
• Nominal diameter: DN80
Application:
• Sea water,freshwater, oil, steam etc
Material:
• Body: GG25
Technical data:
• Max. temperature: 150 °C
• Weight: 19 kg
160
Type No.: 6010

Version: A Stop valve, straight, DN 80, PN 10 6010 000042

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Body: Carbon steel
• Reflective water level gauge, left
• Drain valve body: ASTM A105
• Model 28
Technical data:
Size:
• Nominal diameter: DN 25
• Weight: 25 kg
Application: • Connections between body and cocks are
• For boiler water level indicator made by end tubes and stuffing boxes
160
Drain connection ø 10 x 2.5

mild steel
Type No: 7010 Water level gauge, left, model 28

Version: B 7010 000151
DN 25, PN 25

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Body: Carbon steel
• Reflective water level gauge, right
• Drain valve body: ASTM A105
• Model 28
Technical data:
Size:
• Weight: 25 kg
Application: • Connections between body and cocks are
• For boiler water level indicator made by end tubes and stuffing boxes
160
oo
CM
CO
f
•a
c
a>
J2
.o
loi
Drain connection ø 10 x 2.5

mild steel
Type No: 7010 Water level gauge, right, model 28 7010 000150
Version: B
DN 25, PN 25

AALBORG DATA SHEET
INDUSTRIES
Type:
/^zr7771
• Safety valve, full lift
• 25.941
Size:
Application:
• To blow off steam and/or air.
Material:
• Body: GGG 40.3
• DIN-Material No.: 0.7043
Technical data:
• Weight: 3.5 kg
Body
Type No.: 6040

Version: A Safety valve, DN 15, PN 40 261 1358

'Flange DN100-PN 16 Flange DN25PN16
Title: Drawn Date
Expansion Joint MRJ 20.09.2000

Appr. •ate
•••••••
for safety valve LD 30.11.2000
••••••• Weight Scale: Size
DN65/100, PN 16 outlet flange
iiiitiiiå General arrangement
48kg
Article/Drawing No:
1:5 A4R
Index
AALBORG THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
INDUSTRIES
Plot Date: AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 85Y:013427
AALBORG DATA SHEET
INDUSTRIES
Type: vl .
Jr Couplings (2" Storz) Hose
Nozzle
• Water washing hose with nozzle
•Size:
V-nozzle: 12 mm n-i i
/
• Length: 15 metre (hose)
• Inner diameter 52 mm (hose) L J
Application:
• For spraying of water
m K A • « lfh
Material:
• Hose: full-synthetic material (polyester) ^ ^ '- F
woven in 1/1 binding, ^with inner rubber ^ ^ \
lining 2" connection (male) Couplings (2" Storz)
Technical data:
• Max allowable working pressure: 20 bar
• Water temperature area -30°C-+60°C
• Weight: 5.5 kg
l/min Water flow

210
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
2 3 4 5 6 7 8 9 10 Bar
Type No.: 8500

Version: A Water washing hose with nozzle 8500 000016
V J
Description Index | Date \ Drawn | Appr.
Yard piping
Supplied loose
DN øA øD <9K øB øL C Bolt Number

15 21.3 95 65 22.0 14 14 4 / M12
20 26.9 105 75 27.5 14 16 4 / M12
25 33.7 115 85 34.5 14 16 4 / M12
32 42.4 140 100 43.5 18 18 4 / M16
40 48.3 150 110 49.5 18 18 4 / M16
50 60.3 165 125 61.5 18 20 4 / M16
65 76.1 185 145 77.5 18 22 8 / M16
80 88.9 200 160 90.5 18 24 8 / M16
100 114.3 235 190 116.0 22 '26 8 / M20
125 139.7 270 220 141.5 26 28 8 / M24
150 168.3 300 250 170.5 26 30 8 / M24
200 219.1 360 310 221.5 26 32 12 / M24
250 273.0 425 370 276.5 30 35 12 / M24
300 323.9 485 430 327.5 30 38 16 / M28
Title: Drawn Date

MRJ 970910
Appr. Date
Counter Flanges MSO 981016
Weight Scale: Size
DN15 - DN300 PN25
iiiiiiiii BS4504 type B
1:1 A4R
Affix
INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERIY Of AALBORG INDUSTRIES
AND UUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY ' K16:004096
C 22?
2/2-way-valves ND12 to 50 85000

for neutral gaseous and liquid fluids 85010
Solenoid actuated, with forced lifting
Piston seat valves
Internal threads G1/2 to G 2 or 1/2" NPT to 2" NPT
Operating pressure 0 to 25 bar
Description (standard valve)
Solenoid valve for air, water and oil
Switching function: Normally closed

Flow direction: determined
Fluid temperature: -10 °C to max. +90 °C
Ambient temperature: -10 °C to max. +50 °C
Mounting position: optional, solenoid
preferably vertical
on top
Material
Material Body: Brass

Seat seal: NBR (Perbunan)
Internal parts: Stainless steel, Brass, Gun metal
For contaminated fluids insertion of a strainer is recommended (see accessories).
Features
Flat piston valve
Valve operates without pressure differential (Ap)
High flow rate
Damped operation
Suitable for vacuum
Symbol
EH tZrVW
Ordering information
To order, quote model number from table overleaf; e. g. 8500200.8301 for a G1/2 valve with standard solenoid.
Characteristic data
See page 2 valve and solenoid informations
D106102.01 Vdlvc Technology and System!» Buschjost

11/01 liVI NORGRCN BUSCHJOST G M B H - CO KG
ttuucbloit Series 8 5 0 0 0 / 8 5 0 1 0 2/2-way valves N D 1 2 to ND 50
Characteristic data
Valves
Catno .. " • Catno. v ND ".Connection Operating pressure * kv-value** '? Weight - '
Solenoid DC Solenoid AC (mm) min max (bar) (Båse m'/h) (kg)
8500200.8301 8500200.8304 GI/2

12 0 25 3,80 1,45
8501200.8301 8501200.8304 1/2- NPT
8500300.8401 8500300.8404 G 3/4
20 0 25 11,00 3,65
8501300.8401 8501300.8404 3/4' NPT
8500400.8401 8500400.8404 GI
25 0 25 13,00 3,50
8501400.8401 8501400.8404 T NPT
8500500.8401 8500500.8404 G 11/4
32 0 25 30,00 5,30
8501500.8401 8501500.8404 1 1/41 NPT
8500600.8401 8500600.8404 G I 1/2
40 0 25 31,00 5,10
8501600.8401 8501600.8404 1 1/2" NPT
8500700.8401 8500700.8404 G2
50 0 25 46,00 6,60
8501700.8401 8501700.8404 2" NPT
* with gaseous and liquid fluids up to 40 mmVs (cSt) State voltage [V] and frequenzy [Hz]
** Cv-value (US) - kv-value x 1,2
18301/8304 and 8401/8404 Solenoid Further models (valves)

Standard voltages XXXXX01 .XXXX Normally open, mounting position: solenoid vertical
on top a
DC AC :•
40 Hz to 60 Hz
XXXXX02.XXXX Manual override, from G 3/4 (3/4" NPT)
XXXXX03.XXXX Seat seal FPM,
24 V 24 V
max. fluid temperature +110 °C "
- 110V XXXXX06.XXXX Seat seal PTFE,
max. fluid temperature +110 °C1),
205 V 230 V max. operating pressure 16 bar
Design acc. to VDE 0580 XXXXX14.XXXX Seat seal EPDM,
Voltage rage ±10% max. fluid temperature +110 °C
100 % duty cycle XXXXX17.XXXX Normally open,
Protection class acc. to DIN EN 175301-803 (10/00) IP65 seat seal FPM, max. fluid temperature +110 °C,
Socket acc. to DIN 43 650-A
mounting position: solenoid vertical on top 2|
AC solenoid with rectifier
XXXXX22.XXXX max. operating pressure 40 bar2)
XXXXX23.XXXX Position indicator with two solenoid switches2)
Power consumption XXXXX25.XXXX Seat seal FPM with larger bleed orifices in the pis-
According to VDE 0580 at coil temperature +20 °C. In operating the ton, for e. g. fuel and oil, viscosity max. 80 mm2/s
solenoid decrease the power consumption appr. 30%. (cSt),max. fluid temperature +110 °C "
XXXXX28.XXXX Temperature design; < -10 °C, all materials suitable
Solenoid DC AC XXXXX34.XXXX Enlarged closing force at 20 % kv-value-reduce -
Inrush Holding
advisable at low flow rate and low switching cycles
8301 22 W _ _ On request further versions
8304 - 25 VA 25 VA
Further models (solenoids)
8401 40W - _
XXXXXXX.8402 Solenoid for higher temperature, max. fluid temper-
8404 - 45 VA 45 VA
ature +200 °C, mounting position: vertical, with so-
lenoid underneath, only for DC
Attention!
XXXXXXX.8406 Same as 8402, only for AC
Restricted temperature range for explosion proof solenoids Solenoid in protection class EEx me T4, begin at
XXXXXXX.8436
For technical details see catalog register „Solenoids" DN20
XXXXXXX.8900 Solenoid in protection class EEx de MC T4 and T5
XXXXXXX.8920 Solenoid in protection class EEx d MC T4 und T5
On request Overexcitation, protection class EEx d I, protection class EEx de I
resp. Special connections
1) max. fluid temperaturen +200 °C see solenoid for higher temperatures

2) G 1/2 with solenoid 8401/8404
D106102.02 Subject to change 11/01

Series 85000/85010 2/2-way valves ND12 to ND 50 Bn««li|o«t
Sectional drawings
to G1/2 resp. 1/2" NPT from G 3/4 resp. 3/4" NPT
101 Valve body 1400 Socket

*102 O-Ring 1501 Hexagon screw
*103 Valve plate 1502 Round plate
*104 Grooved ring 1504 Gasket
*105 Valve spindle
1505 O-Ring
*106 Screw piece
*107 Pressure spring, at G 3/4 (3/4" NPT) * These individual parts form a complete wearing unit.
108 Body cover
109 Spring washer When ordering spare parts please state Cat. No. and series-No.
110 Cheese head cap screw

111 Hexagon nut
400 Solenoid
701 Core tube
702 Core
704 Round plate
*705 Pressure spring
*712 0-Ring,justG1/2and1/2"NPT
11/01 Subject t o change D106102.03

BiMchlost Series 85000/85010 2/2-way valves ND12 to ND 50
Dimensional drawing
Solenoid may be rotated 360°

Socket turnable 4 x 90°
Cat.-No. AxB C DD E H H1 L R T
8500200.830X G 1/2 14,0

52x65 65 45 26 160 145 67
8501200.830X VT NPT 13,5
8500300.84OX G 3/4 12,5
72x92 75 70 31 196 172 95
8501300.840X 3/4' NPT 14,0
85004 00.840X Gl 14,0
72x92 75 70 31 196 172 95
8501400.840X T NPT 17,0
8500S00.840X G l 1/4 18,0
72x92 75 96 31 220 187 132
8501500.840X 11/4" NPT 17,0
85006 00.840X G 11/2 18,0
72x92 75 96 31 220 187 132
8501600.840X 1 1/2- NPT 17,0
8500700.840X G2 20,0
72x92 75 112 31 238 198 160
85O17O0.840X 2" NPT 17,5
EU Manufacturer's Declaration Note

as denned in EU Machinery Guideline 98/37/EC, Appendix II B These flat piston valves are intended for fitting in a machine. They must not
We hereby declare that the flat piston valves were developed and designed be commissioned until it has been established that the machine as a whole
using the following harmonised standards: conforms to the EU guideline.
EN 292 Machine Safety Note on Ell guideline

The valves shall be provided with an electrical circuit which ensures the limits
EN 983 Pneumatic Systems of the harmonised standards EN 50081-1 and EN 50082-1 are observed, and
hence the requirements of the Electromagnetic Compatibility Guideline
EN 60204-1 Electrical Equipment for Machinery (89/336/EEC) satisfied.
B u s c h j o s t and the picture Czi_Ju are registered trademarks of the IMI Norgren Buschjost GmbH + Co. KG, Germany.
D106102.04 Subject to change 11/01

AALBORG DATA SHEET
INDUSTRIES
Type:
• Level float switch
• RBA 24
Size:
• DN25
Application:
• Low water level switch
Material:
• St. 35.9
• C 22.8
Technical data:
• Drain connection: ø 12 mm
• Cable connection: PG 11
• Max. working pressure: 32 bar
• Max. working temperature: 239°C
• Flanges according to DIN 263 5-C
• Magnetic switch: 2 x M130
• Switching voltage: 6-250V
• Switch current max: 1A ac; 0.5A dc
• Protection of switch housing: IP 54
Type No.: 8100

Version: C Level float switch RBA 24, DN 25, PN 40 8100 000008

AALBORG DATA SHEET
INDUSTRIES
m m
Type:
1 \
i
• Temperature switch
• ATHs-20/a (O
(O
Application:
• For exhaust gas
Material:
|
=1 E «
,
• Steel *
i ' i
Technical data:
• Measuring range: + 20 - +500 °C lO
• Protection: IP54 00
• Cable entry: PG 13.5
% \'
t \-f G1/2"
,
300
'
„8
An
M
Il
II
4 1 2
Type No.: 8070

Version: A Temperature switch ATHs-20/a 632 0110

WH
Technical data CR 32
Dimensional sketches Dimensions and weights

Dimensions [mm] Net
Pump t y p e weight
B1 B2 B1 + 8 2 D1 D2 D3
[kg]
CR 32-1-1 505 281 786 178 110 135 79
CR 32-1 505 335 840 178 110 143 85
CR 32-2-2 575 391 966 220 134 298 103
CR 32-2-1 575 391 966 220 134 298 103
CR 32-2 575 391 966 220 134 298 107
CR 32-3-2 755 464 1219 260 172 350 148
CR 32-3 755 464 1219 260 172 350 148
CR 32-4-2 825 464 1289 260 172 350 158
CR 32-4 825 478 1303 306 197 350 185
CR 32-5-2 895 478 1373 306 197 350 189
CR 32-5 895 478 1373 306 197 350 199
CR 32-6-2 965 478 1443 306 197 350 203
CR 32-6 965 478 1443 306 197 350 203
CR 32-7-2 1035 600 1635 364 269 350 260
CR 32-7 1035 600 1635 364 269 350 260
CR 32-8-2 1105 667 1772 404 306 400 342
CR 32-8 1105 667 1772 404 306 400 342
CR 32-9-2 1175 667 1842 404 306 400 346
CR 32-9 1175 667 1842 404 306 400 346
CR 32-10-2 1245 667 1912 404 306 400 350
Electrical data 3 x 220-277/380-480 V, 60 Hz

Motor
Full load c u r r e n t Power factor Motor efficiency 'start
Pump t y p e
P2 [kW] li/1 [ A ] Cos q>„, n [%]
'1/1
CR 32-1-1 2.2 8.05-6.95/4.65-4.00 0.90-0.81 83.0-84.5 6.50-9.50

CR 32-1 3.0 10.6-9.00/6.10-5.20 0.90-0.83 85.0-86.0 7.40-11.0
CR 32-2-2 5.5 18.8-15.6/10.8-9.00 0.92-0.85 86.5-88.5 8.20-12.4
CR 32-2-1 5.5 18.8-15.6/10.8-9.00 0.92-0.85 86.5-88.5 8.20-12.4
CR 32-2 7.5 25.5-22.6/14.6-13.0 0.92-0.80 87.5-89.0 9.50-11.6
CR 32-3-2 11 38.0-32.5/22.0-18.8 0.92-0.86 89.0-91.0 6.80-8.60
CR 32-3 11 38.0-32.5/22.0-18.8 0.92-0.86 89.0-91.0 680-8.60
CR 32-4-2 11 38.0-32.5/22.0-18.8 0.92-0.86 89.0-91.0 6.80-8.60
CR 32-4 15 48.8-41.0/28.1-23.7 0.91-0.86 90.0-92.0 5.40-9.15
CR 32-5-2 15 48.8-41.0/28.1-23.7 0.91-0.86 90.0-92.0 5.40-9.15
CR 32-5 18.5 58.7-56-8/34-0-32-8 0.87 91.0-93.0 6.0-7.9
CR 32-6-2 18.5 58.7-56-8/34-0-32-8 0.87 91.0-93.0 6.0-7.9
CR 32-6 18.5 58.7-56-8/34-0-32-8 0.87 91.0-93.0 6.0-7.9
CR 32-7-2 22 75.0-61.0/43.0-35.0 0.86 91.0-93.0 5.1-7.9
CR 32-7 22 75.0-61.0/43.0-35.0 0.86 91.0-93.0 5.1-7.9
CR 32-8-2 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1
CR 32-8 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1
CR 32-9-2 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1
CR 32-9 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1
CR 32-10-2 30 100-78.0/58.0-45.0 0.87 91.0-93.0 5.0-8.1
General data Vertical multistage centrifugal pumps
CR 32, 45, 64 and 90 CRN 32, 45, 64 and 90
Materials: CR Materials: CRN

Pos. Description Materials DIN W. -Nr. AISI/ASTM Pos. Description Materials DIN W- Nr. AISI/ASTM
Cast iron ASTM 1 Pump head Stainless steel 1.4408 AISI-316UN
1 Pump head EN-JS1050
EN-GJS-500-7 80-55-06 Cast iron
2 Motor stool EN-JL1030 ASTM 25B
Cast iron EN-GJL-200
2 Motor stool EN-JL1030 ASTM 25B
EN-GJL-200 3 Shaft Stainless steel 1.4462
3 Shaft Stainless steel 1.4057 AISI 431 4 Impeller Stainless steel 1.4401 AISI 316
4 Impeller Stainless steel 1.4301 AISI 304 5 Chamber Stainless steel 1.4401 AISI 316
5 Chamber Stainless steel 1.4301 AISI 304 6 Outer sleeve Stainless steel 1.4401 AISI 316
6 Outer sleeve Stainless steel 1.4301 AISI 304
O-ring for
7 EPDM or FKM
O-ring for outer outer sleeve
7 EPDM or FKM
sleeve 8 Stainless steel 1.4408 AISI316LN
Base
Cast iron ASTM Acoflon 215
8 Base EN-JS1050 9 Neck ring
EN-GJS-500-7 80-55-06
10 Shaft seal
9 Neck ring Acoflon 215
11 Bearing ring HY49
10 Shaft seal
Bottom
11 Bearing ring Bronze 12 TC/TC *
bearing ring
Bottom
12
bearing ring
Terre* Cast iron EN- ASTM
13 Base plate EN-GJS-500-7 JS1050 80-55-06
Rubber parts EPDM or FKM
Stainless steel
* TC= Tungsten Carbide (cemented) Rubber parts EPDM or FKM
* TO!= Tungsten Carbide (cemented)
Performance curves CR 32
P -I n -
[MPal [m]-
CR 32
60 Hz
260- ISO 9906 Annex A
- - 9 —
2.4-
—-8
—8-2—
2.0-
200-
—"1——
-7-2
~
1.6-
140- -5
52
1.2-
-4-2
3
0.8-
-3-2
60-
—2 -—:
•2-1
0.4-
_-1
•11
20-
0.0 J ' 1
' ' ' ' ' ' 1
' '
1 ' 121
8 16 20 24 28 32 36 40 44 Q [m3/h]
1^
10 12 Q [l/S]
P2 P2 Eta
[hp] [kW]- - [%]
32 80
4- P2 1/1
Eta •60
3- P2 2/3
2 •40
———'
1 - •20
0-
y^
1 1 1
' ' '
12 16 20 24 28 32 36 40 44 Q [rtfVh]
P H NPSH
[m] NPSH [m]
[kPa]
32-
QH 3500 rpm 1/1
240- 24 QH 3500 rpm 2/3-
160- 16-
80 8-
1
0-
12 20 24 28 32 36 40 44 Q [m3/h]
AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure gauge, type P1116
Size:
• 0 63
Application:
• For all gaseous and liquid media
Material:
• Case: Stainless steel
• Socket: Cu-alloy
• Liquid filling: Glycerine
Technical data.
• Connection: G l/4"-m
• Measuring range: -1 to + 5 / - 0.1 to 0.5
[bar], [kg/cm2], [MPa]
• Pressure utilisation:
Static pressure: 75% of Pmax
Dynamic pressure: 66% of Praax
• Operating temperature: -20 to +80°C
• Accuracy: EN 837 Class 1,6
32
0
00
CO
G 1/4" -m
Type No.: 8050

Version: A Pressure gauge, ø 63 663 3118

AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure gauge, type P1116
Size:
• ø63
Application:
• For all gaseous and liquid media
Material:
• Case: Stainless steel
• Socket: Cu-alloy
• Liquid filling: Glycerine
Technical data:
• Connection: G l/4"-m (1/4 BSP)
• Measuring range: 0 - 25 / 2.5
[bar], [kg/cm2], [MPa]
• Pressure utilisation:
Static pressure: 75% of Pmax
Dynamic pressure: 66% of Pmax
• Operating temperature: -20 to +80°C
• Accuracy: EN 837 Class 1,6
32
oo
(O
G1/4"-m
Type No.: 8050

Version: A Pressure gauge, ø 63 663 3121
Type P1116

AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure switch
• KPS45
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
enamelled pressure die cast aluminium
(GD-AISi 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
removed, and the locking screw (5) is
loosened, the range can be set with the
spindle (1) while at the same time the
scale (2) is being read. In units having
an adjustable differential, the: spindle (3)
must be used to make the adjustment.
The differential obtained can be read
direct on the scales (4). 1 Range spindle
• To ensure that the plant functions 2 Range scale
properly, a suitable differential pressure 3 Differential spindle
is necessary. Too small a differential 4 Differential scale
will give rise to short running periods 5 Locking screw
with a risk of hunting. Too high a
differential will result in large pressure
oscillations.
Technical data:
• Operating pressure: 4 - 4 0 bar
• Differential: 2.2 - 11 bar
• Test pressure: 180 bar
• Pressure connection: G 1/4 -f
• Cable entry: Pg 13.5 for cable diameters
5 to 14 mm.
• Weight: 1.3 kg
Type No.: 8030

Version: A Pressure switch 631 0 3 4 0
KPS45

AALBORG DATASHEET
INDUSTRIES
Type:
• Full bore ball valve,
• EURO-SFER 1720
Size:
Application:
• Assembly in rigid pipe system
• Direction of flow in both directions
Specification:
• Thread ends: female - female UNI ISA 7/1 -rp
• Lever: aluminium handle UNI 5076
painted black with epoxy powder
DN I L IH CH , M , > ,'Ky FN"

"if*
i ii '
VA 8 11 51,5 23 20 50 42 5,4 64 0,13
Type No.:6666
Version:A Full bore ball valve 666 6006
EURO-SFER, 1720

AALBORG DATA SHEET
INDUSTRIES
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
. G W.- f
Type No.: 6210

Version: F Needle valve, straight, 1/2" x 1/2", PN 400 2541002

Description Index Date Drawn Appr
R<R0.1
w////////,\ v/////////,
R<R0.1
To be stamped: DN 65/ø10
0127
Plate
ø127x6 AISI316/GB4238
Item Pes. Cert.
Dimension Material type Detail drawing No.
Title: Drawn Date

LD 970616
Appr. Date
Orifice DN 65/010 MRJ 970616
••••••• Weight Scale: Size
iiiiiiiii Article/Drawing No:

1:1 A4R
Affix
AALBORG
INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN ISTOEPROPERTY OF AALBORG INDUSTRIES
AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY K18:003559
AALBORG DATA SHEET
INDUSTRIES
Technical data:
Type:
Max pressure: 123 bar
• Dosing pump P.E. 100 with chemical
Capacity: 2.5 1/h
tank
Max pressure suction side: 35 bar
Application: Max operating temperature: 50°C
• For chemical dosing Enclosure rating: IP 44
Insulation class: F
Material: Chemical tank volume: 100 1
Pump Colour: RAL 1028
Liquid end: PVC Weight: 28 kg
Check valve cartridge: PVC
Seats: PVC
Balls: Glass
Contour plate: PVC
Seals: Viton
Chemical tank: Polyethylene
Dosing head: Stainless steel
Chemical dosing unit item 9296 000002
Feed water line to boiler
ntSngs, item 246 2 7 0 7
Max 4.0 m from dosing pump

to feed water line
ratings, item 246 2707- Tank ventilation
Dosing valve, item 257 3307 Riling connection DN 15, PN 16, DIN 2633
ratings, item 246 2707
Dosing line ø12 x 1.5 mm

stainless steel
or steel pipe
Yard supply
Chemical tank
Dosing pump
Fittings, item 246 2707
Pressure valve
Suction valve
Filter
680
Type No.: 9296

Version: A Chemical dosing unit 9296 000002

AALBORG DATA SHEET
INDUSTRIES
Dosing valve item 257 3307

Fitting item 246 2707
12 12.5
L
0
a
0
5 —i •
Performance curves
2f
CO
O
20 —
10 1/h
10-
8l/h
10 20 40 80 100 Pressure (bar)
Type No.: 9296

Version: A Chemical dosing unit 9296 000002

AALBORG DATA SHEET
INDUSTRIES
Material:
Type:
• Sample cooler: austenitic stainless steel
• Sample cooler
grade316L
Size: • Cooling water inlet valve: stainless steel
• SCS 20 • Sample inlet valve: stainless steel.
• Compression fitting: carbon steel
Application:
Technical data:
• The sample cooler is designed for taking
manual samples of boiler water for • Coil design pressure: 32 bar g
analysis. The cooling water is turned on • Coil design temperature: 300°C
and the sample inlet valve is adjusted • Body design pressure: 10 barg
until a sample of boiler water is obtained • Body design temperature: 100°C
at a suitable temperature. For manual
sampling it is not normally necessary to
measure sample or cooling water flow
rates.
0 90
Sample in a 6 mm O/D
Customer supply
2. Sample inlet valve

1/4" BSP (each ends)
Compression fittings
for sample in 1/4" BSP
Cooling water out 1/2" BSP

Customer supply
. 1. Sample cooler
4. Cooling water Sample out

inlet valve 1/2" BSP
Cooling water in 1/2" BSP
Customer supply
Type No.: 7050

Version: A Sample cooler 875 0005

AALBORG DATA SHEET
INDUSTRIES
• Allow the sample to run for a while

Installation: before collection. This will ensure that a
• Fit the SCS 20 so that the bottom of the true sample is collected for analysis.
unit is accessible for the collection of • When enough liquid has been collected
the cooled sample. close the sample inlet valve first and
• Connect the cooling water inlet in !4" then the cooling water inlet valve.
nominal bore pipe via an inlet valve. • After closing the sample inlet valve the
• The cooling water outlet should be piped sample out connection may drip for a
to an open drain or tundish. few minutes while the coil drains.
• The sample inlet pipe should be in 6 mm
O/D tubes. Performance:
• The sample inlet to the cooler can be • When it is required to predict the
taken direct from a boiler or steam line performance of the sample cooler
isolating valve. system, the table below gives the sample
outlet temperature to be expected for
Operation: two boiler pressures an for two cooling
• Sample pipe work will become very hot water flow rates.
under normal working conditions, and
will cause burns if touched. Example
• Open the cooling water inlet valve first • A sample flow rate of 30 1/h is required
and ensure that a flow can be seen at the from a boiler operating at 10 barg. For a
cooling water outlet. cooling water flow rate of 0.4 1/s, from
• It is essential that cooling water is the table the sample outlet temperature
flowing before opening the sample inlet would be 4K (4°C) above the cooling
valve. water inlet temperature. If the cooling
• Gradually open the samples inlet valve water is 15°C, the sample temperatures
and regulate the flow to achieve a would be 19°C.
cooled sample at about 25°C.
Cooling water flow rate Cooling water flow rate

0.25 1/s (900 1/h) 0.4 1/s (1440 1/h)
Sample flow rate Boiler pressure
10 barg 20 barg 10 barg 20 barg
1/h 1/min Sample outlet temperature above cooling water inlet temperature K (°C)
10 0.17 3 3 1 1
20 0.33 5 5 2 3
30 0.50 7 9 4 5
40 0.67 8 10 5 7
50 0.83 10 12 6 8
60 1.00 11 13 7 10
80 1.33 12 16 8 12
100 1.67 15 19 9 14
120 2.00 17 22 10 16
Type No.: 7050

Version: A Sample cooler 875 0005

4M1V2,
• Am
AVN HYDRAULIK A-S
Excess flow check valves, 399669
DN 6 - 3/8" RG
sw3
Body and poppet valve steel galvanized - Valve guide brass - Seals elastomere.
All galvanized parts passivated for additional surface protection.
Application for fluid-lines with hydraulic fluids on mineral oil basis according to
DIN 51524 and DIN 51525.
For hydraulic fluids not easily inflammable according to VDMA 24317, for
Compressed air and other gases as well as for water hydraulics in adequate materials
On request.
Temperature range: from -30° up to +100° C.
Symbol —OV\A^-
Design poppet lifted from the seat by a spring with metallic seat
Fitting position any
Flow direction indicated with arrow
Pressure media mineral oils -30° up to +150° C, other

media and temperatures on request
Working pressure up to 400 bar
Viscosity up to 400 cSt (53° E)
Closing pressure l/min see schedule at 35 cSt (4,7° E) max.
Dimensions in mm Order numbers

t, l2 SW3 Closing pressure
DN PN d2
mm mm mm l/min
6 400 14 50 22 5 3/8" 39 96 69
/4rf/c/e A/o. éoZO 0ÛDOZ&

AALBORG DATASHEET
INDUSTRIES
• Input signal: 4-20 mA

Type: • Ambient temperature: -30°C to +80°C
• Control globe valve, straight with • Protection: IP 65
pneumatic actuator and I/P positioner
• 23.470, DP 33 Technical data unit:
• Design closing pressure: 25 bar
Size: • Weight: 34 kg
Installation:
Application:
• Only as shown in the picture
• For cooling, water, steam, brine and/or
gas flow 0 300
Material valve:
• Body: GGG 40.3
DIN -Material No. 0.7043
• Seat:X20Crl3
• Plug:X20Crl3
• Stuffing box: PTFE V-ring unit (-10°C to
+ 220°C)
Technical data, valve:
• Positioning ratio: 50:1
• Flow characteristic: Equal percentage
• Standard kv value: 25 m3/h
• Stroke: 30 mm
• Plug type: Parabolic shaft guided
• Flanges according to DIN Stuffing box
Technical data, actuator:

• Spring range: 1.5 - 3.0 bar
• Diaphragm area: 400 cm2
• Filling volume: 2.3 1
• Max air pressure: 6 bar
• Action: Normally closed valve on air
failure
Technical data, I/P positioner:
• Air connection: G %"
• Inlet air supply: 1.4 to 7 bar, instrument
air
• Air inlet consumption in stable state:
O.ôxKPNmVh
• Cable inlet: M20 x 1.5
Pneumatic control valve DN 40, PN 25,

Type No.: 6050
Version: B
with DP actuator 6050 000050
and I/P positioner

AALBORG DATA SHEET
INDUSTRIES
Type:
• Filter regulator with automatic drain
Size:
• Connections ports 1/4" BSP
• Gauge ports 1/8" BSP
Application:
• Instrument air for regulating pressure
Technical data:
• Medium: instrument air only
• Max. inlet pressure: 17 bar
• Operating temp.: -20 °C to + 65 °C
• Filter element: 5 f^m
• Recommend pressure regulating range:
0.14-7.0 bar
• Pressure gauge: 0 - 1 0 bar
• Weight: 0.4 kg Connections ports
i
Material: /y-J-j\
• Body: Steel B ftJP •
SW19J
• Bin: Steel i
i
• Handle: Acetal 41
Flow characteristics
In let pre«sur e 7 oar

bar
6
P
3 h
</>
res
4
Q.
tie
3
3 \
O 2
X
l
1 2 3 4 5 6 7 8 9 10
3
Ar flow [dm /s]
Type No.: 8000

Version: A Filter regulator with automatic drain 291 5101

AALBORG DATA SHEET
INDUSTRIES
Conductivity kit, loose supply.

