Boiler O&M Manual

1-1 Safety precautions
1-2 System description
1-3 Mainflow diagram / Component list
1-4 Technical Data Sheets B

O
WASTE HEAT RECOVERY
1-5 Transportation O
K
SYSTEM FOR 1-6 Installation 1
HYUNDAI HEAVY INDUSTRIES CO LTD
1-7 Operation
1-8 General Instructions
1-9 Spare parts information
2-1 Maintenance
2-2 Exhaust Gas Boiler

INSTRUCTION
2-3 Exhaust Gas Damper
MANUAL
2-4 Feed Water Tank
2-5 Heat Recovery Container
BOOK 1/4 2-6 Auxiliary Boiler B

O
GENERAL 2-7 Burner O
K
for 2-8 Steam Header 2
TERMONORTE DFPP 93 2-9 Blow Down Tank
MW
2-10 Pumps
COLOMBIA 2-11 Control units
2-12 LFO Tank
2-13 Condensate tank

B
3 Instructions for Instruments
3
B
Alfa Laval Aalborg Oy's Ref:
4 Electrical
4
5514 / TERMONORTE DFPP 93 MW
Customer's Ref: BOOK 1 GENERAL

REVISION LOG Revision List
REV. DATE MADE BY NOTES

- 17.8.2017 EWA Manual released.
SAFETY PRECAUTIONS
Subject Group Ref. No. Page

Safety precautions Safety - 1/8
precautions
Project name Project no Issued by Date Rev.
General - rev. TRu 31-01-2017 b
CONTENT:
1. GENERAL ................................................................................................................................................ 2
1.1 PERSONNEL QUALIFICATION AND TRAINING ................................................................................................ 2

1.2 NON-COMPLIANCE WITH SAFETY INSTRUCTIONS AND UNAUTHORIZED MODIFICATIONS ................................. 2
2. SAFETY INSTRUCTIONS AND WARNINGS....................................................................................... 3
3. SAFETY ASPECTS IN CONNECTION TO STARTING THE SYSTEM ............................................. 3
4. SAFETY ASPECTS IN CONNECTION TO THE OPERATOR / USER............................................... 4
5. SAFETY ASPECTS IN CONNECTION TO THE MAINTENANCE .................................................... 4
6. SAFETY ASPECTS IN CONNECTION TO THE RELATED EQUIPMENT....................................... 5
7. SAFETY RISKS BECAUSE OF DIRTY EXHAUST GAS BOILER ..................................................... 5
8. SAFETY RISKS BECAUSE OF LOW WATER LEVEL (LACK OF WATER) ................................... 7
9. SAFETY RISKS BECAUSE OF HIGH PRESSURE AND TEMPERATURE ....................................... 7
10.SAFETY RISKS IF SAFETY DEVICE OPENS IN USE ........................................................................ 7
11.RISK OF ELECTRICAL SHOCK........................................................................................................... 8
© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

Subject Ref. No. Rev. Page
Safety precautions - b 2/8
1. GENERAL
The purpose of this Alfa Laval Aalborg Heat Recovery System is to generate steam
and to heat up water. All other use is prohibited.
These operating and maintenance instructions contain fundamental information which
is to be used during installation, operation and maintenance. Therefore this operating
manual must be read and understood by all personnel, who are involved in the Heat
Recovery System. In addition, the end-user is responsible for ensuring that the
content of these operating and maintenance instructions is fully understood.
These operating and maintenance instructions are to be kept close to the operated
equipment with easy access.
Special attention should be paid to equipment, specially marked with general hazard
signs as indication of possible hazardous risk.
National and local requirements for safety regulations must be taken under
consideration before Heat Recovery System is built up and is taken under use.
1.1 Personnel qualification and training
All personnel, related to the operation, maintenance, inspection and installation of the
Heat Recovery System must be fully qualified to carry out the work involved.
The operating personnel shall be trained to carry out the correct activities in all
situations and to be aware of the operation of pressure vessels. If the personnel in
question does not already possess the requisite know-how, appropriate training must
be provided e.g. through hand by hand education by the supplier. Furthermore the
risks for injury in using the equipment must be clear acknowledged by the users.
Personnel responsibilities, competence and supervisions are to be clearly defined by
the end-user. Using child labour is strictly forbidden.
1.2 Non-compliance with safety instructions and unauthorized

modifications
Neglect of the safety precautions, installation instructions, operational instructions,

maintenance instructions or other related instructions for Heat Recovery System may
cause damages to the equipment and/or cause safety risk to persons running them.
The equipment guarantee may also lapse unless the above-mentioned procedures
are followed.
The limits stated in technical data sheets must not be exceeded under any
circumstances.
The welding, flame cutting, boring or other similar changing of the pressure vessels
structure, and all changes having an effect on strength technical properties are
prohibited without Alfa Laval Aalborg permission.

2. SAFETY INSTRUCTIONS AND WARNINGS

The following symbols in this manual point out safety precautions. It means your
special attention is needed. In addition, make sure that all national, classification
authority and local safety requirements are observed.
WARNING
This pictogram is used to indicate the presence of a hazard, which can or will cause
severe personal injury, if the warning is ignored.
WARNING - High Voltage!

This pictogram is used to warn against electric shock hazard. Only qualified
electricians may work on the system's electrical equipment.
WARNING – Hot surfaces!

This pictogram is used to warn against the danger of hot surfaces. Only qualified staff
may work on the burner system.
CAUTION
Certain passages of the text will be marked with a caution mark. This mark indicates
the presence of hazard, which will or can cause property damage if the instructions are
not observed.
NOTE
This type of instruction indicates a situation, which, if not avoided, could result in
damage to the equipment
3. SAFETY ASPECTS IN CONNECTION TO STARTING THE

SYSTEM
The pressure vessels are to be taken in a regular operation after they have been
adjusted and the commissioning inspection is made. The necessary safety equipment
must also be connected, inspected and approved before the regular operation. All
safety devices need to be taken under operation before the steam system is started.
This is in responsibility of the person in charge of the Heat Recovery System.
Before starting the Heat Recovery System the system description and operation must
be cleared on and all activities mentioned under “preparation for use” has been made.
Before starting up the engines make sure that all cleaning and inspection hatches are
properly closed. It is also important that sufficient amount of tools, utensils and spare
parts are easily available for the Heat Recovery System before it is taken to the
regular operation.

4. SAFETY ASPECTS IN CONNECTION TO THE OPERATOR /

USER
Even though the Heat Recovery System can mainly be controlled from the control
room, it is vitally important to maintain regular on field checkups so that possible
malfunctions or other abnormal situations are detected beforehand to avoid them
causing eventual safety risks. The system’s proper operation must be observed
continuously, especially during and after the initial start up of the steam generation or
when system has been out of use. The on field activities should be organized to that
they will not contribute other safety risks for users.
User safety factors during normal operation are for instance:
- Proper protective clothing for using the hot equipment and/or related
components
- Free entrance to alarm stops
- Temperature and pressure values are stabile and according to instructions
- Operation of equipment is without any abnormal noise, vibration or
overheating
The observed shortages and deviations must immediately be informed to the person
in charge of operation.
Safe use of equipment requires that checks and services recommended by

manufacturer are made regularly. Equipment faults and irregularities should be
cleared up and taken care of without any delay by skilled personnel and/or by working
according to the manufacturer’s instructions.
Correct use and careful maintenance of the system increases its operation life and
minimizes the security risks.
5. SAFETY ASPECTS IN CONNECTION TO THE MAINTENANCE

The equipment manufacturer’s instructions must be followed in service, repair and
cleaning work as well as during installation phase. Prior to any maintenance work, the
service and maintenance instructions including the equipment specific data should be
familiarized and/or repeated. The safety risks involved to a particular work must be
cleared up. While the system is in steam producing-mode, all service and repair work is
prohibited, except the normal control work for the heat recovery system; such as;
control of the water quality with delivered equipment, cleaning as safely applicable.
Before any maintenance activities, working safety has to be ensured, i.e. it must be
ensured that the engine will not get inadvertently started during the maintenance.
Equipment, vessel, component or corresponding device which can be pressurized from
the common steam/water source shall be isolated behind two closing devices (closing
valve, blind…) and be locked/noted avoiding inadvertently opening/starting.
The following basic principles should be followed in connection with the service and
maintenance work:

- Have a permission for fire / electric / maintenance work

- All interlocking devices are activated to prevent unintended operation of machinery
during service. For example safety switch should be locked into “0” position with
padlock.
- Scaffolding and security hoist are installed/used and inspected before work at
height level is started
- Use of proper instruments
- Proper protective clothing for using the hot equipment and/or related components
- Proper special instructions should be followed during welding.
- Use of genuine spare parts
- After the service or maintenance work it should be secured that all safety
equipment are working properly
- All service measures should be recorded to the service protocol.
The service and repair work is best controlled by following the control procedure of that
particular work. The person responsible for the operation of the equipment should be in
all cases informed about any taken actions.
6. SAFETY ASPECTS IN CONNECTION TO THE RELATED

EQUIPMENT
The following safety aspects are to be taken under the consideration:
- Sufficient lighting must be provided for working platforms.

- The gangways and working platforms must be kept open.
- Maintenance areas shall be clearly marked by warning signs/tape or fenced in.
- All necessary safety equipment must be connected, inspected and approved before
regular operation.
- All hot components that posing a risk for hazard must be equipped with a proper
cover or the risk of injury eliminated otherwise.
- Possible hazardous leakages should be considered in order to avoid any danger to
persons or environment.
- All chemicals and hazardous media are contained, handled and stored in a proper
way in order to avoid any danger to persons or environment.
Equipment, vessels, components or corresponding devices which are to be integrated

to the Heat Recovery System, must be equipped with an own safety devices; e.g. rapid
pressure rising outside of the Heat Recovery System needs to be released controllable
by integrated safety device.
7. SAFETY RISKS BECAUSE OF DIRTY EXHAUST GAS BOILER

The risk of a soot fire exists in an exhaust gas boiler with a dirty heat surface. Dry
running of a dirty boiler is strictly prohibited because of the risk of soot fire. Principally
the boiler construction allows dry-running, but Alfa Laval Aalborg does not take any
responsibility in such a case due to the increased risk of soot fire. See general
instructions, Checking of boiler dirtiness and Dry running of exhaust gas boiler.
The soot fire in an exhaust gas boiler can be very intense and cause damage to the
whole exhaust gas boiler. Therefore special attention must be paid to the cleanness of
the exhaust gas boiler. See general instructions, Manual water cleaning of Exhaust gas
boiler

To minimize the risk for a soot fire, the operator should note the following instructions.
Action for prevention of soot fire:
1. Cleaning of the exhaust gas boiler. The exhaust gas boiler is to be kept clean
enough in all situations according to the maintenance instruction. The heat
surface and internal steel structure of the boiler needs to be inspected regularly
and always when it is possible. Impurities which can increase the risk of soot
fire are to be removed immediately.
2. Always when relate engine is running and ~24 hours after shut down maintain
water circulation / level in boiler. This should secure sufficient cooling of heating
surfaces and avoid soot fire to initiate.
3. Exhaust gas temperature after the boiler is to be observed regularly. This value
should be compared to the value of the clean boiler and possible deviations are
to be clarified immediately.
4. Heavy smoke from engine. If an excessive amount of smoke is observed the

boiler should afterwards be checked and cleaned if necessary.
It is presumed that the power plant is equipped with a sufficient amount of fire
hydrants or water supply for extinction of fire is organized otherwise.
If a soot fire has initiated in the exhaust gas boiler, the following procedure
should be done immediately:
1. Alarm the fire-fighting department or other instance skilled for extinction of fire.
2. If possible activate the existing soot blowing system of the boiler and ensure the
water or steam supply for that.
3. Make sure that normal water level in the steam drum is maintained. The circulation
water pump must remain in operation.
4. The by-pass damper (if exist) in the exhaust gas duct is opened to the by-pass line.
The engine must be stopped and oxygen flow to the burning boiler is to be
prevented e.g. by blocking the air supply through the engine.
5. If possible in safety wise, the topmost service hatch in the boiler is opened and
plenty of water is applied to the whole area of the heat service or directly to the heart
of the fire. Depending on the fire area and considering the working safety, other
service hatches are opened in order to extinguish the soot fire inside the boiler
Note!
After the soot fire, the boiler is to be inspected completely. Please contact us
in that case.
ALFA LAVAL AALBORG OY

P.O. Box 9, FI-26101 Rauma, Finland
Phone: + 358 10 838 3800
www.alfalaval.com

8. SAFETY RISKS BECAUSE OF LOW WATER LEVEL (LACK OF

WATER)
Boiler should never let to boil dry, because then cooling effect is lost and it may cause
a sootfire on the boiler tube surfaces. Sootfire normally severe damages boiler. In case
of Low-Low water alarm (LALL) in steam drum/boiler is triggered the boiler is bypassed
(if bypassing is possible) and necessary corrective actions e.g. manual level control by
operator are taken
If despite above function water level in drum still continues fall, engine shall be stopped
before boiler is dry.
9. SAFETY RISKS BECAUSE OF HIGH PRESSURE AND

TEMPERATURE
Because in the exhaust gas boiler the water is pressurized and temperature is above
100 °C there remains a risk of burn injury during operation, maintenance or other
similar situation. The temperature of exhaust gas is naturally extremely high and
therefore safety risks are to be clarified for maintenance and operational persons by
the end-user’s person in charge. The risk of burn injury exists also always in areas
with surface temperature is above 40 °C. In generally all surfaces like pipes, valves
and related components, which are not insulated and are connected to the steam
producing, involve the risk of burn injury.
Pump units, casing of exhaust gas boiler and other similar items are to be insulated
with a mineral wool and covered with cladding in order to minimize the above-
mentioned burn injury risks. Before items are insulated, proper work of them are to be
ensured. Worth noticing is that some valves, related control and other temperature-
sensitive equipment may not be insulated due to high temperature interactions. If in
such a case the heat retaining precautions are not effectively done, the risks of burn
injury may exist.
10. SAFETY RISKS IF SAFETY DEVICE OPENS IN USE

If pressure vessel safety valve opens (or other safety device reacts) during the
operation and the proper safety precautions are neglected, there may be a risk of injury
(e.g. burn or hearing).
In order to avoid any injure because of this risk, manufacturer’s instructions need to be
followed. Safety valve blow out pipes must be directed to a safe place determined by
the end-user.

11. RISK OF ELECTRICAL SHOCK

Cabinets used in the steam system are designed for professional use. Only trained and
briefed personnel are permitted to access the electrical cabinet.
All work performed inside the cabinets are highly recommended to be done without live
voltage. If work is done with power on international and local live electricity work
procedures are to be followed.

SYSTEM DESCRIPTION

Heat recovery system Documents 5514-142 1/6
Termonorte DFPP 5514 POS 7-8-2017 -
Content:
1 GENERAL ........................................................................................................................... 2
2 SCOPE OF SUPPLY ........................................................................................................... 2
3 SYSTEM DESCRIPTION ..................................................................................................... 3
3.1 Condensate system................................................................................................................ 3
3.2 Feed water tank ..................................................................................................................... 3
3.3 Feed water supply / Pump minimum flow control .................................................................... 3
3.4 Exhaust gas boilers ................................................................................................................ 4
3.4.1 Capacity control ........................................................................................................... 4
3.4.2 Soot blowing ................................................................................................................ 4
3.4.3 Feed water control ....................................................................................................... 4
3.5 Oil fired boiler ......................................................................................................................... 5
3.6 Diesel oil day tank .................................................................................................................. 5
3.7 Distribution and use of steam ................................................................................................. 5
3.8 Blow down system ................................................................................................................. 5
3.9 Water / steam analysing ......................................................................................................... 6
3.10 Electrical system .................................................................................................................... 6
3.11 Safety .................................................................................................................................... 6

System description 5514 - 2/6
1 GENERAL
The function of the Heat Recovery System is represented on two levels; Principle of the
process is described in the system description and electrical control of the process is
described in the electrical system description. Main components of the system are
described in the paragraph 2 Scope of supply.
Both system descriptions are to be studied and followed before installation, using and
maintenance of the Heat Recovery System.
The heat recovery system is shown in the main flow diagram no: 5514i10001
2 SCOPE OF SUPPLY
This Alfa Laval Aalborg´s Heat Recovery system is used for generating saturated steam
by utilizing waste heat energy of exhaust gases from diesel engines. The system
includes the following main items. Detailed information of devices could be found on data
sheets.
Pieces Device: Code:
4 Exhaust gas boiler type-HU, including: EGB 001 – 004
- exhaust gas damper,
- feed water control unit and
- feed water flow meter
1 Atmospheric feed water tank SVS-7, including: FWT 001
- steam heating control unit and
- make up water control unit
1 Condensate tank unit C-1, including: CTU 001
- two condensate pumps and
- oil detector unit
1 Steam header SH-250 SH 001
1 Auxiliary container AIC-40HC, including: AUX 001
- oil fired boiler with feed water ctrl unit, AUXB 001
- common control panel, CP 001
- feed water pump unit, FWPU 001
- chemical dosing unit CDU 001
- blow down tank and BDT 001
- two oil detectors ODU 001, 002
1 Diesel oil day tank LFO 001

3 SYSTEM DESCRIPTION
3.1 Condensate system
Condensate from the tank farm area is collected to condensate tank unit (CT 001). Part
of the returning condensate is directed through the oil detector in order to give an alarm
for operator panel in case of oily condensate. In case of the oil alarm, the inlet valve to
condensate tank should be closed and the oily condensate directed to drain. The drain
valve is to be installed by customer in suitable place.
There are two pumps in the condensate unit for transferring condensate to the feed water
tank. The operating pump is starting when the level control low (LCL) is activated and
stopping when the level control high (LCH) is reached. If condensate reaches the level
alarm low low (LALL), the running condensate pump is stopped in order to prevent dry
running of the pump. Another pump is in stand-by position and starts automatically in
case of an electrical failure in the running pump.
Condensate return from the both power house areas #1 and #2 are returned by own
pipes directly to the feed water tank. The part of the condensate from each line is directed
to oil detectors installed inside the auxiliary container (AUX 001).
3.2 Feed water tank

The flow of the make-up water into the feed water tank is controlled by the pneumatic
operated control valve (FWT 001.V015) which receives a signal from the water level
control system of the feed water tank. Level control low (LCL) opens the valve and level
control high (LCH) closes it.
The chemical dosing unit (CDU 001) is installed inside the container. Dosing rate of
chemical to feed water tank is adjusted on unit motor. On AUTO mode chemical dosing
follows make-up water valve position.
Demineralised make-up water and applicable chemical usage guarantees the sufficient
quality of the feed water. See 110G001f-(Water treatment) in O&M manual, Book 1:
General instructions and contact chemical and water treatment equipment suppliers.
NOTE!
Do not plug the venting pipe in the feed water tank or condensate tank. The gases have
to be able to escape the tank to atmosphere. Some visible vapour should billow from the
venting pipe. This is a sign that the thermal de-gassing is working
3.3 Feed water supply / Pump minimum flow control

Feed water to exhaust gas boilers as well as oil fired boiler is supplied with the feed water
pump unit (FWPU 001) located inside the container. There are two pumps in feed water
pump unit. One pump is running continuously and the other one is in stand-by position.
Minimum flow of the feed water pump is ensured by continuous return flow to the feed
water tank through the orifice (FWT A003). Strainers are installed in each pump suction
side in order to protect pumps. Strainers shall be regularly cleaned.

3.4 Exhaust gas boilers

The exhaust gas boilers are vertical smoke tube boilers that generate saturated steam.
Normal operating pressure for the boilers is 7 bar(g).
3.4.1 Capacity control

The capacity of the boilers is controlled by keeping the steam pressure in constant value
by modulating the exhaust gas damper with a linear actuator. The damper controls the
amount of exhaust gases flowing through the boiler. When the damper is fully open all
gases will flow through the boiler and the steam generation is at its highest, respectively
in closed position the exhaust gases by-pass the boiler.
Safety position of the by-pass damper is closed. In case of control or position feedback
signal is lost or high pressure alarm is received, by-pass blade is automatically turned to
boiler closed position. If main voltage for the actuator is lost, the blade inside the dampers
stop and must be closed manually with a special manual tool supplied with the damper.
The pressure regulating system is based on the pressure measurement from the
common steam header. The pressure transmitter (SH 001.P002) gives a signal to the
control system, which opens or closes the dampers according to pressure. The
modulating operation of the by-pass damper is continuous, meaning that the controller
is trying to reach a steady position to match steam production with steam consumption.
In AUTO mode dampers of all boilers are moving in parallel.
3.4.2 Soot blowing

Some saturated steam from the individual boiler main steam line is used for cleaning the
respective boiler by manual steam soot blowing. The exhaust gas boilers are equipped
with two automatic soot blowers for on-service cleaning. Soot blowing is considered a
secondary cleaning method, used for prolonging the interval for the off-service manual
brush cleaning / water washing. Soot blowing should be carried out regularly, preferably
daily during normal operation. Manual water washing should be carried out during
prolonged engine standstills whenever possible. Water washing is carried out through
boiler service hatches by fire hose/pressure washer or similar. Washing water is drained
from the boiler through the drain connection in the bottom. For detailed water washing
instructions document: 100G037 “Manual cleaning of smoke tube boiler” in O&M Manual
book 2
3.4.3 Feed water control

Each boiler has its own feed water control unit installed in the feed water line for
regulating the flow according to steam drum surface level. The flow is controlled by
electric operated feed water control valve (EGB V017) that is trying to stabilize the water
level in boiler corresponding to Normal Water Level (NWL). Valve safety position is
closed but if control voltage is lost line/valve shall be manually closed. Flow meter (EGB
F001) is also installed for each boiler for measuring the feed water flow.
NOTE !
Dry running of the boiler is not allowed, unless the boiler is properly cleaned before dry
running and manually prepared for dry-running. Please note that dry-running is only
allowed with the user’s responsibility. Alfa Laval Aalborg Oy does not take any
responsibility in case of a soot fire or other damages in a boiler.

3.5 Oil fired boiler

The system contains an auxiliary steam boiler (located inside the container), which can
be used for steam production by firing light fuel oil in start-up of the power plant and as
back up for the exhaust gas boilers. The capacity of a three-stage burner is controlled
with pressure switches according to the auxiliary boiler’s pressure. The auxiliary boiler
should always be under pressure when used as a back-up boiler.
The auxiliary boiler uses the same common feed water pumps as the exhaust gas boilers.
The flow to the auxiliary boiler is controlled by the auxiliary boiler’s feed water control
valve (AUXB V016). The control valve receives the signal from the water level control
system of the auxiliary boiler. There is also the water flow meter (AUXB F001) installed
in feed water line. The steam from the auxiliary boiler is led to steam header.
3.6 Diesel oil day tank

The fuel oil tank is equipped with a float-type level alarm switches for high and low level.
There is also continuous level measurement based on the pressure. Overfilling of the
tank is secured with float type switch. However during the filling, the fuel level must be
continuously monitored and the tank shall not be left unsupervised. During auxiliary boiler
operation the fuel level inside the tank shall be kept at an adequate limit, as dry running
will quickly damage the burner!
3.7 Distribution and use of steam

The saturated steam from the exhaust gas boilers is collected into the common steam
header (SH 001), and distributed to steam consumers. The main consumers are tank
farm area and power house areas #1 & #2 whose each have the own connection in the
steam header.
The temperature in the feed water tank is kept at 95°C by supplying steam through the
perforated lance pipe into the feed water tank. Temperature indication is transmitted to
PLC which controls valve FWT 001.V025.
NOTE!
Header and live steam line should always be preheated by manually after downtime
period.
3.8 Blow down system

The content of dissolved salts and other impurities in the steam system is controlled by
blowing sufficient amount of water out from the boilers and feed water tank. The blow-
out procedure is manual. The bottom blow-out is used 2-3 times per day by keeping
valve open 2-3 seconds. The scum blow out valve from the water surface is normally
kept slightly open all the time. The flow is adjusted based on the water quality and
pressure difference over the valve. Curves are represented in a valve enclosure.
Blow out water is led to blow down tank located inside the container. In blow down tank
part of hot water flashes to steam and cooled blow out water flows to the drain.

3.9 Water / steam analysing

The amount of blow-out is determined with regularly taken and analysed boiler water
sample. Due to high temperature boilers are equipped with sample coolers. See more
information from general instruction 110G001f “Water treatment” in O&M manual, Book
1: General instructions. A chemical supplier shall be contacted in order to find correct
chemicals.
3.10 Electrical system

The control panel for heat Recovery control system is installed inside the auxiliary
container. The control panel is used for controlling and/or monitoring the steam system.
For more electrical information, see document: “Electrical system description” and “HMI
– panel instruction” in O&M Manual book 4.
3.11 Safety
The overloading of the steam system is controlled step by step; if the pressure is raised
over the pre-set value, the high pressure is alarmed. If the boiler pressure still continues
to increase after the high pressure alarm, the bypass damper will be fully opened. If
despite this, the steam pressure is still increased, the safety valves will open. This
releases the surplus steam to atmosphere and lowers the boiler pressure immediately.
The safety valves are dimensioned so that they can safely release the whole steam
production capacity of the boiler.
Set points of safety valves:

Exhaust gas boilers: V002, V003: 10 bar(g)
Oil fired boiler: V001, V002: 10 bar(g)
NOTE!
The blow-out pipes from the safety valves are always to be pointed to a safe place so
that under no circumstances can a possible opening of the safety valves cause injury to
site personnel.
NOTE!
Only qualified personnel shall be allowed to operate the steam system after proper
induction and familiarization with the system. Under no circumstances shall any safety
device be by-passed or otherwise tampered with.

Part Oper.
No Part Code Material / Cert. Qty Component Description Type Enc. DN / PN PO/TO Range Power Voltage Manufacturer Notes Item No Price Conn.
bar(g) /
1 AUX001.A001 SFe / 1 VENTING GRILLE BLOWER PROTECTION 600x600 ºC 70003400150RA
bar(g) /
2 AUX001.A002 SFe / 1 VENTING GRILLE VENTILATION 600x1200 ºC 70003400157RA
bar(g) /
3 AUX001.A003 Steel / 1 OIL DETECTOR FOR OIL DETECTION ORGS 11-2 10151 ºC 230V/60Hz Gestra with valves 94104920178RA
bar(g) /
4 AUX001.A004 Steel / 1 OIL DETECTOR FOR OIL DETECTION ORGS 11-2 10151 ºC 230V/60Hz Gestra with valves 94104920178RA
1602PPE bar(g) / 16bar 2,1
5 AUX001.A005 / 1 CHEMICAL DOSING UNIT FOR WATER QUALITY ADJUSTING +PE tank 20134 ºC l/h 230V/60Hz Prominent 80004540157RA
MFS 50- bar(g) /
6 AUX001.M001 / 1 AXIAL-FLOW FAN D=500 (PULL) FOR CONTAINER VENTILATION 100/6B ºC 0.55 kW 440-480V 60HZ MIRACO 55504160171RA
bar(g) /
7 AUX001.V001 A105 / 1 BALL VALVE BOILER DRAIN Alfa 20R CS 10009 1''-female ºC Alfa Valvole 60007340416RA
1/2''- bar(g) /
8 AUX001.V002 A105 / 1 BALL VALVE SERVICE WATER TAP Alfa 20R CS 10009 female ºC Alfa Valvole 60007340402RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: AUX001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: HEAT RECOVERY CONTAINER, 40'HC REV BY: POS DATE: 19.6.2017 5514-14D
TERMONORTE DFPP 93 MW APPROVED BY: VLE DATE: 12.6.2017
Colombia Hyundai Heavy Industries Co Ltd Rev. REVISION: PAGE:
P-I DIAGRAM NO: 5514-3i E A 1/12
Part Oper.
7 bar(g) 480V/60Hz,
1 AUXB001.A001 / 1 LIGHT FUEL OIL BURNER 480V / 60Hz WM-L 30/2 T ºC 220V/60Hz Weishaupt 55605020261RA
7 bar(g) /
2 AUXB001.A002 AISI 304 / 1 SAMPLE COOLER SAMPLE COOLING NJ40 20092 ºC Finlon with valves 70004500150RA
DN100 7 bar(g) /
3 AUXB001.A003 1.0460 / 1 FLANGE FOR LEVEL PROBES FOR LEVEL SENSORS 3/4'' - 3/4'' PN40 ºC Gestra 81254780150RA
18 / EN-10204 7 bar(g) /
37 AUXB001.A004 3.2 / Class ?? 1 SIMPLEX FILTER FUEL OIL FILTRATION 1.12.2.85.95 DN25 ºC Boll&Kirch with basket-type filter element 70407120146RA
DN25 7 bar(g) /
4 AUXB001.F001 / 1 MAGNETIC FLOWMETER FEED WATER FLOW MEASUREMENT PN40 ºC 24 VDC Endress+Hauser Promag 50P25
1.4571/PTFE/Al 7 bar(g) /
5 AUXB001.L001 / 1 LEVEL CONTROL ELECTRODE CAPASITIVE LAH, LCH, LCL, LAL NRG 26-40 10168 3/4'' PN40 ºC Gestra 500 mm 81254620150RA
PANEL COMPONENT FOR 7 bar(g) / 4-20 mA
6 AUXB001.L001.1 Plastic / 1 LEVEL CONTROLLER FOR NRG 26-40 CAPASITIVE SENSOR NRR 2-40b 10166 ºC out 230 V 50/60 Hz Gestra panel installation 81254620241RA
7 bar(g) /
7 AUXB001.L002 1.4571 / 1 LEVEL CONTROL ELECTRODE CONDUCTIVE LALL NRG 16-4 10310 3/4'' PN40 ºC Gestra 500 mm 81254760188RA
PANEL COMPONENT FOR 7 bar(g) /
8 AUXB001.L002.1 / 1 LOW LEVEL SWITCH FOR NRG 16-4 CONDUCTIVE SENSOR NRS 1-53 10311 ºC 24VDC Gestra 81254740197RA
A105 / EN DN25 7 bar(g) /
9 AUXB001.L003 10204-3.1 1 LEVEL GAUGE REFLEX LOCAL LEVEL INDICATION DS Reflex 10100 PN40 ºC 340 mm Diesse 70108540199RA
PRESSURE GAUGE LIQUID FILLED WITH RED MARK 6 bar LM 1/2'' - D 7 bar(g) /
10 AUXB001.P001 AISI 316/304 / 1 POINTER LOCAL PRESSURE INDICATION G1/2B -red 20032 100 ºC 0-16 bar WIKA 80508400276RA
7 bar(g) / diff.0,3-
11 AUXB001.P002 1.4301/Brass / 1 PRESSURE SWITCH BURNER CONTROL RT 116 20025 3/8'' (M) ºC 1,3 Danfoss with sigth glass, IP66 80008120213RA
SS1.436/nickel 7 bar(g) / 1-10 bar /
14 AUXB001.P005 plated steel / 1 PRESSURE SWITCH, MAX RESET PAH BCP4H 20020 1/2'' (M) ºC diff 0,55 Danfoss IP65, PED 80008120353RA
200C.L1=25 1/2'' - D 7 bar(g) /
15 AUXB001.T001 AISI 316/304 / 1 THERMOMETER WITH POCKET 250 MM LOCAL TEMPERATURE INDICATION 0/8.G1/2B.A 20037 100 ºC 0-200°C WIKA 80808340227RA
GGG40.3 / EN DN 32/50 7 bar(g) /
16 AUXB001.V001 10204-3.1 1 SAFETY VALVE OVER PRESSURE RELEASE 25.912 10002 PN40 ºC ARI Armaturen Set point 10 bar(g) + blow out certificate 60407560178RA
GGG40.3 / EN DN 32/50 7 bar(g) /
17 AUXB001.V002 10204-3.1 1 SAFETY VALVE OVER PRESSURE RELEASE 25.912 10002 PN40 ºC ARI Armaturen Set point 10 bar(g) + blow out certificate 60407560178RA
GGG40.3 / EN DN25 7 bar(g) /
18 AUXB001.V003 10204-3.1 1 GLOBE VALVE VENTING 22.006 10011 PN16 ºC ARI Armaturen 60107200269RA
GGG40.3 / EN DN25 7 bar(g) /
19 AUXB001.V004 10204-3.1 1 GLOBE VALVE FOR MANIFOLD 22.006 10011 PN16 ºC ARI Armaturen 60107200269RA
DN25 7 bar(g) /
20 AUXB001.V005 1.4571 / 1 NON-RETURN VALVES, DISCO UNDER PRESSURE PROTECTION RK 86A 10113 PN6-40 ºC Gestra 60407580171RA
7 bar(g) /
21 AUXB001.V006 A105 / 1 BALL VALVE MANIFOLD FILLING / BLOW OUT Alfa 20R CS 10009 1''-female ºC Alfa Valvole 60007340416RA
GGG40.3 / EN DN100 7 bar(g) /
22 AUXB001.V007 10204-3.1 1 GLOBE VALVE STEAM OUTLET 22.006 10011 PN16 ºC ARI Armaturen 60107200311RA
DN25 7 bar(g) /
23 AUXB001.V008 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO FEED WATER INLET RK 76 10113 PN6-40 ºC Gestra 60207520248RA
GGG40.3 / EN DN25 7 bar(g) /
24 AUXB001.V009 10204-3.1 1 GLOBE VALVE FEED WATER INLET 22.006 10011 PN16 ºC ARI Armaturen 60107200269RA
GGG40.3 / EN DN25 7 bar(g) /
25 AUXB001.V010 10204-3.1 1 GLOBE VALVE BOTTOM BLOW OUT 22.006 10011 PN16 ºC ARI Armaturen 60107200269RA
A105 / EN Alfa 68 CS- DN25 7 bar(g) / 180C 14
26 AUXB001.V011 10204-3.1 1 BALL VALVE BOTTOM BLOW OUT TGV 10128 PN40 ºC bar Alfa Valvole 60007340423RA
GLOBE VALVE THROTTLING PLUG WITH LOCKING DN25 7 bar(g) /
27 AUXB001.V012 GGG40.3 / 1 DEVICE SCUM BLOW OUT 22.046SK 10001 PN16 ºC ARI Armaturen 60007570278RA
DN25 7 bar(g) /
28 AUXB001.V013 GG25 / 1 GLOBE VALVE FEED WATER CTRL ISOLATION 12.006 10011 PN16 ºC ARI Armaturen 60107200185RA
DN25 7 bar(g) /
29 AUXB001.V014 GG25 / 1 GLOBE VALVE FEED WATER CTRL BY PASS 12.006 10011 PN16 ºC ARI Armaturen 60107200185RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: AUXB001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: FIRED BOILER, BH-3000L REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
DN25 7 bar(g) /
30 AUXB001.V015 GG25 / 1 GLOBE VALVE FEED WATER CTRL ISOLATION 12.006 10011 PN16 ºC ARI Armaturen 60107200185RA
GGG40.3 / EN DN25 7 bar(g) /
31 AUXB001.V016 10204-3.1 1 CONTROL VALVE PREMIO AND POTENTIOMETER FEED WATER CONTROL 23.470 10165 PN25 ºC 2,2 kN 230 V / 60 Hz ARI Armaturen linear, kvs 2.5 60507940172RA
7 bar(g) /
32 AUXB001.V017 A105 / 1 BALL VALVE OIL FROM BURNER Alfa 20R CS 10009 1''-female ºC Alfa Valvole 60007340416RA
7 bar(g) /
33 AUXB001.V018 A105 / 1 BALL VALVE OIL TO BURNER Alfa 20R CS 10009 1''-female ºC Alfa Valvole 60007340416RA
DN25 7 bar(g) /
34 AUXB001.V019 GG25 / 1 GLOBE VALVE FEED WATER INLET 12.006 10011 PN16 ºC ARI Armaturen 60107200185RA
1/2'' PN 7 bar(g) /
35 AUXB001.V100 AISI 316 / 5 GAUGE VALVE WITH H TEST CONNECTION FOR PRESSURE EQUIPMENT DIN 16271 20086 400 ºC 80007800192RA
1/2'' PN 7 bar(g) /
36 AUXB001.V101 AISI 316 / 1 GAUGE VALVE SAMPLE DIN 16270 20090 400 ºC 80007800199RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: AUXB001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: FIRED BOILER, BH-3000L REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
DN15 bar(g)
1 BDT001.V001 GG25 / 1 GLOBE VALVE COOLING WATER INLET 12.006 10011 PN16 ºC ARI Armaturen 60107200171RA
1/2'' (F) bar(g) /
2 BDT001.V002 Ms / 1 TEMPERATURE CONTROL VALVE SELF ACTING COOLING WATER CONTROL AVTA 15 20045 PN16 ºC 10-80 C Danfoss with 1/2'' 1.4301 pocket 003N0196 60508020172RA
A105 / EN Alfa 10N/F DN32 bar(g) / 180C 12
3 BDT001.V003 10204-3.1 1 BALL VALVE DRAIN CS-PTFE 10035 PN40 ºC bar Alfa Valvole 60007340304RA
GGG40.3 / EN DN25 bar(g) /
4 BDT001.V004 10204-3.1 1 GLOBE VALVE AUXB BLOW DOWN INLET 23.006 10011 PN25 ºC ARI Armaturen 60107200360RA
DN25 bar(g) /
5 BDT001.V005 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO AUXB BLOW DOWN INLET RK 76 10113 PN6-40 ºC Gestra 60207520248RA
GGG40.3 / EN DN32 bar(g) /
6 BDT001.V006 10204-3.1 1 GLOBE VALVE EGBS BLOW DOWN INLET 23.006 10011 PN25 ºC ARI Armaturen 60107200367RA
DN32 bar(g) /
7 BDT001.V007 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO EGBS BLOW DOWN INLET RK 76 10113 PN6-40 ºC Gestra 60207520255RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: BDT001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: BLOW DOWN TANK, BDT-150 REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
HARDOX PRESSURE LOSS FOR OIL 0 bar(g)
1 CT001.A001 HX400 / 1 ORIFICE PLATE DETECTOR FLOW s=8mm 20005 95ºC DN50, hole d=14mm 20506140157RA
0 bar(g) / 115/230 V 50/60
34 CT001.A002 Steel / 1 OIL DETECTOR FOR OIL DETECTION ORGS 11-2 10151 95ºC Hz Gestra with valves 94104920178RA
/ EN 10204-3.-- 0 bar(g) /
2 CT001.D001 - 1 CENTRIFUGAL PUMP CONDENSATE SUPPLY CR 5-8 95ºC 480 V/60 Hz GRUNDFOS Type:CR 5-8 A-F-FGJ-A-E-HQQE Low NPSH 55408580360RA
/ EN 10204-3.-- 0 bar(g) /
3 CT001.D002 - 1 CENTRIFUGAL PUMP CONDENSATE SUPPLY CR 5-8 95ºC 480 V/60 Hz GRUNDFOS Type:CR 5-8 A-F-FGJ-A-E-HQQE Low NPSH 55408580360RA
DN25 0 bar(g) /
4 CT001.L001 1.4571 / 1 MAGNETIC LEVEL INDICATOR LOCAL LEVEL INDICATION BNA 10303 PN40 95ºC 600mm Kübler 5 pcs BGU-5SIL limit switches 70108500310RA
5 CT001.P001 AISI 316/304 / 1 POINTER LOCAL PRESSURE INDICATION G1/2B -red 20032 100 95ºC 0-10 bar WIKA 80508400192RA
6 CT001.P002 AISI 316/304 / 1 POINTER LOCAL PRESSURE INDICATION G1/2B -red 20032 100 95ºC 0-10 bar WIKA 80508400192RA
120C.L1=20 1/2'' - D 0 bar(g) /
68 CT001.T001 AISI 316/304 / 1 THERMOMETER WITH POCKET 200 MM LOCAL TEMPERATURE INDICATION 0/8.G1/2B.A 20037 100 95ºC 0-120°C WIKA 80808340157RA
AISI 316 / EN Alfa 10N/F DN25 0 bar(g) / 180C 12
7 CT001.V001 10204-3.1 1 BALL VALVE FOR LEVEL INDICATOR 316-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340507RA
AISI 316 / EN Alfa 10N/F DN25 0 bar(g) / 180C 12
8 CT001.V002 10204-3.1 1 BALL VALVE FOR LEVEL INDICATOR 316-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340507RA
Alfa 20R 316- 1/2''- 0 bar(g) /
9 CT001.V003 AISI 316 / 1 BALL VALVE LEVEL INDICATOR DRAIN TGV 10009 female 95ºC Alfa Valvole 60007340563RA
1/2'' PN 0 bar(g) /
10 CT001.V004 AISI 316 / 1 GAUGE VALVE SAMPLE DIN 16270 20090 400 95ºC 80007800199RA
DN32 0 bar(g) /
11 CT001.V005 GG25 / 1 GLOBE VALVE DRAIN 12.006 10011 PN16 95ºC ARI Armaturen 60107200192RA
1/2''- 0 bar(g) /
12 CT001.V006 A105 / 1 BALL VALVE DRAIN Alfa 20R CS 10009 female 95ºC Alfa Valvole 60007340402RA
1/2''- 0 bar(g) /
13 CT001.V007 A105 / 1 BALL VALVE DRAIN Alfa 20R CS 10009 female 95ºC Alfa Valvole 60007340402RA
A105 / EN Alfa 10N/F DN65 0 bar(g) / 180C 10
14 CT001.V008 10204-3.1 1 BALL VALVE PUMP SUCTION CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340325RA
15 CT001.V009 10204-3.1 1 BALL VALVE PUMP SUCTION CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340325RA
DN32 0 bar(g) /
16 CT001.V010 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO PRESSURE SIDE RK 76 10113 PN6-40 95ºC Gestra 60207520255RA
DN32 0 bar(g) /
17 CT001.V011 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO PRESSURE SIDE RK 76 10113 PN6-40 95ºC Gestra 60207520255RA
DN32 0 bar(g) /
18 CT001.V012 GG25 / 1 GLOBE VALVE THROTLING PLUG WITH LOCKING PRESSURE THROTTLING 12.006SK 10011 PN16 95ºC ARI Armaturen 60007460171RA
DN32 0 bar(g) /
19 CT001.V013 GG25 / 1 GLOBE VALVE THROTLING PLUG WITH LOCKING PRESSURE THROTTLING 12.006SK 10011 PN16 95ºC ARI Armaturen 60007460171RA
GGG40.3/1.440 DN125 0 bar(g) /
20 CT001.V014 1/ 1 BUTTERFLY VALVE WITH SOFT SEAL CONDENSATE INLET 22.012 10098 PN16 95ºC Ari Armaturen EPDM 60007740178RA
1/2''- 0 bar(g) /
21 CT001.V015 A105 / 1 BALL VALVE WATER TO OIL DETECTOR Alfa 20R CS 10009 female 95ºC Alfa Valvole 60007340402RA
1/2''- 0 bar(g) /
22 CT001.V016 A105 / 1 BALL VALVE WATER FROM OIL DETECTOR Alfa 20R CS 10009 female 95ºC Alfa Valvole 60007340402RA
1/2'' PN 0 bar(g) /
23 CT001.V100 AISI 316 / 2 GAUGE VALVE WITH H TEST CONNECTION FOR PRESSURE EQUIPMENT DIN 16271 20086 400 95ºC 80007800192RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: CT001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: CONDENSATE TANK UNIT, CU-1 REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
EGB001 - ATL40 RL2 bar(g)
1 004.A001 / 4 LINEAR ACTUATOR BLADE ADJUSTMENT C500 TS SP 379ºC 3x480VAC 60Hz Servomech 80014560192RA
EGB001 - I3 Pepperl & bar(g) /
2 004.A002 / 4 INDUCTIVE SENSOR DAMPER POSITION INDICATION Fuchs 379ºC Pepperl & Fuchs 80014560199RA
EGB001 - bar(g) /
3 004.A003 AISI 304 / 4 SAMPLE COOLER SAMPLE NJ40 20092 379ºC Finlon with valves 70004500150RA
EGB001 - DN100 bar(g) /
4 004.A004 1.0460 / 4 FLANGE FOR LEVEL PROBES FOR LEVEL SENSORS 3/4'' - 3/4'' PN40 379ºC Gestra 81254780150RA
EGB001 - DN25 bar(g) /
5 004.F001 / 4 MAGNETIC FLOW METER FEED WATER FLOW MEASUREMENT PN40 90°C 24 VDC Endress+Hauser Promag 50P25
EGB001 - 1.4571/PTFE/Al bar(g) /
6 004.L001 / 4 LEVEL CONTROL ELECTRODE CAPASITIVE LAH, LCH, LCL, LAL NRGT 26-1 10174 3/4'' PN40 379ºC 4-20 mA 24VDC Gestra 700 mm 81254640255RA
EGB001 - bar(g) /
7 004.L002 1.4571 / 4 LEVEL CONTROL ELECTRODE CONDUCTIVE LALL NRG 16-4 10310 3/4'' PN40 379ºC 1000mm Gestra 81254760188RA
EGB001 - bar(g) /
8 004.L002.1 / 4 LOW LEVEL SWITCH FOR NRG 16-4 LALL NRS 1-53 10311 379ºC 24VDC Gestra 81254740197RA
EGB001 - A105 / EN DN25 bar(g) /
9 004.L003 10204-3.1 4 LEVEL GAUGE REFLEX LOCAL LEVEL INDICATION DS Reflex 10100 PN40 379ºC 600 mm Diesse 70108540213RA
EGB001 - PRESSURE GAUGE LIQUID FILLED WITH RED MARK 6 bar LM 1/2'' - D bar(g) /
10 004.P001 AISI 316/304 / 4 POINTER STEAM OUTLET TEMPERATURE G1/2B -red 20032 100 379ºC 0-16 bar WIKA 80508400276RA
EGB001 - bar(g) / 1-10 bar /
11 004.P002 1.4301/Brass / 4 PRESSURE SWITCH WITH RESET BUTTON PAH RT 116 20025 3/8'' (M) 379ºC diff.0,3 Danfoss with sigth glass, IP54 80008120220RA
EGB001 - 500C.L1=60 1/2'' - D bar(g) /
12 004.T001 AISI 316/304 / 4 THERMOMETER WITH POCKET 600 MM EXHAUST GAS IN 0/8.G1/2B.A 20037 100 379ºC 0-500°C WIKA 80808340269RA
EGB001 - 500C.L1=60 1/2'' - D bar(g) /
13 004.T002 AISI 316/304 / 4 THERMOMETER WITH POCKET 600 MM EXHAUST GAS OUT 0/8.G1/2B.A 20037 100 379ºC 0-500°C WIKA 80808340269RA
EGB001 - 250C.L1=25 1/2'' - D bar(g) /
14 004.T003 AISI 316/304 / 4 THERMOMETER WITH POCKET 250 MM BOILER TEMPERATURE 0/8.G1/2B.A 20037 100 379ºC 0-250°C WIKA 80808340248RA
EGB001 - GGG40.3 / EN DN20 bar(g) /
15 004.V001 10204-3.1 4 GLOBE VALVE VENTING 22.006 10011 PN16 379ºC ARI Armaturen 60107200262RA
EGB001 - GGG40.3 / EN DN 40/65 bar(g) /
16 004.V002 10204-3.1 4 SAFETY VALVE OVER PRESSURE RELEASE 25.912 10002 PN40 379ºC ARI Armaturen Set point 10 bar(g) + blow out certificate 60407560185RA
EGB001 - GGG40.3 / EN DN 40/65 bar(g) /
17 004.V003 10204-3.1 4 SAFETY VALVE OVER PRESSURE RELEASE 25.912 10002 PN40 379ºC ARI Armaturen Set point 10 bar(g) + blow out certificate 60407560185RA
18 004.V004 1.4571 / 4 NON-RETURN VALVES, DISCO VACUUM BREAKER RK 86A 10113 PN6-40 379ºC Gestra 60407580164RA
EGB001 - GGG40.3 / EN DN100 bar(g) /
19 004.V005 10204-3.1 4 GLOBE VALVE STEAM OUTLET 22.006 10011 PN16 379ºC ARI Armaturen 60107200311RA
34 004.V006 10204-3.1 4 GLOBE VALVE STEAM TO SOOT BLOWERS 22.006 10011 PN16 379ºC ARI Armaturen 60107200283RA
EGB001 - EG-MS- 40mm bar(g) /
21 004.V007 Brass / 4 SOLENOID VALVE SOOT BLOWING GM88- 20071 (11/2'') 379ºC 230 V / 60 Hz Burkert normally closed 62408000191RA
22 004.V008 10204-3.1 4 GLOBE VALVE CONDENSATE OUTLET 22.006 10011 PN16 379ºC ARI Armaturen 60107200255RA
23 004.V009 C22.8 / 4 STEAM TRAP CONDENSATE OUTLET BK 45 10120 PN40 379ºC Gestra 70207080157RA
24 004.V010 10204-3.1 4 GLOBE VALVE BOTTOM BLOW OUT 22.006 10011 PN16 379ºC ARI Armaturen 60107200269RA
EGB001 - A105 / EN Alfa 10N/F DN25 bar(g) / 180C 12
25 004.V011 10204-3.1 4 BALL VALVE BOTTOM BLOW OUT CS-PTFE 10035 PN40 379ºC bar Alfa Valvole 60007340297RA
26 004.V012 10204-3.1 4 GLOBE VALVE THROTTLING PLUG WITH LOCKING SCUM BLOW OUT 22.006SK 10011 PN16 379ºC ARI Armaturen 60007460227RA
EGB001 - EG-MS- 40mm bar(g) /
27 004.V013 Brass / 4 SOLENOID VALVE SOOT BLOWING GM88- 20071 (11/2'') 379ºC 230 V / 60 Hz Burkert normally closed 62408000191RA
EGB001 - DN25 7 bar(g) /
28 004.V014 GG25 / 4 GLOBE VALVE FEED WATER CTRL ISOLATION 12.006 10011 PN16 ºC ARI Armaturen 60107200185RA
EGB001 - DN25 7 bar(g) /
29 004.V015 GG25 / 4 GLOBE VALVE BY-PASS 12.006 10011 PN16 ºC ARI Armaturen 60107200185RA
EGB001 - DN25 7 bar(g) /
30 004.V016 GG25 / 4 GLOBE VALVE FEED WATER CTRL ISOLATION 12.006 10011 PN16 ºC ARI Armaturen 60107200185RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: EGB001 - 004. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: EXHAUST GAS BOILER, H REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
EGB001 - GGG40.3 / EN DN25 7 bar(g) /
31 004.V017 10204-3.1 4 CONTROL VALVE PREMIO AND POTENTIOMETER FEED WATER CONTROL 23.470 10165 PN25 ºC 2,2 kN 230 V / 60 Hz ARI Armaturen linear, kvs 2.5 + RI21 4-20mA + open/closed limits 60507940172RA
32 004.V018 1.4107/1.4571 / 4 NON-RETURN VALVES, DISCO FEED WATER INLET RK 76 10113 PN6-40 379ºC Gestra 60207520248RA
20 004.V019 10204-3.1 4 GLOBE VALVE FEED WATER INLET 22.006 10011 PN16 379ºC ARI Armaturen 60107200269RA
EGB001 - 1/2'' PN bar(g) /
74 004.V100 AISI 316 / 8 GAUGE VALVE WITH H TEST CONNECTION FOR PRESSURE EQUIPMENT DIN 16271 20086 400 ºC 80007800192RA
EGB001 - 1/2'' PN bar(g) /
33 004.V101 AISI 316 / 4 GAUGE VALVE FOR SAMPLE COOLER DIN 16270 20090 400 ºC 80007800199RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: EGB001 - 004. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: EXHAUST GAS BOILER, H REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
/ EN 10204-3.-- DN50 bar(g) 95C 12
1 FWPU 001.D001 - 1 CENTRIFUGAL PUMP FEED WATER SUPPLY CR 15-6 PN16 ºC bar 480 V/60 Hz GRUNDFOS Type: CR 15-6 A-F-A-E-HQQE 55408580325RA
/ EN 10204-3.-- DN50 bar(g) / 95C 12
2 FWPU 001.D002 - 1 CENTRIFUGAL PUMP FEED WATER SUPPLY CR 15-6 PN16 ºC bar 480 V/60 Hz GRUNDFOS Type: CR 15-6 A-F-A-E-HQQE 55408580325RA
PRESSURE GAUGE LIQUID FILLED WITH RED MARK 6 bar LM 1/2'' - D bar(g) /
3 FWPU 001.P001 AISI 316/304 / 1 POINTER LOCAL PRESSURE INDICATION G1/2B -red 20032 100 ºC 0-16 bar WIKA 80508400276RA
PRESSURE GAUGE LIQUID FILLED WITH RED MARK 6 bar LM 1/2'' - D bar(g) /
4 FWPU 001.P002 AISI 316/304 / 1 POINTER LOCAL PRESSURE INDICATION G1/2B -red 20032 100 ºC 0-16 bar WIKA 80508400276RA
1/+3 bar LM 1/2'' - D bar(g) /
5 FWPU 001.P003 AISI 316/304 / 1 PRESSURE GAUGE LIQUID FILLED INLET PRESSURE INDICATOR G1/2B 20032 100 ºC -1-+3 bar WIKA 80508400206RA
DN50 bar(g) /
6 FWPU 001.V001 GG25 / 1 GLOBE VALVE THROTLING PLUG WITH LOCKING FOR PRESSURE THROTTLING 12.006SK 10011 PN16 ºC ARI Armaturen 60007460185RA
DN50 bar(g) /
7 FWPU 001.V002 GG25 / 1 GLOBE VALVE THROTLING PLUG WITH LOCKING FOR PRESSURE THROTTLING 12.006SK 10011 PN16 ºC ARI Armaturen 60007460185RA
DN50 bar(g) /
8 FWPU 001.V003 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO PRESSURE SIDE RK 76 10113 PN6-40 ºC Gestra 60207520269RA
DN50 bar(g) /
9 FWPU 001.V004 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO PRESSURE SIDE RK 76 10113 PN6-40 ºC Gestra 60207520269RA
DN15 bar(g) /
10 FWPU 001.V005 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO RETURN FROM PUMP RK 76 10113 PN6-40 ºC Gestra 60207520234RA
DN15 bar(g) /
11 FWPU 001.V006 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO RETURN FROM PUMP RK 76 10113 PN6-40 ºC Gestra 60207520234RA
DN65 bar(g) / screen
12 FWPU 001.V007 GG25 / 1 STRAINER WITH BLEED SCREW 1'' SUCTION SCREEN 12.050 10063 PN16 ºC 1,25mm ARI Armaturen 70407120192RA
DN65 bar(g) / screen
13 FWPU 001.V008 GG25 / 1 STRAINER WITH BLEED SCREW 1'' SUCTION SCREEN 12.050 10063 PN16 ºC 1,25mm ARI Armaturen 70407120192RA
14 FWPU 001.V009 10204-3.1 1 BALL VALVE WATER INLET CS-PTFE 10035 PN16 ºC bar Alfa Valvole 60007340332RA
15 FWPU 001.V010 10204-3.1 1 BALL VALVE WATER INLET CS-PTFE 10035 PN16 ºC bar Alfa Valvole 60007340332RA
1/2''- bar(g) /
16 FWPU 001.V011 A105 / 1 BALL VALVE DRAIN Alfa 20R CS 10009 female ºC Alfa Valvole 60007340402RA
1/2'' PN 12 bar(g)
17 FWPU 001.V100 AISI 316 / 3 GAUGE VALVE WITH H TEST CONNECTION FOR PRESSURE EQUIPMENT DIN 16271 20086 400 / 95ºC 80007800192RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: FWPU 001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: FEED WATER PUMP UNIT, in container REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
0 bar(g) ARI
1 FWT001.A001 / 1 STEAM INJECTOR STEAM INJECTOR 54.651 20080 R 1 PN25 95ºC ARMATUREN 20006920318RA
AIR SET WITH METAL TANK MOUNTED TO GT 0 bar(g) /
2 FWT001.A002 / 1 ACTUATOR FOR PNEUMATIC ACTUATOR Riegler 1/4'' 95ºC Riegler 80007800276RA
HARDOX 0 bar(g) /
3 FWT001.A003 HX400 / 1 ORIFICE PLATE PUMP MIN. FLOW s=8mm 20005 DN25 95ºC DN25, hole d=6 mm 20506140157RA
HARDOX PRESSURE LOSS FOR OIL 0 bar(g) /
4 FWT001.A004 HX400 / 1 ORIFICE PLATE DETECTOR FLOW s=8mm 20005 DN50 95ºC DN50, hole d=12 mm 20506140157RA
HARDOX PRESSURE LOSS FOR OIL 0 bar(g) /
5 FWT001.A005 HX400 / 1 ORIFICE PLATE DETECTOR FLOW s=8mm 20005 DN50 95ºC DN50, hole d=12 mm 20506140157RA
HARDOX 0 bar(g) /
6 FWT001.A006 HX400 / 1 ORIFICE PLATE FEED WATER FLOW RESTRICTOR s=8mm 20005 DN32 95ºC DN32, hole d=10mm 20506140157RA
LEVEL INDICATOR WITH LIMIT DN25 0 bar(g) /
7 FWT001.L001 1.4571 / 1 MAGNETIC LEVEL INDICATOR SWITCHES BNA 10303 PN40 95ºC 1300mm Kübler 5 pcs BGU-5SIL limit switches 70108500318RA
120C.L1=25 1/2'' - D 0 bar(g) /
8 FWT001.T001 AISI 316/304 / 1 THERMOMETER WITH POCKET 250 MM LOCAL TEMPERATURE INDICATION 0/8.G1/2B.A 20037 100 95ºC 0-120°C WIKA 80808340213RA
1/2'' PN 0 bar(g) /
9 FWT001.V001 AISI 316 / 1 GAUGE VALVE SAMPLE DIN 16270 20090 400 95ºC 80007800199RA
GGG40.3 / EN DN32 0 bar(g) /
10 FWT001.V002 10204-3.1 1 GLOBE VALVE DRAIN 22.006 10011 PN16 95ºC ARI Armaturen 60107200276RA
20M-20C- 0 bar(g) /
11 FWT001.V003 A316 / 1 BALL VALVE CHEMICAL DOSING 1/4 20149 1/4'' 95ºC 60007340745RA
RHZ10LRE 10mm x 0 bar(g) /
12 FWT001.V004 1.4571 / 1 NON-RETURN VALVE CHEMICAL DOSING D71 20150 G 1/4'' 95ºC 60407580184RA
13 FWT001.V005 10204-3.1 1 BALL VALVE FEED WATER SUPPLY CS-PTFE 10035 PN16 95ºC bar Alfa Valvole 60007340367RA
DN25 0 bar(g) /
14 FWT001.V006 GG25 / 1 GLOBE VALVE RETURN FROM PUMP 12.006 10011 PN16 95ºC ARI Armaturen 60107200185RA
DN25 0 bar(g) /
15 FWT001.V007 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO RETURN FROM PUMP RK 76 10113 PN6-40 95ºC Gestra 60207520248RA
1/2''- 0 bar(g) /
16 FWT001.V008 A105 / 1 BALL VALVE LEVEL INDICATOR DRAIN Alfa 20R CS 10009 female 95ºC Alfa Valvole 60007340402RA
17 FWT001.V009 10204-3.1 1 BALL VALVE FOR LEVEL INDICATOR CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340297RA
18 FWT001.V010 10204-3.1 1 BALL VALVE FOR LEVEL INDICATOR CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340297RA
DN25 0 bar(g) /
19 FWT001.V011 1.4317/1.4571 / 1 NON-RETURN VALVES DISCO TANK HEATING RK 86 10241 PN6-40 95ºC Gestra 60207520311RA
GGG40.3 / EN DN25 0 bar(g) / 30-100°C, AWH/ARI
20 FWT001.V012 10204-3.1 1 TEMPERATURE CONTROL VALVE SELF ACTING TEMPERATURE CONTROL 22.772 10203 PN16 95ºC size I Armaturen with 1'' protection tube 60508020199RA
GGG40.3 / EN DN25 0 bar(g) /
21 FWT001.V013 10204-3.1 1 GLOBE VALVE TANK HEATING 22.006 10011 PN16 95ºC ARI Armaturen 60107200269RA
DN32 0 bar(g) /
22 FWT001.V014 GG25 / 1 GLOBE VALVE INLET 12.006 10011 PN16 95ºC ARI Armaturen 60107200192RA
A105 / EN Alfa 10N/F DN32 0 bar(g) /
23 FWT001.V015 10204-3.1 1 BALL VALVE WITH PNEUMATIC ACTUATOR WATER FLO CONTROL CS GT83SE 10134 PN40 95ºC 230 VAC Alfa Valvole with solenoid valve, NC, open/closed limits 60007360171RA
0 bar(g) /
24 FWT001.V015.1 / 1 SPEED RESTRICTOR FOR ACTUATOR 261309 95ºC RC mounting between solenoid and actuator 60007380164RA
DN32 0 bar(g) /
25 FWT001.V016 GG25 / 1 GLOBE VALVE OUTLET 12.006 10011 PN16 95ºC ARI Armaturen 60107200192RA
DN32 0 bar(g) /
26 FWT001.V017 GG25 / 1 GLOBE VALVE BY-PASS 12.006 10011 PN16 95ºC ARI Armaturen 60107200192RA
27 FWT001.V018 10204-3.1 1 BALL VALVE WATER FROM OIL DETECTOR CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340283RA
28 FWT001.V019 10204-3.1 1 BALL VALVE WATER TO OIL DETECTOR CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340283RA
29 FWT001.V020 10204-3.1 1 BALL VALVE WATER FROM OIL DETECTOR CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340283RA
30 FWT001.V021 10204-3.1 1 BALL VALVE WATER TO OIL DETECTOR CS-PTFE 10035 PN40 95ºC bar Alfa Valvole 60007340283RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: FWT001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: FEED WATER TANK, SVS-7 REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
GGG40.3/1.440 DN80 0 bar(g) /
31 FWT001.V022 1/ 1 BUTTERFLY VALVE WITH SOFT SEAL CONDENSATE INLET 22.012 10098 PN16 95ºC Ari Armaturen EPDM 60007740164RA
GGG40.3/1.440 DN80 0 bar(g) /
32 FWT001.V023 1/ 1 BUTTERFLY VALVE WITH SOFT SEAL CONDENSATE INLET 22.012 10098 PN16 95ºC Ari Armaturen EPDM 60007740164RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: FWT001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: FEED WATER TANK, SVS-7 REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
DS akryl DN20 bar(g)
1 LFO001.L001 / 1 LEVEL GAUGE AKRYL TUBE LOCAL LEVEL INDICATOR tube 10100 PN40 ºC 1200 mm Diesse 70108520157RA
HIF-92-VU- 92x92 bar(g) /
2 LFO001.L002 316Ti / 1 HORIZONTAL FLOAT SWITCH LAH KL100-V44 10249 PN16 ºC KSR Kuebler 81254800150RA
DN25 bar(g) / VDC 3-
3 LFO001.L003 316L / 1 LEVEL TRANSMITTER REMOTE LEVEL INDICATOR (LIT) CERABAR 20089 PN10-40 ºC wire PNP 4-20mA HART Endress+Hauser Exact type: PMP51-AA21RA1KGAGCJA1+Z1 81254850160RA
HIF-92-VU- 92x92 bar(g) /
4 LFO001.L004 316Ti / 1 HORIZONTAL FLOAT SWITCH LAL KL100-V44 10249 PN16 ºC KSR Kuebler 81254800150RA
5 LFO001.V001 10204-3.1 1 BALL VALVE LFO INLET CS-PTFE 10035 PN40 ºC bar Alfa Valvole 60007340297RA
6 LFO001.V002 10204-3.1 1 BALL VALVE DRAIN CS-PTFE 10035 PN40 ºC bar Alfa Valvole 60007340297RA
7 LFO001.V003 10204-3.1 1 BALL VALVE LFO TO BURNER CS-PTFE 10035 PN40 ºC bar Alfa Valvole 60007340297RA
8 LFO001.V004 10204-3.1 1 BALL VALVE LFO RETURN CS-PTFE 10035 PN40 ºC bar Alfa Valvole 60007340297RA
bar(g) /
9 LFO001.V005 / 1 FLOAT VALVE MECHANICAL STOP SWITCH 10308 DN25 ºC Mankenberg Type NV 93 Z/w, DN25 81254800180RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: LFO001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: LFO DAY TANK, LFO-2 REV BY: POS DATE: 19.6.2017 5514-14D
Part Oper.
6 bar LM 1/2'' - D 7 bar(g)
1 SH001.P001 AISI 316/304 / 1 PRESSURE GAUGE LIQUID FILLED LOCAL PRESSURE INDICATION G1/2B 20032 100 170ºC 0-16 bar WIKA 80508400255RA
7 bar(g) / 24 VDC / 4-
2 SH001.P002 AISI316L / 1 PRESSURE TRANSMITTER FOR PRESSURE CONTROL MBS3100 20021 1/2'' (M) 170ºC 0-16 bar 20mA Danfoss Accuracy 0,5%, Marine approved, IP65 80008200164RA
GGG40.3 / EN DN100 7 bar(g) /
3 SH001.V001 10204-3.1 1 GLOBE VALVE STEAM INLET 22.006 10011 PN16 170ºC ARI Armaturen 60107200311RA
DN100 7 bar(g) /
4 SH001.V002 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO STEAM INLET RK 76 10113 PN6-40 170ºC Gestra 60207520290RA
GGG40.3 / EN DN100 7 bar(g) /
DN100 7 bar(g) /
GGG40.3 / EN DN100 7 bar(g) /
DN100 7 bar(g) /
GGG40.3 / EN DN100 7 bar(g) /
DN100 7 bar(g) /
GGG40.3 / EN DN100 7 bar(g) /
11 SH001.V009 10204-3.1 1 GLOBE VALVE STEAM OUTLET 22.006 10011 PN16 170ºC ARI Armaturen 60107200311RA
DN100 7 bar(g) /
12 SH001.V010 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO STEAM OUTLET RK 76 10113 PN6-40 170ºC Gestra 60207520290RA
GGG40.3 / EN DN100 7 bar(g) /
DN100 7 bar(g) /
14 SH001.V012 1.4107/1.4571 / 1 NON-RETURN VALVES, DISCO STEAM OUTLET RK 76 10113 PN6-40 170ºC Gestra 60207520290RA
GGG40.3 / EN DN150 7 bar(g) /
DN150 7 bar(g) /
16 SH001.V014 1.0619/1.4006 / 1 NON-RETURN VALVES DISCO STEAM OUTLET RK 86 10241 PN10-16 170ºC Gestra 60207520367RA
GGG40.3 / EN DN100 7 bar(g) /
DN100 7 bar(g) /
GGG40.3 / EN DN25 7 bar(g) /
GGG40.3 / EN DN15 7 bar(g) /
20 SH001.V018 10204-3.1 1 GLOBE VALVE DRAIN 23.006 10011 PN25 170ºC ARI Armaturen 60107200346RA
GGG40.3 / EN DN15 7 bar(g) /
21 SH001.V019 10204-3.1 1 GLOBE VALVE CONDENSATE OUTLET 23.006 10011 PN25 170ºC ARI Armaturen 60107200346RA
DN15 7 bar(g) /
22 SH001.V020 C22.8 / 1 STEAM TRAP CONDENSATE OUTLET BK 45 10120 PN40 170ºC Gestra 70207080157RA
GGG40.3 / EN DN15 7 bar(g) /
23 SH001.V021 10204-3.1 1 GLOBE VALVE CONDENSATE OUTLET 23.006 10011 PN25 170ºC ARI Armaturen 60107200346RA
1/2'' PN 7 bar(g) /
24 SH001.V100 AISI 316 / 2 GAUGE VALVE WITH H TEST CONNECTION FOR PRESSURE EQUIPMENT DIN 16271 20086 400 170ºC 80007800192RA
1/2'' PN 7 bar(g) /
24 SH001.V100 AISI 316 / 2 GAUGE VALVE WITH H TEST CONNECTION FOR PRESSURE EQUIPMENT DIN 16271 20086 400 170ºC 80007800192RA
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: SH001. MADE BY: POS DATE: 5.6.2017 COMPONENT LIST NO:
5514 DEVICE NAME: STEAM HEADER, SH-250D REV BY: POS DATE: 19.6.2017 5514-14D
1 EGB 001-004 Exhaust gas boiler
2 AUXB 001 Auxiliary Boiler
3 FWT 001 Feed Water Tank
4 SH 001 Steam Header
5 LFO 001 LFO Tank
6 BDT 001 Blow Down Tank
7 FWPU 001 Feed Water Pump Unit
8 CT 001 Condensate tank unit
CONTENTS OF
CHAPTER 1.4
TECHNICAL
DATA SHEETS
1.4 Data Sheets

TECHNICAL DATA SHEET
Exhaust Gas Boiler
Subject / customer Ref. No. Issubed by Date Ref. No. Rev. Page
Exhaust gas boiler VLE 5.5.2017 5514D4056 - 1 (1)
PROJECT INFO:
PROJECT NAME TERMONORTE
PROJECT NUMBER 5514
DEVICE CODE EGB 001-004
DEVICE Exhaust gas boiler
MODEL AALBORG H
TYPE Smoke tube boiler
HEAT SECTIONS Evaporator
MANUFACTURER Alfa Laval Aalborg Oy
SERIAL NUMBER 10146-10149
YEAR OF MANUFACTURING 2017
CLASSIFICATION PED
MAIN DIMENSIONS H=7260, ø3110 (with insulation)
WEIGHT: DRY / OPERATION / MAX 22100 / 29600 / 37000 kg
WATER VOLUME 11,03 m³
MAIN VOLTAGE 480 V / 60 Hz
CONTROL VOLTAGE 220 VAC
CONSTRUCTION INFO:
Aalborg H exhaust gas boiler is a vertical smoke tube exhaust gas boiler for heat recovery from diesel engine exhaust gas. The boiler system
generates saturated steam. The heat transfer surface consists of vertical steel tubes, which are surrounded by water. The tubes are connected to
inlet and outlet exhaust gas chambers. Exhaust gas flow is directed first downward to the reverse chamber from where it is turned to upward.
Cleaning as well as visual inspection is done via manhole in the waterside and via service openings in the flue gas side. The capacity of the exhaust
gas boiler is controlled with integrated exhaust gas damper.
DIMENSIONING DATA: BASIC VALUE FIXED VALUE POSITION

EXHAUST GAS FLOW IN 16 kg/s / 379 °C
EXHAUST GAS FLOW OUT 16 kg/s / 239 °C
TEMPERATURE IN FEED WATER TANK 95 °C
CONDENSATE TEMPERATURE 95 °C
CONDENSATE RETURN % 98 %
CAPACITY 2466 kW
OPERATING PRESSURE / TEMPERATURE 7 bar (g) / 170 °C
DESIGN PRESSURE / TEMPERATURE 10 bar (g) / 184°C
EXHAUST GAS PRESSURE DROP (CLEAN) 979 Pa
PRESSURE TEST VALUE 16,8 bar (g)
SAFETY VALVE SET POINT 10 bar (g) V002, V003
DESIGN CODE EN 12953
PROCESS DATA SET VALUE FIXED VALUE POSITION

TEMPERATURE INDICATION (TI), exhaust gas inlet 379 °C T001
TEMPERATURE INDICATION (TI), exhaust gas outlet 39 °C T002
TEMPERATURE INDICATION (TI), pressure part 170 °C T003
PRESSURE INDICATION (PI) 7 bar (g) P001
PRESSURE ALARM HIGH (PAH), reset button 8,5 bar (g) P002
LOCAL WATER LEVEL INDICATOR see below
LEVEL CONTROLLING +224 mm to top of the probe flange
Level alarm high (LAH, alarmed) 100 mm L001
Level control high (LCH) 170 mm L001
Level control low (LCL) 250 mm L001
Level alarm low (LAL, alarmed) 350 mm L001
Level alarm low low (LALL) 450 mm L002

Feed Water Tank
Feed water tank VLE 2.5.2017 5514D4053 1 (1)
PROJECT INFO:
PROJECT NUMBER 5514
DEVICE CODE FWT 001
DEVICE Feed water tank
MODEL SVS-7
SERIAL NUMBER 4395
CLASSIFICATION -
MAIN DIMENSIONS L=4162 mm, W=2160 mm, H=abt. 3505 mm
WEIGHT: MAX / OPERATION / DRY 8600 / 5600 / 1600 kg
WATER VOLUME: OPERATION / MAX 5,5 / 7,6 m³
MAIN VOLTAGE 480 VAC / 60 Hz
CONSTRUCTION INFO:
SVS-7 is an all-welded horizontal tank consisting of horizontal steel cylinder and dished ends. Tank is insulated and equipped with service hatch,
valves and instruments.

Dimensioning is based on thermal data of the system
OPERATING PRESSURE / TEMPERATURE Atmosperic / 95°C
DESIGN PRESSURE / TEMPERATURE Atmosperic / 100°C
PRESSURE TEST VALUE Water filling test
DESIGN CODE ALA standard

TEMPERATURE INDICATION (TI) 95 °C T001
TEMPERATURE CONTROL, steam injection 95 °C V011
LEVEL CONTROLLING - L001
Level alarm high (LAH, alarmed) 50 mm (6,9 m³ ) LAH (L001)
Level control high (LCH) 290 mm (5,8 m³ ) LCH (L001)
Normal water level (NWL) 330 mm (5,55 m³)
Level control low (LCL) 370 mm (5,3 m³ ) LCL (L001)
Level alarm low (LAL, alarmed) 690 mm (3,3 m³ ) LAL (L001)
Level alarm low low (LALL, 1210 mm (0,5 m³ ) LALL (L001)

pump stopped)
Level indication (LI) see above LI (L001)
EXTRA INFO
Steam header
Subject / customer Ref. No. Issued by Date Ref. No. Rev. Page
Steam header VLE 2.5.2017 5514D4056 1 (1)
PROJECT INFO:
PROJECT NUMBER 5514
DEVICE CODE SH 001
DEVICE Steam header
MODEL SH-250D
MANUFACTURING NUMBER 4397
CLASSIFICATION PED 97/23/EC
MAIN DIMENSIONS L=3700 mm, W=840 mm, H=1662 mm, ø 273 mm
WEIGHT: DRY / OPERATION / MAX 950 / 1000 / 1050 kg
CONSTRUCTION INFO:
SH-250D is a steam pipe with removable blind flange connection in the both ends. The header is equipped with valves and instruments. Saturated
steam from boiler is collected to the header from which it is distributed to the consumers.
DIMENSIONING DATA: BASIC VALUE FIXED VALUE

OPERATING PRESSURE / TEMPERATURE 7 bar (g) / 170°C
DESIGN PRESSURE / TEMPERATURE 10 bar (g) / 184°C
PRESSURE TEST VALUE 15 bar (g)
DESIGN CODE EN 13480

PRESSURE INDICATION (PI) 7 bar (g) P001
PRESSURE TRANSMITTER (PT) 7 bar (g) (0-16 bar) P002
LFO-Day Tank
LFO-day tank, LFO-2 VLE 2.5.2017 5514D4054 - 1 (1)
PROJECT INFO:
PROJECT NUMBER 5514
DEVICE CODE LFO 001
DEVICE LFO-day tank
MODEL LFO-2
SERIAL NUMBERS 4399
MAIN DIMENSIONS ø 1300 mm, W=abt. 1490, H=2625 mm,
WEIGHT: OPERATION / DRY 2500 / 500 kg
VOLUME 2 m³
MAIN VOLTAGE 480 VAC / 60 Hz
CONSTRUCTION INFO:
All welded vertical steel cylinder with dished ends, legs and pipe joints. The LFO-day tank is without insulation and equipped with valves and
instruments. By the side of the tank there is a hatch for service.

LFO IN, PRESSURE /TEMP max. 2 bar(g) / 5-40°C
LFO IN, VOLUMETRIC FLOW min 0.9 m³/h

LEVEL CONTROLLING
Level indication transmitter (LIT) LIT (L003)
Level alarm high (LAH, alarmed) LAH (L002)
Level alarm low (LAL, alarmed) LAL (L004)
EXTRA INFO
Blow Down Tank
Blow down tank VLE 5.5.2017 5514D4057 - 1 (1)
PROJECT INFO:
PROJECT NUMBER 5514
DEVICE CODE BDT 001
DEVICE Blow down tank
MODEL BDT-150
SERIAL NUMBER 4398
CLASSIFICATION -
MAIN DIMENSIONS H=2280, ø=557 mm
WEIGHT: OPERATION / DRY 360 / 250 kg
WATER VOLUME: MAX 0,15 m³
MAIN VOLTAGE 480 VAC / 60Hz
CONSTRUCTION INFO:
Blow out procedures must be executed periodically for any type of steam boiler to remove concentrations of solids, which would otherwise buildup in
the boiler water. The blowdown tank is designed to safely handle those hot discharges with a self-acting temperature control of cooling water.

COOLING WATER IN, PRESSURE /TEMP 2-5 bar(g) / 10-30°C
COOLING WATER IN, VOLUMETRIC FLOW 2,6 m³/h
DESIGN CODE SEP

TEMPERATURE CONTROL, cooling water 60° C
EXTRA INFO
Feed Water Pump Unit
Feed water pump unit POS 15.8.2017 5474D4058 1 (1)
PROJECT INFO:
PROJECT NUMBER 5514
DEVICE CODE FWPU001
DEVICE Feed water pump unit
MODEL FWPU
SERIAL NUMBER
CLASSIFICATION -
MAIN DIMENSIONS
WEIGHT Pump gross weight 171 kg / pump
PUMP TYPE, see details from pump card CR 15-6 A-F-A-E-HQQE
PUMP MOTOR, see details from pump card 11 Kw / 3520-3550 rpm / 480V, 60Hz
MAIN VOLTAGE 3 x 380 - 480 VAC / 60Hz
CONTROL VOLTAGE 230 VAC / 60Hz
CONSTRUCTION INFO:
Feed water pumps (2 pcs, one as standby) with motors, valves, pressure gauges and orifice equipped to the return line, are installed to the common unit. To
pressure side of the unit is installed also feed water control valve.

CAPACITY 2 x 16 m³/h, at Δp 10,0 bar(g)
ORIFACE PLATE HOLE ø ø6 mm
OPERATING PRESSURE 10,0 bar (g) + inlet press.
OPERATING TEMPERATURE 95°C
DESIGN PRESSURE / TEMPERATURE -
MIN. ALLOWABLE OPERATING TEMPERATURE 5 °C
MAX. ALLOWABLE OPERATING TEMPERATURE 100 °C
PRESSURE TEST VALUE -
DESIGN CODE ALA standard

PRESSURE INDICATION (PI), pressure side 11 bar(g)+inlet press. P001
PRESSURE INDICATION (PI), pressure side 11 bar(g)+inlet press. P002
PRESSURE INDICATION (PI), suction (inlet) side Min. 0,2 bar(g) P003
EXTRA INFO
96503823 CR 15-6 60 Hz
H CR 15-6, 3*480 V, 60Hz eta
[m] [%]
Q = 12 m³/h
H = 117 m
Pumped liquid = Water
Liquid temperature = 293 K
130 Density = 998.2 kg/m³
120
110
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
Eta pump = 64.3 %
Eta pump+motor = 59.1 %
0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 Q [m³/h]
P NPSH
[kW] [m]
10 10
P1
8 P2 8
6 6
4 4
2 2
P1 = 6.5 kW
P2 = 5.98 kW
NPSH = 1.2 m
0 0
Printed from Grundfos CAPS [2014.01.045] 1/5

Description Value H CR 15-6, 3*480 V, 60Hz eta
[m] [%]
Q = 12 m³/h
Product name: CR 15-6 A-F-A-E-HQQE 130
H = 117 m
Product No: 96503823 120 Pumped liquid = Water
EAN number: 5700396277875 110 Liquid temperature = 293 K
Density = 998.2 kg/m³
Price: On request 100 100
90 90
Technical: 80 80
Speed for pump data: 3529 rpm 70 70
Actual calculated flow: 12 m³/h 60 60
Resulting head of the pump: 117 m 50 50
Head max: 123 m 40 40
Impellers: 06
30 30
Shaft seal: HQQE
20 20
Approvals on nameplate: CE,TR Eta pump = 64.3 %
10 10
Curve tolerance: ISO 9906:1999 Annex A Eta pump+motor = 59.1 %
0 0
Pump type: CR 15 0 5 10 15 20 25 Q [m³/h]
Stages: 6 P NPSH
Pump version: A [kW] [m]
Model: A 10 10
P1
P2
Materials:
Pump housing: Cast iron 5 5
P1 = 6.5 kW
EN-JL1030 P2 = 5.98 kW
ASTM A48-30 B NPSH = 1.2 m
0 0
Impeller: Stainless steel
DIN W.-Nr. 1.4301
AISI 304
4 x ø13.5
ø165
Material code: A ø125
Code for rubber: E
ø65
Installation:
215
256
Maximum ambient temperature: 333 K
ø18.1
Max pressure at stated temp: 16 bar / 120 °C
16 bar / -20 °C 352 20
Flange standard: DIN G 1/2
Connect code: F
Pipe connection: DN 50
314
130
176
300
Pressure stage: PN 16
204
G 1/2
G 1/2
Flange size for motor: FF300

90
Liquid: 471 709
Pumped liquid: Water
Liquid temperature range: 253 .. 393 K
Liquid temp: 293 K THERMISTORS PTC ACCORDING TO DIN 44082
Density: 998.2 kg/m³ CONNECTED TO AMPLIFIER RELAY FOR CONTROL OF MAIN SUPPLY
IEC TP211 THERMALLY PROTECTED WHEN THE THERMISTORS ARE
Kinematic viscosity: 1 mm2/s
Electrical data:
Motor type: 160MB
IE Efficiency class: IE2 - IE3
+T
+T
L3
L3
Number of poles: 2
L2
L2
Rated power - P2: 11 kW

+T
+T
L1
L1
Power (P2) required by pump: 11 kW

11 kW
+T
+T
TO AMPLIFIER
TO AMPLIFIER
Mains frequency: 60 Hz
RELAY
RELAY
Rated voltage: 3 x 220-277 D/380-480 Y V

Rated current: 36,0-30,0/20,8-17,2 A
Starting current: 580-890 %
Cos phi - power factor: 0,89-0,83
Rated speed: 3520-3550 rpm
Efficiency: IE2 90,2% - IE3 91,0%
Motor efficiency at full load: 90,2-91,0 %
Motor efficiency at 3/4 load: 91,1-91,4 %
Enclosure class (IEC 34-5): 55 (Protect. water jets/dust)
Insulation class (IEC 85): F
Motor protec: PTC
Motor No: 85U07524
Others:
Label: Grundfos Blueflux
Minimum efficiency index, MEI ≥: 0.7
Net weight: 143 kg
Gross weight: 171 kg

Description Value
Shipping volume: 0.56 m3

96503823 CR 15-6 60 Hz
204
314
471
352
G 1/2 G 1/2
709
ø18.1
G 1/2 ø125
ø165
20
90
4 x ø13.5
130 ø65
176 215
300 256
Note! All units are in [mm] unless others are stated.

Disclaimer: This simplified dimensional drawing does not show all details.
Printed from Grundfos CAPS [2014.01.045]

4/5
96503823 CR 15-6 60 Hz
+T +T +T
CONNECTED TO AMPLIFIER RELAY FOR CONTROL OF MAIN SUPPLY

IEC TP211 THERMALLY PROTECTED WHEN THE THERMISTORS ARE
TO AMPLIFIER
RELAY
L1 L2 L3
THERMISTORS PTC ACCORDING TO DIN 44082

+T +T +T
TO AMPLIFIER
RELAY
L1 L2 L3

Condensate Tank unit
Condensate tank unit VLE 2.5.2017 5514D4055 - 1 (1)
PROJECT INFO:
PROJECT NUMBER 5514
DEVICE CODE CT001
DEVICE Condensate tank unit
MODEL C-1
SERIAL NUMBER 4396
MAIN DIMENSIONS L=1955, W=1200, H=2380
WEIGHT: MAX / OPERATION / DRY 2300 / 1800 / 1300 kg
PUMP TYPE, see details from pump card CR 5-8 (see pump card for details)
PUMP MOTOR, see details from pump card 2,2 kW
WATER VOLUME: OPERATION / MAX 0.2 / 1.0 m³
MAIN VOLTAGE 480V / 60Hz Hz
CONSTRUCTION INFO:
C-1 unit is an all-welded horizontal condensate tank module, where condensate pumps (2 pcs, one as standby), service hatch and some valves and
fittings are ready assembled. Some of equipment is delivered loose to avoid the damages during the transportation. The tank and hot pipes in module are
insulated. The C-1 unit is equipped with oil detector.

DESIGN CODE SEP
DESIGN CAPACITY 10 m³/h,at Δp 2.5 bar(g)
MAX. ALLOWABLE OPERATING TEMPERATURE 120 °C

TEMPERATURE INDICATION (TI) 95 °C T001
LEVEL CONTROLLING L001
Level alarm high (LAH, alarmed) 60 mm LAH (L001)
Level control high (LCH) 160 mm LCH (L001)
Level control low (LCL) 260 mm LCL (L001)
Level alarm low (LAL, alarmed) 360 mm LAL (L001)
Level alarm low low (LALL, 530 mm LALL (L001)

safe locking with reset button)
PRESSURE INDICATION (PI), pressure side 3 bar(g) P001
PRESSURE INDICATION (PI), pressure side 3 bar(g) P002
96557252 CR 5-8 60 Hz
H CR 5-8, 3*480 V, 60Hz eta
[m] [%]
Q = 5.03 m³/h
H = 69.7 m
Pumped liquid = Water
Liquid temperature = 20 °C
Density = 998.2 kg/m³
80
70
60
50 100
40 80
30 60
20 40
10 20
Eta pump = 59 %
Eta pump+motor = 50.9 %
0 0
0 1 2 3 4 5 6 7 8 9 10 Q [m³/h]
P NPSH
[kW] [m]
2.5 10
P1
2.0 8
P2
1.5 6
1.0 4
0.5 2
P1 = 1.88 kW
P2 = 1.62 kW
NPSH = 1.3 m
0.0 0

Description Value H CR 5-8, 3*480 V, 60Hz eta
[m] [%]
Q = 5.03 m³/h
Product name: CR 5-8 A-FGJ-A-E-HQQE H = 69.7 m
Product No: 96557252 Pumped liquid = Water
EAN number: 5700399070435 Liquid temperature = 20 °C
80 Density = 998.2 kg/m³
Price: On request
Technical: 70
Speed for pump data: 3501 rpm
Actual calculated flow: 5.03 m³/h 60
Resulting head of the pump: 69.7 m
Head max: 85.1 m 50 100
Impellers: 8
Shaft seal: HQQE
40 80
Approvals on nameplate: CE,TR
Curve tolerance: ISO 9906:1999 Annex A
Pump type: CR 5 30 60
Stages: 8
Pump version: A 20 40
Model: A
10 20
Materials:
Eta pump = 59 %
Pump housing: Cast iron Eta pump+motor = 50.9 %
EN-JL1030 0 0
0 1 2 3 4 5 6 7 8 9 Q [m³/h]
ASTM A48-30 B P NPSH
Impeller: Stainless steel [kW] [m]
DIN W.-Nr. 1.4301 2.5
P1
10
AISI 304
Material code: A 2.0
P2
8
Code for rubber: E
1.5 6
Installation:
Maximum ambient temperature: 60 °C 1.0 4
Max pressure at stated temp: 25 bar / 120 °C
25 bar / -20 °C 0.5 P1 = 1.88 kW 2
Flange standard: DIN P2 = 1.62 kW
NPSH = 1.3 m
Connect code: FGJ 0.0 0
Pipe connection: DN 25 / DN 32
Pressure stage: PN 16 / PN 25
Flange size for motor: FT115
Liquid:
Pumped liquid: Water
Liquid temperature range: -20 .. 120 °C
Liquid temp: 20 °C
Density: 998.2 kg/m³
Kinematic viscosity: 1 mm2/s
Electrical data:
Motor type: 90LC
IE Efficiency class: IE2 - IE3
Number of poles: 2
Rated power - P2: 2.2 kW
Power (P2) required by pump: 2.2 kW
2.2 kW
Mains frequency: 60 Hz
Rated voltage: 3 x 380-480 D V
Rated current: 4,45-3,70 A
Starting current: 780-1100 %
Cos phi - power factor: 0,91-0,85
Rated speed: 3470-3530 rpm
Efficiency: IE2 85,5% - IE3 86,5%
Motor efficiency at full load: 85,5-86,5 %
Enclosure class (IEC 34-5): 55 (Protect. water jets/dust)
Insulation class (IEC 85): F
Motor protec: NONE
Motor No: 85U15908
Others:
Label: Grundfos Blueflux
Minimum efficiency index, MEI ≥: 0.57
Net weight: 42.2 kg
Gross weight: 46.2 kg

96557252 CR 5-8 60 Hz
110
178
321
463
G 1/2 19 x 24.5
ø100
ø140
ø89
75
20
100 ø35 4 x ø13.5

141 180
250 220

Disclaimer: This simplified dimensional drawing does not show all details.

96557252 CR 5-8 60 Hz
LOW VOLTAGE
DIRECTION OF ROTATION
L1 L2 L3
HIGH VOLTAGE
DIRECTION OF ROTATION
L1 L2 L3

TRANSPORTATION

Transportation Transpor- - 1/3
tation
General - Tiia Koivu 20-08-2002 -
CONTENT:
1. GENERAL TRANSPORTATION INSTRUCTIONS ..........................................................................2

2. LIFTING ........................................................................................................................................... 2
3. STORING ......................................................................................................................................... 2
4. PACKING ......................................................................................................................................... 3
4.1 Packing dimensions ...................................................................................................................3
4.2 Packing lists ...............................................................................................................................3
4.3 Labels ........................................................................................................................................3
4.4 Material checking .......................................................................................................................3

Transportation - - 2/3
1. GENERAL TRANSPORTATION INSTRUCTIONS

Transport of the project goods requires proper preparations and handling. The method
of transportation is to be chosen so that goods are transported safe and risks for
damages are minimized. The reloading of goods should also be eliminated. By sea
transport; seaworthy packages and standard linear containers can be located on the
deck, all other type of packages are to be located under the deck. Depending on
method of transportation all packages need to be loaded, located and secured properly.
The responsibility for transportation will be on the forwarding company in question and
therefore transport insurance is recommended in order to avoid confusions with claims.
Additional transportation and protection supports have been installed when considered
and they must remain on their position during the transportation. These supports have
been marked with yellow tape or paint and are to be removed after the transportation.
2. LIFTING
The items can only be lifted either from the lifting lugs, which are clearly visible in each
equipment and/or devices, or from the bottom of wooden cases. The lifting points have
been marked to the cases with paint. The equipment have been fastened into the
cases, but still special attention has to be paid to a careful lifting and handling e.g.
packages are not allowed to keel.
The lifting should be done from as many lifting lugs as possible, however at least from
two lugs, preferably by using beams. The lugs have been designed for vertical load.
Also special care should be shown when handling insulated equipment because the
insulation covering can easily be damaged.
3. STORING
The transportation is planned to be done without longer periods of storing. Even
thought equipment and/or devices have been protected according to maker’s
instructions, in order to avoid corrosion during the transportation, still special attention
must be paid to the cover of goods in case sea fright. These types of protections are
not sufficient for a longer period of storing and thus immediate installation is preferred.
In case of forced need for short time storage, items must be located under a roof and
above zero ambient temperature.
Please become acquainted with detailed storing instructions under the general
instructions, General Instructions: “50G003 Storage instructions for components
supplied by Alfa Laval Aalborg Oy”

Transportation - - 3/3
4. PACKING
4.1 Packing dimensions
The dimensions and types of cases are specified in the packing dimensions, which are
enclosed in the end of this chapter. Also the case numbers and main equipment and/or
devices inside the cases are listed in the document.
4.2 Packing lists
The packing lists contain all the loose parts inside the cases, i.e. parts that are ready
mounted e.g. to the feed water tank, pump module or exhaust gas boiler, are not
shown in these lists.
4.3 Labels
For helping the quantity checking and assembly, all the loose equipment have been
marked with labels informing the part number in the assembly drawing in question (if
exists), possible position code or other corresponding data. The position codes of
valves are corresponding to the device diagram. On the labels there are shown the
packing list number and related assembly drawing information.
When installation is made in the site, these labels will help to make a proper
identification of the components. For identification reasons, the position codes are
never to be taken away.
4.4 Material checking
It is presumed that items supplied by Alfa Laval Aalborg are checked immediately after
delivery and possible lacks and/or faults are reported to us. Checking is to be done
according to packing lists and possible remarks are to be assigned to us by filling the
“Supply report”. This checking is prerequisite in order to secure an undisturbed
installation of steam system. Liability to compensate of any possible missing parts is
out of our responsibility if this material checking is neglected.

INSTALLATION

Installation Installation - 1/7
General - rev. TRu 14-01-2016 C
CONTENT:
1. GENERAL INSTALLATION INSTRUCTIONS ...................................................................................................... 2

2. FOUNDATION ........................................................................................................................................................... 2
3. INSTALLATION ........................................................................................................................................................ 3
3.1 PLACING AND FASTENING ........................................................................................................................................ 3
3.2 RELATED EQUIPMENT .............................................................................................................................................. 3
3.3 THERMAL MOVEMENTS ............................................................................................................................................ 3
3.4 JOINTS .................................................................................................................................................................... 4
4. GENERAL INSTRUCTIONS .................................................................................................................................... 4
5. ELECTRICAL CONNECTIONS............................................................................................................................... 4
5.1 GENERAL ................................................................................................................................................................ 4
5.2 CABLE INSTALLATION AND CONNECTION .................................................................................................................. 4
5.3 CONTROL PANELS .................................................................................................................................................... 5
5.4 ELECTRIC MOTORS AND DEVICES ............................................................................................................................. 5
6. CLEANING AND PREPARATION FOR COMMISSIONING ................................................................................ 6
6.1 INSPECTION OF INSTALLATION AND ACCEPTANCE FOR STEAM SYSTEM ....................................................................... 6
6.2 PRESSURE TEST ....................................................................................................................................................... 6
6.3 FLUSHING ............................................................................................................................................................... 6
6.4 PICKLING ................................................................................................................................................................ 6
6.5 BOILING OUT ........................................................................................................................................................... 7
6.6 COMMISSIONING PREPARATION ................................................................................................................................ 7
6.7 CHEMICALS FOR STEAM SYSTEM .............................................................................................................................. 7

Installation - C 2/7
1. GENERAL INSTALLATION INSTRUCTIONS
Installation of the equipment is to be done complying with drawings and associated

instructions in order to guarantee the proper function of the equipment. Special
attention has to be paid to the correct flow direction of water/steam in all the devices.
The installation persons shall be qualified and familiar with equipment of the Heat
Recovery System. Installation is normally out of Alfa Laval Aalborg responsibility. In
order to bring guarantees into force, our commissioning engineer or our representative
needs to make a final checking of the installation and possible lacks and/or faults are to
be corrected before start up by end-user.
It is presumed that personnel are familiar with operating and maintenance instructions
before installation phase. Therefore the following documents related directly to the
installation should be available:
DOCUMENT PLACE IN OPERATING MANUAL

Safety precautions Book 1
Main flow diagram Book 1
Component list Book 1
Installation Book 1
General Instructions Book 1
Main dimension drawings Book 2, Under the equipment in question
Assembly drawings Book 2, Under the equipment in question
Instructions for components Book 3
Electrical drawings, components Book 4
National and local regulations/lows shall be taken into the consideration during
installation by the erection contractor/owner.
The labels of the loose supplied parts include the part number of the assembly drawing.
The valves also include the position code mentioned in the device diagrams.
2. FOUNDATION
The foundations need to be designed so that all loadings from equipment and
surroundings are to be considered.
The general Alfa Laval Aalborg recommendation for equipment erection is that the
installation onto foundation is done by welding or molding. If welding, the foundation
plates should be assembled to the concrete floor during the molding. (Foundation
plates and fixing bolts are only partly included in the scope of supply, see the main
dimension and assembly drawings).
In case of onto the concrete floor erection, the use anchor bolts is also possible.

