Documentation

Unit type: Comb. LO CW module

Customer: Caterpillar Power Generation systems
Ktr.number: 265 104
Our order number: 6220384-5
Powerstation: “SOMITA”
Establish date of the documentation: 11.08.2006
 Customer
Somita

System type Order Number

Comb. LO CW module
Documentation 6220384-5

Manufacturer Delivery date

DIRECTORY
m a s GmbH May 24, 2006

DIRECTORY:

1. General ....................................................................................................................................... 2
2. Order dependent section of the module...................................................................................... 3
2.1 General component overview of the module......................................................................... 3
3. Annex Components .................................................................................................................... 3

1
 Customer
Somita

System type Order Number

Comb. LO CW module
Documentation 6220384-5

Manufacturer Delivery date

General
m a s GmbH May 24, 2006

1. General
The technology and design of the module is based on Caterpillar development.
The assembly and choice of the components took place under consideration of the rules from
Caterpillar and common standardize and guiding rules.

2
 Customer
Somita

System type Order Number

Comb. LO CW module
Documentation 6220384-5

Manufacturer Delivery date

Annex components
m a s GmbH May 24, 2006

2. Order dependent section of the module

2.1 General component overview of the module

pcs pos.no. title type DN PN supplier

1,00 FV01 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI

1,00 FV02 butterfly valve, EPDM, CuAl-disc 22.0130065G1 65 16 ARI

1,00 header 150 16 mas

1,00 FK01 angle-thermometer (0-100 °C), Tt=100mm 3503011 1/2" WIKA
V3NBC-316-020-
1 FV03 ball valve n/c LD 20 25 Valve-tek

1,00 FV04 butterfly valve, EPDM, CuAl-disc 22.0120125G1 125 16 ARI

1,00 FK02 glycerin vac. pressure gauge (d=100, -0.1 to + 0.15 MPa) 7201871 1/2" 25 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 FP03 LT cooling water pump LUBL100G180L 100 4 Edur
1,00 FV05 non-return valve RK 41125 125 16 HTI
1,00 FK03 glycerin vac. pressure gauge (d=100, 0 to + 1.0 MPa) 7162140 1/2" 10 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 FV06 butterfly valve, EPDM, CuAl-disc 22.0120125G1 125 16 ARI

1,00 header 150 16 mas

1,00 FK04 angle-thermometer (0-100 °C), Tt=100mm 3503011 1/2" WIKA
V3NBC-316-020-
1 FV07 ball valve n/c LD 20 25 Valve-tek

1 FV09 ball valve V3NBC-316-025 25 25 Valve-tek

1,00 FV08 orifice, DN100, d = 85 mm manufacturer 100 16 mas

1 FV10 ball valve V3NBC-316-025 25 25 Valve-tek

1,00 FR03 LT cooling water temp. control valve 431410Hc 100 16 kfm
1,00 FV11 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI
1,00 FV12 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI
damko SPB
1,00 FV13 orifice DN125 125 16 damko
V3NBC-316-020-
1 FV14 ball valve n/c LD 20 25 Valve-tek
1,00 FK06 straight-thermometer (0-100 °C), Tt=100mm 3205371 1/2" WIKA

3
 Customer
Somita

System type Order Number

Comb. LO CW module
Documentation 6220384-5

Manufacturer Delivery date

Annex components
m a s GmbH May 24, 2006

pcs pos.no. title type DN PN supplier

NT 150S HV,
89Pl., 1.4301, 0.5,
NBR, B-10, S235-
1,00 LH01 lube oil cooler JRG2 150 16 GEA ECO
V3NBC-316-020-
1 FV15 ball valve n/c LD 20 25 Valve-tek
1,00 FK07 straight-thermometer (0-100 °C), Tt=100mm 3205371 1/2" WIKA

1,00 FV16 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI

1,00 header 150 16 mas

1,00 FK09 angle-thermometer (0-100 °C), Tt=100mm 3503011 1/2" WIKA
V3NBC-316-020-
1 FV18 ball valve n/c LD 20 25 Valve-tek

1,00 FV30 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI

damko SPB
1,00 FV31 orifice DN125 125 16 damko
1,00 FK08 straight-thermometer (0-100 °C), Tt=100mm 3205371 1/2" WIKA
1,00 FR01 HT cooling water temp. control valve 431410Hc 100 16 kfm
1,00 FV17 orifice, DN100, d = 65 mm manufacturer 100 16 mas
1,00 FV32 butterfly valve, EPDM, CuAl-disc 22.0130065G1 65 16 ARI
1,00 FV33 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI
1,00 FV34 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI

1,00 FV19 butterfly valve, EPDM, CuAl-disc 22.0120125G1 125 16 ARI

1,00 FK10 glycerin vac. pressure gauge (d=100, -0.1 to + 0.9 MPa) 7233323 1/2" 10 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 FP01 HT cooling water pump LUBL100G180L 100 4 Edur
1,00 FV20 non-return valve RK 41125 125 16 HTI
1,00 FK11 glycerin vac. pressure gauge (d=100, 0 to + 1.0 MPa) 7162140 1/2" 10 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 FV21 butterfly valve, EPDM, CuAl-disc 22.0120125G1 125 16 ARI
1,00 header 150 16 mas
1,00 FK12 angle-thermometer (0-100 °C), Tt=100mm 3503011 1/2" WIKA
V3NBC-316-020-
1 FV22 ball valve n/c LD 20 25 Valve-tek
1,00 FV23 butterfly valve, EPDM, CuAl-disc 22.0130100G1 100 16 ARI

1 FV24 ball valve V3NBC-316-040 40 25 Valve-tek

1,00 FK13 straight-thermometer (0-100 °C), Tt=40mm 3516983 1/2" WIKA

4
 Customer
Somita

System type Order Number

Comb. LO CW module
Documentation 6220384-5

Manufacturer Delivery date

Annex components
m a s GmbH May 24, 2006

pcs pos.no. title type DN PN supplier

1,00 FK14 glycerin vac. pressure gauge (d=100, -0.1 to + 0.9 MPa) 7233323 1/2" 25 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
TP 40-160/2 AE-
1,00 FP05 cooling water preh. pump F-A-AUUE 40 6 Grundfos
1,00 FH03 cooling water preheater, 28 kW, 2 steps EH-W15 / L=850 40 16 Aalborg
V1-316-299-015-
1 FV25 ball valve n/c LD 1/2'' 25 Valve-tek
V1-316-299-015-
1 FV29 ball valve n/c LD 1/2'' 25 Valve-tek
1,00 FV28 savety valve, opening pressure 6 bar 4373.2604 1/2" Leser
1,00 electric step thermostat, TempSwitch2000 0628-017 1/4" Barksdale
1,00 connection box 907-0357 Barksdale
1,00 FV26 non-return valve RK 4140 40 16 HTI
1,00 FK15 glycerin vac. pressure gauge (d=100, 0 to + 1.0 MPa) 7162140 1/2" 10 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 FK16 angle-thermometer (0-100 °C), Tt=40mm 1/2" 16 WIKA
1 FV27 ball valve V3NBC-316-040 40 25 Valve-tek

1,00 LV07 butterfly valve, Viton, CuAl-disc 22.0130065G1 65 16 ARI

1,00 LF01 strainer 2 mm 4-A-15796 65 16 HTI
1,00 LK07 glycerin vac. pressure gauge (d=100, -0.1 to + 0.15 MPa) 7201871 1/2" 25 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 LP01 lube oil prelubricating pump Bfük 25,0 S GL 65 5 Trik
1,00 LK08 glycerin vac. pressure gauge (d=100, 0 to + 1.0 MPa) 7162140 1/2" 10 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden

1,00 LV12 butterfly valve, Viton, CuAl-disc 22.0130065G1 65 16 ARI

1,00 LV11 non-return valve RK 4165 65 16 HTI
1,00 LV10 3-way valve (manual) R35LH444 65 16 HTI
1,00 LV09 non-return valve RK 4165 65 16 HTI
1,00 LV08 butterfly valve, Viton, CuAl-disc 22.0120065G1 65 16 ARI

1,00 LV01 butterfly valve, Viton, CuAl-disc 22.0130125G1 125 16 ARI

1,00 LK01 angle-thermometer (0-100 °C), Tt=100mm 3503011 1/2" WIKA
1,00 LK02 glycerin vac. pressure gauge (d=100, 0 to + 1.0 MPa) 7162140 1/2" 10 WIKA
1,00 dumping pipe 5-422-K POELL

5
 Customer
Somita

System type Order Number

Comb. LO CW module
Documentation 6220384-5

Manufacturer Delivery date

Annex components
m a s GmbH May 24, 2006

pcs pos.no. title type DN PN supplier

1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 LF02 Automatic filter , 30 micron 6.46 100 16 Boll&Kirch
1,00 LV02 butterfly valve, Viton, CuAl-disc 22.0120125G1 125 16 ARI
1,00 LK03 straight-thermometer (0-100 °C), Tt=100mm 3205371 1/2" WIKA
V3NBC-316-020-
1 LV03 ball valve n/c LD 20 25 Valve-tek
V3NBC-316-020-
1 LV04 ball valve n/c LD 20 25 Valve-tek
1,00 LK04 straight-thermometer (0-100 °C), Tt=100mm 3205371 1/2" WIKA
1,00 LV05 butterfly valve, Viton, CuAl-disc 22.0120125G1 125 16 ARI
1,00 LR01 lube oil temp. control valve 431412Hd 125 16 kfm
1,00 LI08 temperature sensor, PT100, Sensycon 06023-92-0 1/2" 16 ABB
1,00 LK05 angle-thermometer (0-100 °C), Tt=100mm 3503011 1/2" WIKA
1,00 LK06 glycerin vac. pressure gauge (d=100, 0 to + 1.0 MPa) 7162140 1/2" 10 WIKA
1,00 dumping pipe 5-422-K POELL
1,00 pressure gauge and test valve 007200090015 1/2" 250 Doden
1,00 LV06 butterfly valve, Viton, CuAl-disc 22.0130125G1 125 16 ARI

6
 Customer
Somita

System type Order Number

Comb. LO CW module
Documentation 6220384-5

Manufacturer Delivery date

Annex components
m a s GmbH May 24, 2006

3. Annex components

CW preheating pump 21 pages

Lube oil prelubricating pump 11 pages
LT CW temp. Control valve 03 pages
Duplexfilter 2.05.5 25 pages

LT/HT CW pump 24 pages

CW preheater 06 pages
LO temp. Control valve 03 pages
Lube oil cooler 59 pages

Non return valve 13 pages

Pressure gauge 02 pages
Thermometer 04 pages
Pressure gauge valve and test 01 pages

Ball valve 06 pages

Safety valve 18 pages
Electric step thermostat 02 pages
2/3 way valve manuel operation 01 page

Butterfly valve 14 pages

Orifice 02 pages
Strainer 01 page

Electrical diagrams 07 pages

7
 Declaration of Conformity Konformitätserklärung
We GRUNDFOS declare under our sole responsibility that the products Wir GRUNDFOS erklären in alleiniger Verantwortung, daß die Produkte
TP and TPD, to which this declaration relates, are in conformity with the TP und TPD, auf die sich diese Erklärung bezieht, mit den folgenden
Council Directives on the approximation of the laws of the EEC Member Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EG-Mit-
States relating to gliedstaaten übereinstimmen:
– Machinery (98/37/EEC). – Maschinen (98/37/EWG).
Standard used: EN 292. Norm, die verwendet wurde: EN 292.
– Electromagnetic compatibility (89/336/EEC). – Elektromagnetische Verträglichkeit (89/336/EWG).
Standards used: EN 61 000-6-2 and EN 61 000-6-3. Normen, die verwendet wurden: EN 61 000-6-2 und EN 61 000-6-3.
– Electrical equipment designed for use within certain voltage limits – Elektrische Betriebsmittel zur Verwendung innerhalb bestimmter Span-
(73/23/EEC). nungsgrenzen (73/23/EWG).
Standards used: EN 60 335-1 and EN 60 335-2-51. Normen, die verwendet wurden: EN 60 335-1 und EN 60 335-2-51.

Deklaracja zgodno⁄ci ProhlÃ˛enÚ o konformitš

My, GRUNDFOS, o⁄wiadczamy z pe°n¿ odpowiedzialno⁄ci¿, ¢e My firma GRUNDFOS prohla˛ujeme na svou plnou
nasze wyroby TP oraz TPD, kt†rych deklaracja niniejsza odpovšdnost, e v»robky TP a TPD na nš se toto prohlÃ˛enÚ
dotyczy, s¿ zgodne z nastõpuj¿cymi wytycznymi Rady d/s vztahuje, jsou v souladu s ustanovenÚmi smšrnice Rady pro
ujednolicenia przepis†w prawnych kraj†w cz°onkowskich EWG: sblÚ enÚ prÃvnÚch p■edpisª Òlensk»ch stÃtª EvropskÕho
˚ maszyny (98/37/EWG), spoleÒenstvÚ v oblastech:
zastosowana norma: EN 292. ˚ strojÚrenstvÚ (98/37/EWG),
˚ zgodno⁄Ì elektromagnetyczna (89/336/EWG), pou ità norma: EN 292.
zastosowane normy: EN 61 000-6-2 i EN 61 000-6-3. ˚ elektromagnetickà kompatibilita (89/336/EWG),
˚ wyposa¢enie elektryczne do stosowania w okre⁄lonym pou itÕ normy: EN 61 000-6-2 a EN 61 000-6-3.
zakresie napiõÌ (73/23/EWG), ˚ provozovÃnÚ spot■ebiÒª v toleranci napštÚ (73/23/EWG),
zastosowane normy: EN 60 335-1 i EN 60 335-2-51. pou itÕ normy: EN 60 335-1 a EN 60 335-2-51.

Déclaration de Conformité Dichiarazione di Conformità

Nous GRUNDFOS déclarons sous notre seule responsabilité que les pro- Noi GRUNDFOS dichiariamo sotto la nostra esclusiva responsabilità che
duits TP et TPD auxquels se réfère cette déclaration sont conformes aux i prodotti TP e TPD ai quali questa dichiarazione se riferisce sono con-
Directives du Conseil concernant le rapprochement des législations des formi alle Direttive del Consiglio concernente il ravvicinamento delle
Etats membres CEE relatives à legislazioni degli Stati membri CEE relative a
– Machines (98/37/CEE). – Macchine (98/37/CEE).
Standard utilisé: EN 292. Standard usato: EN 292.
– Compatibilité électromagnétique (89/336/CEE). – Compatibilità elettromagnetica (89/336/CEE).
Standards utilisés: EN 61 000-6-2 et EN 61 000-6-3. Standard usati: EN 61 000-6-2 e EN 61 000-6-3.
– Matériel électrique destiné à employer dans certaines limites de tension – Materiale elettrico destinato ad essere utilizzato entro certi limiti di ten-
(73/23/CEE). sione (73/23/CEE).
Standards utilisés: EN 60 335-1 et EN 60 335-2-51. Standard usati: EN 60 335-1 e EN 60 335-2-51.

Declaración de Conformidad Declaração de Conformidade

Nosotros GRUNDFOS declaramos bajo nuestra única responsabilidad Nós GRUNDFOS declaramos sob nossa única responsabilidade que os
que los productos TP y TPD a los cuales se refiere esta declaración son produtos TP e TPD aos quais se refere esta declaração estão em confor-
conformes con las Directivas del Consejo relativas a la aproximación de midade com as Directivas do Conselho das Comunidades Europeias
las legislaciones de los Estados Miembros de la CEE sobre relativas à aproximação das legislações dos Estados Membros respeitan-
– Máquinas (98/37/CEE). tes à
Norma aplicada: EN 292. – Máquinas (98/37/CEE).
– Compatibilidad electromagnética (89/336/CEE). Norma utilizada: EN 292.
Normas aplicadas: EN 61 000-6-2 y EN 61 000-6-3. – Compatibilidade electromagnética (89/336/CEE).
– Material eléctrico destinado a utilizarse con determinadas límites de Normas utilizadas: EN 61 000-6-2 e EN 61 000-6-3.
tensión (73/23/CEE). – Material eléctrico destinado a ser utilizado dentro de certos limites de
Normas aplicadas: EN 60 335-1 y EN 60 335-2-51. tensão (73/23/CEE).
Normas utilizadas: EN 60 335-1 e EN 60 335-2-51.

ƒfi΢ÛÁ ”ıÏϸ҈˘ÛÁÚ Overeenkomstigheidsverklaring

≈ÏÂflÚ Á GRUNDFOS ‰ÁβÌÔıÏ Ï ·ðÔÍÎÂÈÛÙÈÍ‹ ‰ÈÍfi Ï·Ú ÂıË˝ÌÁ ¸ÙÈ Wij GRUNDFOS verklaren geheel onder eigen verantwoordelijkheid dat
Ù· ðÒÔȸÌÙ· TP Í·È TPD ÛıÏÏÔÒˆ˛ÌÔÌÙ·È Ï ÙÁÌ œ‰Á„fl· ÙÔı de produkten TP en TPD waarop deze verklaring betrekking heeft in over-
”ıÏ‚ÔıÎflÔı Âðfl ÙÁÚ Û˝„ÍÎÈÛÁÚ Ù˘Ì Ì¸Ï˘Ì Ù˘Ì Ò·Ù˛Ì MÂÎ˛Ì ÙÁÚ eenstemming zijn met de Richtlijnen van de Raad inzake de onderlinge
≈ıÒ˘ð·ÈÍfiÚ ≈Ì˘ÛÁÚ Û ۘ›ÛÁ Ï ٷ aanpassing van de wetgevingen van de Lid-Staten betreffende
ñ ÃÁ˜·ÌfiÏ·Ù· (98/37/EEC). – Machines (98/37/EEG).
—Ò¸ÙıðÔ ðÔı ˜ÒÁÛÈÏÔðÔÈfiËÁÍÂ: EN 292. Norm: EN 292.
ñ «ÎÂÍÙÒÔÏ·„ÌÁÙÈÍfi ÛıÏ‚·Ù¸ÙÁÙ· (89/336/EEC). – Elektromagnetische compatibiliteit (89/336/EEG).
—Ò¸Ùıð· ðÔı ˜ÒÁÛÈÏÔðÔÈfiËÁÍ·Ì: EN 61 000-6-2 Í·È EN 61 000-6-3. Normen: EN 61 000-6-2 en EN 61 000-6-3.
ñ «ÎÂÍÙÒÈÍ›Ú ÛıÛÍÂı›Ú ۘ‰ȷÛÏ›ÌÂÚ „È‹ ˜ÒfiÛÁ ÂÌÙ¸Ú ÔÒÈÛÏ›Ì˘Ì – Elektrisch materiaal bestemd voor gebruik binnen bepaalde spannings-
ÔÒfl˘Ì ÁÎÂÍÙÒÈÍfiÚ Ù‹ÛÁÚ (73/23/EEC). grenzen (73/23/EEG).
—Ò¸Ùıð· ðÔı ˜ÒÁÛÈÏÔðÔÈfiËÁÍ·Ì: EN 60 335-1 Í·È EN 60 335-2-51. Normen: EN 60 335-1 en EN 60 335-2-51.

Försäkran om överensstämmelse Vastaavuusvakuutus

Vi GRUNDFOS försäkrar under ansvar, att produkterna TP och TPD, som Me GRUNDFOS vakuutamme yksin vastuullisesti, että tuotteet TP ja TPD,
omfattas av denna försäkran, är i överensstämmelse med Rådets Direktiv jota tämä vakuutus koskee, noudattavat direktiivejä jotka käsittelevät EY:n
om inbördes närmande till EU-medlemsstaternas lagstiftning, avseende jäsenvaltioiden koneellisia laitteita koskevien lakien yhdenmukaisuutta
– Maskinell utrustning (98/37/EC). seur.:
Använd standard: EN 292. – Koneet (98/37/EY).
– Elektromagnetisk kompatibilitet (89/336/EC). Käytetty standardi: EN 292.
Använda standarder: EN 61 000-6-2 och EN 61 000-6-3. – Elektromagneettinen vastaavuus (89/336/EY).
– Elektrisk material avsedd för användning inom vissa spänningsgränser Käytetyt standardit: EN 61 000-6-2 ja EN 61 000-6-3.
(73/23/EC). – Määrättyjen jänniterajoitusten puitteissa käytettävät sähköiset laitteet
Använda standarder: EN 60 335-1 och EN 60 335-2-51. (73/23/EY).
Käytetyt standardit: EN 60 335-1 ja EN 60 335-2-51.

Overensstemmelseserklæring
Vi GRUNDFOS erklærer under ansvar, at produkterne TP og TPD, som Bjerringbro, 1st September 2002
denne erklæring omhandler, er i overensstemmelse med Rådets direktiver
om indbyrdes tilnærmelse til EF medlemsstaternes lovgivning om
– Maskiner (98/37/EØF).
Anvendt standard: EN 292.
– Elektromagnetisk kompatibilitet (89/336/EØF).
Anvendte standarder: EN 61 000-6-2 og EN 61 000-6-3.
– Elektrisk materiel bestemt til anvendelse inden for visse spændings- Svend Aage Kaae
grænser (73/23/EØF). Technical Manager
Anvendte standarder: EN 60 335-1 og EN 60 335-2-51.
CONTENTS 2. Delivery and handling
Page
2.1 Delivery
1. General 4
The pump is delivered from the factory in a carton
2. Delivery and handling 4 with a wooden bottom, which is specially designed
2.1 Delivery 4 for transport by fork-lift truck or a similar vehicle.
2.2 Handling 4
Lifting eyes for motors of 4 kW and up are supplied
3. Applications 5 with the pump.
3.1 Pumped liquids 5
4. Installation 5 2.2 Handling
4.1 Pipework 6
4.2 Terminal box positions 7 The lifting eyes fitted to large pump motors
4.3 Base plate 7 can be used for lifting the pump head (mo-
4.4 Frost protection 7 tor, motor stool and impeller). The lifting
eyes must not be used for lifting the entire
5. Electrical connection 7
pump.
5.1 Frequency converter operation 7
TPD: The centrally positioned thread of
6. Start-up 7
the pump housing must not be used for
6.1 Priming 7
lifting purposes as the thread is placed be-
6.2 Checking the direction of rotation 8
low the centre of gravity of the pump.
6.3 Starting 8
6.4 Frequency of starts and stops 8 Pumps fitted with motors smaller than 4 kW should
7. Maintenance and service 8 be lifted by means of nylon straps, see fig. 1.
7.1 Pump 8 Fig. 1
7.2 Motor 8
7.3 Service 8
7.4 Shaft adjustment 9 TP
7.5 Blanking flanges 9
8. Technical data 10
8.1 Ambient temperature 10

TM02 5499 3302

8.2 Liquid temperature 10
8.3 Operating pressure/test pressure 10
8.4 Inlet pressure 10
8.5 Enclosure class 10
8.6 Electrical data 10
8.7 Sound pressure level 10
8.8 Environment 10
9. Fault finding chart 11
TPD
10. Disposal 12

Before beginning installation procedures,

these installation and operating instruc-
tions should be studied carefully. The in-
stallation and operation should also be in
TM02 5500 3302

accordance with local regulations and ac-

cepted codes of good practice.

1. General
These instructions apply to the pump types TP and
TPD fitted with GRUNDFOS motors, type MG, MMG,
or motors, type MEZ 63. If the pump is fitted with an-
other motor make, please note that the motor data
may differ from the data stated in these instructions.

1
Pumps fitted with motors of 4 kW and up should be 3.1 Pumped liquids
lifted by means of nylon straps and shackles, see
Thin, clean, non-aggressive and non-explosive liq-
fig. 2.
uids, not containing solid particles or fibres that may
Fig. 2 attack the pump mechanically or chemically.
Examples:
• central heating system water (it is recommended
TP that the water meets the requirements of ac-
cepted standards on water quality in heating sys-
tems, e.g. the German standard VDI 2035),
• cooling liquids,
• domestic hot water,

TM02 5501 3302

• industrial liquids,
• softened water.
The pumping of liquids with a density and/or kine-
matic viscosity higher than that of water will cause
• a considerable pressure drop,
• a drop in hydraulic performance,
TPD • a rise in power consumption.
In such cases, the pump should be fitted with a big-
ger motor. If in doubt, contact GRUNDFOS.
The EPDM O-rings fitted as standard are primarily
suitable for water.
If the water contains mineral/synthetic oils or chemi-
cals or if other liquids than water are pumped, the
O-rings should be chosen accordingly.
TM02 5502 3302

4. Installation
When pumping hot liquids, care should be
taken to ensure that persons cannot acci-
dentally come into contact with hot sur-
faces.
3. Applications When installing pumps with oval bolt holes in the
pump flange (PN 6/10), washers must be used as
The pumps are designed to circulate hot or cold wa-
shown in fig. 3.
ter in for instance
Fig. 3
• heating systems,
• district heating plants,
Installation
TM01 0683 1997

• central heating systems for blocks of flats,

• air-conditioning systems and
• cooling systems
in housing, institutional and industrial applications.
In addition, the pump range is used for liquid transfer Washer Pump
and water supply in for instance
• washing systems, The pump should be sited in a well ventilated, but
• domestic hot water systems and frost-free position.
• industrial systems in general. Arrows on the pump housing show the direction of
flow of liquid through the pump.
To ensure optimum operation, the dimensioning
range of the system must fall within the performance Pumps with motors up to 7.5 kW can be installed in
range of the pump. horizontal or vertical pipework.
Pumps with motors of 7.5 kW and up may only be in-
stalled in horizontal pipework with the motor in verti-
cal position.
Note: The motor must never fall below the horizontal
plane.

2
For inspection and motor/pump head removal, the 4.1 Pipework
following clearance is required above the motor:
Isolating valves should be fitted either side of the
• 300 mm for motors up to and including 4.0 kW. pump to avoid draining the system if the pump needs
• 1 metre for motors of 5.5 kW and up. to be cleaned or repaired.
See fig. 4. The pump is suitable for pipeline mounting, provided
Fig. 4 that the pipework is adequately supported either side
of the pump. TP 25-50, 25-90, 32-50, 32-90, 40-50
0.25 and 40-90 are designed for pipeline mounting only.
0.25 -- 4.0
4.0 kW
kW 5.55.5
kW- and
kWup
For pumps with motors of 7.5 kW and up, it is advis-
able to mount the pump on a concrete pedestal and
to install vibration dampers, see fig. 7. This may also
300 mm 1m be relevant for smaller motors.
Fig. 7

TM00 3733 2802

A

TM02 4993 3202

Twin-head pumps installed in horizontal pipes must
be fitted with an automatic air vent in the upper part B
of the pump housing, see fig. 5.
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The automatic air vent is not supplied with the pump.

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Fig. 5

A: Expansion joint
B: Concrete pedestal
C: Vibration damper
TM00 9834 0497

When installing the pipes, it must be ensured that the

pump housing is not stressed by the pipework.
The suction and discharge pipes must be of an ade-
quate size, taking the pump inlet pressure into ac-
count.
To avoid sediment build-up, do not fit the pump at
If the liquid temperature falls below the ambient tem- the lowest point of the system.
perature, condensation may form in the motor during Install the pipes so that air locks are avoided, espe-
inactivity. In this case, it must be ensured that the cially on the suction side of the pump, see fig. 8.
drain hole in the motor flange, see fig. 6, is open and Fig. 8
points downwards.
Fig. 6
TM00 2263 0195
TM00 9831 3202

Drain hole
Note: The pump is not allowed to run against a
If twin-head pumps are used for pumping liquids with closed discharge valve as this will cause an increase
a temperature below 0°C/32°F, condensed water in temperature/formation of steam in the pump which
may freeze and cause the coupling to get stuck. The may cause damage to the pump.
problem can be remedied by installing heating ele- If there is any danger of the pump running against a
ments. Whenever possible (pumps with motors closed discharge valve, a minimum liquid flow
smaller than 7.5 kW), the pump should be installed through the pump should be ensured by connecting
with the motor shaft in horizontal position, see fig. 5. a bypass/a drain to the discharge pipe. The drain
can for instance be connected to a tank. A minimum
Note: The technical data in section 8 must be ob-
flow rate equal to 10% of the flow rate at maximum
served.
efficiency is needed at all times. Flow rate and head
at maximum efficiency are stated on the pump name-
plate.
3
4.2 Terminal box positions Note: Do not start the pump until it has been filled
with liquid and vented.
Before starting work on the pump, make
sure that the electricity supply has been 5.1 Frequency converter operation
switched off and that it cannot be acciden-
tally switched on. All three-phase motors can be connected to a fre-
quency converter.
The terminal box can be turned to any of four posi- Depending on the frequency converter type, this may
tions, in 90° steps. cause increased acoustic noise from the motor. Fur-
Change the terminal box position as follows: thermore, it may cause the motor to be exposed to
1. If necessary, remove the coupling guards using a detrimental voltage peaks.
screwdriver. Do not remove the coupling. Note: Motors types MEZ 63, MG 71 and MG 80 for
2. Remove the screws securing the motor to the supply voltages up to and including 440 V (see motor
pump. nameplate) must be protected against voltage peaks
3. Turn the motor to the required position. higher than 650 V between the supply terminals.
It is recommended to protect all other motors against
4. Replace and tighten the screws. voltage peaks higher than 850 V.
5. Replace the coupling guards. The above disturbances, i.e. both increased acoustic
noise and detrimental voltage peaks, can be elimi-
4.3 Base plate nated by fitting an LC filter between the frequency
Single-head pumps (apart from TP 25-50, 25-90, converter and the motor.
32-50, 32-90, 40-50 and 40-90) have two tapped For further information, please contact the frequency
holes in the bottom of the pump housing which can converter supplier or GRUNDFOS.
be used for fitting a GRUNDFOS base plate to the
pump. The base plate is available as an optional ex- 5.1.1 Other motor makes than GRUNDFOS
tra. Contact GRUNDFOS or the motor manufacturer.
Twin-head pumps have four tapped holes in the bot-
tom of the pump housing. For some twin-head
pumps, a base plate consisting of two halves is avail- 6. Start-up
able. Note: Do not start the pump until it has been filled
Base plates with dimensions are shown on page with liquid and vented. To ensure correct venting, the
131. vent screw should point upwards.

4.4 Frost protection 6.1 Priming

Pumps which are not being used during periods of Closed systems or open systems where the liq-
frost should be drained to avoid damage. uid level is above the pump inlet:
1. Close the discharge isolating valve and loosen
5. Electrical connection the air vent screw in the motor stool, see fig. 9.
Pay attention to the direction of the vent
The electrical connection should be carried out in ac-
hole and take care to ensure that the es-
cordance with local regulations.
caping water does not cause injury to per-
Before removing the terminal box cover sons or damage to the motor or other
and before any removal/dismantling of the components.
pump, make sure that the electricity supply In hot-water installations, special attention
has been switched off. should be paid to the risk of injury caused
The pump must be connected to an exter- by scalding hot water.
nal mains switch with a minimum contact 2. Slowly open the isolating valve in the suction pipe
gap of 3 mm in all poles. until a steady stream of liquid runs out of the vent
The operating voltage and frequency are marked on hole.
the pump nameplate. Make sure that the motor is 3. Tighten the air vent screw and completely open
suitable for the electricity supply on which it will be the isolating valve(s).
used. Open systems where the liquid level is below the
Single-phase standard motors incorporate a thermal pump inlet:
switch and require no additional motor protection. The suction pipe and the pump must be filled with
Three-phase motors must be connected to a motor liquid and vented before the pump is started.
starter. 1. Close the discharge isolating valve and open the
Motors of 3 kW and up incorporate thermistors isolating valve in the suction pipe.
(PTC). The thermistors are designed according to 2. Loosen the air vent screw, see fig. 9.
DIN 44 082.
3. Remove the plug from one of the pump flanges,
The electrical connection should be carried out as depending on the pump location.
shown in the diagram inside the terminal box cover.
4. Pour liquid through the priming port until the suc-
The motors of twin-head pumps are to be connected tion pipe and the pump are filled with liquid.
separately.
5. Replace the plug and tighten securely.
4
6. Tighten the air vent screw. • If twin-head pumps are used for pumping domes-
The suction pipe can to some extent be filled with liq- tic hot water, the duty and standby pumps should
uid and vented before it is connected to the pump. be alternated on a regular basis, i.e. once a day,
A priming device can also be installed before the to avoid blocking of the standby pump due to de-
pump. posits (calcareous deposits, etc.).
Automatic pump change is recommended.
Fig. 9

7. Maintenance and service

Before starting work on the pump, make
Vent screw sure that the electricity supply has been
switched off and that it cannot be acciden-

TM00 9832 3202

tally switched on.

7.1 Pump
The pump is maintenance-free.
If the pump is to be drained for a long period of inac-
tivity, inject a few drops of silicone oil on the shaft
between the motor stool and the coupling. This will
6.2 Checking the direction of rotation
prevent the shaft seal faces from sticking.
Do not start the pump to check the direction of rota-
tion until it has been filled with liquid. 7.2 Motor
Note: The direction of rotation should not be The motor should be checked at regular intervals. It
checked with the motor alone, as an adjustment of is important to keep the motor clean in order to en-
the shaft position is required when the coupling has sure adequate ventilation. If the pump is installed in
been removed. a dusty environment, the pump must he cleaned and
The correct direction of rotation is shown by arrows checked regularly.
on the motor fan cover or on the pump housing. Lubrication:
The bearings of motors up to 11 kW are greased for
6.3 Starting
life and require no lubrication.
1. Before starting the pump, completely open the The bearings of motors of 11 kW and up must be
isolating valve on the suction side of the pump greased in accordance with the indications on the
and leave the discharge isolating valve almost motor nameplate.
closed.
The motor should be lubricated with a lithium-based
2. Start the pump. grease meeting the following specifications:
3. Vent the pump during starting by loosening the • NLGI grade 2 or 3.
air vent screw in the motor stool, see fig. 9, until a
steady stream of liquid runs out of the vent hole. • Viscosity of basic oil: 70 to 150 cSt at 40°C
(~ +104°F).
Pay attention to the direction of the vent
• Temperature range: –30°C (~ –22°F) to 140°C
hole and take care to ensure that the es-
(~ +284°F) during continuous operation.
caping water does not cause injury to per-
sons or damage to the motor or other
7.3 Service
components.
In hot-water installations, special attention If the pump has been used for a liquid
should be paid to the risk of injury caused which is injurious to health or toxic, the
by scalding hot water. pump will be classified as contaminated.
4. When the piping system has been filled with liq-
uid, slowly open the discharge isolating valve un- If GRUNDFOS is requested to service the pump,
GRUNDFOS must be contacted with details about
til it is completely open.
the pumped liquid, etc. before the pump is returned
6.4 Frequency of starts and stops for service. Otherwise GRUNDFOS can refuse to ac-
cept the pump for service.
Maximum 100 starts per hour.
Possible costs of returning the pump are paid by the
• On twin-head pumps, the duty and standby pumps customer.
should be alternated on a regular basis, i.e. once
a week, to ensure an even distribution of the oper-
ating hours on both pumps.
Pump change can be effected either manually or
automatically by installing a suitable pump control-
ler.

5
7.4 Shaft adjustment 7.4.2 Pumps with integral shaft/coupling
If the motor has been removed during installation or For pumps with integral shaft/coupling, it is advisable
for repair of the pump, the pump shaft must be ad- not to remove the motor. If the motor has been re-
justed after the motor has been replaced. moved, it is necessary to remove the motor stool in
order to refit the motor correctly. Otherwise the shaft
7.4.1 Pumps with two-part coupling seal may be damaged.
Make sure that the shaft pin is fitted in the pump
shaft. 7.5 Blanking flanges
Adjust the pump shaft as follows: For twin-head pumps, a blanking flange with a pump
1. Remove the coupling guards using a screwdriver. housing gasket is available, see fig. 12.
2. Fit the hexagon socket head screws in the cou- Fig. 12
pling and leave loose.
3. Raise the coupling and the pump shaft as far as
possible (towards the motor) by means of a
screwdriver or a similar tool so that the pump and
motor shafts touch each other, see fig. 10.
Fig. 10

TM00 6360 3495

TM00 6415 3695

If one pump requires service, the blanking flange is

fitted to allow the other pump to continue operating.

4. Tighten the hexagon socket head screws in the

coupling to 5 Nm (0.5 kpm).
5. Check that the gaps either side of the coupling
halves are equal.
6. Tighten the screws two and two (one side at a
time), see fig. 11, to the torque stated below.

Hexagon socket
Torque
head screw
M6 x 20 13 Nm (1.3 kpm)
M8 x 25 31 Nm (3.1 kpm)

7. Fit the coupling guards.

Fig. 11
TM00 6416 3695

6
8. Technical data
8.1 Ambient temperature
Maximum +40°C (~ +104°F).

8.2 Liquid temperature

–25°C (~ –13°F) up to +140°C (~ +288°F).
The maximum liquid temperature depends on the
mechanical shaft seal type and the pump type.
Depending on the cast-iron version and the pump
application, the maximum liquid temperature may be
limited by local regulations and laws.
The maximum liquid temperature is marked on the
pump nameplate.
Note: If the pump is operating with liquids at high
temperatures, the life of the shaft seal may be re-
duced. It may be necessary to replace the shaft seal
more often.

8.3 Operating pressure/test pressure

The pressure test has been made with water con-
taining anti-corrosive additives at a temperature of
+20°C (~ +68°F).

Operating Test
Pressure pressure pressure
stage
bar MPa bar MPa
PN 6 6 0.6 10 1.0
PN 6/
10 1.0 15 1.5
PN 10
PN 16 16 1.6 24 2.4

8.4 Inlet pressure

To ensure optimum and quiet pump operation, the
inlet pressure (system pressure) must be adjusted
correctly. See table on page 124.
For the calculation of specific inlet pressures, con-
tact the local GRUNDFOS company or see the data
booklet for TP(D)/TPE(D), if at hand.

8.5 Enclosure class

Closed drain hole in motor: IP 55.
Open drain hole in motor: IP 44.
(Drain hole, see fig. 6.)

8.6 Electrical data

See motor nameplate.

8.7 Sound pressure level

Pumps with single-phase motors:
The sound pressure level of the pump is lower than
70 dB(A).
Pumps with three-phase motors:
See table on page 130.

8.8 Environment
Non-aggressive and non-explosive atmosphere.
Relative air humidity: Maximum 95%.

7
9. Fault finding chart

Before removing the terminal box cover and before removal/dismantling of the pump, make sure that
the electricity supply has been switched off and that it cannot be accidentally switched on.