Type: Consisting of:
• Test kits Drew AGKIOO supplemented Power supply: AC 110V or 220V
with Amerzine test. 1 Conductivity meter
Size: 1 Low range cell, white band, range 1-500
1 High range cell, range 20-10.000
• Dimension of box for AGK 100 test kit: 1 Conductivity cylinder, 100 ml
Height 105 mm, length 270 mm, 1 Thermometer
width 185 mm 1 Gallic acid
• Dimension of box for amerzine test kit: 1 Brass spoon
Height 45 mm, length 195 mm, Weight: 4 kg
width 155 mm
• Dimensions of box for hardness test kit:
Height 145 mm, Length 250 mm,
Width 165 mm
• Dimensions of conductivity meter:
Height 230 mm, length 140 mm,
width 130 mm
Application:
• Test kits for boiler water treatment.
• Test kit AGKIOO should only be used with
Amerzine test kit
Technical data:
• AGKIOO test kit.
Consisting of:
1 Comparator, phosphate, 0-20 ppm.
1 Snapping cup.
1 Plastic vial.
1 Glass tube vial.
1 Dropper.
30 Phosphate test tubes.
2 Hydrate alkalinity, rgt. A.
1 Hydrate alkalinity, rgt. B.
1 Phenolphthalein
• Amerzine Test Kit.
Consisting of:
1 Cylindrical comperator, Amerzine
1 Sample cup
30 Ampoules.
• Hardness test kit.
Consisting of:
1 Snapping cup
2 Boxes ampoules, 30 each
Type No.: 8500 Water testing equipment, AGK 100 with 880 0050
Version: D amerzine test

Description Index Date Lora
|_ D r a w n Appr.
Pipe dim. DN 100 -726 Pipe dim. DN80

M87
VENT. TO DECK
OPEN AIR
f==r~~i
,-lø~ ^ / i — . STEAM 6-7 bar g
-u *VJ—' 1055 kg/h [20 t/h]
1266kg/h[24t/h]
1319 kg/h [25 t/h]
HOT WELL TANK
7000000020
2.2
-v7
o
o
OJ
ç
fc£ M88
M87
Injector
1 1/2"
Vacuum breaker
1/2" Brass
2.2
2.2
7000000014
6000000010
Check valve 6020000006

'E M86 SS W S 1.4313
2.2
DN40 PN40
Temp.switch+pocket+4m cap.tube 8070000010
M85 40-105 "C
M89 Control valve 6000000042
M84 D N 4 0 PN16 Cast Iron
2.2
l— Filter 7040000016
M83 2.2
± DN40 PN16 Cast Iron
-i M82.6+M86.6
Counter flange (not shown) 8500000347
DN40
o screw and nut (not shown) 3000000024
o M82.2-M86.2 20
M16 8.8
/ Gasket (not shown) 3520000067
\ M82.1-M86.1 DN40 Graphite
CM M88 v- $ Stop valve DIN 1693 6010000043
M82 2.2
D N 4 0 PN16 GGG-40.3
Tag No. Detail drawing No.
Dimension Material type
ea-
rn --/ Title:
BiL 030828
c Steam injection system Appr.
for steam amount of 20, 24 and 25 t/h BZ 030828

Weight Size
5 Steam pressure: 6 bar
1:10 A3
Injectors seen from above (Type E)
INDUSTtlES TWS DRAWWG AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORO INDUSTRIES
AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 64Z:027665
Version: C Date: 1998-09-11 Pos. M 82
Description
A flanged bellows sealed stop valve, type BSAl, for use on
steam, condensate and water systems.
Limiting conditions
Body design conditions PN 16
Max. design temperature 300°C
Max. hydraulic test pressure 24 bar g
Size and pipe connection

DN40, Flanged DIN 2533/BS4504/ISO 7005 PN16.
Material specification
1 Body Cast iron DIN GG25
2 Bonnet SG iron DIN GGG 40.3
3 Seat Stainless steel AISI420
4 Disc Stainless steel DIN 17440 X30 Cr 13
5 Bellows Stainless steel DIN 17440 X6
Cr Ni Ti 1810
6 Stem Stainless steel AISI 420
7 Handwheel Pressed steel BS 1449 CR4
8 Stem packing Graphite
9 Bonnet screw Steel DIN931Gr5.6
10 Body/
Bonnet gasket Graphite laminate with
stainless steel insert
Dimensions in mm
DN 40
A 200
B 243
C 200
Weight, kg 10
Data Sheet
6010 000043
Stop Valve DN40,PN16 Page 1 of 1
AALBORG
INDUSTRIES
Version: B Date: 1998-09-11 Pos. M 83
Description
Standard screen stainless steel 0.8 mm perforations,
type Fig. 33.
Limiting conditions
Max. hydraulic test pressure 24 bar g

DN40. Standard flange: DIN PN 16.
Materials
1 Body Cast iron DIN 1691 GG20
2 Cap SGiron DIN 1693 GGG40
3 Cap gasket Reinforced exfoliated graphite
4 Strainer screen Stainless steel ASTMA240 316L
5 Cap studs Steel BS 4439 Gr 8.8
Cap nuts Steel BS 3692 Gr 8
Dimensions (approximate) in mm
DN 40
A 200
B 145
C 240
Screening area, cm 164
Weight, kg 7.2
Installation
Thé strainer should be installed in the direction of flow
as indicated on the body, in a vertical or horizontal
pipe line.
Data Sheet
7040 000016
Cast Iron Strainer, DN401PN16
Page 1 of 1
AALBORG
INDUSTRIES
Version: A Date: 2003-01-13 Pos. M 84
Available type
Normally open, single seat with phosphor bronze
balancing bellows with flanged connections, type
KB33.
Limiting conditions
Max. differential pressure, DN 40 8.2 bar

Standard flange BS 4504, PN 16.
1 Body Cast iron DIN 1691 GG 20
2 Bonnet Cast iron DIN 1691 GG 20
3 Valve closure
Member Stainless steel BS 970 431 S29
4 Valve seat ring Stainless steel BS 970 431 S29
5 Valve seat gasket Reinforced exfoliated graphite
6 Return spring Stainless steel BS 2056 302 S26
7 Stem Brass BS 2874 CZ 121
8 Bonnet gasket Reinforced exfoliated graphite
12 Bonnet studs Steel BS 4439 Gr 8.8
Bonnet nuts Steel BS 3692 Gr 8
DN40 MIO x 35 mm
13 Bellows Phosphor Bronze
14 Bellows gasket Reinforced exfoliated graphite
15 Bonnet bush Brass BS 2874 CZ 121
16 Plunger Brass BS 2874 CZ 121
DN 40
B 200
Cl 152
Weight, kg 11.2
Installation
The valve should be fitted in a horizontal line with the
actuator vertically below the line.
•• •
• ••
•••• Data Sheet
6000 000042
Control Valve, DN40, PN 16 Page 1 of 1
AALBORG
INDUSTRIES
Version: A Date: 2003-09-05
Description
A range of self powered control systems that
-Z
incorporate sensor, actuator, set point controller /
indicator, type 121.
Temperature range40 to 105°C

-1" BSP
1 Sensor Brass
2 Actuator Brass
3 Capillary tube Copper PVC Covered
4 Adjustment head Polypropylene
5 Union kit Brass
6 Mounting bracket Steel
7 Clip Polypropylene
8 Adaptor plate Steel
9 Pocket Stainless steel
BS3605CFS316S18
Control system
A 271
B 148
C 424
D 25
3 4000
Weight, kg 2.0
Pocket
F 430
G 28
Error! Not a valid link.

Pocket
Data Sheet
8070 000010
Temperature switch, 40-105°C
Page 1 of 1
AALBORG
INDUSTRIES
Version: C Date: 2002-09-26
Description
DCV2 Wafer check valves are designed to be sandwiched between
flanges. They are suitable for use on a wide range of fluids for
applications in process lines, hot water systems, steam and
condensate systems etc.
1 Body Ferritic Stainless steel WS 1.4313
2 Disc Austenitic Stainless steel BS 1449 316 S 11
3 4 21
3 Spring retainer Austenitic Stainless steel BS 1449 316 S 11
4 Heavy duty spring Austenitic Stainless steel BS 2056 316 S 42
Dimensions in mm
DN 40
A 101
B 85
C 79
D 31.5
E 65.5
F 40
Weight, kg 0.74
Installation
DCV Wafer Check Valves must be fitted in accordance
with the direction of flow arrow indicating correct fluid
flow direction.
Flange Joint
When fitted with a spring they can be installed in any Gasket (Supplied
plate. When supplied without a spring these must be by Installer)
fitted in a vertical flow line with the flow from bottom

to top.
The "cam" design of the body allows the various flange
types to be accommodated. The body is rotated to touch
the flange joint bolts ensuring that the valve is centred in
the pipeline.
Note:
Dies Check valves are not suitable for use where heavily
pulsating flow exists, such as close to a compressor.
» • «
• ••
••• •
Data Sheet
6020 000006
Wafer Check Valve, DN40, PN40 Page 1 of 1
AALBORG
I N D U S T R I E S
Version: B Date: 1998-09-11 Pos. M87
Description
The VB14 is a small purpose designed vacuum breaker
for general purpose applications on condensing vapour
(steam) or liquid systems.
Limiting conditions
Max. cold hydraulic test pressure 24 bar g

1/2" (System connection) Screwed BSP or NPT.
1 Cap Brass CU ZN 39 PB2
2 Valve Stainless steel Z 100 CD 17
3 Valve seat Stainless steel Z15 CN 16 02
4 Body Brass CU ZN 39 PB2
5 Gasket Stainless steel AISI304
Size 1/2"
A 55
B (A/F) 34
C 39
Weight, kg 0.35
Installation
The VB14 Vacuum Breaker must be installed in a
vertical position with the system connection at the
bottom.
• •*
• ••
••• Data Sheet
6000 000010
Vacuum Breaker, BSP 1/2' Page 1 of 1
AALBORG
INDUSTRIES
Version: A Date: 2000-10-30 Pos. M88
Description
• Steam injectors use steam to raise the
temperature of water or other liquids. They
work by using a jet of steam to draw in the
liquid through radial ports, mix it, and
distribute the heated liquid throughout the
tank or vessel. The circulation induced by
the injector ensures thorough mixing and
avoids temperature stratification.
Limiting conditions
• Body design rating: PN25
• Max. saturated steam condition: 17 bar g at
207°C
• Maximum heated liquid temperature
(tank/vessel vented to atmosphere): 90°C
• Weight: 1.6 kg
Materials
• Austenitic stainless steel grade 316L. 115
Installation Steam injector type IN40M

• Steam supply pipework must be firmly
anchored to prevent vibration and stress in
the tank wall. For more, information, see
drawing "Steam injection system".
• ••
• • •
• • • • Data Sheet
7000 000014
Steam Injector, B S P VA"
Page 1 of 1
AALBORG
INDUSTRIES
Version: A Date: 2000-10-30 Pos. M89
Description
• Steam injectors use steam to raise the
temperature of water or other liquids. They
work by using a jet of steam to draw in the
liquid through radial ports, mix it, and
distribute the heated liquid throughout the
tank or vessel. The circulation induced by
the injector ensures thorough mixing and
avoids temperature stratification.
Limiting conditions
• Body design rating: PN25
• Max. saturated steam condition: 17 bar g at
207°C
• Maximum heated liquid temperature
(tank/vessel vented to atmosphere): 90°C
• Weight: 0.8 kg
Materials
• Austenitic stainless steel grade 316L.
Steam injector type IN25M
Installation
• Steam supply pipework must be firmly
anchored to prevent vibration and stress in
the tank wall. For more information, see
drawing "Steam injection system".
• ••
• ••
••* Data Sheet
7000 000020
Steam Injector, BSP 1" Page 1 of 1
AALBORG
INDUSTRIES
Purpose and Application Electrode supply voltage
Delta voltage 0.5 V„/1000 Hz for LRS1 -5b
Continuous monitoring of the conductivity of liq- delta voltage 1.3 Vp/67 Hz for LRS 1 -6b
uids with the AI conductivity electrode
Mains supply
types ERL 16, LRG 16-4, LRG 17 or LRG 19.
120 V/60 Hz, 220V/50 Hz, 240V/50 Hz, 3.5 VA
Signalling of preselected conductivity limit value.
(please state voltage when ordering)
Application in steam boiler plants for feedwa-
Protection
ter and condensate monitoring; for conden-
IP 40
sate monitoring in district heating plants, in the
paper and pulp industry and in catering kitch- Permissible ambient temperature
ens; for conductivity monitoring in water 0...55°C
treatment plants; for monitoring of cooling Case materials
towers; for dyebath monitoring in dye works. Base: ABS plastic, black
Cover: ABS plastic, stone-grey
Design Weight
Approx. 0.5 kg
Plug-in unit in plastic case for installation in
control cabinets. The terminals in the case are
accessible after loosening two screws and un- Important Notes Conductivity limit switch LRS 1 -5b, LRS 1-6b
plugging the unit from its base. The avoid con-
fusion with other plug-in units of the AI Cable required for wiring to the electrode:
range, inserts are fitted in the bases so that Screened cable, e. g. 4 x 0.8 mm2, cable length
only the correct unit may be plugged into each
base.
The plug-in units may be snapped onto a
35 mm supporting rail or screwed into position
on a mounting panel.
Field enclosures for several plug-in units are
available on request.
Technical Data
Function
Measuring transducer with switch contact for
conductivity used with the conductivity elec-
trode types ERL 16, LRG 16-4, LRG 17 or
LRG 19, manual temperature compensation at
operating point
Input
Four connections for one conductivity elec-
trode ERL or LRG
Output
1 volt-free relay contact;
max. contact rating: 250 V, 500 W, 3 A resistive
with a life of 4 x 105 switching cycles or 0.35 A
inductive with a life of 2 x 106 cycles;
contact material silver, hard-gold plated
Limit value
Continuously adjustable within the respective
range
0.4...10mS/cmor0.04...1 mS/cmforLRS1-5b,
selection between the two ranges by switch on

front panel, values referred to 25 °C
Temperature influence can be compensated
with the aid of adjuster up to max. 250 °C on
reaching service temperature, initial position
calibrated to 25 °C
Switching hysteresis
1%
Indicators
Two LEDs: green for 0 < limit value
red for o > limit value
Cell constant of conductivity electrode
C - 1,0 [1 /cm]
Aalborg Industries Data sheet No. 8210 000005 1/2

Dimensions
Side view
Base with terminal s Front view Base Cover
j-H r" —• "

0 4,3 01 igJ
i fP-2 0
BHLRS1-...b
3 0 ^ D3I»0
4 0
CM
u
c
\t, 6
^
5 0
0
7 0
8 0
(o)
cr[s] <5>
9 0
10 0
c.OT- O
1
'J 0 T=25°C 1
12 0
m \
Cable
/
entries
^r
-J-
4i — - 51 •
Screws to fasten
cover to base Mounting clip for 35 mm supporting rail
- ( J- holes to be drilled to 4.3 mm dia for installation of unit in boiler panel

- hole drilled for mounting clip
Dimensions of conductivity limit switch types LRS 1-5b
Wiring Diagrams
LRS 1-5b
1
Ù 10
I
12
n
Alarm U
Mains
N
(
Conductivity electrode /*» f\ / \ / * \

ERL16orURG16-4 |3 |2 |1 | l
15
A AAA
Conductivity electrode |
LRG17orLRG19
| C - 1 cm"' J
Wiring diagram for conductivity limit switch type LRS 1 -5b,

illustrated position of contact: relay de-energized, i.e. alarm

Technical data for conductive electrode ERL 16-1
Technical data:
Max. service pressure:

32 barg at saturation temperature 238 degr. C
(higher pressures available on request)
Connection: Thermal
ERL 16-1: screwed 3/4" BSP, PN 40 to DIN 228 insulation
y
Length (L) supplied: jj Screwed %"
ERL 16-1: 99 mm - DN228
Materials:
Body: X 6 CrNiMoTi 17 12 2 (1.4571)
Electrode rod: X 6 CrNiMoTi 17 12 2 (1.4571)
Electrode tip: X 6 CrNiMoTi 17 12 2 (1.4571) Conductivity electrode type ERL 16-1, 3h°
Insulating sleeving: PTFE
Terminal box and connector: plastics
Permissible conductivity range:

From 1 micro S/cm
Max. permissible ambient temperature at terminal box:

60 degr. C
Electric connection:
Via four-pole connector with screw terminals,
cable strain relief and cable gland Pg 11.
Approx. weight:
0.9 kg
Design:
The conductivity electrode is provided with an electrode
rod completely insulated by a PTFE sleeving except for
the measuring surface. A pressure-tight sealing between
electrode rod and body is ensured by a Teflon tube.
Installation:
The conductivity electrode can be installed vertically,
horizontally, or radially inclined. The electrode tip must
be constantly submerged by at least 100 mm.
Installation on a side connection (measuring pot) is highly
recommended.
Aalborg Industries Data sheet No. 8620 000003

AALBORG DATA SHEET
INDUSTRIES
Type:
• Control unit for oil detection equipment
Application:
• The control unit is operated together with
an ultrasonic sensor.
• The equipment provides for oil detection
in feed/make-up water.
Material:
• Control device cabinet: Polycarbonate
Technical data:
• Power supply (selector switch):
110/120Vor220/240VAC
• Relay output: DPCO
• Enclosure: IP 65
• Holes for glands 3 of ø 16
1.
G O Normal O
O Alarm
O Fault
oc
•0
'
188 Holes for mounting
r
in
<&- ©©• o
^ Holes for glands

40
« .
130
160
200 ^
Type No.: 8210

Version: A Control unit for oil detection equipment 8210 000025

AALBORG DATA SHEET
INDUSTRIES
Type:
• Ultrasonic sensor for oil detection
equipment
Application:
• The ultrasonic sensor is operated
together with a control unit.
• The equipment provides for oil detection
in feed/make-up water.
Material:
• Sensor: Stainless steel
Technical data:
• Temperature: -70°C to 150°C
• Design of duty: Chemical interface
• Liquid type: Clean, viscous with solids
• Cable: 6 metre
258
.20.1.25, 152 .26
T -
Type No.: 8310 Ultrasonic sensor 8310 000005

Version: A for oil detection equipment

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

- Nominal pressure PN 160 1 mbar to 30 bar
- Nominal pressure PN 420 2.5 mbar to 30 bar
• Lower measuring limit
- Measuring cell with silicone oil filling -100 % of max. span or 30 mbar (absolute)
- Measuring cell with inert filling liquid
For process temperature
-20 "C < i» < 60 °C 30 mbar (absolute)
For process temperature 30 mbar (abs.) + 20 mbar (abs.) {-a - 60 °C)/°C
+60 "C < i3 S 100 "C (max. +85 °C
for 30-bar measuring cell)
• Upper measuring limit 100 % of max. span (max. 160 bar with oxygen measurement
and inert filling liquid)
• Start-of-scale (continuously adjust.) Between the measuring limits
Output
Output signal 4 to 20 mA
• Lower limit (continuously adjustable) 3.55 mA, factory-set to 3.84 mA
• Upper limit (continuously adjustable) 23.0 mA, factory-set to 20.5 mA or optional 22.0 mA
• Ripple (without HART communication) /pp s 0.5 % of max. output current
• Electric damping
- Adjustable time constant (T63) 0 to 100 s in steps of 0.1 s, factory-set to 0.1 s
• Current transmitter Adjustable from 3.55 to 23 mA
• Signal on alarm Adjustable from 3.55 to 23 mA
Load
• Without HART communication R B S (U H -10.5 V) / 0.023 A in ft UH: power supply in V
Characteristic Linear rising or falling or square-rooted
Accuracy
Reference conditions Increasing characteristic, start-of-scale value 0 bar, stainless steel seal diaphragm (with level:
mounting flange without tube), silicone oil filling and room temperature (25 °C)
r = max. span/set span = span ratio
Error in measurement with fixed-point
setting (including hysteresis and
repeatability)
- Linear characteristic
rslO s 0.1 %
10<r<30 S 0.2 %
30<r<100 <, (0.005 • r + 0.05 %)
- Square-root characteristic
Flow > 50 % <0.1 % a t r < 1 0
<, 0.2 % at
10<rs30
Flow 25 to 50 % £0.2%atr<10
< 0.4 % at
10<rS30
• Repeatability Included in error in measurement
• Hysteresis Included in error in measurement
Response time Approx. 0.2 s. approx. 0.3 s with 20- and 60 mbar measuring cells
(T63, without electric damping)
< m i . A o/
20-mbar measuring cell < (0.2 r) %
Ambient temperature effect
1
• At-10 to+60 °C ä (0.1 r + 0.2) "/o *
• At -40 to -10 °C and +60 to +85 °C < (0.1 r + O.ISr/o/IOK 1 1

Influence of static pressure
• On start-of-scale <, (0.15 r ) % per 100 bar
- 20-mbar measuring cell <. (0.15 r ) % per 100 bar
• On span <, 0.2% per 100 bar
- 20-mbar measuring cell <, 0.2 % per 32 bar
Influence of mounting position < 0.7 mbar per 10° inclination
Influence of power supply 0.005 % per 1 V change in voltage
Rated operating conditions
Installation conditions
• Installation instructions Any mounting position
Ambient conditions
• Ambient temperature
(observe temperature class in
potentially explosive atmospheres)
- Measuring cell with silicone oil filling -40 to +85 °C
30-bar measuring cell -20 to +85 °C
- Measuring cell with inert filling liquid -20 to +85 "C
- Digital display -30 to +85 °C
• Ambient temperature limits See ambient temperature
• Storage temperature -50 to +85 °C
• Climate class
- Condensation Permissible
• Degree of protection (to EN 60 529) IP 65
• Electromagnetic compatibility
- Emitted interference To EN 50 081-1
- Noise immunity To EN 50 082-2 and NAMUR NE 21
Medium conditions
• Process temperature
- Measuring cell with silicone oil filling -40 to +100 °C
30-bar measuring cell -40 to +85 °C (-20 to +85 "C for 7MF4533)
- Measuring cell with inert filling liquid -20 to +100 °C
30-bar measuring cell -20 to +85 °C
• Process temperature limits See process temperature
• Process pressure limits Nominal pressure (PN)
Design
Weight (without options) Approx. 4.5 kg
Dimensions See drawing
Material
• Wetted parts materials
- Seal diaphragm Stainless steel, mat. No. 1.4404. Hastelloy C276, mat. No. 2.4819,
Monel, mat. No. 2.4360, tantalum or gold
- Process flanges and
sealing screw Stainless steel, mat. No. 1.4408, Hastelloy C4. mat. No. 2.4610 or Monel. mat. No. 2.4360
- O-ring
FPM (Viton) or as option: PTFE, FEP, FEPM and NBR
• Non-wetted parts materials
- Electronics housing Die-cast aluminium, low in copper, GD-ALSi 12, or stainless steel precision casting,
polyester-based lacquer, stainless steel rating plate
- Process flange screws Steel, galvanized and yellow-passivized, or stainless steel
- Mounting bracket (option) Steel, galvanized and yellow-passivized, or stainless steel
Measuring cell filling Silicone oil or inert filling liquid (max. 160 bar with oxygen measurement)
Process connection Female thread 'A -18 NPT and flange connection to DIN 19 213 with
mounting thread M10 (M12 for PN 420) or 7/16-20 UNF
Electrical connection Screw terminals, cable inlet via screwed gland Pg 13.5 (adapter),
M20 x 1.5 or Vz -14 NPT, or Han 7D/Han 8U pluq
Displays and controls
Input keys 3 for local programming directly on transmitter
Digital display Built-in, cover with window (option)
Power supply (U H )
Terminal voltage on transmitter DC 10.5 to 45 V and DC 10.5 to 30 V in intrinsically-safe mode
Ripple Upp S 0.2 V (47 to 125 Hz)
Noise U r m s <1.2mV(0.5to10kHz)

Certificates and approvals Exclusively decisive are the data in the official EU prototype test certificate
and the respectively valid supplements
CENELEC To DIN EN 50 014: 1997, EN 50 020: 1994 and EN 50 284:1999
• Intrinsic safety © H1/2GEExiallCT4/T5/T6
- EU prototype test certificate TÜV99ATEX1494
- Max. ambient temperature +85 °C temperature class T4
+70 °C temperature class T5
- Connection to certified intrinsically- L/| = 30V, /|= 100 mA,
safe circuits with maximum values Pi = 750 mW, R, = 300 n
- Effective internal inductance /-i = 0.25mH
- Effective internal capacitance Q = 6nF

• Explosion-proof ©H1/2GEExdllCT4/T6
- Conformity certificate PTB99ATEX1160
- Max. ambient temperature +85 °C temperature class T4
11
S)v^yc±
—<.
flî > 15
* 45 for Pg 13.5 68
120
1 a Process connection of low-pressure side V* 18NPT 5 Terminal side
1b Process connection of high-pressure side V4 -18 NPT 6 Electronics side, digital display
2 Mounting thread M10, M12 or 7 / 16 - 20 UNF 7 Protective cover over keys
3 Blanking plug 8 Sealing screw with valve
4 Electrical connection: 9 Vent on side for liquid measurements
screwed gland Pg 13.5 (adapter), M20 x 1.5 or 10 Vent on side for gas measurement (suffix H02)
14-14 NPT or Han 7D/Han 8U plug 11 Mounting bracket (option)

AALBORG duHflMBflWHIB^^^^^M
Table of contents
Steam atomising burner
General 1
Steam atomising burner, type KBSA
Precautions with fuel oil 1

General system description 2
Functional description 3
Operation instruction 4
Commissioning 5
Manual operation 6
Maintenance instructions 7
Faults and rectifying faults 8
Steam atomising burner settings 9
Photo cell
Description 1
Viscosity - temperature chart
Description 1

AALBORG STEAM ATOMISING BURNER OM5580#01.0
INDUSTRIES
Steam atomising burner

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

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

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

AALBORG STEAM ATOMISING BURNER, TYPE KBSA OM5580#02.1
INDUSTRIES
Steam atomising burner, type KBSA
1 Precautions with fuel oil

Fuel oil is usually the residue of crude oil after the removal by distillation of the
most volatile oils and gases. Fuel oil in its liquid state is very difficult to ignite in
bulk and not capable of spontaneous combustion. The vapour, however, is explosive
when mixed with air, and being heavier than air, tends to accumulate in low levels,
such as bilges and bottoms of tanks where it may remain undiscovered until ignited.
It is always present in a partly filled oil tank, or in a tank which has contained fuel
oil and from which the vapour has not been removed by artificial means, and is
given off through the vents from tanks in process of being filled.
A leak in any part of the oil burning system, if allowed to continue, may result in an
accumulation of this explosive vapour.
Ignition of the vapour has been 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 has been communicated from galley or fires under boilers.
Warning: 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 preventative of accident than adherence to any set of rules that may be
prescribed. The following precautions, however, should be rigidly enforced:
• When oil is being received no naked light, or electrical apparatus liable to spark
should be permitted within 20 m of the oil hose, tank, or compartment
containing the tank, or the vent from the tank, excepting 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 tank, except the vents, are closed.
No naked lights or electrical apparatus, liable to spark should be permitted at
any time in a compartment containing a fuel oil tank. Electric lamps used in
such compartments should have a wire protector around the bulb, or be of a type
that will ensure the breaking of a circuit through the lamp in the event of the
lamp being broken.
• No one should be allowed to enter a fuel oil tank until it has been gas freed, and
any person then entering the tank must have a life line around his body properly
tended in order that he may be hauled out if overcome by gas.
Electrical fuses and switches, unless of 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 at all times intact.

INDUSTRIES
• Dampers fitted in the uptakes of the boilers, must be kept fully open while
burning oil. Otherwise gas may accumulate dangerously in the furnace with a
resultant blowing out into the boiler or engine room.
• The valves on glass gauges on fuel oil storage or settling tank should be kept
habitually shut. When a reading of the gauge is desired the valves may be
opened, but must at once be closed again.
• In each boiler or engine room fitted for oil burning there should be fire
extinguishing apparatus in accordance with the requirements/rules of the
authorities and classification societies in question. The fire extinguishing
apparatus can for example be a fire hose, permanently coupled and of sufficient
length to reach all parts of the boiler or engine room and either:
— a box containing at least 85 litres of dry sand with a large scoop, or
— chemical fire extinguisher of the tank type.
• When the fuel oil system has not been in use for a longer 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 lighted. During
the test a careful inspection for leaks should be carried out.
• Fuel oil should not be habitually heated above 65°C for light oils and 120°C for
heavy oils and never above the flash point of the oil in any part of the system.
Care must be taken to prevent accumulation of oil or vapour in any place outside
the system, and in ships, particularly in bilges under the furnace. This can be
accomplished by rigid cleanliness.
• In the event of a considerable accumulation of oil in the furnace, such as may be

caused by a sudden extinguishing of the burners, the vapour must be blown out
through the boiler into uptake and funnel by fan or steam hose before the fires
are again lighted.
Note: This furnace purge is done automatically when the burner is operating
in "auto-mode", but has to be done manually when the burner is in
"manual-mode".
General system description

The following contains a general description of the components in the burner unit.
The burner unit consists of a steam atomising burner and supply systems for oil,
steam, and combustion air with the required data for correct burner performance.
The burner is mounted on the top or the side of the boiler, and the combustion air
fan must be connected to the burner via an air duct. The burner is capable of burning
both diesel oil and heavy fuel oil. An illustration of the KBSA burner is shown in
Figure 1.

INDUSTRIES
Illustration of a KBSA burner
Figure 1 kbsal.cdr
2.1 Burner design
The steam atomising burner gives the thermal input to the oil-fired boiler in order to
achieve the specified steam demand in the operating range. The burner is designed
so that the flame fits the actual furnace dimensions and gives a correct combustion
provided the supply conditions of fuel, air and steam are correct.
The burner consists of a wind box and an air register with divided swirler. The guide
vanes of the inner swirler have a fixed design whereas the guide vanes of the outer
annular swirler have a design depending on the furnace geometry.
2.1.1 Wind box design

The steel wind box is the main structural part of the burner unit and is provided for
mounting or welding onto the boiler. On the burner wind box the front plate is
mounted in which for lance, ignition burner, flame scanner and peep-hole are
incorporated.
The valve arrangement for fuel oil and atomising steam is mounted directly on wind
box, flexible hoses connect the valve arrangement to the lance.
2.1.2 Burner register
The burner register is the duct between the wind-box and the furnace. The ignition
burner, the burner lance with the atomiser, and the flame stabiliser are placed in the
burner register.
For maintenance and inspection purposes the burner lance can be dismounted from
the front plate, making cleaning and replacement of the atomiser very easy.

INDUSTRIES
The flame stabiliser is designed to create an internal re-circulation of hot gases to

provide continuous ignition, and hereby to stabilise the flame which results in less
pulsation.
2.1.3 Burner lance

The burner lance, illustrated in Figure 2, contains the Y-jet atomiser, where steam
and fuel are mixed and ejected. This oil mist is then mixed with primary and
secondary combustion air, and the combustion is completed. Ignition is achieved by
a flame from the ignition burner. Both lance and ignition burner are purged during
normal stop to prevent drip and build-up of carbon deposits.
Burner lance
Steam inlet
Figure 2 gun.cdr
2.1.4 Y-jet Atomiser

The Y-jet atomiser, illustrated in Figure 3, operates on the principle of the atomising
medium [B] (steam or compressed air) and fuel oil [A] at high velocity, impacting
within the intersecting atomising medium and oil passage of the nozzle. To achieve
this, passages are in an Y-configuration and disposed radial around the nozzle, and
the dimension and number of passages are dependent on the oil burner capacity.
This has the advantage of maintaining the high passage velocity right up to the point
of impact. Further atomisation takes place in the combined mixing and ejection of
the atomiser.
Y-jet atomiser
Figure 3 Y-jet.cdr

INDUSTRIES
Atomisation is almost independent of oil pressure and consequently the excellent

quality is maintained down to the minimum firing rate.
The atomising medium and oil are supplied from the shut-down valves through
flexible hoses to the burner lance.
In addition to the very low consumption of the atomising fluid (approx.1% of the oil
weight at full load), the Y-jet burner has a high turndown ratio, up to 10:1,
dependent on size.
2.1.5 Flame failure equipment
Flame failure during light up and normal operation is detected by a photo electric
cell mounted on the burner unit and coupled to an amplifier mounted inside the
control panel.
On loss of flame this flame failure equipment will automatically shut down the
burner.
The number of photo cells for automatic service and manual service depends on the
classification society.
2.2 Atomising steam/air system
Steam for atomising is supplied from the boiler drum or common steam line, and the
steam pressure is reduced to 6 bar or lower. The steam pressure at the burner is
automatically lowered for stabilisation of flame when the burner load is decreased.
When the burner is stopped normally, the purge valve will open automatically and
the oil remaining in the burner lance will be atomised and fired into the furnace and
the burner lance is cleaned. The atomising steam valve is closed after the end of the
-purge period.-
If steam is not available, compressed air at a pressure of approximately 7 bar can be
used as atomising medium for starting up.
2.2.1 Atomising steam pressure control
The steam pressure is controlled by an electrically operated regulating valve, and the
corresponding controller keeps a pre-set pressure according to the fuel flow to the
burner.
2.2.2 Atomising steam pipe - drain
A thermostatic steam trap can be fitted to drain the condensate in order to have dry
steam at the burner.
2.3 Ignition oil system
The diesel oil is supplied by a pump which is only running during ignition. In plants
which consist of two boilers each burner has its own ignition oil pump, and a
solenoid valve between these two pumps which is normally closed.
2.3.1 Ignition oil pump
The ignition oil pump is a gear pump fitted with a pressure limiting valve and a filter
inside the housing. The pump pressure should be adjusted to give 8-10 barg at the
ignition burner.
If a pump fails, in a double boiler plant, the other can be selected to supply diesel oil
for ignition to both burners, and in this mode the solenoid valve must be open.

