Screw Pump MANUAL Imo

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Screw pumps

A Member of the Low pressure pumps


COLFAX PUMP GROUP

Installation and Start-up Instruction

This instruction is valid for all standard low pressure pumps:


LPD, ACD, ACE, ACG/UCG, ACF/UCF, LPQ and ABQ
Contents Page
Pump identification 2
Installation 3
Start-up 8
Trouble shooting 10
Before commencing any work, read this instruction carefully! Failure to comply
! with these instructions may cause damage and personal injury!

LP 1205GB
July 2001
These instructions are valid for all low pressure pumps as specified in the Pump identification chart below.

Pump identification

Pump name Size Rotor Design Material Shaft- Mounting Valve Also Comments
(1) lead modification pump- seal (2) (3) valid for
(1) body design option
(1) (1)

LPD 015 N 1 I V B P Pumpunit


020 without shaft
coupling

ACD 025 L 6 I V B P Pumpunit


N N T without shaft
coupling

ACE 025 K V
032 L T
038 N 3 N B P A101
Q

ACG/UCG 045 K 6 I V B E A101 O = max 6 bar


052 N N T F G A327
060 O A020
070 P A385

ACF/UCF 080 K 4 I R B E A020 O = max 10 bar


090 L N V F O A084
100 N P A087
110 A101
125

LPQ 100 L 1 I R Y P
110 N
125 P
140 J

ABQ 160 B 5 I R Y O A328 O = max 5 bar


180 L P
N

(1) See Product description or Service instruction for specified Option


pump model A020 Pump with surface treated casing(s)
A084 Pump with lifetime greased ball bearing
(2) B = Flange mounting
A087 Pump with CCW-rotation and lifetime greased ballbearing
F = Foot mounting
A101 Pump with CCW-rotation, when not standard
Y = Vertical foot mounting
A327 Pump with Tuning®
(3) E = Without valve A328 Pump with Tuning®
G = Valve with external return A385 A101 + A327
O = Valve with internal return for reduced pressure range
P = Valve with internal return for total pressure range

2 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB


E-mail: info@imo.se, Web: www.imo.se July 2001
Identification of safety instructions Safety instructions which shall be considered for
Non compliance of safety instructions Safety instructions where reasons of safe operation of the pump or pump
identified by the following symbol - electrical safety is involved, unit and/or protection of the pump or pump unit
could affect safety for persons. are identified by: itself are marked by the sign:
ATTENTION

Installation
BEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!

Design limitations and technical data for each pump are found in the Product description.
Installation of IMO AB low pressure pumps does not require special skills. However, these instructions
presume that the work is carried out by experienced fitters.
Maintenance and service instructions, which are specific for each pump are presented in a separate docu-
ment.

Failure to comply with these instructions


! may cause damage and personal injury!

Transport and storage


Always protect the pump against ingress of water
and other impurities. Store the pump in a clean, dry
and warm environment. The pump is delivered with
the internals oiled and with protective covers over
the pipe connections and drain openings. These
covers should remain in place for as long as possible
during the mounting and installation procedure but
must be removed before start up.

All work carried out on the pump has to be


! performed in such a manner that risks for
personal injury are observed!
Fig. 1 Clean and dry environment.

max 90°
Lifting of pump min 60°
max 90°
All pumps should be lifted with straps min 60°
! securely attached to the pump or pump unit,
so that the center of gravity is located be-
tween the straps in order to avoid tipping of
the pump.

Use two eye bolts (M 20) securely fastened to the max 90°
front cover for pumps LPQ and ABQ. Pump and min 60°
connecting frame are lifted together using two eye
bolts securely fastened to the top of the connecting
frame. (Thread dimension is M 16, except for frame
size 600, where it is M 20).

Fig. 2 Lifting of pump


LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 3
July 2001 E-mail: info@imo.se, Web: www.imo.se
Lifting of the complete pump unit with the lifting
device attached to the motor, should be avoided as
A
the motor’s lifting provisions may not be able to
carry the combined weight of the pump and motor.

Lifting a complete pump unit, using slings


! or hooks attached to the pump or connecting
frame may be dangerous since the centre of
gravity of the pump unit may be higher than Distance Circular Angular
the points of attachments. between run-out alignment
coupling halves
t
Mounting
The pump must be securely mounted on a firm
stable foundation and positioned so that it is easily D
accessible for inspection and servicing.
Provisions for collecting oil spillage when servicing max
0.1°
the pump should be considered.

See table below D4 ø max 0.3 mm An angular


ATTENTION D6 ø max 0.4 mm
E4 ø max 0.4 mm misalignment of
The installation must always be designed to 0.1° corresponds to
minimise damage. Should an operational or approx. 0.2 mm
functional failure occur. E.g. precautions deviation/100 mm.
should be considered to collect oil spillage
due to a broken pipe or pump housing, to
stop pump operation if overheating should B
occur or if the oil volume is below a mini-
mum tank level.

Alignment and shaft couplings


The pump shall be connected to its driver via a
flexible shaft coupling. Pumps of type ACG/UCG
and ACF/UCF may also be driven via gears or
pulleys as specified in the Product Description,
ØD

provided the radial forces are kept within the


specified range.
x=y-t
t
An angular misalignment of 0.1° corresponds to X Y
approx. 0.2 mm deviation/100 mm.
The coupling and alignment shall be selected not to
transmit any axial or radial loads on the shaft ends.
IMO AB standard couplings shall have a distance
between the coupling halves as per table, fig 4. the
coupling halves shall be secured by lock screws.
For other types of couplings, please refer to respec-
tive maker’s manual.

Fig. 3 Alignment of the IMO AB standard coupling


When fitting the shaft coupling, do not use a
! hammer or similar as this may damage the
ball bearing and shaft seal.
Use some kind of press tool. Outer diameter Distance between Outer diameter Distance between
of coupling coupling halves of coupling coupling halves
(D mm) (t mm) (D mm) (t mm)
A B A B
When handling liquids that may harm skin 50 26 2.0 8 148 3.5
! use gloves and/or protective clothing. 67 40 2.5 16 168 3.5
82 55 3.0 18 194 3.5
97 65 3.0 20 214 4.0
112 80 3.5 24 240 4.0
128 95 3.5 26
When handling liquids which may involve
! fire hazards appropriate precautions to avoid Fig 4. Distance between coupling halves.
danger are to be taken. (IMO AB standard coupling)

4 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB


E-mail: info@imo.se, Web: www.imo.se July 2001
Measures shall be provided to avoid acci- For direct driven pumps the alignment between
! dental contact with the rotating shaft cou- pump and motor shafts must be kept within the
pling. Any installed coupling guard following limits:
shall permit easy access to the pump shaft
for maintenance and inspection of the Max run-out Max angular
pump bearing and seal housing. misalignment
(mm) (degrees)
Type LPD
Pipe connections and ACD (n/a short coupled)
The pipe work shall be installed and supported so Other types 0.3 0.1
that no pipe stresses are transfered to the pump
body. Fig 5.
The pipe work should be tight in order to avoid
leakage and infiltration of foreign particles and/or
air.
Shut off valves should be installed in both suction
and discharge pipes, so that the pump can be hy-
draulically isolated.

Suction line
The suction pipe should be designed so that the total
pressure drop, measured at the pump inlet flange,
does not exceed the suction capability of the pump.
Make a proper calculation of the suction line includ- Fig. 6 Pipe connections
ing components such as valves, strainer, pipe bends
etc. Generally, the pressure drop in the suction line
should be as low as possible, which is achieved if the
suction pipe is short, straight and has a suitable
diameter.
The velocity in the suction line should be kept in the
range 0.5 - 1.2 m/s. For L.O. circulating systems, we
recommend to keep it as low as possible.
The suction line must be equipped with a port that
allows filling the pump before start.

Discharge line
The discharge line should be dimensioned to keep
the velocity in the range 1 - 3 m/s. Fig.7 Suction line

Deaeration
In installations with negative suction head, where
the pump might be started against a pressurized
system, a deaeration pipe with an orifice (2-3 mm
recommended) has to be installed. The deaeration
pipe should be connected to the outlet pipe’s highest
point.
This must also be installed when the pump is used
as an stand-by pump.

Fig. 8 Deaeration
LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 5
July 2001 E-mail: info@imo.se, Web: www.imo.se
Strainer
The pump has to be protected from foreign matter,
such as weld slag, pipe scale, etc., that could enter
the pump via the suction line. If the cleanliness of
the system cannot be guaranteed, a strainer must be
installed in the inlet pipe near the pump. For practi-
cal reasons a suction strainer with 0.5 - 2 mm mesh
openings is recommended:
Small pumps (LPD, ACD, ACE) 0.5-0.8 mm
Large pumps (ACG/UCG, ACF/UCF, LPQ,/ABQ)
0.8-2.0 mm
The size of the strainer should be selected so that it
is large enough to allow adequate pressure at the
pump inlet. The pressure drop across the strainer Fig. 9 Strainer
should preferably not exceed 0.1 bar at max. flow
rate and normal operating viscosity. A vacuum
gauge between the strainer and the pump inlet is
recommended to indicate when the strainer needs
cleaning.

Shaft seal drain


The pump should be installed so that any leakage
from the shaft seal does not become a hazard. As the
shaft seal has to be lubricated a small amount of oil
dripping cannot be avoided.
Provisions to collect the leakage from the shaft seal
must be made.
A drain pipe can be connected to the drain connec-
tion on the pump, (not applicable to pump series
LPD). However, when pumping heavy fuel oil or
any other liquid that is likely to become very viscous
at ambient temperature, we recommend that the
liquid is allowed to drop freely from the drain

;;;;
opening.
Fig. 10 Shaft seal drain

;;;;
SealGuard

;;;;
For heavy fuel oil high temperature applications, a
SealGuard should be applied to the pump. Further
information about SealGuard, read the Installation
and Start-up Instruction for SealGuard.

Liquid trap
In some mounting arrangements the pump may not
retain the liquid at stand still. In such installations
the suction pipe should be arranged so it forms a
liquid trap together with the pump, keeping the
pump half filled with liquid. See fig. 11.

Fig. 11 Liquid trap

6 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB


E-mail: info@imo.se, Web: www.imo.se July 2001
Gauges
Gauges for monitoring the pump’s working condi-
tions are recommended. These gauges should be
placed readable as close to the pump’s in- and outlet
flanges as possible. On standard pumps, series ACE,
ACG/UCG, ACF/UCF and LPQ, there are gauge
connections for both in- and outlet.

bar

Fig. 12 Gauges

Pressure relief valve


All systems with screw pumps must be equipped
with a pressure relief valve installed immediately
adjacent to the pump.
In the standard versions of IMO AB low pressure
pumps, this pressure relief valve is an integral part
of the pump to protect the system against excess
pressure.
When liquid is circulated through the valve it heats
up in proportion to the set pressure level and the
percentage of by-passed liquid. 100% by-pass can
only be tolerated for less than about 3 minutes, 50 %
by-pass generally for unlimited periods of time. Fig. 13 Pressure relief valve
If more than 50% recirculation is anticipated, a value
specific to each application should be determined by
closely monitoring the pump body temperature.
If the pump is operating in line with a separate
pressure control valve (see fig. 13), the setting of the
relief valve should be high enough so as not to
interfere with the control valve. Likewise, if two
pumps are operating in parallel, the setting should
be such that interference between the two valves is
avoided.

Pressure testing and flushing


The system must be flushed and pressure tested
before connecting the pump. If corrosive liquid, such
as water is used, the system must be thoroughly
drained, dried and protected against corrosion after
having been flushed.

Oil leakage may make the floor slippery and


! cause personal injury.
Fig. 14 External control with pressure relief valve

LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 7


July 2001 E-mail: info@imo.se, Web: www.imo.se
Start-up
Before starting
After installation and whenever it can be assumed
that the pump has been emptied, the pump must be
thoroughly filled with liquid. See fig 15.
For ACE Generation 3, ACG Generation 6 and ACF
Generation 4 delivered after 1997, the pumps has
been fitted with deaeration plugs making venting of
the shaft seal compartment easy before start-up.
In installations with positive suction pressure: After
opening the inlet and outlet valves, simply open the
deaeration plug a few turns until oil sips out.
Tighten the plug.
In installation with negative suction pressure: After
opening the inlet and outlet valves, remove the
deaeration plug and fill the shaft seal compartment Fig. 15 Filling the pump
with oil. Fit and tighten the plug. See fig. 16.
Note! Not applicable on LPQ/ABQ.
Deaeration
plug
Deaeration
Make sure the prime mover is locked out plug
! and can not be started accidentally.
ACE
Rotate the shaft by hand while filling the pump, to Deaeration
ensure that the rotor bores and the shaft seal cavity plug
is filled. On the smaller pumps: (LPD, ACD, ACE,
ACG/UCG), this is done by rotating the fan on the
electric motor after removing the fan cover.
ACG
Do not forget to fit the motor fan cover again
! before making start of motor possible.

IMO AB
Deaeration plug
On the ACF/UCF, LPQ and ABQ pumps, the pump
can be turned using the shaft coupling. If the suction
pipe cannot be completely filled, it is important to
ensure that the trapped air is evacuated without any
pressure build up. (See fig. 8 Deaeration).
ACF

ATTENTION
Starting a dry pump is likely to cause
damage, especially to the shaft seal.
Fig. 16 Deaeration plugs

Direction of rotation
When the pump is ready to be started, switch the
motor briefly on and off and check that the drive
motor rotates in the correct direction as indicated by
the rotation arrow.

The arrow is placed on different spots depending on


the pump series.

ATTENTION
Don't mix up with arrow for inlet and outlet!
Fig. 17 Direction of rotation

8 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB


E-mail: info@imo.se, Web: www.imo.se July 2001
Starting 3. Turn the upper screw and continue to reduce the
Check that all valves necessary for the operation are noise level. (If turned too much the noise will
fully opened in both discharge and suction lines. increase again).
The first time, the pump should be started with the 4. Repeat item 2. and 3. in order to achieve the
adjusting spindle of the pressure relief valve tight- lowest possible noise level.
ened to half of the available turns (the valve setting
Setting of tuning of the ACG/UCG and ACF/UCF:
is increased when the spindle is turned clockwise).
By monitoring the pressure gauge it can be deter- 1. Before starting the setting, check that the setting
mined when the suction line is primed and the screw (8 mm: ACG/UCG, 12 mm: ACF/UCF,
pump begins to work. Should the pump not operate socket head cap screw on the discharge side) are
normally soon after start, stop the pump within half closed.
a minute. Start again after about 3-5 minutes (the 2. Turn the screw CCW until the noise level be-
shaft seal must have time to cool off) and run for comes the lowest (if turned too much the noise
half a minute. This procedure may need to be will increase again).
repeated a couple of times if the suction line is
Once set, the tuning needs no further adjustment,
extremely long. Should the pump still not work, it
providing the operating conditions stay the same.
must be assumed there is a problem in the system
that needs to be remedied. Check the suction line NOTE: It´ s not possible to accidentally turn the
calculation on page 5 and/or see ”Trouble shoot- tuning spindle too far.
ing”, page 10.
If operating temperature exceeds 60°C
Pumps with external ball bearing including ! (149°F), appropriate measures to avoid
! grease nipple, must be regreased after one skin contact shall be provided.
hour of running, while the pump is
operating
Use hearing protections whenever high
! noise can be expected from pump, motor
Setting the pressure relief valve and/or environment.
The setting of the opening pressure is made as
follows: Tighten the valve spindle by rotating
clockwise to the maximum extent. The system
pressure is regulated by throttling to required value.
The pressure relief valve is eased until the pressure
is just beginning to decrease by turning the spindle
CCW. The valve is now preset for desired opening
pressure. Open the throttling valve entirely.
NOTE: The set screw on LPD is hidden behind a
plate.

Adjusting the tuning


The tuning adjustment, which is a standard feature
on ACF/UCF and LPQ (option on ACG/UCG and
ABQ) pumps, is a device for minimizing the effects Fig. 18 Adjusting the tuning
of dissolved and free air in lube oil systems. The
tuning principle is described in the Product Descrip-
tion.
The tuning should be adjusted while the pump is
working under normal operating conditions. This is
done by turning the tuning spindle with an Allen
key (size 8 mm for ACG/UCG , 12 mm for ACF/
UCF and LPQ ) to a position where the noise level
comes to a minimum. On a double acting pump like
the LPQ pump, there are two tuning valves, which
must be adjusted individually.
Setting of tuning of the LPQ:
1. Before starting the setting check that both setting
screws (8 mm socket head cap screw on the
discharge side) are closed.
2. Turn the lower screw until the noise level obtains
a minimum.(If turned too much the noise will
increase again).

LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 9


July 2001 E-mail: info@imo.se, Web: www.imo.se
Trouble shooting
Problem Cause What to do
Wrong direction of rotation - Electric cables to motor wrongly Reverse the terminal connection
connected. on electric motor.

Connecting and discon-


necting of electric cables
must be done only by
personnel authorized to
do such work.

The pump cannot be primed - Wrong direction of rotation. See above.


- Suction line is not open or Check all components in suction
pressure drop in the suction line line. The inlet condition should
is too high. be checked with a vacuum
gauge at the pump inlet.
- Major air leakage into the Check the suction line.
suction line.
- The pump cannot evacuate the See the chapter on Deaeration
air through the discharge line (see page 5).
due to excessive counter
pressure.
No flow - The pump is not primed. See above.
- The pressure relief valve is set Readjust the pressure relief
below the counter pressure. valve to a value above counter
pressure.
Flow too low - The pressure relief valve is set Readjust the pressure relief
too low (Discharge pressure also valve
low).
- Something is restricting the flow Check all components in the
in the suction line. (This would suction line (strainers, valves
usually cause noise). etc.).
- The pumped liquid contains a See the chapter on Noise and
significant amount of com Vibration. ( Page 11).
pressible gas, such as free air.
(This would usually cause
noise).

Pressure too low - The pressure relief valve is set Readjust the pressure relief
too low. valve.
- Counter pressure in the dis- Check the components in the
charge line is too low due to a discharge line inclusive the
major leakage. recipients.
- The valve piston is stuck in open Check the valve. See Mainte-
position. nance and Service instruction for
respective pump.
- Something is restricting the flow Check all components in the
in the suction line. (This would suction line (strainers, valves
usually cause noise). etc.).
- The pumped liquid contains a See the chapter on Noise and
significant amount of com- Vibration. ( Page 11).
pressible gas, such as free air.
(This would usually cause
noise).
- A too small pump has been Contact your IMO AB
chosen. representative.

10 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB


E-mail: info@imo.se, Web: www.imo.se July 2001
Disturbance Cause What to do
Pressure too high - The pressure relief valve is set Readjust the pressure relief valve.
too high.

- The oil is too cold (or has higher Reduce the pressure setting until
viscosity than anticipated). operational temperature has been
reached.

- Counter pressure in the dis- Check the discharge line.


charge line is too high.

Drive motor difficult to start - Counter pressure too high. See above: Pressure too high.
or tends to stop by tripping
the motor overload relay - Liquid too cold. Readjust the pressure relief valve
to a lower value. Thus the power
consumption for the pumping is
relieved and overloading due to
the high viscosity may be
avoided. When the liquid has
reached normal temperature and
thus flows easily, the relief valve
is reset to normal pressure.

- Motor is undersized for the Check the motor.


prevailing conditions.

- Electrical power supply faulty. Check the motor and motor


connection.

- Motor overload relay set too low Readjust or replace the relay.
or is faulty.

- Incorrect setting of Y/D starter. Readjust the setting of the start-


ing sequence. The time before the
motor overload relay is tripped
should not exceed 10-15 seconds.

Noise and vibrations - The flow to the pump is insuffi- See chapter: The flow is too low.
cient.
Monitor the pump - Insufficient support of pipe Check for pipe vibrations in the
! function and shut down work. pump connections. Check that
if any sign of mal- the pipes are sufficiently
function is noticed. clamped.

- Bad alignment Check alignment, see page 4.

- Air leakage into the suction line. Check the suction line for air
leakage.

- Free air in the liquid or gas For pumps with Tuning:


cavitation. Adjust the Tuning. If this does
not help or for pumps without
Tuning: Contact your IMO
representative or IMO service
dept.

- Faulty electrical supply. Check all three phases of the


supply.

LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 11


July 2001 E-mail: info@imo.se, Web: www.imo.se
Screw pumps

A Member of the
COLFAX PUMP GROUP
ACE3
Maintenance and Service
Instruction

This instruction is valid for all ACE pump models shown on page 2
Contents Page
List of components 2
Exploded view 3
Ordering code/Service intervals 4
Sectional view 5
Useful tools/Shaft seal-assembly drawing 6
Dismantling/reassembly 7
Pressure relief valve/SealGuard 11

ACE 0620GB
June 2000
Before commencing any work, read this instruction carefully! Failure to comply with
! these instructions may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we refer to the
ACE Product description. For more information about the pumps installation, Start-up and trouble shooting
we refer to the IMO Installation and Start-up instruction for Low Pressure Pumps.

List of components
Valid for all pumps in sizes: ACE 025/032/038 Rotor diameter and Generation: L3/K3/N3
With version codes: N V B P Also valid for pump options: A101
T The version code is composed of the letters in the 4 columns.
Q Example of pump designations std: ACE 025L3 NTBP;
option: ACE 038N3 NVBP A101

Components included in spare parts sets:

Pos Denomination Q-ty G011 G012 G050 G053 G054 G057 G070 G082 Notes Explanations:
no
1010 Power rotor 1 x (x)
1020 Power rotor 1 x x G011: Rotor set
113 Key 1 x x x
122 Ball bearing 1 x x x G012: Rotor set
125 Secondary seal 1 x x x x 1
201 Idler rotor 2 x (x) G050: Shaft seal
202 Idler rotor 2 x x
351 Balancing bush 1 x x x G053: Minor kit
401 Pump body 1
416 Suction flange 1 G054: Major kit
417 Screw 8
418 Gasket to 1 x x x G057: Joint kit
suction flange
423 Gasket to 1 x x x G070: Valve element
discharge flange
427 Discharge flange 1 G082: Seal Guard kit
440 Return valve 1
451 Screw 4 Notes:
453 Screw 4 1) Version NTBP
462 Plug 1 and NQBP
462A Sealing washer 1 x x x 2) Version NQBP
463 Plug 1 only
463A Sealing washer 1 x x x 3) Including
501 Front cover 1 Gasgenerator
506 Gasket 1 x x x
509 Shaft seal 1 x x x
537 Deaeration plug 2
537A Washer 2 x x x
551 Rear cover 1
556 Gasket 1 x x x
557 Plug 1
557A Washer 1 x x x
605 O-ring 1 x x x x
608 Valve spindle 1 x x
608A Tension pin 1 x x
6120 Set screw 1 x x
613 Pin 1 x x
614 Valve piston 1 x x
615 Valve spring 1 x x
7310 Compl. Seal 1 x 2,3
Guard
732 Gas generator 1 x 2

ACE 0620GB 2
June 2000
Exploded view

202
1020
113
351
122
509
462
462A
417 416
418
427
xVxx
453
423
xTxx
xQxx
551
537 556
537A
(608A)

451 463 463A 401

440 (605)
506 (608)
537A 537
(6120)
(613)
557A 557 (615)
(614)
125 501 7310
732
xTxx, xQxx xQxx
xQxx

Fig. 1

All work carried out on the pump has to be When handling liquids which may involve
! performed in such a manner that risks for ! fire hazards appropriate precautions to
personal injury are observed! avoid danger are to be taken.

When handling liquids that may harm skin In case of failure for a system with elevat-
! use gloves and/or protective clothing. ! ing pressure fluid jets may cause injury
and/or damage.
Before any maintenance work, ensure that
! the driver is deenergized and the pump Oil leakage may make the floor slippery
hydraulically isolated. ! and cause personal injury.

Connecting and disconnecting of electric


cables must be done only by personnel
authorized to do such work.

3 ACE 0620GB
June 2000
Ordering code
Part numbers for pump size
Item Spare Parts sets 025 032 038 Recommendation:
For maintenance the following spare
G012 Rotor set CW-rotation (std) part sets are recommended:
Low lead-L3 190486 190485 –
Low lead-K3 – – 190482 Set: To be used:
Normal lead-N3 190487 190484 190483 G057 Joint kit
G011 Rotor set CCW-rotation For dismantling the pump.
Normal lead-N3 190492 190491 190488
G050 Shaft seal-xVxx 189964 189964 189964 G053 Minor kit
Shaft seal-xTxx 190495 190495 190497 For service.
Shaft seal-xQxx 190495 190495 190497
G054 Major kit
G053 Minor kit-xVxx 190501 190710 190500 For repair after damage or greater
Minor kit-xTxx 190503 190712 190499 wear.
Minor kit-xQxx 190503 190712 190499
G054 Major kit=G012(G011)+G053+G070
Ordering example:
G057 Joint kit-xVxx 190525 190714 190522 For IMO-pump ACE 032N3 NVBP,
Joint kit-xTxx 190524 190713 190523 serial number 456789:
Joint kit-xQxx 190524 190713 190523 Shaft seal pos G050 p/n 189964
G070 Valve element 189873 189873 189873 Valve element pos G070 p/n 189873
G082 Sealguard-kit xQxx 190526 190526 190527
125 Secondary seal xTxx, xQxx 190469 190469 190468
732 Gas generator xQxx 190530 190530 190530

Service intervals Inspection of shaft seal


The intervals for inspection and replacement of wear Excessively leaking shaft seals (more than 10 drops
parts vary greatly with the properties of the pumped per hour) should be changed without delay, as the
liquid and can only be determined by experience. leakage normally will grow worse and cause addi-
Pumping liquid which contains abrasive materials, tional damage.
or liquid that is corrosive, will significantly reduce In installations where unplanned shut downs must
service life and call for shorter service intervals. be avoided, it is advisable to dismantle the pump for
Wear will normally show as unnormal: a thorough inspection and thereby change out shaft
• Vibration seal and ball bearing, every three years as a max
period.
• Noise It is recommended always to have the spares in-
• Loss of capacity cluded in minor spare part kit available.
• Reduction in flow/pressure
• Leakage Inspection of rotors
A quick inspection of the idler rotors can be made
If the pumps operating temperature exceeds simply by removing the rear cover. Note that the
! 60°C let the pump cool off before any service, driver must be deenergized and the pump hydrauli-
maintenance or dismantling work is com- cally isolated before the rear cover is removed.
menced to avoid burn injury. If a more thorough investigation is needed, proceed
as under ”Dismantling/Reassembly”.

ACE 0620GB 4
June 2000
Sectional view

125 (xTxx, xQxx)

C-C E-E
463 463A
732
7310

537 537A

(xQxx)

Fig. 2

5 ACE 0620GB
June 2000
Useful tools
d

Allen key Fine Oil can


5 mm and emery
3 mm Mounting tool kit
D
Plastic D= 25,5 mm Screw
Screw mallet driver
spanner
16 mm
Puller
Tool 1 Tool 2
Sliding calliper
For dimension and material,
please contact IMO AB Service.

Fig. 3

Shaft seal - assembly drawing


Shaft seal G050 (509)
Seat slot
S2 S6 S4 S8
S7 S1 Version code xVxx
Front S1 Seat
cover S2 O-ring
retaining S4 Seal ring
tab S6 O-ring
S7 Spring unit
S8 Stop screw
Seat retaining lug

Stationary member Rotating member

S5 S8 Version code xTxx


S3 S2 S1 S4 S7 S6 S1 Seat
S2 O-ring
Seat slot
S3 Retainer
S4 Seal ring
S5 Carrier
S6 O-ring
S7 Spring unit
S8 Stop screw
Retainer lug
+ Secondary seal 125
Stationary member Rotating member
Version code xQxx
S4, S7 is one unit
xTxx + Complete
SealGuard 7310

Fig. 4

ACE 0620GB 6
June 2000
Dismantling
B.
A. OFF ON

• Turn the electricity OFF.

• Close the valves.


• Remove the pump
from the system.

ATTENTION
Use appropriate vessels to collect oil spill- • Note the position of the shaft coupling.
age when removing and opening the pump.
• Release the stop screw.
Fig. 5 Fig. 6

C. D.

113

• Remove the shaft • Remove the key 113.


coupling.

Fig. 7 Fig. 8

E. F. 1020
451

5011

• Remove the • Remove the front cover 501 and power


screws 451. rotor 1020.

Fig. 9 Fig. 10

7 ACE 0620GB
June 2000
G. H. xTxx and xQxx

501 125

501
1020

• Separate the front


cover 501 and the
power rotor 1020.
• Remove the secondary seal 125 with a
suitable screw driver.

Fig. 11 Fig. 12

I. J. xVxx

xTxx
xQxx
501

xVxx

• Place the front cover 501 on a pair of


wooden pieces.
• Press out the shaft seal, stationary member
• Loosen the shaft seal rotating member.
with a suitable tool.

Fig. 13 Fig. 14

K. xTxx and xQxx L. 202


Rotating
Member

• Insert two suitable


screw drivers in the
carrier S5 slots and
gently push the
rotating member
S4, S7 off the rotor
shaft.
S8 S5
• Loosen the two
stop screws S8
(3 mm Allen key)
on the carrier S5 • Remove and inspect the
and pull it off. idler rotors 202.

Fig. 15 Fig. 16
ACE 0620GB 8
June 2000
Reassembly
B.
A. • Un-pack a new shaft seal 509.
202

S8
xVxx xTxx, xQxx S8

S6 S6

S4 S5

401
• Lubricate S4,S7
the idler rotors 202 • Check that the O-ring S6 is in place.
and fit them into the pump body 401.