3. INSTALLATION
3.1 Placing and fastening
First check that the foundations for the equipment are duly located, clean and plain,
see the layouts and foundation drawings (external to Alfa Laval Aalborg scope). Check
also that the dimensions and the load carrying capacities are according to the main
dimension drawings.
Remove protective plugs and plates before installation.
Then place and level the equipment to the correct positions onto foundations, so that
the pipe connections, dismantling spaces etc. will be in right directions.
The required service spaces in front and on the top of the equipment are shown in the
main dimension drawings.
Lifting and turning of device; always follow lifting instruction of the particular device, see
general instruction, Book 1 or specific drawing, Book 2. Improper lifting may cause
severe health and asset damages.
3.2 Related equipment
To connect pipelines to the equipment, see the main dimension drawings along with
the system diagram. The counter flanges delivered by Alfa Laval Aalborg (or otherwise
corresponding flanges) have to be used when connecting the pipelines and the
equipment delivered by Alfa Laval Aalborg.
There may not be copper parts in the water circulation circuit because of the risk of
galvanic corrosion.
3.3 Thermal movements
In any circumstance sliding plates should be assembled to ensure the free movement
of the equipment. This does not apply for the pump units, which are to be installed so
that the unit body will not be moved after the installation. This kind of fixed installation
is extremely important because of the proper working of the pumps. After final
assembly the alignment of pumps is to be checked before the pump start-up is allowed.
Pipelines has to be installed and equipped so that no greater than allowed mass or
thermal forces will be directed to any devices or component delivered by Alfa Laval
Aalborg. See allowable loads in Main Dimension Drawing.

3.4 Joints
Gaskets, bolts and nuts delivered by Alfa Laval Aalborg should be used in the flange
connections of the Alfa Laval Aalborg components.
Note!
Tightening of bolted connections must be carried out according to screw tightening
torque table. See general instruction.
Check the tightening of the assemblies after steam producing is stabilized (working
pressure and temperature) because thermal movement of joints may require
retightening.
4. GENERAL INSTRUCTIONS
General instructions include common or individual instructions for supplied equipment
related e.g. storing, installation, commissioning and using. These instructions are
essential in order to make a successful implementation of Heat Recovery System and
therefore are needed to be studied and followed before and during the final installation
and assembly.
General instructions are under chapter “general instructions”.
5. ELECTRICAL CONNECTIONS
5.1 General
The main voltage and control voltage of this system is mentioned in the electrical folder.
All the connections must be made according to drawings of the control system. The
cabling work must be made according to the cabling diagram. All electrical information
is enclosed in the electrical folder.
5.2 Cable installation and connection
During cable installation and connections the site’s main contractor’s quality
instructions have to be followed.
All cable installation and connections must be done according to electrical design files.
Possible demand of Hazardous area Zones must be taken into the consideration
Electrical work must be done by qualified supervisors and technicians.
Cable types and sizes must be as rated in electrical files.
Cables have to be installed on cable trays and into protective pipes
Cables have to be protected against all possible damage.
Cables have to be properly fastened.
Cable installation work must be done so that the cables are not damaged.
Power/signal cables are to be laid on safe distance from each other.
All cables have to be marked from both ends as stated in design files.
Special attention has to be taken care of that earthings are installed according to
design before switching systems on.
5.3 Control panels
The electrical work must be done by qualified supervision and technicians.

The devices in control panel have to be in good condition. Damages in control panel
are not accepted.
Name plates and rating plates of components have to be checked.
After external cable work the panel has to be re ordered / cleaned .
All connections must be visually checked before switching main power on
Special attention has to be taken care of purity and dryness of connection plinths and
spaces and all devices.
Electrical panels must be installed so that they are protected against rain, sun and
humidity and the ambient temperature cannot rise to more than +50°C.
The main voltage and frequency must be measured to correspond the design values.
Normally +/- 10% main voltage variation is permitted.
The phase direction must be checked with measurement.
To be secured that welding on site near electrical devices causes NO interference
voltage or other damage for them. Level control equipment inside the control panel,
cables and all other electrical devices must be protected (or removed) during the
welding work of the components
5.4 Electric motors and devices
Pumps commissioning must be done according to pumps and motor supplier

instructions.
Safety items should be on acceptable level; platforms, gangways, ladders etc.
Before starting pumps pipe work must be completed, flushed, cleaned and pressure
tested. On horizontal pumps alignment must be checked.
Check free rotation of pump and motor.
The phase direction must be checked.
Earthings done as stated in design files.
The motor protection devises rates have to be checked before start up.
Measure insulation resistance before commissioning or if winding dampness is
suspected;
When insulation resistance tests are performed, the insulation resistance

measured 500 V d.c. between the power circuit conductors and the protective
bonding circuit shall be not less than 10Mohm.
Windings should be discharged immediately after measurement to avoid risk of electric

shock!
Insulation resistance reference value is halved for each 20°C rise in ambient
temperature. If the reference resistance value is not attained, the winding is too damp
and must be oven dried. Oven temperature should be 90°C for 12-16 hours followed by
105°C for 6-8 hours.

6. CLEANING AND PREPARATION FOR COMMISSIONING
6.1 Inspection of installation and acceptance for steam system
Before the start up process will take place, all equipment is to be installed and
preliminary inspected according to the supplied Installation Instructions. Furthermore
necessary safety aspects shall be taken into the consideration in order to prevent risk
of injure. The final inspections need to be done in presence of Alfa Laval Aalborg
commissioning engineer or equal Alfa Laval Aalborg representative. Since all
inspections and approval procedures are carried out the delivered steam system can
be taken under the start up process.
6.2 Pressure test
All pressurized (classified) equipment delivered by Alfa Laval Aalborg have been
pressure tested at the workshop. However, before the start-up process is started, it is
presumed that the complete steam system (i.e. equipment including pipes) is pressure
tested as a whole assembly. Whatever equipment or assembly is pressure tested, the
value of the test pressure shall be ensured based on the information from the technical
data sheets or weakest point of the system.
6.3 Flushing
The system has to be washed properly after finishing the welding work in order to
remove storing liquid and any other impurities. The flushing can be made either by
circulating water through the system or by using pressurized air. See general
instruction 100G038.
Particles in boiler water cause most of the pump damages. It is extremely important to
wash the system properly in order to save the mechanical seals of the pumps.
Strainers shall be cleaned more often during the first weeks of operation.
6.4 Pickling
Alfa Laval Aalborg’s equipment is delivered without pickling and therefore it is

recommended that the whole system is pickled before the commissioning in order to
secure a long lifetime of the system. An expert, who knows the risks of an improper
pickling, must carry out the pickling. It is recommended that pickling process is done by
skilled workers (specialized experts) and it should contain the following procedures, but
not limited to: soda washing – water flushing – pickling – water flushing – neutralizing –
passivating.
Note!
Pickling is recommended in a steam turbine application.
Before pickling secure that the equipment will not be damaged because of the pickling
chemicals. The pumps delivered by Alfa Laval Aalborg cannot be used for circulating of
chemicals.

The pickling work has to be made only 3-5 days before starting the system, because
the protection layer formed with chemicals will disappear if the system is not started
soon enough after pickling. Otherwise the pickling has to be repeated before the
commissioning.
6.5 Boiling out
Before putting the steam system into the operation for the first time, it should be boiled
out to remove all protecting remedies and impurities from the equipment in the steam
system.
It is recommended that boiling out procedure is done just before the start-up moment or
during heating up phase and under supervision of Alfa Laval Aalborg commissioning
engineering. See general instruction 100G001.
6.6 Commissioning preparation
The above specified works for commissioning shall be finished before final
commissioning will take place. The form 130G002 “Inquiry for commissioning
readiness” about the stage of readiness has to be returned when inviting the
commissioner.
6.7 Chemicals for steam system
All chemicals for cleaning, preparation for commissioning and for normal steam
generation are delivered by customer (a water treatment / analyzing specialist).
Chemical dosing unit is to be filled with proper chemicals complying with the water
treatment requirements, see General Instruction;110G001 water treatment.
It is recommended that chemical supply is arranged so, that based on regularly boiler
water sampling and analyzing, a specialized company takes care of the chemical
delivery. This secures that a right composition is used at all times for sufficient water
treatment.
Especially in steam turbine application the water treatment is very important in order to
secure the required steam quality.

1 50G001 Protection of nozzles and holes
Storage instruction for components

2 50G003
supplied by AI Oy
3 50G013 Recycling & Disposal instructions
Minimum wall thickness for steel

4 70G001
pipes
5 70G002 DIN-standards for materials
6 90G001 Tolerance for perpendicularity
7 90G002 Tolerance for leveling
8 90G003 Principle supporting for hot pipes

CONTENTS OF Gaskets and tensioning torques of
9 90G004
CHAPTER 1.8 flanged connections
10 90G005 Installation of pressure gauge
11 90G006 Installation of pressure switch
12 90G007 Installation of pressure transmitter

GENERAL
13 90G008 Installation of thermometer
INSTRUCTIONS
14 90G009 General req. for steam piping inst.
Installation and draining of safety

15 90G010
valve outlet pipe
16 90G012 Principle pump installation
Boiler installation; fastening of boiler

17 90G013
legs
18 90G015 Assembly of horizontal vessel
19 90G016 Assembly of vertical vessel
20 90G017 Assembly of pump unit
21 90G026 Lifting and installation of U boiler
22 110G001 Water treatment
23 130G001 Comissioning period
24 130G002 Inquiry for commissioning readiness
1.8 General Instructions

GENERAL INSTRUCTION

Storage instructions for components supplied by Alfa Laval Packing- 50G003 1/3
Aalborg Oy storing
General VLE 26-09-2014 B
STORAGE INSTRUCTIONS BEFORE INSTALLATION

The project goods might require different kind of storage and/or size of goods set limits for package,
therefore different type of packages are used and right storage is to be taken under the considera-
tion in order to prevent any kind of damages. Packages must be handled and stored according to
case markings which are attached on the sides of the packages. If not otherwise agreed, it is end
user’s responsibility to take care of goods under the storage phase.
Seaworthy packages are allowable to storage outdoor for short time (max 3 months). In case of
forced need for longer time storage, items must be located under the roof and below mentioned in-
spections are to be performed.
Containers are allowable to storage outdoor as far as below mentioned inspections are to be per-
formed. All other kind of packages must be located under the roof or other sufficient protections are
to be used. Furthermore below mentioned inspections are to be followed.
According to the table 1, all packages and manholes have to be opened and internal and external
inspection performed. If there is corrosion, it has to be removed. Also the corrosion protection has
to be renewed with the mixture of anticorrosion and storing liquid. Special attention shall be paid
for local climate conditions, i.e. low/high temperature, moisture, freezing etc. After renewed protec-
tion all manholes and packages must be closed carefully.
Nitrogen filled pressure vessels

Nitrogen purging is a dangerous activity if performed in a confine space as depletion of oxygen will
occur. Ensure the area ventilation is sufficient for this activity.
For storage: Pressure should be inspected at least once a week. If the pressure gets below 45 kPa,
Nitrogen has to be re-filled to get pressure to within 50 kPa - 100 kPa.
During storage, the boiler should be clearly marked with relevant warning signs. For example;

Packing- storing / Storage instructions for components supplied by Alfa 50G003 B 2/3
Laval Aalborg Oy
STORAGE INSTRUCTIONS AFTER INSTALLATION
Storing of a cold boiler partly filled with water is not allowed because of the risk of corrosion.
For the time the exhaust gas boiler is out of service it has to be protected from the corrosion. The
measures required depend on the construction of boiler and how long time it is out of service.
In the end of manufacturing phase the boiler is pressure tested and protected against corrosion.
This procedure concerns also other pressure vessels supplied by Aalborg Industries Oy.
Before supplied components are taken in use, boiler, pipes and related equipments are to be
cleaned from these protection liquid and other impurities.
In case that the components and the water circuit have been cleaned and for some reason the
boiler or/and other related equipments are needed to be taken out of water/steam producing or for
storage, therefore it is very important to ensure that equipments are to be protected against corro-
sion. To ensure best result it is necessary to store the boiler and the whole circuit according to the
given instructions.
In order to prevent heating surface from corroding the boiler is to be cleaned and dried according
to the manufacturers cleaning instruction, see manual book.
If not otherwise agreed it is end user’s responsibility to ensure that water/steam system is protect-
ed and stored against corrosion and the system is being able to be taken in use after storing period
without permanent damages.
Short downtime:
If the boiler and related equipments are likely to be out of service only for few days, water circula-
tion of the exhaust gas boiler is kept on during the downtime.
Long downtime with no service at all
Before the water/steam system is stored for a long time, the heating surfaces of the exhaust gas
boiler need to be cleaned according to the manufacturer’s instructions.
Special attention should be paid to the protection against the corrosion. In case the ambient tem-
perature falls below 0 °C, it must be taken care to ensure that water in the system will not freeze in
any part.
Before storing the following measures are to be done:
1. The system is to be filled with treated boiler water where water solution includes antifreeze
liquid with suitable corrosion inhibitors and storing liquids. Using of pure glycol is not allowed.
Recommended is to use solution with glycol, which includes 10 % corrosion inhibitor. Fur-
thermore solution should be included 3 % Zerust Axxatec 77C liquid for storing phase. The
amount of the above mentioned solution depends on ambient temperature during storing
time. Still minimum amount of solution in boiler water should be about 2 %.
2. Treated boiler water is to be pumped through the water/steam system and finally all vessels
need to be filled totally in order to corrosion protection covers all areas and related equip-
ments. For filling procedure of vessels water level control equipments are to be passed in or-
der to ensure total filling. The best way is to pump water until it overflows out of vessel.

Packing- storing / Storage instructions for components supplied by Alfa 50G003 B 3/3
Laval Aalborg Oy
3. After filling procedure the system must be emptied carefully according to the manufacturer’s
instructions, see manual book. Immediately after that all openings need to be protected with
flanges or threaded plugs.
4. If there is a risk that during storing period humidity might be extreme high or temperature var-
ies, it is recommended that silica gel or quicklime is placed inside the vessels. Amount 1,5
kg/m3.
The corrosion protection needs to be checked regularly. Still protection procedure needs to be
renewed according to the table 1.
Table 1
TIME FOR NEW CORRO- HUMIDITY
DAILY TEMPERATURE VARIATION
SION PROTECTION
2 years <5°C <30 %

1year <10°C <40 %
6 months <20°C <60 %
3 months >20°C >60 %

GENERAL INSTRUCTION

Recycling and disposal instructions for equipment supplied by Packing- 50G013 1/3
Alfa Laval Aalborg Oy storing
General - TRu 03-08-2016 B
1 GENERAL
1.1 Purpose of instruction
The purpose of this instruction is to ensure that waste is sorted and disposed of in accordance
with the instruction below. Component manufacturer’s instructions are to be followed as well
as national regulations for the waste handling and recycling instructions are to be taken under
the consideration.
It’s the responsibility of the owner that company has detailed waste handling and recycling in-
structions, proper storage for the waste as well as education of all employees concerning han-
dle waste in accordance with principles of sustainable development.
1.2 Removing from the use
In case that some equipment or component is removed from use, waste must be identified for
sorting and further handling purposes. The same procedure is to be followed with handling of
packing materials, spare parts, and in generally during the normal operation and maintenance
of equipment.
In order to minimalize waste and to treat it in a proper way the following aspects are to be tak-
en under the consideration:
- reuse of material or component

- waste for recycling
- waste for incineration
- waste for special handling, hazardous waste
- chemical waste
All waste that can be recycled must be sorted separately.
In generally, equipment which is removed from the use is to be drained from all liquid (water or
chemical) and moved into the area where waste sorting is possible to be done environmentally
friendly and safely. Drain water, like boiler, feed or make-up water can be returned back into
the system. Other chemicals and/or hazardous material are to be stored air-tight sealed ves-
sels and post treated according to chemical safe instructions.
Packing materials are identified, sorted and stored into those specially reserved areas/ con-
tainers for further treatment.
Note! Waste materials are not allowed to be disposed by burning, breaking or other way
handled without having proper equipment for such purposes and know-how. Waste
handling operator is responsible to guarantee the correct and safe use of handling
equipment and the proper safety clothes and safe working conditions for workers.

Removing from the use 50G013 B 2/3
2 IDENTIFICATION / SORTING OF WASTE
The waste is sorted according to following guide lines:

Example of use: Material: RECYCLING
component / material identification / type Suitable for energy Suitable for re-
waste: use: (melting etc.)
YES / NO YES / NO
PLASTIC
plastic bottles, textiles PET or PETE (poly-
ethylene tereph- YES
thalate)
plastic packing PE-HD (high-density
YES
polyethylene)
plastic pipes, hoses, pack- PVC (polyvinyl chlo-
NO YES
ing ride)
carrier bags, films PE-LD (low-density
YES
polyethylene)
packing material, technical PP (polypropylene)
YES
components
plastic boxes, packing PS (polystyrene) YES
INSULATION
thermal insulation in boil- Stone wool
NO YES
er, tank, pipes etc. Glass wool
METAL
∂ boiler (pipes and carbon steel, stainless
frame) steel, aluminum, cop-
per NO YES
∂ tanks
∂ steel structures
WOOD
wood pallets several wood species
packing wood YES
ELECTRICAL
∂ monitors, displays several plastic materi-
∂ batteries al,
∂ in generally electrical
NO NO
components inside the
control panels, junc-
tions boxes etc.
∂ cables, electrical mo- copper
YES
tors
PAPER
packing paper, card YES
CHEMICALS
boil-out chemical NaOH (= Caustic so-
NO NO
da, sodium hydroxide)
boil-out chemical Na3PO4 (tri-
NO NO
sodiumphosphate)
GLASS NO YES
Removing from the use 50G013 B 3/3
For correct handling, storage and disposal of chemicals, the instructions given in mate-
rial safety data sheet of each specific chemical must be carefully followed.
If other types of waste than the above described types occur and/ or sorting is unclear,
the environmental manager shall be contacted in order to be agreed with correct waste
handling and disposal.
Waste must always be disposed of in accordance with federal, state and local environ-
mental control regulations!

GENERAL INSTRUCTION

Minimum wall thickness for steel pipes Materials 70G001 1/1

STEAM PIPING SYSTEMS WITH

PRESSURE < 16 BAR
TEMPERATURE < 300 º C
NOMINAL SIZE EXTERNAL MINIMUM WALL MINIMUM WALL

DIAMETER THICKNESS THICKNESS
DN DIN 2448, DIN 2458 FOR AUSTENITIC STEEL
( mm ) ( mm ) ( mm )
20 26,9 2,3 1,5
25 33,7 2,6 1,5
32 42,4 2,6 1,5
40 48,3 2,6 1,5
50 60,3 2,9 1,5
65 76,1 2,9 2,0
80 88,9 3,2 2,0
100 114,3 3,6 2,0
125 139,7 4,0 2,0
150 168,3 4,5 2,0
200 219,1 5,9 2,5
250 273,0 6,3 3,0
300 323,9 7,1 3,5
350 355,6 8,8 4,0
400 406,4 8,8 4,5
(450) 457,2 10,0 5,0
500 508,0 11,0 5,5
Note:
Wall thicknesses are calculated for straight pipes. If pipe is bended the minimum thickness requirement
needs to be checked afterwards.
Note for austenitic steels:

Wall thicknesses are based on rules of EN 13480 for materials EN 1.4307 and EN 1.4436.
Corresponding materials like ASTM 304L, 316L, SS2352 and SS2343 can be used.
The following issues need to be taken under the consideration by using austenitic steel pipes:
- more pipe supports due to thinner wall thickness
- higher coefficient of heat expansion
- risk for electrochemical corrosion if galvanic pairs exist
- corrosion and tolerance allowances

GENERAL INSTRUCTION

Din-standards for materials Materials 70G002 1/1

PRESSURE VESSELS
Item Material Dimension
Material
standard standard
Boiler plates and man holes *) H II P265GH DIN 17155 DIN 1543
EN 10028-2
Pipes St. 35.8 / I DIN 17175 DIN 2448
St. 37.8 / I DIN 17177
Neck flanges C 22.8 DIN 17243 DIN 2633
Valves, body material GG 25,

GGG 40.3, GS
Gaskets for steam pipes Graphite DIN 3754 DIN 2690
UNPRESSURIZED EQUIPMENT
Item Material Dimension
Material
standard standard
Steel for common constructions Rst 37-2 DIN 17100 DIN 1543
S235JRG2 EN 10025
Angle and flatbars, hotrolled Rst 37-2 DIN 17100 DIN 1029
St 44.4U DIN 17100
RHS-pipes St 52-3 DIN 17100 ISO 657/14
Pipes for other constructions St 33 DIN 1629/3 DIN 2440

St 35
Flanges St 37.2 DIN 2401 DIN 2576
C22.8 DIN 17243 DIN 2633
Screws in screws joints 8.8 DIN 2401 DIN 931
Gaskets for other pipes 70 SERVICE

BA-R etc.
*) Materials according classification societies

GENERAL INSTRUCTION
Subject Group Ref.No. Page

Tolerance for perpendicularity Installation 90G001 1/1
Allowed tolerance for perpendicularity
+15mm
9m Height
+10mm
6m
+5mm
3m
Baseline
CL

GENERAL INSTRUCTION

Principle of hot pipe supporting Installation 90G003 1/1
THERMAL EXPANSION IN PIPING

Thermanl expansion in piping should be controlled with sensible supporting and with bellows.
Coefficient of thermal expansion is 0,012mm/°C for steel pipes.
DISTANCE OF SUPPORTS
Fixed support Maximum distance of fixed supports, see table

column A. Fixed support can be equipment,
where pipe is mounted.
Sliding support
Maximum distance of sliding supports, see
table column B (distance between sliding and
Bellows fixed supports)
Bellows are always between the fixed supports

or fixed points.
MAXIMUM DISTANCE OF SUPPORTS

size of pipe distance A distance B
Support (fixed or sliding) are usually mounted near branches, both sides of bellows, near equipment
and valves, to upper part of vertical pipes and both sides of horizontal bends. To avoid thermal
stresses, more supports are to be mounted if necessary.
NOTE! All Alfa Laval Aalborg Oy’s equipment must be kept free of external forces.

GENERAL INSTRUCTION

Gaskets and tensioning torques of flanged connections Installation 90G004 1/1
Gasket type Max. temperature

Flowing material Max. pressure
f.ex ’70 service’ etc. Water 16 bar 120 °C
Graphite Steam 25 bar 550 °C

DIN 2690 / DIN
3754
f.ex ‘ba-r’ etc. Exhaust gas 0,5 bar 450 °C
These tensioning torques can only be used under following conditions:
♣ Used material of the gasket is according to above mentioned
♣ Flange connections are not affected by any significant external force
♣ Nominal pressure is below 25 bar
♣ Nominal size is between DN25…600, except exhaust gas pipes nominal size is up to DN 2000
♣ The gasket is lubricated with heat-resisting grease when assembled
♣ The screw connection is manually tightened with a torque wrench
♣ If pneumatically or electrically tightened, the value of tension torque in the following table must be
multiplied with a correction factor 0.93
♣ The tightening screws have to be of the strength class 8.8
Screw size
Tensioning torque
M10 35 Nm
M12 65 Nm
M16 160 Nm
M20 310 Nm
M24 530 Nm
M27 780 Nm
M30 1050 Nm
Pre tensioning torque should be about 70% of final.

Tightening crosswise.

1 2 3 4
A
1
B
Water siphon not needed when
connected to separate header
or gauge board.
6 C
3
6 5
Length according
4 to insulation.
D
6 3 GASKET WASHER R1/2'' 17/6.5x2 DIN 126 CU 35205140150RA 0,0

5 1 UNION NUT G1/2''LH G1/2''RH DIN 16283 EN 1.4436 20006820213RA 0,1
E
4 1 WELDING STUD -MALE THREAD G 1/2'' LH L=145 dwg:0010S400174 P250GH 0,4
3 1 GAUGE VALVE WITH H TEST CONNECTION 1/2'' PN 400 DIN 16271 80007800178RA 0,6
2 1 WATER SIPHON FOR PRESSURE GAUGE 1/2'' / 1/2'' PN 100 DIN 16282 Form C EN 1.4571 80007800220RA 0,5
1 1 PRESSURE GAUGE WITH RED MARK 1/2'' - D 100 10 bar LM G1/2B EN 1.4401 80508400192RA 0,0
Pos Qty Name Size Dim Std/Type Material Code/Dwg Weight
Date/Drawn
GENERAL INSTRUCTION 1.2.2017/JAS
Date/Checked
/
Date/Approved
/
Installation of pressure gauge Weight/kg Scale F
1,6 kg 1:4
Marine & Diesel Division THIS DRAWING IS OUR PROPERTY. IT IS Page Size Drawing No. Rev Pages
NOT TO BE REPRODUCED OR SHOWN TO
Rauma, Finland
A THIRD PARTY WITHOUT A SPECIAL
PERMISSION OF ALFA LAVAL AALBORG.
A4 90G005 - 1 /1
1 2 3 4
7
1
8
B
6
or gauge board.
6 5
D
Length according
to insulation.
4
8 1 GASKET WASHER R 3/8'' 14/6.5x1.5 DIN 126 CU 35205140164RA 0,0

7 1 REDUCING NIPPLE / MALE-FEMALE G1/2'' RH G3/8'' RH Parker S355J0 20006840164RA 0,1
E
1 1 PRESSURE SWITCH 3/8'' (M) RT 116 EN 1.4301 80008120213RA 1,0
Date/Drawn
Date/Checked
/
Date/Approved
/
Installation of pressure switch Weight/kg Scale F
2,7 kg 1:4
Rauma, Finland
A4 90G006 - 1 /1
1 2 3 4
A
1
6

or gauge board.
2
C
6
6 D
5
Length according
4 to insulation.

E
1 1 PRESSURE TRANSMITTER 1/2'' (M) 0-16 bar MBS3100 EN 1.4404 80008200164RA 0,2
Date/Drawn
Date/Checked
/
Date/Approved
/
Installation of pressure transmitter Weight/kg Scale F
1,8 kg 1:3
Rauma, Finland
A4 90G007 - 1 /1
GENERAL INSTRUCTION

General requirements for steam piping installation Installation 90G009 1/1
General - MPU 02-06-2000 -
STEAM DISTRIBUTION PIPES

1. Safety circumstances are important STEAM OPERATION AND CONDENSATE PIPES
2. Heating valve for smooth heating 20. Condensate has to be removed without any delay
3. Saturated steam: the ratio between pressure and 21. Effective removing of condensate is important
temperature is fixed 22. After the steam trap, the condensate pipe should
4. ALA Oy’s equipment are not affected by any not go upwards
external mass or thermal force 23. Choosing the type of steam trap has to be done
5. Steam pipe: speed of saturated steam should be considerately
15-25 m/s 24. Make-up water supply line
6. Insulation = saves thermal losses 25. Good deaeration = more capacity for the system
7. Pipe clamps and fixtures must be insulated 26. Each steam device must be trapped separately
8. Suction height has to be sufficient for hot water 27. Control valve is normally smaller than the pipe line
pumps, according NPSHr 28. Temperature adjusting: pressure inside of
9. Downslope in steam pipes must be 1 - 0,5% (1 – equipment is variable and also vacuum is possible
0,5cm/m) 29. Downslope in condensate pipes must be 1 – 0,5%
10. Drain pipes must be taken from full-size T-branches (1 – 0,5cm/m)
11. Max. distance between drain pipes is about 25m 30. Condensate branch must lead above the pipe
12. Steam header has to be big enough 31. Size of condensate pipe must be big enough
13. Steam header must be provided with drain valves 32. Safety valve protects people / equipment
14. Steam branch must be taken above the pipe 33. The heat from heat exchanger should be recovered
15. Thermal expansion has to be compensated when possible
16. Pipe clamping and guiding considerately 34. Condensate tank and pumps are located lower than
17. All pockets must be equipped with traps the steam system
18. Pipe ends must be equipped with steam trap / air 35. Condensate back to the feed water tank through
trap deaerator
36. Gas removing from feed water

GENERAL INSTRUCTION

Installation and draining of safety valve pipe Installation 90G010 1/1
General - MPU 31-05-2000 -
1. Safety valve mounted vertically

2. Pipework adequately supported
3. Discharge to safety place
4. Wire for remote launching
5. Boiler or other pressure vessel
6. Continuous fall
7. Drain discharge to safety place
-The safety valve should always be fitted with the centreline of the spring housing vertically above the valve
-There should not be any shut-off devices on the inlet or outlet of the safety valve
-The discharge pipework must not be smaller in diameter than the valve outlet
-No undue stress should be imposed on the installation which may cause distortion and leakage
-If a rise in the discharge pipework cannot be avoided, a small bore should be provided at the point where water
could collect
-Discharge pipework should be sized in such a way that built-up pressure does not exceed 12% of the set
pressure to a maximum of 17 bar

GENERAL INSTRUCTION

Principle pump assembly Installation 90G012 1/1
General - MPU 21-06-2000 -
THROTTLING INSTRUCTIONS FOR PUMPS:

These instructions need to be used together with instructions of the pump manufacturer.
Detailed instructions and technical documents of pump manufacturer need to be studied very carefully before pump is taken
in use.
Above are shown example curves of a cetrifugal pump. Specified operating point is shown with dot i.e. 10 bar and 5 m3/h. If
the above-mentioned example counter pressure on the pressure side is less than 10 bars, it means that the operating point
is moved to the right according to its functional curve. At the same time operating point on the NPSHr curve is moved to the
right as well. This means that more water is required and NPSHr value will be higher than NPSha value.
The result of that will be high risk for pump cavitation because of NPSHa value has been designed according to the
operating point. For that reason, the throttling valve should be throttled so much that the operating point is reached.
If there is pressure on the suction side, as is the case when circulation water pumps are taking suction from pressure vessel,
the adjustment should be done by reading the pressure difference between pressure and suction side. After adjustment of
throttling, the valve needs to be locked in it’s place or hand wheel is to be removed to avoid misuse.
in some cases the centrifugal pump can be constructed of a few stages and the functional curve is shown only on one stage.
If there is, for some reason, more counter pressure than specified, the operating point is moved to the left according to it’s
functional curve. This means that the pumped amount will be reduced accordingly.
The overflow release valve has been adjusted so that the required minimum overflow can flow through the pump. In some
cases required minimum overflow through the pump has been realised by using orifice plate and adjustment of that is fixed.
The set up of the above-mentioned pump overflow is not allowed to be changed without sufficient know how about the
pumps. If necessary, contact the pump manufacturer.

GENERAL INSTRUCTION

Boiler installation: fastening of boiler legs Installation 90G013 1/1
General - MPU 07-03-2001 -
THE INSTALLATION PRINCIPLE IS THAT ALL FOUR LEGS ARE WELDED TO THE BASE PLATES.
ONE OF THE LEGS IS DIFFERENT THAN THE OTHERS AND THIS THICKER PLATE IS TO BE
THE FIXED POINT OF THE BOILER. THE OTHER THREE LEGS CONSIST OF TWO PLATES,
WHICH ARE FASTENED TOGETHER WITH A SCREW CONNECTION. THE LOWER PLATE IS
WELDED TO THE BASE PLATE SO THAT THE UPPER PLATE CAN SLIDE ALONG THE LOWER
PLATE. BY THIS CONSTRUCTION, THE HEAT EXPANSION OF THE BOILER STRUCTURE IS
TAKEN CARE OF.
IMPORTANT:
IN ADDITION TO THE FIXED LEG (THE THICKEST PLATE), ONLY THE SLIDING PLATES
(LOWER PLATES) ARE ALLOWED TO BE WELDED TO THE BASE PLATES. THE FREE SLIDING
OF THE UPPER PLATES HAS TO BE GUARANTEED.

GENERAL INSTRUCTION 19.9.2016/BLT
19.9.2016/TRU
EXHAUST GAS BOILER
19.9.2016/JMI
AALBORG U-TYPE
LIFTING AND INSTALLATION -
90G026 C A2 1 1
GENERAL INSTRUCTION

Water treatment Operation 110G001 1/7
General - Ilkka Herrala 31-05-2013 F
1.1 Concept of water treatment
1.2 Treatment of make-up and feed water in general
1.3 Chemical and mechanical control of the system
1.4 Sampling
1.5 Determinations to be made and ratings
1.6 Analysing instructions for water treatment
APPENDICES
REFERENCES

Operation / Water treatment 110G001 F 2/7
1.1 Concept of water treatment
General
The most important aspects having effect on safety, life cycle and security of boiler plant are the
correct treatment and maintenance of water.
The quality of water and functioning of the treatment equipment must be regularly observed and any
potential defects must be immediately eliminated. This way a faultless operation of the plant is
ensured.
A book of water values and functioning of devices must also be kept. In case of potential
malfunctioning, conclusions on reasons for them can be drawn on this basis.
The conditioning of the make-up, feed and boiler water is an essential part of the boiler operation and
operation philosophy. The target of the water treatment is to create and maintain optimal conditions
for magnetite layer (Fe3O4) in the water-steam system and protect the system from corrosion, scaling,
water foaming etc. The design and construction of the treatment system should therefore be
considered carefully during layout of the plant. Alfa Laval gives some general guidelines concerning
the conditions of the make-up, feed and boiler water. However, there are several ways to obtain these
results, or similar, by using different treatment systems. The following should therefore be considered
already at the layout stage:
∂ Choose the treatment system that should be used.

∂ Present the whole water and steam circuit system to the supplier of the treatment system and
inform about the operation philosophy of the Plant.
∂ Let the supplier indicate where the injection points should be located and also inform if special
equipment is required.
∂ Let the supplier inform about the chemicals based on chosen treatment philosophy.
∂ Let the supplier inform about which test facilities are needed.
∂ Purchase the recommended equipment and install them in the correct way.
∂ Use the treatment system immediately the boiler is taken into operation.
Instructions for use
The following instructions for use and analysis related to water treatment of steam boilers have been
drawn up on the basis of different sources and practical experience. The facts that must be
considered as most important for a boiler and its devices have been taken under continuous
observance.

1.2 Treatment of make-up and feed water in general
Treatment of feed water can be divided into the following phases:
A. Thermal degassing in order to eliminate oxygen and carbonic acid dissolved in water. The aim
of this is to reduce corrosion in boiler, steam and condense piping and related devices.
B. Chemical treatment of water, which can be divided into:
a) Phosphate feed mainly for binding the residual hardness in feed water.
b) Feed and/or boiler water conditioning with alkalizing agents to control pH value.
The use of amines is recommended for this purpose.
c) Oxygen scavenging for eliminating the residual oxygen in feed water.
In addition to the above, the blow-out arrangement is considered to be part of water treatment.
Furthermore it is presumed that all make-up water is led through a water softener, if evaporated water
is not available.
Gas removing and feed water tank
Make-up water and returning condense shall flow as evenly as possible into the feed water tank.
The temperature of the atmospheric feed water is maintained close to 95°C by incoming condensate
at high temperature and control of steam heating. This minimizes the need for gas removal chemicals.
Some oxygen scavenger is required for residual oxygen removal. This ensures that the amount of
gases dissolved in feed and condense water stays at the minimum level at all times.
In case that gas removal is realised with thermal system, i.e., the system is equipped with pressurized
feed water tank (deaerator), the temperature is kept minimum at 105°C by incoming steam flow in
order to keep the dissolved oxygen content low. With these systems gases separate from water
thermally and are blown out through the air vent valve, which is kept partially open all the time.
However, the need for post treatment of the feed water is to be checked by regular water analysing.
The required temperature in the feed water tank is dependent on process-related factors and must be
checked separately in each project.
Dosing of chemicals
The amount of dosing chemicals is to be determined in accordance with recommended make-up, feed
and boiler water requirements. Chemical types and dosing points depend on the chosen operation
philosophy.
Note:
The use of sodium hydroxide is not recommended in connection with superheated steam system due
to an increased risk of alkali corrosion and stress corrosion cracking (through caustic embrittlement)
of steel material.

Control of pH
The condense water pH shall, at the minimum, be 7,5 (preferably approx. 8,5), but generally this is
hard to achieve. If, however, pH is considerably below 7, it is best to consult a specialist.
The make-up water pH should be approx. 8,5. If it is below 8,5 special attention shall be paid on feed
and boiler water pH, and if even these are below given rating, feed of alkali must be increased. On the
basis of make-up water pH alone, there is no need to take any other actions.
Control of salinity
The salinity of boiler water is maintained within ratings by means of periodical blow-out. The salinity of
feed water is controlled by a salinometer. The exceeding of the rating should be followed carefully.
Note!
Boiler water always contains also other solids than NaCl.
If the dissolved solids content is bigger than the given design value, the boiler blow-out must be
increased.
Salinity can also be measured with a device measuring electrical conductivity.
The indication of a device measuring electrical conductivity is expressed as microsiemens per

centimetres (µS/cm). The indication of the device measuring electrical conductivity can be turned into
dissolved solids content according to the following formula.
s= k * φ, where
s= salinity (mg/l)
k= 0,6 when measured from boiler water and
0,7 when measured from condense water
φ= conductivity (λS/cm)
There are also formulas on electrical conductivity which give salt volumes, if the volume of dissolved
salt is known.
Blow-out
The boiler blow-out is used for maintaining the quality of boiler water within desired limits, which have
been given, in the rating table.
It is important that the proportion of out blown water and make-up water remains constant, because
the chemical dosing succeeds only on that condition. On the other hand, the volume of blow-out
should be as small as possible and, however, sufficiently large to prevent exceeding of critical
analysis values in boiler water.
The volume of blow-out can be roughly calculated as the proportion of the make-up water salinity and
the biggest allowed salinity of boiler water. If, e.g. the salinity of make-up water is 50 mg/l and the

biggest allowed concentration of boiler water is 1000 mg/l, the volume of blowout is 50/1000 = 0,05 or
5 % of the make-up water volume.
1.3 Chemical and mechanical control of the system
Chemical analyses are used to control functioning of water treatment equipment of the boiler plant
and dosing of chemicals. In addition, mechanical functioning of the devices is controlled, as well.
1.4 Sampling
Before a chemical analysis there is always a sampling to be analysed. The correct sampling is as
important as the analysis itself.
The sampling is performed in such a way that the sample really contains the water to be examined.
Therefore, before sampling, water is let run with considerable speed so long that it is changed 3-4
times in the sampling pipe line (30 seconds at minimum) and only then the actual sample needed for
analysis is taken. It is best to take boiler water sample through a special condensing coil designed for
this purpose. If this is not available, the following coefficient numbers must be multiplied with the
analysis results in order to correct the fault caused by evaporation loss:
Boiler pressure bar Coefficient

6 0,88
8 0,86
10 0,84
15 0,81
20 0,78
1.5 Determinations to be made and ratings
The following tables 1 and 2 show the water treatment ratings for the boilers using non-demineralised
make-up and feed water. Beside the ratings there are small letters marking how often the
corresponding determination should be made, with “d” meaning daily, “w” weekly and “m” monthly.
While starting up a new boiler or after a downtime, analyses must be performed more frequently than
stated in the table. After finding out that sampling continuously give the same results, the analyses
can be done according to the table. Hardness of softened water must be defined the more often the
longer the softening filter has been in use, counted from regeneration.
In steam turbine application, minimum water quality requirements for make-up water and condensate
are to meet steam turbine supplier’s requirements. For feed and boiler water requirements refer to
VGB-Standard /2/, Chapter 6.2, Tables 4-9.

Table 1. Recommended analysis values for non-demineralised make-up and feed water:
Boiler pressure < 20 bar
make-up
Make-up and feed water feed water
water
N N AL 1 AL 2 AL 3
pH - d 6,5 – 9,5 9,2 – 9,5 <9,2 <8,8 <8,0
>9,5 >10,0 >10,5
Oxygen (O2) μg / l w not 5 20 50 100
specified
Total Hardness mmol / l d <0,02 <0,005 0,02 0,05 0,2
(Ca + Mg)
Iron (Fe), total μg / l m <50 <30 50 200 -
Copper (Cu), total μg / l m <20 <3 20 50 -
Silica (SiO2) μg / l not specified – consider boiler water
Conductivity μS / cm not specified – consider boiler water
Appearance - d clear, free from suspended solids
Oil / Grease / Organic substances are generally a mixture of several different compounds. The composition of such
mixtures and the behaviour of their individual components under the conditions of boiler operation are
Organics (TOC) difficult to predict. Organic substances can decompose to form carbonic acid or other acidic
decomposition products, which increase the acid conductivity and cause corrosion or deposits. They
also can lead to foaming and/or priming, which shall be kept as low as possible.
N: Normal level
AL 1,2,3: Action level 1,2,3
For definitions and characteristic of normal and action levels see Table 3 in Appendix 1.
Table 2. Recommended analysis values for boiler water:

Boiler pressure < 20 bar, feed water with high-salinity content (conductivity > 30 μS/cm)
Boiler water N AL 1 AL 2 AL 3
pH - d 10,8 – 11,5 <10,5 <10,0 <9,5
>12,0 >12,2 >12,5
Conductivity μS / cm d <AL 1 see App. 1,2 x AL 1 1,5 x AL 1
2
Alkalinity (Ap) mmol / l d 2-5 <1 - -
>15 *)
Silica (SiO2) mg / l w <AL 1 see App. 1,25 x AL 1 -
3
Phosphate (PO4) mg / l d 15 <10
>20 >30 >50
Appearance - d clear, no stable foam
Oil / Grease / Organics Organic substances are generally a mixture of several different compounds. The composition
of such mixtures and the behaviour of their individual components under the conditions of
(TOC) boiler operation are difficult to predict. Organic substances can decompose to form carbonic
acid or other acidic decomposition products, which increase the acid conductivity and cause
corrosion or deposits. They also can lead to foaming and/or priming, which shall be kept as low
as possible.
*) with superheater consider 50% of the indicated upper value as max. value for alkalinity.
N: Normal level
AL 1,2,3: Action level 1,2,3
For definitions and characteristic of normal and action levels see Table 3 in Appendix 1.
For boiler water conductivity (pressure dependent) see Figure 5.1 in Appendix 2.
For boiler water silica content (pressure dependent) see Figure 5.3 in Appendix 3.
Note:
In steam turbine application, minimum water quality requirements for make-up water and condensate
are to meet steam turbine supplier’s requirements. For feed and boiler water requirements refer to
VGB-Standard /2/, Chapter 6.2, Tables 4-9.
1.6 Analysing instructions for water treatment
The proof of compliance with the values given in tables 1 and 2 shall be provided in accordance with
written procedures applying analysis methods / standards listed below:
Conductivity ISO 7888

Copper ISO 8288
Iron ISO 6332
Oxygen ISO 5814
pH ISO 10523
Phosphate ISO 6878
Silica *)
TOC ISO 8245
Total hardness as Ca + Mg ISO 6059
*) Up to now no European or International Standard is available; see e.g. DIN 38405-21 German standard methods for the
examination of water, waste water and sludge; anions (group D); determination of dissolved silicate by spectrometry (D 21).
Changes in the appearance of water regarding suspended solids, colour or foam can indicate that
uncontrolled changes have occurred or are about to occur at the plant.
If the analyses are performed according to other standards or by indirect methods, calibrations for the
methods shall be made.
APPENDICES:
APPENDIX 1: Definitions and characteristic of normal and action levels in analysis values.
APPENDIX 2: Boiler water conductivity depending on pressure. /1/
APPENDIX 3: Boiler water silica content depending on pressure. /1/
REFERENCES:
1) EN 12952-12, Edition: 2003-11-10, Water-tube boilers and auxiliary installations. Part 12: Requirements
for boiler feedwater and boiler water quality.
2) VGB-Standard VGB-S-010-T-00;2011-12.EN (formely VGB-R 450 Le): Feed Water, Boiler Water and
Steam Quality for Power Plants / Industrial Plants. VGB PowerTech Service GmbH, Essen.

GENERAL INSTRUCTION

Commissioning period Commissioning 130G001 1/1
Status and progress on site at the moment when steam plant commissioner is invited should be
according to the following list. These hints are intended to help the site manager to have the shortest
possible commissioning time of the steam system.
1. Equipment installations completed
2. Pipe works completed, flushed, cleaned and pressure tested
3. Pump alignments checked (when horizontal pumps)
4. Electrical works completed

♣ cables installed, connected and marked
♣ electric supply connected and ready for use
5. Possibility to run diesel engines with 70-100 % load
6. Steam consumers or condenser ready to take steam
7. Make-up water, (fuel supply if any oil fired boilers on scope), compressed air and boiler
chemicals should be available.
8. If three shift running is needed, operation staff should be available.
9. Safety items should be on acceptable level: gangways, platforms, ladders, lights etc. should
be ready for use
10. No “force major” situations in force (fire, war, mobilisation, requisition, embargo, currency
restrictions, insurrection etc).

Inquiry for commissioning readiness
Customer Group Ref. No.

130G002 Rev.A
Project name Project no Issued by / Signature Date
The following items to be confirmed in writing before the commissioning visit of a

commissioning engineer of Alfa Laval Aalborg Oy:
Mark “X” to the column “readiness state” if ready, otherwise readiness on %

Mark estimated work finishing date to the column “complete”
WORK READINESS COMPLETE NOTES
STATE TIME
1 Equipment and fitting installations according to instructions to be
completed.
2 Piping works completed: supported, insulated, flushed, cleaned and pressure
tested.
- steam
- water
- fuel
- pneumatic air
- exhaust gas funnel
- combustion air funnel
3 Pump alignments checked (in case of horizontal pumps) and
realigned after piping works.
4 Electrical works completed:
- cables installed, connected and marked
- electric supplies connected and ready for use
- ordinary voltage and cycle available. Phase sequence checked.
5 Possibility to run diesel engines with 70-100 % load (for exhaust gas
boilers only)
6 Steam consumers or condenser ready for consuming.
7 Engine room fans in service.
8 Make-up water, fuel oil (LFO/HFO/GAS), pneumatic air, electric
supply and boiler chemicals for boiling out and steam production
should be available.
9 Mechanical and electrical engineer availability during comm.
10 Safety items should be on acceptable level: lightning, gangways,
platforms, ladders etc. should be ready for use, cleanliness
acceptable, accessibility to the operational outfitting arranged.
11 No “force major” situations in force (fire, war, mobilization,
requisition, embargo, currency restrictions, insurrection etc.)
Estimation of the commissioning schedule

Delivery time of the project to the end user:
I confirm that the above marked items are fulfilled:

Date: Signature
Contact person name and position

(IN CAPITALS):
Contact details (phone, e-mail)
(IN CAPITALS):
To be returned: Handled in Alfa Laval Aalborg Oy by:
Alfa Laval Aalborg Oy, fax. +35810 838 3808 Aki Oksanen
by e-mail: [email protected] Manager, Commissioning / +358 400 246 501
© Copyright Alfa Laval Aalborg Oy / General Instruction no: 130G002 www.alfalaval.com

OPERATION

Waste heat recovery system Documents 1/17
Termonorte DFPP 5514 POS 15.8.2017 -
CONTENT
1. PREPARATION FOR USE ...................................................................................................................... 2
1.1 GENERAL .................................................................................................................................................. 2
1.3 PREPARATION OF THE CHEMICAL DOSING.................................................................................................... 2
1.2 PREPARATION OF THE MAKE-UP WATER SYSTEM ......................................................................................... 3
1.4 PREPARATION OF THE CONDENSATE SYSTEM ............................................................................................... 3
1.5 PREPARATION OF THE FEED WATER SYSTEM ................................................................................................ 4
1.6 PREPARATION OF BLOW DOWN SYSTEM ...................................................................................................... 5
1.8 PREPARATION OF THE EXHAUST GAS BOILERS ............................................................................................. 5
1.10 PREPARATION OF THE BY-PASS DAMPERS .................................................................................................. 6
1.9 PREPARATION OF AUXILIARY BOILER ......................................................................................................... 7
1.10 PREPARATION OF HEAT RECOVERY CONTAINER ......................................................................................... 8
1.11 PREPARATION OF CONTROL SYSTEM ......................................................................................................... 8
1.12 GENERAL PREPARATIONS ......................................................................................................................... 8
2. START-UP ................................................................................................................................................. 9
2.1 START-UP OF STEAM SYSTEM ..................................................................................................................... 9
2.2 HEATING-UP OF COLD SYSTEM ................................................................................................................... 9
2.3 START-UP OF WARM SYSTEM .................................................................................................................... 11
2.4 AUTOMATIC START-UP OF THE SYSTEM ..................................................................................................... 12
2.5 HEATING-UP OF COLD AUXILIARY BOILER ................................................................................................. 12
2.6 HEATING-UP OF WARM AUXILIARY BOILER ............................................................................................... 14
3. CONNECTION TO CONSUMPTION................................................................................................... 14
4. OPERATION .......................................................................................................................................... 15
4.1 GENERAL ................................................................................................................................................ 15
4.2 BOILER BOOK .......................................................................................................................................... 15
5. CAPACITY CONTROL OF STEAM PRODUCTION ......................................................................... 16
5.1 ADJUSTING THE STEAM PRODUCTION ........................................................................................................ 16
5.2 CLOSING OF STEAM PRODUCTION ..................................................................................................... 17
5.3 REMOVING FROM SERVICE ....................................................................................................................... 17
6. DRY RUNNING...................................................................................................................................... 17
Alfa Laval Aalborg Oy Tel: +358 10 838 3800 Skandinaviska Enskilda Banken AB (publ)
Kaivopuistontie 33 Fax: +358 10 838 3808 IBAN:FI7433010001134402 (EUR account)
P.O.BOX 9 Email: [email protected] SWIFT: ESSEFIHX
FI-26101 Rauma [email protected] VAT number FI06865929
FINLAND Web: www.alfalaval.com Reg number 0686592-9
Operation / 5514 - 2 / 17
1. PREPARATION FOR USE

1.1 General
In this phase it is presumed that all equipment are installed and accepted according to
Alfa Laval Aalborg Oy instructions.
At the beginning of the commissioning phase, any possible lacks, errors or other bunch-
listed notes are to be corrected before proceeding to the start-up of the steam system.
After each sub-system is commissioned, commissioning certificate is filled with set-up
values and notes of necessary corrective actions, if any.
Applicable tests and inspections made by Aalborg Industries ensure the warranty
reservations.
For starting the plant, the following items must be checked:

1. The availability of the voltage.
2. Boiler and generally whole steam system have been prepared for commissioning
according to Installation Instruction and procedures mentioned in “Inquiry for
commissioning readiness” have been done (130G002).
3. Check that all valves are closed (basic dead condition).
4. All manholes and service hatches are closed.
All preparation work will be made manually.
It is presumed that auxiliary boiler and related equipments have been commissioned
before this phase and for example heating steam for feed water tank is available.
1.3 Preparation of the chemical dosing

1. Make sure that the correct amount of chemicals has been added to the dosing
unit and fill the chemical dosing unit with make-up water.
2. Open the chemical dosing inlet valves in the feed water tank. The chemical
dosing will be automatically handled in parallel with the make-up water valve of
the feed water tank or it could be adjusted working continuously.
Check the operation of dosing pump by following manufacturer’s instructions.

Operation / 5514 - 3 / 17
1.2 Preparation of the make-up water system

1. Check that feed water tank is clean inside
2. Check availability of make-up water
3. Check that make-up water is treated with correct methods before taking water
into the feed water tank. Refer to ALA instruction 100G001 for boil out instructions
and 110G001 for water treatment requirements.
4. Check the operation of the ON/OFF make-up water valve
5. Open the inlet valves in the feed water tank and ensure that venting on the top of
the tank is freely open
6. Open the closing valves for the level indicator
7. Fill the feed water tank to the normal water level (between LCL and LCH)
8. After right water level has been reached in the feed water tank, close the by-pass
line and completely open closing valves in the make-up water control unit
The valves mentioned above should remain in open position. The level control system
of the feed water tank will open and close automatically the make-up water control valve
depending on water needs in the feed water tank.
1.4 Preparation of the condensate system

Check the availability of condensate from all sources and ensure that all condensate
systems are ready for operation.
1. Check the availability of condensate and that the condensate line is prepared for
operation.
2. Ensure water supply to oil detector by opening valves before and after oil detector
3. Check that the condensate return system and condensate inlet valves are opened.
(not in ALA scope)
4. Further open the following valves in the feed water system:
· Ensure that venting on the top of the tank is freely open.
· Valves for water level indicator in the feed water tank (if not opened yet)
6. Check that level control system in the tank is working properly i.e. interlocking to the
pumps and alarms to the main control system are correct. Check the operation of
the all instruments.
Otherwise it is presumed that the whole condensate system has been prepared before
this phase by others.

Operation / 5514 - 4 / 17
1.5 Preparation of the feed water system

1. Open the following valves in the feed water tank:
· suction valve for feed water pump unit
· minimum flow valve from feed water pump unit
· steam heating valves
· valves for water level indicator
· check that feed water pump’s strainer filters are clean
2. After that open the following valves in the feed water pump unit:
· suction valves for feed water pumps
· gauge valves for pressure gauges
3. Further open the following valves in the steam system:
· by pass valve in the feed water control unit
· air venting valve in boiler
· feed water valve in the boiler
· closing valves for water level indicator and gauge valves for pressure gauges
and pressure control equipment
NOTE!
Always when opening big valves in place where there is pressure behind, be careful and
open the valve very smoothly, i.e. first very little and after a few seconds or when you
cannot hear anymore noises open more and then all.
4. Follow the pump manufacturer’s instructions in order to set (throttling) pumps to

the operation point, see also general instruction no. 90G012.
5. Switch on the feed water pump and fill the first boiler to the normal water level.
6. After right water level has been reached in the boiler, close the by-pass line and
completely open closing valves in the feed water control unit.
After this the pump is to be left on running/automatic -position, and the level control
system of boiler will open and close automatically the control valve in the feed water
control unit depending on water needs in the boiler.
One of two feed water pumps runs continuously at a constant capacity and the other one
is set in the stand-by position. In case of failure, the stand-by pump gets a starting signal
from the protection switch of the first pump motor if it releases.
In the feed water pump unit there is a return connection to the feed water tank after the
pumps, and part of the flow is circulated back to feed water tank in order to ensure a
minimum flow for the pump protection. The centrifugal pump cannot run longer period
against a closed valve. The amount of the return flow is limited by the orifice plate which
is located in the return pipeline.

Operation / 5514 - 5 / 17
If the low-low water level of the feed water tank is reached, the feed water pump will be
stopped automatically to prevent the harmful dry-running.
7. After filling of feed water tank make sure that self acting steam heating valve is
able to keep temperature inside the feed water tank 95°C as follows:
· Check that temperature in the valve is in the set up value 95°
Wait before switching on the feed water pump, until the all boilers have been prepared
for operation.
1.6 Preparation of blow down system

The boilers are equipped with manually operated scum blow out valve and bottom blow
out valve.
1. Fill also the blow down tank during the filling of the boiler through the boiler’s blow
out line by opening the blow out valves. Close these valves after the filling. Scum
can be left slightly open if necessary.
2. The closing valves between the tank and the bottom blow out valve should be
opened and remained open as long as the boiler is in use.
3. Open the cooling water valve for the blow down tank and make sure that cooling
water is available.
4. Check that the thermostatically operated cooling valve installed in the blow down
tank is set to temperature area 50-75ºC and it works properly.
Now the blow down system is ready for use.
1.8 Preparation of the exhaust gas boilers

1. Open the following valves for preparation of the exhaust gas boiler:
· gauge valves for pressure gauges and switches and transmitters
· venting valve in the boiler (if not open already)
· needle valves before and after pressure difference indicators
· closing valves for water level indicator and level sensor’s protection tube
2. Check that all the service hatches and holes in the boiler are closed. Check that
all the drain valves are closed.
3. Make sure that boiler is filled with water to operation level and all air is removed
from the system. After air is removed close venting valve on the top of the boiler
4. Check that all level control equipment has been installed and all control levels are
correct. Make sure that level control system is working. Check function of
thermometers, pressure gauges, pressure switches and pressure transmitters.
5. Check that safety valves are able to open freely and blow out pipes of the safety
valves are directed to the safety place

Operation / 5514 - 6 / 17
6. Ensure cooling water supply to the sample cooler. Close sample lines to the cooler
and close cooling water line.
7. Keep main steam valve closed until the boiler is under steam production
8. Make sure that there is free way for boiler cleaning i.e service space is reserved
on boiler service side.
9. Ensure steam availability for manual steam sootblower.
Do not take any exhaust gas through the boiler before the whole steam system is
prepared for use.
Repeat these procedures for other exhaust gas boilers. Do not take any exhaust gas
through the boiler before the whole steam system is prepared for use.
1.10 Preparation of the by-pass dampers

1. Make sure that by-pass damper is closed (exhaust gas directed to by-pass line).
2. Use the damper manually in order to check that flap is moving freely.
3. Actuator is used manually by rotating it’s second shaft by hand wheel or other
tool.
NOTE!
Second shaft is rotating always when motor is running. Never leave any tool to second
shaft after electric is switched on to the motor.
Whenever damper is overhauled actuator’s safety switch must be switched off.
See detailed start up instructions from the controller instruction EM-279guide. 100G040
rev. b-(MAMA-Commissioning of exhaust gas damper)-ENG
NOTE!
The final checking is to be done after by-pass damper is used under the normal
operational temperature.
Connection arms, bearings and actuators are to be locked after the final adjustment. Tag
welding is recommended to be used. See additional information from manufacturer’s
instructions.

Operation / 5514 - 7 / 17
1.9 Preparation of Auxiliary boiler

1. Check that make-up water system, condensate and feed water system are
prepared for use.
2. Open the following valves in the auxiliary boiler.
· Feed water by pass valve in the boiler
· Closing valve before pressure manifold
· Gauge valves before pressure gauges, pressure switches and pressure
transmitters
· Closing valves of level indicators and protection tube of water level sensors
· Oil supply valves before burner. Ensure oil supply from LFO-day tank by
opening closing valves in the tank (oil from and to the burner )
· Air venting valve in the boiler
3. Check that all the service hatches and holes in the boiler are closed. Check that
all the drain valves are closed.
4. After that open the following valves in the feed water pump unit and check the
Chapter 1.5 “Preparation of the feed water system” carefully: Same pumps are
serving the auxiliary boiler and the exhaust gas boilers
· suction valve for feed water pump
· gauge valves for pressure gauges
5. Follow the pump manufacturer’s instructions in order to set (throttling) pumps to
the operation point, see also general instruction no. 90G012 “Principle pump
assembly”.
6. Switch on the feed water pump and fill the auxiliary boiler to the normal water
level.
7. After right water level has been reached in the boiler, close the by-pass line and
open complete closing valves in the feed water control unit.
After this the pump is left on running / automatic -position, and the level control system
of the boiler will open and close automatically the control valve in the feed water control
unit depending on water need in the auxiliary boiler.
If the low-low water level of the feed water tank is reached, the feed water pump will be
stopped automatically to prevent the harmful dry-running. Feed water pumps are also
stopped in case of oily condensate alarm.
1. Check that all level control equipment has been installed and all control levels
are correct. Make sure that level control system is working. Check function of
thermometers, temperature transmitters, pressure gauges, pressure switches
and pressure transmitters.
2. Check that safety valves are able to open freely and blow out pipes of the safety
valves are directed to the safety place.
3. Prepare blow down system of the auxiliary boiler according to Chapter 1.6
“Preparation of blow down system”.
Operation / 5514 - 8 / 17
4. See burner manufacturer’s instruction in manual book 2 / 4 and make necessary

actions to the burner.
5. Ensure cooling water supply to the sample cooler. Close sample lines to the
cooler and close cooling water line.
6. Keep main steam valve closed until the boiler is under steam production Take
boiler to use by following instruction: starting the auxiliary boiler.
1.10 Preparation of heat recovery container

· Check that all equipment inside the container are prepared to use according
instructions
· Check that all drain bits are clean and water is able to flow out from the
container
· Close valve before service tap
· Check that all walkways are open
· Check that container cooling fan is working and air can freely flow in to the
container and out from the container
1.11 Preparation of control system

See manual book 4 / 4 electrical (Electrical documents and instruments)
1.12 General preparations

· Check cleanliness of the equipment.
· Ensure that all blind flanges are removed from the system.
· Open valves before manifolds, closing valves before water level indicators and
all gauge testing valves before instruments.
· Check that all drain valves are closed.
· Check that all necessary valves in the water circuit are open.
· Open all closing valves before steam traps.
· Check that instrument air is available where it is needed.
· Make sure that safety valves are working and blow out pipes are connected to
safety place.
· Check that all water level sensors are installed and working properly.
· Check condition and operation of all instruments from manufacturers’ instructions
(closing valves, control valves, steam traps, strainers, pressure gauges, pressure
transmitters, pressure switches, thermometers etc.).

Operation / 5514 - 9 / 17
2. START-UP
2.1 Start-up of steam system
The procedure of start-up for the steam system depends on readiness of Heat Recovery
System to produce steam where particularly temperature and pressure of the boiler
water are to be followed before steam producing is started. Start-up of the exhaust gas
boilers shall take place in conjunction with the heating of the diesel engine in order to
minimize thermal stresses caused by temperature differences.
Start-up procedure is to be defined according to following aspects:
System cold
If the temperature of the boiler water is below 135…150 ºC and / or the pressure in the
system is considerably under the normal level the start-up needs to be done by following
instructions under “Heating-up of cold system”. This is also recommended procedure
when new system is implemented; although the system is warm and ready to produce
steam. This is because new system will require more attention during the start-up and
therefore operators need to study behaviour of the new steam system in order to avoid
thermal shocks or other damages.
System warm
If temperature and pressure are nearly on normal level the start-up is done according to
instructions under “Start-up of warm system”
2.2 Heating-up of cold system

The meaning of heating-up process is steady start-up of steam system and heating cold
boilers in order to minimize thermal stresses caused by temperature differences.
Heating-up of the exhaust gas boilers shall take place after all commissioning
preparations (e.g. pickling) for the steam system are done. Also it is recommended that
engines, DeNox and other possible equipment are commissioned as well.
As indicated in paragraph “Installation” the boiling-out procedure can be done during the
heating-up.
After boiling-out it is secured that all chemicals are removed from the system and all
equipments with related valves are in right position for heating-up process. If boiling-out
is in question, see detailed instructions from General instructions, “Boiling-out”.
Exhaust gas boilers are to be taken under the heating-up manually one by one.
Estimated time for one boiler is 3…5 hours.

Operation / 5514 - 10 / 17
The heating-up is carried out as follows:
1. Check that the whole steam system is prepared for use

2. Check that the feed water tank is filled to the normal level and water temperature is
around 90-95 ºC. If only colder water is available the heating of the system must
bedone very carefully.
3. Check that exhaust gas and all other pipelines are completely connected to boiler
and all service hatches are closed.
4. Check that the by-pass damper is in by-pass position (boiler off).
5. Check that drain valves of the exhaust gas boiler are closed.
6. Check that the venting valve and the steam heating valve in the boiler are opened.
7. Make sure that condensate is removed from steam pipe lines, i.e. lines are equipped
with necessary steam traps and they are in use.
8. Fill the exhaust gas boiler as described on commissioning phase.
9. Make sure that water can flow freely from feed water tank to the boiler.
10. Start the feed water pump according instructions.
11. Open the by-pass damper manually (boiler on), first 10-20 %. Now part of exhaust
gas flows through the boiler heating surface resulting an evaporation of water. The
boiler starts generating steam. Always use damper with local control during
heating up process.
12. Let the steam pressure reach a few bars in the boiler and open the by-pass damper
gradually until it is fully open. When continuous steam flows through the venting
valve, the valve to be closed. Open exhaust gas boiler main steam heating valve
slightly open and wait until steam line is heated-up. This procedure is essential to
avoid great thermal stresses in the steam line.
13. When a normal working pressure of the boiler is reached the main steam valve to
the consumers is opened very slowly and carefully, see note below.
Now the steam system is heated-up and saturated steam is available from first boiler.
The heating-up procedure is to be repeated in accordance with these instructions for all
boilers. Also when any of boilers has been out of steam producing the heating-up
procedure is to done according to these instructions.
When the heating-up of steam system is done the first time, behavior of boiler and related
equipments are to be followed very carefully, i.e. that thermal expansion happens as
designed, no steam or water leakage appear, no unusual noises or vibrations appear
and that the steam system generally works steadily and according to the manufacturer’s
instructions.
NOTE!
If the safety valve has been open, make sure that it does not leak continuously because
of any remaining impurities between the sealing surfaces. If necessary, the safety valve
is tripped manually by releasing the relieve valve with a sudden movement.

Operation / 5514 - 11 / 17
Steam is not allowed to be led straight to the steam line, because the temperature
variation causes explosions in the big pipelines. For heating the steam line, the main
closing valves are slowly opened and the steam lines heated up. After the lines have
been properly heated, the closing valves can be slowly opened completely.
Always when opening big valves in a pressurized place, pay special attention to the
careful and smooth opening of the valve, i.e. first very little and some more after 30...40
seconds or when you can’t hear any more noise. After that the valve can be completely
opened carefully.
Observe the pressure in all the components while starting up the system. The system
has been designed so that the pressure is controlled by the bypass control and secured
by several safety valves, but still special attention must be paid for quick pressure rises.
If the bypass has been open for a longer period of time, make sure – through the
maintenance door – that the boiler tubes are clean before starting up. It is requested
that dirty tubes must always be water-cleaned because of the risk of soot fire!
THE FIRST START-UP PROCEDURE IS TO BE MADE BY OR UNDER

SUPERVISION OF A COMMISSIONER AUTHORIZED BY ALFA LAVAL AALBORG
OY.
2.3 Start-up of warm system

It is presumed that Heat Recovery System has been in use and for some reason the
steam producing has been stopped and is started again. Exhaust gas boilers are to be
started-up manually one by one.
1. Close the main steam valve to the consumers.

2. Check that the by-pass damper is in by-pass position (boiler off).
3. Open the by-pass damper gradually (boiler on).
4. When almost a level of normal working pressure in the boiler is reached and, the
main steam valve to the consumers is opened very slowly and carefully, see note for
opening of big valves.
5. Make sure that condensate is removed from the steam pipe lines, i.e. steam traps
are in use.
Now the one exhaust gas boiler is started-up and saturated steam is available from
boiler. If the whole steam system has been closed out of consumption, an instruction
under “Connection to consumption” needs to be followed.

Operation / 5514 - 12 / 17
2.4 Automatic start-up of the system

Steam system could be started automatically from the operator’s panel. Operator should
make automatic start-up according to PLC-program.
THE OPERATOR ALWAYS HAS TO BE AWARE ABOUT THE COMPLETE STEAM

SYSTEM CONDITION. OPERATOR IS ALWAYS RESPONSIBLE THAT AUTOMATIC
START IS MADE SAFELY.
2.5 Heating-up of cold auxiliary boiler

The auxiliary steam boiler located inside the container is used for steam production by
firing light fuel oil in start-up of the power plant and as a back-up for the exhaust gas
boilers.
The heating-up of auxiliary boiler is carried out as follows:

1. Check that steam system is prepared to use in order to produce steam with auxiliary
boiler.
2. Check that the feed water tank is filled to the normal level and water temperature is
around 90-95 ºC.
3. Check that exhaust gas line and all other pipelines are completely connected to the
boiler and all service hatches are closed.
4. Check that the drain valves of the auxiliary boiler are closed.
5. Make sure that condensate is removed from steam pipe lines, i.e. lines are equipped
with necessary steam traps and they are in use.
6. Check that the venting valve is opened.
7. Fill the auxiliary boiler as described on preparation on use phase.
8. Start the feed water pump according to instructions.
9. Start the burner (see detailed instructions from manufacturer’s instructions). During
the start-up procedure the burner is operated manually and with stage 1.
10. Rise the boiler temperature very slowly. Stop the burner and close the venting valve
when the continuous steam flows through the venting valve and the boiler is under
pressure. Warming the boiler to this point should take 1-2 hours. This procedure is
essential to avoid great thermal stresses in the boiler.
11. Keep the burner stopped 1-2 hours in order to avoid great thermal stresses.
12. Start the burner and raise the boiler pressure to 2-3 bar. After reaching this pressure
stop the burner and keep burner stopped for 1-2 hours.
13. Start the burner and raise the boiler pressure to 5-6 bar. After reaching this pressure
stop the burner and keep burner stopped 1-2 hours.
14. Start the burner and when a normal working pressure is reached, the main steam
valve to the consumers is opened very slowly and carefully.
15. Open all necessary outlet valves in the steam header if not open and led steam to
consumers.
16. Now the auxiliary boiler is ready for standard service and boiler could be operate
with full capacity or set to stand-by position as a backup for the exhaust gas boilers.

Operation / 5514 - 13 / 17
Time for cold start-up is estimated 5-8 hours

Now the auxiliary boiler system is heated-up and saturated steam is available from the
boiler.
The heating-up procedure is to be repeated in accordance with these instructions always

when the boiler has been out of steam producing.
When the heating-up of auxiliary boiler system is done the first time, behavior of boiler
and related equipments are to be followed very carefully, i.e. that thermal expansion
happens as designed, no steam or water leakage appear, no unusual noises or
vibrations appear and that the steam system generally works steadily and according to
the manufacturer’s instructions.
NOTE!
If the safety valve has been open, make sure that it does not leak continuously because
of any remaining impurities between the sealing surfaces. If necessary, the safety valve
is tripped manually by releasing the relieve valve with a sudden movement.
Steam is not allowed to be led straight to the steam line, because the temperature
variation causes explosions in the big pipelines. For heating the steam line, the main
closing valves are slowly opened and the steam lines heated up. After the lines have
been properly heated, the closing valves can be slowly opened completely.
Always when opening big valves in a pressurized place, pay special attention to the
careful and smooth opening of the valve, i.e. first very little and some more after 30...40
seconds or when you can’t hear any more noise. After that the valve can be completely
opened carefully.
Observe the pressure in all the components while starting up the system. The boiler has
been designed so that the pressure is controlled by the burner and secured by safety
valves, but still special attention must be paid for quick pressure rises.
Check through the maintenance door – that the boiler is clean before starting up. It is
requested that dirty boiler must always be water-cleaned because of the risk of soot fire!
THE FIRST START-UP PROCEDURE IS TO BE MADE BY OR UNDER

SUPERVISION OF A COMMISSIONER AUTHORIZED BY AALBORG INDUSTRIES
OY.

Operation / 5514 - 14 / 17
2.6 Heating-up of warm auxiliary boiler

It is presumed that Heat Recovery System has been in use and for some reason the
steam producing has been stopped and now it is started again. Exhaust gas boilers are
to be taken under the start-up manually one by one
1. Close the main steam valve to the consumers

2. Check that all valves in the water circuit are open
3. Start burner gradually
4. When almost a level of normal working pressure in the boiler is reached and, the
main steam valve to the consumers is opened very slowly and carefully, see note
for opening of big valves.
Now the auxiliary boiler is started-up and saturated steam is available from the boiler.
3. CONNECTION TO CONSUMPTION
Now the steam system has been heated up and it is ready for steam production. It is
presumed that steam consumers can take saturated steam and all related equipments
are ready for taking into use.
Each boiler can be connected to the consumption independently.

Operation / 5514 - 15 / 17
4. OPERATION
4.1 General
During operation of the exhaust gas boilers the operation of the pumps must be followed
so that the boilers are not allowed to boil/run dry.
When starting and also when using the engine with a partial load (<50 %) for a long period
of time, set the damper to by-pass position.
If the loading of the main engine is close to 50 %, there is a risk that boiler will get dirty
very quickly and therefore cleaning cycle needs to be shortened from the normal use cycle.
Also dirtiness of the boiler is to be checked manually more often than usual. Special
attention shall be paid to purity of boilers in the beginning of start-up process of the whole
plant.
During operation of the exhaust gas boilers, the outlet temperature of exhaust gases and
backpressure measured over the boiler must be observed and the results shall be booked
to a record.
Water treatment is to be taken under the consideration in the beginning of the start up and
chemicals added as illustrated in chapter, General Instructions, “Water
treatment”(110G001).
Since Heat Recovery System has been taken into the service all maintenance actions i.e.
cleaning of boiler, blow downs etc. need to be taken introduce as well, ref. individual
equipment maintenance instructions under the folder 2.
NOTE!
When the exhaust gas temperature falls below the design value, operation of the exhaust
gas boiler can cause a risk of sulfuric acid corrosion.
If outlet temperature of the exhaust gas is below 170C, the sulfur dew point of the exhaust
gas may be reached. The sulfur dew point must be found out by contacting the engine
manufacturer / fuel supplier.
4.2 Boiler book

Operators have to collect information from steam system during operation and mark all
collected information to boiler book. Every shift should mark all values (temperature,
pressure, engine load etc) of the steam system to the boiler book. Both indications local
and remote have to be booked. Also systems general condition have to be checked during
shifts (leaks, working of the device and components, running of the pumps, oil burner,
alarms in the operators panel/boiler’s control panel, sootblowers) and result should be
booked to boiler book.
In case of exceptional situation in the steam system person who has responsibility of the
steam system should be informed and necessary actions have to be made.
Operation / 5514 - 16 / 17
Boiler book is very important in order to follow working of the steam system during
long period. The validity of the warranty presumes that operational data is recorded
into boiler book regularly.
5. CAPACITY CONTROL OF STEAM PRODUCTION
5.1 Adjusting the steam production

The steam capacity of the boiler is adjusted by modulating exhaust gas damper. The
damper is keeping steam pressure in the set value by opening and closing the flaps.
Normal position of the by-pass damper is closed, which means that exhaust gas flows
to the by-pass line.
The overloading of the steam system is controlled step by step; if the pressure is raised
over the pre-set value, the high pressure is alarmed. If the boiler pressure still continues
to increase after the high pressure alarm, the bypass damper will be fully opened. If
despite this, the steam pressure is still increased, the safety valves will open. This should
release the surplus steam to atmosphere and lower the boiler pressure immediately.
The bypass damper is a single flap -design. If voltage for the actuator of the bypass
damper is lost, the bypass flap inside the damper is stopped and the flap is to be turned
to the bypass position (full open) manually motor’s second shaft by using a handwheel
or other tool.
The capacity can be also adjusted by leaving engine out of service, because the
capacity follows the efficiency of the running engine (In case when more than one boiler
in the system). If there is a short stop (days) of engine, the boiler water is proposed to
be kept warm in order to avoid risk of corrosion. The by-pass damper must be kept open
(boiler off).
If the boiler and connected engine will remain out of service for a longer period of time
(weeks), the boiler and related equipment’s are to be drained.
See emptying of the boiler, chapter Maintenance Instructions and storage instructions,
chapter General Instructions.
NOTE!
Capacity adjustment is never allowed to be done by throttling the water circulation of
the exhaust gas boiler. This will rapidly cause damage to the boiler.

Operation / 5514 - 17 / 17
5.2 Closing of steam production

When the engine is shutdown or by-pass damper is turned to the by-pass position, the
exhaust gas boiler will stop producing steam. Since the working pressure and steam
flow is increased, non return valves blocks in question of boiler out of steam system.
5.3 Removing from service

Removing from service is to be done in conjunction with closing of steam producing.
Service procedures, except cleaning of boiler, are not allowed until temperature of boiler
or temperatures with associated parts are cooled to the safety level.
If the water system of the exhaust gas boiler is led to become unpressurized, the boiler
tubes must be emptied of water (keeping the damper open does not overrule the above
instruction).
NOTE!
It is not allowed to remove the boiler from service while the exhaust gases are passing
through the boiler, because of a risk of a soot fire.
Furthermore, the tightness of the bypass damper is not 100 % therefore it is not
recommended to make any service measures inside the gas ducts, which are closed
only with by-pass damper.
6. DRY RUNNING
Dry running of the boilers is not allowed, unless the boilers are properly cleaned before
dry running. Please note that dry running is only allowed with the user’s responsibility.
Alfa Laval Aalborg Oy does not take any responsibility in case of a soot fire in a boiler.

WARRANTY & SERVICE
INFORMATION

Spare part information Warranty - 1/5
General - EWA 19-10-2016 B
CONTENT:
1. WARRANTY ................................................................................................................................... 2
2. ALFA LAVAL AALBORG OY SERVICE RANGE ........................................................................... 3
Monitoring & Improvement ........................................................................................................................... 4
Spare parts .................................................................................................................................................. 4
3. HOW TO ORDER ............................................................................................................................ 4

Spare part information - B 2/5
1. WARRANTY
The terms of warranty to all units and components supplied by Alfa Laval Aalborg Oy is stated in the
project contract. However, if not otherwise mentioned the warranty period is 12 (twelve) months from
commissioning or max of 18 (eighteen) months from Alfa Laval Aalborg Oy’s delivery.
The validity of the warranty presumes that all instructions and common carefulness are followed at
any time and that only educated service personal is used.
The warranty does not apply to rusting or mechanical parts, regarded as normal consumable spare
parts nor breakage due to defective use or gas explosions.
If any parts are broken during warranty time, please contact to Alfa Laval Aalborg Oy’s Warranty
department.
When any part is broken please clarify to Alfa Laval Aalborg Oy:
How it happened
When it happened
Possible reasons
If there has been any exceptional function in the system
Instrument information, see folder 1, chapter 3
Equipment information, see folder 2
All of this information is needed when Alfa Laval Aalborg is trying to examine reason to problem.
Broken part should always be delivered back to Alfa Laval Aalborg in order to make further
examinations. If broken parts are not delivered back to Alfa Laval Aalborg we are not able to consider
broken part as a warranty matter.
Contact information in warranty matters
Mail Address: Delivery address:

Alfa Laval Aalborg Oy Alfa Laval Aalborg Oy
P. O. Box 9 Kaivopuistontie 33
FIN-26101 Rauma FIN-26100 Rauma
Finland Finland
Tel + 358 10 8383 800

Fax + 358 10 8383 808
E-mail: [email protected]

2. ALFA LAVAL AALBORG OY SERVICE RANGE

Alfa Laval Aalborg Oy (BC RAUMA) supports markets with following services on case-by-case basis,
focusing on installations made with our products and/or deliveries from ALA/Rauma;
Alfa Laval 360˚ Service Portfolio
Job descriptions
Job title Description

Automation specialist / PLC Engineer, Water chemist, External
Specialist
consultant, Project Manager, WHR specialist, Condition auditor
Trouble shooting, Service work, Repair works, Root cause
Service engineer
analyze, Senior commissioning Engineer
Installation supervising, Installation inspections, Pre
Commissioning / Supervision engineer commissioning, Regular Commissioning, After commissioning
(such as operation, measuring)
Work / team leading on site, Inspections of delivery, Equipment
Site engineer
storage inspections, installation inspections.
Licensed Welder & Electrician Licensed welder for pressure vessels, Licensed electrician
Other workers Fitter, Bricklayer, Insulator, Helper etc.

Monitoring & Improvement
Referring to 360° Service portfolio BC Rauma has dedicated specialists available for
o monitoring services, such as WHR system and fired boiler Condition and
Performance Audits at site and onboard the ship.
o improvement services, such as Equipment upgrades, Redesign, Replacement &

Retrofit of the single cycle plants and/or existing WHR systems and fired boilers incl.
related auxiliaries.
These Monitoring and Improvement services are available on request. Please contact for
special offer/price info to your application from Alfa Laval Aalborg Oy sales department,
[email protected].
Spare parts
As boiler systems OEM, we offer all respective system spares, tailored to your demands.
Our spare part packages are divided into five different categories (ref. table on page 5 of
this document):
o Critical: Parts which cause significant downtime of the production process if they fail
o Safety: Parts with impact to the operational safety of the plant
o Operational: Spare part sets for agreed period (1-, 2-, 5- years as an example)
o Consumable: Parts which wear out under normal use
o Individual
Please contact Alfa Laval Aalborg Oy Service for special offer of spares for your application,
[email protected].
3. HOW TO ORDER
Following information is needed when ordering warranty parts or spare parts.
Alfa Laval Aalborg’s project number
Alfa Laval Aalborg’s project name
Equipment name and code
Drawing number
Part name and code
Position code / or spare part code


Part Material / Oper.
No Part Code Cert. Qty Component Description Type Enc. DN / PN PO/TO Range Power Voltage Manufacturer Notes Item No Price Conn.
A54/2.100.0 1/2'' - D bar(g) /
1 SPARE.SP001 AISI 316/304 / 2 THERMOMETER WITH POCKET 600 MM FOR EXHAUST GAS BOILER /500C.L1=6 20037 100 379ºC 0-500°C WIKA 80808340269RA
A54/2.100.0 1/2'' - D bar(g) /
2 SPARE.SP002 AISI 316/304 / 1 THERMOMETER WITH POCKET 250 MM GENERAL SPARE PARTS /250C.L1=2 20037 100 379ºC 0-250°C WIKA 80808340248RA
7 bar(g) / 24 VDC / 4-
3 SPARE.SP003 AISI316L / 1 PRESSURE TRANSMITTER FOR STEAM HEADER MBS3100 20021 1/2'' (M) 170ºC 0-16 bar 20mA Danfoss Accuracy 0,5%, Marine approved, IP65 80008200164RA
PRESSURE GAUGE LIQUID FILLED WITH RED MARK 233.50.100. 1/2'' - D bar(g) /
4 SPARE.SP004 AISI 316/304 / 2 POINTER GENERAL SPARE PARTS 10 bar LM 20032 100 ºC 0-10 bar WIKA 80508400192RA
1.5x320x 7 bar(g) /
5 SPARE.SP005 GRAPHITE / 4 GASKET FOR MANHOLE 320X420 FOR EGB & AUXB 420 B=20 170ºC AI DK 35205200178RA
bar(g) /
6 SPARE.SP006 / 7 GLASS FIBRE CORD FOR BOILER MANHOLE 25x25 ºC 35303100213RA
D=556/51 bar(g) /
7 SPARE.SP007 EPDM / 1 GASKET FOR MANHOLE D500 FOR FEED WATER TANK 6 S=5 ºC 35205200150RA
bar(g) /
8 SPARE.SP008 / 1 PUMP SPARES FOR FEED WATER PUMP ºC Type: CR 15-6 A-F-A-E-HQQE 95008850145RA
bar(g) /
9 SPARE.SP009 / 1 PUMP SPARES FOR CONDENSATE PUMP ºC Type: CR 5-8 A-FGJ-A-E-HQQE Low NPSH 95008850145RA
DN15 bar(g) /
10 SPARE.SP010 GRAPHITE / 2 FLANGE GASKET GENERAL SPARE PARTS PN10-40 ºC s=1,5mm 35205180262RA
DN20 bar(g) /
DN25 bar(g) /
DN32 bar(g) /
DN40 bar(g) /
DN50 bar(g) /
DN65 bar(g) /
DN80 bar(g) /
DN100 bar(g) /
DN125 bar(g) /
DN150 bar(g) /
PROJECT: WASTE HEAT RECOVERY SYSTEM FOR: DEVICE CODE: SPARE. MADE BY: DATE: SPARE PART LIST NO:
5514 DEVICE NAME: SPARE PARTS FOR commissioning REV BY: DATE: 5514-183D
TERMONORTE DFPP 93 MW APPROVED BY: DATE:
P-I DIAGRAM NO: 5514-3i E 1/1

O
WASTE HEAT RECOVERY
K
1-7 Operation
2-1 Maintenance

INSTRUCTION
MANUAL
2-4 Feed Water Tank

O
EQUIPMENT 2-7 Burner O
K
MW
2-10 Pumps
2-12 LFO Tank

B
3
B
4 Electrical
4
Customer's Ref: BOOK 2 EQUIPMENT

1 Summary of maintenance intervals
2 100G001 Boil out
3 100G002 Checking of boiler dirtiness
4 100G005 Visual checking of operation
5 100G006 Checking of manual steam sootblower
Internal inspection of wearing and

6 100G007
corrosion
7 100G008 Tightness test
8 100G009 Pressure testing

CONTENTS OF
9 100G011 Manual bottom and scum blow out
CHAPTER 2.1
10 100G012 Water sampling and analysing
11 100G013 Manual cleaning of the tanks
Emptying of pressurized feed water

12 100G015
tank
MAINTENANCE 13 100G017 Empying of blow down tank
14 100G018 Emptying of pump unit
15 100G023 Emptying of LFO-tank
16 100G028 Emptying of steam header
17 100G031 Emptying of auxiliary boiler
Manual water clening of auxiliary

18 100G032
boiler
19 100G033 Checking of auxiliary boiler dirtiness
20 100G034 Checking of burner function
21 100G035 Emptying of H U Boiler
22 100G037 Manual cleaning of smoke tube boiler
Commissioning for exhaust gas

23 100G040
damper
2.1 Maintenance
SUMMARY OF MAINTENANCE INTERVALS

Summary of maintenance intervals 1/2
TERMONORTE DFPP 93 MW 5514 EWA 7.8.2017 -
EXHAUST GAS FEED WATER BLOW DOWN STEAM EXHAUST GAS

Device PUMPS
BOILER TANK TANK HEADER DAMPER
Maintenance Interval D W M Y D W M Y D W M Y D W M Y D W M Y D W M Y
Job Description:
Sootblowing D
Bottom and scum blow-
D
out
Water sampling and
D
analysing
Checking of dirtiness W
Visual checking of
D D D D D D
operation
Manual water cleaning M Y Y Y Y
Checking of soot blowers M
Inspection of instruments M M M M M M
Internal inspection of
Y Y Y Y Y
wearing and corrosion
Pump capacity inspection Y
Tightness test Y Y Y Y Y Y
Pressure testing Y Y Y Y
Emptying of device Y Y Y Y Y
System flushing and
Y Y Y Y Y
pickling
Further information 1 1

Summary of maintenance intervals - 2/2
NOTE! The maintenance activities are to be documented and registered by using of O&M diary.
Maintenance D-daily (after 12 hours or ones per shift): W-weekly: M-monthly: Y-yearly: 1-see detailed maintenance instructions under the related device
intervals
Inspection of Instructions for instruments are to be studied from O&M book and maintenance activities are to done according to maker’s instructions
instruments
Pump capacity Pump capacity test is carried out according to General Instruction, Principle pump assembly
test
Pressure testing Needs for testing according to local requirements.
Emptying of Only when necessary in maintenance point of view.
device
System cleaning Regarding boiler cleaning, our demand is that required water quality values are to be met. We do not require any certain methods for reaching
and treatment those water quality values. It is therefore up to the operator or contractor to determine the suitable method for reaching the proper water quality
values. According to our knowledge, among other methods, both pickling and boiling out procedures have been successfully used. In case of
new system is implemented or existing system is modified, it’s recommended that pickling process is done by skilled workers (specialized
experts), see O&M book.
Tools All maintenance tasks are carry out with standard tools. For sootblower manual operation there is special tool delivered.
Spare parts Only OEM spare parts to be used. Gaskets have to be replaced always when opening flanged connections or hatches, see Spare part info from
O&M book
This page gives guidelines for regular maintenance intervals for the main devices. Detailed work instructions are to be followed according to Maintenance Cards and
instructions for related equipment are to be followed from Operating and Maintenance Instruction book.

GENERAL INSTRUCTION

Boil-out Maintenance 100G001 1/2
- Ilkka Herrala 22-10-2015 E
Before putting the steam system into operation for the first time, it should be boiled out to
remove all protecting remedies and impurities from the equipment in the steam system.
Boil-out will take place after all other cleaning procedures have been done, as informed
under the chapter “Installation”. Furthermore, preparations for use have been done
according to chapter “Operation”. Boil-out procedure can be part of heating-up actions, ref.
chapter “Operation, heating-up of cold system”. Boil-out procedure will start the formation of
a protective magnetite layer on boiler tube surfaces, which will develop further during a
consecutive start-up procedure.
The boil-out procedure is recommended to be carried out as described below:
Caution: Extreme care should be taken while handling boil-out chemicals. The person
handling the chemicals / their solution should be properly dressed /
protected and must carefully follow safety measures described in
Material Safety Data Sheet of the chemical.
∂ Fill the steam system with a solution consisting of 4-5 kg trisodiumphosphate Na 3PO4 and
0,5 kg caustic soda (NaOH) per 1000 kg water. The chemicals are normally added directly
through the manhole of a smoke-tube boiler or through the safety valve of steam drum in
connection of a water-tube boiler. In certain cases, the chemicals can be added through the
manhole of a feed-water tank serving for boil-out of several boilers consecutively.
∂ Trisodiumphosphate does not dissolve into cold water; water temperature of min. 50°C and
thorough mixing are required.
∂ Before adding chemicals through a safety valve, fill first the feed water tank / steam drum
with make-up / feed water, until its level reaches the mid-line of the water gauge. When
adding chemicals through a manhole, fill first with make-up / feed water close to its bottom
line. After chemical addition, use the make-up water / feed water pump(s) in order to fill the
feed water tank / steam drum to the upper line of its water gauge.
∂ Filling evaporator section in the boiler(s) with the solution takes place automatically during
heating-up of natural circulation boiler, ref. chapter “Operation, heating-up of cold system”
∂ Close the water supply to the feed water tank (e.g. close the make-up water or/and
condensate valves).
∂ When the boil-out solution is prepared in a feed water tank, the solution can be pumped
until reaching the LL-level of feed water tank. After that a new solution must be prepared.

Maintenance / Boiling out 100G001 E 2/2
Caution: Fill feed water into the boiler very carefully and slowly, if the temperature
difference between boiler and feed water exceeds 50°C.
∂ Raise steam pressure slowly to working pressure (~5 bars), and keep the pressure for
approx. 12 hours with closed main steam valve.
By this procedure grease and other impurities are removed from the internal surfaces of the
boiler and other pressure vessels.
∂ Stop the boil-out procedure of an auxiliary boiler by switching off its burner and / or the
exhaust gas boiler by preventing exhaust gas flow through it (switching the by-pass
damper(s) to the by-pass position and stopping the engine).
∂ Remember to open the venting valves, to avoid a vacuum in the pressure vessels when the
pressure falls back close to atmospheric pressure.
∂ Let the steam system cool down to 120-130°C before drainage.
∂ Blow off the boiler water by opening the draining valves in the boiler as well as the blow
down valves in the steam drum and in the feed water tank.
∂ Make sure that bottom blow down valves are clean after the boiling out. This is because
deposits / foreign substances will usually be accumulated in these valves causing leakage,
if they are not clean.
∂ Inspect the pressure vessels and remove any remaining deposits and foreign substances.
∂ If necessary, new gaskets are to be fitted in all hand- and manholes before refilling the
steam system with water.
The steam system is now ready to be re-filled from feed water tank and taken under the
start-up.
Note: During the first two weeks in operation we recommend to carry out a more
frequent skimming and bottom blow down sequence in order to remove
impurities entering the boiler from the pipe system. After that these
measures will be taken according to normal water treatment guidelines.

GENERAL INSTRUCTION

Checking of boiler dirtiness Maintenance 100G002 1/3
- rev. TRu 01-09-2015 a
DEVICE Exhaust gas boiler (water tube or smoke tube)

MAINTENANCE INTERVAL Weekly
MANHOURS 2
SERVICE MEN 1
SPARE PARTS -
SPECIAL TOOLS -
STEP: JOB DESCRIPTION: CHECKING WHEN SYSTEM IS IN USE

Before measurement, ensure that engine load and damper position are
1 corresponding the set down value related to defining needs of cleaning during
reference period, see remarks and O&M.
The primary method for determining boiler dirtiness is measuring the exhaust
gas temperature after the exhaust gas boiler. When the temperature has
2 increased to 20-30 °C above the values of a clean boiler, the heat surfaces must
be cleaned. Note! Steam/hot water production decreases remarkably with
dirty boiler.
Secondary method is measuring back pressure over the exhaust gas boiler.
Increased value may indicate boiler dirtiness and a possible need of cleaning is
to be visually checked by opening the maintenance doors. The trend of back
3
pressure is to be compared to the value of the clean boiler. The pressure
difference is observed from a manometer connected to the inlet and outlet
connections of the boiler.
STEP: JOB DESCRIPTION: CHECKING WHEN SYSTEM IS NOT IN USE

1 Open all maintenance doors of the exhaust gas boiler.
Inspect visually that heat surfaces and the inside of the boiler are clean. Special
attention shall be paid to oil deposits or corresponding impurities and the inside
2
structure of boiler must be free from all kinds of corrosion. If there is visible soot
layer, the boiler is to be cleaned. See examples of a dirty boiler in pictures 1- 4.
3 Close all maintenance doors before the engine is started.
REMARKS:
Results of temperature and pressure difference measurements must always be compared
with the values of a clean boiler, recorded at the beginning of the reference period (e.g.
time of initial startup). The temperature and back pressure range as well as the cleaning
frequency are determined based on this record. Measurements shall be carried out every
time with the same measuring point during a high engine load (~100%), and the results
shall be recorded.
The heat surface and internal steel structure of the boiler need to be inspected regularly
and always when it is possible. Note! Dirty surfaces re markably increase the risk of
soot fire.
During the internal inspection, observe the condition of the sealing gasket of the
maintenance doors and replace with new one if needed.
WARNINGS:

Maintenance / Checking of boiler dirtiness 100G002 - 2/3
Hot components and/or surfaces , see manual “Safety precautions”
Picture 1-2. Dirty fin tube surfaces

Maintenance / Checking of boiler dirtiness 100G002 - 3/3
Picture 3-4 Dirty smoke tube boiler

GENERAL INSTRUCTION

Visual checking of operation Maintenance 100G005 1/2
DEVICE All equipment and instruments

MAINTENANCE INTERVAL Daily / Monthly
MANHOURS 4
SERVICE MEN 1
SPARE PARTS Sealing gaskets for flange connections, sealing for
gland packing (concern globe valves with gland seal)
SPECIAL TOOLS -
STEP: JOB DESCRIPTION: VISUAL CHECKING OF OPERATION

Operation of equipment, instruments and components are to be visually checked
regularly in order to maintain safe and reliable steam generation. Process
1
values, such as; temperatures, pressures and water levels (local and remote-
control) are to be observed and recorded to the O&M diary.
Assembled equipment are to be checked visually so that any external leaks are
2
not shown.
If some flange connection leaks, you can try to repair it by retightening all
screws; method is cross-tightening if not otherwise indicated. Do not exceed the
3
tightening torques set down in General Instructions. If retightening does not help,
the sealing gasket needs to be replaced by new one.
If some valve leaks from spindle box and there is a gland packing, you can try to
repair leaking by retightening packing of grad seal. If it does not help check
4 gland packing and replace it by new one if necessary. Otherwise valve part or
whole valve has to be replaced by new one. For detailed instructions, see
related maker’s instructions.
In case of some equipment (vessel, pipe or corresponding part) is leaking, the
5 reason is to be determined immediately and correction activities are started. See
repair instructions under the related equipment.
STEP: JOB DESCRIPTION: SAFETY VALVES LEAKING TEST (MONTHLY)

1 Make sure that vessel in question is pressurized with a normal working pressure.
2 Close all pressure side valves.
Safety valve should be opened by using manual grip and it should be kept open
few seconds. After the grip has been released safety valve has to be observed in
case of any leaks. If safety valve is leaking it could be repaired by grinding the
3
sealing surface. If grinding won’t stop the leaking valve part or whole valve has
to be replaced by new one. For detailed instructions, see related maker’s
instructions.
4 Reopen closed valves.
REMARKS:
Use always new sealing gaskets when opening screw connections.
If new device, instrument, sealing gasket or corresponding assembly part is installed,
screw assemblies and connections are to be retightened after working pressure and
temperature of pressure vessel are stabilized.
Before repairing work, the leaking component is to be prevented from the system.
Maintenance / Visual checking of operation 100G005 - 2/2
WARNINGS:

GENERAL INSTRUCTION

Checking of manual steam sootblowers Maintenance 100G006 1/2
DEVICE Exhaust gas boiler

MAINTENANCE INTERVAL Monthly
MANHOURS 6
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS -
STEP: JOB DESCRIPTION:

Condition of sooting nozzles and cleaning of tubes must be checked at regularly
Open the maintenance door in question of tube section in order to behold the
1 whole soot blower pipe(s). Typically the soot blowers are located between, on
the top or below the tube sections inside the boiler.
2 Check that soot blower pipe is in order and clean.
Check that sooting nozzles are in good condition i.e. drillings in nozzles are open
3
and equal along the whole pipe.
By rotating sooting blower, make sure that above mentioned points are checked
4
from both side of the pipe.
Check that spindle’s shaft gasket does not leak to the inside or to the outside of
the boiler. If required you can try to repairing leaking by retightening packing of
grad seal screws; method is cross-tightening if not otherwise indicated. Do not
5
exceed the tightening torques set down in General Instructions. If retightening
does not help, check gland packing and replace it by new one if necessary. For
detailed instructions, see related maker’s instructions.
Soot blower is equipped with two grease nipples which are to be relubricated
6 regularly in order to lubricate the spindle and its shaft gasket. The proper
lubricating prevents also exhaust gas leakage outside the soot blower.
Gland packing
Graese nipples
Sooting nozzle

Maintenance / Checking of manual steam sootblowers 100G006 - 2/2
REMARKS:
If inspection of sooting pipe can not be done sufficient reliability, the whole soot blower is
to be drown out of the boiler and checked separately.
Use always new sealing gaskets when open screw connections.
It is advisable that condition of the sooting blowers are checked while manual water
cleaning is taken place.
WARNINGS:
Before the checking work, ensure that the engine remains off during the whole procedure.

