Instruction Manual
Instruction Manual
LP 1205GB
July 2001
These instructions are valid for all low pressure pumps as specified in the Pump identification chart below.
Pump identification
Pump name Size Rotor Design Material Shaft- Mounting Valve Also Comments
(1) lead modification pump- seal (2) (3) valid for
(1) body design option
(1) (1)
ACE 025 K V
032 L T
038 N 3 N B P A101
Q
LPQ 100 L 1 I R Y P
110 N
125 P
140 J
Installation
BEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!
Design limitations and technical data for each pump are found in the Product description.
Installation of IMO AB low pressure pumps does not require special skills. However, these instructions
presume that the work is carried out by experienced fitters.
Maintenance and service instructions, which are specific for each pump are presented in a separate docu-
ment.
max 90°
Lifting of pump min 60°
max 90°
All pumps should be lifted with straps min 60°
! securely attached to the pump or pump unit,
so that the center of gravity is located be-
tween the straps in order to avoid tipping of
the pump.
Use two eye bolts (M 20) securely fastened to the max 90°
front cover for pumps LPQ and ABQ. Pump and min 60°
connecting frame are lifted together using two eye
bolts securely fastened to the top of the connecting
frame. (Thread dimension is M 16, except for frame
size 600, where it is M 20).
Suction line
The suction pipe should be designed so that the total
pressure drop, measured at the pump inlet flange,
does not exceed the suction capability of the pump.
Make a proper calculation of the suction line includ- Fig. 6 Pipe connections
ing components such as valves, strainer, pipe bends
etc. Generally, the pressure drop in the suction line
should be as low as possible, which is achieved if the
suction pipe is short, straight and has a suitable
diameter.
The velocity in the suction line should be kept in the
range 0.5 - 1.2 m/s. For L.O. circulating systems, we
recommend to keep it as low as possible.
The suction line must be equipped with a port that
allows filling the pump before start.
Discharge line
The discharge line should be dimensioned to keep
the velocity in the range 1 - 3 m/s. Fig.7 Suction line
Deaeration
In installations with negative suction head, where
the pump might be started against a pressurized
system, a deaeration pipe with an orifice (2-3 mm
recommended) has to be installed. The deaeration
pipe should be connected to the outlet pipe’s highest
point.
This must also be installed when the pump is used
as an stand-by pump.
Fig. 8 Deaeration
LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 5
July 2001 E-mail: info@imo.se, Web: www.imo.se
Strainer
The pump has to be protected from foreign matter,
such as weld slag, pipe scale, etc., that could enter
the pump via the suction line. If the cleanliness of
the system cannot be guaranteed, a strainer must be
installed in the inlet pipe near the pump. For practi-
cal reasons a suction strainer with 0.5 - 2 mm mesh
openings is recommended:
Small pumps (LPD, ACD, ACE) 0.5-0.8 mm
Large pumps (ACG/UCG, ACF/UCF, LPQ,/ABQ)
0.8-2.0 mm
The size of the strainer should be selected so that it
is large enough to allow adequate pressure at the
pump inlet. The pressure drop across the strainer Fig. 9 Strainer
should preferably not exceed 0.1 bar at max. flow
rate and normal operating viscosity. A vacuum
gauge between the strainer and the pump inlet is
recommended to indicate when the strainer needs
cleaning.
;;;;
opening.
Fig. 10 Shaft seal drain
;;;;
SealGuard
;;;;
For heavy fuel oil high temperature applications, a
SealGuard should be applied to the pump. Further
information about SealGuard, read the Installation
and Start-up Instruction for SealGuard.
Liquid trap
In some mounting arrangements the pump may not
retain the liquid at stand still. In such installations
the suction pipe should be arranged so it forms a
liquid trap together with the pump, keeping the
pump half filled with liquid. See fig. 11.
bar
Fig. 12 Gauges
IMO AB
Deaeration plug
On the ACF/UCF, LPQ and ABQ pumps, the pump
can be turned using the shaft coupling. If the suction
pipe cannot be completely filled, it is important to
ensure that the trapped air is evacuated without any
pressure build up. (See fig. 8 Deaeration).
ACF
ATTENTION
Starting a dry pump is likely to cause
damage, especially to the shaft seal.
Fig. 16 Deaeration plugs
Direction of rotation
When the pump is ready to be started, switch the
motor briefly on and off and check that the drive
motor rotates in the correct direction as indicated by
the rotation arrow.
ATTENTION
Don't mix up with arrow for inlet and outlet!
Fig. 17 Direction of rotation
Pressure too low - The pressure relief valve is set Readjust the pressure relief
too low. valve.
- Counter pressure in the dis- Check the components in the
charge line is too low due to a discharge line inclusive the
major leakage. recipients.
- The valve piston is stuck in open Check the valve. See Mainte-
position. nance and Service instruction for
respective pump.
- Something is restricting the flow Check all components in the
in the suction line. (This would suction line (strainers, valves
usually cause noise). etc.).
- The pumped liquid contains a See the chapter on Noise and
significant amount of com- Vibration. ( Page 11).
pressible gas, such as free air.
(This would usually cause
noise).
- A too small pump has been Contact your IMO AB
chosen. representative.
- The oil is too cold (or has higher Reduce the pressure setting until
viscosity than anticipated). operational temperature has been
reached.
Drive motor difficult to start - Counter pressure too high. See above: Pressure too high.
or tends to stop by tripping
the motor overload relay - Liquid too cold. Readjust the pressure relief valve
to a lower value. Thus the power
consumption for the pumping is
relieved and overloading due to
the high viscosity may be
avoided. When the liquid has
reached normal temperature and
thus flows easily, the relief valve
is reset to normal pressure.
- Motor overload relay set too low Readjust or replace the relay.
or is faulty.
Noise and vibrations - The flow to the pump is insuffi- See chapter: The flow is too low.
cient.
Monitor the pump - Insufficient support of pipe Check for pipe vibrations in the
! function and shut down work. pump connections. Check that
if any sign of mal- the pipes are sufficiently
function is noticed. clamped.
- Air leakage into the suction line. Check the suction line for air
leakage.
A Member of the
COLFAX PUMP GROUP
ACE3
Maintenance and Service
Instruction
This instruction is valid for all ACE pump models shown on page 2
Contents Page
List of components 2
Exploded view 3
Ordering code/Service intervals 4
Sectional view 5
Useful tools/Shaft seal-assembly drawing 6
Dismantling/reassembly 7
Pressure relief valve/SealGuard 11
ACE 0620GB
June 2000
Before commencing any work, read this instruction carefully! Failure to comply with
! these instructions may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we refer to the
ACE Product description. For more information about the pumps installation, Start-up and trouble shooting
we refer to the IMO Installation and Start-up instruction for Low Pressure Pumps.
List of components
Valid for all pumps in sizes: ACE 025/032/038 Rotor diameter and Generation: L3/K3/N3
With version codes: N V B P Also valid for pump options: A101
T The version code is composed of the letters in the 4 columns.
Q Example of pump designations std: ACE 025L3 NTBP;
option: ACE 038N3 NVBP A101
Pos Denomination Q-ty G011 G012 G050 G053 G054 G057 G070 G082 Notes Explanations:
no
1010 Power rotor 1 x (x)
1020 Power rotor 1 x x G011: Rotor set
113 Key 1 x x x
122 Ball bearing 1 x x x G012: Rotor set
125 Secondary seal 1 x x x x 1
201 Idler rotor 2 x (x) G050: Shaft seal
202 Idler rotor 2 x x
351 Balancing bush 1 x x x G053: Minor kit
401 Pump body 1
416 Suction flange 1 G054: Major kit
417 Screw 8
418 Gasket to 1 x x x G057: Joint kit
suction flange
423 Gasket to 1 x x x G070: Valve element
discharge flange
427 Discharge flange 1 G082: Seal Guard kit
440 Return valve 1
451 Screw 4 Notes:
453 Screw 4 1) Version NTBP
462 Plug 1 and NQBP
462A Sealing washer 1 x x x 2) Version NQBP
463 Plug 1 only
463A Sealing washer 1 x x x 3) Including
501 Front cover 1 Gasgenerator
506 Gasket 1 x x x
509 Shaft seal 1 x x x
537 Deaeration plug 2
537A Washer 2 x x x
551 Rear cover 1
556 Gasket 1 x x x
557 Plug 1
557A Washer 1 x x x
605 O-ring 1 x x x x
608 Valve spindle 1 x x
608A Tension pin 1 x x
6120 Set screw 1 x x
613 Pin 1 x x
614 Valve piston 1 x x
615 Valve spring 1 x x
7310 Compl. Seal 1 x 2,3
Guard
732 Gas generator 1 x 2
ACE 0620GB 2
June 2000
Exploded view
202
1020
113
351
122
509
462
462A
417 416
418
427
xVxx
453
423
xTxx
xQxx
551
537 556
537A
(608A)
440 (605)
506 (608)
537A 537
(6120)
(613)
557A 557 (615)
(614)
125 501 7310
732
xTxx, xQxx xQxx
xQxx
Fig. 1
All work carried out on the pump has to be When handling liquids which may involve
! performed in such a manner that risks for ! fire hazards appropriate precautions to
personal injury are observed! avoid danger are to be taken.
When handling liquids that may harm skin In case of failure for a system with elevat-
! use gloves and/or protective clothing. ! ing pressure fluid jets may cause injury
and/or damage.
Before any maintenance work, ensure that
! the driver is deenergized and the pump Oil leakage may make the floor slippery
hydraulically isolated. ! and cause personal injury.
3 ACE 0620GB
June 2000
Ordering code
Part numbers for pump size
Item Spare Parts sets 025 032 038 Recommendation:
For maintenance the following spare
G012 Rotor set CW-rotation (std) part sets are recommended:
Low lead-L3 190486 190485 –
Low lead-K3 – – 190482 Set: To be used:
Normal lead-N3 190487 190484 190483 G057 Joint kit
G011 Rotor set CCW-rotation For dismantling the pump.
Normal lead-N3 190492 190491 190488
G050 Shaft seal-xVxx 189964 189964 189964 G053 Minor kit
Shaft seal-xTxx 190495 190495 190497 For service.
Shaft seal-xQxx 190495 190495 190497
G054 Major kit
G053 Minor kit-xVxx 190501 190710 190500 For repair after damage or greater
Minor kit-xTxx 190503 190712 190499 wear.
Minor kit-xQxx 190503 190712 190499
G054 Major kit=G012(G011)+G053+G070
Ordering example:
G057 Joint kit-xVxx 190525 190714 190522 For IMO-pump ACE 032N3 NVBP,
Joint kit-xTxx 190524 190713 190523 serial number 456789:
Joint kit-xQxx 190524 190713 190523 Shaft seal pos G050 p/n 189964
G070 Valve element 189873 189873 189873 Valve element pos G070 p/n 189873
G082 Sealguard-kit xQxx 190526 190526 190527
125 Secondary seal xTxx, xQxx 190469 190469 190468
732 Gas generator xQxx 190530 190530 190530
ACE 0620GB 4
June 2000
Sectional view
C-C E-E
463 463A
732
7310
537 537A
(xQxx)
Fig. 2
5 ACE 0620GB
June 2000
Useful tools
d
Fig. 3
Fig. 4
ACE 0620GB 6
June 2000
Dismantling
B.
A. OFF ON
ATTENTION
Use appropriate vessels to collect oil spill- • Note the position of the shaft coupling.
age when removing and opening the pump.
• Release the stop screw.
Fig. 5 Fig. 6
C. D.
113
Fig. 7 Fig. 8
E. F. 1020
451
5011
Fig. 9 Fig. 10
7 ACE 0620GB
June 2000
G. H. xTxx and xQxx
501 125
501
1020
Fig. 11 Fig. 12
I. J. xVxx
xTxx
xQxx
501
xVxx
Fig. 13 Fig. 14
Fig. 15 Fig. 16
ACE 0620GB 8
June 2000
Reassembly
B.
A. • Un-pack a new shaft seal 509.
202
S8
xVxx xTxx, xQxx S8
S6 S6
S4 S5
401
• Lubricate S4,S7
the idler rotors 202 • Check that the O-ring S6 is in place.
and fit them into the pump body 401.
Fig. 17 Fig. 18
Oil can
C. xVxx D. xTxx and xQxx
S5 Emery
122
• Polish the power rotor shaft
1020 with a fine emery and oil.
• Fit the carrier S5 tight against the
ball bearing. Make sure the carrier
is not fitted upside down.
Rotating
• Firmly tight the two stop screws S8. member
• Lubricate the O-ring S6 in the rotat-
ing member with oil.
• Polish the power rotor shaft
• Press the rotating member S4, S7
1020 with a fine emery and oil.
gently on to the rotor shaft and make
• Fit the rotating member above sure the driving lugs enters the slots
the ball bearing 122 and lock it in the carrier S5.
with its stop screws S8.
Fig. 19 Fig. 20
1020
Tool 1 1 2 Tool 2
125
401 • Press the Secondary
seal 125 in place with
a suitable tool in two
steps as shown. Use a
column drill machine
as a press tool.
NOTE! 501
Tool nr 2 has
one end for sizes
025, 032 and one
• Insert the Power rotor 1020 into the pump
body 401. end for size 038
Fig. 21 Fig. 22
9 ACE 0620GB
June 2000
G. xVxx H. xTxx and xQxx Tool 1
Tool 1
S1
• Fit the spring unit S7 in place. • Fit the retainer S3 S2
Note the position for the Seat S1 in place. Note the
slots and lugs. position for the S3
S2 501
(See fig 4.) retainer lugs and
• Lubricate the O-ring S7 cover slots.
501 (See fig 4.)
S2 and put it on the
seat S1. Fit the seat • Lubricate the
S1 on top of the O-ring S2 and
spring unit. Watch put it on the
position of the Seat seat S1. Fit the seat S1
slots and lugs. on top of the retainer.
(See fig 4.) Watch the position of the seat
• Press the seat gently into the recess in the slots and lugs. (See fig 4.)
front cover 501 with a suitable tool as • Press the seat gently into the recess in the
shown. front cover 501 with a suitable tool as shown.
• Turn the front cover 501 up-side down. The • Turn the front cover 501 up-side down. The
seat shall now remain in the cover. seat shall now remain in the cover.
Fig. 23 Fig. 24
I. J.
451
501
Fig. 25 Fig. 26
K. L.
• Press on the shaft coupling
to its original position.
• Tighten the stop screw.
Fig. 27 Fig. 28
ACE 0620GB 10
June 2000
453
Pressure relief valve
551
ATTENTION
Spring tension.
SealGuard
Version code N Q B P
Recharging
1) Disconnect the pipe connector (4) from the ATTENTION 9
0 12
6
1 3
dispenser (2). Remove the check valve (3). The SealGuard can be
readjusted or switched off
2) Remove the cover disk (10). Remove the gas Gas generator
during operation.
generator (9) from the dispenser (2) with a 21 10
Depending on temperature
mm socket. Dispose the generator in the recyc-
and setting, it can take from 9
ling system for batteries, where available. Push
hours to a couple of days
the piston to its ”filled” position, and fill the
after starting, until oil is 2
dispenser with high-temperature resistant engine
being dispensed.
oil. Fit the check valve (3) and the connector (4)
to the dispenser.
1
3) Feed oil into the hose (5) and seal compartment,
For more information about
for example with an oil-filled grease gun. Recon-
SealGuard, read the Installa-
nect the hose (5) to the connector (4). 3
tion and start-up Instruction
4) Fit a new gas generator (9) to the dispenser (2). for SealGuard. 4
Tighten with approx. 2 Nm. Clip on the cover
disk (10). Note!
Must be open
5) Turn the gas generator set knob (3 mm Allen
key) to no. 6 which will make the oil last for
about 3 months.
5
NOTE!
For longer periods of stand-by, the gas gene-
rator set-knob could be set to zero to avoid
unnecessary oil consumption. 8 7
6
11 ACE 0620GB
June 2000
Screw pumps
ACG/UCG
Maintenance and Service
Instruction
ACG1 © IMO AB
This instruction is valid for all ACG/UCG pump models shown on page 2
Contents Page
List of components 2
Exploded view/Ordering code 3
Service intervals 4
Shaft seal/Service for ball bearing 4
Lubricating intervals/Useful tools 5
Inspection of rotors 5
Sectional view 6
Dismantling 7
Reassembly 9
Pressure relief valve 11
ACG 0620GB
September 1999
Before commencing any work, read this instruction carefully! Failure to comply
! with these instructions may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we refer to the
ACG/UCG Product description. Fore more information about the pumps installation, Start-up and trouble
shooting we refer to the IMO Installation and Start-up instruction for low pressure pumps.