Fig. 17 Fig. 18

Oil can
C. xVxx D. xTxx and xQxx
S5 Emery
122
• Polish the power rotor shaft
1020 with a fine emery and oil.
• Fit the carrier S5 tight against the
ball bearing. Make sure the carrier
is not fitted upside down.
Rotating
• Firmly tight the two stop screws S8. member
• Lubricate the O-ring S6 in the rotat-
ing member with oil.
• Polish the power rotor shaft
• Press the rotating member S4, S7
1020 with a fine emery and oil.
gently on to the rotor shaft and make
• Fit the rotating member above sure the driving lugs enters the slots
the ball bearing 122 and lock it in the carrier S5.
with its stop screws S8.
Fig. 19 Fig. 20

E. F. xTxx and xQxx

1020
Tool 1 1 2 Tool 2
125
401 • Press the Secondary
seal 125 in place with
a suitable tool in two
steps as shown. Use a
column drill machine
as a press tool.
NOTE! 501
Tool nr 2 has
one end for sizes
025, 032 and one
• Insert the Power rotor 1020 into the pump
body 401. end for size 038

Fig. 21 Fig. 22

9 ACE 0620GB
June 2000
G. xVxx H. xTxx and xQxx Tool 1
Tool 1
S1
• Fit the spring unit S7 in place. • Fit the retainer S3 S2
Note the position for the Seat S1 in place. Note the
slots and lugs. position for the S3
S2 501
(See fig 4.) retainer lugs and
• Lubricate the O-ring S7 cover slots.
501 (See fig 4.)
S2 and put it on the
seat S1. Fit the seat • Lubricate the
S1 on top of the O-ring S2 and
spring unit. Watch put it on the
position of the Seat seat S1. Fit the seat S1
slots and lugs. on top of the retainer.
(See fig 4.) Watch the position of the seat
• Press the seat gently into the recess in the slots and lugs. (See fig 4.)
front cover 501 with a suitable tool as • Press the seat gently into the recess in the
shown. front cover 501 with a suitable tool as shown.
• Turn the front cover 501 up-side down. The • Turn the front cover 501 up-side down. The
seat shall now remain in the cover. seat shall now remain in the cover.

Fig. 23 Fig. 24

I. J.
451

501

506 • Fit the screws


451.
• Tight them crosswise,
step by step to avoid
deformation on bearing
• Replace the gasket outer ring and seal
506. damages.
• Carefully fit the • Turn the shaft to check
Front cover 501 on that it moves without
the pump. too much force.

Fig. 25 Fig. 26

K. L.
• Press on the shaft coupling
to its original position.
• Tighten the stop screw.

• Install the pump


back into the
113 system and proceed
according to in-
structions under
• Fit the key 113 back in place. ”Start-up” in the
Installation manual.

Fig. 27 Fig. 28
ACE 0620GB 10
June 2000
453
Pressure relief valve
551
ATTENTION
Spring tension.

• Release spring tension by turning set screw 6120 612


6120

CCW as much as possible. 605

• Loosen and remove the screws 453.


• Separate the valve element from the rear cover
551.
556
• If necessary, replace the gasket 556 and the
O-ring 605.
• Reassemble the parts in reverse order. Be careful
to tighten the screws 453 crosswise.
• Readjust the valve pressure according to the
”Installation and Start-up Instruction for IMO Fig. 29
Low pressure pumps”.

SealGuard
Version code N Q B P

Recharging
1) Disconnect the pipe connector (4) from the ATTENTION 9

0 12

6
1 3

dispenser (2). Remove the check valve (3). The SealGuard can be
readjusted or switched off
2) Remove the cover disk (10). Remove the gas Gas generator
during operation.
generator (9) from the dispenser (2) with a 21 10
Depending on temperature
mm socket. Dispose the generator in the recyc-
and setting, it can take from 9
ling system for batteries, where available. Push
hours to a couple of days
the piston to its ”filled” position, and fill the
after starting, until oil is 2
dispenser with high-temperature resistant engine
being dispensed.
oil. Fit the check valve (3) and the connector (4)
to the dispenser.
1
3) Feed oil into the hose (5) and seal compartment,
For more information about
for example with an oil-filled grease gun. Recon-
SealGuard, read the Installa-
nect the hose (5) to the connector (4). 3
tion and start-up Instruction
4) Fit a new gas generator (9) to the dispenser (2). for SealGuard. 4
Tighten with approx. 2 Nm. Clip on the cover
disk (10). Note!
Must be open
5) Turn the gas generator set knob (3 mm Allen
key) to no. 6 which will make the oil last for
about 3 months.
5

NOTE!
For longer periods of stand-by, the gas gene-
rator set-knob could be set to zero to avoid
unnecessary oil consumption. 8 7
6

Keep away from open fire when


!
removing the gas generator.
Fig. 30

11 ACE 0620GB
June 2000
Screw pumps

ACG/UCG
Maintenance and Service
Instruction
ACG1 © IMO AB

This instruction is valid for all ACG/UCG pump models shown on page 2
Contents Page
List of components 2
Exploded view/Ordering code 3
Service intervals 4
Shaft seal/Service for ball bearing 4
Lubricating intervals/Useful tools 5
Inspection of rotors 5
Sectional view 6
Dismantling 7
Reassembly 9
Pressure relief valve 11
ACG 0620GB
September 1999
Before commencing any work, read this instruction carefully! Failure to comply
! with these instructions may cause damage and personal injury!

For more information about the pumps identification code, technical data and performance we refer to the
ACG/UCG Product description. Fore more information about the pumps installation, Start-up and trouble
shooting we refer to the IMO Installation and Start-up instruction for low pressure pumps.

List of components
Valid for all pumps in sizes: ACG/UCG 045/052/060/070; Rotor diameter and generation: K6/N6
With version codes: I T B E Also valid for pump options: A020, A101, A327
N V F O Example of pump designations
R P std: ACG 045N6 IVBP; option ACG 070N6 IVBO A101
G

Qty Components included in Spare parts sets: Explanations:


G011: Rotor set
PosNo Denomination G011 G012 G050 G053 G054 G057 G070 Note CCW-rotation option
1010 Power rotor CCW-rot. 1 x (x)
1020 Power rotor CW-rot. 1 x x G012: Rotor set
106 Balancing piston 1 x x x 5 CW-rotation (std)
113 Shaft key 1 x x x
120 Distance sleeve 1 G050: Shaft seal
122 Ball bearing 1 x x x
124 Retaining ring 1 x x x G053: Minor kit
124A Support ring 1 x x x (G050 + G057)
133 Dust protection ring 1 x x x
201 Idler rotor CCW-rot. 2 x (x) G054: Major kit consisting
202 Idler rotor CW-rot. 2 x x of: G053+G012 (G011)
359 Distance washer 1 +615
359A Support ring 1 x x x
401 Pump body 1 G057: Joint kit
424 Sleeve 1 4
424A Washer 1 4 G070: Valve element
429 Spindle 1 4
437 O-ring 1 4 ACG Pump with DIN
440 Return valve 1 flanges
451 Screw 4/6
453 Screw 4 UCG Pump with ANSI
462 Plug 2 1 flanges
462A Sealing washer 2 x x x 1
473 Grease nipple 1
473A Grease nipple cover 1 Notes:
480 Valve housing 1 2 1) Excluded in xxxG
5010 Front cover 1 2) Excluded in xxxE
502 Tension pin 1 6 3) Valid for xxxE
502A Plug 1 6 4) Valid for pump option
506 Gasket 1 x x x A327
509 Shaft seal 1 x x x 5) Included in item 1020
514 Retaining ring 1 x x x or 1010
520 Cover 1 6) Included in item 5010
520A Screw 4
537 Plug 2
537A Sealing washer 2
545 Tension pin 1 6
551 Rear cover 1 3
556 Gasket 1 x x x
601 Valve cover 1 x 2
602 Sealing washer 1 x x x x 2
605 O-ring 1 x x x x 2
606 Valve housing plug 1 x 2 IMO AB
ACG2 © IMO AB

607 Sealing washer 1 x x x x 2


608 Valve spindle 1 x 2
608A Retaining ring 1 x 2
612 Set screw 1 x 2
614 Valve piston 1 x 2
615 Valve spring 1 x x 2
Name plate of the pump
631 Dog washer 1 x 2

ACG 0620GB 2
September 1999
Exploded view
551 453

ACG/UCG xxBE/BO/BP/BG xxxE 462

462A
608A
462 601

401 602
556 480
537 453 605
5010
537A
608
462
612
506 462A
451 615
462 631
607 614
124A 122 120
606
124
520

133 xxxO/xxxP

359 202 453


514 480
520A
359A 473A
537 473 xxxG
537A 607
Vxx
T 606
iion x
VVeerrss 113
202
1020

509
CW rotation 201
ACG3 © IMO AB

113

Details in pump option A327


xxxx See the sectional view p. 6 1010
onnxxVT
Veerrssiio
CCW rotation (non-standard)

Fig. 1

Ordering code
Pos Spare parts sets Part numbers, sizes Recommendation:
No 045 052 060 070 For maintenance the
following spare part
Rotor set CW-rotation (std): sets are recommen-
G012 Normal lead - pump version N6 178913 179507 179515 179523 ded:
" Low lead - pump version K6 187542 187559 187567 187575 Set: To be used:
G057 Joint kit
Rotor set CCW-rotation (non-std): For dismantling of
G011 Normal lead - version N6 186478 186486 186494 186502 the pump
Low lead - version K6 189641 189642 189643 189644
G050 Complete shaft seal - version code xVxx 190335 190336 190338 190340 G053 Minor kit
” ” - version code xTxx 174094 174102 174110 174128 For service
G053 Minor kit - version code xVxx 189196 189198 189200 189202 G054 Major kit
” ” - version code xTxx 189197 189199 189201 189203 For repair after
G054 Major kit=G012(G011)+G053+615 - - - - damage or greater
wear.
G057 Joint kit 179531 179549 179556 179564
Ordering example:
G070 Valve element - version code xxxP/G 190201 190201 190202 190202 For IMO-pump ACG 045N6
” ” - version code xxxO 190200 190200 190203 190203 IVBP, serial number 456789
Shaft seal
615 Valve spring - version code xxxP/G 074294 074294 074302 074302
pos G050 p/n 176198
” ” - version code xxxO 157370 157370 157388 157388
Valve spring
Fig. 2 pos 615 p/n 074294

3 ACG 0620GB
September 1999
Service intervals Inspection of shaft seal
The intervals for inspection and replacement of wear As the seal faces of a mechanical shaft seal are
parts vary greatly with the properties of the pumped lubricated by the fluid a certain leakage will always
liquid and can only be determined by experience. be present. Ten drops per hour can be considered as
All internal parts of the ACG-pump are lubricated acceptable.
by the pumped liquid. Pumping liquid which An external visual inspection of the pump is advis-
contains abrasive materials, or liquid that is corro- able at least every two days to assure that the shaft
sive, will significantly reduce service life seal is not leaking too much.
and call for shorter service intervals. Excessively leaking shaft seals should be changed
Wear in the pump may be indicated by: without delay, as the leakage normally will grow
• Vibration worse and cause additional damage.
• Noise Follow the instructions in the dismantling/reassem-
bly session.
• Loss of capacity
When working with a shaft seal, cleanliness is of
• Reduction in flow/pressure utmost importance. Avoid touching the seal faces. If
• Leakage necessary, the seal faces should be cleaned immedi-
In installations where unplanned shut downs must ately prior to assembly, using a dustfree cloth and
be avoided, it is advisable to have a complete pump clean solvent.
available for replacement, should any malfunction Never use grease on the seal faces.
occur. Furthermore we recommend planned inspec-
tion and overhaul at regular intervals, not exceeding Connecting and disconnecting of electric
3 years. ! cables must be done only by personnel
It is recommended always to have the spares in- authorized to do such work.
cluded in minor spare part kit available.
If the pumps operating temperature exceeds
All work carried out on the pump has to be ! 60°C let the pump cool off before any
! performed in such a manner that risks for service, maintenance or dismantling work is
personal injury are observed! commenced to avoid burn injury.

Shaft seal - assembly drawing


Shaft seal G050 (pos 509)
S1 Seat
S2 O-ring
Version code xTxx S4 Seal ring
S5 Seal ring carrier
ATTENTION S6 O-ring
Be careful to mount S7 Spring
these parts in right S2 S1 S4 S6 S9 S7 S5 S9 Stop washer
order and in right
direction. S1 Seat
ACG8 © IMO AB

S2 O-ring
Version code xVxx S4 Seal ring
S5 Bellows unit

S2 S1 S4 S5
Fig. 3

Service for ball bearing


The ACG-pump is fitted with an external grease Use an appropriate type of grease, as per table and a
lubricated ball bearing. grease gun suitable for grease nipple (pos 473)
When delivered from IMO AB, the ball bearings in according to DIN 71 412 (ISO 6392).
pump version xRxx and xVxx are filled with grease On vertical mounted units the greasing intervals are
of type B. For version xTxx, type C is used. reduced to half.
Whenever the ball bearing is removed, it is recom- Installed in dusty or dirty premises or in a corrosive
mended to exchange it for a new one. environment it should be lubricated at more fre-
Fit the new ball bearing properly greased and quent intervals.
regrease it after one hour of running, while the If using others than these recommended greases
pump is operating. check if it is possible to mix them with each other,
otherwise clean before using a new grease.

ACG 0620GB 4
September 1999
Lubricating intervals in working hours
Temp Pump sizes 045 and 052 Pump sizes 060 and 070
max Grease Speed, r/min Speed, r/min
°C type 3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950
70 A 8500 10000 10000 10000 10000 10000 7500 8500 10000 10000 10000 10000
90 A 3350 3950 5350 5950 6350 7500 2950 3350 4750 5150 5950 6750
110 B 2650 3150 4250 4700 5000 5950 2350 2650 3750 4100 4700 5350
130 B 1050 1250 1650 1850 2000 2350 900 1050 1500 1600 1850 2100
155 C 650 750 1050 1150 1250 1500 600 650 950 1000 1150 1300
*) at rotation speed > 3 500 r/min special instructions are given by IMO AB.
Recommended greases (the availability of the greases can differ locally):
Type A: BP Energrease LS 3, Esso Beacon 2, Mobilgrease HP 222, Shell Alvania G3, Texaco Multifak EP2, SKF LGMT2,
Q8 REMBRANDT EP2, CASTROL APS2, ELF ROLEXA 3, TOTAL MULTIS TIR EP3, FINA MARSON L3.
Type B: BP Energrease LC2, CHEVRON SRI GREASE 2, Esso Unirex N3, Mobilith SHC220, SHELL RETINAX LX,
SHELL Albida LX, VAL-PLEX EP GREASE, Texaco Hytex EP2, SKF LGHQ 3, Q8 RUBENS, CASTROL LMX,
INDUSTRIAL GREASE HEAVY, TOTAL MULTIS THT2, FINA PLUTON L2.
Type C: Mobilith SHC 460

When handling liquids which may involve


Pump size 045 052 060 070 ! fire hazards appropriate precautions to
Grease amount (g) 4 6 7 9 avoid danger are to be taken.

Before any maintenance work, ensure In case of failure for a system with elevated
! that the driver is deenergized and the ! pressure, fluid jets may cause injury and/or
pump hydraulically isolated. damage.

Useful tools Inspection of rotors


If an indication of a worn pump is noticed (see service
intervals above), a brief inspection of the idler rotors
is recommended.
A quick inspection of the idler rotors can be made
simply by removing the rear cover or valve cover.
Note that the driver must be deenergized and the
pump hydraulically isolated before the rear cover is
removed. Provisions to handle the fluid are to be
ACG7 © IMO AB

made. If a more thorough investigation is needed,


Plastic Pair of
mallet pliers proceed as under ”Dismantling”.
Puller Internal clearances in the pump, which are vital for its
Slide calliper proper function, may have been affected by wear.
Acceptable wear can be determined only by experi-
d
ence of the actual application. As a rule of thumb the
following max clearance values may apply:
L • Between rotor and bores or bushings: 0.2 mm
GREASE
• Between rotor flanks: 0.4 mm
Allen Fine Oil can Grease For light duties (low pressure, medium viscosity)
keys D emery even bigger clearances may be acceptable but for low
Moun- 2 pcs of visc./high pressure duties the limit will be lower.
ting screw Also check if there are major scratches on these parts.
sleeve driver

Mounting sleeve dimensions When handling liquids that may harm


Pump size D d L Part No ! skin use gloves and/or protective clothing.
ACG/UCG 045 ø 25.0 ø 21.0 100 188887
ACG/UCG 052 ø 31.0 ø 26.0 100 188888
ACG/UCG 060 ø 35.0 ø 31.0 100 188889 Oil leakage may make the floor slippery
ACG/UCG 070 ø 42.0 ø 36.0 100 188890 ! and cause personal injury.

Fig. 4

5 ACG 0620GB
September 1999
Sectional view
506 440 556

(502A) 537A 537 608A


601

(502) 602

520A 605
520 612
122 615
124A 608
124 614

1020 631

133 480

514 462

520 462A

359 607

451 606

5010 473 473A (545) (106)

401 202 453


509
359A
120

537 537A
Version xxBO and xxBP
Version xxBO and xxBP

608A
601
602
556
605
551
612
462A 615
424A 462 608
424 614
437 480
ACG5 © IMO AB
ACG6 © IMO AB

429 631
607
556 606
Option A327 Version xxxE Version xxxG
Fig. 5

ACG 0620GB 6
September 1999
Dismantling
A. B.
• Turn the
electricity OFF.

• Close the valves.


• Remove the pump ACG9 © IMO AB

from the system.

ACG10 © IMO AB
ATTENTION
Use appropriate vessels to collect oil spill- • Note the axial position of the shaft coupling.
age when removing and opening the pump.
• Release the stop screw.

Fig. 6 Fig. 7

C. D.
113

• Remove the shaft • Remove the key


coupling. 113.
ACG12 © IMO AB
ACG11 © IMO AB

Fig. 8 Fig. 9

E. F.
133
451
520
4 mm 124
• To remove the dust
124A
protection ring 133
520A
514 and the cover 520,
lift the cover 520
with two screw
drivers from the
shaft.
ACG13 © IMO AB

• Remove the re-


taining rings 124
ACG14 © IMO AB

and 514.
• Remove the sup-
• Remove the screws 451 and 520A. port ring 124A.
Fig. 10 Fig. 11
7 ACG 0620GB
September 1999
G. H.
122

120

359

359A

• Remove the • Push out the ball


front cover 5010
bearing 122 together
5010 with a with the distance
sleeve 120. If there is
ACG15 © IMO AB

puller.
5010 tight fit use a mount-
ing sleeve and a
mallet.

ACG16 © IMO AB
Fig. 12 • Remove the distance
washer 359 and the
Mounting support ring 359A.
I. sleeve

Fig. 13
S1

S2
No tools
J – xVxx.
506 from this Shaft seal S4
side
5010 Version xVxx
S5
The sealing
! surfaces of the S4
shaft seat
ACG17 © IMO AB

should not be S5
touched with
the fingers.

• Turn the front cover 5010 upside down.


• Push out the seat from the front cover 5010.
ACG18 © IMO AB

• Remove the o-ring S2.


• Remove the gasket 506.
1020
Fig. 14
• Pull the power rotor 1020 out of the pump
body and place it into the jaws of a jaw vice
J – xTxx. with soft jaws or a column drilling machine.
Shaft seal • Unscrew the • Push with two drivers as shown on the
Version xTxx seal ring sketch, to remove the shaft seal.
carrier S5
S4 screws and
Fig. 15
take off the
S6 seal ring
carrier S5
S5
together with
the seal ring S4 K. 202
• Take out the
and the o-ring idler rotors.
S6.
• Clean all parts
that are going
to be used
ACG20 © IMO AB

again.
ACG19 © IMO AB

Fig. 16 Fig. 17

ACG 0620GB 8
September 1999
Reassembly
A. B–xVxx.
202
Version xVxx • Carefully place the
• Lubricate the power rotor 1020
idler rotors and into the jaw vice
fit them into the with soft jaws.
pump. • Lubricate all
Lubrication S4 surfaces of the
groove turned power rotor 1020.
ACG21 © IMO AB

downwards. S5
• Open a package
with a new sealing
509, version xVxx.
1020
• Place the bellows
Fig. 18
S5 and the seal

ACG22 © IMO AB
ring S4 on the shaft
of the power rotor
B–xTxx. 1020.
Version xTxx
• Open a package
with a new shaft Fig. 19
seal 509 version
xTxx.
• Lubricate the O-
S4 • Place the seal ring
S6 ring S2 and the
carrier S5 on the C.
S5 recess of the front
shaft of the power
cover 5010.
rotor 1020 flush S1
Balance against the bal- • Clean the sealing
piston ance piston and S2 faces and fit the
lock it with its seat S1 into the
stop screws. Fit front cover 5010.
Mind the position
ACG24 © IMO AB

the o-ring S6 and


ACG23 © IMO AB

the seal ring S4. of the retaining


5010 pin if applicable.

Fig. 20 Fig. 21

D. Mounting sleeve

122
120 Grease • Lubricate the balance piston 106 with a
thick oil (ISO VG 460).
359 • Fit the front cover 5010 on the power rotor
1020 and press the shaft seal 509 into place
359A with the front cover 5010.
• Fit the support ring 359A and the distance
5010 washer 359 into the front cover. Mind the
1020 position of the distance washer 359.
• Fit the distance sleeve 120 into the front
cover 5010.
106
• Lubricate the new ball bearing 122 and
press it into the front cover 5010 with a
mounting sleeve. Make sure that the power
rotor is standing on firm support.

Fig. 22

9 ACG 0620GB
September 1999
E. 133

520
• Fit the support ring 124A and the retain-
124 ing ring 124 on the shaft.
124A • Fit the retaining ring 514 back in place.
• Place the cover 520 and the dust protec-
514 tion ring 133 on the shaft according to the
dimensions A above. If there is a tight fit
use the mounting sleeve, see page 5.
G26 © IMO AB

Fig. 23

F. G.
520A Pump size A A

045-052 4.0 mm
060-070 4.5 mm
• Fit the screws
520A and
tighten them
crosswise. ACG27 © IMO AB
ACG28 © IMO AB

133

Fig. 24 Fig. 25

H. Only use a mallet on the shaft coupling


• Fit the key back in position, see fig. 9. ! if the power rotor is standing on firm
• Fit the shaft coupling back into place, support. If not, heat up the coupling half
(see fig. 7 and 8) and lock with locking screw. before mounting.

Fig. 26

I. 537
537A
• Remove the plug 537 and washer 537A.
• Hold the rotor unit horizontally with the
bore for 537 upwards. Carefully fill the
space completely with thin oil
(f. ex. ISO VG 46).
• When the oil is flooding, reassemble the
above parts in reverse order.

1020
• Slowly turn the shaft a few turns to make
sure it moves freely (a certain resistance
5010 from the shaft seal is normal but it must be
the same during the turns).

Fig. 27

ACG 0620GB 10
September 1999
J.
• Place the gasket 506 on the pump body 401.
• Lubricate the power rotor 1020 and fit the
451 front cover 5010 together with the rotor set
into the pump body. Mind the position of
the tension pin 545.
5010
• Fit the screws 451 and tighten them cross-
wise.

1020
506
ACG29 © IMO AB

401

Fig. 28

K.
• Put the pump back into the system and
proceed according to instructions under
”Start-up” in the installation manual.

Fig. 29

Pressure relief valve


ATTENTION
608A
Spring tension.
601
Version
• Release spring tension by turning the spindle 608 P and O 602
480
CCW with an allen key. 453 605
• The valve piston 614, the dog washer 631 and 462
608
valve spring 615 can be pulled out by unscrew-ing 612
the plug 606. 462A
615
• To replace the O-ring 605 do as follows: 462 631
- Unscrew the valve cover 601. 607 614
606
- Remove the retaining ring 608A.
- Pull off the valve spindle 608 from the valve
housing 480.
Version G
- Replace the O-ring 605.
453
ACG30 © IMO AB

- Reassemble in reversed order. 480


• Readjust the valve pressure according to the
”Installation and Start-up Instruction for IMO
Low pressure pumps”. 607
606

Fig. 30

11 ACG 0620GB
September 1999
IMO AB: P.O. Box 42090, S-126 14 STOCKHOLM, Sweden. Telephone: + 46 8 50 622 800
Telex: 11548 IMO S, Telefax: + 46 8 645 15 09, E-mail: info@imo.se
Valve block for dual pump installation

In all application were there is a demand for two pumps, either for redundancy or for operational
reasons, a valve block is an option to save space and installation cost.

The valve block can be equipped with IMO ACE series of pumps that have a flow range up to
11 m3/h.

The valve block is a substitute for a number of components normally installed in a dual pump
application such as:
• Welding joints
• Shut off valves on in and outlet side
• Non return valves
• Strainers
• Pressure gauge adapters

System drawing of the T5 Valve Block. In a conventional system each component has to be added
manually
11
10

8
2

7 6 5

Components

1. Valve Block Body


2. Inlet pressure gauge adapter (Outlet pressure gauge on backside of block, not shown)
3. In and outlet flange set, including bolts, washers and o-rings
4. Shut off valves inlet side
5. Drainage plug
6. Combined shut off and non return valves, outlet side
7. Outlet valve covers, including bolts, washers and o-rings
8. Inlet valve covers, including bolts, washers and o-rings
9. Blind flanges for optional in and outlet position, including bolts, washers and o-rings
10. Filter baskets
11. Filter chamber covers, including bolts, washers, gaskets, plugs and protection plate
Function of the valve block

The block is equipped with inlet and outlet ports on both sides; hence there are several options for
inlet outlet configurations. The valve block is delivered with one set of inlet - outlet flanges and
one set of blind flanges.

The inlet and outlet chambers are equipped with a shut off valves regulated by an Allen key if one
of the pumps or the filter has to be removed during operation. The shut off valves on the outlet side
are a combined non return valve that prevents reversed flow through the non operating pump.

Before the inlet of the pump, flow passes through the filter chamber equipped with 500 µm
strainers. The covers for the filter chambers are equipped with de-pressurizing plugs and a
protection cover to avoid opening when the chambers are pressurized.

In the lower end there is a drainage plug to drain the valve block in case of service or inspection.

Cross section of the T5 Valve Block showing the inlet flow passing by the open shut off valve
through the strainer and into the pump. From the pump the flow is transported to the outlet side
were the combined shut off/non return valve is located.

Operating modes

1. One pump in operation and one in stand-by


2. Both pump are operating
The valve block can be equipped with different size pumps to full fill three flow demands;
Low flow pump in operation, large flow pump in operation, both pumps in operation.
Accessories

Additional flange set


Pressure gauge panel set
• Panel stand
• 2 inlet pressure gauges and 2 outlet pressure gauges.
• Root valve or 3 way test valve
• Seal pot
Spare Parts – Repair – Maintenance

CONTOIL® control (VZF / VZFA) DN 15…50


standard (VZE / VZEA)
classic (VZO / VZOA)

VI 14-419 def 09.2006 1


Table of Contents Page
Meter configuration .................................................................................................................................... 3
Supplementary Instructions ....................................................................................................................... 3
Version of Measuring chamber .................................................................................................................. 3
List of Spare parts and part numbers ........................................................................................................ 4
Flow sensors for CONTOIL® .........................................................................................................................................................4
Screw torque ..................................................................................................................................................................................4
VZF(A) Meter with transducer and multifunctional display ..............................................................................................................5
Conversion Kit VZE(A) / VZO(A) to VZF .........................................................................................................................................5
VZE(A) Meter with electronic counter .............................................................................................................................................6
VZE(A) Meter with electronic counter and NAMUR pulser type INA ...............................................................................................6
VZO(A) Meter with roller counter 130°C / 180°C ............................................................................................................................7
VZO(A) Meter with roller counter and Reed pulser type RV 130°C ................................................................................................ 8
VZO(A) Meter with roller counter and Reed pulser type RV 180°C ................................................................................................ 9
VZO(A) Meter with roller counter and NAMUR pulser type IN 10
........................................................................................................
Figures ...................................................................................................................................................... 11
Fault analysis ........................................................................................................................................... 14
Repair instructions and trouble shooting ................................................................................................ 15

2 VI 14-419 def 09.2006


Meter configuration

VZO / VZOA
VZF / VZFA VZE / VZEA
Transducer Ancillary modules
130°C / 180°C 70°C / 130°C / 180°C

Flow sensors
130°C / 180°C

CONTOIL® oil meters consist of a flow sensor and a measurement transducer with display, totaliser and signal
outputs where applicable. The flow rate range determines the nominal size of the flow sensor. The measurement
transducer is either one complete ("universal") unit (e.g. VZF) or is a combination of ancillary modules (transducer
group) which can be chosen to suit a particular application ( VZO, VZE).
The flow sensor and the measurement transducer are calibrated jointly and form one metering unit.
If the measurement transducer is replaced at a later stage, a certain divergence in measured values is to be
expected.

Supplementary Instructions

Part number

Mounting instructions
20288
CONTOIL® DN15 … 50
Operating instructions
20312
CONTOIL® classic: VZO / VZOA, standard: VZE / VZEA
Operating instructions
20313
CONTOIL® control: VZF / VZFA
Conversion Kit for CONTOIL® classic and standard to VZF
20328

Version of measuring chamber


Measuring chamber, single part with integrated flange Measuring chamber with separate flange
DN 20 all
DN 40 serial no. ≤ 3'741'525 DN 15/25 all
DN 50 serial no. ≤ 3'587'216 DN 40 serial no. > 3'741'525
DN 50 serial no. > 3'587'216

Description Quantity Part number

VI 14-419 def 09.2006 3


CONTOIL® Flow sensors for : VZF(A) / VZE(A) / VZO(A)

DN15 DN20 DN25 DN40 DN50


Housing (no spare part)
Cap nut for version USA 2 37470 2961 2887 -- --

Inlet filter 1 12968 19021 12969 12970 12971

Gasket, FPM 1 13002 13002 12985 12985 12985

PN 16,25 1 12856 19008 12861 12859 12860


Cover of the measuring chamber PN 40 1 12857 19389 12862 12864 12866

Gasket, FPM 1 13003 19020 16028 12994 13004

max. 130 °C 1 19154 19155 19156 19157 19383


Driver max. 180 °C 1 19095 19045 13160 13161 13162

1 12790 19022 12881 12882 12883


Rotary piston

max. 130 °C 1 13024 19848 12963 12965 12967


Separating plate max. 180 °C 1 13025 19390 13026 13027 13028

VZFA / VZEA / VZOA max. 130 °C 1 20003 20005 20008 20011 20013
Guide roller VZFA / VZEA / VZOA max. 180 °C 1 13146 19391 13147 13148 13149
VZF / VZE / VZO max. 130 °C 1 20004 20006 20009 20012 20014
VZF / VZE / VZO max. 180 °C 1 19163 19763 19164 19165 19166
PN 16 1 -- 19007 -- -- --
Measuring chamber PN 25 1 12841 19032 12851 19551 19506
PN 40 1 12842 19387 12844 19550 19507
DN 40, DN 50:
When replacing a measuring chamber with integrated flange by the current version, the two
following positions (flange and screws) are needed too. See remark on page 3.