Fault Cause
1. Motor does not run when a) Supply failure.
started. b) Fuses blown.
c) Motor starter overload has tripped out.
d) Main contacts in motor starter are not making contact or the coil is
faulty.
e) Control circuit fuses are defective.
f) Motor is defective.
2. Motor starter overload trips a) Supply failure.
out immediately when supply b) Contacts in motor starter overload are faulty.
is switched on. c) Cable connection is loose or faulty.
d) Motor winding is defective.
e) Pump mechanically blocked.
f) Overload setting too low.
3. Motor starter overload trips a) Overload setting too low.
out occasionally. b) Supply voltage periodically too low or too high.
c) Differential pressure across pump too low.
4. Motor starter has not tripped a) Check the electricity supply.
out but the pump does not b) Check fuses.
run. c) Check main contacts in motor starter and coil.
d) Check the control circuit.
5. Pump capacity not constant. a) Pump inlet pressure is too low.
b) Suction pipe/pump partly blocked by impurities.
c) Pump draws in air.
6. Pump runs but gives no water. a) Suction pipe/pump blocked by impurities.
b) Foot or non-return valve blocked in closed position.
c) Leakage in suction pipe.
d) Air in suction pipe or pump.
e) Motor rotates in the wrong direction.
7. Pump runs backwards when a) Leakage in suction pipe.
switched off.* b) Foot or non-return valve defective.
c) Foot or non-return valve blocked in open or partly open position.
8. Leakage in shaft seal. a) Pump shaft position is incorrect.
b) Shaft seal is defective.
9. Noise. a) Pump is cavitating.
b) Pump does not rotate freely (frictional resistance) because of incorrect
pump shaft position.
c) Frequency converter operation:
- See section 5.1 Frequency converter operation.
- Resonance in the installation.
d) Foreign bodies in the pump.
10. Pump runs constantly a) Stop pressure is too high in relation to the required quantity of water.
(applies only to pumps with b) The water consumption is larger than anticipated.
automatic start/stop). c) Leakage in discharge pipe.
d) The direction of rotation of the pump is incorrect.
e) Pipes, valves or strainer blocked by impurities.
f) Pump controller, if used, is defective.
11. Period of operation is too long a) Stop pressure is too high in relation to the required quantity of water.
(applies only to pumps with b) Pipes, valves or strainer blocked by impurities.
automatic start/stop). c) Pump partly blocked or furred up.
d) The water consumption is larger than anticipated.
e) Leakage in discharge pipe.

* In twin-head pump installations, the standby pump will often rotate slowly.

8
10. Disposal
Disposal of this product or parts of it must be carried
out according to the following guidelines:
1. Use the local public or private waste collection
service.
2. In case such waste collection service does not
exist or cannot handle the materials used in the
product, please deliver the product or any haz-
ardous materials from it to your nearest GRUND-
FOS company or service workshop.

Subject to alterations.
9
GB: Inlet pressure stated in bar relative pressure (pressure gauge value measured on the suction side of the
pump)
D: Zulaufdruck in bar Relativdruck (Manometerdruck auf der Saugseite der Pumpe gemessen)
PL: Ci⁄nienie na kr†Ìcu ssawnym pompy wyra¢one w barach (mierzone manometrem na stronie
ssawnej pompy)
CZ: Tlak na sÃnÚ vyjÃd■en» v barech je relativnÚ tlak (hodnota na manometru mš■enà na sacÚ stranš
Òerpadla)
F: Pression d’entrée indiquée en bar (valeur mesurée à l’aide d’un manomètre placé sur le côté aspiration
de la pompe)
I: Pressione di aspirazione indicata in bar (valore misurato con un manometro posto sul lato aspirazione
della pompa)
E: Presión de aspiración indicada en bar como presión relativa (valor del manómetro medido en la aspira-
ción de la bomba)
P: Pressão de entrada com a pressão relativa apresentada em bar (ponto de medida na parte de aspiração
da bomba)
GR: ¶›ÂÛË ·Ó·ÚÚfiÊËÛ˘ Û bar Û¯ÂÙÈ΋˜ ð›ÂÛ˘ (ÌÂÙÚÔ‡ÌÂÓË ÙÈÌ‹ ð›ÂÛ˘ ÛÙËÓ ðÏÂ˘Ú¿ ·Ó·ÚÚfiÊËÛ˘
Ù˘ ·ÓÙÏ›·˜)
NL: Inlaatdruk weergegeven in bar relatieve druk (drukopnemer waarde, gemeten aan de zuigkant van de
pomp)
S: Tilloppstrycket angivet i bar relativt tryck (manometervärde mätt på pumpens sugsida)
SF: Tulopaine ilmoitettuna baareina on suhteellinen paine (painemittarin lukema mitattu pumpun imupuo-
lella)
DK: Tilløbstrykket angivet i bar relativt tryk (manometerværdi målt på pumpens sugeside)

50 Hz, 2-pole

Pump type p [bar]

50 Hz, 2-pole 20°C 60°C 90°C 110°C 120°C 140°C

TP 25-50R/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 25-90R/2 0.1 0.1 0.1 0.8 1.4 3.1

TP 32-50R/2 0.1 0.1 0.1 0.8 1.4 3.1

TP 32-90R/2 0.1 0.1 0.1 0.8 1.4 3.1

TP(D) 32-60/2 0.1 0.1 0.2 1.0 1.5 3.2

TP(D) 32-120/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 32-150/2 0.1 0.3 0.8 1.6 2.1 3.8
TP(D) 32-180/2 0.5 0.7 1.2 2.0 2.5 4.2
TP(D) 32-230/2 0.7 0.9 1.4 2.2 2.7 4.4
TP(D) 32-200/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-250/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-320/2 0.1 0.1 0.6 1.4 1.9 3.6
TP(D) 32-380/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 32-460/2 0.1 0.2 0.7 1.4 2.0 3.7
TP(D) 32-580/2 0.2 0.4 0.9 1.6 2.2 3.9

TP 40-50/2 0.1 0.1 0.1 0.8 1.4 3.1

TP 40-90/2 0.1 0.1 0.1 0.8 1.4 3.1

TP(D) 40-60/2 0.1 0.1 0.5 1.2 1.8 3.5

TP(D) 40-120/2 0.1 0.1 0.4 1.2 1.7 3.4
TP(D) 40-180/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 40-190/2 0.1 0.3 0.8 1.6 2.1 3.8

10
 Pump type p [bar]

50 Hz, 2-pole 20°C 60°C 90°C 110°C 120°C 140°C

TP(D) 40-230/2 0.7 0.9 1.4 2.2 2.7 4.4
TP(D) 40-270/2 0.7 0.9 1.4 2.2 2.7 4.4
TP(D) 40-240/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-300/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-360/2 0.2 0.4 0.9 1.6 2.2 3.9
TP(D) 40-470/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-580/2 0.2 0.4 0.9 1.6 2.2 3.9

TP(D) 50-60/2 0.1 0.1 0.4 1.1 1.7 3.4

TP(D) 50-120/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 50-180/2 0.1 0.2 0.7 1.4 2.0 3.7
TP(D) 50-160/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-190/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-240/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-290/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-360/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-430/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-440/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-570/2 0.1 0.3 0.8 1.6 2.1 3.8
TP(D) 50-710/2 0.6 0.8 1.3 2.0 2.6 4.3
TP(D) 50-830/2 0.5 0.7 1.2 2.0 2.5 4.2
TP(D) 50-960/2 1.0 1.2 1.7 2.5 3.0 4.7

TP(D) 65-60/2 0.1 0.3 0.8 1.5 2.1 3.8

TP(D) 65-120/2 0.5 0.7 1.2 2.0 2.5 4.2
TP(D) 65-180/2 0.3 0.5 1.0 1.8 2.3 4.0
TP(D) 65-190/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-230/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-260/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-340/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-410/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-460/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-550/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-660/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-720/2 0.1 0.1 0.6 1.3 1.9 3.6
TP(D) 65-930/2 0.6 0.8 1.3 2.0 2.6 4.3

TP(D) 80-120/2 1.2 1.4 1.9 2.7 3.2 4.9

TP(D) 100-120/2 1.9 2.1 2.6 3.4 3.9 5.6

11
50 Hz, 4-pole

Pump type p [bar]

50 Hz, 4-pole 20°C 60°C 90°C 110°C 120°C 140°C

TP(D) 32-30/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-40/4 0.1 0.1 0.1 0.9 1.4 3.1
TP(D) 32-60/4 0.1 0.1 0.3 1.1 1.6 3.3
TP(D) 32-80/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-100/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-120/4 0.1 0.1 0.1 0.8 1.4 3.1

TP(D) 40-30/4 0.1 0.1 0.2 0.9 1.5 3.2

TP(D) 40-60/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-90/4 0.1 0.1 0.3 1.0 1.6 3.3
TP(D) 40-100/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-160/4 0.1 0.1 0.1 0.8 1.4 3.1

TP(D) 50-30/4 0.1 0.1 0.1 0.9 1.4 3.1

TP(D) 50-60/4 0.1 0.1 0.2 0.9 1.5 3.2
TP(D) 50-90/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-110/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-160/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-230/4 0.1 0.1 0.1 0.8 1.4 3.1

TP(D) 65-30/4 0.1 0.2 0.7 1.5 2.0 3.7

TP(D) 65-60/4 0.2 0.4 0.9 1.6 2.2 3.9
TP(D) 65-90/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-110/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-150/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-170/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-240/4 0.1 0.1 0.1 0.8 1.4 3.1

TP(D) 80-30/4 0.8 1.0 1.5 2.2 2.8 4.5

TP(D) 80-60/4 0.8 1.0 1.5 2.3 2.8 4.5

TP(D) 100-30/4 0.8 1.0 1.5 2.2 2.8 4.5

TP(D) 100-60/4 0.6 0.8 1.3 2.0 2.6 4.3

12
60 Hz, 2-pole

Pump type p [bar]

60 Hz, 2-pole 20°C 60°C 90°C 110°C 120°C 140°C

TP 32-80/2 0.4 0.4 0.4 1.2 1.7 3.4
TP 32-160/2 0.4 0.6 1.1 1.9 2.4 4.1
TP 32-220/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 32-260/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 32-330/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 32-300/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-360/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-450/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-550/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-680/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-820/2 0.5 0.7 1.2 1.9 2.5 4.2

TP 40-80/2 0.1 0.3 0.8 1.6 2.1 3.8

TP 40-160/2 0.1 0.2 0.7 1.5 2.0 3.7
TP 40-240/2 0.4 0.6 1.1 1.9 2.4 4.1
TP 40-270/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 40-330/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 40-390/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 40-370/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-450/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-550/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-740/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-850/2 0.1 0.1 0.6 1.4 1.9 3.6
TP 40-930/2 0.3 0.5 1.0 1.7 2.3 4.0

TP 50-80/2 0.1 0.1 0.6 1.4 1.9 3.6

TP 50-160/2 0.4 0.6 1.1 1.9 2.4 4.1
TP 50-240/2 0.3 0.5 1.0 1.8 2.3 4.0
TP 50-250/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-300/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-350/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-410/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-440/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-540/2 0.1 0.2 0.7 1.4 2.0 3.7
TP 50-720/2 0.1 0.3 0.8 1.6 2.1 3.8
TP 50-790/2 0.5 0.7 1.2 1.9 2.5 4.2
TP 50-880/2 0.8 1.0 1.5 2.2 2.8 4.5
TP 50-1050/2 1.1 1.3 1.8 2.6 3.1 4.8

TP 65-80/2 0.6 0.8 1.3 2.1 2.6 4.3

TP 65-160/2 1.1 1.3 1.8 2.6 3.1 4.8
TP 65-240/2 0.9 1.1 1.6 2.4 2.9 4.6
TP 65-220/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-260/2 0.1 0.1 0.1 0.8 1.4 3.1

13
 Pump type p [bar]

60 Hz, 2-pole 20°C 60°C 90°C 110°C 120°C 140°C

TP 65-340/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-390/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-480/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-540/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-630/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-740/2 0.1 0.1 0.6 1.3 1.9 3.6
TP 65-910/2 0.1 0.2 0.7 1.5 2.0 3.7
TP 65-1050/2 0.1 0.2 0.7 1.5 2.0 3.7

TP 80-160/2 2.1 2.3 2.8 3.6 4.1 5.8

14
60 Hz, 4-pole

Pump type p [bar]

60 Hz, 4-pole 20°C 60°C 90°C 110°C 120°C 140°C

TP 32-40/4 0.1 0.1 0.1 0.9 1.4 3.1
TP 32-80/4 0.1 0.1 0.5 1.3 1.8 3.5
TP 32-120/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-140/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-190/4 0.1 0.1 0.1 0.8 1.4 3.1

TP 40-40/4 0.1 0.1 0.3 1.1 1.6 3.3

TP 40-80/4 0.1 0.1 0.2 1.0 1.5 3.2
TP 40-120/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-160/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-220/4 0.1 0.1 0.1 0.8 1.4 3.1

TP 50-40/4 0.1 0.1 0.3 1.1 1.6 3.3

TP 50-80/4 0.1 0.1 0.3 1.1 1.6 3.3
TP 50-110/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-120/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-140/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-240/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-270/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-340/4 0.1 0.2 0.7 1.4 2.0 3.7

TP 65-40/4 0.4 0.6 1.1 1.9 2.4 4.1

TP 65-80/4 0.7 0.9 1.4 2.2 2.7 4.4
TP 65-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-150/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-230/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-310/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-330/4 0.1 0.1 0.1 0.8 1.4 3.1

TP 80-40/4 1.5 1.7 2.2 3.0 3.5 5.2

TP 80-80/4 1.6 1.8 2.3 3.1 3.6 5.3

TP 100-40/4 1.4 1.6 2.1 2.9 3.4 5.1

TP 100-80/4 1.2 1.4 1.9 2.7 3.2 4.9

15
Maximum sound pressure level

50 Hz 60 Hz
Three-phase motors [dB(A)] [dB(A)]
[kW]
2-pole 4-pole 2-pole 4-pole

0.12 <70 <70 <70 <70

0.18 <70 <70 <70 <70
0.25 <70 41.2 <70 45.0
0.37 56.2 44.8 57.0 45.0
0.55 56.6 41.8 56.0 45.0
0.75 56.3 41.5 57.0 49.0
1.1 59.0 50.0 63.0 53.0
1.5 58.0 50.0 64.0 53.0
2.2 60.0 52.0 65.0 55.0
3.0 59.0 52.0 64.0 55.0
4.0 63.0 54.0 68.0 57.0
5.5 63.0 58.0 67.0 62.0
7.5 68.0 58.0 73.0 62.0
11.0 65.0 60.0 69.0 64.0
15.0 65.0 60.0 69.0 64.0
18.5 66.0 61.0 70.0 65.0
22.0 68.0 61.0 72.0 65.0
30.0 69.0 62.0 73.0 66.0
37.0 69.0 65.0 73.0 69.0

16
Fig. A
235
195 35
2xø18

2xø14

160
195
80

2xø14

TM00 9835 0497

2xø18
4xø14
120
200

Fig. B
235
195 35
2xø14
195
96

2xø18

TM00 3755 5097

4xø14
144

Fig. C
35

175 2xø18
TM 02 5336 2602
47
67

300
2xø14
330

17
Denmark France Japan Singapore
GRUNDFOS DK A/S Pompes GRUNDFOS Distribution GRUNDFOS Pumps K.K. GRUNDFOS (Singapore) Pte. Ltd.
Poul Due Jensens Vej 7A S.A. 1-2-3, Shin Miyakoda 24 Tuas West Road
DK-8850 Bjerringbro Parc d’Activités de Chesnes Hamamatsu City Jurong Town
Tlf.: +45-87 50 50 50 57, rue de Malacombe Shizuoka pref. 431-21 Singapore 638381
Telefax: +45-87 50 51 51 F-38290 St. Quentin Fallavier Phone: +81-53-428 4760 Phone: +65-6865 1222
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Argentina Tél.: +33-4 74 82 15 15
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S.A. GRUNDFOS Pumps Korea Ltd. Bombas GRUNDFOS España S.A.
Ruta Panamericana km. 37.500 Germany 2nd Fl., Dong Shin Building Camino de la Fuentecilla, s/n
Lote 34A GRUNDFOS GMBH 994-3 Daechi-dong, Kangnam-Ku E-28110 Algete (Madrid)
1619 - Garin Schlüterstr. 33 Seoul 135-280 Tel.: +34-91-848 8800
Pcia. de Buenos Aires 40699 Erkrath Phone: +82-2-5317 600 Telefax: +34-91-628 0465
Phone: +54-3327 414 444 Tel.: +49-(0) 211 929 69-0 Telefax: +82-2-5633 725
Telefax: +54-3327 411 111 Telefax: +49-(0) 211 929 69-3799 Sweden
e-mail: [email protected] Malaysia GRUNDFOS AB
Australia Service in Deutschland: GRUNDFOS Pumps Sdn. Bhd. Box 63, Angeredsvinkeln 9
GRUNDFOS Pumps Pty. Ltd. e-mail: kundendienst@grund- 7 Jalan Peguam U1/25 S-424 22 Angered
P.O. Box 2040 fos.de Glenmarie Industrial Park Tel.: +46-771-32 23 00
Regency Park 40150 Shah Alam Telefax: +46-31 331 94 60
South Australia 5942 Greece Selangor
Phone: +61-8-8461-4611 GRUNDFOS Hellas A.E.B.E. Phone: +60-3-5569 2922 Switzerland
Telefax: +61-8-8340 0155 20th km. Athinon-Markopoulou Telefax: +60-3-5569 2866 GRUNDFOS Pumpen AG
Av. Bruggacherstrasse 10
Austria P.O. Box 71 Mexico CH-8117 Fällanden/ZH
GRUNDFOS Pumpen Vertrieb GR-19002 Peania Bombas GRUNDFOS de Mexico Tel.: +41-1-806 8111
Ges.m.b.H. Phone: +0030-210-66 83 400 S.A. de C.V. Telefax: +41-1-806 8115
Grundfosstraße 2 Telefax: +0030-210-66 46 273 Boulevard TLC No. 15
A-5082 Grödig/Salzburg Parque Industrial Stiva Aerop- Taiwan
Tel.: +43-6246-883-0 Hong Kong uerto GRUNDFOS Pumps (Taiwan) Ltd.
Telefax: +43-6246-883-30 GRUNDFOS Pumps (Hong Kong) Apodaca, N.L. 66600 14, Min-Yu Road
Ltd. Mexico Tunglo Industrial Park
Belgium Unit 1, Ground floor Phone: +52-81-8144 4000 Tunglo, Miao-Li County
N.V. GRUNDFOS Bellux S.A. Siu Wai Industrial Centre Telefax: +52-81-8144 4010 Taiwan, R.O.C.
Boomsesteenweg 81-83 29-33 Wing Hong Street & Phone: +886-37-98 05 57
B-2630 Aartselaar 68 King Lam Street, Cheung Sha Netherlands Telefax: +886-37-98 05 70
Tél.: +32-3-870 7300 Wan GRUNDFOS Nederland B.V.
Télécopie: +32-3-870 7301 Postbus 104 Thailand
Kowloon GRUNDFOS (Thailand) Ltd.
Phone: +852-27861706/27861741 NL-1380 AC Weesp
Brazil Tel.: +31-294-492 211 947/168 Moo 12, Bangna-Trad Rd.,
GRUNDFOS do Brasil Ltda. Telefax: +852-27858664 K.M. 3,
Telefax: +31-294-492244/492299
Rua Tomazina 106 Hungary Bangna, Phrakanong
CEP 83325 - 040 GRUNDFOS Hungária Kft. New Zealand Bangkok 10260
Pinhais - PR Park u. 8 GRUNDFOS Pumps NZ Ltd. Phone: +66-2-744 1785 ... 91
Phone: +55-41 668 3555 H-2045 Törökbalint, 17 Beatrice Tinsley Crescent Telefax: +66-2-744 1775 ... 6
Telefax: +55-41 668 3554 Phone: +36-34 520 100 North Harbour Industrial Estate
Albany, Auckland Turkey
Canada Telefax: +36-34 520 200 GRUNDFOS POMPA SAN. ve TIC.
Phone: +64-9-415 3240
GRUNDFOS Canada Inc. India Telefax: +64-9-415 3250 LTD. STI
2941 Brighton Road GRUNDFOS Pumps India Private Bulgurlu Caddesi no. 32
Oakville, Ontario Limited Norway TR-81190 Üsküdar Istanbul
L6H 6C9 Flat A, Ground Floor GRUNDFOS Pumper A/S Phone: +90 - 216-4280 306
Phone: +1-905 829 9533 61/62 Chamiers Aptmt Strømsveien 344 Telefax: +90 - 216-3279 988
Telefax: +1-905 829 9512 Chamiers Road Postboks 235, Leirdal
N-1011 Oslo United Arab Emirates
China Chennai 600 028 GRUNDFOS Gulf Distribution
Phone: +91-44 432 3487 Tlf.: +47-22 90 47 00
GRUNDFOS Pumps (Shanghai) Co. Telefax: +47-22 32 21 50 P.O. Box 16768
Ltd. Telefax: +91-44 432 3489 Jebel Ali Free Zone
22 Floor, Xin Hua Lian Building Indonesia Poland Dubai
755-775 Huai Hai Rd, (M) PT GRUNDFOS Pompa GRUNDFOS Pompy Sp. z o.o. Phone: +971-4- 8815 166
Shanghai 200020 Jl. Rawa Sumur III, Blok III / CC-1 ul. Klonowa 23 Telefax: +971-4-8815 136
PRC Kawasan Industri, Pulogadung Baranowo k. Poznania
Phone: +86-512-67 61 11 80 PL-62-081 Przezmierowo United Kingdom
Jakarta 13930 GRUNDFOS Pumps Ltd.
Telefax: +86-512-67 61 81 67 Phone: +62-21-460 6909 Phone: +48-61-650 13 00
Telefax: +48-61-650 13 50 Grovebury Road
Czech Republic Telefax: +62-21-460 6910/460 Leighton Buzzard/Beds. LU7 8TL
GRUNDFOS s.r.o. 6901 Portugal Phone: +44-1525-850000
Cajkovského 21 Ireland Bombas GRUNDFOS Portugal, S.A. Telefax: +44-1525-850011
779 00 Olomouc GRUNDFOS (Ireland) Ltd. Rua Calvet de Magalhães, 241
Phone: +420-68-5716 111 Apartado 1079 U.S.A.
Unit 34, Stillorgan Industrial Park GRUNDFOS Pumps Corporation
Telefax: +420-68-543 8908 Blackrock P-2780 Paço de Arcos
Tel.: +351-21-440 76 00 17100 West 118th Terrace
Finland County Dublin Olathe, Kansas 66061
Phone: +353-1-2954926 Telefax: +351-21-440 76 90
OY GRUNDFOS Pumput AB Phone: +1-913-227-3400
Mestarintie 11 Telefax: +353-1-2954739 Russia Telefax: +1-913-227-3500
Piispankylä Italy OOO GRUNDFOS
FIN-01730 Vantaa (Helsinki) GRUNDFOS Pompe Italia S.r.l. Shkolnaya 39
Phone: +358-9 878 9150 Via Gran Sasso 4 RUS-109544 Moscow
Telefax: +358-9 878 91550 I-20060 Truccazzano (Milano) Phone: +7-095 564 88 00, +7-095
Tel.: +39-02-95838112 737 30 00
Telefax: +39-02-95309290/ Telefax: +7-095 564 88 11, +7-
95838461 095 737 75 36
e-mail: grundfos.moscow@grund-
fos.com

Addresses revised 04.11.2002

 Being responsible is our foundation
Thinking ahead makes it possible
Innovation is the essence

96 40 49 99 1102
Repl. 96 40 49 99 0902
74
 TRIK Sheet:1
PUMPEN
KIEL BfüK 40,0 S GL
 TRIK Sheet:2
PUMPEN
KIEL BfüK 40,0 S GL

Contents

1. Technical data and description

1.1. Technical data Sheet 3

1.2. Brief description Sheet 3

2. Operation Sheet 4

3. Maintenance

3.1. Mechanical seal Sheet 5

4. Spare parts list

4.1. Sectional drawing Sheet 8

4.2. List of parts Sheet 9
 TRIK Sheet:3
PUMPEN
KIEL BfüK 40,0 S GL

1. Technical data and description

1.1 Technical Data

Capacity m³/h 30,0

Delivery head bar 5,0

Speed rpm 1450

Necessary power kW 15,1

Motor power kW 18,5

Medium SAE 40

Temperature of medium -

Viscosity of medium -

Inside diameter of suction pipe - mm 80

Inside diameter of pressure pipe - mm 80

1.2 Brief Description

The gear pumps of this type are pumps with inside bearings and control
valve. The pumps are delivered with mechanical seal ready for use.
 TRIK Sheet:4
PUMPEN
KIEL BfüK 40,0 S GL

2. Operation

Fill up the pump before the first starting !

Attention:Before fitting the pump and immediately before switching on,

unscrew the hexagon screws (29) and fill the opening hole
with absolutely clean oil, to avoid dry running of the axial
face seal when the pump is restarted. Screw in the hexagon
screw (29) with copper ring (30) on the bearing lid drive side
and tighten.

Make sure that the pump runs in the proper sense of rotation as
indicated. For a short time (to empty hose or suction pipe) the pump may
run in the opposite sense of rotation. As the valve cannot work under
these conditions pay attention to pressure rise.

Adjusting the overflow valve:

Remove the cap nut and adjust to desired pressure by tightening or
loosening the setting screw.

3. Maintenance
 TRIK Sheet:5
PUMPEN
KIEL BfüK 40,0 S GL

The mechanical seal should be inspected after 3500 running hours (3.1).
In case of unusual using marks or excessively leaking the mechanical
seal should be changed without delay.

The gears, shafts and bearing bushes should be inspected after 3500
running hours. Check the optical condition of gears, shafts and bearing
bushes. In case of unusual using marks the parts should be changed

See also data on spare parts list: sheet 5-8

Before carrying out any work on a mechanical seal, make sure that the
system has been shut down, is nolonger pressurized and has cooled off.

Note: The axial face seal should only be changed by specialist

personnel. Also all other repairs to the pump should be carried
out by specialists only.

3.1 Mechanical seal

Work sequence:

1. Removing the axial face seal :

1.1 Unscrew the two screws on the lid (27) of the axial face seal

1.4 Pull axial face seal out towards the front.

1.5 Thoroughly clean the axial face seal lid (27) and fitting area in the
bearing lid, as well as the shaft, with a clean cloth.

2. Fitting the new axial face seal :

 TRIK Sheet:6
PUMPEN
KIEL BfüK 40,0 S GL
Important information:
Fitting a new axial face seal is to be carried out with extreme care, as
the counter ring and the sliding ring are extremely fragile !

2.1 Before fitting the axial face seal, clean the seal compartement and
examine for signs of damage. Check the installation and connection
dimensions. Check the accuracy of the axial and radial run-out-
tolerance between the shaft and the casing. Assemble under extra-
clean conditions and with great care. Use no force! This could results
in permanent deformations and broken ceramic parts. To reduce
friction during assembly, wet all sliding surfaces for the O-rings with
water or alcohol or lubricate with silicone grease.

2.2 Elastomer bellows seals are to be pushed onto the shaft using low-
surface-water (addition of a detergent) and a screwing movement.
Use no oil or grease! Apply pressure only on the corner rings. When
you are finished with the assembly, check that the corner rings, the
spring and the seal face fit correctly.

2.3 Carefully push the axial face seal lid (27) against the axial face seal
onto the shaft. Evenly screw in both lid screws carefully and tighten.

Avoid tilting the axial seal lid (27), as this will lead to destruction of
the axial face seal.

First Use :

Attention:Before fitting the pump and immediately before switching on,

unscrew the hexagon screws (29) and fill the opening hole
with absolutely clean oil, to avoid dry running of the axial
face seal when the pump is restarted. Screw in the hexagon
screw (29) with copper ring (30) on the bearing lid drive side
and tighten.

Should these instructions be ignored, this will lead to destruction of

the axial face seal and the warranty becomes invalid.
 TRIK Sheet:7
PUMPEN
KIEL BfüK 40,0 S GL
 TRIK Sheet:8
PUMPEN
KIEL BfüK 40,0 S GL

When order spare parts please name the serial number and type of pump
and also item and description of the spare parts.

Item Description / Notes Piece Standard no.

1 Housing 1
2 Bearing plate driving side 1
3 Bearing plate end side 1
4 Driving shaft with gear 1
5 Driven shaft with gear 1
8 Packing 2
10 Bearing bushing 2
11 Bearing bushing 1
12 Bearing bushing 1
13 Overflow housing 1
14 Valve piston 1
15 Setting screw 1
16 Counter nut 1
17 Valve spring 1
18 Packing 1
19 Cap nut 1
20 Valve bush 1
21 Disk 1
22 Screw 1
23 Hexagon nut 1
24 Overflow pipe 1
25 Pipe connection 2
26 Mechanical Seal 1
27 Mechanical seal cover 1
28 O-Ring 1
29 Hexagonal screw 1
30 Copper ring 1
 TRIK Sheet:9
PUMPEN
KIEL BfüK 40,0 S GL
 TRIK Sheet:10
PUMPEN
KIEL BfüK 40,0 S GL
 TRIK Sheet:11
PUMPEN
KIEL BfüK 40,0 S GL
 Installation and operating manual B4E
for motor control valves
_______________________________________________________________________

Installation:

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.
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.
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 manual.

technische Änderungen vorbehalten 4BA-E.DOC / 0209504

 Motor control valve in three way form 431 ...Ha/b/c/d E
PN 16 / 25, GGG-40.3
_______________________________________________________________________

Body: GGG-40.3, three way form,

for water and steam, as mixing valve,
(diverted purpose restricted,
see page 038 990)
Pressure range: PN 16, PN 25
Flanges acc. to DIN,
Spindle sealing: spring-loaded PTFE-V-ring unit
for media temperatures up to 250°C
alternatively: graphite-packing
Internal parts: stainless steel
Flow characteristic: linear
Leakage: acc. to VDI/VDE 2174

Actuator: with integrated manual emergency

and load dependent limit switches
Thrust: 1,2 kN / 6,6 W (appendix ..a)
2,0 kN / 6,6 W (appendix ..b)
4,5 kN / 32 W (appendix ..c)
6,0 kN / 33 W (appendix ..d)
Power supply: 230V / 50Hz
alternatively: 230V / 60Hz (appendix ..a/B/C/D)
Protection class: IP65

Accessories, special designs:

Add. signal switches load dependent
Add. signal switches travel dependent
Feedback potentiometer
Integrated positioner
Other voltages (on request)
Other positioning speed (on request)
Reduced kvs-values (on request)

Order text:
Motor control valve PN . ., DN . .
in three way form with PTFE-V-ring unit,
Power supply . . ., List-No. 431 . . . H .

Max. operating pressure:

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

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

PN 16 PN 25 m³/h mm sec 1,2 kN 2,0 kN 4,5 kN 6,0 kN
15 431 400H. 431 500H. 4,0 20 50 23,0 25,0
20 431 401H. 431 501H. 6,3 20 50 23,0 25,0
25 431 402H. 431 502H. 10 20 50 14,6 25,0
32 431 403H. 431 503H. 16 20 50 8,5 17,3 25,0
40 431 404H. 431 504H. 25 20 50 5,0 10,8 25,0
50 431 405H. 431 505H. 40 20 50 2,8 6,6 18,4 25,0
65 431 406H. 431 506H. 63 30 75 1,2 3,4 10,5 14,8
80 431 408H. 431 508H. 100 30 75 2,0 6,8 9,6
100 431 410H. 431 510H. 160 30 75 1,1 4,1 6,0
125 431 412H. 431 512H. 230 35 88 2,5 3,7
150 431 415H. 431 515H. 330 40 100 1,6 2,4

data subject to alteration 431HAD-E / 0309504

 Motor control valve in three way form 431 ...Ha/b/c/d E
PN 16 / 25, GGG-40.3
_______________________________________________________________________
145
Aktuator type: 15
180 Space required
to remove
1,2 kN: 4eh1-25 the bonnet
2,0 kN: 4eh2-25(B)
4,5 kN: 4eh4-25(C)
6,0 kN: 4eh6-25(D)

Cap nut

42
Bonnet

Hand wheel

Coupling
with plate

H
Spindle

Coupling

Mounting rod

PTFE-V-ring-unit

Spindle
A AB
Plug
H1

Valve body type: vg31... B

DN 15 20 25 32 40 50 65 80 100 125 150

Height H 536 550 544 551 556 559 602 602 610 765 780
Stud lenght H1 65 70 75 80 90 100 120 130 150 200 210
Immersion lenght L 130 150 160 180 200 230 290 310 350 400 480
Weight kg 15 16 17 20 21 24 39 43 57 98 128

Electrical wiring: Accessories (optionaly):

Limit switches Signal switches
load dependent load dependent
for valve position Signal switches Potentiometer for valve position
OPEN CLOSED travel dependent OPEN CLOSED
M

1 2 3 10 11 12 13 14 15 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39

N
L on 11= Straightway opens
L on 14= Straightway closes

data subject to alteration 431HAD-E / 0309504

 DESCRIPTION AND OPERATING INSTRUCTIONS

FOR THE DUPLEX FILTER

Contents:

1. Type sheet

2. Spare parts drawing and spare parts list

3. Description and Operating Instructions for the duplex filter

4. Description and Operating Instructions for the filter element cleaning

5. Data Sheet for the Differential Pressure Indicator (to order)

6. Spare parts drawing for the Differential Pressure Indicator (to order)
 °D
°G

°e

°G

°G 120¦C °D °e
 ERSATZTEILLISTE TYP 2.05.5 UND 2.05.5.4
SPARE PART LIST LISTE DES PIECES DE RECHANGE

Typenschlüssel:
2.05.5 = Doppelfilter duplex filter Filtre doubles
G = Gehäusedurchmesser cabin diameter diamétre du corps
Q = Filtereinsatzlänge length of the filter element longueur du panier
DN = Anschlußflansche connection flanges brides désirées

Pos. Bezeichnung Gr. 265.500 St. Gr. 265.750 St. Gr. 265.500 St. Gr. 265.750 St. Gr. 340.500 St. Gr. 340.750 St.
Nr. designation NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS
désignation 100 100 125 125 150 150
Verschlußschraube
3 screw plug 2000193 2 2000193 2 2000193 2 2000193 2 2000193 2 2000193 2
vis
Dichtung
4 gasket 3274855 2 3274855 2 3274855 2 3274855 2 3274855 2 3274855 2
joint
O-Ring (Viton) 3030183 3030183 3030183 3030183 3030184 3030184
6 O-Ring 2 2 2 2 2 2
O-Ring (Perbunan) 3040131 3040131 3040131 3040131 3040135 3040135
Verschlußschraube
7 screw plug 2000189 2 2000189 2 2000189 2 2000189 2 2000189 2 2000189 2
vis
Dichtung
8 gasket 3270004 2 3270004 2 3270004 2 3270004 2 3270004 2 3270004 2
joint
Stiftschraube
9 stud bolt 2009088 12 2009088 12 2009088 12 2009088 12 2000009 12 2000009 12
vis
Mutter
10 nut 2100007 12 2100007 12 2100007 12 2100007 12 2100008 12 2100008 12
écrou
Siebeinsatz Fabr.Nr. Fabr.No. Fabr.No. Fabr.Nr. Fabr.No. Fabr.No.
12 filter element Filtertyp Filtertype Type de Filtre Filtertyp Filtertype Type de Filtre
élément filtrant
 Pos. Bezeichnung Gr. 265.500 St. Gr. 265.750 St. Gr. 265.500 St. Gr. 265.750 St. Gr. 340.500 St. Gr. 340.750 St.
Nr. designation NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS
désignation 100 100 125 125 150 150
Anker WN 5.1.91 WN 5.1.94 WN 5.1.91 WN 5.1.94 WN 5.1.91 WN 5.1.94
13 bolt 2 2 2 2 2
vis WN 5.1.92 WN 5.1.95 WN 5.1.92 WN 5.1.95 WN 5.1.92 WN 5.1.95
Stiftschraube 2000104 (1) 2003830 (1) 2000104 (1) 2003830 (1) 2003830 (1) 2003830 (1)
13 a stud bolt 2 2 2 2 2 2
vis 2004950 (2) 2000968 (2) 2004950 (2) 2000968 (2) 2000968 (2) 2000968 (2)
Mutter
14 nut 2100035 2 2100035 2 2100035 2 2100035 2 2100035 2 2100035 2
écrou
Druckausgleich
16 equalization of pressure 0202001 1 0202001 1 0203221 1 0203221 1 0203221 1 0203221 1
equilibrage de pression
Verschlußschraube
18 screw plug 2002885 1 2002885 1 2002885 1 2002885 1 2002885 1 2002885 1
vis
Dichtung
19 gasket 3270002 1 3270002 1 3270002 1 3270002 1 3270002 1 3270002 1
joint
Dichtung
20 gasket 3540022 2 3540022 2 3540022 2 3540022 2 3540017 2 3540017 2
joint
Stiftschraube
21 stud bolt 2009088 12 2009088 12 2009088 12 2009088 12 2009088 12 2009088 12
vis
Mutter
22 nut 2100007 12 2100007 12 2100007 12 2100007 12 2100007 12 2100007 12
écrou
Küken
23 cock 4-17977 1 4-17977 1 4-17957 1 4-17957 1 4-17643 1 4-17643 1
robinet
Sotef-Dichtung
24 sotef-gasket 3420011 1 3420011 1 3420011 1 3420011 1 3420011 1 3420011 1
sotef-joint
Pos. 13 + 13a = Bei Mantelsieb (1) und Gewebeeinsteckkerzeneinsatz (2) zusätzlich.
These itemsare supplementary by multimantle element (1) and filter-candle-element (2)
En supplément avec panier á manteaux (1) et cartouches (2) filtrantes
Pos. Bezeichnung Gr. 265.500 St. Gr. 265.750 St. Gr. 265.500 St. Gr. 265.750 St. Gr. 340.500 St. Gr. 340.750 St.
Nr. designation NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS
désignation 100 100 125 125 150 150
O-Ring (Viton) 3030178 3030178 3030180 3030180 3030182 3030182
25 O-Ring 1 1 1 1 1 1
O-Ring (Perbunan) 3040124 3040124 3040164 3040164 3040129 3040129
O-Ring (Viton) 3030080 3030080 3030083 3030083 3032130 3032130
28 O-Ring 2 2 2 2 2 2
O-Ring (Perbunan) 3040163 3040163 3040127 3040127 3040130 3040130
Stiftschraube
29 stud bolt 2009088 8 2009088 8 2009088 8 2009088 8 2000008 8 2000008 8
vis
Mutter
30 nut 2100007 8 2100007 8 2100007 8 2100007 8 2100008 8 2100008 8
écrou
Hahnschlüssel
31 reversing handle 8650481 1 8650481 1 8650481 1 8650481 1 8650481 1 8650481 1
clé
Differenzdruckanzeiger Typ Type Type Typ Type Type
diff.pressure indicator
32 indicator de difference
Druck Pressure Pression Druck Pressure Pression
de pression
Verschlußschraube
33 screw plug 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2 2002885 2
vis
Dichtung
34 gasket 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2 3270002 2
joint
Dichtung
41 gasket 3380049 2 3380049 2 3380049 2 3380049 2 3380049 2 3380049 2
joint
Stiftschraube
42 stud bolt 2000001 4 2000001 4 2000001 4 2000001 4 2000001 4 2000001 4
vis
Mutter
43 nut 2100004 4 2100004 4 2100004 4 2100004 4 2100004 4 2100004 4
écrou
Pos. Bezeichnung Gr. 420.500 St. Gr. 420.750 St. Gr. 420.750 St. Gr. 520.750 St.
Nr. designation NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS
désignation 200 200 250 250
Verschlußschraube
3 screw plug 2000193 2 2000193 2 2000193 2 2000193 2
vis
Dichtung
4 gasket 3274855 2 3274855 2 3274855 2 3274855 2
joint
O-Ring (Viton) 3034406 3034406 3034406 3031074
6 O-Ring 2 2 2 2
O-Ring (Perbunan) 3040151 3040151 3040151 3040155
Verschlußschraube
7 screw plug 2000189 2 2000189 2 2000189 2 2000189 2
vis
Dichtung
8 gasket 3270004 2 3270004 2 3270004 2 3270004 2
joint
Stiftschraube
9 stud bolt 2000011 16 2000011 16 2000011 16 2009094 24
vis
Mutter
10 nut 2100008 16 2100008 16 2100008 16 2100009 24
écrou
Siebeinsatz Fabr.Nr. Fabr.No. Fabr.No. Fabr.Nr.
12 filter element Filtertyp Filtertype Type de Filtre Filtertyp
élément filtrant
Anker WN 5.1.92 WN 5.1.94 WN 5.1.94 WN 5.1.95
13 bolt 2 2 2 4-7094 (2) 2
vis WN 5.1.98 WN 5.1.95 WN 6.1.95
Stiftschraube 2004950 (1) 2000102 (1) 2000102 (1)
13 a stud bolt 2 2 2 7203893 2
vis 2008279 (2) 2004950 (2) 2004950 (2)
Mutter
14 nut 2100035 2 2100035 2 2100035 2 2100035 2
écrou
Pos. 13 + 13a = Bei Mantelsieb (1) und Gewebeeinsteckkerzeneinsatz (2) zusätzlich / These itemsare supplementary by multimantle element (1) and
filter-candle-element (2)
En supplément avec panier á manteaux (1) et cartouches (2) filtrantes
Pos. Bezeichnung Gr. 420.500 St. Gr. 420.750 St. Gr. 420.750 St. Gr. 520.750 St.
Nr. designation NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS
désignation 200 200 250 250
Druckausgleich
16 equalization of pressure 0203221 1 0203221 1 0203568 1 0203568 1
equilibrage de pression
Verschlußschraube
18 screw plug 2002885 1 2002885 1 2002885 1 2002885 1
vis
Dichtung
19 gasket 3270002 1 3270002 1 3270002 1 3270002 1
joint
Dichtung
20 gasket 3540024 2 3540024 2 3540028 2 3540028 2
joint
Stiftschraube
21 stud bolt 2000009 16 2000009 16 2000101 20 2000101 20
vis
Mutter
22 nut 2100008 16 2100008 16 2100009 20 2100009 20
écrou
Küken
23 cock 3-19029 1 3-19029 1 3-21142 1 3-21142 1
robinet
Sotef-Dichtung
24 sotef-gasket 3420011 1 3420011 1 3420013 1 3420013 1
sotef-joint
O-Ring (Viton) 3033860 3033860 3030185 3030185
25 O-Ring 1 1 1 1
O-Ring (Perbunan) 3040132 3040132 3040136 3040136
O-Ring (Viton) 3031065 3031065 3031066 3031066
28 O-Ring 2 2 2 2
O-Ring (Perbunan) 3040133 3040133 3050256 3050256
Stiftschraube
29 stud bolt 2000009 12 2000009 12 2000010 16 2000010 16
vis
Mutter
30 nut 2100008 12 2100008 12 2100008 16 2100008 16
écrou
Pos. Bezeichnung Gr. 420.500 St. Gr. 420.750 St. Gr. 420.750 St. Gr. 520.750 St.
Nr. designation NW/NS/DS NW/NS/DS NW/NS/DS NW/NS/DS
désignation 200 200 250 250
Hahnschlüssel WN 48-1 WN 48-1 WN 48-1 WN 48-1
31 reversing handle 1 1 1 1
clé 8650055 8650055 8650481 8650481
Differenzdruckanzeiger Typ Type Type Typ
32 diff.pressure indicator Druck Pressure Pression Druck
indicator de difference
de pression
Verschlußschraube
33 screw plug 2002885 2 2002885 2 2002885 2 2002885 2
vis
Dichtung
34 gasket 3270002 2 3270002 2 3270002 2 3270002 2
joint
Dichtung
41 gasket 3380049 2 3380045 2 3380045 2 3380045 2
joint
Stiftschraube
42 stud bolt 2000001 4 2000001 4 2000001 4 2000003 4
vis
Mutter
43 nut 2100004 4 2100004 4 2100004 4 2100005 4
écrou
Passfeder
45 parallel keys 2400004 1 2400004 1
ressort d'adjustage
Stirnzahnrad
46 spur wheel 2700015 1 2700015 1
pignon
Ritzelwelle
47 pinion shaft 5600131 1 5600131 1
arbre de pignon
Schraube
49 screw 2000155 4 2000155 4
vis
 INSTALLATION AND OPERATING INSTRUCTIONS FOR

BOLL DUPLEX FILTERS

1. Description

Duplex filters which can be changed over consist of two filter housings operated in
parallel by a two-stage change-over device. The filter housings are designed to
meet the current regulations for a particular pressure range, the filter elements are
provided with an appropriate safety factor for the differential pressures indicated on
the filter nameplates. The maximum differential pressure for filter meshes is 0.8 bar,
for micro-cartridges 2 bar.
Duplex filters are used in cases where the contaminated filter elements have to be
regenerated without interrupting the filtration process.