List of components
Valid for all pumps in sizes: ACG/UCG 045/052/060/070; Rotor diameter and generation: K6/N6
With version codes: I T B E Also valid for pump options: A020, A101, A327
N V F O Example of pump designations
R P std: ACG 045N6 IVBP; option ACG 070N6 IVBO A101
G
ACG 0620GB 2
September 1999
Exploded view
551 453
462A
608A
462 601
401 602
556 480
537 453 605
5010
537A
608
462
612
506 462A
451 615
462 631
607 614
124A 122 120
606
124
520
133 xxxO/xxxP
509
CW rotation 201
ACG3 © IMO AB
113
Fig. 1
Ordering code
Pos Spare parts sets Part numbers, sizes Recommendation:
No 045 052 060 070 For maintenance the
following spare part
Rotor set CW-rotation (std): sets are recommen-
G012 Normal lead - pump version N6 178913 179507 179515 179523 ded:
" Low lead - pump version K6 187542 187559 187567 187575 Set: To be used:
G057 Joint kit
Rotor set CCW-rotation (non-std): For dismantling of
G011 Normal lead - version N6 186478 186486 186494 186502 the pump
Low lead - version K6 189641 189642 189643 189644
G050 Complete shaft seal - version code xVxx 190335 190336 190338 190340 G053 Minor kit
” ” - version code xTxx 174094 174102 174110 174128 For service
G053 Minor kit - version code xVxx 189196 189198 189200 189202 G054 Major kit
” ” - version code xTxx 189197 189199 189201 189203 For repair after
G054 Major kit=G012(G011)+G053+615 - - - - damage or greater
wear.
G057 Joint kit 179531 179549 179556 179564
Ordering example:
G070 Valve element - version code xxxP/G 190201 190201 190202 190202 For IMO-pump ACG 045N6
” ” - version code xxxO 190200 190200 190203 190203 IVBP, serial number 456789
Shaft seal
615 Valve spring - version code xxxP/G 074294 074294 074302 074302
pos G050 p/n 176198
” ” - version code xxxO 157370 157370 157388 157388
Valve spring
Fig. 2 pos 615 p/n 074294
3 ACG 0620GB
September 1999
Service intervals Inspection of shaft seal
The intervals for inspection and replacement of wear As the seal faces of a mechanical shaft seal are
parts vary greatly with the properties of the pumped lubricated by the fluid a certain leakage will always
liquid and can only be determined by experience. be present. Ten drops per hour can be considered as
All internal parts of the ACG-pump are lubricated acceptable.
by the pumped liquid. Pumping liquid which An external visual inspection of the pump is advis-
contains abrasive materials, or liquid that is corro- able at least every two days to assure that the shaft
sive, will significantly reduce service life seal is not leaking too much.
and call for shorter service intervals. Excessively leaking shaft seals should be changed
Wear in the pump may be indicated by: without delay, as the leakage normally will grow
• Vibration worse and cause additional damage.
• Noise Follow the instructions in the dismantling/reassem-
bly session.
• Loss of capacity
When working with a shaft seal, cleanliness is of
• Reduction in flow/pressure utmost importance. Avoid touching the seal faces. If
• Leakage necessary, the seal faces should be cleaned immedi-
In installations where unplanned shut downs must ately prior to assembly, using a dustfree cloth and
be avoided, it is advisable to have a complete pump clean solvent.
available for replacement, should any malfunction Never use grease on the seal faces.
occur. Furthermore we recommend planned inspec-
tion and overhaul at regular intervals, not exceeding Connecting and disconnecting of electric
3 years. ! cables must be done only by personnel
It is recommended always to have the spares in- authorized to do such work.
cluded in minor spare part kit available.
If the pumps operating temperature exceeds
All work carried out on the pump has to be ! 60°C let the pump cool off before any
! performed in such a manner that risks for service, maintenance or dismantling work is
personal injury are observed! commenced to avoid burn injury.
S2 O-ring
Version code xVxx S4 Seal ring
S5 Bellows unit
S2 S1 S4 S5
Fig. 3
ACG 0620GB 4
September 1999
Lubricating intervals in working hours
Temp Pump sizes 045 and 052 Pump sizes 060 and 070
max Grease Speed, r/min Speed, r/min
°C type 3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950
70 A 8500 10000 10000 10000 10000 10000 7500 8500 10000 10000 10000 10000
90 A 3350 3950 5350 5950 6350 7500 2950 3350 4750 5150 5950 6750
110 B 2650 3150 4250 4700 5000 5950 2350 2650 3750 4100 4700 5350
130 B 1050 1250 1650 1850 2000 2350 900 1050 1500 1600 1850 2100
155 C 650 750 1050 1150 1250 1500 600 650 950 1000 1150 1300
*) at rotation speed > 3 500 r/min special instructions are given by IMO AB.
Recommended greases (the availability of the greases can differ locally):
Type A: BP Energrease LS 3, Esso Beacon 2, Mobilgrease HP 222, Shell Alvania G3, Texaco Multifak EP2, SKF LGMT2,
Q8 REMBRANDT EP2, CASTROL APS2, ELF ROLEXA 3, TOTAL MULTIS TIR EP3, FINA MARSON L3.
Type B: BP Energrease LC2, CHEVRON SRI GREASE 2, Esso Unirex N3, Mobilith SHC220, SHELL RETINAX LX,
SHELL Albida LX, VAL-PLEX EP GREASE, Texaco Hytex EP2, SKF LGHQ 3, Q8 RUBENS, CASTROL LMX,
INDUSTRIAL GREASE HEAVY, TOTAL MULTIS THT2, FINA PLUTON L2.
Type C: Mobilith SHC 460
Before any maintenance work, ensure In case of failure for a system with elevated
! that the driver is deenergized and the ! pressure, fluid jets may cause injury and/or
pump hydraulically isolated. damage.
Fig. 4
5 ACG 0620GB
September 1999
Sectional view
506 440 556
(502) 602
520A 605
520 612
122 615
124A 608
124 614
1020 631
133 480
514 462
520 462A
359 607
451 606
537 537A
Version xxBO and xxBP
Version xxBO and xxBP
608A
601
602
556
605
551
612
462A 615
424A 462 608
424 614
437 480
ACG5 © IMO AB
ACG6 © IMO AB
429 631
607
556 606
Option A327 Version xxxE Version xxxG
Fig. 5
ACG 0620GB 6
September 1999
Dismantling
A. B.
• Turn the
electricity OFF.
ACG10 © IMO AB
ATTENTION
Use appropriate vessels to collect oil spill- • Note the axial position of the shaft coupling.
age when removing and opening the pump.
• Release the stop screw.
Fig. 6 Fig. 7
C. D.
113
Fig. 8 Fig. 9
E. F.
133
451
520
4 mm 124
• To remove the dust
124A
protection ring 133
520A
514 and the cover 520,
lift the cover 520
with two screw
drivers from the
shaft.
ACG13 © IMO AB
and 514.
• Remove the sup-
• Remove the screws 451 and 520A. port ring 124A.
Fig. 10 Fig. 11
7 ACG 0620GB
September 1999
G. H.
122
120
359
359A
puller.
5010 tight fit use a mount-
ing sleeve and a
mallet.
ACG16 © IMO AB
Fig. 12 • Remove the distance
washer 359 and the
Mounting support ring 359A.
I. sleeve
Fig. 13
S1
S2
No tools
J – xVxx.
506 from this Shaft seal S4
side
5010 Version xVxx
S5
The sealing
! surfaces of the S4
shaft seat
ACG17 © IMO AB
should not be S5
touched with
the fingers.
again.
ACG19 © IMO AB
Fig. 16 Fig. 17
ACG 0620GB 8
September 1999
Reassembly
A. B–xVxx.
202
Version xVxx • Carefully place the
• Lubricate the power rotor 1020
idler rotors and into the jaw vice
fit them into the with soft jaws.
pump. • Lubricate all
Lubrication S4 surfaces of the
groove turned power rotor 1020.
ACG21 © IMO AB
downwards. S5
• Open a package
with a new sealing
509, version xVxx.
1020
• Place the bellows
Fig. 18
S5 and the seal
ACG22 © IMO AB
ring S4 on the shaft
of the power rotor
B–xTxx. 1020.
Version xTxx
• Open a package
with a new shaft Fig. 19
seal 509 version
xTxx.
• Lubricate the O-
S4 • Place the seal ring
S6 ring S2 and the
carrier S5 on the C.
S5 recess of the front
shaft of the power
cover 5010.
rotor 1020 flush S1
Balance against the bal- • Clean the sealing
piston ance piston and S2 faces and fit the
lock it with its seat S1 into the
stop screws. Fit front cover 5010.
Mind the position
ACG24 © IMO AB
Fig. 20 Fig. 21
D. Mounting sleeve
122
120 Grease • Lubricate the balance piston 106 with a
thick oil (ISO VG 460).
359 • Fit the front cover 5010 on the power rotor
1020 and press the shaft seal 509 into place
359A with the front cover 5010.
• Fit the support ring 359A and the distance
5010 washer 359 into the front cover. Mind the
1020 position of the distance washer 359.
• Fit the distance sleeve 120 into the front
cover 5010.
106
• Lubricate the new ball bearing 122 and
press it into the front cover 5010 with a
mounting sleeve. Make sure that the power
rotor is standing on firm support.
Fig. 22
9 ACG 0620GB
September 1999
E. 133
520
• Fit the support ring 124A and the retain-
124 ing ring 124 on the shaft.
124A • Fit the retaining ring 514 back in place.
• Place the cover 520 and the dust protec-
514 tion ring 133 on the shaft according to the
dimensions A above. If there is a tight fit
use the mounting sleeve, see page 5.
G26 © IMO AB
Fig. 23
F. G.
520A Pump size A A
045-052 4.0 mm
060-070 4.5 mm
• Fit the screws
520A and
tighten them
crosswise. ACG27 © IMO AB
ACG28 © IMO AB
133
Fig. 24 Fig. 25
Fig. 26
I. 537
537A
• Remove the plug 537 and washer 537A.
• Hold the rotor unit horizontally with the
bore for 537 upwards. Carefully fill the
space completely with thin oil
(f. ex. ISO VG 46).
• When the oil is flooding, reassemble the
above parts in reverse order.
1020
• Slowly turn the shaft a few turns to make
sure it moves freely (a certain resistance
5010 from the shaft seal is normal but it must be
the same during the turns).
Fig. 27
ACG 0620GB 10
September 1999
J.
• Place the gasket 506 on the pump body 401.
• Lubricate the power rotor 1020 and fit the
451 front cover 5010 together with the rotor set
into the pump body. Mind the position of
the tension pin 545.
5010
• Fit the screws 451 and tighten them cross-
wise.
1020
506
ACG29 © IMO AB
401
Fig. 28
K.
• Put the pump back into the system and
proceed according to instructions under
”Start-up” in the installation manual.
Fig. 29
Fig. 30
11 ACG 0620GB
September 1999
IMO AB: P.O. Box 42090, S-126 14 STOCKHOLM, Sweden. Telephone: + 46 8 50 622 800
Telex: 11548 IMO S, Telefax: + 46 8 645 15 09, E-mail: info@imo.se
Valve block for dual pump installation
In all application were there is a demand for two pumps, either for redundancy or for operational
reasons, a valve block is an option to save space and installation cost.
The valve block can be equipped with IMO ACE series of pumps that have a flow range up to
11 m3/h.
The valve block is a substitute for a number of components normally installed in a dual pump
application such as:
• Welding joints
• Shut off valves on in and outlet side
• Non return valves
• Strainers
• Pressure gauge adapters
System drawing of the T5 Valve Block. In a conventional system each component has to be added
manually
11
10
8
2
7 6 5
Components
The block is equipped with inlet and outlet ports on both sides; hence there are several options for
inlet outlet configurations. The valve block is delivered with one set of inlet - outlet flanges and
one set of blind flanges.
The inlet and outlet chambers are equipped with a shut off valves regulated by an Allen key if one
of the pumps or the filter has to be removed during operation. The shut off valves on the outlet side
are a combined non return valve that prevents reversed flow through the non operating pump.
Before the inlet of the pump, flow passes through the filter chamber equipped with 500 µm
strainers. The covers for the filter chambers are equipped with de-pressurizing plugs and a
protection cover to avoid opening when the chambers are pressurized.
In the lower end there is a drainage plug to drain the valve block in case of service or inspection.
Cross section of the T5 Valve Block showing the inlet flow passing by the open shut off valve
through the strainer and into the pump. From the pump the flow is transported to the outlet side
were the combined shut off/non return valve is located.
Operating modes
VZO / VZOA
VZF / VZFA VZE / VZEA
Transducer Ancillary modules
130°C / 180°C 70°C / 130°C / 180°C
Flow sensors
130°C / 180°C
CONTOIL® oil meters consist of a flow sensor and a measurement transducer with display, totaliser and signal
outputs where applicable. The flow rate range determines the nominal size of the flow sensor. The measurement
transducer is either one complete ("universal") unit (e.g. VZF) or is a combination of ancillary modules (transducer
group) which can be chosen to suit a particular application ( VZO, VZE).
The flow sensor and the measurement transducer are calibrated jointly and form one metering unit.
If the measurement transducer is replaced at a later stage, a certain divergence in measured values is to be
expected.
Supplementary Instructions
Part number
Mounting instructions
20288
CONTOIL® DN15 … 50
Operating instructions
20312
CONTOIL® classic: VZO / VZOA, standard: VZE / VZEA
Operating instructions
20313
CONTOIL® control: VZF / VZFA
Conversion Kit for CONTOIL® classic and standard to VZF
20328
VZFA / VZEA / VZOA max. 130 °C 1 20003 20005 20008 20011 20013
Guide roller VZFA / VZEA / VZOA max. 180 °C 1 13146 19391 13147 13148 13149
VZF / VZE / VZO max. 130 °C 1 20004 20006 20009 20012 20014
VZF / VZE / VZO max. 180 °C 1 19163 19763 19164 19165 19166
PN 16 1 -- 19007 -- -- --
Measuring chamber PN 25 1 12841 19032 12851 19551 19506
PN 40 1 12842 19387 12844 19550 19507
DN 40, DN 50:
When replacing a measuring chamber with integrated flange by the current version, the two
following positions (flange and screws) are needed too. See remark on page 3.
PN 16 1 12874
Flange of measuring chamber PN 25…40 1 12877
PN 16…40 1 -- -- 12978 19547 19508
M 6 x 16 PN 16 4 12958 -- -- -- --
Screws M 6 x 16 PN 25/40 6 12958 -- -- -- --
M 6 x 12 PN 16 4 -- 19035 -- -- --
M 6 x 16 PN 25/40 6 -- 12958 -- -- --
M 8 x 25 6 -- -- 13101 -- --
M 12 x 40 8 -- -- -- 19548 --
M 16 x 50 10 -- -- -- -- 19549
Screw torque
Nominal size DN 15 DN 20 DN 25 DN 40 DN 50
Screws M6 M6 M8 M 12 M 16
Screw torque 6 Nm 6 Nm 16 Nm 47 Nm 100 Nm
Conversion Kit
Conversion kit CONTOIL to VZF130 / 180 °C 1 20319 20320 20321 20322 20322
(incl. manuals)
This conversion kit upgrades the VZO(A) or VZE(A) to the VZF version to take full advantage of
all the functions offered by the new transducer.
Modifying a Meter
All ancillary modules are to be replaced. The flow sensor remains in place throughout.
A power supply of 6 to 30 V DC is required.
The electronics has preset values for each nominal diameter being used. Individual preadjustment to a particular
hydraulic sensor must be carried out by personnel installing the kit.
The electronic and insulation modules are a single unit. Modifying a meter invalidates any type approval that may
have been issued. (Exception: type approval for ships. GL, DNV and LRS remain valid). Modifying a meter used in
custody transfer applications is not permitted.
or
or
Head ring RV, without sight glass 1 13070 13070 13070 13070 13070
RV 0.1 l 1 40248
Roller counter, litres RV 1 l 1 40249 40251 40253 40240
RV 10 l 1 40241 40242
RV 100 l 1 40243
or
RV 10ppg 1 40261 40262
Roller counter, US gallons RV 1ppg 1 40263
RV 0.1ppg 1 40264 40264
or
Head ring RV, without sight glass 1 13070 13070 13070 13070 13070
RV 0.1 l 1 40238 -- -- -- --
Roller counter, litres RV 1 l 1 40239 40245 40240 40240 --
RV 10 l 1 -- 40246 40241 40241 40242
RV 100 l 1 -- -- -- -- 40243
or
RV 10ppg 1 -- -- -- -- --
Roller counter, US gallons RV 1ppg 1 -- -- -- -- --
RV 0.1ppg 1 -- -- -- 40264 40264
or
or
Options
Isolating piece (incl. screws and extensions) 1 13172 13172 13172 13172 13172
Housing and sealing face
Positioning of rotary piston within measuring chamber
Positioning of driver within cover of measuring chamber
Positioning of cover and measuring chamber
Location of Gaskets
Positioning of housing onto measuring chamber
Safety notes
⋅ The applicable working regulations must be complied with during all work on the plant
⋅ When removing from pipe or reinstalling, safety instructions in the operating manual must be observed.
⋅ Extra caution is required when using inflammable cleaning substances. Room must be ventilated well.
⋅ Prior to disassembly, the measuring instrument must be free from dangerous or noxious residues. Clean and
rinse thoroughly as necessary.
