Screw Pump MANUAL Imo
Screw Pump MANUAL Imo
Screw Pump MANUAL Imo
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)
ACE 025 K V
032 L T
038 N 3 N B P A101
Q
LPQ 100 L 1 I R Y P
110 N
125 P
140 J
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.
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).
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.
;;;;
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.
bar
Fig. 12 Gauges
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.
ATTENTION
Don't mix up with arrow for inlet and outlet!
Fig. 17 Direction of rotation
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.
- The oil is too cold (or has higher Reduce the pressure setting until
viscosity than anticipated). operational temperature has been
reached.
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 overload relay set too low Readjust or replace the relay.
or is faulty.
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.
- Air leakage into the suction line. Check the suction line for air
leakage.
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
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)
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.
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
ACE 0620GB 4
June 2000
Sectional view
C-C E-E
463 463A
732
7310
537 537A
(xQxx)
Fig. 2
5 ACE 0620GB
June 2000
Useful tools
d
Fig. 3
Fig. 4
ACE 0620GB 6
June 2000
Dismantling
B.
A. OFF ON
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
Fig. 7 Fig. 8
E. F. 1020
451
5011
Fig. 9 Fig. 10
7 ACE 0620GB
June 2000
G. H. xTxx and xQxx
501 125
501
1020
Fig. 11 Fig. 12
I. J. xVxx
xTxx
xQxx
501
xVxx
Fig. 13 Fig. 14
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
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
Fig. 25 Fig. 26
K. L.
• Press on the shaft coupling
to its original position.
• Tighten the stop screw.
Fig. 27 Fig. 28
ACE 0620GB 10
June 2000
453
Pressure relief valve
551
ATTENTION
Spring tension.
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
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
ACG 0620GB 2
September 1999
Exploded view
551 453
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
509
CW rotation 201
ACG3 © IMO AB
113
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.
S2 O-ring
Version code xVxx S4 Seal ring
S5 Bellows unit
S2 S1 S4 S5
Fig. 3
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
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.
Fig. 4
5 ACG 0620GB
September 1999
Sectional view
506 440 556
(502) 602
520A 605
520 612
122 615
124A 608
124 614
1020 631
133 480
514 462
520 462A
359 607
451 606
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.
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
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
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
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.
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
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
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
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
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
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
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
Conversion Kit
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.
or
or
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
or
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
or
or
Options
Isolating piece (incl. screws and extensions) 1 13172 13172 13172 13172 13172
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
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.
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.
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.
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.
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.
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.
10.1. Installation
10.1.1. Lifting
When lifting the heat exchanger, following methods are allowed:
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.
10.1.3. 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.
10.2.2. 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.
===================================================================
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.
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 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 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.
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.)
4.4 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.
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)
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
Type 2200
Table of Contents
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
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
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
F1 to F3 each 1 A
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).
After a few moments, the parameterised controller type is displayed in the second line:
When a flushing cycle is started, the following messages appear in the first line of the display,
depending on the source:
When a flushing cycle is started, the following messages appear in the second line of the display,
depending on the source, e.g.:
“ 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
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.
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).
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
Note: This parameter is only visible with filter type P0 = 6, 7, 8, 9, 10, 11, 12, 13, 14, 15.
Note: This parameter is only visible with filter types P0 = 4, 5, 8, 9, 14, 15.
Note: This parameter is only visible with filter types P0 = 4, 5, 8, 9, 14, 15.
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”
Note: This parameter is only visible with filter types P0 = 0, 6, 7, 8, 9, 12, 13, 14, 15.
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.)
The user can choose between English, French, German and Spanish.
The test code switches the control box to a test mode that is accessible only for authorised
persons.
When the master switch is in position ON, the contact is closed (made).
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.
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.
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.
When key C “Number of flushing cycles” is pressed, the number of flushing cycles performed
appears on the display for 3 seconds.
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
Inputs
Pressure switch “DP reached – Back-flushing filter” 75%
Pressure switch “DP too high – Back-flushing filter” 100%
Outputs
Motor
Flushing valve
Description of functions
The function of the filter is described in the operating manual.
Additional inputs with 6.61.07 and 6.61.07 Alarm DP (Flushing oil conditioning)
Pressure switch
DP too high – Flushing oil conditioning 100%
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 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.
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.
Additional output
Relief valve
10. Servicing
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 can be undercooled or overheated during storage but remains
fully usable when returned to normal temperature.
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.
13.3 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 )
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.
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
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
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.
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
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.
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.
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.
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:)
Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)
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.
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:
* = channel no. in case of multiple measuring inputs or control loops. # = acc. to range
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
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)
on
So E Make contact above setpoint. Relay picks
of f
up as actual value increases (Ein = on) SA
Sd
of f
US A Relay drops out with increasing actual Sd
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
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
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
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-)
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
VISCOMASTER DYNAMIC
Technical Manual
CHAPTER 1 - INTRODUCTION
CHAPTER 4 - MAINTENANCE
CHAPTER 5 - SPECIFICATION
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.
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.
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).
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:
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.
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
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.
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.
4?(100mm) 6? 150mm)
vertical pipe vertical pipe
2봖chedule 40
Pocket or 밫
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
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..
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.
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.
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.
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.
Note: The schematic shown may vary without notice, although overall dimensions will remain unchanged.
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.
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.
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.
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
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 *
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:
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.
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.
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.
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.
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.
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.
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.
Note: If you encounter communication difficulties with RS485, swap over the ‘A’ and ‘B’ signal
connections at one end of the network.
OR
9-PIN DIN CONNECTOR VERSION:
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.
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.
7. Finally, screw the housing cap on fully and VIEW FROM UNDERNEATH THE ELECTRONICS:
TIGHTEN
CAP
TIGHTEN
GRUB
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.
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.
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.
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
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.
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.
Viscosity reads high Pump coated with Check pump delivery; service pump.
after engine shutdown asphaltenes.
and restart
Bypass not fully closed. Close bypass
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.
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.
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.
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.
5.2.2 ENVIRONMENTAL
Number of channels: 2
Repeatability: ±0.05% FS
(-40°C to +85°C)
5.2.6 APPROVALS
EMC: EN 61326:1997 +A1
Analog outputs are set to provide line kinematic viscosity (in cSt) and temperature (in °C). Units are kg/m3 for the density
parameter.
Viscomaster Dynamic
Parameter
Factory default value
Output averaging 5s
time:
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
Order text:
Motor control valve PN . ., DN . .
in two way form with PTFE-V-ring unit,
Power supply . . ., List-No. 421 . . .
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
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
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
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.
Order text:
Electric actuator, thrust . . ., power supply . . .,
pos. time . . ., mounting rod lenght . . .,
List-No. 4e1 . . .
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
Motor
Gear
Base plate
Cable bushing
Spring housing
Mounting rod
Stroke
Hand wheel with
blocking lever Cmax
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
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.
Fig.1
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
01
02
03
04
05
06
07
08
09
10
11
01
03
04
05
06
A AB
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
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.
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
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.
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.
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.
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:)
Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)
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.
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:
* = channel no. in case of multiple measuring inputs or control loops. # = acc. to range
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
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)
on
So E Make contact above setpoint. Relay picks
of f
up as actual value increases (Ein = on) SA
Sd
of f
US A Relay drops out with increasing actual Sd
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
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
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
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-)
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
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