GENERAL INSTRUCTION

Internal inspection of wearing and corrosion Maintenance 100G007 1/1
DEVICE All pressure vessels and tanks

MAINTENANCE INTERVAL Yearly
MANHOURS 8
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS -

Before any internal inspections, the device is to be isolated from plant steam
1
generation.
2 Device is to be emptied and cleaned according to the related instructions.
Before internal inspections, let the components and surfaces to be cooled to
3
safe level.
4 Maintenance doors are opened and internal inspection is carried out.
During inspection, the following items should be observed:
1. Inside surfaces are free any kind of corrosion
∂ In case that corrosion has been found possible corrosion allowances
have to be checked
∂ if there is more than 2-3 mm deep corrosion faults visible in steel parts,
this area should be renewed by welding a new steel plate. Ref. related
device repair instructions.
2. Inside steel structure is in good condition
5
∂ if there is some deformations due to thermal expansions etc., clarify
possible reason for that and try to eliminate it. If necessary take contact
Aalborg Industries.
3. Make a general inspection for purity of device. Ref. related device
maintenance cards as Checking of dirtiness, Manual water cleaning.
4. Check that the inside welding seams are corresponding to requirements.
∂ if necessary make a pressure test and/or use NDT methods for ensuring.
Ref. Pressure testing
After inspections close all maintenance doors and take the device under the
6
service according to O&M instructions.
REMARKS:
Before preparing any repair activities ensure requirements for fusion welding/ flame cutting
for pressure vessels.
Inspection of welding seams requires expert knowledge about pressure vessels and
therefore it is recommended that inspections for pressure parts are made by third part.
WARNINGS:

GENERAL INSTRUCTION

Tightness test Maintenance 100G008 1/1
DEVICE All equipment and instruments

MANHOURS 8
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS Torque wrench

All screw assemblies and connections are to be retightened after working
1 pressure and temperature of implemented system are stabilized. Furthermore
checking for thickness of screws is required to be done regularly.
2 Tightening method is cross-tightening if not otherwise indicated.
3 Do not exceed the tightening torques set down in General Instructions.
It is recommended to use torque wrench in order to ensure right tightening
4
torque.
If some component or joint is leaking, see additional instructions from
5
Maintenance card, Visual checking of operation.
REMARKS:
WARNINGS:

GENERAL INSTRUCTION

Pressure testing Maintenance 100G009 1/2
General - rev. Tru 23.12.2014 A
DEVICE All pressure vessels

MAINTENANCE INTERVAL Yearly or when necessary
MANHOURS 8
SERVICE MEN 2
SPARE PARTS Flange gaskets
SPECIAL TOOLS Separate test pump for pressurization. Test bench for test
of safety valves. Calibrated pressure gauge.
STEP: JOB DESCRIPTION: PRESSURE TEST FOR VESSEL

Before pressure test, the vessel is to be isolated from plant steam generation. Make
1
sure that related engine is stopped.
Use proper blind flanges between the pressure vessel and connected
2 components/assemblies so that only the vessel in question will be pressurized
during the pressure test.
Pressure vessel is to be cleaned and emptied according to related equipment
3
instructions.
4 Install calibrated pressure gauge suitable place in the vessel.
Fill the vessel with clean and treated industrial water. Make sure that all air is
5 removed from the pressure parts by opening venting valves until water flows
through.
Read pressure test value from related Technical Data Sheet or pressure vessel
6 shield. The pressure vessel is pressurized with separate test pump or
corresponding device in order to control right test value.
The pressure vessel is kept under the pressure test during 15 minutes and at the
same time visual inspections are made for main seams with steel plate
7
connections, nozzle/flange connections, manifolds, headers and other pressure
parts.
No water leaking or construction deformations are allowed. If some leaks noticed,
8 the fault needs to be repaired before pressure vessel is taken in use, see related
equipment repairing instruction.
Release pressure by opening venting valve. Note! In case pressure vessel test
9 pressure exceeds venting valve test pressure, it shall not be used for this purpose.
Empty the vessel (if necessary) and remove temporary blinds and other covers.
10 Take the pressure vessel part of steam generation according to O&M instructions.
STEP: JOB DESCRIPTION: PRESSURE TEST FOR SAFETY VALVE

It is recommended that pressure test for safety valve is part of pressure test of
1
related pressure vessel.
Read pressure test values (open/reset) from related Technical Data Sheet.
Pressure vessel is pressurized as above mentioned until safety valve opens. Let
2
the pressure released until safety valve is completely closed. Open and close
values are recorded and compared to the set-up values.
3 If operation of safety valve is not proper, see further maker’s instructions.
4 Safety valve can be tested separately in a special test bench.

Maintenance / Pressure testing 100G009 - 2/2
REMARKS:
Inspection of welding seams requires expert knowledge about pressure vessels and therefore
it is recommended that inspections during pressure test are made by third part.
Use always new sealing gaskets when opening screw connections.
WARNINGS:

GENERAL INSTRUCTION

Manual bottom and scum blow out Maintenance 100G011 1/1
General - rev. TRu 09-09-2015 a
DEVICE Steam drum, Boiler, Feed water tank (pressurized)

MAINTENANCE INTERVAL Bottom blow 1-3 /day, scum blow out continuously or
daily.
MANHOURS 0,5
SERVICE MEN 1
SPARE PARTS -
SPECIAL TOOLS -
STEP: JOB DESCRIPTION: BOTTOM BLOW-OUT (INTERMITTENT BLOW DOWN)

1 Make sure that the closing valve before the bottom blow-out valve is open.
The bottom blow-out is made by turning the bottom blow-out valve quickly into
2 open position, and closing it also quickly after 2-5 seconds. Sludge removing is
based on high flow velocity sucking effect on the vessel bottom.
STEP: JOB DESCRIPTION: SCUM BLOW-OUT (CONTINUOUS BLOW DOWN)

Make sure that the closing valve before the scum blow out valve is open (if
1
installed)
Primary method: Scum blow out is kept slightly open in order to remove foam
2
from surface as well as replace concentrated boiler water with a fresh water.
Secondary method: Scum blow out can also be carried out as bottom blow
3 down. Valve is opened and kept opened certain time e.g. 10 seconds and then
closed.
REMARKS:
Continuous blow down water amount shall be based on regular water quality analysing,
i.e. decrease/increase amount accordingly. Ref. instruction 110G0001 Water treatment
It is recommended that bottom blow down between vessels/boilers are operated
sequentially, not simultaneously. This will allow cooling time for blow down tank.
Make sure that Blow down tank is ready for blow-outs e.g. the cooling water flow to the
blow down tank, drain line is open etc.
Study the blow down valves operating/adjusting instruction from manufacturer’s enclosure
in manual.
WARNINGS:
Hot water from blow down tank venting because of simultaneous blow down or insufficient
cooling.

GENERAL INSTRUCTION

Water sampling and analysing Maintenance 100G012 1/1
DEVICE Pressure vessels and atmospheric vesssel

MAINTENANCE INTERVAL Daily
MANHOURS 1
SERVICE MEN 1
SPARE PARTS -
SPECIAL TOOLS -
STEP: JOB DESCRIPTION: PRESSURE VESSELS (with sample cooler)

1 Open the cooling water valve to the sample cooler.
2 Open the cock valve between pressure vessel and sample cooler.
The sampling is performed in such a way that the sample really contains the
water to be examined. Therefore, before sampling, water is let run with
3 considerable speed so long that it is changed 3-4 times in the sampling pipe line
(30 seconds at the minimum) and only then the actual sample needed for
analysing is taken.
4 Close the cock and cooling valves
Sample is to be analysed in a way that water properties, indicated in General
5 Instruction, Water treatment, are detected. If result departs from instructions,
corrective procedures are to be done immediately.
STEP: JOB DESCRIPTION: ATMOSPHERIC VESSELS (with sample cock)

1 Open the the sample cock in the vessel.
The sampling is performed in such a way that the sample really contains the
water to be examined. Therefore, before sampling, water is let run with
2 considerable speed so long that it is changed 3-4 times in the sampling pipe line
(15 seconds at the minimum) and only then the actual sample needed for
analysing is taken.
3 Close the cock
Sample is to be analysed in a way that water properties, indicated in General
4 Instruction, Water treatment, are detected. If result departs from instructions,
corrective procedures are to be done immediately.
REMARKS:
WARNINGS:
The temperature of the sample is very hot due to the pressure and therefore sample may
be evaporated unless not cooled properly.

GENERAL INSTRUCTION

Manual cleaning of the tanks Maintenance 100G013 1/1
General - EWA 08-06-2017 A
DEVICE Tanks
MANHOURS 2-8
SERVICE MEN 2
SPARE PARTS Manhole gasket
SPECIAL TOOLS Sludge barrel, soaking liquid if necessary, boiling out
chemicals if necessary

1 Emptying the tank, see emptying instructions
2 Open manhole and ensure that the tank is empty.
In case that inside of the tank is dirty remove all sludge and other waste from the
bottom and walls of the tank. Use brush and collect all sludge to the barrel.
3 Wash the tank with water by using clean water. If necessary, use suitable
soaking liquid in order to remove all sludge. Remove all washing water from the
tank and ensure that tank is clean.
4 Close the manhole and change gasket if old is damaged.
Fill-up the tank with water and take it under the service according to O&M
5
instructions
REMARKS:
Best time for cleaning will be during maintenance stops when the steam system is down.
Boiling out procedure is recommended to be made if any sludge or waste has been found
from the tank/system.
Before manhole is opened, make sure that the tank is completely empty.
WARNINGS:
Hot components and/or surfaces, see manual “Safety precautions”

GENERAL INSTRUCTION

Emptying of pressurized feed water tank Maintenance 100G015 1/1
DEVICE Feed water tank, pressurized

MANHOURS 4
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS -

The feed water tank is taken out of service and all electrical controls (hard &
1
soft) are by-passed .
The feed water pump(s) is stopped and water supply to the pump unit is to be
2
prevented by closing shut-off valve in the tank.
Chemical dosing pump is stopped and chemical supply to the tank is to be
3
prevented by closing shut-off valve in the tank
All incoming water connections have to be closed by closing shut-off valves
4 (feed water inlet & condensate inlet(s)). Make-up and condensate water pumps
have to be stopped (In case that system has mentioned pumps).
Close pre-heating connection and ensure that no steam is able to come to the
5
tank during emptying
Release over pressure from the tank by opening venting valve. Keep venting
6
valve open during whole operation in order to avoid vacuum.
7 Tank is recommended to be cooled to the safety level before emptying.
8 Tank is emptied by opening bottom blow-out valves.
Now the tank is emptying through the blow down tank. After the tank is empty,
9 the bottom blow-out valve is closed; the venting valve can be left in open
position if not question of storage procedures
Before maintenance activities, manifold and water level indicator have to be
10 emptied by opening drain valves in the end of the manifold pipe and bottom of
the indicator.
REMARKS:
Feed water tank is connected to the whole steam system so during emptying whole steam
system has to be down.
Ensure that water can freely flow via blow down tank to drainage place and the place is
able to take all draining water.
WARNINGS:

GENERAL INSTRUCTION

Emptying of blow down tank Maintenance 100G017 1/1
DEVICE Blow down tank

MANHOURS 4
SERVICE MEN 1
SPARE PARTS -
SPECIAL TOOLS -

1 Blow out connections in boilers, drums and feed water tank are closed.
2 Shut-off valve for cooling water of the tank is closed
3 Tank is recommended to be cooled to the safety level before emptying.
4 Tank is emptied by opening drain valve.
Now the tank is emptying through the drain valve. After the tank is empty, the
5
drain valve is closed.
REMARKS:
It is not allowed to make blow down operation during emptying.
WARNINGS:

GENERAL INSTRUCTION

Emptying of pump unit Maintenance 100G018 1/1
DEVICE Pump unit

MAINTENANCE INTERVAL yearly
MANHOURS 2
SERVICE MEN 1
SPARE PARTS -
SPECIAL TOOLS -

Water supply from the pump(s) to the system is disconnected when pump unit is
1
emptied.
The pump is stopped and water supply to the pump unit is to be prevented by
closing necessary shut-off valves:
∂ Pump unit under service: Close shut-off valve(s) in the water supply tank,
2 close shut-off valve(s) before device where water is pumped, close shut-
off valve in the pump’s return connection (if existing).
∂ Pump under service: Close shut-off valves in the pump unit before and
after the pump.
3 The pump unit is recommended to be cooled to the safety level before emptying
4 Pump unit is emptied by opening drain valve in the pump unit.
Pump itself is emptied as well; Example by opening venting and drain
5
connections..
Now the pump unit and pump itself is emptying through the drain valves of the
6 unit and pump. After the unit and the pump are empty, drain valves and pump
venting are closed.
REMARKS:
When pump unit is empty, water supply is not possible to the devices connected to the
pump unit.
Regulating valve after the pump is adjusted after restarting the pump
Always see pump manufacturers instructions.
WARNINGS:

GENERAL INSTRUCTION

Emptying of LFO-day tank Maintenance 100G023 1/1
DEVICE LFO-day tank, atmospheric

MANHOURS 2
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS -

The LFO-day tank is taken out of service and all electrical controls (hard & soft)
1
are by-passed .
2 Oil supply to the tank to be prevented by closing shut-off valve in the tank.
3 Oil connections have to be closed by closing shut-off valves (oil to / from burner).
4 Tank is emptied by opening drain valve in the bottom of the tank.
Now the tank is emptying through the drain valve. After the tank is empty, the
5
drain valve is closed.
Before maintenance activities, Oil level indicator have to be emptied by opening
6
drain valves in the bottom of the indicator.
REMARKS:
LFO-day tank is connected to the auxiliary boiler so during emptying the auxiliary boiler is
out of service.
Ensure that oil can freely flow via drain valve to oil bit and the bit is able to take all draining
oil.
WARNINGS:

GENERAL INSTRUCTION

Emptying of steam header Maintenance 100G028 1/1
DEVICE Steam header

MANHOURS 2
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS -

Steam production has to be stopped from steam drums / auxiliary boiler
1
connected to the steam header
2 Main steam lines from steam drums and auxiliary boiler have to be closed.
3 All steam inlet / outlet valves in the header have to be closed
Release over pressure and possible condensate water from the header by
4 opening drain valve. The drain valve can be left in open position if not question
of storage procedures.
The header is recommended to be cooled to the safety level before opening the
5
header
The header is emptied when opening the drain valve. Inside the header is only
6
condensate water during normal operation.
Before maintenance activities other blind flange should be removed in order to
7
open the header. Header is equipped with flanged connections in the both ends..
REMARKS:
If maintenance activities consider only the steam header, it can not be taken out of service
without related drum (s) / auxiliary boilers are out of service as well.
WARNINGS:

GENERAL INSTRUCTION

Emptying of auxiliary boiler Maintenance 100G031 1/1
DEVICE Auxiliary boiler

MANHOURS 8
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS -

The burner has to be stopped. The burner has to be switched to 0-position from
1 the burner and control panel in order to prevent starting of the burner during
emptying
2 The main steam valve is closed
Water supply to the boiler is to be prevented by closing shut-off valve before the
3 boiler. The feed water pump is stopped if auxiliary boiler has own feed water
pump.
Release over pressure by opening venting valves in the boiler. Keep venting
4
valves open during whole operation.
5 Boiler water is recommended to be cooled to the safety level before emptying.
6 Blow out valve is opened
7 Now the boiler is emptying through the blow down tank
8 Drain valve is opened after water is not coming anymore from the blow down line
After the boiler is totally empty, blow out/drain valves will be closed. The venting
9 valve can be left in open position if not storage procedures for longer period in
question
Before maintenance activities, manifold, water level indicator and protection tube
for water level controllers of the boiler have to be emptied by opening drain
10
valves in the end of the manifold pipe and bottom of the indicator / protection
tube.
REMARKS:
Burner has to be stopped all the time when boiler is without water
Storing of a cold boiler partly filled with water is not allowed because of the risk of
corrosion
For storing boiler longer period see additional instructions under “General Instructions”
WARNINGS:
The boiler water is recommended to be cooled to the safety level before emptying.

GENERAL INSTRUCTION

Manual water cleaning of auxiliary boiler Maintenance 100G032 1/2

MAINTENANCE INTERVAL Yearly (or more often if necessary)
MANHOURS 8
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS High pressure washer (e.g. 2…5m³/h at 120…150 bar),
cleaning brush

The burner has to be stopped and switched to 0-position from the burner and control
1 panel in order to prevent starting of the burner during washing. All other electrical
components have to be also switched off.
Open the burner and protect burner against washing water by covering it e.g. with
2
plastic
3 Open maintenance door in the burner side and inspection hatch in the opposite side
Check that water can flow freely out of the boiler’s maintenance door and inspection
hatch to the drains. It is recommended (in order to protect surrounding of the boiler):
o To make temporary pipe connection from the inspection hatch to the drain.
4
o To protect whole burner side against dirty boiler washing water when using
high pressure water.
o To make temporary water connection from maintenance door to the drain.
Start to feed the washing water with high pressure washer and clean through all the
smoke tubes. Brush all the tubes with cleaning brush after all tubes have been
5
washed with water. Repeat water washing to the tubes after brushing until out
flowing water is clean.
Start to feed the washing water with high pressure washer to the burner’s furnace
6
tube until out flowing water is clean
Check (e.g. by using flashing light) that the boiler’s smoke tubes and burner’s
7 furnace tube are clean (free from soot or corresponding impurities). If necessary
repeat cleaning procedure.
Remove all water, sludge and other waste from reversal chamber trough the
8
inspection hatch side and from the maintenance door side.
Check that inside structure and heat surfaces of the boiler are clean from sludge and
9
other waste
10 Clean surrounding of the boiler and remove temporary washing arrangement
11 Close the maintenance door, inspection hatch and burner
12 Dry up washing water from the exhaust gas boiler by starting the burner

Maintenance / Manual water cleaning of auxiliary boiler 100G032 - 2/2
REMARKS:
A manual water cleaning is performed with burner stopped, but the auxiliary boiler is still hot
(surface temperature below 150°C); this ensures the best results
In case the deposits are very “sticky” making it difficult to get the boiler cleaned properly, it is
possible to be used purpose of use suitable soaking agent with manual water cleaning.
Fire hydrant where the water flow and pressure of the water are sufficient high can be used if
high pressure washer is not available.
Check burner cleanliness and condition (especially nozzles). See burner manufacturer’s
instructions
WARNINGS:
Before the cleaning, ensure that the burner remains off during the whole cleaning procedure.

GENERAL INSTRUCTION

Checking of auxiliary boiler dirtiness Maintenance 100G033 1/1

MAINTENANCE INTERVAL Monthly
MANHOURS 2
SERVICE MEN 1
SPARE PARTS -
SPECIAL TOOLS -
STEP: JOB DESCRIPTION

The burner has to be stopped and switched to 0-position from the burner and
1
control panel in order to prevent starting of the burner during checking.
Open the burner, maintenance door in the burner side and inspection hatch in
2
the opposite side
Check burner cleanliness and condition (especially nozzles). See burner
3
manufacturer’s instructions and make necessary actions for burner
Check (e.g. by using flashing light) that the boiler’s smoke tubes, outlet chamber,
4 reversal chamber and burner’s furnace tube are clean (free from soot or
corresponding impurities)
The boiler should be manually cleaned if the boiler is dirty inside (clearly visible
5
soot layer). See maintenance card ”Manual water cleaning of the auxiliary boiler”
Close the maintenance door, inspection hatch and burner if cleaning is not
6
necessary
REMARKS:
The heat surface and internal steel structure of the boiler needs to be inspected regularly
and always when it is possible.
During internal checking, observe quality of sealing gasket in maintenance doors, replace
by new one if needed.
Burner adjustment should be checked in case of clearly visible soot layer
WARNINGS:

GENERAL INSTRUCTION

Checking of the burner function Maintenance 100G034 1/1
DEVICE Burner of the auxiliary boiler

MAINTENANCE INTERVAL Daily / Weekly / Monthly / Yearly
MANHOURS 0,5 / 1 / 2 / 8
SERVICE MEN 1
SPARE PARTS -
SPECIAL TOOLS -
STEP: JOB DESCRIPTION; DAILY

1 Switch burner off and swing burner open
2 Check / clean ignition electrodes
3 Clean photocell.
4 Check visually burner cleanliness inside and outside. Keep burner clean.
5 Check visually any fuel leaks in burner or fuel lines.
6 Check that burner starts and stops normally.
7 Check the burner pump pressure.
8 Check that the boiler doesn’t smoke from the stack
STEP: JOB DESCRIPTION, WEEKLY

1 Switch burner off and swing burner open
2 Clean and inspect nozzles.
Check visually diffuser disc and flame cone. Use a flash light to check cleanliness of
3
the boiler flue.
Cleaning the filters:
o Close fuel line valves
o Clean fuel filter
o Clean burner pump filter
4
o .Open fuel line valves. NOTE!. Starting the burner against closed valves
will break the burner pump.
o Check any fuel leaks.
Cleaning frequency can be increased or decreased according dirtiness
Perform a photocell test. While a burner is running, take photocell out and cover with
your hand. Burner must stop and go to a flame failure. Keep photocell covered in
5
your hand and reset the burner from control box. It should start and 5-10 seconds
after it ignites the flame, it must stop again and go to a flame failure.
STEP: JOB DESCRIPTION, MONTHLY

1 Test all burner alarms, stops and other indicator lights.
STEP: JOB DESCRIPTION, YEARLY
1 See manufactures instructions
REMARKS:
Follow always burner manufacturer’s instructions when making maintenance work
WARNINGS:

GENERAL INSTRUCTION

Emptying of H/ U -boiler Maintenance 100G035 1/1
DEVICE Exhaust gas boiler, H–boiler for steam or hot water

generation.
MANHOURS 4
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS -

Engine has to be stopped or by-pass damper has to be turned to the open position
1
(boiler off).
2 The boiler main outlet valve is closed.
The water supply to the boiler is to be stopped or prevented i.e. pump is stopped or
3
water inlet valve in the boiler is closed.
Release over pressure by opening venting valve(s) in the boiler. Keep venting valve
4
open during the whole operation to avoid vacuum.
Each drain valves are opened. Boiler drain valve(s) is located the lowest point of the
5
boiler shell.
Now the boiler is emptying through the drain valve(s). After the boiler is empty, drain
6 valve(s) is closed. The venting valve(s) can be left in open position if not question of
storage procedures.
7 The boiler water circuit valves are to be closed.
REMARKS:
The exhaust gas boiler shall be emptied always according to the procedure given above.
Water in exhaust gas boiler may never be emptied by evaporating. This would result in layering
and corrosion at the inner surfaces of water tubes and thus damage the boiler.
Compressed air must be used to assist emptying of a cold boiler to ensure successful
emptying.
Engine has to be stopped or by-pass damper has to be turned open position (gases pass the
boiler) all the time when the boiler is without water; there is risk of the soot fire if hot gases are
lead trough the empty boiler , see manual “Safety precautions”
Storing of a cold boiler partly filled with water is not allowed because of the risk of corrosion.
For storing see additional instructions under “General Instructions”
WARNINGS:
The boiler water is recommended to be cooled to the safety level before emptying.

GENERAL INSTRUCTION

Manual cleaning of smoke tube boiler Maintenance 100G037 1/1
DEVICE Exhaust gas boiler, smoke tube type, hot water or steam
boiler
MAINTENANCE INTERVAL Yearly (or more often if necessary)
MANHOURS 15-24
SERVICE MEN 2
SPARE PARTS -
SPECIAL TOOLS High pressure washer with special nozzle acc. to smoke
tube, cleaning brush

A manual cleaning is performed with engine stopped, but the exhaust gas boiler is
still hot (surface temperature below 100°C); this ensures the best results. Before
1
cleaning, please make sure that the engine will not get started during the cleaning
and related electrical components are also switched off.
Open the boiler water washing drain valve or connection to the washing line.
2
Check that water can freely flow out from the boiler.
3 Open the maintenance door(s) in the boiler exhaust gas side.
Start to feed washing water thoroughly the smoke tubes one by one. Use the smoke
4
tube brush, where necessary, to loosen soot from the tube surface. Flush with water.
Check (e.g. by using flash light) that the boiler’s smoke tubes are clean (checking is
5 to be done from both ends) and free from soot or corresponding impurities. If
necessary repeat the cleaning procedure.
Remove all sludge and other waste form boiler. Finish the procedure by flushing the
6 exhaust gas inlet/outlet boxes, until out flowing water is clean. Check that inside
structure and heat surfaces of the boiler are clean from soot, sludge and other waste.
7 Close the maintenance door(s)
8 Dry up cleaning water from the exhaust gas boiler by starting the engine.
9 Close the washing water drain connections
REMARKS:
Water cleaning has to be carried out at least once a heating season or according to readings of
pressure difference indicator and thermometers. Best result will be reached by using water
cleaning.
It is most important to dry up the exhaust gas boiler after water cleaning in order to avoid
damage by corrosion that may otherwise be drastic.
The pressure of washing water can be increased (e.g. applying a special cleaning company) or
a suitable soaking agent can be tried.
WARNINGS:

WORKING INSTRUCTION
Subject Document no. Page

Commissioning of exhaust gas damper control 100G040 1 / 13
Group Issued (by / date) Revised (by / date) Rev.
Maintenance TRu/02-09-2015 SSc/31-5-2016 B
Table of Contents
Technical info & parameter descriptions .................................................................................................................................................................................................................................................. 2

Parameter setup ........................................................................................................................................................................................................................................................................................ 3
Taking EM-279B in to use .......................................................................................................................................................................................................................................................................... 4
EM-279B Block diagram ............................................................................................................................................................................................................................................................................. 6
Spare parts ................................................................................................................................................................................................................................................................................................. 7
Working instructions & Troubleshooting .................................................................................................................................................................................................................................................. 8
EM-236 Interface unit .............................................................................................................................................................................................................................................................................. 12

Subject Document no. Rev. Page
Commissioning of exhaust gas damper control 100G040 B 2 / 13
TECHNICAL DATA: PARAMETER DESCRIPTION:
AC-supply 220- 500VAC 1. Minimum relay ”ON” time

Relay contact 3-ph. AC-motor up to 750W Defines minimum "ON" time for relay. For example: parameter value 20 means that relay
EM-279B specially DC supply 18-35Vdc will be pulled at least for 200ms
manufactured for Alfa Current consumption max 0.1A 2. Relay dead time
Laval Aalborg OY mA-input impedance 470R Limits change over time of relays. For example: if parameter is 100 it means that opposite
Control-inputs impedance 4.7k (PNP logic) direction relay can't pull sooner
Position output 4-20mA, load range 0-400ohm than 1s after the other has released
EM-279B WIRING (Program v.2.4) END IND outputs, NPN open coll. max 35V / 3. Startup time
279Bwir 100mA Sets starting time where current limit is disabled. For example: parameter value 40
Alarm-out N.C. contact max. 35V / 1A disables current limit function for 400ms after start
Feedback input 0-5V / 0/4...20mA impedance 4. Time out
1Mohm / 250ohm Limits maximum running time to one direction
Feedback sensor supply (pin-4) 5/12Vdc max. 5. Dead zone
20mA This is the margin of acceptable position. For example. parameter 5 value 2 means that
Dimensions 100x130mm, height 80mm non reacting range is 1% of full range. If set value with 4-20mA signal range is eg. 12mA
Din-rail mountable then value can change ±0.08mA (1%) before
positioning servo gives start command. Dead zone 1% is 11.92...12.08mA in this example
MONITOR VALUES 6. Feedback mode
Setting makes it possible to use feedback input signal also as inverted
Fault codes 7. Offset for 4 mA output
1= I-limit Sets minimum output value of the 4...20mA position signal output (ter.10) after learning.
2= Feedback error 8. Current limit delay time
3= Timeout Defines the delay for current limit reaction after start up time (par. 3)
4= Relay error 9. Current limit OUT
5= Set <3.5mA Set current limit “OUT” value. If value is exceeded device will shut down relays (motor).
6= Feedback low 10. Current limit IN
7= Feedback high Set current limit “IN” value. If value is exceeded device will shut down relays (motor).
2. Motor current (10=1A) 11. Forced run to “OUT” end trig.point
3. Start counter 0-65535 Sets triggering point for forced run “OUT”. If value is exceeded then device will run the
4. Start counter overlap 0-65535 motor until soft limit value (par.16) is reached
220-500VAC / max. 750W 5. Relay monitor voltage 0-255 12. Forced run to “IN” end trig.point
Sets triggering point for forced run “IN. If value is exceeded then device will run the motor
PARAMETER SETTING and until soft limit value (par.17) is reached
MONITORING 13. Emergency mode priority / start counter reset
This is combined parameter. First function is to select the manual drive mode when device
The parameter setting and monitoring is on “EMERGENCY MODE” (ter.22 activated). Another function is reset the start counter.
is done with interface unit EM-236. For resetting set parameter to “2” and push SAVE (interface unit EM-268).
Interface unit is plugged to socket 14. Drive direction for set <3,5mA
which is under the rubber cap. Select Defines the direction of forced run in case the set signal value goes under 3.5mA (ter.5)
15. I-out 20mA trim
"yes" for LOAD and EDIT to set parameters,
or MONITOR to see monitorable values. This is for fine tuning of max. output value of 20mA position output (ter.10) after learning.
After parameter changes the values must Make this adjust after set minimum parameter 7
be stored with long bush of SAVE button, or 16. End stop soft limit “OUT”
they will be lost after power off. Stops motor when soft limit "OUT" is reached. The percentages are calculated from full
range (4..20mA). Example. If parameter value is set to 2, stop point is 19,68mA
(16mAx0.02= 0.32mA). This setting must be less than parameter 11
17. End stop soft limit “IN”
Stops motor when soft limit "IN" is reached. The percentages are calculated from full range
(4..20mA). Example. If parameter value is set to 2 stop point is 4,32mA (16mAx0.02=
0.32mA ). This setting must be less than parameter 12
18. Emergency position preset
Defines target position in emergency in command situation (ter.22)
19. 3ph voltage
Defines the used motor supply voltage for relay failure check

Factory
Settable parameters Scale Adjust Set
Default
1 Minimum relay ”ON” time 10-500ms 1–50 / step=10ms 20 50

Damper blade Open/Close
2 Relay dead time 0,01 – 2 s 1-200 / step=10ms 100 200 Actuator’s stroke position, voltages and
current values
3 Startup time 0-2 s 0-200 / step=10ms 40 20
0-255 / step=1s
4 Time out 0-255s 100 35
0=disabled
5 Dead zone 0-10% 0-20 / step=0,5% 2 4
0 = direct
6 Feedback mode 1=inverted 0 1
7 Offset for 4 mA output 4 - 4,5 mA 0-5 / step=0,1 mA 0 0

8 Current limit delay time 0-1s 0-100 / step=10ms 10 10
9 Current limit OUT 0-5A 0-50 / step=0,1A 10 10
10 Current limit IN 0-5A 0-50 / step=0,1A 10 10 L1= 88 mm
11 Forced run to “OUT” end trig.point 0-20% 1-20 / step=1% 6 6 I1= 5,8 mA(DC)
Direction: Open (gas to bypass/boiler)
12 Forced run to “IN” end trig.point 0-20% 1-20 / step=1% 6 6
0=enable
Emergency mode priority / start counter
13 1=disabled 0 0
reset
2=reset L2= 400 mm
1=in I2= 17,0 mA(DC)
14 Drive direction for set <3,5mA 1 1
2=out Direction: Close (gas to boiler/bypass)
15 I-out 20mA trim -4%..0..+4 % 1-9 / step=1% 6 6
16 End stop soft limit “OUT” 0-5% 0-5 / step=1% 2 0 NOTE!
Values may change. They are set & measured by the commissioning engineer
17 End stop soft limit “IN” 0-5% 0-5 / step=1% 2 0 during commissioning according to project.
18 Emergency position preset 0-100% 0-100 / step=1% 40 0
19 3ph voltage 0–500Vac 0-500 / step=1Vac 230 400
NOTE!
Parameters are set by the commissioning engineer during commissioning.

TAKING EM-279B IN TO USE

Connect the EM-279B according to the instructions in 279Bwir.
You can also find the info for the operating range there
PARAMETERS
Switch on the supply and green POWER LED is lit.

In case you want to change the parameter values, connect interface unit EM-236
to the connector under the rubber hood. Enter to the LOAD & EDIT –menu,
change desired values and press SAVE –button for 2s. Interface unit will display
“SEND & SAVED” after successful saving. More info and the list of parameters
can be found in parameter descriptions.
DEFAULT SETTING
The parameter defaults will suite the most common applications, but the current
limit value should always be checked so that it won’t exceed the nominal
maximum of the used motor. Also a change of parameter for the operating
direction of the feedback sensor can be needed. Set system voltage for
parameter 19 (default 230V).
LEARNING
The device has an automatic learning function, with this function the device
scales different feedback input equalling 4…20mA set value. The position output
should be the same scale as the set value after learning. The suitable input
range for feedback sensor can be 0-20mA, 4-20mA or 0-5V.
Set the device to MANUAL –mode (pin 9 to +24Vdc) Make short runs to OPEN-
and CLOSE directions to see that connections are ok. Then give a simultaneous
OPEN and CLOSE command for 5 seconds. This will start the learning
sequence. Detailed teaching procedure is shown in separate instruction
100G040 rev. a-(MAMA-Commissioning of exhaust gas damper)-ENG
After successful teaching AUTOMATIC –mode can be used.
1. Motor is driven to the other end
2. Current limit will cut the run
3. Motor starts automatically to the opposite direction
4.Motor drives a full stroke and the mA-output is scaled
5. Current limit will stop the run
In the end of the learning mA-output is set to abt. 20mA.
The value can be fine-tuned (±4%) with parameter 15
In the other end of the stroke mA-output value should be 4mA.
If possible, make a check run.
If learning won’t work and the mA-output will not scale itself, change parameter
6, or snap two phases to the motor and try again. Other reason might be that the
transducer is out of range. The transducer value can be measured from terminals
3 and 6. The value should stay between 0,4V-4,6V during the full stroke (with
MIDORI-transducer) and between 0,8-19,2 with mA-sensor. Notice that FB-link
©should
Copyrightbe
AlfainLaval
right position.
Aalborg Oy www.alfalaval.com
AUTOMATIC (servo use)
After successful learning the servo use can be tested by setting MANUAL MODE
SELECT pin 9 to “low”. Check also that AUTO DRIVE ENABLE IN pin 21 is set
“high” and EMERGENCY IN pin 22 is set to “low”.
Start to adjust SET signal to 12mA. When AUTOMATIC is switched ON, motor
should drive to middle position of the stroke and stop there. Value of mA-output
should settle to 12mA. If you change the control value a little, the motor should
follow. If motor starts to beat back and forth and won’t settle down, the dead
zone is too small. Increase the value of parameter 5.
On both ends of the stroke there are forced end run limit values. After exceeding
the se limits the motor is driven to the hard end and the current limit stops the
run. Motor will not start before the control value returns inside the limits. These
limits can be set with parameters 11 and 12. In the example drawing, the limits
are set to 5mA and 19mA. If end soft-stop function is enabled, the motor will stop
1-5% before the hard end. This function can be selected with parameters 16 and
17.
SPECIAL FUNCTIONS
These functions work only when AUTOMATIC mode is selected.
If EMERGENCY IN is set to ”high”, it activates run to preset position, which is set

with parameter 18. EMERGENCY IN works only if AUTO mode is activated.
AUTO DRIVE ENABLE enables AUTO mode. If it is set to “low”, then the device
start to run end which is defined with parameter 14.
If set value goes lower than 3.5mA, device will give alarm and run end which is
defined with parameter 14.


SPARE PARTS
Please contact Alfa Laval Aalborg Oy Service for special offer of spares for your application,
[email protected]
Spare parts:
Interface Unit EM-236, 85620410093RA

Control card for damper EM-279B, 80014560152RA
Inductive sensor, 80014560199RA
Optional spare parts:
Local control box for dampers, 93005320178RA

Limit switch for damper type FD531-1M2, 95005349572RA or
Limit switch for damper type HDLSYAB1A, 95005349581RA

DEVICE Exhaust gas damper with electrical linear actuator TANex TM

MAINTENANCE INTERVAL As needed
MANHOURS 2
SERVICE MEN 1 (basic knowledge of electric safety e.g. de-energizing )
EQUIPMENT / TOOLS Basic hand tools, multimeter for mA measuring, EM-236 interface unit
SPARE PARTS -
SPECIAL TOOLS Manual hand wheel or suitable drilling machine for actuator manual operating (just in case of electricity malfunction)
The damper controller EM-279A_B TM (ref. fig.1 and appendix) demands a learning function. With this function the device scales the feedback output range of damper to equal
4...20mA.
The feedback signal is based on the distance difference between the inductive proximity sensor and eccentric cam, which is fixed on the damper shaft. (ref. fig 2).
Before running the teaching procedure, ensure that the sensor distance to the cam is:
-On by-pass position 5-6 mm.
-On boiler position it is normally less than 15 mm.
Adjust the distance if needed. (ref. fig 3.)
Note! Small holes on the cam mark the eccentric. Ensure cam is not out of area when setting by-pass position.
When the distance is correct, follow the steps 1 to 5:
1. Set the damper control to manual mode either in local control box (ref. fig 4.) or individual boiler panel.
2. Drive damper manually about 20-30 degrees out of by-pass position.
3. Move manual control switch to 0 and leave damper control on manual
4. Turn the teach switch to ON inside the damper local control box.(ref. fig. 5)
5. After damper starts moving turn the switch back to OFF position.
6. Damper is driving automatically close and open position and thus both ends are learned and feedback signal scale is set.
7. After the teaching procedure, the damper stops to the other end and damper control is set back to the auto mode. The damper runs (or stays) to by-pass position if safety
loop is not activated
8. Check that the feedback is correct according to damper movements.
NOTES
Teaching procedure should be done (again) when the damper is in operation temperature.
Boiler pressure controlling/ safety functions are only active when AUTO mode in local control (ref. fig 4)- and main control box (ref fig. 6) is active.

TROUBLESHOOTING
Problem Possible cause Remedy activity

Damper control does not work and Loss of feedback signal or feedback Read fault code from the controller power
damper is automatically closed to boiler signal out of scale led (see appendix 1), assure feedback
(safety position) sensor is not out of scale (ref. fig.3),
assure that the sensor is transmitting mA
signal to controller
Damper does not move Broken actuator Turn the actuator to the safety position
using its motor second shaft, repair or
change actuator and repeat teaching
procedure
Broken controller Turn the actuator to the safety position
using its motor´s second shaft. Read fault
code from controller power led (see
appendix 1). Try to de / re-energize
controller. Replace the controller.
Loss of power supply Turn the actuator to the safety position
using its motor´s second shaft. Track the
malfunctioning device. Check the wiring
and cabling. Check that the motor safety
switch is in the correct position.
NOTE! The actuator motor shall always be isolated by a safety switch before the actuator manual operation is permitted
Table 1. Typical problems, causes and remedy activities

Appendix: Instruction for damper controller EM-279B TM

Figure 1. Damper controller EM-279A (located in the control panel) Figure 2. Inductive proximity sensor and eccentric cam

Figure 3. Sensor position Figure 4. Local control box (located near the damper)
Figure 5. Teach switch inside panel Figure 6. Damper control in the main control panel

EM-236 INTERFACE UNIT
FEATURES:
• Accurate and easy adjustments
• Good adjustment repeatability
• Saves space in products
• Gives economical advance
• Enables dynamic monitoring
• Easy to use
EM-236 Interface unit is made for adjusting and copying adjustments of

Electromen driver devices and for
monitoring dynamic values during drive.
EM-236 enables the searching of the right settings and adjustments for the
aplication, and after that these
TECHNICAL DATA settings can be reliably loaded to other units.
Supply 3-6V / 30mA EM-236 is handy in instrumentation and allso a simple tool in production.
Baud rate 9600b/s ±10% The use in short:
Display 2x16digits, LCD After the driver unit is powered the cable from EM-236 with red "Micro Match"
Memory 5 slots, each can store connector is connected to the
one set of parameters. driver unit, (Notice the hole in board for polarity tab). The display of interface unit
Lead lenght 180mm wakes up and after some
Measures 90x60x20mm anouncements it is ready to load up parameters from the target driver
Weight 100g (Load&Edit), if there is need to edit, the
values can be changed with + and - buttons. Then the parameters can be saved
with 2 seconds push of the
"2sec. save" button. If the operation of the driver is OK. the red connector can be
connected to the next driver
and with a push of "Copy to device" button the same parameters are loaded to
the next unit and to as many
units as the user desires.

FUNCTIONS OF EM-236
Load & Edit
This will pick up the parameters from the driver
unit. Parameters will be displayed and you can
scroll and edit those with EM-236. After editing a
value, it will blink three times before it is valid.
NOTE. Edited parameter list is only in RAM until
you save. After saving (pressing 2sec save button)
new edited parameters will be sent to driver unit
and stocked in to selected memory slotts of the
EM-236 Interface unit.
Copy to device
This command will send the parameter list in
selected slot in to the driver unit.
Monitor values
This will enable user to monitor some dynamic
values during the use of the driver. Monitorable
values can be scrolled with arrow -buttons.
Memory
* Show selected
From here you can see the parameter list which is
stored in the slot which is selected at the time.
First you get a message, which slot is selected and
for what product the parameters are. Then you are
displayed the parameters, which you can scroll
trough, but not edit until those are saved.
* Select slot
Here you choose which one of the 5 memory slots
is active. When you save, copy, or go to
"Show selected", the operation is referred to the
slot you have chosen here.
SAVING
1. In "Load & Edit" press "2sec save" -button.
The displayed parameters (edited or not) will be
sent to the driver device and saved to the interface
units active slot.
2. "Copy to device" will send the parameters that
are in the interface units active slot to the driver device.
3. In all other situations, pressing "2sec save" -button
will send the parameters from active slot to driver unit.
NOTE: If you by mistake leave from the "Load & Edit"
window with out saving the edited parameters. The edits
will stay there if you dont do any saving or copying, or
you dont un plug the supply.
To save edited parameters you have to go back to
"Load & Edit" and push "2sec save" button. Then the
edited parameters are saved to active slot and sent to
the driver device.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B 12.06.17 JJN Max.- and Operating weight Recalculated

C 15.06.17 JJN 2 POSITONS DIRECTIONS CHANGED
A D 16.06.17 JJN SMOKE CHANNEL LEVEL CORRECTED
A
E 27.06.2017 FIRASHN Flanges added to C2, F, G, K1 and K2.
Aa6 Aa5 Aa2 F 6.7.2017 FIRASHN Counterflanges, cable trays and pipe supports added.
Aa3
D
C
W B1 D
Aa3 A A
B Aa1 K2 B
D
X11 X14 M27 BOLTS

B2
8
8
H X11
Aa7 X13
C C
C2
D F D
B
B
E E
Ad2
Ad
K1
C3 G
C C F
C4
Z
C4
F B F
X
B1
X14
G G
X13
D
H H
K2
Ac2
Ac3
B2
X16 Q Ae1 Ae2
J W A-A ( 1:30 ) J
K K
4 1
K1
L L
3
2
F
Y 5514 TERMONORTE 93 MW, COLOMBIA 8.6.2017/JJN
C3
C Hyundai Heavy Industries 7.7.2017/VLE
X Exhaust gas boiler HU 7.7.2017/PON
M C-C ( 1:30 ) A Main dimensions M
24667,1 1:30
Thermal expansion has been taken into kg
consideration in leg construction B-B ( 1:30 ) A1 5514-1M F 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A 27.06.2017 FIRASHN POS. 80 and 81 modified.
66 10 74 47 B 6.07.2017 FIRASHN Added POS. 100-107.

A 2 A
7 6 4 43 46 78 35
35 103
67 64
1
66 11 74
12 8 61
56
13 67 50
B B
D 18
B
47 64 61 56 50 18
17 44 16 62 65 75
62 47
44 53 34
53 50
19 51 46
44 15
C B-B ( 1:25 ) C
A A
34 37 58 60 63
75
26
106 107 36
54
45 B D
D D
D-D ( 1:25 )
71 38
100
E 32 E
105 20
3 39 40 55 61 64 68 71 77
E ( 1:10 ) 104 57
73
C C 61
64
101
F 33 41 66 F
45
102 E
5
42 45
G G
24
3
33 21 45 28 31
45 25 80
39
54 40 77 64 61 55 48 23 22 70 53 62 65 72 76
73 64 61 29 45 30
68
59 41 48 48
C-C ( 1:25 )
H 64 33 H
36
45
J J
27
76
K 35 K
11
9
69
45
L L
14
67
75
16.6.2017/JJN
72 52 49
79 EXHAUST GAS BOILER HU 7.7.2017/VLE
ASSEMBLY DRAWING 7.7.2017/PON
M 24667,1 1:25
M
kg
A-A ( 1:25 )
A1 5514-95A B 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Pos Qty Name Size Dim Std/Type Material Item No Weight
MAINTENANCE INSTRUCTIONS

Exhaust gas boiler U-type Maintenance - 1/5
General - MPU 11-07-2012 -
CONTENT:
1. GENERAL ........................................................................................................................... 2
2. MAINTENANCE INSTRUCTIONS FOR BOILER ................................................................ 2
2.1 Defining the need for cleaning of the Exhaust Gas Boiler............................................... 2
2.1.1 When the exhaust gas boiler is in need of cleaning? .......................................... 2
2.1.2 Methods for defining the need of cleaning the exhaust gas boiler ..................... 2
2.2 Methods of cleaning of an exhaust gas boiler ................................................................ 3
2.2.1 Cleaning with soot blowers ................................................................................... 3
2.2.2 Manual water cleaning ........................................................................................... 3
2.3 Other maintenance instructions for boiler and instruments ............................................. 4
2.3.1 Visual checking of operation. ................................................................................ 4
2.3.2 Checking of soot blowers. ..................................................................................... 4
2.3.3 Inspection of instruments. ..................................................................................... 4
2.3.4 Internal inspection of wearing and corrosion....................................................... 4
2.3.5 Tightness test ......................................................................................................... 4
2.3.6 Pressure test for pressure vessel and safety valve ............................................. 4
2.3.7 Emptying of exhaust gas boiler. ............................................................................ 5
2.3.8 Bottom and scum blow out .................................................................................... 5
2.3.9 Water sampling and analyzing .............................................................................. 5
2.3.10 Electrical safety test ............................................................................................. 5

Maintenance / Exhaust gas boiler U-type - - 2/5
1. GENERAL
This part describes how to maintain the Exhaust Gas Boilers. In case any major
problems occur within the steam system, please contact Alfa Laval Aalborg.
The maintenance activities should be documented and registered. The use of O&M
diary, i.e. the record of executed daily activities ensures sufficient management of the
steam system and traceability. It also minimizes the risk for confusions and/or
malpractices. The diary could also be helpful in possible questions of warranty.
General conditions of boiler and all instruments have to be noticed during normal
operation. In order to guarantee the safe operation in the plant all damages have to be
repaired without any delay. Instructions under this paragraph are meant to be studied
during the new steam system is implemented and the additional instructions are to be
followed from Maintenance Cards which are enclosed to the end of this chapter. These
cards include the information for carrying out the regular maintenance works at any
available shutdowns or prescheduled maintenance stops.
2. MAINTENANCE INSTRUCTIONS FOR BOILER
2.1 Defining the need for cleaning of the Exhaust Gas Boiler
2.1.1 When the exhaust gas boiler is in need of cleaning?
Exhaust gas boiler must be cleaned regularly. The cleaning frequency is determined
case by case. The influencing factors are quality of exhaust gases, temperature,
operation intervals, load factor etc. As a result, the cleaning intervals are determined on
the basis of inspections and experience. When starting and also when using the main
engine with partial load (<65%) for a long period of time. If the load of the engine remains
close to 65%, there is a risk that the boiler will get more dirty, more quickly than usual. In
order to prepare for this case, the sootblowing cycle must be shortened from the normal
case, furthermore, the intervals should be visually checked more often.
2.1.2 Methods for defining the need of cleaning the exhaust gas boiler
Ref.: Maintenance Card, “Checking of dirtiness”.
1. Exhaust gas temperature after exhaust gas boiler must be checked. When it has
been raised to 20-30 °C from values of a clean boiler, the heat surfaces must be
cleaned.
2. The exhaust gas temperature after the boiler is decisive factor to define need of
cleaning interval. Furthermore the back pressure over the exhaust gas boiler is
checked. Increasing value may indicate boiler dirtiness and a possible need of cleaning
is to be checked. The pressure difference can be observed from a manometer
connected to the inlet and outlet connections of the boiler.
Results of exhaust gas outlet temperature after boiler and pressure difference over the
boiler must be booked for values as clean boiler during the start up of new boiler.
These values are to be determined with a high load factor of the engine and they
should be values as well, which are used to reach steam capacity of boiler. Needs of
cleaning is to be carried out with the same way as clean boiler values have been
booked.
3. An internal inspection is carried out through the maintenance hatches. It is advisable

to perform the inspection at intervals, even if the gauging do not that require. Special
inspection shall be paid to the following items:
Heating surfaces are clean from oil deposits or corresponding impurities
The inside structure of boiler is free from all kind of corrosion.
2.2 Methods of cleaning of an exhaust gas boiler

2.2.1 Cleaning with soot blowers
Ref.: Maintenance Card, “Manual steam sootblowing”.
The exhaust gas boiler is equipped with a manual soot blower. The boiler, through
which exhaust gas flows, must be cleaned at least twice a day or, if necessary, even
more often. It is recommended that if the engine is mostly running on a partial load, the
cleaning should be carried out more often. Sootblowing must be done with engine
running.
2.2.2 Manual water cleaning
Ref.: Maintenance Card, “Manual water cleaning of boiler”.
Note!
In case the deposits are very “sticky” making it difficult to get the boiler cleaned
properly, it is possible to be used purpose of use suitable soaking agent with manual
water cleaning. The pressure of washing water can be increased (e.g. applying a
special cleaning company) or a suitable soaking agent can be tried.
Condition of sooting nozzles and cleaning of tubes must be checked at regularly

through the maintenance doors.
After cleaning, check that no sludge remains in the boiler. Potential sludge must be
removed because its content of sulfuric acid causes a risk of corrosion.
Special attention shall be paid to the cleaning of exhaust gas boiler if:
∂ a higher grade of heavy oil is introduced in the operation of engine

∂ consumption of lubrication oil of the engine increases above normal
∂ engine is running for a longer period of time with partial load
∂ fuel spraying valves of the engine are not operating properly. This is the most
evident cause of fires because of its unpredictability in boilers that normally remain
clean in operation.
Important!
Dry-running of a dirty boiler is strictly prohibited because of a risk of soot fire. The boiler
construction allows the dry-running. Before dry running the boiler has to be manually
water washed and secured that boiler is clean. Because the temperature in the whole
boiler in dry running mode is more than 300 °C the level sensors and any other
components, which can be damaged have to be taken off
See general instruction “Dry running of smoke tube boiler”

2.3 Other maintenance instructions for boiler and instruments
2.3.1 Visual checking of operation.
Ref.: Maintenance Card, “Visual checking of operation”.
2.3.2 Checking of soot blowers.
Ref.: Maintenance Card, “Checking of manual soot blower”.
2.3.3 Inspection of instruments.
See related instrument maker’s instructions from book 3.
2.3.4 Internal inspection of wearing and corrosion .
Ref.: Maintenance Card, “Internal inspection of wearing and corrosion”.
2.3.5 Tightness test
Ref.: Maintenance Card, “Tightness test”.
Note!
All screw assemblies and connections are to be retightened after working pressure and
temperature of pressure vessel are stabilized. Especially this will take place during an
implementation of a new pressure vessel.
2.3.6 Pressure test for pressure vessel and safety valve
Ref.: Maintenance Card, “Pressure testing”.
Note!
Although individual pressure vessels have been pressure tested in the end of
manufacturing phase, before new pressure equipment (assembly where related valves,
pipes etc. components are connected to the pressure vessel) is taken in use, it needs
to be pressure tested. Requirements of pressure testing for delivered pressure vessel
are informed in related Maintenance Card and Technical data sheets. Furthermore the
local requirements and laws regarding pressure vessel and pressure equipment are to
be taken into the consideration before steam generation is started. Liability of register
or other licenses are out of Alfa Laval Aalborg responsibility.

2.3.7 Emptying of exhaust gas boiler .
Ref.: Maintenance Card, “Emptying of H/U -boiler”.
Note!
corrosion and/or frozen.
Storing of boiler shall be made by taking into consideration instructions about corrosion
protection. Suitable protection has to be added inside the boiler and all connections
closed properly. For storing see additional instructions under the chapter 8 general
instructions, General Instruction no: 50G003.
2.3.8 Bottom and scum blow out
Ref.: Maintenance Card, “Manual bottom and scum blow out”.
Note!
The needs of blow outs are described under the “General Instructions, water treatment”.
During initial start up the quality of the boiler water is to be observed more often and
therefore system may require that blow outs are to be done more often as indicated in
related Maintenance card.
2.3.9 Water sampling and analyzing
Ref.: Maintenance Card, “Water sampling and analyzing”.
Note!
See above note.
2.3.10 Electrical safety test
Ref.: Book 4, Electrical Information

REPAIR INSTRUCTIONS

Exhaust gas boiler (UNEX H) Repair - 1/4
CONTENT:
1. REPAIR INSTRUCTIONS OF THE EXHAUST GAS BOILER ............................................. 2

1.1 Repairing water leakage in boiler tube ........................................................................... 2
1.2 Repairing an individual damage ..................................................................................... 3
1.3 Repairing large damage ................................................................................................. 3
1.4 Examinations connected to the welding of pressure parts .............................................. 4

Repair / Exhaust gas boiler (UNEX H) - - 2/4
1. REPAIR INSTRUCTIONS OF THE EXHAUST GAS BOILER
1.1 Repairing water leakage in boiler tube
On the side of the exhaust gas boiler there are maintenance doors, through which the
condition of plain tubes can be inspected. Heating surface is created with plain smoke
tubes.
The heating surface consists of vertical or horizontal plain steel tubes, which are
surrounded by water. The tubes are connected to inlet and outlet exhaust gas
chambers. The exhaust gas flows across the tubes. The water space as well as
exhaust gas chambers are welded steel structure
Sootblowers can be in the out or inlet chamber. Soot blowers are defined case by case
taking into the consideration cleaning requirements of the boiler.
Before any repairing work the all safety instructions are to be followed. Special
attention shall be paid if plant steam producing is maintained and the same time some
boiler is to be taken under the repairing work. Therefore it needs to be ensured that
exhaust gas flow can not flow inside the boiler, feed water and steam supply to the
repairing boiler are isolated etc. The emptying of boiler needs to be done according to
related instructions, see Maintenance Card, Emptying of exhaust gas boiler”.

1.2 Repairing an individual damage
If a smoke tube is leaking, this can be shut off from service by passing the leaking plain
tube as follows:
See figure 1.
Weld steel plate to the both end of the leaking tube.This procedure can be followed if
leak appears only in one or a few pipes without any significant cut in the exhaust gas
boiler capacity.
Ø according
boiler pipe
size
Ø according
boiler pipe
size
Figure 1
1.3 Repairing large damage
When more plain tubes are leaking, or if an individual leaking point can’t be otherwise
located, larger repair work is required. Case like this take contact Alfa Laval Aalborg in
order to have further information.

1.4 Examinations connected to the welding of pressure parts
After welding of tubes the exhaust gas boiler needs to be pressure tested. Pressure
test procedure has been described in the maintenance cards. Also it is recommended
that some of welded seams are exanimate with suitable NDT methods in order to
ensure the right welding procedure. Furthermore the local requirements and laws
related of repairing pressure parts are to be taken into the consideration before any
work.

Technical Information
Proline Promag 50P, 53P

Electromagnetic Flow Measuring System
Flow measurement of liquids in chemical or process applications
Application Connection to process control system:

Electromagnetic flowmeter for bidirectional • HART
measurement of liquids with a minimum • PROFIBUS DP/PA
conductivity of ≥ 5 μS/cm: • FOUNDATION Fieldbus
• Acid, alkalis • MODBUS RS485
• Paints
• Pastes
Your benefits
• Water, wastewater etc.
Promag measuring devices offer you cost-effective flow
• Flow measurement up to 9600 m³/h (42268 gal/min) measurement with a high degree of accuracy for a wide
• Fluid temperature up to +180 °C (356 °F) range of process conditions.
• Process pressures up to 40 bar (580 psi)
The uniform Proline transmitter concept comprises:
• Lengths in accordance with DVGW/ISO
• Modular device and operating concept resulting in a
Application-specific lining materials: higher degree of efficiency
• PTFE • Software options for batching, electrode cleaning and
• PFA for measuring pulsating flow
• High degree of reliability and measuring stability
Approvals for hazardous area:
• Uniform operating concept
• ATEX
• IECEx The tried-and-tested Promag sensors offer:
• FM • No pressure loss
• CSA • Not sensitive to vibrations
• NEPSI • Simple installation and commissioning
• TIIS
TI047D/06/en/11.09
71106271
Table of contents
Function and system design. . . . . . . . . . . . . . . . . . . . . 3 Mechanical construction . . . . . . . . . . . . . . . . . . . . . . 25

Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Design, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Measuring tube specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Material load diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Measured variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fitted electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Measuring ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Process connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operable flow range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Surface roughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Input signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Human interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Signal on alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Language groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remote operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Low flow cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Galvanic isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Switching output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Certificates and approvals . . . . . . . . . . . . . . . . . . . . . 42
CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
C-tick mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure measuring device approval . . . . . . . . . . . . . . . . . . . . . . 42
Electrical connection, measuring unit . . . . . . . . . . . . . . . . . . . . . . 7
Ex approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical connection, terminal assignment . . . . . . . . . . . . . . . . . . 8
Other standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical connection, remote version . . . . . . . . . . . . . . . . . . . . . . 9
FOUNDATION Fieldbus certification . . . . . . . . . . . . . . . . . . . . . 42
Supply voltage (power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MODBUS RS485 certification . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PROFIBUS DP/PA certification . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remote version cable specifications . . . . . . . . . . . . . . . . . . . . . . . . 9
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power supply failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ordering information. . . . . . . . . . . . . . . . . . . . . . . . . 43
Potential equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Performance characteristics. . . . . . . . . . . . . . . . . . . . 13
Reference operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maximum measured error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Registered trademarks . . . . . . . . . . . . . . . . . . . . . . . . 43
Operating conditions: Installations . . . . . . . . . . . . . . 14
Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inlet and outlet run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Length of connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operating conditions: Environment. . . . . . . . . . . . . . 20

Ambient temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Storage temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Shock and vibration resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . 20
Operating conditions: Process . . . . . . . . . . . . . . . . . . 21

Medium temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Medium pressure range (nominal pressure) . . . . . . . . . . . . . . . . . 22
Pressure tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Limiting flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Endress+Hauser
Function and system design

Measuring principle Following Faraday's law of magnetic induction, a voltage is induced in a conductor moving through a magnetic
field.
In the electromagnetic measuring principle, the flowing medium is the moving conductor.
The voltage induced is proportional to the flow velocity and is supplied to the amplifier by means
of two measuring electrodes. The flow volume is calculated by means of the pipe cross-sectional area.
The DC magnetic field is created through a switched direct current of alternating polarity.
Ue
V
B
I
L
A0003191
Ue = B · L · v
Q=A·v
Ue Induced voltage
B Magnetic induction (magnetic field)
L Electrode spacing
v Flow velocity
Q Volume flow
A Pipe cross-section
I Current strength
Measuring system The measuring system consists of a transmitter and a sensor.

Two versions are available:
• Compact version: Transmitter and sensor form a mechanical unit.
• Remote version: Sensor is mounted separate from the transmitter.
Transmitter:
• Promag 50 (user interface with push buttons for operation, two-line display, illuminated)
• Promag 53 ("Touch Control" without opening the housing, four-line display, unilluminated)
Sensor:
• Promag P (DN 15 to 600 / ½ to 24")
Endress+Hauser 3
Input
Measured variable Flow velocity (proportional to induced voltage)
Measuring ranges Measuring ranges for liquids

Typically v = 0.01 to 10 m/s (0.03 to 33 ft/s) with the specified accuracy
Operable flow range Over 1000 : 1
Input signal Status input (auxiliary input)

• U = 3 to 30 V DC, Ri = 5 kΩ, galvanically isolated
• Configurable for: totalizer(s) reset, measured value suppression, error-message reset
Status input (auxiliary input) with PROFIBUS DP and MODBUS RS485
• Switching level: 3 to 30 V DC, independent of polarity
• Configurable for: totalizer(s) reset, measured value suppression, error-message reset,
batching start/stop (optional), batch totalizer reset (optional)
Current input (only Promag 53)
• active/passive selectable, galvanically isolated, full scale value selectable, resolution: 3 μA,
temperature coefficient: typ. 0.005% o.r./°C (o.r. = of reading)
• active: 4 to 20 mA, Ri ≤ 150 Ω, max. 24 V DC, short-circuit-proof
• passive: 0/4 to 20 mA, Ri < 150 Ω, max. 30 V DC
Output
Output signal Promag 50
Current output
active/passive selectable, galvanically isolated, time constant selectable (0.01 to 100 s),
full scale value selectable, temperature coefficient: typ. 0.005% o.r./°C (o.r. = of reading), resolution: 0.5 μA
• active: 0/4 to 20 mA, RL < 700 Ω (HART: RL ≥ 250 Ω)
• passive: 4 to 20 mA, operating voltage VS : 18 to 30 V DC, Ri ≥ 150 Ω
Pulse/frequency output
passive, open collector, 30 V DC, 250 mA, galvanically isolated
• Frequency output: full scale frequency 2 to 1000 Hz (fmax = 1250 Hz), on/off ratio 1:1, pulse width max. 10s
• Pulse output: pulse value and pulse polarity selectable, max. pulse width configurable (0.5 to 2000 ms)
PROFIBUS DP interface
• Transmission technology (Physical Layer): RS485 in accordance with ANSI/TIA/EIA-485-A: 1998,
galvanically isolated
• Profil version 3.0
• Data transmission rate: 9,6 kBaud to 12 MBaud
• Automatic data transmission rate recognition
• Function blocks: 1 × analog Input, 1 × totalizer
• Output data: volume flow, totalizer
• Input data: positive zero return (ON/OFF), totalizer control, value for local display
• Cyclic data transmission compatible with previous model Promag 33
• Bus address adjustable via miniature switches or local display (optional) at the measuring device
PROFIBUS PA interface
• Transmission technology (Physical Layer): IEC 61158-2 (MBP), galvanically isolated
• Current consumption: 11 mA
• Permissible supply voltage: 9 to 32 V
• Bus connection with integrated reverse polarity protection
• Error current FDE (Fault Disconnection Electronic): 0 mA
• Function blocks: 1 × analog input, 2 × totalizer
• Input data: positive zero return (ON/OFF), control totalizer, value for local display
4 Endress+Hauser
Promag 53
Current output
active/passive selectable, galvanically isolated (Ex i version: only passive)
• active: 24 V DC, 25 mA (max. 250 mA during 20 ms), RL > 100 Ω
• passive: open collector, 30 V DC, 250 mA
• Frequency output: full scale frequency 2 to 10000 Hz (fmax = 12500 Hz), EEx-ia: 2 to 5000 Hz;
on/off ratio 1:1, pulse width max. 10 s
• Output data: volume flow, calculated mass flow, totalizer 1 to 3
• Available output combination → ä 8
MODBUS RS485 interface
• MODBUS device type: Slave
• Adress range: 1 to 247
• Supported MODBUS function codes: 03, 04, 06, 08, 16, 23
• Broadcast: supported with the function codes 06, 16, 23
• Übertragungsmodus: RTU oder ASCII
• Supported baudrate: 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 Baud
• Response time:
– Direct data access = typically 25 to 50 ms
– Auto-scan buffer (data range) = typically 3 to 5 ms
Endress+Hauser 5
FOUNDATION Fieldbus interface

• FOUNDATION Fieldbus H1
• ITK version 5.01
• Function blocks:
– 5 × Analog Input (execution time: 18 ms each)
– 1 × PID (25 ms)
– 1 × Digital Output (18 ms)
– 1 × Signal Characterizer (20 ms)
– 1 × Input Selector (20 ms)
– 1 × Arithmetic (20 ms)
– 1 × Integrator (18 ms)
• Output data: volume flow, calculated mass flow, temperature, totalizer 1 to 3
• Input data: positive zero return (ON/OFF), reset totalizer
• Link Master (LM) functionality is supported
Signal on alarm • Current output → failure response selectable (e.g. in accordance with NAMUR recommendation NE 43)
• Pulse/frequency output → failure response selectable
• Status output (Promag 50) → non-conductive by fault or power supply failure
• Relay output (Promag 53) → de-energized by fault or power supply failure
Load see "Output signal"
Low flow cutoff Switch points for low flow cutoff are selectable.
Galvanic isolation All circuits for inputs, outputs and power supply are galvanically isolated from each other.
Switching output Status output (Promag 50, Promag 53)

Open collector, max. 30 V DC / 250 mA, galvanically isolated.
Configurable for: error messages, Empty Pipe Detection (EPD), flow direction, limit values.
Relay outputs (Promag 53)
Normally closed (NC or break) or normally open (NO or make) contacts available
(default: relay 1 = NO, relay 2 = NC), max. 30 V / 0,5 A AC ; 60 V / 0,1 A DC, galvanically isolated.
Configurable for: error messages, Empty Pipe Detection (EPD), flow direction, limit values, batching contacts.
6 Endress+Hauser
Power supply
Electrical connection,
A B C
measuring unit
d d
g g
b b
a
a
a
b d/(g) (d)
HART* PROFIBUS PA*

FOUNDATION Fieldbus*
– 27 PA(–)/FF(–) 27
+ 26 PA(+)/FF(+) 26
– 25 d – 25 d
+ 24 + 24
f – 23 e f – 23 e
+ 22 + 22
– 21 – 21
+ 20 + 20
N (L-) 2 c N (L-) 2 c
L1 (L+)1 L1 (L+) 1
b b
PROFIBUS DP* PROFIBUS DP**

MODBUS RS485**
A (RxD/TxD-N) 27 A (RxD/TxD-N) 27
B (RxD/TxD-P) 26 B (RxD/TxD-P) 26
– 25 d – 25 d
+ 24 + 24
f – 23 e f – 23 e
+ 22 + 22
– 21 – 21
+ 20 g + 20 g
N (L-) 2 c N (L-) 2
c
L1 (L+) 1 L1 (L+) 1
b b
A0002441
Connecting the transmitter, cable cross-section max. 2.5 mm2 (14 AWG)
A View A (field housing)
B View B (stainless steel field housing)
C View C (wall-mount housing)
*) fixed communication boards
**) flexible communication boards
a Connection compartment cover
b Cable for power supply: 85 to 260 V AC / 20 to 55 V AC / 16 to 62 V DC
- Terminal No. 1: L1 for AC, L+ for DC
- Terminal No. 2: N for AC, L– for DC
c Ground terminal for protective conductor
d Signal cable: see "Electrical connection, terminal assignment" → ä 8
Fieldbus cable:
- Terminal No. 26: DP (B) / PA + / FF + / MODBUS RS485 (B) / (PA, FF: with polarity protection)
- Terminal No. 27: DP (A) / PA – / FF – / MODBUS RS485 (A) / (PA, FF: with polarity protection)
e Ground terminal for signal cable shield / Fieldbus cable / RS485 line
f Service adapter for connecting service interface FXA193 (Fieldcheck, FieldCare)
g Signal cable: see "Electrical connection, terminal assignment" → ä 8
Cable for external termination (only for PROFIBUS DP with fixed assignment communication board):
- Terminal No. 24: +5 V
- Terminal No. 25: DGND
Endress+Hauser 7
Electrical connection, Terminal assignment, Promag 50

terminal assignment
Order variant Terminal No. (inputs/outputs)
20 (+) / 21 (–) 22 (+) / 23 (–) 24 (+) / 25 (–) 26 (+) / 27 (–)
50***-***********W – – – Current output HART
50***-***********A – – Frequency output Current output HART
50***-***********D Status input Status output Frequency output Current output HART
50***-***********H – – – PROFIBUS PA
50***-***********J – – +5 V (external PROFIBUS DP
termination)
50***-***********S – – Frequency output, Current output, Ex i,
Ex i, passive passive, HART
50***-***********T – – Frequency output, Current output, Ex i,
Ground terminal → ä 7
Terminal assignment, Promag 53

The inputs and outputs on the communication board can be either permanently assigned or variable, depending
on the version ordered (see table). Replacements for modules which are defective or which have to be replaced
can be ordered as accessories.

20 (+) / 21 (–) 22 (+) / 23 (–) 24 (+) / 25 (–) 26 (+) / 27 (–)
Fixed communication boards (fixed assignment)
53***-***********B Relay output 2 Relay output 1 Frequency output Current output HART
53***-***********F – – – PROFIBUS PA, Ex i
53***-***********G – – – FOUNDATION Fieldbus, Ex i
53***-***********H – – – PROFIBUS PA
53***-***********J – – – PROFIBUS DP
53***-***********K – – – FOUNDATION Fieldbus
53***-***********Q – – Status input MODBUS RS485
53***-***********S – – Frequency output, Ex i Current output, Ex i,
passive, HART
53***-***********T – – Frequency output, Ex i Current output, Ex i,
passive, HART
Flexible communication boards
53***-***********C Relay output 2 Relay output 1 Frequency output Current output HART
53***-***********D Status input Relay output Frequency output Current output HART
53***-***********L Status input Relay output 2 Relay output 1 Current output HART
53***-***********M Status input Frequency output Frequency output Current output HART
53***-***********N Current output Frequency output Status input MODBUS RS485
53***-***********P Current output Frequency output Status input PROFIBUS DP
53***-***********V Relay output 2 Relay output 1 Status input PROFIBUS DP
53***-***********2 Relay output Current output Frequency output Current output HART
53***-***********4 Current input Relay output Frequency output Current output HART
53***-***********5 Status input Current input Frequency output Current output HART
53***-***********7 Relay output 2 Relay output 1 Status input MODBUS RS485
8 Endress+Hauser
remote version
c d
GND
S1
E1
E2
S2
E
S
6 5 7 8 4 37 36 42 41
a
c d
n.c. n.c. n.c.
b
5 7 4 37 42 41
E1
E2
GND
E
A0011722
Connecting the remote version

a Wall-mount housing connection compartment
b Sensor connection housing cover
c Signal cable
d Coil current cable
n.c. Not connected, insulated cable shields
Terminal no. and cable colors: 6/5 = brown; 7/8 = white; 4 = green; 36/37 = yellow
Supply voltage (power supply) • 85 to 260 V AC, 45 to 65 Hz

• 20 to 55 V AC, 45 to 65 Hz
• 16 to 62 V DC
PROFIBUS PA and FOUNDATION Fieldbus
• Non-Ex: 9 to 32 V DC
• Ex i: 9 to 24 V DC
• Ex d: 9 to 32 V DC
Cable entry Power supply and signal cables (inputs/ outputs):

• Cable entry M20 × 1.5 (8 to 12 mm / 0.31 to 0.47")
• Sensor cable entry for armoured cables M20 × 1.5 (9.5 to 16 mm / 0.37 to 0.63")
• Thread for cable entries, ½" NPT, G ½"
Connecting cable for remote version:
Remote version cable Coil cable

specifications • 2 × 0.75 mm2 (18 AWG) PVC cable with common, braided copper shield (∅ ∼ 7 mm / 0.28")
• Conductor resistance: ≤ 37 Ω/km (≤ 0.011 Ω/ft)
• Capacitance core/core, shield grounded: ≤ 120 pF/m (≤ 37 pF/ft)
• Operating temperature: –20 to +80 °C (–68 to +176 °F)
• Cable cross-section: max. 2.5 mm2 (14 AWG)
• Test voltage for cable insulation: ≤ 1433 AC r.m.s. 50/60 Hz or ≥ 2026 V DC
Signal cable
• 3 × 0.38 mm2 (20 AWG) PVC cable with common, braided copper shield (∅ ∼ 7 mm / 0.28") and individual
shielded cores
• With empty pipe detection (EPD): 4 × 0.38 mm2 (20 AWG) PVC cable with common,
braided copper shield (∅ ∼ 7 mm / 0.28") and individual shielded cores
• Capacitance core/shield: ≤ 420 pF/m (≤ 128 pF/ft)
Endress+Hauser 9
1
2
3
4
5
6
7
a b
A0003194
a Signal cable
b Coil current cable
1 Core
2 Core insulation
3 Core shield
4 Core jacket
5 Core reinforcement
6 Cable shield
7 Outer jacket
Operation in zones of severe electrical interference

The measuring device complies with the general safety requirements in accordance with EN 61010 and
the EMC requirements of IEC/EN 61326 and NAMUR recommendation NE 21.
" Caution!
Grounding is by means of the ground terminals provided for the purpose inside the connection housing.
Ensure that the stripped and twisted lengths of cable shield to the ground terminal are as short as possible.
Power consumption • AC: < 15 VA (incl. sensor)

• DC: < 15 W (incl. sensor)
Switch-on current:
• Max. 3 A (< 5 ms) for 260 V AC
• Max. 13.5 A (< 50 ms) for 24 V DC
Power supply failure Lasting min. ½ cycle frequency: EEPROM saves measuring system data
• EEPROM or T-DAT (Promag 53 only) retain the measuring system data in the event of a power supply failure
• S-DAT: exchangeable data storage chip which stores the data of the sensor (nominal diameter, serial number,
calibration factor, zero point etc.)
10 Endress+Hauser
Potential equalization
# Warning!
The measuring system must be included in the potential equalization.
Perfect measurement is only ensured when the fluid and the sensor have the same electrical potential. This is
ensured by the reference electrode integrated in the sensor as standard.
The following should also be taken into consideration for potential equalization:
• Internal grounding concepts in the company
• Operating conditions, such as the material/ grounding of the pipes (see table)
Standard situation
Operating conditions Potential equalization
When using the measuring device in a:

• Metal, grounded pipe
Potential equalization takes place via the ground terminal of the
transmitter.
! Note!
When installing in metal pipes, we recommend you connect the
ground terminal of the transmitter housing with the piping.
A0011892
Via the ground terminal of the transmitter
Special situations

• Metal pipe that is not grounded
This connection method also applies in situations where:
• Customary potential equalization cannot be ensured.
• Excessively high equalizing currents can be expected.
Both sensor flanges are connected to the pipe flange by means of
a ground cable (copper wire, at least 6 mm² / 0.0093 in²) and
grounded. Connect the transmitter or sensor connection
housing, as applicable, to ground potential by means of the
ground terminal provided for the purpose.
• DN ≤ 300 (12"): the ground cable is mounted directly on the DN £ 300 DN ³ 350
conductive flange coating with the flange screws.
• DN ≥ 350 (14"): the ground cable is mounted directly on the
transportation metal support.
! Note!
The ground cable for flange-to-flange connections can be
ordered separately as an accessory from Endress+Hauser.
A0011893
Via the ground terminal of the transmitter and the

flanges of the pipe

• Plastic pipe
• Pipe with insulating lining
Potential equalization takes place using additional ground disks,
which are connected to the ground terminal via a ground cable
(copper wire, at least 6 mm² / 0.0093 in²). When installing the
ground disks, please comply with the enclosed Installation A0011895
Instructions. Via the ground terminal of the transmitter and the

optionally available ground disks
Endress+Hauser 11

• Pipe with a cathodic protection unit
The device is installed potential-free in the pipe.
Only the two flanges of the pipe are connected with a ground
cable (copper wire, at least 6 mm² / 0.0093 in²). Here, the
ground cable is mounted directly on the conductive flange
coating with flange screws.
Note the following when installing:
• The applicable regulations regarding potential-free installation
must be observed. A0011896
• There should be no electrically conductive connection Potential equalization and cathodic protection
between the pipe and the device.
• The mounting material must withstand the applicable 1 Power supply isolation transformer
torques. 2 Electrically isolated
12 Endress+Hauser
Performance characteristics
Reference operating As per DIN EN 29104 and VDI/VDE 2641:
conditions • Fluid temperature: +28 °C ± 2 K (+82 °F ± 2 K)
• Ambient temperature: +22 °C ±2 K (+72 °F ± 2 K)
• Warm-up period: 30 minutes
Installation conditions:
• Inlet run > 10 × DN
• Outlet run > 5 × DN
• Sensor and transmitter grounded.
• The sensor is centered in the pipe.
Maximum measured error Promag 50:

• Current output: also typically ± 5 μA
• Pulse output: ±0.5% o.r. ± 1 mm/s (±0.5% o.r. ± 0.04 in/s)
optional: ±0.2% o.r. ± 2 mm/s (±0.2% o.r. ± 0.08 in/s) (o.r. = of reading)
Promag 53:
• Pulse output: ±0.2% o.r. ± 2 mm/s (±0.2% o.r. ± 0.08 in/s) (o.r. = of reading)
Fluctuations in the supply voltage do not have any effect within the specified range.
[%]
2.5
2.0
0.5 %
1.5
0.2 %
1.0
0.5
0
0 1 2 4 6 8 10 [m/s]
v
0 5 10 15 20 25 30 32 [ft] A0005531
Max. measured error in % of reading
Repeatability Max. ±0.1% o.r. ± 0.5 mm/s (±0.1% o.r. ± 0.02 in/s) (o.r. = of reading)
Endress+Hauser 13
Operating conditions: Installations

Installation instructions Mounting location
Entrained air or gas bubble formation in the measuring tube can result in an increase in measuring errors.
Avoid the following installation locations in the pipe:
• Highest point of a pipeline. Risk of air accumulating!
• Directly upstream from a free pipe outlet in a vertical pipeline.
h ³ 2 x DN
A0011899
Mounting location
Installation of pumps
Sensors may not be installed on the pump suction side. This precaution is to avoid low pressure and the
consequent risk of damage to the lining of the measuring tube. Information on the pressure tightness of the
measuring tube lining → ä 22, Section "Pressure tightness".
Pulsation dampers may be needed when using piston pumps, piston diaphragm pumps or hose pumps.
Information on the shock and vibration resistance of the measuring system → ä 20, Section "Shock and
vibration resistance".
A0011900
14 Endress+Hauser
Partially filled pipes

Partially filled pipes with gradients necessitate a drain-type configuration.
The empty pipe detection function (EPD) provides additional security in detecting empty or partially filled
pipes.
" Caution!
Risk of solids accumulating. Do not install the sensor at the lowest point in the drain. It is advisable to install a
cleaning valve.
³ 2 x DN
³ 5 x DN
A0011901
Installation with partially filled pipes
Down pipes
Install a siphon or a vent valve downstream of the sensor in down pipes h ≥ 5 m (16.4 ft). This precaution is
to avoid low pressure and the consequent risk of damage to the lining of the measuring tube. This measure also
prevents the liquid current stopping in the pipe which could cause air locks. Information on the pressure
tightness of the measuring tube lining → ä 22, Section "Pressure tightness".
2 h
A0011902
Installation measures for vertical pipes

1 Vent valve
2 Pipe siphon
h Length of the down pipe
Endress+Hauser 15
Orientation
An optimum orientation helps avoid gas and air accumulations and deposits in the measuring tube. However,
the measuring device also offers the additional function of empty pipe detection (EPD) for detecting partially
filled measuring tubes or if outgassing fluids or fluctuating operating pressures are present.
Vertical orientation
This is the ideal orientation for self-emptying piping systems and for use in conjunction with empty pipe
detection.
A0011903
Horizontal orientation
The measuring electrode axis should be horizontal. This prevents brief insulation of the two measuring
electrodes by entrained air bubbles.
" Caution!
Empty pipe detection only works correctly with horizontal orientation if the transmitter housing is facing
upwards. Otherwise there is no guarantee that empty pipe detection will respond if the measuring tube is only
partially filled or empty.
A
1
2 2
A
3
A0011904
1 EPD electrode for empty pipe detection
2 Measuring electrodes for signal detection
3 Reference electrode for potential equalization
16 Endress+Hauser
Vibrations
Secure the piping and the sensor if vibration is severe.
" Caution!
If vibrations are too severe, we recommend the sensor and transmitter be mounted separately. Information on
the permitted shock and vibration resistance → ä 20, Section "Shock and vibration resistance".
A0011906
Measures to prevent vibration of the measuring device

L > 10 m (33 ft)
Foundations, supports
If the nominal diameter is DN ≥ 350, mount the transmitter on a foundation of adequate load-bearing strength.
" Caution!
Do not allow the casing to take the weight of the sensor. This would buckle the casing and damage the internal
magnetic coils.
A0003209
Endress+Hauser 17
Inlet and outlet run If possible, install the sensor well clear of assemblies such as valves, T-pieces, elbows etc.
Note the following inlet and outlet runs to comply with measuring accuracy specifications:
• Inlet run: ≥ 5 × DN
• Outlet run: ≥ 2 × DN
³ 5 x DN ³ 2 x DN
A0011905
Inlet and outlet run
Adapters Suitable adapters to DIN EN 545 (double-flange reducers) can be used to install the sensor in larger-diameter
pipes. The resultant increase in the rate of flow improves measuring accuracy with very slow-moving fluids.
The nomogram shown here can be used to calculate the pressure loss caused by reducers and expanders.
! Note!
The nomogram only applies to liquids of viscosity similar to water.
1. Calculate the ratio of the diameters d/D.
2. From the nomogram read off the pressure loss as a function of flow velocity (downstream from the
reduction) and the d/D ratio.
[mbar] 100
8 m/s
7 m/s
6 m/s
10
5 m/s
4 m/s
max. 8°
3 m/s
d D
2 m/s
1
1 m/s
d/D 0.5 0.6 0.7 0.8 0.9

A0011907
Pressure loss due to adapters
18 Endress+Hauser
Length of connecting cable When mounting the remote version, please note the following to achieve correct measuring results:
• Fix cable run or lay in armored conduit. Cable movements can falsify the measuring signal especially in the
case of low fluid conductivities.
• Route the cable well clear of electrical machines and switching elements.
• If necessary, ensure potential equalization between sensor and transmitter.
• The permitted cable length Lmax is determined by the fluid conductivity. A minimum conductivity of
20 μS/cm is required for measuring demineralized water.
• When the empty pipe detection function is switched on (EPD),
the maximum connecting cable length is 10 m (33 ft).
[μS/cm]
200
100
L max
5
[m]
10 100 200 L max
[ft]
0 200 400 600
A0010734
Permitted length of connecting cable for remote version

Area marked in gray = permitted range; Lmax = length of connecting cable in [m] ([ft]); fluid conductivity in [μS/cm]
Endress+Hauser 19
Operating conditions: Environment
Ambient temperature range Transmitter

• Standard: –20 to +60 °C (–4 to +140 °F)
• Optional: –40 to +60 °C (–40 to +140 °F)
! Note!
At ambient temperatures below –20 °C (–4 °F)the readability of the display may be impaired.
Sensor
• Flange material carbon steel: –10 to +60 °C (+14 to +140 °F)
• Flange material stainless steel: –40 to +60 °C (–40 to +140 °F)
" Caution!
The permitted temperature range of the measuring tube lining may not be undershot or overshot
→ ä 21, Section "Medium temperature range".
Please note the following points:
• Install the device in a shady location. Avoid direct sunlight, particularly in warm climatic regions.
• The transmitter must be mounted separate from the sensor if both the ambient and fluid temperatures are
high.
Storage temperature The storage temperature corresponds to the operating temperature range of the measuring transmitter and the
appropriate measuring sensors.
" Caution!
• The measuring device must be protected against direct sunlight during storage in order to avoid unacceptably
high surface temperatures.
• A storage location must be selected where moisture does not collect in the measuring device. This will help
prevent fungus and bacteria infestation which can damage the liner.
• Do not remove the protective plates or caps on the process connections until the device is ready to install.
Degree of protection • Standard: IP 67 (NEMA 4X) for transmitter and sensor.

• Optional: IP 68 (NEMA 6P) for sensor for remote version.
• For information regarding applications where the device is buried directly in the soil or is installed in a
flooded wastewater basin please contact your local Endress+Hauser Sales Center.
Shock and vibration resistance Acceleration up to 2 g following IEC 600 68-2-6
Electromagnetic compatibility • As per IEC/EN 61326 and NAMUR recommendation NE 21.