Instruction Manual
TM
for VESTA MX
Table of contents for instruction manual
1. General Description......................................................................................... 1
2. Installation Space Requirements ..................................................................... 2
3. Storage............................................................................................................. 2
4. Mounting and Installation ............................................................................... 2
5. Connecting the Heat Exchanger ...................................................................... 3
6. Operation ......................................................................................................... 3
7. Conservation during shut down periods .......................................................... 4
8. Maintenance and Cleaning .............................................................................. 4
9. Dismantling and reassembling of the tube section .......................................... 5
10. Safety measures ............................................................................................... 5
11. Spare Parts ....................................................................................................... 6
Appendix:
- Spare Parts Drawing
- Dimensional Drawing
1. General Description
Aalborg Industries' Vesta MX heat exchangers are of the shell and tube type with
u-tubes.
The Vesta MX heaters range from 0,5 m² to 60 m² heating surface with design
pressures 16 or 30 BAR.
Other capacities may be manufactured at request.
All heaters may be delivered as immersion or outflow heaters for insertion in
tanks.
Vesta MX heat exchangers are primarily used as fuel oil, lubrication oil, or water
heaters (JCW).
INSTRUCTIONS FOR SHELL & TUBE HEATER
The heating media used is either steam, hot water or thermal oil.
3. Storage
3.1. Damp and humidity
Store the heater only in a dry storage room before installation. If the room is
damp the heater must be isolated with bags of silica gel. To avoid damage it is
recommended the heater be stored in the original packaging.
If the heater is placed vertically the inlet and outlet tubes as well as the media
inlet must be at the bottom and the heater must be equipped with an air escape
screw at the top end.
The steam regulator (optional) must always be placed horizontally.
The steam trap (optional) should be mounted as close to the condensate outlet as
possible and somewhat lower. The steam trap is always to be placed horizontally.
Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts into the holes and tighten up at one end, while the other is left suffi-
ciently loose to allow for movement caused by thermal expansion. The bolts at
the expansion end must be secured with counter nuts.
6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securely
tightened.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.
Heater main flange bolts tightening schedule (dry & smooth values) – T30 types
No bolts Size Torque [Nm] Tightening schedule
MX15 8 M16 164 14725836
MX20 12 M20 158 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M20 234 1 7 11 4 9 2 6 12 5 10 3 8
Always use a torque wrench when tightening the flange bolts.
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.
6.4. Output
The output of the heater is subject to the supply of heating media at the inlet
steam valve. The steam pressure/heating media temperature applied, is to be ac-
cording to heater size calculation.
The output is furthermore subject to correct type of steam trap being used. Cor-
rect layout of the condensate system avoids negative effect of counter pressure.
10.1. Installation
10.1.1. Lifting
When lifting the heat exchanger, following methods are allowed:
a) Two or four point lifting with straps and shackles in the holes or lifting lugs
on the mounting brackets.
b) Two point lifting with wide support straps around the heater body.
Other ways of lifting the heat exchanger may damage it or cause risk of dropping
it.
10.1.3. Insulation
The heat exchangers are delivered with thermal insulation according to the scope
of supply stated in the contract. The main flanges are not insulated, since the
class stamps are placed on the rim of the flanges, neither are branch pipes, noz-
zles or connecting flanges, since this would hamper the installation process. In-
sulation of these parts should be completed during the commissioning phase,
Aalborg Industries recommend an insulation thickness of 50 mm mineral wool or
equivalent heat barrier. Any insulation delivered with the heat exchanger is de-
signed for a maximum surface temperature of 60°C at engine room conditions,
so no special warnings of hot surfaces is required.
10.2.2. Maintenance
During disassembly, inspection, reassembly and testing it is important that safety
measures of this manual as well as the ships safety procedures are observed. The
fluids in the systems can be both hot and flammable as well as posing a health
risk if ingested. Therefore it is important that proper depressurising, isolation and
draining is performed, as well as spillage control during disassembly and clean-
ing. Procedures for reassembly must be followed and the mandatory pressure test
be carried out with great care. Insulation and splash guards must be fitted during
recommissioning.
Type 6.72.1
Nominal diameter DN 65
Filter element Filter candle
Print document on both sides
NOTE:
Siemensstraße 10 - 14
50170 Kerpen
Germany
www.bollfilter.de
1/72
2 / 72 Operating instructions 6.72.1
Betriebsanleitung 6.72.1
Table of Contents
1 Preamble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Obligations of the user/operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Selection and qualifications of staff . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.2 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.1 Filtered media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Overview of automatic filter assembly group . . . . . . . . . . . . . . . . . . 15
5.3 Overview of bypass filter and plug valve circuit assembly group. . . 19
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.1 Floor fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.2 Installation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.3 Identifying the flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.4 Filter inlet/outlet pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.5 Flushing oil outlet pipe connection. . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.6 Filter heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.7 Connection of compressed air supply . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.9 Potential equalisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1 Functional description of the automatic filter . . . . . . . . . . . . . . . . . . 29
7.1.1 Filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.3 Differential pressure monitoring system . . . . . . . . . . . . . . . . . . . . . 29
7.1.4 Air tank and flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.5 Pivoting actuator (pneumatic) with limit switch . . . . . . . . . . . . . . . . 32
7.1.6 Flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
These operating instructions are for the user of the filter and the user's staff. They
contain text and drawings which, without the express permission of the
manufacturer must not be
• reproduced,
• distributed or
• otherwise made available to others, either in full or in part.
Failure to comply will require compensation.
DANGER!
Denotes immediate hazard with high risk which will cause death or serious
physical injury if not avoided.
WARNING!
Denotes possible hazard with medium risk which may cause death or serious
physical injury if not avoided.
CAUTION!
Denotes a hazard with low risk which could cause light or medium physical injury
or material damages if not avoided.
NOTE
Denotes special user tips and other particularly useful or important information.
DISPOSAL
Denotes special measures for environmental protection.
2.6.1 General
• Follow the respective valid national and international regulations for the
prevention of accidents.
• Adhere to the maintenance tasks and intervals set out in the operating
instructions, including instructions on the replacement of parts/equipment.
• Only use original spare parts.
• If the filter is subject to a regular inspection by an inspection and testing
organisation, with regard to temperature, steam pressure and the
dangerousness of the medium, the inspection periods must be adhered to by
the user.
2.7 Consumables
• Observe the regulations for environmental protection. Make sure that
consumables are disposed of properly and in an environmentally friendly
manner.
• When handling media which are to be filtered, make sure you follow the
respective safety regulations for the media.
• When handling the cleaning agents, make sure you follow the respective
safety regulations for the cleaning agents.
3.2 Storage
CAUTION!
Improper storage will cause damage to the filter and filter elements
If stored incorrectly and improperly, moisture and contamination, for example,
may cause damage to the filter and the filter elements.
• Protect the filter and filter elements from moisture and contamination during
storage.
• Do not store the filter and filter elements below the frost line.
• If the filter and the filter elements have been stored for more than one year,
check that all seals are fully functional before installation.
DISPOSAL
Observe the regulations for environmental protection. Make sure that the
packaging material is disposed of properly and in an environmentally friendly
manner.
NOTE
You will find the technical data in the appendix of these operating instructions.
NOTE
When making enquiries or ordering spare parts, always provide the information
on the type plate.
12 2
11
10 8
NOTE
Depending on the filter configuration, the differential pressure monitoring system
can be fitted to the bypass filter, see section 5.3.
NOTE
In conjunction with a bypass filter, the shut-off valve are positioned on the plug
valve switch-over circuit, see section 5.3.
3
6
N1
5
N2
N4
N5 N3
1 2 3 4
8
7
9
14
N1 10
11
12
14
N2 7
N4
N5
13
Fig. 5-5 Overview of assembly groups (view II, with differential pressure signal)
NOTE
Contact the manufacturer with any special questions you may have regarding
installation. The contact data for the respective national subsidiaries can be
found in the appendix of the operating instructions.
DANGER!
Combustible medium
When filtering combustible medium expelled medium may cause fires and
personal injuries.
• Adhere to the valid fire safety regulations when carrying out any work on the
filter.
A B
1 3 2 3
A B
1 2 3 3 2
Fig. 6-2 Bypass filter, floor fastening
2
3
6
8
7 6
NOTE
• The filter inlet/outlet and flushing oil outlet are indicated by the inscriptions
(Ein/In), (Aus/Out) and (Spülölaustritt/Flushing oil).
• The direction of flow is also shown in the technical data sheet which is
included in the appendix of these operating instructions.
NOTE
BOLL & KIRCH Filterbau GmbH recommends installing shut-off fittings in the
piping in front and in back of the filter.
X Establish the connection between the flushing oil outlet and piping.
X Welded joints must be made in line with the valid regulations.
X Use the appropriate seal.
X Select a pipe cross section which is at least equal in size to the pipe cross
section shown in the technical data sheet. A cross section which is too small
may cause backpressure. The pipe must also be laid with an inclination and
bled.
X The pipe may need to be provided with additional supports, depending on the
installation conditions. When installing the piping, the filter housing must not
be twisted.
The filter heating is used during the filtering process to cover heat loss in the filter
and before starting up the plant in order to heat up the medium in the filter. The
filter can be heated with water vapour, hot water or thermal oil.
DANGER!
Risk of accidents from expelled hot medium
Too much pressure in the heating system can cause hot medium to be expelled
and lead to damage to the filter and accidents.
• Adhere to the maximum permitted operating temperature and operating
pressure for the filter heater.
X Connect the medium-carrying pipes to the filter heating on the plant side.
X Welded joints must be made in line with the valid regulations.
X Use the appropriate seals.
X The pipes for the heating medium inlet and outlet may need to be provided
with additional supports, depending on the installation conditions. When
installing the piping, the filter housing must not be twisted.
2
3
1 Air tank
2 Ball valve
3 One-way restrictor valve
X Connect the plant's compressed air supply line to the one-way restrictor
valve on the ball valve.
DANGER!
Risk of accidents from electric shock
When connecting to the power supply, the supply voltage can cause accidents
from electric shock.
• All the electrical connections on the filter must be made by a qualified
electrician and in line with the rules of electrical engineering.
Controller
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
NOTE
You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the manufacturer's
documentation.
NOTE
BOLL & KIRCH Filterbau GmbH differential pressure indicators have potential-
free contacts.
The filter housing, comprising the lower housing section with the filter heating or
floor fastening without filter heating (optional), the upper housing section and
filter housings, contains all the pipe connections. The flushing valve is installed
on the upper section of housing.
The filter housings are arranged around the central drilled hole for fitting the plug
valve on the upper section of housing. A cover seals the plug valve off from the
outside, The pivoting actuator is fitted to it with a spacer.
7.1.2 Controller
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
NOTE
• You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the
manufacturer's documentation.
• The differential pressure can also be displayed optically on the differential
pressure monitoring system.
• The control line for the differential pressure monitoring system is fitted with
shut-off valves (e.g. shut-off valves).
The location for installation of the differential pressure monitoring system varies
depending on the filter configuration
Optional pressure gauges allow you to quantify the differential pressure.
The optional 3-way ball valves make it possible to check that the differential
pressure monitoring system is fully functional as and when required. The levers
have to point downwards when in operation.
1
2
1 Air tank
2 Pressure gauge
3 Safety valve
4 Pressure controller
5 Solenoid valve (flushing valve)
6 Ball valve
7 One-way restrictor valve
The compressed air in the air tank expands explosively when the solenoid valve
(flushing valve) is switched and opens the flushing valve. The flow which this
causes, pushes the medium on the clean side through the filter candles in the
counterflow direction at high speed. The pressure level in the air tank can be read
from the pressure gauge and set using a pressure controller. The air tank is
equipped with a safety valve to prevent the air tank from being damaged by
excessive positive pressure.
If the pressure gradient between the dirty side and the clean side reaches a set
value due to the growing layer of dirt on the filter material, the automatic filter
chamber regeneration is triggered. The pivoting actuator turns the plug valve so
that the flow to the soiled filter chambers is shut off and, at the same time, the
stand-by filter chamber is activated. If the plug valve reaches the filter chamber
which is to be cleaned, the pivoting movement is stopped. The pivoting actuator
is actuated by a solenoid valve (pivoting actuator). The limit switch monitors the
position of the plug valve. If the plug valve is in the incorrect position, the flushing
process in the soiled filter chamber does not start.
The pneumatically actuated flushing valve opens and closes the flushing oil
outlet at the start and end of the backflushing phases respectively. After a delay,
when the flushing valve is opened by the valve tappet, the compressed air supply
for backflushing flushing from the air tank is opened. A solenoid valve (flushing
valve) regulates the supply of compressed air for actuation of the flushing valve.
N1
N2
3
11
5
10
6
N1 9
8
N2
N3
NOTE
After backflushing is complete, the next backflushing cycle (manual or triggered
by the differential pressure monitoring system) can only be started with a time
delay. This time delay is the time set on the time relay or the preset time on the
controller. It is needed to ensure that the cleaned filter chamber can be filled.
The backflushing process is completed; the cleaned filter chamber remains shut
off from the filtration process until the next backflushing process.
CAUTION!
Risk of damage to the filter from improper flushing
Flushing an only partially filled filter causes increased strain on the filter candles.
• Never perform backflushing due to installation or control circumstances in an
only partially filled filter. A completely drained filter can be flushed for test
purposes without any restrictions.
A B C
1 2 1 2 1 2
Fig. 7-5 Position of the plug valve circuit
1 Automatic filters
2 Bypass filter
A Automatic filter in operation
B Automatic filter and bypass filter in operation
C Bypass filter in operation
The switch-over is performed manually using the attachable lever. The mark
sawn into the neck of the plug valve shows the direction of flow and indicates
which filter is in operation. The construction of the circuit prevents both filters
from being shut down at the same time.
A pressure compensation valve is fitted to the plug valve switch-over circuit to
compensate pressure between the two connected filters. It is opened and closed
manually.
NOTE
The measuring points for the differential pressure monitoring system are situated
at the inlet and outlet to the plug valve switch-over circuit.
CAUTION!
Risk of damage or expelled medium if the pressure compensation is
positioned incorrectly
Depending on the operating stage, if the pressure compensation valve is in the
wrong position, medium may be expelled or damage may be caused.
• The pressure compensation valve must always remain open during
operation.
• The pressure compensation valve must only be closed when cleaning the
automatic filter or bypass filter.
1 2
1 2 3 4
The housing cover safety device has the task of preventing pressurised medium
from being expelled uncontrolledly in case of incorrect operation. The cover
sheet covers a minimum number of cover screws so that the cover cannot be
removed without opening the vent to bleed the system.
The filter chamber is relieved via the vent. When the filter is shut off, the operating
pressure is immediately relieved and hardly any medium is expelled. Otherwise,
close the vent immediately and the expulsion of medium is limited.
1
1
2 2
3
3
1 Filter candle
2 Candle holder
3 Seal
Filter inserts with filter candles are used for filtration. The flow runs from the
outside to the inside into the individual filter candles.
Particles of dirt in the flow are thus filtered off by the filter material in the filter
candles. The cleaned medium exits from the bottom of the filter candles and is
fed back into the plant.
The filter insert comprises several filter candles arranged in parallel. The filter
candles all have the same dimensions; they are interchangeable and can also be
removed separately. They are screwed into the candle holder.
The type, design and number of filter candles used depends on the medium
being filtered.
For media with a high ferrite content, the filter candle on the filter candle insert
can be replaced with an optional magnetic primary filter.
The candle holder secures the filter candles and thus protects the filter material
on the filter candles from damage during removal and installation.
The dirty side is sealed off from the clean side by a seal on the candle holder.
1
2
5
4
Star-pleated filter elements are used for filtration. The direction of flow through
the star pleated-filter element is from the outside to the inside.
Particles of dirt in the flow are thus filtered off by the star-pleated filter element.
The cleaned medium then exits from the star-pleated filter element and is fed
back into the plant.
The bypass filter is fitted with a star-pleated filter element.
The star-pleated filter element is attached with the open end on the element
support.
The dirty side is sealed off from the clean side by seal on the star-pleated filter
element.
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
CAUTION!
Risk of damage to the filter if operated without compressed air supply
If the controller is switched on and the filter is commissioned without compressed
air supply, the solenoid valves may become damaged.
• Always open the filter's ball valve first when commissioning in order to ensure
that compressed air is supplied.
NOTE
After backflushing is complete, the next backflushing cycle (manual or triggered
by the differential pressure monitoring system) can only be started with a time
delay. This time delay is the time set on the time relay or the preset time on the
controller. It is needed to ensure that the cleaned filter chamber can be filled.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
X Open the vent on the top of the housing of the bypass filter. The bypass filter
is filled via the open pressure compensation valve.
X Close the vent as soon as medium is expelled from a vent without any
bubbles.
X Carry out backflushing once more manually using the controller.
X The filter is ready for operation.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
X After each time you commission the filter, check the filter for leaks and
eliminate them as necessary.
X Allow the filter to operate for 24 hours with differential pressure and record
the number of flushes from the flushing cycle counter or the controller. In
order to allow the filter to operate for 24 hours with differential pressure, you
have to deactivate the intervals for forced flushing on the controller.
X Calculate the average of all flushing intervals.
X Reset the flushing interval time (which should be 30 % shorter) on the
controller.