PN 16 1 12874
Flange of measuring chamber PN 25…40 1 12877
PN 16…40 1 -- -- 12978 19547 19508
M 6 x 16 PN 16 4 12958 -- -- -- --
Screws M 6 x 16 PN 25/40 6 12958 -- -- -- --
M 6 x 12 PN 16 4 -- 19035 -- -- --
M 6 x 16 PN 25/40 6 -- 12958 -- -- --
M 8 x 25 6 -- -- 13101 -- --
M 12 x 40 8 -- -- -- 19548 --
M 16 x 50 10 -- -- -- -- 19549

Screw torque

Nominal size DN 15 DN 20 DN 25 DN 40 DN 50
Screws M6 M6 M8 M 12 M 16
Screw torque 6 Nm 6 Nm 16 Nm 47 Nm 100 Nm

4 VI 14-419 def 09.2006


Description Quantity Part number

Meter with transducer and multifunctional display VZF / VZFA

DN15 DN20 DN25 DN40 DN50_

Transducer with display130 / 180 °C 1 20319 20320 20321 20322 20322


(incl. material for fastening)

Conversion Kit

DN15 DN20 DN25 DN40 DN50_

Conversion kit CONTOIL to VZF130 / 180 °C 1 20319 20320 20321 20322 20322
(incl. manuals)

This conversion kit upgrades the VZO(A) or VZE(A) to the VZF version to take full advantage of
all the functions offered by the new transducer.

Modifying a Meter
All ancillary modules are to be replaced. The flow sensor remains in place throughout.
A power supply of 6 to 30 V DC is required.
The electronics has preset values for each nominal diameter being used. Individual preadjustment to a particular
hydraulic sensor must be carried out by personnel installing the kit.
The electronic and insulation modules are a single unit. Modifying a meter invalidates any type approval that may
have been issued. (Exception: type approval for ships. GL, DNV and LRS remain valid). Modifying a meter used in
custody transfer applications is not permitted.

VI 14-419 def 09.2006 5


Description Quantity Part number

Meters with electronic register

DN15 DN20 DN25 DN40 DN50

Cover 1 13423 13423 13423 13423 13423

M 6 x 16 max. 70 °C 4 12958 12958 12958 12958 12958


Screws M 6 x 93 130 / 180 °C 4 13167 13167 13167 13167 13167

Head ring RW 1 12903 12903 12903 12903 12903

Electronic register, Litres or US gallons 1 19757 19757 19757 19757 19757

max. 70 °C 1 13221 13221 13222 19740 19741


Adaptation piece 130 / 180 °C 1 19742 19743 19744 19745 19746

VZE / VZEA with pulser INA

DN15 DN20 DN25 DN40 DN50

Cover 1 13423 13423 13423 13423 13423

M 6 x 55 max. 70 °C 4 12959 12959 12959 12959 12959


Screws M 6 x 93 max. 180 °C 4 13167 13167 13167 13167 13167

Head ring RW 1 12903 12903 12903 12903 12903

Electronic register, Litres or US gallons 1 19757 19757 19757 19757 19757

max. 70 °C 1 19747 19748 19749 19750 19751


Pulser module (without detector ) max. 180 °C 1 19752 19753 19754 19755 19756

Plug-in detector INA 1 13240 13240 13240 13240 13240

following accessories included

Contact pins 4 5560 5560 5560 5560 5560

Plug body 1 13243 13243 13243 13243 13243


Options

Plug-in detector for Japan 1 20080 20080 20080 20080 20080

cable mounted 1 80019 80019 80019 80019 80019

6 VI 14-419 def 09.2006


Description Quantity Part number

Meters with roller register


DN15 DN20 DN25 DN40 DN50
VZO max. 130°C

Cover 1 13423 13423 13423 13423 13423

M 6 x 16 4 12958 12958 12958 -- --


Screws M 6 x 55 4 -- -- -- 12959 12959

Head ring RW 1 12903 12903 12903 12903 12903

Roller counter, litres 1 40247 40250 40252 40236 40237

or

Roller counter, US gallons 1 40255 40256 40257 40260 40260

Adaptation piece 1 13221 13221 13222 -- --

Adjustment gear, litres 1 -- -- -- 12943 12888

or

Adjustment gear, US gallons 1 -- -- -- 19451 19452

DN15 DN20 DN25 DN40 DN50


VZOA / VZO max. 180°C

Cover 1 13423 13423 13423 13423 13423

M 6 x 16 4 12958 12958 12958 -- --


Screws M 6 x 55 4 -- -- -- 12959 12959

Head ring RW 1 12903 12903 12903 12903 12903

Roller counter, litres 1 40235 40244 40236 40236 40237

Adjustment gear, litres 1 12889 12944 12942 12943 12888

VI 14-419 def 09.2006 7


Description Quantity Part number

Meters with pulser RV

DN15 DN20 DN25 DN40 DN50


VZO… RV max. 130°C

Cover 1 13423 13423 13423 13423 13423

M 6 x 16 4 12958 12958 12958 -- --


Screws M 6 x 55 4 -- -- -- 12959 12959

Sight glass 1 13558 13558 13558 13558 13558

Head ring RV, without sight glass 1 13070 13070 13070 13070 13070

RV 0.1 l 1 40248
Roller counter, litres RV 1 l 1 40249 40251 40253 40240
RV 10 l 1 40241 40242
RV 100 l 1 40243
or
RV 10ppg 1 40261 40262
Roller counter, US gallons RV 1ppg 1 40263
RV 0.1ppg 1 40264 40264

Adaptation piece 1 13221 13221 13222 -- --

Adjustment gear, litres 1 -- -- -- 12943 12888

or

Adjustment gear, US gallons 1 -- -- -- 19451 19452

8 VI 14-419 def 09.2006


Description Quantity Part number

Meters with pulser RV

DN15 DN20 DN25 DN40 DN50


VZO… RV max. 180°C

Cover 1 13423 13423 13423 13423 13423

Screws M 6 x 55 4 12959 12959 12959 12959 12959

Sight glass 1 13558 13558 13558 13558 13558

Head ring RV, without sight glass 1 13070 13070 13070 13070 13070

RV 0.1 l 1 40238 -- -- -- --
Roller counter, litres RV 1 l 1 40239 40245 40240 40240 --
RV 10 l 1 -- 40246 40241 40241 40242
RV 100 l 1 -- -- -- -- 40243
or
RV 10ppg 1 -- -- -- -- --
Roller counter, US gallons RV 1ppg 1 -- -- -- -- --
RV 0.1ppg 1 -- -- -- 40264 40264

Adjustment gear, litres 1 12889 12944 12942 12943 12888

or

Adjustment gear, US gallon 1 19449 19075 19450 19451 19452

VI 14-419 def 09.2006 9


Description Quantity Part number

VZO/VZOA Meters with pulser IN


DN15 DN20 DN25 DN40 DN50
VZO… IN / VZOA … IN

Cover 1 13423 13423 13423 13423 13423

Screws M 6 x 93 4 13167 13167 13167 13167 13167

VZOA / VZO max. 180°C additionally


4 13166 13166 13166 13166 13166
Extension

Head ring RW 1 12903 12903 12903 12903 12903

Roller counter, litres 1 40235 40244 40236 40236 40237

or

Roller counter, US gallons 1 40258 40259 40259 40260 40260

IN 0,01 l 1 13261 13261 -- -- --


Pulser module without detector IN 0,1 l 1 -- -- 13261 13261 --
IN 1 l 1 -- -- -- -- 13261
or
IN 1000ppg 1 13261 -- -- -- --
Pulser module, US gallons IN 100ppg 1 -- 13261 13261 -- --
IN 10ppg 1 -- -- -- 13261 13261

Plug-in detector IN 1 13240 13240 13240 13240 13240

following accessories included

Contact pins 4 5560 5560 5560 5560 5560

Plug body 1 13243 13243 13243 13243 13243

Options

Plug-in detector for Japan 1 20080 20080 20080 20080 20080

cable mounted 1 80019 80019 80019 80019 80019

Adjustment gear, litres 1 12889 12944 12942 12943 12888


or
Adjustment gear, US gallon 1 19449 19075 19450 19451 19452

VZOA / VZO max. 180°C additionally

Isolating piece (incl. screws and extensions) 1 13172 13172 13172 13172 13172

10 VI 14-419 def 09.2006


figures


Housing and sealing face


Positioning of rotary piston within measuring chamber


Positioning of driver within cover of measuring chamber


Positioning of cover and measuring chamber


Location of Gaskets


Positioning of housing onto measuring chamber

VI 14-419 def 09.2006 11


Fault analysis

Fault symptoms Possible causes Procedures 1)


• Pointers on roller counter • This is normal at high flow rates • No action required
rotate irregularly and has no effect on accuracy of
measurement
• Counter runs backwards • Meter mounted in wrong direction • Install meter with arrow pointing in
flow direction
• No reading 2)3) • No power supply 2) • Check wiring
• Battery discharged 3) • Replace battery
• Transducer defective 2) • Replace transducer
• Electronic counter defective 3) • Replace electronic counter
• Counter not running • Flow rate outside allowed range • Check flow rate
• No flow rate indicated 2) 3) (below Qmin or above Qmax of • If too high, reduce flow or install
• Indicated quantity or flow meter) larger meter
rate too small • If too low, increase flow or install
smaller meter
• Moving parts heavily worn out due • install larger meter
to continuous overload
• Dirt trap / filter heavily soiled • Clean dirt trap, replace filter
• Safety filter in meter intake clogged • Replace safety filter
• Install dirt trap / filter with correct
mesh size
• Moving parts jammed • clean measuring chamber, replace
defective parts
• Separating plate broken by • Check and rectify operating
o Pressure hammer conditions and meter position
• Fill pipes slowly
o Gas inclusions
• De-aerate pipes thoroughly
• Indicated quantity or flow • Meter positioned wrongly (e.g. at • Check and rectify operating
rate too high highest point) conditions and meter position
• Gas or air inclusion in fluid • De-aerate pipes carefully
• pressure drop at meter too • Dirt trap or filter heavily soiled • Clean dirt trap, replace filter
high
• No frequency signal 2) • No flow • Check flow using Indication
• No current signal 2) • Wrong parameterisation 2) • Set correct parameters for outputs
• No pulse output signal • Transducer defective 2) • Replace transducer
• Pulser sensor defective 4) • Replace sensor
• Pulser module defective 4) • Remove sensor and check if pulser
disk does rotate
• Pulser disk does not rotate 4) • Remove pulser module, place
counter on first module, and check
flow indication
• If indication is positive, replace
pulser module
• otherwise see ‘Counter not running’
• Reed pulser defective 5) • Replace roller counter
1) Consult operating instructions
2) CONTOIL® control VZF, VZFA only
3) CONTOIL® standard VZE, VZEA only
4) pulser type IN / INA only
5) pulser type RV only

12 VI 14-419 def 09.2006


Repair instructions and trouble shooting
This meter is a measuring instrument and should be treated accordingly.
Fuel Oil meters must only be tested and operated with fluids with lubricating properties!
The electronic transducer has to be replaced completely as it cannot be repaired.

Safety notes
⋅ The applicable working regulations must be complied with during all work on the plant
⋅ When removing from pipe or reinstalling, safety instructions in the operating manual must be observed.
⋅ Extra caution is required when using inflammable cleaning substances. Room must be ventilated well.
⋅ Prior to disassembly, the measuring instrument must be free from dangerous or noxious residues. Clean and
rinse thoroughly as necessary.

Repair instructions for measuring sensors


Detaching of measuring chamber
 Mark or memorise markings (dot, dash, embossment) at measuring chamber and housing.
⋅ Remove screws of measuring chamber.
⋅ Remove measuring chamber and cover from housing.
⋅ Remove deposits from housing surface and seating using fine emery cloth (Fig. 1).
⋅ Clean housing connections with a cloth.
⋅ For cleaning the use of non-fraying cloths and kerosene or solvents is recommended.
Replacing of filter
 When removing the filter, small chips may form, which must not be allowed to enter the measuring chamber.
Therefore its recommended to remove the housing from the measuring unit first (as above).
⋅ Pull filter out using a screwdriver or similar and replace it.
⋅ Put new filter in place. Press the metal ring into position using an appropriate tool (cylindric bar).
 Take care, not to press on the bottom of the filter!
⋅ Rinse housing or remove possible chips with a cloth.
Cleaning or repairing measuring unit
⋅ Pull off cover from measuring chamber.
⋅ Remove driver, rotary piston, separating plate, and guide roller from measuring chamber. Clean and check if
worn or damaged. Replace such parts and clean all others.
Assembly of measuring chamber
⋅ Place guide roller onto pin at bottom of measuring chamber.
⋅ Insert separating plate into measuring chamber.
⋅ Insert the rotary piston with eccentric driver pin (∅ 3 mm) pointing upwards into the measuring chamber.
Position it so that the driver pin and separating plate lie on one axis.
 Note: The centric guide pin of the rotary piston is now seated in the bottom of the measuring chamber
⋅ Place the driver onto the pin of the cover of the measuring chamber and align the driver’s long, deep groove
to the axis of the separating plate (Fig. 3).
⋅ Place cover of measuring chamber with aligned driver onto the measuring chamber, so that the separating
plate and driver pin of the rotary piston engage into the corresponding groove and driver (Fig. 4).
 The cover should be flush and the rotary piston should move freely.
Mounting of measuring chamber
⋅ Fit the new gaskets lightly greased with silicon (Fig. 5).
⋅ Align inlet/outlet openings of the housing to the openings in the cover of the measuring chamber (Fig. 6).
⋅ The openings must correspond to each other.
⋅ Join housing and measuring chamber and check the markings
 Align marking (dot, dash, embossment) on the measuring chamber base at right angles to the meter axis.
⋅ Insert measuring chamber screws and tighten them with correct torque (see page 4).

Repair instructions for ancillaries


 The modules are not screwed together individually and may fall apart when being dismounted.
⋅ Mark or memorise the position of lid, modules and pulser connection in relation to the meter housing.
⋅ Remove Allen screws.
⋅ Lift off head ring with cover and counter module with spring ring.
⋅ Replace worn or damaged modules.
 After replacement of adjustment gear, the meter is considered to be uncalibrated.
⋅ Reassemble in reverse order.

VI 14-419 def 09.2006 13


Aquametro AG Aquametro SA Aquametro Aquametro Aquametro s.r.o.
Messtechnik GmbH BELGIUM SPRL
Ringstrasse 75 Rue du Jura 10 Zum Panrepel 24 Dallaan, 67 Prosecká 811 / 76a
CH-4106 Therwil CH-1800 Vevey D-28307 Bremen B-1933 Sterrebeek CZ-190 00 Praha
Tel. 061 725 11 22 Tel. 021 923 51 30 Tel. 0421 / 871 64-0 Tel. 02 / 241 62 01 Tel. 02 / 86 88 77 78
Fax 061 725 15 95 Fax 021 922 58 44 Fax 0421 / 871 64-19 Fax 02 / 216 22 63 Fax 02 / 86 88 95 59
info@aquametro.com info@aquametro.com info.amd@aquametro.com info.amb@aquametro.com info.amc@aquametro.com

14 VI 14-419 def 09.2006


INSTRUCTIONS FOR SHELL & TUBE HEATER

Instruction Manual
TM
for VESTA MX
Table of contents for instruction manual
1. General Description......................................................................................... 1
2. Installation Space Requirements ..................................................................... 2
3. Storage............................................................................................................. 2
4. Mounting and Installation ............................................................................... 2
5. Connecting the Heat Exchanger ...................................................................... 3
6. Operation ......................................................................................................... 3
7. Conservation during shut down periods .......................................................... 4
8. Maintenance and Cleaning .............................................................................. 4
9. Dismantling and reassembling of the tube section .......................................... 5
10. Safety measures ............................................................................................... 5
11. Spare Parts ....................................................................................................... 6
Appendix:
- Spare Parts Drawing
- Dimensional Drawing

1. General Description
Aalborg Industries' Vesta MX heat exchangers are of the shell and tube type with
u-tubes.
The Vesta MX heaters range from 0,5 m² to 60 m² heating surface with design
pressures 16 or 30 BAR.
Other capacities may be manufactured at request.
All heaters may be delivered as immersion or outflow heaters for insertion in
tanks.
Vesta MX heat exchangers are primarily used as fuel oil, lubrication oil, or water
heaters (JCW).
INSTRUCTIONS FOR SHELL & TUBE HEATER

The heating media used is either steam, hot water or thermal oil.

Safety valve, thermometer, and pressure gauge may be mounted on a standard


outlet tube (optional).
Regulating equipment for either oil, steam or water is optional.
Vesta MX heat exchangers have been type approved by all major classification
societies.

2. Installation Space Requirements


2.1. Space allowance
When mounting the heater sufficient space must be allowed for withdrawal of
the tube insert for cleaning, inspection, or replacement purposes.
Please refer to dimensional drawing for withdrawal space requirements.

2.2. Installation surface


The heater must be placed on a level and stable surface.

3. Storage
3.1. Damp and humidity
Store the heater only in a dry storage room before installation. If the room is
damp the heater must be isolated with bags of silica gel. To avoid damage it is
recommended the heater be stored in the original packaging.

3.2. Hydrostatic testing


All Aalborg Industries heat exchangers have undergone hydrostatic pressure test-
ing before delivery. The testing fluid used contains a certain amount of corrosion
protection (Castrol Rustilo Aqua 2); hence no further actions regarding storage
are required before installation.

3.3. Extended storage


When heat exchangers are to be kept in storage for an extended period of time
we recommend Castrol Rustilo Aqua 2 be used as protection against corrosion.

4. Mounting and Installation


The heat exchanger is designed for vertical or horizontal installations.
In case of horizontal installation, the inlet pipe and media outlet pipe must face
upwards.

Instruction manual for heat exchanger type VESTATM MX 2/8


Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T30 series torque added.
C:\Documents and Settings\LJW\바탕 화면\F.O SUPPLY UNIT 업무 관련 사항\MANUAL\3.HEATER_1_2.doc
INSTRUCTIONS FOR SHELL & TUBE HEATER

If the heater is placed vertically the inlet and outlet tubes as well as the media
inlet must be at the bottom and the heater must be equipped with an air escape
screw at the top end.
The steam regulator (optional) must always be placed horizontally.
The steam trap (optional) should be mounted as close to the condensate outlet as
possible and somewhat lower. The steam trap is always to be placed horizontally.
Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts into the holes and tighten up at one end, while the other is left suffi-
ciently loose to allow for movement caused by thermal expansion. The bolts at
the expansion end must be secured with counter nuts.

5. Connecting the Heat Exchanger


5.1. Preparation and pipe connection of the heat exchanger
Remove all plugs and cover flanges before connecting the heater. Make sure
sand and other impurities are removed from all connections. Set up the pipe con-
nections and make sure that no forces are transferred to the heat exchanger.

6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securely
tightened.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.

6.2. Initial adjustments


The safety valve must be adjusted to maximum design pressure or lower.

6.3. Initial start-up


IMPORTANT: Fluid flow through the heat exchanger must be established be-
fore the heating medium is applied.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.
Heater main flange bolts tightening schedule (dry & smooth values) – T16 types
No bolts Size Torque [Nm] Tightening schedule
MX10 8 M16 50 14725836
MX15 8 M20 83 14725836
MX20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8

Instruction manual for heat exchanger type VESTATM MX 3/8


Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T30 series torque added.
C:\Documents and Settings\LJW\바탕 화면\F.O SUPPLY UNIT 업무 관련 사항\MANUAL\3.HEATER_1_2.doc
INSTRUCTIONS FOR SHELL & TUBE HEATER

MX25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8


MX30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
MX40 16 M27 245 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2

Heater main flange bolts tightening schedule (dry & smooth values) – T30 types
No bolts Size Torque [Nm] Tightening schedule
MX15 8 M16 164 14725836
MX20 12 M20 158 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M20 234 1 7 11 4 9 2 6 12 5 10 3 8
Always use a torque wrench when tightening the flange bolts.
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.

6.4. Output
The output of the heater is subject to the supply of heating media at the inlet
steam valve. The steam pressure/heating media temperature applied, is to be ac-
cording to heater size calculation.
The output is furthermore subject to correct type of steam trap being used. Cor-
rect layout of the condensate system avoids negative effect of counter pressure.

7. Conservation during shut down periods


Corrosion occurrences in shut down periods are mainly caused by oxygen. The
corrosion occurs if non-distilled or alkaline water remains in the heat exchanger.
However, even when fully emptied, heaters are exposed to corrosion caused by
water residues or condensation. Hence, heaters out of service should be protected
against corrosion.
If the heater is out of service for an extended period of time – in particular during
winter seasons with frost – it must be carefully emptied. Open the air escape
valve and check for clogging.

8. Maintenance and Cleaning


8.1. Regular cleaning periods
The heater should be cleaned regularly every six months by removing the tube
insert or at any time there is a decrease in output not related to other causes.
Note: The heat exchanger must be emptied before removing the tube section.
Check if any deposits have collected on the tubes.

Instruction manual for heat exchanger type VESTATM MX 4/8


Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T30 series torque added.
C:\Documents and Settings\LJW\바탕 화면\F.O SUPPLY UNIT 업무 관련 사항\MANUAL\3.HEATER_1_2.doc
INSTRUCTIONS FOR SHELL & TUBE HEATER

8.2. Cleaning of tubes


Cleaning of the tube system from the outside is carried out after removing the
tube insert using a sharp liquid jet (citric acid or water).
Cleaning of the tube system from the inside is carried out after removing the
cover by flushing the tubes with e.g. citric acid.

8.3. Heavy contamination


If the heater is heavily contaminated with carbon deposits Aalborg Industries
recommends the heater chemically cleaned with a carbon remover.
After cleaning has been completed the heater must be flushed carefully with
fresh water and allowed to dry afterwards.

8.4. Checking the safety valves


Once every year the safety valve must be checked for correct set point.

9. Dismantling and reassembling 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 not fixed.
The primary connection for heating media must be dismantled before disman-
tling the tube section for inspection, cleaning, etc. The tube flange has threaded
holes for dismantling screws and for mounting eyebolts for lifting devices.
Gasket surfaces are to be cleaned and protected against damage. New gaskets are
to be fitted every time the flange connection has been dismantled.
IMPORTANT: Fluid flow through the heat exchanger must be established be-
fore the heating medium is applied.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to the schedule on page 3.
A pressure test should be carried out to prove tight joints.
Note: Pressure testing to be carried out only with insert mounted in shell.
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.

10. Safety measures


During installation, commissioning, operation and maintenance, the following
measures must be observed:

10.1. Installation

10.1.1. Lifting
When lifting the heat exchanger, following methods are allowed:

Instruction manual for heat exchanger type VESTATM MX 5/8


Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T30 series torque added.
C:\Documents and Settings\LJW\바탕 화면\F.O SUPPLY UNIT 업무 관련 사항\MANUAL\3.HEATER_1_2.doc
INSTRUCTIONS FOR SHELL & TUBE HEATER

a) Two or four point lifting with straps and shackles in the holes or lifting lugs
on the mounting brackets.
b) Two point lifting with wide support straps around the heater body.
Other ways of lifting the heat exchanger may damage it or cause risk of dropping
it.

10.1.2. Connecting the flanges


It is important that the connecting pipes are arranged in such a way, that no
forces other than short leg thermal expansion forces are transferred to the heater.
Pipe supports are to be placed adjacent to the nozzle flange connection, and any
vibrations in the system must be sufficiently damped. Excess force may cause
the nozzle weld to crack, with subsequent leakage of the fluid.
When tightening the bolts on the nozzle flanges, it is important that the applied
force corresponds to the gasket material used. If this is not observed, there is a
risk of leakage or gasket blow out. Flange connections which are not insulated
after installation should be fitted with blow out guards/screens.

10.1.3. Insulation
The heat exchangers are delivered with thermal insulation according to the scope
of supply stated in the contract. The main flanges are not insulated, since the
class stamps are placed on the rim of the flanges, neither are branch pipes, noz-
zles or connecting flanges, since this would hamper the installation process. In-
sulation of these parts should be completed during the commissioning phase,
Aalborg Industries recommend an insulation thickness of 50 mm mineral wool or
equivalent heat barrier. Any insulation delivered with the heat exchanger is de-
signed for a maximum surface temperature of 60°C at engine room conditions,
so no special warnings of hot surfaces is required.

10.2. Operation & maintenance

10.2.1. High pressure


The heat exchanger is a part of a large pressurised system, and does as such not
carry an individual warning sign. This is considered unnecessary, since there are
no quick opening devices on the pressure part and since safety valves and valves
for drain and venting must be installed with discharge piping.

10.2.2. Maintenance
During disassembly, inspection, reassembly and testing it is important that safety
measures of this manual as well as the ships safety procedures are observed. The
fluids in the systems can be both hot and flammable as well as posing a health
risk if ingested. Therefore it is important that proper depressurising, isolation and
draining is performed, as well as spillage control during disassembly and clean-
ing. Procedures for reassembly must be followed and the mandatory pressure test
be carried out with great care. Insulation and splash guards must be fitted during
recommissioning.

Instruction manual for heat exchanger type VESTATM MX 6/8


Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T30 series torque added.
C:\Documents and Settings\LJW\바탕 화면\F.O SUPPLY UNIT 업무 관련 사항\MANUAL\3.HEATER_1_2.doc
INSTRUCTIONS FOR SHELL & TUBE HEATER

11. Spare parts


When ordering spare parts please state the serial number of the heat exchanger
(located on the nameplate).
For spare parts and further information please contact Aalborg Industries.

Instruction manual for heat exchanger type VESTATM MX 7/8


Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T30 series torque added.
C:\Documents and Settings\LJW\바탕 화면\F.O SUPPLY UNIT 업무 관련 사항\MANUAL\3.HEATER_1_2.doc
DESCRIPTION AND OPERATING INSTRUCTIONS
FOR THE BACK-FLUSHING FILTER TYPE 6.60.1

===================================================================

Commission No.:

CONTENTS

1. Type Sheet
2. General Information on the Automatic Filter
3. Filter Installation
4. Commissioning
5. Filtration Phase
6. Back-Flushing Operation
7. Description of the EL.-Control System
8. Circuit Diagram
9. Equipment List for EL.-Control System
10. Servicing
11. Servicing Tools
12. Cleaning Agents for Candle Elements
13. Manual Cleaning of Candle Elements
14. Maintenance instructions bypass filter
15. Spare Part Drawing for Type 6.60.1 and 6.60
16. Spare Part List for Type 6.60.1
17. Type Sheet for the Differential Pressure Indicator with Electrical Contacts
18. Spare Part Drawing for the Differential Pressure Indicator

BOLL & KIRCH assumes no liability for any mistakes by any misuse of the product.
We reserve the right to change this description without any prior notice!
2. General

The fully automatic back-flushing filter is used to filter a variety of fluids, but chiefly
for the filtration of fuels, lubricating oils, caustic solutions and emulsions. The filter
element assemblies are cleaned automatically by compressed air assisted back-
flushing without causing interruption to the filtration process. One clean chamber
is always held in reserve.

This self-cleaning filter consists basically of the following parts:

The lower housing with connection flange for the removal of flushing fluid (sludge
discharge).
The change-over system housing with the filter inlet and outlet flanges.

The automatically vented filter chambers containing the candle elements.


In the centre of the housing is the shut-off plug with refill bore.

The pneumatic swivel drive with attached control valve and end position switch.

The air supply with non-return valve, shut-off valve and pressure regulator.

The safety valve.

The differential pressure indicator Δp1.

The flushing valve with manual initiation.

The EL.-control system in its own switch box separate from the filter.
3. Installation of the Filter

Care must be taken during installation of the filter that the pipelines attached to the
filter inlet and outlet are clean and not under tension.

The pipeline selected for the sludge discharge is to be no smaller than the size
indicated on the type sheet. In order to prevent back-pressure arising in the pipe, it
is to be laid on a gradient and vented.

The terminal board on the filter is to be connected to the terminal board in the
switch cabinet by means of the control system cable (see circuit diagram).

When the filter is used in aqueous media, it is imperative to observe the following:
3.1 It must be ensured that the filter does not run dry even after the supply
pump has been switched off (owing to hardening of dirt).
3.2 If this condition cannot be fulfilled, at least the EL.-control must be
designed so that, even when the supply pump is switched off, back-
flushing is initiated every 2 hours by a time relay.

Flushing operations into a completely empty chamber for test


purposes are permitted without any restrictions. Flushing into a
partially filled chamber results in increased loading of the filter
candles. Back-flushing for installation (pipe) or control reasons into
a filter chamber which is only partially filled is therefore
inadmissible.

The filter housings are only designed for internal overpressure in


accordance with the AD Information Sheets. Additional external
forces and moments at the filter connection flanges are to be
avoided (possibly by supporting the supply lines).

When installing the filters, make sure that any oil or fuel which
leaks due to improper handling cannot result in a fire or injury.
4. Commissioning

The following requirements must be met for the commissioning of the filter:
4.1 Clean and dry compressed air for the control system at between 4 and 10 bar
operating pressure, must be available at the open shut-off valve.

4.2 Switch on the electricity using the "Main Switch" on the switch box. The
"Power" lamp respectively LED-operating display lights up. (Activation of the
main switch initiates a back-flushing cycle.)

4.3 To check the EL.-control system a back-flushing cycle should now be


performed by activating the "Manual" trip on the switch box.

4.4 Open the slide valve at the filter outlet. Slowly open the slide valve at the filter
inlet (avoiding pipe hammer). A further back-flushing cycle is to be performed
using the "Manual" trip on the switch box. Once the back-flushing operation is
completed, the "Flushing" respectively the display "SP.1" lamp goes out. If
these conditions are met, the filter is in the start position and is therefore
ready for operation.