(EMC)
20 Endress+Hauser
Operating conditions: Process
Medium temperature range The permitted temperature depends on the lining of the measuring tube:
• PTFE: –40 to +130 °C (–40 to +266 °F) (DN 15 to 600 / ½ to 24"), restrictions → see diagrams
• PFA: –20 to +180 °C (–4 to +356 °F) (DN 25 to 200 / 1 to 8"), restrictions → see diagrams
TA [°F] [°C] HT
140 60
40
100
n
20
PFA
0 -20
m
PTFE
-40 -40
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
TF
-40 0 100 200 300 360 [°F]
A0002660
Compact version (with PFA or PTFE lining)

TA = Ambient temperature, TF = Fluid temperature, HT = High temperature version with insulatio
➀ Gray shaded area → temperature range from –10 to –40 °C (–14 to –40 °F) applies only to stainless steel flanges
n HE + IP 68 to 130 °C (266 °F) only
TA [°F] [°C] HT
140 60
40
100
n
20
PFA
0 -20
m
PTFE
-40 -40
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
TF
-40 0 100 200 300 360 [°F]
A0002671
Remote version (with PFA or PTFE lining)

n HE + IP 68 to 130 °C (266 °F) only
Endress+Hauser 21
Conductivity The minimum conductivity is:

• ≥ 5 μS/cm for fluids generally
• ≥ 20 μS/cm for demineralized water
! Note!
In the remote version, the necessary minimum conductivity also depends on the cable length
(→ ä 19, Section "Length of connecting cable").
Medium pressure range • EN 1092-1 (DIN 2501)

(nominal pressure) – PN 10 (DN 200 to 600 / 8 to 24")
– PN 16 (DN 65 to 600 / 3 to 24")
– PN 25 (DN 200 to 600 / 8 to 24")
– PN 40 (DN 15 to 150 / ½ to 6")
• ANSI B 16.5
– Class 150 (DN ½ to 24")
– Class 300 (DN ½ to 6")
• JIS B2220
– 10 K (DN 50 to 300 / 2 to 12")
– 20 K (DN 15 to 300 / ½ to 12")
• AS 2129
– Table E (DN 25, 50 / 1", 2")
• AS 4087
– PN 16 (DN 50 / 2")
Pressure tightness Measuring tube lining: PTFE
Nominal diameter Limit values for abs. pressure [mbar] ([psi]) at fluid temperatures:
25 °C (77 °F) 80 °C (176 °F) 100 °C (212 °F) 130 °C (266 °F)
[mm] [inch] [mbar] [psi] [mbar] [psi] [mbar] [psi] [mbar] [psi]
15 ½" 0 0 0 0 0 0 100 1.45
25 1" 0 0 0 0 0 0 100 1.45
32 – 0 0 0 0 0 0 100 1.45
40 1½" 0 0 0 0 0 0 100 1.45
50 2" 0 0 0 0 0 0 100 1.45

65 – 0 0 * * 40 0.58 130 1.89
80 3" 0 0 * * 40 0.58 130 1.89
100 4" 0 0 * * 135 1.96 170 2.47
125 – 135 1.96 * * 240 3.48 385 5.58

150 6" 135 1.96 * * 240 3.48 385 5.58
200 8" 200 2.90 * * 290 4.21 410 5.95
250 10" 330 4.79 * * 400 5.80 530 7.69
300 12" 400 5.80 * * 500 7.25 630 9.14
350 14" 470 6.82 * * 600 8.70 730 10.6
400 16" 540 7.83 * * 670 9.72 800 11.6
450 18"
500 20" Partial vacuum is impermissible!
600 24"
* No value can be specified.
22 Endress+Hauser
Measuring tube lining: PFA
25 °C (77 °F) 80 °C (176 °F) 100 to 180 °C (212 to 356 °F)
[mm] [inch] [mbar] [psi] [mbar] [psi] [mbar] [psi]
25 1" 0 0 0 0 0 0
32 – 0 0 0 0 0 0
40 1½" 0 0 0 0 0 0
50 2" 0 0 0 0 0 0
65 – 0 0 * * 0 0
80 3" 0 0 * * 0 0
100 4" 0 0 * * 0 0
125 – 0 0 * * 0 0
150 6" 0 0 * * 0 0
200 8" 0 0 * * 0 0
Limiting flow The diameter of the pipe and the flow rate determine the nominal diameter of the sensor.
The optimum flow velocity is between 2 to 3 m/s (6.5 to 9.8 ft/s). The velocity of flow (v), moreover, has to
be matched to the physical properties of the fluid:
• v < 2 m/s (6.5 ft/s): for abrasive fluids such as potter's clay, lime milk, ore slurry etc.
• v > 2 m/s (6.5 ft/s): for fluids causing build-up such as wastewater sludges etc.
Flow characteristic values (SI units)

Diameter Recommended flow rate Factory settings
Min./max. full scale value Full scale value, current output Pulse value Low flow cut off
[mm] [inch] (v ~ 0.3 or 10 m/s) (v ~ 2.5 m/s) (~ 2 pulses/s) (v ~ 0.04 m/s)
15 ½" 4 to 100 dm3/min 25 dm3/min 0.20 dm3 0.50 dm3/min
25 1" 9 to 300 dm3/min 75 dm3/min 0.50 dm3 1.00 dm3/min
32 – 15 to 500 dm3/min 125 dm3/min 1.00 dm3 2.00 dm3/min

40 1½" 25 to 700 dm3/min 200 dm3/min 1.50 dm3 3.00 dm3/min

150 6" 20 to 600 m3/h 150 m3/h 0.03 m3 2.50 m3/h
200 8" 35 to 1100 m3/h 300 m3/h 0.05 m3 5.00 m3/h
250 10" 55 to 1700 m3/h 500 m3/h 0.05 m3 7.50 m3/h
300 12" 80 to 2400 m3/h 750 m3/h 0.10 m3 10.0 m3/h
350 14" 110 to 3300 m3/h 1000 m3/h 0.10 m3 15.0 m3/h
400 16" 140 to 4200 m3/h 1200 m3/h 0.15 m3 20.0 m3/h
450 18" 180 to 5400 m3/h 1500 m3/h 0.25 m3 25.0 m3/h
500 20" 220 to 6600 m3/h 2000 m3/h 0.25 m3 30.0 m3/h
600 24" 310 to 9600 m3/h 2500 m3/h 0.30 m3 40.0 m3/h
Endress+Hauser 23
Flow characteristic values (US units)
[inch] [mm] (v ~ 0.3 or 10 m/s) (v ~ 2.5 m/s) (~ 2 pulses/s) (v ~ 0.04 m/s)
½" 25 1.0 to 26 gal/min 6 gal/min 0.10 gal 0.15 gal/min
1" 25 2.5 to 80 gal/min 18 gal/min 0.20 gal 0.25 gal/min
1½" 40 7 to 190 gal/min 50 gal/min 0.50 gal 0.75 gal/min
2" 50 10 to 300 gal/min 75 gal/min 0.50 gal 1.25 gal/min

Pressure loss • No pressure loss if the sensor is installed in a pipe with the same nominal diameter.
• Pressure losses for configurations incorporating adapters according to DIN EN 545
(→ ä 18, Section "Adapters").
24 Endress+Hauser
Mechanical construction
Design, dimensions Transmitter remote version, wall-mount housing (non Ex-zone and II3G/Zone 2)
D
Esc
- + E
B
C
F G
A E
H J K J
N
S S
M
R
L
O
P Q P
A0001150
Dimensions (SI units)
A B C D E F G H J
215 250 90.5 159.5 135 90 45 > 50 81
K L M N O P Q R S
53 95 53 102 81.5 11.5 192 8 × M5 20
All dimensions in [mm]
Dimensions (US units)
A B C D E F G H J
8.46 9.84 3.56 6.27 5.31 3.54 1.77 > 1.97 3.18
K L M N O P Q R S
2.08 3.74 2.08 4.01 3.20 0.45 7.55 8 × M5 0.79
All dimensions in [inch]
Endress+Hauser 25
Transmitter remote version, connection housing (II2GD/Zone 1)
A
A*
B C
B* D
e r Sp annu
ht unt ng
Nic öffnen
Nicht-eigensichere
Ke ircuit s a re aliv ile
Kee ircuits are ali hile

Stromkreise durch
ove r tight wh
e
c
IP40-Abdeckung geschützt
p cover tight w
Non-intrinsically safe
circuits Ip40 protected
E
ep c
Esc
Boucles de courant - +
c
E
ve
sans sécurité intrinsèque
protégées par Ip40
sou s nsion l Ne
pas o t e pparei
uvrir l’a
M
L
J
K
F
G
A0002128
A A* B B* C D E ØF G H J K L M
8.6
265 242 240 217 206 186 178 100 130 100 144 170 355
(M8)
0.34
10.4 9.53 9.45 8.54 8.11 7.32 7.01 3.94 5.12 3.94 5.67 6.69 14.0
(M8)
26 Endress+Hauser
There is a separate mounting kit for the wall-mounted housing. It can be ordered from Endress+Hauser as an
accessory. The following installation variants are possible:
• Panel-mounted installation
• Pipe mounting
Installation in control panel
+0.5 (+0.019)
–0.5 (–0.019)
210 (8.27)
+0.5 (+0.019)
–0.5 (–0.019)
245 (9.65)
mm (inch) ~110 (~4.33)
A0001131
Pipe mounting
Ø 20…70
(Ø 0.79…2.75)
~155 (~ 6.1)
mm (inch)
A0001132
Endress+Hauser 27
Compact version DN ≤ 300 (12")
A B
A* C
D
Esc
- + E
F
E
G
H
K L
A0005423
High temperature version DN ≤ 300 (12")

D1
(4.33)
110
E1
mm (inch)
A0005529
Measurement D1, E1 = Measurement D, E of the standard compact version plus 110 mm (4.33")
28 Endress+Hauser
DN L 1) A A* B C D E F G H K
EN (DIN) / JIS / AS 2)
15 200 341 257 84 94 120
25 200 341 257 84 94 120
32 200 341 257 84 94 120
40 200 341 257 84 94 120
50 200 341 257 84 94 120
65 200 391 282 109 94 180
80 200 227 207 187 168 160 391 282 109 94 180
100 250 391 282 109 94 180

125 250 472 322 150 140 260
150 300 472 322 150 140 260
200 350 527 347 180 156 324
250 450 577 372 205 166 400
300 500 627 397 230 166 460

1)
The length is regardless of the pressure rating selected. Fitting length to DVGW.
2)
Only DN 25 and DN 50 are available for flanges according to AS.
ANSI
½" 7.87 13.4 10.1 3.31 3.70 4.72
1" 7.87 13.4 10.1 3.31 3.70 4.72
1½" 7.87 13.4 10.1 3.31 3.70 4.72
2" 7.87 13.4 10.1 3.31 3.70 4.72
3" 7.87 15.4 11.1 4.29 3.70 7.09

8.94 8.15 7.36 6.61 6.30
4" 9.84 15.4 11.1 4.29 3.70 7.09
6" 11.8 18.6 12.7 5.91 5.51 10.2
8" 13.8 20.8 13.7 7.09 6.14 12.8
10" 17.7 22.7 14.7 8.07 6.54 15.8
12" 19.7 24.7 15.6 9.06 6.54 18.1

1)
Endress+Hauser 29
Compact version DN ≥ 350 (14")
A B
A* C
D
Esc
- + E
F
E
G
J
H L
A0005424
DN L 1) A A* B C D E F G H J
EN (DIN)
350 550 738.5 456.5 282.0 564 276

400 600 790.5 482.5 308.0 616 276
450 650 227 207 187 168 160 840.5 507.5 333.0 666 292
500 650 891.5 533.0 358.5 717 292

600 780 995.5 585.0 410.5 821 402
1)
ANSI
14" 21.7 29.1 18.0 11.1 22.2 10.9
16" 23.6 31.1 19.0 12.1 24.3 10.9
18" 25.6 8.94 8.15 7.36 6.61 6.30 33.1 20.0 13.1 26.2 11.5
20" 25.6 35.1 21.0 14.1 28.2 11.5

24" 30.7 39.2 23.0 16.2 32.3 15.8
1)
30 Endress+Hauser
Sensor, remote version DN ≤ 300 (12")
A B
C
F
E
G
J
H L
A0012462
D1
(4.33)
110
E1
mm (inch)
A0005570
Measurement D1, E1 = Measurement D, E of the standard remote version plus 110 mm (4.33")
Endress+Hauser 31
DN L 1) A B C D E F G H J
15 200 286 202 84 120 94
25 200 286 202 84 120 94
32 200 286 202 84 120 94
40 200 286 202 84 120 94
50 200 286 202 84 120 94
65 200 336 227 109 180 94
80 200 129 163 143 102 336 227 109 180 94
100 250 336 227 109 180 94

125 250 417 267 150 260 140
150 300 417 267 150 260 140
200 350 472 292 180 324 156
250 450 522 317 205 400 166
300 500 572 342 230 460 166

1)
2)
ANSI
½" 7.87 11.3 7.95 3.31 4.72 3.70
1" 7.87 11.3 7.95 3.31 4.72 3.70
1½" 7.87 11.3 7.95 3.31 4.72 3.70
2" 7.87 11.3 7.95 3.31 4.72 3.70
3" 7.87 13.2 8.94 4.29 7.09 3.70

5.08 6.42 5.63 4.02
4" 9.84 13.2 8.94 4.29 7.09 3.70
6" 11.8 16.4 10.5 5.91 10.2 5.51
8" 13.8 18.6 11.5 7.08 12.8 6.14
10" 17.7 20.6 12.5 8.07 15.8 6.54
12" 19.7 22.5 13.5 9.06 18.1 6.54

1)
32 Endress+Hauser
Sensor, remote version DN ≥ 350 (14")
A B
C
F
E
G
J
H L
A0003220
EN (DIN)
350 550 683.5 401.5 282.0 564 276

400 600 735.5 427.5 308.0 616 276
450 650 129 163 143 102 785.5 452.5 333.0 666 292
500 650 836.5 478.0 358.5 717 292

600 780 940.5 530.0 410.5 821 402
1)
ANSI
14" 21.7 26.9 15.8 11.1 22.2 10.9
16" 23.6 29.0 16.8 12.1 24.3 10.9
18" 25.6 5.08 6.42 5.63 4.02 30.9 17.8 13.1 26.2 11.5
20" 25.6 32.9 18.8 14.1 28.2 11.5

24" 30.7 37.0 20.9 16.2 32.3 15.8
1)
Endress+Hauser 33
Ground disk for flange connections
DN ≤ 300 (12") DN ≥ 350 (14")
ØE ØE
D
ØB ØB A
A ØC
Ø ØC
Ø
t t
A0003221
DN 1) A B C D E t
2)
EN (DIN) / JIS / AS PTFE, PFA
15 16 43 61.5 73
25 26 62 77.5 87.5
32 35 80 87.5 94.5
40 41 82 101 103
50 52 101 115.5 108
65 68 121 131.5 118

80 80 131 154.5 135
6.5
100 104 156 186.5 153
125 130 187 206.5 160

150 158 217 256 184 2
200 206 267 288 205
250 260 328 359 240

3)
300 312 375 413 273
300 4) 310 375 404 268
3)
350 343 433 479 365
3)
400 393 480 542 395
450 3) 439 538 583 417 9.0
3)
500 493 592 650 460
3)
600 593 693 766 522
1) Ground disks at DN 15 to 250 (½ to 10") can be used for all flange standards/pressure ratings.
2)
3)
PN 10/16
4) PN 25, JIS 10K/20K
34 Endress+Hauser
DN 1) A B C D E t
ANSI PTFE, PFA
½" 0.63 1.69 2.42 2.87
1" 1.02 2.44 3.05 3.44
1½" 1.61 3.23 3.98 4.06
2" 2.05 3.98 4.55 4.25
3" 3.15 5.16 6.08 5.31

0.26
4" 4.09 6.14 7.34 6.02
6" 6.22 8.54 10.08 7.24
8" 8.11 10.5 11.3 8.07 0.08

10" 10.2 12.9 14.1 9.45
12" 12.3 14.8 16.3 10.8
14" 13.5 17.1 18.9 14.4
16" 15.45 18.9 21.3 15.6
18" 17.3 21.2 23.0 16.4 0.35
20" 19.4 23.3 25.6 18.1
24" 23.4 27.3 30.1 20.6

1) Ground disks can be used for all flange standards/pressure ratings.
Endress+Hauser 35
Weight Weight in SI units
Weight data in kg
Nominal Compact version Remote version (without cable)

diameter
Sensor Transmitter
[mm] [inch] EN (DIN) / JIS ANSI EN (DIN) / JIS ANSI Wall-mount housing
AS 1) AS 1)
15 ½" 6.5 6.5 6.5 4.5 4.5 4.5
25 1" 7.3 7.3 7.3 5.3 5.3 5.3

PN 40
PN 40
32 – 8.0 7.3 – 6.0 5.3 –
40 1½" 9.4 8.3 9.4 7.4 6.3 7.4
50 2" 10.6 9.3 10.6 8.6 7.3 8.6
65 – 12.0 11.1 – 10.0 9.1 –

10K
10K
80 3" 14.0 12.5 14.0 12.0 10.5 12.0
PN 16
PN 16
100 4" 16.0 14.7 16.0 14.0 12.7 14.0
Class 150
Class 150
125 – 21.5 21.0 – 19.5 19.0 –
6.0
150 6" 25.5 24.5 25.5 23.5 22.5 23.5
200 8" 45 41.9 45 43 39.9 43

250 10" 65 69.4 75 63 67.4 73
300 12" 70 72.3 110 68 70.3 108
350 14" 115 175 113 173

PN 10
PN 10
400 16" 135 205 133 203
450 18" 175 255 173 253
500 20" 175 285 173 283

600 24" 235 405 233 403
1)
For flanges to AS, only DN 25 and 50 are available.
• Transmitter (compact version): 3.4 kg, high temperature version: +1.5 kg
• Weight data valid for standard pressure ratings and without packaging material.
36 Endress+Hauser
Weight in US units (only ANSI)
Weight data in lbs
Nominal diameter Compact version Remote version (without cable)
Sensor Transmitter
[mm] [inch] ANSI ANSI Wall-mount housing
15 ½" 14.3 9.92
25 1" 16.1 11.7
40 1½" 20.7 16.3

50 2" 23.4 19.0
80 3" 30.9 26.5
100 4" 35.3 30.9
150 6" 56.2 51.8
Class 150
Class 150
200 8" 99.2 94.8 13.2
250 10" 165.4 161.0
300 12" 242.6 238.1
350 14" 385.9 381.5
400 16" 452.0 447.6
450 18" 562.3 557.9

500 20" 628.4 624.0
600 24" 893.0 888.6
• Transmitter (compact version): 7.50 lbs, high temperature version: +3.31 lbs
Measuring tube specifications Diameter Pressure rating Internal diameter
EN (DIN) AS 2129 AS 4087 ANSI JIS PFA PTFE

[mm] [inch] [bar] [lbs] [mm] [inch] [mm] [inch]
15 ½" PN 40 – – Cl.150 20K – – 15 0.59
25 1" PN 40 Table E – Cl.150 20K 23 0.91 26 1.02
32 – PN 40 – – – 20K 32 1.26 35 1.38
40 1½" PN 40 – – Cl.150 20K 36 1.42 41 1.61
50 2" PN 40 Table E PN 16 Cl.150 10K 48 1.89 52 2.05
65 – PN 16 – – – 10K 63 2.48 67 2.64
80 3" PN 16 – – Cl.150 10K 75 2.95 80 3.15
100 4" PN 16 – – Cl.150 10K 101 3.98 104 4.09
125 – PN 16 – – – 10K 126 4.96 129 5.08
150 6" PN 16 – – Cl.150 10K 154 6.06 156 6.14
200 8" PN 10 – – Cl.150 10K 201 7.91 202 7.95

250 10" PN 10 – – Cl.150 10K – – 256 10.1
300 12" PN 10 – – Cl.150 10K – – 306 12.0
350 14" PN 10 – – Cl.150 – – – 337 13.3

400 16" PN 10 – – Cl.150 – – – 387 15.2
450 18" PN 10 – – Cl.150 – – – 432 17.0
500 20" PN 10 – – Cl.150 – – – 487 19.2
600 24" PN 10 – – Cl.150 – – 23 593 23.3
Endress+Hauser 37
Material • Transmitter housing

– Compact housing: powder-coated die-cast aluminum
– Wall-mount housing: powder-coated die-cast aluminum
• Sensor housing
– DN 25 to 300 (1 to 12"): powder-coated die-cast aluminum
– DN 350 to 600 (14 to 24"): with protective lacquering
• Measuring tube
– DN ≤ 300 (12"): stainless steel 1.4301 or 1.4306/304L;
(for flanges made of carbon steel with Al/Zn protective coating)
– DN ≥ 350 (14"): stainless steel 1.4301 or 1.4306/304L;
(for flanges made of carbon steel with protective lacquering)
• Electrodes: 1.4435, Platinum, Alloy C-22, Tantalum, Titanium
• Flanges
– EN 1092-1 (DIN 2501): 1.4571/316L; RSt37-2 (S235JRG2); C22; FE 410W B
(DN ≤ 300 (12"): with Al/Zn protective coating; DN ≥ 350 (14") with protective lacquering)
– ANSI: A105; F316L
– AWWA: 1.0425
– JIS: RSt37-2 (S235JRG2); HII; 1.0425/316L
– AS 2129
– DN 25 (1"): A105 or RSt37-2 (S235JRG2)
– DN 40 (1 ½"): A105 or St44-2 (S275JR)
– AS 4087: A105 or St44-2 (S275JR)
• Seals: to DIN EN 1514-1
• Ground disks: 1.4435/316L or Alloy C-22
Material load diagram
" Caution!
The following diagrams contain material load diagrams (reference curves) for flange materials with regard to
the medium temperature. However, the maximum medium temperatures permitted always depend on the
lining material of the sensor and/or the sealing material (→ ä 21).
Flange connection to EN 1092-1 (DIN 2501)

Material: RSt37-2 (S235JRG2) / C22 / Fe 410W B
[psi] [bar]
600
40
PN 40
500 35
30
400
25
PN 25
300 20
200 15
PN 16
10
PN 10
100
5 PN 6
0 0
-60 -40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0005594
38 Endress+Hauser

Material: 316L / 1.4571
[psi] [bar]
600
40
PN 40
500 35
30
400
25
PN 25
300 20
200 15 PN 16
10
PN 10
100
5 PN 6
0 0
-60 -40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]

A0005304
Flange connection to ANSI B16.5

Material: A 105
[psi] [bar]
900 60
800
700 50 Class 300
600 40
500
400 30
300 20 Class 150
200
10
100
0 0
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0003226

Material: F316L
[psi] [bar]
900 60
800
700 50
600 40 Class 300
500
400 30
300 20
200 Class 150
10
100
0 0
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0005307
Endress+Hauser 39
Flange connection to JIS B2220

Material: RSt37-2 (S235JRG2) / HII / 1.0425 / 316L
[psi] [bar]
30
400
20K
300 20
200
10K
10
100
0 0
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0003228
Flange connection to AS 2129 Table E or AS 4087 PN 16

Material: A105 / RSt37-2 (S235JRG2) / St44-2 (S275JR)
[psi] [bar]
300 20
PN 16
200 15
Table E
10
100
5
0 0
-40 -20 0 20 40 60 80 100 120 140 160 [°C]
-40 0 100 200 300 [°F]
A0005595
Fitted electrodes Measuring electrodes, reference electrodes and empty pipe detection electrodes:
• Standard available with 1.4435, Alloy C-22, tantalum, platinum/rhodium 80/20, titanium
• Optional: measuring electrodes made of platinum/rhodium 80/20
Process connections Flange connection:

• EN 1092-1 (DIN 2501), DN ≤ 300 (12") form A, DN ≥ 350 (14") form B
(Dimensions to DIN 2501, DN 65 PN 16 and DN 600 (24") PN 16 exclusively to EN 1092-1)
• ANSI B16.5
• JIS B2220
• AS 2129 Table E
• AS 4087 PN 16
Surface roughness • PFA liner: ≤ 0.4 μm (15.7 μin)

• Elektroden
– 1.4435, Alloy C-22, titanium: ≤ 0.3 to 0.5 μm (≤ 11.8 to 19.7 μin)
– Tantal, Platin/Rhodium: ≤ 0.3 to 0.5 μm (≤ 11.8 to 19.7 μin)
(All data refer to parts in contact with medium)
40 Endress+Hauser
Human interface
Display elements • Liquid crystal display: backlit, two lines (Promag 50) or four lines (Promag 53) with 16 characters per line
• Custom configurations for presenting different measured-value and status variables
• Totalizer
– Promag 50: 2 totalizers
Operating elements Unified operation concept for both types of transmitter:

Promag 50:
• Local operation via three keys (S, O, F)
• Quick Setup menus for straightforward commissioning
Promag 53:
• Application-specific Quick Setup menus for straightforward commissioning
Language groups Language groups available for operation in different countries:

Promag 50, Promag 53:
• Western Europe and America (WEA):
English, German, Spanish, Italian, French, Dutch, Portuguese
• Eastern Europe and Scandinavia (EES):
English, Russian, Polish, Norwegian, Finnish, Swedish, Czech
• South and east Asia (SEA):
English, Japanese, Indonesian
Promag 53:
• China (CN):
English, Chinese
You can change the language group via the operating program "FieldCare".
Remote operation • Promag 50: Remote control via HART, PROFIBUS DP/PA
• Promag 53: Remote control via HART, PROFIBUS DP/PA, MODBUS RS485, FOUNDATION Fieldbus
Endress+Hauser 41
Certificates and approvals

CE mark The measuring system is in conformity with the statutory requirements of the EC Directives.
Endress+Hauser confirms successful testing of the device by affixing to it the CE mark.
C-tick mark The measuring system meets the EMC requirements of the "Australian Communications and Media Authority
(ACMA)".
Pressure measuring device Measuring devices with a nominal diameter smaller than or equal to DN 25 correspond to Article 3(3)
approval of the EC Directive 97/23/EC (Pressure Equipment Directive) and have been designed and manufactured
according to good engineering practice. Where necessary (depending on the medium and process pressure),
there are additional optional approvals to Category II/III for larger nominal diameters.
Ex approval Information about currently available Ex versions (ATEX, IECEx, FM, CSA, NEPSI) can be supplied by your
Endress+Hauser Sales Center on request. All explosion protection data are given in a separate documentation
which is available upon request.
Other standards and • EN 60529

guidelines Degrees of protection by housing (IP code)
• EN 61010
Protection Measures for Electrical Equipment for Measurement, Control, Regulation and Laboratory
Procedures.
• IEC/EN 61326
“Emission in accordance with requirements for Class A”.
Electromagnetic compatibility (EMC requirements)
• NAMUR NE 21:
Electromagnetic compatibility (EMC) of industrial process and laboratory control equipment.
• NAMUR NE 43:
Standardization of the signal level for the breakdown information of digital transmitters with analog output
signal.
• NAMUR NE 53:
Software of field devices and signal-processing devices with digital electronics.
• ANSI/ISA-S82.01
Safety Standard for Electrical and Electronic Test, Measuring, Controlling and related Equipment - General
Requirements Pollution degree 2, Installation Category II.
• CAN/CSA-C22.2 No. 1010.1-92
Safety requirements for Electrical Equipment for Measurement and Control and Laboratory Use.
Pollution degree 2, Installation Category II
FOUNDATION Fieldbus The flow device has successfully passed all the test procedures carried out and is certified and registered by the
certification Fieldbus Foundation. The device thus meets all the requirements of the following specifications:
• Certified to FOUNDATION Fieldbus Specification
• The device meets all the specifications of the FOUNDATION Fieldbus H1.
• Interoperability Test Kit (ITK), revision status 5.01 (device certification number: on request)
• The device can also be operated with certified devices of other manufacturers
• Physical Layer Conformance Test of the Fieldbus Foundation
MODBUS RS485 certification The measuring device meets all the requirements of the MODBUS/TCP conformity test and has the “MOD-
BUS/TCP Conformance Test Policy, Version 2.0”. The measuring device has successfully passed all the test
procedures carried out and is certified by the “MODBUS/TCP Conformance Test Laboratory” of the University
of Michigan.
PROFIBUS DP/PA The flow device has successfully passed all the test procedures carried out and is certified and registered by the
certification PNO (PROFIBUS User Organisation). The device thus meets all the requirements of the following
specifications:
• Certified to PROFIBUS PA, profile version 3.0 (device certification number: on request)
• The device can also be operated with certified devices of other manufacturers (interoperability)
42 Endress+Hauser
Ordering information
Your Endress+Hauser service organization can provide detailed ordering information and information on the
order codes on request.
Accessories
Various accessories, which can be ordered separately from Endress+Hauser, are available for the transmitter
and the sensor. Your Endress+Hauser service organization can provide detailed information on the order codes
in question.
Documentation
• Flow Measurement (FA005D/06)
• Operating Instructions Promag Promag 50 (BA046D/06 and BA049D/06)
• Operating Instructions Promag Promag 50 PROFIBUS PA (BA055D/06 and BA056D/06)
• Operating Instructions Promag Promag 53 FOUNDATION Fieldbus (BA051D/06 and BA052D/06)
• Operating Instructions Promag Promag 53 MODBUS RS485 (BA117D/06 and BA118D/06)
• Operating Instructions Promag Promag 53 PROFIBUS DP/PA (BA053D/06 and BA054D/06)
• Supplementary documentation on Ex-ratings: ATEX, IECEx, FM, CSA, NEPSI
Registered trademarks
HART®
Registered trademark of the HART Communication Foundation, Austin, USA
PROFIBUS®
Registered trademark of the PROFIBUS Nutzerorganisation e.V., Karlsruhe, D
FOUNDATION™ Fieldbus
Registered trademark of the Fieldbus Foundation, Austin, USA
MODBUS®
Registered trademark of the MODBUS Organisation
HistoROM™, S-DAT®, T-DAT™, F-CHIP®, FieldCare®, Fieldcheck®, FieldXpert™, Applicator®
Registered or registration-pending trademarks of Endress+Hauser Flowtec AG, Reinach, CH
Endress+Hauser 43
Instruments International
Endress+Hauser
Instruments International AG
Kaegenstrasse 2
4153 Reinach
Switzerland
Tel. +41 61 715 81 00

Fax +41 61 715 25 00
www.endress.com
[email protected]
TI047D/06/en/11.09
71106271
FM+SGML6.0 ProMoDo
KA00026D/06/EN/18.16
71321439
Products Solutions Services
Brief Operating Instructions

Proline Promag 50
Electromagnetic flowmeter
These Brief Operating Instructions are not intended to replace

the Operating Instructions provided in the scope of supply.
Detailed information is provided in the Operating Instructions
and the additional documentation on the CD-ROM supplied.
The complete device documentation consists of:
• These Brief Operating Instructions
• Depending on the device version:
– Operating Instructions and the Description of Device Funct.
– Approvals and safety certificates
– Special safety instructions in accordance with the approvals
for the device (e.g. explosion protection, pressure
equipment directive etc.)
– Additional device-specific information
Proline Promag 50 Table of contents
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Safety conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Transporting to the measuring point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Installing the Promag E sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Installing the Promag H sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Installing the Promag L sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 Installing the Promag P sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Installing the Promag W sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.8 Installing the transmitter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Post-installation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Connecting the various housing types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Connecting the remote version connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Potential equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4 Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.5 Post-connection check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Hardware settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Device address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Terminating resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1 Switching on the measuring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 Navigating within the function matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4 Calling the Commissioning Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5 Software settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Endress+Hauser 3
Safety instructions Proline Promag 50
1 Safety instructions
1.1 Designated use
• The measuring device is to be used only for measuring the flow of conductive liquids in closed
pipes. A minimum conductivity of 20 μS/cm is required for measuring demineralized water.
Most liquids can be measured as of a minimum conductivity of 5 μS/cm.
• Any use other than that described here compromises the safety of persons and the entire
measuring system and is, therefore, not permitted.
• The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Installation, commissioning and operation

• The measuring device must only be installed, connected, commissioned and maintained by
qualified and authorized specialists (e.g. electrical technicians) in full compliance with the
instructions in these Brief Operating Instructions, the applicable norms, legal regulations and
certificates (depending on the application).
• The specialists must have read and understood these Brief Operating Instructions and must
follow the instructions they contain. If you are unclear on anything in these Brief Operating
Instructions, you must read the Operating Instructions (on the CD-ROM). The Operating
Instructions provide detailed information on the measuring device.
• The measuring device should only installed in a de-energized state free from outside loads or
strain.
• The measuring device may only be modified if such work is expressly permitted in the
Operating Instructions (on the CD-ROM).
• Repairs may only be performed if a genuine spare parts kit is available and this repair work is
expressly permitted.
• If performing welding work on the piping, the welding unit may not be grounded by means of
the measuring device.
1.3 Operational safety

• The measuring device is designed to meet state-of-the-art safety requirements, has been
tested, and left the factory in a condition in which it is safe to operate. Relevant regulations
and European standards have been observed.
• The manufacturer reserves the right to modify technical data without prior notice. Your
Endress+Hauser distributor will supply you with current information and updates to these
Operating Instructions.
• The information on the warning notices, nameplates and connection diagrams affixed to the
device must be observed. These contain important data on the permitted operating
conditions, the range of application of the device and information on the materials used.
• If the device is not used at atmospheric temperatures, compliance with the relevant marginal
conditions as specified in the device documentation supplied (on CD-ROM) is mandatory.
• The device must be wired as specified in the wiring and connection diagrams. Interconnection
must be permitted.
4 Endress+Hauser
Proline Promag 50 Safety instructions
• All parts of the device must be included in the potential equalization of the system.
• Cables, certified cable glands and certified dummy plugs must be suitable to withstand the
prevailing operating conditions, such as the temperature range of the process. Housing
apertures that are not used must be sealed with dummy plugs.
• The device should only be used for fluids to which all the wetted parts of the device are
sufficiently resistant. With regard to special fluids, including fluids used for cleaning,
Endress+Hauser will be happy to assist in clarifying the corrosion-resistant properties of
wetted materials.
However, minor changes in temperature, concentration or in the degree of contamination in
the process may result in variations in corrosion resistance.
For this reason, Endress+Hauser does not accept any responsibility with regard to the
corrosion resistance of wetted materials in a specific application. The user is responsible for
the choice of suitable wetted materials in the process.
• When hot fluid passes through the measuring tube, the surface temperature of the housing
increases. In the case of the sensor, in particular, users should expect temperatures that can
be close to the fluid temperature. If the temperature of the fluid is high, implement sufficient
measures to prevent burning or scalding.
• Hazardous areas
Measuring devices for use in hazardous areas are labeled accordingly on the nameplate.
Relevant national regulations must be observed when operating the device in hazardous
areas. The Ex documentation on the CD-ROM is an integral part of the entire device
documentation.
The installation regulations, connection data and safety instructions provided in the Ex
documentation must be observed. The symbol and name on the front page provides
information on the approval and certification (e.g. 0 Europe, 2 USA, 1 Canada). The
nameplate also bears the documentation number of this Ex documentation (XA***D/../..).
• For measuring systems used in SIL 2 applications, the separate manual on functional safety
(on the CD-ROM) must be observed.
• Hygienic applications
Measuring devices for hygienic applications have their own special labeling. Relevant national
regulations must be observed when using these devices.
• Pressure instruments
Measuring devices for use in systems that need to be monitored are labeled accordingly on the
nameplate. Relevant national regulations must be observed when using these devices. The
documentation on the CD-ROM for pressure instruments in systems that need to be
monitored is an integral part of the entire device documentation. The installation regulations,
connection data and safety instructions provided in the Ex documentation must be observed.
• Endress+Hauser will be happy to assist in clarifying any questions on approvals, their
application and implementation.
Endress+Hauser 5
1.4 Safety conventions

# Warning!
"Warning" indicates an action or procedure which, if not performed correctly, can result in injury
or a safety hazard. Comply strictly with the instructions and proceed with care.
"Caution!
"Caution" indicates an action or procedure which, if not performed correctly, can result in
incorrect operation or destruction of the device. Comply strictly with the instructions.
Note! "Note" indicates an action or procedure which, if not performed correctly, can have an
indirect effect on operation or trigger an unexpected response on the part of the device.
6 Endress+Hauser
Proline Promag 50 Installation
2 Installation
2.1 Transporting to the measuring point
• Transport the measuring device to the measuring point in the original packaging.
• Do not remove the covers or caps until immediately before installation.
2.1.1 Transporting flanged devices DN  300 (12")
To transport the unit, use slings slung around the

process connections or use lugs (if available).
# Warning!
Risk of injury! The device can slip.
The center of gravity of the measuring device may be
higher than the holding points of the slings.
Always ensure that the device cannot slip or turn around
its axis.
A0007408
Do not lift measuring devices by the transmitter housing

or the connection housing in the case of the remote
version. Do not use chains as they could damage the
housing.
A0007409
2.1.2 Transporting flanged devices DN > 300 (12")

Use only the metal eyes provided on the flanges to transport, lift or position the sensor in the
piping.
" Caution!
Do not attempt to lift the sensor with the tines of a fork-lift truck beneath the metal casing!
This would buckle the casing and damage the internal magnetic coils.
A0008153
Endress+Hauser 7
Installation Proline Promag 50
2.2 Installation conditions

2.2.1 Dimensions
For the dimensions of the measuring device, see the associated Technical Information on the
CD-ROM.
2.2.2 Mounting location

The accumulation of air or formation of gas bubbles in the measuring tube can result in an
increase in measuring errors.
For this reason avoid the following mounting locations in the pipe:
• At the highest point of a pipeline. Risk of air accumulating!
• Directly upstream from a free pipe outlet in a down pipe.
h ³ 2 x DN
A0008154
Do not install the sensor on the intake side of a pump. This precaution is to avoid low pressure
and the consequent risk of damage to the lining of the measuring tube. It might be necessary to
use pulse dampers in systems incorporating piston pumps, piston diaphragm pumps or
peristaltic pumps.
Information on the measuring system's pressure tightness and resistance to vibration and shock
can be found in the Operating Instructions of the CD-ROM.
A0003203
8 Endress+Hauser

The empty pipe detection (EPD) function offers additional protection by detecting empty or
partially filled pipes.
" Caution!
Risk of solids accumulating! Do not install the sensor at the lowest point in the drain. It is
advisable to install a cleaning valve.
Installation in a partially filled pipe
³2 x DN
³5 x DN
A0008155
Down pipes
Install a siphon or a vent valve downstream of the sensor in down pipes longer than 5 meters
(16 ft). This precaution is to avoid low pressure and the consequent risk of damage to the lining
of the measuring tube. This measure also prevents the system losing prime, which could cause
air pockets.
For information on the pressure tightness of the measuring tube lining, see the Operating
Instructions on the CD-ROM.
Measures for installation in a down pipe (h > 5 m / 16 ft)

1 1. Vent valve
2. Siphon
2
h
A0008157
Endress+Hauser 9
2.2.3 Orientation
An optimum orientation helps avoid gas and air accumulations and buildup in the measuring
tube. The measuring device, nevertheless, supplies a range of functions and tools to measure
problematic fluids correctly:
• Electrode cleaning circuitry (ECC) to prevent electrically conductive deposits in the measuring
tube, e.g. for fluids causing buildup
• Empty pipe detection (EPD) for detecting partially filled measuring tubes, e.g. in the case of
degassing fluids or varying process pressures
• Exchangeable measuring electrodes for abrasive fluids (only Promag W)
This orientation is optimum for self-emptying piping

systems and when using empty pipe detection (EPD) or
open electrode detection (OED).
A0008158
The measuring electrode plane should be horizontal. This prevents brief insulation of the two
"Caution!
In the case of horizontal orientation, empty pipe detection only works correctly if the transmitter
housing is facing upwards. Otherwise there is no guarantee that empty pipe detection will
respond if the measuring tube is only partially filled or empty.
1. EPD electrode for empty pipe detection

A (not for Promag H, DN 2 to 15 / 1/12 to ½").
1 2. Measuring electrodes for signal detection
3. Reference electrode for potential equalization
(not for Promag H)
2 2
A
A0008159
10 Endress+Hauser
Inlet and outlet runs

If possible, install the sensor upstream from fittings such as valves, T-pieces, elbows, etc.
The following inlet and outlet runs must be observed in

³ 5 x DN ³ 2 x DN order to meet accuracy specifications:
• Inlet run:  5 × DN
• Outlet run:  2 × DN
A0008160
2.2.4 Vibrations
Secure and fix both the piping and the sensor if vibrations are severe.
Measures to prevent device vibration

L (L > 10 m / 33 ft)
" Caution!
It is advisable to install the sensor and transmitter
separately if vibration is excessively severe. For
information on the permitted shock and vibration
resistance, see the Operating Instructions on the
CD-ROM.
A0008161
Endress+Hauser 11
2.2.5 Foundations, supports

If the nominal diameter is DN  350 (14"), mount the sensor on a foundation of adequate
load-bearing strength.
"
Caution!
Risk of damage! Do not support the weight of the sensor on the metal casing.
A0008163
2.2.6 Length of connecting cable

Comply with the following instructions in order to ensure correct measuring results:
• Secure the cable run or route the cable in an armored conduit. Movement of the cable can
falsify the measuring signal, particularly if the fluid conductivity is low.
• Ensure potential equalization between the sensor and transmitter, if necessary.
• The permissible cable length Lmax depends on the fluid conductivity.
Gray shaded area = permissible

[µS/cm] range
200
Lmax = length of connecting
cable in [m]/[ft]
Fluid conductivity in (μS/cm]
100
L max
5 [m]
10 100 200 L max
[ft]
0 200 400 600
A0008164
12 Endress+Hauser
2.3 Installing the Promag E sensor

" Caution!
• The plates mounted on the two sensor flanges protect the PTFE which is turned over the
flanges and, consequently, should not be removed until immediately prior to mounting the
sensor.
• The protective plates must always remain mounted while the device is in storage.
• Make sure that the lining at the flange is not damaged or removed.
Note! Screws, nuts, seals, etc. are not included in the

scope of supply and must be supplied by the
customer.
The sensor is installed between the two pipe flanges:
• The requisite torques must be observed  ä 13
• If grounding disks are used, follow the mounting
instructions which will be enclosed with the
shipment.
a0008165
2.3.1 Seals
Comply with the following instructions when installing seals:
• No seals are required for PFA or PFTE measuring tube lining.
• For DIN flanges, only use seals to DIN EN 1514-1.
• Make sure that the mounted seals do not protrude into the piping cross-section.
" Caution!
Risk of short circuit! Do not use electrically conductive sealing compounds such as graphite! An
electrically conductive layer could form on the inside of the measuring tube and short-circuit the
measuring signal.
2.3.2 Ground cable

If necessary, special ground cables can be ordered as accessories for potential equalization.
2.3.3 Tightening torques for threaded fasteners (Promag E)

Please note the following:
• The tightening torques listed below are for lubricated threads only.
• Always tighten the screws uniformly and in diagonally opposite sequence.
• Overtightening the screws will deform the sealing faces or damage the seals.
• The tightening torques listed below apply only to pipes not subjected to tensile stress.
Endress+Hauser 13
Promag E tightening torques for EN (DIN)
Nominal diameter EN (DIN) Threaded Max. tightening torque

[mm] Pressure rating [bar] fasteners [Nm]
15 PN 40 4 × M 12 11
25 PN 40 4 × M 12 26
32 PN 40 4 × M 16 41
40 PN 40 4 × M 16 52
50 PN 40 4 × M 16 65
65 * PN 16 8 × M 16 43
80 PN 16 8 × M 16 53
100 PN 16 8 × M 16 57
125 PN 16 8 × M 16 75
150 PN 16 8 × M 20 99
200 PN 10 8 × M 20 141
200 PN 16 12 × M 20 94
250 PN 10 12 × M 20 110
250 PN 16 12 × M 24 131
300 PN 10 12 × M 20 125
300 PN 16 12 × M 24 179
350 PN 6 12 × M 20 200
350 PN 10 16 × M 20 188
350 PN 16 16 × M 24 254
400 PN 6 16 × M 20 166
400 PN 10 16 × M 24 260
400 PN 16 16 × M 27 330
450 PN 6 16 × M 20 202
450 PN 10 20 × M 24 235
450 PN 16 20 × M 27 300
500 PN 6 20 × M 20 176
500 PN 10 20 × M 24 265
500 PN 16 20 × M 30 448
600 PN 6 20 × M 24 242
600 PN 10 20 × M 27 345
600 * PN 16 20 × M 33 658
* Designed acc. to EN 1092-1 (not to DIN 2501)
14 Endress+Hauser
Promag E tightening torques for ANSI
Nominal diameter ANSI Max. tightening torque
Pressure rating Threaded PTFE

[mm] [inch] [lbs] fasteners [Nm] [lbf · ft]
15 ½" Class 150 4 × ½" 6 4
25 1" Class 150 4 × ½" 11 8
40 1 ½" Class 150 4 × ½" 24 18
50 2" Class 150 4 × 5/8" 47 35
80 3" Class 150 4 × 5/8" 79 58
100 4" Class 150 8 × 5/8" 56 41
150 6" Class 150 8 × ¾" 106 78
200 8" Class 150 8 × ¾" 143 105
250 10" Class 150 12 × 7/8" 135 100
300 12" Class 150 12 × 7/8" 178 131
350 14" Class 150 12 × 1" 260 192
400 16" Class 150 16 × 1" 246 181
450 18" Class 150 16 × 1 1/8" 371 274
500 20" Class 150 20 × 1 1/8" 341 252
600 24" Class 150 20 × 1 ¼" 477 352
Promag E tightening torques for JIS
Nominal diameter JIS Max. tightening torque [Nm]

[mm] Pressure rating Threaded fasteners PTFE
15 20K 4 × M 16 16
25 20K 4 × M 16 32
32 20K 4 × M 16 38
40 20K 4 × M 16 41
50 10K 4 × M 16 54
65 10K 4 × M 16 74
80 10K 8 × M 16 38
100 10K 8 × M 16 47
125 10K 8 × M 20 80
150 10K 8 × M 20 99
200 10K 12 × M 20 82
250 10K 12 × M 22 133
300 10K 16 × M 22 99
Endress+Hauser 15
2.4 Installing the Promag H sensor

Depending on the order specifications, the sensor is supplied with or without ready-mounted
process connections. Mounted process connections are fixed to the sensor with 4 or 6
hexagonal-headed bolts.
"
Caution!
Depending on the application and length of the pipe, the sensor may have to be supported or
additionally secured. The sensor must be secured if using plastic process connections. An
appropriate wall mounting kit can be ordered separately from Endress+Hauser as an accessory.
2.4.1 Seals
When mounting the process connections, make sure that the seals in question are free from dirt
and centered correctly.
"
Caution!
• The screws must be securely tightened in the case of metal process connections. Together
with the sensor, the process connection forms a metal connection that ensures defined seal
compression.
• With regard to process connections made of plastic material, comply with the max. torques
for lubricated threads (7 Nm / 5.2 lbf ft). A seal must always be used between the connection
and counterflange for plastic flanges.
• The seals should be replaced periodically depending on the application, particularly if molded
seals are used (aseptic version)! The intervals between seal replacement depend on the
frequency of the cleaning cycles and the fluid and cleaning temperatures. Replacement seals
can be ordered as an accessory.
2.4.2 Using and mounting grounding rings (DN 2 to 25 / 1/12 to 1")

In the case of process connections made of plastic (e.g. flange connections or adhesive
couplings), potential equalization between the sensor and fluid must be ensured via additional
grounding rings.
If grounding rings are missing, this can affect accuracy or result in the destruction of the sensor
due to electrochemical electrode reduction.
"
Caution!
• Depending on the order option, appropriate plastic disks are used instead of grounding rings
for the process connections. These plastic disks only act as a kind of "place holder" and do not
have any potential equalization function whatsoever. In addition, they also assume an
important sealing function at the sensor/connection interface. Thus, these plastic disks/seals
should never be removed and should always be mounted for process connections without
metal grounding rings!
• Grounding rings can be ordered separately from Endress+Hauser as an accessory.
When ordering, make sure that the grounding rings are compatible with the electrode
material. Otherwise there is the risk that electrodes can be damaged by electrochemical
corrosion! For information on materials, see the Operating Instructions on the CD-ROM.
16 Endress+Hauser
• Grounding rings, incl. seals, are mounted inside the process connections.
The face-to-face length is not affected.
Installing the grounding rings
1 = Process connection hexagonal-headed bolts

2 = O-ring seals
4 = Sensor
3 = Grounding ring or plastic disk (place holder)
1
2 3 2 4
a0008168
a. Release the 4 or 6 hexagonal-headed bolts (1) and remove the process connection from the sensor (4).
b. Remove the plastic disk (3) including the two O-ring seals (2) from the process connection.
c. Insert one of the O-ring seals (2) back into the groove of the process connection.
d. Place the metal grounding ring (3) into the process connection as illustrated.
e. Now insert the second O-ring seal (2) into the groove of the grounding ring.
f. Mount the process connection back onto the sensor. In doing so, make sure to observe the max. torques for lubricated
threads (7 Nm) (5.2 lbf ft).
2.4.3 Welding the sensor into the pipe (weld nipples)
"
Caution!
Risk of destroying the electronics! Make sure that the welding system is not grounded via the
sensor or transmitter.
a. Secure the sensor with a few welding points in the pipe.
A welding jig suitable for this purpose can be ordered separately as an accessory.
b. Release the screws on the process connection flange and remove the sensor, including the
seal, from the pipe.
c. Weld the process connection into the pipe.
d. Mount the sensor back into the pipe.
In doing so, make sure the seals are clean and correctly positioned.
Note! •When welding is performed correctly with thin-walled pipes carrying food, the seal is
not damaged by the heat even when it is mounted. It is recommended, however, to
disassemble the sensor and seal.
• For the disassembly work, it must be possible to open the pipe approx. 8 mm (0.31 in) in
total.
Endress+Hauser 17
2.5 Installing the Promag L sensor

"
Caution!
• The protective covers mounted on the two sensor flanges (DN 25 to 300 / 1 to 12") are used
to hold the lap joint flanges in place and to protect the PTFE liner during transportation.
Consequently, do not remove these covers until immediately before the sensor is installed in
the pipe.

customer.
shipment.
• To comply with the device specification, a concentrical
installation in the measuring section is required
a0008165
2.5.1 Seals
• Hard rubber lining  additional seals are always required!
• Polyurethane lining  no seals are required.
• No seals are required for PFTE measuring tube lining.
"
Caution!
Risk of short circuit!
Do not use electrically conductive sealing compounds such as graphite! An electrically
conductive layer could form on the inside of the measuring tube and short-circuit the measuring
signal.
2.5.2 Ground cable

2.5.3 Screw tightening torques (Promag L)

18 Endress+Hauser
Promag L tightening torques for EN (DIN)
Nominal dia- EN (DIN) Max. tightening torque

meter
Hard rubber Polyurethane PTFE
[mm] Pressure Threaded [Nm] [Nm] [Nm]
rating fasteners
[bar]
25 PN 10/16 4 × M 12 - 6 11
32 PN 10/16 4 × M 16 - 16 27
40 PN 10/16 4 × M 16 - 16 29
50 PN 10/16 4 × M 16 - 15 40
65* PN 10/16 8 × M 16 - 10 22
80 PN 10/16 8 × M 16 - 15 30
100 PN 10/16 8 × M 16 - 20 42
125 PN 10/16 8 × M 16 - 30 55
150 PN 10/16 8 × M 20 - 50 90
200 PN 16 12 × M 20 - 65 87
250 PN 16 12 × M 24 - 126 151
300 PN 16 12 × M 24 - 139 177
350 PN 6 12 × M 20 111 120 -
350 PN 10 16 × M 20 112 118 -
400 PN 6 16 × M 20 90 98 -
400 PN 10 16 × M 24 151 167 -
450 PN 6 16 × M 20 112 126 -
450 PN 10 20 × M 24 153 133 -
500 PN 6 20 × M 20 119 123 -
500 PN 10 20 × M 24 155 171 -
600 PN 6 20 × M 24 139 147 -
600 PN 10 20 × M 27 206 219 -
700 PN 6 24 × M 24 148 139 -
700 PN 10 24 × M 27 246 246 -
800 PN 6 24 × M 27 206 182 -
800 PN 10 24 × M 30 331 316 -
900 PN 6 24 × M 27 230 637 -
900 PN 10 28 × M 30 316 307 -
1000 PN 6 28 × M 27 218 208 -
1000 PN 10 28 × M 33 402 405 -
1200 PN 6 32 × M 30 319 299 -
1200 PN 10 32 × M 36 564 568 -
1400 PN 6 36 × M 33 430 - -
1400 PN 10 36 × M 39 654 618 -
1400 PN 16 36 × M 45 729 762 -
1600 PN 6 40 × M 33 440 417 -
1600 PN 10 40 × M 45 946 893 -
Endress+Hauser 19

meter
rating fasteners
[bar]
1600 PN 16 40 × M 52 1007 1100 -
1800 PN 6 44 × M 36 547 521 -
1800 PN 10 44 × M 45 961 895 -
1800 PN 16 44 × M 52 1108 1003 -
2000 PN 6 48 × M 39 629 605 -
2000 PN 10 48 × M 45 1047 1092 -
2000 PN 16 48 × M 56 1324 1261 -
2200 PN 6 52 × M 39 698 - -
2200 PN 10 52 × M 52 1217 - -
2400 PN 6 56 × M 39 768 - -
2400 PN 10 56 × M 52 1229 - -
Promag L tightening torques for ANSI
Nominal dia- ANSI Threaded Max. tightening torque

meter fasteners
Pressure Hard rubber Polyurethane PTFE
rating
[mm [inch [lbs] [Nm] [lbf · [Nm] [lbf · [Nm] [lbf ·
] ] ft] ft] ft]
25 1 Class 150 4 × 5/8" - - 5 4 14 13
40 1½ Class 150 4 × 5/8" - - 10 7 21 15
50 2" Class 150 4 × 5/8" - - 15 11 40 29
80 3" Class 150 4 × 5/8" - - 25 18 65 48
100 4" Cla ss 150 8 × 5/8" - - 20 15 44 32
150 6" Class 150 8 × ¾" - - 45 33 90 66
200 8" Class 150 8 × ¾" - - 65 48 87 64
250 10" Class 150 12 × 7/8" - - 126 93 151 112
300 12" Class 150 12 × 7/8" - - 146 108 177 131
350 14" Class 150 12 × 1" 135 100 158 117 - -
400 16" Class 150 16 × 1" 128 94 150 111 - -
450 18" Class 150 16 × 1 1/8" 204 150 234 173 - -
500 20" Class 150 20 × 1 1/8" 183 135 217 160 - -
600 24" Class 150 20 × 1 ¼" 268 198 307 226 - -
20 Endress+Hauser
Promag L tightening torques for AWWA
Nominal dia- AWWA Threa- Max. tightening torque

meter ded faste-
ners
Pressure Hartgummi Polyurethane PTFE
[mm [inch rating [Nm] [lbf · [Nm] [lbf · [Nm] [lbf ·
] ] ft] ft] ft]
700 28" Class D 28 × 1 ¼" 247 182 292 215 - -
750 30" Class D 28 × 1 ¼" 287 212 302 223 - -
800 32" Class D 28 × 1 ½" 394 291 422 311 - -
900 36" Class D 32 × 1 ½" 419 309 430 317 - -
1000 40" Class D 36 × 1 ½" 420 310 477 352 - -
1050 42" Class D 36 × 1 ½" 528 389 518 382 - -
1200 48" Class D 44 × 1 ½" 552 407 531 392 - -
1350 54" Class D 44 × 1 ¾" 730 538 - - - -
1500 60" Class D 52 × 1 ¾" 758 559 - - - -
1650 66" Class D 52 × 1 ¾" 946 698 - - - -
1800 72" Class D 60 × 1 ¾" 975 719 - - - -
2000 78" Class D 64 × 2" 853 629 - - - -
2150 84" Class D 64 × 2" 931 687 - - - -
2300 90" Class D 68 × 2 ¼" 1048 773 - - - -
Promag L tightening torques for AS 2129
Nominal AS 2129 Threaded Max. tightening torque

diameter fasteners
rating
[mm] [Nm] [Nm] [Nm]
350 Table E 12 × M 24 203 - -
400 Table E 12 × M 24 226 - -
450 Table E 16 × M 24 226 - -
500 Table E 16 × M 24 271 - -
600 Table E 16 × M 30 439 - -
700 Table E 20 × M 30 355 - -
750 Table E 20 × M 30 559 - -
800 Table E 20 × M 30 631 - -
900 Table E 24 × M 30 627 - -
1000 Table E 24 × M 30 634 - -
1200 Table E 32 × M 30 727 - -
Endress+Hauser 21

diameter fasteners
rating
[mm] [Nm] [Nm] [Nm]
350 PN 16 12 × M 24 203 - -
375 PN 16 12 × M 24 137 - -
400 PN 16 12 × M 24 226 - -
450 PN 16 12 × M 24 301 - -
500 PN 16 16 × M 24 271 - -
600 PN 16 16 × M 27 393 - -
700 PN 16 20 × M 27 330 - -
750 PN 16 20 × M 30 529 - -
800 PN 16 20 × M 33 631 - -
900 PN 16 24 × M 33 627 - -
1000 PN 16 24 × M 33 595 - -
1200 PN 16 32 × M 33 703 - -
22 Endress+Hauser
2.6 Installing the Promag P sensor

" Caution!
sensor.

customer.
shipment.
a0008165
2.6.1 Seals
" Caution!
measuring signal.
2.6.2 Ground cable

Endress+Hauser 23
2.6.3 Installing the high-temperature version (with PFA lining)

The high-temperature version has a housing support for the thermal separation of sensor and
transmitter. The high-temperature version is always used for applications
in which high ambient temperatures are encountered in conjunction with high fluid
temperatures. The high-temperature version is obligatory if the fluid temperature exceeds
+150 °C.
Note! You will find information on permissible temperature ranges in the Operating
Instructions of the CD-ROM
Insulation
Pipes generally have to be insulated if they carry very hot fluids, in order to avoid energy losses
and to prevent accidental contact with pipes at temperatures that could cause injury. Guidelines
regulating the insulation of pipes have to be taken into account.
"
Caution!
Risk of measuring electronics overheating. The housing support dissipates heat and its entire
surface area must remain uncovered. Make sure that the sensor insulation does not extend past
the top of the two sensor shells.
Esc
max.
- + E
A0004300
24 Endress+Hauser
2.6.4 Tightening torques for threaded fasteners (Promag P)

Promag P tightening torques for EN (DIN)
Nominal EN (DIN) Threaded Max. tightening torque [Nm]

diameter fasteners
[mm] Pressure rating [bar] PTFE PFA
15 PN 40 4 × M 12 11 –
25 PN 40 4 × M 12 26 20
32 PN 40 4 × M 16 41 35
40 PN 40 4 × M 16 52 47
50 PN 40 4 × M 16 65 59
65 * PN 16 8 × M 16 43 40
65 PN 40 8 × M 16 43 40
80 PN 16 8 × M 16 53 48
80 PN 40 8 × M 16 53 48
100 PN 16 8 × M 16 57 51
100 PN 40 8 × M 20 78 70
125 PN 16 8 × M 16 75 67
125 PN 40 8 × M 24 111 99
150 PN 16 8 × M 20 99 85
150 PN 40 8 × M 24 136 120
200 PN 10 8 × M 20 141 101
200 PN 16 12 × M 20 94 67
200 PN 25 12 × M 24 138 105
250 PN 10 12 × M 20 110 –
250 PN 16 12 × M 24 131 –
250 PN 25 12 × M 27 200 –
300 PN 10 12 × M 20 125 –
300 PN 16 12 × M 24 179 –
300 PN 25 16 × M 27 204 –
350 PN 10 16 × M 20 188 –
350 PN 16 16 × M 24 254 –
350 PN 25 16 × M 30 380 –
400 PN 10 16 × M 24 260 –
400 PN 16 16 × M 27 330 –
400 PN 25 16 × M 33 488 –
450 PN 10 20 × M 24 235 –
Endress+Hauser 25

diameter fasteners
450 PN 16 20 × M 27 300 –
450 PN 25 20 × M 33 385 –
500 PN 10 20 × M 24 265 –
500 PN 16 20 × M 30 448 –
500 PN 25 20 × M 33 533 –
600 PN 10 20 × M 27 345 –
600 * PN 16 20 × M 33 658 –
600 PN 25 20 × M 36 731 –
Promag P tightening torques for ANSI
Nominal diameter ANSI Threaded fasteners Max. tightening torque
Pressure rating PTFE PFA

[mm] [inch] [lbs] [Nm] [lbf · ft] [Nm] [lbf · ft]
15 ½" Class 150 4 × ½" 6 4 – –
15 ½" Class 300 4 × ½" 6 4 – –
25 1" Class 150 4 × ½" 11 8 10 7
25 1" Class 300 4 × 5/8" 14 10 12 9
40 1 ½" Class 150 4 × ½" 24 18 21 15
40 1 ½" Class 300 4 × ¾" 34 25 31 23
50 2" Class 150 4 × 5/8" 47 35 44 32
50 2" Class 300 8 × 5/8" 23 17 22 16
80 3" Class 150 4 × 5/8" 79 58 67 49
80 3" Class 300 8 × ¾" 47 35 42 31
100 4" Class 150 8 × 5/8" 56 41 50 37
100 4" Class 300 8 × ¾" 67 49 59 44
150 6" Class 150 8 × ¾" 106 78 86 63
150 6" Class 300 12 × ¾" 73 54 67 49
200 8" Class 150 8 × ¾" 143 105 109 80
250 10" Class 150 12 × 7/8" 135 100 – –
300 12" Class 150 12 × 7/8" 178 131 – –
350 14" Class 150 12 × 1" 260 192 – –
400 16" Class 150 16 × 1" 246 181 – –
450 18" Class 150 16 × 1 1/8" 371 274 – –
500 20" Class 150 20 × 1 1/8" 341 252 – –
600 24" Class 150 20 × 1 ¼" 477 352 – –
26 Endress+Hauser
Promag P tightening torques for JIS

[mm] Pressure rating Threaded fasteners PTFE PFA
25 10K 4 × M 16 32 27
25 20K 4 × M 16 32 27
32 10K 4 × M 16 38 –
32 20K 4 × M 16 38 –
40 10K 4 × M 16 41 37
40 20K 4 × M 16 41 37
50 10K 4 × M 16 54 46
50 20K 8 × M 16 27 23
65 10K 4 × M 16 74 63
65 20K 8 × M 16 37 31
80 10K 8 × M 16 38 32
80 20K 8 × M 20 57 46
100 10K 8 × M 16 47 38
100 20K 8 × M 20 75 58
125 10K 8 × M 20 80 66
125 20K 8 × M 22 121 103
150 10K 8 × M 20 99 81
150 20K 12 × M 22 108 72
200 10K 12 × M 20 82 54
200 20K 12 × M 22 121 88
250 10K 12 × M 22 133 –
250 20K 12 × M 24 212 –
300 10K 16 × M 22 99 –
300 20K 16 × M 24 183 –
Promag P tightening torques for AS 2129
Nominal diameter AS 2129 Threaded fasteners Max. tightening torque [Nm]

[mm] Pressure rating PTFE
25 Table E 4 × M 12 21
50 Table E 4 × M 16 42
Nominal diameter AS 4087 Threaded Max. tightening torque [Nm]

[mm] Pressure rating fasteners PTFE
50 PN 16 4 × M 16 42
Endress+Hauser 27
2.7 Installing the Promag W sensor

customer.
shipment.
a0008165
2.7.1 Seals
• Hard rubber lining  additional seals are always necessary.
• For DIN flanges, use only seals according to EN 1514-1.
• Make sure that the seals do not protrude into the piping cross-section.
"
Caution!
signal.
2.7.2 Ground cable

2.7.3 Screw tightening torques (Promag W)

Promag W tightening torques for EN (DIN)
Nominal diameter EN (DIN) Threaded Max. tightening torque [Nm]

fasteners
[mm] Pressure rating [bar] Hard rubber Polyurethane
25 PN 40 4 × M 12 - 15
32 PN 40 4 × M 16 - 24
40 PN 40 4 × M 16 - 31
50 PN 40 4 × M 16 48 40
28 Endress+Hauser

fasteners
65* PN 16 8 × M 16 32 27
65 PN 40 8 × M 16 32 27
80 PN 16 8 × M 16 40 34
80 PN 40 8 × M 16 40 34
100 PN 16 8 × M 16 43 36
100 PN 40 8 × M 20 59 50
125 PN 16 8 × M 16 56 48
125 PN 40 8 × M 24 83 71
150 PN 16 8 × M 20 74 63
150 PN 40 8 × M 24 104 88
200 PN 10 8 × M 20 106 91
200 PN 16 12 × M 20 70 61
200 PN 25 12 × M 24 104 92
250 PN 10 12 × M 20 82 71
250 PN 16 12 × M 24 98 85
250 PN 25 12 × M 27 150 134
300 PN 10 12 × M 20 94 81
300 PN 16 12 × M 24 134 118
300 PN 25 16 × M 27 153 138
350 PN 6 12 × M 20 111 120
350 PN 10 16 × M 20 112 118
350 PN 16 16 × M 24 152 165
350 PN 25 16 × M 30 227 252
400 PN 6 16 × M 20 90 98
400 PN 10 16 × M 24 151 167
400 PN 16 16 × M 27 193 215
400 PN 25 16 × M 33 289 326
450 PN 6 16 × M 20 112 126
450 PN 10 20 × M 24 153 133
450 PN 16 20 × M 27 198 196
450 PN 25 20 × M 33 256 253
500 PN 6 20 × M 20 119 123
500 PN 10 20 × M 24 155 171
500 PN 16 20 × M 30 275 300
500 PN 25 20 × M 33 317 360
600 PN 6 20 × M 24 139 147
600 PN 10 20 × M 27 206 219
600 * PN 16 20 × M 33 415 443
600 PN 25 20 × M 36 431 516
700 PN 6 24 × M 24 148 139
700 PN 10 24 × M 27 246 246
700 PN 16 24 × M 33 278 318
Endress+Hauser 29

fasteners
700 PN 25 24 × M 39 449 507
800 PN 6 24 × M 27 206 182
800 PN 10 24 × M 30 331 316
800 PN 16 24 × M 36 369 385
800 PN 25 24 × M 45 664 721
900 PN 6 24 × M 27 230 637
900 PN 10 28 × M 30 316 307
900 PN 16 28 × M 36 353 398
900 PN 25 28 × M 45 690 716
1000 PN 6 28 × M 27 218 208
1000 PN 10 28 × M 33 402 405
1000 PN 16 28 × M 39 502 518
1000 PN 25 28 × M 52 970 971
1200 PN 6 32 × M 30 319 299
1200 PN 10 32 × M 36 564 568
1200 PN 16 32 × M 45 701 753
1400 PN 6 36 × M 33 430 398
1400 PN 10 36 × M 39 654 618
1400 PN 16 36 × M 45 729 762
1600 PN 6 40 × M 33 440 417
1600 PN 10 40 × M 45 946 893
1600 PN 16 40 × M 52 1007 1100
1800 PN 6 44 × M 36 547 521
1800 PN 10 44 × M 45 961 895
1800 PN 16 44 × M 52 1108 1003
2000 PN 6 48 × M 39 629 605
2000 PN 10 48 × M 45 1047 1092
2000 PN 16 48 × M 56 1324 1261
Promag W tightening torques for ANSI
Nominal ANSI Threaded fasteners Max. tightening torque

diameter Hard rubber Polyurethane
Pressure
[mm] [inch] rating [lbs] [Nm] [lbf · ft] [Nm] [lbf · ft]
25 1" Class 150 4 × ½" - - 7 5
25 1" Class 300 4 × 5/8" - - 8 6
40 1 ½" Class 150 4 × ½" - - 10 7
40 1 ½" Class 300 4 × ¾" - - 15 11
50 2" Class 150 4 × 5/8" 35 26 22 16
50 2" Class 300 8 × 5/8" 18 13 11 8
80 3" Class 150 4 × 5/8" 60 44 43 32
30 Endress+Hauser

Pressure
80 3" Class 300 8 × ¾" 38 28 26 19
100 4" Class 150 8 × 5/8" 42 31 31 23
100 4" Class 300 8 × ¾" 58 43 40 30
150 6" Class 150 8 × ¾" 79 58 59 44
150 6" Class 300 12 × ¾" 70 52 51 38
200 8" Class 150 8 × ¾" 107 79 80 59
250 10" Class 150 12 × 7/8" 101 74 75 55
300 12" Class 150 12 × 7/8" 133 98 103 76
350 14" Class 150 12 × 1" 135 100 158 117
400 16" Class 150 16 × 1" 128 94 150 111
450 18" Class 150 16 × 1 1/8" 204 150 234 173
500 20" Class 150 20 × 1 1/8" 183 135 217 160
600 24" Class 150 20 × 1 ¼" 268 198 307 226
Promag W tightening torques for JIS
Nominal diameter JIS Threaded Max. tightening torque [Nm]

[mm] Pressure rating fasteners Hard rubber Polyurethane
25 10K 4 × M 16 - 19
25 20K 4 × M 16 - 19
32 10K 4 × M 16 - 22
32 20K 4 × M 16 - 22
40 10K 4 × M 16 - 24
40 20K 4 × M 16 - 24
50 10K 4 × M 16 40 33
50 20K 8 × M 16 20 17
65 10K 4 × M 16 55 45
65 20K 8 × M 16 28 23
80 10K 8 × M 16 29 23
80 20K 8 × M 20 42 35
100 10K 8 × M 16 35 29
100 20K 8 × M 20 56 48
125 10K 8 × M 20 60 51
125 20K 8 × M 22 91 79
150 10K 8 × M 20 75 63
150 20K 12 × M 22 81 72
200 10K 12 × M 20 61 52
200 20K 12 × M 22 91 80
250 10K 12 × M 22 100 87
250 20K 12 × M 24 159 144
300 10K 16 × M 22 74 63
Endress+Hauser 31

300 20K 16 × M 24 138 124
Promag W tightening torques for AWWA
Nominal AWWA Max. tightening torque

diameter
Pressure Threaded Hard rubber Polyurethane

[mm] [inch] rating fasteners [Nm] [lbf · ft] [Nm] [lbf · ft]
700 28" Class D 28 × 1 ¼" 247 182 292 215
750 30" Class D 28 × 1 ¼" 287 212 302 223
800 32" Class D 28 × 1 ½" 394 291 422 311
900 36" Class D 32 × 1 ½" 419 309 430 317
1000 40" Class D 36 × 1 ½" 420 310 477 352
1050 42" Class D 36 × 1 ½" 528 389 518 382
1200 48" Class D 44 × 1 ½" 552 407 531 392
1350 54" Class D 44 × 1 ¾" 730 538 633 467
1500 60" Class D 52 × 1 ¾" 758 559 832 614
1650 66" Class D 52 × 1 ¾" 946 698 955 704
1800 72" Class D 60 × 1 ¾" 975 719 1087 802
2000 78" Class D 64 × 2" 853 629 786 580
Promag W tightening torques for AS 2129

[mm] Pressure rating fasteners Hard rubber
50 Table E 4 × M 16 32
80 Table E 4 × M 16 49
100 Table E 8 × M 16 38
150 Table E 8 × M 20 64
200 Table E 8 × M 20 96
250 Table E 12 × M 20 98
300 Table E 12 × M 24 123
350 Table E 12 × M 24 203
400 Table E 12 × M 24 226
450 Table E 16 × M 24 226
500 Table E 16 × M 24 271
600 Table E 16 × M 30 439
700 Table E 20 × M 30 355
750 Table E 20 × M 30 559
800 Table E 20 × M 30 631
900 Table E 24 × M 30 627
1000 Table E 24 × M 30 634
32 Endress+Hauser

1200 Table E 32 × M 30 727

50 Table E 4 × M 16 32
80 PN 16 4 × M 16 49
100 PN 16 4 × M 16 76
150 PN 16 8 × M 20 52
200 PN 16 8 × M 20 77
250 PN 16 8 × M 20 147
300 PN 16 12 × M 24 103
350 PN 16 12 × M 24 203
375 PN 16 12 × M 24 137
400 PN 16 12 × M 24 226
450 PN 16 12 × M 24 301
500 PN 16 16 × M 24 271
600 PN 16 16 × M 27 393
700 PN 16 20 × M 27 330
750 PN 16 20 × M 30 529
800 PN 16 20 × M 33 631
900 PN 16 24 × M 33 627
1000 PN 16 24 × M 33 595
1200 PN 16 32 × M 33 703
Endress+Hauser 33
2.8 Installing the transmitter housing

2.8.1 Turning the transmitter housing
Turning the aluminum field housing
Aluminum field housing for non-Ex area
b d
£ 180° £ 180°
c
a f
A0007540
Aluminum field housing for Zone 1 or Class I Div. 1

For Zone 1 or Class I Div. 1:
max. 360° a. Release the setscrew.
b b. Turn the transmitter housing
c gently clockwise until the stop
(end of the thread).
Nic
ht unt
er Spannu
ng
c. Turn the transmitter
counterclockwise (max. 360°)
öffnen
Nicht-eigensichere
Kee ircuits are alive ile
to the desired position.

Stromkreise durch
p cover tight wh
p cover tight w
a
d. Retighten the setscrew.

Boucles de courant
c
ve

sous nsion l Ne
pas o te apparei
uvrir l’
d
A0008036
Turning the stainless steel field housing
£ 180° c £ 180°
a b
e
A0007661
34 Endress+Hauser
2.8.2 Turning the onsite display
a. Press in the side latches on the display module and

remove the module from the cover plate of the
electronics compartment.
4 × 45° b. Turn the display to the desired position (max.
4 × 45° in both directions) and reset it onto the
cover plate of the electronics compartment.
b
a
A0007541
2.8.3 Installing the wall-mount housing
" Caution!
• Make sure that the ambient temperature does not exceed the permitted range.
• Always install the wall-mount housing in such a way that the cable entries point downwards.
Mounted directly on the wall
1. Connection compartment
35 (1.38) mm (inch) 2. Securing screws M6 (max. ø 6.5 mm (0.25"); screw
head max. ø 10.5 mm (0.4")
3. Housing bores for securing screws
2 3 3
81.5 (3.2)
90 (3.54) 192 (7.56)

A0007542
Endress+Hauser 35
Pipe mounting
mm (inch) " Caution!

Danger of overheating! If the device is mounted on a
Ø 20…70
warm pipe, make sure that the housing temperature
(Ø 0.79…2.75) does not exceed +60 °C (+140 °F) which is the
maximum temperature permitted.
~155 (~ 6.1)
A0007543
Panel mounting
+0.5 (+0.019)
–0.5 (–0.019)
210 (8.27)
+0.5 (+0.019)
–0.5 (–0.019)
245 (9.65)
mm (inch)
~110 (~4.33)
A0007544
36 Endress+Hauser
2.9 Post-installation check

• Is the measuring device damaged (visual inspection)?
• Does the device correspond to specifications at the measuring point, including process
temperature and pressure, ambient temperature, minimum fluid conductivity, measuring
range, etc.?
• Does the arrow on the sensor nameplate match the actual direction of flow through the pipe?
• Is the position of the measuring electrode plane correct?
• Were all screws tightened to the specified torques when the sensor was installed?
• Were the correct seals used (type, material, installation)?
• Are the measuring point number and labeling correct (visual inspection)?
• Were the inlet and outlet runs respected?
– Inlet run  5 × DN
– Outlet run  2 × DN
• Is the measuring device protected against moisture and direct sunlight?
• Is the sensor adequately protected against vibration (attachment, support)?
Acceleration up to 2 g by analogy with IEC 600 68-2-8.
Endress+Hauser 37
Wiring Proline Promag 50
3 Wiring
# Warning!
Risk of electric shock! Components carry dangerous voltages.
• Never mount or wire the measuring device while it is connected to the power supply.
• Before connecting the power supply, check the safety equipment.
• Route the power supply and signal cables so they are securely seated.
• Seal the cable entries and covers tight.
"
Caution!
Risk of damaging the electronic components!
• Connect the power supply in accordance with the connection data on the nameplate.
• Connect the signal cable in accordance with the connection data in the Operating Instructions
or the Ex documentation on the CD-ROM.
In addition, for the remote version
"
Caution!
• Only connect sensors and transmitters with the same serial number.
• Observe the cable specifications of the connecting cable  Operating Instructions on the
CD-ROM.
Note! Install the connecting cable securely to prevent movement.
In addition, for measuring devices with fieldbus communication
"
Caution!
• Observe the cable specification of the fieldbus cable  Operating Instructions on the
CD-ROM.
• Keep the stripped and twisted lengths of cable shield as short as possible.
• Screen and ground the signal lines  Operating Instructions on the CD-ROM.
• When using in systems without potential equalization  Operating Instructions on the
CD-ROM.
In addition, for Ex-certified measuring devices
# Warning!
When wiring Ex-certified measuring devices, all the safety instructions, wiring diagrams,
technical information etc. of the related Ex documentation must be observed
 Ex documentation on the CD-ROM.
38 Endress+Hauser
Proline Promag 50 Wiring
3.1 Connecting the various housing types

Wire the unit using the terminal assignment diagram inside the cover.
3.1.1 Compact version
Transmitter connection:
1 Connection diagram inside the connection compartment
3 cover
4 2 Power supply cable
2 3 Signal cable or fieldbus cable
4 Optional
1
A0007545
3.1.2 Remote version (transmitter): non-Ex Zone, Ex Zone 2, Class I Div. 2
cover
2 Power supply cable
3 Signal cable
4 Fieldbus cable
Connecting the connecting cable ( ä 40):

2 3 4 5 1 5 Sensor/transmitter connecting cable
A0012690
3.1.3 Remote version (transmitter): Ex Zone 1, Class I Div. 1
ht unter Spannun
Nic öffnen g
3
Ke ircuits are alive le
cover
over tight whi
c
p cover tight w
4
ep c

ve
c
2
Ne sous tension reil
3 Signal cable or fieldbus cable

pas ou r l’appa
vri
1 4 Optional
5 1 Connecting the connecting cable ( ä 40):

5 Sensor/transmitter connecting cable
A0008218
3.1.4 Remote version (sensor)
1 cover
5
Connecting cable connection:
A0008037 5 Sensor/transmitter connecting cable
Endress+Hauser 39
3.2 Connecting the remote version connecting cable

3.2.1 Connecting cable for Promag E/P/L/W
Connecting cable termination

Terminate the signal and coil current cables as shown in the figure below (Detail A).
Fit the fine-wire cores with cable end ferrules (Detail B).
Signal cable termination

Make sure that the cable end ferrules do not touch the wire shields on the sensor side! Minimum
distance = 1 mm (0.04 in), exception "GND" = green cable.
Sensor Transmitter
mm (inch) mm (inch)
a* = 170 (6.69") a* b* a* a* = 100 (3.94")
b* = 20 (0.79") c b = 80 (3.15")
d b
c = 80 (3.15") c = 50 (1.97")
d = 17 (0.67")
e f A c d d = 17 (0.67")
e = 8 (0.31") e = 8 (0.31")
f = 50 (1.97")
g = 1 (0.04") e
m B m
m
n n
g m
n GND GND n
m
n n
m n
a0008171
m = Cable end ferrules, red, 1.0 mm (0.04"); n = Cable end ferrules, white, 0.5 mm (0.02")
* = Stripping for armored cables only
Coil current cable termination

Insulate one core of the three-core cable at the level of the core reinforcement; you only require
two cores for the connection.
Sensor Transmitter
mm (inch) mm (inch)
a* = 160 (6.3") a* b* a* a* = 90 (3.54")
b* = 20 (0.79") c b b = 70 (2.76")
c = 70 (2.76") d c c = 50 (1.97")
d = 50 (1.97") e f A d e d = 10 (0.39")
e = 8 (0.31") e = 8 (0.31")
f = 10 (0.39")
m B m
m m
m m
a0008172
40 Endress+Hauser
3.2.2 Promag H connecting cable


Sensor Transmitter
mm (inch) mm (inch)
a = 80 (3.15") a = 80 (3.15")
b = 15 (0.59") a a b = 50 (1.97")
c = 17 (0.67") c c = 17 (0.67")
b A b c
d = 8 (0.31") d d = 8 (0.31")
e = 1 (0.04")
d
B m
n m
n
n m
e GND n
n GND m
m n
n
a0008173

Sensor Transmitter
mm (inch) mm (inch)
a = 70 (2.76") a a a = 70 (2.76")
b = 40 (1.57") b = 50 (1.97")
c = 15 (0.59")
b b c = 10 (0.39")
d = 8 (0.31")
d c A c d d = 8 (0.31")
B m
m m
m m
a0008175
Endress+Hauser 41
3.2.3 Connecting cable connection
A B S1 E1 E2 S2GND E S
ht unter Spannun
Nic öffnen g
6 5 7 8 4 37 36 42 41
Ke ircuits are alive e

l
over tight whi
c
p cover tight w
ep c
ve
c

pas ou r l’appa
vri
b c
b c
a
b c b c b c
n.c. n.c. n.c.
b 5 7 4 37 42 41
E1 E2 GNDE
C D E
A0008180
A Transmitter housing on connection housing, remote version

B Wall-mount housing on connection housing, remote version
C Sensor connection housing, remote version for Promag E/L/P/W

D Sensor connection housing, remote version for Promag H, DN 25 (1")
E Sensor connection housing, remote version for Promag H, DN 40 (1½")
a Ground terminals (are provided for potential equalization connection)

b Coil circuit connecting cable
c Signal circuit connecting cable (electrodes)
n.c. = not connected, isolated cable shields
Cable colors for terminal numbers:

5/6 = brown
7/8 = white
4 = green
36/37 = yellow
42 Endress+Hauser
3.3 Potential equalization

Perfect measurement is only ensured when the medium and the sensor have the same electrical
potential. Most sensors have a reference electrode installed as standard, which guarantees the
required potential connection. This usually means that the use of ground disks or other
measures are unnecessary.
• Promag E/L/P/W
Reference electrode available as standard.
• Promag H
– No reference electrode available. There is always an electrical connection to the fluid via the
metal process connection.
– In the case of plastic process connections, potential equalization must be ensured through
the use of grounding rings.
Standard situation
Potential equalization takes place via the ground terminal of the transmitter when using the
device in metal, grounded pipes.
A0004375
Note! Potential equalization for other areas of application  Operating Instructions on the
CD-ROM.
Endress+Hauser 43
3.4 Degree of protection

The devices meet all the requirements for IP 67.
After mounting in the field or service work, the following points have to be observed to ensure
that IP 67 protection is retained:
• Install the measuring device in such a way that the cable entries do not point upwards.
• Do not remove the seal from the cable entry.
• Remove all unused cable entries and plug them with suitable/certified drain plugs.
• Use cable entries and drain plugs with a long-term operating temperature range in
accordance with the temperature specified on the nameplate.
A0007549 A0007550
Tighten the cable entries correctly. The cables must loop down before they enter the
cable entries ("water trap").
3.5 Post-connection check

• Are cables or the device damaged (visual inspection)?
• Does the supply voltage match the information on the nameplate?
• Do the cables used comply with the necessary specifications?
• Do the mounted cables have adequate strain relief and are they routed securely?
• Is the cable type route completely isolated? Without loops and crossovers?
• Only remote version:
- Is the flow sensor connected to the matching transmitter electronics?
- Is the connecting cable between sensor and transmitter connected correctly?
• Are all screw terminals firmly tightened?
• Have all the measures for grounding and potential equalization been correctly implemented?
• Are all cable entries installed, firmly tightened and correctly sealed?
• Cable routed as a "water trap" in loops?
• Are all the housing covers installed and securely tightened?
In addition, for measuring devices with fieldbus communication:
• Are all the connecting components (T-boxes, junction boxes, connectors, etc.) connected with
each other correctly?
• Has each fieldbus segment been terminated at both ends with a bus terminator?
• Has the max. length of the fieldbus cable been observed in accordance with the specifications?
• Has the max. length of the spurs been observed in accordance with the specifications?
• Is the fieldbus cable fully shielded and correctly grounded?
44 Endress+Hauser
Proline Promag 50 Hardware settings
4 Hardware settings
This section only deals with the hardware settings needed for commissioning. All other settings
(e.g. output configuration, write protection, etc.) are described in the associated Operating
Note! No hardware settings are needed for measuring devices with HART or FOUNDATION
Fieldbus-type communication.
4.1 Device address

Has to be set for measuring devices with the following communication methods:
• PROFIBUS DP/PA
The device address can be configured via:
• Miniature switches  see description below
• Local operation  see Software settings section  ä 52
Addressing via miniature switches
# Warning!
Risk of electric shock! Risk of damaging the electronic components!
• All the safety instructions for the measuring device must be observed and all the warnings
heeded  ä 38.
• Use a workspace, working environment and tools purposely designed for electrostatically
sensitive devices.
# Warning!
Switch off the power supply before opening the device.
a. Loosen the cheese head screw of the securing clamp
O
N
with an Allen key (3 mm)
b. Unscrew cover of the electronics compartment from
1 E
2 W
3
4
O
N
1 E
2 W
3
4
O
N
1 E
2 W
3
the transmitter housing.

4
c. Loosen the securing screws of the display module

and remove the onsite display (if present).
d. Set the position of the miniature switches on the
I/O board using a sharp pointed object.
c
Installation is the reverse of the removal procedure.
O
N
1 E
2 W
3
4 O
N
a 1 E
2 W
3
4 O
N
d
1 E
b
2 W
3
4
A0007551
Endress+Hauser 45
Hardware settings Proline Promag 50
PROFIBUS
Device address range: 0 to 126

Factory setting: 126
DP PA
OFF ON OFF ON a. Miniature switches for device address
1 1 1 Example shown:
1+16+32 = device address 49
2 2 2 b. Miniature switches for the address mode (method
c
3 4 3 of addressing):
4 8 4 – OFF (factory setting) = software addressing via
a
local operation/operating program
1 16 1 1 – ON = hardware addressing via miniature
2 32 2 2 switches
c. Miniature switches not assigned.
3 64 3 4
4 b 4 8 a
1 1 16
2 2 32
c
3 3 64
4 4 b
OFF ON OFF ON
A0007552
46 Endress+Hauser
4.2 Terminating resistors

Note! If the measuring device is used at the end of a bus segment, termination is required.
This can be performed in the measuring device by setting the terminating resistors on the
I/O board. Generally, however, it is recommended to use an external bus terminator and not
perform termination at the measuring device itself.
• PROFIBUS DP
– Baudrate 1.5 MBaud  Termination can be performed at the measuring device, see
graphic
– Baudrate > 1.5 MBaud  An external bus terminator must be used
# Warning!
heeded  ä 38.
sensitive devices.
Setting the terminating switch SW1

on the I/O board:
ON - ON - ON - ON
O
N
1 E
2 W
3
4
O
N
1 E
2 W
3
4
O
N
1 E
2 W
3
4
+5V
SW 1 390 W
1
2
3
4
O
N
E
W
1
2
1
2
3
4
O
N
E
W
220 W
3
O
N
1 E
2 W
3
4 O
N
1 E
2 W
3
4
4
OFF ON 390 W
A0007556
Endress+Hauser 47
Commissioning Proline Promag 50
5 Commissioning
5.1 Switching on the measuring device
On completion of the installation (successful post-installation check), wiring (successful
post-connection check) and after making the necessary hardware settings, where applicable,
the permitted power supply (see nameplate) can be switched on for the measuring device.
When the power supply is switched on, the measuring device performs a number of power-up
checks and device self-checks. As this procedure progresses the following messages can appear
on the onsite display:
Display examples:
PROMAG 50 Start-up message
START-UP
Æ
DEVICE SOFTWARE Displays the current software
V XX.XX.XX
Æ
SYSTEM OK Beginning of operation
OPERATION
The measuring device starts operating as soon as the startup procedure is complete.
Various measured values and/or status variables appear on the display.
Note! If an error occurs during startup, this is indicated by an error message.

The error messages that occur most frequently when a measuring device is commissioned
are described in the Troubleshooting section  ä 52.
48 Endress+Hauser
Proline Promag 50 Commissioning
5.2 Operation
5.2.1 Display elements
Display lines/fields
3 4 1. Main line for primary measured values
2. Additional line for additional measured
variables/status variables
1 +48.25 xx/yy 3. Current measured values
4. Engineering units/time units
2 +3702.6 x
A0007557
5.2.2 Operating elements
Operating keys
Esc
1. (–) Minus key for entering, selecting
- + E 2. (+) Plus key for entering, selecting
3. Enter key for calling the function matrix, saving
When the +/– keys are pressed simultaneously
1 2 3 (Esc):
• Exit the function matrix step-by-step:
A0007559
• > 3 sec. = cancel data input and
return to the measured value display
5.2.3 Displaying error messages
1. Type of error:
P = Process error, S = System error
1 P XXXXXXXXXX 5 2. Error message type:
$ = Fault message, ! = Notice message
2 #000 00:00:05 3. Error number
4. Duration of the last error that occurred:
Hours: Minutes: Seconds
3 4 5. Error designation
List of all error messages, see associated
A0007561
Operating Instructions on the CD-ROM
Endress+Hauser 49
5.3 Navigating within the function matrix
Esc
Esc Esc
- + E >3s
q – + r – +
m E
o
E E E E E
– + p
q
+
n –
A0007562
1. F Enter the function matrix (starting with measured value display)

2. P Select the group (e.g. OPERATION)
F Confirm selection
3. NSelect function (e.g. LANGUAGE)
4. P Enter code 50 (only for the first time you access the function matrix)
F Confirm entry
P Change function/selection (e.g. ENGLISH)

5. Q Return to measured value display step by step
6. Q > 3 s Return immediately to measured value display
50 Endress+Hauser
5.4 Calling the Commissioning Quick Setup

All the functions needed for commissioning are called up automatically with the Quick Setup.
The functions can be changed and adapted to the process in question.
2. P Select the group QUICK SETUP
3. QUICK SETUP COMMISSIONING function appears.
4. Intermediate step if configuration is blocked:
P Enter the code 50 (confirm with F ) and thus enable configuration
5. P Go to Commissioning Quick Setup
6. P Select YES
7. F Start Commissioning Quick Setup
8. Configure the individual functions/settings:
– Via P-key, select option or enter number
– Via F-key, confirm entry and go to next function
– Via Q-key, return to Setup Commissioning function
(settings already made are retained)
Note! Observe the following when performing the Quick Setup:
• Configuration selection: Select the ACTUAL SETTING option
• Unit selection: This is not offered again for selection after configuring a unit
• Output selection: This is not offered again for selection after configuring an output
• Automatic configuration of the display: select YES
– Main line = Mass flow
– Additional line = Totalizer 1
– Information line = Operating/system conditions
• If asked whether additional Quick Setups should be executed: select NO
All the available functions of the measuring device and their configuration options as well as
additional Quick Setups, if available, are described in detail in the "Description of Device
Functions" Operating Instructions. The related Operating Instructions can be found on the
CD-ROM.
The measuring device is ready for operation on completion of the Quick Setup.
Endress+Hauser 51
5.5 Software settings

5.5.1 Device address
• PROFIBUS DP/PA  device address range 0 to 126, factory setting 126
• Miniature switches  see Hardware settings  ä 45
• Local operation  see description below
Note! The COMMISSIONING SETUP must be executed before setting the device address.
Calling the Communication Quick Setup

3. N Select the QUICK SETUP COMMUNICATION function
4. Intermediate step if configuration is blocked: P Enter the code 50
(confirm with F ) and thus enable the configuration
5. P Go to Communication Quick Setup
6. P Select YES; F confirm selection
7. F Start Communication Quick Setup
CD-ROM.
5.6 Troubleshooting
A complete description of all the error messages is provided in the Operating Instructions on the
CD-ROM.
Note! The output signals (e.g. pulse, frequency) of the measuring device must correspond to the
higher-order controller.
52 Endress+Hauser
Endress+Hauser 53
54 Endress+Hauser
Endress+Hauser 55
www.addresses.endress.com
1
Flow Calibration with Adjustment

21522151-4144899
¸
3034509811 FCP-6.9
Purchase order number Calibration rig
FI-3005791099-10 / Endress+Hauser Flowtec AG 2.45437 l/s ( ≙ 100%)

Order Nº/Manufacturer Calibrated full scale
50P25-EA0A1AA0AFAA Service interface

Order code Calibrated output
PROMAG 50 P DN25 0.8218

Transmitter/Sensor Calibration factor
M61B0619000 0
Serial Nº Zero point
EGB001 - 001.F001 31.7 °C

Tag Nº Water temperature
Flow Flow Duration V target V meas. ∆ o.r.* Outp.** Measured error % o.r.
[%] [l/s] [s] [l] [l] [%] [mA] Tolerance limit: ±0.5% o.r.* ± Zero stability
40.4 0.99264 60.2 59.755 59.762 0.01 10.47 1.5
40.5 0.99295 60.2 59.774 59.765 -0.02 10.47

1
99.2 2.4343 60.2 146.533 146.568 0.02 19.87
- - - - - - - 0.5
- - - - - - - 0
- - - - - - -
- - - - - - - -0.5
- - - - - - - -1
- - - - - - -
- - - - - - - -1.5
*o.r.: of reading 0 10 20 30 40 50 60 70 80 90 100 [%]

**Calculated value (4 - 20 mA) Flow
For detailed data concerning output specifications of the unit under test, see Technical Information (TI), chapter Performance characteristics.
Traceability to the national standard for all test instruments used for the calibration is guaranteed.
Endress+Hauser Flowtec operates ISO/IEC 17025 accredited calibration facilities in Reinach (CH), Cernay (FR), Greenwood (USA),
Aurangabad (IN), Suzhou (CN) and Itatiba (BR).
02.08.2017 S. Most
Date of calibration Operator
Endress+Hauser Flowtec AG Certified acc. to

Rue de l'Europe 35 / Kägenstrasse 7 ISO 9001
F-68700 Cernay / CH-4153 Reinach
Page 1 / 1
Parameter Setting
21412700-4144899
¸
3034509811 PROMAG 50 P
Purchase order number Transmitter/Sensor
3005791099-10 / Endress+Hauser Flowtec AG DN25

Order Nº/Manufacturer Nominal diameter
50P25-EA0A1AA0AFAA EGB001 - 001.F001

Order code Tag Nº
M61B0619000
Serial Nº
The below parameters are set according to your order.