NOTE
When using the filter in watery media, it is imperative to adhere to the following:
• Do not allow the filter to run to empty after switching off the supply pump. Dirt
may otherwise be allowed to harden.
• If the above condition cannot be met, set the controller so that backflushing
is triggered every 2 hours even if the supply pump is switched off.
NOTE
When removing the filter and taking it out of service for longer periods, pay
attention to the following points:
• The filter must be completely emptied.
• Disconnect all connections from the filter.
• The filter must be thoroughly cleaned.
• The filter must be sealed by applying an appropriate anticorrosive, if
necessary.
• The connection flange openings must be sealed with plastic (or similar)
dummy plugs.
7.7.3 Disposal
DISPOSAL
When the filter or individual components and consumables are finally disposed
of, make sure that they are disposed of in an environmentally friendly manner.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
You can tell that the filter elements are becoming increasingly blocked because
the flushing intervals become shorter and shorter.
The number of backflushing cycles performed is recorded by the controller.
CAUTION!
Risk of damage to the filter and the plant from damaged filter elements
If the flushing intervals suddenly become longer, this may indicate that the filter
elements are damaged.
• In such an event, check all filter elements for damage immediately. Replace
any damaged filter elements as necessary.
NOTE
The filter elements are subject to wear from two-way strain. It is therefore
recommendable to keep a complete set of filter elements in stock.
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
X Set the key on the plug valve switch-over circuit to the "Bypass filter in
operation" position. The bypass filter is thus in operation.
X Close the pressure compensation valve.
X Trigger backflushing on the controller.
X Afterwards, close the ball valve for the filter's compressed air supply.
X Then, carry out manual backflushing for the filter chamber which has not yet
been flushed.
X Switch off the controller.
DANGER!
Risk of accidents due to controller being switched on unintentionally
During maintenance accidents may be caused if the controller is switched on
unintentionally, e.g. by starting up the drives or from expelled medium.
• Secure the controller to prevent it from being switched on unintentionally, e.g.
by attaching a lock.
X Check the pressure gauge to establish whether the air tank is genuinely
depressurised.
X The filter chambers are now drained and depressurised.
CAUTION!
Risk of accidents from hot components
Hot surfaces can cause serious injuries if touched.
• Take the filter heating out of operation and allow the filter to cool down.
• Wear the appropriate safety clothing.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the filter chamber.
• Depressurise and lower the level of medium before removing the filter insert.
1 Venting line
2 Filter housing
3 Screw
4 Upper section of housing
2
3
5
6
CAUTION!
Risk of damage to the filter elements due to improper installation / removal
for the filter housings
• When installing / removing the filter housings, proceed with extreme care.
• Use the guide pins to install / remove the filter housings.
1 Filter element
2 Candle holder
3 Seal
X Remove the filter inserts from the housing by pulling vertically upwards.
X Allow the filter inserts to drip dry in a suitable container.
CAUTION!
Risk of damage to the filter insert from improper cleaning
If the filter insert is cleaned or handled improperly, the filter insert may become
damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the "BOLL CLEAN 2000" cleaning agent must not
exceed 24 hours.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not
exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not exceed
a maximum of 60 bar. When cleaning using a high-pressure cleaner, keep a
sufficient distance (at least 20 cm) from the filter material to prevent damage.
• When cleaning the filter insert using a cleaning gun and compressed air, the
pressure must not exceed a maximum of 4 bar.
• Particles of dirt must not be allowed to enter the clean side of the filter
element.
• Do not place the filter elements on top of each other as you may otherwise
cause damage.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
X Place the filter insert in a container with cleaning agent, with the opening of
the filter elements facing downwards. This way, particles detaching from the
filter elements can sink to the bottom.
X Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
X After soaking, remove the filter insert from the container and place it on a
suitable surface (e.g. perforated plate) with openings of the filter elements
facing downwards. Allow the cleaning agent to drip dry.
X Turn the filter insert around and place it down with the openings facing
upwards.
X Blow out the filter elements with compressed air from the inside to the
outside.
X Then dip the filter insert in the container with fresh cleaning agent again, with
the openings of the filter elements facing downwards. Rinse the filter insert
through again by turning it and moving it up and down in the cleaning agent.
X Allow the filter insert to drip dry again.
X Blow out the filter elements with compressed air from the inside to the
outside.
X Then check all filter elements for damage. Replace any damaged filter
elements/seals as necessary.
X In case of heavier soiling, you can clean using the high-pressure cleaner
procedure mentioned above. For cleaning, use water or water with cleaning
agent.
In case the filter elements are heavily soiled (lacquer contamination, incrustation,
tar residue, fibres, chippings), the individual filter elements will have to be
removed and cleaned.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH
cleaning unit with rotating nozzle and flat-jet nozzle for cleaning purposes.
If you do not have a filter element cleaning unit available, proceed as follows:
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
X Place the filter insert in a container with cleaning agent, with the opening of
the filter elements facing upwards. The openings on the filter elements have
to protrude out of the cleaning agent. This prevents dirt from penetrating into
the clean side.
X Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
X Remove the filter insert from the cleaning agent. Allow the filter insert to drip
dry with the openings pointing downwards.
X Unscrew and remove the filter elements from the candle holder using the key
included in the scope of delivery.
X Then spray the filter elements through using the high-pressure cleaner with
suitable cleaning agent. First clean from the inside to the outside, then from
the outside to the inside. Repeat the process several times as necessary.
Finally, spray the filter elements from the inside to the out.
X Carefully rinse out the filter elements in fresh cleaning agent and allow the
filter elements to drip dry.
X Blow out the filter elements with compressed air from the inside to the
outside.
X Remove any particles collected on the magnetic candle (if fitted).
X Re-assembly is performed by carrying out the steps for disassembly in
reverse order. Clean the candle holder as necessary before assembly.
X Clean any soiling which has collected on the inside of the filter.
X Check all the seals for damage. Replace any damaged seals as necessary.
X Insert the filter inserts vertically into the housing from above.
X Make sure that the seals are properly in place.
1 Double nipple
2 Float ball
3 Filter housing
X Check the condition of the vent (automatic) and check that it is functioning:
X Check the condition of the double nipple and
X the condition of the float ball and make sure it moves easily,
Replace any damaged components as necessary.
X Check the seals for damage. Replace any damaged seals as necessary.
X Place the filter housings on the upper section of housing. Make sure that the
seals are properly in place.
X Unscrew and remove the guide pins from the change-over housing.
X Screw the filter housings to the upper section of housing. Tighten the screw
connection evenly, gradually tightening opposite screws step-by-step.
X Connect the venting lines to the filter housings.
X Put the filter back into operation. See the section "Commissioning".
X Set the key on the plug valve switch-over circuit to the "Automatic filter in
operation" position. The automatic filter is thus in operation.
X Close the pressure compensation valve.
DANGER!
Risk of accidents from hot components
Hot surfaces can cause serious injuries if touched.
• Take the filter heating out of operation and allow the filter to cool down.
• Wear the appropriate safety clothing.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the vent.
• Proceed with extreme caution.
• Wear the appropriate safety equipment and clothing.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the drain hole.
• Proceed with extreme caution.
• Wear the appropriate safety equipment and clothing.
• Collect the expelled medium in a suitable container.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
X Empty the filter. Carefully open the drain valve (partial draining).
NOTE
If required, you can fully drain the filter housing by opening the drain (complete
drainage).
X Remove the filter element from the housing by pulling it vertically upwards.
X Allow the filter element to drip dry in a suitable container.
CAUTION!
Risk of damage to the filter element from improper cleaning
If the filter element is cleaned or handled improperly, the filter element wire mesh
may become damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the cleaning agent is 1 - 4 hours, depending on the level
of contamination. Check the progress of cleaning whilst the element is
soaking.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not
exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not exceed
a maximum of 60 bar. When cleaning using a high-pressure cleaner, keep a
sufficient distance (at least 20 cm) from the surface of the filter material to
prevent damage.
• Particles of dirt must not be allowed to enter the clean side of the filter
element.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
X Place the filter element in a container of suitable cleaning agent with the
opening pointing upwards.
X Allow the filter element to soak.
X Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH
cleaning unit with rotating nozzle and flat-jet nozzle for cleaning purposes.
X Then spray the filter element with a filter cleaning unit. Cleaning is performed
from the inside to the outside and from the outside to the inside. In the final
working step, the filter element has to be jet cleaned in the opposite direction
to the direction of filtration, i.e. from the inside to the outside.
X Rinse the filter element carefully and allow it to drip dry.
X Check the filter element for damage. Replace any damaged filter elements/
seals as necessary.
X Clean any contamination which has collected on the inside of the filter
chamber.
X Check the seal for damage. Replace any damaged seals as necessary.
X Insert the filter element into the housing from above.
X Make sure that the seal is properly in place.
X Check the seal for damage. Replace any damaged seals as necessary.
X Place the cover on the housing. Make sure that the seal is properly in place.
X Screw the cover to the housing. Tighten the screw connection evenly,
gradually tightening opposite screws step-by-step.
X Pivot the securing plate on the housing cover safety device by the screws
which have to be secured, and screw the vent screw tight.
X Put the filter back into operation. See the section "Commissioning".
1 IVG Pumpen- und Filtrationstechnik Gera Denmark / Sweden / Norway / 1 2 3 Switzerland / Liechtenstein
Prehlis 13 A Iceland / Finland / Lithuania / EIG CRUSTAG
D - 07552 Gera Latvia / Estonia 120 Route de Frontenex
Tel.:+49/(0)365/42 00 07 4 1 2 3 BOLLFILTER Nordic ApS CH - 1208 Genève
Fax: +49/(0)365/42 00 07 5 Hammerbakken 21 Tel.: +41/(0)22/73 59 50 0
E-Mail: ivg-neubert@superkabel.de DK - 3460 Birkerød Fax: +41/(0)22/78 66 17 1
www.ivg-neubert.de Tel.: +45/(0)45/42 12 00 E-Mail: info@eig-crustag.ch
Fax: +45/(0)45/42 12 99 www.eig-crustag.ch
1 BOLL & KIRCH Filterbau GmbH E-Mail: info@bollfilter.dk
Geschäftsstelle Süd www.bollfilter.dk 1 2 3 Spain / Portugal / Argentina /
Rangaustraße 7a Chile / Peru / Uruguay
D - 91639 Wolframs-Eschenbach BOLLFILTER España S.L.
Tel.: +49/(0)9875/884 (Herr Henkelmann) Greece / Bulgaria Zona Cami Ral
Tel.: +49/(0)9875/971 865 (Herr Pirkl) 1 2 3 FILTERKON Paseo del Ferrocarril, 339 3ª – 2 a
Fax: +49/(0)9875/885 8, Mitsaion Str. E - 08860 Castelldefels
E-Mail: norbert.henkelmann@bollfilter.de GR - 117 42 Athen Tel.: +34/(0)93/634 26 80
www.bollfilter.de Tel.: +30/(0)210/92 17 671 Fax: +34/(0)93/665 22 79
Fax: +30/(0)210/92 42 242 E-Mail: info@bollfilter.es
Europe E-Mail: filterkon@filterkon.com www.bollfilter.com
Austria / www.filterkon.com
Czech Republic / 1 2 3 The Netherlands
Slovakia / Slovenia Great Britain and Ireland Lubrafil B.V.
1 2 3 Schmachtl GmbH 1 2 3 BOLLFILTER UK Limited Aalborg 2
Pummererstrasse 36 Unit 9 Station Way NL - 2993 LP Barendrecht
A - 4020 Linz UK - Tolleshunt D'arcy, Essex CM9 8TY Tel.: +31/(0)180/55 62 55
Tel.: +43/(0)732/76 46 0 Tel.: +44/(0)1621/86 21 80 Fax: +31/(0)180/55 62 65
Fax: +43/(0)732/78 50 36 Fax: +44/(0)1621/86 92 57 E-Mail: lubrafil@lubrafil.nl
E-Mail: g.oehler@schmachtl.at E-Mail: sales@bollfilter.co.uk www.lubrafil.nl
www.schmachtl.at www.bollfilteruk.co.uk
1 Turkey
Belgium/Luxembourg Italy ARES MAKíNA LTD. STI.
1 2 3 AUXIMECA N.V. 1 2 DECOSTA S.r.l. Ataúehir Bulvari 48.
Wijtschotbaan 3/3 Via Bicetti de Buttinoni, 12 Ada Mimoza 2/4 Daire : 1
B - 2900 Schoten I - 20156 Mailand Ataúehir, Istanbul
Tel.: +32/(0)3 646 61 80 Tel.: +39/(0)0238/00 52 83 Tel.: +90/(0)216/580 92 15
Fax: +32/(0)3 646 93 98 Fax: +39/(0)0238/00 36 31 Fax: +90/(0)216/580 92 19
E-Mail: info@auximeca.be E-Mail: sales@decosta.it E-Mail: sami.uygurer@aresmakina.com
www.auximeca.com www.decosta.it www.aresmakina.com
Type 6.72.1
Nominal diameter DN 40
Filter element Filter candle
Print document on both sides
NOTE:
Siemensstraße 10 - 14
50170 Kerpen
Germany
www.bollfilter.de
1/70
2 / 70 Operating instructions 6.72.1
Betriebsanleitung 6.72.1
Table of Contents
1 Preamble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Obligations of the user/operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Selection and qualifications of staff . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.2 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.1 Filtered media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Overview of automatic filter assembly group . . . . . . . . . . . . . . . . . . 15
5.3 Overview of bypass filter and plug valve circuit assembly group. . . 19
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.1 Floor fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.2 Installation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.3 Identifying the flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.4 Filter inlet/outlet pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.5 Flushing oil outlet pipe connection. . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.6 Filter heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.7 Connection of compressed air supply . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.9 Potential equalisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Functional description of the automatic filter . . . . . . . . . . . . . . . . . . 27
7.1.1 Filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.3 Differential pressure monitoring system . . . . . . . . . . . . . . . . . . . . . 27
7.1.4 Air tank and flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.5 Pivoting actuator (pneumatic) with limit switch . . . . . . . . . . . . . . . . 30
7.1.6 Flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
These operating instructions are for the user of the filter and the user's staff. They
contain text and drawings which, without the express permission of the
manufacturer must not be
• reproduced,
• distributed or
• otherwise made available to others, either in full or in part.
Failure to comply will require compensation.
DANGER!
Denotes immediate hazard with high risk which will cause death or serious
physical injury if not avoided.
WARNING!
Denotes possible hazard with medium risk which may cause death or serious
physical injury if not avoided.
CAUTION!
Denotes a hazard with low risk which could cause light or medium physical injury
or material damages if not avoided.
NOTE
Denotes special user tips and other particularly useful or important information.
DISPOSAL
Denotes special measures for environmental protection.
2.6.1 General
• Follow the respective valid national and international regulations for the
prevention of accidents.
• Adhere to the maintenance tasks and intervals set out in the operating
instructions, including instructions on the replacement of parts/equipment.
• Only use original spare parts.
• If the filter is subject to a regular inspection by an inspection and testing
organisation, with regard to temperature, steam pressure and the
dangerousness of the medium, the inspection periods must be adhered to by
the user.
2.7 Consumables
• Observe the regulations for environmental protection. Make sure that
consumables are disposed of properly and in an environmentally friendly
manner.
• When handling media which are to be filtered, make sure you follow the
respective safety regulations for the media.
• When handling the cleaning agents, make sure you follow the respective
safety regulations for the cleaning agents.
3.2 Storage
CAUTION!
Improper storage will cause damage to the filter and filter elements
If stored incorrectly and improperly, moisture and contamination, for example,
may cause damage to the filter and the filter elements.
• Protect the filter and filter elements from moisture and contamination during
storage.
• Do not store the filter and filter elements below the frost line.
• If the filter and the filter elements have been stored for more than one year,
check that all seals are fully functional before installation.
DISPOSAL
Observe the regulations for environmental protection. Make sure that the
packaging material is disposed of properly and in an environmentally friendly
manner.
NOTE
You will find the technical data in the appendix of these operating instructions.
NOTE
When making enquiries or ordering spare parts, always provide the information
on the type plate.
12
3
11
6
8
10
NOTE
Depending on the filter configuration, the differential pressure monitoring system
can be fitted to the bypass filter, see section 5.3.
NOTE
In conjunction with a bypass filter, the shut-off valve are positioned on the plug
valve switch-over circuit, see section 5.3.
6
3
4
N1
N2
N4
N3
N5
1 2 3 4 5 6
9
15
N1
10
11
15 12
N2 N4
13
N5
14
Fig. 5-4 Overview of assembly groups (view I)
Fig. 5-5 Overview of assembly groups (view II, with differential pressure signal)
NOTE
Contact the manufacturer with any special questions you may have regarding
installation. The contact data for the respective national subsidiaries can be
found in the appendix of the operating instructions.
DANGER!
Combustible medium
When filtering combustible medium expelled medium may cause fires and
personal injuries.
• Adhere to the valid fire safety regulations when carrying out any work on the
filter.