After completion of a back-flushing cycle, the next backflushing


operation can only be initiated (manually or by means of the
differential pressure indicator) after a time delay.
This time delay corresponds to the time preset on the time relay
"K1A" or the preselected time "PA.5" in the electronic control. It is
needed to guarantee that the cleaned filter chamber is filled.

NOTE: Possible time interval calculation for time-dependent back-flushing


Let the filter run for 24 hours using the differential pressure and establish the
number of back-flushing operations (flushing cycle counter or display).
Calculate the average flushing interval.
Set the flushing interval (shortened by 30%) on the time relay or PA.2.
5. Filtration Phase
(see Drawing Z 32330 p. 1 or Z 33703 p. 1)

The medium to be filtered flows down into the change-over system housing and
passes from there through the chamber inlet and the connected filter chambers to
the candle elements. The medium flows through the filter elements from the
outside to the inside and the contamination in the medium is retained on the filter
mesh of the candle elements. The cleaned fluid passes to the filter outlet.

In this position the air supply (by means of the solenoid valve) keeps the sludge
discharge closed and compressed air is maintained in the air receiver ready for the
next backflushing cycle.
6. Back-Flushing Operation
(See Drawing Z 32330 p. 2 or Z 33703 p. 2)

The contamination retained on the candle elements produces an increasing


pressure differential between the filter inlet and outlet. This difference in pressure
is indicated optically on the differential pressure indicator when a set value is
reached and an electrical contact initiates the back-flushing.

When the back-flushing cycle is initiated, the pneumatic swivel drive is switched by
the attached control valve and the plug rotates from the chamber held in reserve to
the filter chamber to be cleaned. The connection of the reserve chamber, with its
clean candle elements, causes an immediate reduction in the pressure
differential. When the stop plug reaches the filter chamber to be cleaned the
turning motion of the pneumatic swivel drive is stopped by means of the attached
end position switch.

The solenoid valve (mounted on the sludge discharge) is then switched electrically
and air from the air supply passes to the rear side of the sludge discharge valve
shaft. The sludge discharge valve opens and pressure is released from the
chamber now shut off. (See Note!)

This allows the compressed air in the upper region of the plug to
immediately expand and thus creates additional space for the fluid
displaced (by the air) in the backflushing cycle.

While the sludge discharge valve shaft is opening, the control system air reaches
the attached flushing valve (once the pressure has been released on the filter
chamber). The flushing valve opens and the compressed air from the air receiver
dispatches the clean fluid present and pushes it in the counter current direction
through the mesh of the screw-in candle elements. The pressure drop thus
generated flushes off the contamination deposited on the mesh and washes it out
of the filter housing via the open sludge discharge valve.
The air flow is continued for a short period (flushing period) before the solenoid
valve (on the sludge discharge) is electrically switched over, causing the sludge
discharge valve to close. At the same time the flow of air from the control system
to the connected flushing valve is interrupted and thus also stops the flow of the
stored back-flushing air.
The back-flushed filter chamber is now refilled with clean medium through the
refill bore until operating pressure is achieved.
Only then is the delay of the electric control cancelled for the next back-flushing
operation.
Operating and Installation Manual

Electronic Control Box

Type 2200
Table of Contents

1 General Information ................................................................................................................. 4


Safety Instructions ...................................................................................................................... 4

2 Components of the Control Box and Cabinet ........................................................................ 5


2.1 Power Section .................................................................................................................. 5
2.1.1 Incoming Feeder Supply .................................................................................... 5
2.1.2 Motor Controller ................................................................................................. 5
2.1.3 Voltage Supply .................................................................................................. 5
2.1.4 Fuses ................................................................................................................. 5
2.2 Control Box Displays and Functions ................................................................................. 6
2.2.1 Display and Operating Elements ....................................................................... 6
2.3 Inputs and Outputs on Controller pcb ............................................................................... 6
2.3.1 Optocoupler-Inputs (E1 – E5), Terminals 31 – 40.............................................. 6
2.3.2 Live Relay Outputs ............................................................................................ 6
2.3.3 Potential free Relay-Outputs ............................................................................. 6

3 Operation .................................................................................................................................. 7
3.1 Text Messages ................................................................................................................ 7
3.1.1 Messages in „Operation“ Mode ........................................................................ 7
3.1.2 Alarm Messages ............................................................................................... 9
3.2 Setting and Operation ...................................................................................................... 9
3.2.1 Setting Level – Parameter Selection and Viewing ........................................... 9
3.2.2 Setting Level – Parameter Editing and Saving ................................................. 9
3.2.3 Return to the Operating Level .......................................................................... 9
3.3 List and Descriptions of Parameter ................................................................................ 10
3.3.1 P0 Filter type ................................................................................................ 10
3.3.2 P1 Multiple Flushing .................................................................................... 10
3.3.3 P2 Timer-controlled Back-flushing ............................................................. 10
3.3.4 P3 Timer-controlled Back-flushing ............................................................. 10
3.3.5 P4 Back-flushing Time ................................................................................. 11
3.3.6 P5 Filling time............................................................................................... 11
3.3.7 P6 After-blowing Time ................................................................................. 11
3.3.8 P7 Delay Time – Cartridge Alarm ................................................................ 11
3.3.9 P8 DP-Alarm (Flushing Frequency Monitoring) ........................................... 12
3.3.10 P9 Motor Fault ............................................................................................. 12
3.3.11 P10 Back-flushing Time ................................................................................. 12
3.3.12 P11 Language ............................................................................................... 13
3.3.13 P12 Test Code................................................................................................ 13
4 Control Procedure, System Functions .................................................................................. 14
4.1 Master Switch – Operating Feedback Contact ................................................................ 14
4.2 Control Voltage Monitoring.............................................................................................. 14
4.3 Motor Fault ..................................................................................................................... 14
4.4 Differential Pressure Too High – Flushing Oil Conditioning – Cartridge Alarm ............... 14
4.5 DP Too High – Back-Flushing Filter ................................................................................ 14
4.6 Key C (Number of Flushing Cycles) ................................................................................ 14
4.7 Multiple Flushing ............................................................................................................. 14
4.8 DP Alarm (Flushing Frequency Monitoring).................................................................... 14

5 Description and Function of the Controllers ........................................................................ 16


5.1 Controller of Type 6.18 / 6.19 / 6.44................................................................................. 16
5.2 Controller of Type 6.23 / 6.24 .......................................................................................... 17
5.3 Controller of Type 6.60..................................................................................................... 17
5.4 Controller of Type 6.61..................................................................................................... 19
5.5 Controller of Type 6.62..................................................................................................... 21
5.6 Controller of Type 6.64..................................................................................................... 22
1 General Information

Safety Instructions

Incorrect installation of the control box Type 2200 or interfaced equipment can result in failure of
the control box, serious personal injury or even fatal injuries. Therefore please observe the
following points in addition to the general safety regulations for equipment in industrial electrical
installations:

Installation of the control box Type 2200 may only be carried out by qualified electricians in
accordance with the provisions of IEC 364, DIN VDE 0105 for electrical power installations.

All the laws, regulations, ordinances and specifications for the erection of electrical power
installations applicable at the installation location must be observed.

Adjustments to equipment with protection class IP00 without covers may only be carried out by
qualified electricians with the equipment switched off and in compliance with the local safety
and accident prevention regulations.

The control box Type 2200 may only be employed in the approved operating range.
2 Components of the Control Box and Cabinet

2.1 Power Section

2.1.1 Incoming Feeder Supply

Incoming feeder supply L1-L2-L3 directly to the 4-pole master switch.

2.1.2 Motor Controller

Motor connection U-V-W directly to the motor contactor.

2.1.3 Voltage Supply

Primary voltages 0 - 220 V, 380 V, 400 V, 440 V, 500 V, 550 V

Secondary voltages
0 V AC - 230 V AC Solenoid voltage 230 V AC
0 V AC - 115 V AC Solenoid voltage 115 V AC
0 V DC - 24 V DC Solenoid voltage 24 V DC
0 V AC - 20 V AC Supply voltage to control pcb

2.1.4 Fuses

Fuses in the control box

F1 to F3 each 1 A

Fuses on the control pcb

Fuse F1 0.8 A slow-blow


Fuse F2 2.0 A slow-blow
2.2 Control Box Displays and Functions

2.2.1 Display and Operating Elements

1 text display, 2 lines each with 16 characters


1 LED, green, “ON”
1 LED, yellow, “Service”
1 LED, red, “Alarm”
1 membrane keypad, 3 keys

2.3 Inputs and Outputs on Controller pcb

2.3.1 Optocoupler Inputs (E1 - E5), Terminals 31 - 40

2.3.2 Live Relay Outputs

Outputs VE1 - VN1 to VE3 - VN3 Terminals 8 - 13

The connections and designations vary, depending on the


filter type, and can be found in the respective control
cabinet circuit diagrams.

2.3.3 Potential free Relay Outputs

Outputs A1 - A15 Messages 1 - 5 (change-over) Terminals 16 - 30

The connections and designations vary, depending on the


filter type, and can be found in the respective control
cabinet circuit diagrams.
3 Operation
3.1 Text Messages

Messages in “Operation” Mode

The green LED lights up when the mains voltage is switched on if the control box Type 2200 is in
the operating mode (“Operation” mode).

Text display after switching on:

“ Boll & Kirch ” Company designation


“ xxxxxxxxxx ” Program number

After a few moments, the parameterised controller type is displayed in the second line:

“ 6.18/6.19/6.44 ” Controller type 0 wiring diagram Z46140


“ 6.23/6.24 ” Controller type 1 wiring diagram Z46141
“ 6.60 ” Controller type 2 wiring diagram Z46142
“ 6.60 Alarm DP ” Controller type 3 wiring diagram Z46142
“ 6.60.07 ” Controller type 4 wiring diagram Z46143
“ 6.60.07 Al. DP ” Controller type 5 wiring diagram Z46143
“ 6.61 ” Controller type 6 wiring diagram Z46144
“ 6.61 Alarm DP ” Controller type 7 wiring diagram Z46144
“ 6.61.07 ” Controller type 8 wiring diagram Z46145
“ 6.61.07 AL. DP ” Controller type 9 wiring diagram Z46145
“ 6.62 ” Controller type 10 wiring diagram Z46146
“ 6.62 Alarm DP ” Controller type 11 wiring diagram Z46146
“ 6.64 ” Controller type 12 wiring diagram Z46147
“ 6.64 Alarm DP ” Controller type 13 wiring diagram Z46147
“ 6.64.07 ” Controller type 14 wiring diagram Z46148
“ 6.64.07 AL. DP ” Controller type 15 wiring diagram Z46148
In “Operation” mode, the following text is displayed:

“ forced fl. 00:01 ” Remaining time until automatic flushing 00 h 01 min


“ C - F - Q ” Key instructions (see below)

Key C: When pressed, displays the number of flushing cycles.


Key F: When pressed, initiates a manual flushing cycle.
Key Q: When pressed, acknowledges alarm messages.

When a flushing cycle is started, the following messages appear in the first line of the display,
depending on the source:

“ Mains flushing ” When flushing is initiated by “Mains voltage ON”


“ Manual flushing ” When flushing is initiated with key F
“ forced flushing ” When flushing is initiated by a back-flushing timer control
“ DP flushing ” When flushing is initiated via differential pressure back-flushing filter

When a flushing cycle is started, the following messages appear in the second line of the display,
depending on the source, e.g.:

“ Flush. time 3S” Remaining flushing time


“ After bl. t. 3S” Remaining after-blowing time

Note: 3S means that the remaining flushing or after-blowing time is 3 seconds.

When key C is pressed, the following message appears on the display:

“ No.of flushes ”
“ XXXXXX cycles ” Number of flushing cycles

The number of flushing cycles is stored and is safe against mains power failure.
3.1.2 Alarm Messages

The red alarm LED comes on with every alarm message.


All alarm messages are stored and are safe against mains power failure.
In the second line of the text display, the alarm message is displayed alternately with the
operating messages every 2 seconds
When key Q is pressed, the alarm messages are deleted, but only on condition that the cause
of the alarm has been remedied. If the alarm condition is not eliminated, the alarm messages
appears again.

Alarm messages on the text display:

At alarm “Motor fault” “ Motor fault “


At “Differential pressure to high Filter 100%” “ DP too high “
At “Differential pressure too high flushing oil conditioning 100%“ “ Cartridge alarm “

When flushing frequency monitoring is switched on:


“DP alarm back-flushing triggered by differential pressure 75%“ ” DP alarm “

3.2 Setting and Operation

3.2.1 Setting Level – Parameter Selection and Viewing

In order to call up setting level “Parameter selection and viewing“, press the keys ∇ and Δ
simultaneously until the green LED goes out (approx. 3 seconds). The upper display line shows the
parameter, the lower line the parameter value. All the parameters can now be displayed in turn by
repeatedly pressing the Δ or ∇ κey.

3.2.2 Setting Level – Parameter Editing and Saving

In order to call up setting level “Parameter editing and saving“, press the middle key until the green
LED starts to flash (approx. 3 seconds). The parameter can now be changed by repeated pressing
of the Δ or ∇ κey. To save the set value and return to the setting level “Parameter selection and
viewing“, press the middle key until the green LED goes out (approx. 3 seconds).

3.2.3 Return to the Operating Level

To return to the operating level, press the keys ∇ and Δ simultaneously until the green LED comes
on (approx. 3 seconds).
3.3 List and Descriptions of Parameters

3.3.1 P0 Filter Type

Variable in increments of 1 Range 0 - 15


Works setting Default value 0

Text display, line 1 “ P0 Filter type ”


Text display, line 2 “ 6.18/6.19/6.44 ”

3.3.2 P1 Multiple Flushing

Note: This parameter is only visible with filter type P0 = 6, 7, 8, 9, 10, 11, 12, 13, 14, 15.

Variable in increments of 1 Range 1 - 99


Works setting Default value 1

Text display, line 1 “ P1 multiple fl. ”


Text display, line 2 “ XXX chambers ”

3.3.3 P2 Timer-controlled Back-flushing

Variable in 1 hour increments Range 0 - 59 h


Works setting Default value 2 h

Text display, line 1 “ P2 forced flush.”


Text display, line 2 “ XXX hours ”

3.3.4 P3 Timer-controlled Back-flushing

Variable in 1 minute increments Range 0 - 59 min


Works setting Default value 0 min

Text display line 1 “ P3 forced flush.”


Text display line 2 “ XXX minutes ”
3.3.5 P4 Back-flushing Time

Note: This parameter is not visible with filter type P0 = 1.

Variable in 1 second increments Range 5 - 100 s


Works setting Default value 20 s

Text display, line 1 “ P4 flushing time ”


Text display, line 2 “ XXX seconds ”

3.3.6 P5 Filling time

Note: This parameter is not visible with filter types P0 = 0 and P0 = 1.

Variable in 10 second increments Range 10 - 600 s


Works setting Default value 180 s

Text display, line 1 “ P5 Filling time ”


Text display, line 2 “ XXX seconds ”

3.3.7 P6 After-blowing Time

Note: This parameter is only visible with filter types P0 = 4, 5, 8, 9, 14, 15.

Variable in 1 second increments Range 5 - 100 s


Works setting Default value 30 s

Text display, line 1 “ P6 After blow t. ”


Text display, line 2 “ XXX seconds ”

3.3.8 P7 Delay Time – Cartridge Alarm

Note: This parameter is only visible with filter types P0 = 4, 5, 8, 9, 14, 15.

Variable in 10 second increments Range 10 - 600 s


Works setting Default value 30s

Text display, line 1 “ P7 Cartridge al. ”


Text display, line 2 “ XXX seconds ”
3.3.9 P8 DP Alarm (Flushing Frequency Monitoring)

Note: This parameter is only visible with filter types P0 = 3, 5, 7, 9, 11, 13, 15.

Variable: ON / OFF
Works setting Default value “ON”

Text display, line 1 “ P8 DP alarm ”


Text display, line 2 “ OFF ”
or
Text display, line 2 “ ON ”

3.3.10 P9 Motor Fault

Note: This parameter is only visible with filter types P0 = 0, 6, 7, 8, 9, 12, 13, 14, 15.

Variable in 0.01 A increments Range 0.10 to 0.99 A


Works setting Default value 0.4 A

Text display, line 1 “ P9 Motor fault ”


Text display, line 2 “ 0000 mA ”

3.3.11 P10 Back-flushing Time

Note: This parameter is only visible with filter type P0 = 1, Type 6.23/6.24.
The parameter is not required with the setting P0 ≠ 1.)

Setting: For ND 32 = 1 / ND 40 = 2 / ND 50 = 3 (ND = Nominal diameter)


A certain control time from a table is assigned, depending on the nominal diameter.

Variable in increments of 1 Range 0 to 2


Works setting Default value ND 32 = 2 s

Text display, line 1 “ P10 flush. time ”


Text display, line 2 “ ND=XX =XX sec ”
3.3.12 P11 Language

The user can choose between English, French, German and Spanish.

Works setting = 0 (German)

Text display, line 1 “ P11 Language ”


Text display, line 2 “ D German ”

3.3.13 P12 Test Code

Note: This parameter is only visible with filter type P0 = 0.

The test code switches the control box to a test mode that is accessible only for authorised
persons.

Variable in increments of 1 Range 0 - 250


Works setting Default value 0

Text display, line 1 “ P12 Testcode ”


Text display, line 2 “ XXX ”
4 Control Procedure, System Functions

4.1 Master Switch – Operating Feedback Contact

When the master switch is in position ON, the contact is closed (made).

4.2 Control Voltage Monitoring

As soon as the master switch is actuated, the mains supply voltage has been switched ON and the
control box is functioning correctly, the green ON LED lights up and the “Control voltage
monitoring” relay is energised. In the event of an operating voltage failure or blown fuse on the
control pcb, no LED comes on and the “Control voltage monitoring” relay is no longer energised.

4.3 Motor Fault

If the measured motor current exceeds the set nominal value for parameter P9, a message
appears on the display and a potential free message is sent to the relay outputs. The motor and
back-flushing are immediately switched off. After remedying the fault, the operator has to cancel
the alarm message by pressing key Q.

4.4 Differential Pressure Too High – Flushing Oil Conditioning – Cartridge Alarm

The signal generator is a pressure switch contact that is connected to the optocoupler input
“Differential pressure indicator DP too high Flushing oil conditioning”. If the condition exists for
longer than the time set with parameter P7, an alarm message appears on the display. After
remedying the fault, the operator has to cancel the alarm message by pressing key Q.

4.5 DP Too High – Back-flushing Filter (100%)

The signal generator is a pressure switch contact that is connected to the optocoupler input
“Differential pressure indicator DP too high Back-flushing filter”. If the condition exists for longer
than 2 seconds, an alarm message appears on the text display and the red alarm LED lights up.
After remedying the fault, the operator has to cancel the alarm message by pressing key Q.

4.6 Key C (Number of Flushing Cycles)

When key C “Number of flushing cycles” is pressed, the number of flushing cycles performed
appears on the display for 3 seconds.

4.7 Multiple Flushing

The parameterised number of chambers is flushed at each flushing command.

4.8 DP Alarm (Flushing Frequency Monitoring)

If a “DP flushing” is activated before expiry of the time set for “Timer-controlled back-flushing” ,
a message appears on the display (yellow LED – Service).
5 Description and Function of the Controllers

5.1 Controller 6.18 / 6.19 / 6.44

Inputs
Pressure switch “DP reached – Back-flushing filter” 75%
Pressure switch “DP too high – Back-flushing filter” 100%

Outputs
Motor
Flushing valve

Potential free contacts


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault, consisting of: Output A4, A5, A6
Alarm “Maximum differential pressure reached” and
Alarm “Motor fault”
3) Alarm “Motor fault” Output A7, A8, A9
4) Message “Flushing active” Output A10, A11, A12

Description of functions
The function of the filter is described in the operating manual.

A flushing cycle is triggered by :


1) The F key
2) Expiry of the automatic flushing time
3) Pressure switch “DP reached – Back-flushing filter”

Points of particular note


All alarms are displayed, signalled via potential free contacts and stored.
If the controller is in parameterisation mode, manual triggering of a flushing cycle will not be
accepted.
If the parameter “Controller type” is changed, the functions are restarted.
5.2 Controllers of Type 6.23 / 6.24

Inputs 6.23 und 6.24


Pressure switch “DP reached – Back-flushing filter” 75%
Pressure switch “DP too high – Back-flushing filter” 100%

Outputs 6.23 and 6.24


Flushing valve

Potential free contacts and messages 6.23 and 6.24


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Alarm “Maximum DP reached” Output A4, A5, A6

Description of functions 6.23 and 6.24


The function of the filter is described in the operating manual.

A flushing cycle is triggered by :


1) The F key
2) Expiry of the automatic flushing time.
3) Pressure switch „DP reached – Back-flushing filter“

Points of particular note


All alarms are displayed, signalled via potential free contacts and stored.
If the controller is in parameterisation mode, manual triggering of a flushing cycle will not be
accepted.
If the parameter “Controller type” is changed, the functions are restarted.

5.3 Controllers of Type 6.60

Inputs 6.60 and 6.60 Alarm DP (Flushing Frequency Monitoring)


Limit switch “Position reached”
Pressure switch “DP reached – Back-flushing filter” 75%
Pressure switch “DP too high – Back-flushing filter” 100%

Additional inputs with 6.60.07 (Flushing oil conditioning)


Pressure switch “DP too high – Flushing oil conditioning” 100%
Outputs 6.60 and 6.60 Alarm DP
Flushing valve
Chamber valve

Additional outputs with 6.60.07 and 6.60.07 Alarm DP


After-blowing valve

Potential free contacts and messages 6.60


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault: Alarm “Maximum differential pressure reached” Output A4, A5, A6

Potential free contacts and messages 6.60 Alarm DP


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault: Alarm “Maximum differential pressure reached” Output A4, A5, A6
3) Alarm “Back-flushing triggered by DP” Output A7, A8, A9

Potential free contacts and messages 6.60.07


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault, consisting of: Output A4, A5, A6
Alarm “Maximum differential pressure reached” and
Alarm “Cartridge” (DP alarm – Flushing oil conditioning)

Potential free contacts and messages 6.60.07 Alarm DP


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault, consisting of: Output A4, A5, A6
Alarm “Maximum differential pressure reached” and
Alarm “Cartridge” (DP alarm – Flushing oil conditioning)
3) Alarm “Back-flushing triggered by DP” Output A7, A8, A9

Description of functions 6.60


The function of the filter is described in the operating manual.

A flushing cycle is triggered by :


1) Switching on the mains voltage supply
2) The F key
3) Expiry of the automatic flushing time.
4) Pressure switch “DP reached – Back-flushing filter”
Additional functions with 6.60 Alarm DP (Flushing frequency monitoring)
If a flushing cycle is triggered via the pressure switch “DP reached – Back-flushing filter” before
expiry of the automatic flushing time, a DP alarm will be triggered (flushing frequency alarm).

Points of particular note


All alarms are displayed, signalled via potential free contacts and stored.
If the controller is in parameterisation mode, manual triggering of a flushing cycle will not be
accepted.
If the parameter “Controller type” is changed, the functions are restarted.

5.4 Controllers of Type 6.61

Inputs 6.61 and 6.61 Alarm DP (Flushing frequency monitoring)


Limit switch “Position reached”
Pressure switch “DP reached – Back-flushing filter” 75%
Pressure switch “DP too high – Back-flushing filter” 100%

Additional inputs with 6.61.07 and 6.61.07 Alarm DP (Flushing oil conditioning)
Pressure switch
DP too high – Flushing oil conditioning 100%

Outputs 6.61 and 6.61 Alarm DP


Flushing valve
Motor

Additional outputs with 6.61.07 and 6.61.07 Alarm DP


After-blowing valve

Potential free contacts and messages 6.61


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault, consisting of: Output A4, A5, A6
Alarm “Maximum differential pressure reached” and
Alarm “Motor fault”
Potential free contacts and messages 6.61 Alarm DP
1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault, consisting of: Output A4, A5, A6
Alarm “Maximum differential pressure reached” and
Alarm “Motor fault”
3) Alarm “Back-flushing triggered by DP“ Output A7, A8, A9

Potential free contacts and messages 6.61.07


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault, consisting of: Output A4, A5, A6
Alarm “Maximum differential pressure reached” and
Alarm “Motor fault” and
Alarm “Cartridge” (DP alarm – Flushing oil conditioning)

Potential free contacts and messages 6.61.07 Alarm DP


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault, consisting of: Output A4, A5, A6
Alarm “Maximum differential pressure reached” and
Alarm “Motor fault” and
Alarm “Cartridge” (DP alarm – Flushing oil conditioning)
3) Alarm “Back-flushing triggered by DP“ Output A7, A8, A9

Description of functions 6.61


The function of the filter is described in the operating manual.

A flushing cycle is triggered by :


1) Switching on the mains supply voltage.
2) The F key.
3) Expiry of the automatic flushing time.
4) Pressure switch “DP reached – Back-flushing filter”.

Points of particular note


In the case of flushing by switching on the mains supply voltage and with the limit switch open,
a flushing cycle starts directly with the flushing valve.
If the controller is in parameterisation mode, manual triggering of a flushing cycle will not be
accepted.
If the parameter “Controller type” is changed, the functions are restarted.
5.5 Controllers of Type 6.62

Inputs 6.62
Limit switch “Position reached”
Pressure switch “DP reached – Back-flushing filter” 75%
Pressure switch “DP too high – Back-flushing filter” 100%

Outputs 6.62
Flushing valve
Chamber valve cycled

Potential free contacts and messages 6.62


1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault: Alarm “Max differential pressure reached” Output A4, A5, A6

Potential free contacts and messages 6.62 Alarm DP (Flushing frequency monitoring)
1) Alarm “Control voltage monitoring” Output A1, A2, A3
2) Group fault: Alarm “Max differential pressure reached” Output A4, A5, A6
3) Alarm “Back-flushing triggered by DP” Output A7, A8, A9

Description of functions
The function of the filter is described in the operating manual.

A flushing cycle is triggered by :


1) Switching on the mains supply voltage.
2) The F key.
3) Expiry of the automatic flushing time.
4) Pressure switch “DP reached – Back-flushing filter”.

Points of particular note


In the case of flushing by switching on the mains supply voltage and with the limit switch open,
a flushing cycle starts directly with the flushing valve.
If the controller is in parameterisation mode, manual triggering of a flushing cycle will not be
accepted.
If the parameter “Controller type” is changed, the functions are restarted.
5.6 Controllers of Type 6.64

The controller type has the same function as the controller types 6.61 , 6.61 Alarm DP, 6.61.07 and
6.61.07 Alarm DP.

Points of particular note


A relief valve is connected in parallel with the flushing valve.

Additional output
Relief valve
10. Servicing

Even automatic filters require inspection and servicing at regular intervals. It is to


be noted in particular that despite regular back-flushing the filter mesh can
become clogged in the course of time, depending on the quality of the medium
and the by-pass cleaning available. Contamination on the mesh can be removed
by cleaning the candle element manually using an appropriate solvent (see
Section 13). An increase in the clogging on the mesh can be inferred from the
progressively shorter intervals between back-flushing cycles. The number of back-
flushing cycles can be seen on the "Flushing Cycle Counter" respectively display
on the switch box.

To maintain trouble-free operation the following points are to be noted:


a) All connections are to be regularly checked for leaks.
b) Candle elements are to be dismantled and inspected initially after 500
flushing cycles, then after 5.000 and later every 10.000 flushing cycles. If,
however, a sharp reduction in the intervals between back-flushing cycles
should occur, inspection and cleaning should be carried out sooner. If
sudden lengthening of the intervals between back-flushing cycles should
occur all candle elements must be inspected without fail for damage.

Before the cartridge elements are dismantled, the automatic filter


must be completely drained by automatic back-flushing (i.e. all
filter chambers). "Manual" activation on the control box. Care must
be taken to ensure that the liquid level is below the cartridge
element before the element is dismantled.

The candles are subjected to wear through reciprocal loading. It is


therefore recommended that a complete candle filter element, the
number of candle elements depending on the size of the filter, be
kept in stock.
It is expedient to renew all seals when overhauling the filter.

Check the sludge discharge for leaks every 10.000 flushing cycles.
No medium should run from the end of the sludge discharge line
during the filtration phase (except during the flushing cycle).

10.1 You must close the compressed air supply valve (item 127), then starting a
manual back flushing, before you are allowed to removed the manometer
(item 72). This well ensure that the compressed air reservoir (item 13) is
pressure released.
12. Candle Element Cleaning Agent "BOLL CLEAN 2000"

The choice of cleaning medium depends on the type of the contamination. With
fuels precipitation of paraffin and asphalt or with lubricating oils mixing of different
types of oil can form solid encrustations on the mesh. Effective cleaning of fine
meshes is achieved by soaking in "BOLL CLEAN 2000" followed by blasting with
compressed air using a cleaning gun.

PRODUCT DESCRIPTION:
BOLL CLEAN 2000 is a fluid cleaning and degreasing agent with a wide range of
application. It can be used for practically all cleaning and degreasing purposes.
BOLL CLEAN 2000 cleans rapidly, thoroughly and extremely economically.
Use of BOLL CLEAN 2000 renders safety precautions superfluous.
BOLL CLEAN 2000 has these outstanding characteristics without exhibiting the
disadvantages of solvent cleaners

BOLL CLEAN 2000 is non-flammable


does not require special marking
does not have an irritating odour
is not caustic
is physiologically unobjectionable
is biologically degradable
is registered with the Federal Office
for the Environment, Reg.-No. 04860019

BOLL CLEAN 2000 can be undercooled or overheated during storage but remains
fully usable when returned to normal temperature.