INDUSTRIES
2.3.2 Ignition burner

The ignition burner, illustrated in Figure 4, operates on the principle of mechanical
pressure jet atomisation. The ignition burner is retractable and inserted/retracted by
an air cylinder.
Combustion air for the ignition burner is supplied from the compressed air system,
and can be adjusted by means of the throttle valve, placed after the solenoid valve.
The ignition burner is automatically purged by compressed air.
At the end of the furnace purge period the solenoid valves for diesel oil and
combustion air to the ignition burner are released and the ignition burner is ignited
by means of an electric high-tension spark. The ignition burner is simultaneously
moved into ignition position. When the ignition flame is stable the pick-up of this
release the oil for the main burner. The ignition burner must ignite the main burner
within the pre-set ignition period. At the end of the ignition period the solenoid
valves to the ignition burner are switched off and closed, the ignition burner is
purged with compressed air and returns to starting point in the retracted position.
Ignition burner
-UL
Oil inlet
3G
^H3^
Air inlet
* L
Figure 4 ignitor.cdr
2.4 Combustion air system
The combustion air system supplies air to the burner according to the demands of
the control system.
The draft loss of the burner air register is measured by a differential pressure
transmitter, which converts the signal to a flow signal used by the control system for
automatic air/oil ratio control.
The combustion air is supplied by a directly driven centrifugal fan. The fan is
mounted on a common bed frame with motor, inlet vanes, and servo-drive unit. The
air flow to the burner is regulated by inlet vanes mounted on the fan suction side.
The inlet vanes are of a multi-blade design and regulated by a servo-driven unit
comprising an air cylinder and an I/P positioner. A silencer can be mounted on the
fan suction side.
2.5 Oil supply system
This section describes the oil system in general terms together with some of the
requirements needed to have a safe and reliable burner operation.
The burner and the oil system are designed for both diesel oil and heavy fuel oil
operation. A diagram of the oil system for steam atomising burners is shown in
Figure 5. The diagram shown is for a plant with two steam atomising burners. Please
note that the oil system can be designed somewhat differently from plant to plant
depending on the requirements.

AALBORG STEAM ATOMISING BURNER. TYPE KBSA OM5580#02.1
INDUSTRIES
The oil system consists of oil tanks for diesel oil and heavy fuel oil, mixing tube, oil
pumps, heaters, ignition oil pumps, and equipment for oil pressure and temperature
control.
The automatic shut-off valves, re-circulation valve, solenoid valves, and the rest of
the necessary burner mountings are all fixed on the wind-box. All shut-off valves are
ball valves, and the automatic valves are with electric/pneumatic actuators.
The arrangement of the components on the burner is made as simple as possible and
is hence very user friendly regarding operation and maintenance.
To avoid blockage, all pipelines carrying heavy fuel oil must be traced either by
means of steam or electrically.
The oil flow control valve is fitted with a pneumatic converter/positioner. To obtain
a very accurate regulation of the oil, which is very important to have a large turn-
down ratio, the valve is also fitted with an adjustable Cv-adjuster. This Cv-adjuster
makes it possible to adjust the pressure loss coefficient of the valve whereby the oil
flow regulation can be optimised to each single installation. The oil flow is
measured by a screw-type flow meter.
The fuel oil temperature before the burner inlet is kept precisely at the desired value
by means of an electric actuated control valve, a single loop PID-controller, and a
PtlOO temperature transmitter.
The fuel oil pressure control loop includes an electric actuated control valve to
ensure the correct pressure at the fuel oil inlet of the burner, and thereby providing a
larger turn-down ratio of the control valve. A single loop PID-controller and a
standard 4-20 mA pressure transmitter ensure optimum and accurate functionality.
The air/oil ratio is controlled automatically. The oil flow is measured by a screw-
type flow meter and the air flow is measured as a differential pressure across the
burner air register.
The modulation of the burner is fully automatic on each fuel type. The operator can
change to manual operation. The change from diesel oil to heavy fuel oil and the
change from air atomising to steam atomising and vice versa are achieved by
manual operation.
Functional description
This section contains a functional description of the burner plant and the flow ways
in the system.
3.1 Fuel oil supply system
To give a clear picture of the fuel oil supply system the system is split into two
separate systems, a part ("Part one") containing the accessories connected to the fuel
oil tanks, pumps and heaters, and a part ("Part two") containing accessories related
to the burner and regulating system.
The two subsystems of the fuel oil system are described in the following two
subsections and they are illustrated schematic in Figure 5 and Figure 6 respectively.

INDUSTRIES
3.2 Fuel oil supply system, "Part one"
"Part one" of the fuel oil supply system is characterised as the part of the system
which is connected to the fuel oil tanks and heater. The primary system is schematic
illustrated in Figure 5. The oil system is shown as a plant with two boilers, but is
also valid for a plant with only one boiler.
Schematic illustration of fuel oil supply system, "Part one"
Figure 5 F_oilsys.cdr
3.2.1 Oil tanks

The heavy fuel oil tank may be provided with a heating coil for heating up the fuel
oil in the tank to at least 50°C, at which temperature it will be possible to pump the
oil. The oil temperature in the tank should not heated too much in order to keep the
oil temperature controlled by the heater units.
Whenever a boiler plant is intended to operate on heavy fuel oil, all pipes carrying
fuel oil must be insulated and traced in order not to cool the oil if the circulation is
stopped. The tracing can be done either by means of steam heating or by means of
electric heating cables.

INDUSTRIES
3.2.2 Fuel selection

The fuel type is selected by manually operating the three-way valve (Gl 15) in the
oil system.
The heavy fuel oil can be taken from both the service tank and settling tank. If the
heavy fuel oil is taken from the settling tank the suction level from the tank must be
arranged in a sufficient level height to prevent e.g. water, sand, or particles from
entering the oil system.
3.2.3 Return flow from the burner

When the burner is in stand-by mode, a minimum of fuel oil is returned via the oil
return line to the three-way valve ( G i l l ) . From here the fuel oil is either led to the
pump suction side via the mixing tube (Gl 10) for degassing or to the heavy fuel oil
settling tank. The three-way valve normally returns the fuel oil to the mixing tube.
The three-way valve is a pneumatically operated actuator controlled by a solenoid
valve (Gl 13). The solenoid valve has a manual operator screw-type slot for
emergency operation.
If the fuel is changed from diesel oil to heavy fuel oil by means of the three-way
valve (Gl 15), the three-way valve ( G i l l ) automatically changes position and
returns the oil to the heavy fuel oil settling tank for a period of time.
This arrangement is necessary to avoid that diesel oil is heated by the pre-heater in
this specific operating sequence. The viscosity of the re-circulated diesel oil will
decrease and hereby also the lubrication characteristic. If the oil is led to the pumps
this will cause damage to the pumps.
After the pre-set time period has expired, the three-way valve ( G i l l ) returns to
normal position, and the fuel flows to the mixing tube (Gl 10).
The time period must be set with regard to oil pressure and the quantity of oil in the
pipe system.
3.2.4 Fuel oil supply pump

The oil system is fitted with one set of supply oil pumps suitable for both diesel oil
and heavy fuel oil (G05 and G12).
The supply oil pumps (Gl47) is a twin type package in which two screw spindle
pumps with driving motors are connected by a cross over arrangement to the valve
housing. Each pump is fitted with a pressure relief valve, a filter (G02 and G09), a
mano/vacuum gauge (G04 and Gl 1) at the filter, and stop valves (G07 and G14).
The pumping capacities for each of the pumps are calculated in such a way that
there will be sufficient oil flow to the burner(s) and the pressure regulating valve in
full load condition.
The control system receives a signal from the pressure transmitter (G99). If the
pressure drops below the pre-adjusted set point, the operating pump stops, and the
stand-by pump starts. If the pressure continues to drop, the control system gives
alarm for low oil pressure and stops the burner(s).
3.2.5 Fuel oil pressure control

A part of the fuel oil returns to the pump suction side through the oil pressure
control valve (Gl00) which keeps a pre-set pressure in the fuel oil system.
The fuel oil pressure control loop includes an electric control valve (Gl00) to ensure
the correct pressure at the fuel oil inlet of the burner. This provides larger turn-down
ratio of the control valve. A single loop PID-controller and a standard 4-20 mA
pressure transmitter (G99) ensure optimum and accurate functionality.

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3.2.6 Pre-heater
The oil system is provided with pre-heater(s) (G22) heating the heavy fuel oil to the
correct temperature/viscosity by means of steam.
The fuel oil is changed by means of the manually operated three-way valve (Gl 15).
When diesel oil is selected, the stop valve (G51) must be opened, and the stop
valve(s) (G25) must be closed. When heavy fuel oil is selected, the stop valve(s)
(G25) must be opened, and the stop valve (G51) must be closed.
3.2.7 Fuel oil temperature control

The heavy fuel oil temperature after the pre-heater(s) is kept at the desired value by
means of a flow control valve (G20), a single loop PID-controller, and a PtlOO
temperature transmitter (G28).
3.2.8 Ignition oil system
The ignition system always operates on diesel oil no matter if the steam atomising
burner operates on diesel oil or heavy fuel oil. This secures a reliable ignition.
The diesel oil is supplied by an ignition oil pump (G72) with filter (G70). The pump
is only operated in ignition mode. The ignition oil pump is a gear pump fitted with a
pressure limiting valve and a filter inside the housing. The pump should be set to 8-
10 bar.
A plant with two boilers is provided with two ignition oil pumps. If a pump fails, the
other can be selected to supply diesel oil for the ignition to both burners.
3.3 Fuel oil supply system, "Part two"
"Part two" of the fuel oil supply system is the part of the system which is situated
next to or on the burners. The secondary system is schematic illustrated for a single
burner in Figure 6.
Schematic illustration of the fuel oil supply system, "Part two"

1 - Stop valve
2 - Isolating valve
3 - By-pass valve
4 - By-pass valve
5 - Stop valve
6 - Fuel flow transmitter
7 - Stop valve
8 - Stop valve
9 - Fuel oil flow control valve
10 - Stop valve
11 - Fuel oil thermometer
12 - Fuel oil pressure gauge
13 - Air filter/reduction
14 - Stop valve
15 - Isolating valve
Fuel oil supply from
16 - Fuel oil pressure gauge heaters/pumps
17-Shut-offvalve
18 - Air filter/reduction
19 - Three-way valve
Return flow to
mixing tube
Figure 6 B_sys03c.cdr

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From the fuel oil heater or by-pass line the fuel flows to the stop valve (5), fuel flow
transmitter (6), stop valve (7), stop valve (8), fuel oil flow control valve (9), and stop
valve (10). The by-pass valves (3 and 4) is arranged for the fuel flow transmitter and
the fuel oil flow control valve.
At the burner the fuel is either re-circulated directly back to the mixing tube (if the
burner is stopped) or into the burner (if the burner is in operation) through the three-
way valve (19).
If the burner is in operation, the fuel flows through the shut-off valve (17) and stop
valve (14) and finally enters the burner lance.
If the burner is stopped, the fuel will flow through the three-way valve (19) to the
throttle valve (1), which directs the flow back to the diesel oil tank or the heavy fuel
oil tank.
3.4 Atomising steam system
The atomising steam system is illustrated schematic in Figure 7, and is described in

the following.
Steam is supplied from the boiler drum valve or the common steam line, and flows
through the stop valve (1), the pressure regulating valve (2), the non-return valve
(3), and the stop valve (4).
At the burner the steam enters the condensate separator (12), and flows through the
shut-off valve (23), and the stop valve (16), and finally enters the burner lance.
Atomising steam system
BURNER
1 - Stop valve
2 - Pressure regulating valve
3 - Non-return valve
4 - Stop valve
6 - Stop valve
7 - Stop valve
8 - Steam trap
9 - Stop valve
11 - By-pass valve
12 - Condensate separator
13 - Purge valve
15 - Stop valve
16 -Stop valve
18 - Pressure gauge
20 - Low pressure switch
22 - Pressure transmitter
23 - Shut off-valve
From boiler
Atomizing steam, 7 to 12 barg / ,
Compressed air (7 bar)
Figure 7 B_sys05a.cdr

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The purge valve (13) is opened automatically, when the burner is stopped normally,
in order to clean the burner lance for oil.
The condensate from the condensate separator (12), flows through the stop valve (7),
the steam trap (8), the stop valve (9), and the non-return valve (10). The by-pass
valve (11), is arranged for the steam trap.
When steam is not available (for example at start-up), compressed air can be used by
opening the stop valve (6) and then air flows through the non-return valve (5), the
shut-off valve (23), and the stop valve (16), and finally enters the burner lance.
3.5 Combustion air system
A general schematic illustration of the combustion air system is shown in Figure 8.
Combustion air system
A I R INLET
C o m p r e s s e d air, 7 b a r
20- Silencer
21- Air cylinder
22- Inlet vanes
Fan
40- Air filter regulator
41 • I/P positioner
42- Limit switch
DPT25 - Diff. Pres. Transmitter
Furnace p r e s s u r e
Figure 8 B_sys06.cdr
The combustion air is taken directly from the engine room through the silencer (20),
if provided, reducing the noise level from the suction side to approximately 95
dB(A).
The inlet vanes (22), regulates the air flow to the fan. The inlet vanes are regulated
by an air cylinder (21), which is controlled by an I/P positioner (41). The I/P
positioner receives a 4-20 mA signal from the combustion control system. The inlet
vanes closed positions are proven by a limit switch (42).
The control air pressure for the I/P positioner is controlled by the air filter regulator
(40).
From the fan discharge side the combustion air flows through the air duct to the
burner wind box.

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3.5.1 Air Register

The combustion air enters the wind box through the inlet flange and then the burner
air register after passing a perforated plate to give an even air distribution.
Passing through and leaving the burner air register tube, the air passes the primary
air swirler, giving air mixture with oil/steam mist and flame stabilisation, and the
secondary air swirler respectively, giving air for combustion zone.
Both swirlers give the air a rotation and the correct distribution of air flow between
primary air and secondary air.
The burner air register draft loss is measured by a differential pressure transmitter
(DPT25). The signal is converted to a combustion air flow signal in the control
system.
Operation instruction
4.1 Start in working mode
The following text contains a description of how to start the burner in working mode
with both diesel oil and heavy fuel oil. The item numbers mentioned in the text are
referring to Figure 5, Figure 6, and Figure 7.
4.1.1 Diesel oil mode - start
When the oil supply system is supplying diesel oil for the burner, the following
procedure must be followed, with reference to Figure 5:
Step A: Open the stop valve (G49) and the stop valve after the diesel oil tank.
Furthermore, the stop valve to the heavy fuel oil settling tank must also be
opened.
Step B: Select diesel oil on the three-way valve (Gl 15).
Step C: Open the stop valves on the suction and discharge side of the oil pumps.
Step D: Open the needle valve for the pressure transmitter (G99).
Step E: Open the stop valves before and after the pressure regulating valve (Gl00).
Step F: Close the by-pass valve at the pressure regulating valve (Gl00).
Step G: Close the inlet valves (G25) to the pre-heaters.
Step H: Open the stop valve (G51) to by-pass the pre-heaters.
Step I: Open the stop valve placed just before and after the ignition pumps.
Step J: Open the stop valves placed just before the ignition burner.
The item nos. mentioned in the following work steps (K-M) refer to Figure 6.
Step K: Open the stop valves (5, 7, 8, and 10).
Step L: Close the by-pass valves (3 and 4).

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Step M: Open the stop valves (1 and 14).

The item nos. mentioned in the following work steps (N-Q) refer to Figure 7.
Step N: Open the stop valves (1,4, and 16).
Step O: Open the stop valves (7 and 9).
Step P: Close the by-pass valve (11).
Step Q: If atomising steam pressure (6 bar) is not available, open the stop valve (6)
and close the stop valve (4).
Make sure that the system has been inspected in accordance with the recommended
periodical maintenance.
For the automatic control of start up and normal running, see separate instruction for
control system.
4.1.2 Heavy fuel oil mode
When the oil supply system to supplying heavy fuel oil to the burner, the following
procedure must be followed, with reference to Figure 5:
Step A: Open the stop valve (G49) and the stop valve after the heavy fuel oil tank.
opened.
Step B: Select diesel oil on the three-way valve (G115).
Step C: Open the stop valves on the suction and discharge side of the oil pumps.
Step D: Open the needle valve for the pressure transmitter (G99).
Step E: Open the stop valves before and after the pressure regulating valve (Gl00).
Step F: Close the by-pass valve at the pressure regulating valve (Gl00).
Step G: Close the drain valves for the pre-heaters.
Step H: Open the inlet valve (G25) for the pre-heater which should be in service.
Step I: Close the by-pass valve (G51) for the pre-heaters.
Step J: Open the stop valves before and after the steam trap for the pre-heaters.
Step K: Open the stop valves placed just before and after the temperature regulating
valve (G20).
Step L: Close the by-pass valve placed at the temperature regulating valve (G20).
Step M: Open the stop valves placed just before and after the ignition pumps.
Step N: Open the stop valves placed just before the ignition burner.
The item nos. mentioned in the following work phases (O-Q) refer to Figure 6.

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Step O: Open the stop valves (5, 7, 8, and 10).
Step P: Close the by-pass valves (3 and 4).
Step Q: Open the stop valves (1 and 14).

The item nos. mentioned in the following work steps (R-U) refer to Figure 7.
Step R: Open the stop valves (1,4, and 16).
Step S: Open the stop valves (7 and 9).
Step T: Close the by-pass valve (11).

Step U: If atomising steam pressure (6 bar) is not available, open the stop valve (6)
and close the stop valve (4).
Make sure that the system has been inspected in accordance with the recommended
periodical maintenance.
For the automatic control of start up and normal running, see separate instruction for
control system.
Commissioning
The following commissioning instructions are valid for steam atomising burners
type KBSA with Y-atomisers and with a standard delivery of individual parts for the
burner unit and supply systems from AALBORG INDUSTRIES.
Prior to the commissioning, the instructions for the individual parts of the burner
unit and supply systems should be studied. The special instructions for the boiler and
the control system should also be consulted. The instructions should only be
considered as a guideline. This is due to the fact that each plant should be
commissioned individually to obtain the best burner performance for the specific
plant.
During the commissioning of the burner unit and supply systems, it might be
necessary to adjust some regulation parameters or timer settings in the control
system to optimise the function of the plant. These adjustments are not described in
the following sections, but should be carried out as the optimisation requirements
emerge. Please see the instructions for the control system.
5.1 Commissioning start
When the system is started at commissioning, the following procedure must be

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

below normal water level.

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5.1.2 Electrical installation
Step A: Check that the wiring is correct.
Step B: Rotate all oil pumps, and the combustion air fan(s) by hand to ensure a free
rotation.
Step C: Set all motor starter overloads to suit the motor full load current. See motor
identification plate and/or electrical diagrams.
Step D: Install the fuses and check the rotation direction.
Note: Oil pumps must be primed with oil before power is switched on.
Step E: Check/adjust limit switches in the following items:
Fuel oil pressure control valve (Gl00), Figure 5

Fuel oil temperature regulating valve (G20), Figure 5
Fuel oil regulating valve (9), Figure 6
Atomising steam regulating valve (2), Figure 7
Three-way valve ( G i l l and Gl 15), Figure 5
Shut-off valve (three-way valve) (19), Figure 6
Shut-off valve (two-way valve) (17), Figure 6
Lance in position
Ignition burner in position
Air damper in closed position
Step F: Check/adjust all interlocks and alarms for burner plant as follows:
Start of stand by fuel oil pump

Fuel oil temperature, high/low
Low fuel oil pressure
Low atomising steam pressure
Flame scanner, automatic
Flame scanner, manual
Other safety interlocks
5.1.3 Oil system - diesel oil mode

Item nos. mentioned in the following mainly refer to Figure 5. An exception to this
rule is item nos. referred to in work steps (J-M), where the mentioned item nos. are
described in Figure 6.
Step A: Check that the piping system is according to the flow diagrams.

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Step B: Open the stop valve (G49) and the stop valve after the diesel oil tank.
opened.
Step C: Select diesel oil on the three-way valve (Gl 15).
Step D: Open the stop valves on the suction and discharge side of the oil pumps.
Step E: Open the needle valve for the pressure transmitter (G99).
Step F: Open the by-pass valve at the pressure regulating valve (Gl00).
Step G: Close the stop valves before and after the pressure regulating valve (G100).
Step H: Open the stop valve (G51) to by-pass the pre-heaters.
Step I: Close the stop valves (G25) to the pre-heaters.
Step J: Close the stop valves (5, 7, 8, and 10).
Step K: Open the by-pass valves (3 and 4).
Step L: Open the stop valve (1).
Step M: Close the stop valve (14).
Step N: Make sure that the oil pump is primed with diesel oil.
Caution: Water must under no circumstances come to the pump as water will
damage the pump.
Check that the pump and installation are in accordance with the pump instructions.
Step O: Start one of the fuel oil pumps and flush the piping system for a few hours.
Step P: Open the stop valve (G25) to one of the pre-heaters and close the by-pass
valve (G51). Continue flushing of piping system for at least one hour.
Warning: The heaters must not be heated.
Step Q: Open the stop valve (G25) to the other pre-heater and close the stop valve
(G25) to the first pre-heater. Continue flushing of piping system for at least
one more hour.
StepR: Open the by-pass valve (G51) and close the stop valve (G25) to the pre-
heater being flushed.
Step S: Stop the pump.

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Step T: Open the stop valves before and after the pressure regulating valve (Gl00),
and close the by-pass valve.
Step U: Adjust the set point for the fuel oil pressure control valve (Gl00) to
approximately 20-25 bar when the pump has been started again. Flush the
piping system for another few hours.
When continuing the flushing, by-passing of the flow meter and the fuel oil
regulating valve is not necessary.
The item nos. mentioned in work steps V through X refer to Figure 6.
Step V: Open the stop valves (5, 7, 8, and 10).
Step W: Close the by-pass valves (3 and 4).
Step X: Check and adjust Cv (valve characteristic) to fit the plug and seat ring by
moving the adjustment knob along the Cv scale. Table 1 shows the C v
setting for each burner size.
Adjustment of Cv
Burner size Maximum flow coefficient C v Setting C v
KBSA 600 0.6 0.5
KBSA 750 1.2 0.85
KBSA 950 1.2 0.85
KBSA 1050 1-2 0.95
KBSA 1200 1.2 1.2
KBSA 1550 2.3 1.4
KBSA 1900 2.3 1.5
KBSA 2250 2.3 1.6
KBSA 2650 2.3 1.85
KBSA 2950 2.3 2.3
KBSA 3350 2.3 2.3
KBSA 4200 3.8 3.4
Table 1
Whenflushingthe oil system, the minimum and maximum oil flow through the fuel
oil regulating valve (9) can be checked and adjusted.
Step Y: After completing theflushing,the internal spring loaded by-pass valves of
the fuel oil pumps must be adjusted to a pressure of approximately 3 bar
above the set point of the oil pressure control valve (Gl00) (this may be
readjusted after the final commissioning).
The set point of the fuel oil pumps must be below the set point (30 bar) of the safety
valves, on the fuel oil heater.
Step Z: Clean the fuel oil pump filters.
5.1.4 Burners - diesel oil mode

On delivery from Aalborg Industries, the burner unit has been pre-adjusted to fit the
task. Even though the burner unit has been pre-adjusted, it is advisable to carry out
additional checks during commissioning. These checks should be carried out with

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regard to adjustment of the atomiser and flame stabiliser distance, ignition

electrodes, etc. This means that it is necessary to pull out the burner lance, flame
stabiliser, and ignition burner.
Before the burner unit is assembled, check and note the commissioning
measurements. The obtained measurements should be inserted in the "measurement
and settings scheme".
Step A: Check that the burner gun and nozzle are clean.
Step B: The nozzle tip should be adjusted to approximately 40 mm in front of

swirler.
Step C: If no atomising steam is available, the burner can be started with

compressed air 3-6 barg for atomising. From 3 barg in low load up to
approximately 30% load and then the air pressure should be increased
gradually up to 6 barg at approximately 60% load and kept constant at
higher loads.
Step D: When atomising steam is available, the controller for atomising steam must
be checked and adjusted to 3-6 bar depending on the burner load.
Step E: Close the stop valves (14, Figure 6) and check burner start/stop sequence.
Attention: Before and during start-up, the furnace must be checked with
regular intervals for oil spillage. If an oil spillage is present in the
furnace, the cause must be determined and the failure must be
rectified. The furnace should be purged until it is free of oil.
Step F: To facilitate the commissioning, switch to "Burner - manual operation" on

the control panel and follow the instruction.
Note: During commissioned, the boiler pressure and temperature must not be
intensified too rapidly as this might cause stresses in the boiler. The
burner should be kept in minimum firing position during the first
commissioning period.
Step G: Check and adjust the diesel oil/air ratio. The combustion air flow signal and
the fuel oil flow signal must be set in the controller on the control panel to
obtain an O2 content of approximately 3-4% and a soot number of 1-3
Bachrach at loads above 30%. At lower loads the O2 content is higher.
When the controller is set up, there is a function key on the control panel marked
"Air/fuel ratio" where the normal adjusting of air/oil ratio can be carried out. This
could be necessary if the bunker type is changed.
In the same controller the max./min. oil flow and the ignition oil flow are set. Oil
flow for ignition will be found during commissioning, typically 15% of full load.
Step H: Check/adjust all interlocks and alarms for burner.

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Step I: Check the burner in automatic mode by switching the detachable key switch
to "Automatic operation".
Step J: Check the master-slave function, for plants intended to operate in this mode
(see the instructions regarding the control system).
5.1.5 Oil system - heavy fuel oil mode

When the burner has been commissioned on diesel oil and when steam is available
for heating, the commissioning on heavy fuel oil can be carried out.
Caution: Heating of diesel oil in the piping system must be avoided.
The change of fuel from diesel oil to heavy fuel oil is achieved by manually
operating the three-way valve (Gl 15). When heavy fuel oil is selected, the three-
way valve ( G i l l ) automatically changes position and returns the oil to the heavy
fuel oil settling tank for a period of time. This arrangement is necessary to avoid
heating of the re-circulated diesel oil when the burner is in stop mode. The viscosity
of the re-circulated diesel oil decreases and with it also the lubrication characteristic.
This will cause damage to the oil pumps.
After the pre-set time period has expired, the three-way valve ( G i l l ) returns to
normal position. The time period must be set with regard to minimum oil flow and
the quantity of oil in the system.
To operate the oil system in heavy fuel oil mode the procedure mentioned below
must be followed (the stated item numbers refer to Figure 5):
Step A: Check that the burner is stopped.
Step B: Check that oil is present in the heavy fuel oil tank. Check that the stop valve
which connects the heavy fuel oil tank to the oil system is open. To avoid
cavitation of the oil pumps, the viscosity of the oil in the heavy fuel oil tank
should not exceed 400 cSt. If necessary, the oil tank should be heated.
Step C: Check and adjust the switchover time for the three-way valve (Gill).
Step D: Select heavy fuel oil on the manually operated three-way valve (Gl 15).
Step E: Check that the three-way valve (Gl 11) changes position. It should also be
checked that the valve is changed back to normal position when the time
period has expired.
Step F: Select one of the pre-heaters for operation. The other pre-heater should be in
stand-by mode.
Step G: Open the stop valves for the operational pre-heater and check that the stop
valves are closed for the stand-by pre-heater.
Step H: Close the stop valve (G51).
Step I: Close the drain valves for the pre-heaters.
Step J: Open the stop valves before and after the steam trap for the pre-heaters.

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Step K: Open the stop valves placed just before and after the temperature regulating
valve (G20).
Step L: Close the by-pass valve placed at the temperature regulating valve (G20).
Step M: Open the stop valve, placed in the steam pipe just before the pre-heater, for
the operational pre-heater and close the stop valve for the stand-by pre-
heater.
Step N: Adjust the temperature set point for the temperature regulating valve (G20)
in the control system. The viscosity of the oil at the atomiser should be
between 15-20 cSt. The pre-heating temperature can be determined by
means of the "viscosity-temperature chart" found in this manual.
Step O: Check that the steam regulating valve (G20) for the pre-heaters is
operational and that the temperature is raised to the desired set point. Adjust
if necessary.
Step P: Check that the tracing systems for the oil system and the burner unit are
operational.
Step Q: Bleed air from fuel oil heaters by opening air valve on heater until fuel oil
is observed at air bleed outlet pipe.
Step R: Check the alarm set points for too low oil temperature, low warning, high
warning, and too high oil temperature. Adjust if necessary.
5.1.6 Burners - heavy fuel oil mode

When the burner is commissioned on heavy fuel oil, final adjustments of the
combustion process should be carried out to achieve high quality performance data.
The aim is to operate the burner with lowest possible O2 content and highest
possible CO2 content without the risk of an uncompleted combustion (black smoke).
At the same time the reliability of the burner must be ensured.
A number of initiative actions can be performed to improve and optimise the
combustion process such as adjusting the air/fuel ratio, the steam atomising
pressure, etc. Adjustments of the air/fuel ratio and the steam atomising pressure are
made by settings in the control system.
The air/fuel ratio should be checked and adjusted through the entire burner load
range to ensure a correct combustion. The air/fuel ratio can be checked by
measurements of the soot spot No. and the 0 2 content and/or the C0 2 content in the
flue gas. The visual appearance of the flame should also be checked. If the amount
of combustion air to the burner for a given oil flow is too low, the combustion will
be uncompleted, and it produces black smoke. Although the 0 2 content is low and
the CO2 content is high, the air flow should be increased. If, on the other hand, the
O2 content is high and the C0 2 content is low, it indicates that the air flow for the
combustion process must be decreased.
It is not only the air/fuel ratio which is an important factor for the combustion
process, but also the pressure of the atomising steam.
The steam atomising pressure should be adjusted and optimised to suit the
combustion process through the complete burner range. The pressure can be checked
by measurements of the soot spot No. and visible control of the flame. If the steam

INDUSTRIES
atomising pressure is too low at a given burner load, the flame has a tendency to
sparkle and the soot spot No. increases. Furthermore, the flame becomes unstable at
low loads due to poor atomisation of the oil. If the steam atomising pressure is too
high, the combustion zone is cooled and the flame becomes unstable at low loads.
The following commissioning steps imply that the lighting-up procedure of the
boiler is completed and that a sufficient load demand is present to carry out
adjustments at 100% load.
Step A: Check that the correction factor of the air/fuel ratio is in neutral position on
the control panel. The correction factor is used to adjust the air/fuel ratio if
the calorific value of the oil is changed, e.g. when the bunker type is
changed.
Step B: Start the burner and check that it ignites when the oil valves open and
remains ignited when the ignition burner is shut-off. Adjust the ignition oil
flow, the air/fuel ratio, or the steam atomising pressure if necessary.
Step C: Start the burner several times to ensure a reliable ignition of the burner.
Step D: Set the oil flow regulation valve into manual mode after start-up and adjust
the oil flow to minimum.
Step E: Check that the flame is stable and carry out measurements of the soot spot
No. and O2 content and/or CO2 content. Adjust the minimum oil flow, the
air/fuel ratio, or the steam atomising pressure if necessary.
Step F: Carry out the same measurements through the burner load range in steps of
10%. Adjust the air/fuel ratio and/or the steam atomising pressure if
necessary.
Step G: The measurements obtained for the combustion process through the
complete range together with a number of comparable combustion data
should be noted and inserted in the "measurements and settings" scheme.
Step H: When the burner is in operation, increase or decrease the load until the oil
pressure at the atomiser and the steam atomising pressure are identical.
Step I: Set this load as the steam purge position load in the control system.
Step J: Stop the burner and check it during steam purging. The burner must not
produce black smoke or blow out the flame before the combustion is
completed. Adjust the steam purge position load if necessary.
5.2 Normal stop
In modulation free mode, the control system attempts to maintain the steam pressure
at the desired set point by regulation of the burner load. The burner can be regulated
through the complete load range from minimum firing load to full load.
However, should the steam demand decrease below the minimum firing load of the
burner, the steam pressure will increase to the set point for burner stop. The burner
stops and remains stopped until the set point for burner operation is reached again.