1 3 3
A B
3
2
7 6
NOTE
• The filter inlet/outlet and flushing oil outlet are indicated by the inscriptions
(Ein/In), (Aus/Out) and (Spülölaustritt/Flushing oil).
• The direction of flow is also shown in the technical data sheet which is
included in the appendix of these operating instructions.
NOTE
BOLL & KIRCH Filterbau GmbH recommends installing shut-off fittings in the
piping in front and in back of the filter.
X Establish the connection between the flushing oil outlet and piping.
X Welded joints must be made in line with the valid regulations.
X Use the appropriate seal.
X Select a pipe cross section which is at least equal in size to the pipe cross
section shown in the technical data sheet. A cross section which is too small
may cause backpressure. The pipe must also be laid with an inclination and
bled.
X The pipe may need to be provided with additional supports, depending on the
installation conditions. When installing the piping, the filter housing must not
be twisted.
The filter heating is used during the filtering process to cover heat loss in the filter
and before starting up the plant in order to heat up the medium in the filter. The
filter can be heated with water vapour, hot water or thermal oil.
DANGER!
Risk of accidents from expelled hot medium
Too much pressure in the heating system can cause hot medium to be expelled
and lead to damage to the filter and accidents.
• Adhere to the maximum permitted operating temperature and operating
pressure for the filter heater.
X Connect the medium-carrying pipes to the filter heating on the plant side.
X Welded joints must be made in line with the valid regulations.
X Use the appropriate seals.
X The pipes for the heating medium inlet and outlet may need to be provided
with additional supports, depending on the installation conditions. When
installing the piping, the filter housing must not be twisted.
2
3
1 Air tank
2 Ball valve
3 One-way restrictor valve
X Connect the plant's compressed air supply line to the one-way restrictor
valve on the ball valve.
DANGER!
Risk of accidents from electric shock
When connecting to the power supply, the supply voltage can cause accidents
from electric shock.
• All the electrical connections on the filter must be made by a qualified
electrician and in line with the rules of electrical engineering.
Controller
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
NOTE
You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the manufacturer's
documentation.
NOTE
BOLL & KIRCH Filterbau GmbH differential pressure indicators have potential-
free contacts.
The filter housing, comprising the lower housing section with the filter heating or
floor fastening without filter heating (optional), the upper housing section and
filter housings, contains all the pipe connections. The flushing valve is installed
on the upper section of housing.
The filter housings are arranged around the central drilled hole for fitting the plug
valve on the upper section of housing. A cover seals the plug valve off from the
outside, The pivoting actuator is fitted to it with a spacer.
7.1.2 Controller
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
NOTE
• You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the
manufacturer's documentation.
• The differential pressure can also be displayed optically on the differential
pressure monitoring system.
• The control line for the differential pressure monitoring system is fitted with
shut-off valves (e.g. shut-off valves).
The location for installation of the differential pressure monitoring system varies
depending on the filter configuration
Optional pressure gauges allow you to quantify the differential pressure.
The optional 3-way ball valves make it possible to check that the differential
pressure monitoring system is fully functional as and when required. The levers
have to point downwards when in operation.
3 1
1 Air tank
2 Pressure gauge
3 Safety valve
4 Pressure controller
5 Solenoid valve (flushing valve)
6 Ball valve
7 One-way restrictor valve
The compressed air in the air tank expands explosively when the solenoid valve
(flushing valve) is switched and opens the flushing valve. The flow which this
causes, pushes the medium on the clean side through the filter candles in the
counterflow direction at high speed. The pressure level in the air tank can be read
from the pressure gauge and set using a pressure controller. The air tank is
equipped with a safety valve to prevent the air tank from being damaged by
excessive positive pressure.
If the pressure gradient between the dirty side and the clean side reaches a set
value due to the growing layer of dirt on the filter material, the automatic filter
chamber regeneration is triggered. The pivoting actuator turns the plug valve so
that the flow to the soiled filter chambers is shut off and, at the same time, the
stand-by filter chamber is activated. If the plug valve reaches the filter chamber
which is to be cleaned, the pivoting movement is stopped. The pivoting actuator
is actuated by a solenoid valve (pivoting actuator). The limit switch monitors the
position of the plug valve. If the plug valve is in the incorrect position, the flushing
process in the soiled filter chamber does not start.
The pneumatically actuated flushing valve opens and closes the flushing oil
outlet at the start and end of the backflushing phases respectively. After a delay,
when the flushing valve is opened by the valve tappet, the compressed air supply
for backflushing flushing from the air tank is opened. A solenoid valve (flushing
valve) regulates the supply of compressed air for actuation of the flushing valve.
N1
N2
3
11
5
10
6
N1 9
8
N2
N3
NOTE
After backflushing is complete, the next backflushing cycle (manual or triggered
by the differential pressure monitoring system) can only be started with a time
delay. This time delay is the time set on the time relay or the preset time on the
controller. It is needed to ensure that the cleaned filter chamber can be filled.
The backflushing process is completed; the cleaned filter chamber remains shut
off from the filtration process until the next backflushing process.
CAUTION!
Risk of damage to the filter from improper flushing
Flushing an only partially filled filter causes increased strain on the filter candles.
• Never perform backflushing due to installation or control circumstances in an
only partially filled filter. A completely drained filter can be flushed for test
purposes without any restrictions.
1 5
2 4
The switch-over is performed manually using the attachable lever. The sign on
the cover, in conjunction with the marking on the plug valve neck, indicates the
direction of flow and thus shows which filter is in operation and whether the
pressure compensation valve is open or closed. The construction of the circuit
prevents both filters from being shut down at the same time.
CAUTION!
Risk of damage to the filter if the plug valve switch-over circuit is
positioned incorrectly
With a closed pressure compensation valve, the medium may be subject to heat
expansion and cause an increased build-up of pressure in the filter chamber
which is shut off.
• The pressure compensation valve must always remain open during
operation.
• The pressure compensation valve must only be closed when cleaning the
automatic filter or bypass filter.
1 2 3 4
The housing cover safety device has the task of preventing pressurised medium
from being expelled uncontrolledly in case of incorrect operation. The cover
sheet covers a minimum number of cover screws so that the cover cannot be
removed without opening the vent to bleed the system.
The filter chamber is relieved via the vent. When the filter is shut off, the operating
pressure is immediately relieved and hardly any medium is expelled. Otherwise,
close the vent immediately and the expulsion of medium is limited.
1 1
2 2
3 3
1 Filter candle
2 Candle holder
3 Seal
Filter inserts with filter candles are used for filtration. The flow runs from the
outside to the inside into the individual filter candles.
Particles of dirt in the flow are thus filtered off by the filter material in the filter
candles. The cleaned medium exits from the bottom of the filter candles and is
fed back into the plant.
The filter insert comprises several filter candles arranged in parallel. The filter
candles all have the same dimensions; they are interchangeable and can also be
removed separately. They are screwed into the candle holder.
The type, design and number of filter candles used depends on the medium
being filtered.
For media with a high ferrite content, the filter candle on the filter candle insert
can be replaced with an optional magnetic primary filter.
The candle holder secures the filter candles and thus protects the filter material
on the filter candles from damage during removal and installation.
The dirty side is sealed off from the clean side by a seal on the candle holder.
1
2
5
6
NOTE
The shape of the filter element clamp may vary depending on the nominal
diameter of the filter.
Star-pleated filter elements are used for filtration. The direction of flow through
the star pleated-filter element is from the inside to the outside.
Particles of dirt in the flow are thus filtered off by the star-pleated filter element.
The cleaned medium then exits from the star-pleated filter element and is fed
back into the plant.
The bypass filter is fitted with a star-pleated filter element.
The filter element clamp fastens the star-pleated filter element in the filter
chamber.
The dirty side is sealed off from the clean side by a seal.
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
CAUTION!
Risk of damage to the filter if operated without compressed air supply
If the controller is switched on and the filter is commissioned without compressed
air supply, the solenoid valves may become damaged.
• Always open the filter's ball valve first when commissioning in order to ensure
that compressed air is supplied.
NOTE
After backflushing is complete, the next backflushing cycle (manual or triggered
by the differential pressure monitoring system) can only be started with a time
delay. This time delay is the time set on the time relay or the preset time on the
controller. It is needed to ensure that the cleaned filter chamber can be filled.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
X Open the vent on the top of the housing of the bypass filter. The bypass filter
is filled via the open pressure compensation valve.
X Close the vent as soon as medium is expelled from a vent without any
bubbles.
X Carry out backflushing once more manually using the controller.
X The filter is ready for operation.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
X After each time you commission the filter, check the filter for leaks and
eliminate them as necessary.
X Allow the filter to operate for 24 hours with differential pressure and record
the number of flushes from the flushing cycle counter or the controller. In
order to allow the filter to operate for 24 hours with differential pressure, you
have to deactivate the intervals for forced flushing on the controller.
X Calculate the average of all flushing intervals.
X Reset the flushing interval time (which should be 30 % shorter) on the
controller.
NOTE
When using the filter in watery media, it is imperative to adhere to the following:
• Do not allow the filter to run to empty after switching off the supply pump. Dirt
may otherwise be allowed to harden.
• If the above condition cannot be met, set the controller so that backflushing
is triggered every 2 hours even if the supply pump is switched off.
NOTE
When removing the filter and taking it out of service for longer periods, pay
attention to the following points:
• The filter must be completely emptied.
• Disconnect all connections from the filter.
• The filter must be thoroughly cleaned.
• The filter must be sealed by applying an appropriate anticorrosive, if
necessary.
• The connection flange openings must be sealed with plastic (or similar)
dummy plugs.
7.7.3 Disposal
DISPOSAL
When the filter or individual components and consumables are finally disposed
of, make sure that they are disposed of in an environmentally friendly manner.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
You can tell that the filter elements are becoming increasingly blocked because
the flushing intervals become shorter and shorter.
The number of backflushing cycles performed is recorded by the controller.
CAUTION!
Risk of damage to the filter and the plant from damaged filter elements
If the flushing intervals suddenly become longer, this may indicate that the filter
elements are damaged.
• In such an event, check all filter elements for damage immediately. Replace
any damaged filter elements as necessary.
NOTE
The filter elements are subject to wear from two-way strain. It is therefore
recommendable to keep a complete set of filter elements in stock.
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
X Set the key on the plug valve circuit to the "Bypass filter in operation,
pressure compensation valve to automatic filter closed" position. The bypass
filter is thus in operation. The closed pressure compensation valve prevents
any medium from flowing into the automatic filter.
X Trigger backflushing on the controller.
X Afterwards, close the ball valve for the filter's compressed air supply.
X Then, carry out manual backflushing for the filter chamber which has not yet
been flushed.
X Switch off the controller.
DANGER!
Risk of accidents due to controller being switched on unintentionally
During maintenance accidents may be caused if the controller is switched on
unintentionally, e.g. by starting up the drives or from expelled medium.
• Secure the controller to prevent it from being switched on unintentionally, e.g.
by attaching a lock.
X Check the pressure gauge to establish whether the air tank is genuinely
depressurised.
X The filter chambers are now drained and depressurised.
CAUTION!
Risk of accidents from hot components
Hot surfaces can cause serious injuries if touched.
• Take the filter heating out of operation and allow the filter to cool down.
• Wear the appropriate safety clothing.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the filter chamber.
• Depressurise and lower the level of medium before removing the filter insert.
1 Venting line
2 Filter housing
3 Screw
4 Upper section of housing
2
3
5
6
CAUTION!
Risk of damage to the filter elements due to improper installation / removal
for the filter housings
• When installing / removing the filter housings, proceed with extreme care.
• Use the guide pins to install / remove the filter housings.
1 Filter element
2 Candle holder
3 Seal
X Remove the filter inserts from the housing by pulling vertically upwards.
X Allow the filter inserts to drip dry in a suitable container.
CAUTION!
Risk of damage to the filter insert from improper cleaning
If the filter insert is cleaned or handled improperly, the filter insert may become
damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the "BOLL CLEAN 2000" cleaning agent must not
exceed 24 hours.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not
exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not exceed
a maximum of 60 bar. When cleaning using a high-pressure cleaner, keep a
sufficient distance (at least 20 cm) from the filter material to prevent damage.
• When cleaning the filter insert using a cleaning gun and compressed air, the
pressure must not exceed a maximum of 4 bar.
• Particles of dirt must not be allowed to enter the clean side of the filter
element.
• Do not place the filter elements on top of each other as you may otherwise
cause damage.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
X Place the filter insert in a container with cleaning agent, with the opening of
the filter elements facing downwards. This way, particles detaching from the
filter elements can sink to the bottom.
X Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
X After soaking, remove the filter insert from the container and place it on a
suitable surface (e.g. perforated plate) with openings of the filter elements
facing downwards. Allow the cleaning agent to drip dry.
X Turn the filter insert around and place it down with the openings facing
upwards.
X Blow out the filter elements with compressed air from the inside to the
outside.
X Then dip the filter insert in the container with fresh cleaning agent again, with
the openings of the filter elements facing downwards. Rinse the filter insert
through again by turning it and moving it up and down in the cleaning agent.
X Allow the filter insert to drip dry again.
X Blow out the filter elements with compressed air from the inside to the
outside.
X Then check all filter elements for damage. Replace any damaged filter
elements/seals as necessary.
X In case of heavier soiling, you can clean using the high-pressure cleaner
procedure mentioned above. For cleaning, use water or water with cleaning
agent.
In case the filter elements are heavily soiled (lacquer contamination, incrustation,
tar residue, fibres, chippings), the individual filter elements will have to be
removed and cleaned.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH
cleaning unit with rotating nozzle and flat-jet nozzle for cleaning purposes.
If you do not have a filter element cleaning unit available, proceed as follows:
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
X Place the filter insert in a container with cleaning agent, with the opening of
the filter elements facing upwards. The openings on the filter elements have
to protrude out of the cleaning agent. This prevents dirt from penetrating into
the clean side.
X Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
X Remove the filter insert from the cleaning agent. Allow the filter insert to drip
dry with the openings pointing downwards.
X Unscrew and remove the filter elements from the candle holder using the key
included in the scope of delivery.
X Then spray the filter elements through using the high-pressure cleaner with
suitable cleaning agent. First clean from the inside to the outside, then from
the outside to the inside. Repeat the process several times as necessary.
Finally, spray the filter elements from the inside to the out.
X Carefully rinse out the filter elements in fresh cleaning agent and allow the
filter elements to drip dry.
X Blow out the filter elements with compressed air from the inside to the
outside.
X Remove any particles collected on the magnetic candle (if fitted).
X Re-assembly is performed by carrying out the steps for disassembly in
reverse order. Clean the candle holder as necessary before assembly.
X Clean any soiling which has collected on the inside of the filter.
X Check all the seals for damage. Replace any damaged seals as necessary.
X Insert the filter inserts vertically into the housing from above.
X Make sure that the seals are properly in place.
1 Double nipple
2 Float ball
3 Filter housing
X Check the condition of the vent (automatic) and check that it is functioning:
X Check the condition of the double nipple and
X the condition of the float ball and make sure it moves easily,
Replace any damaged components as necessary.
X Check the seals for damage. Replace any damaged seals as necessary.
X Place the filter housings on the upper section of housing. Make sure that the
seals are properly in place.
X Unscrew and remove the guide pins from the change-over housing.
X Screw the filter housings to the upper section of housing. Tighten the screw
connection evenly, gradually tightening opposite screws step-by-step.
X Connect the venting lines to the filter housings.
X Put the filter back into operation. See the section "Commissioning".
X Set the key on the plug valve switch-over circuit to the "Automatic filter in
operation, pressure compensation valve to bypass filter closed" position. The
automatic filter is thus in operation. The closed pressure compensation valve
prevents any medium from flowing into the bypass filter.
DANGER!
Risk of accidents from hot components
Hot surfaces can cause serious injuries if touched.
• Take the filter heating out of operation and allow the filter to cool down.
• Wear the appropriate safety clothing.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the vent.
• Proceed with extreme caution.
• Wear the appropriate safety equipment and clothing.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the drain hole.
• Proceed with extreme caution.
• Wear the appropriate safety equipment and clothing.
• Collect the expelled medium in a suitable container.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
X Remove the filter element from the housing by pulling it vertically upwards.
X Allow the filter element to drip dry in a suitable container.
CAUTION!
Risk of damage to the filter element from improper cleaning
If the filter element is cleaned or handled improperly, the filter element wire mesh
may become damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the cleaning agent is 1 - 4 hours, depending on the level
of contamination. Check the progress of cleaning whilst the element is
soaking.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not
exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not exceed
a maximum of 60 bar. When cleaning using a high-pressure cleaner, keep a
sufficient distance (at least 20 cm) from the surface of the filter material to
prevent damage.
• Particles of dirt must not be allowed to enter the clean side of the filter
element.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
X Place the filter element in a container of suitable cleaning agent with the
opening pointing upwards.
X Allow the filter element to soak.
X Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH
cleaning unit with rotating nozzle and flat-jet nozzle for cleaning purposes.
X Then spray the filter element with a filter cleaning unit. Cleaning is performed
from the outside to the inside and from the inside to the outside. In the final
working step, the filter element has to be jet cleaned in the opposite direction
to the direction of filtration, i.e. from the outside to the inside.