Please refer to the Operating Manual for any parameters not mentioned.
Communication type HART

Device software V2.04.00
Device revision Dev.9/DD.1 [ID 41 (hex)]
Device address 0
Units
Unit volume flow dm³/min
Unit volume dm³
User interface
Assign line 1 Volume flow
Assign line 2 Totalizer 1
Totalizer
Unit volume totalizer 1 dm³
Assign totalizer 1 Volume flow
Current output 1
Assign current output Volume flow
Current span 4-20 mA HART NAMUR
Value 20 mA 75 dm³/min
Time constant 3s
Failsafe mode Minimum current
02.08.2017
Date
Endress+Hauser Flowtec AG
Rue de l'Europe 35 / Kägenstrasse 7
Page 1 / 2
Parameter Setting
21412700-4144899
¸
Pulse output 1
Assign pulse Volume flow
Pulse value 0.5 dm³
Pulse width 100 ms
Output signal passive/positive
Failsafe mode Fallback value
02.08.2017
Date
Page 2 / 2
1

21522078-4144900
¸
3034509811 FCP-6.9


PROMAG 50 P DN25 0.8195

M61B0719000 -1
EGB001 - 002.F001 31.5 °C

40.0 0.98262 60.2 59.149 59.144 -0.01 10.41 1.5
40.1 0.98311 60.2 59.179 59.184 0.01 10.41

1
100.9 2.4767 60.2 149.097 149.137 0.03 20.15
- - - - - - - 0.5
- - - - - - - 0
- - - - - - -
- - - - - - - -0.5
- - - - - - - -1
- - - - - - -
- - - - - - - -1.5
*o.r.: of reading 0 10 20 30 40 50 60 70 80 90 100 [%]

02.08.2017 S. Most

Page 1 / 1
Parameter Setting
21412605-4144900
¸
3034509811 PROMAG 50 P

50P25-EA0A1AA0AFAA EGB001 - 002.F001

Order code Tag Nº
M61B0719000
Serial Nº


Device address 0
Units
Unit volume dm³
User interface
Totalizer
Current output 1
Time constant 3s
02.08.2017
Date
Page 1 / 2
Parameter Setting
21412605-4144900
¸
Pulse output 1
Pulse width 100 ms
02.08.2017
Date
Page 2 / 2
1

21522067-4144901
¸
3034509811 FCP-6.9


PROMAG 50 P DN25 0.8248

M61B0819000 -8
EGB001 - 003.F001 31.5 °C

40.2 0.98689 60.2 59.411 59.411 0.00 10.43 1.5
40.2 0.98746 60.2 59.440 59.438 0.00 10.44

1
99.0 2.4306 60.2 146.319 146.345 0.02 19.85
- - - - - - - 0.5
- - - - - - - 0
- - - - - - -
- - - - - - - -0.5
- - - - - - - -1
- - - - - - -
- - - - - - - -1.5
*o.r.: of reading 0 10 20 30 40 50 60 70 80 90 100 [%]

02.08.2017 S. Most

Page 1 / 1
Parameter Setting
21412653-4144901
¸
3034509811 PROMAG 50 P

50P25-EA0A1AA0AFAA EGB001 - 003.F001

Order code Tag Nº
M61B0819000
Serial Nº


Device address 0
Units
Unit volume dm³
User interface
Totalizer
Current output 1
Time constant 3s
02.08.2017
Date
Page 1 / 2
Parameter Setting
21412653-4144901
¸
Pulse output 1
Pulse width 100 ms
02.08.2017
Date
Page 2 / 2
1

21522138-4144902
¸
3034509811 FCP-6.9


PROMAG 50 P DN25 0.8222

M61B0919000 4
EGB001 - 004.F001 31.8 °C

40.1 0.98344 60.2 59.201 59.199 0.00 10.41 1.5
40.1 0.98420 60.2 59.247 59.242 -0.01 10.42

1
99.2 2.4340 60.2 146.517 146.516 0.00 19.87
- - - - - - - 0.5
- - - - - - - 0
- - - - - - -
- - - - - - - -0.5
- - - - - - - -1
- - - - - - -
- - - - - - - -1.5
*o.r.: of reading 0 10 20 30 40 50 60 70 80 90 100 [%]

02.08.2017 S. Most

Page 1 / 1
Parameter Setting
21412659-4144902
¸
3034509811 PROMAG 50 P

50P25-EA0A1AA0AFAA EGB001 - 004.F001

Order code Tag Nº
M61B0919000
Serial Nº


Device address 0
Units
Unit volume dm³
User interface
Totalizer
Current output 1
Time constant 3s
02.08.2017
Date
Page 1 / 2
Parameter Setting
21412659-4144902
¸
Pulse output 1
Pulse width 100 ms
02.08.2017
Date
Page 2 / 2
SD00115D/06/EN/15.14 Products Solutions Services
71249502
Valid as of version
V 02.00.zz (device software)
Functional Safety Manual

Proline Promag 50, 53
with 4 to 20 mA output signal
Application Your benefits

Monitoring of maximum and/or minimum flow in systems
• For flow monitoring (Min., Max., range) up to SIL 2 –
which are required to comply with particular safety system
independently assessed (Functional Assessment) by
requirements as per IEC/EN 61508 and IEC/EN 61511-1.
exida.com as per IEC/EN 61508 and IEC/EN 61511-1
The measuring device fulfils the requirements concerning: • Continuous measurement
• Functional safety as per IEC/EN 61508 and IEC/EN 61511-1 • Measurement is virtually independent of product properties
• Explosion protection (depending on the version) • Permanent self-monitoring
• Electromagnetic compatibility as per EN 61326-3-2 and • Easy installation and commissioning
NAMUR recommendation NE 21 • Proof test possible without removal of the measuring device
Table of contents
SIL Declaration of Conformity . . . . . . . . . . . . . . . . . . . . .3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Depiction of a safety system (protection function) . . . . . . . . . . 4
Measuring system layout with Promag 50, 53 . . . . . . .5

System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety function data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Supplementary device documentation . . . . . . . . . . . . . . . . . . . . 5
Settings and installation instructions . . . . . . . . . . . . . .6

Setting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Monitoring options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Setting instructions for evaluation unit . . . . . . . . . . . . . . . . . . . 7
Response in operation and failure . . . . . . . . . . . . . . . . . . . . . . . . 8
Information on the useful lifetime of electric components . . . 8
Proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Proof test of the measuring system . . . . . . . . . . . . . . . . . . . . . . . 9
Exida Management Summary . . . . . . . . . . . . . . . . . . . 11
Appendix (safety-related characteristic values) . . . 15

Introductory comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Endress+Hauser
SIL Declaration of Conformity
Antoine Simon
Kägenstrasse 7, 4153 Reinach
SIL Declaration of Conformity Promag 50/Promag 53

Functional Safety of a flow measuring device according to IEC 61508/IEC 61511
Endress+Hauser Flowtec AG, Kägenstrasse 7, 4153 Reinach

declares as manufacturer, that the flow measuring devices
Promag 50 (420 mA) and Promag 53 (420 mA)
are suitable for the use in a safety instrumented system up to SIL 2 according to IEC 61511-1 und IEC 61508 if the
installation is conform to the safety manual and if enclosed safety instructions are observed.
The FMEDA with analysis of the safety critical and dangerous faults provides under the assumption of a functional
test cycle of two years the following parameters for the worst case of the tested configurations:
SIL (Safety Integrity Level) : 2

HFT (Hardware Fault Tolerance) : 0 1)
Device Type : Type B (complex component)
SFF (Safe failure fraction) : >76%

PFDAVG (Average Probability of Failure on Demand)2) : ô1.29 · 10-3 p.a.
Failure rates according to IEC 61508, based on the worst case configuration:
Odu (failure rate dangerous undetected failures) : 295 · 10-9/h (295 FIT)
Odd (failure rate dangerous detected failures) : 756 · 10-9/h (756 FIT)
Osu (failure rate safe undetected failures) : 265 · 10-9/h (265 FIT)
Osd (failure rate safe detected failures) : 0 · 10-9/h (0 FIT)
1) According to clause 11.4 of IEC 61511-1

2) The PFDAVG values are also within the range for SIL 2 according to ISA S84.01.
The assessment of the proven-in-use demonstration covers the device and its software (as of software version
V2.00.00 (amplifier), and 1.04.00 (communication module)) including the modification process.
Reinach, 05.10.2006
FEE/SA
SIL2-50-53-Conformity-en.pdf
Endress+Hauser 3
Introduction
Depiction of a safety system The following tables define the achievable Safety Integrity Level (SIL) or the requirements regarding
(protection function) the "Average Probability of Failure on Demand" (PFDAVG), the "Hardware Fault Tolerance" (HFT) and the
"Safe Failure Fraction" (SFF) of the safety system. The specific values for the Promag measuring system
can be found in the tables in the appendix.
In general, the following permitted failure probability of the complete safety function applies,
depending on the SIL for systems which must react on demand - e.g. a defined max. flow exceeded -
(Source: IEC 61508, Part 1):
SIL PFDAVG
4  10–5 to < 10–4
3 10–4 to < 10–3
2 10–3 to < 10–2
1 10–2 to < 10–1
The following table shows the achievable SIL as a function of the safe failure fraction and the hardware
fault tolerance of the complete safety system for type B systems (complex components, for definition
see IEC 61508, Part 2):
SFF HFT
0 1 (0)1) 2 (1)1)
< 60% Not permitted SIL 1 SIL 2

60 % to < 90 % SIL 1 SIL 2 SIL 3
90 % to < 99 % SIL 2 SIL 3
99 % SIL 3
1) In accordance with IEC 61511-1 (section 11.4.41 ), the HFT can be reduced by one (values in brackets)
if the devices used meet the following conditions:
- The device is proven in use
- Only process-relevant parameters can be changed at the device (e.g. measuring range, … )
- Changing the process-relevant parameters is protected (e.g. password, jumper, … )
- The function requires less than SIL 4
The Promag measuring system meets these conditions.
The measuring device can be used in safety relevant SIL 2 loop. In a safety relevant SIL 3 loop the
measuring device must be used in addition to a different measuring principle. Two Promag in
homogenous redundancy do not fulfill the SIL 3 requirements.
! Note!
General information on functional safety (SIL) is available at:
www.de.endress.com/SIL and in Competence Brochure CP002Z "Functional Safety in the Process
Industry - Risk Reduction with Safety Instrumented Systems" (available in the download section of the
Endress+Hauser website: www.endress.com  Download  Document code: CP002Z).
4 Endress+Hauser
Measuring system layout with Promag 50, 53

System components
1 2 3
A0015443
System components
1 Pump
2 Measuring device
3 Valve
4 Automation system
An analog signal (4–20 mA) proportional to the flow rate is generated in the transmitter. This is sent
to a downstream automation system where it is monitored to determine whether it falls below or
exceeds a specified limit value.
! Note!
• The safety-related signal is the 4 to 20 mA analog output signal of the measuring device. All safety
functions refer exclusively to current output 1.
• The measuring device must be protected against unauthorized access see "Locking" section
( ä 7).
• The application program in the safety automation system is designed in such a way that "fail high"
and "fail low" failures are detected by the safety function regardless of the effect (safe or dangerous).
• If communication also takes place via the HART protocol in the Promag 53 measuring device, HART
write protection must be activated see "Locking" section ( ä 7).
The characteristic values determined (see appendix) apply only to the current output (4 to 20 mA) of
the following versions:
• Promag 50***–***********(*)
(*) = Order option for inputs/outputs: A / W / D / S / T
• Promag 53***–***********(*)
(*) = Order option for inputs/outputs: A / B / C / L / M / S / T / 2 / 4
Safety function data The mandatory settings and safety function data emanate from the section "Settings and installation
instructions" ( ä 6) and the appendix ( ä 15). The measuring system's response time is 2 s. The
monitoring function's alarm delay does not start until after this.
! Note!
8 hours is set for the time between when the failure occurs and the failure is eliminated (MTTR).
Supplementary device The following documentation must be available for the measuring system:
documentation
Device type Operating Instructions Description of the device functions
Promag 50 BA00046D/06 BA00049D/06
Promag 53 BA00047D/06 BA00048D/06
This document also includes information on application limits and ambient conditions as well as the
functional specifications of the current output.
For devices with an explosion protection approval, the corresponding Safety Instructions (XA) or
Control Drawings (ZD) must also be observed.
Endress+Hauser 5
Settings and installation instructions

Installation instructions Instructions for the correct installation of the measuring device can be found in the Operating
Instructions (BA) supplied see "Further applicable device documentation" ( ä 5).
Suitability of the measuring device

Carefully select the nominal diameter of the measuring device in accordance with the application's
expected flow rates. The maximum flow rate during operation must not exceed the specified maximum
value for the sensor. In safety-related applications, it is also recommended to select a limit value for
monitoring the minimum flow rate that is not smaller than 5 % of the specified maximum value of the
sensor.
The measuring device must be used correctly for the specific application, taking into account the
medium properties and ambient conditions. Carefully follow instructions pertaining to critical process
situations and installation conditions from the device documentation.
Avoid applications that cause buildup or corrosion in the measuring pipe.
In general, there are no specific requirements for single-phase, liquid media with properties similar to
those of water.
! Note!
Please contact your Endress+Hauser sales office for further information.
Setting instructions The measuring device can be configured in various ways in process control protection systems:
• Via onsite operation (LCD display)
• Via HART handheld terminal DXR 375
• Via PC (remote operation) using service and configuration software (e.g. "FieldCare")
The tools mentioned can also be used to retrieve information on the software and hardware revision
of the device.  ä 5Further instructions on the settings can be found in the corresponding Operating
Instructions see "Supplementary device documentation" ().
Monitoring options The measuring device can be used in protective systems to monitor the volume flow (Min., Max. and
range):
! Note!
The device must be correctly installed to guarantee safe operation.
4 Min. Max. 20 [mA]
A0015277
Monitoring options in protective systems

A Min. alarm
B Max. alarm
C Range monitoring
= Safety function activated
= Permitted operating status
6 Endress+Hauser
The following table shows the settings which are necessary to use the measuring device in a safety-
related application. The settings refer to the 4 to 20 mA output value of the current output which
corresponds to the flow value.
Group Name of function in the group Allowed setting when Promass is used for a
safety function
CURRENT OUTPUT ASSIGN CURRENT OUTPUT Volume flow
CURRENT OUTPUT CURRENT SPAN – 4–20 mA (………):

All settings with a current output
configuration to 4-20 mA.
– 0…20 mA:
Setting is not allowed.
Promag 50
All configuration options 4 to 20 mA with HART
communication are not permitted.
Promag 53
communication are only permitted if HART
write protection is activated ( ä 7, "Locking"
section)
CURRENT OUTPUT FAILSAFE MODE – Min. current

– Max. current
CURRENT OUTPUT SIMULATION CURRENT OFF

SYSTEM PARAMETER POSITIVE ZERO RETURN OFF
SUPERVISION ASSIGN SYSTEM ERROR OFF

(the assignment of information messages and
fault messages may not be changed)
SUPERVISION ALARM DELAY 0…20 s
SIMULATION SYSTEM SIMULATION FAILSAFE MODE OFF
SIMULATION SYSTEM SIMULATION MEASURAND OFF
A detailed description of the functions of the device can be found in the appropriate "Description of
Device Functions" see "Further applicable device documentation" ( ä 5).
Locking In order to protect the process relevant parameters against change, the software has to be locked.
This is done via a code set by the customer.
Software lock for local programming

Function DEFINE PRIVATE CODE Freely choosable code number (except for 0)
Promass 53:
When using HART communication, the HART write protection must be activated. This can be done
with the aid of a jumper on the I/O board. Please refer to the appropriate Operating Instructions for the
correct procedure to activate the HART write protection see "Further applicable device
documentation" ( ä 5).
Setting instructions for The determined limit value (mA value corresponding to chosen max. and/or min. flow) must be
evaluation unit entered at the subsequent limit contactor (automation system). For all adjustment and setting
procedures, please refer to the relevant Operating Instructions see "Further applicable device
Endress+Hauser 7
Response in operation and The response in operation and failures is described in the Operating Instructions of the device
failure see "Further applicable device documentation" ( ä 5).
! Note!
• Repair: The repair of the devices must principally be performed by Endress+Hauser.
Is the repair carried out by other people, the safety related functions can no longer be assured.
Exception: The replacement of modular components by original spare parts is permitted by qualified
personnel of the customer, if trained by Endress+Hauser for this purpose.
• A failure of a SIL marked Endress+Hauser product, which was operated in a safety instrumented
system, shall be reported to [email protected] including product type, serial number and description
of the failure.
Device failures must be reported to the manufacturer. The user provides a detailed statement to the
manufacturer describing the failure and any possible effects. There is also information flow as to
whether this is a dangerous failure or a failure which cannot be detected directly.
• If a SIL-type Endress+Hauser device which was used in a protective function fails, the "Declaration of
contamination and cleaning" must be enclosed with a note specifying "Use as SIL device in a
protective system" when returning the defective device.
Information on the useful The established failure rates of electrical components apply within the useful lifetime as per IEC/
lifetime of electric EN 61508-2, section 7.4.7.4, note 3.
components
! Note!
The manufacturer and plant owner/operator must take appropriate measures to achieve a longer
service life as per DIN EN 61508-2, note NA4.
8 Endress+Hauser
Proof test
Proof test of the measuring Check the operativeness of safety functions at appropriate intervals. The operator must determine the
system checking interval and take this into account when determining the probability of failure PFDavg of the
sensor system.
! Note!
In a single-channel architecture, the PFDavg value to be used depends on the diagnostic coverage of the
proof test (PTC = Proof Test Coverage) and the intended lifetime (LT = Lifetime) in accordance with
the following formula:
PFDavg ≈ ldu . [ PTC/2 . Ti + (1 – PTC )/2 . LT ]

A0015275
The functional test must be carried out in such a way that it verifies correct operation of the safety
device in conjunction with all of the other components. Each test must be fully documented.
The accuracy of the measured value must first be checked in order to test the safety function (Min.,
Max., range). This involves approaching the configured limit values upon which the safety function
(including actuator) should be activated. Checking the accuracy of the measured values is sufficient in
order to test the "Range" safety function.
During the proof test, alternative monitoring measures must be taken to ensure process safety.
A proof test of the device can be performed in the following steps:
1. Checking the digital measured value
One of the following tests must be carried out depending on the measured variable to be
monitored and the available equipment:
a. Test sequence A – Checking the digital measured value with a calibration rig
Volume flow
The measuring device is recalibrated using a calibration rig that is certified in accordance with
ISO 17025. This can be done on an installed device using a mobile calibration rig or using
factory calibration if the device has been disassembled. The amount of deviation between the
measured flow rate and the set point must not exceed the maximum measured error specified
in the Operating Instructions.
! Note!
Please contact your Endress+Hauser sales office for further information on standard methods
for on-site calibration of flowmeters.
b. Test sequence B – Checking the digital measured value using the installed totalizer
Volume flow
A calibrated measuring vessel is filled with the medium at a flow rate which approximately
corresponds to the limit value to be monitored. The change in the volume in the measuring
vessel is read off before and after filling and compared with the totalizer installed in the
measuring device. The amount of deviation must not exceed the maximum measured error
specified in the Operating Instructions. For range monitoring, this test must be carried out
separately for the upper and lower limit value.
c. Test sequence C – Checking the digital measured value using Fieldcheck
Volume flow
Verification of the measuring device in an installed state with Fieldcheck as described in
Operating Instructions BA00067D/06. Fieldcheck displays the test results (passed/failed)
automatically.
This test can be carried out without removal of the flowmeter and makes periodic inspection
easier. The high diagnostic coverage means that > 90 % of undetected failures are detected
whereby the level of increase in the average probability of failure PFDAVG is lower than
without the check ( graphic below). The average probability of failure PFDAVG can be
estimated using the formula for this ( ä 9) and taking into account the intended lifetime t.
When used in conjunction with the "FieldCare" software package, test results can be imported
into a database, printed and used as verification for the relevant certification body.
Endress+Hauser 9
SIL 1
ck
he
PFD
tc
SIL 2 PFD avg
ou
th
wi
heck
riodic c
with pe
SIL 3
Checking interval Ti Operating time LT

A0015615-EN
Single-channel system architecture 1oo1
2. Checking the 4–20 mA current output

Using the current simulation (fixed current value) option available in the operating menu, set the
current output of the device to the values 3.6 mA, 4.0 mA, 20.0 mA and 22.0 mA one after
another and compare with the measured values of a calibrated, external current measuring
device.
3. Checking the safety function

Correct activation of the safety function - including actuator - must be checked by outputting
suitable current values on the 4–20 mA interface per current simulation (just below and above
the switch point). For range monitoring, this test must be carried out separately for the upper and
lower limit value.
4. Completing the proof test

Switch the 4–20 mA current output to measured value output (if necessary).
! Note!
The proof test is only completed when steps 1 to 4 are accomplished.
98 % of dangerous, undetected failures are detected using test sequences 1a to 1b, whereas 90 % of
dangerous, undetected failures are detected using test sequence 1c. If one of the test criteria from the
test sequences described above is not fulfilled, the device may no longer be used as part of a protective
system.
The influence of systematic faults on the safety function are not covered by the test and must be
examined separately. Systematic faults can be caused, for example, by medium properties, operating
conditions, build-up or corrosion.
10 Endress+Hauser
Exida Management Summary
FMEDA and Proven-in-use Assessment
Project:
Electromagnetic Flow Measuring System PROMAG 50/53
Customer:
Reinach
Switzerland
Contract No.: E+H 06/02-03

Report No.: E+H 06/02-03 R039
Version V1, Revision R1, October 2006
Stephan Aschenbrenner
The document was prepared using best effort. The authors make no warranty of any kind and shall not be liable in
any event for incidental or consequential damages in connection with the application of the document.
© All rights on the format of this technical report reserved.
SIL2-50-53-Manag-Summary-Page1
Endress+Hauser 11
Management summary
This report summarizes the results of the hardware assessment with proven-in-use
consideration according to IEC 61508 / IEC 61511 carried out on the electromagnetic flow
measuring system PROMAG 50/53 with 4..20 mA HART® output and software version
02.00.00. The statements made in this report are also valid for further software versions as long
as the assessed IEC 61508 modification process is considered. Any changes are under the
responsibility of the manufacturer. Table 1 gives an overview of the different types that belong
to the considered electromagnetic flow measuring system PROMAG 50/53.
The hardware assessment consists of a Failure Modes, Effects and Diagnostics Analysis
(FMEDA). A FMEDA is one of the steps taken to achieve functional safety assessment of a
device per IEC 61508. From the FMEDA, failure rates are determined and consequently the
Safe Failure Fraction (SFF) is calculated for the device. For full assessment purposes all
requirements of IEC 61508 must be considered.
Table 1: Version overview
Version Type Commodul Options

V1 50***-***********W C03 Current
50***-***********A C03 Current + Frequency
50***-***********D C03 Current + Frequency + Status output + Status
input
V2 53***-***********C C05 Current + Frequency + 2 * Relays
53***-***********L C05 Current + 2 * Relays + Status input
53***-***********M C05 Current + 2*Frequency + Status input
53***-***********2 C05 Current + Current2 + Frequency + Relay
53***-***********4 C05 Current + Frequency + Current input + Relay
V3 53***-***********A C06 Current + Frequency
53***-***********B C06 Current + Frequency + 2 * Relays
V4 53***-***********S C07 Current active + Frequency passive
V5 53***-***********T C07 Current passive + Frequency passive
For safety applications only the 4..20 mA current output was considered. All other possible
output variants or electronics are not covered by this report. The different devices can be
equipped with or without display.
The failure rates used in this analysis are the basic failure rates from the Siemens standard
SN 29500.
According to table 2 of IEC 61508-1 the average PFD for systems operating in low demand
mode has to be t10-3 to < 10-2 for SIL 2 safety functions. A generally accepted distribution of
PFDAVG values of a SIF over the sensor part, logic solver part, and final element part assumes
that 35% of the total SIF PFDAVG value is caused by the sensor part.
For a SIL 2 application operating in low demand mode the total PFDAVG value of the SIF should
be smaller than 1,00E-02, hence the maximum allowable PFDAVG value for the sensor part
would then be 3,50E-03.
© exida.com GmbH e+h 06-02-03 r039 v1 r1.doc, October 4, 2006

Stephan Aschenbrenner Page 2 of 4
12 Endress+Hauser
The electromagnetic flow measuring system PROMAG 50/53 is considered to be a Type B1

sub-system with a hardware fault tolerance of 0.
Type B sub-systems with a SFF of 60% to < 90% must have a hardware fault tolerance of 1
according to table 3 of IEC 61508-2 for SIL 2 (sub-) systems.
As the electromagnetic flow measuring system PROMAG 50/53 is supposed to be a
proven-in-use sub-system, an assessment of the hardware with additional proven-in-use
demonstration was carried out. Therefore according to the requirements of IEC 61511-1 First
Edition 2003-01 section 11.4.4 and the assessment described in section 6 a hardware fault
tolerance of 0 is sufficient for SIL 2 sub- systems being Type B sub-systems and having a SFF
of 60% to < 90%.
The proven-in-use investigation was based on field return data collected and analyzed by
Endress+Hauser Flowtec AG.
According to the requirements of IEC 61511-1 First Edition 2003-01 section 11.4.4 and the
assessment described in section 6 the device is suitable to be used, as a single device, for
SIL 2 safety functions. The decision on the usage of proven-in-use devices, however, is always
with the end-user.
Endress+Hauser Flowtec AG performed a qualitative analysis of the mechanical parts of the
electromagnetic flow measuring system PROMAG 50/53 (see [D7]). This analysis was used by
exida to calculate the failure rates of the sensor elements using exidas experienced-based
data compilation for the different components of the sensor elements (see [R1]). The results of
the quantitative analysis were used for the calculations described in sections 5.1 to 5.6.
Assuming that the application program in the safety logic solver is configured to detect under-
range and over-range failures and does not automatically trip on these failures, these failures
have been classified as dangerous detected failures. The following tables show how the above
stated requirements are fulfilled.
2
Table 2: Summary for the worst case version Failure rates
Failure category Failure rates (in FIT)

Fail Dangerous Detected 756
3
Fail dangerous detected (internal diagnostics or indirectly ) 598
Fail high (detected by the logic solver) 7
Fail low (detected by the logic solver) 140
Annunciation detected 11
Fail Dangerous Undetected 295
Fail dangerous undetected 285
Annunciation undetected 10
No Effect 265
Not part 194
1
Type B sub-system: Complex sub-system (using micro controllers or programmable logic); for details see
7.4.3.1.3 of IEC 61508-2.
2
It is assumed that practical fault insertion tests can demonstrate the correctness of the failure effects assumed
during the FMEDAs.
3
indirectly means that these failure are not necessarily detected by diagnostics but lead to either fail low or fail high
failures depending on the transmitter setting and are therefore detectable.

Endress+Hauser 13
Table 3: Summary for the worst case version IEC 61508 Failure rates
OSD OSU 4 ODD ODU SFF DCS 5 DCD 3

0 FIT 265 FIT 756 FIT 295 FIT 77% 0% 71%
Table 4: Summary for the worst case version PFDAVG values

T[Proof] = 1 year T[Proof] = 5 years T[Proof] = 10 years
PFDAVG = 1,29E-03 PFDAVG = 6,43E-03 PFDAVG = 1,28E-02
The boxes marked in yellow ( ) mean that the calculated PFDAVG values are within the
allowed range for SIL 2 according to table 2 of IEC 61508-1 but do not fulfill the requirement to
not claim more than 35% of this range, i.e. to be better than or equal to 3,50E-03. The boxes
marked in green ( ) mean that the calculated PFDAVG values are within the allowed range for
SIL 2 according to table 2 of IEC 61508-1 and do fulfill the requirement to not claim more than
35% of this range, i.e. to be better than or equal to 3,50E-03. The boxes marked in red ( )
mean that the calculated PFDAVG values do not fulfill the requirements for SIL 2 according to
table 2 of IEC 61508-1.
The failure rates listed above do not include failures resulting from incorrect use of the
electromagnetic flow measuring system PROMAG 50/53, in particular humidity entering through
incompletely closed housings or inadequate cable feeding through the inlets.
The listed failure rates are valid for operating stress conditions typical of an industrial field
environment similar to IEC 60654-1 class C (sheltered location) with an average temperature
over a long period of time of 40ºC. For a higher average temperature of 60°C, the failure rates
should be multiplied with an experience based factor of 2,5. A similar multiplier should be used
if frequent temperature fluctuation must be assumed.
A user of the electromagnetic flow measuring system PROMAG 50/53 can utilize these failure
rates in a probabilistic model of a safety instrumented function (SIF) to determine suitability in
part for safety instrumented system (SIS) usage in a particular safety integrity level (SIL). A full
table of failure rates is presented in sections 5.1 to 5.6. along with all assumptions.
It is important to realize that the no effect failures are included in the safe undetected failure
category according to IEC 61508. Note that these failures on its own will not affect system
reliability or safety, and should not be included in spurious trip calculations.
The failure rates are valid for the useful life of the electromagnetic flow measuring system
PROMAG 50/53 (see Appendix 3).
4
Note that the SU category includes failures that do not cause a spurious trip
5
DC means the diagnostic coverage (safe or dangerous).

14 Endress+Hauser
Appendix (safety-related characteristic values)

Introductory comments Depending on the order code, Promag flow measuring systems are supplied with different signal inputs
and outputs. For the purposes of clarity, similar types of electronics modules are grouped into
categories.
! Note!
• The safety-related characteristic values are described separately for each of these categories see
sections "Category 1-7". The tables provided in these category sections contain all the important
characteristic values. The values apply to all possible applications:
• The failure rates indicated refer to the failure rates of Siemens Standard SN29500 at an ambient
temperature of +40 °C (+104 °F).
Measuring system / Outputs and inputs Category

electronics  ä 16
Product structure
Promag 50
50 *** – ***********W Curr. outp. 1
50 *** – ***********A Curr. outp. / freq. outp. 1
50 *** – ***********D Curr. outp. / frequency outp. / status outp. / status inp. 1
50 *** – ***********S Current outp. active (Ex i) / frequency outp. passive (Ex i) 6
50 *** – ***********T Current outp. passive (Ex i) / frequency outp. passive (Ex i) 7
Promag 53
53 *** – ***********C Curr. outp. / frequency outp. / relay / relay 2 2
53 *** – ***********L Curr. outp. / relay / relay 2 / status inp. 2
53 *** – ***********M Curr. outp. / frequency outp. / frequency outp. 2 / status inp. 2
53*** – ***********2 Curr. outp. / curr. outp. 2 / frequency outp. / relay 2
53*** – ***********4 Curr. outp. / frequency outp. / relay / curr. inp. 2
53 *** – ***********B Curr. outp. / frequency outp. / relay / relay 2 3
• ATEX II2G/D, FM/CSA Cl.1 Div.1, TIIS and NEPSI are available options for Promag H/P/W
• ATEX II3G/D is an available option for Promag E/H/P/W
• FM/CSA Cl.1 Div.2 is an available option for Promag D/E/H/L/P/W
Comments on the term "dangerous undetected failures"

Situations in which the process does not respond to a demand (i.e. the measuring device does not
demonstrate the predefined failsafe mode) or in which the output signal deviates more than the total
measured error as specified. Please refer to the "Performance characteristics" section of the Operating
Instructions for more detailed information on the total measured error.
The following presumptions are made:
• The failure rates are constant, wear out mechanisms are not included.
• Failure propagation is not relevant.
• The HART protocol is only used to read out data during normal operation.
• The recovery time after a safe failure is 8 hours.
• The test time of the automation system to react to a detected failure is one hour.
• All modules are operated in the "low demand mode".
• Only current output 1 is used for safety-related applications.
• Failure rates of the external power supply are not included.
• The stress levels are average values for an industrial environment and can be compared to the
"Ground Fixed" classification of MIL-HDBK-217F. Alternatively, the presumed environment is similar
to IEC 60654-1, Class C (protected mounting location) with temperature limits within the
manufacturer's specifications and an average temperature of +40 °C (+104 °F) for the transmitter
over an extended period. Humidity is assumed within the manufacturer's specification.
Endress+Hauser 15
• Only the versions described are used for safety applications.

• As the optional display does not constitute a part of the safety function, the failure rate of the display
is not taken into account in the calculations.
Categories • SIL (Safety Integrity Level) = 2

• HFT (Hardware Fault Tolerance In accordance with IEC 61511-1, section 11.4) = 0
• Device type = Type B (complex components)
Category SFF1) PFDAVG du dd su sd
1 year 2 years 5 years
1 76.68 % 1.27 · 10–3 2.54 · 10–3 6.35 · 10–3 291 FIT 705 FIT 253 FIT 0 FIT
2 77.58 % 1.29 · 10–3 2.58 · 10–3 6.45 · 10–3 295 FIT 756 FIT 265 FIT 0 FIT
–3 –3 –3
3 76.89 % 1.28 · 10 2.56 · 10 6.40 · 10 292 FIT 711 FIT 260 FIT 0 FIT
–3 –3 –3
4 81.06 % 1.25 · 10 2.50 · 10 6.25 · 10 285 FIT 854 FIT 365 FIT 0 FIT
5 80.29 % 1.21 · 10–3 2.42 · 10–3 6.05 · 10–3 277 FIT 847 FIT 283 FIT 0 FIT
–3 –3 –3
6 80.29 % 1.24 · 10 2.50 · 10 6.25 · 10 285 FIT 854 FIT 365 FIT 0 FIT
–3 –3 –3
7 80.29 % 1.20 · 10 2.42 · 10 6.05 · 10 277 FIT 847 FIT 283 FIT 0 FIT
 Safe Failure Fraction
16 Endress+Hauser
Endress+Hauser 17
18 Endress+Hauser
Endress+Hauser 19
1 2 3 4 5 6 7 8 9 10 11 12
Surface treatment:
According to 60G010 / opt 1
A
2
1 5 905 2065
B
140
Damper is divided into 2 pieces for
transportation. Yellow temporary
319
supports are installed to both pieces.
179
242
A
C Blade / linkage stopper
mechanism to be installed
to boiler frame, if needed.
2850 (outside)
2838
2970
4
Both sides
of damper
3
DETAIL A Operating position

F SCALE 1 : 10
G 1780 (linkage centerline) 6 Blade
5 Service free bearing unit Ø80 1

4 Inductive sensor Pepperl+Fuchs IA15-30GM-I3 1
3377 3 Shaft sealing unit Ø80 1
2 Bearing block Ø80 1
1 Frame 1
Part Description Material Dimensions, shape, model Standard Default
Untoleranced Weight (kg) Project
dimensions:
695.6 5514 Termonorte
ED
EN ISO 13920-AE Size Customer
O V ISO 2768-mK
A2 Alfa Laval Aalborg Oy
R
ISO 9013-IB
H APP
SFS 5803-m
Scale Units Description
Welding acc.
THIS DOCUMENT AND ANY INFORMATION HEREIN
SFS-EN ISO 5817 / C 1:20 mm
CONTAINED ARE THE PROPERTY OF SAMMET
DAMPERS OY. THE UNAUTHORIZED COPYING BY,
USE BY, OR DISCLOSURE TO PERSONS WHO ARE
By-Pass Damper Ø2850
NOT ENTITLED TO RECEIPT OF SUCH DISCLOSURE, Designed KMi 08.05.2017
OR DISCLOSURE TO PERSONS WHO ARE LIKELY TO
MISUSE THIS DOCUMENT OR INFORMATION, IS Dwg No. Rev
PROHIBITED. ANY BREACH AGAINST THE ABOVE Revision Description Revised By Revision Approved by Checked
17036-202398 00.01
PROHIBITION IS LIABLE TO ENFORCEMENT, WITH
DAMAGES PAYABLE TO THOSE AGGRIEVED AND
OTHER REMEDIES AVAILABLE BY LAW OR EQUITY. Approved KMi 19.05.2017
1 2 3 4 5 6 7 8 9 10 11 12
A3 XX1 A4
A 5.5.2017 FIRAPTA A3,A4 changet to DN50
B 15.6.2017 FIRAPTA Corrections
C 28.06.2017 FIRASHN CON. C modified.
A D 10.7.2017 FIRAAPO CON. R modified. A
A2 Q
X11
B B
XX1
A2
Aa XX2
R
A1
C C
K
A X12 A
+Z
H B +X
D C Ad F1 B
D
A1 M
H
E E
+Y
F F
+X
G G
B C
B ( 1:10 ) Fx Fy Fz Mx My Mz
C ( 1:10 )
Max. Loads (kN) Max. Moments (kNm) 10.4.2017/FIRAPTA
Termonotre 93 MW dual fuel power plant
ALLOWABLE FORCES AND MOMENTS 21.4.2017/POS
H - Not to be subjected to any fluctuating loads. FEED WATER TANK, SVS-7 11.4.2017/MJÄ
H
- All loads are only static (+-).
- Forces given in the table are not allowed 1:25
to be exceeded.
1688,5 kg
- Other pipelines to be designed so that
A-A ( 1:25 ) the mass forces and thermal expansions
are compensated. A2 5514-5M D 1 /1
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A 28.06.2017 FIRASHN POS. 39 and 37 added

B 6.7.2017 FIRAAPO Updated cable protection and pneumatic air nozzle connection.
A A
83 74
74 70 75
B 70 59 71 B
27
61 85 63
82 83 4 52 60 70 74 82
32 54 86
74 81 74 28 49 64 73 79
70 74 70
5
C 59 70 61 C
52 59 31 30
29
D 34 D
B
E E
48 59 70 74 85
39
40
15 3 14 13 46
74 70 58 81 10 59 16 37 92 25 58 70 74 81
80 80 80 84
70 69 35
F F
57 65 23 62 70 74 81 2 87
74 73
69 74
82 79 26
73
58
70 38 44 49 69 73 79 91
G 67 66 88 74 G
81
53
36
33
18 22 58 70 74 81
H 41 H
B ( 1:10 )
80
64 45 77
51 58 70 74 81
73 47 77
8 77
J J
9 43 76
7
11 12 42 78
K A K
55 69 72 89 90 68
17
80
L L
64 A ( 1:10 )
73 69 57 80 19 20 21 80 56 69 73 50
73
Termonotre 93 MW dual fuel power plant 10.4.2017/FIRAPTA

10.4.2017/POS
ASSEMBLY INSTRUCTIONS FOR CHEMICAL DOSING VALVES Feed water tank SVS-7 10.4.2017/MJÄ
M Assembly M
SEE DRW. 0010A300226 1691,6 kg 1:25
A1 5514-6A A 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Feed water tank (Atmospheric) Maintenance - 1/3
CONTENT:
1. GENERAL ........................................................................................................................... 2
2. MAINTENANCE INSTRUCTIONS FOR FEED WATER TANK ........................................... 2
2.1 Water sampling and analyzing ....................................................................................... 2
2.2 Visual checking of operation .......................................................................................... 2
2.3 Manual water cleaning ................................................................................................... 2
2.4 Inspection of instruments ............................................................................................... 3
2.5 Internal inspection of wearing and corrosion .................................................................. 3
2.6 Tightness test ................................................................................................................ 3
2.7 Emptying of feed water tank ........................................................................................... 3
2.8 Electrical safety test ....................................................................................................... 3

Maintenance / Feed water tank (Atmospheric) - - 2/3
1. GENERAL
This part describes how to maintain the Feed Water Tank. In case any major problems
occur within the steam system, please contact to Alfa Laval Aalborg.
General conditions of device and all instruments have to be noticed during normal
2. MAINTENANCE INSTRUCTIONS FOR FEED WATER TANK
2.1 Water sampling and analyzing
Note!
See above note.
2.2 Visual checking of operation

Note!
The new implemented steam system, some new instruments are installed / changed, or
when system has been out of service, visual checking is to be done more often than
indicated in related Maintenance card.
2.3Manual water cleaning
Ref.: Maintenance Card, “Cleaning of tanks”.

Maintenance / Feed water tank (Atmospheric) - - 3/3
2.4 Inspection of instruments
Note!
2.5 Internal inspection of wearing and corrosion
2.6 Tightness test
Note!
temperature of pressure vessel are stabilized. Especially this will take place during new
pressure vessel is implemented.
2.7 Emptying of feed water tank
Ref.: Maintenance Card, “Emptying of atmospheric feed water tank”.
Note!
Before feed water tank’s manhole is opened, make sure that it is complete empty and
until maintenance actions to the inside of feed water tank, the temperature of all steel
surfaces have been cooled to the safe level.
Storing of a cold feed water tank partly filled with water is not allowed because of the risk
of corrosion and/or frozen.
Storing of feed water tank shall be made by taking into consideration instructions about
corrosion protection. Suitable protection has to be added inside the tank and all
connections closed properly. For storing see additional instructions under the chapter 8
general instructions, General Instruction no: 50G003.
2.8 Electrical safety test
Ref.: Folder 4, Electrical Information

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A 18.5.2017 FIRAPTA Drain ect. changes

B 15.6.2017 FIRAPTA Changes
A C 27.06.2017 FIRASHN C1, C3, G3 modified. A
D 10.7.2017 FIRAAPO F2 and F3 size updated. Added foundation bed sketch.
E 21.7.2017 FIRAPTA D3 size upd. Foundation sketch upd. S voltage upd.
B B
CUSTOMER K ( 1:10 )
LOCATION All flanges
B G7 F3
C C
G4 F2
D C C D
G2
D3 D2
G3
Ae2 Ae1
E E
Z
X
B
F1 G5 C4
B2 C1 Q B1 G7 F3 G4 F2 G1 A G2 D3 A2 LEFT SIDE ( 1:50 )
G3 C3 Chimney removed from view to show connections
F F
±2
±3 K
±10
±5
±2
±5
±5
G ±20 MM G
S
T
H H
C-C ( 1:50 )
TOP VIEW (1:50)
Y
X
J P J
C1 C3
P
Y ( 1 : 25 ) P-P ( 1:10 )
K LOADINGS
K
WIND LOADS ARE CALCULATED BY USING SAFETY MARGINAL AND ON THE LEVEL +-0.000.
LOADS FROM TRAFFIC, SNOW ETC. ARE TO BE TAKEN INTO CONSIDERATION BY OTHERS.
LEGS OF AUXILIARY CONTAINER

MAX. TOTAL SHEAR (kN): 25,8
MAX. UPLIFT FORCE (kN): 5,8
MAX. COMPRESSIVE FORCE (kN): 76,7
L CHIMNEY - W1 L
MAX. VERTICAL FORCE (kN): 14,1
MAX. SHEAR FORCE (RESULTANT) (kN): 8,8
MAX. BENDING MOMENT (RESULTANT) (kNm): 41,5
W2 (kN): 26 Fx Fy Fz Mx My Mz
Max. Loads (kN) Max. Moments (kNm) 10.4.2017/FIRAPTA

Termonotre 93 MW dual fuel power plant
ALLOWABLE FORCES AND MOMENTS Hyundai 21.4.2017/POS
Y C1 - Not to be subjected to any fluctuating loads.
HEAT RECOVERY CONTAINER 21.4.2017/MJÄ
M - Forces given in the table are not allowed Main dimensions 23405,3 1:50
M
to be exceeded.
Baseplates for container (not in scale) - Other pipelines to be designed so that kg
B-B ( 1:50 ) CORNERS OF CONTAINER (40FT ALSO IN THE MIDDLE) the mass forces and thermal expansions
are compensated. A1 5514-8M E 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A 27.06.2017 FIRASHN - Flanges added to POS 131 and 133

B 10.7.2017 FIRAAPO Counterflanges added to POS 133.
A A
B B
115
C C
67
63 64 117
64
15 52 55
60
41 36 40
63 127
34 30 70
53 20 41 52 63
D D
A A 2
46
47
131
E E
63 64
52 55 136 133 129 66 63 39 32 32 39 63 66 129 133 136

125 26
F 41 38 16 F
27 27 18
116 3
to be installed in pipe line acc.

19 6 to PI-diagram 5508i10001
G G
B B 5
A-A ( 1:50 ) L 31 38 55 64
L
G
68 17 B 25 32 39 53 63
38
25
H H
55
114 39
64
113 53
31 38 55 64
112 58
111 67 63 L-L ( 1:50 )
J 64 66 64 66 J
55 63 A 61
C
36 57 38
123 52
25 4 25
25 41
25
K K
2 1
E
L L
118 9 F 8 69
H
25 38 61 67
Thermonotre 93MW, Colombia 10.5.2017/FIRAPTA
10 43 45 B-B ( 1:50 ) 10.5.2017/POS
125 25 38 54 61 64 67
48 49 Heat Recovery Container 10.5.2017/MJÄ
M Assembly 23388,1 1:50
M
25 38 61 64 67 126 kg
A1 5514-119A B 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
73 73 75 77 72 75 72
A 72 A
72 65 65 75 66 62 64 65 64
72 64
64 67 60 60 74 61 82 82 57 59 60 59
67 67
64 59
59 67 43 67 52 52 65 53 8 6 56 49 52 49
43 43
59 51
51 42 42 42 17 16 60 3 5 7 40 9 22 27
42 42
B 49 24 B
35 52
48 35 35 35 35 35
19 23
21 20 10 13 14 35
11 12
24
46 41 36
C 36 C
A
64 59 50
68 45
D 31 D
2
49
55
59 47 83 3 DOUBLE NIPPLE / MALE-MALE R1'' / R1'' LVI0728 S355J0 20006840240RA 0,3
58 82 2 GASKET WASHER R3/4'' 32/26.5x2 DIN 126 CU 35205140157RA 0,0
64 28 29 30 80 1 FEMALE UNION R 1'' ISO 4144 S355J0 0,4
79 1 BOILER TUBE SEAMLESS 33,7x5 L=1855 EN 10216-2 P235GH TC1 10002580234RA 6,6
34 4 63 78 1 BLIND FLANGE DN25 PN40 EN 1092-1:05/A P265GH 20706210164RA 1,4
72 26 25 47 52 53 77 1 Water level signs 85703320199RA 0,0
5 49 76 1 DEVICE SHIELD PE 85703280269RA 0,1
75 3 FLANGE GASKET DN100 PN25-40 EN1514-1 GRAPHITE 35205180318RA 0,2
E 54 49 60 60 74 1 FLANGE GASKET DN50 PN10-40 EN1514-1 GRAPHITE 35205180297RA 0,0 E
Kattila kiinnitet n kontin 59 73 2 FLANGE GASKET DN32 PN10-40 EN1514-1 GRAPHITE 35205180283RA 0,0
64 59 lattiaan hitsaamalla 65 65 72 14 FLANGE GASKET DN25 PN10-40 EN1514-1 GRAPHITE 35205180276RA 0,2
71 1 GASKET WASHER -THERMOMETER R1/2'' 21/26.5x2 DIN 126 CU 35205140192RA 0,0
64 70 1 GASKET WASHER -THERMOMETER R1'' 39/33x2 DIN 126 CU 35205140178RA 0,0
72 64 74 68 1 GASKET WASHER R1/4'' 11/6x1.5 DIN 126 CU 35205140171RA 0,0
72 67 13 GASKET WASHER R1/2'' 17/6.5x2 DIN 126 CU 35205140150RA 0,1
66 32 Washer 20 DIN 126 FE-ZN HOT 30903920206RA 0,5
72 65 64 Washer 16 DIN 126 FE-ZN HOT 30903920199RA 0,7
78 64 108 Washer 12 DIN 126 FE-ZN HOT 30903920185RA 0,7
62 16 Washer Stainless 5 DIN 126 EN 1.4404 30903900150RA 0,0
F 61 16 HEXAGONAL NUT M20 DIN 934 / 8 FE-ZN HOT 30803800206RA 1,1 F
60 32 HEXAGONAL NUT M16 DIN 934 / 8 FE-ZN HOT 30803800199RA 1,1
57 8 HEXAGONAL NUT M5 DIN 934 / A4-70 EN 1.4404 30803780157RA 0,0
72 56 8 HEXAGONAL SCREW M5 x 20 DIN 933 / A4-70 EN 1.4404 30103600150RA 0,0
55 2 HEXAGONAL SCREW M8 x 25 DIN 933 / 8.8 FE-ZN HOT 30103540255RA 0,0
64 53 16 HEXAGONAL SCREW M20 x 80 DIN 931 / 8.8 FE-ZN HOT 30103520451RA 4,4
59 50 8 HEXAGONAL SCREW M12 x 70 DIN 931 / 8.8 FE-ZN HOT 30103520304RA 0,6
G 70 49 71 48 1 Neck Flange DN25 PN40 EN 1092-1:11/B P250GH 20505740164RA 1,3 G
47 2 Connector 15xG1/2'' Parker Stainless 20006900276RA 0,1
Steel,
44 76 18 15 Austenitic
46 1
STRAIGHT PRESS COUPLING -MALE 10xG1/2'' Parker EN 1.4571 20006900262RA 0,0
45 1
STRAIGHT PRESS COUPLING -MALE 10xG1/4'' Parker EN 1.4571 20006900248RA 0,0
44 1
PLUG FOR SOCKET -MALE G1'' L=26 S355J0 20006840276RA 0,1
43 3
REDUCING NIPPLE / MALE-FEMALE G1/2'' RH G3/8'' RH FIG.87/7 EN 1.4404 20006840171RA 0,3
42 6
UNION NUT G1/2''LH G1/2''RH DIN 16283 EN 1.4436 20006820213RA 0,6
41 1
STEEL TUBE STAINLESS 10x1 L=463 EN 10217-7 EN 1.4404 10002700171RA 0,1
37 40 1
PLATE FOR LEVEL SIGNS DN25 CC-400 dwg:0010S40046 2,4
39 1
Fuel Hose 1,3
H 38 1
Fuel Hose 1,5 H
37 1
SIMPLEX FILTER DN25 AUXB001.A004 70407120146RA 8,0
37 1
Safety Valve Drain 0,7
36 1
GAUGE VALVE 1/2'' PN 400 AUXB001.V101 80007800199RA 0,8
36 1
Flame Observation Cooling dwg:0010S35406 1,2
35 5
GAUGE VALVE WITH H TEST CONNECTION 1/2'' PN 400 AUXB001.V100 80007800192RA 5,0
1 35 1
STEEL ASSEMBLY BH-3000L dwg:10S20261 6772,0
34 1
GLOBE VALVE DN25 PN16 AUXB001.V019 60107200185RA 5,0
33 1
BALL VALVE 1''-female AUXB001.V018 60007340416RA 0,7
32 1
BALL VALVE 1''-female AUXB001.V017 60007340416RA 0,7
31 1
CONTROL VALVE PREMIO AND POTENTIOMETER DN25 PN25 AUXB001.V016 60507940172RA 11,0
30 1
29 1
J 28 1
GLOBE VALVE DN25 PN16 AUXB001.V013 60107200185RA 5,0 J
79 27 1
GLOBE VALVE THROTTLING PLUG WITH LOCKING DN25 PN16 AUXB001.V012 60007570278RA 5,6
DEVICE
26 1 BALL VALVE DN25 PN40 AUXB001.V011 60007340423RA 2,7
25 1 GLOBE VALVE DN25 PN16 AUXB001.V010 60107200269RA 5,4
80 83 33 24 1 GLOBE VALVE DN25 PN16 AUXB001.V009 60107200269RA 5,4
23 1 NON-RETURN VALVES. DISCO DN25 PN6-40 AUXB001.V008 60207520248RA 0,5
21 1 BALL VALVE 1''-female AUXB001.V006 60007340416RA 0,7
20 1 NON-RETURN VALVES. DISCO DN25 PN6-40 AUXB001.V005 60407580171RA 0,5
83 32 19 1 GLOBE VALVE DN25 PN16 AUXB001.V004 60107200269RA 5,4
K 17
16
1 SAFETY VALVE
1 SAFETY VALVE
DN 32/50 PN40
DN 32/50 PN40
AUXB001.V002
AUXB001.V001
60407560178RA
60407560178RA
14,0
14,0
K
37 83 38 39 15 1 THERMOMETER WITH POCKET 250 MM 1/2'' - D 100 AUXB001.T001 80808340227RA 0,3
14 1 PRESSURE SWITCH. MAX RESET 1/2'' (M) AUXB001.P005 80008120353RA 1,0
Pipe to be bent acc. to project. 13 1 PRESSURE SWITCH 3/8'' (M) AUXB001.P004 80008120213RA 1,0
1" male thread at ends. A ( 1:20 ) 12 1 PRESSURE SWITCH 3/8'' (M) AUXB001.P003 80008120213RA 1,0
11 1 PRESSURE SWITCH 3/8'' (M) AUXB001.P002 80008120213RA 1,0
10 1 PRESSURE GAUGE LIQUID FILLED WITH RED 1/2'' - D 100 AUXB001.P001 80508400276RA 0,9
MARK POINTER
9 1 LEVEL GAUGE REFLEX DN25 PN40 AUXB001.L003 70108540199RA 12,0
8 1 LOW LEVEL SWITCH FOR NRG 16-4 AUXB001.L002.1 81254740197RA 0,0
7 1 LEVEL CONTROL ELECTRODE CONDUCTIVE 3/4'' PN40 AUXB001.L002 81254760188RA 2,5
6 1 LEVEL CONTROLLER FOR NRG 26-40 AUXB001.L001.1 81254620241RA 0,2
L 5 1 LEVEL CONTROL ELECTRODE CAPASITIVE 3/4'' PN40 AUXB001.L001 81254620150RA 2,5 L
4 1 MAGNETIC FLOWMETER DN25 PN40 AUXB001.F001 5,7
3 1 FLANGE FOR LEVEL PROBES DN100 PN40 AUXB001.A003 81254780150RA 0,5
2 1 SAMPLE COOLER AUXB001.A002 70004500150RA 8,0
1 1 LIGHT FUEL OIL BURNER AUXB001.A001 55605020261RA 221,0
Date/Drawn
Thermonorte 93MW dual fuel power plant 13.7.2017/FIRAPTA
Date/Checked
Hyundai 17.7.2017/POS
Date/Approved
Aux Boiler BH-3200L 17.7.2017/MJ
M Assembly Weight/kg
7208,6 kg
Scale
1:20
M
Rauma, Finland
A1 5514-33A - 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Auxiliary boiler Maintenance - 1/4
CONTENT:
1. GENERAL ........................................................................................................................... 2
2. MAINTENANCE INSTRUCTIONS FOR AUXILIARY BOILER ............................................ 2
2.1 Defining the need for cleaning of the auxiliary boiler ...................................................... 2
2.1.1 When the auxiliary boiler is in need of cleaning? ................................................ 2
2.1.2 Methods for defining the need of cleaning the auxiliary boiler ........................... 2
2.2 Methods of cleaning the auxiliary boiler ......................................................................... 2
2.2.1 Manual water cleaning ........................................................................................... 2
2.3 Other maintenance instructions for auxiliary boiler and instruments ............................... 3
2.3.1 Visual checking of operation. ................................................................................ 3
2.3.2 Checking of burner. ................................................................................................ 3
2.3.3 Inspection of instruments. ..................................................................................... 3
2.3.4 Internal inspection of wearing and corrosion....................................................... 3
2.3.5 Tightness test ......................................................................................................... 3
2.3.6 Pressure test for pressure vessel and safety valve ............................................. 3
2.3.7 Emptying of auxiliary boiler. .................................................................................. 4
2.3.8 Bottom and scum blow out .................................................................................... 4
2.3.9 Water sampling and analyzing .............................................................................. 4
2.3.10 Electrical safety test ............................................................................................. 4

Maintenance / Auxiliary boiler - - 2/4
1. GENERAL
This part describes how to maintain the auxiliary boiler. In case any major problems
occur within the steam system, please contact Alfa Laval Aalborg.
General conditions of boiler and all instruments have to be noticed during normal
2. MAINTENANCE INSTRUCTIONS FOR AUXILIARY BOILER
2.1 Defining the need for cleaning of the auxiliary boiler

2.1.1 When the auxiliary boiler is in need of cleaning?
Auxiliary boiler must be cleaned at least once a year. The cleaning frequency is
determined case by case. The influencing factors are quality of used fuel, operation
intervals, etc. As a result, the cleaning intervals are determined on the basis of
inspections and experience.
2.1.2 Methods for defining the need of cleaning the auxiliary boiler
Ref.: Maintenance Card, “Checking of auxiliary boiler dirtiness”.
An internal inspection is carried out through the maintenance hatches. It is advisable to

perform the inspection at intervals. Special inspection shall be paid to the following
items:
Smoke tubes and other steel surfaces are clean from oil deposits or corresponding
impurities
The inside structure of boiler is free from all kind of corrosion.
2.2 Methods of cleaning the auxiliary boiler
2.2.1 Manual water cleaning
Ref.: Maintenance Card, “Manual water cleaning of auxiliary boiler”.

Note!
In case the deposits are very “sticky” making it difficult to get the boiler cleaned
properly, it is possible to be used purpose of use suitable soaking agent with manual
water cleaning. The pressure of washing water can be increased (e.g. applying a
special cleaning company) or a suitable soaking agent can be tried.
After cleaning, check that no sludge remains in the boiler. Potential sludge must be
removed because its content of sulfuric acid causes a risk of corrosion.
2.3 Other maintenance instructions for auxiliary boiler and instruments
2.3.1 Visual checking of operation.
2.3.2 Checking of burner.
Ref.: Maintenance Card, “Checking of burner function”.
Always when making maintenance or checking the burner manufacturer’s instruction

have to used and followed
2.3.3 Inspection of instruments.
2.3.4 Internal inspection of wearing and corrosion.
2.3.5 Tightness test
Note!
temperature of pressure vessel are stabilized. Especially this will take place during an
implementation of a new pressure vessel.
2.3.6 Pressure test for pressure vessel and safety valve
Note!
manufacturing phase, before new pressure equipment (assembly where related valves,
pipes etc. components are connected to the pressure vessel) is taken in use, it needs
to be pressure tested. Requirements of pressure testing for delivered pressure vessel

are informed in related Maintenance Card and Technical data sheets. Furthermore the
be taken into the consideration before steam generation is started. Liability of register
or other licenses are out of Alfa Laval Aalborg responsibility.
2.3.7 Emptying of auxiliary boiler.
Ref.: Maintenance Card, “Emptying of auxiliary boiler”.
Note!
Storing of boiler shall be made by taking into consideration instructions about corrosion
protection. Suitable protection has to be added inside the boiler and all connections
closed properly. For storing see additional instructions under the chapter 8 general
instructions, General Instruction no: 50G003.
2.3.8 Bottom and scum blow out
Ref.: Maintenance Card, “Manual bottom and scum blow out”.
Note!
The needs of blow outs are described under the “General Instructions, water treatment”.
During initial start up the quality of the boiler water is to be observed more often and
therefore system may require that blow outs are to be done more often as indicated in
related Maintenance card.
2.3.9 Water sampling and analyzing
Note!
See above note.
2.3.10 Electrical safety test
Ref.: Book 4, Electrical Information


Electromagnetic Flow Measuring System
Flow measurement of liquids in chemical or process applications
Application Connection to process control system:

Electromagnetic flowmeter for bidirectional • HART
measurement of liquids with a minimum • PROFIBUS DP/PA
conductivity of ≥ 5 μS/cm: • FOUNDATION Fieldbus
• Acid, alkalis • MODBUS RS485
• Paints
• Pastes
Your benefits
• Water, wastewater etc.
Promag measuring devices offer you cost-effective flow
• Flow measurement up to 9600 m³/h (42268 gal/min) measurement with a high degree of accuracy for a wide
• Fluid temperature up to +180 °C (356 °F) range of process conditions.
• Process pressures up to 40 bar (580 psi)
The uniform Proline transmitter concept comprises:
• Lengths in accordance with DVGW/ISO
• Modular device and operating concept resulting in a
Application-specific lining materials: higher degree of efficiency
• PTFE • Software options for batching, electrode cleaning and
• PFA for measuring pulsating flow
• High degree of reliability and measuring stability
Approvals for hazardous area:
• Uniform operating concept
• ATEX
• IECEx The tried-and-tested Promag sensors offer:
• FM • No pressure loss
• CSA • Not sensitive to vibrations
• NEPSI • Simple installation and commissioning
• TIIS
TI047D/06/en/11.09
71106271
Table of contents
Function and system design. . . . . . . . . . . . . . . . . . . . . 3 Mechanical construction . . . . . . . . . . . . . . . . . . . . . . 25

Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Design, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Measuring tube specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Material load diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Measured variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fitted electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Measuring ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Process connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operable flow range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Surface roughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Input signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Human interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Signal on alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Language groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remote operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Low flow cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Galvanic isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Switching output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Certificates and approvals . . . . . . . . . . . . . . . . . . . . . 42
CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
C-tick mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure measuring device approval . . . . . . . . . . . . . . . . . . . . . . 42
Electrical connection, measuring unit . . . . . . . . . . . . . . . . . . . . . . 7
Ex approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical connection, terminal assignment . . . . . . . . . . . . . . . . . . 8
Other standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical connection, remote version . . . . . . . . . . . . . . . . . . . . . . 9
FOUNDATION Fieldbus certification . . . . . . . . . . . . . . . . . . . . . 42
Supply voltage (power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MODBUS RS485 certification . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PROFIBUS DP/PA certification . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remote version cable specifications . . . . . . . . . . . . . . . . . . . . . . . . 9
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power supply failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ordering information. . . . . . . . . . . . . . . . . . . . . . . . . 43
Potential equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Performance characteristics. . . . . . . . . . . . . . . . . . . . 13
Reference operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maximum measured error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Registered trademarks . . . . . . . . . . . . . . . . . . . . . . . . 43
Operating conditions: Installations . . . . . . . . . . . . . . 14
Inlet and outlet run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Length of connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operating conditions: Environment. . . . . . . . . . . . . . 20

Ambient temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Storage temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Shock and vibration resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . 20
Operating conditions: Process . . . . . . . . . . . . . . . . . . 21

Medium temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Medium pressure range (nominal pressure) . . . . . . . . . . . . . . . . . 22
Pressure tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Limiting flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Endress+Hauser

Measuring principle Following Faraday's law of magnetic induction, a voltage is induced in a conductor moving through a magnetic
field.
In the electromagnetic measuring principle, the flowing medium is the moving conductor.
The voltage induced is proportional to the flow velocity and is supplied to the amplifier by means
of two measuring electrodes. The flow volume is calculated by means of the pipe cross-sectional area.
The DC magnetic field is created through a switched direct current of alternating polarity.
Ue
V
B
I
L
A0003191
Ue = B · L · v
Q=A·v
Ue Induced voltage
B Magnetic induction (magnetic field)
L Electrode spacing
v Flow velocity
Q Volume flow
A Pipe cross-section
I Current strength
Measuring system The measuring system consists of a transmitter and a sensor.

Two versions are available:
• Compact version: Transmitter and sensor form a mechanical unit.
• Remote version: Sensor is mounted separate from the transmitter.
Transmitter:
• Promag 50 (user interface with push buttons for operation, two-line display, illuminated)
• Promag 53 ("Touch Control" without opening the housing, four-line display, unilluminated)
Sensor:
• Promag P (DN 15 to 600 / ½ to 24")
Endress+Hauser 3
Input
Measured variable Flow velocity (proportional to induced voltage)
Measuring ranges Measuring ranges for liquids

Typically v = 0.01 to 10 m/s (0.03 to 33 ft/s) with the specified accuracy
Operable flow range Over 1000 : 1
Input signal Status input (auxiliary input)

• Configurable for: totalizer(s) reset, measured value suppression, error-message reset
Status input (auxiliary input) with PROFIBUS DP and MODBUS RS485
• Switching level: 3 to 30 V DC, independent of polarity
• Configurable for: totalizer(s) reset, measured value suppression, error-message reset,
batching start/stop (optional), batch totalizer reset (optional)
Current input (only Promag 53)
• active/passive selectable, galvanically isolated, full scale value selectable, resolution: 3 μA,
temperature coefficient: typ. 0.005% o.r./°C (o.r. = of reading)
• active: 4 to 20 mA, Ri ≤ 150 Ω, max. 24 V DC, short-circuit-proof
• passive: 0/4 to 20 mA, Ri < 150 Ω, max. 30 V DC
Output
Output signal Promag 50
Current output
passive, open collector, 30 V DC, 250 mA, galvanically isolated
• Frequency output: full scale frequency 2 to 1000 Hz (fmax = 1250 Hz), on/off ratio 1:1, pulse width max. 10s
• Input data: positive zero return (ON/OFF), control totalizer, value for local display
4 Endress+Hauser
Promag 53
Current output
active/passive selectable, galvanically isolated (Ex i version: only passive)
• active: 24 V DC, 25 mA (max. 250 mA during 20 ms), RL > 100 Ω
• passive: open collector, 30 V DC, 250 mA
• Frequency output: full scale frequency 2 to 10000 Hz (fmax = 12500 Hz), EEx-ia: 2 to 5000 Hz;
on/off ratio 1:1, pulse width max. 10 s
MODBUS RS485 interface
• MODBUS device type: Slave
• Adress range: 1 to 247
• Supported MODBUS function codes: 03, 04, 06, 08, 16, 23
• Broadcast: supported with the function codes 06, 16, 23
• Übertragungsmodus: RTU oder ASCII
• Supported baudrate: 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 Baud
• Response time:
– Direct data access = typically 25 to 50 ms
– Auto-scan buffer (data range) = typically 3 to 5 ms
Endress+Hauser 5
FOUNDATION Fieldbus interface

• FOUNDATION Fieldbus H1
• ITK version 5.01
• Function blocks:
– 5 × Analog Input (execution time: 18 ms each)
– 1 × PID (25 ms)
– 1 × Digital Output (18 ms)
– 1 × Signal Characterizer (20 ms)
– 1 × Input Selector (20 ms)
– 1 × Arithmetic (20 ms)
– 1 × Integrator (18 ms)
• Output data: volume flow, calculated mass flow, temperature, totalizer 1 to 3
• Input data: positive zero return (ON/OFF), reset totalizer
• Link Master (LM) functionality is supported
Signal on alarm • Current output → failure response selectable (e.g. in accordance with NAMUR recommendation NE 43)
• Pulse/frequency output → failure response selectable
• Status output (Promag 50) → non-conductive by fault or power supply failure
• Relay output (Promag 53) → de-energized by fault or power supply failure
Load see "Output signal"
Low flow cutoff Switch points for low flow cutoff are selectable.
Galvanic isolation All circuits for inputs, outputs and power supply are galvanically isolated from each other.
Switching output Status output (Promag 50, Promag 53)

Open collector, max. 30 V DC / 250 mA, galvanically isolated.
Configurable for: error messages, Empty Pipe Detection (EPD), flow direction, limit values.
Relay outputs (Promag 53)
Normally closed (NC or break) or normally open (NO or make) contacts available
(default: relay 1 = NO, relay 2 = NC), max. 30 V / 0,5 A AC ; 60 V / 0,1 A DC, galvanically isolated.
Configurable for: error messages, Empty Pipe Detection (EPD), flow direction, limit values, batching contacts.
6 Endress+Hauser
Power supply
A B C
measuring unit
d d
g g
b b
a
a
a
b d/(g) (d)
HART* PROFIBUS PA*

FOUNDATION Fieldbus*
– 27 PA(–)/FF(–) 27
+ 26 PA(+)/FF(+) 26
– 25 d – 25 d
+ 24 + 24
f – 23 e f – 23 e
+ 22 + 22
– 21 – 21
+ 20 + 20
N (L-) 2 c N (L-) 2 c
L1 (L+)1 L1 (L+) 1
b b
PROFIBUS DP* PROFIBUS DP**

MODBUS RS485**
A (RxD/TxD-N) 27 A (RxD/TxD-N) 27
B (RxD/TxD-P) 26 B (RxD/TxD-P) 26
– 25 d – 25 d
+ 24 + 24
f – 23 e f – 23 e
+ 22 + 22
– 21 – 21
+ 20 g + 20 g
N (L-) 2 c N (L-) 2
c
L1 (L+) 1 L1 (L+) 1
b b
A0002441
Connecting the transmitter, cable cross-section max. 2.5 mm2 (14 AWG)
A View A (field housing)
B View B (stainless steel field housing)
C View C (wall-mount housing)
*) fixed communication boards
**) flexible communication boards
a Connection compartment cover
b Cable for power supply: 85 to 260 V AC / 20 to 55 V AC / 16 to 62 V DC
- Terminal No. 1: L1 for AC, L+ for DC
- Terminal No. 2: N for AC, L– for DC
c Ground terminal for protective conductor
d Signal cable: see "Electrical connection, terminal assignment" → ä 8
Fieldbus cable:
- Terminal No. 26: DP (B) / PA + / FF + / MODBUS RS485 (B) / (PA, FF: with polarity protection)
- Terminal No. 27: DP (A) / PA – / FF – / MODBUS RS485 (A) / (PA, FF: with polarity protection)
e Ground terminal for signal cable shield / Fieldbus cable / RS485 line
f Service adapter for connecting service interface FXA193 (Fieldcheck, FieldCare)
g Signal cable: see "Electrical connection, terminal assignment" → ä 8
Cable for external termination (only for PROFIBUS DP with fixed assignment communication board):
- Terminal No. 24: +5 V
- Terminal No. 25: DGND
Endress+Hauser 7
Electrical connection, Terminal assignment, Promag 50

terminal assignment
20 (+) / 21 (–) 22 (+) / 23 (–) 24 (+) / 25 (–) 26 (+) / 27 (–)
50***-***********W – – – Current output HART
50***-***********D Status input Status output Frequency output Current output HART
50***-***********H – – – PROFIBUS PA
50***-***********J – – +5 V (external PROFIBUS DP
termination)
50***-***********S – – Frequency output, Current output, Ex i,
50***-***********T – – Frequency output, Current output, Ex i,
Terminal assignment, Promag 53

The inputs and outputs on the communication board can be either permanently assigned or variable, depending
on the version ordered (see table). Replacements for modules which are defective or which have to be replaced
can be ordered as accessories.

20 (+) / 21 (–) 22 (+) / 23 (–) 24 (+) / 25 (–) 26 (+) / 27 (–)
Fixed communication boards (fixed assignment)
53***-***********B Relay output 2 Relay output 1 Frequency output Current output HART
53***-***********F – – – PROFIBUS PA, Ex i
53***-***********G – – – FOUNDATION Fieldbus, Ex i
53***-***********H – – – PROFIBUS PA
53***-***********J – – – PROFIBUS DP
53***-***********K – – – FOUNDATION Fieldbus
53***-***********Q – – Status input MODBUS RS485
53***-***********S – – Frequency output, Ex i Current output, Ex i,
passive, HART
53***-***********T – – Frequency output, Ex i Current output, Ex i,
passive, HART
Flexible communication boards
53***-***********C Relay output 2 Relay output 1 Frequency output Current output HART
53***-***********D Status input Relay output Frequency output Current output HART
53***-***********L Status input Relay output 2 Relay output 1 Current output HART
53***-***********M Status input Frequency output Frequency output Current output HART
53***-***********N Current output Frequency output Status input MODBUS RS485
53***-***********P Current output Frequency output Status input PROFIBUS DP
53***-***********V Relay output 2 Relay output 1 Status input PROFIBUS DP
53***-***********2 Relay output Current output Frequency output Current output HART
53***-***********4 Current input Relay output Frequency output Current output HART
53***-***********5 Status input Current input Frequency output Current output HART
53***-***********7 Relay output 2 Relay output 1 Status input MODBUS RS485
8 Endress+Hauser
remote version
c d
GND
S1
E1
E2
S2
E
S
6 5 7 8 4 37 36 42 41
a
c d
n.c. n.c. n.c.
b
5 7 4 37 42 41
E1
E2
GND
E
A0011722
Connecting the remote version

a Wall-mount housing connection compartment
b Sensor connection housing cover
c Signal cable
d Coil current cable
n.c. Not connected, insulated cable shields
Terminal no. and cable colors: 6/5 = brown; 7/8 = white; 4 = green; 36/37 = yellow
Supply voltage (power supply) • 85 to 260 V AC, 45 to 65 Hz

• 20 to 55 V AC, 45 to 65 Hz
• 16 to 62 V DC
PROFIBUS PA and FOUNDATION Fieldbus
• Non-Ex: 9 to 32 V DC
• Ex i: 9 to 24 V DC
• Ex d: 9 to 32 V DC
Cable entry Power supply and signal cables (inputs/ outputs):

Connecting cable for remote version:
Remote version cable Coil cable

specifications • 2 × 0.75 mm2 (18 AWG) PVC cable with common, braided copper shield (∅ ∼ 7 mm / 0.28")
• Capacitance core/core, shield grounded: ≤ 120 pF/m (≤ 37 pF/ft)
• Test voltage for cable insulation: ≤ 1433 AC r.m.s. 50/60 Hz or ≥ 2026 V DC
Signal cable
• 3 × 0.38 mm2 (20 AWG) PVC cable with common, braided copper shield (∅ ∼ 7 mm / 0.28") and individual
shielded cores
• With empty pipe detection (EPD): 4 × 0.38 mm2 (20 AWG) PVC cable with common,
braided copper shield (∅ ∼ 7 mm / 0.28") and individual shielded cores
• Capacitance core/shield: ≤ 420 pF/m (≤ 128 pF/ft)
Endress+Hauser 9
1
2
3
4
5
6
7
a b
A0003194
a Signal cable
b Coil current cable
1 Core
2 Core insulation
3 Core shield
4 Core jacket
5 Core reinforcement
6 Cable shield
7 Outer jacket
Operation in zones of severe electrical interference

The measuring device complies with the general safety requirements in accordance with EN 61010 and
the EMC requirements of IEC/EN 61326 and NAMUR recommendation NE 21.
" Caution!
Grounding is by means of the ground terminals provided for the purpose inside the connection housing.
Ensure that the stripped and twisted lengths of cable shield to the ground terminal are as short as possible.
Power consumption • AC: < 15 VA (incl. sensor)

• DC: < 15 W (incl. sensor)
Switch-on current:
• Max. 3 A (< 5 ms) for 260 V AC
• Max. 13.5 A (< 50 ms) for 24 V DC
Power supply failure Lasting min. ½ cycle frequency: EEPROM saves measuring system data
• EEPROM or T-DAT (Promag 53 only) retain the measuring system data in the event of a power supply failure
• S-DAT: exchangeable data storage chip which stores the data of the sensor (nominal diameter, serial number,
calibration factor, zero point etc.)
10 Endress+Hauser
Potential equalization
# Warning!
The measuring system must be included in the potential equalization.
Perfect measurement is only ensured when the fluid and the sensor have the same electrical potential. This is
ensured by the reference electrode integrated in the sensor as standard.
The following should also be taken into consideration for potential equalization:
• Internal grounding concepts in the company
• Operating conditions, such as the material/ grounding of the pipes (see table)
Standard situation

• Metal, grounded pipe
Potential equalization takes place via the ground terminal of the
transmitter.
! Note!
When installing in metal pipes, we recommend you connect the
ground terminal of the transmitter housing with the piping.
A0011892
Via the ground terminal of the transmitter
Special situations

• Metal pipe that is not grounded
Both sensor flanges are connected to the pipe flange by means of
a ground cable (copper wire, at least 6 mm² / 0.0093 in²) and
grounded. Connect the transmitter or sensor connection
housing, as applicable, to ground potential by means of the
ground terminal provided for the purpose.
• DN ≤ 300 (12"): the ground cable is mounted directly on the DN £ 300 DN ³ 350
conductive flange coating with the flange screws.
• DN ≥ 350 (14"): the ground cable is mounted directly on the
transportation metal support.
! Note!
The ground cable for flange-to-flange connections can be
ordered separately as an accessory from Endress+Hauser.
A0011893
Via the ground terminal of the transmitter and the

flanges of the pipe

• Plastic pipe
• Pipe with insulating lining
Potential equalization takes place using additional ground disks,
which are connected to the ground terminal via a ground cable
(copper wire, at least 6 mm² / 0.0093 in²). When installing the
ground disks, please comply with the enclosed Installation A0011895
Instructions. Via the ground terminal of the transmitter and the

optionally available ground disks
Endress+Hauser 11

• Pipe with a cathodic protection unit
The device is installed potential-free in the pipe.
Only the two flanges of the pipe are connected with a ground
cable (copper wire, at least 6 mm² / 0.0093 in²). Here, the
ground cable is mounted directly on the conductive flange
coating with flange screws.
Note the following when installing:
• The applicable regulations regarding potential-free installation
must be observed. A0011896
• There should be no electrically conductive connection Potential equalization and cathodic protection
between the pipe and the device.
• The mounting material must withstand the applicable 1 Power supply isolation transformer
torques. 2 Electrically isolated
12 Endress+Hauser
Performance characteristics
Reference operating As per DIN EN 29104 and VDI/VDE 2641:
conditions • Fluid temperature: +28 °C ± 2 K (+82 °F ± 2 K)
• Ambient temperature: +22 °C ±2 K (+72 °F ± 2 K)
• Warm-up period: 30 minutes
Installation conditions:
• Inlet run > 10 × DN
• Outlet run > 5 × DN
• Sensor and transmitter grounded.
• The sensor is centered in the pipe.
Maximum measured error Promag 50:

• Pulse output: ±0.5% o.r. ± 1 mm/s (±0.5% o.r. ± 0.04 in/s)
optional: ±0.2% o.r. ± 2 mm/s (±0.2% o.r. ± 0.08 in/s) (o.r. = of reading)
Promag 53:
• Pulse output: ±0.2% o.r. ± 2 mm/s (±0.2% o.r. ± 0.08 in/s) (o.r. = of reading)
Fluctuations in the supply voltage do not have any effect within the specified range.
[%]
2.5
2.0
0.5 %
1.5
0.2 %
1.0
0.5
0
0 1 2 4 6 8 10 [m/s]
v
0 5 10 15 20 25 30 32 [ft] A0005531
Max. measured error in % of reading
Repeatability Max. ±0.1% o.r. ± 0.5 mm/s (±0.1% o.r. ± 0.02 in/s) (o.r. = of reading)
Endress+Hauser 13
Operating conditions: Installations

Installation instructions Mounting location
Entrained air or gas bubble formation in the measuring tube can result in an increase in measuring errors.
Avoid the following installation locations in the pipe:
• Highest point of a pipeline. Risk of air accumulating!
• Directly upstream from a free pipe outlet in a vertical pipeline.
h ³ 2 x DN
A0011899
Mounting location
Sensors may not be installed on the pump suction side. This precaution is to avoid low pressure and the
consequent risk of damage to the lining of the measuring tube. Information on the pressure tightness of the
measuring tube lining → ä 22, Section "Pressure tightness".
Pulsation dampers may be needed when using piston pumps, piston diaphragm pumps or hose pumps.
Information on the shock and vibration resistance of the measuring system → ä 20, Section "Shock and
vibration resistance".
A0011900
14 Endress+Hauser

The empty pipe detection function (EPD) provides additional security in detecting empty or partially filled
pipes.
" Caution!
Risk of solids accumulating. Do not install the sensor at the lowest point in the drain. It is advisable to install a
cleaning valve.
³ 2 x DN
³ 5 x DN
A0011901
Installation with partially filled pipes
Down pipes
Install a siphon or a vent valve downstream of the sensor in down pipes h ≥ 5 m (16.4 ft). This precaution is
to avoid low pressure and the consequent risk of damage to the lining of the measuring tube. This measure also
prevents the liquid current stopping in the pipe which could cause air locks. Information on the pressure
tightness of the measuring tube lining → ä 22, Section "Pressure tightness".
2 h
A0011902
Installation measures for vertical pipes

1 Vent valve
2 Pipe siphon
h Length of the down pipe
Endress+Hauser 15
Orientation
An optimum orientation helps avoid gas and air accumulations and deposits in the measuring tube. However,
the measuring device also offers the additional function of empty pipe detection (EPD) for detecting partially
filled measuring tubes or if outgassing fluids or fluctuating operating pressures are present.
This is the ideal orientation for self-emptying piping systems and for use in conjunction with empty pipe
detection.
A0011903
The measuring electrode axis should be horizontal. This prevents brief insulation of the two measuring
" Caution!
Empty pipe detection only works correctly with horizontal orientation if the transmitter housing is facing
upwards. Otherwise there is no guarantee that empty pipe detection will respond if the measuring tube is only
partially filled or empty.
A
1
2 2
A
3
A0011904
1 EPD electrode for empty pipe detection
2 Measuring electrodes for signal detection
3 Reference electrode for potential equalization
16 Endress+Hauser
Vibrations
Secure the piping and the sensor if vibration is severe.
" Caution!
If vibrations are too severe, we recommend the sensor and transmitter be mounted separately. Information on
the permitted shock and vibration resistance → ä 20, Section "Shock and vibration resistance".
A0011906
Measures to prevent vibration of the measuring device

L > 10 m (33 ft)
Foundations, supports
If the nominal diameter is DN ≥ 350, mount the transmitter on a foundation of adequate load-bearing strength.
" Caution!
Do not allow the casing to take the weight of the sensor. This would buckle the casing and damage the internal
magnetic coils.
A0003209
Endress+Hauser 17
Inlet and outlet run If possible, install the sensor well clear of assemblies such as valves, T-pieces, elbows etc.
Note the following inlet and outlet runs to comply with measuring accuracy specifications:
• Inlet run: ≥ 5 × DN
• Outlet run: ≥ 2 × DN
³ 5 x DN ³ 2 x DN
A0011905
Inlet and outlet run
Adapters Suitable adapters to DIN EN 545 (double-flange reducers) can be used to install the sensor in larger-diameter
pipes. The resultant increase in the rate of flow improves measuring accuracy with very slow-moving fluids.
The nomogram shown here can be used to calculate the pressure loss caused by reducers and expanders.
! Note!
The nomogram only applies to liquids of viscosity similar to water.
1. Calculate the ratio of the diameters d/D.
2. From the nomogram read off the pressure loss as a function of flow velocity (downstream from the
reduction) and the d/D ratio.
[mbar] 100
8 m/s
7 m/s
6 m/s
10
5 m/s
4 m/s
max. 8°
3 m/s
d D
2 m/s
1
1 m/s
d/D 0.5 0.6 0.7 0.8 0.9

A0011907
Pressure loss due to adapters
18 Endress+Hauser
Length of connecting cable When mounting the remote version, please note the following to achieve correct measuring results:
• Fix cable run or lay in armored conduit. Cable movements can falsify the measuring signal especially in the
case of low fluid conductivities.
• If necessary, ensure potential equalization between sensor and transmitter.
• The permitted cable length Lmax is determined by the fluid conductivity. A minimum conductivity of
20 μS/cm is required for measuring demineralized water.
• When the empty pipe detection function is switched on (EPD),
the maximum connecting cable length is 10 m (33 ft).
[μS/cm]
200
100
L max
5
[m]
10 100 200 L max
[ft]
0 200 400 600
A0010734
Permitted length of connecting cable for remote version

Area marked in gray = permitted range; Lmax = length of connecting cable in [m] ([ft]); fluid conductivity in [μS/cm]
Endress+Hauser 19
Operating conditions: Environment
Ambient temperature range Transmitter

• Standard: –20 to +60 °C (–4 to +140 °F)
• Optional: –40 to +60 °C (–40 to +140 °F)
! Note!
At ambient temperatures below –20 °C (–4 °F)the readability of the display may be impaired.
Sensor
• Flange material carbon steel: –10 to +60 °C (+14 to +140 °F)
• Flange material stainless steel: –40 to +60 °C (–40 to +140 °F)
" Caution!
The permitted temperature range of the measuring tube lining may not be undershot or overshot
→ ä 21, Section "Medium temperature range".
Please note the following points:
• Install the device in a shady location. Avoid direct sunlight, particularly in warm climatic regions.
• The transmitter must be mounted separate from the sensor if both the ambient and fluid temperatures are
high.
Storage temperature The storage temperature corresponds to the operating temperature range of the measuring transmitter and the
appropriate measuring sensors.
" Caution!
• The measuring device must be protected against direct sunlight during storage in order to avoid unacceptably
high surface temperatures.
• A storage location must be selected where moisture does not collect in the measuring device. This will help
prevent fungus and bacteria infestation which can damage the liner.
• Do not remove the protective plates or caps on the process connections until the device is ready to install.
Degree of protection • Standard: IP 67 (NEMA 4X) for transmitter and sensor.

• Optional: IP 68 (NEMA 6P) for sensor for remote version.
• For information regarding applications where the device is buried directly in the soil or is installed in a
flooded wastewater basin please contact your local Endress+Hauser Sales Center.
Shock and vibration resistance Acceleration up to 2 g following IEC 600 68-2-6
Electromagnetic compatibility • As per IEC/EN 61326 and NAMUR recommendation NE 21.

(EMC)
20 Endress+Hauser
Operating conditions: Process
Medium temperature range The permitted temperature depends on the lining of the measuring tube:
• PTFE: –40 to +130 °C (–40 to +266 °F) (DN 15 to 600 / ½ to 24"), restrictions → see diagrams
• PFA: –20 to +180 °C (–4 to +356 °F) (DN 25 to 200 / 1 to 8"), restrictions → see diagrams
TA [°F] [°C] HT
140 60
40
100
n
20
PFA
0 -20
m
PTFE
-40 -40
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
TF
-40 0 100 200 300 360 [°F]
A0002660
Compact version (with PFA or PTFE lining)

n HE + IP 68 to 130 °C (266 °F) only
TA [°F] [°C] HT
140 60
40
100
n
20
PFA
0 -20
m
PTFE
-40 -40
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
TF
-40 0 100 200 300 360 [°F]
A0002671
Remote version (with PFA or PTFE lining)

n HE + IP 68 to 130 °C (266 °F) only
Endress+Hauser 21
Conductivity The minimum conductivity is:

• ≥ 5 μS/cm for fluids generally
• ≥ 20 μS/cm for demineralized water
! Note!
In the remote version, the necessary minimum conductivity also depends on the cable length
(→ ä 19, Section "Length of connecting cable").
Medium pressure range • EN 1092-1 (DIN 2501)

(nominal pressure) – PN 10 (DN 200 to 600 / 8 to 24")
– PN 16 (DN 65 to 600 / 3 to 24")
– PN 25 (DN 200 to 600 / 8 to 24")
– PN 40 (DN 15 to 150 / ½ to 6")
• ANSI B 16.5
– Class 150 (DN ½ to 24")
– Class 300 (DN ½ to 6")
• JIS B2220
– 10 K (DN 50 to 300 / 2 to 12")
– 20 K (DN 15 to 300 / ½ to 12")
• AS 2129
– Table E (DN 25, 50 / 1", 2")
• AS 4087
– PN 16 (DN 50 / 2")
Pressure tightness Measuring tube lining: PTFE
25 °C (77 °F) 80 °C (176 °F) 100 °C (212 °F) 130 °C (266 °F)
[mm] [inch] [mbar] [psi] [mbar] [psi] [mbar] [psi] [mbar] [psi]
15 ½" 0 0 0 0 0 0 100 1.45
25 1" 0 0 0 0 0 0 100 1.45
32 – 0 0 0 0 0 0 100 1.45
40 1½" 0 0 0 0 0 0 100 1.45
50 2" 0 0 0 0 0 0 100 1.45

65 – 0 0 * * 40 0.58 130 1.89
80 3" 0 0 * * 40 0.58 130 1.89
100 4" 0 0 * * 135 1.96 170 2.47
125 – 135 1.96 * * 240 3.48 385 5.58

150 6" 135 1.96 * * 240 3.48 385 5.58
200 8" 200 2.90 * * 290 4.21 410 5.95
250 10" 330 4.79 * * 400 5.80 530 7.69
300 12" 400 5.80 * * 500 7.25 630 9.14
350 14" 470 6.82 * * 600 8.70 730 10.6
400 16" 540 7.83 * * 670 9.72 800 11.6
450 18"
500 20" Partial vacuum is impermissible!
600 24"
22 Endress+Hauser
Measuring tube lining: PFA
25 °C (77 °F) 80 °C (176 °F) 100 to 180 °C (212 to 356 °F)
[mm] [inch] [mbar] [psi] [mbar] [psi] [mbar] [psi]
25 1" 0 0 0 0 0 0
32 – 0 0 0 0 0 0
40 1½" 0 0 0 0 0 0
50 2" 0 0 0 0 0 0
65 – 0 0 * * 0 0
80 3" 0 0 * * 0 0
100 4" 0 0 * * 0 0
125 – 0 0 * * 0 0
150 6" 0 0 * * 0 0
200 8" 0 0 * * 0 0
Limiting flow The diameter of the pipe and the flow rate determine the nominal diameter of the sensor.
The optimum flow velocity is between 2 to 3 m/s (6.5 to 9.8 ft/s). The velocity of flow (v), moreover, has to
be matched to the physical properties of the fluid:
• v < 2 m/s (6.5 ft/s): for abrasive fluids such as potter's clay, lime milk, ore slurry etc.
• v > 2 m/s (6.5 ft/s): for fluids causing build-up such as wastewater sludges etc.
Flow characteristic values (SI units)

[mm] [inch] (v ~ 0.3 or 10 m/s) (v ~ 2.5 m/s) (~ 2 pulses/s) (v ~ 0.04 m/s)
15 ½" 4 to 100 dm3/min 25 dm3/min 0.20 dm3 0.50 dm3/min

40 1½" 25 to 700 dm3/min 200 dm3/min 1.50 dm3 3.00 dm3/min

150 6" 20 to 600 m3/h 150 m3/h 0.03 m3 2.50 m3/h
200 8" 35 to 1100 m3/h 300 m3/h 0.05 m3 5.00 m3/h
250 10" 55 to 1700 m3/h 500 m3/h 0.05 m3 7.50 m3/h
300 12" 80 to 2400 m3/h 750 m3/h 0.10 m3 10.0 m3/h
350 14" 110 to 3300 m3/h 1000 m3/h 0.10 m3 15.0 m3/h
400 16" 140 to 4200 m3/h 1200 m3/h 0.15 m3 20.0 m3/h
450 18" 180 to 5400 m3/h 1500 m3/h 0.25 m3 25.0 m3/h
500 20" 220 to 6600 m3/h 2000 m3/h 0.25 m3 30.0 m3/h
600 24" 310 to 9600 m3/h 2500 m3/h 0.30 m3 40.0 m3/h
Endress+Hauser 23
Flow characteristic values (US units)
[inch] [mm] (v ~ 0.3 or 10 m/s) (v ~ 2.5 m/s) (~ 2 pulses/s) (v ~ 0.04 m/s)
½" 25 1.0 to 26 gal/min 6 gal/min 0.10 gal 0.15 gal/min
1" 25 2.5 to 80 gal/min 18 gal/min 0.20 gal 0.25 gal/min
1½" 40 7 to 190 gal/min 50 gal/min 0.50 gal 0.75 gal/min

Pressure loss • No pressure loss if the sensor is installed in a pipe with the same nominal diameter.
• Pressure losses for configurations incorporating adapters according to DIN EN 545
(→ ä 18, Section "Adapters").
24 Endress+Hauser
Design, dimensions Transmitter remote version, wall-mount housing (non Ex-zone and II3G/Zone 2)
D
Esc
- + E
B
C
F G
A E
H J K J
N
S S
M
R
L
O
P Q P
A0001150
A B C D E F G H J
215 250 90.5 159.5 135 90 45 > 50 81
K L M N O P Q R S
53 95 53 102 81.5 11.5 192 8 × M5 20
A B C D E F G H J
8.46 9.84 3.56 6.27 5.31 3.54 1.77 > 1.97 3.18
K L M N O P Q R S
2.08 3.74 2.08 4.01 3.20 0.45 7.55 8 × M5 0.79
Endress+Hauser 25
Transmitter remote version, connection housing (II2GD/Zone 1)
A
A*
B C
B* D
e r Sp annu
ht unt ng
Nic öffnen
Nicht-eigensichere
Ke ircuit s a re aliv ile

Stromkreise durch
ove r tight wh
e
c
p cover tight w
E
ep c
Esc
Boucles de courant - +
c
E
ve
sou s nsion l Ne
pas o t e pparei
uvrir l’a
M
L
J
K
F
G
A0002128
8.6
265 242 240 217 206 186 178 100 130 100 144 170 355
(M8)
0.34
10.4 9.53 9.45 8.54 8.11 7.32 7.01 3.94 5.12 3.94 5.67 6.69 14.0
(M8)
26 Endress+Hauser
There is a separate mounting kit for the wall-mounted housing. It can be ordered from Endress+Hauser as an
accessory. The following installation variants are possible:
• Panel-mounted installation
• Pipe mounting
Installation in control panel
+0.5 (+0.019)
–0.5 (–0.019)
210 (8.27)
+0.5 (+0.019)
–0.5 (–0.019)
245 (9.65)
mm (inch) ~110 (~4.33)
A0001131
Pipe mounting
Ø 20…70
(Ø 0.79…2.75)
~155 (~ 6.1)
mm (inch)
A0001132
Endress+Hauser 27
Compact version DN ≤ 300 (12")
A B
A* C
D
Esc
- + E
F
E
G
H
K L
A0005423

D1
(4.33)
110
E1
mm (inch)
A0005529
Measurement D1, E1 = Measurement D, E of the standard compact version plus 110 mm (4.33")
28 Endress+Hauser
15 200 341 257 84 94 120
25 200 341 257 84 94 120
32 200 341 257 84 94 120
40 200 341 257 84 94 120
50 200 341 257 84 94 120
65 200 391 282 109 94 180
80 200 227 207 187 168 160 391 282 109 94 180
100 250 391 282 109 94 180

125 250 472 322 150 140 260
150 300 472 322 150 140 260
200 350 527 347 180 156 324
250 450 577 372 205 166 400
300 500 627 397 230 166 460

1)
2)
ANSI
½" 7.87 13.4 10.1 3.31 3.70 4.72
1" 7.87 13.4 10.1 3.31 3.70 4.72
1½" 7.87 13.4 10.1 3.31 3.70 4.72
2" 7.87 13.4 10.1 3.31 3.70 4.72
3" 7.87 15.4 11.1 4.29 3.70 7.09

8.94 8.15 7.36 6.61 6.30
4" 9.84 15.4 11.1 4.29 3.70 7.09
6" 11.8 18.6 12.7 5.91 5.51 10.2
8" 13.8 20.8 13.7 7.09 6.14 12.8
10" 17.7 22.7 14.7 8.07 6.54 15.8
12" 19.7 24.7 15.6 9.06 6.54 18.1

1)
Endress+Hauser 29
Compact version DN ≥ 350 (14")
A B
A* C
D
Esc
- + E
F
E
G
J
H L
A0005424
EN (DIN)
350 550 738.5 456.5 282.0 564 276

400 600 790.5 482.5 308.0 616 276
450 650 227 207 187 168 160 840.5 507.5 333.0 666 292
500 650 891.5 533.0 358.5 717 292

600 780 995.5 585.0 410.5 821 402
1)
ANSI
14" 21.7 29.1 18.0 11.1 22.2 10.9
16" 23.6 31.1 19.0 12.1 24.3 10.9
18" 25.6 8.94 8.15 7.36 6.61 6.30 33.1 20.0 13.1 26.2 11.5
20" 25.6 35.1 21.0 14.1 28.2 11.5

24" 30.7 39.2 23.0 16.2 32.3 15.8
1)
30 Endress+Hauser
Sensor, remote version DN ≤ 300 (12")
A B
C
F
E
G
J
H L
A0012462
D1
(4.33)
110
E1
mm (inch)
A0005570
Measurement D1, E1 = Measurement D, E of the standard remote version plus 110 mm (4.33")
Endress+Hauser 31
15 200 286 202 84 120 94
25 200 286 202 84 120 94
32 200 286 202 84 120 94
40 200 286 202 84 120 94
50 200 286 202 84 120 94
65 200 336 227 109 180 94
80 200 129 163 143 102 336 227 109 180 94
100 250 336 227 109 180 94

125 250 417 267 150 260 140
150 300 417 267 150 260 140
200 350 472 292 180 324 156
250 450 522 317 205 400 166
300 500 572 342 230 460 166

1)
2)
ANSI
½" 7.87 11.3 7.95 3.31 4.72 3.70
1" 7.87 11.3 7.95 3.31 4.72 3.70
1½" 7.87 11.3 7.95 3.31 4.72 3.70
2" 7.87 11.3 7.95 3.31 4.72 3.70
3" 7.87 13.2 8.94 4.29 7.09 3.70

5.08 6.42 5.63 4.02
4" 9.84 13.2 8.94 4.29 7.09 3.70
6" 11.8 16.4 10.5 5.91 10.2 5.51
8" 13.8 18.6 11.5 7.08 12.8 6.14
10" 17.7 20.6 12.5 8.07 15.8 6.54
12" 19.7 22.5 13.5 9.06 18.1 6.54

1)
32 Endress+Hauser
Sensor, remote version DN ≥ 350 (14")
A B
C
F
E
G
J
H L
A0003220
EN (DIN)
350 550 683.5 401.5 282.0 564 276

400 600 735.5 427.5 308.0 616 276
450 650 129 163 143 102 785.5 452.5 333.0 666 292
500 650 836.5 478.0 358.5 717 292

600 780 940.5 530.0 410.5 821 402
1)
ANSI
14" 21.7 26.9 15.8 11.1 22.2 10.9
16" 23.6 29.0 16.8 12.1 24.3 10.9
18" 25.6 5.08 6.42 5.63 4.02 30.9 17.8 13.1 26.2 11.5
20" 25.6 32.9 18.8 14.1 28.2 11.5

24" 30.7 37.0 20.9 16.2 32.3 15.8
1)
Endress+Hauser 33
Ground disk for flange connections
DN ≤ 300 (12") DN ≥ 350 (14")
ØE ØE
D
ØB ØB A
A ØC
Ø ØC
Ø
t t
A0003221
DN 1) A B C D E t
2)
EN (DIN) / JIS / AS PTFE, PFA
15 16 43 61.5 73
25 26 62 77.5 87.5
32 35 80 87.5 94.5
40 41 82 101 103
50 52 101 115.5 108
65 68 121 131.5 118

80 80 131 154.5 135
6.5
100 104 156 186.5 153
125 130 187 206.5 160

150 158 217 256 184 2
200 206 267 288 205
250 260 328 359 240

3)
300 312 375 413 273
300 4) 310 375 404 268
3)
350 343 433 479 365
3)
400 393 480 542 395
450 3) 439 538 583 417 9.0
3)
500 493 592 650 460
3)
600 593 693 766 522
1) Ground disks at DN 15 to 250 (½ to 10") can be used for all flange standards/pressure ratings.
2)
3)
PN 10/16
4) PN 25, JIS 10K/20K
34 Endress+Hauser
DN 1) A B C D E t
ANSI PTFE, PFA
½" 0.63 1.69 2.42 2.87
1" 1.02 2.44 3.05 3.44
1½" 1.61 3.23 3.98 4.06
2" 2.05 3.98 4.55 4.25
3" 3.15 5.16 6.08 5.31

0.26
4" 4.09 6.14 7.34 6.02
6" 6.22 8.54 10.08 7.24
8" 8.11 10.5 11.3 8.07 0.08

10" 10.2 12.9 14.1 9.45
12" 12.3 14.8 16.3 10.8
14" 13.5 17.1 18.9 14.4
16" 15.45 18.9 21.3 15.6
18" 17.3 21.2 23.0 16.4 0.35
20" 19.4 23.3 25.6 18.1
24" 23.4 27.3 30.1 20.6

1) Ground disks can be used for all flange standards/pressure ratings.
Endress+Hauser 35
Weight Weight in SI units
Weight data in kg
Nominal Compact version Remote version (without cable)

diameter
Sensor Transmitter
[mm] [inch] EN (DIN) / JIS ANSI EN (DIN) / JIS ANSI Wall-mount housing
AS 1) AS 1)
15 ½" 6.5 6.5 6.5 4.5 4.5 4.5
25 1" 7.3 7.3 7.3 5.3 5.3 5.3

PN 40
PN 40
32 – 8.0 7.3 – 6.0 5.3 –
40 1½" 9.4 8.3 9.4 7.4 6.3 7.4
50 2" 10.6 9.3 10.6 8.6 7.3 8.6
65 – 12.0 11.1 – 10.0 9.1 –

10K
10K
80 3" 14.0 12.5 14.0 12.0 10.5 12.0
PN 16
PN 16
100 4" 16.0 14.7 16.0 14.0 12.7 14.0
Class 150
Class 150
125 – 21.5 21.0 – 19.5 19.0 –
6.0
150 6" 25.5 24.5 25.5 23.5 22.5 23.5
200 8" 45 41.9 45 43 39.9 43

250 10" 65 69.4 75 63 67.4 73
300 12" 70 72.3 110 68 70.3 108
350 14" 115 175 113 173

PN 10
PN 10
400 16" 135 205 133 203
450 18" 175 255 173 253
500 20" 175 285 173 283

600 24" 235 405 233 403
1)
For flanges to AS, only DN 25 and 50 are available.
• Transmitter (compact version): 3.4 kg, high temperature version: +1.5 kg
36 Endress+Hauser
Weight in US units (only ANSI)
Weight data in lbs
Nominal diameter Compact version Remote version (without cable)
Sensor Transmitter
[mm] [inch] ANSI ANSI Wall-mount housing
15 ½" 14.3 9.92
25 1" 16.1 11.7
40 1½" 20.7 16.3

50 2" 23.4 19.0
80 3" 30.9 26.5
100 4" 35.3 30.9
150 6" 56.2 51.8
Class 150
Class 150
200 8" 99.2 94.8 13.2
250 10" 165.4 161.0
300 12" 242.6 238.1
350 14" 385.9 381.5
400 16" 452.0 447.6
450 18" 562.3 557.9

500 20" 628.4 624.0
600 24" 893.0 888.6
• Transmitter (compact version): 7.50 lbs, high temperature version: +3.31 lbs
Measuring tube specifications Diameter Pressure rating Internal diameter
EN (DIN) AS 2129 AS 4087 ANSI JIS PFA PTFE

[mm] [inch] [bar] [lbs] [mm] [inch] [mm] [inch]
15 ½" PN 40 – – Cl.150 20K – – 15 0.59
25 1" PN 40 Table E – Cl.150 20K 23 0.91 26 1.02
32 – PN 40 – – – 20K 32 1.26 35 1.38
40 1½" PN 40 – – Cl.150 20K 36 1.42 41 1.61
50 2" PN 40 Table E PN 16 Cl.150 10K 48 1.89 52 2.05
65 – PN 16 – – – 10K 63 2.48 67 2.64
80 3" PN 16 – – Cl.150 10K 75 2.95 80 3.15
100 4" PN 16 – – Cl.150 10K 101 3.98 104 4.09
125 – PN 16 – – – 10K 126 4.96 129 5.08
150 6" PN 16 – – Cl.150 10K 154 6.06 156 6.14
200 8" PN 10 – – Cl.150 10K 201 7.91 202 7.95

250 10" PN 10 – – Cl.150 10K – – 256 10.1
300 12" PN 10 – – Cl.150 10K – – 306 12.0
350 14" PN 10 – – Cl.150 – – – 337 13.3

400 16" PN 10 – – Cl.150 – – – 387 15.2
450 18" PN 10 – – Cl.150 – – – 432 17.0
500 20" PN 10 – – Cl.150 – – – 487 19.2
600 24" PN 10 – – Cl.150 – – 23 593 23.3
Endress+Hauser 37
Material • Transmitter housing

– Compact housing: powder-coated die-cast aluminum
– Wall-mount housing: powder-coated die-cast aluminum
• Sensor housing
– DN 25 to 300 (1 to 12"): powder-coated die-cast aluminum
– DN 350 to 600 (14 to 24"): with protective lacquering
• Measuring tube
– DN ≤ 300 (12"): stainless steel 1.4301 or 1.4306/304L;
(for flanges made of carbon steel with Al/Zn protective coating)
– DN ≥ 350 (14"): stainless steel 1.4301 or 1.4306/304L;
(for flanges made of carbon steel with protective lacquering)
• Electrodes: 1.4435, Platinum, Alloy C-22, Tantalum, Titanium
• Flanges
– EN 1092-1 (DIN 2501): 1.4571/316L; RSt37-2 (S235JRG2); C22; FE 410W B
– ANSI: A105; F316L
– AWWA: 1.0425
– JIS: RSt37-2 (S235JRG2); HII; 1.0425/316L
– AS 2129
– DN 25 (1"): A105 or RSt37-2 (S235JRG2)
– DN 40 (1 ½"): A105 or St44-2 (S275JR)
– AS 4087: A105 or St44-2 (S275JR)
• Seals: to DIN EN 1514-1
• Ground disks: 1.4435/316L or Alloy C-22
Material load diagram
" Caution!
The following diagrams contain material load diagrams (reference curves) for flange materials with regard to
the medium temperature. However, the maximum medium temperatures permitted always depend on the
lining material of the sensor and/or the sealing material (→ ä 21).