MESH CONTAMINATED WITH HEAVY OIL:


Elements contaminated with heavy oil must be soaked in a standard commercial
solvent. After soaking the elements are cleaned in the BOLL & KIRCH Type 5.04
Cleaning Device using BOLL CLEAN 2000 and high pressure pump.
INSTRUCTIONS FOR USE:
Use of BOLL CLEAN 2000 is not restricted to a particular method of cleaning.
Depending on the operating conditions, BOLL CLEAN 2000 can be used in a dip
bath, in a spraying plant, in steam jetting or in manual application using a cloth,
brush or sponge. It can be used warm or cold. BOLL CLEAN 2000 is miscible with
water - even seawater.
Concentration for mesh cleaning: 1 : 2,5
Temperature: up to a maximum of 60 °C
The concentration depends on the type and thickness of the adhesive substance
to be removed. When used in concentration below 1 : 30 rinsing is usually not
required.
No visible film remains on the surface.
13. Manual Cleaning of the Candle Filter Elements

Before the cartridge elements are dismantled, the automatic filter


must be completely drained by automatic back-flushing (i.e. all
filter chambers). "Manual" activation on the control box. Care must
be taken to ensure that the liquid level is below the cartridge
element before the element is dismantled.

13.1 Remove the whole filter element assembly. Then soak the filter element assembly,
with the opening of the candle elements facing down, in a suitable tank filled with
solvent. Detached contaminants can then sink downwards out of the candle.

13.2 The soaking time and the relevant solvents are:


a) In cold BOLL CLEAN 2000 cleaner the maximum soaking time is 24 hours.
b) In Filterclean (Vecom) the maximum soaking time is 12 hours.
c) In Reiniger B85 (Vecom) the maximum soaking time is 12 hours.
d) In gas oil the maximum soaking time is 48 hours.

13.3 After soaking remove the whole filter element assembly from the tank and place it
on a suitable stand (e.g. perforated sheet metal) with the candle element opening
pointing down and allow the solvent to drain.

13.4 Now with the cleaning gun supplied blow compressed air through the candles from
the inside to the outside.

13.5 After this procedure the complete filter element assembly should be immersed in
fresh cleaner, with the candle element opening downwards, and rinsed through
with an up and down motion.
The washing procedure described in Section 13.5 should only be
carried out in a separate tank using clean solvent. The solvent can
then be used again for the next soaking procedure.

13.6 Allow the element assembly to drain again and dry it by blowing compressed air
through it again from the outside to the inside. The manual cleaning procedure
described here has produced adequate results (ca. 60 % clean) in similar
applications.

13.7 Almost 100 % cleaning is only possible manually, in our experience, by using the
Type 5.04 High Pressure Cleaning Unit with BOLL CLEAN 2000.
See the separate description "Filter Cleaning Unit Type 5.04".
14. Maintenance instructions ( bypass filter )

Take the bypass filter out of operation before carrying out


maintenance work on it!

To remove the screen insert, proceed as follows:

1. Slacken venting screw (item 332) of the cover retaining arrangement and in this
way check that the filter housing is not pressurized.

2. Unscrew the venting screw until the cover panel (item 335) over the concealed
cover screws (item 323) can be swivelled.

3. Remove cover (item 306) after slackening the cover screws and pull screen insert
out of the filter housing.

4. Clean screen insert with suitable solvents (see KV349) and then blow through with
compressed air from the inside to the outside.

5. Check seals and replace any damaged seals.

6. Assemble filter in the reverse order.


DOCUMENTATION PARTS LIST Date 17.02.06
Page 1
Document Description
0639320 automatic filter combination
6.60.1 Gr.05 DN50

Material EN-JS1030
EN-GJS-400-15
EN 1563
Assembly Z32522+Z31214
Dimension drawing Z32570

Filter room:
max. allowable pressure : 16 bar
max. allowable temperature : 160°C
Heating room:
max. allowable pressure: 14 bar
max. allowable temperature : 200°C
Test pressure : 2 x Calculation pressure

------------------------------------------------------------------------------------
Item ID no. Description Qty Unit
------------------------------------------------------------------------------------
00001 6530355 housing lower part 1 pcs.
00002 6530354 change-over housing 1 pcs.
00003 6537759 filter chamber 2 pcs.
00003 2000004 stud bolt 4 pcs.
00004 6335469 cock plug 1 pcs.
00005 5007847 candle support 2 pcs.
00006 1104422 filter candle according to order 16 pcs.
00007 5906594 cover 2 pcs.
00007 5218298 nozzle 2 pcs.
00007 6712641 bow 2 pcs.
00007 2000266 slotted cheese head screw 4 pcs.
00008 2610023 float 2 pcs.
00008 2611123 pin 2 pcs.
00008 3530032 threaded pipe fitting 2 pcs.
00009 6530356 cover switchover housing 1 pcs.
00011 6530357 heating chamber 1 pcs.
00012 5000011 counter flange 1 pcs.
00013 6533516 air reservoir 1 pcs.
00014 5229568 valve housing 1 pcs.
00015 5000486 valve ram 1 pcs.
00016 5005528 valve face 1 pcs.
00017 5005609 housing 1 pcs.
00018 5006510 valve cover 1 pcs.
00019 5007512 disc 1 pcs.
00020 5006512 valve ram 1 pcs.
00021 5700156 distance piece 1 pcs.
00022 5701532 rectangular tube 1 pcs.
00022 2300011 Spring Type Straight Pin 1 pcs.
00022 5701533 square bar steel 1 pcs.
00023 5700158 mounting sheet 1 pcs.
00025 4101224 isolation plate 1 pcs.
00030 3030066 o-ring 3 pcs.
00031 3030661 o-ring 2 pcs.
00032 3030761 o-ring 2 pcs.
00033 3132369 o-ring 2 pcs.
................................................................................
DOCUMENTATION PARTS LIST Date 17.02.06
Page 2
0639320 automatic filter combination
6.60.1 Gr.05 DN50
------------------------------------------------------------------------------------
Item ID no. Description Qty Unit
------------------------------------------------------------------------------------
00034 3038188 o-ring 3 pcs.
00035 3096894 o-ring 2 pcs.
00036 3096995 o-ring 1 pcs.
00037 3030063 o-ring 1 pcs.
00038 3094563 o-ring 2 pcs.
00039 3380001 high pressure gasket 3 pcs.
00040 2785451 seal piston 1 pcs.
00041 3038126 o-ring 1 pcs.
00042 3098361 o-ring 2 pcs.
00043 3038361 o-ring 1 pcs.
00044 3380049 high pressure gasket 1 pcs.
00045 3430001 double grooved ring 1 pcs.
00050 2800062 square counter flange 3 pcs.
00052 3380199 flat gasket 1 pcs.
00053 3040224 o-ring 4 pcs.
00055 4500016 double piston slewing gear 1 pcs.
00056 2656655 solenoid valve 1 pcs.
00056 4206553 coil 1 pcs.
00056 4105912 connector plug 1 pcs.
00056 2614072 sound absorber 1 pcs.
00057 4200143 limit switch 1 pcs.
00058 2708947 deep groove ball bearing 1 pcs.
00059 2307427 pressure spring 1 pcs.
00060 2656655 solenoid valve 1 pcs.
00060 4206553 coil 1 pcs.
00060 4105912 connector plug 1 pcs.
00060 2614072 sound absorber 1 pcs.
00063 5950196 connection box 1 pcs.
00064 8450198 cover for connection box 1 pcs.
00065 4105616 clamp 0 pcs.
00065 4105617 clamp 0 pcs.
00065 4100015 distance plate 0 pcs.
00066 2000258 slotted cheese head screw 0 pcs.
00067 4105805 mounting rail 0 pcs.
00069 4160350 cable gland 0 pcs.
00069 4160349 reducing ring 0 pcs.
00069 4100104 cable gland 0 pcs.
00069 4870017 plug 0 pcs.
00070 2650017 high pressure control device 1 pcs.
00071 2660005 safety valve 1 pcs.
00072 2602689 pressure gauge 1 pcs.
00073 9902572 DPI acc. to order 1 pcs.
00075 2560063 angle ball valve 2 pcs.
00076 2200235 spring ring 4 pcs.
00077 2002155 hexagon socket head cap screw 2 pcs.
00078 2002155 hexagon socket head cap screw 2 pcs.
00079 2000121 hexagon socket head cap screw 2 pcs.
00080 2000482 stud bolt 4 pcs.
00080 2100011 hexagon nut 4 pcs.
00081 2010326 hexagon socket head cap screw 4 pcs.
00082 2000132 hexagon socket head cap screw 4 pcs.
00083 2000122 hexagon socket head cap screw 4 pcs.
................................................................................
DOCUMENTATION PARTS LIST Date 17.02.06
Page 3
0639320 automatic filter combination
6.60.1 Gr.05 DN50
------------------------------------------------------------------------------------
Item ID no. Description Qty Unit
------------------------------------------------------------------------------------
00084 2010108 hexagon socket head cap screw 8 pcs.
00085 2100006 hexagon nut 4 pcs.
00086 2009095 stud bolt 4 pcs.
00087 2000036 hexagon screw 8 pcs.
00088 2000122 hexagon socket head cap screw 4 pcs.
00089 2010310 hexagon socket head cap screw 3 pcs.
00090 2010329 hexagon socket head cap screw 2 pcs.
00091 2010321 hexagon socket head cap screw 4 pcs.
00092 2000122 hexagon socket head cap screw 2 pcs.
00093 2000131 hexagon socket head cap screw 2 pcs.
00094 2000261 slotted cheese head screw 0 pcs.
00095 2000001 stud bolt 4 pcs.
00096 2000132 hexagon socket head cap screw 1 pcs.
00097 2209969 spring ring 1 pcs.
00098 2004354 stud bolt 1 pcs.
00099 2100047 hexagon nut 4 pcs.
00100 2100006 hexagon nut 8 pcs.
00101 2100006 hexagon nut 4 pcs.
00102 2003587 threaded flange screw 4 pcs.
00103 2100004 hexagon nut 4 pcs.
00104 2110593 hexagon nut 1 pcs.
00105 2004715 hexagon screw 1 pcs.
00106 5006107 disc 1 pcs.
00107 2200007 disc 1 pcs.
00108 5000243 ring 1 pcs.
00109 2200005 disc 2 pcs.
00110 2001578 headless screw 1 pcs.
00111 2209799 spring ring 4 pcs.
00112 2614171 sound absorber 5 pcs.
00113 2100003 hexagon nut 2 pcs.
00114 2608775 non return valve 1 pcs.
00115 2500024 screwing 1 pcs.
00116 2500025 screwing 2 pcs.
00116 2500025 screwing 6 pcs.
00117 2505496 screwing 1 pcs.
00118 2500029 screwing 2 pcs.
00119 2507461 screwing 1 pcs.
00121 2508115 screwing 2 pcs.
00123 2507808 screwing 1 pcs.
00124 2001772 screwed sealing plug 1 pcs.
00124 3275525 gasket 1 pcs.
00125 2000186 screwed sealing plug 1 pcs.
00125 3270001 gasket 1 pcs.
00126 2500083 screwed socket 2 pcs.
00127 2560356 angle ball valve 1 pcs.
00128 0602645 tubing set 1 pcs.
00130 9401690 type plate 1 pcs.
00131 9407569 label: "in / out" 1 pcs.
00131 9400997 label: "on / off" 1 pcs.
00131 9407396 label: "mud drain" 1 pcs.
00131 9402898 label 1 pcs.
00131 9405704 label: " ... 2 lugs ... " 1 pcs.
................................................................................
DOCUMENTATION PARTS LIST Date 17.02.06
Page 4
0639320 automatic filter combination
6.60.1 Gr.05 DN50
------------------------------------------------------------------------------------
Item ID no. Description Qty Unit
------------------------------------------------------------------------------------
00131 9403614 label: "compressed air connection" 1 pcs.
00131 9404642 label: "Delta P differential pressure 1 pcs.
00140 4300000 control box according to order 1 pcs.
00150 6705030 key 1 pcs.
00150 6705032 key for unscrewing the filter element 1 pcs.
00150 5700721 guiding bolt 2 pcs.
00300 6235819 cock casing 1 pcs.
00301 6329196 cock plug 1 pcs.
00303 6406236 cover 1 pcs.
00304 8650098 key 1 pcs.
00305 6436188 housing 1 pcs.
00306 6432960 cover 1 pcs.
00307 6532077 heating chamber 1 pcs.
00308 1174632 pleated filter element 1 pcs.
00310 3031222 o-ring 1 pcs.
00311 3034299 o-ring 1 pcs.
00313 3421241 tec-ring 1 pcs.
00314 3031525 o-ring 2 pcs.
00315 3270002 gasket 1 pcs.
00316 3270006 gasket 1 pcs.
00317 3380001 high pressure gasket 4 pcs.
00318 3380049 high pressure gasket 1 pcs.
00320 2307145 quick fixing device 1 pcs.
00322 2010327 hexagon socket head cap screw 2 pcs.
00323 2000143 hexagon socket head cap screw 6 pcs.
00325 2000004 stud bolt 16 pcs.
00326 2000004 stud bolt 8 pcs.
00327 2000001 stud bolt 4 pcs.
00328 2004354 stud bolt 2 pcs.
00330 2100006 hexagon nut 16 pcs.
00331 2100004 hexagon nut 4 pcs.
00332 5215002 screw for air escape 1 pcs.
00333 2000191 screwed sealing plug 1 pcs.
00334 5000011 counter flange 1 pcs.
00335 6706685 tab washer 1 pcs.
00336 3039056 o-ring 1 pcs.
00337 9401114 label: "cock position" 1 pcs.
00338 9400220 label 1 pcs.
00340 6709832 holding device 1 pcs.
00341 2010320 hexagon socket head cap screw 2 pcs.
00342 2200007 disc 2 pcs.
00350 9902572 DPI acc. to order 1 pcs.
00351 2000121 hexagon socket head cap screw 2 pcs.
00352 2000123 hexagon socket head cap screw 2 pcs.
00353 2100003 hexagon nut 2 pcs.
00354 5700108 mounting 1 pcs.
00355 2500008 angle 2 pcs.
00356 2500025 screwing 2 pcs.
00357 2500083 screwed socket 2 pcs.
00358 2560770 ball cock 2 pcs.
00359 2500024 screwing 2 pcs.

Überarbeitet am : 25.06.04
Überarbeitet von : Bogda
Bei Service- und Ersatzteilbedarf wenden Sie sich bitte an das Stammhaus oder an unsere Niederlassungen, Vertretungen oder Service-Stellen.
If you need service or spares for our products please contact our head office or our branch-offices, agencies or service-stations.

Europa / Europe
Deutschland/Germany
Zentrale / Headquarters

BOLL & KIRCH Filterbau GmbH Cyprus


Postfach 1420, 50143 Kerpen M.I.E. Services Ltd.
Siemensstr. 10-14, D-50170 Kerpen The Hawk Building
Tel.: +49/2273/562-0 124 Gladstonos Street
Fax.: +49/2273/562-223 CY-3032 Limassol
E-Mail: info@bollfilter.de Tel.: +357/25889999
Fax.: +357/25345639
BOLL & KIRCH Filterbau GmbH E-mail: info@mieserv.cy.net
Geschäftsstelle Nord
An der Strusbek 34 Denmark/Sweden/Norway/Iceland
22926 D-Ahrensburg Finland/Lithuania/Latvia/Estonia
Tel.: +49/4102/4740-0 BOLLFILTER Nordic
Fax.: +49/4102/4740-22 Hammerbakken 21
E-Mail: ursula.bauer@bollfilter.de DK - 3460 BirkerØd
Tel.: +45/ 45/ 42 12 00
IVG Pumpen- und Filtrationstechnik Gera Fax.: +45/ 45/ 42 12 99
Prehlis 13 A E-mail: info@bollfilter.dk
D-07552 Gera
Tel.: +49/365/42 00 07 4 Greece / Bulgaria
Fax.: +49/365/42 00 07 5 FILTERKON
E-Mail: ivg-neubert@superkabel.de 8, Mitsaion Str.
GR - 117 42 Athen
BOLL & KIRCH Filterbau GmbH Tel.: +30/210/9217671
Geschäftsstelle Süd Fax.: +30/210/9242242
Rangaustraße 7 a E-Mail: filterko@otenet.gr
D-91639 Wolframs-Eschenbach
Tel.: +49/9875/884 (Herr Henkelmann) Italy
Tel.: +49/9875/971865 (Herr Pirkl) DeCoSta S.R.L.
Fax.: +49/9875/885 Via Bicetti de Buttinoni, 12
E-Mail: norbert.henkelmann@bollfilter.de I-20156 Milano
Tel.: +39-02-38 00 52 83
Austria/Czech.Rep./ Fax.: +39-02-38 00 36 31
Rep. of Slovakia/Slovenia E-Mail: sales@decosta.it
Schmachtl GmbH
Pummererstraße 36 Netherlands
A - 4021 Linz Lubrafil B.V.
Tel.: +43/732/76 46 0 Aalborg 2
Fax.: +43/732/78 50 36 NL - 2993 LP Barendrecht
E-Mail: g.oehler@schmachtl.at Tel.: +31/180/556255
Fax.: +31/180/556265
Belgium/Luxembourg E-mail: lubrafil@lubrafil.nl
AUXIMECA N.V.
Wijtschotbaan 3/3 Russia / Ukraine / Belorussia
B - 2900 Schoten Dr. Alexej Simakov
Tel.: +32/3/646.6.180 P.O. Box 133
Fax.: +32/3/646.9.398 RUS - 198262 St. Petersburg
E-mail: info@auximeca.be Tel. + Fax.: +7/812/756-07-47
E-Mail: simakov@rol.ru
Croatia
Marine Trade d.o.o.
Vladimira Nazora 6
HR-47000 Karlovac, Kroatien
Tel.: +385-47-61 13 65
Fax.: +385-47-61 42 81
E-Mail: marine-trade@ka.t-com.hr

Verkaufsbüro Lager Service PC003-99 / Bl. 1 / 2


Agency Stockist Service Stand: 01.09.2006
Spain/Portugal India
Bollfilter España S.L. A.K. Dutta
Zona Cami Ral IND - Navi Mumbay 400614
Paseo del Ferrocarril, 339 3-2 Tel.: +91/222/75 60 147
E - 08860 Castelldefels Fax.: +91/222/75 60 146
Tel.: +34- 93-634 26 80 E-mail: akdutta123@vsnl.net
Fax.: +34-93-665 22 79
E-mail: carlos.martinez@bollfilter.es Japan
Bollfilter Japan Ltd.
Switzerland/Liechtenstein/Poland Japan / Kobe, 651-0085
Equipement Industriel Genève S.A. Tel.: +81/78/242 8550
120 Route de Frontenex Fax.: +81/78/242 8515
CH - 1208 Genève E-mail: info@bollfilter.jp
Tel.: +41/22/73 59 50 0
Fax.: +41/22/78 66 17 1 Singapore / Malaysia / Indonesia
E-Mail: info@eig-sa.ch MNM Corporation Pte. Ltd.
SGP - Singapore 629021
Turkey Tel.: +65/6/86 14 22 2
Ares Ltd. Fax.: +65/6/86 24 22 2
DES Sanayi Sitesi E-Mail: mnmcorp@singnet.com.sg
117.Sokak C24 Blok
81260 Y.Dudullu / Istanbul South Korea
Tel: + 90 (0) 216 4996252 Pbx Blohm & Voss (Korea) Ltd.
Fax: + 90 (0) 216 4996276 ROK - Pusan / Korea
E-Mail: sami.uygurer@aresmakina.com Tel.: +82/51/74 05 70 1
Fax.: +82/51/74 05 70 4
U.K. and Ireland E-Mail: bvkorea@kornet.net
BOLLFILTER UK LTD
Commerce Park, Whitehall Road United Arabian Emirates
GB - Colchester, Essex C02 8HX Middle East
Tel.: +44-120679 22 34 M/S Safe Technical Supply Co. L.L.C.
Fax.: +44-1206-79 30 04 P.O. Box 4832
E-Mail: sales@bollfilter.co.uk Dubai
Tel.: +971-4-3243240
Amerika / America Fax.: +971-4-3243786
BOLL FILTER CORPORATION E-Mail: info@safetech.ae
USA - Plymouth, MI 48170
Tel.: +1 -734-451-4680 Australien / Australia
Fax.: +1 -734-451-4681 Peacock & Smith Pty Ltd.
E-Mail: latorre@bollfilterusa.com AUS - Kensington Vic. 3031
Tel.: +61/39/37 64 49 9
Motor-Services Hugo Stamp, Inc. Fax.: +61/39/37 62 16 5
USA - Ft. Lauderdale, Florida 33315 E-Mail: filters@peacocks-aus.com
Tel.: +1 (954) 763-3660
Fax.: +1 (954) 763-2872 Afrika / Africa
South Africa
Brazil Afrifil Industrial Filters (Pty) Ltd.
Petersen Matex Ltd. ZA - Isando, 1600
BR - 20093-900-Rio de Janeiro Tel.: +27/11/452 5444
Tel.: +55/21/2211-5050 Fax.: +27/11/609 9535
Fax.: +55/21/2518-2220 E-Mail: sales@afrifil.co.za
E-Mail: Max.Herrmann@pml.com.br

Asien / Asia
Hongkong/P.R. of China/Macao
BVI Marine Systems Ltd.
HK - Hong Kong SAR
Tel.: +852-3181 7830
Fax.: +852-2541 2171
E-mail: info@bvi-marine.com.hk
PC003-99 / Bl. 2 / 2
Stand: 01.09.2006
industry controller KFM 92 / KFM 93 B 9200 E
operating instructions Page 1 of 8

1
1 Digital display actual value
2 2nd digital display (if aktive) 3
2
3 LED-display relais function
4 Key for setpoint and parameter mode
5 Setpoint adjustment 6
6 Parameter mode lock switch (back face)
4 5

DIN-certificate: TR (TW) 949 ..

Brief description:
KFM 92 is a microprozessor based industry controller series in panel mounting- format 96 x 96 mm.
Design and operating elements are especially devised for easy and convenient handling and operation.
An assembly system renders possible the simple basic version as well as a plurality of variants with
up to 8 relays, several digital and analog out- and inputs and other additional devices.

Types: Inputs:
(depending on configuration*): type: max. 4 measuring inputs, type suffix
indicator 9201. acc. to sub-type:
one stage controller 9210. Pt100 DIN, 0...400°C none (or 0)
two stage controller 9220. Pt100 DIN, 0...100°C 1.
heating / cooling controller 9230. thermo couple Ni Cr NI (type K)0...1200°C n.
positioner / follow-up controller 9240. thermo couple Fe Cu NI (type J)0... 900°C f.
two- point- PID controller 9250. thermo couple Pt Rh Pt (type S)0...1700°C p.
three- point- PID controller 9260. feedback device 0...100 up to 1000 Ω w.
three- point- step controller 9270. standard signal 0(4)...20mA, 0(2)...10V e.
continuous controller 9280. combined input Pt100 / standard signal q.
continuous controller, 2 outputs 9281. Ranges:
Sub-types: suffix (*) Pt 100: 0...400°C, switchable to °F, optional: other
basic function .0 ranges; for standard signal range adjustable -999 to
basic function + 1 additional contact .1 4000. Setpoint ranges can be limited by menu
basic function + 2 additional contacts .2 Displays:
2 x basic function .3 2 four- figured digital displays, decimal point
extension: logik output ..L adjustable, upper display: actual value, lower
function extensions suffix (*) display: other selectable data,
cascade controller 991k up to 8 LEDs for relays function display.
program controller 991p Display of function:
ramp set point value 991r Hold down the P-key for more than 5 sec
step controller 991t to get a short-cut message of the configured function on
the display (=position 3-5 of list number)
Additional devices: (*) (in case of locked parameter mode only ).
additional analog inputs (99) a Measuring line monitoring:
external set value incl. switch-over (99) bwa Display "Err 1...4" in case of measuring line fault
second set value incl. switch-over (99) bwz and adjustable safety shut down of all outputs
binary input to switch special functions (99) b..
additional switching contacts (99) f.. Outputs:
analog signal outputs (99) o. up to 8 relays with potential free change over switch,
serial interface RS 232/485 (99) s. as control outputs or as additional contacts,
interface Profibus, Interbus S, other (99) sp/si. capacity: 250V 2A,
incl. spark extinction (for normally open contacts)
* In case of more than 1 extension there is at the 1-2 continuous outputs 0/4...20mA, 0/2...10V as
data plate only once '99' , f.e. 92700-99aw-ogx-rü. control or signal outputs(apparent ohmic load 500 Ω)
For more information see corresponding data sheets.'
data subjects to alteration 9200e1.doc / 0510208
Industry controller type KFM 9... B 9... E
Installation and connection Page 2 of 8

Installation:
Before installation inspect the controller for any visible signs of damage caused during transport
Check power supply acc. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the
fastening devices supplied.

Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following the
wiring diagram; wire cross section max. 1,5 mm2
- To avoid cross interference all low voltage measuring lines and pilot wires must be encased
in a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally to protect the output relays.
- Phase wire and neutral wire must not be transposed.

Putting into operation:


Switch on power supply. Digital display and control lamps will light up according to
the setpoint after some seconds. If nothing happens check the fine-wire fuse on the back panel
of the controller and the electrical wiring. Adjust set value and check other adjustments.

Maintenance:
All electronic controllers in the KFM range are virtually maintenance-free. Provided that the
controller is correctly installed and put into operation and is protected against mechanical
damage and inadmissible operating conditions, it should give years of trouble-free service.
In case of faults repair work by the customer should be restricted to the externally accessible
leads and connections and components the customer is expressly permitted to deal with himself.
(bridge circuits, fuses).

All further work, especially on internal components will terminate warranty, makes subsequent
inspection and fault repair more difficult and can cause considerable damage to the circuitry.

For repair remittance remove plug board with connected leads on the rear side,
loosen fastening devices and remove controller from the panel.

In case of remittance please give precise details of the fault to reduce time and cost of repair.

Error messages:
Err 1...6 Fault on measuring input nr. ...
check measuring lines for short circuit or breakage
check measuring input by connecting a RTD
Err 55 Fault on loading the parameter;
press any key, the controller starts in emergency operation mode,
configuration of the parameters has to be checked
Err 50 Hardware error in program section
Err 52 Hardware error in data section
no further operation possible, remit controller for repair

Error messages during self adaptation:


Err 202 Ambient conditions are not suitable for self adaptation;
adjust parameter manually
Err 205 routine exceeded the setpoint
raise setpoint or lower actual value and start adaptation again
Err 206 Fault on measuring input during adaptation;
check the wiring and start adaptation again

data subjects to alteration 9_E2.DOC /0010803


Industry controller type KFM 9... B 9... E
Operation Page 3 of 8

Operating status:

The upper display shows the actual value (channel / measuring input 1),
the lower display remains empty or (depending on the version and settings) shows
- the attendant unit of measure (°C, °F, %...)
- an additional actual value, the setpoint value or the controller output value Y
- or the additional actual value only when the key is pressed.
Alternative type:
switch over the upper display to the several actual values by pressing the key,,
the lower display shows the number of the attendant measuring input.

Setpoint value setting:

press - key shortly (do not hold down)

The upper display shows the abbreviation of


the activated setpoint adjustment mode,
the lower display shows the adjusted value.

The indicated value can now be changed by the (lower) and (higher) -keys..
Each variation of the set value is immediately active, without any more operating steps.
The arrow keys have a built-in accelerator mode:
longer pressing causes faster alterations.

Return to operating level:


Press - key shortly (or automatically after 30 seconds without any key-action)

optional: Press - key shortly again: *SP =set values of further control loops (*=no.) /
SP* =further set values of the control loop / SPE =external setpoint (display mode only);
flashing display signifies that the function is not active at the moment.

Manual operation: (optional)

Hold down - key and press - key, then release both keys..
(optional: switch on and off using separate - key)
(for multi-channel controllers first enter the channel number*,
and press - key, then:)

The lower diplay shows „H *“ and - if activated - the output position.


The upper display still shows the actual value. The automatic control is interrupted.

Manual control is now possible using the ... - keys..

Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)

optional: starting the self adaptation (ref. to chapter Optimization):


On manual operation level - key >5 sec ;
the lower display indicates „-Ad-“.
Cancel: - key >5 sec again

data subjects to alteration 9_E2.DOC /0010803


Industry controller type KFM 9... B 9... E
Parameter level Page 4 of 8

Access from operating level.

Unlock the access first:


Turn the switch on the rear panel of the controller to position „U“ = unlocked
(Lock access after the adjustments: Switch position to „L“ = locked).

After the parameter level (refer to the instructions to each level ) has been invoked,
the first setting is shown and can be modified.

It is not possible to invoke the parameter level when the switch is locked .
In this case the display shows the abbreviation of the configured controller type.

Confirm the entry and / or move on to next parameter:


press the -key briefly

Settings in detail:
(not available on all types)

Level 1: Invoke: Hold down the - key for more than 5 sec.
until the display changes factory setting: notes:

CH channel selection (no.) for multi-channel controller (only)


*P proportional range Xp (%) (ref. to chapter „Optimization“) 25,0 ___
*I integral action time Tn (min) (ref. to chapter „Optimization“) 7,0 ___
*d rate time Tv (min) (ref. to chapter „Optimization“) 0,2 ___
*Sh sensitivity of response Xsh (%) 0,1 ___
*SA.. switching interval (absolut value) for following (additional) contact no... 5,0* ___
SP.. set point for independent additional contact no... 0,0 ___
*Sd.. switching difference for additional contact no... 3,0 ___
(*201,701/SA3:10,0)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)

Level 2: Invoke: Hold down - key and press - key,


y,
hold down both keys for more than 5 sec. until display changes.
Unit switch-over the displayunit (°C / °F) C ___
*bLo/*bHI start / end of display range for voltage- / current -input (only) # ___
*ELo/*EHI start / end of range for external setpoint (only), referring to signal # ___
*SLo/*SHI start / end of range for signal output (only), referring to signal # ___
nSt modification of decimal point characters (0 / 1 / 2) 0 ___
*Lo / *HI start / end of setpoint range (°C /°F or value) # ___
dSPL select display function for lower display (AUS / SP / Y / IST2) AUS ___
(AUS = off, SP = setpoint, Y = output, Ist2 = actual value of channel / measuring input 2)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)

* = channel no. in case of multiple measuring inputs or control loops. # = acc. to range

data subjects to alteration 9_E4.DOC / 9910414


Industry controller type KFM 9... B 9... E
Optimization Page 5 of 8

1. manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to balance
an appearing deviation as quickly, non-oscillating and exactly as possible,
according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replaced
by this brief information.
The following informations are for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;
- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):
lower value= shorter impulse gaps, faster balancing
higher value= longer impulse gaps, slower balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;
- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):
increases the controller reaction in case of fast actual value or setpoint alterations
(adjust only if necessary). Higher values cause higher increase.

2. Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjusts
the optimum control parameters Xp, Tn and Tv.
Operation, if contained in supply schedule:
(Parameter-safety-switch on the rear panel of the controller has to be unlocked: position „u“)
Check starting assumptions:
Actual value at least 20% below the adjusted set value,(e.g.:heating phase), otherwise first:
Lower actual value adequately by manual operation (position of final control element) (quick circuits)
or increase setpoint adequately, if admissible. (faster procedure for slower circuits)
Call manual operation level: Press - key plus - key (optional: seperate key).
Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down - key for more than 5 sec. on manual operation level.
During operation the lower display shows: „-Ad-“,
the upper display still shows permanently the actual value.
Information about computer operation: First the self-adaptation program waits for stabilization
of the actual value according to the given controller output (actual value alteration < 0,1% / min),
then it increases the output signal about 10% or, in case of three- point- step controller operation,
it triggers an output impulse with about 10% of the adjusted regulating time.
The optimum parameters are computed according to the unit- step response.
Cancel: Press - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
to operating level.
Unsuccessful adaptation ( Display shows error code, ref.to chapter error messages):
Press - key again: Return to manual operation level
eliminate the indicated error
start adaptation again: - key > 5 sec.
or return to operating level: - key shortly

data subjects to alteration 9_E5.DOC / 9910420


Industry controller type KFM 9... B 9... E
Configuration Page 6 of 8

Access from the operating level.


Unlock the access first: Turn the switch on the rear panel of the controller to position „U“
(= unlocked). It is not possible to configure the controller with locked switch.
(Lock access after the adjustments: Switch position to „L“= locked)
Hold down the - key and press the - key,
y,
hold down both keys for more than 5 sec. until the display changes

Enter the code number (password) ... (1...9999), factory setting: 1


move on to next input: briefly press - key
y
Alternatively: Hold down key after entering code for more than 10 sec.
Possibility to modify code number (optional)

Select control function (type dependent): the displayed ID number for the configured
control function can be changed by pressing the - key..
(Example Type 930K31: choose (92..) 200, 201, 700, 701)

Return to operating level: briefly press the - key


y
or
move on to following adjustments: hold down - key for more than 5 sec.
Note: when switching is continued after a function has been changed, the display will first
flash for several seconds, only then will the controller return to the selected level.
Configurations are displayed in succession (type and design dependent)
and can be changed: ...
(move on to next input: press - key shortly)
factory setting
Ist* correction value to change the controller display (+ / -) 0.0
EinG type of measuring input Pt 100 / DC-signal: „rtd / Iu“ rtd
Ain* type of DC signal for input No.*:rtd/ 0/4-20mA/ 0/2...10V 4...20 mA
(observe different terminal connection I/U) (91..:rtd)
SP 2/E kind of 2nd/ external setpoint: Add/ Sub/ AbS AbS
(adding / subtracting / absolute)
*Y’ ‘ travel time of the actuator „6...600“ (sec.) 60 sec.
*cy’ ‘ switching frequency for 2-point controllers: „2...120“ (sec.) 20 sec.
*out adjusting kind of output signal „0...20/ 4...20(mA)/ 0...10/ 2..10(V)” 4...20 mA
*out adjusting output characteristics direct / inverted „di / in“ in
(for 2 output signals:“in in / in di / di in / di di“)
*td for 2 output signals: deadpoint between output 1 and 2 „0...10%“ 0
AP correction of the output signal operation position 50%
FG A/E automatical adjustment for teletransmitter input (ref. sheet 99ar)
Sou* adjusting type of information signal „0..20/4..20(mA)/0..10/2..10(V)“ 4...20 mA
Sou* adjusting kind of information signal „Ist/Soll..“ (actual/ setp.value) 4...20 mA
(*Sout= signal 1, Sou2= signal 2)
*Y_S behaviour of the output in case of measuring line fault:
relay position:“rel1 / rel2 / AUS“ ( AUS = relays off) rel2(70.),rel1(20.)
continuous output position: „0...100“ (%) 0
reL.. function selection for add. switching contacts :
add. contact 1 (relay-no.*) SoA(701),StA(201)
add. contact 2 (relay-no.*) Su A
select the corresponding measuring input / control circuit CH 1
relay condition in case of measuring line fault: „SiE/SiA“(on/off) Si A
Adr bus adress (adress no.) (for interface equipment only) 5
Return to operating level: briefly press the - key
y again

* = In case of multiple measuring inputs or control loops: relay- or channel number

data subjects to alteration 9_E6.DOC / 9910419


Industry controller type KFM 9... B 9... E
Facilities for Setting Supplementary Contacts Page 7 of 8

Selectable switching functions (depending on version):


For setting please refer to configuration level under „reL...“
Switching functions for trailing contacts: on
off
Sd Sd
LC A Break contact on either side of setpoint SA SA
(Limit comparator). Relay drops out as
deviation increases (Aus = off) on
of f
LC E Make contact on either side of setpoint Sd
SA SA
Sd

(Limit comparator). Relay picks up as


deviation increases (Ein = on) on
of f
Su A Break contact below setpoint. Relay drops Sd
SA
out as actual value decreases (Aus = off)
on

Su E Make contact below setpoint. Relay picks of f


Sd
SA
up as actual value decreases (Ein = on)
on
So A Break contact above setpoint. Relay drops of f
Sd
out as actual value increases (Aus = off) SA

on
So E Make contact above setpoint. Relay picks
of f
up as actual value increases (Ein = on) SA
Sd

St A Heating stage below setpoint. Relay on

drops out actual value increases (Aus = of f


Sd
SA actual v alue
off) SP
(s etpoint)

Switching functions for independent contacts: on

of f
US A Relay drops out with increasing actual Sd

value (Aus = off) on

of f
US E Relay picks up with increasing actual Sd
actual value
value (Ein = on) SP
Switching point
Service function:
Ein/Aus contact is constantly switched on (Ein) or
off (Aus) respectively

Only for units with program option


Pr A Relay switched off (aus) during SP program level, otherwise switched on
Pr E Relay switched on (ein) during SP program level, otherwise switched off
Special function:
SF6 as SoA but switching point at setpoint, control output around SA below

In each case additional settings follow under "rEL." after the selection is acknowledged (P key)
(depending on version):
Ist./ Y assigned value: actual value no. ... or Y (actuating signal)
CH../.SP.(only) for trailing contacts: assigned control circuit / channel (no.) or
assigned setpoint (1SP., rSP, SP.1, ..)
for independent contacts: assignment of parameter input (channel no..)
"Safety" shut down (in case of measuring line fault):
SI E Relay for "Safety" behaviour in event of measuring circuit error: relay on
SI A Relay for "Safety" behaviour in event of measuring circuit error: relay off

data subjects to alteration 9_E7.DOC / 0010516


Industry controller 92 E
Technical data Page 8 of 8

Characteristics: stage controller (invers)


Adjustment on parameter level, with lock switch, K2 K1
on
pre adjusted on customer´s demand.
off Sd2 Sd1 actual value
(parameters depending on sub type:)
SA2
Proportional band Xp: 0,1...999,9 % SP
Integral action time Tn: 0,0...999,9 min three- point- step- controller (invers)
Rate time Tv: 0,0...99,9 min K1(+) K2(-)
Sensitivity of response Xsh: 0,1...1,0 % on
Travel time of the actuator Tm: 6...600 sec off actual value
Sh
Switching frequency cy: 2...120 sec
SP
Function characteristics: direct / inverted
Switching interval SA (add. contacts): 0..100,0 K continuous controller
Switching difference Sd: 0,1...100,0 K single output double output

100% Y1
Additional contact functions: AP
in in..
Y2
di di..
As switching interval above and below setpoint or 0%
P ..di
independent adjustable with own setpoint and -100% P1 td td P2
..in

measuring input, switching function adjustable l92-d4990419


(ref. to chapter additional switching contacts)
Other data:
Installation dimensions:
Housing for panel mounting, 96 x 96 mm (type 92..,
93..) or 72 x 144 mm (type 94)
L Power supply: 230VAC +/- 10 %, 48...62Hz
alternative 115 VAC, 48 VAC, 24 VAC, 24 VDC
B +0,8
Power consumption: approx. 14 VA
Protective system DIN 40050: IP54 (terminals IP20)
H +0,8
Permissible ambient temperature: 0...60°C
Nominal temperature: 20°C
Climatic category: KUF to DIN 40050
Relative humidity <= 75 % yearly average,
Form 96x96: L= 150mm, B= 92mm H=92mm no condensation
Form 72x144: L= 170mm, B=168mm H=139mm EMC: refer to EN 50081-2 and EN 50082-2

Wiring diagram:
(Example, depending on sub type some details can be missed
valid for each delivered controller is the wiring diagram on its casing only)

A927_e59710718
controller electronics
fu se: (+) (-)
2 4 V :T 0 ,5 A
1 1 5 V :T 0 ,2 A
2 3 0 V :T 0 ,1 A
18V / external digital power control logic signal
40mA analog inputs set value inputs supply output outp. output relay outputs
Ist 3 Ist 4 dig 3 dig 4 Y 2 log 2 Sout 2 Rel 5 Rel 6 Rel 7 Rel 8
7 8 9 10 11 12 23 24 25 26 32 31 37 36 41 31 62 63 64 65 66 67 68 69 70 71 72 73
U+ Ist 1 Ist 2 SPE dig 1 dig 2 Y 1 log 1 Sout 1 Rel 1 Rel 2 Rel 3 Rel 4
99 1 2 3 4 5 6 13 14 15 19 20 21 22 27 28 29 30 31 35 36 40 31 50 51 52 53 54 55 56 57 58 59 60 61
I U L N + + + (protect relay outputs py external fuse 2A)
(L+) (L-)

wiring examples (for input 1 each)


Pt100 Pt100 standard signal "e" standard signal "q" external set value connecting-example
3 wire 2 wire 0/4..20mA 0/2..10V 0/4..20mA 0/2..10V 0/4..20mA 0/2..10V actuator
a92zu_60311202

1 2 3 1 2 3 1 3 2 3 10 3 11 3 13 15 14 15 50 51 52 53 54 55

L
+ - + - + - + - + - + - M
~
open close N

thermo- feedback standard signal incl. feed voltage switch-over optional:


"e" "q" SP active SP2/SPE
couple device power selection 6 7 8 9
1 2 3 1 2 3 99 1 99 10 19 20 19 20 a b c d
- + A S E
230V 1 2 3 4 5
+ - + -
115V RS 232 / 485

data subjects to alteration 9_e8.doc / 0510422


January 2007

VISCOMASTER DYNAMIC
Technical Manual

VISCOMASTER DYNAMIC – Technical Manual Page 1 of 35


VERY IMPORTANT
HANDLE THE VISCOMASTER DYNAMIC WITH CARE

DO NOT …drop the transmitter.

DO NOT …use liquids incompatible with materials of construction.

DO NOT …operate the VISCOMASTER DYNAMIC above its rated


pressure.

DO NOT …pressure test beyond the specified Test pressure.

ENSURE …all explosion proof requirements are applied

ENSURE …transmitter and associated pipework are pressure


tested to 1½ times the maximum operating pressure
after installation.

ALWAYS …store and transport the VISCOMASTER DYNAMIC in its


original packaging.

VISCOMASTER DYNAMIC – Technical Manual Page 2 of 35


Contents

CHAPTER 1 - INTRODUCTION

1.1 ABOUT THE VISCOMASTER DYNAMIC .............................................. 5


1.1.1 What is it? ........................................................................................................ 5
1.1.2 ViscoMaster Dynamic measurements .............................................................. 5
1.1.4 What is it used for ? ......................................................................................... 6

CHAPTER 2 - MECHANICAL INSTALLATION

2.1 INTRODUCTION ..................................................................................... 7

2.2 INSTALLATION EFFECTS ..................................................................... 8


2.2.1 Boundary effects .............................................................................................. 8
2.2.2 Fluid conditioning ........................................................................................... 10
2.2.3 Temperature and thermal insulation .............................................................. 10
2.2.4 Entrained gas ................................................................................................. 10
2.2.5 Solids contamination ...................................................................................... 11
2.2.6 Vibration effects ............................................................................................. 11

2.3 GENERAL FITTING NOTES ................................................................. 11

2.4 VISCOMASTER IN-LINE ADAPTER .................................................... 12

2.5 COMMISSIONING ................................................................................. 13

2.6 DURING NORMAL RUNNING .............................................................. 13

2.7 REMOVAL AND REFITTING PROCEDURE ........................................ 13

CHAPTER 3 - ELECTRICAL INSTALLATION

3.1 INTRODUCTION ................................................................................... 15

3.2 INSTALLATION CONSIDERATIONS ................................................... 16


3.2.1 Power supply ................................................................................................. 16
3.2.2 EMC ............................................................................................................... 16
3.2.3 Ground connections ....................................................................................... 16
3.2.4 Cabling ........................................................................................................... 17
3.2.5 Surge protection............................................................................................. 17

3.3 WIRING THE VISCOMASTER SERIES TRANSMITTER ..................... 18

3.4 POWER SUPPLY INPUT ...................................................................... 18

VISCOMASTER DYNAMIC – Technical Manual Page 3 of 35


3.5 MODBUS (RS-485) ................................................................................ 19

3.6 4-20mA OUTPUT .................................................................................. 20

3.7 WIRING PROCEDURE .......................................................................... 21

CHAPTER 4 - MAINTENANCE

4.1 GENERAL .............................................................................................. 23

4.2 GENERAL MAINTENANCE .................................................................. 24


4.2.1 Physical checks ............................................................................................. 24
4.2.2 Electrical checks ............................................................................................ 24
4.2.3 Performance checks ...................................................................................... 24
4.2.4 Calibration check ........................................................................................... 24

4.3 FAULT ANALYSIS AND REMEDIAL ACTION ..................................... 25


4.3.1 Mechanical servicing ..................................................................................... 27
4.3.2 Time Period Trap ........................................................................................... 27

CHAPTER 5 - SPECIFICATION

5.1 GENERAL .............................................................................................. 28

5.2 SPECIFICATION ................................................................................... 28


5.2.1 Sensor performance ...................................................................................... 28
5.2.2 Environmental................................................................................................ 29
5.2.3 Transmitter power supply .............................................................................. 29
5.2.4 Analog output ................................................................................................ 29
5.2.5 RS485 Interface ............................................................................................. 30
5.2.6 Approvals....................................................................................................... 30

5.3 FACTORY DEFAULT CONFIGURATION ............................................. 31

VISCOMASTER DYNAMIC – Technical Manual Page 4 of 35


1
Introduction
1.1 ABOUT THE VISCOMASTER DYNAMIC
1.1.1 WHAT IS IT?
The Viscomaster Dynamic is a digital viscosity transmitter, designed for use with Heavy Fuel Oils (HFOs). Based on
proven tuning fork technology, it is an all-welded sensor designed to be mounted directly in-line or into a tank.
Viscosity are determined from the resonance of the tuning fork immersed in the fluid. A temperature sensor (PRT) is
also fitted within the transmitter, which is used to measure the transmitter’s temperature. The wetted parts of the
transmitter are available in stainless steel (type 316) and the immersed tines are coated with PTFE to inhibit the build
up of asphaltenes.

The transmitter contains integral electronics that allow sensor and calculation configuration, enabling it to perform a
variety of calculations. Two forms of output are available:

1. Two 4-20mA analog outputs, factory set but have individually configurable span, bias, limits and
filter options. The standard factory settings for these outputs are Line Kinematic Viscosity on
Analog Output 1 and Temperature on Analog Output 2.

Alternatively, each output may be controlled by one of the following:


• Line dynamic viscosity.
• Line temperature.
Note: The Viscomaster Dynamic’s analog output 2 is factory set to Temperature and only the span,
bias and limits can be changed.

2. An RS485 (Modbus) interface, giving access to other measurement results, system information
and configuration parameters.

No signal converter is required, which simplifies wiring and enables the Viscomaster to be connected directly to a
plant monitoring / control systems or a local indicator.

Re-configuration of the transmitter’s default settings (see chapter 5) is achieved by linking a PC to the Modbus
(RS485) connection and running ADView software. Once configured, the PC can be removed.

1.1.2 VISCOMASTER DYNAMIC MEASUREMENTS


The Viscomaster Dynamic directly measures the following fluid properties:
• Line dynamic viscosity (measured in centiPoise - cP).
• Temperature (measured in °C or °F).

VISCOMASTER DYNAMIC – Technical Manual Page 5 of 35


From these measurements, Viscomaster Dynamic calculates:
• Line kinematic viscosity (measured in centiStokes - cSt).

Note: The Line Kinematic Viscosity calculation requires the user input of a base (or reference) density value and a
temperature (at which the base density value is valid).

1.1.3 WHAT IS IT USED FOR?


The Viscomaster is designed specifically to control the viscosity of Heavy Fuel Oil (HFO) used by large diesel engines.
This is typically achieved by adjusting the heating of incoming HFO to maintain the viscosity within the limits set by
the engine manufacturer.

HFO is a low cost, high viscosity fuel derived from refinery wastes. The quality of the oil and its viscosity/temperature
characteristics can vary due to:

• Stratification within storage tanks.


• Contamination in transit storage.
• Variations in the production process at the refinery or at the blending plant.

HFO heating is usually required to ensure that the viscosity of the oil at the injectors of a large diesel engine or burner
nozzle is maintained at the optimum value (typically between 10 and 20cSt). Failure to observe the viscosity limits
results in inefficient combustion, pollution problems and higher operating costs (either due to excessive fuel being burnt
or premature wear to engine components).

Since simple temperature control has been shown to be ineffective due to the variability of oil quality in HFO, viscosity
control is usually performed.

A typical HFO fuel circuit is shown in figure 1.

Note: In some installations, equipment may be installed in between the viscosity transmitter and the burner
/ engine to remove contaminants from the fuel; the efficient operation of this equipment may also depend
on the viscosity of the HFO.

1
2
Relay Viscosity alarm (to AMS)
* *

*
3

* *

*
* Not supplied by Aquametro

Figure 1

VISCOMASTER DYNAMIC – Technical Manual Page 6 of 35


2
Mechanical Installation
2.1 INTRODUCTION
There are a variety of external factors which affect the ability of the Viscomaster to operate successfully. In order to
ensure that your system works correctly, the effects of these factors must be taken into consideration when designing
your installation.

There are two main aspects to consider:


1. The accuracy and repeatability of the measurements;
2. The relevance of the measurements to the overall purpose of the system.

Factors which may adversely affect accuracy and repeatability include:


• The presence of gas or bubbles within the fluid being measured.
• Non-uniformity of the fluid.
• The presence of solids as contaminants.
• Fouling of the transducer.
• Temperature gradients – thermal insulation must be placed near the sensor chamber and body.
• Cavitations and swirls caused by valves or discontinuities in the pipework.
• Operating at temperatures below the wax point of heavy fuel oil (HFO).
• The correct pipe diameter that corresponds to the calibration of the Viscomaster.

In some applications, absolute accuracy is less important than repeatability. For example, in a system where the control
parameters are initially adjusted for optimum performance, and thereafter only checked periodically.

The term achievable accuracy can be used to describe a measure of the product quality that can be realistically obtained
from a process system. It is a function of measurement accuracy, stability and system response. High accuracy alone is no
guarantee of good product quality if the response time of the system is measured in tens of minutes, or if the measurement
bears little relevance to the operation of the system. Similarly, systems which require constant calibration and maintenance
cannot achieve good achievable accuracy.

Factors which may adversely affect the relevance of the measurements could include:
• Measurement used for control purposes being made too far away from the point of control, so that the
system cannot respond properly to changes.
• Measurements made on fluid which is unrepresentative of the main flow.

This chapter has the following sections:


• Section 2.2 – The importance of installation effects.
• Section 2.3 – General fitting notes.
• Section 2.4 – Mechanical details for mounting and installing Viscomaster.
• Section 2.5 – Commissioning the system.
• Section 2.6 – During normal running.
• Section 2.7 – Removal and refitting procedure.

VISCOMASTER DYNAMIC – Technical Manual Page 7 of 35


2.2 INSTALLATION EFFECTS
Unlike other Mobrey’s sensors, the vibrating tines of the Viscomaster are not totally enclosed. The walls of the pipe or
tank in which the transmitter is installed will introduce boundaries to the fluid flow, and this will have an effect on the
calibration of the sensor. To overcome this, Mobrey calibrates the Viscomaster under a variety of pre-defined
conditions corresponding to the installation and pipe schedule. This condition is selected when ordering the
Viscomaster, so that by calibrating the sensor under the same boundary conditions as the installation, the need for
additional on-site calibration is eliminated.

2.2.1 BOUNDARY EFFECTS


Any insertion device or transducer can only measure the properties of the fluid within the region of fluid to which it is
sensitive.

For practical reasons it is helpful to consider the sensitive or effective region for the transmitter as an three-
dimensional ellipse centred on the tips of the tines with its long axis aligned with the direction in which the tines
vibrate, as shown below. The Viscomaster is insensitive to the properties of the fluid outside this region.

long axis

short
axis

If part of this volume is taken up by the pipework or fittings there is said to be a boundary effect; i.e. the intrusion of
the pipe walls will alter the calibration.

The diagram below illustrates the Viscomaster installed in a pocket on the side of a 4” (100mm) horizontal pipe line
(viewed from above). The effective region is completely enclosed within the pipe line and thus is completely fluid.

2봖chedule 40 4?horizontal pipe


Pocket or 밫

Top or Plan view

VISCOMASTER DYNAMIC – Technical Manual Page 8 of 35


This next view shows other pipe outlines superimposed:

4?(100mm) 6? 150mm)
vertical pipe vertical pipe

2봖chedule 40
Pocket or 밫

Top or Plan view

The smaller circle represents a 4” vertical pipe, which intersects the effective region. The 6” (150mm) pipe is the
smallest pipe diameter to completely enclose the effective region when the pipe is vertical. Thus smaller pipe
diameters can lead to a variety of different geometries which would each require a separate calibration.

An alternative condition is shown in the next diagram where the side pocket is extended until it passes completely
through the effective region producing a “core”:

2봖chedule 40
Pocket or 밫

Top or Plan view

From this, it would appear that almost every installation requires a separate in situ calibration - a very undesirable
situation. The problem is resolved by providing standard calibration geometries which can be used in all pipe work
configurations and thereby allow the factory calibration conditions to be reproduced in the process. These standard
geometries are described in Section 오류! 참조 원본을 찾을 수 없습니다..

VISCOMASTER DYNAMIC – Technical Manual Page 9 of 35


2.2.2 FLUID CONDITIONING
The fluid in at the Viscomaster must be of uniform composition and at uniform temperature, and it must be
representative of the fluid flow as a whole. This is achieved either by mixing of the fluid either using a static inline
mixer or taking advantage of any natural pipe condition that tends to cause mixing, such as pump discharge, partially
open valves etc.

2.2.3 TEMPERATURE AND THERMAL INSULATION


Always insulate the Viscomaster and surrounding pipework thoroughly (see photograph below). Insulation should
completely cover installation kit / flow-through chamber and Viscomaster assembly, up to the electronics housing.
Insulation must be a minimum of 25mm (1”) thick rockwool / calcium silicate and enclosed in a sealed protective casing.

Avoid direct heating or cooling of the Viscomaster and associated pipework upstream and downstream that is likely to
create temperature gradients. If it is necessary to provide protection against cooling due to loss of flow, electrical
trace heating may be applied, provided it is thermostatically controlled and the thermostat is set to operate below the
minimum operating temperature of the system.

2.2.4 ENTRAINED GAS


Gas pockets can disrupt the measurement. A brief disruption in the signal caused by transient gas pockets can
be negated in the internal signal conditioning software, but more frequent disruptions or serious gas
entrainment must be avoided. This can be achieved by observing the following conditions:
• Keep pipe lines fully flooded at all times.
• Vent any gas prior to the Viscomaster.
• Avoid sudden pressure drops or temperature changes which may cause dissolved gases to break out
of the fluid.
• Maintain a back pressure on the system sufficient to prevent gas break out. (E.g. back pressure
equivalent to twice the head-loss plus twice vapour pressure).
• Maintain flow velocity at the sensor within the specified limits.

VISCOMASTER DYNAMIC – Technical Manual Page 10 of 35


2.2.5 SOLIDS CONTAMINATION
• Avoid sudden changes of velocity that may cause sedimentation.
• Install the transmitter far enough downstream from any pipework configuration which may cause
centrifuging of solids (e.g. bends).
• Maintain flow velocity at the sensor within the specified limits.
• If necessary, use a suitable screen or filter to trap objects or lumps which may block or damage the
sensor or flow chamber. (Viscomaster can handle normal slurries.)

2.2.6 VIBRATION EFFECTS


The Viscomaster series transmitters have been extensively tested under severe vibration conditions, both in the test
laboratory and Marine/Power Station/Burner applications. The Viscomaster transmitters are approved according to
the Lloyds Register standard, levels ENV 1,2 and 3 and operate correctly up to the classification level of ENV4
(vibration test 2). This vibration level, ENV 4 includes correct operation at vibration levels of 4g rms between
frequencies of 5-100Hz, and is used to describe the requirements for engine mounted equipment.

If vibration levels exceed these limits, or the Viscomaster series transmitters are not installed as recommended by
Mobrey, Mobrey cannot take responsibility for the correct operation of these units.

2.3 GENERAL FITTING NOTES


The Viscomaster uses a 1.5” Swagelok style of fitting which requires no seals, minimising maintenance and spares.
These fittings are leak proof over a wide range of pressure and temperature conditions, and during rapid temperature
cycling, which may occur during the transfer from HFO to distillate fuel.

The Viscomaster should normally be installed horizontally, with the slot between the tines vertical; this ensures that,
for low flow rates, any solids or gas bubbles are not trapped. When installed in a flow-through chamber, however,
provided that the flow rate is within the recommended range, the transmitter can be mounted horizontally or vertically.

Allow at least 200mm (7.8”) clearance to enable the Viscomaster to be removed from the fitting.

VISCOMASTER DYNAMIC – Technical Manual Page 11 of 35


2.4 VISCOMASTER IN-LINE ADAPTER

Conditions:
Temperature: -50 to +200°C
Flow: 10 to 330 l/min (0.6 to 20 m3/hr) (2.6 to 87 US gal./min)
Viscosity limit: Up to 100cSt
Pressure: As defined by process flanges.
Viscometer
calibration boundary: 2½“ Schedule 40

This adapter has been specifically designed to provide a simple, direct replacement for existing vibration-type
viscometers. Typically, the flange-to-flange distance is 150mm. Usually, no pipework changes are necessary.

The viscometer is mounted 25mm away from the main flow line, allowing good product mixing, sensor protection and
stable measurement conditions.

Typical dimensions are shown in the drawing.

Note: The schematic shown may vary without notice, although overall dimensions will remain unchanged.

VISCOMASTER DYNAMIC – Technical Manual Page 12 of 35


2.5 COMMISSIONING
1. Once the pipework installation has been prepared, and before installing the Viscomaster and thermal
insulation, fit a blanking compression nut to the Viscomaster mounting, and pressurise and flush the
system.

2. Isolate the system, depressurise and remove the blanking compression nut.

3. Install the Viscomaster, and tighten the fitting nut, but do not fit the thermal insulation.

4. Slowly pressurise the system and check for leaks, particularly if the normal operating temperature is
high, or the Viscomaster has been fitted cold; tighten as necessary.

5. Now tighten the nut again, if necessary. Once you are satisfied with the integrity of the seal, the
insulation can be fitted.

6. Once the system has stabilised and is leak free, fit the insulation material.

2.6 DURING NORMAL RUNNING


Observe and record the normal operating temperatures and viscosity readings.

When several systems are run in parallel and use the same fuel source, comparison of the readings between
installations can be a useful indicator of possible system faults. Differences between readings or changes from the
normally observed conditions should always be investigated to confirm that instrumentation is functioning correctly.

Particular attention should be paid to the conditions before and after engine shutdowns in order to detect any
possibility of asphaltenes coating (precipitation of asphaltenes from the HFO caused by dilution with distillate fuel)
which may cause the instrument to read high. If the re-circulation flow is high enough or the instruments have been
supplied with PTFE coating, asphaltenes or any other deposits should quickly be removed and the expected
operating temperatures should be restored.

If Viscomaster is still reading high and the oil quality is known not to have changed, then the instrument should be
removed and cleaned with a rag. Removal should only be performed in accordance with the engine or burner
manufacturers’ recommendations or in accordance with safe site practice. This must include isolation and
depressurisation, as detailed below.

2.7 REMOVAL AND REFITTING PROCEDURE


All national and international safety regulations should be observed.
Observe safe working practice, wear protective clothing and safety glasses, and use suitable gloves to prevent burns
or absorption of hot oil.

Check that the isolation valves have been fully closed, remove insulation and allow to cool to a safe level (cooling will
tend to reduce any retained pressure) and de-pressurise the system if a drain valve or pressure relieving valve is
fitted.

When the above conditions are satisfied, slacken the lock nut by 1½ to 2 turns, sufficient for the sensor to be rocked.
(If necessary, jolt the Viscomaster loose with a blow of the hand to the amplifier housing.) This will allow the seal between
the sensor and the chamber retro-fit kit to be broken. Do not slacken the lock nut further unless the seal is broken and
the sensor is definitely loose in the fitting.

VISCOMASTER DYNAMIC – Technical Manual Page 13 of 35


Note: If the system is still pressurised, the Viscomaster may lift and be held against the retaining nut. Rocking and
alternately pushing the sensor in and out of the pocket within the limits allowed by the slackened nut will break any
seal and allow oil under pressure to seep past the lock nut. If this leakage is excessive, re-tighten the lock nut and
take further action to de-pressurise the system.