The change-over devices, i.e. cylindrical plugs, ball valves or double-stage change-
over valves, permit change-over without pressure shocks. Owing to the design of
the change-over device it is not possible for both filter chambers to be switched off
at the same time.

According to the AD Information Sheets, the filter housings

are only rated for internal overpressure. Additional external
forces and moments at the connection flanges of the filter
are to be avoided (possibly support feed lines).
2. Installation

When the filter is attached to its foundation, the filter housing must be free from
strain. The same applies to the connected piping. The connections for the inlet and
outlet depend on the strainer element used (see works standard WN 211). Pay
attention to the arrow marked on the housing.

Heated filters with shut-off devices:

- Special equipment needed for heatable filters -

a) Steam-heated filters:
Safety valves for the filter chamber set to operate at the
relief pressure which is 10 % above the max. admissible
operating pressure of the filter housing.

b) Electrically heated filters:

Thermostats which cut off the power supply to the
heating element at a max. admissible temperature of
150 °C in the filter chamber and one safety valve per
filter pot.

Heating of the filter serves to offset the heating loss at the filter during the filtration process
or before start-up of the plant to heat the liquid in the filter.

It is imperative for the pressure equalising cock to only

remain closed in the cleaning phase so that there is no
inadmissible pressure build-up through the thermal
expansion of the medium in the isolated chamber.
 In smaller duplex filters without pressure compensation the
heat expansion of the medium is so low that there is no
risk to the components.

3. Start-up

3.1 Pressure filters (> 0.1 bar pressure in the filter)

Set the change-over device to the mid-position, both chambers in service, pressure
equalising cock open.
Open air vents of both chambers (with venting screws only about 1 turn).
Start plant up slowly.
Close air vents when the air has escaped and the liquid has started to emerge.
Isolate one filter chamber by operating the change-over device, leave the pressure
equalising cock open; while one of the filter chambers is being used for filtering, the
isolated chamber is on stand-by until the admissible differential pressure has built up
as a result of clogging.
At a differential pressure of 0.8 bar in filter meshes or 2 bar in micro-cartridge filters
change over to the clean filter chamber as follows:

Cleaning

• Check that the pressure equalising cock is open and whether the stand-by
chamber is full by briefly opening the air vents.
• Change over.
• Close pressure equalising cock.
• Open the air vent on the isolated filter; this releases the liquid pressure and it is
then possible to check whether the change-over device has cut off the flow to the
filter chamber.
In contrast to the change-over and ball valve devices, complete sealing is not
possible with the plug-type system; by opening the sludge outlet, liquid leaking
during the cleaning process can be drained off.
• Remove the housing cover from the isolated filter chamber.
• Drain liquid down to the strainer base in the case of basket strainers; drain filter
housing completely in the case of mantle strainers, cartridge strainers and micro-
cartridges.
• Remove the filter element vertically upwards.
• Clean filter element (see operating instructions "Strainer cleaning"); renew
disposable elements and install them in the filter.
• Before mounting the cover, check that the seal is in perfect condition and seated
properly.
It is imperative to renew seals which have become hardened and deformed.
Screw cover on, the air vent remains open.
Open pressure equalising cock or, if not installed, set change-over device to mid
position until the air has been vented.
• Close air vent. This filter is now on stand-by.
3.2 Suction filters (< 0.1 bar pressure in filter)

Recommended container filling for suction filters

drain

filling line

• Fill and vent both filter halves.

• Isolate one of the filters with the change-over device, close pressure equalising
cock.
• Start up the plant. While one filter chamber is being used for filtration, the isolated
chamber is on stand-by. When the differential pressure across the filter reaches
the maximum allowed by the pump suction head, a change-over to the other filter
half must be made.
• Open pressure equalising cock.
• Change over.
• Close pressure equalising cock.
• Open air vent on the isolated filter half.

Air may be drawn in if the level drops.

• Dismantle the housing cover from the isolated filter half.

• Drain liquid down to the strainer base.
• Remove filter element vertically upwards.
• Clean filter element (see operating instructions "Strainer cleaning"). Renew
disposable elements and install in the filter.
• Fill filter housing (see Fig.).
• Before mounting the cover, check that the seal is in perfect condition and seated
properly.
It is imperative to renew seals which have become hardened and deformed.
Close air vent.
• The cleaned filter half is ready on stand-by. This procedure is to be repeated from
section as and when required.
It is not permitted to fill the filter against the
indicated flow direction of the filter elements.
4. Servicing:
Servicing of the duplex filter comprises checking and, if necessary, renew the
seals and filter elements. If the filter is provided with rust-inhibiting paint, touch up or
repaint as and when required.
When filtering cooling water or media which may cause sedimentation on the
change-over device, it is advisable to activate the change-over device as often as
possible and at regular intervals in order to prevent clogging.

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!
 DESCRIPTION AND OPERATING INSTRUCTIONS FOR
SEGMENTAL COCK CHANGE-OVER VALVE TYPE 2.05.5

General

The segmental cock change-over valve is

intended for installation in duplex filters or
double-stage 3-way cocks. The special design
of the segmental cock (23) prevents the
occurrence of flow interruptions and pressure
surges during change-over and at the same
time guarantees ease of movement owing to
low frictional forces. The segmental cock only
requires an O-ring at two locations: on the
dividing plate (25) and at the cock neck (24).
The O-ring at the cock neck is additionally
embedded in a wear-resistant Teflon ring.

Operation of the valve

The marking engraved in the cock neck
indicates the direction of flow and thus shows
which filter chamber is in operation (see Fig. 2).
Before changing over from one filter chamber to
the other, a check is to be made to see whether
the pressure equalisation cock (16) is open.
Then turn the segmental cock completely to the
right or left using the lever (31).
In the central position both filter chambers are in
operation (see Fig. 2).
After change-over and before the filter chambers are opened, the pressure equalisation cock must
be closed again. After the filter chambers have been filled, the cock housing (17) is to be vented
using the venting screw (18).

It is imperative to read the operating instructions "BA Duplex Filters"

for this work.

1. Dismantling and installation of the segmental cock (for DN 100 - DN 200)

1.1 Drain medium as described in the operating instructions for duplex filters.
1.2 Undo venting screw (18).
1.3 Undo the cock housing cover (15) with the hexagon nut (30) and lift off.
1.4 Remove segmental cock and check seals (24, 25 + 28) as well as cocks and cock
housing bore for damage.
Grind down any scoring on the cock and bore. Replace O-rings.
1.5 After cleaning the cock housing and segmental cock, introduce the latter back into the
housing together with the oiled and mounted seals (24, 25 + 28).
1.6 Move segmental cock (23) into the central position.
1.7 The dowel pin (27) must be firmly seated in the cock housing. Close the cock housing
cover with seal (28) again. The dowel pin governs the position of the cover and thus the
stop of the segmental cock (23). Mount hexagon nut (30).

This position guarantees the perfect stop of the segmental cock.

1.8 Fill up filters as described in the operating instructions for duplex filters. Close vent (18)
when the medium emerges free of bubbles.
2. Dismantling and installation of the segmental cock (for DN 250) (Fig. 3)
2.1 Drain medium (see operating instructions
for duplex filters).
2.2 Remove hexagon socket screw (49) from
transmission cover (48).
2.3 Remove transmission cover (48).
2.4 Pull gear (46) off cock shaft.
Remove pinion (47).
2.5 Remove cover hexagon nuts (30).
2.6 Lift off cock housing cover (15).
2.7 Insert an eye-bolt M12 to DIN 580 into
the cock shaft.
2.8 Lift out cock (23) with lifting tackle.
2.9 Examine cock (23) and cock housing
bore for damage in the form of scoring
and, if necessary, grind surface.
2.10 Replace any damaged O-rings
(24,25+28).
2.11 Introduce segmental cock (23) with oiled O-rings (24 + 28) into the cock housing bore.
2.12 Move segmental cock (23) into the central position.
2.13 Mount cock housing cover (15) with inserted O-ring (28).
The dowel pin (27) must engage the cock housing cover (15).
2.14 Screw on the cock housing cover (15).
2.15 Install gear (46) and pinion (47) and screw on transmission cover (48).
2.16 The segmental cock must be easy to move using the lever (31).
2.17 Should the segmental cock be sluggish, undo the hexagon nuts (30), move the
segmental cock and retighten the hexagon nuts (30) so that the segmental cock is
sitting optimally.

3. Commissioning
3.1 Fill up filters and commission as described in the operating instructions for duplex filters.
3.2 Carefully vent all three pressure vessels.

BOLL & KIRCH assumes no liability for any faults due to improper use of the product.
We reserve the right to change this description without any prior notice!
 Cleaning / Maintenance of Filter-Candles in Insert Assembly

1. Description
The insert as an assembly consists
essentially of the candle-holding
"cage"in which are installed spring-
loaded filtercandles (3) all in
service in parallel, of the same size,
interchangeable and reusable: "O"-
ring seals: top and bottom plates
and tierods. The insert and its
candles are only for Boll manual
filters (simplex and duplex).

Each candle is individually secured;

at bottom-plate (2) where it is held
against top-plate (1) by means of
spring (4). Each candle's clean-side
is sealed from the dirty by O-ring (5)
between candle and top-plate of the
insert. The insert's top and bottom-
plates and candle-array are
secured with tie-bars (6).
Lifting-bail(s) (7) facilitate removal/insertion of the insert complete.

Outer mantle (9) protects the candles from damage during the insert's
removal/replacement.

Optionally, a spring-loaded magnet-candle (8) can be fitted in the insert

peripherally between filter candles.
Where the requisite flow-rate has been met with a complement of candles less than
the maximum that can be accommodated, the unused sockets are factory-sealed
with plugs.
2. Cleaning of the insert and its candles
2.1 Submerge the candle-insert complete in a tank of suitable cleaning fluid, with the
openends of the candles facing upwards. Loose particles will be removed and
settle-out during the soaking period, which should not exceed 4 hours.
Remove insert from the tank and insert BOLL Cleaning-gun Type 5.01 (11) with
active airsupply, carefully and sequentially into each candle, moving the Gun
throughout each candle's length to blowthrough the candles from inside to out.
2.2 Put the assembly once more in fresh cleaning-fluid and then allow to drain.
Blow through again with the Cleaning-gun. (With some cleaning-fluids the cleaning
effect is improved by rinsing with hot or cold water before blowing-through for the
second time).
Stand the candle-assembly upside-down to allow cleaning-fluid and/or water to
drain. (If the candles are only lightly-contaminated an alternative cleaning
procedure is to rinse the insert-assembly complete with its candles by gently
rotating/moving it up-and-down in the cleaning-bath).
2.3 From time-to-time, inspect each candle for damage, replacing with new one(s)
where necessary (see also Para. 3.4 and 3.5).
2.4 Dirt-laden fluid remaining in the filter-housing(s) should be voided via the drain-
plug(s).
2.5 Close and secure drain(s): put back the insert (make sure candle-seals (5) are in
place):
secure filter chamber-cover(s): re-fill and air-vent housing(s) (see the Filter's
Operating manual).
2.6 For heavy contamination the same cleaning-sequence can be followed but using
highpressure cleaning at 60 bars. The cleaing-fluid can be water; or water in
solution with a cleaning-agent (e.g. BOLL CLEAN 2000 concentrate) but with either
cleaning-liquid the temperature should not exceed 60 °C.
3. Cleaning Obstinate Contamination from the Filter-candles
3.1 If the candles are heavily contaminated (e.g. by gum-deposition, incrustation, tar-
residues, fibres, ferritic fragments) the candles should be removed from the insert
and cleaned individually.
The BOLL High-pressure Cleaning-trolley 5.04 is strongly recommended (see 4.3).
Its Rotary Spray-nozzle is highly effective in candle-cleaning; and its Flat-nozzle
will handle other parts of the insert-assembly.
If you do not have a Cleaning-trolley then follow the procedure in 3.2 etc.
3.2 Remove base-plate (10); carefully lift off the protective outer mantle (9). Remove
candles by pressing downwards and lifting out at an angle. Remove the candle-
seals (5). (See Fig. 3)
3.3 Put the obstinately-contaminated candles to soak in a cleaning-fluid tank, say for
maximum 4 hours.

Do not lay the candles across one another - this can damage the
meshes.

3.4 Place each candle with its open end on a suitable "spike"; or put it individually in
the candleholding cage, which should be secured to prevent it toppling. Wash-
down each candle allround and thoroughly from the outside using an highpressure
Cleaning-gun with Flatjet nozzle. Pressure must not exceed 60 bars.

When using high-pressure cleaning, ensure the nozzle is at all

times held clear of the mesh in order to avoid damage/displace-
ment of the mesh-filaments.

By this means most of the contaminant will be washed-off. Dirt-particles equivalent

to the pore-size of the mesh which sometimes can be found entrapped in the mesh
are pushed through and safely rinsed away.
 As cleaning fluid, either water alone; or water in solution with a
cleaning-agent (e.g. BOLL CLEAN 2000 concentrate) may be
used: but always at a temperature not exceeding 60 °.

3.5 Now, rinse the candles individually in the cleaning-fluid: blow them through with
compressed-air and leave to drain/dry with open end(s) downwards. The simplest
way to test their cleanliness is by a torch-beam directed inside each candle -
optimum cleaning will have been achieved when the light shines with uniform
brightness through the entire area of the mesh.
3.6 Ensure that inner, facing sides of top and bottom plates are themselves clean.
3.7 Re-assemble insert, its candles etc. in reverse order to the procedure described in
3.2 (see also 2.5).
3.8 For other recommended Cleaning-agents.

4. Cleaning Equipment
For the most effective cleaning of candles, in-situ in insert, or individually, the
BOLL Cleaning-trolley 5.04 is to be highly-recommended and best used in
conjunction with BOLL CLEAN 2000 concentrate. The Cleaning-trolley will handle
all types of BOLL filterelements and affords additionally a safe and simple means of
cleaning other small assemblies.

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!
COVER SECURING DEVICE FOR DOUBLE FILTERS

The function of the cover securing

device is to prevent the uncontrolled
excape of lubricantes and fuels in the
case of operating errors. The cover
plate (2) covers a minimum number of
cover screws (3), so that the cover (1)
cannot be removed with out actuating
the venting facility (4).

The filter chamber is relieved through

the venting screw (4). With the correct
switching position, the service pressure
of the filter chamber falls immediately
and hardly any fuel excapes. Otherwise,
the venting screw is immediately closed
and the fuel discharge is limited.
 Operation:

1. Establish on the circuit diagram

(5) with chamber is switched off.

2. Unscrew the venting screw of this

chamber (4) to the point where the
cover plate (2) can swivel over the
cover screws (3)

3. Loosen cover screws (3) and remove

cover (1).

4. Assemble in reverse order

Check seals items 6 and 7

for damage.

5. For sieve cleaning and

commissioning, see Sieve Cleaning
Operating Instructions and Double
Filter Operating Instructions.

BOLL & KIRCH assumes no liability for any mistakes due to misuse of the product.
We reserve the right to change this description without prior notice!
MAX. TEMPERATURE 150°C
 DESCRIPTION AND OPERATING INSTRUCTIONS
FOR BACK-FLUSHING FILTER TYPE 6.46

Order No.

LIST OF CONTENTS
1. Type sheet
2. General notes on the automatic filter
3. Installation of the filter
Installation drawings Z39347 + Z39349
4. Commissioning
5. Filtration phase
Filtration phase Z39293 sheet 1
6. Back-flushing phase
Back-flushing phase Z39293 sheet 2
7. Functioning of the overflow valves
Overflow valves Z39293 sheet 3
8. Maintenance
9. Filter candle inspection and cleaning
10. Technical information BOLL CLEAN 2000
11. Sources of faults and their remedy
12. Spare parts drawing for type 6.46
13. Spare parts list for type 6.46
14. Type sheet differential pressure contact indicator
15. Spare parts drawing for the differential pressure indicator

BOLL & KIRCH assumes no liability for any mistakes by improper use of the product.
We reserve the right to change this description without prior notice!
2. General notes on the automatic filter

The back-flushing Filter type 6.46 satisfies the safety standard

for ships' main propulsion units. It is registered by GL, LRS
and other ship classification bodies.

The back-flushing filter type 6.46 is suitable for filtering oils with a viscosity of max.
50 cSt. and an operating pressure of min. 3 bar to max. 10 bar.

The filter works with permanent back-flushing using its own process fluid; the back-
flushed fluid is fed back into the circulation tank or the oil trough again.

No external power is required to operate the automatic filter.

The function of the automatic filter is to protect the bearings, journals and shafts in
the engine from noxious impurities in the oil.

Treating the lubricating oil, i.e. removing the solids discharge, is carried out by a
separator, a centrifuge, a bypass filter or the attached flushing oil treatment unit.

The filter can be mounted both vertically and horizontally directly on the engine or
on the base frame.

In order to satisfy the different requirements of the engine manufacturers, the filter
type 6.46 can be combined with a wide variety of engine attachments.
The filter type 6.46 mainly consists of the following:

- the housing with the inlet and outlet flanges

- the filter element with the appropriate number of filter candles, depending on the
nominal width
- the excess pressure safety devices
- the downstream second filter stage [protective filter (8)]
- the entire flushing facility
- the gear unit including drive turbine.
3. Installation of the filter

Care must be taken during installation of the filter to ensure that clean pipes are
connected to the filter inlet and the filter outlet without any strain.
The inlet and outlet of the filter are marked.
The flushing oil line is to be at least as large as specified in the information sheet.
This line is to be laid without any shut-off device but with a gradient and vented to
prevent any build-up in the pipe.

The potential-free contacts of the differential pressure indicator (24) installed (see
"Differential pressure indicator, section 14) must be wired to monitor the degree of
contamination of the filter elements (7) and the protective filter (8).

The filter housings are only designed for internal overpressure in

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

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

4.1 Check to see whether all connections have been made properly.

4.2 Check to see whether the ball cocks in the control line to the differential pressure
indicator are open.

4.3 The following must be observed before switching on the pump:

- Close shut-off device in the bypass line
- Open shut-off device at the filter outlet
- Only partially open the shut-off device at the filter inlet and, after switching on
the pump (to prevent pressure surges), slowly open it fully.

4.4 If the pressure downstream of the filter is less than 2 bar, the shut-off device
downstream of the filter is to be regulated until the appropriate operating pressure
has built up.

4.5 The rotary motion of the flushing facility can now be seen at the visible shaft end in
the filter cover.

If there is an inadmissible rise in the differential pressure during

commissioning (with new plants poss. greater initial
contamination) in spite of perfect back-flushing, a signal is
emitted via the differential pressure indicator. The Filter must be
taken out of service (open the bypass line and close the shut-off
devices on the Filter). Dismantle the Filter element completely
and clean the Filter candles individually (oberserve section 9
"Filter candle inspection and cleaning").
5. Filtration phase
(see drawing Z39293 sheet 1 or Z101308 sheet 1 )

The fluid to be filtered passes through the inlet flange and turbine (14) to the bottom
end of the filter candles (7); a partial stream of about 50% is passed through the
central connection tube (4) to the top end of the filter candles (7). This means that
the fluid flows through the filter candles (7) at both ends from the inside outwards
and most of the dirt particles are retained in the inside of the filter candles (7).
The fluid filtered in this way now passes through the protective filter (8) to the filter
outlet.
6. Back-flushing phase
(see drawing Z39293 sheet 2 or Z101308 sheet 2)

The back-flushing filter type 6.46 operates as a continuous flushing filter and
does not require any external power to drive the back-flushing facility.

The flow energy drives the turbine (14) installed in the inlet flange. The high speed
of the turbine (14) is reduced by the worm gear unit (13) and gear (15) to the lower
speed required for turning the flushing arm (3).

The individual filter candles (7) are now connected successively to the atmosphere
by means of the continuously rotating flushing arm (3), the flushing bush (17) and
nozzle (21).

The pressure gradient thus produced (operating pressure to atmosphere)

results in an extremely efficient cleaning action.

The unfiltered fluid passes through the optimally designed bores of the top cover
plate (9) into the individual filter candles (7) from above. The resultant turbulent
stream in the longitudinal direction of the filter candles (7) (cross-flow back-flushing)
and the counter-flow back-flushing through the filter candles (7) result in a
particularly effective and lasting back-flushing action.

Counter flow back-flushing:

The lower pressure in the interior of the filter candles (7) during
the back-flushing operation (connected with the atmosphere)
and the higher pressure (operating pressure) outside the filter
candles (7) produce a counter-flow through the mesh from the
clean filter side through the dirty filter side to the atmosphere.

This newly developed cross-flow back-flushing feature in conjunction with

the time-tested counter-flow back-flushing principle means that the pressure
drop at the filter remains constant for a longer period.
7. Functioning of the overflow valves
(see drawing Z39293 sheet 3 or Z101308 sheet 3)

Should for any reason the filter candles (7) (first filter stage) no longer be
adequately cleaned, the overflow valves (19) are opened at a differential pressure
of 2 bar upwards and some of the fluid is filtered through the protective filter (8)
(second filter stage).

However, before this situation arises, the installed differential pressure indicator
(24) emits a differential pressure warning (first contact). The cause must now be
localised and remedied.

If this warning is not heeded, an alarm is emitted by the second contact of the
differential pressure indicator (24).

The filter may only be operated in this emergency condition for a

short time (opened overflow valves and differential pressure
warning). Prolonged operation in this mode can result in
damage to downstream components.

The overflow valves are closed under normal operating conditions, even
during start-up at lower fluid temperatures.
8. Maintenance

Section 9 - Filter candle inspection and cleaning - must also be observed.

Even with automatic filters inspections and maintenance must be performed at

regular intervals.
It is extremely important to remember that in spite of constant back-flushing the
mesh may become clogged over the course of time, depending on the quality of the
fluid and whether a bypass treatment unit installed.

In order to maintain trouble-free operation, the following aspects are to be observed

during maintenance:

8.1 The filter must be switched off for all maintenance work.

8.2 Check filter and connections for leaks.

8.3 Conduct visual inspection of all filter candles (7) once a year.

Should a higher differential pressure occur beforehand, all the

filter candles (7) and the protective filter (8) must be checked
and, if necessary, cleaned.
Observe section 9 "filter candle inspection and cleaning".

A highly contaminated protective filter (8) is a sign of

prolonged operation with defective or clogged filter candles (7)
and thus (from a differential pressure of 2 bar upwards)
opened overflow valves (19).
It is imperative to check these components.
8.4 Check the ease of movement of the worm gear unit (13), the turbine (14)
including gear (15) with flushing arm (3).

To this end the cover (34) or the screw plug (34) must be removed. Now check
the ease of movement with a suitable spanner (on the hexagon of the worm
gear unit).
If movement is sluggish, refer to section "Sources of faults and their remedy".

8.5 Replace the dyn. loaded seals (66) as and when required.
It is advisable to replace all static seals during an overhaul.
9. Filter candle inspection and cleaning
(see drawing Z39293 sheet 2 or Z101308 sheet 2)

9.1 Open bypass line.

9.2 Close shut-off devices at the filter inlet and outlet.
9.3 Now drain the filter from the drain screw.
9.4 Pull the entire filter element incl. flushing arm (3) and gear (15) out of the
housing.

Make sure that the exposed gear (15) is not damaged.

9.5 Remove the upper cover plate (9).

9.6 The filter candles (7) can now be pushed out from below or pulled out from
above.
9.7 Place the filter candles (7) in the cold cleaner BOLL CLEAN 2000, max.
soaking time 24 hours.
9.8 After immersing the filter candles (7), clean them from the outside inwards
using high pressure.

It must be ensured that the filter candles are cleaned at a

pressure of max. 60 bar and at a minimum distance of the
cleaning nozzle of 20 cm. Otherwise, damage to the mesh is
possible.

In our experience it is only possible to achieve an almost 100

% cleaning effect by hand with the high-pressure cleaning unit
type 5.04 using BOLL CLEAN 2000.
Refer to the separate description "Filter cleaning unit type
5.04".
 9.9 If operating an engine on heavy fuel

If operating on heavy fuel, the filter elements must be checked

after 2 years at the latest and any damaged ones must be
replaced.
We recommend the general replacement of all filter elements
after 4 years.

If operating an engine on diesel oil

If operating on diesel oil, the filter elements must be checked

after 4 years at the latest and any damaged ones must be
replaced.
We recommend the general replacement of all filter elements
after 6 years.

Defective filter candles (7) must not be used again.

Before installation of the entire filter element, the ease of motion

of the flushing facility must be checked.
The flushing arm (3) must not grind against the bottom filter
plate (5).

9.10 Now push the entire filter element into the housing.
By slightly turning the flushing shaft (10), the gear (15) is forced into the drive
pinion of the gear unit (13).

Now re-assemble the filter in the reverse sequence to that described

under points 9.1 - 9.9.
10. Technical information BOLL CLEAN 2000
Solvent-free cold cleaner

Product description
BOLL CLEAN 2000 is a liquid cleaning and degreasing agent for a wide range of
applications. It can be used for virtually all cleaning and degreasing work.
BOLL CLEAN 2000 is miscible with any water - even sea water.
BOLL CLEAN 2000 cleans quickly and thoroughly and is extremely economical.
Even mixed with water in concentration ranges of 1:50, it exhibits good cleaning and
degreasing properties. When BOLL CLEAN 2000 is used, no safety precautions are
needed. BOLL CLEAN 2000 exhibits these outstanding properties without having
the disadvantages of solvent cleaners.
BOLL CLEAN 2000 is non-flammable
does not need to be identified
does not have a pungent smell
is a non-irritant
is physiologically safe
is biodegradable
Federal Office of the Environment Reg. No. 04860019
BOLL CLEAN 2000 can become cold or hot during storage but can be readily used
again at normal temperature.

Field of application
BOLL CLEAN 2000 is suitable for cleaning and degreasing all metals, plastics,
highly adhesive paints etc. It removes oil, wax, grease, rust and numerous other
kinds of dirt.
BOLL CLEAN 2000 is used, for example, in the automobile, engine, aviation, oil (for
drilling equipment), food and drinks, and metalworking industries, in overhauling
and machine workshops, shipping, diesel and electric locomotives, and in electricity
works for cleaning the generators.
Mesh contaminated with heavy oil
Filters contaminated with heavy oil must be soaked in a commercially available
solvent. After being soaked, the filters are cleaned in the BOLL & KIRCH cleaning
unit type 5.04 with BOLL CLEAN 2000 and a high-pressure pump.

Instructions for use

The use of BOLL CLEAN 2000 does not involve any specific cleaning method.
BOLL CLEAN 2000 can be employed in an immersion bath, in a spraying plant, in a
steam jet cleaner or using a manual application process with a cloth, brush or
sponge, depending on the circumstances.
It can be used either cold or warm.
BOLL CLEAN 2000 is miscible with water - even sea water.
Concentration for cleaning mesh: 1:2.5
Temperature: up to max. 60°C
The concentration depends on the type and thickness of the adhering material to be
removed. When used in a concentration of 1:30 and more, rinsing is not necessary.
No visible film remains on the surface.
11. Sources of faults and their remedy

Fault Cause Reasons and remedy

Viscosity too high Wait for normal operating conditions

High volume of dirt Check bypass treatment unit for
operability
Filter candles clogged Clean candles
Flushing volume too low Check flow control device in outlet
and sludge discharge line for
clogging
Shaft end does not turn Turbine jammed
Remove parts jammed between
turbine and wall
∆p rises — Gear unit defective
Check for ease of movement
(as per section 8 "Maintenance")
Replace gear unit if necessary
Flushing arm (3) jammed, Remove
any foreign matter
Operating pressure < 2 bar
Run for prolonged period at higher
pressure 5-6 bar and thus eliminate
the blockage
Oil quantity too low / Increase oil
quantity
UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE

19044 ALT 03 17.12.03 1

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0000 0629044 6.46 NW150 RUECKSP. 19044 03 1.000 ST

BACK FLUSHING FILTER
................................................................................
ZUSAMMENSTELLUNG : Z42564
ASSEMBLY DRAWING
MASSBLATT : TYP6.46
DIMENSION PAGE
AUSLEGUNGSUEBERDRUCK: 10 BAR / 100 GRD C
DESIGN PRESSURE

.
................................................................................
********************
................................................................................
0001 6521235 GEHAEUSE 1.000 ST
HOUSING
................................................................................
0002 6022216 DECKEL 1.000 ST
COVER
................................................................................
0003 6551249 SPUELARM 1.000 ST
FLUSHING CANAL
................................................................................
0004 5151255 VERBINDUNGSROHR 1.000 ST
JOINING TUBE
................................................................................
0005 5101245 SIEBPLATTE (UNTEN) 1.000 ST
SIEVE PLATE
................................................................................
0006 5101246 SIEBPLATTE (OBEN) 1.000 ST
SIEVE PLATE
................................................................................
0007 1345456 FILTERKERZE 66.000 ST
FILTER ELEMENT
................................................................................
0008 5709913 SCHUTZSIEB 1.000 ST
SIEVE
................................................................................
0008 7108807 LOCHBLECHZUSCHNITT 1.000 ST
PLATE BLANK
................................................................................
0009 5108372 ABDECKPLATTE 1.000 ST
PLATE
................................................................................
0010 5300219 SPUELARMWELLE 1.000 ST
FLUSHING CANAL SHAFT
................................................................................
0011 6853849 TURBINENGEHAEUSE 1.000 ST
TURBINE HOUSING
................................................................................
/ 2
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19044 ALT 03 17.12.03 2

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0012 5301235 FLANSCHBEFESTIGUNG 1.000 ST

FLANGE FASTENING
................................................................................
0013 2709131 SCHNECKENGETR.KURZ A 1.000 ST
GEAR
................................................................................
0014 2784402 FLUEGEL MIT NABE 1.000 ST
TURBINE WING WITH WH
................................................................................
0015 2705519 ZAHNRAD 1.000 ST
TOOTHED WHEEL
................................................................................
0016 5300723 BEFESTIGUNGSBUCHSE 1.000 ST
BUSH
................................................................................
0017 5060722 SPUELBUCHSE 1.000 ST
BUSH
................................................................................
0018 0209130 UEBERSTROEMVENTIL 6.46 D=34 19130 10.000 ST
VALVE
................................................................................
0021 5004689 DUESE 1.000 ST
NOZZLE
................................................................................
0022 2310058 DRUCKFEDER 1.000 ST
PRESSURE SPRING
................................................................................
0023 2703600 RILLENKUGELLAGER 2.000 ST
DEEP GROOVE BALL BEA
................................................................................
0024 0550001 4.36.2 P = 0.8 DDA 09322 08 1.000 ST
PRESSURE DIFFERENT.CONTACT INDICATOR
................................................................................
0025 2000257 ZYL.-SCHRAUBE 1.000 ST
SLOTTED CHEESE HEAD
................................................................................
0026 2301130 STECKKERBSTIFT 1.000 ST
PIN
................................................................................
0027 2300010 SPANNSTIFT 1.000 ST
SPRING TYPE STRAIGHT
................................................................................
0028 2560063 WINKELKUGELHAHN 2.000 ST
ANGLE BALL COCK
................................................................................
0030 2009089 STIFTSCHRAUBE 16.000 ST
STUD
................................................................................
0031 2100007 SECHSKANTMUTTER 16.000 ST
HEXAGON NUT
................................................................................
/ 3
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19044 ALT 03 17.12.03 3

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0033 2000190 VERSCHLUSSCHRAUBE 1.000 ST

HEXAGON HEAD SCREW P
................................................................................
0034 2000194 VERSCHLUSSCHRAUBE 1.000 ST
HEXAGON HEAD SCREW P
................................................................................
0035 2000187 VERSCHLUSSCHRAUBE 1.000 ST
HEXAGON HEAD SCREW P
................................................................................
0037 2000142 ZYL.-SCHRAUBE 6.000 ST
SLOTTED CHESSE HEAD
................................................................................
0038 2000121 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0039 2000121 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0040 2000143 ZYL.-SCHRAUBE 1.000 ST
SLOTTED CHESSE HEAD
................................................................................
0041 2003658 STIFTSCHRAUBE 1.000 ST
BOLT
................................................................................
0042 2000122 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0043 2000154 ZYL.-SCHRAUBE 4.000 ST
HEXAGON SOCKET HEAD
................................................................................
0044 2000121 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0045 2000121 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0046 2200005 SCHEIBE 3.000 ST
DISK
................................................................................
0047 5008712 SCHEIBE 1.000 ST
DISC
................................................................................
0048 2200007 SCHEIBE 1.000 ST
WASHER
................................................................................
0049 2200009 SCHEIBE 4.000 ST
DISK
................................................................................
0050 2001635 SECHSKANTSCHRAUBE 4.000 ST
HEXAGON SCREW
................................................................................
/ 4
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19044 ALT 03 17.12.03 4

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IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0051 6024503 BODENBEF. 1.000 ST

BOTTOM FASTENING
................................................................................
0052 5708316 BEFESTIGUNGSBLECH 1.000 ST
PLATE
................................................................................
0053 2000122 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0054 2100003 SECHSKANTMUTTER 2.000 ST
HEXAGON NUT
................................................................................
0055 2500024 VERSCHRAUB. 3.000 ST
SCREWING
................................................................................
0056 2500025 VERSCHRAUB. 1.000 ST
SCREWING
................................................................................
0057 7300002 PRAEZ.-ROHR NBK 1.000 M
TUBE
................................................................................
0058 3040115 O-RING 1.000 ST
GASKET
................................................................................
0060 3040154 O-RING 1.000 ST
GASKET
................................................................................
0061 3040021 O-RING 1.000 ST
GASKET
................................................................................
0062 3040021 O-RING 2.000 ST
GASKET
................................................................................
0063 3040023 O-RING 66.000 ST
GASKET
................................................................................
0064 3140003 RUNDSCHNURRING 66.000 ST
ROUND CORD RING
................................................................................
0065 3031743 O-RING 1.000 ST
GASKET
................................................................................
0066 3040115 O-RING 1.000 ST
GASKET
................................................................................
0068 3290012 DICHTRING 1.000 ST
GASKET
................................................................................
0069 3270002 DICHTRING 1.000 ST
GASKET
................................................................................
/ 5
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19044 ALT 03 17.12.03 5

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IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0070 3332814 FLACHDICHTUNG 1.000 ST

GASKET
................................................................................
0071 3048235 O-RING 1.000 ST
GASKET
................................................................................
0075 2209799 FEDERRING 3.000 ST
SPRING RING
................................................................................
0076 2000122 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0077 2100047 SECHSKANTMUTTER 1.000 ST
HEXAGON NUT
................................................................................
0078 3270005 DICHTRING 1.000 ST
SEAL
................................................................................
0079 2000115 ZYL.-SCHRAUBE 1.000 ST
HEXAGON SOCKET HEAD
................................................................................
0080 9400997 SCHILD "EIN/IN 1.000 ST
LABEL " IN "
................................................................................
0080 9407569 SCHILD "AUS/OU 1.000 ST
LABEL " OUT "
................................................................................
0080 9402913 TYPENSCHILD WN26 1.000 ST
NAME PLATE
................................................................................
0081 3529686 ANZEIGEBUCHSE 1.000 ST
INDICATION BUSH
................................................................................
0082 5209684 SPANNRING 1.000 ST
TENSION RING
................................................................................
0083 4707080 SCHAUGLAS 1.000 ST
INSPECTION GLAS
................................................................................
0085 2311117 WELLENFEDER 1.000 ST
SPRING
................................................................................
 Operating Instruction
Type LTU/LUB

Please keep your operating instruction in a safe place!