X Rinse the filter element carefully and allow it to drip dry.
X Check the filter element for damage. Replace any damaged filter elements/
seals as necessary.
X Clean any contamination which has collected on the inside of the filter
chamber.
X Check the seal for damage. Replace any damaged seals as necessary.
X Insert the filter element into the housing from above.
X Make sure that the seal is properly in place.
X Check the seal for damage. Replace any damaged seals as necessary.
X Place the cover on the housing. Make sure that the seal is properly in place.
X Screw the cover to the housing. Tighten the screw connection evenly,
gradually tightening opposite screws step-by-step.
X Pivot the securing plate on the housing cover safety device by the screws
which have to be secured, and screw the vent screw tight.
X Put the filter back into operation. See the section "Commissioning".
1 IVG Pumpen- und Filtrationstechnik Gera Denmark / Sweden / Norway / 1 2 3 Switzerland / Liechtenstein
Prehlis 13 A Iceland / Finland / Lithuania / EIG CRUSTAG
D - 07552 Gera Latvia / Estonia 120 Route de Frontenex
Tel.:+49/(0)365/42 00 07 4 1 2 3 BOLLFILTER Nordic ApS CH - 1208 Genève
Fax: +49/(0)365/42 00 07 5 Hammerbakken 21 Tel.: +41/(0)22/73 59 50 0
E-Mail: ivg-neubert@superkabel.de DK - 3460 Birkerød Fax: +41/(0)22/78 66 17 1
www.ivg-neubert.de Tel.: +45/(0)45/42 12 00 E-Mail: info@eig-crustag.ch
Fax: +45/(0)45/42 12 99 www.eig-crustag.ch
1 BOLL & KIRCH Filterbau GmbH E-Mail: info@bollfilter.dk
Geschäftsstelle Süd www.bollfilter.dk 1 2 3 Spain / Portugal / Argentina /
Rangaustraße 7a Chile / Peru / Uruguay
D - 91639 Wolframs-Eschenbach BOLLFILTER España S.L.
Tel.: +49/(0)9875/884 (Herr Henkelmann) Greece / Bulgaria Zona Cami Ral
Tel.: +49/(0)9875/971 865 (Herr Pirkl) 1 2 3 FILTERKON Paseo del Ferrocarril, 339 3ª – 2 a
Fax: +49/(0)9875/885 8, Mitsaion Str. E - 08860 Castelldefels
E-Mail: norbert.henkelmann@bollfilter.de GR - 117 42 Athen Tel.: +34/(0)93/634 26 80
www.bollfilter.de Tel.: +30/(0)210/92 17 671 Fax: +34/(0)93/665 22 79
Fax: +30/(0)210/92 42 242 E-Mail: info@bollfilter.es
Europe E-Mail: filterkon@filterkon.com www.bollfilter.com
Austria / www.filterkon.com
Czech Republic / 1 2 3 The Netherlands
Slovakia / Slovenia Great Britain and Ireland Lubrafil B.V.
1 2 3 Schmachtl GmbH 1 2 3 BOLLFILTER UK Limited Aalborg 2
Pummererstrasse 36 Unit 9 Station Way NL - 2993 LP Barendrecht
A - 4020 Linz UK - Tolleshunt D'arcy, Essex CM9 8TY Tel.: +31/(0)180/55 62 55
Tel.: +43/(0)732/76 46 0 Tel.: +44/(0)1621/86 21 80 Fax: +31/(0)180/55 62 65
Fax: +43/(0)732/78 50 36 Fax: +44/(0)1621/86 92 57 E-Mail: lubrafil@lubrafil.nl
E-Mail: g.oehler@schmachtl.at E-Mail: sales@bollfilter.co.uk www.lubrafil.nl
www.schmachtl.at www.bollfilteruk.co.uk
1 Turkey
Belgium/Luxembourg Italy ARES MAKíNA LTD. STI.
1 2 3 AUXIMECA N.V. 1 2 DECOSTA S.r.l. Ataúehir Bulvari 48.
Wijtschotbaan 3/3 Via Bicetti de Buttinoni, 12 Ada Mimoza 2/4 Daire : 1
B - 2900 Schoten I - 20156 Mailand Ataúehir, Istanbul
Tel.: +32/(0)3 646 61 80 Tel.: +39/(0)0238/00 52 83 Tel.: +90/(0)216/580 92 15
Fax: +32/(0)3 646 93 98 Fax: +39/(0)0238/00 36 31 Fax: +90/(0)216/580 92 19
E-Mail: info@auximeca.be E-Mail: sales@decosta.it E-Mail: sami.uygurer@aresmakina.com
www.auximeca.com www.decosta.it www.aresmakina.com
1
1 Digital display actual value
2 2nd digital display (if aktive) 3
2
3 LED-display relais function
4 Key for setpoint and parameter mode
5 Setpoint adjustment 6
6 Parameter mode lock switch (back face)
4 5
Brief description:
KFM 92 is a microprozessor based industry controller series in panel mounting- format 96 x 96 mm.
Design and operating elements are especially devised for easy and convenient handling and operation.
An assembly system renders possible the simple basic version as well as a plurality of variants with
up to 8 relays, several digital and analog out- and inputs and other additional devices.
Types: Inputs:
(depending on configuration*): type: max. 4 measuring inputs, type suffix
indicator 9201. acc. to sub-type:
one stage controller 9210. Pt100 DIN, 0...400°C none (or 0)
two stage controller 9220. Pt100 DIN, 0...100°C 1.
heating / cooling controller 9230. thermo couple Ni Cr NI (type K)0...1200°C n.
positioner / follow-up controller 9240. thermo couple Fe Cu NI (type J)0... 900°C f.
two- point- PID controller 9250. thermo couple Pt Rh Pt (type S)0...1700°C p.
three- point- PID controller 9260. feedback device 0...100 up to 1000 Ω w.
three- point- step controller 9270. standard signal 0(4)...20mA, 0(2)...10V e.
continuous controller 9280. combined input Pt100 / standard signal q.
continuous controller, 2 outputs 9281. Ranges:
Sub-types: suffix (*) Pt 100: 0...400°C, switchable to °F, optional: other
basic function .0 ranges; for standard signal range adjustable -999 to
basic function + 1 additional contact .1 4000. Setpoint ranges can be limited by menu
basic function + 2 additional contacts .2 Displays:
2 x basic function .3 2 four- figured digital displays, decimal point
extension: logik output ..L adjustable, upper display: actual value, lower
function extensions suffix (*) display: other selectable data,
cascade controller 991k up to 8 LEDs for relays function display.
program controller 991p Display of function:
ramp set point value 991r Hold down the P-key for more than 5 sec
step controller 991t to get a short-cut message of the configured function on
the display (=position 3-5 of list number)
Additional devices: (*) (in case of locked parameter mode only ).
additional analog inputs (99) a Measuring line monitoring:
external set value incl. switch-over (99) bwa Display "Err 1...4" in case of measuring line fault
second set value incl. switch-over (99) bwz and adjustable safety shut down of all outputs
binary input to switch special functions (99) b..
additional switching contacts (99) f.. Outputs:
analog signal outputs (99) o. up to 8 relays with potential free change over switch,
serial interface RS 232/485 (99) s. as control outputs or as additional contacts,
interface Profibus, Interbus S, other (99) sp/si. capacity: 250V 2A,
incl. spark extinction (for normally open contacts)
* In case of more than 1 extension there is at the 1-2 continuous outputs 0/4...20mA, 0/2...10V as
data plate only once '99' , f.e. 92700-99aw-ogx-rü. control or signal outputs(apparent ohmic load 500 Ω)
For more information see corresponding data sheets.'
data subjects to alteration 9200e1.doc / 0510208
Industry controller type KFM 9... B 9... E
Installation and connection Page 2 of 8
Installation:
Before installation inspect the controller for any visible signs of damage caused during transport
Check power supply acc. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the
fastening devices supplied.
Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following the
wiring diagram; wire cross section max. 1,5 mm2
- To avoid cross interference all low voltage measuring lines and pilot wires must be encased
in a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally to protect the output relays.
- Phase wire and neutral wire must not be transposed.
Maintenance:
All electronic controllers in the KFM range are virtually maintenance-free. Provided that the
controller is correctly installed and put into operation and is protected against mechanical
damage and inadmissible operating conditions, it should give years of trouble-free service.
In case of faults repair work by the customer should be restricted to the externally accessible
leads and connections and components the customer is expressly permitted to deal with himself.
(bridge circuits, fuses).
All further work, especially on internal components will terminate warranty, makes subsequent
inspection and fault repair more difficult and can cause considerable damage to the circuitry.
For repair remittance remove plug board with connected leads on the rear side,
loosen fastening devices and remove controller from the panel.
In case of remittance please give precise details of the fault to reduce time and cost of repair.
Error messages:
Err 1...6 Fault on measuring input nr. ...
check measuring lines for short circuit or breakage
check measuring input by connecting a RTD
Err 55 Fault on loading the parameter;
press any key, the controller starts in emergency operation mode,
configuration of the parameters has to be checked
Err 50 Hardware error in program section
Err 52 Hardware error in data section
no further operation possible, remit controller for repair
Operating status:
The upper display shows the actual value (channel / measuring input 1),
the lower display remains empty or (depending on the version and settings) shows
- the attendant unit of measure (°C, °F, %...)
- an additional actual value, the setpoint value or the controller output value Y
- or the additional actual value only when the key is pressed.
Alternative type:
switch over the upper display to the several actual values by pressing the key,,
the lower display shows the number of the attendant measuring input.
The indicated value can now be changed by the (lower) and (higher) -keys..
Each variation of the set value is immediately active, without any more operating steps.
The arrow keys have a built-in accelerator mode:
longer pressing causes faster alterations.
optional: Press - key shortly again: *SP =set values of further control loops (*=no.) /
SP* =further set values of the control loop / SPE =external setpoint (display mode only);
flashing display signifies that the function is not active at the moment.
Hold down - key and press - key, then release both keys..
(optional: switch on and off using separate - key)
(for multi-channel controllers first enter the channel number*,
and press - key, then:)
Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)
After the parameter level (refer to the instructions to each level ) has been invoked,
the first setting is shown and can be modified.
It is not possible to invoke the parameter level when the switch is locked .
In this case the display shows the abbreviation of the configured controller type.
Settings in detail:
(not available on all types)
Level 1: Invoke: Hold down the - key for more than 5 sec.
until the display changes factory setting: notes:
* = channel no. in case of multiple measuring inputs or control loops. # = acc. to range
1. manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to balance
an appearing deviation as quickly, non-oscillating and exactly as possible,
according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replaced
by this brief information.
The following informations are for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;
- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):
lower value= shorter impulse gaps, faster balancing
higher value= longer impulse gaps, slower balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;
- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):
increases the controller reaction in case of fast actual value or setpoint alterations
(adjust only if necessary). Higher values cause higher increase.
2. Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjusts
the optimum control parameters Xp, Tn and Tv.
Operation, if contained in supply schedule:
(Parameter-safety-switch on the rear panel of the controller has to be unlocked: position „u“)
Check starting assumptions:
Actual value at least 20% below the adjusted set value,(e.g.:heating phase), otherwise first:
Lower actual value adequately by manual operation (position of final control element) (quick circuits)
or increase setpoint adequately, if admissible. (faster procedure for slower circuits)
Call manual operation level: Press - key plus - key (optional: seperate key).
Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down - key for more than 5 sec. on manual operation level.
During operation the lower display shows: „-Ad-“,
the upper display still shows permanently the actual value.
Information about computer operation: First the self-adaptation program waits for stabilization
of the actual value according to the given controller output (actual value alteration < 0,1% / min),
then it increases the output signal about 10% or, in case of three- point- step controller operation,
it triggers an output impulse with about 10% of the adjusted regulating time.
The optimum parameters are computed according to the unit- step response.
Cancel: Press - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
to operating level.
Unsuccessful adaptation ( Display shows error code, ref.to chapter error messages):
Press - key again: Return to manual operation level
eliminate the indicated error
start adaptation again: - key > 5 sec.
or return to operating level: - key shortly
Select control function (type dependent): the displayed ID number for the configured
control function can be changed by pressing the - key..
(Example Type 930K31: choose (92..) 200, 201, 700, 701)
on
So E Make contact above setpoint. Relay picks
of f
up as actual value increases (Ein = on) SA
Sd
of f
US A Relay drops out with increasing actual Sd
of f
US E Relay picks up with increasing actual Sd
actual value
value (Ein = on) SP
Switching point
Service function:
Ein/Aus contact is constantly switched on (Ein) or
off (Aus) respectively
In each case additional settings follow under "rEL." after the selection is acknowledged (P key)
(depending on version):
Ist./ Y assigned value: actual value no. ... or Y (actuating signal)
CH../.SP.(only) for trailing contacts: assigned control circuit / channel (no.) or
assigned setpoint (1SP., rSP, SP.1, ..)
for independent contacts: assignment of parameter input (channel no..)
"Safety" shut down (in case of measuring line fault):
SI E Relay for "Safety" behaviour in event of measuring circuit error: relay on
SI A Relay for "Safety" behaviour in event of measuring circuit error: relay off
100% Y1
Additional contact functions: AP
in in..
Y2
di di..
As switching interval above and below setpoint or 0%
P ..di
independent adjustable with own setpoint and -100% P1 td td P2
..in
Wiring diagram:
(Example, depending on sub type some details can be missed
valid for each delivered controller is the wiring diagram on its casing only)
A927_e59710718
controller electronics
fu se: (+) (-)
2 4 V :T 0 ,5 A
1 1 5 V :T 0 ,2 A
2 3 0 V :T 0 ,1 A
18V / external digital power control logic signal
40mA analog inputs set value inputs supply output outp. output relay outputs
Ist 3 Ist 4 dig 3 dig 4 Y 2 log 2 Sout 2 Rel 5 Rel 6 Rel 7 Rel 8
7 8 9 10 11 12 23 24 25 26 32 31 37 36 41 31 62 63 64 65 66 67 68 69 70 71 72 73
U+ Ist 1 Ist 2 SPE dig 1 dig 2 Y 1 log 1 Sout 1 Rel 1 Rel 2 Rel 3 Rel 4
99 1 2 3 4 5 6 13 14 15 19 20 21 22 27 28 29 30 31 35 36 40 31 50 51 52 53 54 55 56 57 58 59 60 61
I U L N + + + (protect relay outputs py external fuse 2A)
(L+) (L-)
1 2 3 1 2 3 1 3 2 3 10 3 11 3 13 15 14 15 50 51 52 53 54 55
L
+ - + - + - + - + - + - M
~
open close N
VISCOMASTER DYNAMIC
Technical Manual
CHAPTER 1 - INTRODUCTION
CHAPTER 4 - MAINTENANCE
CHAPTER 5 - SPECIFICATION
The transmitter contains integral electronics that allow sensor and calculation configuration, enabling it to perform a
variety of calculations. Two forms of output are available:
1. Two 4-20mA analog outputs, factory set but have individually configurable span, bias, limits and
filter options. The standard factory settings for these outputs are Line Kinematic Viscosity on
Analog Output 1 and Temperature on Analog Output 2.
2. An RS485 (Modbus) interface, giving access to other measurement results, system information
and configuration parameters.
No signal converter is required, which simplifies wiring and enables the Viscomaster to be connected directly to a
plant monitoring / control systems or a local indicator.
Re-configuration of the transmitter’s default settings (see chapter 5) is achieved by linking a PC to the Modbus
(RS485) connection and running ADView software. Once configured, the PC can be removed.
Note: The Line Kinematic Viscosity calculation requires the user input of a base (or reference) density value and a
temperature (at which the base density value is valid).
HFO is a low cost, high viscosity fuel derived from refinery wastes. The quality of the oil and its viscosity/temperature
characteristics can vary due to:
HFO heating is usually required to ensure that the viscosity of the oil at the injectors of a large diesel engine or burner
nozzle is maintained at the optimum value (typically between 10 and 20cSt). Failure to observe the viscosity limits
results in inefficient combustion, pollution problems and higher operating costs (either due to excessive fuel being burnt
or premature wear to engine components).
Since simple temperature control has been shown to be ineffective due to the variability of oil quality in HFO, viscosity
control is usually performed.
Note: In some installations, equipment may be installed in between the viscosity transmitter and the burner
/ engine to remove contaminants from the fuel; the efficient operation of this equipment may also depend
on the viscosity of the HFO.
1
2
Relay Viscosity alarm (to AMS)
* *
*
3
* *
*
* Not supplied by Aquametro
Figure 1
In some applications, absolute accuracy is less important than repeatability. For example, in a system where the control
parameters are initially adjusted for optimum performance, and thereafter only checked periodically.
The term achievable accuracy can be used to describe a measure of the product quality that can be realistically obtained
from a process system. It is a function of measurement accuracy, stability and system response. High accuracy alone is no
guarantee of good product quality if the response time of the system is measured in tens of minutes, or if the measurement
bears little relevance to the operation of the system. Similarly, systems which require constant calibration and maintenance
cannot achieve good achievable accuracy.