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5.3 Prolonged stop
When the boiler plant is stopped for a long period of time, the oil system including
the pre-heaters should be flushed with diesel oil before the plant is shut-down.
Furthermore, the tracing must be switched off.
Manual operation
In the rare event of a total break down of the control system, the burner unit with
belonging systems can be operated in manual operation (also called emergency
operation). Due to the fact that the majority of the safety interlock trips and alarms
are overruled in emergency mode, the safety precautions for the plant must be
observed very carefully.
Please note that in emergency operation mode the safety interlocks are reduced to:
Too low water level
Flame failure
Warning: When the burner operates in emergency mode, it is very important

that the boiler plant is carefully and continuously supervised by the
ship engineering personnel. Pay special attention to the steam
pressure and water level.
The emergency equipment comprises the following components:

• Key switch for emergency operation
• Control and signalling components
• Additional flame detector
• Push buttons for ignition and operating of the electric/pneumatic oil and steam
valves
Both "manual" and "automatic" flame scanners must be clean and placed in position
at burner front to monitor the flame.
When changing to manual operation, the following operations are necessary.
Step A: Turn the key-operated switch on control panel to "Manual operation".
Step B: Start the combustion air fan manually on the control panel.
Step C: Switch the load controller to "Manual".

Step D: Purge the furnace by increasing the combustion air flow to maximum and
keep flow in maximum position for approximately 60 seconds.
Step E: Open the steam atomising valve (16, Figure 7).
Step F: Reduce the air flow to ignition load, approx. 15% load.

INDUSTRIES
Step G: Push the ignition button on the local burner panel. When the ignition flame
has been established, push the button for oil valve.
Step H: When the lamp (flame on) flashes up, release the ignition button.
Step I: The burner can now be operated from the control panel by
increasing/decreasing the oil and air amount on the load controller.
Step J: Check the flame monitoring equipment by pulling out the "manual" flame
scanner from its mounting flange and by covering the cell window by hand.
The fuel oil supply must then be cut off automatically.
Note: Only flame failure and too low water level cut the burner off
automatically in this mode.
Maintenance instructions
To ensure a safe and reliable function of the burner, inspection must take place with
frequent intervals as described below. The inspection should be carried out by
competent and properly trained personnel familiar with the operating and
maintenance procedures relevant for this type of plant.
7.1 Safety regulations for maintenance work
Always ensure that the electrical power is off and that nobody can start the boiler
unit before commencing maintenance work.
All pipes, drums, etc. must be depressurised before any maintenance work is carried
out on these.
7.2 Continuous maintenance
• Control panels and other electrical equipment should be kept clean and dry.
Check that no foreign matter accumulates in or around them.
• Replace lamps, contactors, and other components when they cease to function or
show signs of deterioration. A part, replaced before it actually fails, could save a
costly delay.
7.3 Periodical maintenance
The following check list should be followed every two weeks. Dependent on the
operation conditions, however, some items may need more frequent attention.
For maintenance work procedures, we refer to the separate instructions concerning
each item.
7.3.1 Periodical maintenance - burner and fuel oil supply system
• Check that all connections are tightened and that the wiring is in a good
condition.

INDUSTRIES
• Check that the fan inlet is kept clean of unintended obstructions.

• Check pipe work for leaks, particularly on flanges, joints, and connections.
Repair any leaks which may cause safety risks.
• Check the general condition of pipe work, lagging, and tracing.
• Check that the glands of manual valves are tight enough to prevent easy
operation of the valve.
• Oil filters should be inspected and cleaned.
• Manually operated valves should be periodically operated, if possible, to ensure
free movement.
• Check the pneumatic shut-off valves, placed just before the burner lance, for
leaks.
• Check and clean the flame scanner.
7.3.2 Burner air register and swirler

If the burner plant is to perform according to the specification, it is important that
the burner register is kept clean and in good condition. Inspection should be carried
out at regular intervals.
Large quantities of dust-laden air will pass through the register, and inevitably this
tends to build up deposits. These deposits should be brushed off.
The primary and secondary swirlers as well as all other surfaces exposed to radiation
heat should be checked for being free of carbon or heat erosion.
The refractory should be inspected for general condition and examined for being
free of carbon deposit, cracks, and heat erosion.
7.3.3 Atomiser
Before any examination can be made, the atomiser must be cleaned. This is
normally done by soaking in a paraffin or carbon remover to wash any oil films.
This also has the purpose of loosening carbon deposits. It may also be necessary to
use a soft metal scraper to lift away any heavy carbon deposits. A hardened scraper
should not be used as it could possibly damage the atomiser.
The cleaned atomiser should then be examined for damage, and the nozzle holes
checked for wear.
The O-ring must be replaced every time the atomiser is disassembled.
Before fitting the cap nut, the thread should be covered with an un-hardening high
temperature compound.
7.3.4 Ignition burner
The ignition burner is one of the most exposed items and needs a frequent
maintenance.
• The electrodes should be cleaned and the insulation material checked for any
damage. Be careful not to damage the ceramic insulation pieces.
• The nozzle should be checked and cleaned.
• If the spray pattern hits the other parts of the ignition burner despite it is
cleaned, the nozzle should be changed.

INDUSTRIES
Note: Be careful not to change position of nozzle and electrodes as this may
cause problems with, e.g. ignition instability, or build-up of carbon
deposit.
8 Faults and rectifying faults

The trouble shooting list is based on a proper set-up of the burner plant during
commissioning and/or service and that no further adjustments of the air/fuel ratio,
etc. have taken place.
Please note that the trouble shooting list is general for steam atomising burners and
has not been made for any particular plant, but is based on several years of
experience. Therefore, the cause for your specific problem may not be mentioned
and vice versa. You are always welcome, however, to contact our service
department for advice or service assistance.
Check availability of power and fuel supplies before commencing detailed checks.
Ensure that burner plant wiring diagrams relevant to the particular installation are
available.
When the cause of a lockout should be located, it can be of assistance to know the
start/stop cycle or at which point of operation the lockout occurred, e.g. modulating.
The trouble shooting list can be seen in Table 2.
Fault finding chart

Fault Possible causes Remedy
No ignition/ignition flame Ignition burner oil pump faulty Repair or Replace oil pump/ motor
failure Oil pressure too low Restore oil pressure
Oil nozzle blocked/worn out Clean/replace nozzle
Ignition electrodes dirty/out of adjustment Clean/readjust
Ignition transformer faulty Replace ignition transformer
Solenoid valve faulty Exchange solenoid valve unit
Burner control faulty Replace/repair control unit
Smoke during ignition Ignition oil pressure too high/low Check ignition oil pressure, adjust to 8-10
barg measured at the ignition burner
Flame failure of main flame Ignition flame not established See above
during ignition Oil valves not open Check air pressure/replace oil valve
Atomising air/steam pressure too low Check air/steam pressure
Purge steam valve open Check purge valve
Oil temperature too high/low Adjust temperature
Oil flow too low Adjust oil flow/clean atomiser
Unstable main flame Oil amount too low Raise the oil amount
Oil temperature too low/high Readjust oil temperature
Blocking of some of the steam/oil holes in the
atomiser Clean atomiser
Water in the atomising steam Check the water trap, if provided
Flame smoky or red Too much fuel oil or too little air Readjust air/oil ratio
Flame white or colourless Too much air or too little oil Readjust air/oil ratio
Flame with starlets or Poor atomisation, low oil temperature or atomising Reset fuel oil temp, to correct value/ensure
sparks air/steam incorrect pressure condensate-free steam
Damaged atomiser nozzle Replace nozzle
Flame flutters and goes out Too little oil in min. load Reset fuel quantities
Burner shut down Shut down due to safety circuits or faulty Please refer to the electrical layout/diagram
components for specific information
Table 2

INDUSTRIES
Steam atomising burner settings

Each plant has its individual service conditions depending on the actual design and
layout of the burner and the boiler plant. Exact values for the burner cannot be
given, but have to be determined at the commissioning or by later adjustments.
The following tables show the standard measurements and settings for a plant which
includes a KBSA burner. This enables the user to obtain some of the most important
measurements and settings related to the burner for later reference.
It is recommended that the user completes the scheme shortly after the
commissioning when normal service conditions have been established.
Burner settings chart

Ship's name:
Boiler type/No.:
Burner type/No.:
Atomiser ID. No.:
1 Date
2 Time
3 Oil type /viscosity/density
4 Load Min. 25% 50% 75% Max.
5 Oil amount 1/h
6 Oil temp, inlet burner °C
7 Oil press, at burner barg
8 Atomising steam press. barg
9 Atomising steam temp. °C
10 Oil press. Before fuel oil valve bar
11 Oil temp, after pre-heater °C
12 Oil temp, before pre-heater °C
13 Oil temp, in tank °C
14 Air temp, inlet combustion air fan °c
15 Static pressure after combustion air fan mmWC
16 Static pressure in wind box mmWC
17 Static pressure in furnace mmWC
18 Static pressure in uptake mmWC
19 Temp, in uptake
20 0 2 in uptake %
21 C0 2 in uptake %
22 Soot (Bachrach) No.
23 Drum pressure barg
24 Feed water temp. °c
25 Feed water flow m3/h
26 +/- Normal drum level mm
Table 3

INDUSTRIES
During commissioning an adjustment of some measures related to the ignition

burner, burner lance, and burner register may be necessary. These measures are
shown in Figure 9. In the following table is the original measures written and a
column is reserve for writing the measures established during commissioning.
Commissioning measures
Top mounted Wall mounted

Figure 9 kbsa2.cdr
table for commissioning measures

Yard & hull No.: Guangzhou Shipyard International Co. Ltd. Hull Nos. 03130007, 03130008
Date of commissioning:
Project No.: 736950, 736952
Mounting position: Top mounted
Measures Original Commissioning

A 25 mm mm
B 205 mm mm
C 140 mm mm
D 80 mm mm
E 5 mm mm
Nozzle type 6666062
Table 4

AALBORG PHOTO CELL OM8630#01.0
INDUSTRIES
Photo cell
1 Description
The RAR7 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
selenium photo cell. When illuminated, it generates DC voltage which causes a
current to flow to the input of the flame signal amplifier in the control unit. Hence,
the selenium photo cell is an active detector.
The cell is insensitive to infrared radiation. If the burner is started with an
illuminated combustion chamber, e.g. due to glowing firebrick, the start sequence of
the burner commences, but an alarm for flame failure will be indicated.
The number of photo cells for automatic operation and emergency operation depend
on the classification society.
1.1 Commissioning
The intensity of the light radiation can be checked by measuring the detector current
by means of a DC ammeter (internal resistance 5000 W). Figure 1 shows the
measuring circuit. The photo cell is adjusted by changing the position in proportion
to the oil flame in order to obtain the maximum detector current.
Note: If the wiring of the photo cell is connected incorrectly, it is not possible to
start the oil burner.
Measuring circuit
10 LAE10
24 LAL2...,LOK16... I
Ammeter
connection
Figure 1 photcirc.cdr

AALBORG VISCOSITY - TEMPERATURE CHART OM9280#01.1
INDUSTRIES

1 Description
The preheating temperature can be determined by means of the viscosity -

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

Known:
Oil viscosity: 380 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
intersection 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.

AALBORG VISCOSITY - TEMPERATURE CHART OM9280#01.1
INDUSTRIES
H -15 -10 0 10 20 30 40 50 60 70
TEMPERATURB
80 90 100 110 120 130 140 ISO 160 170 I«
Q'OM 9ÖÖO
40,0001-
8tø»
*K„~ 7,000
30,000- _,_1_Mta. 6,000
20000- 5,000
4,500
15,000- 4,000
inm 3.500
3,000
10,000- 2J00
2^00
8,000- 2,000
uoo
5,000-
4,000-
900
3,000- 800
700 700
600 600
2,000-
m 400
1,500- 400
350
350
300
moo-
800-
s 25° 200
S 20 °
ISO
iiso
S 600-
J 100
g 90
1 œ^ '' ^N. ~ "„> ,
200-
150-
" SO
45
40
©
35
35 30
30
100- 25
90- 20
80- V ' "^S«c
', •' 'ft'"
0
*>C
70-
IS
r' ^ V
"S-^L
'S (?) !"j>-»^,
7
5
4
1 i i 1 1 1 1 I 1 1 1 1 1 1 1
1 1 1 1 i 1 1 1 1 1 1 j i 1 1 3S0
1
10 20 30 40 5 70 80 90 100 110 121Ï 130 1 10 ISO 160 170 200 21C 10 240 250 260 270 280 290 3«) 310 3 !0 330 340
0 60 1B0 190 220 2
TEMPERATURE
Q Recommended cup viscosity for rotary cup burners

( 2 ) Recommended nozzle viscosity for steam atomising burners
( y Recommended nozzle viscosity for pressure atomising burners
Figure 1 viscl.cdr

AALBORG ^JSBH8H8BMBSHS^^^W^B
INDUSTRIES ^ÊÈÈÈÊMÈ^ÊBKÊÈÈÈÈËÈÈ^^^^^^^^^^KËM
Table of contents
Oil flow regulating valve

General 1
Cv-adjustment 2
Installation 3
Commissioning 4
Manual operation 5
Calibration 6
Maintenance 7

AALBORG OIL FLOW REGULATING VALVE OM6050#04.0
INDUSTRIES
Oil flow regulating valve

1 General
The burner load is controlled by the control system, which receives a continuous
signal from a steam pressure transmitter. This signal is compared with different set
points, feed back signals, and parameters in the control system. The output from the
control system is used to control the oil flow regulation valve, which is
pneumatically operated by an I/P converter.
To obtain a very accurate regulation of the oil flow, which is very important to have
a large turn-down ratio, the valve is fitted with an adjustable Cy-adjuster. This Cy-
adjuster makes it possible to adjust the pressure loss coefficient of the valve
whereby the oil flow regulation can be optimised to each single installation.
The position numbers referred to in the following sections appear from the
illustrations shown in Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, and Figure 6.
Cv-adjustment
2.1 Mid band setting
During calculation of the valve sizing, a trim set should be chosen so that the mean
estimated Cv will be at the mid band setting. This is called the risk-free setting since
it provides the means to either increase or decrease the available Cv if the actual
conditions change.
Figure 1 shows an example of the possible settings for a trim set. A mean Cv of 0.07
for a trim No. 5 allows subsequent adjustment to Cv 0.10, if the flow coefficient is
increased, or to Cv 0.04 in the opposite case.
2.2 Adjustment setting at maximum Cv
The adjustment knob should be set towards maximum Cv making it possible to scale
downwards, if desired. This should be done if valve sizing calculations and actual
service conditions indicate that the full rated Cv of the valve will initially be required
but may subsequently lessen
2.3 Adjustment setting at minimum Cv
The adjustment knob should be set towards minimum Cv making it possible to scale
upwards, if desired. This should be done if valve sizing calculations and actual
service conditions indicate that initial conditions require a relatively low Cv but will
then increase to a higher maximum

INDUSTRIES
Example of a valve adjusted at mid band setting
Cv/signal Cv plate Recommended Example Adjustment

adjustment of application option
Nominal Cv to
0.10 <Ù3 ^ M a x | | 2 ; | ! be subsequently
// reduced
0.09
//
// •
0.08 Mid band setting:
>/
n/ n Service conditions
Cv
0.07
ft
//
<3
E 1 may vary, Cv to be
adjusted upwards
0.06 —Æ- or downwards
ts
0.05 / Jf // i—ip Nominal Cv to

•
0.04 // <*=q be subsequently
// J
v increased
• ; /
à
Cv adjustment knob
Signal
200 400 600 800 1000 mbar
3 6 9 12 15 psi
4 8 12 16 20 MA
Figure 1 cvsignal.cdr
Illustration of the name plate
m là
ISÏZETOiMNoL 1"
AIRTC OPEN ISOPPLYl 18 PSI
XXXXX MIN. CV MAX. CV
tiBOBYi
Jiiiiiic
XXXXX
0.04 0.1
o XXXXX o
|l||Iipijl!l XXXXX
3-15 PSI
XXXXX
SERIAL No I XXXXX
n w
Figure 2 namevari.cdr

INDUSTRIES
Illustration of the oil flow regulation valve (front view)
26 184 114 25 24 23 116 117 115 120 119 118 121 122 112c 124 22
Figure 3 vari 04.cdr

INDUSTRIES
Illustration of the oilflowregulation valve (side view)
138a

INDUSTRIES
Illustration of the coupling details of lever No. 1 and 2
„112b
112a
21
Lever No. 1
105
Pivot pin No. 1 184
Pivot pin No. 2
18' 22 '
Pivot pin No. 3 Lever No. 2
Illustration of the air connections

I YY
109
©
O
137 1/4" NPT 1/4" NPT instrument

supply port signal port

INDUSTRIES
Position numbers referring to Figure 3, Figure 4, Figure 5, and Figure 6

No. Part name No. Part name No. Part name
2 Seat ring gasket 104 a,b Clevis 138a Union elbow
Seat ring at different 105 Pivot pin No. 1 139 Cover cap screw
3 a,b,c,d,e
C v values 106 Conical comp. Spring 140 Tubing
3f Spacer, Cv max. < 0.10 107 Grommet 141 a,b Screw
4 Seat ring retainer 108 Actuator bracket 142 Output gauge
5 Packing spacer 109 Cover screw 143 Instrument gauge
6 Packing 110 Cover 144 Manifold block
7 Packing flange stud U2a,b,c Retainer clip 145 Shim
8a Packing flange nut 114 Force balance spring 146 Gaskets
8b Mounting nut 115 Spring clamp 147 Positioner block
9 Packing follower 116 Take-up screw 148 Slotted flat c. screw
10 Packing flange 117 Lock nut 149 Binding head screw
11 Safety pin 118 Hand wheel lock nut 150 Lock wasker
Plug stem at different 119 Hand wheel bushing 151 Spring bracket
12 a,b,c,d
C v values 120 Hand wheel 152 Positioner diaphragm
13a,b Body 121 Hand wheel lock 153 O-ring
18 Pivot pin No. 3 122 Lever arm stop 154 Spring
21 Lever No. 1 124 Pivot pin No. 4 155 Sleeve
22 Lever No. 2 125 Lock nut 156 Spool
23 C v adjustment pin 126 Indicator 157 Spring
24 C v adjustment knob 127 Indicator plate 158 Spring
25 C v adjustment plate 131 Piston Retainer ring
182
26 Adjustment plate screw 134 Actuator spring (C v max. <0.1)
101 Grommet plate 135 Serial plate 184 Pivot pin No. 2
102 Spring button 136 Diaphragm - -
103 Lock nut 137 Diaphragm cover - -
Table 1
Installation
The oil flow regulating valve must be installed as flange connected. Place the
gaskets according to the process between the valve body and the pipe flanges.
3.1.1 Alignment
Hold the valve body during installation of the studs. Special bosses are provided to
centre the valve in the line and prevent rotation before final tightening of the studs.
The valve must be installed with the flow tending to open. The flow arrow stamped
on the valve body must be pointing in the direction of the flow. Install bolting and
tighten evenly in a cross fashion.
3.1.2 Air piping

Install pipe supply and instrument signal lines to the appropriate connections in the
positioner Block (144), see Figure 6. Use 1/4" O.D. tubing or equivalent for air lines
Important: Air supply to the oil flow regulating valve must be instrument air.

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

Burner type/size Maximum flow coefficient C v Setting C v
KBSA 600 0.6 0.5
KBSA 750 1.2 0.85
KBSA 950 1.2 0.85
KBSA 1050 1.2 0.95
KBSA 1200 1.2 1.2
KBSA 1550 2.3 1.4
KBSA 1900 2.3 1.5
KBSA 2250 2.3 1.6
KBSA 2650 2.3 1.85
KBSA 2950 2.3 2.3
KBSA 3350 2.3 2.3
KBSA 4200 3.8 3.4
KBSD 950 1.2 0.85
KBSD 1200 1.2 1.2
KBSD 1500 2.3 1.4
KBSD 1900 2.3 1.5
KBSD 2250 2.3 1.6
KBSD 2650 2.3 1.85
KBSD 3000 2.3 2.3
KBSD 3350 2.3 2.3
KBSD 4150 3.8 3.4
Table 2
Step D: Apply air to the I/P converter. Adjust the air pressure at the belonging
filter/reduction unit. The pressure setting appears from the identification
plate on the converter.
Step E: Apply supply air to the oil flow regulation valve. Adjust the air pressure at
the belonging filter/reduction unit. The pressure setting appears from the
identification plate on the valve.

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

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

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

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

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

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

Spring ran ?e Supply max.
Cv
m bar psi Colour code m bar psi
3.8 to 1.5
414
2.3 to 0.9
6-24 Red 2100 30
1.2 to 0.5
1660
0.6 to 0.25
0.25 to 0.10
0.10 to 0.04
207
0.050 to 0.020
3-15 Green 1250 18
0.025 to 0.010
1035
0.010 to 0.004
0.004 to 0.0016
Table 3

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

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

AALBORG OIL FLOW.REGULATING VALVE OM6050#04.0
INDUSTRIES
Step C: Loosen lock nut (103) and turn anti-clockwise through 1 3/4 turns by using
a screwdriver applied at the plug stem end. Shut off the signal and pressure
supplies. Slightly retighten the lock nut (103) against the clevis.
Step D: Loosen the lock nut (117) and fully unscrew the take-up screw (116).
Remove the spring clamp (115) from lever No. 2 and force the balance
spring (114) from the positioner.
Step E: Remove the retainer clips (112b) from the two pivot pins (184) and pull
them out from lever No. 1 and clevis (104a).
Note: This operation will be facilitated by relieving the load on the plug clevis
exerted by the conical compression spring (106). While driving out the
pins, using a screwdriver, push on the plug stem end.
Step F: Remove the two retainer clips (112c) from pivot pin No. 4 (124) and
disengage it to the uncouple piston clevis (104b) from lever No. 2 (22).
Step G : Remove the two retainer clips (112a) from pivot pin No. 1 (105) and
disengage it to the uncouple lever No. 1 from the actuator bracket (108).
Disengage the adjustment pin smooth end (23) from the lever line No. 2 and
remove the adjustment knob (24) and adjustment pin (23) from lever No. 1.
Step H: Drive out the pivot pin No. 3(18) and remove lever No. 2 (22).
Step I: Hold the plug stem in place by using a screwdriver put to its end and unlock
the nut (103). Unscrew the clevis (104a) and lock nut (103). Remove the
spring button (102), spring (106), and grommet plate (101).
Step J: Remove the two packing flange nuts (8b), packing flange (10), and packing
follower (9). Remove the two bracket securing nuts (8a) as well as the
bracket (108).
Step K: By using a packing hook, remove the largest number of packing rings (6)
from the packing box. Remove the safety pin (11) and pull the plug stem to
remove the packing spacer (5), plug and stem, together with the rest of the
packing rings.
Step L: By using a 9/16" or 14 mm piece of hex stock and a wrench, unlock and
pull out the seat ring retainer (4).
Step M: Pull out the seat ring (3) and then the gasket (2) by using a hook made from
steel wire (diameter approximately 3 mm). Carefully fettle the hook end.

INDUSTRIES
Note: The seat ring with a C v max. < 0.10 consists of two parts; The seat ring
proper (3e) and a spacer (3f). The small size of the orifice of these parts
does not allow for their removal by means of a hook. Therefore, it is
necessary for this operation to remove the body from the pipe and turn it
over and, if needed, to hit the bottom by means of a wooden mallet.
Should the seat ring be jammed in its housing, it is possible to move it
using a screwdriver inserted through the outlet orifice. Valves with C v
max. 3.8 do not feature any seat ring gasket (2).
7.4 Assembly
Before assembly, clean thoroughly the inside of the valve body and parts. Gasket
seating surfaces and surfaces in contact with others must be thoroughly cleaned. On
assembly, a new seat ring gasket (2) and a new packing (6) must be used.
Step A: Place a new seat ring gasket (2) in the valve body (13) and install the seat
ring (3) taking care to correctly centre the gasket on the seat ring shoulder.
Orient it in such a manner that one of its ports lines up with the body outlet
orifice.
Note: In the event of a maximum C v smaller than 0.10, the seat ring (3e) must
first be positioned on the new gasket (2) taking the same precautions as
shown above. Secondly, engage the spacer (3f) and orient one of its ports
towards the body outlet orifice. Valves with C v max. 3.8 do not feature
any seat ring gasket (2).
Carefully apply grease (Never Seez or equivalent) on the threads and bottom of the
retainer (4). With a 9/16" or 14 mm piece of hex stock and a wrench, torque the
retainer to 8 Nm if equipped with a graphite gasket st. reinforced, or to 5.5 Nm if
equipped with a glass filled P:T:F:E: gasket.
Note: In case of a valve with maximum Cc 3.8, torque the retainer to 2 Nm.
Step B: Engage the plug and stem assembly in the seat ring. In the case of a
maximum Cv < 0.10, ensure that there is no hard point during the stocking
of the plug. In case of a hard point, loosen the retainer (4) and replace the
seat ring (3e) in the correct position until the stem smoothly slides. Align
the hole in the spacer (5) with the safety pin (11) hole in the valve body.
Note: In the event of a maximum Cv smaller than 0.10 ensure that the
retaining ring (182) is placed on the plug before engaging it in the spacer
(3f). If the retainer ring is damaged, replace it.
Step C: Wrap the safety pin (11) with two turns of P:T:F:E: tape (Teflon). Screw it
into the bonnet five and a half to six turns from where the thread

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

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

INDUSTRIES
Step K: Couple the clevis (104a) to lever No. 1. To perform this operation push to
align the holes in the clevis and lever No. 1 by means of a screwdriver on
the plug stem end. Couple by means of the two pins (184) and retainer clips
(112b).
Note: Insert the clips on the pins between the slides of the clevis and lever No.
1.
Step L: With the take-up screw (116) fully unscrewed from the spring clamp (115),
place the latter in position after hooking the force balanced spring (114)
first on the positioner spring bracket (151) and secondly on the spring
clamp (115).
Note: The spring clamp (115) has two holes. If it is a close-on-air failure
actuator the spring must be hooked in the upper hole. In case of valve
open-on-air failure, the spring must be hooked in the lower hole.
Step M: Admit supply and signal pressures and complete the calibration. Replace
the cover (110) and turn the hand wheel clockwise to engage it in the lever
arm stop (122). Tighten the cover screws (109).
Step N: If the valve has been removed from the line, reinstall it according to the
section "Installation" and then set the valve back into service.
7.5 Packing quick change method
The fastest and simplest way to replace the packing is to remove the entire actuator
without disturbing the actuator parts or calibration. However, this is not
recommended for valves with a small Cy (Cy < 0.6) due to the very fineness of their
plug. Vent the valve pressure and proceed as follows:
Step A: Be sure that the plug is off the seat ring. With an air-to-open valve, admit
air pressure under the diaphragm or turn the hand wheel to move the plug
off its seat ring.
StepB: Remove the safety pin (11) from the body. The safety pin engages the
packing spacer (5). The function of the safety pin and spacer is to prevent
the plug from being pushed out if the actuator is removed while the valve is
still pressurised. The valve internal parts cannot be removed unless the
safety pin is removed first. Remove the two packing flange nuts (8b) and
back off the two mounting nuts (8a) as far as possible.
Step C: With a block of wood and a mallet, tap the actuator plug assembly off the
valve. Clean the packing box and plug stem and carefully place the new
rings of packing around the stem. Position the skive cut of each packing
ring 120° from that of the adjacent ring.

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

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

•••••
iijjijjji
AALBORG ^BîlH8H9ilWH!HSW^^^MI
Table of contents
Oil flow meter

General 1
Commissioning 2
Dismounting and mounting instructions 3
Trouble shooting 4

AALBORG OIL FLOW METER OM8160#01.4
INDUSTRIES
Oil flow meter

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

INDUSTRIES
sleeve. The spring must be able to press the pick-up insert smoothly to the front side
of the dry sleeve. It is important for the function of the sensor system that the dry
sleeve is free of foreign substance. The sensor system is shown in Figure 4.
The sensor system (pick-up sensor and cable) must not be in an area of
electromagnetic field pulses with high intensity. This could cause measuring errors
or even destruction of the sensor system.
Illustration of the nameplate
OM G XXX
No. XX P/l 231.1
\
I II II II II >
l/min
bar
1 -
-
36
40
°c
mm2/s 4
-
-
150
25 V
Figure 2 omg02.cdr
Accuracy - diagram
+0.3
+0.2
+0.1
- T Ï .-TÏ. m: —= T=S> r-m-i
o 0 +& Tl».
1 1000 mm2/s
CO •j? i
•s ^ * *«- — 150mm7s
Ü
o
-0.1 / 40 mm2/s
^ 5 mm7s
< -0.2
-0.3
50 100 150
Flow rate (% Qmax.)
Figure 3 omg01.cdr
Illustration of the sensor system
, 1 2 ,3 4
1. Dry sleeve
2. Pick-up sensor
3. Spring
4. Milled nut
Figure 4 beg44.cdr

INDUSTRIES
Illustration of the oil flow meter, type OMG 20
Flange
Head bolt Socket screw
End cover O-ring
O-ring Grooved pin
Pole wheel Spacer
Circlip
Circlip Spacer
Spacer
Deep groove
Deep groove ball bearing
ball bearing
Spindle set
Measuring
casing Deep groove
ball bearing
Deep groove
ball bearing Socket screw
O-ring
End cover
Circlip Circlip
Head bolt Flange
Y, '/.
Figure 5 omg04a.cdr
Illustration of the oil flow meter, type OMG 32
Socket screw Flange

O-ring
End cover
Head bolt
Pole wheel
Grooved pin
O-ring
Spacer
Circlip
Spacer Circlip
Spacer
Deep groove
ball bearing Deep groove
ball bearing
Measuring
casing Spindle set
Deep groove Deep groove

ball bearing ball bearing
O-ring
Socket screw
End cover Head bolt
Circlip Circlip
Flange
Figure 6 omg05a.cdr

INDUSTRIES
Commissioning
Step A: Ensure that the oil system has been thoroughly flushed for impurities and
that it is free from air.
Note: Impurities cause the oil flow meter to be blocked, and air affects the
accuracy of the oil flow meter.
Step B: Check that the oil flow meter and pick-up sensor are installed correctly.
Step C: Set the values for max. oil and beats/10 litre in the control system. The max.
oil value is the maximum oil flow in 1/h at 100% burner load on heavy fuel
oil (provided this is the main fuel). The value for beats/litre can be taken
from the identification of the oil flow meter (see Figure 2).
Step D: Unscrew the pick-up sensor from the oil flow meter.
Step E: Tap the pick-up sensor quickly against an object and check that the control
system records the signals.
Step F: Mount the pick-up sensor again.
Step G: Check and adjust the oil flow settings for minimum load, ignition load, etc.
in the control system.
Dismounting and mounting instructions

For dismounting and mounting the oil flow meter and sensor system please also see
Figure 1, Figure 4, Figure 5, and Figure 6.
3.1 Oil flow meter
3.1.1 Dismounting
Step A: Remove the oil flow meter from the pipe line.
Step B: Remove the flange covers and end covers.
Step C: Press out the spindle set with rolling bearings and distance sleeve from the
measuring casing.
Note: If the spindle set or measuring casing must be replaced, the oil flow
meter must be re-calibrated.

INDUSTRIES
3.1.2 Change of bearings
Step A: Remove the pressed-on pole wheel from the measuring spindle.
Step B: Remove the circlips, spacers, and rolling bearings.
Step C: Remove the O-rings.
Note: The O-rings are specially designed for the oil flow meter. If a
replacement is necessary, only original O-rings must be used.
Step D: Clean all parts carefully, take care not to scratch the sealing surfaces.
3.1.3 Mounting
Step A: Mount the O-rings.
Step B: Press the rolling bearings on the measuring spindle and mount the circlips
and spacers.
Step C: Press on the pole wheel.
Step D: Insert the spindle set into the measuring case.
Step E: Press the distance sleeve into the measuring case.
Step F: Mount the end covers and flange covers.
Step G: Tighten the screws crosswise.
Step H: Install the oil flow meter in the pipe line again.
3.2 Pick-up sensor
3.2.1 Cleaning/replacing the pick-up sensor
Step A: Dismount the pick-up sensor by unscrewing the milled nut.
Step B: Clean or replace the pick-up sensor. The pick-up sensor can be changed
without performing any regulation of the distance between the pick-up
sensor and pole wheel.
Step C: Mount the pick-up sensor and screw on the milled nut.
Note: The dry sleeve must not be turned.