Type

Serial No.

EDUR-Pumpenfabrik Postfach 1949 · D-24018 Kiel

Eduard Redlien GmbH & Co. KG Tel. (+431) 689868 · Fax (+431) 6898800
E-mail: [email protected] · http://www.edur.de
2

Contents
1 Security 3
1.1 Identification of Safety Instructions in the
Operating Manual 3
1.2 Qualification and Training of Operating
Personnel 3
1.3 Hazards in the Event of Non-Compliance
with the Safety Instructions 3
1.4 Compliance with Regulations Pertaining to
Safety at Work 4
1.5 Safety Instructions relevant for Operation 4
1.6 Safety Instructions relevant for Maintenance,
Inspection and Assembly Work 4
1.7 Unauthorized Alterations and Production of
Spare Parts 4
1.8 Unauthorized Modes of Operation 4

2 Transport and Intermediate Storage 4

2.1 Transport 4
2.2 Intermediate Storage 5
2.2.1 Internal Preservation 5
2.2.2 Preservation Control 5
2.2.3 Removal of Preservation 5

3 Description 5
3.1 Design 5
3.2 Place of Operation 6
3.3 Connected Loads 6
3.4 Direction 6
3.5 Coupling Protection 6
3.6 Piping 6
3.6.1 General Remarks 7
3.6.2 Suction Pipeline 7
3.6.3 Pressure Pipeline 7
3.6.4 Additional Connections 7
4 Starting Operation/ Stopping Operation 7
4.1 Preparations for Initial 7
4.2 Initial Starting 7
4.3 Restarting 7
4.4 Stopping Operation 7
5 Service/Maintenance 7
5.1 Supervision of Operation 7
5.1.1 Mechanical Seal 7
5.2 Maintenance 7
5.2.1 Preparation 7
5.2.2 Dismounting 7
5.2.2.1 Pump 7
5.2.2.2 Dismounting of Mechanical Seal 7
5.2.2.3 Motor 7
5.2.3 Mounting 7
5.2.3.1 General Remarks 7
5.2.3.2 Mounting of the Motor 7
5.2.3.3 Mounting of Mechanical Seal 8
6 Disturbance 9
7 Pump View and list of Spare Parts 10
7.1 LUB 65 · LUB 80 10
7.2 LUBL 65 · LUBL 80 · LUBL 100 11
7.3 LTU 12
 3

General Instructions non-compliance with which would

give rise to malfunctioning of the machinery are
The most important operational data are identify by the word
mentioned on the type label. The sound
pressure LpA following VDI-guidelines 3743 sheet 1
CAUTION
depending on the nominal pump power input P
will be seen from the diagram underneath.
It is imperative that signs affixed to the machine,
e. g.

- arrow indicating the direction of rotation

- symbols indicating fluid connections

be observed and kept legible.

1.2 Qualification and Training of

Operating Personnel
Fig. Noise emission The personnel responsible for operation,
The actual sound level ascertained at place of maintenance, inspection and assembly must be
installation will possibly differ considerably from adequately qualified. Scope of responsibility and
these values due to the operating conditions and supervision of the personnel must be exactly
the conditions of installation. defined by the plant operator. If the staff does not
have the necessary knowledge, they must be
trained and instructed, which may be performed
by the machine manufacturer or supplier on
1 Security behalf of the plant operator. Moreover the plant
operator is to make sure that the contents of the
This operating manual gives basic instructions
operating manual are fully understood by the
which are to be observed during installation,
personnel.
operation and maintenance of the pump. it is
therefore imperative that this manual be read by
the responsible personnel/operator prior to
assembly and commissioning. It is always to be 1.3 Hazards in the Event of
kept available at the installation site. Non-Compliance with the Safety
It is not only the general safety instructions Instructions
contained under this main heading safety that are
Non-compliance with the safety instructions may
to be observed but also the specific information
produce a risk to the personnel as well as to the
provided under the other main headings.
environment and the machine and results in a
loss of any right to claim damages.

1.1 Identification of Safety For example, non-compliance may involve the

Instructions in the Operating following hazards:
Manual - Failure of important functions of the
machine/plant
Safety instructions given in this manual - Failure of specified procedures of
non-compliance with which would affect safety are maintenance and repair
identified by the following symbol: - Exposure of people to electrical, mechanical
and chemical hazards
- Endangering the environment owing to
hazardous substances being released
see DIN 4844-W9
or where electrical safety is involved, with

see DIN 4844-W8

4

1.4 Compliance with Regulations 1.7 Unauthorized Alterations and

Pertaining to Safety at Work Production of Spare Parts
When operating the pump, the safety instructions Any modifications may be made to the machine
contained in this manual, the relevant national only after consultation with the manufacturer.
accident prevention regulations and any other Using spare parts and accessories authorised by
service and safety instructions issued by the plant the manufacturer is in the interest of safety. Use
operator are to be observed. of other parts may exempt the manufacturer from
any liability.

1.5 Safety Instructions relevant for

Operation 1.8 Unauthorized Modes of
Operation
- If hot or cold machine components involve
hazards, they must be guarded against The reliability of the machine delivered will be only
accidental contact. guaranteed if it is used in the manner intended, in
- Guards for moving parts (e.g. coupling) accordance with our order documentation,
must not be removed from the machine especially with the order confirmation.
while in operation. The limit values specified in the data sheet must
- Any leakage of hazardous (e.g. explosive, under no circumstances be exceeded.
toxic, hot) fluids (e.g. from the shaft seal)
must be drained away so as to prevent any
risk occurring to persons or the environment. 2 Transport and Intermediate Storage
Statutory regulations are to be complied
with. 2.1 Transport
- Hazards resulting from electricity are to be
When transporting the complete pump unit by
precluded (see, for example, the
crane, mount the ropes as shown in the figure.
VDE Specifications and the bye-laws of the
local power supply utilities). The crane facility and the ropes
CAUTION
must be of sufficient capacity.
The ring loop of the motor must not be used for
1.6 Safety Instructions relevant for transport of the complete pump unit.
Maintenance, Inspection and
Assembly Work
It shall be the plant operator's responsibility to
ensure that all maintenance, inspection and
assembly work is performed by authorized and
qualified personnel who have adequately
familiarized themselves with the subject matter by
studying this manual in detail.

Any work on the machine shall only be performed Fig. 2.1a Pumps of structural form LUB
when it is at a standstill, it being imperative that
the procedure for shutting down the machine
described in this manual be followed.

Pumps and pumps units which convey hazardous

media must be decontaminated.

On completion of work all safety and protective

facilities must be re-installed and made operative
again.

Prior to restarting the machine, the instructions

listed under Initial commissioning are to be
observed.

Fig. 2.1b Pumps of structural form LT

 5

2.2 Intermediate Storage 3.3 Connected Loads

On delivery, all pumps are preserved. Thus, they Work must only be executed when
can be stored for 6-12 months. If the storage time electricity is switched off. Make sure
is longer or the pumps are not in operation, they that the system cannot be powered
must receive additional preservation on the inside. on accidentally.
The preservation means (please consult us)
depends on the used materials and conditions of Prior to connecting the pump to
operation. CAUTION the power system, fill it with
The storage room must be roofed and well pumped liquid. The pump must
ventilated. Avoid temperatures below zero and by no means be operated without liquid!
high humidity.
The pump must be connected according to
international national requirements as well as
according to the requirements of the local mains
2.2.1 Internal Preservation system. Voltage and frequency must correspond
to the winding of the electric drive. For details of
Close the suction branch securely. Fill the pump the respective winding, see the type label.
with the preservation means and slowly turn the The motor must not be operated without motor
rotor manually. Close the pressure branch protection facility.
securely. For motors with explosion protection, the range of
temperature of the motor indicated on the type
label must correspond to the range of the fuel
2.2.2 Preservation Control gas.

Check the filling level of the pump and turn the

rotor by hand at regular intervals of 3 months.
Refill preservation means, if necessary.
3.4 Direction
Switch on the motor briefly in order to check the
direction of rotation. The motor must not reach its
2.2.3 Removal of Preservation operational speed. The direction of rotation must
correspond to the arrow indicating the direction of
Prior to operation, the pump must be rinsed rotation on top of the pump. If the direction of
thoroughly. In the case of additional preservation, rotation is not correct, perform the relevant
the preservation means on the inside must at first modifications at the phase-sequence
be removed.

3.5 Coupling Protection

3 Description
The pump must not be operated if
3.1 Design
coupling protection is not fitted. If this
Horizontal and vertical, single-stage or multi-stage coupling protection is not supplied by
ring section pumps, with or without an electric the manufacturer, the operator of the pump must
drive unit, on a common bed-plate or unit- supply it himself.
construction pumps, available in different
construction materials, sizes and with different
shaft sealings. 3.6 Piping
3.6.1 General Remarks
3.2 Place of Operation The nominal widths of the pipes must be at least
The pump unit must be freely accessible for the as wide as those of the pump connection joints.
purpose of supervision, servicing, maintenance, For adapters, use extension angles of 8°, if
mounting and dismounting. possible.
Avoid using it in corrosive and very dusty The pipes must be gathered and secured right in
surroundings. front of the pump so that their weight does not
The limiting values of the electric drive unit with affect the pump. The negative effects of variations
regard to the insulation material class and the in temperature and occurring oscillation may be
types of protection must be observed. reduced by installing a suitable bellow expansion
For other drive units supplied, see the enclosed joint (see section 4.6).
separate operating instructions. Measuring equipment for supervision of the pump
operation is required.
6

Prior to operation, all parts in contact with liquids 4.2 Initial Starting
must be thoroughly cleaned.
The pump must not be started until the outlet stop
valve is closed so as to avoid overload of the
3.6.2 Suction Pipeline motor. Immediately after reaching the operational
speed, slowly open the stop valve of the pressure
The suction pipeline must be as short as possible. pipeline and adjust the operating point.
Variations in diameter and additional piping must
The pump must never be operated for
be kept to a minimum. The suction pipeline
a longer period if the outlet stop valve
towards the pump must be rising, the inlet must
is closed. The pump unit will be
be descending to prevent an air pocket from being
damaged if the pumped liquid exceeds the
formed. For non-self-priming pumps, installation
permitted temperature.
of a foot valve into the suction pipeline is
compulsory in order to avoid that, in case of a
standstill, the pump and the suction pipeline run
out of liquid during suction operation. 4.3 Restarting
Contamination of the pumped liquid is to be
avoided by using a suction hose or a filter. By no Do not restart the pump until the pump shaft
means must air penetrate through the liquid level stands still.
via the suction hose or dirt be whirled up from the Backflow of liquid must not result
liquid pool. Clean the suction hose and filter CAUTION
in a change of direction of
regularly. rotation of the pump. If this is the case,
To close the suction pipeline in the case of mechanical seals dependent on direction of
mounting or maintenance work, a stop valve must rotation may be damaged.
be provided near the pump. The stop valve must
not be used for adjustment and must be
completely open during operation.
4.4 Stopping Operation
Close stop valve of the pressure pipeline. If there is
3.6.3 Pressure Pipeline a backflow stop and sufficient counter pressure in
the pipeline, the stop valve can remain open.
For adjustment, repair and mounting of the pump, Switch off the motor and observe that it slows down
a stop valve is to be provided near the pressure smoothly. Close stop valve of the pressure pipeline.
joint. If the pumped liquid reaches temperatures below
zero and/or if longer periods of standstill occur,
the pump must be drained completely and be
3.6.4 Additional Connections preserved (see section 2.2.1).

For the position and dimension of required

additional connections as e.g. for rinse, stop and
quench liquid, refer to the labels supplied with the 5 Service/Maintenance
pump or to the drawings in the operating
5.1 Supervision of Operation
instructions. The rinse, stop and quench liquids
must be checked at regular intervals. Ensure that the pump runs free of vibration and
Connections for ventilation and release of the smoothly
leakage liquid are also described in the drawings. The pump must by no means be operated without
liquid.
There is only a minimal or invisible loss of leakage
4 Starting Operation/ Stopping (steam) if the mechanical seals function correctly.
Operation Gland packings should drip slightly.
Do not operate the pump for a longer period with
4.1 Preparations for Initial a closed stop valve.
The maximum permitted environmental
Prior to the start, the pump and the suction temperature is 40oC. The storing temperature
pipeline must be drained of air and be completely measured at the motor or pump casing may
filled with the pumped liquid. The stop valve in the exceed the environmental temperature by 50oC. It
suction or inlet pipeline must be completely open, must not exceed 90oC. Only operate the pump at
if there is one. For self-priming pumps, the pump a higher temperature with the manufacturer's
must only be completely drained of air and filled approval.
with the pumped liquid. Installed pumps must be powered on and off
briefly once a week in order to guarantee that they
are ready for operation.
 7

5.1.1 Mechanical Seal pump can remain in the piping. First, remove the
coupling protection and loosen the hexagon
The mechanical seals are maintenance-free. If screws of the coupling. After having loosened the
leakages occur after a longer period of operation, hexagon screws at the motor flange, remove the
replace the complete seal. motor from the pump.

5.2 Maintenance 5.2.3 Mounting

5.2.1 Preparation 5.2.3.1 General Remarks
In order to make sure that the pump Prior to mounting, all parts must be cleaned
cannot be started, separate the power thoroughly. Remove remaining parts of the seals.
cable from the motor. Secure the unit Slight scratches and grooves on the shaft near
against accidental switch-on. the shaft seal and on other sealing surfaces of the
casings are to be polished with linen. If this is not
Close the stop valve of the pressure and suction possible, replace the parts. Gaskets must always
pipelines. The pump casing must have reached be renewed. Check O-rings for damage and
the environmental temperature and be drained of replace them, if necessary.
liquid and pressure. In the case of pumps in Mounting is effected in the reverse order of
unit-construction with mounting flange, the dismounting. Heat up the coupling joints of rigid
container must be drained completely. couplings to approximately 250°C prior to
mounting them onto the shaft.

5.2.2 Dismounting CAUTION In the case of flexible couplings,

the coupling half on the pump
By no means use force while dismounting the shaft must be tightened thoroughly by means of
pump. the shaft nut and/or the hexagon nut. If this is not
Proceed as follows for the different pump types: observed, the bearings will be damaged.
For fixed parts of the casings, impellers and The starting torques for the tie bolts and locking
couplings, use appropriate dismounting facilities. screws non lubricated condition are displayed in
Impellers, which cannot easily be removed from fig. 6.2.3.1a.
the shaft, can be pushed back from the shaft by
means of two hexagon screws. thread M 10 M 12 M 14 M16 M20
torque 30 50 75 110 120
Nm 70*
* for pumps with more than 4 tie bolts
5.2.2.1 Pump Abb. 6.2.3.1a Starting torque
The pump is always dismounted on the suction
side and with the shaft in a horizontal position.
Refer to enclosed drawings on page 10, 11 and 5.2.3.2 Mounting of the Motor
12 or in the supplementary sheet for the
dismounting sequence. For initial mounting of motor and pumps with rigid
coupling, first of all, remove the transport
safeguards of the lantern or of the intermediate
flange, then remove the motorside coupling half.
5.2.2.2 Dismounting of Mechanical Seal Subsequently, put this part onto the motor shaft.
In order to replace the mechanical seal, the pump This coupling half must be next to the motor shaft
must be dismounted (see Fig. 5.2.2) first. After collar. Tighten screws, join motor and pump
that the pump must be dismantled before the seal centrically without tilting them. Tighten screws
can be removed. Dismantle the pump in the between motor and lantern or intermediate flange
sequence shown in the exploded view diagrams, and then coupling screws.
pages 10,11 or 12. Remove impeller (230), casing The inner parts of the pump will
(108,117), key (940.1) and the circlip (932), pull CAUTION be damaged if motor and pump
the delivery casing (107) off the shaft with the are connected and the
mechanical seal (433). motorside or pumpside coupling half has been
installed incorrectly or not at all.

5.2.2.3 Motor
For vertical pumps and unit-construction pumps, it
is not necessary to dismount the pump unit. The
8

5.2.3.3 Mounting of Mechanical Seal For details of the individual types of mechanical
seals observe the following procedures.
When mounting the mechanical seals, you must
proceed very carefully and with precision. 1. Stressed mechanical seal independent of
direction of rotation with elastomer bellows
Do not touch the surfaces of the seal. Do not
(fig. 6.2.3.3a)
damage the sealing parts. To facilitate the
mounting, moisten elastomer with low-surface
tension water.

Mechanical seals and sealingparts

with elastomer made of EP rubber
must by no means come in contact
with oil or grease.

The shape of spare mechanical seals may differ

from those of the installed mechanical seal.
However, the dimensions of the spare mechanical
seal are the same and for that reason it can be
replaced. Fig. 6.2.3.3a

To avoid distortion of the counter-ring, mechanical Carefully press angle collar (1) together with
seals with doubled PTFE-wrapped sealing O rings counter ring (2) into the counter ring fit.
are additionally secured by a leading pin inside Twist the rotating unit (3,4,5) onto the shaft
the casing. The pin must be removed when as far as the counter ring. Put on supporting
replacing the type of mechanical seals and when ring and mount circlip and/or push shaft
using a type with different O-ring material. sleeve for mechanical seal onto the shaft.

For details of the individual types of mechanical 2. Stressed mechanical seal dependent on
seals observe the following procedures. direction of rotation with conical springs
(fig. 6.2.3.3b)

Fig. 6.2.3.3b

Insert O Ring (1) into counter ring fit and

carefully press counter ring (2) into it. Push
mechanical seal (3) onto the shaft as far as
the counter ring. Press O Ring (4) into the
mechanical seal by means of the supporting
ring. The pivot of the pressure spring (6)
must be situated in the groove of the
mechanical seal ring. Put on locking
ring (7). Mount circlip and/or shaft sleeve for
mechanical seal.
9 9

6 Disturbance

To eliminate disturbance, the pump must have

CAUTION reached the environmental temperature and must
be drained of air and pressure.

The chart shows a list of potential errors and their possible causes. For
errors which are not listed here or which have other reasons, please
consult us.

Bearing temperature too high

Pump is becoming too hot

Motor protection activated
Leakages at the casing

Shaft seal leaks badly

Pump operates badly

Overload of the drive

Rates of flow too low
Pump is blocked

Heads too low

Coupling fault

Cause Elimination
Pump and/or suction pipeline is not Drain of air and fill
z z completely drained of air/filled
Suction level too high, NPSH value of
Completely open stop slide in the suction
the unit too highpipeline, check suction bag/footing valve, if
z z z z necessary, increase liquid level, if
necessary
Air inclusion in the pumped liquid too Seal suction pipeline once again, check
z z z high suction bag, increase liquid level, if
necessary
Formation of air bag in suction pipeline Change suction pipeline/attach drain valve
z z z z
Direction of rotation incorrect Check and change phase sequence, if
z z necessary
z Rates of flow too low Readjust operating point
z z Wear of inner parts Replace inner parts
z z z Pump operates out of tolerance Readjust operating point
z Shaft seal damaged Replace shaft seal
Stuffing box gland jammed or tightened Correct
z
too heavily
Air entry through shaft sealing on Check liquid sealing or replace packing
z z z z
suction side
z z Speed too low Increase speed1)
z z Speed too high Reduce speed1)
z Connecting screws, seals Tighten connecting screws, replace seals
z z Pump/motor not adjusted Replace defective parts, adjust pump/motor
Problems via piping Check pipe connections/pump
z z z fasteners/bearing distance of pipe clips,
installation with oscillation absorbers
2)
Insufficient, excessive or wrong Add, remove or change grease
z
lubrication grease
z Incorrect coupling gap Readjust motor
z Defective bearing Replace bearing
1)
Density/viscosity of pumped liquid
z z z z
higher than indicated in the order
Motor protection unit set incorrectly or Check motor protection unit, replace it, if
z defective necessary
Impeller blocked Clean interior parts from particles and
z impurities
1)
Please consult us
2)
Only pumps with lubricator
 10

7 Pump View and list of Spare Parts

7.1 LUB 65 · LUB 80

Part no. designation

100 casing
160 cover
177 sealing chamber
230 impeller
411 joint ring
412 o-ring
433 mechanical seal
507 deflector
551 disc spacer
554 washer
901 heaxagon screw
903 screwed plug
905 tie bolt
918 slotted countersunk head
______³³³screw
920 nut
930 tooth lock washer
932 circlip
940 key

When ordering spare parts, please

indicate serial no,, type no. and
parts no. by all means.
7.2 LUBL 65 · LUBL 80 · LUBL 100

Part no. designation

100 casing
160 cover
177 sealing chamber
210 shaft
230 impeller
341 lantern
411 joint ring
412 o-ring
433 mechanical seal
551 disc spacer
554 washer
681 coupling guard
844/.1 coupling half
901/.1-.2 hexagon screw
903 screwed plug
904 screwed plug
905 tie bolt
918 slotted countersunk head
______³³³screw
920 nut
930/.1 tooth locker washer
932 circlip
940/.1 key

When ordering spare parts, please

indicate serial no,, type no. and
parts no. by all means.
11
 12

7.3 LTU

Part no. designation

106 suction casing

107 delivery casing
117 end stage casing
210 shaft
230 impeller
341 lantern
400 gasket
411 joint ring
433 mechanical seal
554/.1 washer
681 coupling guard
712 support clumn
844/.1 coupling guard
901/.1-.4 hexagon screw
903 screwed plug
904 hexagon socket set
_____³³³2screw
905 tie bolt
930/.1-.2 tooth lock washer
932/.1 circlip
940/.1 key

When ordering spare parts, please

indicate serial no,, type no. and
parts no. by all means.
 13

Declaration of Conformity
As defined by machinery directive 98/37/EC Annex II A

1)
Herewith we declare that the pump unit supplied with mounted electric drive
complies with the following provisions applying to it

EC-machinery directive (98/37/EC, Annex I No. 1)

EC-low voltage directive (73/23/EEC)

Applied harmonized standards

EN 809 EN 953
EN 292-1 EN 60204-1 section 16
EN 292-2 EN 60034-5
EN 294

In case of a modification of the pump unit without being coordinated with us this declaration will not longer be
valid.

___________________
(QM-Supervisor)

1) other driving motor see separate declaration of conformity

Declaration by the manufacturer

As defined by machinery directive 98/37/EC, Annex II B

Herewith we declare that the pump supplied without driving motor is intended to be incorporated into
machinery or assembled with other machinery to constitute machinery covered by this directive and must not
be put into service until the machinery into which it is to be incorporated has been declared in conformity with
the provisions of the directive, version 98/37/EC.

Applied harmonized standards

EN 809
EN 292-1
EN 292-2

In case of a modification of the pump without being coordinated with us this declaration will not longer be
valid.

___________________
(QM-Supervisor)
14

BE7 20326_2 / 040811

 15

BE7 20326_2 / 040811

16

BE7 20326_2 / 040811

 Versatile booster, auxiliary
oil and water heater

VESTA™ EH
ELECTRICAL HEATER

VESTA™ EH is a flow-through electrical

heater, ideal for heating of oil or water.
Its heat load capacities range from 3 to
235 kW, with design conditions up to 16
bar and 160°C. The standard VESTA™ EH
can be mounted both vertically and hori-
sontally, but is also available as outflow
suction heater or tank mounted immer-
sion heater. The VESTA™ EH heater is
approved by all major marine classifica-
tion societies, and is CE marked.
 INSTRUCTIONS FOR ELECTRIC HEATER

Instruction Manual
for VESTATM EH
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 Heater .....................................................................................3
6. Operation.........................................................................................................3
7. Maintenance and Cleaning ..............................................................................4
8. Spare Parts.......................................................................................................6
Appendix:
- Spare Parts Drawing
- Dimensional Drawing
- Connection Diagram
- Electric Diagram (optional)
- Thermostats, working and safety (optional)

1. General Description
Aalborg Industries electrical heaters are of the flow through type. They are
manufactured with a heating capacity of 5 – 235 kW and a surface heat load
ranging from 1 to 3 W/cm2 depending on the heated medium.
Other capacities can be manufactured at request.
All electric heaters can be delivered as immersion heaters with a capacity of 5 to
121 kW, or as outflow heaters with a capacity of 5 to 171 kW.
Aalborg Industries electrical heaters are primarily used for heating of fuel oil, lu-
brication oil or water.
Cable assembly box, terminal box, safety thermostat and control thermostat are
placed in the vessel extension.
 INSTRUCTIONS FOR ELECTRIC HEATER

The control thermostat (optional) is supplied as 1 to 8 steps corresponding to the

number of power groups specified.
The heaters are supplied with a ½ inch socket for drain and safety valves.
Safety valve, thermometer, and pressure gauge may be mounted on a standard
outlet tube (optional).
All heaters have been hydrostatic pressure tested before delivery.
Aalborg Industries electrical heaters are type approved by all major classification
societies.

2. Installation Space Requirements

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

2.2. Installation surface

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

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

3.2. Hydrostatic testing

All Aalborg Industries heaters have undergone hydrostatic pressure testing be-
fore delivery. The testing fluid used contains a certain amount of corrosion pro-
tection (Castrol Rustilo Aqua 2); hence no further actions regarding storage are
required before installation.

3.3. Extended storage

When heaters are to be kept in storage for an extended period of time we rec-
ommend Castrol Rustilo Aqua 2 be used as protection against corrosion.

4. Mounting and Installation

The heater may be installed vertically or horizontally.
In case of vertical installation the terminal box and the medium outlet socket
must be top placed.

Instruction manual for heat exchanger type Vesta EH 2/6

Manufactured in Aalborg, Denmark
DEC 2000, rev. 2 – torque values added
C:\Documents and Settings\hdu\Desktop\Manuals\Documents\Word\EH_manual_english.doc; Print Date: 07/11/2002 2:49 PM
 INSTRUCTIONS FOR ELECTRIC HEATER

In case of horizontal installation the outlet socket must be pointing upwards.

Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts in the holes and tighten up.

5. Connecting the Heater

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

5.2. Electrical connection of the heater

Set up the cable connections between the control panel and the connection box
mounted on the heater. Make sure that suitable cable glands are used to ensure
tight ducts.

6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securely
tightened and that the heater has been tested for earth faults with a resistance me-
ter before connected to the power supply.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.

6.2. Storage facilities without humidity control

If the heater has been stored in storage facilities without humidity control special
attention has to be paid before commissioning may continue.
Before applying full power load the heater must be conditioned to avoid short
circuits due to accumulated moisture in the heating elements. Apply a low volt-
age to the heater connections for reduced and slow heating of the elements. The
conditioning voltage should not exceed 25 % of the nominal voltage, please refer
to specification. Condition for minimum 1 hour and observe the heater for ab-
normal temperature rise or signs of short circuits. When the heater is conditioned
the main power supply may be applied.

6.3. Initial adjustment of thermostats

The safety thermostat must be set to maximum design temperature or 10 °C
above normal working temperature.
The multistep working-thermostat (optional) must be adjusted to the required set
point. (See separate instruction).

Instruction manual for heat exchanger type Vesta EH 3/6

Manufactured in Aalborg, Denmark
DEC 2000, rev. 2 – torque values added
C:\Documents and Settings\hdu\Desktop\Manuals\Documents\Word\EH_manual_english.doc; Print Date: 07/11/2002 2:49 PM
 INSTRUCTIONS FOR ELECTRIC HEATER

The number of steps to be connected can be selected on the control panel.

6.4. Initial connecting to power supply

IMPORTANT: Full fluid flow through the heater must be established before
connecting to power supply.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.

Heater main flange bolts tightening schedule (dry values)

Heater No bolts Size Torque [Nm] Tightening schedule
EH15 8 M20 83 14725836
EH20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8
EH25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8
EH30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
EH35 16 M24 188 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2
EH40 16 M27 245 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2

Always use a torque wrench when tightening the flange bolts.

The heater must be carefully vented and carefully inspected for leakage during
the whole start-up period.
Make sure the power supply source and the design voltage on the heater and con-
trol panel (optional) are the same.
Switch on the power on the control panel main switch. The multistep thermostat
will automatically switch the individual step on and off.

6.5. Stopping the heater

IMPORTANT: When the heater is stopped (power switched off) after a period
of service it is very important to maintain fluid flow through the heater for at
least 10 minutes to remove the accumulated heat energy in the heating elements
(keep the pumps running).
Hence it is essential to make arrangements to maintain flow through the heater
also during emergency stops of the heater (keep the pumps running).

7. Maintenance and Cleaning

7.1. Mechanical maintenance
After every 2500 hours of operation the flange with heating elements must be
removed to check if deposits have gathered on the heating elements.

Instruction manual for heat exchanger type Vesta EH 4/6

Manufactured in Aalborg, Denmark
DEC 2000, rev. 2 – torque values added
C:\Documents and Settings\hdu\Desktop\Manuals\Documents\Word\EH_manual_english.doc; Print Date: 07/11/2002 2:49 PM
 INSTRUCTIONS FOR ELECTRIC HEATER

NOTE: The heater must be emptied before removing the flange with heating
elements.
In case of deposits chemical or steam cleaning must be performed.
If the heater is heavily contaminated with carbon deposits it is recommended the
heater be chemically cleaned with a carbon remover.
After cleaning has been completed the heater must be flushed carefully with
fresh water and allowed to dry afterwards.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.
Heater main flange bolts tightening schedule (dry values)
Heater No bolts Size Torque [Nm] Tightening schedule
EH15 8 M20 83 14725836
EH20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8
EH25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8
EH30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
EH35 16 M24 188 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2
EH40 16 M27 245 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2

Always use a torque wrench when tightening the flange bolts.

The heater must be carefully vented and carefully inspected for leakage during
the whole start-up period.
Make sure the power supply source and the design voltage on the heater and con-
trol panel (optional) are the same.
Switch on the power on the control panel main switch. The multistep thermostat
will automatically switch the individual step on and off.

7.2. Thermostats and control panel

Once a year the thermostats must be checked for correct set point.
All circuit breakers must be checked once a year for correct functioning.

7.3. Checking heating elements

In order to check the elements an ampere meter may be connected in series with
each single heating element to check the current.
If a heating element is open circuit it must be replaced. It is important to make
sure that the element tube is perfectly cleaned and 100% dry before replacement
of the element. An insulating brick must be placed in the bottom of the element
tube before inserting the new element.

Instruction manual for heat exchanger type Vesta EH 5/6

Manufactured in Aalborg, Denmark
DEC 2000, rev. 2 – torque values added
C:\Documents and Settings\hdu\Desktop\Manuals\Documents\Word\EH_manual_english.doc; Print Date: 07/11/2002 2:49 PM
 INSTRUCTIONS FOR ELECTRIC HEATER

7.4. Checking the safety valves

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

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

Instruction manual for heat exchanger type Vesta EH 6/6

Manufactured in Aalborg, Denmark
DEC 2000, rev. 2 – torque values added
C:\Documents and Settings\hdu\Desktop\Manuals\Documents\Word\EH_manual_english.doc; Print Date: 07/11/2002 2:49 PM
 Table of contents

1 Preface ......................................................................... 3

2 PHE safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 Incorrect operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Permitted PHE operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Residual dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1.1 User notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
„ Drawings and figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
„ Operator of the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
„ PHE setter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.2 Safety notes in the text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Manager’s obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6 Intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Overview and description of the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7.1 Basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.4 HE plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.4.1 Chevron pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.4.2 Free Flow design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.4.3 Plate evaporator design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.5 HE plate gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

8 Delivery, transport, and installation of the PHE . . . . . . . . . . . . . . . . . . . . . 24

8.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Setting up the lying PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.3 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1
Plate Heat Exchanger – Revision: 28.06.2002
 Table of contents

8.3.1 Suspended with shackles at the fixed plate

and with sling attachment at the carrying beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.3.2 Suspended at transport eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.3.3 Suspended with sling attachment at the tightening device . . . . . . . . . . . . . . . . . . . 30
8.4 Installation of the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.4.1 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.4.2 Pipe assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.5 PHE disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

9 Operation, start-up, and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

9.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.3 Shutdown of the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.3.1 Short-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.3.2 Long-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

10 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10.1 Preparatory precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10.2 Opening the PHE and removing the HE plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.3 Mounting the HE plates and closing the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.4 Cleaning the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.4.1 Cleaning the HE plates of the closed PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
„ CIP process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
„ Backflushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.4.2 Cleaning the HE plates of an open PHE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
„ Manually cleaning the HE plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
„ Chemically cleaning the HE plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

10.5 Replacing HE gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

10.6 Replacing port rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.7 Maintaining the PHE frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11.1 Impaired PHE performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

11.2 PHE leakages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

12 Technical terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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 Preface

1 Preface
With GEA Ecoflex, you use the technical know how of one of the worldwide lea-
ding manufacturers of plate heat exchangers (PHE).
We would like to make the handling of the PHE as safe and simple as possible. For
this reason, these comprehensive operating instructions serve as your personal ad-
viser who explains everything understandably and clearly: structure, function, in-
stallation, operation, maintenance, troubleshooting, transport and repair.
We especially devote ourselves to the subject of safety, so that all possible dangers
or damages can be avoided from the start. For that reason alone, all employees
who deal with the PHE should be able to reach for these important operating in-
structions at all times.
In the clear table of contents, you will quickly find what you are looking for. If not,
look in the index with page references. In the same way all technical terms are in-
formatively explained. After all, no questions should remain open, and in the case
they do, your GEA Ecoflex agent or the central service department is glad to assist
you further.
Operating instructions for special applications supplement these general operating
instructions.
With this in mind, we wish you a problem-free operation with GEA Ecoflex plate
heat exchangers.
GEA Ecoflex GmbH
Voss-Str. 11/13
D-31157 Sarstedt
Phone: +49/5066/601-0
Fax: +49/5066/601-106
Internet: http://www.gea-ecoflex.de

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 PHE safety

2 PHE safety
2.1 General safety
This chapter advises you on general precautions for the proper handling of the
PHE and which dangers the user can encounter.
If the PHE is employed improperly or not according to the intended purpose, or if
the safety notes are not adhered to, dangers to persons and property can arise.

NOTE

Read this chapter attentively. It contains important information and obligations. It

concerns your health and the trouble-free operation of the PHE.

CAUTION

The operator is responsible for the safe operation of the PHE.

The following points must be adhered to:
„ Always adhere to the general, national, and operational safety regulations, for
example, wearing protective glasses, close-fitting protective clothing, and
safety shoes.
„ Always adhere to the safety notes in the individual chapters of these operating
instructions.
„ The PHE may only be operated in perfect condition. Each change on the PHE
must be immediately reported to the nearest available responsible superior.
„ Before beginning work with the PHE, operators must familiarize themselves
with the possible dangers.
„ Before each start of the PHE, ensure that all parts of the PHE are in perfect con-
dition and function correctly.

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 PHE safety

2.2 Incorrect operating conditions

Operation of the PHE is not permitted, whenever:
„ substantial faults or damages are present,
„ the maintenance is not regularly performed,
„ the operating conditions (e. g. inner pressure, temperature, media, external in-
fluences) are exceeded.

NOTE

GEA Ecoflex accepts no liability for damages caused by incorrect operating condi-
tions.

2.3 Permitted PHE operators

For operating the PHE each operator must:
„ be appropriately trained for the task to be performed,
„ be familiar with the work safety and accident prevention regulations,
„ be instructed in the handling of the PHE and
„ have read and understood these operating instructions.
Persons who are responsible for the set-up, assembly, start-up, maintenance or di-
sassembly of the PHE must have command of the necessary knowledge.

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 PHE safety

2.4 Residual dangers

Residual dangers can never be fully excluded. You can only prevent these dangers
through appropriate behaviour.

CAUTION

Danger of injury!
Heat exchanger (HE) Plates:
The thin HE plates are sharp edged.
When handling HE plates, always
wear suitable protective gloves.
Outside of the PHE
On the edges, threads, or similar
parts, there is a danger of injury. Al-
ways wear suitable protective gloves
when handling the outside of the
PHE.
Hazardous flow-through media
Hazardous flow-through media pre-
sent dangers of chemical burns, bur-
ning, or poisoning. Always wear
suitable protective clothing when
working on the PHE with hazardous
flow-through media.

Opening the PHE:

Before opening the PHE, ensure that
it is unpressurised and empty. When
opening the PHE, always ensure that
the HE plates do not unintendedly
loosen from the frame and tip over,
see chapter 10.2, page 42.
Also ensure that the pressure plate is
secured against unintended slippage
(e. g. on ships).

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 PHE safety

Transporting the PHE:

Before transporting the PHE, always
ensure that the hoisting gear are of
sufficient dimensions and securely
fixed.
Never step underneath suspended
loads.