Material: RSt37-2 (S235JRG2) / C22 / Fe 410W B
[psi] [bar]
600
40
PN 40
500 35
30
400
25
PN 25
300 20
200 15
PN 16
10
PN 10
100
5 PN 6
0 0
-60 -40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0005594
38 Endress+Hauser

Material: 316L / 1.4571
[psi] [bar]
600
40
PN 40
500 35
30
400
25
PN 25
300 20
200 15 PN 16
10
PN 10
100
5 PN 6
0 0
-60 -40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]

A0005304

Material: A 105
[psi] [bar]
900 60
800
700 50 Class 300
600 40
500
400 30
300 20 Class 150
200
10
100
0 0
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0003226

Material: F316L
[psi] [bar]
900 60
800
700 50
600 40 Class 300
500
400 30
300 20
200 Class 150
10
100
0 0
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0005307
Endress+Hauser 39
Flange connection to JIS B2220

Material: RSt37-2 (S235JRG2) / HII / 1.0425 / 316L
[psi] [bar]
30
400
20K
300 20
200
10K
10
100
0 0
-40 -20 0 20 40 60 80 100 120 140 160 180 [°C]
-40 0 100 200 300 360 [°F]
A0003228
Flange connection to AS 2129 Table E or AS 4087 PN 16

Material: A105 / RSt37-2 (S235JRG2) / St44-2 (S275JR)
[psi] [bar]
300 20
PN 16
200 15
Table E
10
100
5
0 0
-40 -20 0 20 40 60 80 100 120 140 160 [°C]
-40 0 100 200 300 [°F]
A0005595
Fitted electrodes Measuring electrodes, reference electrodes and empty pipe detection electrodes:
• Standard available with 1.4435, Alloy C-22, tantalum, platinum/rhodium 80/20, titanium
• Optional: measuring electrodes made of platinum/rhodium 80/20
Process connections Flange connection:

• EN 1092-1 (DIN 2501), DN ≤ 300 (12") form A, DN ≥ 350 (14") form B
(Dimensions to DIN 2501, DN 65 PN 16 and DN 600 (24") PN 16 exclusively to EN 1092-1)
• ANSI B16.5
• JIS B2220
• AS 2129 Table E
• AS 4087 PN 16
Surface roughness • PFA liner: ≤ 0.4 μm (15.7 μin)

• Elektroden
– 1.4435, Alloy C-22, titanium: ≤ 0.3 to 0.5 μm (≤ 11.8 to 19.7 μin)
– Tantal, Platin/Rhodium: ≤ 0.3 to 0.5 μm (≤ 11.8 to 19.7 μin)
(All data refer to parts in contact with medium)
40 Endress+Hauser
Human interface
Display elements • Liquid crystal display: backlit, two lines (Promag 50) or four lines (Promag 53) with 16 characters per line
• Custom configurations for presenting different measured-value and status variables
• Totalizer
Operating elements Unified operation concept for both types of transmitter:

Promag 50:
• Quick Setup menus for straightforward commissioning
Promag 53:
• Application-specific Quick Setup menus for straightforward commissioning
Language groups Language groups available for operation in different countries:

Promag 50, Promag 53:
• Western Europe and America (WEA):
English, German, Spanish, Italian, French, Dutch, Portuguese
• Eastern Europe and Scandinavia (EES):
English, Russian, Polish, Norwegian, Finnish, Swedish, Czech
• South and east Asia (SEA):
English, Japanese, Indonesian
Promag 53:
• China (CN):
English, Chinese
You can change the language group via the operating program "FieldCare".
Remote operation • Promag 50: Remote control via HART, PROFIBUS DP/PA
• Promag 53: Remote control via HART, PROFIBUS DP/PA, MODBUS RS485, FOUNDATION Fieldbus
Endress+Hauser 41

CE mark The measuring system is in conformity with the statutory requirements of the EC Directives.
Endress+Hauser confirms successful testing of the device by affixing to it the CE mark.
C-tick mark The measuring system meets the EMC requirements of the "Australian Communications and Media Authority
(ACMA)".
Pressure measuring device Measuring devices with a nominal diameter smaller than or equal to DN 25 correspond to Article 3(3)
approval of the EC Directive 97/23/EC (Pressure Equipment Directive) and have been designed and manufactured
according to good engineering practice. Where necessary (depending on the medium and process pressure),
there are additional optional approvals to Category II/III for larger nominal diameters.
Ex approval Information about currently available Ex versions (ATEX, IECEx, FM, CSA, NEPSI) can be supplied by your
Endress+Hauser Sales Center on request. All explosion protection data are given in a separate documentation
which is available upon request.
Other standards and • EN 60529

guidelines Degrees of protection by housing (IP code)
• EN 61010
Protection Measures for Electrical Equipment for Measurement, Control, Regulation and Laboratory
Procedures.
• IEC/EN 61326
“Emission in accordance with requirements for Class A”.
Electromagnetic compatibility (EMC requirements)
• NAMUR NE 21:
Electromagnetic compatibility (EMC) of industrial process and laboratory control equipment.
• NAMUR NE 43:
Standardization of the signal level for the breakdown information of digital transmitters with analog output
signal.
• NAMUR NE 53:
Software of field devices and signal-processing devices with digital electronics.
• ANSI/ISA-S82.01
Safety Standard for Electrical and Electronic Test, Measuring, Controlling and related Equipment - General
Requirements Pollution degree 2, Installation Category II.
• CAN/CSA-C22.2 No. 1010.1-92
Safety requirements for Electrical Equipment for Measurement and Control and Laboratory Use.
Pollution degree 2, Installation Category II
FOUNDATION Fieldbus The flow device has successfully passed all the test procedures carried out and is certified and registered by the
certification Fieldbus Foundation. The device thus meets all the requirements of the following specifications:
• Certified to FOUNDATION Fieldbus Specification
• The device meets all the specifications of the FOUNDATION Fieldbus H1.
• Interoperability Test Kit (ITK), revision status 5.01 (device certification number: on request)
• The device can also be operated with certified devices of other manufacturers
• Physical Layer Conformance Test of the Fieldbus Foundation
MODBUS RS485 certification The measuring device meets all the requirements of the MODBUS/TCP conformity test and has the “MOD-
BUS/TCP Conformance Test Policy, Version 2.0”. The measuring device has successfully passed all the test
procedures carried out and is certified by the “MODBUS/TCP Conformance Test Laboratory” of the University
of Michigan.
PROFIBUS DP/PA The flow device has successfully passed all the test procedures carried out and is certified and registered by the
certification PNO (PROFIBUS User Organisation). The device thus meets all the requirements of the following
specifications:
• Certified to PROFIBUS PA, profile version 3.0 (device certification number: on request)
• The device can also be operated with certified devices of other manufacturers (interoperability)
42 Endress+Hauser
Your Endress+Hauser service organization can provide detailed ordering information and information on the
order codes on request.
Accessories
Various accessories, which can be ordered separately from Endress+Hauser, are available for the transmitter
and the sensor. Your Endress+Hauser service organization can provide detailed information on the order codes
in question.
Documentation
• Flow Measurement (FA005D/06)
• Operating Instructions Promag Promag 50 PROFIBUS PA (BA055D/06 and BA056D/06)
• Operating Instructions Promag Promag 53 FOUNDATION Fieldbus (BA051D/06 and BA052D/06)
• Operating Instructions Promag Promag 53 MODBUS RS485 (BA117D/06 and BA118D/06)
• Operating Instructions Promag Promag 53 PROFIBUS DP/PA (BA053D/06 and BA054D/06)
• Supplementary documentation on Ex-ratings: ATEX, IECEx, FM, CSA, NEPSI
Registered trademarks
HART®
Registered trademark of the HART Communication Foundation, Austin, USA
PROFIBUS®
Registered trademark of the PROFIBUS Nutzerorganisation e.V., Karlsruhe, D
FOUNDATION™ Fieldbus
Registered trademark of the Fieldbus Foundation, Austin, USA
MODBUS®
Registered trademark of the MODBUS Organisation
HistoROM™, S-DAT®, T-DAT™, F-CHIP®, FieldCare®, Fieldcheck®, FieldXpert™, Applicator®
Registered or registration-pending trademarks of Endress+Hauser Flowtec AG, Reinach, CH
Endress+Hauser 43
Instruments International
Endress+Hauser
Instruments International AG
Kaegenstrasse 2
4153 Reinach
Switzerland
Tel. +41 61 715 81 00

Fax +41 61 715 25 00
www.endress.com
[email protected]
TI047D/06/en/11.09
71106271
FM+SGML6.0 ProMoDo
KA00026D/06/EN/18.16
71321439
Products Solutions Services
Brief Operating Instructions

Proline Promag 50
These Brief Operating Instructions are not intended to replace

the Operating Instructions provided in the scope of supply.
Detailed information is provided in the Operating Instructions
and the additional documentation on the CD-ROM supplied.
The complete device documentation consists of:
• These Brief Operating Instructions
• Depending on the device version:
– Operating Instructions and the Description of Device Funct.
– Approvals and safety certificates
– Special safety instructions in accordance with the approvals
for the device (e.g. explosion protection, pressure
equipment directive etc.)
– Additional device-specific information
Proline Promag 50 Table of contents
Table of contents
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Installation, commissioning and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Safety conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Transporting to the measuring point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Installing the Promag E sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Installing the Promag H sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Installing the Promag L sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 Installing the Promag P sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Installing the Promag W sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.8 Installing the transmitter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.9 Post-installation check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.1 Connecting the various housing types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Connecting the remote version connecting cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3 Potential equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4 Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.5 Post-connection check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Hardware settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Device address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Terminating resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1 Switching on the measuring device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 Navigating within the function matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4 Calling the Commissioning Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.5 Software settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Endress+Hauser 3
1 Safety instructions
1.1 Designated use
• The measuring device is to be used only for measuring the flow of conductive liquids in closed
pipes. A minimum conductivity of 20 μS/cm is required for measuring demineralized water.
Most liquids can be measured as of a minimum conductivity of 5 μS/cm.
• Any use other than that described here compromises the safety of persons and the entire
measuring system and is, therefore, not permitted.
• The manufacturer is not liable for damage caused by improper or non-designated use.
1.2 Installation, commissioning and operation

• The measuring device must only be installed, connected, commissioned and maintained by
qualified and authorized specialists (e.g. electrical technicians) in full compliance with the
instructions in these Brief Operating Instructions, the applicable norms, legal regulations and
certificates (depending on the application).
• The specialists must have read and understood these Brief Operating Instructions and must
follow the instructions they contain. If you are unclear on anything in these Brief Operating
Instructions, you must read the Operating Instructions (on the CD-ROM). The Operating
Instructions provide detailed information on the measuring device.
• The measuring device should only installed in a de-energized state free from outside loads or
strain.
• The measuring device may only be modified if such work is expressly permitted in the
Operating Instructions (on the CD-ROM).
• Repairs may only be performed if a genuine spare parts kit is available and this repair work is
expressly permitted.
• If performing welding work on the piping, the welding unit may not be grounded by means of
the measuring device.
1.3 Operational safety

• The measuring device is designed to meet state-of-the-art safety requirements, has been
tested, and left the factory in a condition in which it is safe to operate. Relevant regulations
and European standards have been observed.
• The manufacturer reserves the right to modify technical data without prior notice. Your
Endress+Hauser distributor will supply you with current information and updates to these
Operating Instructions.
• The information on the warning notices, nameplates and connection diagrams affixed to the
device must be observed. These contain important data on the permitted operating
conditions, the range of application of the device and information on the materials used.
• If the device is not used at atmospheric temperatures, compliance with the relevant marginal
conditions as specified in the device documentation supplied (on CD-ROM) is mandatory.
• The device must be wired as specified in the wiring and connection diagrams. Interconnection
must be permitted.
4 Endress+Hauser
Proline Promag 50 Safety instructions
• All parts of the device must be included in the potential equalization of the system.
• Cables, certified cable glands and certified dummy plugs must be suitable to withstand the
prevailing operating conditions, such as the temperature range of the process. Housing
apertures that are not used must be sealed with dummy plugs.
• The device should only be used for fluids to which all the wetted parts of the device are
sufficiently resistant. With regard to special fluids, including fluids used for cleaning,
Endress+Hauser will be happy to assist in clarifying the corrosion-resistant properties of
wetted materials.
However, minor changes in temperature, concentration or in the degree of contamination in
the process may result in variations in corrosion resistance.
For this reason, Endress+Hauser does not accept any responsibility with regard to the
corrosion resistance of wetted materials in a specific application. The user is responsible for
the choice of suitable wetted materials in the process.
• When hot fluid passes through the measuring tube, the surface temperature of the housing
increases. In the case of the sensor, in particular, users should expect temperatures that can
be close to the fluid temperature. If the temperature of the fluid is high, implement sufficient
measures to prevent burning or scalding.
• Hazardous areas
Measuring devices for use in hazardous areas are labeled accordingly on the nameplate.
Relevant national regulations must be observed when operating the device in hazardous
areas. The Ex documentation on the CD-ROM is an integral part of the entire device
documentation.
The installation regulations, connection data and safety instructions provided in the Ex
documentation must be observed. The symbol and name on the front page provides
information on the approval and certification (e.g. 0 Europe, 2 USA, 1 Canada). The
nameplate also bears the documentation number of this Ex documentation (XA***D/../..).
• For measuring systems used in SIL 2 applications, the separate manual on functional safety
(on the CD-ROM) must be observed.
• Hygienic applications
Measuring devices for hygienic applications have their own special labeling. Relevant national
regulations must be observed when using these devices.
• Pressure instruments
Measuring devices for use in systems that need to be monitored are labeled accordingly on the
nameplate. Relevant national regulations must be observed when using these devices. The
documentation on the CD-ROM for pressure instruments in systems that need to be
monitored is an integral part of the entire device documentation. The installation regulations,
connection data and safety instructions provided in the Ex documentation must be observed.
• Endress+Hauser will be happy to assist in clarifying any questions on approvals, their
application and implementation.
Endress+Hauser 5
1.4 Safety conventions

# Warning!
"Warning" indicates an action or procedure which, if not performed correctly, can result in injury
or a safety hazard. Comply strictly with the instructions and proceed with care.
"Caution!
"Caution" indicates an action or procedure which, if not performed correctly, can result in
incorrect operation or destruction of the device. Comply strictly with the instructions.
Note! "Note" indicates an action or procedure which, if not performed correctly, can have an
indirect effect on operation or trigger an unexpected response on the part of the device.
6 Endress+Hauser
2 Installation
2.1 Transporting to the measuring point
• Transport the measuring device to the measuring point in the original packaging.
• Do not remove the covers or caps until immediately before installation.
2.1.1 Transporting flanged devices DN  300 (12")
To transport the unit, use slings slung around the

process connections or use lugs (if available).
# Warning!
Risk of injury! The device can slip.
The center of gravity of the measuring device may be
higher than the holding points of the slings.
Always ensure that the device cannot slip or turn around
its axis.
A0007408
Do not lift measuring devices by the transmitter housing

or the connection housing in the case of the remote
version. Do not use chains as they could damage the
housing.
A0007409
2.1.2 Transporting flanged devices DN > 300 (12")

Use only the metal eyes provided on the flanges to transport, lift or position the sensor in the
piping.
" Caution!
Do not attempt to lift the sensor with the tines of a fork-lift truck beneath the metal casing!
A0008153
Endress+Hauser 7
2.2 Installation conditions

2.2.1 Dimensions
For the dimensions of the measuring device, see the associated Technical Information on the
CD-ROM.
2.2.2 Mounting location

The accumulation of air or formation of gas bubbles in the measuring tube can result in an
increase in measuring errors.
For this reason avoid the following mounting locations in the pipe:
• At the highest point of a pipeline. Risk of air accumulating!
• Directly upstream from a free pipe outlet in a down pipe.
h ³ 2 x DN
A0008154
Do not install the sensor on the intake side of a pump. This precaution is to avoid low pressure
and the consequent risk of damage to the lining of the measuring tube. It might be necessary to
use pulse dampers in systems incorporating piston pumps, piston diaphragm pumps or
peristaltic pumps.
Information on the measuring system's pressure tightness and resistance to vibration and shock
can be found in the Operating Instructions of the CD-ROM.
A0003203
8 Endress+Hauser

The empty pipe detection (EPD) function offers additional protection by detecting empty or
partially filled pipes.
" Caution!
Risk of solids accumulating! Do not install the sensor at the lowest point in the drain. It is
advisable to install a cleaning valve.
Installation in a partially filled pipe
³2 x DN
³5 x DN
A0008155
Down pipes
Install a siphon or a vent valve downstream of the sensor in down pipes longer than 5 meters
(16 ft). This precaution is to avoid low pressure and the consequent risk of damage to the lining
of the measuring tube. This measure also prevents the system losing prime, which could cause
air pockets.
For information on the pressure tightness of the measuring tube lining, see the Operating
Measures for installation in a down pipe (h > 5 m / 16 ft)

1 1. Vent valve
2. Siphon
2
h
A0008157
Endress+Hauser 9
2.2.3 Orientation
An optimum orientation helps avoid gas and air accumulations and buildup in the measuring
tube. The measuring device, nevertheless, supplies a range of functions and tools to measure
problematic fluids correctly:
• Electrode cleaning circuitry (ECC) to prevent electrically conductive deposits in the measuring
tube, e.g. for fluids causing buildup
• Empty pipe detection (EPD) for detecting partially filled measuring tubes, e.g. in the case of
degassing fluids or varying process pressures
• Exchangeable measuring electrodes for abrasive fluids (only Promag W)
This orientation is optimum for self-emptying piping

systems and when using empty pipe detection (EPD) or
open electrode detection (OED).
A0008158
The measuring electrode plane should be horizontal. This prevents brief insulation of the two
"Caution!
In the case of horizontal orientation, empty pipe detection only works correctly if the transmitter
housing is facing upwards. Otherwise there is no guarantee that empty pipe detection will
respond if the measuring tube is only partially filled or empty.
1. EPD electrode for empty pipe detection

A (not for Promag H, DN 2 to 15 / 1/12 to ½").
1 2. Measuring electrodes for signal detection
3. Reference electrode for potential equalization
(not for Promag H)
2 2
A
A0008159
10 Endress+Hauser
Inlet and outlet runs

If possible, install the sensor upstream from fittings such as valves, T-pieces, elbows, etc.
The following inlet and outlet runs must be observed in

³ 5 x DN ³ 2 x DN order to meet accuracy specifications:
• Inlet run:  5 × DN
• Outlet run:  2 × DN
A0008160
2.2.4 Vibrations
Secure and fix both the piping and the sensor if vibrations are severe.
Measures to prevent device vibration

L (L > 10 m / 33 ft)
" Caution!
It is advisable to install the sensor and transmitter
separately if vibration is excessively severe. For
information on the permitted shock and vibration
resistance, see the Operating Instructions on the
CD-ROM.
A0008161
Endress+Hauser 11
2.2.5 Foundations, supports

If the nominal diameter is DN  350 (14"), mount the sensor on a foundation of adequate
load-bearing strength.
"
Caution!
Risk of damage! Do not support the weight of the sensor on the metal casing.
A0008163
2.2.6 Length of connecting cable

Comply with the following instructions in order to ensure correct measuring results:
• Secure the cable run or route the cable in an armored conduit. Movement of the cable can
falsify the measuring signal, particularly if the fluid conductivity is low.
• Ensure potential equalization between the sensor and transmitter, if necessary.
• The permissible cable length Lmax depends on the fluid conductivity.
Gray shaded area = permissible

[µS/cm] range
200
Lmax = length of connecting
cable in [m]/[ft]
Fluid conductivity in (μS/cm]
100
L max
5 [m]
10 100 200 L max
[ft]
0 200 400 600
A0008164
12 Endress+Hauser
2.3 Installing the Promag E sensor

" Caution!
sensor.

customer.
shipment.
a0008165
2.3.1 Seals
" Caution!
measuring signal.
2.3.2 Ground cable

2.3.3 Tightening torques for threaded fasteners (Promag E)

Endress+Hauser 13
Promag E tightening torques for EN (DIN)
Nominal diameter EN (DIN) Threaded Max. tightening torque

[mm] Pressure rating [bar] fasteners [Nm]
15 PN 40 4 × M 12 11
25 PN 40 4 × M 12 26
32 PN 40 4 × M 16 41
40 PN 40 4 × M 16 52
50 PN 40 4 × M 16 65
65 * PN 16 8 × M 16 43
80 PN 16 8 × M 16 53
100 PN 16 8 × M 16 57
125 PN 16 8 × M 16 75
150 PN 16 8 × M 20 99
200 PN 10 8 × M 20 141
200 PN 16 12 × M 20 94
250 PN 10 12 × M 20 110
250 PN 16 12 × M 24 131
300 PN 10 12 × M 20 125
300 PN 16 12 × M 24 179
350 PN 6 12 × M 20 200
350 PN 10 16 × M 20 188
350 PN 16 16 × M 24 254
400 PN 6 16 × M 20 166
400 PN 10 16 × M 24 260
400 PN 16 16 × M 27 330
450 PN 6 16 × M 20 202
450 PN 10 20 × M 24 235
450 PN 16 20 × M 27 300
500 PN 6 20 × M 20 176
500 PN 10 20 × M 24 265
500 PN 16 20 × M 30 448
600 PN 6 20 × M 24 242
600 PN 10 20 × M 27 345
600 * PN 16 20 × M 33 658
14 Endress+Hauser
Promag E tightening torques for ANSI
Nominal diameter ANSI Max. tightening torque
Pressure rating Threaded PTFE

[mm] [inch] [lbs] fasteners [Nm] [lbf · ft]
15 ½" Class 150 4 × ½" 6 4
25 1" Class 150 4 × ½" 11 8
40 1 ½" Class 150 4 × ½" 24 18
50 2" Class 150 4 × 5/8" 47 35
80 3" Class 150 4 × 5/8" 79 58
100 4" Class 150 8 × 5/8" 56 41
150 6" Class 150 8 × ¾" 106 78
200 8" Class 150 8 × ¾" 143 105
250 10" Class 150 12 × 7/8" 135 100
300 12" Class 150 12 × 7/8" 178 131
350 14" Class 150 12 × 1" 260 192
400 16" Class 150 16 × 1" 246 181
450 18" Class 150 16 × 1 1/8" 371 274
500 20" Class 150 20 × 1 1/8" 341 252
600 24" Class 150 20 × 1 ¼" 477 352
Promag E tightening torques for JIS

[mm] Pressure rating Threaded fasteners PTFE
15 20K 4 × M 16 16
25 20K 4 × M 16 32
32 20K 4 × M 16 38
40 20K 4 × M 16 41
50 10K 4 × M 16 54
65 10K 4 × M 16 74
80 10K 8 × M 16 38
100 10K 8 × M 16 47
125 10K 8 × M 20 80
150 10K 8 × M 20 99
200 10K 12 × M 20 82
250 10K 12 × M 22 133
300 10K 16 × M 22 99
Endress+Hauser 15
2.4 Installing the Promag H sensor

Depending on the order specifications, the sensor is supplied with or without ready-mounted
process connections. Mounted process connections are fixed to the sensor with 4 or 6
hexagonal-headed bolts.
"
Caution!
Depending on the application and length of the pipe, the sensor may have to be supported or
additionally secured. The sensor must be secured if using plastic process connections. An
appropriate wall mounting kit can be ordered separately from Endress+Hauser as an accessory.
2.4.1 Seals
When mounting the process connections, make sure that the seals in question are free from dirt
and centered correctly.
"
Caution!
• The screws must be securely tightened in the case of metal process connections. Together
with the sensor, the process connection forms a metal connection that ensures defined seal
compression.
• With regard to process connections made of plastic material, comply with the max. torques
for lubricated threads (7 Nm / 5.2 lbf ft). A seal must always be used between the connection
and counterflange for plastic flanges.
• The seals should be replaced periodically depending on the application, particularly if molded
seals are used (aseptic version)! The intervals between seal replacement depend on the
frequency of the cleaning cycles and the fluid and cleaning temperatures. Replacement seals
can be ordered as an accessory.
2.4.2 Using and mounting grounding rings (DN 2 to 25 / 1/12 to 1")

In the case of process connections made of plastic (e.g. flange connections or adhesive
couplings), potential equalization between the sensor and fluid must be ensured via additional
grounding rings.
If grounding rings are missing, this can affect accuracy or result in the destruction of the sensor
due to electrochemical electrode reduction.
"
Caution!
• Depending on the order option, appropriate plastic disks are used instead of grounding rings
for the process connections. These plastic disks only act as a kind of "place holder" and do not
have any potential equalization function whatsoever. In addition, they also assume an
important sealing function at the sensor/connection interface. Thus, these plastic disks/seals
should never be removed and should always be mounted for process connections without
metal grounding rings!
• Grounding rings can be ordered separately from Endress+Hauser as an accessory.
When ordering, make sure that the grounding rings are compatible with the electrode
material. Otherwise there is the risk that electrodes can be damaged by electrochemical
corrosion! For information on materials, see the Operating Instructions on the CD-ROM.
16 Endress+Hauser
• Grounding rings, incl. seals, are mounted inside the process connections.
The face-to-face length is not affected.
Installing the grounding rings
1 = Process connection hexagonal-headed bolts

2 = O-ring seals
4 = Sensor
3 = Grounding ring or plastic disk (place holder)
1
2 3 2 4
a0008168
a. Release the 4 or 6 hexagonal-headed bolts (1) and remove the process connection from the sensor (4).
b. Remove the plastic disk (3) including the two O-ring seals (2) from the process connection.
c. Insert one of the O-ring seals (2) back into the groove of the process connection.
d. Place the metal grounding ring (3) into the process connection as illustrated.
e. Now insert the second O-ring seal (2) into the groove of the grounding ring.
f. Mount the process connection back onto the sensor. In doing so, make sure to observe the max. torques for lubricated
threads (7 Nm) (5.2 lbf ft).
2.4.3 Welding the sensor into the pipe (weld nipples)
"
Caution!
Risk of destroying the electronics! Make sure that the welding system is not grounded via the
sensor or transmitter.
a. Secure the sensor with a few welding points in the pipe.
A welding jig suitable for this purpose can be ordered separately as an accessory.
b. Release the screws on the process connection flange and remove the sensor, including the
seal, from the pipe.
c. Weld the process connection into the pipe.
d. Mount the sensor back into the pipe.
In doing so, make sure the seals are clean and correctly positioned.
Note! •When welding is performed correctly with thin-walled pipes carrying food, the seal is
not damaged by the heat even when it is mounted. It is recommended, however, to
disassemble the sensor and seal.
• For the disassembly work, it must be possible to open the pipe approx. 8 mm (0.31 in) in
total.
Endress+Hauser 17
2.5 Installing the Promag L sensor

"
Caution!
• The protective covers mounted on the two sensor flanges (DN 25 to 300 / 1 to 12") are used
to hold the lap joint flanges in place and to protect the PTFE liner during transportation.
Consequently, do not remove these covers until immediately before the sensor is installed in
the pipe.

customer.
shipment.
a0008165
2.5.1 Seals
• Hard rubber lining  additional seals are always required!
• No seals are required for PFTE measuring tube lining.
"
Caution!
signal.
2.5.2 Ground cable

2.5.3 Screw tightening torques (Promag L)

18 Endress+Hauser
Promag L tightening torques for EN (DIN)

meter
rating fasteners
[bar]
25 PN 10/16 4 × M 12 - 6 11
32 PN 10/16 4 × M 16 - 16 27
40 PN 10/16 4 × M 16 - 16 29
50 PN 10/16 4 × M 16 - 15 40
65* PN 10/16 8 × M 16 - 10 22
80 PN 10/16 8 × M 16 - 15 30
100 PN 10/16 8 × M 16 - 20 42
125 PN 10/16 8 × M 16 - 30 55
150 PN 10/16 8 × M 20 - 50 90
200 PN 16 12 × M 20 - 65 87
250 PN 16 12 × M 24 - 126 151
300 PN 16 12 × M 24 - 139 177
350 PN 6 12 × M 20 111 120 -
350 PN 10 16 × M 20 112 118 -
400 PN 6 16 × M 20 90 98 -
400 PN 10 16 × M 24 151 167 -
450 PN 6 16 × M 20 112 126 -
450 PN 10 20 × M 24 153 133 -
500 PN 6 20 × M 20 119 123 -
500 PN 10 20 × M 24 155 171 -
600 PN 6 20 × M 24 139 147 -
600 PN 10 20 × M 27 206 219 -
700 PN 6 24 × M 24 148 139 -
700 PN 10 24 × M 27 246 246 -
800 PN 6 24 × M 27 206 182 -
800 PN 10 24 × M 30 331 316 -
900 PN 6 24 × M 27 230 637 -
900 PN 10 28 × M 30 316 307 -
1000 PN 6 28 × M 27 218 208 -
1000 PN 10 28 × M 33 402 405 -
1200 PN 6 32 × M 30 319 299 -
1200 PN 10 32 × M 36 564 568 -
1400 PN 6 36 × M 33 430 - -
1400 PN 10 36 × M 39 654 618 -
1400 PN 16 36 × M 45 729 762 -
1600 PN 6 40 × M 33 440 417 -
1600 PN 10 40 × M 45 946 893 -
Endress+Hauser 19

meter
rating fasteners
[bar]
1600 PN 16 40 × M 52 1007 1100 -
1800 PN 6 44 × M 36 547 521 -
1800 PN 10 44 × M 45 961 895 -
1800 PN 16 44 × M 52 1108 1003 -
2000 PN 6 48 × M 39 629 605 -
2000 PN 10 48 × M 45 1047 1092 -
2000 PN 16 48 × M 56 1324 1261 -
2200 PN 6 52 × M 39 698 - -
2200 PN 10 52 × M 52 1217 - -
2400 PN 6 56 × M 39 768 - -
2400 PN 10 56 × M 52 1229 - -
Promag L tightening torques for ANSI
Nominal dia- ANSI Threaded Max. tightening torque

meter fasteners
rating
[mm [inch [lbs] [Nm] [lbf · [Nm] [lbf · [Nm] [lbf ·
] ] ft] ft] ft]
25 1 Class 150 4 × 5/8" - - 5 4 14 13
40 1½ Class 150 4 × 5/8" - - 10 7 21 15
50 2" Class 150 4 × 5/8" - - 15 11 40 29
80 3" Class 150 4 × 5/8" - - 25 18 65 48
100 4" Cla ss 150 8 × 5/8" - - 20 15 44 32
150 6" Class 150 8 × ¾" - - 45 33 90 66
200 8" Class 150 8 × ¾" - - 65 48 87 64
250 10" Class 150 12 × 7/8" - - 126 93 151 112
300 12" Class 150 12 × 7/8" - - 146 108 177 131
350 14" Class 150 12 × 1" 135 100 158 117 - -
400 16" Class 150 16 × 1" 128 94 150 111 - -
450 18" Class 150 16 × 1 1/8" 204 150 234 173 - -
500 20" Class 150 20 × 1 1/8" 183 135 217 160 - -
600 24" Class 150 20 × 1 ¼" 268 198 307 226 - -
20 Endress+Hauser
Promag L tightening torques for AWWA
Nominal dia- AWWA Threa- Max. tightening torque

meter ded faste-
ners
Pressure Hartgummi Polyurethane PTFE
[mm [inch rating [Nm] [lbf · [Nm] [lbf · [Nm] [lbf ·
] ] ft] ft] ft]
700 28" Class D 28 × 1 ¼" 247 182 292 215 - -
750 30" Class D 28 × 1 ¼" 287 212 302 223 - -
800 32" Class D 28 × 1 ½" 394 291 422 311 - -
900 36" Class D 32 × 1 ½" 419 309 430 317 - -
1000 40" Class D 36 × 1 ½" 420 310 477 352 - -
1050 42" Class D 36 × 1 ½" 528 389 518 382 - -
1200 48" Class D 44 × 1 ½" 552 407 531 392 - -
1350 54" Class D 44 × 1 ¾" 730 538 - - - -
1500 60" Class D 52 × 1 ¾" 758 559 - - - -
1650 66" Class D 52 × 1 ¾" 946 698 - - - -
1800 72" Class D 60 × 1 ¾" 975 719 - - - -
2000 78" Class D 64 × 2" 853 629 - - - -
2150 84" Class D 64 × 2" 931 687 - - - -
2300 90" Class D 68 × 2 ¼" 1048 773 - - - -

diameter fasteners
rating
[mm] [Nm] [Nm] [Nm]
350 Table E 12 × M 24 203 - -
400 Table E 12 × M 24 226 - -
450 Table E 16 × M 24 226 - -
500 Table E 16 × M 24 271 - -
600 Table E 16 × M 30 439 - -
700 Table E 20 × M 30 355 - -
750 Table E 20 × M 30 559 - -
800 Table E 20 × M 30 631 - -
900 Table E 24 × M 30 627 - -
1000 Table E 24 × M 30 634 - -
1200 Table E 32 × M 30 727 - -
Endress+Hauser 21

diameter fasteners
rating
[mm] [Nm] [Nm] [Nm]
350 PN 16 12 × M 24 203 - -
375 PN 16 12 × M 24 137 - -
400 PN 16 12 × M 24 226 - -
450 PN 16 12 × M 24 301 - -
500 PN 16 16 × M 24 271 - -
600 PN 16 16 × M 27 393 - -
700 PN 16 20 × M 27 330 - -
750 PN 16 20 × M 30 529 - -
800 PN 16 20 × M 33 631 - -
900 PN 16 24 × M 33 627 - -
1000 PN 16 24 × M 33 595 - -
1200 PN 16 32 × M 33 703 - -
22 Endress+Hauser
2.6 Installing the Promag P sensor

" Caution!
sensor.

customer.
shipment.
a0008165
2.6.1 Seals
" Caution!
measuring signal.
2.6.2 Ground cable

Endress+Hauser 23
2.6.3 Installing the high-temperature version (with PFA lining)

The high-temperature version has a housing support for the thermal separation of sensor and
transmitter. The high-temperature version is always used for applications
in which high ambient temperatures are encountered in conjunction with high fluid
temperatures. The high-temperature version is obligatory if the fluid temperature exceeds
+150 °C.
Note! You will find information on permissible temperature ranges in the Operating
Instructions of the CD-ROM
Insulation
Pipes generally have to be insulated if they carry very hot fluids, in order to avoid energy losses
and to prevent accidental contact with pipes at temperatures that could cause injury. Guidelines
regulating the insulation of pipes have to be taken into account.
"
Caution!
Risk of measuring electronics overheating. The housing support dissipates heat and its entire
surface area must remain uncovered. Make sure that the sensor insulation does not extend past
the top of the two sensor shells.
Esc
max.
- + E
A0004300
24 Endress+Hauser
2.6.4 Tightening torques for threaded fasteners (Promag P)

Promag P tightening torques for EN (DIN)

diameter fasteners
15 PN 40 4 × M 12 11 –
25 PN 40 4 × M 12 26 20
32 PN 40 4 × M 16 41 35
40 PN 40 4 × M 16 52 47
50 PN 40 4 × M 16 65 59
65 * PN 16 8 × M 16 43 40
65 PN 40 8 × M 16 43 40
80 PN 16 8 × M 16 53 48
80 PN 40 8 × M 16 53 48
100 PN 16 8 × M 16 57 51
100 PN 40 8 × M 20 78 70
125 PN 16 8 × M 16 75 67
125 PN 40 8 × M 24 111 99
150 PN 16 8 × M 20 99 85
150 PN 40 8 × M 24 136 120
200 PN 10 8 × M 20 141 101
200 PN 16 12 × M 20 94 67
200 PN 25 12 × M 24 138 105
250 PN 10 12 × M 20 110 –
250 PN 16 12 × M 24 131 –
250 PN 25 12 × M 27 200 –
300 PN 10 12 × M 20 125 –
300 PN 16 12 × M 24 179 –
300 PN 25 16 × M 27 204 –
350 PN 10 16 × M 20 188 –
350 PN 16 16 × M 24 254 –
350 PN 25 16 × M 30 380 –
400 PN 10 16 × M 24 260 –
400 PN 16 16 × M 27 330 –
400 PN 25 16 × M 33 488 –
450 PN 10 20 × M 24 235 –
Endress+Hauser 25

diameter fasteners
450 PN 16 20 × M 27 300 –
450 PN 25 20 × M 33 385 –
500 PN 10 20 × M 24 265 –
500 PN 16 20 × M 30 448 –
500 PN 25 20 × M 33 533 –
600 PN 10 20 × M 27 345 –
600 * PN 16 20 × M 33 658 –
600 PN 25 20 × M 36 731 –
Promag P tightening torques for ANSI
Nominal diameter ANSI Threaded fasteners Max. tightening torque
Pressure rating PTFE PFA

[mm] [inch] [lbs] [Nm] [lbf · ft] [Nm] [lbf · ft]
15 ½" Class 150 4 × ½" 6 4 – –
15 ½" Class 300 4 × ½" 6 4 – –
25 1" Class 150 4 × ½" 11 8 10 7
25 1" Class 300 4 × 5/8" 14 10 12 9
40 1 ½" Class 150 4 × ½" 24 18 21 15
40 1 ½" Class 300 4 × ¾" 34 25 31 23
50 2" Class 150 4 × 5/8" 47 35 44 32
50 2" Class 300 8 × 5/8" 23 17 22 16
80 3" Class 150 4 × 5/8" 79 58 67 49
80 3" Class 300 8 × ¾" 47 35 42 31
100 4" Class 150 8 × 5/8" 56 41 50 37
100 4" Class 300 8 × ¾" 67 49 59 44
150 6" Class 150 8 × ¾" 106 78 86 63
150 6" Class 300 12 × ¾" 73 54 67 49
200 8" Class 150 8 × ¾" 143 105 109 80
250 10" Class 150 12 × 7/8" 135 100 – –
300 12" Class 150 12 × 7/8" 178 131 – –
350 14" Class 150 12 × 1" 260 192 – –
400 16" Class 150 16 × 1" 246 181 – –
450 18" Class 150 16 × 1 1/8" 371 274 – –
500 20" Class 150 20 × 1 1/8" 341 252 – –
600 24" Class 150 20 × 1 ¼" 477 352 – –
26 Endress+Hauser
Promag P tightening torques for JIS

[mm] Pressure rating Threaded fasteners PTFE PFA
25 10K 4 × M 16 32 27
25 20K 4 × M 16 32 27
32 10K 4 × M 16 38 –
32 20K 4 × M 16 38 –
40 10K 4 × M 16 41 37
40 20K 4 × M 16 41 37
50 10K 4 × M 16 54 46
50 20K 8 × M 16 27 23
65 10K 4 × M 16 74 63
65 20K 8 × M 16 37 31
80 10K 8 × M 16 38 32
80 20K 8 × M 20 57 46
100 10K 8 × M 16 47 38
100 20K 8 × M 20 75 58
125 10K 8 × M 20 80 66
125 20K 8 × M 22 121 103
150 10K 8 × M 20 99 81
150 20K 12 × M 22 108 72
200 10K 12 × M 20 82 54
200 20K 12 × M 22 121 88
250 10K 12 × M 22 133 –
250 20K 12 × M 24 212 –
300 10K 16 × M 22 99 –
300 20K 16 × M 24 183 –
Nominal diameter AS 2129 Threaded fasteners Max. tightening torque [Nm]

[mm] Pressure rating PTFE
25 Table E 4 × M 12 21
50 Table E 4 × M 16 42

[mm] Pressure rating fasteners PTFE
50 PN 16 4 × M 16 42
Endress+Hauser 27
2.7 Installing the Promag W sensor

customer.
shipment.
a0008165
2.7.1 Seals
• Hard rubber lining  additional seals are always necessary.
• For DIN flanges, use only seals according to EN 1514-1.
• Make sure that the seals do not protrude into the piping cross-section.
"
Caution!
signal.
2.7.2 Ground cable

2.7.3 Screw tightening torques (Promag W)

Promag W tightening torques for EN (DIN)

fasteners
25 PN 40 4 × M 12 - 15
32 PN 40 4 × M 16 - 24
40 PN 40 4 × M 16 - 31
50 PN 40 4 × M 16 48 40
28 Endress+Hauser

fasteners
65* PN 16 8 × M 16 32 27
65 PN 40 8 × M 16 32 27
80 PN 16 8 × M 16 40 34
80 PN 40 8 × M 16 40 34
100 PN 16 8 × M 16 43 36
100 PN 40 8 × M 20 59 50
125 PN 16 8 × M 16 56 48
125 PN 40 8 × M 24 83 71
150 PN 16 8 × M 20 74 63
150 PN 40 8 × M 24 104 88
200 PN 10 8 × M 20 106 91
200 PN 16 12 × M 20 70 61
200 PN 25 12 × M 24 104 92
250 PN 10 12 × M 20 82 71
250 PN 16 12 × M 24 98 85
250 PN 25 12 × M 27 150 134
300 PN 10 12 × M 20 94 81
300 PN 16 12 × M 24 134 118
300 PN 25 16 × M 27 153 138
350 PN 6 12 × M 20 111 120
350 PN 10 16 × M 20 112 118
350 PN 16 16 × M 24 152 165
350 PN 25 16 × M 30 227 252
400 PN 6 16 × M 20 90 98
400 PN 10 16 × M 24 151 167
400 PN 16 16 × M 27 193 215
400 PN 25 16 × M 33 289 326
450 PN 6 16 × M 20 112 126
450 PN 10 20 × M 24 153 133
450 PN 16 20 × M 27 198 196
450 PN 25 20 × M 33 256 253
500 PN 6 20 × M 20 119 123
500 PN 10 20 × M 24 155 171
500 PN 16 20 × M 30 275 300
500 PN 25 20 × M 33 317 360
600 PN 6 20 × M 24 139 147
600 PN 10 20 × M 27 206 219
600 * PN 16 20 × M 33 415 443
600 PN 25 20 × M 36 431 516
700 PN 6 24 × M 24 148 139
700 PN 10 24 × M 27 246 246
700 PN 16 24 × M 33 278 318
Endress+Hauser 29

fasteners
700 PN 25 24 × M 39 449 507
800 PN 6 24 × M 27 206 182
800 PN 10 24 × M 30 331 316
800 PN 16 24 × M 36 369 385
800 PN 25 24 × M 45 664 721
900 PN 6 24 × M 27 230 637
900 PN 10 28 × M 30 316 307
900 PN 16 28 × M 36 353 398
900 PN 25 28 × M 45 690 716
1000 PN 6 28 × M 27 218 208
1000 PN 10 28 × M 33 402 405
1000 PN 16 28 × M 39 502 518
1000 PN 25 28 × M 52 970 971
1200 PN 6 32 × M 30 319 299
1200 PN 10 32 × M 36 564 568
1200 PN 16 32 × M 45 701 753
1400 PN 6 36 × M 33 430 398
1400 PN 10 36 × M 39 654 618
1400 PN 16 36 × M 45 729 762
1600 PN 6 40 × M 33 440 417
1600 PN 10 40 × M 45 946 893
1600 PN 16 40 × M 52 1007 1100
1800 PN 6 44 × M 36 547 521
1800 PN 10 44 × M 45 961 895
1800 PN 16 44 × M 52 1108 1003
2000 PN 6 48 × M 39 629 605
2000 PN 10 48 × M 45 1047 1092
2000 PN 16 48 × M 56 1324 1261
Promag W tightening torques for ANSI

Pressure
25 1" Class 150 4 × ½" - - 7 5
25 1" Class 300 4 × 5/8" - - 8 6
40 1 ½" Class 150 4 × ½" - - 10 7
40 1 ½" Class 300 4 × ¾" - - 15 11
50 2" Class 150 4 × 5/8" 35 26 22 16
50 2" Class 300 8 × 5/8" 18 13 11 8
80 3" Class 150 4 × 5/8" 60 44 43 32
30 Endress+Hauser

Pressure
80 3" Class 300 8 × ¾" 38 28 26 19
100 4" Class 150 8 × 5/8" 42 31 31 23
100 4" Class 300 8 × ¾" 58 43 40 30
150 6" Class 150 8 × ¾" 79 58 59 44
150 6" Class 300 12 × ¾" 70 52 51 38
200 8" Class 150 8 × ¾" 107 79 80 59
250 10" Class 150 12 × 7/8" 101 74 75 55
300 12" Class 150 12 × 7/8" 133 98 103 76
350 14" Class 150 12 × 1" 135 100 158 117
400 16" Class 150 16 × 1" 128 94 150 111
450 18" Class 150 16 × 1 1/8" 204 150 234 173
500 20" Class 150 20 × 1 1/8" 183 135 217 160
600 24" Class 150 20 × 1 ¼" 268 198 307 226
Promag W tightening torques for JIS

25 10K 4 × M 16 - 19
25 20K 4 × M 16 - 19
32 10K 4 × M 16 - 22
32 20K 4 × M 16 - 22
40 10K 4 × M 16 - 24
40 20K 4 × M 16 - 24
50 10K 4 × M 16 40 33
50 20K 8 × M 16 20 17
65 10K 4 × M 16 55 45
65 20K 8 × M 16 28 23
80 10K 8 × M 16 29 23
80 20K 8 × M 20 42 35
100 10K 8 × M 16 35 29
100 20K 8 × M 20 56 48
125 10K 8 × M 20 60 51
125 20K 8 × M 22 91 79
150 10K 8 × M 20 75 63
150 20K 12 × M 22 81 72
200 10K 12 × M 20 61 52
200 20K 12 × M 22 91 80
250 10K 12 × M 22 100 87
250 20K 12 × M 24 159 144
300 10K 16 × M 22 74 63
Endress+Hauser 31

300 20K 16 × M 24 138 124
Promag W tightening torques for AWWA
Nominal AWWA Max. tightening torque

diameter
Pressure Threaded Hard rubber Polyurethane

[mm] [inch] rating fasteners [Nm] [lbf · ft] [Nm] [lbf · ft]
700 28" Class D 28 × 1 ¼" 247 182 292 215
750 30" Class D 28 × 1 ¼" 287 212 302 223
800 32" Class D 28 × 1 ½" 394 291 422 311
900 36" Class D 32 × 1 ½" 419 309 430 317
1000 40" Class D 36 × 1 ½" 420 310 477 352
1050 42" Class D 36 × 1 ½" 528 389 518 382
1200 48" Class D 44 × 1 ½" 552 407 531 392
1350 54" Class D 44 × 1 ¾" 730 538 633 467
1500 60" Class D 52 × 1 ¾" 758 559 832 614
1650 66" Class D 52 × 1 ¾" 946 698 955 704
1800 72" Class D 60 × 1 ¾" 975 719 1087 802
2000 78" Class D 64 × 2" 853 629 786 580

50 Table E 4 × M 16 32
80 Table E 4 × M 16 49
100 Table E 8 × M 16 38
150 Table E 8 × M 20 64
200 Table E 8 × M 20 96
250 Table E 12 × M 20 98
300 Table E 12 × M 24 123
350 Table E 12 × M 24 203
400 Table E 12 × M 24 226
450 Table E 16 × M 24 226
500 Table E 16 × M 24 271
600 Table E 16 × M 30 439
700 Table E 20 × M 30 355
750 Table E 20 × M 30 559
800 Table E 20 × M 30 631
900 Table E 24 × M 30 627
1000 Table E 24 × M 30 634
32 Endress+Hauser

1200 Table E 32 × M 30 727

50 Table E 4 × M 16 32
80 PN 16 4 × M 16 49
100 PN 16 4 × M 16 76
150 PN 16 8 × M 20 52
200 PN 16 8 × M 20 77
250 PN 16 8 × M 20 147
300 PN 16 12 × M 24 103
350 PN 16 12 × M 24 203
375 PN 16 12 × M 24 137
400 PN 16 12 × M 24 226
450 PN 16 12 × M 24 301
500 PN 16 16 × M 24 271
600 PN 16 16 × M 27 393
700 PN 16 20 × M 27 330
750 PN 16 20 × M 30 529
800 PN 16 20 × M 33 631
900 PN 16 24 × M 33 627
1000 PN 16 24 × M 33 595
1200 PN 16 32 × M 33 703
Endress+Hauser 33
2.8 Installing the transmitter housing

2.8.1 Turning the transmitter housing
Turning the aluminum field housing
Aluminum field housing for non-Ex area
b d
£ 180° £ 180°
c
a f
A0007540
Aluminum field housing for Zone 1 or Class I Div. 1

For Zone 1 or Class I Div. 1:
max. 360° a. Release the setscrew.
b b. Turn the transmitter housing
c gently clockwise until the stop
(end of the thread).
Nic
ht unt
er Spannu
ng
c. Turn the transmitter
counterclockwise (max. 360°)
öffnen
Nicht-eigensichere
Kee ircuits are alive ile
to the desired position.

Stromkreise durch
p cover tight wh
p cover tight w
a
d. Retighten the setscrew.

Boucles de courant
c
ve

sous nsion l Ne
pas o te apparei
uvrir l’
d
A0008036
Turning the stainless steel field housing
£ 180° c £ 180°
a b
e
A0007661
34 Endress+Hauser
2.8.2 Turning the onsite display
a. Press in the side latches on the display module and

remove the module from the cover plate of the
electronics compartment.
4 × 45° b. Turn the display to the desired position (max.
4 × 45° in both directions) and reset it onto the
cover plate of the electronics compartment.
b
a
A0007541
2.8.3 Installing the wall-mount housing
" Caution!
• Make sure that the ambient temperature does not exceed the permitted range.
• Always install the wall-mount housing in such a way that the cable entries point downwards.
Mounted directly on the wall
1. Connection compartment
35 (1.38) mm (inch) 2. Securing screws M6 (max. ø 6.5 mm (0.25"); screw
head max. ø 10.5 mm (0.4")
3. Housing bores for securing screws
2 3 3
81.5 (3.2)
90 (3.54) 192 (7.56)

A0007542
Endress+Hauser 35
Pipe mounting
mm (inch) " Caution!

Danger of overheating! If the device is mounted on a
Ø 20…70
warm pipe, make sure that the housing temperature
(Ø 0.79…2.75) does not exceed +60 °C (+140 °F) which is the
maximum temperature permitted.
~155 (~ 6.1)
A0007543
Panel mounting
+0.5 (+0.019)
–0.5 (–0.019)
210 (8.27)
+0.5 (+0.019)
–0.5 (–0.019)
245 (9.65)
mm (inch)
~110 (~4.33)
A0007544
36 Endress+Hauser
2.9 Post-installation check

• Is the measuring device damaged (visual inspection)?
• Does the device correspond to specifications at the measuring point, including process
temperature and pressure, ambient temperature, minimum fluid conductivity, measuring
range, etc.?
• Does the arrow on the sensor nameplate match the actual direction of flow through the pipe?
• Is the position of the measuring electrode plane correct?
• Were all screws tightened to the specified torques when the sensor was installed?
• Were the correct seals used (type, material, installation)?
• Are the measuring point number and labeling correct (visual inspection)?
• Were the inlet and outlet runs respected?
– Inlet run  5 × DN
– Outlet run  2 × DN
• Is the measuring device protected against moisture and direct sunlight?
• Is the sensor adequately protected against vibration (attachment, support)?
Acceleration up to 2 g by analogy with IEC 600 68-2-8.
Endress+Hauser 37
3 Wiring
# Warning!
Risk of electric shock! Components carry dangerous voltages.
• Never mount or wire the measuring device while it is connected to the power supply.
• Before connecting the power supply, check the safety equipment.
• Route the power supply and signal cables so they are securely seated.
• Seal the cable entries and covers tight.
"
Caution!
• Connect the power supply in accordance with the connection data on the nameplate.
• Connect the signal cable in accordance with the connection data in the Operating Instructions
or the Ex documentation on the CD-ROM.
In addition, for the remote version
"
Caution!
• Only connect sensors and transmitters with the same serial number.
• Observe the cable specifications of the connecting cable  Operating Instructions on the
CD-ROM.
Note! Install the connecting cable securely to prevent movement.
In addition, for measuring devices with fieldbus communication
"
Caution!
• Observe the cable specification of the fieldbus cable  Operating Instructions on the
CD-ROM.
• Keep the stripped and twisted lengths of cable shield as short as possible.
• Screen and ground the signal lines  Operating Instructions on the CD-ROM.
• When using in systems without potential equalization  Operating Instructions on the
CD-ROM.
In addition, for Ex-certified measuring devices
# Warning!
When wiring Ex-certified measuring devices, all the safety instructions, wiring diagrams,
technical information etc. of the related Ex documentation must be observed
 Ex documentation on the CD-ROM.
38 Endress+Hauser
3.1 Connecting the various housing types

Wire the unit using the terminal assignment diagram inside the cover.
3.1.1 Compact version
3 cover
4 2 Power supply cable
2 3 Signal cable or fieldbus cable
4 Optional
1
A0007545
3.1.2 Remote version (transmitter): non-Ex Zone, Ex Zone 2, Class I Div. 2
cover
3 Signal cable
4 Fieldbus cable
Connecting the connecting cable ( ä 40):

2 3 4 5 1 5 Sensor/transmitter connecting cable
A0012690
3.1.3 Remote version (transmitter): Ex Zone 1, Class I Div. 1
ht unter Spannun
Nic öffnen g
3
Ke ircuits are alive le
cover
over tight whi
c
p cover tight w
4
ep c

ve
c
2
3 Signal cable or fieldbus cable

pas ou r l’appa
vri
1 4 Optional
5 1 Connecting the connecting cable ( ä 40):

5 Sensor/transmitter connecting cable
A0008218
3.1.4 Remote version (sensor)
1 cover
5
Connecting cable connection:
A0008037 5 Sensor/transmitter connecting cable
Endress+Hauser 39
3.2 Connecting the remote version connecting cable

3.2.1 Connecting cable for Promag E/P/L/W


Sensor Transmitter
mm (inch) mm (inch)
a* = 170 (6.69") a* b* a* a* = 100 (3.94")
b* = 20 (0.79") c b = 80 (3.15")
d b
c = 80 (3.15") c = 50 (1.97")
d = 17 (0.67")
e f A c d d = 17 (0.67")
e = 8 (0.31") e = 8 (0.31")
f = 50 (1.97")
g = 1 (0.04") e
m B m
m
n n
g m
n GND GND n
m
n n
m n
a0008171

Sensor Transmitter
mm (inch) mm (inch)
a* = 160 (6.3") a* b* a* a* = 90 (3.54")
b* = 20 (0.79") c b b = 70 (2.76")
c = 70 (2.76") d c c = 50 (1.97")
d = 50 (1.97") e f A d e d = 10 (0.39")
e = 8 (0.31") e = 8 (0.31")
f = 10 (0.39")
m B m
m m
m m
a0008172
40 Endress+Hauser
3.2.2 Promag H connecting cable


Sensor Transmitter
mm (inch) mm (inch)
a = 80 (3.15") a = 80 (3.15")
b = 15 (0.59") a a b = 50 (1.97")
c = 17 (0.67") c c = 17 (0.67")
b A b c
d = 8 (0.31") d d = 8 (0.31")
e = 1 (0.04")
d
B m
n m
n
n m
e GND n
n GND m
m n
n
a0008173

Sensor Transmitter
mm (inch) mm (inch)
a = 70 (2.76") a a a = 70 (2.76")
b = 40 (1.57") b = 50 (1.97")
c = 15 (0.59")
b b c = 10 (0.39")
d = 8 (0.31")
d c A c d d = 8 (0.31")
B m
m m
m m
a0008175
Endress+Hauser 41
3.2.3 Connecting cable connection
A B S1 E1 E2 S2GND E S
ht unter Spannun
Nic öffnen g
6 5 7 8 4 37 36 42 41
Ke ircuits are alive e

l
over tight whi
c
p cover tight w
ep c
ve
c

pas ou r l’appa
vri
b c
b c
a
b c b c b c
n.c. n.c. n.c.
b 5 7 4 37 42 41
E1 E2 GNDE
C D E
A0008180
A Transmitter housing on connection housing, remote version

B Wall-mount housing on connection housing, remote version
C Sensor connection housing, remote version for Promag E/L/P/W

D Sensor connection housing, remote version for Promag H, DN 25 (1")
E Sensor connection housing, remote version for Promag H, DN 40 (1½")
a Ground terminals (are provided for potential equalization connection)

b Coil circuit connecting cable
c Signal circuit connecting cable (electrodes)
n.c. = not connected, isolated cable shields
Cable colors for terminal numbers:

5/6 = brown
7/8 = white
4 = green
36/37 = yellow
42 Endress+Hauser
3.3 Potential equalization

Perfect measurement is only ensured when the medium and the sensor have the same electrical
potential. Most sensors have a reference electrode installed as standard, which guarantees the
required potential connection. This usually means that the use of ground disks or other
measures are unnecessary.
• Promag E/L/P/W
Reference electrode available as standard.
• Promag H
– No reference electrode available. There is always an electrical connection to the fluid via the
metal process connection.
– In the case of plastic process connections, potential equalization must be ensured through
the use of grounding rings.
Standard situation
Potential equalization takes place via the ground terminal of the transmitter when using the
device in metal, grounded pipes.
A0004375
Note! Potential equalization for other areas of application  Operating Instructions on the
CD-ROM.
Endress+Hauser 43
3.4 Degree of protection

The devices meet all the requirements for IP 67.
After mounting in the field or service work, the following points have to be observed to ensure
that IP 67 protection is retained:
• Install the measuring device in such a way that the cable entries do not point upwards.
• Do not remove the seal from the cable entry.
• Remove all unused cable entries and plug them with suitable/certified drain plugs.
• Use cable entries and drain plugs with a long-term operating temperature range in
accordance with the temperature specified on the nameplate.
A0007549 A0007550
Tighten the cable entries correctly. The cables must loop down before they enter the
cable entries ("water trap").
3.5 Post-connection check

• Are cables or the device damaged (visual inspection)?
• Does the supply voltage match the information on the nameplate?
• Do the cables used comply with the necessary specifications?
• Do the mounted cables have adequate strain relief and are they routed securely?
• Is the cable type route completely isolated? Without loops and crossovers?
• Only remote version:
- Is the flow sensor connected to the matching transmitter electronics?
- Is the connecting cable between sensor and transmitter connected correctly?
• Are all screw terminals firmly tightened?
• Have all the measures for grounding and potential equalization been correctly implemented?
• Are all cable entries installed, firmly tightened and correctly sealed?
• Cable routed as a "water trap" in loops?
• Are all the housing covers installed and securely tightened?
In addition, for measuring devices with fieldbus communication:
• Are all the connecting components (T-boxes, junction boxes, connectors, etc.) connected with
each other correctly?
• Has each fieldbus segment been terminated at both ends with a bus terminator?
• Has the max. length of the fieldbus cable been observed in accordance with the specifications?
• Has the max. length of the spurs been observed in accordance with the specifications?
• Is the fieldbus cable fully shielded and correctly grounded?
44 Endress+Hauser
4 Hardware settings
This section only deals with the hardware settings needed for commissioning. All other settings
(e.g. output configuration, write protection, etc.) are described in the associated Operating
Note! No hardware settings are needed for measuring devices with HART or FOUNDATION
Fieldbus-type communication.
4.1 Device address

• PROFIBUS DP/PA
• Miniature switches  see description below
• Local operation  see Software settings section  ä 52
Addressing via miniature switches
# Warning!
heeded  ä 38.
sensitive devices.
# Warning!
Switch off the power supply before opening the device.
a. Loosen the cheese head screw of the securing clamp
O
N
with an Allen key (3 mm)
b. Unscrew cover of the electronics compartment from
1 E
2 W
3
4
O
N
1 E
2 W
3
4
O
N
1 E
2 W
3
the transmitter housing.

4
c. Loosen the securing screws of the display module

and remove the onsite display (if present).
d. Set the position of the miniature switches on the
I/O board using a sharp pointed object.
c
Installation is the reverse of the removal procedure.
O
N
1 E
2 W
3
4 O
N
a 1 E
2 W
3
4 O
N
d
1 E
b
2 W
3
4
A0007551
Endress+Hauser 45
Hardware settings Proline Promag 50
PROFIBUS
Device address range: 0 to 126

Factory setting: 126
DP PA
OFF ON OFF ON a. Miniature switches for device address
1 1 1 Example shown:
1+16+32 = device address 49
2 2 2 b. Miniature switches for the address mode (method
c
3 4 3 of addressing):
4 8 4 – OFF (factory setting) = software addressing via
a
local operation/operating program
1 16 1 1 – ON = hardware addressing via miniature
2 32 2 2 switches
c. Miniature switches not assigned.
3 64 3 4
4 b 4 8 a
1 1 16
2 2 32
c
3 3 64
4 4 b
OFF ON OFF ON
A0007552
46 Endress+Hauser
4.2 Terminating resistors

Note! If the measuring device is used at the end of a bus segment, termination is required.
This can be performed in the measuring device by setting the terminating resistors on the
I/O board. Generally, however, it is recommended to use an external bus terminator and not
perform termination at the measuring device itself.
• PROFIBUS DP
– Baudrate 1.5 MBaud  Termination can be performed at the measuring device, see
graphic
– Baudrate > 1.5 MBaud  An external bus terminator must be used
# Warning!
heeded  ä 38.
sensitive devices.
Setting the terminating switch SW1

on the I/O board:
ON - ON - ON - ON
O
N
1 E
2 W
3
4
O
N
1 E
2 W
3
4
O
N
1 E
2 W
3
4
+5V
SW 1 390 W
1
2
3
4
O
N
E
W
1
2
1
2
3
4
O
N
E
W
220 W
3
O
N
1 E
2 W
3
4 O
N
1 E
2 W
3
4
4
OFF ON 390 W
A0007556
Endress+Hauser 47
5 Commissioning
5.1 Switching on the measuring device
On completion of the installation (successful post-installation check), wiring (successful
post-connection check) and after making the necessary hardware settings, where applicable,
the permitted power supply (see nameplate) can be switched on for the measuring device.
When the power supply is switched on, the measuring device performs a number of power-up
checks and device self-checks. As this procedure progresses the following messages can appear
on the onsite display:
Display examples:
PROMAG 50 Start-up message
START-UP
Æ
DEVICE SOFTWARE Displays the current software
V XX.XX.XX
Æ
SYSTEM OK Beginning of operation
OPERATION
The measuring device starts operating as soon as the startup procedure is complete.
Various measured values and/or status variables appear on the display.
Note! If an error occurs during startup, this is indicated by an error message.

The error messages that occur most frequently when a measuring device is commissioned
are described in the Troubleshooting section  ä 52.
48 Endress+Hauser
5.2 Operation
5.2.1 Display elements
Display lines/fields
3 4 1. Main line for primary measured values
2. Additional line for additional measured
variables/status variables
1 +48.25 xx/yy 3. Current measured values
4. Engineering units/time units
2 +3702.6 x
A0007557
5.2.2 Operating elements
Operating keys
Esc
1. (–) Minus key for entering, selecting
- + E 2. (+) Plus key for entering, selecting
3. Enter key for calling the function matrix, saving
When the +/– keys are pressed simultaneously
1 2 3 (Esc):
• Exit the function matrix step-by-step:
A0007559
• > 3 sec. = cancel data input and
return to the measured value display
5.2.3 Displaying error messages
1. Type of error:
P = Process error, S = System error
1 P XXXXXXXXXX 5 2. Error message type:
$ = Fault message, ! = Notice message
2 #000 00:00:05 3. Error number
4. Duration of the last error that occurred:
Hours: Minutes: Seconds
3 4 5. Error designation
List of all error messages, see associated
A0007561
Operating Instructions on the CD-ROM
Endress+Hauser 49
5.3 Navigating within the function matrix
Esc
Esc Esc
- + E >3s
q – + r – +
m E
o
E E E E E
– + p
q
+
n –
A0007562

2. P Select the group (e.g. OPERATION)
3. NSelect function (e.g. LANGUAGE)
4. P Enter code 50 (only for the first time you access the function matrix)
F Confirm entry
P Change function/selection (e.g. ENGLISH)

5. Q Return to measured value display step by step
6. Q > 3 s Return immediately to measured value display
50 Endress+Hauser
5.4 Calling the Commissioning Quick Setup

All the functions needed for commissioning are called up automatically with the Quick Setup.
The functions can be changed and adapted to the process in question.
3. QUICK SETUP COMMISSIONING function appears.
4. Intermediate step if configuration is blocked:
P Enter the code 50 (confirm with F ) and thus enable configuration
5. P Go to Commissioning Quick Setup
6. P Select YES
7. F Start Commissioning Quick Setup
Note! Observe the following when performing the Quick Setup:
• Configuration selection: Select the ACTUAL SETTING option
• Unit selection: This is not offered again for selection after configuring a unit
• Output selection: This is not offered again for selection after configuring an output
• Automatic configuration of the display: select YES
– Main line = Mass flow
– Additional line = Totalizer 1
– Information line = Operating/system conditions
• If asked whether additional Quick Setups should be executed: select NO
CD-ROM.
Endress+Hauser 51
5.5 Software settings

5.5.1 Device address
• PROFIBUS DP/PA  device address range 0 to 126, factory setting 126
• Miniature switches  see Hardware settings  ä 45
• Local operation  see description below
Note! The COMMISSIONING SETUP must be executed before setting the device address.
Calling the Communication Quick Setup

3. N Select the QUICK SETUP COMMUNICATION function
4. Intermediate step if configuration is blocked: P Enter the code 50
(confirm with F ) and thus enable the configuration
5. P Go to Communication Quick Setup
6. P Select YES; F confirm selection
7. F Start Communication Quick Setup
CD-ROM.
5.6 Troubleshooting
A complete description of all the error messages is provided in the Operating Instructions on the
CD-ROM.
Note! The output signals (e.g. pulse, frequency) of the measuring device must correspond to the
higher-order controller.
52 Endress+Hauser
Endress+Hauser 53
54 Endress+Hauser
Endress+Hauser 55
1

21522023-4144898
¸
3034509812 FCP-6.9


PROMAG 50 P DN25 0.8225

M61B0519000 1
AUXB001.F001 31.4 °C
40.1 0.98363 60.2 59.212 59.207 -0.01 10.41 1.5
40.1 0.98474 60.2 59.277 59.280 0.01 10.42

1
100.3 2.4627 60.2 148.246 148.234 -0.01 20.05
- - - - - - - 0.5
- - - - - - - 0
- - - - - - -
- - - - - - - -0.5
- - - - - - - -1
- - - - - - -
- - - - - - - -1.5
*o.r.: of reading 0 10 20 30 40 50 60 70 80 90 100 [%]

02.08.2017 S. Most

Page 1 / 1
Parameter Setting
21412593-4144898
¸
3034509812 PROMAG 50 P

50P25-EA0A1AA0AFAA AUXB001.F001
Order code Tag Nº
M61B0519000
Serial Nº


Device address 0
Units
Unit volume dm³
User interface
Totalizer
Current output 1
Time constant 3s
02.08.2017
Date
Page 1 / 2
Parameter Setting
21412593-4144898
¸
Pulse output 1
Pulse width 100 ms
02.08.2017
Date
Page 2 / 2
SD00115D/06/EN/15.14 Products Solutions Services
71249502
Valid as of version
V 02.00.zz (device software)
Functional Safety Manual

with 4 to 20 mA output signal

Monitoring of maximum and/or minimum flow in systems
• For flow monitoring (Min., Max., range) up to SIL 2 –
which are required to comply with particular safety system
independently assessed (Functional Assessment) by
requirements as per IEC/EN 61508 and IEC/EN 61511-1.
exida.com as per IEC/EN 61508 and IEC/EN 61511-1
The measuring device fulfils the requirements concerning: • Continuous measurement
• Functional safety as per IEC/EN 61508 and IEC/EN 61511-1 • Measurement is virtually independent of product properties
• Explosion protection (depending on the version) • Permanent self-monitoring
• Electromagnetic compatibility as per EN 61326-3-2 and • Easy installation and commissioning
NAMUR recommendation NE 21 • Proof test possible without removal of the measuring device
Table of contents
SIL Declaration of Conformity . . . . . . . . . . . . . . . . . . . . .3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Depiction of a safety system (protection function) . . . . . . . . . . 4
Measuring system layout with Promag 50, 53 . . . . . . .5

System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety function data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Supplementary device documentation . . . . . . . . . . . . . . . . . . . . 5
Settings and installation instructions . . . . . . . . . . . . . .6

Setting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Monitoring options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Setting instructions for evaluation unit . . . . . . . . . . . . . . . . . . . 7
Response in operation and failure . . . . . . . . . . . . . . . . . . . . . . . . 8
Information on the useful lifetime of electric components . . . 8
Proof test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Proof test of the measuring system . . . . . . . . . . . . . . . . . . . . . . . 9
Exida Management Summary . . . . . . . . . . . . . . . . . . . 11
Appendix (safety-related characteristic values) . . . 15

Introductory comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Endress+Hauser
SIL Declaration of Conformity
Antoine Simon
Kägenstrasse 7, 4153 Reinach
SIL Declaration of Conformity Promag 50/Promag 53

Functional Safety of a flow measuring device according to IEC 61508/IEC 61511
Endress+Hauser Flowtec AG, Kägenstrasse 7, 4153 Reinach

declares as manufacturer, that the flow measuring devices
Promag 50 (420 mA) and Promag 53 (420 mA)
are suitable for the use in a safety instrumented system up to SIL 2 according to IEC 61511-1 und IEC 61508 if the
installation is conform to the safety manual and if enclosed safety instructions are observed.
The FMEDA with analysis of the safety critical and dangerous faults provides under the assumption of a functional
test cycle of two years the following parameters for the worst case of the tested configurations:
SIL (Safety Integrity Level) : 2

HFT (Hardware Fault Tolerance) : 0 1)
Device Type : Type B (complex component)
SFF (Safe failure fraction) : >76%

PFDAVG (Average Probability of Failure on Demand)2) : ô1.29 · 10-3 p.a.
Failure rates according to IEC 61508, based on the worst case configuration:
Odu (failure rate dangerous undetected failures) : 295 · 10-9/h (295 FIT)
Odd (failure rate dangerous detected failures) : 756 · 10-9/h (756 FIT)
Osu (failure rate safe undetected failures) : 265 · 10-9/h (265 FIT)
Osd (failure rate safe detected failures) : 0 · 10-9/h (0 FIT)
1) According to clause 11.4 of IEC 61511-1

2) The PFDAVG values are also within the range for SIL 2 according to ISA S84.01.
The assessment of the proven-in-use demonstration covers the device and its software (as of software version
V2.00.00 (amplifier), and 1.04.00 (communication module)) including the modification process.
Reinach, 05.10.2006
FEE/SA
SIL2-50-53-Conformity-en.pdf
Endress+Hauser 3
Introduction
Depiction of a safety system The following tables define the achievable Safety Integrity Level (SIL) or the requirements regarding
(protection function) the "Average Probability of Failure on Demand" (PFDAVG), the "Hardware Fault Tolerance" (HFT) and the
"Safe Failure Fraction" (SFF) of the safety system. The specific values for the Promag measuring system
can be found in the tables in the appendix.
In general, the following permitted failure probability of the complete safety function applies,
depending on the SIL for systems which must react on demand - e.g. a defined max. flow exceeded -
(Source: IEC 61508, Part 1):
SIL PFDAVG
4  10–5 to < 10–4
3 10–4 to < 10–3
2 10–3 to < 10–2
1 10–2 to < 10–1
The following table shows the achievable SIL as a function of the safe failure fraction and the hardware
fault tolerance of the complete safety system for type B systems (complex components, for definition
see IEC 61508, Part 2):
SFF HFT
0 1 (0)1) 2 (1)1)
< 60% Not permitted SIL 1 SIL 2

60 % to < 90 % SIL 1 SIL 2 SIL 3
90 % to < 99 % SIL 2 SIL 3
99 % SIL 3
1) In accordance with IEC 61511-1 (section 11.4.41 ), the HFT can be reduced by one (values in brackets)
if the devices used meet the following conditions:
- The device is proven in use
- Only process-relevant parameters can be changed at the device (e.g. measuring range, … )
- Changing the process-relevant parameters is protected (e.g. password, jumper, … )
- The function requires less than SIL 4
The Promag measuring system meets these conditions.
The measuring device can be used in safety relevant SIL 2 loop. In a safety relevant SIL 3 loop the
measuring device must be used in addition to a different measuring principle. Two Promag in
homogenous redundancy do not fulfill the SIL 3 requirements.
! Note!
General information on functional safety (SIL) is available at:
www.de.endress.com/SIL and in Competence Brochure CP002Z "Functional Safety in the Process
Industry - Risk Reduction with Safety Instrumented Systems" (available in the download section of the
Endress+Hauser website: www.endress.com  Download  Document code: CP002Z).
4 Endress+Hauser
Measuring system layout with Promag 50, 53

System components
1 2 3
A0015443
System components
1 Pump
2 Measuring device
3 Valve
4 Automation system
An analog signal (4–20 mA) proportional to the flow rate is generated in the transmitter. This is sent
to a downstream automation system where it is monitored to determine whether it falls below or
exceeds a specified limit value.
! Note!
• The safety-related signal is the 4 to 20 mA analog output signal of the measuring device. All safety
functions refer exclusively to current output 1.
• The measuring device must be protected against unauthorized access see "Locking" section
( ä 7).
• If communication also takes place via the HART protocol in the Promag 53 measuring device, HART
write protection must be activated see "Locking" section ( ä 7).
The characteristic values determined (see appendix) apply only to the current output (4 to 20 mA) of
the following versions:
• Promag 50***–***********(*)
(*) = Order option for inputs/outputs: A / W / D / S / T
• Promag 53***–***********(*)
(*) = Order option for inputs/outputs: A / B / C / L / M / S / T / 2 / 4
Safety function data The mandatory settings and safety function data emanate from the section "Settings and installation
instructions" ( ä 6) and the appendix ( ä 15). The measuring system's response time is 2 s. The
monitoring function's alarm delay does not start until after this.
! Note!
8 hours is set for the time between when the failure occurs and the failure is eliminated (MTTR).
Supplementary device The following documentation must be available for the measuring system:
documentation
Device type Operating Instructions Description of the device functions
Promag 50 BA00046D/06 BA00049D/06
Promag 53 BA00047D/06 BA00048D/06
This document also includes information on application limits and ambient conditions as well as the
functional specifications of the current output.
For devices with an explosion protection approval, the corresponding Safety Instructions (XA) or
Control Drawings (ZD) must also be observed.
Endress+Hauser 5
Settings and installation instructions

Installation instructions Instructions for the correct installation of the measuring device can be found in the Operating
Instructions (BA) supplied see "Further applicable device documentation" ( ä 5).
Suitability of the measuring device

Carefully select the nominal diameter of the measuring device in accordance with the application's
expected flow rates. The maximum flow rate during operation must not exceed the specified maximum
value for the sensor. In safety-related applications, it is also recommended to select a limit value for
monitoring the minimum flow rate that is not smaller than 5 % of the specified maximum value of the
sensor.
The measuring device must be used correctly for the specific application, taking into account the
medium properties and ambient conditions. Carefully follow instructions pertaining to critical process
situations and installation conditions from the device documentation.
Avoid applications that cause buildup or corrosion in the measuring pipe.
In general, there are no specific requirements for single-phase, liquid media with properties similar to
those of water.
! Note!
Please contact your Endress+Hauser sales office for further information.
Setting instructions The measuring device can be configured in various ways in process control protection systems:
• Via onsite operation (LCD display)
• Via HART handheld terminal DXR 375
• Via PC (remote operation) using service and configuration software (e.g. "FieldCare")
The tools mentioned can also be used to retrieve information on the software and hardware revision
of the device.  ä 5Further instructions on the settings can be found in the corresponding Operating
Instructions see "Supplementary device documentation" ().
Monitoring options The measuring device can be used in protective systems to monitor the volume flow (Min., Max. and
range):
! Note!
The device must be correctly installed to guarantee safe operation.
4 Min. Max. 20 [mA]
A0015277
Monitoring options in protective systems

A Min. alarm
B Max. alarm
C Range monitoring
= Safety function activated
= Permitted operating status
6 Endress+Hauser
The following table shows the settings which are necessary to use the measuring device in a safety-
related application. The settings refer to the 4 to 20 mA output value of the current output which
corresponds to the flow value.
Group Name of function in the group Allowed setting when Promass is used for a
safety function
CURRENT OUTPUT ASSIGN CURRENT OUTPUT Volume flow
CURRENT OUTPUT CURRENT SPAN – 4–20 mA (………):

All settings with a current output
configuration to 4-20 mA.
– 0…20 mA:
Setting is not allowed.
Promag 50
communication are not permitted.
Promag 53
communication are only permitted if HART
write protection is activated ( ä 7, "Locking"
section)
CURRENT OUTPUT FAILSAFE MODE – Min. current

– Max. current
CURRENT OUTPUT SIMULATION CURRENT OFF

SYSTEM PARAMETER POSITIVE ZERO RETURN OFF
SUPERVISION ASSIGN SYSTEM ERROR OFF

(the assignment of information messages and
fault messages may not be changed)
SUPERVISION ALARM DELAY 0…20 s
SIMULATION SYSTEM SIMULATION FAILSAFE MODE OFF
SIMULATION SYSTEM SIMULATION MEASURAND OFF
A detailed description of the functions of the device can be found in the appropriate "Description of
Device Functions" see "Further applicable device documentation" ( ä 5).
Locking In order to protect the process relevant parameters against change, the software has to be locked.
This is done via a code set by the customer.
Software lock for local programming

Function DEFINE PRIVATE CODE Freely choosable code number (except for 0)
Promass 53:
When using HART communication, the HART write protection must be activated. This can be done
with the aid of a jumper on the I/O board. Please refer to the appropriate Operating Instructions for the
correct procedure to activate the HART write protection see "Further applicable device
Setting instructions for The determined limit value (mA value corresponding to chosen max. and/or min. flow) must be
evaluation unit entered at the subsequent limit contactor (automation system). For all adjustment and setting
procedures, please refer to the relevant Operating Instructions see "Further applicable device
Endress+Hauser 7
Response in operation and The response in operation and failures is described in the Operating Instructions of the device
failure see "Further applicable device documentation" ( ä 5).
! Note!
• Repair: The repair of the devices must principally be performed by Endress+Hauser.
Is the repair carried out by other people, the safety related functions can no longer be assured.
Exception: The replacement of modular components by original spare parts is permitted by qualified
personnel of the customer, if trained by Endress+Hauser for this purpose.
• A failure of a SIL marked Endress+Hauser product, which was operated in a safety instrumented
system, shall be reported to [email protected] including product type, serial number and description
of the failure.
Device failures must be reported to the manufacturer. The user provides a detailed statement to the
manufacturer describing the failure and any possible effects. There is also information flow as to
whether this is a dangerous failure or a failure which cannot be detected directly.
• If a SIL-type Endress+Hauser device which was used in a protective function fails, the "Declaration of
contamination and cleaning" must be enclosed with a note specifying "Use as SIL device in a
protective system" when returning the defective device.
Information on the useful The established failure rates of electrical components apply within the useful lifetime as per IEC/
lifetime of electric EN 61508-2, section 7.4.7.4, note 3.
components
! Note!
The manufacturer and plant owner/operator must take appropriate measures to achieve a longer
service life as per DIN EN 61508-2, note NA4.
8 Endress+Hauser
Proof test
Proof test of the measuring Check the operativeness of safety functions at appropriate intervals. The operator must determine the
system checking interval and take this into account when determining the probability of failure PFDavg of the
sensor system.
! Note!
In a single-channel architecture, the PFDavg value to be used depends on the diagnostic coverage of the
proof test (PTC = Proof Test Coverage) and the intended lifetime (LT = Lifetime) in accordance with
the following formula:
PFDavg ≈ ldu . [ PTC/2 . Ti + (1 – PTC )/2 . LT ]

A0015275
The functional test must be carried out in such a way that it verifies correct operation of the safety
device in conjunction with all of the other components. Each test must be fully documented.
The accuracy of the measured value must first be checked in order to test the safety function (Min.,
Max., range). This involves approaching the configured limit values upon which the safety function
(including actuator) should be activated. Checking the accuracy of the measured values is sufficient in
order to test the "Range" safety function.
During the proof test, alternative monitoring measures must be taken to ensure process safety.
A proof test of the device can be performed in the following steps:
1. Checking the digital measured value
One of the following tests must be carried out depending on the measured variable to be
monitored and the available equipment:
a. Test sequence A – Checking the digital measured value with a calibration rig
Volume flow
The measuring device is recalibrated using a calibration rig that is certified in accordance with
ISO 17025. This can be done on an installed device using a mobile calibration rig or using
factory calibration if the device has been disassembled. The amount of deviation between the
measured flow rate and the set point must not exceed the maximum measured error specified
in the Operating Instructions.
! Note!
Please contact your Endress+Hauser sales office for further information on standard methods
for on-site calibration of flowmeters.
b. Test sequence B – Checking the digital measured value using the installed totalizer
Volume flow
A calibrated measuring vessel is filled with the medium at a flow rate which approximately
corresponds to the limit value to be monitored. The change in the volume in the measuring
vessel is read off before and after filling and compared with the totalizer installed in the
measuring device. The amount of deviation must not exceed the maximum measured error
specified in the Operating Instructions. For range monitoring, this test must be carried out
separately for the upper and lower limit value.
c. Test sequence C – Checking the digital measured value using Fieldcheck
Volume flow
Verification of the measuring device in an installed state with Fieldcheck as described in
Operating Instructions BA00067D/06. Fieldcheck displays the test results (passed/failed)
automatically.
This test can be carried out without removal of the flowmeter and makes periodic inspection
easier. The high diagnostic coverage means that > 90 % of undetected failures are detected
whereby the level of increase in the average probability of failure PFDAVG is lower than
without the check ( graphic below). The average probability of failure PFDAVG can be
estimated using the formula for this ( ä 9) and taking into account the intended lifetime t.
When used in conjunction with the "FieldCare" software package, test results can be imported
into a database, printed and used as verification for the relevant certification body.
Endress+Hauser 9
SIL 1
ck
he
PFD
tc
SIL 2 PFD avg
ou
th
wi
heck
riodic c
with pe
SIL 3
Checking interval Ti Operating time LT

A0015615-EN
Single-channel system architecture 1oo1
2. Checking the 4–20 mA current output

Using the current simulation (fixed current value) option available in the operating menu, set the
current output of the device to the values 3.6 mA, 4.0 mA, 20.0 mA and 22.0 mA one after
another and compare with the measured values of a calibrated, external current measuring
device.
3. Checking the safety function

Correct activation of the safety function - including actuator - must be checked by outputting
suitable current values on the 4–20 mA interface per current simulation (just below and above
the switch point). For range monitoring, this test must be carried out separately for the upper and
lower limit value.
4. Completing the proof test

Switch the 4–20 mA current output to measured value output (if necessary).
! Note!
The proof test is only completed when steps 1 to 4 are accomplished.
98 % of dangerous, undetected failures are detected using test sequences 1a to 1b, whereas 90 % of
dangerous, undetected failures are detected using test sequence 1c. If one of the test criteria from the
test sequences described above is not fulfilled, the device may no longer be used as part of a protective
system.
The influence of systematic faults on the safety function are not covered by the test and must be
examined separately. Systematic faults can be caused, for example, by medium properties, operating
conditions, build-up or corrosion.
10 Endress+Hauser
Exida Management Summary
FMEDA and Proven-in-use Assessment
Project:
Electromagnetic Flow Measuring System PROMAG 50/53
Customer:
Reinach
Switzerland
Contract No.: E+H 06/02-03

Report No.: E+H 06/02-03 R039
Version V1, Revision R1, October 2006
Stephan Aschenbrenner
The document was prepared using best effort. The authors make no warranty of any kind and shall not be liable in
any event for incidental or consequential damages in connection with the application of the document.
© All rights on the format of this technical report reserved.
Endress+Hauser 11
Management summary
This report summarizes the results of the hardware assessment with proven-in-use
consideration according to IEC 61508 / IEC 61511 carried out on the electromagnetic flow
measuring system PROMAG 50/53 with 4..20 mA HART® output and software version
02.00.00. The statements made in this report are also valid for further software versions as long
as the assessed IEC 61508 modification process is considered. Any changes are under the
responsibility of the manufacturer. Table 1 gives an overview of the different types that belong
to the considered electromagnetic flow measuring system PROMAG 50/53.
The hardware assessment consists of a Failure Modes, Effects and Diagnostics Analysis
(FMEDA). A FMEDA is one of the steps taken to achieve functional safety assessment of a
device per IEC 61508. From the FMEDA, failure rates are determined and consequently the
Safe Failure Fraction (SFF) is calculated for the device. For full assessment purposes all
requirements of IEC 61508 must be considered.
Table 1: Version overview
Version Type Commodul Options

V1 50***-***********W C03 Current
50***-***********A C03 Current + Frequency
50***-***********D C03 Current + Frequency + Status output + Status
input
V2 53***-***********C C05 Current + Frequency + 2 * Relays
53***-***********L C05 Current + 2 * Relays + Status input
53***-***********M C05 Current + 2*Frequency + Status input
53***-***********2 C05 Current + Current2 + Frequency + Relay
53***-***********4 C05 Current + Frequency + Current input + Relay
V3 53***-***********A C06 Current + Frequency
53***-***********B C06 Current + Frequency + 2 * Relays
V4 53***-***********S C07 Current active + Frequency passive
V5 53***-***********T C07 Current passive + Frequency passive
For safety applications only the 4..20 mA current output was considered. All other possible
output variants or electronics are not covered by this report. The different devices can be
equipped with or without display.
The failure rates used in this analysis are the basic failure rates from the Siemens standard
SN 29500.
According to table 2 of IEC 61508-1 the average PFD for systems operating in low demand
mode has to be t10-3 to < 10-2 for SIL 2 safety functions. A generally accepted distribution of
PFDAVG values of a SIF over the sensor part, logic solver part, and final element part assumes
that 35% of the total SIF PFDAVG value is caused by the sensor part.
For a SIL 2 application operating in low demand mode the total PFDAVG value of the SIF should
be smaller than 1,00E-02, hence the maximum allowable PFDAVG value for the sensor part
would then be 3,50E-03.

12 Endress+Hauser
The electromagnetic flow measuring system PROMAG 50/53 is considered to be a Type B1

sub-system with a hardware fault tolerance of 0.
Type B sub-systems with a SFF of 60% to < 90% must have a hardware fault tolerance of 1
according to table 3 of IEC 61508-2 for SIL 2 (sub-) systems.
As the electromagnetic flow measuring system PROMAG 50/53 is supposed to be a
proven-in-use sub-system, an assessment of the hardware with additional proven-in-use
demonstration was carried out. Therefore according to the requirements of IEC 61511-1 First
Edition 2003-01 section 11.4.4 and the assessment described in section 6 a hardware fault
tolerance of 0 is sufficient for SIL 2 sub- systems being Type B sub-systems and having a SFF
of 60% to < 90%.
The proven-in-use investigation was based on field return data collected and analyzed by
Endress+Hauser Flowtec AG.
According to the requirements of IEC 61511-1 First Edition 2003-01 section 11.4.4 and the
assessment described in section 6 the device is suitable to be used, as a single device, for
SIL 2 safety functions. The decision on the usage of proven-in-use devices, however, is always
with the end-user.
Endress+Hauser Flowtec AG performed a qualitative analysis of the mechanical parts of the
electromagnetic flow measuring system PROMAG 50/53 (see [D7]). This analysis was used by
exida to calculate the failure rates of the sensor elements using exidas experienced-based
data compilation for the different components of the sensor elements (see [R1]). The results of
the quantitative analysis were used for the calculations described in sections 5.1 to 5.6.
Assuming that the application program in the safety logic solver is configured to detect under-
range and over-range failures and does not automatically trip on these failures, these failures
have been classified as dangerous detected failures. The following tables show how the above
stated requirements are fulfilled.
2
Table 2: Summary for the worst case version Failure rates
Failure category Failure rates (in FIT)

Fail Dangerous Detected 756
3
Fail dangerous detected (internal diagnostics or indirectly ) 598
Fail high (detected by the logic solver) 7
Fail low (detected by the logic solver) 140
Annunciation detected 11
Fail Dangerous Undetected 295
Fail dangerous undetected 285
Annunciation undetected 10
No Effect 265
Not part 194
1
Type B sub-system: Complex sub-system (using micro controllers or programmable logic); for details see
7.4.3.1.3 of IEC 61508-2.
2
It is assumed that practical fault insertion tests can demonstrate the correctness of the failure effects assumed
during the FMEDAs.
3
indirectly means that these failure are not necessarily detected by diagnostics but lead to either fail low or fail high
failures depending on the transmitter setting and are therefore detectable.

Endress+Hauser 13
Table 3: Summary for the worst case version IEC 61508 Failure rates
OSD OSU 4 ODD ODU SFF DCS 5 DCD 3

0 FIT 265 FIT 756 FIT 295 FIT 77% 0% 71%
Table 4: Summary for the worst case version PFDAVG values

T[Proof] = 1 year T[Proof] = 5 years T[Proof] = 10 years
PFDAVG = 1,29E-03 PFDAVG = 6,43E-03 PFDAVG = 1,28E-02
The boxes marked in yellow ( ) mean that the calculated PFDAVG values are within the
allowed range for SIL 2 according to table 2 of IEC 61508-1 but do not fulfill the requirement to
not claim more than 35% of this range, i.e. to be better than or equal to 3,50E-03. The boxes
marked in green ( ) mean that the calculated PFDAVG values are within the allowed range for
SIL 2 according to table 2 of IEC 61508-1 and do fulfill the requirement to not claim more than
35% of this range, i.e. to be better than or equal to 3,50E-03. The boxes marked in red ( )
mean that the calculated PFDAVG values do not fulfill the requirements for SIL 2 according to
table 2 of IEC 61508-1.
The failure rates listed above do not include failures resulting from incorrect use of the
electromagnetic flow measuring system PROMAG 50/53, in particular humidity entering through
incompletely closed housings or inadequate cable feeding through the inlets.
The listed failure rates are valid for operating stress conditions typical of an industrial field
environment similar to IEC 60654-1 class C (sheltered location) with an average temperature
over a long period of time of 40ºC. For a higher average temperature of 60°C, the failure rates
should be multiplied with an experience based factor of 2,5. A similar multiplier should be used
if frequent temperature fluctuation must be assumed.
A user of the electromagnetic flow measuring system PROMAG 50/53 can utilize these failure
rates in a probabilistic model of a safety instrumented function (SIF) to determine suitability in
part for safety instrumented system (SIS) usage in a particular safety integrity level (SIL). A full
table of failure rates is presented in sections 5.1 to 5.6. along with all assumptions.
It is important to realize that the no effect failures are included in the safe undetected failure
category according to IEC 61508. Note that these failures on its own will not affect system
reliability or safety, and should not be included in spurious trip calculations.
The failure rates are valid for the useful life of the electromagnetic flow measuring system
PROMAG 50/53 (see Appendix 3).
4
Note that the SU category includes failures that do not cause a spurious trip
5
DC means the diagnostic coverage (safe or dangerous).

14 Endress+Hauser
Appendix (safety-related characteristic values)

Introductory comments Depending on the order code, Promag flow measuring systems are supplied with different signal inputs
and outputs. For the purposes of clarity, similar types of electronics modules are grouped into
categories.
! Note!
• The safety-related characteristic values are described separately for each of these categories see
sections "Category 1-7". The tables provided in these category sections contain all the important
characteristic values. The values apply to all possible applications:
• The failure rates indicated refer to the failure rates of Siemens Standard SN29500 at an ambient
temperature of +40 °C (+104 °F).
Measuring system / Outputs and inputs Category

electronics  ä 16
Product structure
Promag 50
50 *** – ***********W Curr. outp. 1
50 *** – ***********D Curr. outp. / frequency outp. / status outp. / status inp. 1
Promag 53
53 *** – ***********C Curr. outp. / frequency outp. / relay / relay 2 2
53 *** – ***********L Curr. outp. / relay / relay 2 / status inp. 2
53 *** – ***********M Curr. outp. / frequency outp. / frequency outp. 2 / status inp. 2
53*** – ***********2 Curr. outp. / curr. outp. 2 / frequency outp. / relay 2
53*** – ***********4 Curr. outp. / frequency outp. / relay / curr. inp. 2
53 *** – ***********B Curr. outp. / frequency outp. / relay / relay 2 3
• ATEX II2G/D, FM/CSA Cl.1 Div.1, TIIS and NEPSI are available options for Promag H/P/W
• ATEX II3G/D is an available option for Promag E/H/P/W
• FM/CSA Cl.1 Div.2 is an available option for Promag D/E/H/L/P/W
Comments on the term "dangerous undetected failures"

Situations in which the process does not respond to a demand (i.e. the measuring device does not
demonstrate the predefined failsafe mode) or in which the output signal deviates more than the total
measured error as specified. Please refer to the "Performance characteristics" section of the Operating
Instructions for more detailed information on the total measured error.
The following presumptions are made:
• The failure rates are constant, wear out mechanisms are not included.
• Failure propagation is not relevant.
• The HART protocol is only used to read out data during normal operation.
• The recovery time after a safe failure is 8 hours.
• The test time of the automation system to react to a detected failure is one hour.
• All modules are operated in the "low demand mode".
• Only current output 1 is used for safety-related applications.
• Failure rates of the external power supply are not included.
• The stress levels are average values for an industrial environment and can be compared to the
"Ground Fixed" classification of MIL-HDBK-217F. Alternatively, the presumed environment is similar
to IEC 60654-1, Class C (protected mounting location) with temperature limits within the
manufacturer's specifications and an average temperature of +40 °C (+104 °F) for the transmitter
over an extended period. Humidity is assumed within the manufacturer's specification.
Endress+Hauser 15
• Only the versions described are used for safety applications.

• As the optional display does not constitute a part of the safety function, the failure rate of the display
is not taken into account in the calculations.
Categories • SIL (Safety Integrity Level) = 2

• HFT (Hardware Fault Tolerance In accordance with IEC 61511-1, section 11.4) = 0
• Device type = Type B (complex components)
Category SFF1) PFDAVG du dd su sd
1 year 2 years 5 years
1 76.68 % 1.27 · 10–3 2.54 · 10–3 6.35 · 10–3 291 FIT 705 FIT 253 FIT 0 FIT
2 77.58 % 1.29 · 10–3 2.58 · 10–3 6.45 · 10–3 295 FIT 756 FIT 265 FIT 0 FIT
–3 –3 –3
3 76.89 % 1.28 · 10 2.56 · 10 6.40 · 10 292 FIT 711 FIT 260 FIT 0 FIT
–3 –3 –3
4 81.06 % 1.25 · 10 2.50 · 10 6.25 · 10 285 FIT 854 FIT 365 FIT 0 FIT
5 80.29 % 1.21 · 10–3 2.42 · 10–3 6.05 · 10–3 277 FIT 847 FIT 283 FIT 0 FIT
–3 –3 –3
6 80.29 % 1.24 · 10 2.50 · 10 6.25 · 10 285 FIT 854 FIT 365 FIT 0 FIT
–3 –3 –3
7 80.29 % 1.20 · 10 2.42 · 10 6.05 · 10 277 FIT 847 FIT 283 FIT 0 FIT
 Safe Failure Fraction
16 Endress+Hauser
Endress+Hauser 17
18 Endress+Hauser
Endress+Hauser 19
83250302 • 1/2010-03
X5-02 X5-01 X9-04 X7-02 X4-02 X6-03 X3-05 X3-03
X56
BCI
COM X92
X5-02 1
X5-01 1
X9-04 1
X7-02 1
X4-02 1
X6-03 1
X3-05 1
X3-031
max
min
P max/POC PE
PE
PE
PE
PE
PE
L
L
L
L
L
N
N
LT
MOTOR CONT
IGNITION
V3/PV
SV
P min
P P P
P LT
FLANGE
Installation and operating instruction
MOTOR
ALARM
FUEL X54
SIEMENS
230 VAC
LMV27.210A2WH 50 or 60 Hz
FM
W-FM50
-20C to + 60C Best.-Nr.: 600402
1P - 4 F to +140 F
P
SAFETY
Siemens Building Technologies CE-xxxxxxxxxxxxx Geräte-Nr.: 0503020021
LOOP
L VOLTAGE
DIN VDE
HVAC Products GmbH Rg.xxxxxxxxxxxxxx
Made in Germany Refer to data sheet 7543 S
AIR
N LINE
FLAME
OPERATION
P air
COUNTER U SENSOR
V1
PE
RESET
X53
L
V2
+ 1
FUEL PULSE-IN
P
X3-04
ON/OFF
QRB/C-N
QRB/C
QRA
QRA
3
2
ION
info
PE
PE
PE
N
L
•
L
L
L
L
1 1 1 1 1 1 1 1 FUSE 1
X75 X10-05 X10-06 X3-02 X5-03 X8-04 X8-02 X7-01 T6.3 IEC 60127-2/V
VSD X74 1
X64
+
1
h min s %
esc
1 1 1 1 1 1 1 1 1
X75 X10-05 X10-06 X3-02 X5-03 X8-04 X8-02 X7-01 X3-04 PE N L
–
V
A
VSD
S
F
P
i
Combustion manager W-FM 50

1 User instructions ..................................................................................................................... 4

1.1 User guide ............................................................................................................. 4
1.1.1 Symbols ................................................................................................................. 4
1.1.2 Target group ......................................................................................................... 4
1.2 Guarantee and Liability ....................................................................................... 5
2 Safety ............................................................................................................................................ 6
2.1 Permissible application ....................................................................................... 6
2.2 When gas can be smelled ................................................................................. 6
2.3 Safety measures .................................................................................................. 6
2.3.1 Normal operation ................................................................................................. 6
2.3.2 Electrical connection ........................................................................................... 6
2.3.3 Gas supply ............................................................................................................ 7
2.4 Alterations to the construction of the equipment ......................................... 7
2.5 Noise emission ..................................................................................................... 7
2.6 Disposal ................................................................................................................. 7
3 Product description ............................................................................................................... 8

3.1 Function ................................................................................................................. 8
3.1.1 Valve proving ........................................................................................................ 8
3.1.2 Low gas programme ........................................................................................... 8
3.1.3 Manual load ........................................................................................................... 9
3.1.4 Calculation ......................................................................................................... 10
3.1.5 Data backup ....................................................................................................... 10
3.1.6 Referencing the actuator ................................................................................ 11
3.1.7 Program sequence ........................................................................................... 12
3.2 Inputs ................................................................................................................... 16
3.2.1 Voltage supply ................................................................................................... 16
3.2.2 Safety circuit ...................................................................................................... 16
3.2.3 Reset ................................................................................................................... 16
3.2.4 Load controller via contacts ........................................................................... 17
3.2.5 Load controller analogue input ...................................................................... 18
3.2.6 Load controller building management .......................................................... 18
3.2.7 Air pressure switch ........................................................................................... 19
3.2.8 Minimum pressure switches ........................................................................... 19
3.2.9 High pressure switches ................................................................................... 19
3.2.10 Valve proving gas pressure switch ............................................................... 20
3.2.11 Flame sensor ...................................................................................................... 20
3.2.12 Fuel meter ........................................................................................................... 21
3.3 Outputs ............................................................................................................... 22
3.3.1 Alarm .................................................................................................................... 22
3.3.2 Motor ................................................................................................................... 22
3.3.3 Ignition unit ......................................................................................................... 22
3.3.4 Frequency converter ........................................................................................ 22
3.3.5 Load signal ......................................................................................................... 23
3.4 Technical data ................................................................................................... 24
3.4.1 Electrical data .................................................................................................... 24
3.4.2 Ambient conditions ........................................................................................... 24
3.4.3 Dimensions ......................................................................................................... 25
83250302 • 1/2010-03 • La 2-98

4 Electrical installation ........................................................................................................... 26
5 Operation .................................................................................................................................. 28
5.1 Operating interface .......................................................................................... 28
5.1.1 Operating panel ................................................................................................ 28
5.1.2 Display ................................................................................................................. 29
5.2 Displaying and adjusting parameters ........................................................... 31
5.2.1 Password ............................................................................................................ 32
5.3 Parameters ......................................................................................................... 33
5.3.1 Password level .................................................................................................. 33
5.3.2 Info level .............................................................................................................. 41
5.3.3 Service level ....................................................................................................... 41
6 Commissioning ...................................................................................................................... 42
6.1 Adjust gas side .................................................................................................. 43
6.2 Adjust modulation oil side ............................................................................... 56
6.3 Adjust multi-stage oil side .............................................................................. 69
7 Shutdown .................................................................................................................................. 80
8 Servicing .................................................................................................................................... 81
8.1 Safety components .......................................................................................... 81
9 Troubleshooting .................................................................................................................... 82
9.1 Procedures for fault conditions ..................................................................... 82
9.2 Error codes ......................................................................................................... 84
10 Spares ......................................................................................................................................... 92
11 Technical documentation ................................................................................................. 94

11.1 Frequency converter ........................................................................................ 94
12 Key word index ...................................................................................................................... 96
83250302 • 1/2010-03 • La 3-98

1 User instructions
1 User instructions
These operating instructions form part of the equipment and must be kept on site at
Translation of original all times.
operating instructions
1.1 User guide
1.1.1 Symbols
Immediate danger with high risk.