When the Viscomaster can be rocked in the flow chamber and there is no serious or continuous escape of oil, it is
safe to remove the lock nut.

Always keep all parts of your body away from the axis of the sensor (i.e., the direction in which the sensor
will be withdrawn). If the system is under pressure or suddenly comes under pressure (e.g., due to valve
failure or pump start), and the lock nut is not in place, the instrument may be forcibly ejected from the flow
chamber and cause serious injury.

Clean and maintain the Viscomaster as directed and then refit it, as described in Section 2.5

VISCOMASTER DYNAMIC – Technical Manual Page 14 of 35


3
Electrical Installation
3.1 INTRODUCTION
The Viscomaster Series transmitter has two types of output:

• Two 4-20mA analog outputs:


The Viscomaster Dynamic has a single fully configurable output proportional to a user-specified
parameter.

The parameters that can be output on each analog output are as follows:

Viscomaster Dynamic
Analog Output 1 Analog Output 2
Dynamic viscosity (cP) Temperature *

Kinematic viscosity (cSt)*


Line density
Temperature

* Factory default selection.

Note: In all cases, the Limit values of each analog output are configurable.

• A Modbus (RS485) interface, giving access to other measurement results, system information and
configuration parameters. The Modbus interface is also used to configure the Viscomaster Series
transmitter, using a PC running Mobrey’s ADView software (see separate manual)

It is recommended that both outputs are installed, requiring a minimum of eight wires (two for each output, and two
for power). Although you may not immediately require the Modbus connection, it may be required for in-situ
calibration adjustment and future system enhancements, and the cost of the additional wires is trivial compared to the
expense of installing them retrospectively.

A number of factors must be taken into account when planning the electrical installation. These include:

• Power supply (Section 3.2.1 and Section 3.4)


• EMC (Section 3.2.2)

VISCOMASTER DYNAMIC – Technical Manual Page 15 of 35


• Ground connections (Section 3.2.3)
• Cables (Section 3.2.4)
• Surge protection (Section 3.2.5)
• Modbus connections (Section 3.5)
• Analog Output connections (Section 3.6)

3.2 INSTALLATION CONSIDERATIONS


3.2.1 POWER SUPPLY
The power supply to Viscomaster Series transmitters must have the following specification:

Voltage: Nominally 24V dc, but in the range 20 to 28V dc.


Current: >50mA.

If several Viscomaster Series transmitters are to be used within a local area, one power supply can be used to power
them all; where the transmitters are distributed over a wide area and cabling costs are high, it may be more cost
effective to use several smaller, local power supplies.

Upon leaving the factory, the two 4-20mA analog outputs are non-isolated as they are powered through internal links
to the power supply input. However, if split-pads “LNK A” (Analog Output 1) and “LNK B” (Analog Output 2) by the
terminal block are ‘broken’, they become isolated and require a separate 20-28V dc power supply. (See section 3.6
for further details).

Care should be taken where there is the possibility of significant common-mode voltages between different parts of
the system. For example, if the Viscomaster Series transmitter is local powered from a power supply which is at a
different potential to the RS485 ground connection (if used).

3.2.2 EMC
To meet the EC Directive for EMC (Electromagnetic Compatibility), it is recommended that the transmitter be
connected using a suitable instrumentation cable containing an overall screen. This should be earthed at both ends
of the cable. At the transmitter, the screen can be earthed to the transmitter body (and therefore to the pipework),
using a conductive cable gland.

3.2.3 GROUND CONNECTIONS


It is not necessary to earth the transmitter through a separate connection; this is usually achieved directly through the
metalwork of the installation.

The electronics and communications connections (RS485/Modbus and 4-20mA analog outputs) of a Viscomaster
Series transmitter are not connected to the body of the transmitter. This means that the negative terminal of the
power supply can be at a different potential to the earthed bodywork.

In the majority of applications, it is not necessary to connect the RS485 ground connection. In areas where there is a
significant amount of electrical noise, higher communications integrity may be obtained by connecting the negative
power terminal (pin 2) of the Viscomaster Series transmitter to the communications ground. If this is done, it is
important to ensure that the possibility of ground loops (caused by differences in earth potential) is eliminated.

VISCOMASTER DYNAMIC – Technical Manual Page 16 of 35


3.2.4 CABLING
Although it is possible to connect separate cables to the Viscomaster Series transmitter for power, RS485 and the 4-
20mA analogue output, it is recommended that all connections are made through one instrumentation-grade cable.

Connections for the Analog and Modbus signals should be individually screened twisted-pairs with an overall screen,
foil or braid for the cable. Where permissible, the screen should be connected to earth at both ends. (At the
Viscomaster Series transmitter, this is best done using a conductive cable gland.)

Cables should conform to BS2538. In the USA, use Belden 9402 (two-pair) or Beldon 85220 (single-pair). Other
cables that are suitable are those that meet BS5308 Multi-pair Instrumentation Types 1 and 2, Belden Types 9500,
9873, 9874, 9773, 9774 etc.

The typical maximum recommended cable length for the above cable types is 1000m (3200ft.), but care must be
taken to ensure that the power supply at the transmitter is at least 20V. Thus, for 24V power supply, the overall
resistance for the power supply connections (both wires in series) must be less than 100 ohms.

In order to complete the wiring, you will need the following parts:
• ½” NPT to M20 gland adapter.
• ½” NPT blanking plug.
• M20 x 1 cable gland (not supplied).

The gland adapter and blanking plug are supplied with each Viscomaster Series transmitter. These two parts
are “EExd” rated. However, you will need to get a suitably rated cable gland. Alternative parts may be required
in order to meet local electrical installation regulations.

In hazardous areas, all parts must be explosion-proof.

3.2.5 SURGE PROTECTION


Careful consideration should be given to the likelihood of power supply surges or lightning strikes. The power supply
connections of the Viscomaster Series transmitter have a surge arrestor fitted that gives protection against power
supply transients.

If there is a possibility of lightning strikes, external surge protection devices - one for each pair of signals and the
power supply - should be installed as close to the Viscomaster Series transmitter as possible.

Another method of surge protection is to connect an MOV (Metal Oxide Varistor) (breakdown voltage >30V)
with an NE-2 neon bulb in parallel across each wire and ground. These can be mounted in a junction box close
to the Viscomaster Series transmitter.

VISCOMASTER DYNAMIC – Technical Manual Page 17 of 35


3.3 WIRING THE VISCOMASTER SERIES TRANSMITTER
Figure 3.1 shows the terminal board of the Viscomaster Series transmitter. To reveal the terminal board, it is
necessary to unscrew the housing cap; the procedure is described in Section 3.7.

Note: If the Viscomaster Series transmitter is to be used in hazardous areas, the electrical installation
must strictly adhere to the safety information given in safety instruction booklet 78265061/SI, which
will have accompanied this manual.

The connections to the Viscomaster Series transmitter are:


• Power.
• Modbus (RS485) communications.
• Analog output (4-20mA).

It is recommended that you install all three connections (six cores) at installation, to avoid the possibility of expensive
alterations to the cabling at a later date. Typically, three pairs of shielded 19/0.30mm2 (#16 AWG) to 19/0.15mm2
(#22 AWG) wire are used for wiring.

Figure 3.1: View of the terminal board

3.4 POWER SUPPLY INPUT


Terminals 1 and 2 are for connecting an external 24V dc power supply, as guided in Figure 3.2.
Ensure that the loop resistance of the cable(s) is such that the voltage at the transmitter terminals is greater than 20
volts. (The maximum voltage at the terminals is 28V dc.)

VISCOMASTER DYNAMIC – Technical Manual Page 18 of 35


Figure 3.2: Power supply connections

VISCOMASTER DYNAMIC – Technical Manual Page 19 of 35


3.5 MODBUS (RS485)
Terminals 3 and 4 are for RS485/Modbus connections to a PC, as shown in Figure 3.3.

Note: The PC and converter are always located in a non-hazardous (safe) area.

The RS485/232 converter and PC are not normally installed permanently. However it is strongly recommended that
the wiring to the Viscomaster Series is made at the time of installation.

For detailed information on RS485, see separate manual.

Note: If you encounter communication difficulties with RS485, swap over the ‘A’ and ‘B’ signal
connections at one end of the network.

TERMINAL BLOCK VERSION:

OR
9-PIN DIN CONNECTOR VERSION:

Figure 3.3: Modbus connections < 100 metres

VISCOMASTER DYNAMIC – Technical Manual Page 20 of 35


3.6 4-20mA OUTPUTS
Terminals 5, 6, 7 and 8 are for connecting the two 4-20mA analog outputs to external devices, such as a signal
converter.

Upon leaving the factory, the two 4-20mA analog outputs are non-isolated as they are powered through internal links
to the Power Supply Input.

However, if split-pads “LNK A” (Analog Output 1) and “LNK B” (Analog Output 2) by the terminal block are ‘broken’,
they become isolated and require direct connections to another external 20-28V dc power supply. A second or third
external 20-28V dc supply can be used.

Figure 3.4: 4-20mA Outputs (Isolated)

Note: The external device must be located in a non-hazardous (safe) area unless it is explosion proof and
suitably certified.

The 4-20mA analog outputs can be configured to be proportional to a user-defined base density, referred density,
temperature, or one of the special functions. Fault conditions within the Viscomaster Series are indicated by a 2mA
output. If this is detected, the Modbus link can be used to interrogate the transmitter to establish the likely cause of
the problem.

VISCOMASTER DYNAMIC – Technical Manual Page 21 of 35


3.7 WIRING PROCEDURE

1. Open the Terminal Board side of the


VIEW FROM TOP OF 7829:
Viscomaster Series’s electronics housing by
UNDO THIS CAP
undoing the 2.5mm AF grub screw and
unscrewing the lid anticlockwise. GRUB
SCREW

2. Fit the M20 gland adaptor into the most


convenient ½” NPT hole. Then, fit the M20 x 1
cable gland to the adapter.

Fit a ½” NPT blanking plug to the unused hole.

(1) ½” NPT Blanking Plug.

(2) ½” NPT to M20 adaptor.

(3) M20 cable gland.

3. Insert the cable through the cable gland and


adaptor so that the multi-core cable is gripped
leaving 200mm of free, unscreened wire to
connect to the terminal blocks.

VISCOMASTER DYNAMIC – Technical Manual Page 22 of 35


4. Wire up the cable cores as shown:

6. When you have screwed the wires into the


correct terminals, carefully tuck the wires
around the electronics, and tighten the
cable gland

7. Finally, screw the housing cap on fully and VIEW FROM UNDERNEATH THE ELECTRONICS:

tighten the locking grub screw using the


2.5mm AF hex drive.

TIGHTEN
CAP

TIGHTEN
GRUB

VISCOMASTER DYNAMIC – Technical Manual Page 23 of 35


4
Maintenance
WARNING: If the transmitter being serviced is to be used in a hazardous
area, the rules of compliance with current standards
concerning flameproof equipment must be strictly adhered to.

4.1 GENERAL
The Viscomaster Series transmitter has no moving parts and maintenance is limited to simple visual checks for
leaks and physical damage. ADView’s Data Logging facility can be used whenever necessary to verify that the
transmitter is functioning correctly (See sperate manual).

Check calibrations should be carried out at specified intervals in order to identify a malfunction or deterioration in
transmitter performance. If a fault or a drop in performance is detected, further tests are required to identify the cause
of the fault. Remedial action is limited to cleaning the tines, making good any poor connections and replacing the
internal electronics. In extreme cases, the complete Viscomaster Series transmitter may need to be replaced.

Note: The electronics within the transmitter contain calibration information relevant to that particular transmitter only.
The circuit boards operate as a pair, and therefore both boards must be changed together. Contact Aquametro for
more details if you need to change the boards.

CAUTION: Care is essential in handling of the Viscomaster Series transmitter


during removal from and fitment to the tank, and during
transportation. Wherever possible, retain and use the original
packaging.

VISCOMASTER DYNAMIC – Technical Manual Page 24 of 35


4.2 GENERAL MAINTENANCE
This procedure is recommended for periodic maintenance and can also be used when fault finding.

4.2.1 PHYSICAL CHECKS


a. Examine the transmitter, its electronics housing and cables for any signs of damage and corrosion.
b. Make sure that the spigot connection is tight.
c. Check the transmitter for sign of leakage.
d. Check that there is no ingress of water/fluid into the electronics housing.
e. Ensure that the threads on the covers are well greased (graphite grease) and that the ‘O’ rings are in
good condition.

Note: The covers MUST be completely screwed down and, in the case of an explosion-proof enclosure
application, DO NOT FAIL to tighten the locking screws.

4.2.2 ELECTRICAL CHECK


Check the power supply and current consumption at the transmitter terminals 1 and 2.
These should give:

35mA to 42mA (at 22.8V to 25.2V)


If the current consumption is outside this range, contact Aquametro for advice.

4.2.3 PERFORMANCE CHECK


When several systems are run in parallel and use the same fluid source, comparison of the line viscosity,
base density and temperature readings between installations can be a useful indicator of possible system
faults. Differences between readings, or changes from the normally observed conditions should always be
investigated to confirm that instrumentation is functioning correctly.

4.2.4 CALIBRATION CHECK


a. Carry out a check calibration as detailed in sperate manual.
b. Compare the results obtained with the previous calibration figures to identify any substantial
deterioration in transducer performance or any malfunction.

Notes:
1. A drop in performance is likely due to a build-up of deposition on the tines, which can be removed by
the application of a suitable solvent. See section 4.3.1 for further details.
2. Malfunctions generally could be the result of electrical/electronic faults in either the Viscomaster Series
transmitter or the readout equipment. Always check the readout equipment first before attention is
directed to the Viscomaster Series transmitter.

VISCOMASTER DYNAMIC – Technical Manual Page 25 of 35


4.3 FAULT ANALYSIS AND REMEDIAL ACTION
A fault may be categorised as either an erratic reading or a reading that is outside limits.
Electrical faults can also cause symptoms that appear to affect the readings and it is recommended that the electrical
system be checked first, before removing the transmitter for servicing.

Fault Possible causes Remedies

Readings fluctuate Analog output averaging Increase the averaging time using
slightly, i.e., are noisy time not long enough ADView’s Board Configuration facility
(see separate manual).

Erratic readings Gas bubbles around tines Remove primary cause; e.g.:
Cavitations - install air release units to release
gas; apply back pressure to
Severe vibration discourage bubble formation.
Severe electrical - remove cause of vibration
interference
Alternatively, it may be necessary to
Large amount of adjust the Time Period Trap
contaminants

Readings outside limits Deposition and/or Clean tines


corrosion on the tines.

Analog output = 0mA No power to analogue If voltage across pins 5 and 6 is not 15
output to 28V, replace power supply.
Analog output circuit Use ADView’s facility to set the
failure analogue output to 4, 12 or 20mA (in
Board Configuration) to check whether
the output is functioning. If not, replace
circuit boards.

Analog output is 2mA Alarm condition caused by If voltage across pins 1 and 2 is not 20
lack of power to to 28V, check and replace main power
Viscomaster Series supply.
transmitter
Alarm condition caused by Use ADView Diagnostics to check that
other internal failure phase locked loop is in lock.

Temperature readings If other readings from Return the transmitter to Mobrey for
incorrect transmitter are correct (i.e. servicing. Re-fit the transit cover to the
analog output and Modbus transmitter and secure it with 2 grub
appear to be functioning screws.
correctly), the temperature
sensor has probably failed.

VISCOMASTER DYNAMIC – Technical Manual Page 26 of 35


Fault Possible cause Remedy

Transmitter does not Power failure to Check power supply to transmitter and
communicate with transmitter. converter; replace if necessary.
ADView:
Power supply to Check wiring.
RS485/232 converter
failed.
A and B Modbus Check wiring.
connections reversed.
RS485/232 converter Try another converter.
failed, wired incorrectly,
or connected the wrong
way round.

ADView incorrectly Re-install ADView.


installed on PC.

Incorrect Slave address Check slave address.


chosen for transmitter.

RS232 port on PC failed. Connect to another free RS232 port on


the PC, if available.

Alternatively connect a known working


RS232 device to the PC to check that the
port is working.

Viscosity reads high Thermal insulation is Repair or replace thermal insulation.


during normal running defective.

PTFE laminate damaged, Remove transmitter for visual check;


leading to coating of fork return to Mobrey for servicing.
tines.
Calibration data is Compare calibration data to certificate or
corrupted. stored configuration. Re-program as
necessary.

Viscosity reads high Pump coated with Check pump delivery; service pump.
after engine shutdown asphaltenes.
and restart
Bypass not fully closed. Close bypass

PTFE laminate damaged, Remove transmitter for visual check;


leading to coating of fork return to Mobrey for servicing.
tines.

Calibration data is Compare calibration data to certificate or


corrupted. stored configuration. Reprogram as
necessary.

Return transmitter to Mobrey for


servicing.

VISCOMASTER DYNAMIC – Technical Manual Page 27 of 35


4.3.1 MECHANICAL SERVICING
This mainly comprises the cleaning of any deposition or corrosion from the tines. Deposition is removed by the use of
a suitable solvent. Take care not to damage the PTFE coating. Where extensive corrosion has been treated, it is
highly recommended that a full calibration is carried out to check the transmitter characteristics.

CAUTION: Care is essential in handling the transducer during transit,


installation, and removal from the installation.

4.3.2 TIME PERIOD TRAP


Disturbances in the fluid caused by bubbles, cavitations or contaminants can cause sudden changes in the measured
output, which may, under some circumstances, give rise to instability (i.e. hunting) in a control system relying on the
measurement. The Viscomaster Series transmitter can maintain the analogue output during such perturbations by
ignoring the aberrant measurement, and maintaining the output at the last good measured value. This facility is known
as the Time Period Trap (TPT).

Under all normal circumstances, the factory settings for the TPT should be used. However, in extreme cases it may be
necessary to alter the settings to meet the demands of a particular system. This should only be done after monitoring
the behaviour of the system for some time, to establish the normal running conditions.

Great care must be taken not to reduce the sensitivity of the transmitter so that normal response to fluctuations in the
fluid is impaired.

The time period trap facility works as follows:

After each measurement of the time period (of the Viscomaster Series transmitter’s vibrating tines), the new value is
compared with the previous value. If the difference between them is smaller than the allowable tolerance, the output is
updated to correspond to the new measured value, and the TPT remains inoperative; i.e., operation is normal. If the
difference exceeds the allowable tolerance, the output remains at the previous level, and does not follow the apparent
sudden change in value.

This process is repeated until either:


(a) The latest measured value falls back to the level of the original value, indicating that the transient has
passed; or
(b) The TPT count is reached. At this point, it is assumed that the change in value is not due to a random
disturbance, and the output adopts the value of the latest reading.

Two Modbus Registers control the operation of the Time Period Trap facility. These can be changed, if necessary,
using ADView’s Register Read/Write facility (see separate manual).

Modbus Register 138: contains the maximum allowable change in the time period between readings, specified in μs.
The preset value is 10.

Modbus Register 137: contains the Time period count, which is the maximum number of measurements to be
rejected before resuming normal operation; the preset value is 2. If the value is set to 0, TPT is disabled, and the
output will always follow the time period measurement. If you want to program another value, it should be determined
experimentally, and be equal to the length of the longest undesirable transients which are likely to arise. If the value
is set too high, the Viscomaster Series transmitter will be slow to respond to genuine changes in the fluid properties.

VISCOMASTER DYNAMIC – Technical Manual Page 28 of 35


5
Specification
5.1 GENERAL
The Viscomaster Series transmitter comprises a vibrating fork sensor, with processing electronics within a housing which
allows full configuration; all signal processing, calculations, and calibration adjustments are made without the need for
external electronics.

Two 4-20mA analog outputs are available:


• On the Viscomaster Dynamic, Analogue Output 1 is configurable to output a user-specified parameter,
such as Kinematic Viscosity. Analogue Output 2 is fixed to output Temperature. The zero and span are
configurable. (For further details, see Chapter 3.)

An RS485 serial communications link is also available, which utilises the Modbus protocol to provide a means of
configuring the device, retrieving data measurements, and performing diagnostics.

ADView, a PC software application running under Windows 98, NT, 2000 or XP, is available for data logging,
configuration and diagnostics purposes (see separate manual)

5.2 SPECIFICATION
5.2.1 SENSOR PERFORMANCE

Viscosity measurement
Measurement technology: Tuning Fork driven and sensed by piezoelectric
crystals.

Operating range: 0.5 to 100cSt

Accuracy: ± 1% operating range


(0.5 to 100cSt: ± 0.2%)

Repeatability: ± 0.5% reading

Pressure effect: Negligible

VISCOMASTER DYNAMIC – Technical Manual Page 29 of 35


Temperature
Temperature Technology: PT100 platinum resistance thermometer in tuning fork

Integral PRT Temperature Range: -50° to +200°C

Integral PRT Temperature Accuracy: BS1904 Class B , DIN 43760 Class B

5.2.2 ENVIRONMENTAL

Fluid temperature range: -50°C to +200°C (-58°F to +392°F)

Max. operating pressure: 207 Bar (3000psi)

Enclosure Type: Die cast low copper alloy.


Polyurethane paint finish.
Protection: IP66

Max. weight: 6.7kg.

Max. vibration: 4g rms 5-100Hz


(as specified by Lloyds Register ENV4 specification)

5.2.3 TRANSMITTER POWER SUPPLY


Minimum Input Voltage: 20V

Maximum Input Voltage: 28V

Current Consumption: 35 to 45mA

5.2.4 ANALOG OUTPUT


Note: See Chapter 3 for details of powering the analog outputs.

Number of channels: 2

Range: 3.9mA to 20.8mA

Alarm Condition: 2mA

Nominal Power Supply: 24V

Maximum Terminal voltage: 28V

Minimum Terminal voltage: 15V

Isolation to Main Power Supply: 75Vdc rated

Accuracy @20°C: ±0.1% reading ±0.05% FS

Repeatability: ±0.05% FS
(-40°C to +85°C)

VISCOMASTER DYNAMIC – Technical Manual Page 30 of 35


5.2.5 RS485 INTERFACE
Connections: A and B signals (screw terminals)

Communications protocol: Modbus RTU

Isolation: None (RS485 in same circuit as main power supply)

Baud rate: 9600 (fixed)

Termination: Not required

5.2.6 APPROVALS
EMC: EN 61326:1997 +A1

Approvals: EEx d IIC T4 (ATEX)

CSA Class 1, Division 1, Group C.

VISCOMASTER DYNAMIC – Technical Manual Page 31 of 35


5.3 FACTORY DEFAULT CONFIGURATION
The Viscomaster Series transmitters are supplied in a standard configuration.

Analog outputs are set to provide line kinematic viscosity (in cSt) and temperature (in °C). Units are kg/m3 for the density
parameter.

The complete set of default values are shown below.

Viscomaster Dynamic
Parameter
Factory default value

Analog output 1: Variable Line kinematic viscosity


Units cSt
4mA setting 0
20mA setting As ordered.

Analog output 2: Variable Temperature


Units °C
4mA setting 0
20mA setting 150°C

Alarms: Coverage General system


Analog output
User range
Hysteresis 2%

Alarm user range: Variable Line kinematic viscosity


Units cSt
Low setting 0
High setting 100

Density calculations: Temperature units °C


Temperature offset 0
Pressure units bar
Pressure set value 1.013
Line density units kg/m3
Line density scale factor (Not Applicable)
Line density offset (Not Applicable)

API referral: Product type (Not Applicable)


User K0 (Not Applicable)
User K1 (Not Applicable)
Base temperature (Not Applicable)
Base pressure (Not Applicable)

Output averaging 5s
time:

VISCOMASTER DYNAMIC – Technical Manual Page 32 of 35


Modbus: Slave address 1
Byte order Big Endian
Register size 32 bit

Hardware type: Advanced fork

VISCOMASTER DYNAMIC – Technical Manual Page 33 of 35


Head Office:
Switzerland: Aquametro AG, Ringstrasse 75, CH-4106 Therwil, Phone +41 61 725 11 22, Fax +41 61 725 15 95

Officies:
Switzerland: Aquametro SA, Rue du Jura 10, CH-1800 Vevey, Phone +41 21 923 51 30, Fax +41 21 922 58 44
Belgium: Aquametro Belgium SPRL, Dallaan, 67, B-1933 Sterrebeek, Phone +32 2 241 62 01, Fax +32 2 216 22 63
Czech Republic: Aquametro s.r.o., Prosecká 811 / 76a, CZ-190 00 Praha 9, Phone +42 02 86 88 77 78, Fax +420 02 86 88 95 59
Germany: Aquametro Messtechnik GmbH, Zum Panrepel 24, D-28307 Bremen, Phone +49 421 / 871 64-0, Fax +49 421 / 871 64-19

Marketing-Officies:
Japan: Aquametro Representative Office, Yasuhiko Takahashi, 1-18-4, Nakane, Meguro-ku, Tokyo 152-0031, Phone +81 3 3723 8611, Fax +81 3 5729 4607
Korea (south): Aquametro Representative Office, Dennis Kwak, The # Centum Park 102-2704, Haeundae gu Jaesong 1-dong 1200, Busan Korea, Phone +82 5 1314 3017, Fax +82 5 1988 3017
Singapore: Aquametro Representative Office, Deniel Wong, 273 Thomson Road, #03-03 Novena Gardens, Singapore 307644, Phone +65 6 256 8152, Fax +65 6 256 9917

VISCOMASTER DYNAMIC – Technical Manual Page 34 of 35


www.aquametro.com

VISCOMASTER DYNAMIC – Technical Manual Page 35 of 35


Motor control valve in two way form 421 ... E
PN 16 / 25, GGG-40. Page 1 of 2

Body: GGG-40.3, two way form,


for water and steam,
Pressure range: PN 16, PN 25
Flanges acc. to DIN,
Spindle sealing: spring loaded PTFE-V-ring unit,
for media temperatures up to 250°C
alternatively: graphite-packing
Internal parts: stainless steel
Flow characteristic: equal percentage
Leakage: acc. to VDI/VDE 2174

Actuator: with integrated manual emergency


and load dependent limit switches
Thrust: 2000 N
Power input: 10 VA
alternatively: 4000 N / 20 VA (appendix ..c)
5500 N / 20 VA (appendix ..d)
Power supply: 230V /50...60Hz
other voltages on request
Protection class: IP65

Accessories, special types:


Add. signal switches (see page 49e, 49w)
Feedback potentiometer (see page 49f)
Integrated positioner (see page 49sr)
Other voltages (on request)
Other positioning speed (on request)
Reduced kvs-values (on request)

Order text:
Motor control valve PN . ., DN . .
in two way form with PTFE-V-ring unit,
Power supply . . ., List-No. 421 . . .

Max. operating pressure:


by: 120 200 250 °C
PN 16 16 13 13 bar
PN 25 25 20 18 bar

DN List-No. Kvs Stroke Pos. speed Closing pressure (bar)


PN 16 PN 25 m³/h mm sec 2000N 4000N 5500N
15 421 400 421 500 4,0 20 66 25,0
20 421 401 421 501 6,3 20 66 25,0
25 421 402 421 502 10 20 66 25,0
32 421 403 421 503 16 20 66 17,3 25,0
40 421 404 421 504 25 20 66 10,8 25,0
50 421 405 421 505 40 20 66 6,6 16,0 23,0
65 421 406 421 506 63 30 100 3,4 9,1 13,3
80 421 408 421 508 100 30 100 2,0 5,8 8,6
100 421 410 421 510 160 30 100 1,1 3,5 5,4

data subject to alteration 421-1-E.DOC / 0411517


Motor control valve in two way form 421 ... E
PN 16 / 25, GGG-40. Page 2 of 2

153
Space required
Actuator type: 145 to remove
2kN: 4e1230 (for 4-6kN-actuator: 190) the bonnet
4(6)kN: 4e14(6)30

Bonnet

Motor

Limit switch

Gear

Spring plate-unit H*

Spindle (actuator)

Hand wheel

Mounting rod

PTFE-V-ring-unit

Spindle

Plug

Valve body type: vg21...


L

DN 15 20 25 32 40 50 65 80 100
Height H * 491 505 499 505 511 513 556 557 564
Immersion lenght L 130 150 160 180 200 230 290 310 350
Weight kg 13 14 15 17 18 20 33 37 47
* = add. 45mm for 4-6 kN-actuator

Electrical wiring: Accessories (optional):


Limit switch Potentiometer Signal switch
M load dependent travel dependent
for valve position
CLOSE OPEN

1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36

N L on 2 = Straightway closes
L on 3 = Straightway opens

data subject to alteration 421-2-E.DOC / 0411504


Installation and operating manual B4E
for motor control valves

Installation:

Attention!: - Installation, operation and maintenance should be done only by qualified personnel.
- Disconnect supply before working on the valve.
- It is not permitted to work on the valve body and to exchange the actuator as long as
the valves are subjected to pressure and temperature.
The mounting site should be easily accessible and have sufficient clearance for maintenance
and for removing the actuator. Ensure that the pipe line axes are flush and connection flanges
are parallel. Provide suitable measures to absorb possible tensile and pressure forces.
The valve must not serve as a fixed point. It must be carried by the piping.
Clean pipelines thoroughly prior to installing the control valves in order to avoid damage through
residual installation material, welding beads or forging scale. If possible, provide a dirt trap
in front of each control valve.
Installation position should be vertical to horizontal. Ensure that the installation direction is
correct (directional arrows of the flow on the valve housing). Observe a 10 x DN spacing
to flanges, elbows, etc., to avoid an impaired valve function.
Regard the permitted max. operating pressure and temperatur as described in the
corresponding valve specification sheet.
Observe the ambient temperature limits (-20...+60°C), if necessary, provide a drive heater
at lower temperatures, and for higher temperatures insulate the pipeline, provide conductive
plates or cooling possibilities.
Retighten the screws of all flange connections (also lid and connection piece flanges) prior
to commissioning/start-up and following initial heat-up.