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 Operating instructions

3 Operating instructions
3.1 Operating instructions
These operating instructions are the instructions of the manufacturer for the PHE
managers and for all persons who are responsible for the set-up, operation, main-
tenance and repair of the PHE.
These operating instructions are generally applicable to all bolted/gasketted (not
welded) PHEs manufactured and supplied by GEA Ecoflex.

3.1.1 User notes

Drawings and figures
The drawings in these operating instructions are exemplary. For reasons of clarity,
some drawings have been greatly simplified. The actual details depend on the in-
dividually delivered PHE. You find diagrams and dimensions of the delivered
PHE in the supplied technical documentation.

Operator of the PHE

The operator of the PHE is the person who the PHE manager entitles to operate the
PHE.

PHE setter
These operating instructions contain no details about special tools that are needed
for the setting up and operating the PHE.

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 Operating instructions

3.1.2 Safety notes in the text

In these operating instructions, the following symbols are used in order to draw
your attention to dangers in handling the PHE or give you information about
handling the PHE:

CAUTION

This symbol means danger to life and health of persons.

The following text explains the type of danger and its effects and gives instructions
for averting the danger. Not adhering to the instructions can have health effects up
to and including death.

ATTENTION

This symbol means danger to the PHE or its parts and the surroundings.
The following text explains the type of danger and its effects and gives instructions
for averting the danger. Not adhering to the instructions can cause substantial da-
mages to the PHE.

NOTE

This symbol appears above paragraphs that give you useful or important notes for
the correct handling of the PHE. This information helps you to avoid problems and
makes it easier to handle the PHE.

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 Manager’s obligations

4 Manager’s obligations

CAUTION

Danger of injury
In the case of hazardous media (acids or similar media), high pressures and high/
low temperatures in the PHE, there is a danger of injury during maintenance or
leakages. In this case, you absolutely must have a splash protector. This splash
protector may only be removed when the PHE reaches room pressure and room
temperature, or is empty.

As manager of the PHE, you must ensure that each operator who is responsible for
the set-up, operation, maintenance or repair of the PHE has read and understood,
from beginning to end, the parts of the operating instructions important for the
job.
The PHE is built according to state-of-the-art technology and is reliable in service.
Nevertheless, dangers from the PHE or damages to the PHE can arise if you do not
adhere to the following instructions:
„ These operating instructions must always be accessible to the operators ent-
rusted to work on the PHE.
„ Only operators who are instructed in the handling of the PHE and the basic
work safety and accident prevention regulations may work on the PHE. For
safety reasons, it is forbidden for other persons to be in the area of the PHE.
„ You must verify the safety-conscious work of the operator in regular intervals.
„ As manager you must ensure that:
„ the PHE remains in functional order.
„ no premature wear of certain PHE components due to unfavourable sur-
rounding conditions occurs.
Unfavourable surrounding conditions are for example, for

sealing materials: „ aggressive gases and/or aggressive aerosols in

the surrounding air
„ effects of UV radiation (e.g. sunlight)
„ extreme surrounding temperatures
metallic components: „ aggressive gases and/or aggressive aerosols in
the surrounding air
„ humidity

„ all maintenance/inspections are carried out in regular intervals.

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 Manager’s obligations

„ no changes, additions, or reconstructions to the PHE are carried out without

approval of the PHE manufacturer. A change can lead to the loss of the ope-
rating approval.
„ all – even not here explicitly mentioned– laws and regulations valid for the
PHE as well as the valid accident prevention regulations are adhered to.

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 Functional description

5 Functional description
A series of contoured plates with transfer ports forms a pack of flow channels in
the PHE. The heat exchange media flows through these flow channels in alternate
channels.
Usually a single-pass PHE is employed. In this single-pass PHE, all of the feed and
discharge pipes are connected to the fixed plate, that is, on one side.

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 Functional description

Close temperature differences between the media may demand multi-pass PHE. In
these multi-pass PHEs, the connection pipes are then attached to the fixed plate
and to the pressure plate, that is, on both sides.

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 Intended purpose

6 Intended purpose
This PHE has been specially designed and manufactured for your specified opera-
ting conditions concerning pressure, temperature, flow rates, and type and compo-
sition of the flow-through media.
If a change in the specified operating conditions becomes necessary, GEA Ecoflex
must be consulted. The PHE may only be operated under new operating conditi-
ons after GEA Ecoflex has examined, approved, and altered the PHE documenta-
tion, if necessary.
Usage according to the rules includes:
„ adhering to the valid national and international laws, decrees, regulations, di-
rectives and other rules for the installation site .
„ following all safety notes of these operating instructions.
„ adhering to regular inspection and maintenance work.

NOTE

GEA Ecoflex accepts no liability for damages caused by deviations from the speci-
fied operating conditions for the PHE.

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 Overview and description of the PHE

7 Overview and description of the PHE

7.1 Basic structure
The following figure represents the basic structure of a plate heat exchanger. The
actual design depends on the application.

4
1
5

2
6

3 7

No. Component No. Component

1 Carrying beam 4 Support column
2 Pipe connections 5 Pressure plate
3 Fixed plate 6 HE Plate
7 Guiding bar
8 Gasket
9 Tightening device

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 Overview and description of the PHE

The plate pack consists of contoured

HE plates (1) and the corresponding
gaskets (2) of varying number and ar-
rangement.

7.2 Identification
Each GEA Ecoflex PHE is provided with a name plate. It is attached to the outside
of the PHE’s fixed plate. Here you find details about:
„ plate heat exchanger type
„ serial no.
„ admissible working pressure [bar g]
„ admissible working temperature [° C]
„ test pressure [bar g]
„ volume [L]
„ net weight, year of construction
„ compression dimensions:
"a max." / "a min." [mm]
„ additional details [project specific]

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 Overview and description of the PHE

Examples for the name plate design in conformity with the European Directive on
Pressure Equipment 97/23/EC.

1 2

No. Component
1 PHE without CE index number
2 PHE with CE index number

Each PHE is supplied with a dimension sheet or, alternatively, an assembly dra-
wing, and a flow diagram.
The dimension sheet or the assembly drawing shows the external dimensions as
well as details of the type, size and position of the pipe connections.
The flow diagram shows the HE plate arrangement and the type, the HE plate ma-
terial, the plate thickness as well as the sealing material and the part numbers.

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 Overview and description of the PHE

7.3 Frames
GEA Ecoflex PHE are available in different application specific frame designs.
There are two basic designs, B and CD. The design B is especially employed for
longer plate packs.

B CD

Special stainless steel designs with intermediate elements for separating the indivi-
dual compartments are employed for the foodstuff and pharmaceutical industries.
The frames made of structural steel are given a weather-protective coating. The
tightening bolts and nuts are made of high-strength steel alloys and in some cases
galvanised.
The pipe connections can be attached to the fixed plate, to the pressure plate and
possibly to intermediate elements.

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 Overview and description of the PHE

The pipe connections on the fixed and pressure plate are positioned as follows:
„ From an outside position looking
onto the fixed plate, the connec-
tions 1F-4F are numbered conse-
cutively anticlockwise.

„ From an outside position looking

onto the pressure plate, the con-
nections 1L-4L are numbered
consecutively clockwise.

In order to fulfill customer specific requirements, different connection types are

available.

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 Overview and description of the PHE

As an alternative, the designs B and

CD can be cladded with stainless steel
and equipped with tightening bolts
made of stainless steel. They then
have the additional letter C (for clad-
ded) and frame designation BC and
CDC.
To some extent, these frames are
equipped with height-adjustable
threaded feet. In this case, the feet are
not anchored to the ground. Thrust
plates lie beneath the threaded feet.
These thrust plates are not part of the
standard equipment.

7.4 HE plates

NOTE

The selection of the HE plate material is determined by customer-specific opera-

ting conditions (among others pressure, temperature, media, operating mode). In a
few special applications, the media used typically erodes the material of the HE
plates. This can lead to a malfunction of the HE plates and to a mixing of the me-
dia.

The HE plates and gaskets are essential components of the PHE. GEA Ecoflex dis-
tinguishes between three product groups.

7.4.1 Chevron pattern

The HE plates of the series VARITHERM (VT), NT and LASER welded cassettes
(LWC) belong to this product group.
These HE plates have horizontal and vertical profiles, which are used individually
or combined. They are used for clean media with a low viscosity and also for high
working pressures.
The gaskets of this product group can be fixed with adhesive. Additionally, many
plate types allow adhesive-free fixing (LocIn, EcoLoc).

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 Overview and description of the PHE

7.4.2 Free Flow design

The HE plates of the series FA (free flow) and the N40 plate belong to this group.
The special feature of this product group is the unrestricted broad flow cross sec-
tion between the HE plates. Highly viscose media or media containing solids re-
quire the use of this product group.
The gaskets of this product group are fixed with adhesive. The plate type N40 al-
lows adhesive-free fixing (LocIn).

7.4.3 Plate evaporator design

The HE plates of the series CT (Concitherm) form this product group.
Liquids are concentrated by evaporation using these plates ("evaporator").
The gaskets are fixed with adhesive. The plate type CT187 allows adhesive-free fi-
xing (LocIn). The plate type CT193 consists of LASER welded cassettes.

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 Overview and description of the PHE

7.5 HE plate gaskets

CAUTION

Damages to persons and property !

The use of inadmissible pressures, temperatures and media can lead to an immedi-
ate failure of the gaskets and a grave endangerment of persons and the surroun-
dings. Therefore, never exceed the admissible operating parameters.

ATTENTION

Leakage!
The gaskets are wearing parts and sensitive to chemical, thermal and mechanical
damages. The selection of the gasket material and its properties is determined by
customer-specific operating conditions (pressure, temperature, media). Inadmis-
sible use can lead to a reduction of the service life. Elastomer gaskets are always
subject to the ageing process (e.g. embrittlement).
There are two basic groups of gaskets:
„ Gaskets made of elastomers, available in different materials and design types
(e. g. 2-eye gaskets and 4-eye start and/or end gaskets). The gaskets can, in
principle, be fixed with adhesive, also often without adhesive (LocIn, EcoLoc).
„ Gaskets made of mineral fibres ("hard gaskets"). They are principally fixed with
adhesive. Unlike gaskets made of elastomers, these gaskets made of mineral
fibres cannot compensate for large temperature differences (e. g. start-up and
shutdown). Therefore, leakages may occur during these operating phases.

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 Overview and description of the PHE

All gaskets are designed to enable separating both media from each other at the
transfer ports by means of a double-gasket guidance system. In the event of any
leakage in this area, the leakage chamber formed in this way has the task of out-
wardly discharging the liquid via gaps in the sealing webs (leakage grooves) so
that any leakage immediately becomes apparent.

The materials of the gaskets are clearly marked by coded colours.

The storage of the gaskets must be done properly.
Never exceed the admissible parameters.

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 Delivery, transport, and installation of the PHE

8 Delivery, transport, and installation of

the PHE

CAUTION

Damages to persons and property!

Improper and careless handling of the
PHE can lead to danger to persons
and property. The PHE may never be
lifted underneath the plate pack, at
the connections or at the tightening
bolts.

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 Delivery, transport, and installation of the PHE

8.1 Delivery
The fully assembled PHE is packed and delivered either lying on its side or up-
right, depending on the frame type.
If it is delivered lying on its side, the PHE is anchored by the back of the fixed plate
to solid planks. A forklift truck can pick the PHE up from beneath the planks and
transport it.
The PHE that is packed upright and to be transported upright is top heavy. To be
secured for transport, it is screwed to solid planks and must be unloaded and
transported in suspension, according to chapter 8.3 on page 29. In no case may the
device be lifted under the HE plate pack because this inevitably leads to a dama-
ging of the plate pack.
In the BC frame, the height-adjustable transport feet replace the ball feet. You find
the ball feet in an enclosed package with the PHE.
PHE parts are packed on pallets as well as in suitable cartons on pallets. Upon re-
quest, we will use special air freight, container and wood packages. You, as the
customer, are responsible for the disposal of the PHE packing material.

NOTE

If, in spite of the careful packaging, you should observe damage at delivery, you
must make a note of the extent and type of the damage on the consignment note
and obtain a receipt from the deliverer. Please report any possible damages to us
immediately.

8.2 Setting up the lying PHE

CAUTION

Danger to life!
There is always a danger that the PHE will tip over while righting it. Always
ensure that:
„ the hoisting gear are of sufficient dimensions,
„ the hoisting gear cannot come loose or slide off,
„ no swing movements to the side result when lifting the PHE,
„ the floor at the installation site is sufficiently large, level and able to support the
load.

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 Delivery, transport, and installation of the PHE

ATTENTION

Damage to the PHE!

The connecting pieces can bend or
crack. Attach the hoisting gear
(slings) only as in the following.
When attaching the hoisting gear
(slings), make sure that they are
firmly seated.
Never use a chain or a steel rope, but
only slings.

Proceed as follows to set up the lying PHE:

1. Remove all of the fastening screws
and elements from the PHE and
from the pallet.

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 Delivery, transport, and installation of the PHE

2. Attach a sling to the upper tighte-

ning nut on each side of the PHE.
Ö Do not use a steel rope or
chain!

Ö If the tightening nuts are not

accessible for attaching the
slings, slightly tip the PHE
with an additional sling (al-
ways attach the slings between
2 tightening nuts).
Then attach the slings around
the top tightening nuts.

3. Lift the PHE slowly from the pal-

let over its centre of gravity.

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 Delivery, transport, and installation of the PHE

4. Slowly lower the PHE onto the

edge of the fixed plate or the feet
of the PHE. Align the PHE and
bring it to its final position at the
installation site.

5. Remove the slings and other aids.

Then anchor the PHE to the
ground.

; The PHE has been set up.

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 Delivery, transport, and installation of the PHE

8.3 Transport

CAUTION

Danger to life! Damage to the PHE!

Before transporting the PHE always ensure that:
„ the hoisting gear are of sufficient dimensions,
„ the hoisting gear cannot come loose or slide off,
„ no swing movements to the side result when lifting the PHE,
„ the operating personnel keep a sufficiently large safety distance,
„ the floor at the installation site is sufficiently large, level and able to support the
load.
The suspended transport always starts out from an upright position of the PHE.

8.3.1 Suspended with shackles at the fixed plate

and with sling attachment at the carrying beam
Proceed as follows:
1. Attach two suitable shackles in
both holes intended for that pur-
pose on the upper side of the fixed
plate.
2. Attach a sufficiently long sling to
the carrying beam directly behind
the pressure plate and to both
shackles.
Ö Do not use steel ropes or
chains!
3. Slowly lift the PHE.

; The PHE can now be

transported away.

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 Delivery, transport, and installation of the PHE

8.3.2 Suspended at transport eyes

Proceed as follows:
1. Attach the hoisting gear to both
transport eyes on the top side of
the carrying beam.
2. Slowly lift the PHE.

; The PHE can now be

transported away.

8.3.3 Suspended with sling attachment at the tightening device

Use this transport method only when the above-described fastening possibilities
are not available.
Proceed as follows:
1. Attach a sling around the top tigh-
tening bolts on each side of the
PHE.
Ö Do not use steel ropes or
chains!
2. Slowly tilt the PHE until it reaches
a hanging position.

; The PHE can now be

transported away.

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 Delivery, transport, and installation of the PHE

8.4 Installation of the PHE

CAUTION

Danger to life!
There is always a danger that the PHE will tip over during installation. Always
ensure that:

„ the hoisting gear are of sufficient dimensions,

„ the hoisting gear cannot come loose or slide off,
„ the operating personnel keep a sufficiently large safety distance,
„ the floor at the installation site is sufficiently large, level and able to support the
load.

In case of outdoor installation, take precautions against freezing the flow-through

media in the PHE, if necessary.

8.4.1 Space requirements

Provide enough space around the
PHE. This facilitates access to the
PHE and necessary service tasks (e. g.
replacing individual plates, compres-
sing the plate pack).
The values for the necessary space gi-
ven in the adjacent figure are guide
values and are recommended by
GEA Ecoflex. They provide sufficient
space for accessing the PHE.

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 Delivery, transport, and installation of the PHE

8.4.2 Pipe assembly

The PHEs from GEA Ecoflex are provided with different connection types accor-
ding to the purpose. Pay attention to the following points during pipe assembly:

ATTENTION

Damages to the pipe connections and to the PHE!

Make sure that no forces, moments, or vibrations that are too high are transferred
via the pipes onto the connections of the PHE. By request, you can obtain an over-
view of the admissible forces and moments for the PHE.

8.5 PHE disposal

As a customer, you are responsible for the disposal of the PHE packing materials.
By request, GEA Ecoflex takes on disposal of the PHE. For the cost of labour, the
PHE is disassembled, transported away and professionally disposed.

NOTE

If the PHE or its parts are contaminated, GEA Ecoflex cannot take on the disposal.
In this case, disposal of the PHE is the manager‘s obligation.

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 Operation, start-up, and shutdown

9 Operation, start-up, and shutdown

CAUTION

Danger of injury!
Hazardous flow-through media (corrosive, poisonous, flammable, explosive etc.)
present dangers of chemical burns and burning. Inform yourself beforehand which
flow-through media are used and make sure that a protective covering is on hand.

ATTENTION

Environmental damages! Damage to the PHE!

„ When ecologically harmful flow-through media flow out, serious environmen-
tal damages are possible. Make sure that it is possible to empty the product and
that a drip tray for the entire PHE filling volume is on hand.
„ If the PHE is further compressed
below "a min.", the plates warp.
Make sure that the plate pack is
compressed to the necessary com-
pression dimension
"a min." < "a" < "a max.".

ATTENTION

Damages to the PHE!

„ Quick switching operations (e. g. from valves in the pipes connected to the
PHE) or operation-related events (e. g. spontaneous evaporations, condensa-
tion surges) can lead to high-pressure surges. Avoid high-pressure surges th-
rough the flow-through media in order to avoid damaging the PHE.
„ The PHE may only be tightened in its unpressurised state because otherwise it
may fall below the compression dimension "a min." (see the explanation for
"a min." in chapter 12 on page 56).

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Plate Heat Exchanger – Revision: 28.06.2002
 Operation, start-up, and shutdown

9.1 Start-up
Before start-up, visually inspect the PHE and make sure that:
„ the PHE is not operated with inadmissible flow-through media, pressures and
temperatures.
„ all pipe connections are firmly connected to the PHE.
„ all necessary PHE components are completely installed.
„ the plate pack is not compressed below compression dimension "a min." (see
name plate or flow diagram in chapter 7.2 on page 16). The HE plates could be
permanently damaged.
„ when restarting, no residues of previous processes (e. g. cleaning agents) are
present in the PHE.
„ all air is removed from the PHE.
„ pressure surges are avoided. The proper operation of the PHE could be endan-
gered. Flow-through media could escape.

; If all of these conditions are fulfilled, you can start operating the PHE.

NOTE

If faults occur during start-up of the PHE, see chapter 11, page 53.

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Plate Heat Exchanger – Revision: 28.06.2002
 Operation, start-up, and shutdown

9.2 Operation

CAUTION

Danger of injury! Damages to the PHE!

If the PHE is in operation when working on the PHE, there is a danger of injury or
a danger that the PHE will be damaged. Always shutdown the PHE first, before
you start maintaining or repairing it.

Visually inspect the PHE regularly during operation and make sure that:
„ the PHE is not operated with inadmissible flow-through media, pressures and
temperatures.
„ the minimum and maximum parameters given on the name plate are not ex-
ceeded. If the parameters are exceeded, the operating approval dissolves and
GEA Ecoflex accepts no liability for resulting damages.
„ pressure surges are avoided. The proper operation of the PHE could be endan-
gered. Flow-through media could escape.

NOTE

If faults occur during operation of the PHE, see chapter 11, page 53.

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Plate Heat Exchanger – Revision: 28.06.2002
 Operation, start-up, and shutdown

9.3 Shutdown of the PHE

9.3.1 Short-term shutdown

ATTENTION

Escape of environmentally hazardous flow-through media possible!

Flow-through media can be dangerous and environmentally hazardous. Make sure
that no flow-through media can escape during the shutdown period. In case of
outdoor installation, take precautions (e. g. emptying, heating) against freezing the
flow-through media in the PHE.

9.3.2 Long-term shutdown

ATTENTION

Premature component wear!

The components of the PHE can wear out prematurely due to unfavourable sur-
rounding conditions or due to flow-through media remaining in the PHE. If the
PHE is shutdown for a longer time period, the PHE must be depressurised and
completely emptied. Additionally, we recommend a basic cleaning and an approp-
riate storage until setting the PHE into operation again.

NOTE

You can obtain detailed information about storage conditions from your
GEA Ecoflex service department (see back cover).

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

10 Maintenance and repair

10.1 Preparatory precautions
Before starting work, check the supplied documentation to see with which frame
type the PHE was delivered.

CAUTION

Danger of injury!
There is a danger of injury during maintenance and repair work on the PHE. For
this reason, always adhere to the following points:
„ Always wear suitable protective clothing.
„ If a pressurised or filled PHE is opened, the flow-through media can escape un-
controllably. This is a danger of injury for the operator and bystanders.
„ Before beginning maintenance or repair work, ensure that the PHE is empty
and has reached room pressure.
„ When using hot or very cold flow-through media there is a danger of burning,
or respectively, freezing. Before beginning maintenance or repair work, always
ensure that the PHE has reached room temperature.
„ Hazardous flow-through media (corrosive, poisonous, flammable, explosive
etc.) present an acute danger of injury for the operator and bystanders. Make
sure that the regulations for flow-through media are followed during all work.
„ Ensure that the pressure plate is secured against unintended slippage (e. g. on
ships).
„ The HE plates of the PHE can tip
out sideways and severely injure
persons. Always ensure when sus-
pending the HE plates and when
closing the PHE that the HE plates
do not unintentionally detach
from the frame and tip over.
For this reason, at least two per-
sons must work on a PHE with
CD frame.

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

ATTENTION

Danger of falling over during stacking!

The HE plates can fall over during unchecked stacking. Injuries and damaged HE
plates are the result. Never stack the plates higher than:
„ 60 HE plates for Varitherm/NT
„ 30 cassettes for LWC
„ 30 HE plates for Free Flow/Concitherm/Safetytherm

38
Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

Before opening the PHE you must carry out a few work steps. If necessary, remove
the connected pipes.
In general, you should proceed as follows:
„ Clean the guiding rail (for better
plate mobility).

„ Clean the threads of the tighte-

ning bolts (to remove the contami-
nation and prevent a fretting of
the nuts).

„ Apply a thin film of oil to the

thread.

39
Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

„ To ensure that the plates are reas-

sembled in the right order, we ad-
vise painting a diagonal line
across the side of the plate pack.

„ Be sure to note the current "a" di-

mension.

NOTE

When removing the HE plates, document the order with the help of the flow dia-
gram.
„ The PHE frames are usually
equipped with four tightening de-
vices. In PHEs with more than
four tightening devices, as a rule
four longer tightening devices are
used. These only pretension the
HE plate pack (so-called preten-
sioning bolts).

40
Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

The HE plates are mounted in different ways in the frame, depending on the frame
design of the PHE.
In CD frames, the HE plates rest on the bottom guiding bar and are guided by the
top.
„ In the CD frame, the plates are VT NT
guided by a top and a bottom gui-
ding bar.

In the B frames, the HE plates are suspended at the top carrying beam with a spe-
cial rail. The plates are hooked into the recess of the guiding rail and are guided by
the bottom guiding bar.
„ Top carrying beam with a guiding
rail and a guiding bar.

„ Top carrying beam without a gui-

VT NT
ding rail.

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

10.2 Opening the PHE and removing the HE plates

NOTE

Before loosening/opening the PHE pay attention to the safety notes in

chapter 10.1, page 37 "Preparatory precautions".

Open the PHE as follows:

1. Release the nuts of the tightening devices on the pressure plate.
Ö Release the tightening devices
evenly in small steps on alter-
nate sides (1-2-3-4) and diago-
nally (1-2 and 3-4), in order to
prevent overloading indivi- 1 3
dual tightening devices and
tilting the pressure plate.
Ö Proceed similarly in the case of
frames with more than 4 tigh-
tening devices. 2
4

2. Remove the nuts.

3. Remove all tightening devices.

; The PHE is open.

NOTE

For the CD frame, we recommend leaving the top pretensioning pair (1-3) in the
frame as an additional safety precaution.

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

Remove the HE plates as follows:

1. In the B frame, slide the pressure
plate up to the end support co-
lumn.
In the CD frame, pull the pressure
plate back. A second operator se-
cures the plate pack against sli-
ding.
Ö The individual HE plates are
now accessible.
.

2. For removal, swing the HE plate

out to the side and take it out of
the guiding rail of the carrying
beam.
Ö In the case of some Varitherm
carrying beams, swinging is
only possible to one side.

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

10.3 Mounting the HE plates and closing the PHE

NOTE

Before mounting and closing the PHE, pay attention to the safety notes in
chapter 10.1, page 37 "Preparatory precautions".

ATTENTION

Damage to the HE plates!

Going below the compression dimen-
sion "a min" generally leads to da-
mage to the HE plates and possibly to
a malfunction of the PHE. Ensure that
the plate pack is only compressed to a
the necessary dimension
"a min." < "a" < "a max.".

NOTE

When all the HE plates are correctly installed, the outside of the plate pack must
show a continuous honeycomb pattern.
You can also check that the plates are in the right order by means of the diagonal
line on the outside of the plate pack, which you painted before opening the PHE.

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

Proceed as follows:
1. Make sure that the gaskets and HE plates are free of foreign matter or contami-
nation.
Ö If necessary, clean them with running water and a soft brush.
2. Check that the gaskets fit correctly in the grooves of the HE plates.
3. Clean the sealing faces of the frame gaskets.
4. For a PHE with a B frame: clean
the HE guiding rail at the carrying
beam and apply a thin layer of oil
to it.
5. Clean the threads of the tighte-
ning bolts as well as the tighte-
ning nuts and apply a thin layer of
grease to these.

6. Mount all the HE plates into the PHE frame in the correct order according to
the flow diagram.
Ö Secure the plate pack in CD frames with the help of a second operator.
7. Determine the required compression dimension ("a" dimension).
Ö The required compression dimension "a" is
„ in the case of a complete replacement of the gaskets: the "a max" printed on
the name plate.
„ provided that the HE plates are only cleaned and no gaskets are replaced:
the compression dimension written down before opening the PHE.

45
Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

„ in case of a change in the number of HE plates: the new "a max"-dimension,

which matches the details on the supplied flow diagram and the supplied
modification plate at the name plate.
8. Tighten the tightening devices according to the procedure described in
chapter 10.2, page 42 "Opening the PHE and removing the HE plates" on alter-
nate sides and diagonally to the necessary compression dimension "a".
9. Carry out a leak test before restarting the PHE.

NOTE

The procedure for the occurrence of leakages is described in chapter 11 on page 53.

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

10.4 Cleaning the PHE

10.4.1 Cleaning the HE plates of the closed PHE

Deposits on the HE plates
„ impair the heat transfer between the flow-through media,
„ increase the pressure loss,
„ can cause or accelerate HE plate corrosion.
The particular PHE application determines
„ the necessity,
„ the type and
„ the frequency of a PHE cleaning.

CIP process

ATTENTION

Danger to persons and environment!

The use of aggressive cleaning agents presents poisoning, chemical burns, and bur-
ning dangers. Make sure that:
„ before the CIP process, you have been instructed in the use and have a good
command of all work steps.
„ during work with aggressive cleaning agents you always wear suitable protec-
tive clothing.
„ the cleaning agent you use is completely removed from the PHE after cleaning.
With CIP ("Cleaning in Place"), a cleaning agent flows through the PHE instead of
the flow-through media. Contaminants are removed by the cleaning solution’s dis-
solving capacity, supported by the mechanical action of the turbulence.

ATTENTION

Damage to the PHE!

The improper use of CIP can damage the PHE. Pay attention to the notes on chemi-
cal cleaning of the HE plates in chapter 10.4.2, page 49 "Cleaning the HE plates of
an open PHE".

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

Backflushing
This process is used if the flow-through media contain coarse particles of contami-
nation and thus block the inlet channels. By briefly reversing the direction of flow,
the particles of contamination are removed from the PHE.

The direction of flow is reversed by

using a suitable pipe configuration
with the appropriate valves. If there is
a risk of the released particles of con- 2F 1F
tamination causing damage to the
PHE, preference should be given to
manual cleaning of the HE plates.

3F 4F

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

10.4.2 Cleaning the HE plates of an open PHE

Manually cleaning the HE plates

ATTENTION

Leakage!
„ At every cleaning, ensure that no particles can settle on or under the gaskets
because this leads to leakages.
„ Hard cleaning tools (e. g. brushes with metal bristles) can damage the metallic
surfaces of the HE plates and the surfaces of the gaskets. Damaged metal sur-
faces can lead to corrosion of the HE plates. Damaged gasket surfaces can lead
to leakages of the PHE when restarting it.
Never use hard cleaning tools.
„ Ensure that the stream of the high-pressure jet always directs face-on at the
gaskets in order to avoid loosening them.
In order to manually clean the HE plates, proceed as follows:
1. For coarse contamination, use a
high-pressure cleaner jet to loo-
sen the particles.

49
Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

2. Wash each plate from both sides

with flowing, warm water and a
soft brush.

; The HE plates have been

manually cleaned.

Chemically cleaning the HE plates

ATTENTION

Leakage!
Chemical cleaning processes can attack the gaskets materials and create leaks. Al-
ways use cleaning agents that do not attack the gaskets materials. Choose a sui-
table temperature and do not let the cleaning agent take effect on the materials for
an unnecessarily long time.

NOTE

„ Always follow the safety instructions and recommendations of the cleaning

agent manufacturer. Only use chloride-free or low-chloride water with a low
hardness value for the cleaning liquid.
„ Chlorides in the medium reduce the corrosion resistance of chrome-nickel
steels and chrome-nickel-molybdenum steels (including Hastelloy, Incoloy and
Inconel). The intensity of the effect of the chlorides depends on the tempera-
ture, concentration and pH of the medium.
„ Stubborn contamination, such as coatings on the plate surface, which are not
released by the above-described processes, can be loosened by soaking in an
open chemical bath.

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

„ Choose a cleaning agent suitable for the type of contamination and for the pro-
perties of the HE plates and sealing materials.
Ö You must obtain confirmation from the cleaning agent manufacturer that
the cleaning agents employed will not attack the HE plates or gasket mate-
rials. Clean the HE plates according to the cleaning agent manufacturer’s in-
structions.
„ Before reassembling the cleaned HE plates, always rinse them with sufficient
clean water. Remove foreign matter on the gaskets with a soft brush.

10.5 Replacing HE gaskets

You can find the fixing type of the gasket in the PHE technical documentation. The
gaskets can be either fixed with adhesive into the gasket grooves or pressed into
the grooves without adhesive.
We recommend that you always replace all gaskets at the same time. Use only ori-
ginal GEA Ecoflex gaskets.

NOTE

You can obtain detailed information about replacing gaskets from your
GEA Ecoflex service department (see back cover)

10.6 Replacing port rings

The type of port ring between the HE plate pack and the frame components de-
pends on the frame type.

NOTE

You can obtain detailed information about replacing port rings from your
GEA Ecoflex service department (see back cover)

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Plate Heat Exchanger – Revision: 28.06.2002
 Maintenance and repair

10.7 Maintaining the PHE frame

ATTENTION

Loss of operating approval!

You must consult your GEA Ecoflex service department (see back cover) before
changing or replacing PHE frame components. Always use original PHE compon-
ents from GEA Ecoflex because otherwise loss of the operating approval for the
PHE follows.

Regularly carry out simple maintenance work, for example:

„ external cleaning,
„ greasing and
„ touch up varnish damage on the PHE frame.

NOTE

You can obtain detailed information about maintenance of the PHE frame from
your GEA Ecoflex service department (see back cover).

52
Plate Heat Exchanger – Revision: 28.06.2002
 Troubleshooting

11 Troubleshooting

NOTE

On principle, you should reach an agreement with your GEA Ecoflex service de-
partment (see back cover) before repairing faults, in order to avoid improperly per-
formed work on the PHE and its consequences.

In the following you will find a few typical faults that can occur during operation
of a PHE.

11.1 Impaired PHE performance

Fault Cause Remedy
insufficient heat deposits on the HE plates clean the HE plates
transfer
flow paths, media etc. chan- have GEA Ecoflex examine the
ged from the design design of the PHE with the
new operating data
too high-pressure flow impeded by blockage of clean the HE plates
loss the flow channels of the distri-
butor
flow impeded by incorrect in- check the installation order by
stallation of the HE plates means of the flow diagram
flow paths, media etc. chan- have GEA Ecoflex examine the
ged from the design design of the PHE with the
new operating data

53
Plate Heat Exchanger – Revision: 28.06.2002
 Troubleshooting

11.2 PHE leakages

Fault Cause Remedy
sealing fault bet- false compression dimension check the correct compression
ween the HE plates of the PHE dimension by means of the
data on the name plate
too high working pressures check the working pressures
by means of the data on the
name plate
too high/too low working tem- check the working temperatu-
peratures res by means of the data on the
name plate

gaskets fitted incorrectly open the PHE and correct the

gaskets’ position
gaskets are dirty open the PHE and clean the
gaskets
gaskets are defective open the PHE and replace the
gaskets
sealing fault bet- gaskets or port rings fitted in- open the PHE, correct the posi-
ween HE plates and correctly tion of the gaskets or port rings
frame, intermedi-
ate plates, interme- gaskets or port rings are dirty open the PHE, clean the gas-
diate elements kets or port rings
gaskets or port rings are defec- open the PHE, replace the gas-
tive kets or port rings
sealing fault bet- too high loads at the pipe con- reduce connection loads to the
ween pipe connec- nection due to the pipe admissible parameters
tion and frame plate
seal ring fitted incorrectly loosen the pipe connection and
correct the position of the seal
ring
seal ring is dirty loosen the pipe connection and
clean the seal ring
seal ring is defective loosen the pipe joint and re-
place the seal ring
flange connection is not suffi- check the seal ring and connec-
ciently tightened tion and tighten any loose bolts
damage to the HE over-tightened plate packs replace defective HE plates
plates (compression dimension less
than "a min")
corrosion of the HE plate check the design of the PHE
material concerning flow-through me-
dia, consult GEA Ecoflex

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Plate Heat Exchanger – Revision: 28.06.2002
 Troubleshooting

Fault Cause Remedy

damage to the start incorrect earthing during wel- replace defective HE plates
or end HE plate ding of special connections to
the open connecting pipes of
the PHE frame

55
Plate Heat Exchanger – Revision: 28.06.2002
 Technical terms

12 Technical terms
Term Meaning
B frame An especially stable frame design, which also allows a
high number of HE plates.
backflushing A cleaning process in which the direction of flow is re-
gularly reversed. Reversing the direction of flow flus-
hes the particles of contamination from the PHE.
carrying beam The top component placed between the fixed plate and
support column upon which the HE plates and the
pressure plate are suspended.
Particularity:
In CD frames the carrying beam guides the HE plates.
CD frame A compact PHE frame design (compact design). The
number of HE plates that can be stacked is lower in a
CD frame than in the corresponding B frame.
CIP process (Cleaning in A cleaning process in which the flow channels of the
Place) closed PHE are flushed with specific cleaning soluti-
ons.
collector channel The flow channel which is created by the total passage
openings of the HE plates.
compression dimension Dimension referring to the depressurised (!) PHE.
"a" dimension ("a max."/ Tighten the HE plate pack placed between the frame
"a min") plates to this dimension. Going below the "a min" di-
mension can damage the HE plate pack. The tighte-
ning units adjust the compression dimension.
connection (pipe) The pipe connections intended for the fixed plate and,
if applicable, the pressure plate. The pipe connections
have different designs according to each application
(industrial design, rubber insert piece, metal liner,
flange connection etc.).

connection corner (pipe) Component of the intermediate element in the HE

plate pack. With this intermediate element, multi-stage
designs of a PHE are realised. The connection corners
allow the connection of additional pipes/media (espe-
cially for food applications).
distributor channel see "collector channel"
EcoLoc A fixing system without adhesive for gaskets of the
NT series.

fixed plate The basic component of the PHE frame. The fixed
plate is an unmovable frame plate. Normally, the pipes
are connected to this component.

56
Plate Heat Exchanger – Revision: 28.06.2002
 Technical terms

Term Meaning
flow-through media The term for the media that are responsible for the
heat transfer in the PHE.

frame plates The fixed plate and the pressure plate of the PHE
frame.
gasket of the HE plates An elemental component for sealing the flow channels
from each other and between the HE plates and the
surroundings or leakage chamber. There are gaskets
that are fixed to the HE plates with adhesive or wit-
hout adhesive (LocIn, EcoLoc).
guiding bar Component that guides the HE plates and the pressure
plate at the bottom.
Particularity:
In CD frames the HE plates rest on the bottom guiding
bar.
HE plate pack The collective term for all of the HE plates located bet-
ween the frame plates, including the gaskets.
HE plates The short form for the term Heat Exchanger plates. An
elemental component that keeps the flow-through me-
dia separated from each other and transfers the heat.

intermediate element A component placed within the HE plate pack. The in-
termediate element has pipe connections along the si-
des for multi-stage PHE designs.
intermediate plate A component placed within the HE plate pack. The in-
termediate plate has no pipe connections and is used
for special multi-pass PHE designs.

LocIn A fixing system without adhesive for some elastomer

gaskets.
metal liner A liner of the frame plates in the area of the pipe con-
nections. The material used depends on the applica-
tion (stainless steel, titanium, etc.).

multi-pass PHE A special design of the PHE with internal deflection of

the flow-through media. The construction of multi-
pass PHE always demands pipe connections to the
pressure plate.

multi-stage PHE A special design of the PHE with more than two flow-
through media (use of intermediate elements). With
this PHE design, complex heat transfer tasks are com-
bined in one PHE (heating and cooling, e.g. in the food
stuff industry).
name plate A label attached to the fixed plate of the PHE frame for
identification with the basic data of the PHE (stan-
dardly applied as a gummed label).

57
Plate Heat Exchanger – Revision: 28.06.2002
 Technical terms

Term Meaning

PHE The short form of the term Plate Heat Exchanger.

pressure plate A movable frame plate suspended at the carrying

beam of the PHE frame. This frame plate compresses
the HE plate pack.
The pressure plate can have pipe connections.
rubber insert piece A liner of the frame plates (elastomer) in the area of
the pipe connections. It seals off the pipe connection
and the HE plate pack.
single-pass PHE The standard design of a PHE with two flow-through
media. Normally, the connections are placed on the
fixed plate.

splash protector A safety device attached to the HE plate pack.

GEA Ecoflex generally recommends attaching a splash
protector when using hazardous media.
support column A fixed component of a PHE frame to which the car-
rying beam and the guiding bar are fixed.
suspending (the pressure Suspending the pressure plate at the carrying beam
plate) (normally with a movable roller). The suspension
makes it possible to move the pressure plate on the
carrying beam.
tightening unit The frame component for compressing the HE plate
packs. It consists of tightening bolts, tightening nuts
and washers.