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

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

Failure Reason Remedy
Viscosity of the medium and/or Raise the temperature (check the allowed temperature
Too high pressure flow rate is too high range)
drop Reduce flow rate
Use a different size oil flow meter
Seal is not tightened enough Tighten screws
Leakage Seal is damaged Change seal
Check chemical resistance
Foreign substance Clean oil flow meter
Use filtration
Blocked flow meter Pick-up sensor mounted too far Adjust pick-up sensor
inside
Not enough inlet pressure Raise inlet pressure
Air lock Remove air
Degassing Raise system pressure, reduce temperature
Too high pulsation Change oil pump, modify system
Operation: Change of operating conditions
Too high measuring
• high flow fluctuation
default
• Quantity too small
• Differing operating data
High wear New oil flow meter
Filtration of abrasive material
Defective pick-up insert Screw out the pick-up and check it by tapping 1he pick-up
sensor quickly against an object (control system records)
No signal from pick-
Defective connection Luminous diode
up sensor
Check connections
Wrong power supply Adjust electronics
Defective pick-up insert New pick-up insert
Defective contacts Check contacts
No ordinary signal
External interference Install cables
from pick-up sensor
Distance to the pole wheel not
correct Correct distance
Table 1

•itiiiii.
AALBORG dj5flllill98fiHI8fiE^M^^M
INDUSTRIES ^••••HlBHIIIIBIlHi^^H^HHÎ^H
Table of contents
Differential transmitter
General 1
Technical description 2
Installation 3
Commissioning 4
Operation of the transmitter 5
Maintenance 6

AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0
INDUSTRIES
Dp-transmitter, type 7MF4433
1 General
The following description is valid for a differential pressure transmitter SITRANS P,
type 7MF4433.
Warning: This device may only be assembled and operated after qualified
personnel has ensured, by providing suitable power supplies, that no
hazardous voltages can get into the device in normal operation or in
the event of a failure of the system or parts thereof.
Warning: The device may be operated with high pressure and corrosive media.
Therefore serious injuries and/or considerable material damage
cannot be ruled out in the event of improper handling of the device.
The perfect and safe operation of this equipment is conditional upon proper
handling, installation, and assembly as well as on careful operation and
commissioning.
Technical description
2.1 Application
The SITRANS P transmitter can be used to measure:

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

INDUSTRIES
Figure 1 shows a function diagram of the SITRANS P differential pressure and flow
transmitter. The item numbers referred to in the following description are those
mentioned in the in the figure.
The differential pressure is applied via the diaphragms (4) and the filling liquid (3)
to the silicon pressure sensor (7). If the measuring limits are exceeded, the overload
diaphragm (6) is flexed until one of the diaphragms (4) rests on the measuring cell
body (2), thus protecting the silicon pressure sensor (7) from overloading.
The measuring diaphragm of the silicon pressure sensor is flexed by the applied
differential pressure. The resistance of four piezo-resistors fitted in the diaphragm in
a bridge circuit th+us changes. This change in resistance results in a voltage output
from the bridge proportional to the differential pressure. This voltage is amplified
and converted into a frequency by means of a voltage-to-frequency converter (9).
This signal is evaluated by a micro controller (10), and its linearity and temperature
effect corrected.
The processed signal is converted by a digital-to-analogue converter (11) into an
output signal of 4 - 20 mA.
The data specific to the measuring cell as well as the parameters of the transmitter
are stored in a non-volatile memory (EEPROM).
The cable termination point and the electronics are arranged opposite one another.
Parameterisation of the transmitter is performed using a laptop, PC, HART®
Communicator, or the input keys. Normally the input keys are used to set-up the
transmitter.
Function diagram
12 13
-JiÔO-ÔÔÔob] r f ^ T i
o'A.l/H
Differential pressure 5 O-Ring

:i
/A
as input variable
Output signal
6
7
Overload diaphragm
Silicon pressure sensor
UH Power supply 8 Instrument amplifier
9 Voltage-to-frequency converter
1 Process flange 10 Microcontroller
2 Measuring cell body 11 Digital-to-analog converter
3 Filling liquid 12 LCD (option)
4 Diaphragm 13 Analog indicator (option)
Figure 1 7mf33 01.tif

INDUSTRIES
The following parameters can be set or their current interrogated:

• measuring range
• measured value in mA, %, and unit of pressure
unit of pressure
linear or square rooting characteristic
application point of the square rooting characteristic
electric damping
current transmitter
output current in the event of an error
disabling input keys and/or functions
2.3 Dimensions
SITRANS P, differential pressure and flow transmitter, dimensions
HŒH3£» f:^
161foraeriaeDSwHh PROFIBUS-PA
• 45forPg 13,5 with adapter
1 Process connection V4 - 18 NPT 5 Connection side

tor absolute pressure (+) side 6 Electronics side, digital display
2 Mounting thread M10.M12 or 7 / 1 6 - 2 0 UNF (greater length for cover with window)
3 Dummy plug 7 Protective cover over keys
4 Electrical Connection: 8 Sealing screw
Screwed gland Pg 13.5 (adapter) 9 Side vent for measuring liquid
M20x1.5ortt-14NPTor 10 Side vent for measuring gas (supplement H02)
Han 7D/Han 8 U plug 11 Mounting bracket (optional)

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

• a wall or mounting frame using 2 screws,
or to
• a vertical or horizontal mounting pipe (50 to 60 mm in diameter) using a U-bolt
(see Figure 3).
The transmitter is fastened to the mounting bracket using the four screws supplied.
Fixing the transmitter using a mounting bracket
Figure 3 7mß3 03.tif

INDUSTRIES
3.3 Rotating the measuring cell in relation to the housing
If necessary, the measuring cell of the transmitter can be rotated in relation to the
electronics housing, so that the digital display is visible and/or access the input keys
and the current connection for an external measuring instrument is possible.
Only a limited rotation is permitted. The range of rotation (7), see Figure 4, is
marked at the base of the electronics housing. At the neck of the electronics housing
there is an orientation mark (6) which always must be within the marked range when
rotated.
Step A: Loosen the locking screw (8).
Step B: Rotate the electronics housing in relation to the measuring cell (only within
the marked area.
Step C: Tighten locking screw (torque 3.5+u ' Nm)
Rotating the measuring cell in relation to the housing
./<dl>^,
Figure 4 7mi33 04.tif
Warning: Observe the relevant regulations during the electrical installation. In

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

the specifications regarding the installation of electrical systems in hazardous
areas (VDE 0165), and,
the EC type examination certificate

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

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

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

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

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

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

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

pressure source pressure source
(normal configuration) (non-standard)
Step C: Open the equalising valve (2).

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

I N D U S T R I E S
Measuring steam
1 Transmitter
2 Equalizing valve
3 Pressure inlet valves
4 Impulse lines
5 Isolating valves
7 Outlet valves
10 Pressure source
13 Condensate reservoir
14 Jacket
Figure 9 7mO3_09.tif
Step C: Open the equalising valve (2)
Step D: Wait until the steam in the impulse line (4) and in the condensate reservoirs
(13) has condensed.
Step E: Open the pressure inlet valve (3 A) and venting valve on the positive leg of
the transmitter slightly until no more air escapes.
Step F: Close the venting valve.
Step G: Open the venting valve on the negative leg of the transmitter slightly until
no more air escapes.
Step H: Close pressure inlet valve (3 A).
Step I: Open the pressure inlet valve (3B) slightly until no more air escapes.
Step J: Close the venting valve on the negative leg of the transmitter.
Step K: Open the pressure inlet valve (3A) lA a rotation.
Step L: Check the zero point (4 mA) against start of scale (0) and correct if
necessary.
Step M: Close the equalising valve (2).
Step N: Open the pressure inlet valves (3A and 3B) fully.

INDUSTRIES
Operation of the transmitter
5.1 General
The differential pressure and flow transmitter is adjusted in the field by three input
keys, located on the outside of the instrument, with which the start of scale and full
scale values are set or adjusted. By means of the digital indicator (optional)
additional parameters can be adjusted. The input keys can be accessed, by undoing
the two screws holding the protective cover in place, which can then be moved out
of the way.
Transmitter controls and displays
O
^
* [
JLOOOPv
1) o t au.u ü u O
!y • J'JÆU
^>
Symbols for
Input keys
1 Digitaldisplay
2 Connecting plug
for digital display
3 Mode key
4 Increment key
5 Decrement key
Figure 10 7mt33 10.tif
The functions listed in Table 1 can be selected using the "M" key. When pressing
the "M" key (Mode) 2 appears in the bottom left corner on the LCD display. Every
additional key press increases the mode by one. The parameters, the current value,
or the unit of pressure can be modified using the Ï and 4- keys. In case of error
situations "Error" is displayed on the display, (see section 5.2.7). It generally
applies that:
• The transmitter changes to function "Measured value", if mode 14 is passed by
pressing the "M" key or if 2 minutes elapse without a key being pressed. In case
of the 2 minutes being passed the setting is automatically saved.
• The key lock must be released for keyboard operation.
• Numerical values are always set from the least significant digit still displayed. In
the case of an overflow in the key repetition mode it switches to the next
significant digit and only this continues to be counted. This procedure serves for
fast rough setting over a wide numeric range. For fine setting the desired key ( t

INDUSTRIES
or i) have to be released and pressed again. Exceeding of the upper and lower
measured value limits are shown on the display with the signs t or I.
If the input pressure is displayed, selected in mode 13 (see section 5.2.10), and
the square rooting characteristic in mode 11 (see section 5.2.9) the differential
pressure corresponding to the flow and additionally the sign "V" is displayed on
the display.
Functions of the dp-transmitter, type SITRANS P 7MF4433

Key function
Function Mode l) Display, explanation Section
t 4- t and>P
Output current in mA or % or input pressure in unit
Measured value 5.2.10
of pressure
"Error", if the transmitter is disturbed. Moving text
Error display 5.2.7
indicating reason for disturbance
Current Current Set to
Start of scale 2 Output current in mA 5.2.2
greater smaller 4mA
Current Current Set to
Full scale 3 Output current in mA 5.2.2
greater smaller 20 mA
Damping Damping Time constant T63 in seconds
Electrical damping 4 5.2.3
greater smaller Parameter range: 0.0 to 100.0
Start of scale Pressure Pressure Set to start
5 Start of scale in selected unit of pressure 5.2.4
"blind setting" greater smaller of scale 0
Set to upper
Full scale Pressure Pressure
6 measuring Full scale in selected unit of pressure 5.2.4
"blind setting" greater smaller
limit
Zero adjustment
Vent transmitter (start of scale remains unaffected).
(position 7 -- -- Execute 5.2.5
Measuring value in unit of pressure
correction)2*
Constant output current in mA
Current Current
Current transmitter 8 Switch on 3.6 - 4.0 -12.0 - 20.0 - 22.8 5.2.6
greater smaller
Switch off by "M" key
Output current in Change between the Selected output current
9 5.2.7
the event of an error two values Possible: fault current limits set by user
- - •
"O" = none
"LA" = all disabled
"LO" = all disabled except start of scale
Keys and/or Change between the
10 -- "LS" = all disabled except start of scale and full 5.2.8
function disable five functions
scale
"L" = write protection, operation by HART® not
possible
"Lin" = liniar
"SrLin" = square rooting
Change between the
Characteristic 11 -- (linear up to application point) 5.2.9
three functions
"SroFF" = square rooting
(switched off up to application point)
Application point of
the square rooting 12 Greater Smaller -- Parameter range 5 to 15% flow 5.2.9
characteristic
Measured value Select from three Unit of pressure (input value) or output current in
13 5.2.10
display possibilities mA or %
Unit of pressure 14 Change Technical units of pressure 5.2.11
l}
Change mode by pressing the "M" key.
2)
The start of scale is in a vacuum in absolute pressure transmitters. The zero adjustment in ventilated transmitters leads to mis-adjustments.
Table 1

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

The start of scale and full scale can be set or adjusted with the input keys. Modes 2
and 3 (see Table 1 ) are available for this. This allows implementation of rising or
falling characteristics.
Setting (theoretical relationship)
In setting, a desired start of scale and/or a desired full scale are assigned to the
standard current values (4 mA/20 mA). Pre-requirements: two reference pressures
(Pri, Pß) provided by the process or generated by a pressure transmitter.
Note: The measuring span is not changed when setting the start of scale. By
setting the full scale the start of scale remains unchanged. Therefore the
start of scale should be set first and then the full scale.
The relationship between the measured pressure and the generated output current is
linear. Please note that this does not apply if square rooting characteristic is selected.
In case of linear relationship the output current can be calculated with the following
equation shown in Figure 11 :
Equation for calculation of current output
I = output current
p = pressure p-MA
ME-MA *16mA + 4mA
MA=start of scale
ME = full scale
Example
Given a transmitter with a measuring span of 0 to 16 bar. Set to a measuring span of
2 to 14 bar.
Step A: Apply 2 bar process pressure. Set the device to mode 2 with the "M" key.
The display shows the set mode at the bottom left. Set the start of scale by
pressing the T and 4 keys on the value for about 2 seconds. An output
current of 4 m A is then generated at 2 bar input pressure.

INDUSTRIES
Step B: Apply 14 bar process pressure. Set the device to mode 3 with the "M" key.
The full scale is set by pressing the t and i keys on the value for about 2
seconds. An output current of 20 mA is then generated at 14 bar input
pressure.
Step C: The output current for any input pressure can be calculated with the
specified equation shown in Figure 11.
Adjusting (theoretical relationship)
When adjusting, the start of scale and/or the full scale can be assigned to any desired
current value using one reference pressure. This function is particularly suitable if
the pressures necessary for start of scale and full scale are unavailable.
Requirements: applied pressure (reference pressure) and the set start of scale and full
scale are known. Please note that after adjusting, the measuring range specified on
the measuring point plate may no longer match the setting.
Using the following equation shown in Figure 12 the current that should be adjusted
for the desired start of scale and full scale can be calculated.
Equation for calculation of current (set the start of scale and full scale)
current tob«
P_ -MA
«8»* M* non,
ME^-MAK,
current to be p_j -MA__

MlatMEr«, l „ r-rd nom • 1 6 m A + 4 t n A
ME»,-
nom MA„„
nom
I »output current
p . = appliedreferencepressure MA^, »old start of scale
ME,,,,, -new(idscale
MAJ^ »new start of scale
1
1 To calculate the output currents when sating start of scale and full scale, the reference pressure must
be »elected so that a value between 4 and 20 mA Is obtained for the current.
Figure 12 7mt33 13.tif
Example
Given a transmitter with a measuring span of 0 to 16 bar. Adjust to a measuring span
of 2 to 14 bar. A reference pressure of 11 bar is available.
Step A: Set the device to mode 2 with the "M" key. Using the equation from Figure
12 first calculate the current that should be adjusted for the desired start of
scale (2 bar) at the applied reference pressure and then adjust it with the f
and i keys (13 mA in this example).
Step B: Set the device to mode 3 with the "M" key. Using the equation from Figure
12 calculate the current that should be adjusted for the desired full scale (14
bar) at the applied reference pressure and then adjust it with the t and i
keys (16 mA in this example).

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

The full scale is set by:
Step E: Apply the corresponding pressure.
Step F: Select mode 3 using the "M" key.
Step G: Set the full scale to 20 mA with the T and i keys.
Step H: Save with "M".

Set start of scale and full scale (practical application with reference pressure
available)
If the output current is not set but adjusted continuously, the currents must be
calculated so they can be adjusted mathematically. It is possible to make an
adjustment for the start of scale, the full scale, or both values one after the other.
The start of scale is adjusted by:
Step A: Apply the reference pressure.
Step C: Adjust the output current for the start of scale with the T and 4- keys.
Step D: Save with "M".

The full scale is adjusted by:
Step E: Apply the reference pressure.
Step F: Select mode 3 using the "M" key.
Step G: Adjust the output current for the full scale with the t and 1 keys.
Step H: Save with "M".
5.2.3 Electric damping

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

INDUSTRIES
Step A: Select mode 4 using the "M" key.
Step B: Set the desired damping with the T and i keys.
Step C: Save with "M".
5.2.4 Blind setting of start of scale and full scale

In modes 5 and 6 the start of scale and full scale can be set/adjusted with the input
keys and without applying pressure. It is also possible to change between rising and
falling characteristics.
Theoretical relationship
First select the desired physical unit. The two pressure values can then be
set/adjusted with the T and -l keys and saved in the device. These theoretical
pressure values are assigned to the standard current values 4 mA and 20 mA.
The relationship between the measured pressure and the generated output current is
linear. Please note that this does not apply if square rooting characteristic is selected.
Example
Given a transmitter with a measuring span of 0 to 16 bar. Adjust it to a measuring
span of 2 to 14 bar without applying pressure.
Step A: Set the device to mode 5 with the "M" key. Set the start of scale to 2 bar by
pressing the t or 1 key. If 2 bar input pressure are applied later, an output
current of 4 mA is generated.
Step B: Set the device to mode 6 with the "M" key. Set the full scale to 14 bar by
pressing the Î or •I key. If 14 bar input pressure are applied later, an output
current of 20 mA is generated.
Set start of scale and full scale, blind (practical application)

The device sets the start of scale to the lower and the full scale to the upper sensor
limit when the keys are operated as follows:
The start of scale (blind) is set by:
Step B: Press the t and -l keys simultaneously and hold for 2 seconds. The start of
scale is set to the lower sensor limit.
The full scale (blind) is set by:
Step C: Select mode 6 using the "M" key.
Step D: Press the T and 1 keys simultaneously and hold for 2 seconds. The full
scale is set to the upper sensor limit.
Adjust start of scale and full scale, blind (practical application)
If the pressures for the start of scale and full scale are not to be set but adjusted
continuously, the keys should be operated as follows:
The start of scale (blind) is adjusted by:

INDUSTRIES
Step B: Adjust the pressure value of the start of scale with the T or X keys.

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

The zero error resulting from the installation position can be corrected with a zero
adjustment. To do this, the device must be ventilated to correct the existing offset so
that the value 0 bar (or other unit of pressure) appears in the display. The setting of
the start of scale and full scale remain the same.
The zero adjustment is set by:
Step A: Vent the transmitter.
Step C: Set zero with the Ï and 4 keys.
Step D: Save with "M".
5.2.6 Current transmitter

The transmitter can be switched to constant current mode with the "M" key. In this
case the current no longer corresponds to the process variable'. The following output
currents can be set independently of the input pressure:
— 3.6 mA - 4.0 mA - 12.0 mA - 20.0 mA - 22.8 mA
The current transmitter function can be cancelled again with the "M" key.
The constant current is set by:
Step B: Activate the constant current mode by pressing the Î and i keys
Step C: Activate the constant current level by pressing the t or 4 key.
Step D: Turn off the constant current mode with the "M" key.
Step E: Exit the constant current mode with the "M" key.
5.2.7 Failure current

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

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

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

measured value display "Current" in mA or % first in mode 13.
Otherwise a change in the output variable is not detected when pressing
the t and 4- keys.
The key/function disable is set by:

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

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

INDUSTRIES
current is linear up to the application point (see Figure 13 a) and when "SroFF" is
selected the output current is switched off up to the application point. The
application point can be set between 5% to 15% of the flow.
The characteristic is set by:
Step B: Select the characteristic type with the t or 4- key.

The root application point is set by:
Step E: Select the application point between 5% and 15% with the T or 4- key.
Step F: Save with "M".
Note: Mode 12 cannot be selected when the "linear" measuring mode 11 is set.
If the input pressure is selected as a display in mode 13 and square
rooting characteristic in mode 11, the differential pressure
corresponding to the flow and root sign are displayed.
Transition point of square rooting characteristic
Outputl%!
square ^ ^ ^
root s^
square y^ /
15
so- root / / yS
Adjusting
range for f/ Transition
10 / point
60- transition
/ / pressure point
linear
/ / linear / / pressure
5- •j-j linear
40-
- — '% s
0 fL-""""''^
'• 20- 0 1 2 3 4
a: linear below transition point
; o- ' '; 20
0 40 60 80 100
pressure (%}
0 1 2 3 4
b: cut-off below transition point
Figure 13 7mf33 ll.tif

INDUSTRIES
5.2.10 Measured value display

In mode 13 one of three display types can be set with the input keys.
• Display in mA.
• Display in % (of the set measuring range).
• Display in a unit of pressure (selectable in mode 14).
The unit type is set by:
Step B: Select the type unit with the T or i keys.
5.2.11 Selection of unit of pressure

In mode 14 it is possible to select a desired unit of pressure for the display from a
list with the input keys. The following unit of pressure can be chosen:
Bar, mbar, mm HzCP, in HbCP, ft U20'\ mm Hg, in Hg, psi, Pa, kPa, Mpa, g/cm ,
kg/cm2, Torr, ATM, in WC, mm WC.
** Reference temperature 20°C.
The unit of pressure is set by:
Step B: Select the unit of pressure with the t or 4 key.

If the display capacity of the digital display is exceeded, "9.9.9.9.9" appears in the
display. Please note that in the measuring mode the selected unit is only visible in
the display if a unit of pressure display is selected in mode 13. Otherwise "mA" or
"%" is displayed.
5.3 Operation without LCD display
5.3.1 Setting start of scale and full scale without LCD display
• Please note that the input keys might be disabled. To cancel a set keyboard
disable press the "M" key for 5 seconds.
Step A: Undo the two screws holding the protective cover in place, which can then
be moved out of the way.
Set start of scale (4 mA) and full scale (20 mA)
Assuming the input keys are pressed as described below, the transmitter sets the start
of scale to 4 mA and the full scale to 20 mA. An ammeter is not required.
Start of scale
Step A: Apply a differential pressure corresponding to the start of scale to the
transmitter.

INDUSTRIES
Step B: Press the t and i keys simultaneously for about 2 seconds.
Full scale
Step A: Apply a differential pressure corresponding to the full scale to the
transmitter.
Step B: Press all three input keys, making sure that the "M" key is pressed first,
hold it, and press both the other keys ( t and i).
Calibrate start of scale and full scale

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

hazardous locations and using transmitters conforming to protection
type "Flame-proof enclosure" (Explosion-proof).
Step A: Clean the transmitter to prevent the ingress of dirt.
Step B: Unscrew the cover from the electrical connection box.
Step C: Connect a DC meter to the test plug (see Figure 5).
Warning: For intrinsic safe current circuits only certified current meters are
permitted.
Start of scale
Step A: Apply a differential pressure corresponding to the start of scale to the
transmitter.
Step B: Set the output current for start of scale using the Î and i keys.
Step C: The set output current is saved automatically when the key is released.
Full scale
Step A: Apply a differential pressure corresponding to the full scale to the
transmitter.
Step B: Set the output current for full scale using the "M" key and the Î key or the
"M" key and the i key. Always press the "M" key first, hold it, and press
either the t or the i key.
Step C: The set output current is saved automatically when the key is released.

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

INDUSTRIES
Table of contents
Regulating valves
Electrical actuator, type Premio
General 1
Description 2
Installation 3
Settings 4
Starting up 5
Care and maintenance 6
Dismantlement of the thrust actuator 7
Troubleshooting 8
General 1
Operation 2
Maintenance 3

*#####•
AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04.2

INDUSTRIES
Electrical actuator, type Premio

1 General
These operating instructions contain information necessary to install and operate the
thrust actuator both safely and effectively. If problems arise which cannot be solved
with the aid of this operating instruction, please contact Aalborg Industries for
further information.
1.1 Qualified personnel
This refers to personnel possessing corresponding qualifications and familiar with

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

AALBORG ELECTRICAL ACTUATOR, TYPE PREMIO OM5510#04,2
INDUSTRIES
Description
2.1 Field of application
The PREMIO linear thrust actuators are employed to actuate control or shut-off
valves requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2
kN to 15 kN. The thrust actuators are set to the thrust forces specified in the
technical data. If supplied with the valve, the lift of the thrust actuator will be set to
the stroke distance of the valve. Selection of the proper actuator version in alignment
with the corresponding fitting as well as use of the thrust actuator in accordance with
the specified technical data is the responsibility of the systems engineer.
Attention: Any use of the thrust actuator beyond the specified technical data
or improper use of the actuator is deemed to be not for the intended
purpose.
The ambient conditions have to be conformed to the actual electromagnetic

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

INDUSTRIES
| Technical specifications for Premio actuators

Type Actuator type
Thrust force [kNl 2.2 | 5.0 12.0 | 15.0
Stroke distance max. [mm] 50 80
Duty classification in accordance SI - 100% duty cycle; S 4 - 50%
SI - 100% duty cycle; S4 - 80% duty cycle 1200 c/h
with DIN VDE 0530 duty cycle 1200 c/h
Control speed [mm/sec] 0.25 | 0.38 | 0.38 1.0 079 | 0.38
Motor voltage 230 V - 5 0 Hz/60Hz* 230V,50Hz 230 V - 5 0 Hz/60 Hz*
Power consumption [W] 10.3 | 11.7 | 25.3 52.9 109 | 96
2 only, permanently wired switching capacity 2 pes., permanently wired
Torque switch
10 A, 250 V~ switching capacity 16 A, 250 V~
1 only, permanently wired switching capacity 1 pes., permanently wired
Travel switch
10 A, 250 V~ switching capacity 16 A, 250 V~
Enclosure IEC 60529 IP 65
Max. permissible ambient
-20°C to +70°C
temperature
Hand wheel Yes (rotating during operation) | Yes (can be engage)
Mounting position Any. Exception: motor must not be suspended downwards
50/50 Klüber Isoflex NBU15 Ultra
Gear lubricant Kliiber Unigear LA 02 or similar and Klüber Nontrop KR291 or
similar
Weight fkgl 5.4 | 6.0 | 6.5 10.5
Accessories
Additional travel switches 2 additional travel switches, zero potential, switching capacity 10 A, 250 V~
Additional travel switches for low- 2 additional travel switches, zero potential, with gold contacts, switching capacity max.
voltage / electronic system 0.1 A,4-30Vdc
Potentiometer Max. 2 only. Ohmage optional: 100, 200, 500,1000 ohm; 1.5 W
0 (2) -10 V, 0 (4) - 20 mA - only 1 potentiometer possible.
Electronic position indicator RI21
Using the temperature controller, installation is only possible in the control cabinet.
Electronic position controller ES 0 (2) -10 V, 0 (4) - 20 mA - only 1 potentiometer possible.
11 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
24V,50Hz
24 V-50/60 Hz
24V,60Hz
24 V - 50/60 Hz 115 V-50/60 Hz
Additional voltages / frequencies 115V,50Hz
115 V-50/60 Hz 3-400 V - 5 0 Hz
115V,60Hz
3-440 V - 6 0 Hz
230V,60Hz
2 torque switches and 1 travel switch, zero potential, for
Standard-voltage connection PA --
free wiring, switching capacity 10 A, 250 V ~
2 torque switches and 1 travel switch, zero potential, for
Low-voltage connection board
free wiring, with gold contacts, switching capacity max. --
(electronic system), NA
0.1 A,4-30Vdc
Temperature controller (three-point controller) in micro process technologies.
Three-step temperature-controller in microprocessor-technology.
Integrated temperature-controller Control range: -200°C to 850°C (resistance thermometer).
dTRON 16.1 Voltage: 24 V, 115 V, or 230 V 50/60 Hz.
Compatible with resistance thermometers and thermocouples (provided by customer), or
standardised active current or voltage signals.
Actuator with 400 V - 50 Hz and
Integrated reversing contactor -- 440 V - 6 0 Hz.
Only 1 electronic module possible.
Only in addition with integrated
Phase control relay --
reversing contactor
* Control speed and power consumption are 20% higher at frequency of 60 Hz
Table 1

INDUSTRIES
Diagram for actuators type 2.2 - 5.0 kN
Yoke Version Column Version
/—
50.47 50.53 50.52 50.51 5056
50.55
50S8-
5057
50X2
Figure 1 premio_l.tif

I N D U S T R I E S
Diagram for actuators type 12.0 -15.0 kN
50.12
50.12.1
50.1
50.2
50.56
50.<0
50.38
50.36
Figure 2 premio_2.tif

INDUSTRIES
Part list
Pos. Designation Pos. Designation Pos. Designation
50.1 Gearbox Hexagon head screw DIN EN 50.40 Synchronous motor, complete
50.18
50.1.1 Gearbox cover plate 24017-M10x45 50.41 Head cap screw DIN 912-M4
Cable conduit fitting 50.19 T-head bolt DIN 261-M12x40 50.42 Board support
50.2 2.2-5.0 kN: 2 x P G l l 50.20 Washer DIN 125-13 50.43 Standard board
12-15 kN: 2 x PG13.5/1 x PG9 50.21 Spring washer DIN 128-A12 50.45 Shift lever
50.4 Sealing plug l x P G 11 50.22 Hexagon nut DIN 24032-M12 50.46 Washer
50.5 Gasket 50.23 Lift dial 50.47 Wiring diagram sticker, std.
50.6 Hood 50.24 Distance column 50.48 Connector, 3-pole (standard)
50.7 Hood seal 50.25 Hexagon nut DIN 980-V-M16 50.50 Trip slide
Counter-sunk screw DIN 7991- 50.26 2-ear clamp (stroke indicator) 50.51 Setting spindle for switch S3
50.8
M5x20 50.27 Coupling 50.52 Setting spindle for switch S4
50.9 Sealing washer DIN 125-5.3 50.30 Driving spindle 50.53 Setting spindle for switch S5
50.10 Column 50.31 Spindle safety feature 50.54 Trip cam
50.12 Hand wheel 50.32 Torsion safety feature 50.55 Lock washer DIN 6799-2.3
50.12.1 Turning handle of hand wheel 50.34 Bellow 50.56 Spring PREMIO for trip slide
50.14 Yoke 50.35 Grub screw M6 Head cap screw DIN 912-
50.57
50.15 Flange 50.36 Set collar M4xl0
50.16 Spring washer DIN 128-A10 50.37 Grub screw DIN 913-M3x5 50.58 Protective conductor terminal
50.38 Guide spindle 50.59 Head cap screw DIN 912-M4x6
Hexagon head screw DIN EN
50.17 50.87 Threaded bush
24017-M10x30 50.39 Hexagon nut DIN 24034-M5
50.101 Connector, 8-pole
Table 2
Dimensions diagram
//////////MW//////
ISHJ5HiiSi*'iT"iT
ARI.PREMIOM-SkN ARI-PREMIOV-5kN ARI-PREMIOUlSkN

Nominal itroke max. 30 mm Nominal stroke > 30 mm • 50 mm Nommai stroke max. 80 mm

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

observed:
— Existing operating instructions for valve.
— Complete valve with cross-arm.
— Valve cone approximately in mid lift position - on no account supported inside a
seat.
— Electrical installation in accordance with DIN VDE 0100 and regulations of the
local electricity generating board.
— Conductor cross-section selected to correspond to the given drive power and
existing line length.
— Mains fuse rating max. 6 A.
— Circuit breakers to EN 60335-1 in the plant to cut off the mains supply to the
actuator.
— Conformity of technical data on thrust actuator with field conditions.
— Mains voltage in accordance with data specified on rating plate of thrust
actuator.
— Thrust actuator complete with yoke or distance columns and coupling parts
intended for mounting to the corresponding valve.
— Qualified personnel possessing knowledge of the regulations pertaining to the
erection of power installations.
— Ease of access to installation site and adequate clearance space above the thrust
actuator for removing the hood.
— Install where there is protection against high-energy heat radiation.
— The ambient temperature must not exceed +70°C.
— In case of widely fluctuating ambient temperatures and high atmospheric
humidity, user is recommended to install a heating resistor to minimise
condensation build-up in the actuator.

INDUSTRIES
— Thrust actuator mountable in any position except in downward suspended

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

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

— Turning in counter-clockwise direction --> opens valve.
Hand wheel operation (actuator type 2.2 - 5.0 kN)
Open Close
50.12.1
50.12
In the manual operating mode pay careful attention in the final positions that the
hand wheel is only turned to the point where the torque switch trips (audible click)
as otherwise damage will be caused to the thrust actuator. Since the hand wheel
always follows during motor-driven operation (running indication), never operate by
hand while the motor is running -potential injury hazards.
For actuators type 12.0 -15.0 kN
With the motor in the stationary state, the thrust actuator can be run in the open and
closed state with the engage able hand wheel. Proceed as follows:
Step A: Fold the turning handle out of the hand wheel (A), see Figure 5.
Step B: Turn the hand wheel slightly and push in the engaging button for manual
mode (B) --> the button engages.
— Turning in clockwise direction —> closes valve.