Non observance can lead to serious injury or death.
DANGER
Danger with medium risk.

Non observance can lead to environmental damage,
serious injury or death.
WARNING
Danger with low risk.

Non observance can cause damage to the equipment
and injury to personnel.
CAUTION
Important information.
Requires direct action.
Result after an action.
Itemisation.
Range.
1.1.2 Target group

These installation and operating instructions are intended for the operator and quali-
fied personnel. They should be observed by all personnel working on the unit.
Work on the unit must only be carried out by personnel who have the relevant training
and instruction.
83250302 • 1/2010-03 • La 4-98

1 User instructions
1.2 Guarantee and Liability

Guarantee and liability claims for personal and equipment damage are excluded, if
they can be attributed to one or more of the following causes:
▪ Non approved application of the unit,
▪ non-observance of the installation and operating instruction,
▪ operating the unit with faulty safety equipment,
▪ continual operation despite a fault,
▪ improper installation, commissioning, operation and service of the unit,
▪ alterations to the unit,
▪ the installation of additional components, which have not been tested with the unit,
▪ the installation of combustion chamber inserts, which impede full flame formation,
▪ repairs, which have been carried out incorrectly,
▪ the use of non original Weishaupt parts,
▪ unsuitable fuels,
▪ defects in the supply lines,
▪ acts of God.
83250302 • 1/2010-03 • La 5-98

2 Safety
2 Safety
2.1 Permissible application

The combustion manager W-FM 50 is suitable for use with single fuel burners.
Improper use could:
▪ endanger the health and safety of the user or third parties,
▪ cause damage to the unit or other material assets.
2.2 When gas can be smelled

Avoid open flames and spark generation. For example:
▪ do not operate light switches,
▪ do not operate electronic equipment,
▪ do not use mobile telephones.
▶ Open doors and windows.
▶ Close gas isolating valve.
▶ Warn the inhabitants (do not ring door bells).
▶ Leave the building.
▶ Inform the heating company or gas supplier from outside of the building.
2.3 Safety measures

▪ Rectify safety-relevant defects immediately,
▪ Replace safety-relevant components according to their specified service life (see
Ch. 8.1).
2.3.1 Normal operation

▪ All labels on the unit must be kept in a legible condition,
▪ the unit should only be operated with its cover in the closed position,
▪ do not touch moving parts during operation,
▪ stipulated settings, service and inspection work should be carried out at regular
intervals.
2.3.2 Electrical connection

For all work carried out on live parts:
▪ Observe the accident prevention instructions BGV A3 and adhere to local direc-
tives,
▪ tools in accordance with EN 60900 should be used.
83250302 • 1/2010-03 • La 6-98

2 Safety
2.3.3 Gas supply

▪ Installation, alteration and maintenance work on gas appliances in buildings and
properties must only be carried out by the gas authority or their approved agent,
▪ the pipe work must be subject to a pre and main test and a combined load test
and valve proving test relative to the pressure range intended (e.g.
DVGW-TRGI, work sheet G 600),
▪ inform the gas authority about the type and size of plant prior to installation,
▪ local regulations and guidelines must be observed during installation (e.g.
DVGW-TRGI, work sheet G 600; TRF Band 1 and Band 2),
▪ the gas supply pipe work should be suitable for the type and quality of gas and
should be designed in such a way that it is not possible for liquids to escape
(e. g. condensate), observe the vaporisation temperature of liquid petroleum gas,
▪ use only approved sealing materials. Observe all process information,
▪ re-commission the unit when changing to a different type of gas,
▪ carry out soundness test after each service and fault rectification.
2.4 Alterations to the construction of the equipment

All conversions require written approval from Max Weishaupt GmbH.
▪ No additional components may be fitted, which have not been tested for use with
the equipment,
▪ use only original Weishaupt replacement parts.
2.5 Noise emission

The noise emissions of a combustion system are determined by the acoustic behav-
iour of all components fitted.
High noise levels can lead to loss of hearing. Provide operating personnel with pro-
tective equipment.
A sound attenuator can be installed to further reduce noise emissions.
2.6 Disposal
Dispose of all materials used in a safe and environmentally friendly way. Observe local
regulations.
83250302 • 1/2010-03 • La 7-98

3 Product description
3.1 Function
3.1.1 Valve proving

The valve proving gas pressure switch checks the soundness of the valves. It signals
the combustion manager if the pressure increases or decreases to an impermissible
level during valve proving.
Valve proving is carried out automatically by the combustion manager:
▪ after every controlled shutdown,
▪ prior to burner start following lockout or power outage.
1. Test phase (function sequence for valve proving valve 1):
▪ valve 1 closes,
▪ valve 2 closes after a delay,
▪ the gas escapes and the pressure between valve 1 and valve 2 reduces,
▪ both valves remain closed for 10 seconds.
If the gas pressure increases to above the set value during these 10 seconds, valve
1 is leaking. The combustion manager initiates a controlled shutdown.
2. Test phase (function sequence for valve proving valve 2):
▪ valve 1 opens, valve 2 remains closed,
▪ the gas pressure between valve 1 and valve 2 increases,
▪ valve 1 closes again,
▪ both valves remain closed for 10 seconds.
If the gas pressure decreases to below the set value during these 10 seconds, valve
2 is leaking. The combustion manager initiates a controlled shutdown.
3 sek 10 sek 3 sek 10 sek

V1 V2
80 81 82 82 P P
1 Valve 1
2 Valve 2
3 Pressure between valve 1 and valve 2
4 Valve proving gas pressure switch
5 Operating phases
3.1.2 Low gas programme

The low gas pressure switch checks the gas connection pressure from phase 22. If
the preset gas pressure is not achieved, a low gas programme is initiated.
In the low gas programme the combustion manager carries out a safety shutdown
and initiates a restart after the low gas waiting time (10 seconds). This low gas waiting
time doubles after every unsuccessful start attempt. If the start attempts exceed the
repetition limit value (parameter 223) the combustion manager goes to lockout.
If the burner starts, the repetition counter is reset automatically.
83250302 • 1/2010-03 • La 8-98

3.1.3 Manual load

If a signal is applied to input X5-03:1 (burner ON), each load setting within the load
limit can be selected manually . When manual load is activated, the current load
flashes in the operating display. Manual load can be activated either by key combi-
nation or via parameter 121. Manual load via parameter 121 offers additional func-
tions.
Load default Function
Parameter 121 Key combination
---- Manual load deactivated not possible
0.0 … 19.9 Manual OFF, remains active even after not possible
fuel changeover.
P0 Initiate ignition position (only multi stage not possible
operation)
20.0 … 100.0 Initiate load setting within the load limits. Initiate load setting within the load limits.
P1 … P3
Values outside of the load limits can be Only values within the load limits can be
adjusted, but not initiated. If the load lim- adjusted.
its are extended during active manual
load, the burner reacts accordingly.
For the duration of commissioning (400 Set), manual load is ignored.
With the exception of Manual OFF, manual load is deactivated during fuel change-
over.
Manual load via key combination

Activate manual load:
▶ Press and hold [F] key.
✓ The display shows LoAd.
▶ Set manual load using [+] or [-] key.
✓ The manual load set flashes in the operating display.
Manual load burner OFF:
▶ Drive to minimum load position and release [F] and [-] keys.
▶ Press [F] and [-] keys again.
Deactivate manual load:
▶ Press and hold [esc] key for 5 seconds.
S S
P P
i i
V h min s % V h min s %
S S
P P
i i
V h min s %
5s V h min s %
Manual load via parameter 121

▶ Enter password (see Ch. 5.2.1).
▶ Select parameter 121
▶ Press [ENTER] key.
▶ Set manual load using [+] or [-] key.
✓ Manual load is initiated.
83250302 • 1/2010-03 • La 9-98

3.1.4 Calculation
A calculation can be initiated in modulating commissioning if P1 and P9 are pro-
grammed. During calculation, a straight line is formed from the operating point shown
from P1 or from P9. The values on the straight line form new operating points.
Initiating a calculation from P9: Press [+] key for 3 to 5 seconds.
Initiate a calculation from P1: Press [-] key for 3 to 5 seconds.
If during commissioning only P1 and P9 are programmed, the combustion manager
initiates an automatic calculation when exiting P1 and calculates P2 to P8.
P1 P2 P3 P4 P5 P6 P7 P8 P9 P1 P2 P3 P4 P5 P6 P7 P8 P9
1 Automatic calculation
2 Calculation from P5 to P9
3.1.5 Data backup

In the ABE, the settings of the combustion manager can be saved (Backup) via pa-
rameter 050 (see Ch. 5.3.1). If the unit needs to be replaced, or if the parameters
have unintentionally been altered, the data can be transferred back to the combustion
manager.
As a protection against unintentional data transfer from the ABE to the combustion
manager, the burner data of both units is compared; data will only be transferred
(Restore), if the data matches.
Soot or CO formation because no combustion analysis has been carried out.

At heat demand, the burner starts automatically approx. 30 seconds after the data
transfer (Restore).
WARNING Directly following the data transfer (Restore):
▶ Check sequence of operation
▶ Carry out a combustion analysis at each load point.
Only in conjunction with frequency converter

Following data transfer (Restore) a speed standardisation with subsequent adjust-
ment must be carried out.
83250302 • 1/2010-03 • La 10-98

3.1.6 Referencing the actuator

In operating phase 10 (home run) the combustion manager references the actuators,
whereby the actuator drives over a reference marker. The actuator then drives back
and locates the inner edge of the reference marker. All settings are referenced to this
position.
The combustion manager references the fuel actuators to the reference marker OPEN
and the air actuator to the reference marker CLOSED. The setting range of the air
damper shaft is limited mechanically, therefore the air actuator cannot drive to refer-
ence marker OPEN. If the actuators have been mixed up, a reference fault is identified
(fault 85).
0°
-8°
-6°
90°
108°
112°
1 Reference range CLOSED

2 Reference marker CLOSED (air actuator)
3 Reference range OPEN
4 Reference marker OPEN (fuel actuators)
83250302 • 1/2010-03 • La 11-98

3.1.7 Program sequence
Operating phases
00 Lockout phase
02 Safety phase
10 Home run
12 Standby
22 Fan / safety valve ON
24 Pre-purge position
30 Pre-purge
36 Ignition position
38 Pre-ignition
40 Fuel release
42 Ignition OFF
44 Flame signal
50 Flame stabilisation (only with Gas with pilot ignition)
52 Ignition pilot valve OFF (only with Gas with pilot ignition)
60 Operating setting 1
62 Operating setting 2
70 Post burn time
72 Post purge position
74 Post-purge
78 Post-purge
80 Venting valve train (only during valve proving)
81 Test without pressure (only during valve proving)
82 Fill valve train (only during valve proving)
83 Test with system pressure (only during valve proving)
90 Low gas waiting time
83250302 • 1/2010-03 • La 12-98

Gas with ignition pilot valve
00 02 10 12 22 24 30 36 38 40 42 44 50 52 60 62 70 72 74 78 80 81 82 83 90
X3-03:1, X3-04:1
X5-03:1
X10-05:2
X3-02:1
X5-01:2
X5-02:2
X9-04:2
X3-05:1
X4-02:3
X6-03:3
X8-02:1
X7-01:3
X7-02:3
Signal on input / output activated

No signal on input
Input without influence
1 Operating phases
2 Safety circuit
3 Heat demand from controller
4 Flame signal
5 Air pressure switch
6 Low pressure switch
7 High pressure pressure switch
8 Valve proving pressure switch
9 Fan motor
0 Ignition unit
q Safety valve
w Fuel valve 1
e Fuel valve 2
r Ignition pilot valve
83250302 • 1/2010-03 • La 13-98

Gas direct ignition
00 02 10 12 22 24 30 36 38 40 42 44 50 52 60 62 70 72 74 78 80 81 82 83 90
X3-03:1, X3-04:1
X5-03:1
X10-05:2
X3-02:1
X5-01:2
X5-02:2
X9-04:2
X3-05:1
X4-02:3
X6-03:3
X8-02:1
X7-01:3
X7-02:3

No signal on input
1 Operating phases
2 Safety circuit
4 Flame signal
9 Fan motor
0 Ignition unit
q Safety valve
w Fuel valve 1
e Fuel valve 2
83250302 • 1/2010-03 • La 14-98

Oil modulating or multi-stage
00 02 10 12 22 24 30 36 38 40 42 44 60 62 70 72 74 78
X3-03:1, X3-04:1
X5-03:1
X10-05
X3-02:1
X5-01:2
X5-02:2
X3-05:1
X4-02:3 (1 (1
X6-03:3
X8-02:1
X7-01:3 (2
X7-02:3
(1
Only for longer pre-ignition time (parameter 281)
(2
Only with type of operation 12 (oil modulating)
No signal on input
1 Operating phases
2 Safety circuit
4 Flame signal
8 Fan motor
9 Ignition unit
0 Safety valve
q Fuel valve 1
w Fuel valve 2
e Fuel valve 3
83250302 • 1/2010-03 • La 15-98

3.2 Inputs
3.2.1 Voltage supply

1 The voltage supply is connected to inputs X3-04:3-5 of the W-FM50.
L 2
The mains frequency is set in parameter 125.
X3-04
PE 3 PE
N 4 N
L 5 L
3.2.2 Safety circuit

1 In the diagnostic code, the inputs X3-03:1/2 and X3-04:1/2 are combined as safety
L 2 circuit. If one of the inputs is open, at least one safety shutdown is triggered. If the
X3-04
PE 3 repetition value is exceeded an open input leads to lockout. The repetition value can
N 4 be set in parameter 215.
L 5
At input X3-04:1/2 all external components of the safety circuit are switched in se-
quence, these include:
X3-03
1
2
▪ Emergency-Off switch
L
▪ Safety temperature limiter (STL)
▪ Low water safety interlock, etc.
The burner flange limit switch is connected to input X3-03:1/2.
3.2.3 Reset
(1 (2 A reset button can be connected to input X8-04:1. If lockout occurs, the combustion
X8-04
RESET 1
OPERATION 2 manager can be reset by pressing the push button for 1 to 6 seconds. Longer or
shorter operation of the push button is ignored by the combustion manager and does
1
not lead to a reaction.
L 2
X3-04
PE 3 PE
N 4 N With lockout function (1
L 5 L If the push button is also required for manual lockout, it must be connected to mains
MOTOR 1 input X3-04:5 (L). If the combustion manager is in an operating phase, pressing the
X3-05
ALARM 2 push button for 1to 6 seconds will initiate a manual lockout.
MOTOR CONT 3
Without lockout function (2
If the push button is not required to carry out manual lockout it must be connected to
alarm output X3-05:2.
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3.2.4 Load controller via contacts

The contact for the heat demand is connected to input X5-03:1 (burner ON).
The load control distinguishes between multi-stage and modulating operation. The
type of operation is set in parameter 201.
ON/OFF 1 Modulating operation with load controller

X5-03
2 °C
If input X5-03:2 (CLOSED) is activated, the burner rating reduces. If input
3
X5-03:3 (OPEN) is activated, the burner rating increases. If none of the two inputs is
L 4
activated, the burner rating remains unchanged.
ON/OFF 1 Modulating operation with thermostat

P
X5-03
2
If thermostats or pressure regulators are connected to inputs X5-03, the modulating
3 P fuel can only be operated in sliding two stage operation. At heat demand input
L 4
X5-03:2 (CLOSED) is activated and the burner drives to partial load. If the temper-
ature drops below the value set, input X5-03:3 (OPEN) is activated and the burner
ON/OFF 1 P P drives to full load. If a signal is applied to input X5-03:3, input X5-03:2 is ignored.
X5-03
2 P
3 P P
L 4
Multi-stage operation (fuel oil only)

ON/OFF 1 Two and three stage:
X5-03
2 °C
Input Type of operation
3
L 4 two stage three stage
X5-03:1 stage 1 stage 1
If input X5-03:3 is activated during 3 stage operation, the burner drives to stage 3,
the signal from stage 2 is no longer relevant.
ON/OFF 1 Low impact start:

P
X5-03
2
At heat demand and with a bridge between terminal 1 and 2 the burner ignites in
3 P stage 1 and then automatically drives to stage 2. If input X5-03:2 is also activated
L 4
the burner drives to stage 3.
ON/OFF 1 P
Change-over release:
X5-03
2
A bridge connects terminals 2 and 3. At heat demand the burner drives to stage 1. If
3 P inputs X5-03:2/3 are then activated simultaneously the burner drives via stage 2 to
L 4
stage 3.
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3.2.5 Load controller analogue input

ON/OFF 1 The contact for the heat demand is connected to input X5-03:1 (burner ON).
X5-03
2 °C
The analogue load signal is connected to terminals X64:1 (4 … 20 mA) and

3
+
X64:2 (GND). A signal of less than 3 mA deactivates the analogue input and the load
L 4
presetting at input X5-03:2/3 has priority (parameter 942). If no load controller is
-
connected to input X5-03:2/3, the combustion manager remains at the current rating
4...20 1
until heat demand is interrupted.
GND 2
X64
3
4 Modulating operation
5 In modulating operation, parameter 123 (see Ch. 5.3.1) determines the minimum
setting point.
Signal on X64:1/2 Load W-FM
3 … 4 mA 20 %
20 mA 100 %
Multi-stage operation
In multi-stage operation a hysteresis of 1 mA exists between the operating points,
which eliminates unnecessary load changes.
Two stage:
3 … 5 … 12 mA Stage 1
13 … 15 … 20 mA Stage 2
Three stage:
3 … 5 … 7 mA Stage 1
8 … 10 … 12 mA Stage 2
13 … 15 … 20 mA Stage 3
3.2.6 Load controller building management

ON/OFF 1 A Bus interface for building management can be connected to input COM X92.
▪ Modbus: Bus-Interface Modbus OCI412.10 (Order No.: 660 285)
X5-03
2
3 ▪ eBus: Adapter MPA eBUS (Order No.: 743 090)
L 4
For burner start, input X5-03:1 (burner ON) must be connected to voltage output
COM
X92
Interface X5-03:4. Load presetting is then carried out by the building management system.
The settings required for Bus communication are set in parameters 141 to 148.
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3.2.7 Air pressure switch

P The closing contact of the air pressure switch should be connected to input X3-02.
X3-02
1
If no signal is present once the fan has started, the combustion manager initiates a
L 2
lockout.
3.2.8 Minimum pressure switches

PE 1 P
The closing contact of the low pressure switch should be connected to input
X5-01
min 2 X5-01.
L 3 On burners without low oil pressure switch a bridge must be connected to terminal
2 and terminal 3.
Low gas pressure switch

In gas operation, the combustion manager expects a signal at input X5-01:2 from
phase 22. If the value set at the low pressure switch is not achieved, the pressure
switch contact opens and the combustion manager starts the low gas program
(see Ch. 3.1.2).
Low oil pressure switch

In oil operation, the combustion manager expects a signal at input X5-01:2 from phase
38 or phase 40 (depending on parameter 276). If the value set at the low pressure
switch is not achieved, the pressure switch contact opens and the combustion man-
ager initiates a lockout. In phase 38 (pre-ignition) lockout occurs after a waiting time
of 30 seconds, in the phases following 38 lockout occurs immediately.
3.2.9 High pressure switches

PE 1 The opening contact of the high pressure switch must be connected to in-
X5-02
P
min 2 put X5-02.
L 3 On burners without high pressure switch a bridge must be connected to terminal 2
and terminal 3.
High gas pressure switch

In gas operation the combustion manager expects a signal at input X5-02:2 from
phase 40. If the value set at the pressure regulator is exceeded, the pressure switch
contact opens and the combustion manager initiates a lockout.
Max. oil pressure switch

In oil operation the combustion manager expects a signal at input X5-02:2 from phase
22. If the value set at the pressure switch is exceeded, the pressure switch contact
opens and the combustion manager initiates a lockout. In phase 22 (fan ON) lockout
occurs after a waiting time of 30 seconds, in the phases following 22, lockout is
immediate.
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3.2.10 Valve proving gas pressure switch

PE 1 The opening contact of the valve proving gas pressure switch must be connected to
X9-04
P
min 2 input X9-04. Input X9-04 is only active during valve proving (see Ch. 3.1.1). The time
L 3 of the valve proving can be set in parameter 241.
If the pressure set is not achieved in phase 81 (test without pressure), the contact
closes.
If the pressure set is exceeded in phase 83 (test with system pressure), the contact
opens.
3.2.11 Flame sensor

If the flame signal in phase 44 does not equate to the value required, the combustion
manager initiates a lockout.
If the flame signal during operation does not maintain the required value, the com-
bustion manager initiates a controlled shutdown with restart. Two controlled shut-
downs in sequence lead to lockout.
A flame signal at heat demand (phase 12) leads to start prevention.
A flame signal during pre-purge (phase 30 to 36) or post-purge (phase 78) leads to
lockout after one repetition and repeated occurrence.
Parameter 954 shows the current flame signal as a percentage value.
BR
QRA…
X10-06
QRA 1 +
BU
QRA 2
The flame sensor QRA… (UV cell) is connected to input X10-06.
Flame signal
Parameter 954
Response limit extraneous light greater than 18 %
Operation min 24 %
PE 1 Ionisation electrode
ION 2
X10-05
The ionisation electrode is connected to input X10-05:2.

QRB/C 3
QRB/C-N 4 Flame signal
L 5 Parameter 954
Sensor current min.: 4 µA approx. 30 %
Sensor current max.: 16 … 40 µA 100 %
PE 1 QRB…
ION 2
X10-05
The flame sensor QRB… (photo resistor) is connected to input X10-05:3/4.

QRB/C 3
QRB/C-N 4 Flame signal
L 5 Parameter 954
Response limit extraneous light (resistance less than approx. 10 %
400 kΩ)
Operation (resistance less than 230 kΩ) approx. 16 %
Short circuit identification (resistance less than -
0.5 kΩ)
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3.2.12 Fuel meter

1 A fuel meter with Reed contact can be connected to input X75. However, a prereq-
X75
2 uisite is that there is no frequency converter connected and activated. The meter
impulses per volume unit must be set in parameter 128. The impulse frequency must
not exceed 300 Hz.
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3.3 Outputs
3.3.1 Alarm
MOTOR 1 In lockout position (phase 00) a mains voltage signal is emitted at alarm output
X3-05
ALARM 2 X3-05:2.
MOTOR CONT 3 Additionally, it is also possible to signal a start prevention. To do this parameter 210
should be set to 1.
3.3.2 Motor
MOTOR 1 Normal operation
X3-05
ALARM 2 M
The contactor and the star delta switching of the burner motor are fitted to output
MOTOR CONT 3 L N X3-05:1 as standard.
Continuous operation
MOTOR 1
X3-05
ALARM 2 For continuous running fan the contactor or star delta switching of the burner motor
MOTOR CONT 3 is fitted to output X3-05:3.
M
If an air pressure switch is fitted, an additional vent valve should be fitted and con-
nected to output X3-05:1.
L N
3.3.3 Ignition unit

PE 1 The ignition unit is connected to output X4-02.
X4-02
N 2
L 3 Ignition behaviour Gas
The duration of the pre-ignition time (phase 38) can be altered in parameter 226.
Ignition behaviour Oil

In parameter 281 it can be defined whether the ignition should begin in phase 22 or
phase 38. The duration of the pre-ignition time (phase 38) can be altered in parameter
266.
3.3.4 Frequency converter

24 V 1 A frequency converter and speed sensor can be connect to plug slot X74.
2
X74
0...10 V 3 Frequency converter

4
10 V 5 Terminal X74:1 24 V input; supplied by frequency converter
Terminal X74:2 Signal acquisition
Terminal X74:3 Speed setpoint signal (parameter 645)
Speed measurement
Terminal X74:4 Speed return signal (input actual speed)
Terminal X74:5 10 V; supplied by combustion manager
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3.3.5 Load signal

24 V 1 Instead of the frequency converter, a load dependent analogue signal can be emitted
2 at output X74:1/2.
X74
0...10 V 3
The values given relate to an analogue signal of 0 … 10 V, if a signal of 2 to 10 V or
4
0/2 to 10 V is set in parameter 645, the voltages listed will change.
10 V 5
Conversion: (original value x 0.8)+2 = new value
Modulating operation
Rating Curve point Analogue signal
Off - 0V
Ignition load P0 1V
Partial load (20 %) P1 2V
Full load (100 %) P9 10 V
Two stage operation

Off - 0V
Stage 1 P1 5V
Stage 2 P2 10 V
Three stage operation

Off - 0V
Stage 1 P1 3V
Stage 2 P2 5V
Stage 3 P3P3 10 V
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3.4 Technical data
3.4.1 Electrical data
Combustion Manager
W-FM 50
Mains voltage/frequency 230 V/50 … 60 Hz
Max. consumption 30 W
Max. prefusing 16 A slow
Internal unit fuse 6.3 A slow
Type of protection IP 00
Actuator
STE 50 1.2 Nm STE 50 3 Nm
DC/AC 24 V/ DC/AC24 V/
Mains voltage/frequency
50 … 60 Hz 50 … 60 Hz
Max. consumption 7.5 W 10 W
Torque 1.2 Nm 3 Nm
Setting time 5 s/90° 4 s/90°
Type of protection IP 54 IP 54
Class of protection II II
ABE
Mains voltage DC 5 V
Max. consumption 50 mW
Type of protection (front) IP54 to ICE 529
Type of protection (rear) IP40 to ICE 529
Class of protection II to DIN EN 60 730-1
3.4.2 Ambient conditions

Temperature in operation -20 … +60 °C
Temperature during transport / storage -20 … +60 °C
relative humidity max 95 %, no dew point
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3.4.3 Dimensions
Combustion manager
230
60 217
135
Display and operating unit 122
Recess dimension: 127 x 91 mm ±5 mm
96
18 17 90.6
S
P
i
126.4
132
info
V h min s %
VSD esc
F A - +
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4 Electrical installation
Electric shock when working with voltage applied
The consequence is serious injury or death.
▶ Isolate unit prior to carrying out work and protect against accidental reconnection
DANGER to the mains.
Electric shock despite disconnection from mains

It is possible that electrical components on burners with frequency converters con-
tinue to carry voltage and cause electric shock even after the mains have been
WARNING disconnected.
▶ A waiting time of approx. 5 minutes should therefore be observed until all electric
voltage has dissipated.
The electrical installation must only be carried out by qualified electricians, local reg-
ulations must be observed.
Carry out electrical installation in such a way that the burner can still be hinged open.
Connect combustion manager W-FM

▶ Use cable entry grommets on the housing.
▶ Connect wiring in accordance with the enclosed wiring diagram.
Control circuits, which are taken directly via a 16 AT pre-fuse from a 3 phase or
single phase alternating current supply, must only be connected between a phase
conductor and earth potential neutral conductor.
On mains supply, which does not have a neutral, the control voltage must be supplied
via an isolating transformer.
The pole of the transformer, which is to be used as the neutral conductor, must be
earthed.
Phase L must not be mixed up with the neutral conductor N. Contact protection will
otherwise no longer be given. Malfunctions, which endanger operational safety could
occur.
The cable cross section of the voltage supply must be suitable for the nominal current
of the pre-fusing (maximum 16 AT).
All other cable connections must be suitable for the relevant internal unit fuse
(6.3 AT).
Earthing and neutral conductor must conform to local regulations.
The following applies for cable length:
▪ Display and operating unit, load controller, safety interlock circuit, burner flange,
reset key - maximum 20 m (100 pF/m).
▪ BCI interface - maximum 20 m (100 pF/m).
Connecting the burner motor
The motor must be protected against thermal overload and short circuit. The use of
a motor protection switch is recommended.
▶ Open terminal box on motor.
▶ Carry out voltage supply in accordance to the wiring diagram enclosed, observing
motor rotation.
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Connect gas valve train

The connection should be made to the wiring diagram supplied with the burner.
▶ Connect double gas valve (plug Y2):
▪ Solenoid coil on W-FM or DMV
▪ Actuator on VGD
▶ Connect low gas pressure switch (plug F11)
▶ Install valve proving gas pressure switch (plug F12).
▶ If required, fit high gas pressure switch (plug F33)
Speed control
The supply line to the frequency converter is not screened, if the frequency converter
is fitted to the motor.
If the frequency converter is separate, the control cable and the mains connection
cable between motor and frequency converter are screened.
▶ Connect screen to the designated screen clamp on frequency converter.
▶ Use screen cable glands (metal) on the burner.
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5 Operation
5 Operation
5.1 Operating interface
5.1.1 Operating panel
Display and operating unit (ABE)
S
P
i
V h min s % info
VSD esc
F A - +
No. Key Function

1 [ENTER] back-up of value changes;
entry to parameter and values
[info] press approx. 3 seconds = Info level;
press approx. 5 seconds = Service level
2 [+] navigation through parameter structure;
3 [–] changing the setting values
2 and 3 [+] and [–] simulta- cancel/return
neous (esc)(1
4 [A] (Air) selects the actuator of the the air dampers
5 [F] (Fuel) selects the fuel supply
4 and 5 [A] and [F] simulta- selects the frequency converter (optional)
neously (VSD)(2
(1
Escape
(2
Variable Speed Drive
OFF function
▶ Press [ENTER] key and any other key simultaneously.
✓ Immediate lockout.
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5 Operation
5.1.2 Display
The black cursor in the display shows the status of the inputs and outputs, the unit of
values and the active level.
S
P
i
V h min s %
1 Heat demand by the boiler control (start)

2 Burner motor
3 Ignition
4 Fuel valves
5 Flame signal on
6 Flame failure or lockout
7 Degree of angle setting
8 Percentage value
9 Second
0 Minute
q Hour (together with volume = V/h)
w Volume (m³, l, ft³, gal)
e Actuator OPEN
r Actuator CLOSED
t Service level
z Info level
u Parameter level (heating engineer level)
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5 Operation
Display OFF
The parameter setting is missing, incomplete or has been deleted.
No heat demand from controller (input X5-03:1).
Safety circuit not closed at heat demand (inputs X3-03:1/2 and

X3-04:1/2).
Display Ph
The combustion manager is in an operating phase and waits for
signals or activates outputs depending on the program sequence.
The combustion manager is in an operating phase and shows the
remaining run time programmed (example: pre-purge).
Display Op
The combustion manager is in modulatingoperation and shows
the current load in percent.
The combustion manager is in multi-stage operation and shows
the current fuel stage. When the fuel stage is changed, the addi-
tional display on or off indicates the switching of the relevant fuel
valve.
Display flashes
Manual load is activated. The combustion manager is in manual
load default.
Deactivate manual load:
▶ Press and hold [esc] key for 5 seconds.
Display Error
During a fault condition, the display alternately shows the error code C and diagnostic
code D (see Ch. 9.2).
The combustion manager is in lockout.
Once the fault has been rectified the combustion manager has to
be reset (see Ch. 9.1).
The combustion manager initiates a safety shutdown.

The burner starts automatically, as soon as the cause of the fault
has been eliminated.
The combustion manager shows an occurrence, which does not

lead to a shutdown.
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5 Operation
5.2 Displaying and adjusting parameters

Password level (heating engineer) Info/Service level
Call up level
▶ Press [F] and [A] keys simulta- The Info or Service level can only
neously and then enter the be called up from the standard
password (see Ch. 5.2.1). display.
- For Info level 1 … 3 s
- For Service level 3 … 5 s
Next parameter
▶ Press [+] key. ▶ Press [+] key.
–or–
Briefly press [ENTER].
Previous parameter
▶ Press [-] key. ▶ Press [-] key.
One level lower

▶ Press [ENTER] key. ▶ Press [ENTER] key for
1 … 3 s.
One level higher

▶ Press [esc] key. ▶ Press [ENTER] key for
3 … 5 s.
–or–
Press [esc] key.
Change value
▶ Press [+] or [-] key. not possible
Save value
▶ Press [ENTER] key. not possible
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5 Operation
5.2.1 Password
Enter password
▶ Press keys [F] and [A] simultaneously.
✓ The display shows CodE.
▶ Enter the first digit using [+] or [–] and confirm with [ENTER].
▶ Repeat procedure until the password has been entered.
▶ Exit password entry using [ENTER].
✓ The display shows PArA (parameter level) for a short time and then changes over
to 400: SEt (Setup).
S
P
i
S S
V h min s %P P
i i
S
V h min s % V h min s %P
i
V h min s %
Deactivating password
If no key is activated for 30 minutes, the combustion manager automatically deacti-
vates the password and blocks the level.
In the password level, the password can be aborted early:
▶ Press [esc] key until the display shows CLr CodE.
▶ Let go of the [esc] key.
✓ The combustion manager blocks the password level and changes to the operating
display.
S
P
i
V h min s %
S S
P P 3s
i i
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5 Operation
5.3 Parameters
5.3.1 Password level
Internal parameters (000: Int)

No. Function
050 Data backup (see Ch. 3.1.5)
Overriding the data set between W-FM and ABE with identical burner identification (P113).
If the backup or restore is incorrect, a negative value is displayed. The cause of the fault is described in
error message 137 (see Ch. 9.2).
Save from W-FM to ABE (Backup):
✓ The display shows bAC_up.
▶ Set 1 using [+] key and confirm with [ENTER].
✓ Following successful execution the display is reset to 0.
Save from ABE to W-FM (Restore):
▶ Press [+] key.
✓ The display shows rEStorE.
✓ Following successful execution the display is reset to 0.
055 Burner identification of data backup (read only).
056 ASN excerpts of data backup (read only).
057 Software version when creating backup (read only).
General parameters (100: PArA)

No. Function
102 Date of manufacture DD.MM.YY
103 Production number
104 Parameter default setting: Customer code
105 Parameter default setting: Version
107 Software version
108 Software variation
111 ASN excerpt for comparison with data backup (P056).
113 Burner identification: Identical to the burner serial No. (name plate).
The burner identification has to be reset if the combustion manager has been replaced.
121 Manual load (see Ch. 3.1.3)
123 Minimum setting step in percent
Only load changes, which exceed the value set are initiated, this avoids unnecessary setting movements in
modulating operation.
123.00 = Load default from building management
123.01 = Analogue load controller on X64
123.02 = Load controller contact on X5-03
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5 Operation
No. Function
124 Flame failure test (TÜV test)
The flame failure test can only be carried out in operating setting 1 (Phase 60).
The flame failure test closes the fuel valves and calculates the time up to flame failure. The calculated time
is displayed in the diagnostic code in multiples of 0.2 seconds (Example: Loc.D: 8 = 1.6 seconds).
For the flame failure test the burner drives to the load defined under parameter 133. If no load is defined in
parameter 133, the flame failure test is carried out at the current load.
▶ Set value 1 using [+] key and confirm with [ENTER].
✓ Following successful execution, the display alternately shows the error code Loc.c: 7 and diagnostic
code Loc.d: x.
125 Mains frequency
0 = 50 Hz
1 = 60 Hz
126 Display illumination
128 Fuel meter
The value must correspond to the number of impulses per m³ of the fuel meter. If the value is set to 0, the
fuel meter stops.
130 Delete error history (see Ch. 9.1)
133 Load for flame failure test
141 Operating mode building management
0 = OFF
1 = Modbus, the combustion manager operates as Slave, the RTU transfer mode is used (Remote Ter-
minal Unit)
2 = eBus
142 Recurrence time if communication is interrupted (range: 0…7200 secs.)
If communication to the building management system fails, the next load controller according to priority will
be activated once this time has elapsed. If no other load controller is connected, the burner remains at the
current load or it drives to the load defined in parameter 148.
Priority 1: Load controller building management
Priority 2: Load controller on analogue input X64
Priority 3: Load controller on input X5-03
143 Unit address of combustion manager as eBus participant
1 = Address 03
2 = Address 13
3 = Address 33
4 = Address 73
5 = Address F3
6 = Address 1F
7 = Address 3F
8 = Address 7F
144 Send cycle in seconds for the eBus services 05 and 09
145 Unit address of combustion manager as Modbus participant
146 Baud rate Modbus
The Baud rate of the combustion manager and the building management system must be identical.
0 = 9600
1 = 19200
147 Parity Modbus
The Parity of the combustion manager and the building management system must be identical.
0 = no Parity bit
1 = odd Parity bit
2 = even Parity bit
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5 Operation
No. Function
148 Replacement load (range: 0 … 100 %)
Load default for communication failure with building management system.
–––– = no replacement load
0 … 19.9 = burner OFF
161 Number of lockouts
162 Operating hours since last reset
Reset:
▶ Press [-] key.
✓ The display shows 0, operating hours have been reset.
163 Total operating hours (voltage applied to combustion manager)
164 Start-ups since last reset
Reset:
▶ Press [-] key.
✓ The display shows 0, start-ups have been reset.
166 Total start-ups
167 Fuel volume since last reset.
Reset:
▶ Press [-] key.
✓ The display shows 0, the fuel volume has been reset.
Burner control (200: PAr0)

No. Function
201 Type of operation
–– = not defined (delete curves)
1 = Gas direct ignition
2 = Gas pilot ignition
3, 4 = not used
5 = Oil two stage
6 = Oil three stage
7 … 11 = not used
12 = Oil modulating
13 … 22 = not used
208 Program stop
0 = deactivated
1 = pre-purge position (phase 24)
2 = ignition position (phase 36)
3 = interval time 1 (phase 44)
4 = interval time 2 (phase 52)
210 Alarm at start prevention
Determines whether a signal is given at output X3-05/2 during start prevention
0 = no alarm (no signal at output X3-05/2)
1 = alarm (signal at output X3-05/2)
211 Fan run-up time (range: 2.0 … 60 s)
Time from fan start to start of actuators.
212 Switch off behaviour / max. time to partial load (range: 0.2 … 45 s.)
If heat demand is no longer present, the burner drives as far as possible to partial load in a predetermined
time and then switches off. The burner takes approx. 32 seconds to drive from 100% load to 20% (partial
load).
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5 Operation
No. Function
215 Repetition counter Safety circuit (range: 1 … 16)
Number of safety shutdowns by the safety circuit before lockout occurs (see Ch. 3.2.2).
221 Flame sensor Gas
0 = QRC
1 = Ionisation electrode/QRA
222 Pre-purge Gas
When using a valve proving system and two Class A fuel valves pre-purge following a controlled shutdown
can be omitted (to EN 676).
0 = OFF
1 = ON (pre-purge time parameter 225)
223 Repetition counter low gas pressure switch (range: 1 … 16)
Number of safety shutdowns by the low gas pressure switch before lockout occurs (see Ch. 3.1.2).
225 Pre-purge time Gas in operating phase 30 (range: 20 … 3600 s)
Once the pre-purge positions have been reached, the combustion manager remains in phase 30 for the
duration of the time set.
226 Pre-ignition time Gas (range: 0.2 … 3600 s)
Duration of pre-ignition time in phase 38.
230 Interval time 1 Gas
The interval time 1 in phase 44 acts as stabilisation time after flame formation.
232 Interval time 2 Gas
The interval time 2 in phase 52 acts as stabilisation time after flame formation.
233 Post burn time Gas (range: 0.2 … 60 s)
The combustion manager remains in phase 70 for the duration of the time set, the flame sensor is ignored
during this time.
234 Post-purge time Gas (range: 0.2 … 6480 s)
Once the post-purge position has been reached, the combustion manager remains in phase 74 for the
duration of the time set, the flame sensor is ignored during this time.
236 Low gas pressure switch input / installation position
0 = OFF
1 = Low gas pressure switch fitted in front of valve 1 (factory setting)
2 = Low gas pressure switch fitted between vale 1 and valve 2, valve proving carried out by low gas
pressure switch
237 High gas pressure switch
If a high gas pressure switch is fitted, set parameter to 1.
0 = OFF
1 = High gas pressure switch
2 = Valve closing contact
241 Valve proving
In accordance with DIN EN 676 valve proving is not necessary if pre-purge is activated and the burner
rating is less than 1200 kW.
0 = Valve proving OFF (only for ratings < 1200 kW, parameter 222 must be set to 1 = ON)
1 = Valve proving at stat-up
2 = Valve proving at shutdown (factory setting)
3 = Valve proving at start-up and shutdown
248 Post-purge time 3 Gas (range: 0.2 … 6480 s)
The combustion manager remains in phase 78 for the duration of the time set except if a new heat demand
interrupts the post-purge time 3 in phase 78.
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5 Operation
No. Function
261 Flame sensor Oil
0 = QRB
1 = QRA
265 Pre-purge time Oil in operating phase 30 (range: 15 … 3600 s)
Once the pre-purge positions have been reached, the combustion manager remains in phase 30 for the
duration of the time set.
266 Pre-ignition time Oil (range: 0.6 … 3600 s)
Once ignition position has been reached, the combustion manager remains in phase 38 for the duration of
the time set.
270 Interval time 1 Oil
The interval time 1 in phase 44 acts as stabilisation time following flame formation.
272 not used
273 Post burn time Oil (range: 0.2 … 60 s)
The combustion manager remains in phase 70 for the duration of the time set, the flame sensor is ignored
during this time.
274 Post-purge time Oil (range: 0.2 … 6480 s)
Once the post-purge position has been reached, the combustion manager remains in phase 74 for the
duration of the time set, the flame sensor is ignored during this time.
276 Min. oil pressure switch
0 = OFF
1 = active from phase 38
2 = active from phase 40 with solenoid valve before pressure switch (e.g. pump with valve)
277 Maximum oil pressure switch
If a max. oil pressure switch is fitted set parameter to 1.
0 = OFF
1 = Max. oil pressure switch
2 = Valve closing contact
281 Point of ignition Oil
0 = Ignition on in phase 38 (short pre-ignition)
1 = Ignition on in phase 22 (long pre-ignition at fan start)
284 Post-purge time 3 Oil (range: 0.2 … 6480 s)
The combustion manager remains in phase 78 for the duration of the time set except if a new heat demand
interrupts the post-purge time 3 in phase 78.
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5 Operation
Commissioning parameters (400: SEt)

Parameter set 400 is used to adjust the fuel air compound regulation (see Ch. 6).
Compound (500: PArA)

No. Function
501 Special positions fuel actuator
501.00 = Standby (is activated in phase 10, 12 and 00)
501.01 = Pre-purge position (is activated in phase 24)
501.02 = Post-purge position (is activated in phase 72)
502 Special positions air actuator
503 Special positions frequency converter
522 Drive up ramp (range: 5 … 20 s)
The ramp should be at least 20% slower than that of the frequency converter.
523 Drive down ramp (range: 5 … 20 s)
The ramp should be at least 20% slower than that of the frequency converter.
542 Activating Frequency converter
0 = not activated
1 = activated
545 Lower load limit (range: 20.0 … 100 %)
Defines the lower modulating limit (partial load). If no limit has been defined, the lower load limit in operation
is automatically set to 20 %.
– – – – = no load limit defined (20 %)
546 Upper load limit (range: 20.0 … 100 %)
Defines the upper modulating limit (full load). If no limit has been defined, the upper load limit in operation
is automatically set to 100 %.
– – – – = no load limit defined (100 %)
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5 Operation
Actuators (600: ACtr)

No. Function
606 Range of tolerance of actuator position monitoring with fuel 0 (read only)
The value displayed (1.4° factory setting) minus 0.6° results in the range of tolerance.
Example.: 1.4°-0.6° = 0.8°
Deviation of 0.8° = possible indication of position fault.
Deviation of 1.4° = definite indication of position fault.
606.00 = Fuel actuator
606.01 = Air actuator
641 Speed standardisation
During speed standardisation, a setpoint signal of 95% (9.5 V) is sent to the frequency converter. The speed
achieved is saved as 100% value, which means that a reserve of 5% is available during operation. The
maximum frequency at the frequency converter must therefore be 52.6 Hz. If the frequency converter is
fitted to the burner, the maximum frequency has been factory preset. If the frequency converter is external,
the maximum frequency has to be set to this value.
Starting standardisation:
▶ Set value 1 using [+] key and confirm with [ENTER].
✓ The fan motor starts with air damper open.
Following successful execution, the display is reset to 0, if standardisation fails, a negative value is dis-
played (-X).
The combustion values must be checked after every speed standardisation.
642 Standardised speed
During speed standardisation a 95% signal is signalled to the frequency converter and the speed achieved
is saved as the standard speed.
642.00 = Standard speed saved from micro controller 1.
642.01 = Standard speed saved from micro controller 2.
The speeds of the two micro controllers may vary by up to 1.5 %.
645 Analogue output X74
This output can be used to signal a load dependent analogue signal (see Ch. 3.3.5) or to activate a frequency
converter (see Ch. 3.3.4). If it is used to activate a frequency converter, the voltage at output X74 and at
setpoint input of the frequency converter must be set identically.
0 = DC 0 … 10 V
1 = DC 2 … 10 V
2 = DC 0/2 … 10 V
Fault history (700: HISt)

Parameter set 700 is used to localise and correct faults (see Ch. 9.1).
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5 Operation
Process data (900: dAtA)

No. Function
903 Current rating
903.00 = Fuel
903.01 = Air
922 Step position actuator
935 Absolute speed
Current actual speed (recorded by transmitter disc on motor)
Current speed signal in percent.
942 Active load source (load controller)
The parameter shows the load source currently active. If more than one load source is available, the com-
bustion manager prioritises to the sequence listed below. The priority cannot be altered.
1 = Load by curve setting
2 = Manual load
3 = Load controller via building management system
4 = External load controller via analogue input X64 terminal 1 / terminal 2
5 = External load controller via contactors X5-03 terminal 2 / terminal 3
947 Contact interrogation W-FM (bit coded output)
947.00 = Inputs
1 = Min. pressure switch
2 = Max. pressure switch
4 = Internal fuel selection
8 = Air pressure switch
16 = Load controller OPEN
32 = Load controller ON
64 = Load controller CLOSED
128 = Safety circuit
947.01 = Outputs
1 = Safety valve
2 = Ignition
4 = Fuel valve 1
8 = Fuel valve 2
16 = Fuel valve 3 / Pilot valve
32 = Internal fuel selection 1
950 Relay nominal condition (Bit coded output)
1 = Alarm
2 = Safety valve
4 = Ignition
8 = Fuel valve 1
16 = Fuel valve 2
32 = Fuel valve 3 / Pilot valve
954 Current flame signal in percent (see Ch. 3.2.11)
960 Current fuel throughput
961 Current operating phase (see Ch. 3.1.7)
981 Fault history: Fault codes (see Ch. 9.2)
982 Fault history: Diagnostic codes (see Ch. 9.2)
992 Fault flags
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5 Operation
5.3.2 Info level

In the info level, parameter values can be displayed but not altered.
To show parameter values:
▶ Select parameter using [+] or [-] key.
▶ Press [ENTER] key for 1 … 3 s.
✓ Parameter value appears.
No. Function
167 Fuel volume since last reset
162 Operating hours since last reset
164 Start-ups since last reset
163 Total operating hours (voltage applied to combustion manager)
166 Total start-ups
113 Burner identification: Identical to the burner serial number (name plate)
107 Software version
108 Software variation
102 Date of manufacture DD.MM.YY
103 Production number
104 Parameter default setting: Customer code
105 Parameter default setting: Version
143 Unit address of combustion manager as eBus participant
5.3.3 Service level

In the service level, parameter values can be displayed but not altered.
To show parameter values:
▶ Select parameter using [+] or [-] key.
▶ Press [ENTER] key for 1 … 3 s.
✓ Parameter value appears.
No. Function
954 Current flame signal in percent (see Ch. 3.2.11)
960 Current fuel throughput
121 Manual load (see Ch. 3.1.3)
922 Step position actuator
Current speed signal in percent.
161 Number of lockouts
701 Error history (see Ch. 9.1)
…
725
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6 Commissioning
6 Commissioning
The installation and operating manual of the burner should be observed in addition to
this chapter. This document contains detailed information about:
▪ Prerequisites for commissioning
▪ Setting values and actuator positions
▪ Combustion tests
▪ Gas throughput calculation
▪ Concluding work
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6 Commissioning
6.1 Adjust gas side
Prerequisite
▶ Open gas isolating valve.
✓ Gas pressure in gas valve train increases.
▶ Close isolating valve.
▶ Switch on voltage supply.
✓ The display shows either OFF UPr or OFF.
OFF UPr Burner off and not programmed
OFF Burner off
S S
P P
i i
1. Enter password
S
P
i
S S
V h min s %P P
i i
S
i
V h min s %
2. Switch on burner
▶ Ensure there is a demand for heat.
✓ A black dash appears below the S symbol (start).
For the duration of the commissioning a heat demand is required from the appliance
controller, that means signal on input X5-03/1.
S
P
i
V h min s %
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6 Commissioning
3. Start setup
If the combustion manager has been pre-programmed, the display shows run 1.
▶ Select type of setting (from step 8).
If the combustion manager has not been programmed, the display shows parameter
201 2.
▶ Define parameter 201, 542 and 641 and set P0 (from step 4).
▪ 201 = Type of operation
▪ 542 = Activation frequency converter
▪ 641 = Speed standardisation
S
P
i
S V h min s %
P
i
V h min s % S
P
i
V h min s %
4. Set type of operation
The following steps must only be carried out if the combustion manager is not pro-
grammed. If the combustion manager has been pre-programmed, proceed with step
8.

✓ The display shows only the parameter value.
▶ Using [+] or [–] set type of operation and confirm with [ENTER].
▪ 1 = Direct ignition
▪ 2 = Pilot ignition
▶ Exit entry using [esc].
✓ The display shows parameter 201 with the current type of operation.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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6 Commissioning
5. Activate/deactivate frequency converter

▶ Press [+] key.
✓ The display shows parameter 542.
▶ Activate or deactivate the frequency converter using [+] or [–] and confirm with
[ENTER].
▪ 0 = without frequency converter
▪ 1 = with frequency converter
✓ The display shows parameter 542 with the current setting.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
6. Carry out speed standardisation
If no frequency converter is available or if standardisation has been carried out with

the other fuel, skip speed standardisation 641 using [+] key and continue with step 7.
▶ Press [+] key.

▶ Set value to 1 using the [+] key and start speed standardisation by pressing [EN-
TER].
▶ Check rotation direction of burner motor.
✓ The fan motor starts with the air dampers open. Once standardisation is complete,
the display changes from 1 to 0.
▶ Exit speed standardisation using [esc].
✓ The standardised speed can be selected in parameter 642.
S S S
P P P
i i i
S S
V h min s % P % P % m 3 m 3/h l l/h
i i
S
P
i
V h min s %
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6 Commissioning
7. Preset ignition and full load points

▶ Press [+] key.
✓ The display shows the ignition load point P0.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting 0.0 … 7.0°.
▶ Press and hold [F] key and using [+]/[–] enter gas butterfly position of 8.0 … 14.0°.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and enter speed using [+]/
[–] keys.
✓ The ignition speed should not be less than 70 %.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
h min s %
S
P
i
V h min s %
▶ Press [+] key.

✓ The display shows the full load point P9.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting from setting di-
agram.
▶ Press and hold [F] key and using [+]/[–] enter gas butterfly position of 45.0 …
65.0°.

▶ Press and hold [A] and [F] (VSD) keys simultaneously and set speed to 100 %
using [+]/[–] keys.
▶ Press [+] key.

✓ Exit pre-setting.
The display changes to run.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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6 Commissioning
8. Select type of setting

The following can be selected as type of setting:
▪ Adjustment with flame,
▪ Pre-setting without flame.
Pre-setting without flame is only used, if the operating points are already known (for
example if the combustion manager is exchanged).
Adjustment with flame 1

✓ The burner starts pre-purge Ph12 and stops in ignition position Ph36 without ig-
niting.
The display shows the ignition load point P0.
▶ Set mixing pressure in ignition position (from step 10).
Pre-setting without flame 2

▶ Briefly press [esc] key.
✓ The display shows the operating point P0.
The black dash below the S symbol disappears.
▶ Pre-set operating points without flame (from step 9).
S S
P P
i i
S V h min s % S %
P P
i i
V h min s % S V h min s %
P
i
V h min s %
9. Pre-set points without flame

This step must only be carried out, if the type of setting without flame has been se-
lected previously. The adjustment with flame (from step 10) is not replaced by this
process.
▶ Press [+] key.
▶ Press and hold the [A] key and preset air damper setting using [+]/[–] keys.
▶ Press and hold [F] key and using [+]/[–] pre-set gas butterfly valve position.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and pre-set speed using [+]/
[–] keys.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
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6 Commissioning
▶ Press [+] key.

✓ The display shows CALC.
The combustion manager starts the calculation.
The display then shows the operating point P2.
▶ Set position air dampers [A] and gas butterfly valve [F] or speed [A] and [F] (VSD).
▶ Using [+] key select and pre-set points P3 to P9 in sequence.
S
P
i
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
▶ Exit pre-setting using [esc].

✓ The display shows 400 SEt.
✓ The display shows run.
✓ The burner starts pre-purge and stops in ignition position without igniting.
S
P
i
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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6 Commissioning
10. Check mixing pressure in ignition position

The mixing pressure in ignition position must be between 0.5 and 2.0 mbar.
▶ If necessary, adjust mixing pressure via air damper setting.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and enter speed using [+]/
[–] keys.
✓ The ignition speed should not be less than 70 %.
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
11. Check gas valves

▶ Press [+] key and check if valves open and close correctly.
✓ The burner tries to ignite.
The low gas pressure switch is activated.
The display then shows OFF UPr.
▶ Open gas isolating valve.
▶ Press [ENTER] key, until the burner starts again.
✓ The display shows P0 again with the values already set for mixing pressure in ig-
nition position.
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6 Commissioning
12. Igniting the burner

▶ Press [+] key.
✓ The burner ignites and the actuators stop in the ignition position.
The display shows the following operating phases.
▪ Ph 38 = Ignition ON
▪ Ph 40 = Fuel valve
▪ Ph 42 = Ignition OFF
▪ Ph 44 = Flame in ignition position
S
P S
i P S
i
P
V h % S
i
P
V h % S
i l
P
V h %
i
V h min %
V h min s %
▶ Press [+] key (only for burners with ignition pilot valve).
✓ The ignition pilot valve closes.
▪ Ph 50 = flame stabilisation
▪ Ph 52 = ignition pilot OFF
S
P
S
i
P
S
i l
P
V h min s %
i
V h min s %
V h min s %
13. Adjust setting pressure on pressure regulator

Check the setting pressure at the pressure regulator and if necessary adjust.
14. Check combustion

▶ Determine combustion values at ignition position.
▶ Set O2 content of approx. 4 … 5 % via gas butterfly valve position.
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6 Commissioning
15. Pre-set operating point P1

▶ Press [+] key.
▶ Pre-set gas throughput [F] and air quantity [A] whilst observing combustion values.
✓ The operating point P1 must lie below the partial load required and within the ca-
pacity graph.

A minimum speed of 50% should be aimed for in operating point P1.
▶ Slowly reduce speed using [F] and [A] (VSD) keys, whilst opening air dampers
alternately using the [A] key.
▶ Press [+] key.

If no other points have been defined, the combustion manager carries out a cal-
culation and calculates all missing points up to P9, the display briefly shows
CALC.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P m
i
V h min s %
S
P
i S
P m l l/h
i
V %
V h min s %
16. Drive to full load

▶ Using the [+] key, drive to the points in sequence up to P9.
▶ Check combustion values at each point and if necessary correct via the gas but-
terfly valve position [F].
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
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6 Commissioning
17. Adjust full load

When adjusting full load, the ratings data given by the boiler manufacturer and the
capacity graph of the burner must be observed.
▶ Calculate gas throughput (operating volume VB) to be set.
▶ Set the gas butterfly position [F] in full load to approx. 60 … 70°.
Select fan speed as low as possible, but not less than 80 %, whilst observing the
NOX value and flame stability.
▶ Adjust setting pressure at pressure regulator until gas throughput (VB) is achieved.
▶ Determine combustion limit and using the air supply [A] and/or the fan speed [VSD]
set excess air of 15 to 20 %.
▶ Re-determine gas throughput.
▶ If necessary adjust setting pressure at pressure regulator and reset excess air.
The setting pressure must not be altered once this work has been completed.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
18. Initiate a calculation

To achieve a constant operating behaviour, it is necessary to initiate a calculation from
P9 to P1.
▶ Press [–] key for approx. 4 seconds.
▶ Release [–] key.
✓ The combustion manager starts the calculation.
S S
P P
i i
S
P
i
V h min s %
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6 Commissioning
19. Adjusting the operating points
If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
▶ Briefly press [–] key, if points already calculated or set are not to be overwritten.
The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control and/
or speed control.
▶ Check combustion values
▶ Press and hold [F] key and using [+]/[–] optimise combustion values.
▶ Optimise combustion values at each operating point, until P1 has been reached.
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
20. Define upper load limit (full load)

Full load can be limited via parameter 546.
▶ Exit setting mode using [esc].
✓ The display shows 546 – – – –.
No upper rating range has been defined, that means full load ≙ P9 (100 % load
assignment).
Continue with step 21, if the full load is not to be limited.
▶ Set load limit using [+] or [–] and confirm with [ENTER].
✓ Burner drives to value set.
✓ The display shows 546 with the current upper load limit.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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6 Commissioning
21. Define lower load limit (partial load)

Partial load can be limited via parameter 545.
When adjusting partial load, the ratings data given by the boiler manufacturer and the
▶ Press [+] key.
No lower ratings limit defined, that means partial load ≙ P1.
▶ Determine fuel throughput and if necessary adjust load limit.
✓ The display shows 545 with the current lower load limit.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
22. Save points

✓ The display shows oP (Operate) with the current rating.
S S S
P P P
i i i
V h min s % V h min s % V h min s %
23. Check start behaviour

▶ Switch off and restart burner.
▶ Check start behaviour and if necessary correct ignition load setting.
If the ignition load setting has been changed:
▶ Re-check start behaviour.
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6 Commissioning
24. Data backup

▶ Select 000: Int using [-] key and confirm with [ENTER].
✓ The display shows parameter 050.00: 0
✓ Following successful data backup, the display is reset to 0.
The values have been backed up from the combustion manager to the ABE.
▶ Exit level using [esc].
25. Set pressure switch and carry out concluding work
For further information see installation and operating manual of burner.
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6 Commissioning
6.2 Adjust modulation oil side
Prerequisite
▶ Open oil shut off devices.
OFF Burner off
S S
P P
i i
1. Enter password
S
P
i
S S
V h min s %P P
i i
S
i
V h min s %
2. Switch on burner
S
P
i
V h min s %
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6 Commissioning
3. Start setup
201 2.
▶ define parameter 201, 542 and 641 and set P0 (from step 4).
S
P
i
S V h min s %
P
i
V h min s % S
P
i
V h min s %
grammed. If the combustion manager has been pre-programmed, proceed with
step 9.

▶ Using [+] or [–] set type of operation 12 (oil modulating) and confirm with [ENTER].
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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6 Commissioning

▶ Press [+] key.
[ENTER].
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %

▶ Press [+] key.

TER].
S S S
P P P
i i i
S S
i i
S
P
i
V h min s %
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6 Commissioning
7. Take over or preset ignition load point

▶ Press [+] key.
The ignition load point P0 is factory preset (see burner data sheet). If values are avail-
able continue with step 8. If the combustion manager has not been programmed (e. g.
if the unit has been replaced) the air damper setting and the position of the oil quantity
regulator have to be entered.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting .
▶ Press and hold [F] key and using [+]/[–] key enter position of oil quantity regulator .
The ignition speed should be 100 %.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
h min s %
S
P
i
V h min s %
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6 Commissioning
8. Preset full load point

▶ Press [+] key.
✓ The display shows the full load point P9.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting of 70º to 90º.
▶ Determine the position of the oil quantity regulator from the burner data sheet.
▶ Press and hold [F] key and enter the value using [+]/[–] key.
▶ Press [+] key.

S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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6 Commissioning


niting.

S S
P P
i i
S V h min s % S %
P P
i i
V h min s % S V h min s %
P
i
V h min s %

process.
▶ Press [+] key.
▶ Press and hold the [A] key and preset air damper setting using [+]/[–] keys.
▶ Press and hold [F] key and using [+]/[–] key preset position of oil quantity regulator.
▶ Press and hold [A] and [F] (VSD) keys simultaneously and pre-set speed using [+]/
[–] keys.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
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6 Commissioning
▶ Press [+] key.

The combustion manager starts the calculation.
▶ Set position air dampers [A] and oil quantity regulator [F] or speed control [A]
and [F] (VSD).
▶ Using [+] key select and pre-set points P3 to P9 in sequence.
S
P
i
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i

S
P
i
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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6 Commissioning

The mixing pressure in ignition position must be between 2 … 5 mbar.
In oil operation, the ignition speed should be 100 %.
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
12. Check pump pressure

The pump pressure in ignition position must be approx. 1 to 2 bar less than that of
the full load pressure listed in the burner data sheet.
▶ Check pump pressure at the pressure gauge and adjust if necessary.
▶ Remove closing cap 1 (types T and TA only).
▶ Undo locknut 2 (types T and TA only).
▶ Set pump pressure using pressure regulating screw 3.
▪ Clockwise rotation = increase pressure
▪ Anticlockwise rotation = decrease pressure
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6 Commissioning

▶ Press [+] key.
S
P S
i P S
i
P
V h % S
i
P
V h % S
i l
P
V h %
i
V h min %
V h min s %
14. Check combustion

▶ Determine combustion values at ignition position P0.
▶ Set O2 content of approx. 4 … 5 % by positioning the oil quantity regulator [F],
whilst observing the return pressure and maintaining 6 … 8 bar (depending on
burner).
15. Pre-set operating point P1

In oil operation, the speed should only be reduced so far, that the pump pressure set
at full load does not fall by more than 15 %.
▶ Press [+] key.

▶ Check combustion values and correct if necessary.
▶ Press [+] key.
If no other points have been defined, the combustion manager carries out a cal-
culation and calculates all missing points up to P9, the display briefly shows
CALC.
S
P
i S
P
i S
V h min s %
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P m
i
V h min s %
S
P
i S
P m l l/h
i
V %
V h min s %
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6 Commissioning
16. Drive to full load

▶ Using the [+] key, drive to points P2 to P9 in sequence.
▶ Check combustion values at each point and correct via the position of the oil
quantity regulator [F].
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i


The full load point speed must be 100 %.
The burner has been factory pre-sized for a specific oil throughput (see burner data
sheet).
▶ Set pump pressure and oil quantity regulator position to the data given on the
burner data sheet.
The pump pressure must not be altered once this work has been completed.
▶ Determine oil throughput, if necessary adjust position of oil quantity regulator [F]
until the oil throughput required is achieved.
▶ Determine combustion limit and set excess air of 15 … 20 % via the air supply [A].
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
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6 Commissioning
18. Initiate a calculation

To achieve a constant operating behaviour, it is necessary to initiate a calculation from
P9 to P1.
▶ Press [–] key for approx. 4 seconds.
▶ Release [–] key.
✓ The combustion manager starts the calculation.
S S
P P
i i
S
P
i
V h min s %
19. Adjusting the operating points
If the [–] key is pressed again for more than 4 seconds, a calculation is started from
the point shown to P1.
▶ Briefly press [–] key, if points already calculated or set are not to be overwritten.
The operating points should only be adjusted via the fuel supply [F]. Changes to the
air quantity influence the linearity, which has a negative effect on the load control.
▶ Check combustion
▶ Press and hold [F] key and using [+]/[–] optimise combustion values.
▶ Optimise combustion values at each operating point, until P1 has been reached.
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S S
P P
i i
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6 Commissioning
20. Define upper load limit (full load)

Full load can be limited via parameter 546.
▶ Exit setting mode using [esc].
No upper rating range has been defined, that means full load ≙ P9 (100 % load
assignment).
Continue with step 21, if the full load is not to be limited.
✓ The display shows 546 with the current upper load limit.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
21. Define lower load limit (partial load)

Partial load can be limited via parameter 545.
When adjusting partial load, the ratings data given by the boiler manufacturer and the
▶ Press [+] key.
No lower ratings limit defined, that means partial load ≙ P1.
▶ Determine oil throughput and adjust load limit if required.
✓ The display shows 545 with the current lower load limit.
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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6 Commissioning
22. Save points

✓ The display shows oP (Operate) with the current rating.
S S S
P P P
i i i

24. Data backup
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6 Commissioning
6.3 Adjust multi-stage oil side
Prerequisite
▶ Open oil shut off devices.
OFF Burner off
S S
P P
i i
1. Enter password
S
P
i
S S
V h min s %P P
i i
S
i
V h min s %
2. Switch on burner
S
P
i
V h min s %
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6 Commissioning
3. Start setup
201 2.
▶ Define parameter 201, 542 and 641 and set P0 (from step 4).
S
P
i
S V h min s %
P
i
V h min s % S
P
i
V h min s %
grammed. If the combustion manager has been pre-programmed, proceed with step
8.

▶ Using [+] or [–] set type of operation and confirm with [ENTER].
▪ 5 = two stage
▪ 6 = three stage
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %
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6 Commissioning

▶ Press [+] key.
[ENTER].
S S
P P
i i
S
V h min s % P %
i
V h min s %
S
P
i
V h min s %

▶ Press [+] key.

TER].
S S S
P P P
i i i
S S
i i
S
P
i
V h min s %
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6 Commissioning
7. Preset ignition position

▶ Press [+] key.
▶ Press and hold [A] key and using [+]/[–] enter air damper setting .
In oil operation, the speed in all operating points should be 100 %. If the speed is
reduced operating problems could occur.
▶ Press [+] key.

S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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6 Commissioning


niting.

S S
P P
i i
S V h min s % m 3 m 3/h l l/h %

S
P
P
i
i
V h min s % S
V h min s %
P
i
V h min s %
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6 Commissioning

process.
▶ Using the [+] key, select and preset the following points in sequence.
P1 Operating point 1
P2on Switch point of P1 after P2
P2 Operating point 2
P3on Switch point from P2 after P3 (only with three stage operation)
P3P3 Operating point 3 only with three stage operation)
▶ Press and hold the [A] key at each point and preset air damper setting using [+]/
[–] keys.
S
P
i S
P
i
V h min s %
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
▶ Using the [-] key, select and preset the following points in sequence.
P3oF Switch off point from P3 to P2 (only with three stage operation)
P2oF Switch off point P2 after P1
▶ Press and hold the [A] key at each point and preset air damper setting using [+]/
[–] keys.
S
P
i
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
S
P
i
V h min s %
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6 Commissioning

The mixing pressure in ignition position must be between 2 … 5 mbar.
In multi stage oil operation, the speed in all operating points should be 100 %. If the
speed is reduced operating problems could occur.
S
P
i S
P
i S
V h min s %
P
i
V h min s %
V h min s %
S
P
i
V h min s %
11. Check pump pressure

The pump pressure must be set according to the full load previously selected.
▶ Check pump pressure at the pressure gauge and adjust if necessary.
▶ Remove closing cap 1 (types T and TA only).
▶ Undo locknut 2 (types T and TA only).
▶ Set pump pressure using pressure regulating screw 3.
▪ Clockwise rotation = increase pressure
▪ Anticlockwise rotation = decrease pressure
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6 Commissioning

▶ Press [+] key.
▶ Check pump pressure.
✓ The O2 content should be approx. 5 %.
▶ If necessary adjust air damper setting.
S
P S
i P S
i
P
V h min l/h % S
i
P
V h min l/h % S
i %
V h min l/h % P
i
V h min l/h
V h min s %
13. Adjusting operating point P1

▶ Press [+] key.
If P1 has not been preset, the values from P0 are taken over for P1.
▶ Preset air damper setting [A] whilst observing combustion values.
S
P
i
S
V h Pl l/h %
i
S
P m 3 m h min s %
i
V h min s %
14. Determine switch on point P2on

▶ Press [+] key.
✓ The display shows P2on.
Stage 2 fuel valve remains closed.
If P2on has not been preset, the values from P1 are taken over for P2on.
▶ Set excess air (O2 content approx. 8.1 %) via air damper setting [A] whilst observing
flame stability.
S
P
i
S
V h Pl l/h %
i
S
P m 3 m h min s %
i
V h min s %
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6 Commissioning
15. Set preset point P2_d

▶ Press [+] key.
✓ The display shows the preset point P2_d.
Stage 2 fuel valve remains closed.
▶ Preset air damper setting [A] expected for the operating point P2.
✓ The value is not yet activated.
The preset point reduces the insufficient air at activation of P2.
S
P
i
S
V h Pl l/h %
i
S
P m 3 m h min s %
i
V h min s %
16. Activate operating point P2

▶ Press [+] key.
✓ The display shows P2.
Stage 2 fuel valve opens.
The preset air damper setting from P2_d is activated.
▶ Preset air damper setting [A] whilst observing combustion values.
S
P
i
S
V h Pl l/h %
i
S
P m 3 m h min s %
i
V h min s %

▶ With three stage operation, repeat procedure of step 14, 15 and 16 for
switch point P3_on,
preset point P3_d and
operating point P3.
▶ Determine fuel throughput and if necessary adjust pump pressure.
▶ Set excess air.
The pump pressure must not be altered once this work has been completed.
S S S
P P P
i i i
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6 Commissioning
18. Initiate partial load

▶ Press [-] key.
✓ The display shows the switch off point P3oF.
The switch off point stipulates at which air damper setting the fuel valve of the stage
above closes. The point itself cannot be activated.
▶ Adapt air damper setting [A].

✓ The switch off point usually lies 0 … 5° above the switch point of the individual
stage. It must not lie below the switch point.
▶ Press [–] key and observe switch off behaviour.
▶ Check combustion values in operating point P2.
▶ Set excess air via air damper setting [A], do not alter fuel pressure in the process.
▶ Repeat procedure for operating point P1.
S
P
i
S
V h Pl l/h %
i
S
P m 3 m h min s
i
V h min s
S S
P P
i i
19. Check operating behaviour

▶ Using [+] or [–] key, activate operating points several times and observe switch
over behaviour.
If the flame is unstable:
▶ Decrease air damper setting [A] in the changeover point.
If soot is formed:
▶ Increase air damper setting [A] in the changeover point.
20. Save points
The operating point P1 must be activated once, otherwise the display shows OFF
UPr when exiting commissioning and the combustion manager remains unprogram-
med.
▶ Activate operating point P1.

▶ Press [esc] twice.
✓ The display shows oP (Operate) and an operating point.
S S S
P P P
i i i
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6 Commissioning

22. Data backup
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7 Shutdown
7 Shutdown
▶ For short breaks in operation, e. g. chimney cleaning, switch off the burner.
▶ For longer breaks in operation, switch off the burner and close fuel shut off devices.
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8 Servicing
8 Servicing
8.1 Safety components
Safety components
Vital safety components must be replaced as soon as they reach their predefined
lifetime.
The predefined lifetime is not the warranty time specified in the terms and conditions
of delivery and payment.
Safety Lifetime CEN-Standard
component according to construction
ABE / Combustion Manager 10 years or 250 000 operating cycles EN 230 / 298
Actuators 10 years or 2 000 000 operating cycles EN 12067-2
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9 Troubleshooting
9 Troubleshooting
9.1 Procedures for fault conditions
Fault memory
The combustion manager stores the last 25 faults and lockouts in the fault history
(parameter 700), 701 is is the fault, which occurred last. The fault history can be called
up in the service level or password level.
Display fault history

▶ call up service level or password level (see Ch. 5.2).
▶ Select faults in sequence using [+] or [–] key.
▶ Press [ENTER] key (in service level 1 to 3 s).
✓ Fault level flashes.
▶ Select fault level in sequence using [+] key.
If ·-·- appears in the display in fault level 05 and 06:
▶ Press [ENTER] key (in service level 1 to 3 s).
✓ Value is displayed.
S
P
i
V h min s %
S S
P P
i i
S S
P P
i i
No. Level Meaning

701 .01 = Error codes (see Ch. 9.2)
… .02 = Diagnostic code (see Ch. 9.2)
725 .03 = Fault class (arranges faults 0 = Lockout, highest priority
by priority) 1 = Safety shut down with software reset
2 = Low voltage
3 = Safety shut down in safety phase
4 = Safety shutdown start prevention
5 = Safety shutdown shutdown
6 = Signal without switch off reaction
.04 = Operating phase Operating phase at time of fault (see Ch. 3.1.7.1).
.05 = Start-up counter Number of start-ups at time of fault.
Press [ENTER] key to display.
.06 = Rating Load at time of fault.
Press [ENTER] key to display.
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9 Troubleshooting
Carry out reset
Damage resulting from incorrect servicing

The combustion plant could be damaged.
▶ Do not carry out more than 2 lockout resets successively.
CAUTION ▶ Faults must be rectified by qualified personnel.
▶ Press [ENTER] key for approx. 2 seconds.
✓ rESEt appears.
▶ Release the key.
✓ The burner has been reset.
Exchanging the unit
▶ Select and check fault history and lockout history before replacing the combustion
manager or ABE and include when returning the unit for exchange.
Delete fault history

Only the fault history in the service level can be deleted. The fault history in the pass-
word level is not affected by the deleting process.
▶ Enter password (see Ch. 5.2.1).
▶ Select parameter 130
✓ The display shows value 0.
▶ Set value to 1 within 3 seconds using [+] key, confirm with [ENTER] key, then set
value to 2 and confirm again with [ENTER] key.
✓ When the display changes to 0 the delete process has been completed.
If the display shows –1 the duration of 3 seconds was exceeded and the delete
process was aborted.
S S
P P
i i
S
V h min s % P V h min s %
i
V h min s %
S
P
i 3s
S
P V h min s %
i
V h min s %
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9 Troubleshooting
9.2 Error codes

Error code Diagnostic Cause Rectification
code
2 1 No flame signal in operating phase 44 ▶ Check flame sensor (soiled, defective,
2 No flame signal in operating phase 52 signal strength…)
▶ Correct ignition load point
3 0 No air pressure switch signal from oper- ▶ Check air pressure switch (setting,
ating phase 24 connection)
▶ Clean fan wheel and air guide
▶ Check pressure and negative pres-
sure hoses
1 Air pressure switch signal prior to oper- ▶ Check air pressure switch
ating phase 22
4 Air pressure switch signal prior to start-
up
4 0 Flame signal during pre-purge ▶ Check flame sensor
1 Flame signal during shutdown
2 Flame signal during start-up
7 0 Flame failure ▶ Check flame sensor (soiled, defective,
signal strength…)
▶ Check fuel supply
▶ Check combustion
3 … 255 Flame failure due to TÜV test Duration of fuel values closed to flame
failure.
Solution: value 5 (2 s) = set to 1 s
12 0 Valve proving V1 leaking ▶ Check valve proving pressure switch
1 Valve proving V2 leaking (see Ch. 3.1.1)
▶ Check solenoid valve
14 0 POC open ▶ Check valve closing contact (function,
1 POC closed connection)
64 POC open prior to start-up
20 0 Low pressure switch has reacted ▶ Check low pressure switch
1 Low gas program (see Ch. 3.1.2) ▶ Check gas supply
21 0 High pressure switch has reacted ▶ Check high pressure switch
22 0 Safety circuit / burner flange open ▶ Check safety devices
1 Safety circuit / burner flange open during
start-up
50 … 67 # Internal fault ▶ Replace combustion manager if fault
reoccurs
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9 Troubleshooting

code
70 23 Load invalid
26 Modulating curve point undefined. Set curve points for all actuators
71 0 Standby undefined. Set special positions for all actuators
1 Pre-purge position undefined
2 Post-purge position undefined
3 Ignition position undefined
72 # Internal fault ▶ Replace combustion manager if fault
reoccurs
73 23 Load invalid
26 Multi-stage curve points undefined Set curve points for all actuators
75 1 Current load incorrect
2 Target load incorrect
4 Target position incorrect
16 Different positions reached ▶ Repeat standardisation.
reoccurs
80 1 Combustion manager was unable to cor- Combustion manager has not been
rect speed deviations and has reached standardised for this motor:
the lower regulating limit. ▶ Repeat standardisation.
Frequency converter speed too high The ramp times of the frequency con-
2 Combustion manager was unable to cor- verter are longer than those of the com-
rect speed deviations and has reached bustion manager:
the upper regulating limit. ▶ Check ramp times (parameter 522,
Frequency converter speed too low 523).
The reference line of the frequency con-
verter is not linear:
▶ Adjust combustion manager/frequen-
cy converter control signal (parameter
645).
Frequency converter reacts too slowly:
▶ Check frequency converter settings
(inlet filter, slip compensation, fade-
out of different speeds).
81 1 Interference impulses on sensor line ▶ Improve EMC measures.
speed input
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9 Troubleshooting

code
82 1 Ramp time during run down during ▶ Increase ramp time (parameter 523).
standardisation too short
2 Standardised speed not saved ▶ Repeat standardisation.
3 No speed signal ▶ Check the connection
▶ Check distance speed sensor / trans-
mitter disc.
4 Motor did not achieve stable speed dur- The ramp times of the frequency con-
ing start-up. verter are longer than those of the com-
Frequency converter run-up time too bustion manager:
long. ▶ Check ramp times (parameter 522,
Speed below minimum limit for stand- 523).
ardisation. The reference line of the frequency con-
verter is not linear:
▶ Adjust combustion manager/frequen-
cy converter control signal (parameter
645).
Frequency converter reacts too slowly:
▶ Check frequency converter settings
(inlet filter, slip compensation, fade-
out of different speeds).
Speed of frequency converter is below
the minimum standardised speed (650
rpm)
▶ Increase speed of frequency convert-
er.
5 Incorrect rotation direction ▶ Check rotation direction.
▶ Check installation of transmitter disc.
6 Impulse pattern (60°, 120°, 180°) incor- ▶ Check the connection
rect, interference impulses on the sensor ▶ Check distance speed sensor / trans-
line mitter disc.
▶ Improve EMC measures.
7 Standardised speed is not within the
permitted range
15 Speed deviation between micro control- ▶ Repeat standardisation.
ler 1 und micro controller 2
20 Standardisation in incorrect operating ▶ Switch off heat demand and repeat
phase standardisation.
21 Safety circuit / burner flange open during ▶ Repeat standardisation.
standardisation.
22 Air actuator not referenced ▶ Check actuator.
23 Frequency converter deactivated ▶ Activate frequency converter and re-
peat standardisation.
24 Standardisation started without valid ▶ Check type of operation (parameter
type of operation 201, 301) and repeat standardisation.
128 Frequency converter is activated, but is ▶ Carry out standardisation.
not standardised.
255 Motor is rotating, but is not standardised ▶ Carry out standardisation.
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9 Troubleshooting

code
83 1 Speed not achieved, lower control limit Rectification see error code 80.
was activated
2…3 Speed not achieved, upper control limit Rectification see error code 80.
was activated
4…7 Aborted due to interference impulses on ▶ Improve EMC measures.
sensor line
8 … 15 Modulating operation: Curve gradient ▶ Check ramp times (parameter 522,
frequency converter too steep (speed 523).
not achieved)
Depending on the ramp time (parameter
522, 523), the speed alteration between
two operating points must not exceed a
specific percentage.
10 % at 20 s
20 % at 10 s
40 % at 5 s
16 … 31 No speed signal ▶ Check the connection
▶ Check distance speed sensor / trans-
mitter disc.
32 … 63 Speed deviation too high ▶ Check ramp times (parameter 522,
523).
84 1 Modulating operation: Curve gradient ▶ Check ramp times (parameter 522,
frequency converter too steep 523).
Depending on the ramp time (parameter
522, 523), the speed alteration between
two operating points must not exceed a
specific percentage.
10 % at 20 s
20 % at 10 s
40 % at 5 s
2…3 Modulating operation: Curve gradient The position change between two oper-
fuel actuator too steep ating points must not exceed maximum
31°:
4…7 Modulating operation: Curve gradient air
actuator too steep ▶ Adjust operating points.
85 1 Fuel actuator referencing error ▶ Check, if actuators have been mixed
2…3 Air actuator referencing error up.
▶ Check, if actuator is blocked.
128 … 255 Parameter settings of one actuator have
been changed.
86 0 Fuel actuator position error ▶ Check, if actuator is blocked.
1 Fuel actuator line break min 0.5 V between Pin 5 and 2 or 6 and
2:
▶ Check wiring.
8 Modulating operation: Curve gradient The position change between two oper-
fuel actuator too steep ating points must not exceed maximum
31°:
▶ Adjust operating points.
16 … 255 Fuel actuator overloaded or mechanical- ▶ Check, if actuator is blocked.
ly twisted
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9 Troubleshooting

code
87 0 Air actuator position error ▶ Check, if actuator is blocked.
1 Air actuator line break min 0.5 V between Pin 5 and 2 or 6 and
2:
▶ Check wiring.
8 Modulating operation: Curve gradient air The position change between two oper-
actuator too steep ating points must not exceed maximum
31°:
▶ Adjust operating points.
16 … 255 Air actuator overloaded or mechanically ▶ Check, if actuator is blocked.
twisted
reoccurs
93 3 Flame sensor short circuit ▶ Check flame sensor
▶ Check wiring.
95 # External voltage relay contact (internal) ▶ Check flame sensor
3 Ignition unit ▶ Check wiring.
4 Fuel valve 1
5 Fuel valve 2
6 Fuel valve 3
96 # Relay contact fused (internal) Check relay contact:
3 Ignition unit ▶ Apply voltage.
✓ Output X3-05:1 must be de-ener-
4 Fuel valve 1 gised.
5 Fuel valve 2 ▶ Switch off voltage and unplug plug
6 Fuel valve 3 X3-05.
✓ No ohmic connection must exist be-
tween output X3-05:1 and input
X3-04:4 (N).
If a criteria is not met:
▶ Replace combustion manager.
97 0 Safety relay fused (internal) or external Rectification see error code 96.
voltage applied to safety relay
98 # Relay does not activate (internal) ▶ Replace combustion manager if fault
2 Safety valve reoccurs
3 Ignition unit
4 Fuel valve 1
5 Fuel valve 2
6 Fuel valve 3
99 … 100 # Internal fault relay activation ▶ Replace combustion manager if fault
reoccurs
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9 Troubleshooting

code
105 # Internal fault contact interrogation Can be caused by capacitive loads or
0 Minimum pressure switch direct current feed. The input, at which
the fault occurred is displayed with error
1 High pressure switch code.
4 Load controller OPEN
5 Load controller ON / OFF
6 Load controller CLOSED
7 Safety circuit / burner flange
8 Safety valve
9 Ignition unit
10 Fuel valve 1
11 Fuel valve 2
12 Fuel valve 3
13 Reset
reoccurs
111 # Mains frequency too low
112 # Voltage return No fault
reoccurs
116 # Operating cycle lifespan exceeded ▶ Combustion manager should be re-
placed
117 # Lifespan exceeded ▶ Replace combustion manager.
120 0 Interference impulses on fuel meter input ▶ Improve EMC measures.
121 … 124 # Internal fault ▶ Reset parameters or reset data using
Restore.
▶ Replace combustion manager if fault
reoccurs
125 … 126 # Internal fault ▶ Reset parameters.
reoccurs
127 # Internal fault ▶ Reset parameters or reset data using
Restore.
reoccurs
128 0 Internal fault ▶ Replace combustion manager if fault
reoccurs
reoccurs
reoccurs
reoccurs
136 1 Restore started No fault
83250302 • 1/2010-03 • La 89-98

9 Troubleshooting

code
137 255 (-1) Aborted due to Time-out during Back- ▶ Check the connection
up / Restore or ABE does not have this ▶ Repeat Backup / Restore.
function. ▶ Replace ABE.
254 (-2) Aborted due to transfers error ▶ Repeat Backup / Restore.
253 (-3) Restore cannot be carried out at present
252 (-4) Restore incomplete
251 (-5) No burner identification ▶ Define burner identification (parame-
ter 113).
250 (-6) Backup data set invalid, Restore not
possible
249 (-7) Backup has unsuitable burner identifica-
tion and must not be uploaded.
248 (-8) Restore cannot be carried out at present ▶ Repeat Backup / Restore.
247 (-9) Backup data set invalid, Restore not
possible
246 (-10) Aborted due to Time-out during Restore ▶ Repeat Backup / Restore.
245 (-11) Access error Restore
244 (-12) Software version and Backup data set
incompatible, Restore not possible
243 (-13) Backup data comparison between the ▶ Repeat Backup / Restore.
micro controllers incorrect
242 (-14) Backup is incorrect and cannot not re-
loaded
241 (-15) Backup contains unsuitable ASN and
must not be uploaded
240 (-16) No Backup in ABE
239 (-17) Backup memory in ABE faulty ▶ Repeat Backup / Restore.
157 (-99) Restore successful, however Backup
data less than in current system
146 1 Modbus Time-out
2 eBus Time-out
150 1 (-1) TÜV Test in invalid operating phase ▶ Start TÜV Test in phase 60
2 (-2) Load during TÜV Test less than lower ▶ Adjust load and repeat TÜV Test.
load limit (parameter 545)
3 (-3) Load during TÜV Test higher then upper
load limit (parameter 546)
4 (-4) Manual abort TÜV Test No fault
5 (-5) No flame failure after fuel valves have ▶ Check for extraneous light.
shut down ▶ Check wiring.
▶ Check soundness of valves.
165 … 166 # Internal fault
83250302 • 1/2010-03 • La 90-98

9 Troubleshooting

code
167 1 Manual lockout by contact No fault
2 Manual lockout by ABE
3 Manual lockout by PC-Tool
8 Communication between W-FM and
ABE was interrupted during curve set-
ting
9 Communication between W-FM and
PC-Tool was interrupted during curve
setting
33 Reset attempt by PC-Tool
reoccurs
200 # System fault free
201 1 No type of operation selected
2…3 No fuel supply defined
4…7 No curves defined
8 … 15 Standardised speed undefined
16 … 31 Backup / Restore was not possible
202 # Internal fault type of operation setting ▶ Redefine type of operation (parameter
201).
203 # Internal fault type of operation setting ▶ Redefine type of operation (parameter
201).
reoccurs
204 24 … 52 Program stop is activated. Operating ▶ Deactivate program stop (parameter
phase is shown in diagnostic code. 208).
reoccurs
206 0 Impermissible unit combination (com-
bustion manager - ABE)
207 0 Combustion manager version too old
1 ABE version too old
reoccurs
210 0 Impermissible type of operation ▶ Redefine type of operation (parameter
201).
reoccurs
83250302 • 1/2010-03 • La 91-98

10 Spares
10 Spares
1.01 1.03
1.04
1.02
83250302 • 1/2010-03 • La 92-98

10 Spares
Pos. Description Order No.

1.01 ABE for W-FM 50/54 600 408
1.02 Plug cable ABE-W-FM
–2m 600 406
– 10 m 600 407
1.03 Combustion manager W-FM50 230 V 50/60 Hz 600 402
1.04 W-FM plug
– X3-02 Air pressure switch 716 301
– X3-03 Limit switch burner flange 716 302
– X3-04 Mains and safety circuit 716 303
– X3-05 Fan, alarm 716 410
– X4-02 Ignition unit 716 305
– X5-01 Min. oil pressure switch 716 307
– X5-02 Max. oil pressure switch 716 308
– X5-03 Control circuit 716 309
– X6-03 Safety valve 716 312
– X7-01 Oil valve stage 2 716 313
– X8-04 Operation + LO Reset 50 716 411
– X9-04 Valve proving gas pressure switch 716 418
– X10-05 Flame sensor QRB,QRC, ionisation 716 413
– X10-06 Flame sensor QRA 716 414
– X64 Reserve 4-20mA 716 416
– X74 Connection frequency converter 716 417
– X75 Fuel meter 716 415
83250302 • 1/2010-03 • La 93-98

11 Technical documentation
11.1 Frequency converter

Detailed information can be found in the handbook on the CD of the frequency con-
verter.
The frequency converter fitted to the burner motor when using speed control offers:
▪ an interface 1 for data transfer,
▪ a diagnostic window 2 with 10 LED's for signal status of inputs and outputs,
▪ a status window 3 with 2 red-green LED's to display the operating status.
RJ 12 1 8
RS 232 2 7
9 0 B A
RS 485 3 6
4 5
Interfaces
The interface is used to access the frequency converter via a PC. The Software re-
quired is available as a free Download (http://elcat.nord.com/software/nordcon/
download/nordcon_127.zip). A connection cable RJ12 to Sub-D9 is required.
Diagnostic window
LED Input/Output Meaning
1 (yellow) Digital output Alarm from frequency converter
2 (yellow) Digital input 1 Start release frequency converter
3 (yellow) Digital input 2 Mains adapter 24V DC operation
4 (yellow) Digital input 3
5 (yellow) Digital input 4
6 (yellow) PTC thermistor motor Excess temperature at motor
7 (yellow) Brake Chopper Brake Chopper active
8 (yellow) Mech. brake Mechanical brake active
9 (green) BUS Status 1 off no communication
flashes Bus warning
on Communication
0 (red) BUS Status 2 off no fault
flashes Monitoring fault / Time-out
on no system bus
83250302 • 1/2010-03 • La 94-98

Status window
LED Display Meaning
A (green/red) AS Interface Status -
B (green/red) Operating condition FC off No mains voltage / control voltage
green on Ready for operation
green flashing 2Hz = ready to switch on
0.5Hz = switch on blocked
green on Not ready for operation (control voltage
red flashing applied but no mains voltage)
green flashing Warning
red flashing
red flashing Fault (fault code see handbook fre-
quency converter)
83250302 • 1/2010-03 • La 95-98

12 Key word index
A F
ABE ........................................................................................25 Fan motor ............................................................... 13, 14, 15
Actuator ........................................................................ 11, 40 Fan run-up time ...................................................................35
Adjusting ...............................................................................43 Fault class .............................................................................82
Adjustment ................................................................... 56, 69 Fault history ..........................................................................83
Air actuator ...........................................................................38 Fault memory .......................................................................82
Air pressure switch ................................13, 14, 15, 19, 22 Flame failure test .................................................................34
Alarm .............................................................................. 22, 35 Flame sensor ......................................................... 20, 36, 37
Ambient conditions .............................................................24 Flame signal ................................................... 13, 14, 15, 41
Analogue signal ........................................................... 18, 23 Flame stabilisation time .....................................................36
Flashing ............................................................................ 9, 30
B Frequency .............................................................................34
Frequency converter .................................... 22, 38, 39, 94
Background illumination ....................................................34 Fuel actuator ........................................................................38
Backup .....................................................10, 33, 55, 68, 79 Fuel meter ..................................................................... 21, 34
Baud rate ..............................................................................34 Fuel stage .............................................................................30
Breaks in operation ............................................................80 Fuel valve ............................................................... 13, 14, 15
Building Management ........................................................18 Fuel volume ..........................................................................35
Building management ........................................................34 Full load .................................................................................38
Burner flange limit switch ..................................................16 Fusing ....................................................................................24
Burner identification ...........................................................33
Burner motor ........................................................................22
Burner OFF ..........................................................................28 G
Burner ON .................................................................... 17, 18 Gas connection pressure ................................................... 8
Bus interface ........................................................................18 Gas pressure switch ..........................................................20
Gas valve train ....................................................................... 8
C Guarantee ............................................................................... 5
Calculation ...........................................................................10
Change ..................................................................................31 H
Change value .......................................................................31 Heat demand ..........................................13, 14, 15, 17, 30
Change-over release .........................................................17 Heating engineer ................................................................31
Class of protection .............................................................24 High gas pressure switch ......................................... 19, 36
Combustion Manager ........................................................26 High pressure pressure switch ......................... 13, 14, 15
Condensate ............................................................................ 7 High pressure switch .........................................................19
Connection pressure ........................................................... 8
Consumption .......................................................................24 I
Contact interrogation .........................................................40
Continuous running fan .....................................................22 Ignition pilot valve ...............................................................13
Ignition position ........................................................... 46, 59
Ignition speed .............................................................. 46, 49
D Ignition start .........................................................................22
Data backup ............................................10, 33, 55, 68, 79 Ignition unit ..................................................... 13, 14, 15, 22
Data set .................................................................................33 Illumination ............................................................................34
Diagnostic code ..................................................................84 InF ...........................................................................................30
Dimensions ...........................................................................25 Info level ........................................................................ 31, 41
Direct ignition .......................................................................35 Input X10-05 ........................................................ 13, 14, 15
Display ............................................................. 28, 29, 31, 34 Input X3-02 .................................................... 13, 14, 15, 19
Display and operating unit (ABE) ....................................28 Input X3-03 .............................................13, 14, 15, 16, 30
Disposal .................................................................................. 7 Input X3-04 .............................................13, 14, 15, 16, 30
Input X5-01 .................................................... 13, 14, 15, 19
E Input X5-02 .................................................... 13, 14, 15, 19
Input X5-03 ........................................................... 17, 18, 30
EBus ......................................................................................34 Input X64 ..............................................................................18
Electrical installation ...........................................................26 Input X8-04 ..........................................................................16
Err ...........................................................................................30 Input X9-04 ........................................................... 13, 14, 20
Error .......................................................................................30 Input X10-05 .......................................................................20
Error code .............................................................................84 Input X10-06 .......................................................................20
Error history ..........................................................................41 Input X75 ..............................................................................21
Excess air ..............................................................................76 Input X92 ..............................................................................18
Exchanging the unit ............................................................83 Ionisation electrode ............................................................20
Extraneous light ...................................................................20
83250302 • 1/2010-03 • La 96-98

12 Key word index
L Photo resistor ......................................................................20

LED ........................................................................................94 Pilot ignition ..........................................................................35
Liability ..................................................................................... 5 Point of ignition ...................................................................37
Limit switch ..........................................................................16 Post burn time .....................................................................36
Load .................................................................................. 9, 30 Post-purge position ............................................................38
Load change ........................................................................33 Post-purge time ..................................................................36
Load controller ..................................................... 17, 18, 40 Pre-ignition time .......................................................... 15, 22
Load limit ..............................................................................38 Pre-purge ..............................................................................36
Load signal ................................................................... 23, 39 Pre-purge position ..............................................................38
Loc .........................................................................................30 Pressure regulating screw ........................................ 63, 75
Lockout ......................................................................... 16, 30 Pressure regulator ..............................................................17
Low gas pressure switch .................................................... 8 Pressure switch .............................................................. 8, 20
Low gas pressure switch ..................................................19 Process data ........................................................................40
Low gas program ................................................................19 Program sequence .............................................. 13, 14, 15
Low gas programme ............................................................ 8 Program stop .......................................................................35
Low impact start .................................................................17 Pump pressure ............................................................ 63, 75
Low oil pressure switch .....................................................19
Low pressure switch .................................... 13, 14, 15, 19 Q
QRA .......................................................................................20
M QRB .......................................................................................20
Mains frequency ..................................................................34
Mains voltage ............................................................... 16, 24 R
Manual load ..................................................................... 9, 33 Ramp time ............................................................................38
Manual OFF ........................................................................... 9 Referencing ..........................................................................11
Max. oil pressure switch ....................................................19 Repetition .............................................................................36
Modbus .................................................................................34 Repetition counter ................................................................ 8
Modulating ............................................................. 17, 18, 35 Reset ............................................................................. 16, 83
Modulating limit ...................................................................38 Resetting ...............................................................................83
Motor ........................................................13, 14, 15, 22, 26 Restore .......................................................................... 10, 33
Multi-stage .................................................................... 17, 18 Return pressure ...................................................................64
O S
OFF ........................................................................................30 Safety circuit ................................... 13, 14, 15, 16, 30, 36
OFF function ........................................................................28 Safety measures ................................................................... 6
Oil pressure switch ............................................................15 Safety shutdown .................................................................30
Op ..........................................................................................30 Safety valve ........................................................... 13, 14, 15
Operating cycles .................................................................81 Save ............................................................................... 31, 33
Operating hours ..................................................................35 Save value ............................................................................31
Operating panel ..................................................................28 Saving ....................................................................................10
Operating phase ....................................12, 13, 14, 15, 30 Service level ................................................................. 31, 41
Operating points .................................................................10 Service life .............................................................................. 6
Operating setting ................................................................12 Setting step ..........................................................................33
Operating unit ......................................................................28 Setting time ..........................................................................24
Operation ..............................................................................30 Show parameter ..................................................................31
Output X3-05 ................................................ 13, 14, 15, 22 Shutdown .............................................................................80
Output X4-02 ................................................ 13, 14, 15, 22 Shutdown period ................................................................80
Output X6-03 ....................................................... 13, 14, 15 Smell of gas ........................................................................... 6
Output X7-01 ....................................................... 13, 14, 15 Software version ......................................................... 33, 41
Output X7-02 .............................................................. 13, 15 Solenoid valve ...................................................... 13, 14, 15
Output X74 .................................................................. 22, 23 Special positions ................................................................38
Output X8-02 ....................................................... 13, 14, 15 Speed ........................................ 40, 59, 63, 64, 65, 72, 75
Speed alteration ..................................................................87
P Speed control ......................................................................94
Parameter values ................................................................41 Speed measurement ..........................................................22
Parity ......................................................................................34 Speed standardisation ......................................................39
Partial load ............................................................. 38, 54, 67 Stabilisation time .................................................................36
Password .................................................31, 32, 43, 56, 69 Stage .....................................................................................30
Ph ................................................................................... 12, 30 Standby .................................................................................38
Phase ............................................................................. 12, 30 Start prevention ........................................................... 22, 35
83250302 • 1/2010-03 • La 97-98

12 Key word index
Start-ups ...............................................................................35
Stetting point .......................................................................18
Storage .................................................................................24
Supply pressure .......................................................... 63, 75
Switch off behaviour ..........................................................35
T
Temperature .........................................................................24
Thermostat ...........................................................................17
Three stage .................................................................. 17, 35
Torque ...................................................................................24
Transport ...............................................................................24
Two stage .............................................................. 17, 18, 35
Type of operation ................................................. 17, 18, 35
Type of protection ...............................................................24
U
Unit address .........................................................................34
UV cell ...................................................................................20
V
Valv proving ............................................................................ 8
Valve ....................................................................... 13, 14, 15
Valve proving .................................................................. 8, 36
Valve proving gas pressure switch ............................ 8, 20
Valve proving pressure switch ................................. 13, 14
Valve train ............................................................................... 8
Vent valve .............................................................................22
Voltage supply ............................................................. 16, 24
83250302 • 1/2010-03 • La 98-98

83250302 • 1/2010-03 • La
www.weishaupt.de Max Weishaupt GmbH, D-88475 Schwendi
Weishaupt (UK) Limited Neachells Lane, Willenhall, WV13 3RG

www.weishaupt.co.uk
Printed in Germany. All rights reserved.
Product Description Performance
W-Burners The compact series, proven millions of times over: Up to 570 kW

Economical, reliable, fully automatic. Gas, oil and
dual fuel burners for domestic and commercial appli-
cations. The purflam burner gives almost soot-free
combustion of oil with greatly reduced NOx emissions.
Monarch and The legendary industrial burner: Up to

industrial burners Tried and tested, long lived, clear construction. 11,700 kW
Gas, oil and dual fuel burners for district heat
provision.
multiflam® burners Innovative Weishaupt technology for large burners: Up to

Minimal emission values particularly at ratings over 17,000 kW
one megawatt. Oil, gas and dual fuel burners with
patented fuel distribution system.
WK Modular powerhouses: Up to
industrial burners Adaptable, robust, powerful. 22,000 kW
Oil, gas and dual fuel burners for industrial plant.
Thermo Unit The Thermo Unit heating systems from cast iron or Up to 55 kW
steel: Modern, economic, reliable.
For environmentally friendly heating.
Fuel: Gas or oil as desired.
Thermo Condens The innovative condensing boilers with the SCOT Up to

system: Efficient, low in emissions, versatile. Ideal for 1,200 kW
domestic heating. Floor standing gas condensing
boiler with ratings of up to 1200 kW (cascade), for
higher heat demands.
Heat pumps The heat pump programme offers solutions for Up to 130 kW
utilisation of heat from air, soil and ground water.
The systems are suitable for refurbishment or new
builds. It is possible to use several heat pumps in
cascade operation.
Solar systems Free energy from the sun:

Perfectly coordinated components, innovative, proven.
Pleasantly shaped flat roof collectors to support
heating and of domestic water
Water heater / The attractive domestic water heating range

energy reservoir includes classic water heaters which are supplied
through a heating system and energy reservoirs
which can be fed through solar systems.
Control technology / From control panels to complete building management

building systems – at Weishaupt you can find the entire
management spectrum of modern control technology.
Future oriented, economical and flexible.
83250302 • 1/2010-03 • La
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A 18.4.2017 FIRATAA For customer approval. B2, B3 added

B 26.4.2017 FIRATAA Top view added
A C 07.06.17 firajlo Load table has been added.
A
D 08.06.17 FIRAAPO Updated pos.G. Text insulation out of ALA scope removed.
K1 K2 K3 K4 K5 G B1 B2 B3
B B
C C
D D
E E
A A
+Z
F -Y F
L
L C XX2
G G
H H
UNIT ASSEMBLY TO THE FOUNDATION BED:

1. WITH ANCHOR BOLTS. CHEMICAL ANCHOR BOLTS ARE RECOMMENDED.
2. UNIT LEGS ARE FILLET WELDED AROUND TO THE FOUNDATION PLATES.
FOUNDATION BED IS TO BE MIN. 100 MM WIDER AND 100 MM LONGER THAN UNIT FRAME.
FOUNDATION PLATE IS TO BE MIN. 50 MM WIDER AND 50 MM LONGER THAN UNIT LEG.
FOUNDATION PLATES ARE TO BE BOLTED OR MOULDED TO THE FOUNDATION BED.
DURING INSTALLATION STAGE, THERMAL EXPANSIONS ARE TO BE TAKEN INTO THE CONSIDERATION;
J SEE ALFA LAVAL AALBORG GENERAL INSTRUCTIONS. J
DELIVERY AND DESIGN FOR THE FOUNDATION BED AND PLATES IS OUT OF
ALFA LAVAL AALBORG SCOPE OF SUPPLY.
NOTE !
INSTRUMENTS (VALVES AND FITTINGS) ARE SHOWN AS SPACE AND SERVICE
RESERVATION PURPOSE ONLY. EXACT DIMENSIONS ARE TO BE CHECKED
FROM RELATED INSTRUMENT CATALOGUES.
C ALL INSTRUMENTS ARE DELIVERED LOOSE.