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Plate Heat Exchanger – Revision: 28.06.2002
RK 41 쮕 Betriebsanleitung 808519-02
Rückschlagventile RK

RK 44 
Installation Instructions 808519-02
Non-Return Valves RK

 Instructions de montage et

RK 44s de mise en service 808519-02

Clapets de retenue RK

RK 70 
Instrucciones de montaje y
servicio 808519-02
Válvulas de retención RK

RK 71  Manuale di Istruzioni 808519-02

Valvole di non ritorno RK
Important Safety Note 
The valve must only be installed by qualified staff.

Qualified staff are those persons who – through adequate training in

engineering, the use and application of safety equipment in accordance
with regulations concerning safety systems, and first aid & accident
prevention – have achieved a recognised level of competence
appropriate to the installation and commissioning of this device.

Proper Use

The non-return valves RK are automatic-stop check valves used in

pipes to prevent a backflow of fluid within the admissible pressure/
temperature ratings.
Contact the Factory for specific recommendations concerning the
chemical resistance and suitability of the valve material in a given
application.
 Danger 
The valve is under pressure during operation.

When loosening flanged connections or sealing plugs, hot water,

steam, corrosive fluids or toxic gases may escape. This presents the
risk of severe burns and scalds to the whole body or severe cases of
poisoning.
Installation and maintenance work should only be carried out when the
system is depressurized.

The valve becomes hot or extremely cold during operation. This

presents the risk of severe burns to hands and arms. Installation and
maintenance work should only be carried out at room temperatures.

Sharp edges on internals present a danger of cuts to hands. Always

wear industrial gloves for installation and maintenance work.
Ratings pursuant to article 9 of the PED1) 
Fluid gas liquid None

Fluid group 1 2 1 2 125-200

no
Use no yes no yes
RK 44s
Exception pursuant Exception pursuant I
Category to article 3.3 to article 3.3

Nominal size DN 15-50 65-150 65-200

CE marking no no yes
all
Type all RK 70 RK 70 only DN 200
RK 44s only DN 65-100
1)
PED = Pressure Equipment Directive
Description 
Non-return valve RK with spiral centering ring or self-centering body.
Installation in any position. Exception: Valves without spring can only be
installed in vertical lines with upward flow.

1 Non-return valve with spiral centering ring

2 Non-return valve with self-centering body

3 Position of guide ribs (horizontal installation)

Installation 

TOP

1 2 3
Technical Data 
RK 41/44/44s DN 15-100 RK 41/44/44s DN 125-200
ts [°C] 20 200 250 ts [°C] 20 200 300
[°F] 68 392 482 [°F] 68 392 572
ps [barg] 16 14 13 ps [barg] 16 14 13
[psig] 232 203 189 [psig] 232 203 189

RK 70 DN 15-200 RK 71 DN 15-100
ts [°C] 20 100 130 ts [°C] 20 120 250
[°F] 68 212 266 [°F] 68 248 482
ps [barg] 6 1.5 0.5 ps [barg] 16 16 13
[psig] 87 22 7 [psig] 232 232 189
Max. service temperature for RK 44s with spring: 90°C
For RK 44s without spring see table above.
For more information see data sheets.
Name Plate / Marking 
Type: RK ... Type: RK ...
DN: ... DN: ...
PN: ... PN: ...
.......... ..........

1/02
2002
1
02
2002
 Declaration of Conformity 
We hereby declare that the pressure equipment RK 41, 44, 44s,
DN 65-100, RK 71 PN 16, DN 65-100; RK 70 PN 6, DN 200, conform
to the following European Directive:

EC Pressure Equipment Directive (PED) No. 97/23 of 29 May 1997
GESTRA non-return valves are pressure equipment as defined in
article 1, section 2.1.4 of the PED.
Applied conformity assessment procedure: Module H as described in
Annex II and III.
This declaration is no longer valid if modifications are made to the
equipment without consultation with us.
Bremen, 27. 05. 2002
Academically qualified engineer
GESTRA GmbH Academically qualified engineer
Uwe Bledschun Lars Bohl
Head of the Design Dept. Quality Assurance Representative
GESTRA® www.gestra.de

쮕 GESTRA GmbH
Münchener Str. 77
D-28215 Bremen
 GESTRA ESPAÑOLA S.A
Luis Cabrera, 86-88
E-28002 Madrid
Tel. +49 (0) 421 3503-0 Tel. 00 34 91 / 5 152 032
Fax +49 (0) 421 3503-393 Fax 00 34 91 / 4 136 747, 5 152 036
E-mail: [email protected] E-mail: [email protected]

 Flowserve Flow Control (UK) Ltd.

Burrel Road, Haywards Heath
West Sussex RH 161 TL
 ITALGESTRA s.r.l.
Via Carducci 125
l-20099 Sesto San Giovanni (MI)
Tel. 00 44 14 44 / 31 44 00 Tel. 00 39 02 / 24 10 12.1
Fax 00 44 14 44 / 31 45 40 Fax 00 39 02 / 24 10 12.460
E-mail: [email protected] E-mail: [email protected]

 Flowserve Flow Control S. A. S

10, Avenue du Centaure, BP 8263
F-95801 CERGY PONTOISE CEDEX
 Flowserve Portuguesa, Lda.
Av. Dr. Antunes Guimarães, 1159
Porto 4100-082
Tél. 0 03 31 / 34 43 26 60 Tel. 0 03 51 22 / 6 19 87 70
Fax 0 03 31 / 34 43 26 87 Fax 0 03 51 22 / 6 10 75 75
E-mail: [email protected] E-mail: [email protected]
 ®

GESTRA GmbH
Postfach 10 54 60
D -28054 Bremen
Münchener Str. 77
D-28215 Bremen
Tel. + 49 (0) 421 35 03- 0
Fax + 49 (0) 421 35 03- 393
E-mail [email protected]
Internet www.gestra.de
A Unit of Flowserve Corporation
808519-02/103cs · © 2000 GESTRA GmbH · Bremen · Printed in Germany
 PM 02.02

Bourdon Tube Pressure Gauges

Stainless Steel Series • Model 232.50

Pressure Gauges
Approval German Lloyd

Service intended
All stainless steel pressure gauge.
Suitable for corrosive environments and gaseous or liquid media
that will not obstruct the pressure system.

Design
EN 837-1

Nominal size
63, 100 and 160 mm

Accuracy class per EN 837-1 /6

63 mm: 1.6
100 and 160 mm: 1.0

Scale ranges per EN 837-1 /5

63 mm: 0 ... 1 to 0 ... 1000 bar
100 mm: 0 ... 0.6 to 0 ... 1000 bar
160 mm: 0 ... 0.6 to 0 ... 1600 bar
or other equivalent units of pressure or vacuum.

Working pressure
63 mm: Steady: ¾ of full scale value
Fluctuating: B of full scale value
Short time: full scale value
100 and 160 mm: Steady: full scale value Dial
Fluctuating: 0.9 x full scale value White aluminium with black lettering,
Short time: 1.3 x full scale value 63 mm with pointer stop pin.

Operating temperature Pointer

Ambient: -40 ... +60 °C Black aluminium
Medium: +200 °C maximum
Case
Temperature effect Natural finish stainless steel,
When temperature of the pressure element deviates from with pressure relief in case top (63 mm)
reference temperature (+20 °C): or in case back (100 and 160 mm).
max. ±0.4 %/10 K of true scale value Ranges ≤ 10 bar with compensating valve to vent case.

Ingress protection Window

IP 65 per EN 60 529 / IEC 529 Laminated safety glass

Bezel ring
Cam ring (bayonet type), natural finish stainless steel
Standard features
Optional extras
Pressure connection - Other pressure connection
Material: stainless steel 1.4571 - 3-hole surface or panel mounting flange, stainless steel
Threaded entry (radial or back) per EN 873-1 /7.3 - 3-hole panel mounting flange, stainless steel, polished
63 mm: G ¼ B (male), 14 mm flats - Triangular bezel, stainless steel, with clamp
100 and 160mm: G ½ B (male), 22 mm flats - Alarm contacts (see data sheet AE 08.01)
- Transmitter (model 232.30 with combined Transmitter model
Pressure element
89X.34, see data sheet PM 02.04 and AE 08.02)
Material: stainless steel 1.4571
< 100 bar: C-type Special versions
≥ 100 bar: helical type
Ammonia gauges (100 and 160 mm)
Movement Scale in °C for refrigerant R 717 (NH3),
Stainless steel Pressure range: -1 ... 0 ... 15 bar or
-1 ... 0 ... 26 bar
Dimensions
Standard version

100 mm, radial bottom pressure entry 100 mm, lower back pressur e entry

≤ 10 bar with compensating valve ≤ 10 bar with compensating valve

> 10 bar without compensating valve > 10 bar without compensating valve

1520 806.03 1520 814.03

Nominal Dimensions Weight

size [mm] [kg]

a b b1 b2 D1 D2 e f G h±1 SW
63 9.5 33 33 57 63 62 11.5 - 1) G¼B 54 14 0.16
100 15.5 49.5 49.5 83 101 99 17.5 30 G½B 87 22 0.60
160 15.5 49.5 3) 49.5 2) 83 2) 161 159 17.5 50 G½B 118 22 1.10
Standard pressure entry with parallel thread and seating to EN 837-1 /7.3.
1) Centre back pressure entry
2) Plus 16 mm with pressure ranges ≥ 100 bar
3) Plus 16 mm with pressure range 1600 bar

Printed in Germany
W 863 GB 15 12.00 CM 9019 723

Ordering information
State:
Pressure gauge model / Nominal size / Scale range / Size and location of connection / Optional extras required

Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.

WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße . 63911 Klingenberg
( (0 93 72) 132- 0 . Fax (0 93 72) 132 - 406 / 414
http://www.wika.de . E-mail: [email protected]
 TM 32.02

Machine Glass Thermometer

V-Form • Model 32

Thermometers
Approval German Lloyd*

Service intended
Universal application in plant, machine, tank and apparatus construc-
tion as well as for central and large heating systems.

Measuring principle
Liquid expansion

Limit of error
DIN 16 195

Pressure rating of stem

6 bar maximum (without thermowell)

Stem
10 mm diameter
6.5 mm diameter with NS 200 x 36 with union nut M 24 x 1.5

Case
Aluminium, brass colour anodised

Lettering
printed with special ink, protected by anodised finish

Thermometer glass insert

Rod shape, prismatic capillaries

Nominal size
110, 150 and 200 mm

* only straight design and 90° angle design

Nominal size 110 x 30 mm

Standard features

Design of connection
Connection E, male thread

Straight design ( DIN 16 181)

Male thread
G ½ A, M 20 x 1.5 (Form B to DIN )
G A, M 16 x 1.5 (Form B1 to DIN )
Male thread screwed into case
Length of stem l 1 = 30, 40, 63, 100, 160, 250 or 400 mm Scale ranges
Cu-alloy
Scale range Scale Limit of error Thermometric
90° angle design (DIN 16 182) spacing liquid
Male thread °C °C °C
G ½ A, M 20 x 1.5 (Form S to DIN )
- 30 ... + 50 2
G A, M 16 x 1.5 (Form S1 to DIN ) 1
Male thread inserted into case, removable 0 ... 60 1.5
0 ... 100
Length of stem l 1 = 30, 40, 63, 100, 160, 250 or 400 mm 2 2 blue, wetting
Cu-alloy 0 ... 120
0 ... 160 4 4
135° angle design 0 ... 200 5 5
Male thread
G ½ A, M 20 x 1.5 Models
G A, M 16 x 1.5 Model Location of stem DIN
Male thread screwed into case
G 3200 straight DIN 16 181
Length of stem l 1 = 30, 40, 63, 100, 160, 250 or 400 mm W 3201 90° angle DIN 16 182
Cu-alloy
W 3202 135° angle -

Nominal size 150 x 36 mm

Standard features

Design of connection
Connection E, male thread

Straight design ( DIN 16 185 )

Male thread
G ½ A, M 20 x 1.5 (Form B to DIN )
G ¾ A, M 27 x 2
Scale ranges
Male thread screwed into case
Length of stem l 1 = 63, 100, 160, 250 or 400 mm Scale range Scale Limit of error Thermometric
Cu-alloy spacing liquid

90° angle design ( DIN 16 186 ) °C °C °C

- 60 ... + 40 2 red, wetting
Male thread 2
G ½ A, M 20 x 1.5 (Form S to DIN ) - 30 ... + 50
1
G ¾ A, M 27 x 2 0 ... 60 1.5
Male thread inserted into case, removable 0 ... 100 blue, wetting
2
Length of stem l 1 = 63, 100, 160, 250 or 400 mm 0 ... 120
2
Cu-alloy 0 ... 160
4
0 ... 200
135° angle design
Male thread Models
G ½ A, M 20 x 1.5
Model Location of stem DIN
G ¾ A, M 27 x 2
Male thread screwed into case G 3210 straight DIN 16 185
W 3211 90° angle DIN 16 186
Length of stem l 1 = 63, 100, 160, 250 or 400 mm
Cu-alloy W 3212 135° angle -

2
 TM 32.02
Nominal size 200 x 36 mm

Standard features

Design of connection Design of connection (of choise)

Connection E, male thread Connection no. 3, union nut

Straight design ( DIN 16 189) Straight design ( DIN 16 189)

Male thread Union nut
G ½ A, M 20 x 1.5 (Form B1 to DIN ) G ½, M 20 x 1.5 (Form C1 to DIN )
G ¾ A, M 27 x 2 (Form B to DIN ) G ¾, M 27 x 2 (Form C to DIN )
Male thread screwed into case M 24 x 1.5 (Form F to DIN )
Length of stem l 1 = 63, 100, 160, 250 or 400 mm Connection piece screwed into case, removable
Cu-alloy Length of stem l 1
Form C1: l 1 = 89, 126, 186, 276 or 426 mm
Form C: l 1 = 93, 130, 190, 280 or 430 mm
Form F: l 1 = 155, 215, 275, 295, 355 or 415 mm
Union nut and connection piece in Cu-alloy, tube in St. 35 steel

90° angle design (DIN 16 190) 90° angle design (DIN 16 190)
Male thread Union nut
G ½ A, M 20 x 1.5 (Form S1 to DIN ) G ½, M 20 x 1.5 (Form C1 to DIN )
G ¾ A, M 27 x 2 (Form S to DIN ) G ¾, M 27 x 2 (Form C to DIN )
Male thread inserted into case, removable M 24 x 1.5 (Form F to DIN )
Length of stem l 1 = 63, 100, 160, 250 or 400 mm Connection piece inserted into case, removable
Cu-alloy Length of stem l 1
Form C1: l 1 = 89, 126, 186, 276 or 426 mm
Form C: l 1 = 93, 130, 190, 280 or 430 mm
Form F: l 1 = 155, 215, 275, 295, 355 or 415 mm
Union nut and connection piece in Cu-alloy, tube in St. 35 steel

135° angle design 135° angle design (DIN 16 191)

Male thread Union nut
G ½ A, M 20 x 1.5 (Form B1 to DIN ) G ½, M 20 x 1.5 (Form C1 to DIN )
G ¾ A, M 27 x 2 (Form B to DIN ) G ¾, M 27 x 2 (Form C to DIN )
Male thread screwed into case M 24 x 1.5 (Form F to DIN )
Length of stem l 1 = 63, 100, 160, 250 or 400 mm Connection piece screwed into case, removable
Cu-alloy Length of stem l 1
Form C1: l 1 = 89, 126, 186, 276 or 426 mm
Form C: l 1 = 93, 130, 190, 280 or, 430 mm
Form F: l 1 = 155, 215, 275, 295, 355 or, 415 mm
Union nut and connection piece in Cu-alloy, tube in St. 35 steel
Scale ranges
Scale range Scale Limit of error Thermometric
spacing liquid

°C °C °C
- 60 ... + 40 red, wetting
2
- 30 ... + 50
0 ... 60 1 1.5
0 ... 100 blue, wetting
2
0 ... 120
0 ... 160
2 4
0 ... 200

Models
Model Location of stem DIN
G 3220 straight DIN 16 189
W 3221 90° angle DIN 16 190
W 3222 135° angle DIN 16 191

Optional extras (for all nominal sizes)

- Dual scale °F/°C
- Other scale ranges
- Male thread made of other materials
- Thermowells per DIN (see data sheet TM 90.01)
made of Cu-alloy, steel, stainless steel or other materials

3
Dimensions
Design of connection E, male thread
Straight 90° angle 135° angle

3073 106.01

3073 092.01

3073 114.01

Design of connection no. 3, union nut ( only with nominal size 200)
( Basic connection for thermowells per DIN, Form CD, CE,CS )
Straight 90° angle 135° angle

3073 130.01

3073 122.01 3073 181.01

Dimensions in mm
Nominal
Weight in kg
size
a1 a2 B Ød Ø d1 G G1 H H1 SW
22 G 3/8 A
22
21 M 16 x 1.5
110 44 20 30 10 - 110 130 0.250
26 G½A
27
25 M 20 x 1.5
26 G½A
27
25 M 20 x 1.5
150 46 21 36 10 - 150 170 0.300
G¾A
32 32
M 27 x 2
26 G½A G½
27
25 M 20 x 1.5 M 20 x 1.5
10
200 46 21 36 G¾A G¾ 200 220 0.350
32
M 27 x 2 M 27 x 2 32
6.5 - - M 24 x 1.5
9016023 GB 20 VOL 07.01

Ordering information
State: Model / Nominal size / Scale range / Design and size of connection / Length of stem I 1 / Optional extras required

Specifications and dimensions given in this leaflet are correct at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.

WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße . 63911 Klingenberg
( (0 93 72) 132 - 0 . Fax (0 93 72) 132 - 406 / 414
http://www.wika.de . E-Mail: [email protected]
 Operating, Assembly and Maintenance Recommendation
for Ball Valves

Index: Page

1. General 2
2. Safety instructions 2
3. Transport 2
4. Storage 3
5. Functioning 3
6. Installation 3
7. Initial operation 4
8. Maintenance 4
9. Troubleshooting 4

-1-
1. General:

- When making inquiries or spare part orders please always quote our order no. and, if
possible, the ball valve type and year of manufacture.
- We assume no liability in cases of disregard of operating or safety instructions or of faulty
installation or maintenance.
- Please refer to all data on further automation equipment such as drives, actuators,
electrovalves, limit switches etc.
- Unfortunately, we are unable to take back customer-specific valves.

2. Safety instructions:

- Maintenance, assembly and repair work may only be carried out by duly authorised and
qualified personnel.
- The manufacturer assumes no liability for damages or any other occurrences resulting from
changes made without consulting the manufacturer or use of parts other than original parts.
- These operating instructions do not replace any national accident prevention regulations or
local safety regulations; they are invariably subordinate to these.
- Observe the following before carrying out any repair or maintenance work:
® Always turn off the power supply of the drives before carrying out repair or
maintenance work (danger of bruising!).
® Make sure that no-one puts the plant into operation.
® Evacuate the pipe, prevent pressure build-up or retention.
® Inform yourself on possible dangers emanating from residues of operating material;
wear safety gloves and goggles etc. as necessary.
® Let valves cool off if necessary.
® Ensure that limit values relating to pressure, temperature and the operating material are
not exceeded.

3. Transport:

- Valves should be transported to the building site in a firm packing.

- Do not attach cranes or elevators to the handle or to any mounted drive to prevent damage.
- Check valves for any transport damage immediately upon delivery and report as necessary.
We assume no liability for transport damages that have not been duly reported.

-2-
4. Storage:

- Ball valves must always be stored either completely opened or completely closed. We
advise storing them completely opened to prevent damage to the ball surface.
- Valves that are not needed immediately should be fitted with a protective cap and stored in a
well-aired, dry room.

5. Functioning:

- Ball valves serve as shut-off devices in plants, where they are screwed or welded into the
pipe system.
- Ball valves are OPEN/CLOSE devices which are generally opened and closed by rotation
through 90°. The closing direction according to DIN standards is achieved by rotating the
handele clockwise. They are not intended for throttling or regulating the flow of medium,
and intermediate positions are therefore not permissible.
- Granulate ball valves of the 400 and 190TR series are characterised by bearings located on
either side of the ball and valve sealing on one side only. Granulate ball valves have proven
themselves idelly suited to use with critical media which contain solids or are highly
viscous. The packing on the incoming side is not directly exposed to the flow. This prevents
product material from getting jammed between the ball and housing wall as the ball valve
closes. It is essential that the material always flows in the right direction through the ball
valve.

6. Installation:

- The piplines must be cleaned or flushed before installation, so that any residues and foreign
bodies do not get into the ball valves.
- Should the valves be dirty or contaminated, then set the ball previously to 45° and blow the
interior clean with oil-free comressed air. Then clean the housing.
- Lead the piplines free of stress up to valve to be installed.
- Ensure that the ball valves are in their open position.
- Place the fitting between the pipes using a crane or elevator if necessary. Tighten the flange
screws in opposite directions with the appropriate torque.
- Caution: There is only one permissible direction of flow through type 400 and 190TR
granulate ball valves. The valve should close clockwise and should be mounted facing
horizontally or vertically downward. The piping upstream and downstream of the valve
should be straight over a length of approx. 3x its nominal width, and the valve should be
easily accessible.
- Protect the interior parts of the valve before carrying out any welding (observe maximum
tolerable temperature of gasket!).

-3-
7. Initial operation

- Read and ensure compliance with all operating instructions and check that operating
conditions are as required and the valves has been installed correctly.
- Flush the piping with valves fully opened before testing their function.
- After completing the installation and before putting the valve into operation, check that it
works properly by opening and closing it several times.
- Make sure that the valve works perfectly and that it turns in the right direction.

8. Maintenance:

- The ball valves are designed so that when used as intended no maintenance work at all is
required over a period of 3 years.
- To test the function, the valves should be moved open and closed according to loading every
6 or 12 months thus to confirm safe and leak-free operation.
- It is advisable to check the flange and selector shaft packing for leakage after prolonged
operation.
- In the event of rough operating conditions flush the ball valve via the provided borings if
necessary.

9. Troubleshooting:

® Leakage at the selector shaft

This work can be done in the built-in condition and with the line under pressure.
However, it is prossible to do this work only under increased safety precautions. It should
also be observed that this work may be done under no circumstances at very high or very
low temperatures, with combustible media or with aggressive substances.
® Leakage at the ball
For this work the ball valve must be dismantled from the pipeline and only trained skilled
personnel should be entrusted with this work.

Please turn to us if you have any questions or before attempting repair in the event of
operating trouble.

-4-
Betriebsanl.A1 d(U1-17)+ U4 15.02.2002 9:20 Uhr Seite 1

Betriebsanleitung Operating instructions

Ausgabe Februar 2002 February 2002 edition

Instructions de service Instrucciones de servicio

Edition février 2002 Edición febrero 2002

40

18

16
H

12
54

55
56

60
NPSOutlet
DNAustritt

7
b

do
DNEintritt
NPSInlet
a

Das Sicherheitsventil
Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 2

E
40 Lifting device

18 Adjusting screw

16 Spring plate
H

9 Bonnet
12 Spindle
54 Spring

55 Stud bolt
56 Hexagonal nut

60 Seal
NPSOutlet
DNAustritt

8 Guide
7 Plate

Seat
b

1 Body
do
DNEintritt
NPSInlet
a

18
Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 3

1 Contents The following risks could ensue:

a.) The safety valve does not work correctly or is
1 Contents 19 dimensioned wrongly: the pressure equip-
2 General 19 ment bursts. Hazard caused through the
3 Testing/marking 19 bursting itself and by the hot, poisonous and
4 Pressure 20 aggressive medium.
5 Function of the safety valve 20 b.) The safety valve operates correctly: medium
6 Functional tightness of the safety valve 21 escapes: danger from hot, poisonous and
7 Medium 21 aggressive medium.
8 Temperature of the medium and c.) The safety valves leaks: danger from hot,
environmental temperature 22 poisonous and aggressive medium. E
9 Choice of spring 22 d.) Other dangers caused through the handling
10 Safety valves with bellows 23 of safety valves: these are, e. g., risk of injury
11 Safety valves built into installations 23 from sharp edges, heavy weight, ...).
11.1 Open bonnet 23
11.2 Regular lifting operation 23 In order to minimise the risks from these hazards,
11.3 Forces acting on the safety valve 23 the operating instructions must be adhered to at
11.4 Connections 23 all times. They have been developed through
11.5 Orientation of safety valves 24 practical experience and from the requirements
11.6 Flow-through 24 dictated by the regulations. As a rule these
11.7 Condensation 24 regulations must always be adhered to with
11.8 Transfer of vibrations from the priority over the recommendations given below.
installation 24
11.9 Discharge pipe 25 Sets of rules:
11.10 Unfavourable environmental conditions 25 Pressure Vessel and Steam Boiler Ordinance
11.11 Leaks caused by impurity 25 TRD 421, 721,
11.12 Protection during storage and TRB 403, 801 No. 45,
transportation 25 AD-Merkblätter,
11.13 Corrosion protection 25 Pressure Equipment Directive 97/23/EC,
11.14 Maintenance 25 ASME Code,
11.15 Identification of safety valves 25 API 526, 520
11.16 Lever safety valves 25 and others
12 Setting instructions for spring loaded safety We are in possession of the appropriate product-
valves 26 related certificates to certify that the sets of rules
12.1 Lifting device H3 26 are satisfied and therefore to certify safety.
12.2 Lifting device H4 26
12.3 Spring replacement 26 LESER is certified pursuant to DIN EN ISO 9001
13 Handling 27 (quality management systems), pursuant to DIN
14 Supplementary loading system 27 EN ISO 14000 (environmental management
15 Combined Safety Valve and Bursting Disc 28 system) and Module D of the Pressure Equipment
16 Unexpected conditions 28 Directive (quality assurance in production). This
17 Product overview 28 ensures that all quality requirements and the
18 Declarations of Conformity 30 environment are complied with.

2 General
3 Testing/marking
The following general notes refer to directly
loaded and controlled safety valves (with supple-
After setting and testing, each safety valve is
mentary loading system).
sealed by LESER or by the expert of an official
In order for a safety valve to be able to fulfil the acceptance organisation at the customer’s re-
purpose for which it is installed, all components quest (such as TÜV, Germanischer Lloyd, ...).
are manufactured to great precision. Only this
precision allows precise functioning. Safety If the marking is brought up by means of an im-
valves must therefore be handled with care. pact stamp, etc., the safety valve may not be
Failure could endanger people, animals and damaged. Deformations may lead to leakage or
installations. Even a correctly functioning safety the destruction of the safety valve. An impact
valve can cause hazards, and this has to be taken stamp should not be used especially with thin
into account. walls.

19
Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 4

Safety valves have a type test approval plate with If there is a pressure on the outlet side (super-
the following data: imposed back pressure), this produces a force
- data of order exerted on the rear side of the disc. This in-
- technical data creases set pressure by exactly the value of this
- test pressure pressure. If the superimposed back pressure is
- VdTÜV type test approval number constant, it is possible to set the differential
- CE marking and identification number of the pressure by reducing the test pressure by the
notified body back pressure (test pressure ≠ set pressure).
- further information such as the UV stamp with If there is no superimposed back pressure, the
safety valves approved by ASME set pressure drops. The back pressure provided
E For safety valves without type test approval, only may not be exceeded because then it would also
the order data and technical data are included. fall below the set pressure.

Further marks required are either cast in, or, for The maximum pressure that a safety valve may
safety valves with threaded connections, punch- be operated with regardless of the test pressure
ed in. Safety valves with a heating jacket receive depends upon a number of factors. Among them
a separate plate for the heating jacket. are:
- the selection of materials
If technical changes are made, it should always - the medium temperature
be checked to see whether the identification has - the design pressure
to be adjusted. Only trained personnel may make - the flange pressure stages
changes on valves and identifications (refer to - miscellaneous
section 11.14). This should be taken into consideration when
selecting the safety valve.

4 Pressure The operational pressure must in the long-term

be a least 5 % below the reseating pressure.
Definitions: Otherwise it cannot be guaranteed that the valve
a.) Test pressure: the pressure that LESER sets will close securely after working (exception: if the
the safety valve at. There is ambient pressure valve is fitted with an supplementary loading
on the outlet side of the safety valve. system, refer to section 14).
b.) Set pressure: the pressure at which the safety
valve responds to the plant.
c.) Opening pressure: the pressure where the 5 Function of the safety valve
safety valve drains the recognised mass flow
(this may also be given as the difference from It is necessary to have a performance certificate
the set pressure in % ➜ opening pressure to ensure that it is possible to drain the required
difference). mass flow from the safety valve if necessary.
d.) Reseating pressure: the pressure where the
safety valve closes complete (this may also Pipes going to the safety valves have to be fitted
be given as the difference from the set in such a way as to prevent large hydrodynamic
pressure in % ➜ blow down). losses, and the edges at the pipe inlet should be
e.) Operating pressure: the pressure that the at least chamfered but preferably rounded. The
plant is constantly run with. notes on dimensioning given in the regulations,
f.) Built-up back pressure: pressure built up on standards and manufacturer’s information sheets
the outlet side by flow losses when blowing must be adhered to.
off.
g.) Superimposed back pressure: the pressure in The function of safety valves may only be
the discharge line when this is part of a switched off with shut-off elements if it is ensured
system with pressures greater than the am- that the appropriate pressure device is protected
bient pressure. against overpressure by other safety equipment
h.) Back pressure: the total of built up and su- or is not in operation.
perimposed back pressure.
Flawless functioning is guaranteed to the built-up
Pressure shall be stated as overpressure [bar g or back pressure on the outlet side of a maximum of
psig] above ambient pressure. 15 % of the test pressure minus the super-
imposed back pressure (if available).
If not stated otherwise, LESER always sets the
set pressure specified by the customer at ambi- Built-up and superimposed back pressures may
ent pressure on the outlet side (test pressure = be compensated up to 35 % of the set pressure
set pressure). with a stainless steel bellows specially designed

20
Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 5

for it because the force exerting itself on the rear Before mounting the valve in the installation it
side of the disc is compensated for. The function must be visually inspected and then its tightness
and set pressure remain constant. If it is not clear should be checked while the installation is
whether the bellows compensates for back switched on.
pressure, LESER should be contacted. The
application limits of the bellows for pressure and Sealing surfaces are precisely machined. The
temperature may not be exceeded (refer to tightness is achieved, e. g., by hardening,
section 10). tempering, precise grinding and lapping. This
makes safety valves vulnerable to impact, so they
If discharge lines have equipment that prevents may develop leaks as a result of vibrations. The
rainwater or foreign matter from penetrating, this following notes are to be observed: E
equipment may not obstruct the safety valves in
freely and completely blowing off. - During transportation, fitting and operation
safety valves must be protected from
The blow-off pipe has to be dimensioned using vibrations.
the max. back pressure and the corresponding - Safety valves must be transported with care.
temperature. It should be laid in a streamlined E. g., the lever must never be used as a carrying
fashion and should not be opposite other handle and the safety valve must not be
branches to ensure that it does not impair func- dropped.
tioning or cause damage to the safety valve. The
flowthrough and the functioning of safety valves The force between the seat and the disc falls as a
have also to be guaranteed if blow-off systems function of rising operating pressure. Therefore the
have multiple uses. probability of leaks also rises when the operating
pressure is close to the set pressure (refer to
During blowing-off, reaction forces work on the section 4). Damaged or contaminated sealing
safety valve itself, the pipes connected to it and surfaces in particular tend to develop leaks.
the fixed mounts. The size of the reactive force is
particularly important for the dimensioning of the
fixed mounts. 7 Medium
The following points have to be taken into con-
sideration: Any moving parts have to be protected from
- static, dynamic or thermal loads from the pipe abrasive/corrosive media as then the danger
leading to or from the safety valve must not act develops of seizure or sticking. This can be done
on the valve. by servicing the valve each time it has operated
- Safety valves must be fixed as defined in the or by the use of stainless steel/elastomer bellows.
drawing. Omitting or removing mounts can The limits of application for the bellows have to
result in damage if as a result excessively high be observed.
forces or tensions occur.
- Refer also to section 11.3. The possibility of leaking sealing surfaces in the
case of abrasive media must be considered.
Dangerous media must not enter the environ-
ment. In doubt the safety valve must be replaced
after it has operated.
6 Functional tightness of the safety valve
Soft sealing discs can compensate for minor
One has to expect a slight leakiness with all damage to the seat. In every case the limits of
safety valves with metallic seals. Persons, the application and medium consistency for the
environment and installations must not be elastomer material have to be observed.
endangered by the escaping medium.
The strength of individual components (e. g.,
Safety valves with soft seals seal much more body, spindle, spring, ...) can be decreased
reliably than those with metallic seals. LESER through abrasion. This may lead to leaks or to the
offers a range of elastomer materials for different pressure equipment bursting. If abrasive media
applications. The elastomers must be matched to occur, shorter service intervals should be
the medium and its pressure and temperature. observed.

All LESER products are inspected for damage The sealing surfaces must not stick together.
and leaks. In order to prevent damage during This can be prevented by:
transportation all products are packed with - regular lifting operation (refer to section 11.2)
protectors on flange sealing surfaces, sealing lips - heating or cooling to prevent the seat from
and threads. They should be removed before as- sticking
sembly (refer to section 11.12). - other measures which prevent sticking.

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Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 6

Corrosion damage to body components and During the operation of safety valves, media can
internal components cannot be spotted easily in freeze, which prevents opening and closing. This
all cases. Therefore it must be ensured that the can happen if the temperature falls below the
media to be secured do not attack the materials freezing point of the medium with media that
the safety valve is made from. If this possibility congeal in cold the viscosity may drop
cannot be excluded, monitoring and servicing significantly or if there are freezing vapours
have to be adapted to this situation accordingly. contained in the medium. Icing-up is increased
Special materials can be selected on request. by the expansion of gases as this causes the
temperature to fall further. If there is a danger of
Lubricants based on mineral oils are used as an icing, measures must be taken to ensure that the
E aid during installation and without special pre- safety valve works correctly.
cautions they will get in contact with the medium.
Contact with hot or dangerously cold safety valve
The following points have to be observed: surfaces must be prevented by appropriate
- Lubricants/auxiliary media can reach the protective measures.
medium and contaminate it or cause a chemical
reaction.
- Lubricants can be washed out and make the 9 Choice of spring
dismantling of the safety valve more difficult.
- Safety valves can be designed as oil and The springs used by LESER are designed for
grease-free types. For these types the surfaces defined pressure ranges. The test pressure is
are cleaned from all residues containing mineral always the basis for selecting the spring (refer to
oil and specialist lubricants are used. section 4). The functioning of the springs is
- Bellows prevent the contact of medium and ensured if the spring is designed and used in
lubricant. conformity with the sets of rules. When dismant-
ling the valves, the springs must not be swapped
as the functioning will be impaired if the wrong
8 Temperature of the medium and spring is installed.
environmental temperature In extreme cases the spring will be fully com-
pressed (the turns touch each other) and then the
Minimum and maximum temperatures are given safety valve cannot work.
for LESER safety valves. They always refer to the
medium temperature that may simultaneously be When changing the test pressure it must be
the ambient temperature. Therefore, the ambient checked whether the spring/springs can be used
temperature has to be taken into consideration at the new pressure. This can be done by using
under extreme climatic conditions such as in actual LESER spring tables. If they are not
Scandinavia. available LESER has to be contacted. If the
spring does not permit the new test pressure it
It is necessary to observe the influence of the must be replaced by a valid spring. Changed test
medium temperatures on the maximum permitted pressures always require that the whole safety
pressure. If expansion limits drop at higher valve and its dimensioning are checked.
temperatures or if it tends to be brittle at low
temperatures, this lowers the maximum permitted LESER springs are marked unambiguously.
temperatures. Please observe the regulations in Springs which no longer can be identified or
the appropriate sets of rules and the manufac- damaged springs must not be used.
turer’s specifications.
Springs must not be reused if it cannot be
If the safety valve is supposed to be insulated, estimated how many load changes they have
the bonnet and the cooling zones (if there are experienced. This applies in particular to springs
any) have to be free to prevent the springs from from safety valves which have been exposed to
heating up impermissibly. vibrations, as in this case the actual number of
load changes is practically impossible to
In case of setting the pressure of safety valves estimate.
and ambient temperatur, they can be adjusted for
working at an increased temperature by making The springs in LESER safety valves have been
use of a correction factor. This makes it coordinated with the material in the safety valve
unnecessary for the valve to be adjusted at the with reference to the material. In unfavourable
increased temperature, (procedure: Cold cases, there may be influences leading increased
differential test pressure acc. to the LESER com- temperature or corrosion that make the following
pany standard LWN 001.78). actions necessary:

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Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 7

Temperature influences: 11 Safety valves built into installations

As spring temperatures can depend on many
external conditions, no general temperature of
11.1 Open bonnet
the medium can be specified as the limit of
application. They are always specific to the For open bonnets or lever valves, appropriate
installation and a judgement has to be made as measures must be taken to avoid contact with
to which of the following measures need to be movable parts (e. g., the spring) as otherwise
taken: there is a danger of jamming. Medium can leak
- Using spring materials that are heat resistant or out of the open bonnets or open spindle guides
tough at subzero temperatures of lever safety valves. It must be ensured that
- Providing test pressure with a correction factor leaking medium cannot cause hazards. A E
to compensate for dropping set pressures at sufficient safety distance has to be observed.
higher temperatures (refer to section 8 for cold
adjustment)
11.2 Regular lifting operation
- By the utilisation of highly heat resisting
materials in conjunction with cooling zones, Safety valves must be vented regularly in order
open bonnets and bellows, the effect of the to check their functioning and to remove any
temperature on the spring is reduced. deposits. They can be opened if at least an
operating pressure of ≥ 85 % of the set press-
Corrosion effects: ure is present. Exceptions can only be allowed
- Medium may get into the spring spaces if safety if the functioning is checked regularly in a
valves do not have bellows. Corrosive/abrasive different way, e. g., by appropriate short
media reduce the fatigue strength. This should servicing intervals. The valid regulations for the
be taken into consideration with selecting, application of safety valves have to be adhered
designing and servicing. to.
- Spring materials with increased corrosion
resistance are possible (e. g., stainless steel, After venting, the lever must move freely, i. e.
Hastelloy, ...) the lifting fork in the lifting device is not acting
on the spindle cap.