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

INDUSTRIES
Hand wheel operation (actuator type 12.0 - 15.0 kN)
Engaging button
for manual mode
50.12.1 Open Close
In the manual operating mode pay careful attention in the final positions that the
hand wheel is only turned to the point where the torque switch trips (audible click)
as otherwise damage will be caused to the thrust actuator.
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 30 mm,
proceed as follows (Fig. and position numbers refer to Figure 6):
Step A: Screw coupling (50.27) out of torsion safety feature (50.32) of thrust
actuator (not illustrated).
Step B: Set valve cone position to approximately mid lift position.
Step C: Turn flat hexagon nut if not present on valve spindle (Fig. A).
Step D: Slip coupling (50.27) over valve spindle (Fig. A-B).
Step E: Screw threaded bush (50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut. Setting
dimension (Y) for fitting-projection (X) are 60 and 83 mm = 102 mm.
Step F: Place thrust actuator (50) on valve (Fig. C). Mount thrust actuator on fitting
with two T-head bolts (50.19), two washers (50.20), two spring washers
(50.21), and two hexagon nuts (50.22).
Step G : Swing out hand wheel lever (50.12.1) and use it to move out the thrust
actuator until the driving spindle (50.30) comes to rest on the threaded bush
(50.87), (FIG. D-E).
Step H: Screw the coupling (50.27) firmly into the torsion safety feature (50.32) and
secure in place using grub screw M6 (50.35), (Fig. F).
Step 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.

INDUSTRIES
Step K: Run valve to both final positions and check to ensure that these are safely
reached.
Step L: Carry out electrical connection (see section 3.4) and set travel switch S3
(see section 4.3).
Mounting for valve-lift up to 30 mm (yoke version)
50—.
tura
50.12.1
•HeugonmH
•\Wve spindle
50.19
JJL-50.20 ••!•• i ,-i.'

50.21 T)-U,1P
50.22 ^ ^
3.3.2 Mounting for valve-lift over 30 mm to 80 mm (column version)

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

INDUSTRIES
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 hand wheel (50.12.1), slightly turn the hand
wheel and press in the engaging button for manual mode (only 12-15 kN)
(button engages). Having done this, move out the thrust actuator until
driving spindle (50.30) comes into contact with threaded bush (50.87), (Fig.
D-E).
Step K: Screw coupling (50.27) firmly into torsion safety feature (50.32) and secure
using grub screw M6 (50.35), (Fig. F).
Step L: Move the valve to the lowest position.
Step M: Press 2-ear clamps (50.26) into position according to the stroke so they
cannot slip, with the bottom clamp in the lowest valve position located
directly below torsion safety feature (50.32) and the top clamp in the
highest valve position located directly above the torsion safety feature.
Step N: Move the valve to both travel positions and check that it reaches them
reliably. Fold turning handle of hand wheel (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 standard travel switch S3 (see section 4.3)
Mounting for valve-lift over 30 mm to 80 mm (column version)
B C D E
50.87
50.27
" &~"Vtlve spindle
UÊu
I 1

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

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

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

thrust -actuator terminal strip.
Step 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.
Step L: 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.
Step M: If the directions of movement are contrary to those desired, the pulse lines
governing the move-in and move-out connecting rod will need to be
exchanged.

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(Switching capacity 0.1 A, 4-30VDC) „. Standard-voltage connection board,
Jr l l û n zero potential
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© Û" 0 ES 11 Electronic position controller

"1
lu a ut ii External rcveraing contactor.
IOJO LI, L2, L3 - actuator spindle drives in
L3, L2, LI - actuator spindle drives out
L-U Standard-voltage connection
In all external reversing circuits the tœque PA
switches SI and S2 have to be used to board, zero potential
switch off the actuator motor.
external WE Travel switch, zero potential

levcfnng r Please check the operating direction
contactor J T F* of the actuator!
L1L2LÎ U U
WS Reversing contactor
INDUSTRIES
Settings
4.1 Torque and travel switches -standard feature
Thrust actuators are as standard equipped with a load-dependent travel switch for the
closing direction (SI), a load-dependent travel switch for the opening direction (S2),
and a stroke-dependent travel switch for the opening direction (S3). The load-
dependent travel switches (SI, S2) switch off the motor as soon as the factory-set
thrust force is attained.
Note: The settings of the load-dependent travel switches must on no account

whatsoever be changed.
The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or
stroke is attained. If the thrust actuator is supplied on a straight-way valve, the
stroke-dependent travel switch S3 is set in such a way that the motor of the thrust
actuator is switched off as soon as the maximum valve-lift is attained. If the thrust
actuator is supplied on a three-way valve, the trip cam belonging to travel switch S3
is set in the opening direction in the trip slide to such a downward extent that the
upper final position of the valve is attained prior to travel switch S3 being reached,
thus causing the load-dependent travel switch S2 to switch off the motor.
For this function, all three switches reveal interlock-controlled circuitry on the
board. If the standard travel switches are to be integrated directly into the facility
control system, the standard board can be replaced by optional boards PA or NA
(only 2.2-5.0 kN).
4.2 Connection boards PA or NA (only 2.2 - 5.0 kN)
On connection boards PA or NA, the standard travel switches 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
SI 1/S21, S12/S22, and S13/S23, designed as double-throw contacts, are, in the case
of these boards, brought out on terminals 40 - 48 and can be freely connected.
The switches on the PA optional board (standard-voltage connection board) are
designed for switching capacities of up to 10 A, 250 Vac. The switches on the NA
optional board (low-voltage connection board) are designed for switching capacities
of up to 0.1 A, 4 - 30 V (gold contacts). The optional boards may only be installed
at the factory due to the switching points of the load- dependent switches having to
be reset following installation of these boards.
Note: When using optional boards PA or NA, it must be warranted -due to the
operator's individual circuitry- that, when switching the load-dependent
travel switches Sll/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.

INDUSTRIES
4.3 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) is sealed with
screw glyptal. This setting needs no changing for normal operation.
If reinstalling the thrust actuator on a straight-way valve, the travel switch (S3)
needs to be set as follows:
Step A: Move valve out of the lowest position so as to run valve-lift to up position.
Step B: Using a screw driver, proceed to turn setting spindle for switch (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.

If reinstalling the thrust actuator on a three-way valve, the travel switch (S3) needs
to be set as follows:
Step E: Run valve in both final positions and check in each final position whether
the valve switches off via the load-dependent switches.
Step F: Carry out a check in the top final position the see whether, after switching
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 governing
the travel switch (S3) needs to be turned until the trip cam is situated below
travel switch (S3) without tripping it.
Step G: 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 H: If needed, correct the setting as described above.
4.4 Potentiometers
The potentiometers are used for electrical position acknowledgement on the facility
control system or for the options, electronic position controller 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 ESI 1 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.

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

If retrofitting the potentiometer, proceed as follows:
Step A: Switch off mains voltage and safeguard to prevent it from being switched
back on again accidentally.
Step B: Loosen countersunk screw in hood, carefully remove hood.
Step C: Plug in the flat connectors on grey potentiometer cables onto the middle
connector pins, those of the red cables onto the upper connector pins and
those of the yellow cables onto the lower connector pins of the
potentiometer (see Figure 10, Figure 11, and Table 3).
Step D: Insert the potentiometer into the guide in the way that the pinion (50.73) of
the potentiometer meshes with the gear stick of the trip slide.
Step E: With a valve lift up to 30 mm, hook spiral spring (50.70) into the left-hand
window of board support (50.42) above the potentiometer guide, insert into
the guide between the slide block and the potentiometer guide and hook
into the cut-out below the potentiometer.
Step F: With a valve lift between 30 mm and 50 mm, hook spiral spring (50.70) into
the right-hand window (for 12.0 - 15.0 kN middle window) above the
potentiometer guide, insert into the guide between the slide block and the
potentiometer guide and hook into the cut-out below the potentiometer.
Step G: With a valve lift between 50 mm and 65 mm, hook spiral spring (50.70)
into the middle window in board support (50.42) above the potentiometer
guide, insert into the guide between the slide block and the potentiometer
guide and hook into the cut-out below the potentiometer.
Step H: Check to see whether pinion (50.73) is pressed into toothed rack by spiral
spring (50.70) and is positioned free from backlash.
Step 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.

• • • f •

INDUSTRIES
Installation of potentiometer
50.67.1
50.73
50.72 50.95
Potentiometer connection cable
yellow
Figure 11 premio_ll.tif
Part list for potentiometer

Pos. Designation Pos. Designation Pos. Designation
50.42 Board support Connecting cable for Pinion (selection depends on
50.68 50.73
50.47 Circuit-diagram sticker potentiometer valve lift 20,30, 50,65, 80)
50.67.1 Hexagon nut 50.69 Self-tapping screw Connector, 3-pole
50.74
50.67.2 Tooth lock washer 50.70 Spiral spring (potentiometer) (potentiometer)
50.67.3 Potentiometer 50.71 Slide block (potentiometer)
50.95 Spring washer
50.67.4 Washer from PA 50.72 Set collar
Table 3
4.4.2 Setting the potentiometer

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

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

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

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

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

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

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

INDUSTRIES
8 Troubleshooting
In the event of malfunctions or disturbances in operation, first check whether the
installation and adjustment work has been carried out and concluded in accordance
with these operating instructions. Compare the data referring to operating voltage,
actuating signal and temperature to the data specified on the layout drawing of the
control system. Also check whether the given operating conditions correspond to
those specified on the type identification plate.
Warning: AH relevant safety regulations must be observed when carrying out

the troubleshooting procedure.
Contact the supplier/manufacturer if faults cannot be rectified on the basis of the

following troubleshooting table:
Troubleshooting table
tuuli 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
leakage
-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
(Only for 12.0-15.0 kN)
closest to the cable feed-through.
Hand wheel is still engaged and does
(Manual release of the hand wheel
not disengage when the motor starts up
disengagement mechanism)
Thrust actuator alternates between
Have motor operating capacitor
clockwise and counter-clockwise Motor operating capacitor defective
replaced
rotation
Load-dependent travel switches out of Remove thrust actuator and send to
adjustment / defective factory for repair
Voltage drop due to excessively long
Lay connecting cables in accordance
Thrust actuator fails to run to final connecting cables or inadequate
with requisite output
positions and also produces chatter conductor cross-section
Mains fluctuations beyond permissible Arrange for "clean" mains system
tolerance travels within 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
Travel switch (S3) not set Set travel switch (S3) in accordance
opening direction prior to load-
corresponding to use with operating instructions
dependent switch (three-way valve)
Table 4

INDUSTRIES
1 General
This type of control valve is suited to regulate fluids, gases and steams. The valve
plug is normally a parabolic plug, but can also be supplied in a perforated design.
Both types of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always against the closing direction.
However, with perforated plugs for steam and gases, it is in the closing direction. If
a valve with a perforated plug is operated by means of a pneumatic actuator with the
flow in the closing direction, the pneumatic actuator should have a stronger thrust
force. This is necessary to prevent thumping near to the closing position.
All control valves can be fitted alternately with manual-, pneumatic-, electric- or
hydraulic operation devices.
Illustration of control valves type 470 and 471
Control valve, type 470 Control valve, type 471
Figure 1 val47x.tif

INDUSTRIES

Part Designation Part Designation Part Designation
1 Body 7 Gland flange 15.1 Studs
2 Seat ring 7.1 Screw joint 17 Hexagon nuts
3 Mounting bonnet 8 Spindle guiding 17.1 Hexagon nuts
3.1 Mounting bonnet 10 Stuffing box 19 Spring-type straight pin
4 Guiding bush 10.1 Stuffing-box packing 21 Set-pin
5 Plug 14 Gasket 25 Bellow housing
6 Spindle 14.1 Gasket 26 Bellow unit
6.1 Spindle 15 Studs
Table 1
Operation
2.1 Fitting instructions
The valve should be inserted so that the spindle has a vertical position together with
the actuator. The valve can also be tilted to a maximum horizontal position if the
installation point does not allow any better condition.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length (min. two times the pipe
diameter by inlet and six times by outlet). The piping should be rinsed to clear out
any pollution, welding beads, rust, etc. before inserting the control valves. A strainer
should be fitted in front of the control valve to catch the remaining particles. Bolts
should be tightened after taking into operation.
The flow direction is signalled by an arrow on the valve body. The valves should be
insulated against high temperatures to guard the actuator.
2.2 Actuator assembly
The control valves are normally delivered with actuators already fitted. For
alternations or maintenance of actuator, the assembly should occur in accordance
with the operation instructions for the actuator.
2.3 Setting into operation
When the piping system isfilled,the spindle sealing should be checked for leakage
and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as
the spring tension maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter
than it is necessary for the sealing. Flange connection bolts should never be loosened
or tightened when the valve is under temperature or pressure even if a leakage may
arise.
For actuators please see to the appropriate actuator operation instructions.

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

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

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

INDUSTRIES
Note: Special care should be given to the spindle surface. Rough surfaces wear
the sealing lips enormously and can be due to failure of the packing unit.
3.3 Exchange of the bellow unit
Step B: Unscrew the screw joint (7.1).
Step C : Unscrew the hexagon nuts (17) and remove the bellow housing (25).
Dismantle the plug as described in the next section.
Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1).
Step E: The bellow unit (26) is removed from the bellow housing (25).
Step F: Replace the two gaskets (14.1) and the gasket (14).
Step G: When the bellow unit (26) is replaced, the proper position of the anti-
twisting device must be observed.
Step H: The set pins (21) have to drive within the slots of the anti-twisting device.
Check for friction-free movement.
Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1)
crosswise.
3.4 Exchange of the plug-spindle unit
Step B: Unscrew the gland flange (7).
Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).
Step B: Pull out the plug with the spindle and exchange this unit.
Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6).
Step D: Replace the old parts and assemble it.
Step E: Drill a hole through the plug shaft and insert a new pin.
Step F: Replace the gasket (14) and assemble the mounting bonnet (3).
Step G: Tighten the nuts (17) evenly, crosswise.

INDUSTRIES
Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with
plug (5).
Step B: Drive the spindle in the bottom position and remove the spring-type straight
pin (19).
Step C: Unscrew the plug.
Step D: Screw a new plug at the spindle and drill through the shaft. Drive the
spring-type straight pin (19) into the hole.
Step E: Replace the gasket (14).
Step F: Assemble the bellow housing (25) with plug (5) together with the body (1)
and fix it by screwing the hexagon nuts (17) crosswise.
The spindle can only be completely replaced together with the bellow.
3.5 Changing the seat ring

The seat ring is screwed into the valve body. The seat ring can be obtained after
removing the bonnet and can then be refinished or replaced as required.
Step A: Clean and lubricate the thread and conical sealing surface before insertion.

INDUSTRIES
Table of contents
Ignition burner pump
Technical data for ignition oil pumps
General data 1
Data for ignition oil pump 2
Description 1
Data sheet
Data sheets for pump 1

INDUSTRIES ^mj^gnn^m^gnm^g^^g||||^g|^g|^^||||^^mii^^^^
Technical data for ignition oil pumps

1 General data
• Project No.: 736950, 736952

• Hull No./Project name: 03130007,03130008
• Classification society/Local authority: LRS
• Colour of ignition oil pump unit: Munsell 10GY 8/4
• Weight of ignition oil pump unit: 10 kg
2 Data for ignition oil pump
• Pump type: Gear pump, typeRSA

• Delivery head: 0.7 - 1.4 MPa
• Inlet pressure, maximum: 0.4 MPa
• Inlet pressure, minimum (at pipe bore 12 mm, length 50 m): 1.0 mWC
• Pump capacity at 4 cSt, 7 bar: 61 1/h
• Viscosity range: < 1.3 - 12.0 cSt
• Oil temperature, maximum: 70°C
• Filter mesh: 150 mu
3 Data for pump motor
Motortype: BF7 63 M22

Power supply: 3 x 440V, 60Hz
Rated output for motor: 0,22 kW
Revolutions: 3300 r.p.m.
Starting method: Direct
Starting current: 2.2 A
Operating current (full load): t 0.6 A

AALBORG IGNITION BURNER PUMP OM5540#10.1
INDUSTRIES
1 Description
The ignition burner pump supplies the ignition burner with diesel oil. The pump is
operated by the control system or the manual operating system. The ignition burner
pump is only in operation during the ignition sequence. An illustration of the
ignition burner pump is shown in Figure 1.
Illustration of the ignition burner pump
To burner
From diesel
oil tank
1 Pump
2 Manometer
3 Connection
4 Coupling
5 Motor
6 Ball valve
7 Tee-pice
8 Bend
Figure 1 ignibup_a.cdr
1.1 Function
When the pump is started, oil is drawn through the suction side port "S" via the filter
"H" to the suction side of the gearwheel set "C" as shown in Figure 2. The
gearwheel set pumps the oil to the pressure side.

INDUSTRIES
The pressurised oil is led to the cut-off and regulating valve "V". When the opening
set point is reached, the valve opens. Hereby oil is distributed to the nozzle port "P"
and to the pump return side "R" via the shaft seal "F".
The pressure is controlled and maintained at a constant level by the regulating valve
"V". The opening set point can be adjusted by means of an Allen key.
The quantity of oil supplied to the nozzle port "P" is determined by the pressure set
on the regulating valve "V" and the resistance in the nozzle line and the oil nozzle.
When the pump is stopped, the pump output drops and produces a drop in the oil
pressure. The spring in the regulating valve presses the regulating piston forward
until it seats in port "P". This cuts the oil flow to the nozzle and ensures that the line
is effectively shut off.
Sketch of the oil pump system
Figure 2 ignibupl.tif
If the pump is overloaded, i.e. more oil is demanded than the gearwheel is able to
pump under the given conditions, the oil pressure falls below the set value because
the regulating valve piston moves towards its closed position and partially or wholly
cuts off the return oil via port "O".
This condition can be remedied by:
• Reducing the pump pressure
• Reducing the capacity, i.e. smaller oil nozzle or larger resistance
• Changing to a pump with higher capacity

INDUSTRIES
1.2 Commissioning
When the pump is commissioned, the pump and the pipe system must be filled with
oil and ventilated. The pump can be ventilated on the ventilating screw "M". If the
pump is running without oil for more than five minutes, it may cause damage to the
pump.
1.3 Pipe systems
One pipe system is used when the pump is placed lower than tank level (positive
suction head).
Two pipe system is used when the pump is placed higher than tank level (negative
suction head).
In two-pipe systems the oil is returned direct to the oil tank. In one-pipe systems the
setting screw "A" must be removed to give free flow to the suction side via by-pass
"G" with return port "R" closed.
Normally the pump is delivered as a one-pipe system.
The pump is delivered with two suction ports and two return ports.

Description Index Dat^^krowr Appr.
Coble glond s i ~ c h o n g e d . JMN
17 170
PG 13.5
O.D. 12mm.
Bite-type-joint
*-To burner
Built in m
Strainer o
o
80
40 145 115 50
350
O.D. 12mm.
Bite-type-joint
12 HEXAGON NIPPLE 6638104
11 HEXAGON NIPPLE 6638136
10 STRAIGHT MALE 12mm 6641065
STRAINER (INTERNAL)
8 BEND 6638135
6638134 Final colour : Ace. to spec.
TEE-PIECE
BALL VALVE 6666006 Title: Drown Date
MOTOR 400/460 V - 5 0 / 6 0 Hz 6638133 Ignition oil pump SLJ 05.09.2002

Appr. Date
COUPLING 6638132 Type 2 JMN 05.09.2002
CONNECTION 6638131 Scale: Size
MANOMETER 0 - 2 5 Bar \ Kq/cm2 \ 0-2,5 MPa 6633121

«iiiiiiit G145 Weight
1:2.5 A3
AALBORG 4810000001 Article/Drawing No:
PUMP 6638130 INDUSTRIES
THIS DRAWING AND DESIGN SHOWN HERDS rS THE PROPERTY OF AAL80RC INDUSTRIES
ITEM OBJECT PART NO. Plot Dote: W 0 MUST NOT BE USED Br OR REPRODUCED FOR THIRD PARTY 71Z:024019
•
AALBORG ggjgisBiaaswnasns^^^^^M
Table of contents
Combustion air fan
Technical data for combustion air fan
General data 1
Data for combustion air fan 2
Data for fan motor 3
Data for pressure loss layout 4
Combustion air fan
General 1
Storage 2
Installation 3
Prior to start-up 4
Initial start-up 5
Normal operation 6
Vibration control 7
Maintenance 8
General 1
Mechanic connection of the positioner 2
Electric connection of the positioner 3
Pneumatic connection 4
Commissioning 5
Diagnosis 6
Service and maintenance 7

•• •
AALBORG GBGSÊÊÊBSIÊSSIÊBÊUBBIIIKKÊSÊKWM
INDUSTRIES ^g^ømmg|^gnm^||^^g|||g^^ngm||mm^îg^gi
Technical data for combustion air fan

1 General data
• Project No.: 736950, 736952

• Hull NoTProject name: 03130007, 03130008
• Colour of combustion air fan unit: Munsell 10GY 8/4
2 Data for combustion air fan
• Fan type: , HN 670-560/D

• Actual position designation: RD 0
• Static pressure: 800 mmWC
• Air flow at 45°C: 19891 m3/h
• Silencer type: CA 560x1500
• Noise level for fan with silencer: 100 db(A)
• Vibration damper type: s AR 200
• Numbers of vibration dampers: 6
3 Data for fan motor
Motor make: AEG

Motortype: AM 280
Power supply: 3 x 440 V, 60 Hz
Rated output for motor: 82 kW
Revolutions: 3575 r.p.m.
Starting method: Star/delta
Starting current: 585 A
Operating current (full load): 137 A

AALBORG ^BSmiBSESSSSSESSESßBßlKXUKStBBBIIlBEn
• Power consumption at 15°C: 65.2 kW

• Power consumption at 45°C: 61.6 kW
• Numbers of cable entries: 2
• Cable gland size: M 63
• Heating element (standstill): ,...134 W
• Thermostat protection: None
• Insulation class: F
• Degree of protection: IP54
4 Data for pressure loss layout
• Air duct system (from fan to wind box): 35 mmWC

• Boiler (from furnace to outlet at full load): 188 mmWC
• Flue gas system: 15 mmWC

AALBORG COMBUSTION AIR FAN OM5550#01.2
I N D U S T R I E S
Combustion air fan

1 General
The purpose of the combustion air fan is to supply combustion air to the burner. The
air is supplied by a directly driven centrifugal fan. The fan is mounted on a common
bed frame with motor, inlet vanes, and servo-drive unit. The fan impeller inside the
spiral housing is mounted directly on the motor shaft. The air flow to the burner is
regulated by inlet vanes mounted on the fan suction side.
The inlet vanes are of a multi-blade design and regulated by a servo-driven unit
comprising an air cylinder and I/P positioner. A silencer can be mounted on the fan
suction side.
Figure 1 shows an illustration of the combustion air fan (shown without silencer)
and the location of markings and warning signs.
Illustration of the combustion air fan
il 1
E Ü criitziC€
Nameplate Front of casing
Inlet vanes Vibration dampers ' Flexible connection
Figure 1 bar 02a.cdr
Storage
If the combustion air fan unit is stored for a period of time prior to installation, a
number of initiatives must be observed and considered. They are described in the
following sections.
2.1.1 Combustion air fan (normal conditions)
When the combustion air fan unit is delivered, it is provided with the correct
quantity and type of grease. The optimum storage temperature is 15°C.

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

Storage at temperatures above +35°C and below -5°C have a negative effect on the
state of the bearing grease. By storage in these conditions the maximum rotation
interval is 2 to 3 weeks.
After start-up of the combustion air fan the motor bearings (if provided with
lubricating nipples) should be greased with a small quantity of grease (4 to 5 grease
gun shots).
2.1.3 Prolonged standstill
Rotate the impeller axle at the intervals described above.
Installation
The fan unit must be placed on a plane and sufficiently strong surface. For repair
purposes the distance from the fan unit to the surrounding walls must be sufficient to
disassemble any parts of the fan unit.
Normally the combustion air fan is fixed to the bed at delivery. However, the
vibration dampers are supplied loose. Before installing the fan unit, the vibration
dampers must be fixed to the bed by means of the included bolts. The position of the
vibration dampers can be seen in the fan drawing.
After fixing the vibration dampers to the bed, place the fan unit on the installation
place and mark out the bolt holes which fix the dampers to the surface. This will
prevent twisting of the rubber compartment. When fixing the fan unit to the surface,
use an adequate size of bolts.
3.1.1 Connection of the motor
Figure 2 shows the possible wiring connections at the terminal rows of the motor.
The electrical wiring diagram indicates the actual connection of the motor for the
specified plant.
Electrical connection diagrams
Y A Y/à
L2 L3 L1
W2 U2 V2 W2 U2 V2 * W2 * U2 * V2
O O O O o o O O O
U1 V1 W1 W1 U1 V1 W1
o o o o o o O O O
î î î
L1 L2 L3
î î t
L1 L2 L3
I t t
L2 L3
Figure 2 bar 07.cdr

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

INDUSTRIES
• Set the fan load to 100%. Check the current consumption of the combustion air
fan. The current must not exceed the full load current stated on the motor
identification plate and/or the electric diagrams.
• Set the fan load to 0% (inlet vanes closed) and stop the combustion air fan.
Normal operation
To ensure a safe and reliable function of the combustion air fan, inspection must
take place with frequent intervals as described below.
Step A: Check the motor temperature (maximum 80°C).
Step B: Check for vibrations by touching the combustion air fan.
Step C: Check that the vibration absorbers and flexible connection are intact.
Note: If a fault is observed, it must be corrected at once.
Vibration control
If the fan is operating in a dusty and/or fatty air environment, coats may occur on the
impeller. This might cause abnormal vibrations, which eventually will cause break-
down of the combustion air fan. The cause must be examined immediately.
At the factory the fan has been weighed statically and dynamically in accordance
with the VDI 2056 - G, Standard. Figure 3 shows vibration curves for the fan
according to VDI 2056-G Standard.
Vibration curves for fan
peak
2S0 1 - — 1 VIBRATION CURVE FOR FAN ACC T O V P I M M - 0
Irc ( No M-* r "* v M ï ' T I j r r

TERM >• '
300-
1 <~ J i t . " ' it. W - * S i C = \ , ' 5 R A T r r " NTE-TRU'J
LL* N J 3 A~, jiSLENi C- ,ll>i< 1 - N o
150 -
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Figure 3 bar 03a.cdr

* 4994V*

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

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

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

* ####**

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

lubrication of the bearings. If motors and/or bearings are dismantled, please contact
an expert (electromechanical workshop).
8.3.1 Lubrication of bearings
Motors without grease nipples are pre-lubricated for approximately 10,000 hours or
three years of operation. Motors with grease nipples should be lubricated at the
monthly intervals shown in Table 1 :
Lubrication intervals in months >-

Speed r.p.m. Running hours per Motor size
50 Hz day 160 180 200 225 250 280 300
8 75 69 63 51 27 24 12
970
24 25 23 21 17 9 8 4
8 48 45 39 30 15 15 6
1450
24 16 15 13 10 5 5 2
8 21 18 15 9 6 ' 3 3
2900
24 7 6 5 3 2 1 1
If the operating frequency is 60 Hz with subsequent 20% higher r.p.m., the greasing intervals are reduced to 2/3 of the
above stated intervals (e.g., lubrication interval at 50 Hz = 3 months, lubrication interval at 60 Hz = 2 months.
Table 1
Note: Suitable lubrications must be used, such as e.g., SKF-LGMT 2.

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

INDUSTRIES
Illustration of a function diagram
Supply air
S-ra î-ra
•i-fflfiBLJ
1
1 Motherboard with microcontroller and Input circuit
2 Control panel with LC-disptay and momentary action switch
3 Plezo-valve unit, always built-in
4 Valve unit with double action positioner always built-in
5 ly-moduie for positioner SIPART PS2
6 Alarm module for three alarm outputs and one digital input
7 SIA-modute (Slot Iniöator-Alarm-module)
8 Spring- loaded pneumatic actuator (single action)
9 Spring-loaded pneumatic actuator (double action)
Figure 1 sips2_5a.tif
Mechanic connection of the positioner

Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the
installation guide lines below.
2.1 Mechanic connection to an actuator
Figure 2 shows the mechanic connection of the positioner to an actuator for a control
valve.
Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and
lock washers (16) on the actuator spindle.
Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly.
Set the necessary length and tighten the screws so that the pick-up bracket
can still be shifted.

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

I N D U S T R I E S
Mechanic connection of the positioner (linear actuator)
2) 4
3)
Mounting on yoke
Mounting on yoke
with plane surface
11 with ledge
| ' f / l / O h J Mounting on yoke

U \ Z p > P J with columns
Figure 2 sips2_5b.tif

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

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

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

INDUSTRIES
Mechanic connection of the positioner (rotary actuator)
Figure 3 sips2_5c.tif

iiUU.
INDUSTRIES
Electric connection of the positioner

When the positioner is connected in a two-wire system, the positioner draws its
power exclusively from the 4 to 20 m A set point signal. Figure 4 indicates the input
circuits for the positioner.
View of the controls and connections
14
15
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1 Input: Supply air 7 Silencer

2 Output: Actuating pressure Y l 8 Transmission, ratio selector
3 Display 9 Adjusting wheel slip clutch
4 Output: Actuating pressura Y2 ** 10 Terminals options1 modules
5 Operating keys 12 Dummy plug
6 Restrictor 13 Screw-type cable gland
6.1 RestrlctorY! 14 Terminal: plate on cover
6.2 Restrictor Y2 *) 15 Purging air switch
Figure 4 sips2_5d.tif
Ensure that the air quality is suitable. Grease-free instrumental air with a solid
content < 30 um and a pressure dew point 20 K below the lowest ambient
temperature must be supplied.
Warning: For reasons of safety, pneumatic power may only be supplied after
assembly when the positioner is switched to operating level "P
manual" operation with electrical signal applied.
4.1.1 Selection of P manual mode

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

INDUSTRIES
4.1.2 Pneumatic connections

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

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

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

The purging air changeover switch located above the pneumatic terminal block on
the valve manifold can be accessed when the housing is open. When the switch is in
position "IN" the interior of the housing is purged with very small quantities of
clean and dry instrument air. In position "OUT" the purging air is led directly out of
the instrument.
Commissioning
initialisation, the micro controller automatically determines the zero value, full-scale
value, direction of action and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, hereby optimising the control.
SIPART PS2.
The commissioning of the positioner can be divided into the following steps:
• Preparation for initialisation
Start the automatic initialisation procedure

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

INDUSTRIES
Step I: During the initialisation phase "RUNl" to "RUN5" appear one after another
in the bottom of the display. Please note that the initialisation process may
last up to 15 minutes depending on the actuator.
Note: The ongoing initialisation can be aborted at any time by pressing the
hand symbol key. The previous settings are retained. All the parameters
are reset to the factory setting only after performing a preset
"55.PRST".
Step J: If problems occur, carry out the measures as described in the table "Possible
messages" shown in Figure 7.
Step K: The initialisation is completed when "FINSH" appears in the bottom of the
display.
Step L: When pressing the hand symbol key briefly the menu item line "4.INITA"
is displayed.
Step M: To exit the configuration operating mode, press the hand symbol key for
longer than 5 seconds. The software version is displayed after about 5
seconds. The instrument is in manual operation after releasing the key.
Step N: The positioner can be changed to automatic mode by pressing the " j " key
once as indicated in Figure 5.
Step O: The automatic mode is the normal mode. In this mode the positioner
compares the set point current with the current position and moves the
actuator until the control deviation reaches the dead zone.
Operation in the configuration mode
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Figure 6 sips2_5f.tif

INDUSTRIES
Initialisation process
Automatic initial start-up (starting with factory setting) Possible messages
Step Meaning Display Meaning Measures

Acknowledge message
11
ParU urn tum 90° usingthe hand syrrbol key
actuator 1 YFCT 2 YAGL P 324 Actuator does
RUN 1 not move Check restrictor (E) and open
Linear WAY 33° Strt if necessary
actuator 1 YFCT 2 YAO. 3 YWAY P 324 Drive actuator to working range
fftROR usingthe up and down keys
Strt Press tre up key for > 5 sec. Restart initialisation
2.)
4 INTA Remaining steps are carried out automaticaly
Crengegearing (7)
P 324 Ccnfinueushg up key

3) Direction of action is determined
D RUN 1
Or adjust sliding dutch up
P 884 Down tolerance
h dit» IU band violated to display
Checking of travel and adjustment of P 6.4
«.) 0P RUN
924
2 zero andstroke (from stop to stop) S d< O IU
Determination and display of psitioning time Then only

5) P 824 down(dxx.x), up (uxx.x). Stop with thedown key Centime using the down key
r, RUN 3 Pressing t he up key inliates leakage measurement Linearactuator set pick-up
Once the slipping lever hto horizontal position
P 324 S Et dutch has been usingthe ip and down keys
6) Détermina Bon of minimum here ment length MIDDL
adjusted
Li RUN 4
Continue using hand symbol key
7.)
P 524 Optirrisati on of transient respon se Acknowled ge massage
O RUN 5 usingthe hendsymbol key
98.3 Up tolerance band
Intialisafon terminated successfuly UP > violated Set the next highest travel
(travel in m mfor linear actuatcrs) valueonthe lever
8) 324
FINSH (angjeofrotation for part-turn actuators)
Restart initialisdbn
Continueusiig hand symbol key
Additionally possible with rotary
actuators:
Adjust using up and down keys
up to dspla y:
P 92.8
s a>_95
Continue u sing hand symbol key
Acknowledge message
using the ha nd symbol key
P 19.8 Up/down span
Set the next lowest travel
h U-d < violated value on tte lever
Restart initialisation
Adjust positioning timeushg

1.3 Actuator does resrictor(s)
NOZZL not move.
Positioning Conti nue ushg the
Urne is posslbl e up or down key
1.8 to adjust
NOZ2L
Figure 7 sips2_5g.cdr
5.3 Parameters
After the initialisation process, the positioner can be configured to meet the
requirements of a specified task. The factory settings correspond to the requirements
for a typical application. This means that normally only a few parameters will need
to be changed.
Table 1 shows the parameter list for the positioner. The parameter name is written in
plain text in the "menu line" column. The function of the parameter is described
briefly in the "Function column". In addition, the possible parameter values, the
physical unit and the factory setting of the parameters are shown.