Electrical connection:

Check supply voltage according to the rating plate, loosen screws on the motor hood
and remove hood
Route signal and control lines separately from high-voltage lines, if necessary, run in
screened cables. Insert cables (1.5 mm²) through a wringing nipple or cable screw
connection.
Perform electrical connection with the supply voltage switched off according to the
connection diagram (observe VDE and EVU regulations).
In the event of deviations, the connection diagram in the motor hood has precedence

Maintenance:

Following the initial temperature and pressure load, retighten the screws of all flange connections
(also lid and connection piece flanges), the valve cone should be located in the centre.
Attention! Never loosen the lid and flange screws as long as the fittings are subjected
to pressure and temperature.
Protect valve spindle against soiling, if necessary, clean and grease lightly in order to protect
stuffing boxes and deflector hoods against increased wear.
Retighten stuffing box seals slightly in the event of leaks.
No further maintenance work is required for fittings with deflector hoods or bellows.
Undertake maintenance on the drive in accordance with the corresponding information in the
separate operating instructions.

data subject to alteration 4BA-E.DOC / 0210525


n
c
e
s
g
E
w
A
iar:lc
ie
s
to
r

Electric actuator 4e1 4e1... E


Page 1 of 2

Electric actuator for valves


with integrated manual emergency
Controlling device: 3-point step controller r
Power supply: 230V / 50...60Hz
alternatively: 115V / 50...60Hz (option 49u1)
24V / 50...60Hz (option 49u2)
24V DC (option 49u8)
Thrust: 2000 N
Power input: 10 VA
alternatively: 4000/5500 N / 20 VA
Positioning time: 3,3 s/mm
alternatively: 2,2 s/mm (option 49t12)
Stroke: 41 mm
alternatively: 60 mm (on request)
Protection class: IP 65
Limit switches: 1 changeover switch for each limit position,
load dependent, ratings: 250V / 2A
Mounting position: any, avoid hanging position
(damaging by effluent media possible)
Max. ambient temperature: -15...60° C

Accessories, special designs:


Add. load dependent signal switches (see page 49e)
Add. travel dependent signal switches (see page 49w)
Feedback potentiometer (see page 49f)
Integrated positioner (see page 49sr)

Order text:
Electric actuator, thrust . . ., power supply . . .,
pos. time . . ., mounting rod lenght . . .,
List-No. 4e1 . . .

List-No. Thrust Mounting rod* Pos.time Weight


N mm s/mm kg
4e1134 1500 195 3,3 6
4e1230 2000 200 3,3 6
4e1231 2000 218 3,3 6
4e1232 2000 231 3,3 6
4e1235 2000 250 3,3 6
4e1430 4000 200 3,3 7
4e1431 4000 218 3,3 7
4e1432 4000 231 3,3 7
4e1435 4000 250 3,3 7
4e1630 5500 200 3,3 7
4e1631 5500 218 3,3 7
4e1632 5500 231 3,3 7
4e1635 5500 250 3,3 7
* = other rod lenghts on request

Electrical wiring: Accessories (optionaly):

Limit switches Potentiometer Signal switches


M load dependent travel dependent
for valve position
DOWN UP

1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36

N L on 2 = stroke downwards
L on 3 = stroke upwards
data subject to alteration 4e1-1-E.DOC / 0411504
Electric actuator 4e1 4e1... E
Page 2 of 2

153 Space required to


Bonnet remove the bonnet h

Motor

Gear

Limit switch for


valve end position
“down”
H
Terminal bar

Mounting plate with


wiring diagram

Limit switch for


valve end position
“up”

Base plate

Cable bushing

Spring housing

Disc spring unit


A
Spindle

Mounting rod
Stroke
Hand wheel with
blocking lever Cmax

Coupling nut Cmin


100
Screw collar ring

Type Thrust A Cmin Cmax H h G g


N mm mm mm mm mm mm mm
4e1134 1500 195 40 81 146 145 M12 24
4e1230 2000 200 45 86 146 145 M16 32
4e1231 2000 218 63 104 146 145 M16 32
4e1232 2000 231 76 117 146 145 M16 32
4e1235 2000 250 95 136 146 145 M16 32
4e1430 4000 200 45 86 191 190 M16 32
4e1431 4000 218 63 104 191 190 M16 32
4e1432 4000 231 76 117 191 190 M16 32
4e1435 4000 250 95 136 191 190 M16 32
4e1630 5500 200 45 86 191 190 M16 32
4e1631 5500 218 63 104 191 190 M16 32
4e1632 5500 231 76 117 191 190 M16 32
4e1635 5500 250 95 136 191 190 M16 32
data subject to alteration 4e1-2-E.DOC / 0411504
Electric actuator 4e1 B 4e1... E
Operating instructions Page 1 of 2

Attention:
- Adjustment of and work on the actuator may only be done by skilled labour
- Disconnect power supply before removing the cover
- Observe local instructions and terminal diagram

Actuator disassembly: Actuator assembly:


- disconnect supply - lift actuator onto valve connection and secure nuts (18)
- loosen fixing screw (21) (see Fig.1)
(see Fig.1) - tighten (19) coupling nut and fixing screw (21)
- unscrew coupling nut (19) - connect lines acc.to wiring diagram
- unscrew nuts (18) - if necessary, move actuator in both limit positions and
- take off actuator from valve connection adjust stroke indikators (17) on mounting rod

Maintenance: the spindle has to be kept cleen and lubricated, if necessary, lubricate the spindle with
molykote including grease

Limit switches:

Attention! The limit switches work load dependent and turn off automatically when the valve drives in
end position, so that a readjustment, as for travel dependent limit switches, is not necessary
and not allowed. Change of the factory adjustment endangers correct operation, no warranty
will be given and no liability will be accepted in case of damage of the varnish sealing.
If for extraordinary reasons, for instance by previous damages, a readjustment is exceptionally
necessary, the actuator should preferably be sent in for new factory adjustment. Only if this is
exceptionally not possible, a new coarse adjustment can be directly done, with our agreement
and acc. to the following operating instruction.

Special information for actuators with integrated positioner:


No reaction of limit switch can occur when the positioner turns off the actuator to early,
before the valve is in the end position. Don’t readjust limit switch in this case, control
at first adjustment of positioner and correct it if necessary.

Upper limit switch

Add. upper switch


Add. lower switch

Lower limit switch


Lower limit switch

Fig.1

data subject to alteration 4E1_1BE.DOC / 0310522


Electric actuator 4e1 B 4e1... E
Operating instructions Page 2 of 2

01
02
03
04
05
06

07
08
09
10
11
12
13
detail X

14
15
16
17
19
20

X
18

Fig.2

No. Designation Part-No.


01 Bonnet: 2kN / 4kN e3h136 / e3h180
02 Motor 230V / 50/60Hz: 2kN / 4kN*** e2m220 / e2m220.4
02a Capacitor: 2kN / 4kN e2k033 / e2k068
03 Gear: pos. speed 3,3s/mm / pos. speed 2,2s/mm e2g1875 / e2g1250
04 Limit switch for spindle position "down" eheo
05 Mounting plate for motor e3zp
06 Terminal bar e6k12
07 Gear wheel e3zr75
08 Mounting plate with wiring diagram e3hb
09 Limit switch for spindle position "up" eheu
10 Base plate e3gp
11 Screw-type cable bushing PG11 e1kv11
12 Spring housing e3fg
13 Set of disc springs e5ft355+e5fs335
14 Spindle e3s
15 Mounting rods e3s... / e3s...n
16 Hand wheel with blocking lever ehhr
17 Stroke indicator e5ak
18 Hexagonal nut M16 e8mv16
19 Coupling nut e5vk
20 Screw collar ring e3sr...

*** = only for standard actuator: voltage 230V / 50/60Hz

data subject to alteration 4E1_2BE.DOC / 0310522


Parts list vg21-t E
Control valve in two way form, type 21, GGG-40.3, PN16/25 Page 1 of 2

01

02

03

04

05

06

07

08

09

10

11

No. Designation Part-No.


01 Screw joint with scaper 6a21dv..
02 Gasket 6a21sd..
03 V-rings 6a21dm
04 Mounting bonnet 6a21vd..
05 Guiding bush 6a21gb
06 Spring 6a21f
07 Studs with hexagon nuts 6a21ss..
08 Gasket 6a21dd..
09 Plug with spindle 6a21ks..
10 Seat ring 6a21s..
11 Valve body 6a21vg..

data subject to alteration Vg21-te.doc / 0104518


Replacing of the PTFE-V-ring unit B vg31-badm E
Control valve body in 3-way-form type 31
(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((

01

02 Screw joint complete

03

04

05

06

A AB

%+30)*/1- 2, 5.+ $&#"!’!4/1- 61/5


(8 :.95*,. <1. +.558? ;.*5 2< 2; 78< 7.,.;;*:@ <8 :.68>. <1. ,87<:85 >*5>. /:86 <1. 929.527.
)& ;CKMSC QFC ?AQR?QMO$ RLPAOCT QFC AMJJ?O OGLE DOMK QFC S?JSC PNGLBJC !()" ?LB OCKMSC
QFC AMRNJGLE LRQ ?LB QFC JMAIGLE LRQ GD LCACPP?OU
*& =LPAOCT QFC PAOCT HMGLQ !(*"
+& :RJJ MRQ QFC ERGBGLE @RPF !(." ?LB >%OGLE RLGQ !(-" DOMK QFC PAOCT HMGLQ !(*" MO DOMK KMRLQGLE
@MLLCQ !(," GD LCACPP?OU
487 < -*6*0. <1. 27;2-. ?*55 8/ <1. ;,:.? 3827<!
,& 3JC?L QFC spindle (01) if necessary
Dameged spindle must also be replaced a new V-ring unit will soon start leaking again with
a damaged spindle!
&% :RQ the V-ring unit (05) ?LB QFC ERGBGLE @RPF !(." GLQM QFC PAOCT HMGLQ !(*"
7*4. ;=:. <1*< <1. 9*:<; *:. 27;<*55.- 27 <1. ,8::.,< 8:-.: *7- 98;2<287 ";.. -:*?270 *+8>.#!
.& Replace the gasket (03)
/& :RQ PAOCT HMGLQ RLGQ !(*#(+#(-#(." GLQM QFC KMRLQGLE @MLLCQ$
’*4. ;=:. <1*< <1. )$:270; *:. 78< -*6.0*- <1:8=01 <1. ;927-5.$<1:.*-!
0& <AOCT ML QFC PAOCT HMGLQ !(*" ?LB QGEFQCL GQ !V).( 8K"

B?Q? PR@HCAQ QM ?JQCO?QGML >6+)%2147%5&493 ’ (-()-*-


industry controller KFM 92 / KFM 93 B 9200 E
operating instructions Page 1 of 8

1
1 Digital display actual value
2 2nd digital display (if aktive) 3
2
3 LED-display relais function
4 Key for setpoint and parameter mode
5 Setpoint adjustment 6
6 Parameter mode lock switch (back face)
4 5

DIN-certificate: TR (TW) 949 ..

Brief description:
KFM 92 is a microprozessor based industry controller series in panel mounting- format 96 x 96 mm.
Design and operating elements are especially devised for easy and convenient handling and operation.
An assembly system renders possible the simple basic version as well as a plurality of variants with
up to 8 relays, several digital and analog out- and inputs and other additional devices.

Types: Inputs:
(depending on configuration*): type: max. 4 measuring inputs, type suffix
indicator 9201. acc. to sub-type:
one stage controller 9210. Pt100 DIN, 0...400°C none (or 0)
two stage controller 9220. Pt100 DIN, 0...100°C 1.
heating / cooling controller 9230. thermo couple Ni Cr NI (type K)0...1200°C n.
positioner / follow-up controller 9240. thermo couple Fe Cu NI (type J)0... 900°C f.
two- point- PID controller 9250. thermo couple Pt Rh Pt (type S)0...1700°C p.
three- point- PID controller 9260. feedback device 0...100 up to 1000 Ω w.
three- point- step controller 9270. standard signal 0(4)...20mA, 0(2)...10V e.
continuous controller 9280. combined input Pt100 / standard signal q.
continuous controller, 2 outputs 9281. Ranges:
Sub-types: suffix (*) Pt 100: 0...400°C, switchable to °F, optional: other
basic function .0 ranges; for standard signal range adjustable -999 to
basic function + 1 additional contact .1 4000. Setpoint ranges can be limited by menu
basic function + 2 additional contacts .2 Displays:
2 x basic function .3 2 four- figured digital displays, decimal point
extension: logik output ..L adjustable, upper display: actual value, lower
function extensions suffix (*) display: other selectable data,
cascade controller 991k up to 8 LEDs for relays function display.
program controller 991p Display of function:
ramp set point value 991r Hold down the P-key for more than 5 sec
step controller 991t to get a short-cut message of the configured function on
the display (=position 3-5 of list number)
Additional devices: (*) (in case of locked parameter mode only ).
additional analog inputs (99) a Measuring line monitoring:
external set value incl. switch-over (99) bwa Display "Err 1...4" in case of measuring line fault
second set value incl. switch-over (99) bwz and adjustable safety shut down of all outputs
binary input to switch special functions (99) b..
additional switching contacts (99) f.. Outputs:
analog signal outputs (99) o. up to 8 relays with potential free change over switch,
serial interface RS 232/485 (99) s. as control outputs or as additional contacts,
interface Profibus, Interbus S, other (99) sp/si. capacity: 250V 2A,
incl. spark extinction (for normally open contacts)
* In case of more than 1 extension there is at the 1-2 continuous outputs 0/4...20mA, 0/2...10V as
data plate only once '99' , f.e. 92700-99aw-ogx-rü. control or signal outputs(apparent ohmic load 500 Ω)
For more information see corresponding data sheets.'
data subjects to alteration 9200e1.doc / 0510208
Industry controller type KFM 9... B 9... E
Installation and connection Page 2 of 8

Installation:
Before installation inspect the controller for any visible signs of damage caused during transport
Check power supply acc. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the
fastening devices supplied.

Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following the
wiring diagram; wire cross section max. 1,5 mm2
- To avoid cross interference all low voltage measuring lines and pilot wires must be encased
in a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally to protect the output relays.
- Phase wire and neutral wire must not be transposed.

Putting into operation:


Switch on power supply. Digital display and control lamps will light up according to
the setpoint after some seconds. If nothing happens check the fine-wire fuse on the back panel
of the controller and the electrical wiring. Adjust set value and check other adjustments.

Maintenance:
All electronic controllers in the KFM range are virtually maintenance-free. Provided that the
controller is correctly installed and put into operation and is protected against mechanical
damage and inadmissible operating conditions, it should give years of trouble-free service.
In case of faults repair work by the customer should be restricted to the externally accessible
leads and connections and components the customer is expressly permitted to deal with himself.
(bridge circuits, fuses).

All further work, especially on internal components will terminate warranty, makes subsequent
inspection and fault repair more difficult and can cause considerable damage to the circuitry.

For repair remittance remove plug board with connected leads on the rear side,
loosen fastening devices and remove controller from the panel.

In case of remittance please give precise details of the fault to reduce time and cost of repair.

Error messages:
Err 1...6 Fault on measuring input nr. ...
check measuring lines for short circuit or breakage
check measuring input by connecting a RTD
Err 55 Fault on loading the parameter;
press any key, the controller starts in emergency operation mode,
configuration of the parameters has to be checked
Err 50 Hardware error in program section
Err 52 Hardware error in data section
no further operation possible, remit controller for repair

Error messages during self adaptation:


Err 202 Ambient conditions are not suitable for self adaptation;
adjust parameter manually
Err 205 routine exceeded the setpoint
raise setpoint or lower actual value and start adaptation again
Err 206 Fault on measuring input during adaptation;
check the wiring and start adaptation again

data subjects to alteration 9_E2.DOC /0010803


Industry controller type KFM 9... B 9... E
Operation Page 3 of 8

Operating status:

The upper display shows the actual value (channel / measuring input 1),
the lower display remains empty or (depending on the version and settings) shows
- the attendant unit of measure (°C, °F, %...)
- an additional actual value, the setpoint value or the controller output value Y
- or the additional actual value only when the key is pressed.
Alternative type:
switch over the upper display to the several actual values by pressing the key,,
the lower display shows the number of the attendant measuring input.

Setpoint value setting:

press - key shortly (do not hold down)

The upper display shows the abbreviation of


the activated setpoint adjustment mode,
the lower display shows the adjusted value.

The indicated value can now be changed by the (lower) and (higher) -keys..
Each variation of the set value is immediately active, without any more operating steps.
The arrow keys have a built-in accelerator mode:
longer pressing causes faster alterations.

Return to operating level:


Press - key shortly (or automatically after 30 seconds without any key-action)

optional: Press - key shortly again: *SP =set values of further control loops (*=no.) /
SP* =further set values of the control loop / SPE =external setpoint (display mode only);
flashing display signifies that the function is not active at the moment.

Manual operation: (optional)

Hold down - key and press - key, then release both keys..
(optional: switch on and off using separate - key)
(for multi-channel controllers first enter the channel number*,
and press - key, then:)

The lower diplay shows „H *“ and - if activated - the output position.


The upper display still shows the actual value. The automatic control is interrupted.

Manual control is now possible using the ... - keys..

Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)

optional: starting the self adaptation (ref. to chapter Optimization):


On manual operation level - key >5 sec ;
the lower display indicates „-Ad-“.
Cancel: - key >5 sec again

data subjects to alteration 9_E2.DOC /0010803


Industry controller type KFM 9... B 9... E
Parameter level Page 4 of 8

Access from operating level.

Unlock the access first:


Turn the switch on the rear panel of the controller to position „U“ = unlocked
(Lock access after the adjustments: Switch position to „L“ = locked).

After the parameter level (refer to the instructions to each level ) has been invoked,
the first setting is shown and can be modified.

It is not possible to invoke the parameter level when the switch is locked .
In this case the display shows the abbreviation of the configured controller type.

Confirm the entry and / or move on to next parameter:


press the -key briefly

Settings in detail:
(not available on all types)

Level 1: Invoke: Hold down the - key for more than 5 sec.
until the display changes factory setting: notes:

CH channel selection (no.) for multi-channel controller (only)


*P proportional range Xp (%) (ref. to chapter „Optimization“) 25,0 ___
*I integral action time Tn (min) (ref. to chapter „Optimization“) 7,0 ___
*d rate time Tv (min) (ref. to chapter „Optimization“) 0,2 ___
*Sh sensitivity of response Xsh (%) 0,1 ___
*SA.. switching interval (absolut value) for following (additional) contact no... 5,0* ___
SP.. set point for independent additional contact no... 0,0 ___
*Sd.. switching difference for additional contact no... 3,0 ___
(*201,701/SA3:10,0)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)

Level 2: Invoke: Hold down - key and press - key,


y,
hold down both keys for more than 5 sec. until display changes.
Unit switch-over the displayunit (°C / °F) C ___
*bLo/*bHI start / end of display range for voltage- / current -input (only) # ___
*ELo/*EHI start / end of range for external setpoint (only), referring to signal # ___
*SLo/*SHI start / end of range for signal output (only), referring to signal # ___
nSt modification of decimal point characters (0 / 1 / 2) 0 ___
*Lo / *HI start / end of setpoint range (°C /°F or value) # ___
dSPL select display function for lower display (AUS / SP / Y / IST2) AUS ___
(AUS = off, SP = setpoint, Y = output, Ist2 = actual value of channel / measuring input 2)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)

* = channel no. in case of multiple measuring inputs or control loops. # = acc. to range

data subjects to alteration 9_E4.DOC / 9910414


Industry controller type KFM 9... B 9... E
Optimization Page 5 of 8

1. manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to balance
an appearing deviation as quickly, non-oscillating and exactly as possible,
according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replaced
by this brief information.
The following informations are for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;
- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):
lower value= shorter impulse gaps, faster balancing
higher value= longer impulse gaps, slower balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;
- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):
increases the controller reaction in case of fast actual value or setpoint alterations
(adjust only if necessary). Higher values cause higher increase.

2. Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjusts
the optimum control parameters Xp, Tn and Tv.
Operation, if contained in supply schedule:
(Parameter-safety-switch on the rear panel of the controller has to be unlocked: position „u“)
Check starting assumptions:
Actual value at least 20% below the adjusted set value,(e.g.:heating phase), otherwise first:
Lower actual value adequately by manual operation (position of final control element) (quick circuits)
or increase setpoint adequately, if admissible. (faster procedure for slower circuits)
Call manual operation level: Press - key plus - key (optional: seperate key).
Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down - key for more than 5 sec. on manual operation level.
During operation the lower display shows: „-Ad-“,
the upper display still shows permanently the actual value.
Information about computer operation: First the self-adaptation program waits for stabilization
of the actual value according to the given controller output (actual value alteration < 0,1% / min),
then it increases the output signal about 10% or, in case of three- point- step controller operation,
it triggers an output impulse with about 10% of the adjusted regulating time.
The optimum parameters are computed according to the unit- step response.
Cancel: Press - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
to operating level.
Unsuccessful adaptation ( Display shows error code, ref.to chapter error messages):
Press - key again: Return to manual operation level
eliminate the indicated error
start adaptation again: - key > 5 sec.
or return to operating level: - key shortly

data subjects to alteration 9_E5.DOC / 9910420


Industry controller type KFM 9... B 9... E
Configuration Page 6 of 8

Access from the operating level.


Unlock the access first: Turn the switch on the rear panel of the controller to position „U“
(= unlocked). It is not possible to configure the controller with locked switch.
(Lock access after the adjustments: Switch position to „L“= locked)
Hold down the - key and press the - key,
y,
hold down both keys for more than 5 sec. until the display changes

Enter the code number (password) ... (1...9999), factory setting: 1


move on to next input: briefly press - key
y
Alternatively: Hold down key after entering code for more than 10 sec.
Possibility to modify code number (optional)

Select control function (type dependent): the displayed ID number for the configured
control function can be changed by pressing the - key..
(Example Type 930K31: choose (92..) 200, 201, 700, 701)

Return to operating level: briefly press the - key


y
or
move on to following adjustments: hold down - key for more than 5 sec.
Note: when switching is continued after a function has been changed, the display will first
flash for several seconds, only then will the controller return to the selected level.
Configurations are displayed in succession (type and design dependent)
and can be changed: ...
(move on to next input: press - key shortly)
factory setting
Ist* correction value to change the controller display (+ / -) 0.0
EinG type of measuring input Pt 100 / DC-signal: „rtd / Iu“ rtd
Ain* type of DC signal for input No.*:rtd/ 0/4-20mA/ 0/2...10V 4...20 mA
(observe different terminal connection I/U) (91..:rtd)
SP 2/E kind of 2nd/ external setpoint: Add/ Sub/ AbS AbS
(adding / subtracting / absolute)
*Y’ ‘ travel time of the actuator „6...600“ (sec.) 60 sec.
*cy’ ‘ switching frequency for 2-point controllers: „2...120“ (sec.) 20 sec.
*out adjusting kind of output signal „0...20/ 4...20(mA)/ 0...10/ 2..10(V)” 4...20 mA
*out adjusting output characteristics direct / inverted „di / in“ in
(for 2 output signals:“in in / in di / di in / di di“)
*td for 2 output signals: deadpoint between output 1 and 2 „0...10%“ 0
AP correction of the output signal operation position 50%
FG A/E automatical adjustment for teletransmitter input (ref. sheet 99ar)
Sou* adjusting type of information signal „0..20/4..20(mA)/0..10/2..10(V)“ 4...20 mA
Sou* adjusting kind of information signal „Ist/Soll..“ (actual/ setp.value) 4...20 mA
(*Sout= signal 1, Sou2= signal 2)
*Y_S behaviour of the output in case of measuring line fault:
relay position:“rel1 / rel2 / AUS“ ( AUS = relays off) rel2(70.),rel1(20.)
continuous output position: „0...100“ (%) 0
reL.. function selection for add. switching contacts :
add. contact 1 (relay-no.*) SoA(701),StA(201)
add. contact 2 (relay-no.*) Su A
select the corresponding measuring input / control circuit CH 1
relay condition in case of measuring line fault: „SiE/SiA“(on/off) Si A
Adr bus adress (adress no.) (for interface equipment only) 5
Return to operating level: briefly press the - key
y again

* = In case of multiple measuring inputs or control loops: relay- or channel number

data subjects to alteration 9_E6.DOC / 9910419


Industry controller type KFM 9... B 9... E
Facilities for Setting Supplementary Contacts Page 7 of 8

Selectable switching functions (depending on version):


For setting please refer to configuration level under „reL...“
Switching functions for trailing contacts: on
off
Sd Sd
LC A Break contact on either side of setpoint SA SA
(Limit comparator). Relay drops out as
deviation increases (Aus = off) on
of f
LC E Make contact on either side of setpoint Sd
SA SA
Sd

(Limit comparator). Relay picks up as


deviation increases (Ein = on) on
of f
Su A Break contact below setpoint. Relay drops Sd
SA
out as actual value decreases (Aus = off)
on

Su E Make contact below setpoint. Relay picks of f


Sd
SA
up as actual value decreases (Ein = on)
on
So A Break contact above setpoint. Relay drops of f
Sd
out as actual value increases (Aus = off) SA

on
So E Make contact above setpoint. Relay picks
of f
up as actual value increases (Ein = on) SA
Sd

St A Heating stage below setpoint. Relay on

drops out actual value increases (Aus = of f


Sd
SA actual v alue
off) SP
(s etpoint)

Switching functions for independent contacts: on

of f
US A Relay drops out with increasing actual Sd

value (Aus = off) on

of f
US E Relay picks up with increasing actual Sd
actual value
value (Ein = on) SP
Switching point
Service function:
Ein/Aus contact is constantly switched on (Ein) or
off (Aus) respectively

Only for units with program option


Pr A Relay switched off (aus) during SP program level, otherwise switched on
Pr E Relay switched on (ein) during SP program level, otherwise switched off
Special function:
SF6 as SoA but switching point at setpoint, control output around SA below

In each case additional settings follow under "rEL." after the selection is acknowledged (P key)
(depending on version):
Ist./ Y assigned value: actual value no. ... or Y (actuating signal)
CH../.SP.(only) for trailing contacts: assigned control circuit / channel (no.) or
assigned setpoint (1SP., rSP, SP.1, ..)
for independent contacts: assignment of parameter input (channel no..)
"Safety" shut down (in case of measuring line fault):
SI E Relay for "Safety" behaviour in event of measuring circuit error: relay on
SI A Relay for "Safety" behaviour in event of measuring circuit error: relay off

data subjects to alteration 9_E7.DOC / 0010516


Industry controller 92 E
Technical data Page 8 of 8

Characteristics: stage controller (invers)


Adjustment on parameter level, with lock switch, K2 K1
on
pre adjusted on customer´s demand.
off Sd2 Sd1 actual value
(parameters depending on sub type:)
SA2
Proportional band Xp: 0,1...999,9 % SP
Integral action time Tn: 0,0...999,9 min three- point- step- controller (invers)
Rate time Tv: 0,0...99,9 min K1(+) K2(-)
Sensitivity of response Xsh: 0,1...1,0 % on
Travel time of the actuator Tm: 6...600 sec off actual value
Sh
Switching frequency cy: 2...120 sec
SP
Function characteristics: direct / inverted
Switching interval SA (add. contacts): 0..100,0 K continuous controller
Switching difference Sd: 0,1...100,0 K single output double output

100% Y1
Additional contact functions: AP
in in..
Y2
di di..
As switching interval above and below setpoint or 0%
P ..di
independent adjustable with own setpoint and -100% P1 td td P2
..in

measuring input, switching function adjustable l92-d4990419


(ref. to chapter additional switching contacts)
Other data:
Installation dimensions:
Housing for panel mounting, 96 x 96 mm (type 92..,
93..) or 72 x 144 mm (type 94)
L Power supply: 230VAC +/- 10 %, 48...62Hz
alternative 115 VAC, 48 VAC, 24 VAC, 24 VDC
B +0,8
Power consumption: approx. 14 VA
Protective system DIN 40050: IP54 (terminals IP20)
H +0,8
Permissible ambient temperature: 0...60°C
Nominal temperature: 20°C
Climatic category: KUF to DIN 40050
Relative humidity <= 75 % yearly average,
Form 96x96: L= 150mm, B= 92mm H=92mm no condensation
Form 72x144: L= 170mm, B=168mm H=139mm EMC: refer to EN 50081-2 and EN 50082-2

Wiring diagram:
(Example, depending on sub type some details can be missed
valid for each delivered controller is the wiring diagram on its casing only)

A927_e59710718
controller electronics
fu se: (+) (-)
2 4 V :T 0 ,5 A
1 1 5 V :T 0 ,2 A
2 3 0 V :T 0 ,1 A
18V / external digital power control logic signal
40mA analog inputs set value inputs supply output outp. output relay outputs
Ist 3 Ist 4 dig 3 dig 4 Y 2 log 2 Sout 2 Rel 5 Rel 6 Rel 7 Rel 8
7 8 9 10 11 12 23 24 25 26 32 31 37 36 41 31 62 63 64 65 66 67 68 69 70 71 72 73
U+ Ist 1 Ist 2 SPE dig 1 dig 2 Y 1 log 1 Sout 1 Rel 1 Rel 2 Rel 3 Rel 4
99 1 2 3 4 5 6 13 14 15 19 20 21 22 27 28 29 30 31 35 36 40 31 50 51 52 53 54 55 56 57 58 59 60 61
I U L N + + + (protect relay outputs py external fuse 2A)
(L+) (L-)

wiring examples (for input 1 each)


Pt100 Pt100 standard signal "e" standard signal "q" external set value connecting-example
3 wire 2 wire 0/4..20mA 0/2..10V 0/4..20mA 0/2..10V 0/4..20mA 0/2..10V actuator
a92zu_60311202

1 2 3 1 2 3 1 3 2 3 10 3 11 3 13 15 14 15 50 51 52 53 54 55

L
+ - + - + - + - + - + - M
~
open close N

thermo- feedback standard signal incl. feed voltage switch-over optional:


"e" "q" SP active SP2/SPE
couple device power selection 6 7 8 9
1 2 3 1 2 3 99 1 99 10 19 20 19 20 a b c d
- + A S E
230V 1 2 3 4 5
+ - + -
115V RS 232 / 485

data subjects to alteration 9_e8.doc / 0510422

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