10 Safety valves with bellows

11.3 Forces acting on the safety valve
The pressure and temperature application limits No high static, dynamic or thermal tensions
of bellows shall be complied with. may be transmitted to the safety valves.
These can be caused by:
Defective bellows are recognisable by the - Installation under tension (static)
medium leaking out of the open bonnet or the - Reaction forces when blowing off (static)
vent hole. Hazards from leaking medium must be - Vibrations (dynamic)
prevented. - Temperature expansion (thermal)

Measures against leaking medium: The following measures have to be taken:

- Equipping the valve with an inspection - System must be able to expand
manometer and a drip container. - Pipes of the installation must not be attached
- In the case of open bonnets, the leaking of the in such a way that tensions are created.
medium cannot be prevented if the bellows are - Utilisation of the safety valve brackets for
defective. Hazards have to be prevented, (e. g., secure attachment to the installation.
by a sufficient safety distance, protective in- - Preventing the installation from vibrating.
stallations, utilisation only for harmless media).
11.4 Connections
Defective bellows must be replaced immediately
in order to secure the correct working of the The connections/seals between the safety valve
safety valve. and the plant shall be sufficiently sized. They
also have to be designed in accordance with
Stainless steel bellows for which the number of the sets of rules to prevent the connection from
load changes has been exceeded, or is unknown, failing (also refer to section 4 and 8 for this).
must be replaced. As a rule bellows should be
replaced whenever the valve is dismantled. LESER is not responsible for the correct fitting
of seals for pipes leading into the valve and
Moisture or dirt must not be allowed to enter into pipes for blowing-off or other connections to
the bonnet via the vent hole. Appropriate the safety valves. Therefore LESER will not
protective measures (e. g., connections, pipes, ...) accept any liability for these.
must be taken.

23
Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 8

For the correct fitting one has to ensure that the 11.7 Condensation
flange sealing surfaces are not damaged during
In the outlet chamber of safety valves or in
installation.
parts which are important to their functioning
(spring area, bellows area, ...) no medium or
condensation may remain as this might impair
11.5 Orientation of safety valves
the functioning of the safety valves.
Confirmation by the TÜV Nord:
Directly-loaded safety valves are to be installed The following points have to be observed:
in accordance with AD-A2 “upright with respect - Drainage should always be carried out via the
to the flow direction”: blow-off pipe, which has to be laid sloping
E In addition AD-A2 requires that “safety valves downwards, downstream of the safety valve
must correspond to the state-of-the-art and be so that it can drain itself (figure 3).
suitable for the purpose for which they are - Immediately downstream of the safety valve,
deployed.” no upwards bend may be installed as then
Under the following conditions it is possible to correct drainage is not possible (figure 4).
deviate from the upright installation direction, - Blow-off pipe must be provided with a
and in our view it is also permissible. sufficiently large condensation drainage pipe,
E. g., the safety valves have been granted type which must be attached to the lowest point of
approval for horizontal installation and a note to the pipe. For pipes larger than nominal
this effect is found in the VdTÜV-Merkblatt. diameter 40 the drainage pipe must be at
Adequate experience of installation in applica- least of a nominal diameter 25. (In the case of
tions in an orientation other than upright is steam applications even larger diameters may
available over an extended period. Therefore be necessary. In such cases the regulations
this type of installation can be allowed after must be observed)
discussion between operator, manufacturer and - LESER safety valves are not provided with a
the technical inspector who authorises the drainage hole as the drainage must take place
installation. If applicable, additional measures via the blow-off pipe.
may need to be taken with regard to this Exceptions: Certain regulations require
installation. drainage holes (e. g., on ships with varying
orientation on the water and indefinable pipe
Therefore safety valves may, according to the slope). Safety valves which are intended for
information provided above, be installed in such purposes are equipped with a drainage
directions other than the one specified in AD- hole. Such designs are only manufactured if
A2. they are specifically ordered from LESER.
- It is possible to drill a drainage hole later at
If the conditions mentioned above have been the place intended for this purpose.
fulfilled, the following points have to be Caution: swarfs can cause damage which
observed when installing the valve in a direction may lead to leaks or to the failure of safety
other than the upright direction. valves.
- Drainage has to be built in, in order to prevent - Drainage pipes must be laid sloping
medium or condensation from remaining in downwards and without waisting. It must be
parts which are important for the function of possible to observe the outlet freely, any risks
the valve. the leaking medium may cause must be
- The servicing has to be modified, e. g., the prevented (e. g., through condensation steam
functioning of the drainage has to be gua- traps, drip container, filters, ...).
ranteed. - Drainage holes without function must be
- LESER must be informed of the type of closed.
installation in order to be able to agree to an
orientation deviating from upright. 11.8 Transfer of vibrations from the installation
Any vibrations which might be transferred to the
safety valve must be prevented. Where this is
11.6 Flow-through
not possible the safety valve must be de-
The flow direction must be observed during coupled from the installation, e. g., via bellows,
installation. It can be recognised by the pipe bends, ....
following features: Pressure variations or surges in the medium
Flow direction arrow on the body; also can lead to dangerous vibrations of the
diagrams safety valve. This also has to be avoided.
- In the catalogue,
- In the operating instructions Where the transfer of vibrations cannot be
- In the data sheets and prevented, damping systems can be built in,
- In the installation instructions e. g., o-ring dampers.

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Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 9

11.9 Discharge pipe 11.12 Protection during storage and transportation

When a safety valve is blowing off, in addition
All protective devices for transportation and
to the general hazards from the medium, the
handling have to be removed before installing
following hazards have to be expected
the safety valve.
(refer to section 2):
- High flow rates
After installation, the protection for the lever
- High temperatures
must be removed from the bonnet as otherwise
- Noise emissions
the safety valve cannot be vented. The lever
must move freely, i. e. it must be in its initial
In this context the following has to be observed:
- For steam or gases the blow-off pipe should
position and the coupling at the spindle must E
not be connected to the lever.
point upwards in order to allow blowing off
without danger.
In the case of lever safety valves, the wooden
- For liquids the blow-off pipe should point
wedge, which protects the sealing surfaces
downwards so that the medium can com-
from damage during transportation, has to be
pletely drained out of the blow-off chamber.
removed.
- The outlet flange of safety valves or the blow-
off pipe must point in such a direction that no
11.13 Corrosion protection
danger is caused by the medium blowing out.
These are the options:
Moving parts and parts important to the oper-
- Blowing off into a container
ating must not be impaired. E. g., the blowing-
- Safety valve and blowing-off pipes without
off chamber and the spindle guide must not be
direct access
varnished.
- Design with silencer
The additional load must not be coated with
11.10 Unfavourable environmental conditions
protective paint (refer also to section 14).
All LESER safety valves which could corrode
are painted with a protective coating during 11.14 Maintenance
manufacture which protects the safety valve
during storage and transportation. In corrosive Safety valves may only be serviced by skilled
environments a further corrosion protection is staff.
required (refer to section 11.13). Under extreme
conditions, we recommend stainless steel LESER cannot specify the maintenance
safety valves. The supplementary loading intervals as they depend on many factors:
system may not be given a protective coating. - Corrosive, aggressive and abrasive media
lead to rapid wear and shortened mainten-
Media from outside (e. g., rain water or dirt/dust) ance intervals
in the blowing-off pipe and near components - Frequent operating shortens the maintenance
important for the operating (e. g., guides with intervals
open bonnets) have to be avoided. By analogy, - Maintenance intervals have to be agreed
the statements made in section 7 apply. between the operator, the inspector and the
Simple preventive measures are possible: manufacturer. Inspections must be carried out
- Protection of the blow-off chamber from at the time of the regular outside and inside
extraneous media and dirt examinations of the pressure equipment.
- Protection of the parts important to operating
from extraneous media and dirt. 11.15 Identification of safety valves

11.11 Leaks caused by impurity Before fitting safety valves the documentation
Impurities must not remain in the installation must be checked in order to ensure that the
(e. g., welding beads, sealing material such as correct valve has been selected for fitting.
hemp/Teflon tape, screws, etc.). One option for
avoiding extraneous bodies in the system is to 11.16 Lever safety valves
rinse the system before commissioning.
The set pressure of lever safety valves is
In the case of leaks caused by contamination defined by the mass and the position of the
between the sealing surfaces, the safety valve loading weights. It is not allowed to change
can be vented to clean the surfaces. If this does them.
not remove the leak, one of the sealing surfaces Additional loading weights must not be added.
is probably damaged. In this case the safety It is not allowed to use the lever to hang on any
valve has to receive maintenance. parts, e. g., clothes, ...

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Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 10

12 Setting instructions for spring loaded 12.3 Spring replacement

safety valves
The following items refer to the figures shown
on pages 3/40-3/42 of the LESER complete
The following operating instructions only apply to
catalogue.
valves without additional equipment. If there is
additional equipment (such as O-ring dampers,
1. Loosen the existing lead seal.
proximity switches, bellows, ...), please refer to
2. Press the lever (43) towards the middle until it
the corresponding assembly instructions.
reaches the stop so that the lifting fork (44) no
longer holds the spindle cap (46).
12.1 Lifting device H3
3. Loosen and remove the lever cover (41).
E Remove shaft (45). 4. Loosen the spindle cap (46) from the spindle (12),
Pull lever (43) out to the side. remove the securing ring (91) and the pin (74).
Loosen hexagonal head screw (84). 5. Loosen the lock nut (19) of the adjusting screw
Unscrew and remove lever cover (41). (18).
Loosen lock nut (19). 6. 1) Turn the adjusting screw (18) anticlockwise to
1) Turn adjusting screw (18) to the required set remove all spring tension.
pressure. 7. Remove the hex. nuts (56) from the flange of the
Pay attention to the admissible pressure range bonnet (9).
of the spring! 8. Lift off the bonnet (9).
Clockwise turning of adjusting screw increase 9. Remove the uper spring plate (16).
the spring tension, giving a higher set pressure. 10. Lift off the spring (54) and remove lower spring
Anticlockwise turning of adjusting screw plate (16) and split rings (14).
reduces the spring tension, giving a lower set 11. Remove spindle (12) with guide (8) and disc (7).
pressure. 12. Carefully clean seat (5) and disc (7), and if re-
Reassemble in reverse order and lock at the set quired body internals.
pressure. 13. Refit spindle (12) with guide (8) and disc (7).
14. Fit the split rings (14) into spindle groove and
45 19 retain with the securing ring (59); slip on lower
spring plate (16) to locate on split rings (14).
41
84 15. Replace spring (54).
18 16. Slip on the upper spring plate (16) onto the
43 spindle (12).
17. Align adjusting screw (18), and bonnet (9). over
the spindle (12) and refit.
18. Fit and tighten the hex. nuts (56).
19. 1) Load the spring (54) to obtain the required set
Figure 1
pressure. Clockwise rotation of adjusting screw
(18) increases pressure. Anticlockwise rotation of
12.2 Lifting device H4
adjusting screw (18) reduces pressure.
Loosen the spring cover (41) and simultan- 20. Tighten the lock nut (19) onto the adjusting screw
eously press the lever (43) in the direction of the (18).
bonnet so that the lifting fork (44) comes free. 21. Refit and secure spindle cap (46) by pin (74) and
Remove the lever cover (41). securing ring (91).
Loosen the lock nut (19). 22. Screw-on the lever cover (41).
1) Turn adjusting screw (18) as described in 23. Pull the lever (43) towards the middle so that the
lifting device H3. Pay attention to the ad- lifting fork (44) is pushed under the spindle cap
missible pressure range of the spring! (46).
Reassemble in reverse order and lock at the set 24. Test spindle will lift correctly by pulling lever.
pressure.
These instructions are applicable for relief valves,
43 safety valves and safety relief valves.
44 1) Caution: During all work the spindle has to be
18 secured against twisting in order to prevent dam-
41 age to the sealing surfaces.
19

Figure 2

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Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 11

The safety valves have to be handled with caution

To be observed: as otherwise the vulnerable sealing surfaces can
The pressure setting is wire-locked and sealed be damaged or the safety valve might even be
against unauthorized alteration. The rules of rendered useless.
the TÜV, agreed by the manufacturer, require
the fitting of a type test approval plate stating Safety valves must be stored in a dry place. The
the correct valve data. The manufacturer optimum storage temperature is 2 °C to 40 °C. In
cannot be held responsible for any changes to the case of o-ring discs temperatures below
set pressure or other alterations after despatch freezing should if possible be avoided. The
from our factory. In case of necessary temperature resistance, in particular of the o-ring
modifications we recommend returning the materials, has to be taken into account. E
valve to our supervision of the TÜV or any Upper limit for storage: 50 °C
suitable inspecting authority. Lower limit for storage: -10 °C

14 Supplementary loading system

13 Handling Even if the external energy supply (compressed

air) fails, the direct-loaded safety valve is still fully
There is a risk of injury from sharp edges and functional. In this case the function is equivalent
burrs. For this reason all parts have to be handled to the LESER standard safety valve without
with caution. supplementary loading system.

There is a risk from safety valves falling over. The compressed air filter must be serviced at
They always have to be secured adequately. regular intervals. This is carried out as specified
in the maintenance specifications.
During dismantling the spring must not be
tensed. Otherwise there is the danger of injury The installation should contain an air dryer. The
from flying parts. Observe the installation compressed air should have a dew-point of min.
instructions for the relevant safety valves! +2 °C.

Before dismantling is must always be checked The maximum pressure of the air supply is 10
whether there is, or could be, any, and if it is the bar, the minimum pressure is 3.5 bar. If the
case which, medium there is inside the bonnet. pressure rises above or falls below that specified
High risk of injury, chemical burns or poison- interval, this may lead to temporary or permanent
ing if there is any remaining medium inside the faulty operating of the additional load. Result: the
safety valve. safety valve does not function or it will work as a
standard valve without the supplementary loading
One should use conventional high quality tools in system.
order or minimise the risks arising from bad
quality or mismatched tools. Any necessary The supplementary loading system should be
special tools are indicated in the installation serviced and checked at least once a year by
instructions specially trained staff. For this essential work
LESER offers a maintenance service which may
Safety valves may only be dismantled and be incorporated in a service agreement. Training
assembled by skilled staff. and experience with handling the additional load
The training can be carried out: in combination with the safety valves are abso-
- In the workshop by experienced staff lutely necessary.
- At LESER in training seminars The supplementary loading system has to be
- By means of LESER documentation, e. g., vi- fitted in accordance to the regulations and
deos, operation instructions, catalogues, insta- specifications distributed by LESER. If correctly
llation instructions serviced, failures due to contamination of the
pressure and control lines are impossible.
The maintenance staff must be informed about
the risks during dismantling and installing the The control unit is to be protected from conta-
safety valves. mination. It has to be ensured that it is always
closed. For special applications LESER offers an
Contamination and damage to the safety valve
encapsulated box enclosing the control unit.
must be avoided. Suitable cartons, protective
covers for the flanges, transportation foil, trans-
The actuator on the safety valve itself must be
portation palettes, ... are to be used. The pack-
protected from contamination like the sliding
aging must be completely removed before
parts inside an open bonnet. Otherwise there is
installation as otherwise the function of the safety
the danger of jamming.
valve cannot be guaranteed.

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Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 12

Temperatures: - The alignment of the bursting disc: It should be

The controls and drives are designed for appli- designed in such a fashion that it is not possi-
cation between 2 °C and 60 °C. ble for it to be improperly aligned.
- At temperatures above 60 °C the compressed - The bursting disc has to be free of fragments,
air connections must be as long as possible bursting disc components may not get into the
and equipped with a water seal. inlet connecting pieces of the safety valve thus
- The control unit and the actuator have to be impairing functioning.
positioned in such a location that their temper- - Sets of rules with reference to bursting discs
ature will not exceed 60 °C. (AD-A1, ASME, ...)
- At a temperature below 2 °C there may the
danger of icing up, therefore it may be nece-
ssary to heat the control unit the control lines 16 Unexpected conditions
E and tapping lines.
The supplementary loading system is connected Not all errors can be always prevented up to
to the safety valve via a coupling. The coupling 100 %.
must not be blocked by objects. It is neither
necessary nor permitted to apply a protective However, their consequences must be estimated
coating to the drive. and reduced by:
- A risk analysis for the complete installation
The pressure tapping lines must not be blocked. - An estimate of the risk with the possible dam-
If there are locking devices they have to be age that can be caused
designed in such a way that they cannot be - Instructions about the measures to be taken in
closed, e. g. by means of locking bars or seals. the case of a fault occurring
- Staff training at the manufacturer’s and at the
LESER control units are equipped with a locking operator’s
device for maintenance purposes. They are - Protective measures for people and for the
secured against locking by means of a locking environment.
bar. This locking bar must not be removed.
17 Product overview
The pressure switches are wire-locked and
sealed. This seal indicates that the setting has Refer to section “Declaration of conformity”
not been changed. All manipulations of the
pressure switches are not permitted (e. g.,
opening the seal and modifying the adjustment, The manufacturer reserves the right of
opening the switching contacts, ...)! technical changes and improvements at any
time.
If a locking screw called “test gag“ is used during In detail the type-specific assembly instructions
the pressure testing of the installation it must be have to be observed.
removed after the pressure test.

15 Combined Safety Valve and Bursting Disc

The type test approval of the combination of

bursting discs of a certain manufacturer with
LESER safety valve ensures that both the
functional and performance requirements are
complied with. You may enquire at LESER which
combinations are tested.

If it has been certified that combinations of

LESER safety valves and bursting discs of other
manufacturers satisfy the safety requirements,
they are permissible. This shall be certified in
each individual case.

The following should especially be observed:

- Operating instructions for the bursting disc.
- Safety valves may not be switched off by
placing the bursting disc upstream.
- The intermediate space between the rear side
of the bursting disc and safety valve inlet
should be monitored.

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Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 13

add. drain pipe in case of

E
prepared drain hole

wrong! correct!
Figure 4 Figure 3

29
 Das Sicherheitsventil/The Safety Valve

Declaration of Conformity/Konformitätserklärung
in acc. to the pressure equipment directive 97/23/EC
nach Druckgeräterichtlinie 97/23/EG
LESER GmbH & Co. KG
Wendenstrasse 133-135
D-20537 Hamburg/Germany
Name and address of the manufacturer/Name und Anschrift des Herstellers

Nominal size EC-type examination no. Nominal size EC-type examination no.
Type* Type*
Nennweite EG-Bauteilprüfnummer Nennweite EG-Bauteilprüfnummer
411 20 - 150 / ¾" - 6" 07 202 0111Z00080/02 462 15 - 20 / ¾" - 1" 07 202 0111Z00080/14
421 25 - 100 / 1"- 4" 07 202 0111Z00080/03 532 + 534 20 - 50 / ½" - 6" 07 202 0111Z00080/15
424 25 - 200 07 202 0111Z00080/04 538 10 / ½" 07 202 0111Z00080/16
427 + 429 15 - 150 / ½" - 6" 07 202 0111Z00080/05 539 10 - 15 / ½" - ¾" 07 202 0111Z00080/17
431 + 433 15 - 150 / ½" - 6" 07 202 0111Z00080/06 543 + 544 50 - 100 / 2" - 4"07 202 0111Z00080/18
440 20 - 150 07 202 0111Z00080/07 546 25 - 100 / 1" - 4"07 202 0111Z00080/19
441 + 442 20 - 400 / ¾" - 16" 07 202 0111Z00080/08 483, 484, 485 25, 40 / 1" - 2" 07 202 0111Z00080/20
447 25 - 100 / 1" - 4" 07 202 0111Z00080/09 437, 438, 481 ½", ¾", 3 8" 07 202 0111Z00080/21
448 25 - 100 / 1" - 4" 07 202 0111Z00080/10 700 -- 07 202 0111Z00080/22
455 + 456 25 - 100 / 1" - 4" 07 202 0111Z00080/11 522 50-100/2" – 4" 07 202 0111 Z00080/23
457 + 458 25 - 150 / 1" - 6" 07 202 0111Z00080/12 450/460 15-20/¾" – 1" 07 202 0111 Z00080/24
459 10 - 20 / ½" - 1" 07 202 0111Z00080/13 488 25-100/1"- 4" 07 202 0111 Z00080/25
Description of the pressure equipment/Beschreibung des Druckgerätes * See name plate/siehe Prüfschild

Kategorie IV/Category IV
Applied category in acc. to article 3 and annex II/Angewandte Kategorie nach Artikel 3 und Anhang II

Conformity assessment procedures/ Certificate number/

Module/Modul
Konformitätsbewertungsverfahren Bescheinigungsnummer
B EC type-examination/EG-Baumusterprüfung See table/siehe Tabelle
D/D1 Production quality assurance/Qualitätssicherung Produktion 07 202 0111Z00080/01
Conformity assessment procedures in acc. to article 10/Angewandte Konformitätsbewertungsverfahren nach Artikel 10

TÜV CERT - Zertifizierungsstelle für Druckgeräte der TÜV NORD GRUPPE

Identification number: 0045, Grosse Bahnstrasse 31, D-22525 Hamburg/Germany
Name and address of the notified body (monitoring a.m. conformity assessment procedures)
Name und Anschrift der benannten Stelle (Zertifizierung/Überwachung nach o.g. Modulen)

The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this
pressure equipment meet the requirements of the pressure equipment directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses
Druckgerätes den Anforderungen der Druckgeräterichtlinie entsprechen.

At the moment no harmonized standards available/zurzeit keine harmonisierten Normen verfügbar

Applied harmonized standards/Angewandte harmonisierte Normen

TRB 801. 45, AD-Merkblatt A2, TRB 403, TRD 421, TRD 721, DIN 3320, DIN 3840, VdTÜV 100
AD 2000-Merkblatt A2, AD 2000-Merkblatt A4
Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen
LWN 248.15 - 11/01

14.12.2001
Date Manufacturer stamp Authorized subscriber
LESER GmbH & Co. KG
Hamburg, HRA 82 424 Hausanschrift/Home address Fon +49 (40) 251 65-100 Bank
PhG: Gebr. LESER Verwaltung GmbH, D-20537 Hamburg, Wendenstr. 133-135 Fax +49 (40) 251 65-500 Vereins- und Westbank AG, Hamburg
Hamburg, HRB 38 577 Postanschrift/Postal address e-mail: [email protected] USt-IdNr./VAT-No.: BLZ 200 300 00, Konto 3203171
GF/BoD: Martin Leser, Wolfgang Gorny D-20506 Hamburg, P.O. Box 26 16 51 www.leser.com DE 118840936 SWIFT: VUWB DE HH
 Das Sicherheitsventil/The Safety Valve

Declaration of Conformity/Konformitätserklärung
in acc. to the pressure equipment directive 97/23/EC
nach Druckgeräterichtlinie 97/23/EG

LESER GmbH & Co. KG

Wendenstrasse 133-135
D-20537 Hamburg/Germany
Name and address of the manufacturer/Name und Anschrift des Herstellers

Conformity assessment
Applied category in
Description of procedures in acc. to
Nominal acc. to article 3 and CE-
pressure article 10/
Material/ size/ annex II/ marking/
Type* equipment/ Angewandte
Werkstoff Nenn- Angewandte CE-Kenn-
Benennung des Konformitäts-
weite Kategorie nach Artikel zeichnung
Druckgerätes bewertungsverfahren
3 und Anhang II
nach Artikel 10
1.0619 Art. 3 Par. 3 Not necessary No
DN25
GS-C 25 Change-over Art. 3 Abs. 3 Nicht erforderlich Nein
GP 240 GH Valve
310 Cat. II
DN40, Yes
Kat. II D1
1.4408 DN50 Wechselventil Ja
X5 CrNiMo19-11-2
Description of the pressure equipment/Beschreibung des Druckgerätes * See name plate/siehe Prüfschild

Conformity assessment procedures/ Certificate number/

Module/Modul
Konformitätsbewertungsverfahren Bescheinigungsnummer
D1 Production quality assurance/Qualitätssicherung Produktion 07 202 0111Z00080/01
Certificate number of module D1/Zertifikatsnummer Modul D1

TÜV CERT - Zertifizierungsstelle für Druckgeräte der TÜV NORD GRUPPE

Identification number: 0045, Grosse Bahnstrasse 31, D-22525 Hamburg/Germany
Name and address of the notified body (monitoring a.m. conformity assessment procedures)
Name und Anschrift der benannten Stelle (Zertifizierung/Überwachung nach o.g. Modulen)

The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this pressure
equipment meet the requirements of the pressure equipment directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses Druckgerätes
den Anforderungen der Druckgeräterichtlinie entsprechen.

DIN EN 1503-1, DIN EN 10213-1, DIN EN 10213-2, DIN EN 10213-4

Applied harmonized standards/Angewandte harmonisierte Normen

DIN 3840
Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen

14.12.2001
LWN 248.15 - 11/01

Date Manufacturer stamp Authorized subscriber

LESER GmbH & Co. KG

Hamburg, HRA 82 424 Hausanschrift/Home address Fon +49 (40) 251 65-100 Bank
PhG: Gebr. LESER Verwaltung GmbH, D-20537 Hamburg, Wendenstr. 133-135 Fax +49 (40) 251 65-500 Vereins- und Westbank AG, Hamburg
Hamburg, HRB 38 577 Postanschrift/Postal address e-mail: [email protected] USt-IdNr./VAT-No.: BLZ 200 300 00, Konto 3203171
GF/BoD: Martin Leser, Wolfgang Gorny D-20506 Hamburg, P.O. Box 26 16 51 www.leser.com DE 118840936 SWIFT: VUWB DE HH
 Das Sicherheitsventil/The Safety Valve

Declaration of Conformity/Konformitätserklärung
in acc. to the pressure equipment directive 97/23/EC
nach Druckgeräterichtlinie 97/23/EG

LESER GmbH & Co. KG

Wendenstrasse 133-135
D-20537 Hamburg/Germany
Name and address of the manufacturer/Name und Anschrift des Herstellers

Applied category in Conformity assessment

Description of
Nominal acc. to article 3 and procedures in acc. to article CE-
pressure
Material/ size/ annex II/ 10/ marking/
Type* equipment/
Werkstoff Nenn- Angewandte Kategorie Angewandte Konformitäts- CE-Kenn-
Benennung des
weite nach Artikel 3 und bewertungsverfahren nach zeichnung
Druckgerätes
Anhang II Artikel 10
DN15- Art. 3 Par. 3 Not necessary No
0.6025
DN50 Art. 3 Abs. 3 Nicht erforderlich Nein
GG-25/
DN65- Kat. I Yes
GJL-250 A
DN100 Pressure Reducer Cat. I Ja
612
DN15- Druckminderer Art. 3 Par. 3 Not necessary No
1.0619
DN32 Art. 3 Abs. 3 Nicht erforderlich Nein
GS-C 25/
DN40- Kat. I Yes
GP 240 GH A
DN100 Cat. I Ja
Description of the pressure equipment/Beschreibung des Druckgerätes * See name plate/siehe Prüfschild

Conformity assessment procedures/ Certificate number/

Module/Modul
Konformitätsbewertungsverfahren Bescheinigungsnummer
D1 Production quality assurance/Qualitätssicherung Produktion 07 202 0111Z00080/01
Certificate number of module D1/Zertifikatsnummer Modul D1

TÜV CERT - Zertifizierungsstelle für Druckgeräte der TÜV NORD GRUPPE

Identification number: 0045, Grosse Bahnstrasse 31, D-22525 Hamburg/Germany
Name and address of the notified body (monitoring a.m. conformity assessment procedures)
Name und Anschrift der benannten Stelle (Zertifizierung/Überwachung nach o.g. Modulen)

The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this
pressure equipment meet the requirements of the pressure equipment directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prüfung dieses
Druckgerätes den Anforderungen der Druckgeräterichtlinie entsprechen.

DIN EN 1503-1, DIN EN 1503-3, DIN EN 10213-1, DIN EN 10213-2

Applied harmonized standards/Angewandte harmonisierte Normen

DIN 3840, DIN 1691, DIN EN 1561

Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen

14.12.2001
248.14 - 11/01

Date Manufacturer stamp Authorized subscriber

LWN 248.15

LESER GmbH & Co. KG

Hamburg, HRA 82 424 Hausanschrift/Home address Fon +49 (40) 251 65-100 Bank
PhG: Gebr. LESER Verwaltung GmbH, D-20537 Hamburg, Wendenstr. 133-135 Fax +49 (40) 251 65-500 Vereins- und Westbank AG, Hamburg
Hamburg, HRB 38 577 Postanschrift/Postal address e-mail: [email protected] USt-IdNr./VAT-No.: BLZ 200 300 00, Konto 3203171
GF/BoD: Martin Leser, Wolfgang Gorny D-20506 Hamburg, P.O. Box 26 16 51 www.leser.com DE 118840936 SWIFT: VUWB DE HH
Betriebsanl.A1 d(U1-17)+ U4 15.02.2002 9:24 Uhr Seite 18

LWN 480.1 – 480.28 02/2002 – 10000

LESER GmbH & Co. KG, Hamburg

D-20537 Hamburg, Wendenstrasse 133-135 Fon +49 (40) 251 65-100
D-20506 Hamburg, Postfach/P.O.Box 26 16 51 Fax +49 (40) 251 65-500
www.leser.com e-mail: [email protected]
Leser 416.5/S. 9/10 neu 22.02.2002 9:28 Uhr Seite 1

Normal-Feder-Sicherheitsventil
Safety Relief Valve spring loaded
für Dämpfe, Gase und Flüssigkeiten
for steam, gases and liquids

Anschlüsse
9
NPT Gewindeanschlüsse
Gewindemuffen
Flanschanschlüsse nach DIN/ANSI
Weitere Anschlüsse auf Anfrage

Connections
NPT screwed connections
female screwed connections
flange connections acc. to DIN/ANSI
further connections on request

Type 437
mit Anlüftung H4, gasdicht,
Teller anlüftbar
lifting device H4, gastight,
disc liftable

Eintrittskörperwerkstoff Temperatureinsatzgrenze 1) Artikelnummer

Inlet body material Temperature range 1) Article number
DIN EN ASME DIN EN ASME do [mm]
Werkstoffbezeichnung Werkstoff-Nr. von bis von bis 6 10
Material Designation Material No. from to from to
Long Version Standard Long Version
[°C] [°F] [°C] [°F] [°C] [°F] [°C] [°F]
X 14 CrMoS 17 1.4104 430F -10 +14 +220 +428 -29 -20 +220 +428 4373 – .260* .261*
X 2 CrNiMo 17-12-2 1.4404 1) 2) 316L -270 -454 +280 +536 -268 -450 +280 +536 4374 .312* .314* .315*

* Bitte hier gewünschte Ziffer für Kappe oder Anlüftung anfügen: * Please add number for the required cap or lifting device:
2 = Kappe H2 4 = Anlüftung H4 (gasdicht) 2 = Cap H2 4 = Lifting device H4 (gastight)
1) Zwischen -10 °C und der niedrigsten, angegebenen Anwendungstemperatur 1) Between -10 °C and lowest temperature indicated ”AD-Merkblatt” W10 shall be

ist gemäß AD-Merkblatt W10 zu verfahren. taken into account.

Änderungen behalten wir uns vor. Modifications reserved.

Werkstoffe /Materials
4373 4374
Chromstahl/chrome steel korrosionsfest/corrosion resistant
kaltzäh/cryogenic
Pos. Bauteile Parts Werkstoff Nr. ASME Werkstoff Nr. ASME
Item material no. material no.
1 Eintrittskörper Body (base) 1.4104 430F 1.4404 1) 316L 1) 9
2 Austrittsgehäuse Outlet body 1.4104 430F 1.4404 316L
7 Teller Disc 1.4122 420RM 1.4404 1) 316L 1)
12 Spindel Spindle 1.4021 420 1.4404 316L
16 Federteller Spring plate 1.4104 430F 1.4404 316L
18 Druckschraube Adjusting screw 1.4104 430F 1.4404 316L
mit Buchse with bush PTFE + 15 % Glas PTFE + 15 % Glas
54 Feder Spring 1.4310 302 1.4310 302
40 Kappe H2 Cap H2 1.0718 steel 1.4404 316L
Anlüftung H4 Lifting device H4 1.4104 430F 1.4404 316L
1) d 6 gepanzert 1) d 6 stellited
o o
Electrical connections (scheme)
Operating Instructions Dual Pressure Switch Switch 2000
and Dual Temperature Switch TempSwitch 2000
(Temp) (Temp)
Switch 2000 M12 x 1 TempSwitch 2000 M12 x 1
Switch Switch
2000 * 2000

12
ca.
12
ø 30
* SP2 = Diagnosis output (DESINA®-version)

Operation:

110
118
The pressure switch should be installed and operated only by authorized persons. After being switched on
the UDS 7 runs through a self-test. The device is menu operated and configured with three keys on the
front. With the „M“ key (= mode) you change between the dialog values and the adjusted / actual values.
With the keys „ ⇑ “ = up and „ ⇓ “ = down you change between the dialog values in the menu or change
the values / functions in the menues (see below: „List of functions“).
If the dialog is not continued within two minutes the device automatically returns to the measuring mode.
When the software lock is entered, „LOCK“ appears in the display when an attempt is made to change
values.

12
17
12
Programming:
The setting menu is activated with the mode key. The dialog items are selected with the „ ⇑ “ and „ ⇓ “ keys.
If the mode key is pressed again the corresponding value for the dialog item is shown and can be altered ø6
G1/4
with the „ ⇑ “ and „ ⇓ “ keys. If the dialog with the unit is not continued within two minutes the device auto- Dimensions
Dimensions hex 36 G1/4
matically returns to the measuring mode without accepting the new values. (in mm)
(in mm)
To terminate programming more quickly, you can switch back to the measuring mode (primary menu) SKT19
from any item in the menu by holding the M-key pressed for five seconds.

If the key lock has been activated, the values can be shown, but no changes made. („ “ appears in the 1. Product description
display when an attempt is made to change values). The key lock is activated by pressing the „ ⇑ “ and „ ⇓ “ Intended Applications
keys simultaneously for at least five seconds. Press again to deactivate the key lock again. - The dual pressure switch is a device to monitor system pressure and has up to two switching outputs
and one analog output.
- The dual temperature switch is a device to monitor media temperature into which the probe is immersed
DESINA conformity: and has up to two switching outputs and one analog output..
- According to DESINA® standard.
When the switch operates in systems according to DESINA standard, switching point SP2 has to be - The instruments must only be installed in systems where the maximum pressure Pmax or the maximum
programmed as monitoring function: Enter the value (error output) in programming step and temperature Tmax is not exceeded (according to the values on the type label).
the value (normally closed function) in programming step . - (only TempSwitch 2000) when the rotable display is adjusted the switch has to be fixed with the allen
In case of error idendification (see menu) a diagnosis signal is automatically actuated on the alarm screw at the front side with a 3 Nm torque (allen key 1,5 mm).
- Attention: This device is not designed to be used as the only safety relevant element in pressurized
display on the front panel and on switching point SP2 (pin 2).
systems according PED 97/23/RC.

2. Starting operations
Only assemble or disassemble the device when depressurized!
Connecting the switch
- Mount the pressure switch from bottom to the fitting with a wrench hex 36 (1/4“) resp. 19 with 45 Nm
torque.
Art.-Nr.: 923-1092 - Electrical connection depends on the type of pressure switch (see type label) according to the
Index D, 14. 02. 2004 chart below.
Barksdale GmbH Software version: V 2.1 and higher Electrical Plug Model with 1 Model with 2 Model with 1
Dorn-Assenheimer Strasse 27 connections M 12 x 1, switching output switching outputs switching output
D-61203 Reichelsheim / Germany Specifications are subject to 4-pin (DESINA®) and 1 analog output
Plug 4-pin,
changes without notice. M12 x 1 +Ub (12. ..32 V DC) +Ub (12...32 V DC)
Pin 1 +Ub (12 ..32 V DC)
Tel.: +49 - 60 35 - 9 49-0 SP2 (0,5 A max.) analog
Pin 2 -
Fax: +49 - 60 35 - 9 49-111 and 9 49-113
Pin 3 0V 0V 0V
e-mail: [email protected]
Pin 4 SP1 (0,5 A max.) SP1 (0,5 A max.) SP1 (0,5 A max.)
www.barksdale.de
4 1
List of functions: Switch 2000 List of functions: Switch 2000

Dialog item Value Description Dialog item Value Description

0...400 Display of the actually measured value Only models with analog output:

... Select the display unit Switch 2000 TempSwitch 2000 0...xxx Scale the analog output - start value (e. g. 0 bar = 4 mA)
= mbar = psi x 10 = hPa = °Celsius
0...xxx Scale the analog output - end value (e. g. 400 bar = 20 mA)
= bar = psi = mPa = °Fahrenheit
(output signal start value always corresponds to the display initial value,
... Activation unit display e. g. 0 bar = 4mA)
= unit display on (every 30 sec) Maximum turn-down 4 : 1, i.e. at values below 25 % of the measuring
= no unit display range the analog output is switched off

... = window technology = error output

= standard evaluation

0...xxx Switch-on point for SP1; if the ON value is smaller than the OFF value
the switching point evaluation is falling

0...xxx Switch-off point for SP1 0...xxx Display of peak value „Max“ (xxxx: = max. 125 % f. s.)

Switch-on / switch-off delay for SP1 in seconds ... Delete the maximum value memory
= no deletion
... Inversion of switching output SP1 = delete value
= high-level-fail-save (normally open function)
= low-level-fail-save (normally closed function) Error display:
= no error
= exceeding pos. meas. range
= exceeding pos. meas. range
= sensor error
= error switching output 1
Only models with 2nd switching contact:
= error switching output 2
... = window technology = error output = data error (EEProm)
= standard evaluation = program error
= calibration error
0...xxx Switch-on point for SP2; if the ON value is smaller than the OFF value
= error analog out
the switching point evaluation is falling

0...xxx Switch-off point for SP2

Switch-on / switch-off delay for SP2 in seconds

... Inversion of switching output SP2

= high-level-fail-save (normally open function)
= low-level-fail-save (normally closed function)

3
Nr. Pcs. Title Body material RA 35 T
1 1 Body 1.4408
2 1 Ball 1.4408
3 1 Stem 1.4404 / Antistatik
4 2 Body gasket PTFE
5 2 Seat PTFE
6 1 Stem seal PTFE + GF
7 3 Stem packing PTFE + GF / Antistatik
8 1 Stem packing follower 1.4404
9 2 Belleville washer 1.4310
10 1 Stop 1.4306
11 6 Body screw DIN 934 A2-70
12 12 Body nut DIN934 A2-70
13 1 Stem nut 1.4301
15 2 Centering ring DN80-150: PTFE + GF
17 3 Butt weld end 1.4408
 Operating and installation instructions
Butterfly valves

BR 012 - ZESA®

Contents BR 013 - GESA®

1.0 General information on 4.6 Marking..........................................................................5
operating instructions .............................................2 5.0 Installation................................................................6
2.0 Notes on possible dangers .......................................2 5.1 General remarks on installation .....................................6
2.1 Significance of symbols ................................................ 2 5.2 Installation of accessories ..............................................6
2.2 Safety-related definitions .............................................. 2 5.3 Conversion from lever with detent to clamping lever....7
2.3 Qualified personnel ....................................................... 2 5.4 Retrofitting the THErmo-Appliance (THEA)................8
3.0 Handling ...................................................................3 6.0 Notes on dangers during installation, operation
3.1 Storage .......................................................................... 3 and maintenance......................................................8
3.2 Transport ....................................................................... 3 7.0 Putting the valve into operation .............................9
3.3 Handling before installation.......................................... 3 8.0 Care and maintenance.............................................9
4.0 Descriptions..............................................................3 9.0 Troubleshooting .......................................................9
4.1 Scope of applications .................................................... 3 10.0 Troubleshooting table ..........................................10
4.2 Operating principles...................................................... 3
11.0 Dismantling the valve ..........................................11
4.3 Diagram - assembly ...................................................... 4
4.4 Actuation arrangements ................................................ 4
12.0 Warranty ..............................................................11
4.5 Technical data - remarks ............................................... 5 13.0 EC declaration of conformity /
Manufacturers declaration .................................12

0040000082 4000 englisch

 Operating and installation instructions
Butterfly valves
1.0 General information on operating instructions
These operating instructions contain information necessary to install and operate the valve both safely
and effectively.
If problems arise which cannot be solved with the aid of these operating instructions, please contact the
supplier/manufacturer for further information. These operating instructions comply with applicable EN
safety standards as well as regulations and codes of practice applicable in the Federal Republic of
Germany. If the valve is used outside the Federal Republic of Germany, the operator or the person
responsible for the system design must ensure that valid national codes of practice are complied with.
The manufacturer reserves all rights to implement technical modifications and improvements at any
time.
The use of these operating instructions assumes the user is qualified as described under Section 2.3
"Qualified Personnel".
The operating personnel must be instructed in accordance with the operating instructions.