Factors which may adversely affect the relevance of the measurements could include:
x Measurement used for control purposes being made too far away from the point of control, so that the
system cannot respond properly to changes.
x Measurements made on fluid which is unrepresentative of the main flow.
For practical reasons it is helpful to consider the sensitive or effective region for the transmitter as an three-
dimensional ellipse centred on the tips of the tines with its long axis aligned with the direction in which the tines
vibrate, as shown below. The Viscomaster is insensitive to the properties of the fluid outside this region.
long axis
short
axis
If part of this volume is taken up by the pipework or fittings there is said to be a boundary effect; i.e. the intrusion of
the pipe walls will alter the calibration.
The diagram below illustrates the Viscomaster installed in a pocket on the side of a 4” (100mm) horizontal pipe line
(viewed from above). The effective region is completely enclosed within the pipe line and thus is completely fluid.
The smaller circle represents a 4” vertical pipe, which intersects the effective region. The 6” (150mm) pipe is the
smallest pipe diameter to completely enclose the effective region when the pipe is vertical. Thus smaller pipe
diameters can lead to a variety of different geometries which would each require a separate calibration.
An alternative condition is shown in the next diagram where the side pocket is extended until it passes completely
through the effective region producing a “core”:
From this, it would appear that almost every installation requires a separate in situ calibration - a very undesirable
situation. The problem is resolved by providing standard calibration geometries which can be used in all pipe work
configurations and thereby allow the factory calibration conditions to be reproduced in the process. These standard
geometries are described in Section.
Avoid direct heating or cooling of the Viscomaster and associated pipework upstream and downstream that is likely to
create temperature gradients. If it is necessary to provide protection against cooling due to loss of flow, electrical
trace heating may be applied, provided it is thermostatically controlled and the thermostat is set to operate below the
minimum operating temperature of the system.
If vibration levels exceed these limits, or the Viscomaster series transmitters are not installed as recommended by
Mobrey, Mobrey cannot take responsibility for the correct operation of these units.
The Viscomaster should normally be installed horizontally, with the slot between the tines vertical; this ensures that,
for low flow rates, any solids or gas bubbles are not trapped. When installed in a flow-through chamber, however,
provided that the flow rate is within the recommended range, the transmitter can be mounted horizontally or vertically.
Allow at least 200mm (7.8”) clearance to enable the Viscomaster to be removed from the fitting.
Conditions:
Temperature: -50 to +200qC
Flow: 10 to 330 l/min (0.6 to 20 m3/hr) (2.6 to 87 US gal./min)
Viscosity limit: Up to 100cSt
Pressure: As defined by process flanges.
Viscometer
calibration boundary: 2½“ Schedule 40
This adapter has been specifically designed to provide a simple, direct replacement for existing vibration-type
viscometers. Typically, the flange-to-flange distance is 150mm. Usually, no pipework changes are necessary.
The viscometer is mounted 25mm away from the main flow line, allowing good product mixing, sensor protection and
stable measurement conditions.
Note: The schematic shown may vary without notice, although overall dimensions will remain unchanged.
2. Isolate the system, depressurise and remove the blanking compression nut.
3. Install the Viscomaster, and tighten the fitting nut, but do not fit the thermal insulation.
4. Slowly pressurise the system and check for leaks, particularly if the normal operating temperature is
high, or the Viscomaster has been fitted cold; tighten as necessary.
5. Now tighten the nut again, if necessary. Once you are satisfied with the integrity of the seal, the
insulation can be fitted.
6. Once the system has stabilised and is leak free, fit the insulation material.
When several systems are run in parallel and use the same fuel source, comparison of the readings between
installations can be a useful indicator of possible system faults. Differences between readings or changes from the
normally observed conditions should always be investigated to confirm that instrumentation is functioning correctly.
Particular attention should be paid to the conditions before and after engine shutdowns in order to detect any
possibility of asphaltenes coating (precipitation of asphaltenes from the HFO caused by dilution with distillate fuel)
which may cause the instrument to read high. If the re-circulation flow is high enough or the instruments have been
supplied with PTFE coating, asphaltenes or any other deposits should quickly be removed and the expected
operating temperatures should be restored.
If Viscomaster is still reading high and the oil quality is known not to have changed, then the instrument should be
removed and cleaned with a rag. Removal should only be performed in accordance with the engine or burner
manufacturers’ recommendations or in accordance with safe site practice. This must include isolation and
depressurisation, as detailed below.
Check that the isolation valves have been fully closed, remove insulation and allow to cool to a safe level (cooling will
tend to reduce any retained pressure) and de-pressurise the system if a drain valve or pressure relieving valve is
fitted.
When the above conditions are satisfied, slacken the lock nut by 1½ to 2 turns, sufficient for the sensor to be rocked.
(If necessary, jolt the Viscomaster loose with a blow of the hand to the amplifier housing.) This will allow the seal between
the sensor and the chamber retro-fit kit to be broken. Do not slacken the lock nut further unless the seal is broken and
the sensor is definitely loose in the fitting.
When the Viscomaster can be rocked in the flow chamber and there is no serious or continuous escape of oil, it is
safe to remove the lock nut.
Always keep all parts of your body away from the axis of the sensor (i.e., the direction in which the sensor
will be withdrawn). If the system is under pressure or suddenly comes under pressure (e.g., due to valve
failure or pump start), and the lock nut is not in place, the instrument may be forcibly ejected from the flow
chamber and cause serious injury.
Clean and maintain the Viscomaster as directed and then refit it, as described in Section 2.5
The parameters that can be output on each analog output are as follows:
Viscomaster Dynamic
Analog Output 1 Analog Output 2
Dynamic viscosity (cP) Temperature *
Note: In all cases, the Limit values of each analog output are configurable.
x A Modbus (RS485) interface, giving access to other measurement results, system information and
configuration parameters. The Modbus interface is also used to configure the Viscomaster Series
transmitter, using a PC running Mobrey’s ADView software (see separate manual)
It is recommended that both outputs are installed, requiring a minimum of eight wires (two for each output, and two
for power). Although you may not immediately require the Modbus connection, it may be required for in-situ
calibration adjustment and future system enhancements, and the cost of the additional wires is trivial compared to the
expense of installing them retrospectively.
A number of factors must be taken into account when planning the electrical installation. These include:
If several Viscomaster Series transmitters are to be used within a local area, one power supply can be used to power
them all; where the transmitters are distributed over a wide area and cabling costs are high, it may be more cost
effective to use several smaller, local power supplies.
Upon leaving the factory, the two 4-20mA analog outputs are non-isolated as they are powered through internal links
to the power supply input. However, if split-pads “LNK A” (Analog Output 1) and “LNK B” (Analog Output 2) by the
terminal block are ‘broken’, they become isolated and require a separate 20-28V dc power supply. (See section 3.6
for further details).
Care should be taken where there is the possibility of significant common-mode voltages between different parts of
the system. For example, if the Viscomaster Series transmitter is local powered from a power supply which is at a
different potential to the RS485 ground connection (if used).
3.2.2 EMC
To meet the EC Directive for EMC (Electromagnetic Compatibility), it is recommended that the transmitter be
connected using a suitable instrumentation cable containing an overall screen. This should be earthed at both ends
of the cable. At the transmitter, the screen can be earthed to the transmitter body (and therefore to the pipework),
using a conductive cable gland.
The electronics and communications connections (RS485/Modbus and 4-20mA analog outputs) of a Viscomaster
Series transmitter are not connected to the body of the transmitter. This means that the negative terminal of the
power supply can be at a different potential to the earthed bodywork.
In the majority of applications, it is not necessary to connect the RS485 ground connection. In areas where there is a
significant amount of electrical noise, higher communications integrity may be obtained by connecting the negative
power terminal (pin 2) of the Viscomaster Series transmitter to the communications ground. If this is done, it is
important to ensure that the possibility of ground loops (caused by differences in earth potential) is eliminated.
Connections for the Analog and Modbus signals should be individually screened twisted-pairs with an overall screen,
foil or braid for the cable. Where permissible, the screen should be connected to earth at both ends. (At the
Viscomaster Series transmitter, this is best done using a conductive cable gland.)
Cables should conform to BS2538. In the USA, use Belden 9402 (two-pair) or Beldon 85220 (single-pair). Other
cables that are suitable are those that meet BS5308 Multi-pair Instrumentation Types 1 and 2, Belden Types 9500,
9873, 9874, 9773, 9774 etc.
The typical maximum recommended cable length for the above cable types is 1000m (3200ft.), but care must be
taken to ensure that the power supply at the transmitter is at least 20V. Thus, for 24V power supply, the overall
resistance for the power supply connections (both wires in series) must be less than 100 ohms.
In order to complete the wiring, you will need the following parts:
x ½” NPT to M20 gland adapter.
x ½” NPT blanking plug.
x M20 x 1 cable gland (not supplied).
The gland adapter and blanking plug are supplied with each Viscomaster Series transmitter. These two parts
are “EExd” rated. However, you will need to get a suitably rated cable gland. Alternative parts may be required
in order to meet local electrical installation regulations.
If there is a possibility of lightning strikes, external surge protection devices - one for each pair of signals and the
power supply - should be installed as close to the Viscomaster Series transmitter as possible.
Another method of surge protection is to connect an MOV (Metal Oxide Varistor) (breakdown voltage >30V)
with an NE-2 neon bulb in parallel across each wire and ground. These can be mounted in a junction box close
to the Viscomaster Series transmitter.
Note: If the Viscomaster Series transmitter is to be used in hazardous areas, the electrical installation
must strictly adhere to the safety information given in safety instruction booklet 78265061/SI, which
will have accompanied this manual.
It is recommended that you install all three connections (six cores) at installation, to avoid the possibility of expensive
alterations to the cabling at a later date. Typically, three pairs of shielded 19/0.30mm2 (#16 AWG) to 19/0.15mm2
(#22 AWG) wire are used for wiring.
Note: The PC and converter are always located in a non-hazardous (safe) area.
The RS485/232 converter and PC are not normally installed permanently. However it is strongly recommended that
the wiring to the Viscomaster Series is made at the time of installation.
Note: If you encounter communication difficulties with RS485, swap over the ‘A’ and ‘B’ signal
connections at one end of the network.
OR
9-PIN DIN CONNECTOR VERSION:
Upon leaving the factory, the two 4-20mA analog outputs are non-isolated as they are powered through internal links
to the Power Supply Input.
However, if split-pads “LNK A” (Analog Output 1) and “LNK B” (Analog Output 2) by the terminal block are ‘broken’,
they become isolated and require direct connections to another external 20-28V dc power supply. A second or third
external 20-28V dc supply can be used.
Note: The external device must be located in a non-hazardous (safe) area unless it is explosion proof and
suitably certified.
The 4-20mA analog outputs can be configured to be proportional to a user-defined base density, referred density,
temperature, or one of the special functions. Fault conditions within the Viscomaster Series are indicated by a 2mA
output. If this is detected, the Modbus link can be used to interrogate the transmitter to establish the likely cause of
the problem.
7. Finally, screw the housing cap on fully and VIEW FROM UNDERNEATH THE ELECTRONICS:
TIGHTEN
CAP
TIGHTEN
GRUB
4.1 GENERAL
The Viscomaster Series transmitter has no moving parts and maintenance is limited to simple visual checks for
leaks and physical damage. ADView’s Data Logging facility can be used whenever necessary to verify that the
transmitter is functioning correctly (See sperate manual).
Check calibrations should be carried out at specified intervals in order to identify a malfunction or deterioration in
transmitter performance. If a fault or a drop in performance is detected, further tests are required to identify the cause
of the fault. Remedial action is limited to cleaning the tines, making good any poor connections and replacing the
internal electronics. In extreme cases, the complete Viscomaster Series transmitter may need to be replaced.
Note: The electronics within the transmitter contain calibration information relevant to that particular transmitter only.
The circuit boards operate as a pair, and therefore both boards must be changed together. Contact Aquametro for
more details if you need to change the boards.
Note: The covers MUST be completely screwed down and, in the case of an explosion-proof enclosure
application, DO NOT FAIL to tighten the locking screws.
Notes:
1. A drop in performance is likely due to a build-up of deposition on the tines, which can be removed by
the application of a suitable solvent. See section 4.3.1 for further details.
2. Malfunctions generally could be the result of electrical/electronic faults in either the Viscomaster Series
transmitter or the readout equipment. Always check the readout equipment first before attention is
directed to the Viscomaster Series transmitter.
Readings fluctuate Analog output averaging Increase the averaging time using
slightly, i.e., are noisy time not long enough ADView’s Board Configuration facility
(see separate manual).
Erratic readings Gas bubbles around tines Remove primary cause; e.g.:
Cavitations - install air release units to release
gas; apply back pressure to
Severe vibration discourage bubble formation.
Severe electrical - remove cause of vibration
interference
Alternatively, it may be necessary to
Large amount of adjust the Time Period Trap
contaminants
Analog output = 0mA No power to analogue If voltage across pins 5 and 6 is not 15
output to 28V, replace power supply.
Analog output circuit Use ADView’s facility to set the
failure analogue output to 4, 12 or 20mA (in
Board Configuration) to check whether
the output is functioning. If not, replace
circuit boards.
Analog output is 2mA Alarm condition caused by If voltage across pins 1 and 2 is not 20
lack of power to to 28V, check and replace main power
Viscomaster Series supply.
transmitter
Alarm condition caused by Use ADView Diagnostics to check that
other internal failure phase locked loop is in lock.
Temperature readings If other readings from Return the transmitter to Mobrey for
incorrect transmitter are correct (i.e. servicing. Re-fit the transit cover to the
analog output and Modbus transmitter and secure it with 2 grub
appear to be functioning screws.
correctly), the temperature
sensor has probably failed.
Transmitter does not Power failure to Check power supply to transmitter and
communicate with transmitter. converter; replace if necessary.
ADView:
Power supply to Check wiring.
RS485/232 converter
failed.
A and B Modbus Check wiring.
connections reversed.
RS485/232 converter Try another converter.
failed, wired incorrectly,
or connected the wrong
way round.
Viscosity reads high Pump coated with Check pump delivery; service pump.
after engine shutdown asphaltenes.
and restart
Bypass not fully closed. Close bypass
Under all normal circumstances, the factory settings for the TPT should be used. However, in extreme cases it may be
necessary to alter the settings to meet the demands of a particular system. This should only be done after monitoring
the behaviour of the system for some time, to establish the normal running conditions.
Great care must be taken not to reduce the sensitivity of the transmitter so that normal response to fluctuations in the
fluid is impaired.
After each measurement of the time period (of the Viscomaster Series transmitter’s vibrating tines), the new value is
compared with the previous value. If the difference between them is smaller than the allowable tolerance, the output is
updated to correspond to the new measured value, and the TPT remains inoperative; i.e., operation is normal. If the
difference exceeds the allowable tolerance, the output remains at the previous level, and does not follow the apparent
sudden change in value.
Two Modbus Registers control the operation of the Time Period Trap facility. These can be changed, if necessary,
using ADView’s Register Read/Write facility (see separate manual).
Modbus Register 138: contains the maximum allowable change in the time period between readings, specified in Ps.
The preset value is 10.
Modbus Register 137: contains the Time period count, which is the maximum number of measurements to be
rejected before resuming normal operation; the preset value is 2. If the value is set to 0, TPT is disabled, and the
output will always follow the time period measurement. If you want to program another value, it should be determined
experimentally, and be equal to the length of the longest undesirable transients which are likely to arise. If the value
is set too high, the Viscomaster Series transmitter will be slow to respond to genuine changes in the fluid properties.
An RS485 serial communications link is also available, which utilises the Modbus protocol to provide a means of
configuring the device, retrieving data measurements, and performing diagnostics.
ADView, a PC software application running under Windows 98, NT, 2000 or XP, is available for data logging,
configuration and diagnostics purposes (see separate manual)
5.2 SPECIFICATION
5.2.1 SENSOR PERFORMANCE
Viscosity measurement
Measurement technology: Tuning Fork driven and sensed by piezoelectric
crystals.
5.2.2 ENVIRONMENTAL
Number of channels: 2
Repeatability: r0.05% FS
(-40qC to +85qC)
5.2.6 APPROVALS
EMC: EN 61326:1997 +A1
Analog outputs are set to provide line kinematic viscosity (in cSt) and temperature (in qC). Units are kg/m3 for the density
parameter.