INDUSTRIES
Parameter list
Customer
setting
turn (part-turn actuator)
WAY (linear actuator)
LWAY (linear actuator
without sine correction)
l.YFCT Type of actuator WAY
ncSt (part-turn actuator
withNCS)
-ncSt (part-turn actuator
with NCS, inverted)
Rated angle of rotation for feedback 90°
2.YAGL0 Degrees 33°
(must correspond to gear ratio) 33°
Stroke range (optional setting) OFF
5,10,15,20
When used, the value must correspond with
(short lever 33°)
the set of the leverage ratio on the actuator
3.YWAY2) 25 , 30, 35 mm OFF
Driver pin must be set to the value of the (short lever 90°)
actuator travel or, if this value is not scaled, 40, 50, 60, 70,
to the next lager scale value 90,110,130
(long lever 90°)
4.INITA Initialisation (automatically) noini/no/###.#/Strt no
5.INITM Initialisation (manually) noini/###.#/Strt no
„ . . . . 0 to 20 mA 0MA
6.SCUR Current range off set point . „„ . 4 MA
° 4 to 20 mA 4MA
riSE
7.SDIR Set point
r direction „ ... ° riSE
falling FALL
8.SPRA Set point for start of split range 0.0 to 100.0 % 0.0
9.SPRE Set point for end of split range 0.0 to 100.0 % 0.0
Auto
10.TSUP Set point ramp up s 0
0 to 400
ll.TSDO Set point ramp down 0 to 400 s 0
Set point function
Linear Lin
12.SFCT Equal-percentage 1:25, 1:33, 1:50 1-25 ,1-33 ,1-50 Lin
Inverse equal-percentage 1:25,1:33,1:50 nl-25 , nl-33 , nl-50
Freely adjustable FrEE
13.SL0J) Set point turning point at 0% 0.0
14.SL1 5% 5.0
to to 0.0 to 100.0 % to
32.SL19 95% 95.0
33.SL20 100% 100.0
Auto
34.DEBA Dead zone of controller % Auto
0.1 to 10.0
35.YA Start of manipulated variable limiting 0.0 to 100.0 % 0.0
36.YE End of manipulated variable limiting 0.0 to 100.0 % 100.0
Standardisation of To mech. travel MPOS
37.YNRM MPOS
manipulated variable To flow FLOW
Direction of manipulated Rising riSE
38.YDIR riSE
variable for display Falling FALL
Without no
Tight closing with Top only UP
39.YCLS no
manipulated variable Bottom only do
Top and bottom uPdo
40.YCDO Value for tight closing, bottom 0.0 to 100.0 % 0.5
41.YCUP Value for tight closing, top 0.0 to 100.0 % 99.5

INDUSTRIES
Parameter list continued

Customer
setting
Function of BI 1 :
None OFF
Only message (NO/NC contact) on / -on
Block configuring (NO contact) bLocl
42.BIN14' OFF
Block configuring and manual (NO contact) bLoc2
Drive valve to pos. up (NO/NC contact) uP / -uP
Drive valve to pos. down (NO/NC contact) doWn / -doWn
Block movement (NO/NC contact) StoP / - StoP
Function of BI 2:
None OFF
4) Only message (NO/NC contact) on / -on
43.BIN2 OFF
Drive valve to pos. up (NO/NC contact) uP / -uP
Drive valve to pos. down (NO/NC contact) doWn / -doWn
Block movement (NO/NC contact) StoP / -StoP
Without oFF
.. _ Al=min. A2=max. N,NA
44.AFCT5) Alarm function .. .„ OFF
Al=min. A2=min. N,N
Al=max. A2=max. NA,NA
Function of alarm output
On fault h
47.SFCT 6 ' Fault + not automatic hnA h
Fault + not automatic + BI hnAb
("+" means logical OR operation)
Monitoring time for fault message Auto
48. h TIM s Auto
"control deviation" 0 to 100
Response threshold for fault message Auto
49. h LIM % Auto
"control deviation" 0.0 to 100.0
OFF
50.SSTRK Limit for stroke integral OFF
1 to 1.00E9
OFF
51.hDCHG Limit for direction change OFF
ltol.00E9
OFF
52. S ZERO Limit for end stop monitoring, bottom % OFF
0.0 to 100.0
OFF
53. h OPEN Limit for end stop monitoring, top % OFF
0.0 to 100.0
OFF
54.L,DEBA Limit for dead zone monitoring % • OFF
0.0 to 100.0
Preset (factory setting)
"no" nothing activated no
"Strt" start of factory setting after pressing
55.PRST key for 5 sec. Strt
"oCAY" display following successful
factory setting oCAY
CAUTION: preset results in "NO INIT"
Table 1
!)
If turn is selected it is not possible to set 33°.
2)
Parameter does not appear if 1 .YFCT = turn has been selected.
3)
Turning points only appear with selection 12.SFCT = FrEE.
4)
Alternatively "no" if initialisation has not yet been carried out
5)
NC contact means; action with opened switch or low level. NO contact means;
action with closed switch or high level.
' Normal means: high level without fault. Inverted means: low level without fault.

INDUSTRIES
Diagnosis
In the diagnostic mode the current operating data (such as number of strokes,
number of changes in direction, number of fault messages, etc.) can be displayed.
From the automatic or manual modes the diagnostic mode can be reached by
simultaneously pressing all three keys for at least 2 seconds.
Table 2 shows an overview of the displayable values. The diagnostic display has a
similar structure as the parameter menu displays. The respective next diagnostic
value can be selected with the hand symbol key. Certain values can be set to zero by
pressing the " Î " key for at least 5 seconds. These are menu item line "1,2, 3, and 4".
Some diagnostic values may be greater than 99999. In this case the display switches
to exponential display.
Diagnostic list
No.: Abbreviation Meaning Displayable Unit
value
1 STRKS Number of strokes 0 to 4.29E9 -
2 CHDIR Changes of direction 0 to 4.29E9 -
3 SCNT Fault counter 0 to 4.29E9 -
4 A1CNT Alarm counter 1 0 to 4.29E9 -
5 A2CNT Alarm counter 2 0 to 4.29E9
6 HOURS Operating hours 0 to 4.29E9 Hours
7 WAY Determined actuating path 0 to 130 mmor°
8 TUP Travel time up 0 to 1000 s
9 TDOWN Travel time down 0 to 1000 s
10 LEAK Leakage 0.0 to 100.0 %
11 P0 Potentiometer value below stop (0%) 0.0 to 100.0 %
12 P100 Potentiometer value bottom stop (100%) 0.0 to 100.0 %
13 IMPUP Impulse length up 2 to 100 ms
14 IMPDN Impulse length down 2 to 100 ms
15 DBOP Dead zone up 0.1 to 100.0 %
16 DBDN Dead zone down 0.1 to 100.0 %
17 SSUP Short step zone up 0.1 to 100.0 %
18 SSDN Short step zone down 0.1 to 100.0 %
19 TEMP Current temperature -45 to 85 °C
20 TMIN Minimum temperature -45 to 85 °C
21 TMAX Maximum temperature -45 to 85 °C
22 Tl Number of operating hours in Temperature range 1 0 to 4.29E9 Hours
Store current values as "last maintenance"
33 STORE - -
Press the up key for at least 5 seconds (store)
Table 2

INDUSTRIES
Service and maintenance

The positioner is largely maintenance-free. The positioner is fitted with filters in the
pneumatic connection as protection against coarse particles of dirt. If the pneumatic
energy supply contains particles of dirt, the filters may be clog and impair the
function of the positioner. In this case the filters can be cleaned as follows:
Step A: Switch off the pneumatic power supply and remove the pipes.
Step B: Unscrew the cover.
Step C: Remove the three screws from the pneumatic connector strip.
Step D: Remove the filters and O-rings behind the connector strip.
Step E: Clean the filters (e.g. with compressed air).

Step F: After cleaning first insert the filters in the recesses in the housing and then
place the O-rings on the filters.
Step G: Align the pneumatic connector strip on the two lugs and screw tight with
the three self-tapping screws.
Note: Make sure that the same thread is used. To do this, turn the screws anti-
clockwise until they snap into the thread audibly. Only then should the
screws be tightened.

•••••
AALBORG ^BJHiBBSiHIW^^M^^W
Table of contents
Fuel oil supply pump
Technical data for fuel oil supply pumps
General data 1
Data for fuel oil pumps 2
Fuel oil supply pump, type SPZ
General 1
Structural design 2
Mode of operation 3
Preservation and storage of the pumps 4
Foundation design/fastening type 5
Mounting of the twin aggregate 6
Preparation for start-up 7
Start-up 8
Stopping and restarting 9
Control of operation and maintenance 10
Troubles, causes and remedial action 11
Dismounting and mounting instructions 12
Spare parts 13

AALBORG ^HSBlBSIlîinSHilSBIBlSIllIE^B
Technical data for fuel oil pumps

1 General data
• Project No.: 736950, 736952

• Hull NoTProject name: 03130007, 03130008
• Colour of fuel oil pump unit: Munsell GY10 8/4
2 Data for fuel oil pumps
• Pump: Horizontal three screw pump

• Pump type: SPZ 20-R46 G8.3 FW8
• Delivery head: 2.5 MPa
• Relief valve set point (factory set): 2.85 MPa
• Oil temperature, maximum: 150°C
• Pump capacity at 4 cSt: 2154 1/h
• Pump capacity at 380 cSt: 2796 1/h
• NPSH at 4 cSt: 3 mWC
• NPSH at 380 cSt.: 7 mWC
• Weight of fuel oil pump unit: 120 kg
3 Data for pump motor
• Motor make: AEG

• Motor type: AM 100 LS 2
• Power supply: 3 x 440 V, 60 Hz
• Rated output for motor: 3.6 kW
• Revolutions: 3400 r.p.m.
• Ambient air temperature: 45°C
• Starting method: Direct

• ••• •
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AALBORG gSBIWBIffiliHJBIBIHIBIlSBBKBIilliHEl
• Starting current: 41 A
• Operating current (full load): 6.3 A
• Power consumption at 4 cSt: 2.27 kW
• Power consumption at 380 cSt: 2.88 kW
• Numbers of cable entries with reliefer: 2
• Heating element (standstill): None
• Thermostat protection: None
• Insulation class: F
• Degree of protection: IP44

AALBORG OIL PUMPS, TYPE SPZ OM9295#02.2
INDUSTRIES
Oil pumps, type SPZ
1 General
The SPZ pumps series are employed for handling light and heavy fuel oil. The twin
aggregate is constructed as a compact type in which two screw pumps are
interconnected by way of a reversing valve casing.
1.1 Abbreviation
The abbreviation of the screw pump twin aggregates is set up according to the
following scheme:
Example: SPZ 10 R 38 G 8.3 FE-W20
Where:
• SPZ: series
• 10: size (theoretic delivery in [1/min] with 1450 1/min and 46 degrees pitch
angle
• R: direction of screw pitch (R = right)
• 3 8 : angle of screw pitch (degrees)
• G: kind of bearing (internally slide bearing)
• 8.3 : shaft sealing by mechanical seal
• F: design with filter
• E: design with electric filter-heating of the filter casing
• W20: material design
1.2 Warranty
Our liability for shortcomings in the supply is laid down in our delivery conditions.
No liability will be undertaken for any damages caused by non-compliance with the
operating instructions and service conditions. If at any later date the operating
conditions happen to change (e.g. different fluid conveyed, speed, viscosity,
temperature, or supply conditions), it must be checked by us from case to case and
confirmed, if necessary, whether the pumps are suited for these purposes. In case no
special agreements were made, the pumps supplied by us may, during the warranty
period, only be opened or varied by us or our authorised contractual service stations;
otherwise, our liability for any defects will expire.
1.3 Testing
Prior to leaving our factory, all aggregates are subjected to a thorough test run and
performance test on the test stand. Only properly operating pumps leave the factory

INDUSTRIES
achieving the performances assured by us. Thus, compliance with the following
operating instructions ensures proper operation and full delivery.
1.4 Performance data
• Delivery, Q: up to 6.7 m3/h (with n = 2900 l/min and v = 750 mm2/s.)

• Temperature of the fluid pumped, t: up to 150°C (with higher temperatures,
please inquire)
• Inlet pressure, ps: up to 5 bar
• Pump outlet pressure, pa: up to 40 bar (For the attainable delivery pressure as a
function of viscosity and speed, please refer to the individual characteristics.
The pressure data only apply to nearly static pressure load. With dynamic
pressure change load, please inquire.)
• Viscosity range,v = 3 to 750 mm2/s
• Pressureflange,DNj = 20 to 40 mm
The exact performance data applicable to the pump can be taken from the layout
and/or acceptance certificate, and are engraved on the rating plate.
1.5 Application and installation
The screw pump twin aggregates of series SPZ for a pump outlet pressure up to 40
bar are three-screw, self-priming, rotary positive displacement pumps for handling
lubricating fluids. The fluids must not contain any abrasive particles nor chemically
attack the pump materials.
Both pumps of the aggregate are designed asflange-mountedpumps and via pump
bracket each connected with the driving motor.
Attention: The aggregates are provided for horizontal installation or wall

mounting. For safety purposes, the arrangement with ''motor down-
wards" is not admissible.
Structural design
The screw pump twin aggregates of series SPZ consist of two screw pumps.
Sectional drawings of the pump are shown in Figure 1 and Figure 2. The item
numbers referred to in this section are those indicated on these drawings.
Via a reversing valve casing (301), the two pumps are connected with each other.
The screw pumps are of the three-screw type. A double-threaded driving spindle
(12) and two double-threaded idler spindles (13) are enclosed by the bores in the
pump casing insert (2) with a narrow running clearance. The pump casing (1)
accommodates the pump casing insert (2) and is closed by the pump cover, drive
side (3) and by the pump cover, non drive side (4) and thefiltercasing (9).

INDUSTRIES
Sectional drawing of the SPZ pumps, without filter

Section A - B
126 12( U1 205 355 « 7 301 123 20( 356 108 « 0 206 12S 236
(75 222 1(2 t » 333 3(0 331 12 330 • O 120 « 6 200 250 (SS (71 217 231
Section C - D
201 ( 1 2 151 263 165 161 122 160 290 900 901
} \ ) )
1(5 370 1(7 372
21 976 280 215 (60
Pump size 10 and 20
Denomination Part No. Denomination Part No. Denomination Part No. Denomination Part No.
Pump casing 1(D Joint ring 1420 Socket-head cap screw 222 Stop valve 363
Pump casing insert 2(1) Gasket 1450 Socket-head cap screw 227 Connector 370
Pump cover Joint ring 147 0 Hexagon nut 231 Casing 372
drive side 3 CD Sealing washer 1480 Hexagon nut 236 Hollow screw 373
non-drive side 4(0 Sealing washer 151 CD Hexagon nut 238 Manometer
Bearing ring 10 CD Joint ring 156 0 Clrcllp 2500 connecting branch 374
Driving ecrew 12 CD Joint plug 160 Circllp 2510 Blank flange 440
Idler screw 13 (D Joint plug 161 Supporting washer 263 Blank flange 441
Distance sleeve 20 (D Joint tape 165 0 Rivet 280 Pump bracket 460
Socket-head cap screw 24 Mechanical seal 186 0 Key 290 Foot angle 471
Gasket 100 <D Socket-head cap screw 200 Groove ball bearing 2820 Oil trough {removable) 475
Joint ring 107 0 Socket-head cap screw 201 Reversing valve caalng 301 Clamping sleeve 495
Joint ring 108 0 Hexagon screw 204 Valve cone 3300 Coupling half
O-rlng 1200 Hexagon screw 205 Verve Bpring plate 331 pump side 900
O-rlng 122 0 Socket-head cap screw 208 Adjusting screw 3330 drive side 901
Gasket 123 0 Socket-head cap screw 208 Valve spring 3400 Driving motor 910
Gasket 1240 Socket-head cap screw 215 Stop valve 3560 Name plate 976
Gasket 125 CD Hexagon screw 216 lockable non-return valve 3550
Gasket 1260 Hexagon screw 217 Manometer 3600 0 Spare parta
Figure 1 spz01.tif

INDUSTRIES
Sectional drawing of the SPZ pumps, with filter

Section A - B
143 157 U6 126 124 441 205 355 107 301 123 204 356 106 440 206 125 236 Section E-F 362
159 30 475 222 142 CO 333 340 331 12 3 » 13 D 120 166 200 250 495 471 217 231
Section C - D
9 201 29 1 2 151 263 165 161 122 160 290 900 901
•V*-—-^
374
^-148
——373
145 370 «7 372
292 20 3
Pump size 10 and 20 22s 24 976 280 215 460 Pump size 40 251
Denomination Part No. Denomination Part No. Denomination Part No. Denomination Part No.
Pump casing 1 ® Joint ring 143® Screw plug 222 Connector 364
Pump casing Insert 2® Gasket 145® Venting screw 223 Connector 370
Pump cover Gasket 146® Screw plug 227 Casing 372
drive side 3 6) Joint ring 147® Hexagon nut 231 Hollow screw 373
Casing cover 7® Sealing washer 14B® Screw plug 235 Manometer
Filter casing 9 CD Sealing washer 151® Hexagon nut 236 connecting branch 374
Bearing ring 10® Joint ring 152® Hexagon nut 238 Blank flange 440
Driving screw 12® Joint ring 156® Circlip 250® Blank flange 441
Idler screw 13® Gesket 157® Clrcllp 251® Pump brocket 460
Distence sleeve 20® Joint ring 159® Supporting washer 263 Foot angle 471
Socket-head cap screw 24 Joint plug 160 Rivet 280 Oil trough (removable) 475
Pipe 29 Joint plug 161 Key 290 RBdial screen filter 481®
Pipe 30 Joint tape 165® Groove ball bearing 292® Clamping sleeve 495
Gasket 100® Mechantcat seal 186® Reversing velve ceslng 301 Coupling half
Joint ring 107® Socket-head cap screw 200 Valve cone 330® pump side 900
Joint ring 108® Socket-head cap screw 201 Valve spring plate 331 drive side 901
O-rlng 119® Hexagon screw 204 Adjusting screw 333® Driving motor 910
O-ring 120® Hexagon screw 205 Valve spring 340® Heating shell 962 CD®
O-ring 122® Socket-heed cap screw 206 Stop valve 3S5® Neme plate 976
Gasket 123® Hexagon screw 207 Lockable non-return velve 358®
Gasket 124® Socket-head cap screw 208 Manometer 360® (D A heating shell for each pump
Gasket 125® Socket-head cap screw 215 Manometer 361® is supplied on request only
Gesket 126® Hexagon screw 216 Ball valve 362 (at extra charge).
Joint ring 142® Hexagon screw 217 Stop valve 363 ® Spare parts
Figure 2 spz02.tif

INDUSTRIES
2.1 Shaft seal
The pump has a maintenance-free mechanical seal of the unbalanced type.

Material design of the mechanical seal:
• Rotating seal ring: tungsten carbide
• Stationary seal ring: tungsten carbide
• Joint ring: Viton
• Spring: stainless steel
• Metal parts: stainless steel
2.2 Bearing and lubrication
The radial and axial bearing of the driving spindle of a screw pump is effected by
the bearing ring. At the same time, the delivery chamber is separated from the
sealing chamber by the gap between the compensating piston and bearing ring. The
bearing is lubricated by the fluid pumped.
2.3 Flanges / connections
Blank flanges with screw and gaskets.

• Suction side: PN 16, DIN 2633
• Outlet side: PN 40, DIN 263 5
• Connections:
— SPZ without filter: Ml, M2 manometer
— SPZ with filter: B7 draining filter casing, E7 venting filter casing, Ml, M2, M3
manometer
2.4 Filter
As a protection against contamination, the pumps can be equipped with a filter

casing and an incorporatedfilter.Filter mesh size 0.4 mm.
The mano/vacuum-meters being part of the scope of supply show the pressure
behind the filter. By means of these, the pressure loss in the respective filter can be
detected, and an inadmissible contamination recognised.
2.5 Electric heating
In case of design withfilter,ring heaters may be provided for filter heating.
Pump size Connection for ' ' Heating capacity

SPZ 10 220 V 165 W
SPZ 20 220 V 205 W
Table 1

INDUSTRIES
2.6 Pressure relief valve
As an overload protection, a pressure-relief valve is installed in each pump, which is

serially set to a response pressure approx. 10% above the operating pressure.
2.7 Non-return valves / stop valves
In the reversing valve casing, a non-return valve and a stop valve are provided for
each pump. The non-return valves operate automatically and can be locked by hand.
2.8 Operation control
Manometers:
• SPZ pump without filter:
— Outlet side: a manometer (included in the scope of supply). If a mano/vacuum
meter is requested on the suction side, this must be provided at the side. For
connection, the bore for the screw plug (227) is provided.
• SPZ pump with filter:
— Suction side: two mano/vacuum-meters
— Outlet side: one manometer
Reversing unit:
If a reversing unit was supplied for operation control, its circuitry is such that in case
of failure of the operating pump the stand-by pump is automatically switched on.
Signal lamps denote the respective operating conditions.
Reversing unit Ul: for motors up to 3 kW (380 V operating voltage) for across-the-
line-starting.
Reversing unit U3: for motors up to 3.0 and 5.5 kW (380 V operating voltage),
suited for star delta-starting.
2.9 Oil trough
The twin aggregate is provided with a separately supplied oil trough.

2.10 Drive / coupling
Via the pump brackets flanged to the pumps, electric motors of the most varied
designs are connected with the pumps. In the normal case, these are attached:
Surface-cooled three-phase squirrel-cage induction motors, IMVl type of
construction, enclosure IP 44 according it IEC Standard, class B insulation,
performances and main dimensions according to DIN 42 677.
Motors which are rated for 50 Hz can, without change, be operated also in 60 Hz
mains, speed and performance are changed as shown in Table 2.
Power transmission is effected via a flexible coupling. Additional radial forces must
not act on the driving spindle. The pump brackets serve as protection against
accidental contacts according to DIN 24 295.
Attention: Drive via belt or gear wheel is not admissible.

INDUSTRIES
; Motor wound for SO Hz Connection for 60 Hz Conversion factor for operation at 60 Hz ]

V V Speed Performance
220 V 220 V 1.2 1.0
380 V 380 V 1.2 1.0
380 V 440 V 1.2 1.15
440 V 440 V 1.2 1.0
Table 2
Mode of operation
3.1 Mode of operation of the screw pump twin aggregate
Switching diagrams showing the screw pump twin aggregate can be seen in Figure
3.
Switching diagrams
Series SPZ without filter Series SPZ with filter
1 Operating and stand-by pump

1 Operating and stand-by pump
2 Three-phase motor (910)
2 Three-phase motor (910)
3 Stop valve (3SS)
3 Stop valve (3SS)
4 Filter (481)
5 Lockable non-return valve (356)
5 Lockable non-return valve (356)
7 Manometer with ball valve (360) and (363)
6 Mano-vacuumeter with ball valve (361) and (362)
7 Manometer with ball valve (360) and (363)
Figure 3 spz03.tif
Both screw pumps are jointly attached to the reversing valve casing (301). While
one pump is in operation, the stand-by pump is at standstill.
The pumps can be connected alternately by hand or automatically by means of a
reversing unit (Ul or U3). By way of two separate connecting chambers in the
reversing valve (301), the respective two suction flanges and the two pressure
flanges of the two pumps are connected with one another. Uninterrupted delivery
during the reversing process is thus ensured.
During operation, the two lockable non-return valves (356) and the two stop valves
(355) must be opened so that reversal is optionally possible from the one pump to

INDUSTRIES
the other. The respective connected pump draws the fluid in through the suction
chamber of the reversing valve casing (301). The operating pressure built up in the
delivery chamber of the pump opens the non-return valve (356) of the operating
pump and, through the pressure in the delivery chamber of the reversing valve
casing (301), closes the non-return valve (356) of the non-operating pump. This
prevents the stand-by pump from running in reverse motion.
3.2 Mode of operation of the screw pumps
Through the suction chamber in the reversing valve casing, the material to be
pumped is conveyed into the suction chamber of the pump in operation. From here,
the fluid flows into the spindle chambers which are constantly formed by the rotary
motion at the spindle end on the suction side. By the translatory rotary motion, the
chambers filled with the fluid to be conveyed move from the suction side to the
outlet side. During this process, the closed chamber volume does not change. At the
spindle end on the outlet side the chamber opens towards the delivery chamber. The
fluid conveyed is steadily pushed out into the delivery chamber from where it is
transported, through the delivery chamber, into the pressure pipeline. The axial
thrust acting on the faces of the profile flanks on the outlet side is hydraulically
balanced by an appropriate dimensioning of the compensating piston of the driving
spindle. Thus, the bearing is relieved from the hydraulic axial thrust. By appropriate
dimensioning of the spindles, the drive of the idler spindles is hydraulic. Only the
torque resulting from the liquid friction is transmitted via the profile flanks;
therefore, they are practically stress-free and not subject to any wear. The axial
thrust of the idler spindles is absorbed by the pump cover, non-drive side or by the
filter casing. Sealing chamber and suction chamber are interconnected via a return
bore. Therefore, irrespective of the delivery pressure, only the suction pressure acts
on the shaft seal. All sliding parts are lubricated by the fluid to be pumped and are
within the range of full liquid friction. In spite of spindle rotation, there is no
turbulence. The constant chamber volume excludes squeezing.
The structural design and the mode of operation of the screw pumps ensure a very
low noise level and an almost pulsation-free delivery.
Preservation and storage of the pumps
4.1 Preservation
If required, the screw pumps delivered by us are already provided with the requested
preservation protection according to the storage time specified by the customer. Also
in case of prolonged shutdown, the screw pumps must be protected against
corrosion.
In those cases, an outside and inside preservation is to be provided. The durability of
the protection against corrosion which is limited in time, depends on the
composition of the preservative to be applied. It is therefore recommended to use
such preservatives only which have a minimum durability of 12 months. Below is
listed preservative which can be applied for both outside and inside preservation.

AALBORG OiL PUMPS, TYPE SPZ OM9295#02.2
INDUSTRIES
4.1.1 Outside preservation

All bright and unvarnished parts such as: shaft ends, couplings, flange facings, valve
and manometer connections can be preserve with one of the following preservative:
• TECTYL 506
• A mixture of TECTYL 506 and TECTYL 511-M1
This preservative is to be applied by painting or spraying with a spray gun.
4.1.2 Inside preservation
Pump casing inside, screw spindles, ball bearing, pressure-relief valve, mechanical
seal can be preserve with:
• Mixture of: TECTYL 506 and TECTYL 511-M1
Note: The preservative listed above is to be regarded as a recommendation.

Preservatives having the same preserving properties can also be used.
The preservative is to be applied by filling the pump. For these purposes, the suction
side of the pump must first be closed with a dummy flange. During filling, the
pressure flange must be on a higher level than the suction flange. During the filling
process, the driving spindle must be slowly cranked against the sense of rotation.
Filling must be continued until the preservative reaches the sealing strip of the
delivery flange, bubble-free. Thereafter, the outlet side is to be closed with a dummy
flange.
4.1.3 Control of preservation
In case of prolonged storage, the preservation of the pump must be checked by the
customer at regular intervals.
Step A: Every six months, the pump level must be checked, if necessary,
preservative must be topped up to the sealing strip at the pressure flange.
Step B: At the same time, the packing must be checked for destruction, and
repaired, if necessary.
Note: Liability for damages caused by improper preservation cannot be

predicted.
4.1.4 Durability of the preservative

According to the preservative manufacturer, the durability of TECTYL 506 is 4 to 5
years in case of indoor storage, and 12 to 24 months in case of outdoor storage, and
of TECTYL 511-M approx. 18 months in case of indoor storage. When mixing
TECTYL 506 and TECTYL 511-M in the same proportion, a durability of 254 to 4
years in case of indoor storage, and a maximum of 12 months in case of outdoor
storage under roof can be expected. With additional packing, the service life is
increased.

INDUSTRIES
The active ingredients contained in this preservative provide sufficient protection

against corrosion even in high air humidity (sea, tropical climate). Therefore, a
temperature limitation (+ and -) does not exist.
4.1.5 Degreasing
Prior to setting the screw pump in motion, the preservative applied must be
removed.
The preservative applied for inside preservation can normally be removed by
flushing the pump with the fluid to be conveyed. In addition, a suitable solvent may
be applied for removing the inside and outside preservation.
Appropriate solvents can be: Petroleum, benzene, Diesel fuel, spirit, alkalis
(industrial cleaners) or any other wax solvents. Steam jet cleaning devices with
appropriate admixtures can also be used (allow wax solvent to react previously).
Attention: Prior to start-up, the pump must befilledwith fluid to be conveyed

so as to avoid seizing of the spindles during starting.
Note: If on the plant side, the pipelines, (oil) tanks and gear parts in circulation
are wetted with the paraffin-containing preservative, the entire plant
must be degreased as paraffin deteriorates the air separating capability
of the (oil) filling. This may result in unsteady operation of the pump,
connected with a loud noise development.
4.2 Storage
During storage of the screw pump, the suction and outlet branches and all other
supply and discharge branches must always be closed with dummy flanges or
dummy plugs.
Storage should be in a dust-free and dry room.
Step A: During storage, the screw pump should be cranked at least once a week.
Step B: During this process, the screw spindles should each time change their
turning position.
After prolonged storage, all elastomers (O-rings, mechanical seals) must be checked
for their elasticity of shape.
Step C: Embrittled elastomers must be exchanged.
Note: Only proper storage and packing ensure the durability of the
preservatives applied.

AALBORG OIL PUMPS. TYPE SPZ OM9295#02.2
INDUSTRIES
Foundation design/fastening type

The foundation must be designed so that it can take the weight of the pump
aggregate.
Fastening is effected via the foot angle screw-connected to the intermediate lantern.
Mounting of the twin aggregate
6.1 Control of the sense of rotation at the driving motors
The sense of motor rotation must correspond to the directional marker of the pumps.
For a control of the sense of rotation, the motors may be alternately switched in
temporarily in an uncoupled condition. The sense of rotation being wrong, the
pumps do not prime. This will result in damages to the pumps. The sense of rotation
of the respective three-phase motor can be changed by interchanging any two
phases.
6.2 Installation of a complete twin aggregate
A twin aggregate supplied complete was carefully assembled at the works. As the
pumps and the driving motors are centred in the pump bracket, re-alignment of the
couplings is normally not required.
Note: Improper handling, for example, during transportation, may affect the
alignment provided between pumps and motors. In this case, the
respective motor must be dismounted from the pump bracket.
Exact examination of the alignment is effected by means of a dial gauge with

retaining clip and clamping device fixed to the driving spindle and motor shaft end.
The examination covers the admissible circular and axial run-out between the shaft
ends and the centring diameters and the plane faces at the pump brackets (0.05 mm
admissible as a maximum).
6.3 Installation and assembly of pump and driving motor
The aggregate being completed at the place of service only, the coupling must be
assembled as follows:
Step A: Cover pump and motor shaft ends with a filmy coat of molybdenum
disulphide (e.g. Molykote), and insert keys.
Step B: By means of a mounting device, push coupling halves onto pump and motor
shaft end.