2.0 Notes on possible dangers

2.1 Significance of symbols

Warning of general danger

2.2 Safety-related definitions

The signal definitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.

DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or
considerable damage to property can occur.

WARNING means that if the relevant information is disregarded, there is a danger of serious injury and
/ or damage to property can occur.

CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or
damage to property can occur.

NOTE means that particular attention must be paid to certain technical aspects.

All other information not specifically emphasised such as transport, installation, operating and
maintenance instructions as well as technical data (in the operating instructions, product documentation
and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in
turn can cause serious injury to persons or damage to property.

2.3 Qualified personnel

The term "qualified personnel" relates to persons who are familiarised with installation, assembly, start-
up, operation and maintenance of the product and have the qualifications corresponding to their
responsibilities such as:
Instruction and obligation to comply with all operational, regional and in-company regulations and
requirements;
Training or instruction in accordance with safety technology standards with regard to the upkeep and use
of appropriate safety and work protection equipment; First aid training, etc.
(see TRB 700).

page 2 00400000082 4000

 Operating and installation instructions
Butterfly valves
3.0 Handling
3.1 Storage
- Storage temperature -20˚ to +65˚C dry, free of dirt
- The painting is only a primer, intending to guard against rust during stock or transportation. Don‘t
damage the paintwork.
- A desiccant or heating to prevent condensation is necessary in damp rooms.

3.2 Transport
- Transport temperature -20˚ to +65˚C.
- Protect against external force (impact, vibration etc.).
- Don‘t damage the paintwork.

3.3 Handling before installation

- If flange covers are fitted, remove shortly before maintenance!
- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.

4.0 Descriptions
4.1 Scope of applications
Butterfly valves are used to interrupt or restrict the flow of liquids and gases. It is the responsibility of
the plant designer to decide on their use in a specific application. The meanings of special markings on
the valve must be taken into account.
- Valves for inflammable, aggressive or toxic media, must be off tensile material.
- With applications for media that demand special criteria, please consult.
- -marking for applications acc. to Pressure Equipment Directive.

4.2 Operating principles

The valve is closed by turning the disc shaft clockwise.
The shaft moves through 90˚.

00400000082 4000 page 3

 Operating and installation instructions
Butterfly valves
4.3 Diagram - assembly
rotated view

Material designation:
EP = EPDM or
NBR or
FPM

fig. 1: ZESA® / GESA® - Butterfly valve

4.4 Actuation arrangements

fig. 2: ZESA® / GESA® lever with detent

- The detent pin of the lower lever must be fully disengaged to move the lever..

fig. 3: ZESA® / GESA® clamp lever

- The star knob screw must be slackened before and tightened again after moving the lever.

page 4 00400000082 4000

 Operating and installation instructions
Butterfly valves
- Gear type (actuation by hand wheel, clockwise for closing).
The CLOSE-position can be adjusted by ± 5˚ by a stop screw.
The stop screws are self-sealing and self-locking (see Fig. 7).

Stop screw
Lock nut

Position indicator

fig. 4: Gear
- See separate operating and maintenance manual for drive (electric or pneumatic).
4.5 Technical data - remarks
- Main valve dimensions
See catalogue sheet.
- Pressures and temperatures
See catalogue sheet.

4.6 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Typ Type
Bj. Year of manufacture
Manufacturer
According to the Pressure Equipment Directive part 3, valves without safety function are only
allowed to bear the CE-marking DN32 onwards.

00400000082 4000 page 5

 Operating and installation instructions
Butterfly valves
5.0 Installation
5.1 General remarks on installation
The following points should be taken into account besides the general principles governing installation
work:

- There must be no foreign bodies inside the valve or piping.

- The direction of flow need not be taken into account.

- The shaft can be in any position except for DN350, 400 and 500 (horizontal shaft).

- No gaskets required between flanges, flexible gaskets are not allowed.

- The butterfly valve must be installed in open position, but the disc must not protrude beyond the
housing.

- Corresponding flanges must be parallel and in line with the connecting holes.

- The valve must not serve as a fixing point. It must be carried by the piping.

- Large actuators with horizontal application must be supported.

- Protect the valve from dirt, especially during construction work.

- Avoid damage to the rubber sheathing during handling, storage and installation.

- Install expansion joints to compensate for thermal expansion of the piping.

- Do not heat the valve (e.g. by welding, grinding, etc.) above its service temperature (see data sheets).

- Protect actuators from excessive ambient temperatures (see operating instructions for actuator).

5.2 Installation of accessories

Optional accessories (e.g. limit switches) supplies with valves must be fitted as required for their
functions as shown in the plants of the plant.

page 6 00400000082 4000

 Operating and installation instructions
Butterfly valves
5.3 Conversion from lever with detent to clamping lever

Fenster

fig. 5
The detent lever cap (8.1) can be used for the conversion.
- Set detent lever (20) to detent position 4.
- Slacken socket screw (20.1) (5 of 6 mm AF).
- Remove detent lever (20).
Note: The position of the valve disc is not positively located!
- Dismantle detend lever cap (8.1) and use a screwdriver to break out the window.
- Put the cap, with the nut (13) in it, in place and tighten it.
- Set the clamping lever (21) in position as shown in the diagram.
- Tighten the socket screw (item 21.1).
- Insert star knob screw (item 40) through the hole at the end of the clamping lever (21) and screw into
the hex. nut (item 13).
If the clamping lever must be on the same side as the original lever with detent, the detent lever cap must
be turned through 180°.
For the angle limit stop , an additional nut can be placed in the cap for a locking screw.

00400000082 4000 page 7

 Operating and installation instructions
Butterfly valves
5.4 Retrofitting the THErmo-Appliance (THEA)

fig. 6
- Remove sticker from the hole in the lever (20).
- Insert the THEA temperature indicator (40) into the hole down to the stop.

6.0 Notes on dangers during installation, operation and maintenance

DANGER !
Operation can be completely safe only if the valve is properly installed, put into operation and
maintained by trained personnel (cf. point 2.3 “Qualified personnel”) paying full attention to the
warnings in these operating instructions. In addition, the general installation and safety rules for piping
and plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict
attention must be paid to the operating instructions during all work on the valve and when handling it.
Injury or damage can be caused by ignoring them.
When used as an end-blockage, a safety precaution (e.g. plug-in disc, blind flange etc.) is demanded by
maintenance works.
If the butterfly valve is in operation as a pipeend valve, regarde DIN EN 294 point 5.

page 8 00400000082 4000

 Operating and installation instructions
Butterfly valves
7.0 Putting the valve into operation
- Before putting the valve into operation, check that the material, pressure, temperature and direction of
flow are as specified with the plans of the piping system.
- Regard the TRB 700.
- It is forbidden to use tools to increase the torque of the lever or hand wheel.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.

DANGER !
Before putting a new plant into operation or restarting a plant after repairs or modification, always make
sure that:
- all installation and assembly work has been completed!
- only trained personnel (see point 2.3) are employed to start the plant!
- the valve is in the correct position for its function!
- existing guards have been attached and in good order.

8.0 Care and maintenance

Maintenance and maintenanceintervals have to be defined by the operator according to the service
conditions (see TRB 700).

It is advisable to actuate the valve at least once a month.

9.0 Troubleshooting
In the event of failures or malfunctions, check that the valve was assembled and installed as described in
these instructions.
Regard the TRB 700.

Compare the material, pressure, temperature and direction of flow with the information given in the
plans of the piping system. Check also that the service conditions correspond to the data given on the
data plate and the technical data.

DANGER !
It is essential that the safety regulations are observed when identifying faults!

If malfunctions cannot be eliminate with the help of the following „troubleshooting table“, the supplier
or manufacturer should be consulted.

00400000082 4000 page 9

 Operating and installation instructions
Butterfly valves
10.0 Troubleshooting table

Fault Possible cause Corrective measures

No flow Valve closed. Open valve.

Little flow Valve not sufficiently open. Open valve.

Strainer sieve clogged. Clean / replace sieve.

Relieve pressure first!
Observe points 7.0 and 11.0!

Piping system clogged. Check piping system.

Valve is impossible or diffi- Service conditions (e.g. medium, tempera- Replace valve. Consult supplier or manu-
cult to open or close ture) outside permissible limits. facturer.
Relieve pressure first!
Observe points 7.0 and 11.0!

Power failure. Check power supply.

Wrong direction of rotation. Turn in correct direction (clockwise for

opening).

Valve leaking Not properly closed. Close valve properly or readjust limit
switch/stop screw.

Pressure difference too high. Check plant.

Medium contaminated. Clean valve.

Install strainer sieve upstream of valve.
Relieve pressure first!
Observe points 7.0 and 11.0!

Lining/collars (page 4, Fig. 1-2, item 2) or Replace valve. Consult supplier or manu-
valve disc (page 4, Fig. 1-2, item 3) dama- facturer.
ged by foreign bodies or medium Relieve pressure first!
Observe points 7.0 and 11.0!

Valve with clamping arran- Clamping arrangement tightened. Slacken clamping arrangement.
gement cannot be opened

Caution: - Read point 11.0 prior to dismantling and repair work!

- Read point 7.0 before restarting the plant!

page 10 00400000082 4000

 Operating and installation instructions
Butterfly valves
11.0 Dismantling the valve
The following points must be observed beside the general principals rules and TRB 700 governing the
assembly work:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic media.
- Have assembly work performed only by qualified personnel (see point 2.3).

12.0 Warranty
The extent and period of warranty cover are specified in the "Standard Terms and Conditions of Albert
Richter GmbH & Co. KG" valid at the time of delivery or, by way of departure, in the contract of sale
itself.

We guarantee freedom of faults in compliance with state-of-the-art technology and the confirmed
application.

No warranty claims can be made for any damage caused as the result of incorrect handling or disregard
of operating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and
other applicable codes of practice.

This warranty also does not cover any damage which occurs during operation under conditions deviating
from those laid down by specifications or other agreements.

Justified complaints will be eliminated by repair carried out by us or by a specialist appointed by us.

No claims will be accepted beyond the scope of this warranty. The right to replacement delivery is
excluded.

The warranty shall not cover maintenance work, installation of external parts, design modifications or
natural wear.

Any damage incurred during transport should not be reported to us but rather to the competent cargo-
handling depot, the railway company or carrier company immediately or else claims for replacements
from these companies will be invalidated.

Technology for the Future.

GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: [email protected]

00400000082 4000 page 11

 Operating and installation instructions
Butterfly valves
13.0 EC declaration of conformity / Manufacturers declaration
EC declaration of conformity
as defined by
the Pressure Equipment Directive 97/23/EC and

Manufacturers declaration
as defined by
the Machinery Directive 98/37/EC

Herewith we declare,

ARI-Armaturen Albert Richter GmbH & Co. KG,

Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock

that according to the above mentioned Pressure Equipment Directive (PED) and Machinery Directive
the below listed products comply and have been approved according to Category III , Module H through
Lloyd´s Register of Shipping (NB-No. 0525),
Mönckebergstr. 27, 20095 Hamburg

Certificate-No: 50003/1

Butterfly valves
ZESA® / GESA®
Type 012, 013

Applied standards:
DIN EN 292
DIN EN 294
DIN EN 349
DIN EN 563
DIN 3230
DIN 3840

If the supplied model is intended to be incorporated into machinery or assembled with other machinery
to constitute machinery covered by this directive and must be put into service until the machinery into
which it is be incorporated has been declared in conformity with the provisions of the EC-Machinery
Directive as amended by 98/37/EC.

Schloß Holte Stukenbrock, 13.12.2001

...................................................
(Brechmann, Managing director)

page 12 00400000082 4000

Technical data - ARI-ZESA ®
Figure 22.012
Materials Disc / Shaft Lining

DN ≤ 80 1.4581 / 1.4021 EPDM

NBR
DN 100-300 1.4401 / 1.4021 FPM
EPDM approval for DIN DVGW Reg. water NW6201AQ2024
NBR approval for DIN DVGW Reg. gas NG-4313AQ1489
water NW6201AQ2024

DN ≤ 80 1.4581 / 1.4571
EPDM
DN 25 - 65 DN 80 - 100 DN 100-300 1.4571 / 1.4571 NBR
FPM
DN ≥350 1.4581 / 1.4571

EPDM approval for DIN DVGW Reg. water NW6201AQ2024

NBR approval for DIN DVGW Reg. gas NG-4313AQ1489
water NW6201AQ2024

DN 125 - 150 DN 200

DN 250 - 300 DN 350 - 500

Pressure range: 16 bar Selection of possible applications:

Max. differential 16 bar (DN 25-150) • Cold -and cooling water installations • Swimming pool-installations
pressure: 10 bar (DN 200-500) • Heating installations • Powerstations
• Drinking water and domestic water • Gas installations
Sealing leakage test: DIN 3230 T3 Leakage rate 1
• Waste water • Shipbuilding
Temperature range: EPDM - 10 °C to + 130 °C - Other applications on request -
NBR - 10 °C to + 80 °C
FPM - 10 °C to + 150 °C
(FPM not for hot water useable)
Body material: GGG-40 0.7040 DN 25/32 - DN 300 Order text:
GGG-40.3 0.7043 DN 350 - DN 500 ARI-ZESA - Butterfly valve with eyelets, maintenance free,
Pressure - temperature - classification soft seal gasket/lining in ........
Temperature disc of material-no. .........., PN 6/16, DN .....,
Material PN type of actuator ...............
- 10°C 120°C 130°C 150°C
GGG-40 16 16 bar 16 bar 15,8 bar 15,5 bar
GGG-40.3 16 16 bar 16 bar 15,8 bar 15,5 bar
Operating range depends on existing service conditions and technical regulations.
Intermediate values for max. permissible operational pressures can be determined
by linear interpolation of the given temperature / pressure chart from 120°C upwards.
2 Edition 11/02 - Data subject to alteration
 Technical data - ARI-GESA ®

Figure 22.013
Materials Disc / Shaft Lining

DN ≤ 80 1.4581 / 1.4021 EPDM

NBR
DN 100-300 1.4401 / 1.4021 FPM

DN ≤ 80 1.4581 / 1.4571
EPDM
DN 100-300 1.4571 / 1.4571 NBR
FPM
DN 25 - 65 DN ≥350 1.4581 / 1.4571

DN 80 - 150 DN 200

DN 250 - 300 DN 350 - 500

Pressure range: 16 bar Selection of possible applications:

Max. differential 16 bar (DN 25-150) • Cold -and cooling water installations • Swimmingpool-installations
pressure: 10 bar (DN 200-300) • Heating installations • Powerstations
Sealing leakage test: DIN 3230 T3 Leakage rate 1 • Drinkingwater and domestic water • Gas installations
• Waste water • Shipbuilding
Temperature range: EPDM - 10 °C to + 130 °C - Other applications on request -
NBR - 10 °C to + 80 °C
FPM - 10 °C to + 150 °C
(FPM not for hot water useable)
Body material: GGG-40 0.7040 DN 25/32 - DN 300 Order text:
GGG-40.3 0.7043 DN 350 - DN 500 ARI-GESA - Butterfly valve with threaded eyelets, maintenance free,
Pressure - temperature - classification soft seal gasket/lining in ........
disc of material-no. .........., PN 10/16, DN .....,
Temperature
Material PN type of actuator ..............
- 10°C 120°C 130°C 150°C
GGG-40 16 16 bar 16 bar 15,8 bar 15,5 bar
GGG-40.3 16 16 bar 16 bar 15,8 bar 15,5 bar
Operating range depends on existing service conditions and technical regulations.
Intermediate values for max. permissible operational pressures can be determined
by linear interpolation of the given temperature / pressure chart from 120°C upwards.
Edition 11/02 - Data subject to alteration 3
 Instructions for the Adjustable Throttle DN 125

18

24

1
23
12
10 4

11
20
3
19 21

9 27
28 26 5 2

The adjustable throttle can be adjusted during the running process. There is no need to remove the
throttle in order to change the flow rate. Before you can adjust the throttle, you have to remove the
screw plug (19) with an 8 mm Allen key.

With the same 8 mm Allen key you can adjust the throttle:
Turn right: The throttle will be closed.
Turn left: The throttle will be opened.

If you reach a stop while adjusting the throttle, please turn the key a little bit back again in order to
prevent canting between the disc and the adjust screw.

With the aid of the diagram you can adjust the throttle in every position. The following diagram
shows the flow rate of water with a temperature of 20°C. The number of turns are counted from the
closed position on.

At the end you have to fix the screw plug (19) again.

The smaller screw plugs (18) can be used to mount a differential pressure sensor.
 Flow Characteristics of the Adjustable Throttle
DN125
Water for Water (20°C)
[m³/h]
∆p =
400 2,0 bar

1,8 bar

1,6 bar

1,4 bar

1,2 bar
300
1,0 bar

0,8 bar

0,6 bar
200 0,5 bar

0,4 bar

0,3 bar

0,2 bar

100
0,1 bar

0 1 2 3 4 5 6 7
Close: Open
Turn right Turn left
Number of Turns
of the Adjusting Screw

Example: At a Adjusting Screw position of 4,5 turns counted from the fully closed position
off, you can read a flow rate by the diagram of 120 m³/h at a pressure difference of 1 bar
between the inlet and the outlet of this throttle. The maximum number of turns is 7.
Don´t try to open or to close the throttle with violence - it could destroy the throttle.
 Installation and operating manual B4E
for motor control valves
_______________________________________________________________________

Installation:

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.
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.
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 manual.

technische Änderungen vorbehalten 4BA-E.DOC / 0209504

 Motor control valve in three way form 431 ...He/f/h E
PN 16 / 25, GGG-40.3
_______________________________________________________________________

Body: GGG-40.3, three way form,

for water and steam, as mixing valve,
(diverted purpose restricted,
see page 038 990)
Pressure range: PN 16, PN 25
Flanges acc. to DIN,
Spindle sealing: spring-loaded PTFE-V-ring unit
for media temperatures up to 250°C
alternatively: graphite-packing
Internal parts: stainless steel
Flow characteristic: linear
Leakage: acc. to VDI/VDE 2174

Actuator: with integrated manual emergency

and load dependent limit switches
Thrust: 8 kN / 33 W (appendix e)
12 kN / 50 W (appendix f)
15 kN / 50 W (appendix h)
Power supply: 230V / 50Hz
alternatively: 230V / 60Hz (appendix E/F/H)
Motor rating standard: S4 – 30% ED – 600 c/h
Protection class: IP65
Other voltages on request

Accessories, special designs:

Add. signal switches load dependent
Add. signal switches travel dependent
Feedback potentiometer
Integrated positioner
Other voltages (on request)
Other positioning speed (on request)
Reduced kvs-values (on request)

Order text:
Motor control valve PN . ., DN . .
in three way form with PTFE-V-ring unit,
Power supply . . ., List-No. 431 . . . H .

Max. operating pressure:

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

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

PN 16 PN 25 m³/h mm sec 8 kN 12 kN 15 kN
50 431 405H. 431 505H. 40 20 50 25,0
65 431 406H. 431 506H. 63 30 75 20,4 25,0
80 431 408H. 431 508H. 100 30 75 13,4 20,9 25,0
100 431 410H. 431 510H. 160 30 75 8,4 13,3 17,0
125 431 412H. 431 512H. 230 35 88 5,2 8,4 10,8
150 431 415H. 431 515H. 330 40 100 3,5 5,7 7,4

data subject to alteration 431HEH-E / 0309509

 Motor control valve in three way form 431 ...He/f/h E
PN 16 / 25, GGG-40.3
_______________________________________________________________________
188
Aktuator type: 15
220 Space required
to remove
8 kN: 4eh8-25 (E) the bonnet
12 kN: 4ehf-25 (F)
15 kN: 4ehh-40 (H)

Cap nut 60

Bonnet

Hand wheel

Coupling
with plate

H
Spindle

Coupling

Mounting rod

PTFE-V-ring-unit

Spindle
A AB
Plug
H1
B
Valve body type: vg31...
L

DN 50 65 80 100 125 150

Height H 625 667 667 675 820 835
Stud lenght H1 100 120 130 150 200 210
Immersion lenght L 230 290 310 350 400 480
Weight kg 29 44 48 62 103 133

Electrical wiring: Accessories (optionaly):

Limit switches Signal switches
load dependent load dependent
for valve position Signal switches Potentiometer for valve position
OPEN CLOSED travel dependent OPEN CLOSED
M

1 2 3 10 11 12 13 14 15 19 20 21 22 23 24 25 26 27 34 35 36 37 38 39

N
L on 11= Straightway opens
L on 14= Straightway closes

data subject to alteration 431HEH-E / 0309509

THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

maritime assembly systems GmbH PHONE: + 49 (0) 3841 - 3271 - 0

mas maritime assembly systems GmbH Zum Dock 3 FAX: +49 (0) 3841 - 3271 - 23
23966 Wismar [email protected]
Germany www.mas-wismar.com

CLIENT: CATERPILLAR MANUFACTURER: mas GmbH

POWER GENERATION SYSTEMS ORDER No.: 6220384_5
PROJECT: SOMITA CABINET: =E1 MAIN CABINET
RESPONSIBLE: R.Heidtmann
PLANT: COMBINED WATER & LO MODULE

MAIN DIMENSION (HxWxD): 1600x600x400 CABLE COLOURS: (if not marked differently)

COLOR: RAL 7035 PHASE: BLACK H07V-K min. 1,5mm²

NEUTRAL: DARK BLUE H07V-K min. 1,5mm²
DEGREE OF PROTECTION: IP 23 SAFETY EARTH: GREEN/YELLOW H07V-K min. 1,5mm²

CLASS: CONTROL VOLTAGE 230VAC: RED H07V-K min. 0,75mm²

CONTROL VOLTAGE 0VAC: DARK BLUE H07V-K min. 0,75mm²
VOLTAGE: 400V 50Hz
CONTROL VOLTAGE 24VDC: WHITE H07V-K min. 0,75mm²
NOMINAL POWER: 74kW CONTROL VOLTAGE 0VDC: LIGHT BLUE H07V-K min. 0,75mm²

TABLE OF CONTENT: COVER SHEET

FRONT VIEW
CIRCUIT DIAGRAM
TERMINAL DIAGRAM
LIST OF APPARATUS

System: =E1
Check PS mas maritime assembly systems GmbH Client Part
COVER SHEET
=
Class
Z u m D ock 3
23966 Wismar
CATERPILLAR
POWER GENERATION SYSTEMS
COMBINED WATER & LO MODULE Location: +
Germany
06.04.2006 RH based on Drawing No. Sheet 1
SOMITA
Revision Date Prep
Phone (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3271-23 MAIN CABINET E-1-6220384_5 of 1
THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

H2
Q1 Main switch

H3 H5 H4 T1
Power supply ind.
H1 -
K1-K10
S1 Failure
H2 -

CW preheater
A0 F2-F4 H3 Step 1
CW preheater
H1 H4 Step 2

CW Pump preheater
H5 Ind. Lamp
Q1 CW Pump preheater
S1 off-Autom.
1600

X2

X3
X1

600 400

FRONT SIDE

System: =
Check PS mas maritime assembly systems GmbH Client Part
FRONT VIEW
Class
Z u m D ock 3
23966 Wismar CATERPILLAR COMBINED WATER & LO MODULE Location: +
06.04.2006 RH based on Germany POWER GENERATION SYSTEMS Drawing No. Sheet 1
Revision Date Prep
Phone (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3271-23 SOMITA MAIN CABINET E-1-6220384_5 of 1
THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

1 3 5 33 43

-F1 -F2 -Q2 34 44 -F3

I >I >I >
35A 20A 1,6-2,5A 2 4 6 2A
1 4
H07VK H07VK H07VK
-T1 208-500/2x115V
100VA
3x1x25mm² 3x1x10mm² 3x1x4mm² 31 32

1 1
-F4 -F5
2 4 6 1 3 5 1 3 5 1 3 5 2A 2 2A 2 L1.F5
-Q1 -K4 -K5 -K6 /2.1
63A 1 3 5 /2.4 /2.5 /2.7 N.1
2 4 6 2 4 6 2 4 6 /2.1
-A1
A1 A1
H07VK H07VK H07VK
~
1+ 3+
-K1 -K2
3x1x25mm² 3x1x10mm² 3x1x4mm²
2 = 4
A2 A2

STEP1 STEP2

35mm² 16mm² 16mm² 2,5mm² /2.4 14 /2.5 14

/2.4 12 11 /2.5 12 11
-X1 1 2 3 PE 4 5 6 PE 7 8 9 PE 10 11 12 PE PE -X2 1 2 3 24 4 24
22 21 22 21

U V W PE
1 3 4

2
M

STEP1

STEP2
* SUPPLY -M1 3
SUPPLY
24VDC
400V/50Hz
STEP 1 STEP 2 CW PREHEATING PUMP
18,3kW 9,7kW 1,1kw/2,0A
BARKSDALE-TEMPSWITCH 2000
COOLING WATER PREHEATER *TEMP.CONTROLLER

System: =E1
Check PS mas maritime assembly systems GmbH Client Part
CIRCUIT DIAGRAM
Class
Z u m D ock 3
23966 Wismar CATERPILLAR COMBINED WATER & LO MODULE Location: +INT
06.04.2006 RH based on Germany POWER GENERATION SYSTEMS Drawing No. Sheet 1
Revision Date Prep
Phone (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3271-23 SOMITA MAIN CABINET E-1-6220384_5 No.of.sh. 3
THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

L1.F5
/1.8

0-Autom.
33 13
-Q2 -S1
/1.4 34 14

13
-K6
/2.7 14

11 11
-K1 -K2
/1.7 12 14 /1.8 12 14

12 14 22 24 13 13 33
-K3 -K3 -K4 -K5 -K6
/2.3 11 /2.3 21 /2.4 14 /2.5 14 /2.7 34

X1 X1 A1 A1 X1 A1 X1 A1 X1
-H1 -H2 -K3 -K4 -H3 -K5 -H4 -K6 -H5
white X2 red X2 230AC A2 A30 A2 blue X2 A9 A2 blue X2 A9 A2 blue X2
/1.8 N.1

SOURCE FAILURE FAILURE STEP1 STEP1 STEP2 STEP2 CW PUMP CW PUMP

2,5mm² /2.2 14 /1.2 1 2 /1.3 1 2 /1.41 2
12 11 3 4 3 4 3 4
/2.2 /1.2 /1.3 /1.4
-X2 5 6 7 8 /2.2 24 /1.2 5 6 /1.3 5 6 9 10 /1.45 6
22 21 13 14 13 14 13 14
/2.2 /2.4 /2.5 /2.4
23 24
/2.7 33 34

21 21

22 22

FI 1x09 FH1 * CW PUMP ON/OFF

FAILURE CW PREHEATER CLOSED WHEN
HEATER CABINET THERMOSTAT ENGINE STOPPED

System: =E1
Check PS mas maritime assembly systems GmbH Client Part
CIRCUIT DIAGRAM
Class
Z u m D ock 3
23966 Wismar CATERPILLAR COMBINED WATER & LO MODULE Location: +INT
06.04.2006 RH based on Germany POWER GENERATION SYSTEMS Drawing No. Sheet 2
Revision Date Prep
Phone (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3271-23 SOMITA MAIN CABINET E-1-6220384_5 No.of.sh. 3
THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

16mm² 16mm² 16mm² 16mm²

-X3 1 2 3 PE 4 5 6 PE 7 8 9 PE 10 11 12 PE

U1 V1 W1 U1 V1 W1

-3M1 M
3 -3M3 3
M
PE PE

400V 50Hz 15kW 400V 50Hz 15kW

HT-CW PUMP LT-CW PUMP

FP01 FP03

16mm² 2,5mm² 2,5mm² 2,5mm² 2,5mm² 2,5mm² 2,5mm²

-X3 13 14 15 PE 16 17 18 PE 19 20 21 PE 22 23 24 PE 25 26 PE 27 28 PE 29 30 31 PE

U1 V1 W1 1 14 11 PE 1 14 11 PE 1 14 11 PE 11 1 23

-3M4 M
3 -Y2
M
-Y3
M
-Y4
M -3B1 P -3B3
PE 12 PT100

400V 50Hz 15kW

PRE.LUB PUMP HT CONTROL VALVE 230V LT CONTROL VALVE 230V LO CONTROL VALVE 230V AUTOM.FILTER ALARM LO TEMP.CONTROL SENSOR

LP01 FR01 TR03 LR01 LI06 LI08

System:
Check PS mas maritime assembly systems GmbH Client Part
CIRCUIT DIAGRAM
=E1
Class
Z u m D ock 3
23966 Wismar CATERPILLAR COMBINED WATER & LO MODULE Location: +INT
06.04.2006 RH based on Germany POWER GENERATION SYSTEMS Drawing No. Sheet 3
Revision Date Prep
Phone (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3271-23 SOMITA MAIN CABINET E-1-6220384_5 of 3
THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

1.1
1.1
1.1
1.2
1.2
1.2
1.3
1.3
1.3
1.3
1.4
1.4
1.4
1.4
1.5
1.5
1.5
PAGE

SHEET / PATH

1
3
5

2
4
6

2
4
6

2
4
6

31
INTERNAL
CONNECTION
=E1+INT-X1

INTERNAL
-Q1
-Q1
-Q1

-K4
-K4
-K4

-K5
-K5
-K5

-K6
-K6
-K6

-T1
NAME

LINK
1
2
3
PE
4
5
6
PE
7
8
9
PE
10
11
12
PE
PE
NUMBER

U
V
W
PE
EXTERNAL
CONNECTION
STRIP:

EXTRNAL
NAME
-R1
-R1
-R2

-R4
-R4
-R5

-M1
-M1
-M1
-M1
EXTERNAL KABEL

System: =E1
Check PS mas maritime assembly systems GmbH Client Part
TERMINAL DIAGRAM
Class
Z u m D o ck 3
23966 Wi smar
CATERPILLAR COMBINED WATER & LO MODULE Location: +
Germany POWER GENERATION SYSTEMS Drawing No. Sheet 1
06.04.2006 RH based on SOMITA
Revision Date Prep P h o n e (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3 271-23
MAIN CABINET E-1-6220384_5 of 3
THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

1.7
1.7
1.7
1.8
2.2
2.2
2.3
2.3
2.6
2.6
PAGE

SHEET / PATH

3+
4
A1
A1
11
14
2
33
14
A1
INTERNAL
CONNECTION
=E1+INT-X2

INTERNAL
-A1
-A1
-K1
-K2
-K3
-K3
-F5
-Q2
-S1
-K6
NAME

LINK
1
2
3
4
5
6
7
8
9
10
NUMBER
1
3
4
2

21
22
21
EXTERNAL 22
CONNECTION
STRIP:

EXTRNAL
NAME
-B1
-B1
-B
-B
-B
-B

-B
-B
EXTERNAL KABEL

System: =E1
Check PS mas maritime assembly systems GmbH Client Part
TERMINAL DIAGRAM
Class
Z u m D o ck 3
23966 Wi smar
CATERPILLAR COMBINED WATER & LO MODULE Location: +
Germany POWER GENERATION SYSTEMS Drawing No. Sheet 2
06.04.2006 RH based on SOMITA
Revision Date Prep P h o n e (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3 271-23
MAIN CABINET E-1-6220384_5 of 3
THE INFORMATION HERE ON IS THE PROPERTY
OF mas GmbH, AND/OR ITS SUBSIDARIES.
WHITOUT WRITTEN PERMISSION, ANY COPYING, CABLE CONNECTED BY YARD
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT * SUPPLYED BY YARD
THAT FOR WHICH IT IS LOANED IS PROHIBITED.

1 2 3 4 5 6 7 8

3.1
3.1
3.1
3.2
3.2
3.2
3.3
3.3
3.4
3.4
3.5
3.5
3.1
3.1
3.1
3.1
3.1
3.2
3.2
3.2
3.3
3.3
3.3
3.3
3.4
3.4
3.4
3.4
3.5
3.5
3.5
3.5
3.6
3.6
3.6
3.7
3.7
3.7
3.8
3.8
3.8
3.8
PAGE

SHEET / PATH

INTERNAL
CONNECTION
=E1+INT-X3

INTERNAL
NAME

LINK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PE
PE
16
17
18
PE
PE
19
20
21
PE
PE
22
23
24
PE
PE
25
26
PE
27
28
PE
29
30
31
PE
NUMBER
U1
V1
W1

U1
V1
W1

U1
V1
W1
PE
PE
1
14
11

PE
1
14
11
PE
PE
1
14
11

PE
11
12

1
2
3
EXTERNAL
CONNECTION
STRIP:

EXTRNAL
-3M1
-3M1
-3M1

-3M3
-3M3
-3M3

-3M4
-3M4
-3M4
-3M1
-3M4

-3M3

-3B1
-3B1

-3B3
-3B3
-3B3
NAME

-Y2
-Y2
-Y2

-Y2
-Y3
-Y3
-Y3

-Y3
-Y4
-Y4
-Y4

-Y4
EXTERNAL KABEL

System: =E1
Check PS mas maritime assembly systems GmbH Client Part
TERMINAL DIAGRAM
Class
Z u m D o ck 3
23966 Wi smar
CATERPILLAR COMBINED WATER & LO MODULE Location: +
Germany POWER GENERATION SYSTEMS Drawing No. Sheet 3
06.04.2006 RH based on SOMITA
Revision Date Prep P h o n e (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3 271-23
MAIN CABINET E-1-6220384_5 of 3
 No. Qty. Part No. Description Manufacturer Name Page

Revision
1 1 FSich-3pol -F2 /1.3
2 1 FSich-3pol -F1 /1.2
3 1 1SAM250000R1007 MOTOR PROTECTION SWITCH MS116 1,6-2, ABB -Q2 /1.4
4 1 1SBL141001R8010 CONTACTOR A9-30-10 220-230V50HZ 230- ABB -K5 /2.5 1
5 1 1SBL141001R8010 CONTACTOR A9-30-10 220-230V50HZ 230- ABB -K6 /2.7
1 1SBN010010R1010 AUX.CONTACT CA5-10 1S F.A9-A110, N, ABB /2.7

Date
6 1 1SBL281001R8010 CONTACTOR A30-30-10 220-230V50HZ 230 ABB -K4 /2.4
7 1 1SCA022378R1630 DISCONNECTOR OT63E3HY5X6ST2 63A 3-P ABB -Q1 /1.1
8 1 1SFA619200R1016 SELECTOR SWITCH 1pol 1S ABB -S1 /2.6

06.04.2006 RH
9 1 1SFA619402R5231 INDICATOR LAMP LED red 230V ABB -H2 /2.2

Prep
10 1 1SFA619402R5234 INDICATOR LAMP LED blue 230V ABB -H4 /2.5
OF mas GmbH, AND/OR ITS SUBSIDARIES.

11 1 1SFA619402R5234 INDICATOR LAMP LED blue 230V ABB -H3 /2.4

THE INFORMATION HERE ON IS THE PROPERTY

12 1 1SFA619402R5234 INDICATOR LAMP LED blue 230V ABB -H5 /2.7

Class
WHITOUT WRITTEN PERMISSION, ANY COPYING,
TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT

13 1 1SFA619402R5235 INDICATOR LAMP LED white 230V ABB -H1 /2.1

THAT FOR WHICH IT IS LOANED IS PROHIBITED.

based on
Check PS
14 3 1SNA115124R0700 TERMINAL SCREW gray 35/16 ABB -X1 /1.1
15 15 1SNA115124R0700 TERMINAL SCREW gray 35/16 ABB -X3 /3.1
16 6 1SNA115129R1400 TERMINAL SCREW gray 16/12 ABB -X1 /1.3

mas
17 2 1SNA165453R2300 TERMINAL SCREW gn/ye 16/12 ABB -X1 /1.4
18 1 1SNA165454R2400 TERMINAL SCREW gn/ye 35/16 ABB -X1 /1.2
19 3 1SNA165454R2400 TERMINAL SCREW gn/ye 35/16 ABB -X3 /3.1
3

20 1 1SVR423417R1000 POWER SUPPLY CP-24/2.0 ABB -A1 /1.6

21 1 281-623 FUSE TERMINAL 6x32mm WAGO -F5 /1.6

Germany
22 1 281-623 FUSE TERMINAL 6x32mm WAGO -F4 /1.6

Z u m D o ck 3
23966 Wi smar
23 1 31918+31070+01908+01541 D-Reiter-Sicherungssockel, komplett, Wöhner GmbH & -F3 /1.5

P h o n e (03841) 3271-0
F a x . ( 0 3 8 4 1 ) 3 271-23
24 1 4AM3442-8DD40-0FA0 TRANSFORMER 208-500/2x115V 100 VA SIEMENS -T1 /1.6
25 1 788-312 RELAY 24VDC 2W WAGO -K2 /1.8

maritime assembly systems GmbH

26 1 788-312 RELAY 24VDC 2W WAGO -K1 /1.7
27 1 788-516 RELAY 230VAC 2W WAGO -K3 /2.3
28 16 870-681 TERMINAL CAGE CLAMP 3pin gray 2,5 WAGO -X3 /3.2
4

SOMITA
Client
29 3 870-681 TERMINAL CAGE CLAMP 3pin gray 2,5 WAGO -X1 /1.4
30 8 870-687 TERMINAL CAGE CLAMP 3pin gn/ye 2,5 WAGO -X3 /3.3

CATERPILLAR
31 2 870-687 TERMINAL CAGE CLAMP 3pin gn/ye 2,5 WAGO -X1 /1.5
32 6 870-901 TERMINAL CAGE CLAMP 2pin gray 2,5 WAGO -X2 /1.7

POWER GENERATION SYSTEMS

5

Part
6

MAIN CABINET
COMBINED WATER & LO MODULE
7

Drawing No.
E-1-6220384_5
LIST OF APPARATUS
8

of
Sheet
System:
Location: +

1
1
=E1