Viscomaster Dynamic
Parameter
Factory default value
Output averaging 5s
time:
Head Office:
Switzerland: Aquametro AG, Ringstrasse 75, CH-4106 Therwil, Phone +41 61 725 11 22, Fax +41 61 725 15 95
Officies:
Switzerland: Aquametro SA, Rue du Jura 10, CH-1800 Vevey, Phone +41 21 923 51 30, Fax +41 21 922 58 44
Belgium: Aquametro Belgium SPRL, Dallaan, 67, B-1933 Sterrebeek, Phone +32 2 241 62 01, Fax +32 2 216 22 63
Czech Republic: Aquametro s.r.o., Prosecká 811 / 76a, CZ-190 00 Praha 9, Phone +42 02 86 88 77 78, Fax +420 02 86 88 95 59
Germany: Aquametro Messtechnik GmbH, Zum Panrepel 24, D-28307 Bremen, Phone +49 421 / 871 64-0, Fax +49 421 / 871 64-19
Marketing-Officies:
Japan: Aquametro Representative Office, Yasuhiko Takahashi, 1-18-4, Nakane, Meguro-ku, Tokyo 152-0031, Phone +81 3 3723 8611, Fax +81 3 5729 4607
Korea (south): Aquametro Representative Office, Dennis Kwak, The # Centum Park 102-2704, Haeundae gu Jaesong 1-dong 1200, Busan Korea, Phone +82 5 1314 3017, Fax +82 5 1988 3017
Singapore: Aquametro Representative Office, Deniel Wong, 273 Thomson Road, #03-03 Novena Gardens, Singapore 307644, Phone +65 6 256 8152, Fax +65 6 256 9917
www.aquametro.com
Order text:
Motor control valve PN . ., DN . .
in two way form with PTFE-V-ring unit,
Power supply . . ., List-No. 421 . . .
153
Space required
Actuator type: 145 to remove
2kN: 4e1230 (for 4-6kN-actuator: 190) the bonnet
4(6)kN: 4e14(6)30
Bonnet
Motor
Limit switch
Gear
Spring plate-unit H*
Spindle (actuator)
Hand wheel
Mounting rod
PTFE-V-ring-unit
Spindle
Plug
DN 15 20 25 32 40 50 65 80 100
Height H * 491 505 499 505 511 513 556 557 564
Immersion lenght L 130 150 160 180 200 230 290 310 350
Weight kg 13 14 15 17 18 20 33 37 47
* = add. 45mm for 4-6 kN-actuator
1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36
N L on 2 = Straightway closes
L on 3 = Straightway opens
Installation:
Attention!: - Installation, operation and maintenance should be done only by qualified personnel.
- Disconnect supply before working on the valve.
- It is not permitted to work on the valve body and to exchange the actuator as long as
the valves are subjected to pressure and temperature.
The mounting site should be easily accessible and have sufficient clearance for maintenance
and for removing the actuator. Ensure that the pipe line axes are flush and connection flanges
are parallel. Provide suitable measures to absorb possible tensile and pressure forces.
The valve must not serve as a fixed point. It must be carried by the piping.
Clean pipelines thoroughly prior to installing the control valves in order to avoid damage through
residual installation material, welding beads or forging scale. If possible, provide a dirt trap
in front of each control valve.
Installation position should be vertical to horizontal. Ensure that the installation direction is
correct (directional arrows of the flow on the valve housing). Observe a 10 x DN spacing
to flanges, elbows, etc., to avoid an impaired valve function.
Regard the permitted max. operating pressure and temperatur as described in the
corresponding valve specification sheet.
Observe the ambient temperature limits (-20...+60°C), if necessary, provide a drive heater
at lower temperatures, and for higher temperatures insulate the pipeline, provide conductive
plates or cooling possibilities.
Retighten the screws of all flange connections (also lid and connection piece flanges) prior
to commissioning/start-up and following initial heat-up.
Electrical connection:
Check supply voltage according to the rating plate, loosen screws on the motor hood
and remove hood
Route signal and control lines separately from high-voltage lines, if necessary, run in
screened cables. Insert cables (1.5 mm²) through a wringing nipple or cable screw
connection.
Perform electrical connection with the supply voltage switched off according to the
connection diagram (observe VDE and EVU regulations).
In the event of deviations, the connection diagram in the motor hood has precedence
Maintenance:
Following the initial temperature and pressure load, retighten the screws of all flange connections
(also lid and connection piece flanges), the valve cone should be located in the centre.
Attention! Never loosen the lid and flange screws as long as the fittings are subjected
to pressure and temperature.
Protect valve spindle against soiling, if necessary, clean and grease lightly in order to protect
stuffing boxes and deflector hoods against increased wear.
Retighten stuffing box seals slightly in the event of leaks.
No further maintenance work is required for fittings with deflector hoods or bellows.
Undertake maintenance on the drive in accordance with the corresponding information in the
separate operating instructions.
Order text:
Electric actuator, thrust . . ., power supply . . .,
pos. time . . ., mounting rod lenght . . .,
List-No. 4e1 . . .
1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36
N L on 2 = stroke downwards
L on 3 = stroke upwards
data subject to alteration 4e1-1-E.DOC / 0411504
Electric actuator 4e1 4e1... E
Page 2 of 2
Motor
Gear
Base plate
Cable bushing
Spring housing
Mounting rod
Stroke
Hand wheel with
blocking lever Cmax
Attention:
- Adjustment of and work on the actuator may only be done by skilled labour
- Disconnect power supply before removing the cover
- Observe local instructions and terminal diagram
Maintenance: the spindle has to be kept cleen and lubricated, if necessary, lubricate the spindle with
molykote including grease
Limit switches:
Attention! The limit switches work load dependent and turn off automatically when the valve drives in
end position, so that a readjustment, as for travel dependent limit switches, is not necessary
and not allowed. Change of the factory adjustment endangers correct operation, no warranty
will be given and no liability will be accepted in case of damage of the varnish sealing.
If for extraordinary reasons, for instance by previous damages, a readjustment is exceptionally
necessary, the actuator should preferably be sent in for new factory adjustment. Only if this is
exceptionally not possible, a new coarse adjustment can be directly done, with our agreement
and acc. to the following operating instruction.
Fig.1
01
02
03
04
05
06
07
08
09
10
11
12
13
detail X
14
15
16
17
19
20
X
18
Fig.2
01
02
03
04
05
06
07
08
09
10
11
01
03
04
05
06
A AB
Description
KPS units are pressure-controlled switches. The KPS series covers most outdoor as well as indoor
The position of the contacts depends on the application requirements.
pressure in the inlet connection and the set KPS pressure switches are suitable for use in alarm
scale value. In this series, special attention has and regulation systems in factories, diesel plant,
been given to meeting important demands compressors, power stations and on board ship.
for:
• a high level of enclosure,
• robust and compact construction,
• resistance to shock and vibration.
Contents Page
KPS pressure switches, description .............................................................................................................................1
Approvals .................................................................................................................................................................................2
Ship approvals ........................................................................................................................................................................2
Survey ........................................................................................................................................................................................2
ISO 9001 quality approval ..................................................................................................................................................2
Technical data and ordering..............................................................................................................................................3
Terminology ........................................................................................................................................................................3-4
Installation ...............................................................................................................................................................................5
Function ....................................................................................................................................................................................6
Dimensions and weight ......................................................................................................................................................7
Accessories ..............................................................................................................................................................................8
IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
2 IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
A: Range setting
B: Differential scale
C: Obtained
differential
IC.PD.P10.C2.02 - 520B2981 3
Data sheet Pressure switches and thermostats, type KPS
Scale accuracy
KPS 31: ±0.2 bar KPS 39: ±3.0 bar
KPS 33: ±0.3 bar KPS 43: ±1.0 bar
KPS 35: ±0.5 bar KPS 45: ±4.0 bar
KPS 37: ±1.0 bar KPS 47: ±6.0 bar
Mean value of snap point variation after
400 000 operations
KPS 31: ±0.1 bar KPS 39: ±0.7 bar
KPS 33: ±0.2 bar KPS 43: ±0.2 bar
KPS 35: ±0.3 bar KPS 45: ±1.0 bar
Fig. 4. d.c.-load KPS 37: ±0.4 bar KPS 47: ±1.5 bar
Curve A gives the maximum load.
Hatched area B: Acceptable load for the gold plating
of the contact.
Materials in contact with the medium
KPS 31, 33 Bellows capsule: Deep-drawn plate, material no. 1.0524 (DIN 1624)
Bellows: Stainless steel,material no. 1.4306 (DIN 17440)
Pressure connection: Steel C20, material no. 1.0420 (DIN 1652)
KPS 35, 37,39 Bellows: Stainless steel, material no. 1.4306 (DIN 17440)
Pressure connection: Brass,W.No. 2.0401 (DIN 17660)
KPS 43, 45, 47 Diaphragm capsule: Nickel-plated brass, DIN 50 968 Cu/Ni 5 (DIN 1756)
Diaphragm: Nitrile-Butadien rubber
4 IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
1. Range spindle
2. Range scale
3. Differential spindle
4. Differential scale
Fig. 6 5. Locking screw
Selection of differential
To ensure that the plant functions properly, a
suitable differential pressure is necessary.
Fig. 5 Too small a differential will give rise to short
running periods with a risk of hunting. Too high
a differential will result in large pressure
Water systems oscillations.
Water in the pressure element is not harmful, but
if frost is likely to occur a water-filled pressure Electrical connection
element may burst. To prevent this happening, KPS pressure switches are fitted with a
the pressure control can be allowed to operate Pg 13.5 screwed cable entry that is suitable for
on an air cushion. cable diameters from 5 to 14 mm.
Contact function is shown in fig. 7.
Media-resistance
See table of materials in contact with the
medium, page 4. If seawater is involved, types
KPS 43, 45, 47 are recommended.
Pulsations
If the pressure medium is superimposed with
severe pulsations, which occur in automatic
sprinkler systems (fire protection), fuel systems
for diesel motors (priming lines), and hydraulic
systems (e.g. propeller systems), etc., types Fig. 7
KPS 43,45,47 are recommended. The maximum
permissible pulsation level for these types is
120 bar.
IC.PD.P10.C2.02 - 520B2981 5
Data sheet Pressure switches and thermostats, type KPS
Scale setting
Mechanical
differential
Fig. 8
2. All other KPS pressure switches I. Alarm for rising pressure given at the set
Contacts 1-4 make and contacts 1-2 break when range value.
the pressure rises above the set range value. The II. Alarm for falling pressure given at the set
contacts changeover to their initial position when range value minus the differential.
the pressure again fails to the range value minus
the differential (see fig. 9).
Scale setting
Mechanical
differential
Fig. 9
Example 2
An alarm must be given by a bell when the pressure
in a boiler rises to 10 bar. The normal operating pres-
sure is 9 bar.
Choose a KPS 36 (range from 6 to 18 bar).
The range value of the pressure control must be set
at 10 bar, the differential at 1 bar.
The bell must be connected to terminals 1 and 4.
Example 3
The pressure in a start air reservoir must be
regulated with a compressor controlled by a KPS
pressure switch so that it lies between 30 and 36 bar.
6 IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
Weight:
KPS 31 - 39 approx. 1.0 kg
KPS 43 - 47 approx. 1.3 kg
IC.PD.P10.C2.02 - 520B2981 7
Data sheet Pressure switches and thermostats, type KPS
8 IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
Thermostats KPS thermostats are temperature-controlled The KPS series covers most outdoor as well as
switches. The position of the contacts depends indoor application requirements.
Description on the temperature of the sensor and the set
scale value. In this series, special attention has KPS thermostats are suitable for use in monitoring,
been given to meeting demands for : alarm and regulation systems in factories, diesel
• a high level of enclosure, plant, compressors, power stations and on board
• robust and compact construction, ship.
• resistance to shock and vibration.
Ship approvals Det norske Veritas, Norway Registro Italiano Navale, Italy
American Bureau of Shipping RMRS, Maritime Register of Shipping, Russia
Lloyds Register of Shipping, UK Nippon Kaiji Kyokai, Japan
Germanischer Lloyd, Germany CCS, China Classification Society
Bureau Veritas, France
Includes thermostats with fixed sensor and
pressure controls with armoured capillary tube.
Technical data and ordering When ordering, please state type and code number
Setting Mech. Max. Suitable sensor length Cap. Code no.
range diff. sensor see also “Accessories” tube
adjust- temp. length
able/
fixed
Type
°C °C °C mm m
-10 - 30 3 - 10 80 65 75 110 160 2 060L311266 060L311366 KPS 76
20 - 60 3 - 14 130 - 75 - - - 060L311866 KPS 77
20 - 60 3 - 14 130 - - 110 - - 060L310066 KPS 77
20 - 60 3 - 14 130 - - - 160 - 060L313666 KPS 77
20 - 60 3 - 14 130 65 75 110 160 2 060L310166 060L310266 KPS 77
20 - 60 3 - 14 130 - - 110 160 5 060L311966 060L312066 KPS 77
KPS with rigid sensor 50 - 100 4 - 16 200 - 75 - - - 060L312166 KPS 79
50 - 100 4 - 16 200 - - 110 - - 060L310366 KPS 79
50 - 100 4 - 16 200 - - - 160 - 060L313766 KPS 79
50 - 100 4 - 16 200 65 75 110 160 2 060L310466 060L310566 KPS 79
50 - 100 4 - 16 200 - - 110 160 5 060L312266 060L312366 KPS 79
50 - 100 4 - 16 200 - - 110 160 8 060L312466 060L312566 KPS 79
50 - 100 4 - 16 200 65 75 110 160 3 060L314366 KPS 79
50 - 100 9 200 - 75 - - - 060L3141661) KPS 79
70 - 120 4.5 - 18 220 - 75 - - - 060L312666 KPS 80
70 - 120 4.5 - 18 220 - - 110 - - 060L312766 KPS 80
70 - 120 4.5 - 18 220 - - - 160 - 060L313866 KPS 80
70 - 120 4.5 - 18 220 - - - 200 - 060L315766 KPS 80
70 - 120 4.5 - 18 220 65 75 110 160 2 060L312866 060L312966 KPS 80
KPS with remote sensor 70 - 120 4.5 - 18 220 65 75 110 160 3 060L315666 KPS 80
70 - 120 4.5 - 18 220 - - 110 160 5 060L313066 060L313166 KPS 80
70 - 120 4.5 - 18 220 - - 110 160 8 060L313266 060L313366 KPS 80
60 - 150 5 - 25 250 65 75 110 160 2 060L310666 060L310766 KPS 81
60 - 150 5 - 25 250 - - 110 160 5 060L313466 060L313566 KPS 81
60 - 150 5 - 25 250 - - 110 160 8 060L311166 KPS 81
60 - 150 5 - 25 250 - - 200 - - 060L311066 KPS 81
100 - 200 6.5 - 30 300 65 75 110 160 2 060L310866 060L310966 KPS 83
100 - 200 18 300 65 75 110 160 2 060L3139661) KPS 83
1)
Thermostat with max. reset
Mechanical
differerential
Fig. 6
10 IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
Resistance to media
Material specifications for sensor pockets:
Scale correction
The sensor on KPS thermostats contains an Scale deviation factor
adsorption charge. Therefore function is not affected
whether the sensor is placed warmer or colder than
the remaining part of the thermostatic element
(bellows and capillary tube). However, such a charge
is to some extent sensitive to changes in the
temperature and bellows and capillary tube.
Under normal conditions this is of no importance, Relative
but if the thermostat is to be used in extreme scale
setting
ambient temperatures there will be a scale
in %
deviation. The deviation can be compensated for as
follows:
Scale correction = Z x a
Z can be found from fig. 4, while a is the correction
factor from the table below.
IC.PD.P10.C2.02 - 520B2981 11
Data sheet Pressure switches and thermostats, type KPS
Fig. 5
KPS with remote sensor KPS with remote sensor and armoured KPS with rigid sensor
Weight: ca 1.2 kg capillary tube Weight: ca 1.0 kg
(incl. 2 m capillary tube) Weight : ca 1.4 kg (incl. 2 m capillary tube)
12 IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
Accessories: Sensor pockets Sensor A Thread Code no. Sensor A Thread Code no.
for KPS thermostats pocket mm B pocket m B
Brass 65 1/2 NPT 060L326566
Brass 75 1/2 NPT 060L326466 Steel 18/8 75 G 1/2A 060L326766
75 G 1/2 A 060L326266
75 G 3/8 A 060L326666
75 G 1/2 A (ISO 228/1) 060L328166
Brass 110 1/2 NPT 060L328066 Steel 18/8 110 G 1/2 A 060L326866
110 G 1/2 A 060L327166 110 1/2 NPT 060L327066
110 G 1/2 A (ISO 228/1) 060L340666
110 G 3/4 A (ISO 228/1) 060L340366
Brass 160 G 1/2 A 060L326366 Steel 18/8 160 G 1/2 A 060L326966
160 G 3/4 A (ISO 228/1) 060L340566
Brass 200 G 1/2 A 060L320666 Steel 18(8 200 G 1/2 A 060L323766
200 G 1/2 A (ISO 228/1) 060L340866 200 G 3/4 A 060L323866
200 G 3/4 A (ISO 228/1) 060L340266
Brass 250 G 1/2 A 060L325466
Supplied without gland nut, Brass 330 G 1/2 A 060L325566
gaskets and washer
Brass 400 G 1/2 A 060L325666
For KPS thermostats with sensor fitted in a sensor pocket. Compound for
Heat-conductive
filling sensor pocket to improve heat transfer between pocket and sensor.
compound 041E0114
Application range for compound:between pocket and sensor.
(4.5 cm2 tube)
Application range for compound: –20 to +150 °C, momentarily up to 220°C.
Gasket set For KPS thermostats without armoured capillary tubes 060L327366
Gasket set For KPS thermostats with armoured capillary tubes 060L036666
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
IC.PD.P10.C2.02 - 520B2981 13