INDUSTRIES
Attention: Axial shock loads on the driving spindle of the pumps and the anti-
friction bearings of the driving motors must be excluded during
mounting of the couplings.
Step C: Re-alignment of the couplings is not necessary (please refer to section 6.2).
6.4 Laying the pipelines
6.4.1 Nominal widths

If possible, the nominal widths of the suction and outlet pipeline should be rated so
that the rate of flow does not exceed 1 m/s in the suction line and 3 m/s in the
pressure pipeline as a maximum.
Note: The nominal diameter of the suction and pressure pipeline must be of
the same size as the nominal pump diameter or one nominal diameter
greater. The nominal diameter on the suction side must never be smaller
than the nominal pump diameter, as suction may otherwise be difficult.
6.4.2 Change of cross-sections and directions

Sudden changes of cross-sections and directions, as well as hairpin bends, must be
avoided.
6.4.3 Supports andflangeconnections
By way of the flange connections, the pipelines must be connected to the pump
stress-free. They must be supported close to the pump and should allow easy
screwing to avoid deformations. After the screws have been slackened, the flanges
must neither be inclined nor springy nor rest on top of one another under pressure.
Any thermal stresses that may occur at the pipelines must be kept away from the
pump by taking appropriate measures, e.g. by the installation of compensators.
6.4.4 Cleaning of pipelines prior to attachment
Prior to assembly, all pipeline parts and valves must be thoroughly cleaned.
Especially in the case of welded pipelines, burrs and welding beads must be
removed. Flange packing must not protrude inwards.
Water residues, still in the pipeline network from pressing-out or steeping for
example, must be removed. Delivery of water destroys the pump. The pump relies
on the fluid being conveyed for its lubrication.
At the pressure test of the pipe system the customer is responsible for any damages
and their consequents.
6.4.5 Non-return valves / stop valves
In the reversing valve casing, a non-return valve and a stop valve are provided for
each pump.

INDUSTRIES
Note: With the non-return valve and stop valve closed, filter cleaning of those
pumps may be effected which operate under supply pressure.
6.4.6 Venting
The pumps withoutfiltercan be vented via the screw plug (227).
In case of pumps with filter, the venting screw (223) in the filter and the screw plug
(227) serve for venting. In addition, a vent valve must be provided at the highest
point in the pressure pipeline.
Note: In case of horizontal aggregate installation and with the suction and
pressure flange turned sideways, the filling and venting bores and/or
connections for the manometers must point upwards.
6.4.7 Filtering
In case of aggregates which do not have filters attached at the factory, it is
recommended to mount a filter in the suction pipeline to protect the pump against
solid contamination. Filter mesh and/or gap size 0.1 to 0.5 mm depending upon the
degree of contamination of thefluidto be pumped.
Preparation for start-up
7.1 Filling the pumps with the fluid to be conveyed
Attention: Prior to initial operation, the two pumps must be filled with the
fluid to be conveyed. At the same time, the sealing required for
suction is imparted to the spindles. The pump must not run dry.
7.1.1 Filling and venting of a pump without attached filter

The withfluidto be pumped isfilledin through afillinghole at the suctionflangeof
the pump.
For these purposes:
Step A: The screw plug (227) with the joint ring (156) must be removed.
The pump must be topped up with the fluid to be pumped until this fluid emerges at
the vent hole of the pressureflange,bubble-free.
In case of supply pressure, manual topping-up is not required. The pump is topped
up via the supply pipeline, and vented via thefillingand venting hole.
7.1.2 Filling and venting of a pump with attached filter
Pumps in horizontal installation with attached filter are topped up via thefillinghole
in the (filter) casing cover (7) until the fluid pumped emerges at the vent hole of the
pressure flange, bubble-free.

INDUSTRIES
For these purposes:

Step A: The vent screw (223) and the screw plug (227) with the joint rings (143)
and (156) must be removed.
Pumps in vertical installation with attached filter are topped up with fluid to be
pumped via the filling and vent holes in the casing as described under section 7.1.1.
Note: Instead of the screw plugs (227), manometers may be mounted in the
suction and pressure flange of the pump casing (1). Please refer to
section 2.3.
7.2 Heating of the fluid to be pumped
When pumping heavy fuel oils or other fluids to be pumped congealing when
getting cold, it is necessary to provide a heating system in the plant (e.g. pipe steam
trace).
At the time of pump starting, the fluid to be pumped must be in a flowable and
pumpable condition to avoid damages to the operating pump as well as the stand-by
pump.
Step A: Prior to the pump start-up, heavy fuel oil, for example, must be heated to at
least 10°C above the solidifying point.
Step B: For twin aggregates, with filters attached at the factory, a filter heating may
be provided. A ring heater serves to heat the filter.
The heating capacity of the ring heaters is designed so that with an initial
temperature of 20°C, a minimum heating-up time of 120 min. is necessary. The
temperatures being lower (below 0°C), an appropriately longer heating time must be
expected. The heating system is not appropriate for achieving during operation a
marked temperature increase of the fluid to be pumped. The ring heaters must be
connected to 220 V (provide parallel connection, no series connection).
8 Start-up
8.1 Starting the operating pump
Prior to starting the operating pump:

Step A: The two stop valves on the suction side and the two lockable non-return
valves on the outlet side of the reversing valve casing, and gate valves, if
any, must be opened in the plant.
A pressure-relief valve is installed in each pump which is serially set on our test
field to a response pressure which is approx. 10% above the operating pressure.
Step B: By means of the adjusting screw (333), the opening pressure can be
changed within narrow bounds.

INDUSTRIES
Attention: When starting and stopping the pump under pressure load, make
sure that the speed and viscosity-dependent pressure load is not
exceeded. If this is not ensued, the pump must be started at zero
pressure or disconnected. This also applies to pumps with speed-
controlled driving motors.
The pressure-relief valve must not be used for regulating the delivery flow.
Step C: During starting, a vent valve on the outlet side of the plant must be opened
until the air has escaped from the suction side of the pump. As soon as fluid
to be pumped emerges, the vent valve may be closed. The pump is self-
priming and is automatically vented without counter-pressure.
8.2 Motor
Step A: Switch motor of operating pump in.
8.3 Checking the delivery values
Step A: After the motor has reached its operating speed, inlet pressure and outlet
pressure of pump must be checked via vacuum gauge and manometer.
The motor must not be overloaded. The power consumption can be checked by
means of an ammeter. In this connection, temperature and viscosity of the fluid must
be checked. The values read must be checked against the layout and/or acceptance
report.
Note: Pressure gauges such as vacuum gauges and manometers are normally
equipped with stop valves. The stop valves are to be opened only during
start-up for pressure control purposes. During permanent operation,
these must be kept closed.
Stopping and restarting
9.1 Stopping
9.1.1 Motor
Step A: Switch off motor of the operating pump. Attend to even and smooth
slowing-down of the pump.
9.1.2 Reversing valve casing

The non-return valves and stop valves in the reversing valve casing remain open.

INDUSTRIES
9.2 Restarting
After proper initial operation, the pumps are ready for operation at any time and can
be started without filling.
9.3 Measures in case of prolonged interruption
If a prolonged interruption is projected, the pumps must be drained as described

below.
Step A: The screw plug (222) must be removedfromthe draining bore. Draining of
the filter is effected after loosening of the screw plug (235).
Step B: Thereafter, the pumps must be preserved (please refer to section 4).
Note: After the screw plug (222) has been turned out, the adjusting screw (333)
of the pressure-relief valve must be turned out for drainage. Previously,
by means of a depth gauge, the thread reach of the adjusting screw (333)
in the pump casing (1) must be recorded. When screwing the adjusting
screw (333) in again, this thread reach must be considered in order to
reach the response pressure of the pressure-relief valve again (normally
10% above the operating pressure).
10 Control of operation and maintenance

Regular control and maintenance works performed at the twin aggregate will extend
the service life. The below-listed details apply in general.
10.1 General control
• The pumps must not run dry.

• The driving motors must not be overloaded.
• Check suction and pressure pipelines for tightness. The admission of air into the
delivery system must be avoided.
• The mechanical seal must not be heavily leaking.
• Pressure and temperature monitoring instruments must be observed.
10.2 Control of components
Item numbers mentioned in this section refer to the sectional drawings of the SPZ
pump in Figure 1 and Figure 2.
10.2.1 Bearing and lubrication
Bearing of the driving spindle of each pump is by means of a maintenance-free
sliding bearing lubricated by the fluid pumped.

INDUSTRIES
Under normal operating conditions, the service life of the sliding bearing
corresponds to the lifetime of the screw pump. It depends on the degree of
contamination of the fluid to be handled.
10.2.2 Check couplings
At regular intervals, the couplings must be checked for wear. A worn-out coupling
must be replaced.
10.2.3 Shaft seal
Each pump is equipped with a maintenance-free mechanical seal of the unbalanced
type whose mode of operation corresponds to the requested operating conditions.
A minimum functional leakage in case of non-volatile fluids such as oils must in
principle be expected. In case of heavy leakage due to wear, the mechanical seal
must be replaced.
Attention: As dry operation of the mechanical seal must be avoided, the pumps
may be started in a filled and vented condition only.
10.2.4 Pressure-relief valve

The pressure-relief valves of the two pumps must temporarily, especially after
prolonged idle times, be checked for workability and function. Leaky pressure-relief
valves may result in damages to the pump. If necessary, damaged parts must be
exchanged or replaced.
The pressure-relief valves of both pumps were set to the opening pressure requested
by the customer (normally 10% above the operating pressure). If the opening
pressure is to be changed then:
Step A: The screw plug (222) in the pump cover, non-drive side (4) and/or in the
filter casing (9) mustfirstbe removed. Thereafter, the adjusting screw (333)
is accessible.
Step B: Clockwise rotation increases, anti-clockwise rotation decreases the opening

pressure. Re-adjustment should be effected with a perfect manometer only.
10.2.5 Filtering
The twin aggregates of series SPZ...R..G8.3F have attached filters.
The filter casing (9) is equipped with a mano/vacuum-meter (361) displaying the
pressure behind the filter (481). The pressure loss suggests the degree of filter
contamination. For an exact determination of the differential pressure, it is
recommended to install a manometer in the front of each filter at the suction flange
of the pumps or in the suction and/or supply pipeline. In case of noticeable
differential pressure, thefilter(481) must be cleaned or replaced.
Step A: Before the filter of a pump can be cleaned, it must be switched over to the
stand-by pump. Thereafter, the lockable non-return valve (356) and the stop
valve (355) of the pump at rest are to be closed.

INDUSTRIES
Step B: Filter cleaning is effected in that the filter (481) is removed from the filter
casing (9), cleaned, and the dirt particles deposited at the filter casing
bottom are flushed out.
Step C: After the hexagon screws (207) have been slackened, the (filter) casing
cover (7) can be removed and the filter (481) dismounted from the filter
casing (9).
Step D: Draining of the filter casing (9) is possible via the screw plug (235). For
these purposes, use collecting tank.
For cleaning and for dissolving any encrustations, the filter can be put into an
appropriate tank and placed into a cleansing agent, however, the container may be
submerged in the fluid only to the upper brim as otherwise, the dissolved dirt would
get onto the clean side.
Step E: After draining, blowfilteroff with compressed air from the clean side to the
dirty side (from the inside to the outside, not the other way round!).
Appropriate cleansing agents are benzene, benzine, Diesel fuel or a solvent-free cold
cleaner. Other special cleansing agents may be used with the concentration
depending on the kind and thickness of the dirt deposits to be removed.
A soft brush may service as a cleansing tool. Do not use sharp objects.
In case of excessive contamination, it is recommended to replace the filter (481) at
certain intervals.
StepF: After cleaning the filter (481) is loosely mounted on the pipe (30) in the
filter casing bottom.
Step G: The (filter) casing cover (7) isfixedto thefiltercasing (9) again.
Note: The O-ring (119) must lie in its groove and not be damaged. Replace, if
necessary.
Step H: The (filter) casing cover (7) must be closed air tight, so that the pump may
not draw in any air.
Step I: The non-return valve (356) and the stop vale (355) are to be opened again.
Step J: In case of supply pressure, the filter casing (9) must be vented via the screw
plug (223) for re-starting the pump (please refer to section 9).
11 Troubles, causes and remedial action

The screw pumps operate without trouble, provided they are properly mounted and
the fluid to be pumped and the operating conditions correspond to the right values
listed under section 1.

INDUSTRIES
11.1 Troubles and causes
By means of the table below, the cause of troubles, if any, can be determined. In
case of troubles not listed herein or if they cannot be traced back to any of the causes
listed, it is recommend to check with Aalborg Industries.
I Trouble and cause scheme

Trouble Cause Action nos.
Pump does not deliver Wrong sense of pump rotation 1
Pump without fluid to be handled 2
Stop valves closed 6
Pump is not vented No venting facility 7
Pump operates at minimum output Suction pipeline leaky 3
Filter clogged 12
Pump operates noisily Suction pipeline leaky 3
Geod. suction height to great 4
Air inclusions in the fluid pumped 8
Suction pipeline resistance to great 5
Filter clogged 12
Motor gets warm Power consumption of motor too great 9
Pump is seized Liquid level in tank too low 10
Viscosity too low, pressure too high 11
Filter clogged 12
Table 3
11.2 Measures to be taken for clearing the troubles
The table below shows a list of measures to be taken for clearing the troubles.
Measures scheme
\ction nos. Measures
1 Change any two phases at the motor.
2 Fill pump with fluid to be handled.
3 Retighten flange joints, replace gaskets, if necessary.
4 Raise liquid level in tank. Lower pump.
5 Reduce suction pipeline resistance, e.g. by a greater pipeline cross-section and/or a design providing a
more favourable flow.
6 During operation, the stop valves / gate valves / non-return valves in the pipeline and at the reversing
valve casing must be completely open.
7 Mount vent valve in pressure pipeline.
8 • Attend to better air separation in tank.
9 Check speed and power consumption of the motor. Compare voltage and frequency with the motor type
plate.
10 Dismount pump and check for wear. Fill tank. Replace set of spindles and rotor housing. Replace other
parts as required.
11 Dismount pump and/or have pump overhauled at the works.
12 Clean and/or replace filter insert.
Table 4

INDUSTRIES
12 Dismounting and mounting instructions
12.1 General
The most important dismounting and mounting operations are described in these
instructions. The mounting steps described in the individual sections must be
consistently observed.
Item numbers mentioned in this section refer to the sectional drawings of the SPZ
pump in Figure 1 and Figure 2.
12.2 Dismounting of screw pump
Prior to commencing the dismounting, the following operations must be performed.

Step A: Close non-return valve and stop valve of the pump to be dismounted, and
switch over to the stand-by pump. With the stand-by pump, the operation
can be maintained without any troubles.
Step B: Pinch off power supply cable to the motor of the pump to be dismounted.
Motor must not be capable of being started.
Step C: Drain fluid to be pumped in flowable condition from the pump. For these
purposes, turn out screw plugs for draining.
Note: Use collecting tank.
Step D: Let screw pump cool down to ambient temperature.
Step E: Dismount manometer lines, manometer and holding devicefromthe pump.
12.2.2 Dismounting of a screw pump from the twin aggregate
Step A: Loosen socket-head cap screws (215) at the pump bracket (460), and screw
out.
Step B: Loosen hexagon nuts (236) and (238) at the suction and pressureflange,and
unscrew.
Step C: Remove socket-head cap screws (206) and (208).
Step D: Withdraw pump from the centre bore of the pump bracket (460) and
removefromthe reversing valve casing (301).
Step E: Remove gaskets (125) and (126), and clean sealing surfaces.

•••••#•

INDUSTRIES
12.2.3 Dismounting of the shaft seal G 83
Step A: Withdraw coupling half from the driving spindle (12). Use detaching
device.
Step B: Remove key (290)fromthe driving spindle (12).
Step C: Loosen socket-head cap screws (200) at the pump cover, drive side (3), and
screw out.
StepD: Dismount pump cover, drive side (3) with stationary seal ring (186) over
the driving spindle (12)fromthe pump casing (1).
Step E: Dismount circlip (250)fromthe pump cover, drive side (3).
Step F: By means of an auxiliary tool, dismount stationary seal ring (186) and O-
ring from the pump cover, drive side (3).
Note: Particularly see to it that the stationary seal ring is pressed out
concentrically to avoid any damages.
Step G: Remove rotating part of the mechanical seal (186), consisting of rotating
seal ring, O- ring, and springfromthe driving spindle (12).
12.2.4 Dismounting of the sliding bearing (bearingring)with set of spindles
Step A: Dismount supporting washer (263) from the driving spindle (12).
Step B: Pull set of spindles with bearing ring (10) out of the pump casing insert (2).
Step C: Remove both idler spindles (13)fromthe driving spindle (12).
Step D: Remove bearing ring (10)fromthe driving spindle (12).
Step E: Loosen socket-head cap screws (201) at the pump cover, non-drive side (4)
and filter casing (9), and screw out.
Step F: Withdraw pump cover, non-drive side (4) and/or filter casing (9) from the
pump casing (1).
Step G: Remove gasket (100) and clean sealing surfaces.
Step H: Screw out socket-head cap screw (24) laterally at the pump casing (1).
Note: This socket-head cap screw serves to fix the pump casing insert (2) in the
pump casing (1).

INDUSTRIES
Step I: By means of an appropriate tool, press pump casing insert (2) from the pump
non-drive side out of the pump casing (1). In case of pumps with filter,
previously remove pipe (29) from the pump casing (1).
12.3 Mounting of the screw pump
12.3.1 Mounting of the slide bearing (bearing ring) with set of spindles
Step A: Slightly oil the locating surfaces at the pump casing insert (2).
Step B: By means of an appropriate tool, press the pump casing insert (2) from the
drive side into the pump casing (1).
Note: The bore holes for the idler spindles must be arranged vertically and
symmetrically in the pump casing. That means the location of the upper
bore must form a vertical axis with the suction and outlet branch in the
pump casing.
Step C: Via the lateral bore hole for the socket-head cap screw (24), pin pump
casing (1) together with the pump casing insert (2). Bore diameter: 4 mm.
Bore depth: 6 mm.
StepD: Screw socket-head cap screw (24) with sealing washer (151) laterally into
the pump casing (1), and tighten.
Step E: Push bearing ring (10) over the driving spindle (12) against the collar.
StepF: Slightly oil driving spindle (12) and, together with the bearing ring (10),
press into the pump casing (1) from the drive side.
Note: The driving spindle is concentrically guided through the bearing ring in
the pump casing.
Step G: Insert new joint tape (165) between the bearing ring (10) and the pump
casing (1).
Note: Slight oiling facilitates mounting.
Step H: Turn both idler spindles (13) from the pump end side into the pump casing
insert (2).
Step I: In case of pumps with filter, install pipe (29) in the pump casing (1).
Step J: Place new gasket (100) onto the pump casing (1).

INDUSTRIES
Step K: Fix the pump cover, non-drive side (4) and filter casing (9) with the socket-
head cap screws (201) to the pump casing (1).
Step L: Place supporting washer (263) in front of the collar of the driving spindle
(12).
12.3.2 Mounting of the shaft seal G 8.3
Note: Mechanical seals are high-quality precision parts. Careful handling and
extreme cleanliness during mounting are a condition of proper
functioning. To facilitate mounting, a suitable lubricant must be used
(e.g. oil, no grease).
Step A: Push rotating part of the mechanical seal (186) consisting of rotating seal
ring, O-ring and spring onto the driving spindle (12) in front of the
supporting washer (263).
StepB: Press stationary seal ring (186) with new O-ring into the cleaned pump
cover, drive side (3). Apply appropriate auxiliary tool.
Note: In particular see to it that the rotating seal is concentrically pressed into
the delivery casing and not canted to avoid any damages.
Step C: Insert new O-ring (122) in front of the return bore hole into the pump
casing (1).
Step D: Fix pump cover, drive side (3) with new O-ring (120) and pressed-in
stationary seal ring (186) with the socket-head cap screws (200) to the
pump casing (1).
Note: In doing so, the joint tape (165) is pressed into its end position.
Step E: Install circlip (250) in the pump cover, drive side (3).
Step F: Insert key (290) in the driving spindle (12).
Step G: Mount coupling half on the driving spindle (12). Use mounting device!
12.3.3 Mounting of a screw pump into the twin aggregate
Step A: Place gasket (125) onto the pressure flange and gasket (126) onto the
suction flange.

INDUSTRIES
Note: To facilitate mounting, we recommend to coat the gaskets with a suitable

adhesive.
Step B: Push pump into the centre bore of the pump bracket (460).
Step C: Fasten pump with the socket-head cap screws (206) and (208) and the
hexagon nuts (236) and (238) to the reversing valve casing (301).
StepD: Fasten pump with the socket-head cap screws (215) to the pump bracket
(460).
Following the installation of the pump in the twin aggregate, the following
operations are to be performed:
Step E: Attach manometer lines, manometer and holding devices to the pump.
Step F: Connect power supply cable to the motor. See to sense of rotation.
Step G: Prior to re-starting, fill pump with the fluid to be handled.
13 Spare parts
Parts marked (2) and/or (3) in the parts list, see Figure 1 and Figure 2, are provided
as spare parts.
Driving spindle (12) and idler spindles (13) are supplied as spare parts as complete
sets of spindles only.

AALBORG
INDUSTRIES
gBjaiaaaaamasns^^^^^w
^ m ^ i g g ^ g ^ ^ g i i i m i ^ ^ g m ^ ^ ^ ^ m i ^ ^ ^
Table of contents
Heat exchanger
Technical data for heat exchanger
General data 1
Data for heat exchanger 2
Heat exchanger
General description 1
Operation 2
Maintenance and cleaning 3
Data sheets for heat exchanger
Dimension drawing 1
Spare parts 2

AALBORG TECHNICAL DATA FOR HEAT EXCHANGER SD9010#16.1
INDUSTRIES
Technical data for heat exchanger

General data
Project No.: 736950,736952

Hull Ne/Project name: 03130007,03130008
Classification society/Local authority: LRS
Pressure gauge calibration: MPa
Thermometer calibration: °C
Language for signs: UK
Colour of heat exchanger unit: Heat resistant Silver RAL 9006
Data for heat exchanger
Heat exchanger type: MX15 T32

Number of heaters: 1
Fuel oil capacity: 1663 1/h
Design pressure (oil side): 1.9 MPa
Design temperature (oil side): 165°C
Fuel oil inlet temperature: 50°C
Fuel oil outlet temperature: 145°C
Steam consumption: 131 kg/h
Design pressure (steam side): 3.2 MPa
Design temperature (steam side): 212°C
Min. steam working pressure: 0.7 MPa
Max. steam working pressure: 0.9 MPa
Steam inlet temperature: 165°C
Steam/condensate outlet temperature: 165°C
Weight of heat exchanger unit: 150 kg

AALBORG HEAT-EXCHANGER OM8640#01.0
INDUSTRIES
Heat-exchanger
General description
This chapter describes the operation and the maintenance of the heat-exchanger. An
illustration of the heat-exchanger is shown in Figure 1.
The heat-exchanger is of the shell and tube type with u-bent tubes.
The heat-exchanger has been hydrostatically tested before delivery. The heat-
exchanger is type approved by all major classification societies.
Illustration of the heat-exchanger

- Socket for safety valve Oil outlet
Steam inlet
- Socket for air screw
i ' i ' i Insulation

Steam outlet Oil inlet
Figure 1 heatexcl.cdr
Operation
Before proceeding with start-up of the heat-exchanger make sure that all
connections to the heat-exchanger are securely tightened.
Start-up of the heat-exchanger:
Step A: Adjust the safety valve to the maximum design pressure. The safety valve
can be set to a lower set point.
Step B: Fill the heat-exchanger with oil.
Step C: Ventilate the heat-exchanger. Make sure that the heat-exchanger and all
connecting pipes are completely free of air.
Step D: Remember to tighten the air ventilation plug after ventilation.
Step E: Establish oil flow through the heat-exchanger.

INDUSTRIES
Step F: Establish steam flow through the heat-exchanger.
Step G: Operate the heater for approximately one hour.
Step H: Stop the heat-exchanger by closing the steam inlet valve.
Note: When the heat-exchanger is stopped, it is very important to maintain the

oil flow through the heat-exchanger for at least ten minutes in order to
remove the accumulated energy in the heating elements. It is also
important to make arrangements to ensure oil flow through the heat-
exchanger during emergency stops of the heat-exchanger.
Step I: Stop the oil flow after ten minutes and tighten all screws again.
To obtain the full output of the heat-exchanger, it must be supplied with dry
saturated steam at the correct pressure. The steam pressure appears from the section
"Technical data".
It is important that the condensate system has a suitable outlay and that a correct
type of steam trap is used to secure against the negative effect of counter pressure.
Maintenance and cleaning

The heat-exchanger should be cleaned every six month and in the event of a drop in
the output which is not related to other causes.
Step A: Stop the heat-exchanger as mentioned above.
Step B: Empty the heat-exchanger.
Step C: Remove the tube insert.
Step D: Check for deposits inside and outside the tube insert.
Step E: The outside tube system should be cleaned by using a sharp liquid jet (use
e.g. citric acid or water).
Step F: The inside tube system should be cleaned by flushing the tubes with e.g.
citric acid.
Step G: If the heat-exchanger is heavily contaminated with carbon deposits, it is

recommended to chemically clean the heat-exchanger with a carbon
remover.
Step H: The heat-exchanger must be flushed carefully with clean water and dried
after the tubes have been cleaned.
Step I: After the tube insert has been replaced, the bolts must be securely fastened
and the heat-exchanger checked for leaks.
Step J: Once every year the set point of the safety valve must be checked.

INDUSTRIES
3.2 Dismantling and installation of the tube section
The tube section is inserted into the heater and fastened tightly between the shell
flange and the end flange. The back end of the tube section is free to move.
The steam connections must be dismantled before dismantling the tube section for
inspection, cleaning, etc. The tube flange has threaded holes for dismantling screws
and for mounting eye bolts for lifting device.
Packing surfaces should be cleaned and protected against damages. A new packing
must be mounted every time the flange connection has been dismantled.
When the flange connection is mounted again, all bolts should be tightened evenly
and crosswise. A pressure test will show if the joint leaks.
Operate the heat-exchanger for one hour, stop and tighten all screws.
3.3 Conservation during shut-down periods
Corrosion which occurs in shut-down periods is mainly caused by oxygen. The

corrosion appears where non-distilled or even slightly alkaline water has remained
in the heat-exchanger. However, even when empty, the heat-exchanger is exposed to
corrosion caused by water residues or condensation. For this reason an unused heat-
exchanger should be given an anti-corrosion treatment.
In the event of prolonged off-cycle periods - in particular during winter time with
frost - the heat-exchanger must be carefully emptied. Open the air valve and check
for clogging.
3.4 Spare parts
When spare parts are ordered, please state the serial No. (See the name plate of the
heat-exchanger).
For spare parts and further information please contact Aalborg Industries.

I li n li i H j ^ ^ ^ t I Drawn \ Appr.
1100
975
448 450
250 250
150 125
I . I , I
m 1/2- BSP
z
1/2" BSP
T
Ë
"\
J- 1-^
-J——g_
i
1/2"BSP
1/2" BSP
-+
Dimension (length of tubes) 1200 mm
Design pressure shellside 32 bar/195°C
Design pressure tubeside 19bar/212°C
Test pressure shellside 51.5 bar
Test pressure tubeside 28,5 bar
Volume on the shellside 0,01692 m 3
Volume on the tubeside 0,00624 m 3
A/B shellside in- and outlet DN 25/25 Flanges ace. to DS/EN 1092-1 (DIN 2635)
C/D tubeside in- and outlet DN 20/20 Flanges ace. to DS/EN 1092-1 (DIN 2635)
Heat Exchanger MX15 T32 L=1200 3015120
Desl nation Material code Article no.

Item 9 Pes. Cert
Dimension Material type Detail drawing no.
Remarks:
The minimum withdrawal length
of heater insert, is:
length of tubes + shell diameter. Foundation details Order number No. of heaters: Classification: Painting: Insulation:
1 LRS Heat resistant silver Yes
Heater weight Boiler Data

150 kg pr. heater Scale
Project Dept HEAT EXCHANGER
3200 1: TYPE VESTA™ MX15 T32
Drawn Date Size Dimension Drawing
Withdrawal length
Mdu 09-02-2004 A2
AALBORG Approved Date No.
The tolérance dass In accordance with ISO 2768-1 c
INDUSTRIES 15 K 4555
| Tolaranceklasse Ifølge OS/ISO 2768-1 c This Drawing and Design shown herein, is the property of Aalborg Industries AÆ, and must not be used or reproduced for third party.
Description Index Date Drawn Appr.
Type number changed 250900 JBL
Drawing opdated 30-04-04 MDu
Option
5. Tube Insert
1. Safety valve
87S0038 - 4 Bar / 0,4 Mpa Ref. serial No.
87S0020 - 5 Bar / 0,5 Mpa
87S0029 - 7 Bar / 0,7 Mpa 6. In- and outlet flange gaskets
8750042 - 9 Bar / 0,9 Mpa
8750043 - 12 Bar /1,2Mpa 8913005 (00 0660 042) DN 32
8750040 - 13,5 Bar /1,35 Mpa 8913006 (00 0660 048) DN 40
8750041 - 32 Bar / 3,2 Mpa
8913007 (00 0660 060) DN 50
2. Manometer triple scale (Bar+Mpa+Kg/cm2) 8913008 (00 0660 076) DN 65
6633118 - -1 - +5 Bar / -0,1 - +0,5 Mpa 6633119 0-10 Bar/0-1,0 Mpa 8913009 (00 0660 089) DN 80
6633120 0-16 Bar/0-1,6 Mpa 6633121 0-25 Bar/0-2,5 Mpa
6633122 0-40 Bar / 0-4,0 Mpa
7. Steam and condens flange gaskets
3. Thermometer Straight/Angle
6633008/88T0012 0-120° 8913002 (00 0660 027) DN 20
6633004/88T0001 0-160° 8913003 (00 0660 034) DN 25
88T0003/62T4001 0-200°
88T0007/88T0004 0-300° 8913005 (00 0660 042) DN 32
8913006 (00 0660 048) DN 40
4. Flange gaskets
Ref. serial No.
Please state the serial number when ordering spare parts.

Project Boiler data
Scale
Weight kg. Dept.
HEAT EXCHANGER
• • • • • • < 1:15 Type MX
tUttiib Drawn Date Size
AALBORG JBL 25.09.2000 A4R Spare parts

INDUSTRIES Approved Date No.
MT 25.09.2000 15 14003 B
This Drawing and Design shown herein, is the property of Aalborg Industries A/S, and must not be used or reproduced for third party

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VI Instruction manual for boiler plant, volume 1

©ollor lyiio: I K A Q 1 H 1H000 K<|/li

System concept (vol. 1)

AQ-18 boiler/accessories (vol. 1)

KBSA burner/accessories (vol. 1)

KBSA burner/accessories (vol. 2)

Language UK Page 1/2

Control system/electrical equipment (vol. 2)

Spare parts (vol. 2)

Language UK Page 2/2

Technical data for boiler unit

Language UK Page 1/1

Technical data for boiler unit

• ProjectNo.: 736950, 736952

2 Dimensions for boiler unit

• Height to top of local control panel incl. retraction of burner: 8,650 mm

3 Water/steam process data

• Steam output: 18,000 kg/h

4 Combustion process data

• Min. calorific value of diesel oil: 42200 kJ/kg

Language UK Page 1/3

• Max. viscosity of fuel oil: 700 cSt at 50°C

5 Data for atomising steam

• Atomising steam pressure at burner, max.: 0.6 MPa

6 Data for electric systems

• Power supply: 3 x 440 V, 60 Hz

7 Data for pressure part

• Boiler type: Large oil fired boiler

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• Burner type: Steam atomising, modulating

9 Data for water level operation

• Too high water level alarm: + 200 mm

10 Data for steam pressure operation

• Safety valve: 0.87 MPa

• Language for manuals: UK

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03130011 04130001 1:1 A2

*L2 Control panel 63X03:028295;

W16 l DP-unit Feed water control 70Z:019538

V:\Marine\OrderY736xxx\736950,51,52,53,S4,55,56,57\1300 Documentation\1310 Flow diagrams - steam water\RQ020148A.doc 17-11-04,

V:\Marine\Order\736xxx\736950,51,52,53,54,55,56,57\1300 Documentation\1310 Flow.diagrams - steam water\RQ020148A.doc 17-11-04 ,

List of Parts Boiler Type AQ-18 & AQ-10/16W Rev:d Class.:

M82 1 40 Stop valve for steam injection 64Z:027665

M89 1" Steam injector 64Z:027665

N5 1 40 Steam dump control valve with pneumatic 6050 000050

Title Drawn Date

Hull nos 0 3 1 3 0 0 1 1 , 0 3 1 3 0 0 1 2 , 0 4 1 3 0 0 0 1 & 04130002 added 040625 GKa SøK

Flow diagram Article / Drawing No: Affix

Title Drawn Date

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Vertical Water -Tube Boiler

Access is obtained by the manhole located at the top plate/shell.

Access is obtained by the manhole located at the shell.

Steam atomizing burner

Water level control

Water level control system

Regulating feed water valve

Feed water pumps

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Operation and maintenance

Language UK Page 1/1

3.2 OPERATION DESCRIPTION