C
L
K K
L L
A-A ( 1:10 )
+Y
Fx Fy Fz Mx My Mz x y z
+X Max. Loads (kN) Max. Moments(kNm)

Thermal movements
(mm), T=Design 5514, Termonorte, Colombia 10.4.2017/FIRAPON
ALLOWABLE FORCES AND MOMENTS Hyundai Heavy Industries 19.4.2017/FIRATAA
- Not to be subjected to any fluctuating loads. THERMAL MOVEMENTS Steam Header SH-250D /
M - Forces given in the table are not allowed
- Directions of x, y and
z are shown in dwg.
Main dimensions 1071,6 kg 1:10
M
to be exceeded.
- Origin (0,0,0) at fixed
point of Unit.
the mass forces and thermal expansions
are compensated. A1 5514-9M D 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
A 6.7.2017 FIRAAPO Added chemical anchors with stud bolts POS.31.
48
A A
47 42 33 47 42 47 42 47 43
42 47 42 47 42 47 42 47
42 39 46 46 42 39 42 39 43 40
39 42 39 42 39 42 39 42
39 35 41 38 39 35 39 35 40 37
35 39 35 39 35 39 35 39
34 27 38 41 34 27 34 27 36 28
27 34 27 34 27 34 27 34
9 18 19 30 11 12 13 14 15 16
B 10 7 8 5 6 3 4 17 B
25
C C
1 2
D D
24 24
26 26
23 22 21
44 44 45 41 38 32 29 20 31
32 38
E 38 41 E
41 45
45
F F
G G
5514, Termonorte, Colombia 6.7.2017/FIRAAPO
Hyundai Heavy Industries 6.7.2017/FIRAAKI

H STEAM HEADER SH-250D 6.7.2017/FIRAPON
H
Assembly 1071,6 kg 1:15
A2 5514-30A A 1 /1
1 2 3 4 5 6 7 8 9 10 11 12

Blow down tank, Steam header Maintenance - 1/3
CONTENT:
1. GENERAL ........................................................................................................................... 2
2. MAINTENANCE INSTRUCTIONS FOR BLOW DOWN TANK, STEAM HEADER .............. 2
2.2 Manual water cleaning ................................................................................................... 2
2.5 Tightness test ................................................................................................................ 3
2.6 Pressure test for steam header ...................................................................................... 3
2.7 Emptying of blow down tank........................................................................................... 3

Maintenance / Blow down tank, Steam header - - 2/3
1. GENERAL
This part describes how to maintain the Blow Down Tank and the Steam Header. In
case any major problems occur within the steam system, please contact Alfa Laval
Aalborg.
General conditions of devices and all instruments have to be noticed during normal
2. MAINTENANCE INSTRUCTIONS FOR BLOW DOWN TANK,

STEAM HEADER
Note!
2.2 Manual water cleaning

Note!

Maintenance / Blow down tank, Steam header - - 3/3
2.5 Tightness test

Note!
2.6 Pressure test for steam header
Note!
manufacturing phase, before new pressure equipment (assembly where related valves
pipes etc. equipments are connected to the pressure vessel) is taken in use, it needs to
be pressure tested. Requirements of pressure testing for delivered pressure vessel are
informed in related Maintenance Card and Technical data sheets. Furthermore the
be taken into the consideration before steam producing is started. Liability of register or
other licenses are out of Alfa Laval Aalborg responsibility.
2.7 Emptying of blow down tank
Ref.: Maintenance Card, “Emptying of blow down tank”.
Note!
Before blow down tank’s manhole is opened, make sure that it is completely empty and
until maintenance actions to the inside of the tank, the temperature of all steel surfaces
have been cooled to the safe level.
Storing of a cold blow down tank or steam drum partly filled with water is not allowed
because of the risk of corrosion and/or frozen.
Storing of device shall be made by taking into consideration instructions about corrosion
protection. Suitable protection has to be added inside the equipment tank and all

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A 20.4.2017 FIRAPTA BDT moved into cantainer
A A
D3
B B
Q1
A2
C C
N1
A2
A
A
N1
D D
E E
A1
A1
B B
F C3
F
G G
H H
A2
J J
A1
K K
B-B ( 1:10 )
A-A ( 1:10 ) BASE PLATES
L L
Thermonotre 93 MW dual fuel power plant 11.4.2017/FIRAPTA
BLOW DOWN TANK, BDT-150 21.4.2017/MJÄ
M Main dimensions M
245,0 kg 1:10
A1 5514-21M A 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
REV DATE MADE APPVD. EXPLANATION
A 20.6.2017 FIRAPTA Valve V003 changed to DN32
30
28
A 26 24 22 16 1 A
25 10
14 23
2 19
13 6
B B
17 A A
22 11
24 12
11
26
4 17 22 24 27
C 4 C
17 30 1 FLANGE GASKET DN80 PN10-40 EN1514-1 GRAPHITE 35205180311RA 0,0
22 3 28 4 FLANGE GASKET DN32 PN10-40 EN1514-1 GRAPHITE 35205180283RA 0,1
15 19 23 25 29 26 3 FLANGE GASKET DN15 PN10-40 EN1514-1 GRAPHITE 35205180262RA 0,0
24 27 25 24 Washer 16 DIN 126 FE-ZN HOT 30903920199RA 0,3
27 21 22 16 HEXAGONAL NUT M12 DIN 934 / 8 FE-ZN HOT 30803800185RA 0,3
D 24 20 4 HEXAGONAL SCREW M16 x 100 DIN 931 / 8.8 FE-ZN HOT 30103520388RA 0,8 D
15 1 Neck Flange DN50 PN40 EN 1092-1:11/B P250GH 20505740185RA 2,8
14 1 CURVE PIPE dwg:5514-175 0,8
13 1 CURVE PIPE dwg:5514-174 0,9
12 1 CURVE PIPE dwg:5514-173 4,2
7 20 23 25 28 11 1 CURVE PIPE dwg:5514-172 2,9
10 1 STEEL STRUCTURE dwg:5514-131S BDT-150 206,2
7 1 NON-RETURN VALVES. DISCO DN32 PN6-40 BDT001.V007 60207520255RA 0,8
6 1 GLOBE VALVE DN32 PN25 BDT001.V006 60107200367RA 6,8
E 5 1 NON-RETURN VALVES. DISCO DN25 PN6-40 BDT001.V005 60207520248RA 0,5
E
5 18 22 24 27 3 1 BALL VALVE DN32 PN40 BDT001.V003 60007340304RA 3,8
2 1 TEMPERATURE CONTROL VALVE SELF ACTING 1/2'' (F) PN16 BDT001.V002 60508020172RA 1,2
A-A ( 1:20 ) Date/Drawn
5514 Thermonotre 93MW, Colombia 17.5.2017/FIRAPTA
Date/Checked
Date/Approved
BLOW DOWN TANK BDT-150 17.5.2017/MJ
F Assembly Weight/kg Scale F
245,0 kg 1:20
ALFA LAVAL AALBORG OY A THIRD PARTY WITHOUT A SPECIAL
Rauma, Finland PERMISSION OF ALFA LAVAL AALBORG.
A3 5514-34A A 1 /1
1 2 3 4 5 6 7 8
GRUNDFOS INSTRUCTIONS
CR, CRI, CRN

Installation and operating instructions
English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions. 1. Symbols used in this document
CONTENTS Warning
Page If these safety instructions are not observed, it
1. Symbols used in this document 2 may result in personal injury.
2. Handling 2
Warning
3. Type designation 3
If these instructions are not observed, it may lead
3.1 Type key for CR, CRI, CRN 1s, 1, 3, 5, 10, 15 and 20 3
to electric shock with consequent risk of serious
3.2 Type key for CR, CRN 32, 45, 64, 90, 120 and 150 3
personal injury or death.
4. Applications 3
5. Technical data 3 If these safety instructions are not observed, it
5.1 Ambient temperature and altitude 3 Caution may result in malfunction or damage to the
5.2 Liquid temperature 4 equipment.
5.3 Maximum permissible operating pressure and liquid
temperature for the shaft seal 4 Notes or instructions that make the job easier
Note
5.4 Minimum inlet pressure 4 and ensure safe operation.
5.5 Minimum inlet pressure 5
5.6 Minimum flow rate 5 2. Handling
5.7 Electrical data 5 When lifting the entire pump with motor, follow these instructions:
5.8 Frequency of starts and stops 5 • Pump with motor sizes 0.37 - 5.5 kW:
5.9 Dimensions and weights 5 Lift the pump in the motor flange by means of straps or the
5.10 Sound pressure level 5 like.
6. Installation 5 • Pump with motor sizes 7.5 - 22 kW:
6.1 Foundation 6 Lift the pump by means of the motor eyebolts.
6.2 Vibration dampening 7
• Pump with motor sizes 30-45 kW:
6.3 Outdoor installation 7
Lift the pump by means of the lifting brackets on the motor
6.4 Hot surfaces 7
flange.
6.5 Torques 7
6.6 Flange forces and torques • Pump with motor sizes 55-75 kW:
8
Lift the pump by means of the eyebolts on the motor side.
7. Electrical connection 9
7.1 Cable entry/screwed connection 9
7.2 Three-phase connection 9
7.3 Single-phase connection 10
7.4 Terminal box positions 10
7.5 Frequency converter operation 10
8. Startup 11
8.1 Shaft seal run-in 11
9. Maintenance 11
TM04 0339 0608
TM04 0341 0608
TM04 0341 0608

TM05 9564 4113
10. Frost protection 12
11. Service 12
11.1 Service kits and manuals 12
12. Fault finding 13
13. Disposal 13 0.37 - 5.5 7.5 - 22 30-45 55-75
kW kW kW kW
Warning
Fig. 1 Correct lifting of a CR pump
Prior to installation, read these installation and
operating instructions. Installation and operation In case of CR, CRI and CRN pumps with other motors than MG or
must comply with local regulations and accepted Siemens, we recommend you to lift the pump by means of the
codes of good practice. straps in the motor flange.
Warning
Make sure that the pump remains in a stable
position during unpacking and installation by
means of the straps used for lifting the pump.
Note that typically the centre of gravity of the
pump is close to the motor.
2
3. Type designation 5. Technical data
English (GB)
3.1 Type key for CR, CRI, CRN 1s, 1, 3, 5, 10, 15 and 20 5.1 Ambient temperature and altitude
Example CR 3- 10 X- X- X- X- XXXX Maximum

Maximum
Motor Motor altitude
Type range: CR, CRI, CRN Motor ambient
power efficiency above sea
Nominal flow rate in m3/h make temperature
[kW] class level
[°C]
Number of impellers [m]
Code for pump version Grundfos
0.37 - 0.55 - +40 1000
Code for pipework connection MG
Code for materials Grundfos
0.75 - 22 IE3 +60 3500
MG
Code for rubber pump parts
30 - 75 Siemens IE3 +55 2750
Code for shaft seal
If the ambient temperature exceeds the above temperature
3.2 Type key for CR, CRN 32, 45, 64, 90, 120 and 150 values or the pump is installed at an altitude exceeding the above
altitude values, the motor must not be fully loaded due to the risk
Example CR 32- 2 1- X- X- X- X- XXXX of overheating. Overheating may result from excessive ambient
Pump range: CR, CRN temperatures or the low density and consequently low cooling
effect of the air.
Nominal flow rate in m3/h
In such cases, it may be necessary to use a motor with a higher
Number of stages rated output.
Number of impellers with reduced diameter
Code for pump version P2
Code for pipework connection [%] 3
Code for materials 100 2
Code for rubber pump parts 90
Code for shaft seal 80 1
70
4. Applications 60
50
TM03 2479 4405

Grundfos multistage in-line centrifugal pumps, types CR, CRI and
CRN, are designed for a wide range of applications. 20 25 30 35 40 45 50 55 60 65 70 75 80
t [°C]
CR, CRI, CRN
CR, CRI and CRN pumps are suitable for liquid transfer, 1000 2250 3500 4750 m
circulation and pressure boosting of cold or hot clean liquids.
Fig. 2 Motor output depends on temperature/altitude
CRN
Use CRN pumps in systems where all parts in contact with the
Motor power
liquid are made of high-grade stainless steel. Pos. Motor make
[kW]
Pumped liquids
0.37 - 0.55 MG
Thin, clean, non-flammable, non-combustible or non-explosive 1
liquids, not containing solid particles or fibres. The liquid must not 0.37 - 22 MGE
attack the pump materials chemically. 2 0.75 - 22 MG
When pumping liquids with a density and/or viscosity higher than 3 30-75 Siemens
that of water, use motors with correspondingly higher outputs, if
required. Example
Figure 2 shows that the load of an IE3 motor at an ambient
temperature of 70 °C must not be loaded more than 89 % of the
rated output. If the pump is installed 4750 metres above sea
level, the motor must not be loaded more than 89 % of the rated
output.
In cases where both the maximum temperature and the maximum
altitude are exceeded, the derating factors must be multiplied
(0.89 x 0.89 = 0.79).
For motor bearing maintenance at ambient

Note temperatures above 40 °C, see section
9. Maintenance.
3
5.2 Liquid temperature 5.4 Minimum inlet pressure
English (GB)
The table on page 16 states the relationship between liquid

temperature range and maximum permissible operating pressure.
The maximum permissible operating pressure

Note and liquid temperature ranges apply to the pump
only.
Hf
5.3 Maximum permissible operating pressure and
liquid temperature for the shaft seal
The diagram below applies to clean water and H

Note Pb NPSH
TM02 0118 3800

water containing anti-freeze liquids.
CR, CRI, CRN 1s to 20 and CR, CRN 32 to 150
p [bar]
Hv
35
30 Fig. 4 Schematic view of open system with a CR pump
25
H H H H H
20 Q Q Q HQQE/V Q B The maximum suction lift "H" in metres head can be calculated as
15 Q Q Q Q Q follows:
HBQE/V
TM03 8853 4907

E V E E E
10
H = p b x 10.2 - NPSH - Hf - Hv - Hs
5
0 pb = Barometric pressure in bar.
-60 -40 -20 0 20 40 60 80 100 120 140
(Barometric pressure can be set to 1 bar.)
t [°C] In closed systems, pb indicates the system pressure in
bar.
Fig. 3 Maximum permissible operating pressure and liquid
temperature NPSH = Net Positive Suction Head in metres head (to be read
from the NPSH curve on page 14 at the highest flow the
pump will be delivering).
Motor Max. temperature range Hf = Friction loss in suction pipe in metres head at the
Standard shaft seal
[kW] [°C] highest flow the pump will be delivering.
HQQE 0.37 - 45 -40 °C to +120 °C Hv = Vapour pressure in metres head, see fig. E on page 19.
HBQE 55 -75 0 °C to +120 °C tm = liquid temperature.
HQQV 0.37 - 45 -20 °C to +90 °C Hs = Safety margin = minimum 0.5 metres head.
If the calculated "H" is positive, the pump can operate at a suction
HBQV 55-75 0 °C to +90 °C
lift of maximum "H" metres head.
CRI and CRN pumps using a type H shaft seal with EPDM rubber If the calculated "H" is negative, an inlet pressure of minimum "H"
parts, HxxE, can be cleaned in place (CIP) with liquids up to metres head is required. There must be a pressure equal to the
150 °C for maximum 15 minutes. calculated "H" during operation.
The pumping of liquids above +120 °C may result Example
Note
in periodical noise and reduced pump life. pb = 1 bar.
CR, CRI, CRN pumps are not suitable for the pumping of liquids Pump type: CR 15, 50 Hz.
above 120 °C for long periods. Flow rate: 15 m3/h.
NPSH (from page 14): 1.1 metres head.
Hf = 3.0 metres head.
Liquid temperature: +60 °C.
Hv (from fig. E, page 19): 2.1 metres head.
H = p b x 10.2 - NPSH - Hf - Hv - Hs [metres head].
H = 1 x 10.2 - 1.1 - 3.0 - 2.1 - 0.5 = 3.5 metres head.
This means that the pump can operate at a suction lift of
maximum 3.5 metres head.
Pressure calculated in bar: 3.5 x 0.0981 = 0.343 bar.
Pressure calculated in kPa: 3.5 x 9.81 = 34.3 kPa.
4
5.5 Minimum inlet pressure
Step Action
English (GB)
The table on page 17 states the maximum permissible inlet
pressure. However, the actual inlet pressure + maximum pump 2 This information is stated on
pressure (at no flow) must always be lower than the values stated page 18:
in fig. A, page 16. • port-to-port lengths
TM00 2256 3393

4xø
The pumps are pressure-tested at a pressure of 1.5 times the • dimensions of the base
values stated in fig. B, page 17. L1 B1 • pipework connections
L2 B2 • diameter and position of
5.6 Minimum flow rate foundation bolts.
Due to the risk of overheating, do not use the pump at flows 3 The pump can be installed
below the minimum flow rate. vertically or horizontally (CR,
The curves below show the minimum flow rate as a percentage of CRN 120 and 150, 75 kW, only
the nominal flow rate in relation to the liquid temperature. vertically). However, the motor
- - - - = air-cooled top. must neither fall below the
horizontal plane nor be
Qmin installed upside down.
Ensure that an adequate
TM01 1241 4097

[%]
30 supply of cool air reaches the
motor cooling fan.
20
Motors above 4 kW must be
TM01 2816 2302

10 supported.
0 3a (Additional support for ships’
40 60 80 100 120 140 160 180 t [°C] use)
To minimise pump vibrations,
Fig. 5 Minimum flow rate additional support brackets can
be mounted. The brackets can
be fitted from the motor or the
The pump must not run against a closed
Caution motor stool to the bulkhead of
discharge valve.
the ship. Mount the bracket in
TM05 7705 1013

5.7 Electrical data horizontal position. To minimise
further vibration, mount the
See motor nameplate. bracket at an angle of 30-40 °
to the wall.
5.8 Frequency of starts and stops
4 To minimise possible noise
Motor size from the pump, we advise you
Maximum number of starts per hour to fit expansion joints on either
[kW]
side of the pump.
≤ 2.2 250 The foundation/installation
3-4 100 must be carried out as
5.5 - 11 50 described in section 6.1.
Fit isolating valves on either
18.5 - 22 40
side of the pump to avoid
30 90 draining the system if the pump
37 50 needs to be removed for
cleaning, repair or
TM02 0116 3800
45 80
replacement.
55 50 Always protect the pump
75 50 against backflow by means of a
non-return valve (foot valve).
5.9 Dimensions and weights
5
Dimensions: See fig. C, page 18.
Weights: See label on the packing. Install the pipes so that air
locks do not occur, especially
TM02 0114 3800
5.10 Sound pressure level on the suction side of the

See fig. D, page 19. pump.
6. Installation
6 Fit a vacuum valve close to the
The pump must be secured to a horizontal, plane and solid
foundation by bolts through the holes in the base plate. When pump if the installation has one
installing the pump, follow the procedure below in order to avoid of these characteristics:
damaging the pump. • The discharge pipe slopes
downwards away from the
Step Action pump.
TM02 0115 3800
• There is a risk of siphon

1 effect.
• Protection against backflow
Arrows on the pump base show of unclean liquids is needed.
TM02 0013 3800
the direction of flow of liquid

through the pump.
5
6.1 Foundation
English (GB)
The foundation/installation must be carried out in

accordance with the following instructions.
Note
Non-compliance may result in functional faults
which will damage the pump components.
Grundfos recommends to install the pump on a concrete
foundation which is heavy enough to provide permanent and rigid
support to the entire pump. The foundation must be capable of
absorbing any vibration, normal strain or shock. The concrete
foundation must have an absolutely level and even surface.
Place the pump on the foundation, and fasten it. The base plate
must be supported on the whole area.
TM05 9579 4113

The following instruction applies when mounting the pump in
vertical or horizontal position.
Place the pump on the foundation, and fasten it. See fig. 6.
Fig. 8 Foundation, horizontal mounting
The foundation length and width should always be 200 mm larger

than the length and width of the pump. See fig. 8.
The mass of the foundation must be at least 1.5 times the total
mass of the pump. The minimum height of the foundation (hf) can
then be calculated:
mpump × 1.5
TM04 0342 0608
hf =
Lf × Bf × δconcrete
The density (δ) of concrete is usually taken as 2,200 kg/m3.

In installations where noise-less operation is particularly
Fig. 6 Correct installation
important, we recommend you to use a foundation with a mass up
to 5 times that of the pump.
The foundation must be provided with bolts for fixing the base
plate. See fig. 9.
6.2 Vibration dampening
TM03 4589 2206

Fig. 9 Bolt in foundation
When the foundation bolts are in position, the pump can be

placed on the foundation. The base plate can now be aligned
using shims, if necessary, so that it is completely horizontal.
See fig. 10.
TM04 0343 0608
Fig. 7 Foundation, vertical mounting
The recommended length and width are shown in fig. 7. Note that
TM04 0362 0608
the length and width of the foundation for pumps with motor size
Shims
≤ 30 kW must be 200 mm larger than the base plate.
For pumps with motor size ≥ 37 kW, the length and width must
always be 1.5 x 1.5 (Lf x Bf) metres.
Fig. 10 Alignment with shims
6
6.2 Vibration dampening 6.5 Torques
English (GB)
If vibration dampers are used, they must be installed under the The table shows the recommended torques for bolts in base and
foundation. Pumps with motor size ≤ 30 kW can use vibration flanges.
dampers as shown in fig. 11.
For pumps with motor sizes ≥ 37 kW, use a Sylomer® plate as Base Flange
CR, CRI, CRN
shown in fig. 12. [Nm] [Nm]
1s-5 40 50-60
10-20 50 60-70
32-150 70 70-80
Vibration dampers
TM04 1691 1008

Fig. 11 Pump on vibration dampers
Sylomer® plate
TM04 1692 1008
Fig. 12 Pump on Sylomer® plate
6.3 Outdoor installation

When installed outdoors, we recommend you to provide the motor
with a rain cover. We also recommend you to open one of the
drain holes in the motor flange.
6.4 Hot surfaces
Warning
When pumping hot liquids, care should be taken
to ensure that persons cannot accidentally come
into contact with hot surfaces.
Figure 13 shows which pump parts get as hot as the pumped
liquid.
TM04 0361 0608
Pump head
Pump sleeve
Base
Fig. 13 Hot surfaces on a CR, CRI, CRN pump
7
6.6 Flange forces and torques
English (GB)
If not all loads reach the maximum permissible value stated in the
tables below, one of these values may exceed the normal limit.
Contact Grundfos for further information.
TM04 0346 2013

Fig. 14 Flange forces and torques
Y-direction: Inlet/outlet
Z-direction: Direction of chamber stack
X-direction: 90 ° from inlet/outlet
Forces
CR, CRI, CRN
Y-direction
X-direction
Flange, DN
Z-direction
Force,
Force,
Force,
[mm]
[N]
[N]
[N]
25/32 1s to 5 900 1050 850

40 10 1100 1250 1000
50 15 and 20 1500 1550 1350
65 32 1850 2100 1700
80 45 2500 2050 2250
100 64 and 90 3350 2700 3000
125/150 120 and 150 3350 2700 3000
Torques
CR, CRI, CRN
Y-direction
X-direction
Flange, DN
Z-direction
Torque,
Torque,
Torque,
[mm]
[Nm]
[Nm]
[Nm]
25/32 1s to 5 1100 850 750

40 10 1300 1050 900
50 15 and 20 1400 1150 1000
65 32 1500 1200 1100
80 45 1150 1300 1600
100 64 and 90 1250 1450 1750
125/150 120 and 150 1250 1450 1750
8
7. Electrical connection 7.2 Three-phase connection
English (GB)
The electrical connection should be carried out by an authorised
electrician in accordance with local regulations. Mains supply [V]
Warning Delta connection Star connection

The CR pump must be connected to an external 220-240 / 380-415
mains switch placed close to the pump and to a 50 Hz
380-415 / 660-690
motor-protective circuit breaker or a CUE
220-277 / 380-480 1)
frequency converter. It must be possible to lock 60 Hz
the mains switch in OFF position (isolated). Type 380-480 / 660-690
and requirements as specified in EN 60204-1,
5.3.2. 1) 60 Hz motors, 0.37 - 1.1 kW: 220-277/380-440 V.
Warning
Before removing the terminal box cover and W2 U1 W2 U2 V2
before removing/dismantling the pump, make
TM02 6656 1305

sure that the power supply has been switched off
U1 V1 W1
and that it cannot be accidentally switched on.
W1 U2
The user is to consider whether it is necessary to

Caution V2 V1
install an emergency stop switch. L1 L2 L3
The operating voltage and frequency are marked on the motor Fig. 15 Delta connection
nameplate. Make sure that the motor is suitable for the power
supply on which it will be used and the motor terminal connection U1
is correct. You will find a wiring diagram in the terminal box.
W2 U2 V2
7.1 Cable entry/screwed connection
TM02 6655 1305

U2
All motors are supplied without screwed cable entries. The table W2 U1 V1 W1
below shows the numbers and sizes of cable entry holes of the V2
terminal box (standard EN 50262).
W1 V1 L1 L2 L3
Motor Number and size
Description Fig. 16 Star connection
[kW] of cable entries
The holes have precast If the motor is provided with PTC sensors or PTO contacts, the
0.25 - 0.55 2 x M20 x 1.5 threads and are closed with connection must be in accordance with the wiring diagram in the
knock-out cable entries terminal box.
The holes are closed with Three-phase motors must be connected to a motor-protective
0.75 - 3.0 2 x M20
knock-out cable entries circuit breaker.
The holes are closed with
4.0 - 7.5 4 x M25
knock-out cable entries
2 x M20 The holes are closed with
11-22
4 x M40 knock-out cable entries
30-45 2 x M50 x 1.5 Blanking plug
55-75 2 x M63 x 1.5 Blanking plug
9
7.3 Single-phase connection 7.4 Terminal box positions
English (GB)
The terminal box can be turned to four positions, in 90 ° steps.

Mains supply [V] Follow this procedure:
"Low voltage" "High voltage" 1. If necessary, remove the coupling guards. Do not remove the
coupling.
50 Hz 220-230 / 240 2. Remove the bolts securing the motor to the pump.
3. Turn the motor to the required position.
4. Replace and tighten the bolts.
5. Replace the coupling guards.
Carry out the electrical connection as shown in the diagram
inside the terminal box cover.
7.5 Frequency converter operation
TM04 1693 1008

7.5.1 Motors supplied by Grundfos
All three-phase MG motors with phase insulation can be connected
to a frequency converter.
Fig. 17 Connection, "low voltage", 0.37 - 0.75 kW 7.5.2 Phase insulation MG 71 and 80
MG motors, frame sizes 71 and 80, do not have phase insulation as
standard. The motors are not suitable for frequency converter
operation as they are not protected against the voltage peaks
caused by the frequency converter operation. Only motors with a
rated voltage equal to or above 460 V have phase insulation.
Frequency converter operation of MG motors
TM04 1694 1008
Caution without phase insulation will cause damage to

the motor.
We recommend you to protect all other motors against voltage
peaks higher than 1200 V by 2000 V/μsec.
The above disturbances, i.e. both increased acoustic noise and
Fig. 18 Connection, "high voltage", 0.37 - 0.75 kW detrimental voltage peaks, can be eliminated by fitting an LC filter
between the frequency converter and the motor.
For further information, please contact the frequency converter or
motor supplier.
7.5.3 Other motor makes than those supplied by Grundfos
Please contact Grundfos or the motor manufacturer.
TM04 0345 0608
Fig. 19 Connection, "low voltage", 1.1 - 2.2 kW

TM04 0344 0608
Fig. 20 Connection, "high voltage", 1.1 - 2.2 kW
Single-phase Grundfos motors incorporate a thermal switch and

require no additional motor protection.
10
8. Startup 8.1 Shaft seal run-in
English (GB)
The seal faces are lubricated by the pumped liquid, meaning that
Do not start the pump until it has been filled with
there may be a certain amount of leakage from the shaft seal.
Caution liquid and vented. If the pump runs dry, the pump
bearings and the shaft seal may be damaged. When the pump is started up for the first time, or when a new
shaft seal is installed, a certain run-in period is required before
the leakage is reduced to an acceptable level. The time required
for this depends on the operating conditions, i.e. every time the
TM05 1160 0611 - TM05 8098 1913

operating conditions change, a new run-in period will be started.
Under normal conditions, the leaking liquid will evaporate.
As a result, no leakage will be detected.
However, liquids such as kerosene will not evaporate.
The leakage may therefore be seen as a shaft seal failure.
9. Maintenance
Warning
Fig. 21 Venting valve, standard and an optional solution with Before starting work on the pump, make sure that
hose connection. all power supplies to the pump have been
switched off and that they cannot be accidentally
switched on.
Warning
Pump bearings and shaft seal are maintenance-free.
Pay attention to the direction of the vent hole and
take care to ensure that the escaping water does Motor bearings
not cause injury to persons or damage to the Motors not fitted with grease nipples are maintenance-free.
motor or other components. Motors fitted with grease nipples should be lubricated with a high-
In hot-water installations, pay special attention to temperature, lithium-based grease. See the instructions on the
the risk of injury caused by scalding hot water. fan cover.
Follow the instructions on page 34. In the case of seasonal operation (motor is idle for more than
CR, CRI, CRN 1s to 5 6 months of the year), we recommend you to grease the motor
when the pump is taken out of operation.
For these pumps, we advise you to open the bypass valve during
startup, see fig. 22 for bypass valve location. The bypass valve Depending on the ambient temperature, the motor bearings must
connects the suction and discharge sides of the pump, thus be replaced or lubricated according to the table below. The table
making the filling procedure easier. Close the bypass valve again applies to 2-pole motors. The number of operating hours stated
when the operation is stable. for bearing replacement are guidelines only.
When pumping liquids containing air, we advise you to leave the
Motor size Bearing replacement interval [operating hours]
bypass valve open if the operating pressure is lower than 6 bar.
[kW] 40 °C 45 °C 50 °C 55 °C 60 °C
Close the bypass valve if the operating pressure constantly
exceeds 6 bar. Otherwise the material at the opening will be worn
because of the high liquid velocity. 0.37 - 0.75 18000 - - - -
1.1 - 7.5 20000 15500 12500 10000 7500
Motor size Lubrication interval [operating hours]

[kW] 40 °C 45 °C 50 °C 55 °C 60 °C
11 - 18.5 4500 3400 2500 1700 1100
22 4000 3100 2300 1500 1000
30-55 4000 3000 2000 1500 -
75 2000 1500 1000 500 -
Intervals for 4-pole motors are twice as long as those for 2-pole
motors.
If the ambient temperature is lower than 40 °C, bearings must be
replaced/lubricated at the intervals mentioned under 40 °C.
11
10. Frost protection
English (GB)
Pumps which are not being used during periods of frost should be
drained to avoid damage.
Drain the pump by loosening the vent screw in the pump head
and by removing the drain plug from the base.
Warning
Pay attention to the direction of the vent hole and
take care to ensure that the escaping water does
not cause injury to persons or damage to the
motor or other components.
In hot-water installations, pay special attention to
the risk of injury caused by scalding hot water.
Do not tighten the vent screw and replace the drain plug until the
pump is to be used again.
CR, CRI, CRN 1s to 5
Before replacing the drain plug in the base, screw the bypass
valve out against the stop. See fig. 22.
Drain plug
Bypass valve TM01 1243 4097
Fig. 22 Location of drain plug and bypass valve
Fit the drain plug by tightening the large union nut followed by the
bypass valve.
11. Service
We recommend you to repair pumps with motors of 7.5 kW and
up at pump site. Necessary lifting equipment must be available.
If a pump has been used for a liquid which is

Note toxic or injurious to health, the pump will be
classified as contaminated.
If Grundfos is requested to service the pump, Grundfos must be
contacted with details about the pumped liquid, etc. before the
pump is returned for service. Otherwise, Grundfos can refuse to
accept the pump for service.
Possible costs of returning the pump are to be paid by the
customer.
However, any application for service (no matter to whom it may
be made) must include details about the pumped liquid if the
pump has been used for liquids which are toxic or injurious to
health.
11.1 Service kits and manuals

Service kits and manuals for CR, CRI and CRN, see
www.grundfos.com (WebCAPS), WinCAPS or Service Kit
Catalogue.
12
12. Fault finding
English (GB)
Warning
Before removing the terminal box cover and before removing/dismantling the pump, make sure that the power
supply has been switched off and that it cannot be accidentally switched on.
Fault Cause Remedy

1. Motor does not run a) Supply failure. Connect the power supply.
when started. b) Fuses are blown. Replace fuses.
c) Motor-protective circuit breaker has tripped. Reactivate the motor-protective circuit breaker.
d) Thermal protection has tripped. Reactivate the thermal protection.
e) Main contacts in motor-protective circuit breaker
Replace contacts or magnetic coil.
are not making contact or the coil is faulty.
f) Control circuit is defective. Repair the control circuit.
g) Motor is defective. Replace the motor.
2. Motor-protective circuit a) One fuse/automatic circuit breaker is blown. Replace the fuse/cut in the circuit breaker.
breaker trips b) Contacts in motor-protective circuit breaker are
immediately when Replace motor-protective circuit breaker contacts.
faulty.
power supply is
switched on. c) Cable connection is loose or faulty. Fasten or replace the cable connection.
d) Motor winding is defective. Replace the motor.
e) Pump mechanically blocked. Remove the mechanical blocking of the pump.
f) Motor-protective circuit breaker setting is too
Set the motor-protective circuit breaker correctly.
low.
3. Motor-protective circuit a) Motor-protective circuit breaker setting is too
Set the motor-protective circuit breaker correctly.
breaker trips low.
occasionally. b) Low voltage at peak times. Check the power supply.
4. Motor-protective circuit a) Check 1 a), b), d), e) and f).
breaker has not tripped
but the pump does not
run.
5. Pump performance not a) Pump inlet pressure is too low (cavitation). Check the suction conditions.
constant. b) Suction pipe/pump partly blocked by impurities. Clean the suction pipe/pump.
c) Pump draws in air. Check the suction conditions.
6. Pump runs but gives no a) Suction pipe/pump blocked by impurities. Clean the suction pipe/pump.
water. b) Foot or non-return valve blocked in closed
Repair the foot or non-return valve.
position.
c) Leakage in suction pipe. Repair the suction pipe.
d) Air in suction pipe or pump. Check the suction conditions.
e) Motor runs in the wrong direction of rotation. Change the direction of rotation of the motor.
7. Pump runs backwards a) Leakage in suction pipe. Repair the suction pipe.
when switched off. b) Foot or non-return valve defective. Repair the foot or non-return valve.
8. Leakage in shaft seal. a) Shaft seal is defective. Replace the shaft seal.
9. Noise. a) Cavitation. Check the suction conditions.
b) Pump does not rotate freely (frictional Adjust the pump shaft.
resistance) because of incorrect pump shaft Follow the procedure in fig. F, G or H at the end of
position. these instructions.
c) Frequency converter operation. See section 7.5 Frequency converter operation.
13. Disposal
This product or parts of it must be disposed of in an
environmentally sound way:
1. Use the public or private waste collection service.
2. If this is not possible, contact the nearest Grundfos company
or service workshop.
Subject to alterations.
13
Appendix
14
NPSH
Appendix
TM02 7125 2703 TM01 9884 3801 TM01 9883 3300 TM01 9882 3801 TM02 7387 3403
TM01 1936 0899 TM01 1935 0899 TM01 1934 0899 TM02 7127 2703 TM02 7126 2703
1
TM03 8765 2507 TM03 8764 2507 TM01 1937 0899
15
Appendix
Fig. A
Appendix
Maximum permissible operating pressure / liquid temperature range
Oval PJE - CLAMP - CA - UNION

DIN - FGJ
Operating Liquid temperature Operating Liquid temperature

pressure range pressure range
CR, CRI, CRN 1s 16 bar -20 °C to +120 °C 25 bar -20 °C to +120 °C
CR, CRI, CRN 1 16 bar -20 °C to +120 °C 25 bar -20 °C to +120 °C
CR, CRI 10-1 → 10-16 16 bar -20 °C to +120 °C 16 bar -20 °C to +120 °C
CR, CRI 10-17 → 10-22 - - 25 bar -20 °C to +120 °C
CRN 10 - - 25 bar -20 °C to +120 °C
CR, CRI 15-1 → 15-7 10 bar -20 °C to +120 °C - -
CR, CRI 15-1 → 15-10 - - 16 bar -20 °C to +120 °C
CR, CRI 15-12 → 15-17 - - 25 bar -20 °C to +120 °C
CRN 15 - - 25 bar -20 °C to +120 °C
CR, CRI 20-1 → 20-7 10 bar -20 °C to +120 °C - -
CR, CRI 20-1 → 20-10 - - 16 bar -20 °C to +120 °C
50 Hz
CR, CRI 20-12 → 20-17 - - 25 bar -20 °C to +120 °C
CRN 20 - - 25 bar -20 °C to +120 °C
CR, CRN 32-1-1 → 32-7 - - 16 bar -30 °C to +120 °C
CR, CRN 32-8-2 → 32-14 - - 30 bar -30 °C to +120 °C
CR, CRN 45-1-1 → 45-5 - - 16 bar -30 °C to +120 °C
CR, CRN 45-6-2 → 45-11 - - 30 bar -30 °C to +120 °C
CR, CRN 45-12-2 → 45-13-2 - - 33 bar -30 °C to +120 °C
CR, CRN 64-1-1 → 64-5 - - 16 bar -30 °C to +120 °C
CR, CRN 64-6-2 → 64-8-1 - - 30 bar -30 °C to +120 °C
CR, CRN 90-1-1 → 90-4 - - 16 bar -30 °C to +120 °C
CR, CRN 90-5-2 → 90-6 - - 30 bar -30 °C to +120 °C
CR, CRN 120 - - 30 bar -30 °C to +120 °C
CR, CRN 150 - - 30 bar -30 °C to +120 °C
CR, CRI, CRN 1s 16 bar -20 °C to +120 °C 25 bar -20 °C to +120 °C
CR, CRI 10-1 → 10-10 16 bar -20 °C to +120 °C 16 bar -20 °C to +120 °C
CR, CRI 10-12 → 10-17 - - 25 bar -20 °C to +120 °C
CRN 10 16 bar -20 °C to +120 °C 25 bar -20 °C to +120 °C
CR, CRI 15-1 → 15-5 10 bar -20 °C to +120 °C - -
CR, CRI 15-1 → 15-8 - - 16 bar -20 °C to +120 °C
CR, CRI 15-9 → 15-12 - - 25 bar -20 °C to +120 °C
CR, CRI 20-1 → 20-5 10 bar -20 °C to +120 °C - -
60 Hz CR, CRI 20-1 → 20-7 - - 16 bar -20 °C to +120 °C
CR, CRI 20-8 → 20-10 - - 25 bar -20 °C to +120 °C
CR, CRN 32-1-1 → 32-5 - - 16 bar -30 °C to +120 °C
CR, CRN 32-6-2 → 32-10-2 - - 30 bar -30 °C to +120 °C
CR, CRN 45-1-1 → 45-4 - - 16 bar -30 °C to +120 °C
CR, CRN 45-5-2 → 45-7 - - 30 bar -30 °C to +120 °C
CR, CRN 64-1-1 → 64-3 - - 16 bar -30 °C to +120 °C
CR, CRN 64-4-2 → 64-5-2 - - 30 bar -30 °C to +120 °C
CR, CRN 90-1-1 → 90-3 - - 16 bar -30 °C to +120 °C
CR, CRN 90-4-2 - - 30 bar -30 °C to +120 °C
CR, CRN 120 - - 30 bar -30 °C to +120 °C
CR, CRN 150 - - 30 bar -30 °C to +120 °C
16
Fig. B
Appendix
Maximum inlet pressure for CR, CRI and CRN
50 Hz 60 Hz
CR, CRI, CRN 1s

CR, CRI, CRN 1s-2 → CR, CRI, CRN 1s-36 10 bar CR, CRI, CRN 1s-2 → CR, CRI, CRN 1s-27 10 bar
CR, CRI, CRN 1

CR, CRI, CRN 1-2 → CR, CRI, CRN 1-36 10 bar CR, CRI, CRN 1-2 → CR, CRI, CRN 1-25 10 bar
CR, CRI, CRN 1-27 15 bar
CR, CRI, CRN 3

CR, CRI, CRN 5

CR, CRI, CRN 10

CR, CRI, CRN 15

CR, CRI, CRN 20

CR, CRI, CRN 20-1 → CR, CRI, CRN 20-3 8 bar CR, CRI, CRN 20-1 8 bar
CR, CRN 32
CR, CRN 32-1-1 → CR, CRN 32-4 4 bar CR, CRN 32-1-1 → CR, CRN 32-2 4 bar
CR, CRN 32-11-2 → CR, CRN 32-14 15 bar CR, CRN 32-7-2 → CR, CRN 32-10-2 15 bar
CR, CRN 45
CR, CRN 45-6-2 → CR, CRN 45-13-2 15 bar CR, CRN 45-4-2 → CR, CRN 45-7 15 bar
CR, CRN 64
CR, CRN 64-1-1 → CR, CRN 64-2-2 4 bar CR, CRN 64-1-1 4 bar
CR, CRN 64-2-1 → CR, CRN 64-4-2 10 bar CR, CRN 64-1 → CR, CRN 64-2-1 10 bar
CR, CRN 64-4-1 → CR, CRN 64-8-1 15 bar CR, CRN 64-2 → CR, CRN 64-5-2 15 bar
CR, CRN 90
CR, CRN 90-2-2 → CR, CRN 90-3-2 10 bar CR, CRN 90-2-1 → CR, CRN 90-4-2 15 bar
CR, CRN 90-3 → CR, CRN 90-6 15 bar
CR, CRN 120

CR, CRN 120-1 → CR, CRN 120-2-1 10 bar CR, CRN 120-1 10 bar
CR, CRN 120-2 → CR, CRN 120-5-1 15 bar CR, CRN 120-2-2 → CR, CRN 120-3 15 bar
CR, CRN 150

CR, CRN 150-1-1 → CR, CRN 150-1 10 bar CR, CRN 150-1-1 10 bar
CR, CRN 150-2-1 → CR, CRN 150-4-1 15 bar CR, CRN 150-1 → CR, CRN 150-2 15 bar
17
Appendix
18
Oval PJE CLAMP - FlexiClamp UNION DIN - FGJ
Fig. C
D D DN 4xø
D
Pump
H
H
H
H
Type L1 B1
L L L D L L
L2 B2
TM00 2251 3393

TM00 2252 3393
TM00 2253 3393
TM00 2254 3393
TM00 2255 3393
TM00 2256 3393
L H D L H D L H D L H D L H L1 L2 B1 B2 ∅
[mm] [mm] [Rp] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [G] [mm] [mm] DN [mm] [mm] [mm] [mm] [mm]
CR 1s 160 50 1 - - - - - - - - - 250 75 25/32 100 145 180 220 13
CRI, CRN 1s - - - 210 50 42.2 162 50 30 228 50 2 250 75 25/32 100 150 180 220 13
CR 1 160 50 1 - - - - - - - - - 250 75 25/32 100 145 180 220 13
CRI, CRN 1 - - - 210 50 42.2 162 50 30 228 50 2 250 75 25/32 100 150 180 220 13
CR 3 160 50 1 - - - - - - - - - 250 75 25/32 100 145 180 220 13
CRI, CRN 3 - - - 210 50 42.2 162 50 30 228 50 2 250 75 25/32 100 150 180 220 13
CR 5 160 50 1¼ - - - - - - - - - 250 75 25/32 100 145 180 220 13
CRI, CRN 5 - - - 210 50 42.2 162 50 30 228 50 2 250 75 25/32 100 150 180 220 13
CR 10 200 80 1½ - - - - - - - - - 280 80 40 130 178 215 256 13.5
CRI, CRN 10 - - - 261 80 60.1 202 80 50 - - - 280 80 40 130 200 215 248 13
CR 15 200 80 2 - - - - - - - - - 300 90 50 130 176 215 256 13.5
CRI, CRN 15 - - - 261 90 60.1 202 90 50 - - - 300 90 50 130 200 215 248 13
CR 20 200 80 2 - - - - - - - - - 300 90 50 130 176 215 256 13.5
CRI, CRN 20 - - - 261 90 60.1 202 90 50 - - - 300 90 50 130 200 215 248 13
CR 32 - - - - - - - - - - - - 320 105 65 170 223 240 298 14
CRN 32 - - - - - - - - - - - - 320 105 65 170 226 240 298 14
CR 45 - - - - - - - - - - - - 365 140 80 190 248 266 331 14
CRN 45 - - - - - - - - - - - - 365 140 80 190 251 266 331 14
CR 64 - - - - - - - - - - - - 365 140 100 190 248 266 331 14
CRN 64 - - - - - - - - - - - - 365 140 100 190 251 266 331 14
CR 90 - - - - - - - - - - - - 380 140 100 199 261 280 348 14
CRN 90 - - - - - - - - - - - - 380 140 100 199 261 280 348 14
CR 120 - - - - - - - - - - - - 380 180 125 275 344 380 472 18
CRN 120 - - - - - - - - - - - - 380 180 125 275 344 380 472 18
CR 150 - - - - - - - - - - - - 380 180 125 275 344 380 472 18
CRN 150 - - - - - - - - - - - - 380 180 125 275 344 380 472 18

Fig. D
Appendix
Airborne noise emitted by pumps with motors fitted by Grundfos
50 Hz 60 Hz
Motor
[kW] LpA LpA
[dB(A)] [dB(A)]
0.37 50 55
0.55 50 53
0.75 50 54
1.1 52 57
1.5 54 59
2.2 54 59
3.0 55 60
4.0 62 66
5.5 60 65
7.5 60 65
11 60 65
15 60 65
18.5 60 65
22 66 70
30 71 75
37 71 75
45 71 75
55 71 75
75 73 77
Fig. E
tm Hv
(°C) (m)
190 126
180 100
170 79
160 62
150 45
40
140 35
30
130
25
120 20
110 15
12
100 10
8,0
90
6,0
80 5,0
4,0
70 3,0
60 2,0
1,5
50
1,0
40 0,8
0,6
30 0,4
TM02 7445 3503
0,3
20
0,2
10
0,1
0
19
CR, CRI, CRN 1s, 1, 3 and 5
Appendix
Fig. F
A B
TM02 0459 4600
TM02 0460 4600

C D
M6 - 13 Nm
M8 - 31 Nm
M10 - 62 Nm
M5 - 2.5 Nm
x
TM02 1051 0501
TM02 1052 0501

0.5x
20
E
C
A
Fig. G
M8 - 31 Nm
M6 - 13 Nm
M10 - 62 Nm
CR, CRI, CRN 10, 15 and 20
TM02 8542 0404 TM02 7923 4403 TM02 1045 0501
F
D
B
M5 - 2.5 Nm
TM02 8515 0304 TM02 0459 4600 TM02 8500 0304
21
Appendix
Appendix
C
B
A
22
Fig. H
CR, CRN 32, 45, 64, 90
1
2
1.7 mm
TM01 2146 3600 TM01 9878 4409 TM01 2144 3600

E
C
A
Fig. I
CR, CRN 120 and 150
TM03 8907 2707 TM03 8905 2707 TM03 8903 2707
F
D
B
TM03 8908 2707 TM03 8906 2707 TM03 8904 2707
23
Appendix
Appendix
Designation
Pos.
GB BG CZ DK DE EE
1 Adapter flange Преходен фланец Mezipříruba Mellemflange Zwischenflansch Ülemineku äärik
1a Motor stool Столче на двигателя Lucernaty motoru Mellemstykke Laterne Mootoripukk
2 Pump head Глава на помпата Hlava čerpadla Topstykke Kopfstück Pumba pea
3 Chamber, top Горна камера Horní článek Kammer, øverste Oberste Kammer Ülemine vahepesa
Článek bez mezerového
3a Chamber without neck ring Камера без пръстен Kammer uden tætningsring Kammer ohne Spaltring Tihendusrõngata vahepesa
kroužku
4 Chamber complete Камера - комплект Kompletní článek Kammer komplet Kammer komplett Komplektne vahepesa
Камера с лагерен
4a Chamber with bearing ring Článek s kroužkem ložiska Kammer med lejering Kammer mit Lagerring Laagriga vahepesa
пръстен
5a Chamber complete Камера - комплект Kompletní článek Kammer komplet Kammer komplett Komplektne vahepesa
6 Base Основа Patka Fodstykke Fußstück Alus
6a Stop pin Шплент Zarážkový kolík Rotationslås Sperrzapfen Lukustustihvt
Водеща плоча за Führungsplatte für
6d Guide plate for base Vodicí deska patky Styreplade til fodstykke Aluse juhtplaat
основата Fußstück
6g Bearing ring Ролков лагер Kroužek ložiska Lejering Lagerring Alumine laager
Предпазен капак на
7 Coupling guard Kryt spojky Skærm Schutzschirm Ühendusmuhvi kate
съединителят
7a Screw Винт Šroub Skrue Schraube Kruvi
8 Coupling complete Съединител - комплект Kompletní spojka Kobling komplet Kupplung komplett Komplektne ühendusmuhv
9 Screw Винт Šroub Skrue Schraube Kruvi
10 Shaft pin Шплент на вала Válcový kolík Stift Zylinderstift Võlli tihvt
10a Coupling half
12 Flange (oval)
18 Air vent screw Винт за обезвъздушаване Odvzdušňovací šroub Luftskrue Entlüftungsschraube Õhutusventiil
19 Pipe plug Тапа на тръбата Zátka Rørprop Stopfen Ääriku kork
21 Plug Пробка Zátka Prop Stopfen Kork
23 Plug Пробка Zátka Prop Stopfen Kork
25 Drain plug Пробка за дрениране Vypouštěcí zátka Tømmeprop Entleerungsstopfen Tühjendusava kork
26 Staybolt Шпилка Rozpěrný šroub Støttebolt Stehbolzen Distantspolt
26a Strap Лента Stahovací pás Spændebånd Spannband Klamber
26b Screw Винт Šroub Skrue Schraube Kruvi
26c Washer Шайба Podložka Spændeskive Unterlegscheibe Seib
32 Washer
32a Washer Шайба Podložka Spændeskive Unterlegscheibe Seib
36 Nut Гайка Matice Møtrik Mutter Mutter
36a Nut Гайка Matice Møtrik Mutter Mutter
37 O-ring/gasket О-пръстен/уплътнение O-kroužek/těsnicí kroužek O-ring/pakning O-Ring/Dichtung O-ring/tihend
38 O-ring О-пръстен O-kroužek O-ring O-Ring O-ring
38a O-ring О-пръстен O-kroužek O-ring O-Ring O-ring
39 Gasket
44 Inlet part complete Входяща част - комплект Kompletní vtoková část Indløbsdel komplet Einlaufteil komplett Komplektne imiosa
44a Inlet part upper
44b Inlet part lower
45 Neck ring Пръстен Mezerový kroužek Tætningsring Spaltring Tihendusrõngas
Kompletní mezerový
45a Neck ring complete Пръстен - комплект Tætningsring komplet Spaltring komplett Tihendusrõngas
kroužek
47 Bearing ring Търкалящ лагер Kroužek ložiska Lejering Lagerring Laager
Търкалящ лагер с винт за
47a Bearing with driver Ložisko s unašečem Leje med medbringer Lager mit Mitnehmer Juhikuga vahelaager
застопоряване
47b Bearing ring, rotating Търкалящ лагер - въртящ Kroužek ložiska otočný Lejering, roterende Lagerring, rotierend Laager, pöörlev
47c Bush Лагерна втулка Pouzdro Bøsning Buchse Puks
47d Retaining ring Спирателен пръстен Přídržný kroužek Låsering Haltering Lukustusrõngas
47e Retaining ring Спирателен пръстен Přídržný kroužek Låsering Haltering Lukustusrõngas
Гайка на разрязания
48 Split cone nut Matice upínacího pouzdra Møtrik for klembøsning Mutter für Klemmbuchse Lõhismutter
конус
49 Impeller Работно колело Oběžné kolo Løber Laufrad Tööratas
49a Impeller Работно колело Oběžné kolo Løber Laufrad Tööratas
49b Split cone Разрязан конус Upínací pouzdro Klembøsning Klemmbuchse Survepuks
49c Wear ring Износващ се пръстен Těsnicí kruh Slidring Verschleißring Kulutusrõngas
Discharge part/top guide
50a
vanes
51 Pump shaft Вал на помпата Hřídel čerpadla Pumpeaksel Pumpenwelle Pumba võll
55 Sleeve Външна втулка Vnější plášt’ Svøb Mantel Kattesärk
56 Base plate Основна плоча Základová deska Fodplade Grundplatte Alusplaat
56a Base plate Основна плоча Základová deska Fodplade Grundplatte Alusplaat
56c Screw Винт Šroub Skrue Schraube Kruvi
56d Washer Шайба Podložka Spændeskive Unterlegscheibe Seib
57 O-ring О-пръсетн O-kroužek O-ring O-Ring O-ring
Halter für
58 Seal carrier Носач на уплътнението Unašeč ucpávky Holder for akseltætning Tihendi kandur
Wellenabdichtung
60 Spring Пружина Pružina Fjeder Feder Vedru
61 Seal driver Водач Unašeč Medbringer Mitnehmer Võllitihendi juhik
62 Stop ring Зегерка Dorazový kroužek Stopring Stopring Lukustusrõngas
64 Spacing pipe Дистанционна тръба Distanční pouzdro Afstandsbøsning Distanzhülse Distantspuks
64a Spacing pipe Дистанционна тръба Distanční pouzdro Afstandsbøsning Distanzhülse Distantspuks
64b Spacing pipe
64c Clamp, splined Шлицова клема Drážková spona Spændestykke, spline Spannstück, Vielnut Soontega puks
64d Spacing pipe Дистанционна тръба Distanční pouzdro Afstandsbøsning Distanzhülse Distantspuks
Přídržka mezerového
65 Neck ring retainer Държач на пръстена Holder for tætningsring Halter für Spaltring Tihendusrõnga klamber
kroužku
66 Washer Шайба Podložka Spændeskive Unterlegscheibe Seib
66a Washer Шайба Podložka Spændeskive Unterlegscheibe Seib
24
Appendix
Designation
Pos.
GB BG CZ DK DE EE
66b Lock washer Контра - шайба Pojistná podložka Låseskive Sicherungsblech Vedruseib
67 Nut/screw Гайка/Винт Matice/Šroub Møtrik/Skrue Mutter/Schraube Mutter/Kruvi
69 Spacing pipe Дистанционна тръба Distanční pouzdro Afstandsbøsning Distanzhülse Distantspuks
76 Nameplate set Табела - комплект Sada štítků Skiltesæt Schildersatz Pumba sildik
76a Rivet
77 Pump head cover
100 O-ring О-пръстен O-kroužek O-ring O-Ring O-ring
105 Shaft seal Уплътнение на вала Hřídelová ucpávka Akseltætning Wellenabdichtung Võllitihend
201 Flange Фланец Příruba Flange Flansch Äärik
203 Retaining ring Спирателен пръстен Přídržný kroužek Låsering Haltering Lukustusrõngas
Designation
Pos.
GR ES FR HR IT
1 Φλάντζα προσαρμογής Brida acoplamiento Bride d’adaptation međuprirubnica Flangie adattatrici
1a Στήριγμα κινητήρα Acoplamiento Lanterne moteur međukomad Lanterna del motore
2 Κεφαλή αντλίας Cabezal bomba Tête de pompe glava crpke Testa pompa
3 Θάλαμος, άνω Cámara superior Chambre supérieure gornja komora Camera superiore
Θάλαμος χωρίς δακτύλιο Chambre sans bague komora bez rascijepljenog
3a Cámara sin anillo de junta Camera senza collarino
λαιμού d’étanchéité prstena
4 Θάλαμος πλήρης Cámara completa Chambre complète kompletna komora Camera completa
4a Θάλαμος με δακτύλιο εδράνου Cámara con anillo cojinete Chambre avec bague de palier komora s ležajnim prstenom Camera con cuscinetto
5a Θάλαμος πλήρης Cámara completa Chambre complète kompletna komora Camera completa
6 Βάση Base Pied de pompe nožni dio Base
6a Πείρος συγκράτησης Pasador tope Goupille d’arrêt zatik Molla di arresto
6d Πλάκα οδηγός γιά τη βάση Placa guía para base Plaque pour pied de pompe vodilica za nožni dio Guida per basamento
6g Δακτύλιος εδράνου Anillo cojinete Joint de palier prsten ležaja Cuscinetto
7 Προφυλακτήρας συνδέσμου Protector acoplamiento Protège-accouplement zaštita spojke Giunti di protezione
7a Κοχλίας Tornillo Vis vijak Vite
8 Σύνδεσμος πλήρης Acoplamiento completo Accouplement complet spojka kompletna Giunto completo
9 Κοχλίας Tornillo Vis vijak Vite
10 Πείρος άξονα Pasador eje Goupille cylindrique zatik vratila Molla albero
18 Τάπα εξαερισμού Tornillo purga aire Vis de purge odzračni vijak Vite della ventola
19 Τάπα σωλήνα Tapón tubería Bouchon čep Tappo
21 Τάπα Tapón Bouchon čep Tappo
23 Τάπα Tapón Bouchon čep Tappo
25 Τάπα αποστράγγισης Tapón purga Bouchon de vidange čep za pražnjenje Tappo spurgo
26 Κοχλίες συγκράτησης Espárrago sujeción Goujon sprežni vijak Tiranti
26a Τιράντα Tirante Tirant d’assemblage zatezna traka Tirante
26b Κοχλίας Tornillo Vis vijak Vite
26c Ροδέλα Arandela Rondelle podložna pločica Rondella
32a Ροδέλα Arandela Rondelle podložna pločica Rondella
36 Περικόχλιο Tuerca Ecrou matica Dado
36a Περικόχλιο Tuerca Ecrou matica Dado
37 Δακτύλιος-Ο/παρέμβυσμα Junta tórica/junta Joint/bague O-prsten/brtva O ring/guranizione
38 Δακτύλιος-Ο Junta tórica Joint O-prsten O ring
38a Δακτύλιος-Ο Junta tórica Joint O-prsten O ring
44 Πλήρες εσωτερικό μέρος Parte aspiración completa Partie aspiration complète ulazni dio kompletan Parte interna completa
45 Δακτύλιος λαιμού Anillo tope Bague d’étanchéité rascijepljeni prsten Collarino
45a Δακτύλιος λαιμού πλήρης Anillo tope completo Bague d’étanchéité complète rascijepljeni prsten kompletan Colalrino completo
47 Δακτύλιος εδράνου Anillo cojinete Bague de palier prsten ležaja Cuscinetto
47a Εδρανο με οδηγό Cojinete con engranaje Bague de palier avec driver prsten ležaja sa zahvatnikom Cuscinetto con guida
Δακτύλιος εδράνου
47b Anillo cojinete giratorio Bague de palier tournante prsten ležaja, rotirajući Cuscinetto rotante
στρεφόμενος
47c Φωλιά Manguito Douille tuljak Boccola
47d Δακτύλιος συγκράτησης Anillo cierre Bague de blocage pridržni prsten Anello di arresto
47e Δακτύλιος συγκράτησης Anillo cierre Bague de blocage pridržni prsten Anello di arresto
Περικόχλιο διαιρούμενου
48 Tuerca casquillo cónico Ecrou de cône de serrage matica za konusni prsten Dado bussola conica
κώνου
49 Πτερωτή Impulsor Roue rotor Girante
49a Πτερωτή Impulsor Roue rotor Girante
49b Διαιρούμενος κώνος Casquillo cónico Cône de serrage konusni prsten Bussola conica
49c Δακτύλιος φθοράς Anillo desgaste Bague d’usure potrošni prsten Anello di usura
51 Αξονας αντλίας Eje bomba Arbre de pompe vratilo crpke Albero pompa
55 Εξωτερικό χιτώνιο Camisa exterior Chemise plašt Camicia esterna
56 Πλάκα βάσης Placa base Plaque de base osnovna ploča Basamento
56a Πλάκα βάσης Placa base Plaque de base osnovna ploča Basamento
56c Κοχλίας Tornillo Vis vijak Vite
56d Ροδέλα Arandela Rondelle podložna pločica Rondella
58 Φορέας στυπιοθλίπτη Soporte cierre Toc d’entraînement držač brtve Porta tenuta
60 Ελατήριο Muelle Ressort opruga Molla
61 Οδηγός στεγανοποιητικού Guía de cierre Toc d’entrainement zahvatnik Guida guarnizione
62 Τερματικός δακτύλιος anillo de tope Bague d’arrêt zaustavni prsten Anello di arresto
64 Αποστάτης Casquillo espaciador Douille d’entretoise odstojnik Tubo distanziale
64a Αποστάτης Casquillo espaciador Douille d’entretoise odstojnik Tubo distanziale
64c Στεφάνη με εγκοπές Casquillo ranurado Pièce de serrage zatezni komad, višeutorni Giunto
64d Αποστάτης Casquillo espaciador Douille entretoise odstojnik Tubo distanziale
65 Στήριγμα δακτυλίου λαιμού Retén anillo junta Support pour bague d’étanchéité držač za rascijepljeni prsten Fermo per collarino
25
Appendix
Designation
Pos.
GR ES FR HR IT
66 Ροδέλα Arandela Rondelle podložna pločica Rondella
66a Ροδέλα Arandela Rondelle podložna pločica Rondella
66b Συγκράτηση ροδέλας Arandela cierre Rondelle de blocage sigurnosna pločica Blocco per rondella
67 Περικόχλιο/Κοχλίας Tuerca/Tornillo Ecrou/Vis matica/vijak Dado/Vite
69 Αποστάτης Casquillo espaciador Douille entretoise odstojnik Tubo distanziale
76 Σετ πινακίδας Juego placa identificación Plaque d’identification natpisne pločice Targhetta
105 Στυπιοθλίπτης Cierre Garniture mécanique brtva vratila Tenuta meccanica
201 Φλάντζα Brida Bride prirubnica Flangia
203 Δακτύλιος συγκράτησης Anillo cierre Bague de blocage pridržni prsten Blocca flangia
Designation
Pos.
KZ LT HU NL UA
1 Аралық фланец Tarpinis flanšas csatlakozó karima Adapterflens Перехідник
1a Шам Variklio atrama motortartó közdarab Lantaarnstuk Опора електродвигуна
2 Сорғының жоғарғы бөлігі Siurblio galvutė szivattyúfej Pompkop Головна частина насоса
3 Жоғарғы камера Viršutinė kamera felső kamra Bovenste kamer Камера, верх
Камера без
3a Саңылаусыз тығыздау камерасы Kamera be kaklelio žiedo közkamra résgyűrű nélkül Kamer zonder spaltring
ущільнювального кільця
4 Жинақталған камера Kamera komplett közkamra Kamer compleet Набір камер
Камера з кільцем
4a Подшипник сақинасы бар камера Kamera su guolio žiedu csapágyas közkamra Kamer met lager
підшипника
5a Жинақталған камера Kamera komplett közkamra Kamer compleet Набір камер
6 Табаны Korpusas talp Voetstuk Основа
6a Ұстағыш штифт Fiksatorius rögzítő tüske Anti rotatie stift Штифт зупинки
Тіреулердің/аяқтардың бағыттағыш Направляюча плита для
6d Korpuso centravimo plokštelė áramlásrendező tányér Geleideplaat voor voetstuk
плитасы основи
6g Подшипник сақина Atraminis guolis csapágygyűrű Lager Кільце опори
7 Қорғағыш қаптама Movos apsauga tengelykapcsoló burkolat Koppeling beschermer Захисний кожух
7a Винт Varžtas csavar Schroef Гвинт
8 Жинақталған муфта Visa mova komplett tengelykapcsoló Koppeling compleet Муфта в сборі
9 Винт Varžtas csavar Schroef Гвинт
10 Цилиндрлі штифт Veleno kaištis tengelyretesz Stift Штифт валу
Гвинт вентиляційного
18 Желдету саңылауының винті Oro išleidimo angos varžtas légtelenítő csavar Ontluchtings-schroef
клапана
19 Тығын Vamzdžio kamštelis karima zárócsavar Plug Трубна заглушка
21 Тығын Kamštelis zárócsavar Plug Кабельний ввід
23 Тығын Kamštelis zárócsavar Plug Кабельний ввід
25 Ағызу саңылауының тығыны Skysčio išleidimo kamštelis ürítőcsavar Aftapplug Пробка дренажного отвору
26 Тарту бұрандасы Sąvarža összefogó rúd Trekstag Шпилька
26a Тартқыш бау Juostinė apkaba összefogó pánt Spanband Стрічка
26b Винт Varžtas csavar Schroef Гвинт
26c Шайба Poveržlė távtartó Sluitring Шайба
32a Шайба Poveržlė távtartó Sluitring Шайба
36 Гайка Veržlė csavaranya Moer Гайка
36a Гайка Veržlė csavaranya Moer Гайка
Дөңгелек қималы тығыздағыш сақина/ Ущільнювальне
37 Žiedas/tarpiklis O-gyűrű/tömítés O-ring pakking
аралық қабат кільце/прокладка
38 Дөңгелек қималы тығыздағыш сақина Žiedas O-gyűrű O-ring Ущільнювальне кільце
38a Дөңгелек қималы тығыздағыш сақина Žiedas O-gyűrű O-ring Ущільнювальне кільце
44 Жиналған сорғыш қуыстағы бөлшек Visa įsiurbimo dalis komplett belső rész Inlaatdeel compleet Всмоктуюча частина повна
45 Саңылау тығыздағыш Kakliuko žiedas résgyűrű Spaltring Ущільнювальне кільце
Ущільнювальне кільце
45a Жинақталған саңылау тығыздағыш Visas kakliuko žiedas komplett résgyűrű Spaltring compleet
повне
47 Подшипник сақинасы Guolis csapágygyűrű Lager Кільце опори
47a "Жібі бар" подшипник Įstatoma guolis csapágy, megvezetővel Lager met meenemer Опора з двигуном
Кільце опори, що
47b Подшипниктің айналғыш сақинасы Besisukantis guolis csapágygyűrű, forgórész Lager roterend
обертається
47c Втулка Įvorė persely Bus Втулка
47d Ұстағыш сақина Laikantysis žiedas rögzítő gyűrű Borgring Стопорне кільце
47e Ұстағыш сақина Laikantysis žiedas rögzítő gyűrű Borgring Стопорне кільце
48 Қысқыш втулка гайкасы Skelta kūginė veržlė szorítókúp anya Klembusmoer Гайка для розтискної втулки
49 Жұмыс дөңгелегі Darbaratis járókerék Waaier Робоче колесо
49a Жұмыс дөңгелегі Darbaratis járókerék Waaier Робоче колесо
49b Босату втулкасы Skelta kūginė įvorė szorítókúp Klembus Розтискна втулка
Кільце щілинного
49c Антифрикциялық сақина Dėvėjimosi žiedas kopógyűrű Slijtring
ущільнення
51 Сорғы білігі Siurblio velenas szivattyú tengely Pompas Вал насоса
55 Қаптама Išorinis cilindras köpenycső Mantel Зовнішня втулка
56 Астыңғы плита Korpuso pagrindas alaplap Voetplaat Плита-основа
56a Астыңғы плита Korpuso pagrindas alaplap Voetplaat Плита-основа
56c Винт Varžtas csavar Schroef Гвинт
56d Шайба Poveržlė távtartó Sluitring Шайба
58 Білік тығыздағышының негізгі бөлшегі Riebokšlio laikiklis tömítés zárófedél Houder voor asafdichting Тримач ущільнення
60 Серіппе Spyruoklė rugó Veer Пружина
61 Бүйірлік тығыздау серіппесі Riebokšlio tarpiklis vezető gyűrű Meenemer Оправлення ущільнення
62 Ұстағыш сақина Fiksavimo žiedas stopgyűrű Stopring Стопорне кільце
64 Аралық втулка Tarpinė įvorė távtartó gyűrű Afstandsbus Втулка
64a Аралық втулка Tarpinė įvorė távtartó gyűrű Afstandsbus Втулка
64c Тісті қысқыш гильза Apkaba, skelta hornyos rögzítógyűrű Spanstuk, splined Шлицевий хомут
64d Аралық втулка Tarpinė įvorė távtartó gyűrű Afstandsbus Втулка
Саңылау тығыздағышының негізгі Фіксатор ущільнювального
65 Kakliuko žiedo laikiklis résgyűrű rögzítő Houder voor spaltring
бөлшегі кільця
26
Appendix
Designation
Pos.
KZ LT HU NL UA
66 Шайба Poveržlė távtartó Sluitring Шайба
66a Шайба Poveržlė távtartó Sluitring Шайба
66b Ұстағыш шайба Fiksuojamoji poveržlė rögzítő alátét Borgring Стопорна шайба
67 Гайка/ винт Fiksuojamoji veržlė/Varžtas csavaranya/csavar Moer/Schroef Гайка/гвинт
69 Аралық втулка Tarpinė įvorė távtartó gyűrű Afstandsbus Втулка
Жинақталған техникалық параметрлері
76 Vardinė plokštelė adattábla készlet Typeplaat set Шилдик насоса
бар фирмалық тақташа
105 Білік тығыздағышы Riebokšlis tengelytömítés Asafdichting Торцеве ущільнення валу
201 Фланец Flanšas karima Flens Фланець
203 Ұстағыш сақина Laikantysis žiedas rögzítő gyűrű Borgring Стопорне кільце
Designation
Pos.
PL PT RU RO SK
1 Kołnierz przejściowy Flange do adaptador Промежуточный фланец Flanşa de adaptare Medzipríruba
1a Podstawa silnika Adaptador do motor Фонарь Scaunul motorului Lucerna
2 Głowica pompy Cabeça da bomba Головная часть насоса Capul pompei Horné teleso čerpadla
3 Komora górna Câmara superior Верхняя камера Camera superioară Horná komora
3a Komora bez pierścienia bieżnego Câmara sem aro Камера без щелевого уплотнения Camera fără inel de uzură Komora bez rozperného krúžka
4 Komora, kompletna Câmara completa Камера в сборе Camera completă Kompletná komora
Komora z pierścieniem
4a Câmara com casquilho Камера с подшипниковым кольцом Camera cu lagăr Komora s ložiskovým krúžkom
oporowym łożyska
5a Komora, kompletna Câmara completa Камера в сборе Camera completă Kompletná komora
6 Podstawa Base Основание Baza pompei Spodné teleso čerpadla
6a Kołek ustalający Pino Стопорный штифт Ştift de blocare Uzáverný kolík
Placa de ghidaj pentru Vodiaca platňa pre spodné
6d Dolna płyta kierująca Prato-guia da base Направляющая плита для опоры/лапы
baza pompei teleso
6g Pierścień oporowy łożyska Casquilho Подшипниковое кольцо Lagăr Ložiskový krúžok
7 Osłona sprzęgła Protecção do acoplamento Защитный кожух Apărătoare de protecţie Ochranný kryt spojky
7a Śruba Parafuso Винт Şurub Skrutka
8 Sprzęgło, komplet Acoplamento completo Муфта в сборе Cuplaj complet Kompletná spojka
9 Śruba Parafuso Винт Şurub Skrutka
10 Klin mocujący wału Pino do veio Цилиндрический штифт Ştiftul axului Zylindrický kolík
18 Śruba odpowietrzająca Parafuso de purga Винт вентиляционного отверстия Şurub de aerisire Odvzdušňovacia skrutka
19 Korek Bujão da tubagem Заглушка Dop filetat pentru ţeavă Zátka
21 Korek Bujão da tubagem Заглушка Dop Zátka
23 Korek Bujão da tubagem Заглушка Dop Zátka
25 Korek spustowy Bujão de drenagem Заглушка сливного отверстия Dop (buşon) de golire Vypúšt’acia skrutka
26 Śruba ściągająca Perno Стяжной болт Prezoane St’ahovacie skrutky
26a Ściąg Tirante Стяжная лента Clemă St’ahovacie spony
26b Śruba Parafuso Винт Şurub Skrutka
26c Podkładka Anilha Шайба Şaibă Podložka
31 Śruba Parafuso Śruba Şurub Skrutka
32a Podkładka Anilha Шайба Şaibă Podložka
36 Nakrętka Fêmea Гайка Piuliţă Matica
36a Nakrętka Fêmea Гайка Piuliţă Matica
Уплотнительное кольцо круглого сечения/
37 Pierścień O-ring/uszczelka O-ring/junta O-ring/garnitură O-krúžok/tesnenie
прокладка
38 Pierścień O-ring O-ring Уплотнительное кольцо круглого сечения O-ring O-krúžok
38a Pierścień O-ring O-ring Уплотнительное кольцо круглого сечения O-ring O-krúžok
44 Komora wlotowa Aspiração completa Деталь всасывающей полости в сборе Parte de intrare completă Vtoková čast’ komplet
45 Pierścień bieżny Aro Щелевое уплотнение Inel de etanşare Tesniaci krúžok
45a Pierścień bieżny, obrotowy Aro completo Щелевое уплотнение в сборе Inel de etanşare complet Tesniaci krúžok komplet
47 Pierścień oporowy łożyska Casquilho Кольцо подшипника Lagăr Ložiskový krúžok
47a Łożysko z zabierakiem Casquilho com guia Подшипник с "поводком" Lagăr cu cuzinet Ložisko s unášačom
47b Pierścień łożyskowy Casquilho rotativo Вращающееся кольцо подшипника Lagăr rotativ Ložiskový krúžok, rotujúci
47c Tulejka Manga Втулка Bucşa Medzikrú-žok/vložka
47d Pierścień mocujący Retentor Стопорное кольцо Inel de blocare Držný krúžok
47e Pierścień mocujący Retentor Стопорное кольцо Inel de blocare Držný krúžok
48 Nakrętka tulei stożkowej Fêmea cónica Гайка для зажимной втулки Piuliţă cu strângere pe con Matica so st’ahovacou vložkou
49 Wirnik Impulsor Рабочее колесо Rotor Obežné koleso
49a Wirnik Impulsor Рабочее колесо Rotor Obežné koleso
49b Tuleja stożkowa Casquilho cónico Разжимная втулка Con de strângere St’ahovacia vložka
49c Pierścień bieżny Aro de desgaste Антифрикционное кольцо Inel de uzură Uzatvárací krúžok
51 Wał pompy Veio Вал насоса Axul pompei Hriadeľ
55 Płaszcz Camisa exterior Кожух Manta exterioară Plášt’
56 Podstawa Base Плита-основание Placa de bază Základová platňa
56a Podstawa Base Плита-основание Placa de bază Základová platňa
56c Śruba Parafuso Śruba Şurub Skrutka
56d Podkładka Anilha Шайба Şaibă Podložka
58 Mocowanie uszczelnienia Suporte do empanque Базовая деталь уплотнения вала Suport pentru etanşare Držiak upchávky hriadeľa
60 Sprężyna Mola Пружина Arc Spružina
Distanţier pentru etanşarea
61 Zabierak Batente do espaçador Пружина торцового уплотнения Unášač
mecanică
62 Pierścień stopowy Mola de encosto Стопорное кольцо Semering Dorazový krúžok
64 Tulejka dystansowa Espaçador Промежуточная втулка Tub distanţier Dištančné puzdro
64a Tulejka dystansowa Espaçador Промежуточная втулка Tub distanţier Dištančná puzdro
64c Tulejka wielowypustowa Casquilho escatelado Шлицевая зажимная гильза Suport canelat Španovací kus, drážkovaný
64d Tulejka dystansowa Espaçador Промежуточная втулка Tub distanţier Dištančné puzdro
65 Tulejka dystansowa Retentor do aro Базовая деталь щелевого уплотнения Suport pentru inelul de Držiak pre tesniaci krúžok
etanşare
27
Appendix
Designation
Pos.
PL PT RU RO SK
66 Podkładka Anilha Шайба Şaibă Podložka
66a Podkładka Anilha Шайба Şaibă Podložka
66b Podkładka zabezpieczająca Anilha retentora Стопорная шайба Şaibă de blocare Zaist’ovací plech
67 Nakrętka/Śruba Fêmea/Parafuso Гайка/Śruba Piuliţă/Şurub Matica/Skrutka
69 Tulejka dystansowa Espaçador Промежуточная втулка Tub distanţier Dištančné puzdro
Фирменная табличка с техническими
76 Tabliczka znamionowa Chapa de identificação Eticheta Štítok čerpadla
параметрами в сборе
105 Uszczelnienie wału Empanque mecânico Уплотнение вала Etanşare mecanică Upchávka hriadeľa
201 Kołnierz Flange Фланец Flanşa Príruba
203 Pierścień mocujący Anel retentor Стопорное кольцо Inel de blocare Tesniaci krúžok/tesnenie
Designation
Pos.
SI RS FI SE TR
1 Vmesna prirobnica Prirubnica podešavanja Välilaippa Mellanfläns Küçültme flanşı
1a Konzola motorja Oslonac motora Moottorin jalusta Mellanstycke Motor oturağı
2 Glava črpalke Glava pumpe Pumppupää Toppstycke Pompa başı
3 Najvišja stopnja Gornje kućište Pesä/ylin Kammare, övre Bölme, üst
Mallankammare utan
3a Stopnja brez režnega obroča Kućište bez oslonog prstena Pesä, ilman kaularengasta Boyun halkasız bölme
tätningsring
4 Stopnja komplet Kompletno kućište Täydellinen pesä Kammare komplett Komple bölme
4a Stopnja z ležajnim obročem Kućište sa ležišnim prstenom Pesä laakerirenkailla Mellankammare med lager Yatak halkalı bölme
5a Stopnja komplet Kompletno kućište Täydellinen pesä Kammare komplett Komple bölme
6 Podnožje črpalke Element oslonca Jalkakappale Fotstycke Taban
6a Zaporni zatič Zaustavni štift Pidätintappi, lukitustappi Stoppsprint Stop pimi
6d Vodilna plošča za podnožje črpalke Vodeća ploča osnove Ohjauslevy jalustaan Styrplatta till fotstycke Taban için kılavuz plakası
6g Ležajni obroč Prsten kugličnog ležaja Laakerirengas Bottenlager Yatak halkası
7 Zaščitni pokrov Zaštita spojnice Kytkimen suoja Kopplingsskärm Kaplin koruması
7a Vijak Zavrtanj Ruuvi Skruv Vida
8 Sklopka komplet Komplet spojnice Täydellinen kytkin Koppling komplett Komple kaplin
9 Vijak Zavrtanj Ruuvi Skruv Vida
10 Cilindrični zatič Cilindrični štift Akselitappi Cylinderstift Şaft pimi
18 Odzračevalni vijak Zavrtanj za odzračivanje Ilmausruuvi Luftskruv Hava tahliye vidası
19 Čep Žep cevi Putkitulppa Rörpropp Boru tapası
21 Čep Čep Tulppa Propp Tapa
23 Čep Čep Tulppa Propp Tapa
25 Izpraznjevalni čep Drenažni čep Tyhjennystulppa Tömningspropp Tahliye tapası
26 pritrjevalni vijak Osnovni zavrtanj Pinnapultti Stödbult Germe civatası, saplama
26a Zatezni pas Osigurač Haka (säppi) Spännband Şerit
26b Vijak Zavrtanj Ruuvi Skruv Vida
26c Podložka Podloška Aluslevy Bricka Pul
32a Podložka Podloška Aluslevy Bricka Pul
36 Matica Matica Mutteri Mutter Somun
36a Matica Matica Mutteri Mutter Somun
37 O-tesnilo/ tesnilo O-zaptivni prsten O-rengas tiiviste O-ring/packning O-ring/conta
38 O-tesnilo O-prsten O-rengas O-ring O-ring
38a O-tesnilo O-prsten O-rengas O-ring O-ring
44 Vstopni del komplet Komplet ulazni deo Täydellinen sisäosa Inloppsdel komplett Komple emme kısmı
45 Režni obroč Osloni prsten Kaularengas Tätningsring Boyun halkası
45a Režni obroč komplet Komplet oslonog prstena Täydellinen kaularengas Tätningsring, komplett Komple boyun halkası
47 Ležajni obroč Prsten kugličnog ležaja Laakerirengas Lager Yatak halkası
47a Ležaj z nosilcem Kuglični ležaj sa prstenom Ohjainlaakeri Lager med medbringare Sürücülü yatak halkası
47b Ležajni obroč, rotirajoč Kuglični ležaj rotirajući Laakerirengas, pyörivä Lagerring, roterande Yatak halkası, döner
47c Puša Čaura Holkki Bussning Burç
47d Držalni obroč Noseći prsten Lukitusrengas Låsbricka Tespit halkası
47e Držalni obroč Noseći prsten Lukitusrengas Låsbricka Tespit halkası
48 Matica za pritrdilno pušo Matica konusne čaure Kartioholkki mutteri Mutter för klämbussning Yarık koni somunu
49 Rotor črpalke Obrtno kolo pumpe Juoksupyörä Pumphjul Kanat
49a Rotor črpalke Obrtno kolo pumpe Juoksupyörä Pumphjul Kanat
49b Pritrdilna puša Konusna čaura Kartioholkki Klämbussning Kapalı somun
49c Obrabni obroč Habajući prsten Kulutusrengas Slitring Aşınma halkası
51 Os črpalke Osovina pumpe Pumppuakseli Pumpaxel Mil
55 Plašč Spoljna zaštita Ulompi vaippa Mantel Dış ceket
56 Osnovna plošča Osnovna ploča Jalustalevy Fotstycke Şase
56a Osnovna plošča Osnovna ploča Jalustalevy Fotstycke Şase
56c Vijak Zavrtanj Ruuvi Skruv Vida
56d Podložka Podloška Aluslevy Bricka Pul
58 Držalo drsnega tesnila Kućište zaptivanja osovine Tiivistekannatin Hållare för axeltätning Salmastra taşıyıcı
60 Vzmet Opruga Jousi Fjäder Yay
61 Gonilo tesnila Pogonaš zaptivaca Tiivisteen vetotappi Medbringare Salmastra yuvası
62 Stop prstan Zaustavni prsten Pysäytinrengas Stoppring Kitleme somunu
64 Distančnik Odstojna čaura Väliholkki Avståndsbussning Ayar ara parçası
64a Distančnik Odstojna čaura Väliholkki Avståndsbussning Ayar ara parçası
64c Natezni kos, utorni Osigurač saumetkom Kiristin, rihlattu Avståndsbussning (spline) Kelepçe boru
64d Distančnik Odstojna čaura Väliholkki Avståndsbussning Ayar ara parçası
65 Držalo režnega obroča Držač oslonog prstena Kaulusrenkaan pidin Hållare för tätningsring Boğaz aşınma halkası
28
Appendix
Designation
Pos.
SI RS FI SE TR
66 Podložka Podloška Aluslevy Bricka Pul
66a Podložka Podloška Aluslevy Bricka Pul
66b Varnostna podložka Osiguravajuća podloška Lukitusaluslevy Låsbricka Kitleme pulu
67 Matica/Vijak Matica/Zavrtanj Mutteri/Ruuvi Mutter/Skruv Somun/Vida
69 Distančnik Odstojna čaura Väliholkki Avståndsbussning Ayar ara parçası
76 Tipska ploščica Pločica označavanja Arvokilpisarja Typskylt Etiket
105 Drsno tesnilo Zaptivač osovine Akselitiiviste Axeltätning Mekanik salmastra
201 Prirobnica Prirubnica Laippa Fläns Flanş
203 Držalni obroč Osloni prsten Lukitusrengas Låsbricka Tutucu halka
29
CR, CRI, CRN 1s, 1, 3 and 5
Appendix
50a
51
36a
10a
8 9
10 49
64
105 65
4 45
7a
2 2 7 2
100 28 18
23 100 49
28 36
66a 64a
65
7
76a 4a 45
7a 76
60 26 47a
77 77
49
64c
37
66
67
65
5a 45
55
6 6
37
38
35 12 39 25
203
201
6 6 6
38 25
TM02 0455 3403
56 56 56
30
CR, CRI, CRN 10, 15 and 20
Appendix
36a 51
62
61
69
10a
8 9 3
10
49
49c
10a
1 8 9 64
10
65
28a 45 4
105
18
2 2 2
100
28 36
23 66a
100 49
7 49c
76a
7 7a 76 64
65
26
45 4
77 77
60
37
80
49
49c
64a
65
45 4a
55
47a
37 64d
49
6 6 49c
38a
64b
25 64c
39 66
38 67
12
35 65
45 44a
203
201
6 6 6 26a
38a
25 44b
TM02 7383 3403
26c
38
26b
56 56 56
31
CR, CRN 32, 45, 64 and 90
Appendix
48
49b
49
28a 49c
51
65
26b 45 45a
26c
9
7 8
4
3
47c
47d
7a 47c
1a 47d
26a
48
28
49b
36a 7a
48 49
7 49b 49c
65
7a 49a
58a 49c
105 45 45a
58
36 65 44
66a
76 45 45a
100 2
18 23
100 4a
37
60
47 47b 51
26 47e 66
66b
47a 67
37
55
31
32
6g
21
6
38a
31 38
32
6g
21
38a 6
21 38
38a 203 201 25
TM01 9996 3600
25
38
25
203 201 56
32
CR, CRN 120 and 150
TM03 6001 4106
33
Appendix
Appendix
7
5
3
1
34
Start-up
Appendix
TM01 1409 4497 TM01 1407 4497 TM01 1405 4497 TM01 1403 4497
8
6
4
2
?
TM01 9988 3600 TM01 1408 4497 TM01 1406 4497 TM01 1404 4497
1
Appendix
GB Start-up
1 2
Close the isolating valve on the discharge side of the pump and Remove the priming plug from the pump head and slowly fill the
open the isolating valve on the suction side. pump with liquid. Replace the priming plug and tighten securely.
3 4
See the correct direction of rotation of the pump on the motor fan Start the pump and check the direction of rotation.
cover.
5 6
Vent the pump by means of the vent valve in the pump head. At the Continue to vent the pump. At the same time, open the discharge
same time, open the discharge isolating valve a little. isolating valve a little more.
7 8
Close the vent valve when a steady stream of liquid runs out of it. For further information, see page 11.
Completely open the discharge isolating valve.
BG Пускане в действие
1 2
Затваря се спирателния кран на напорната страна, а този на Демонтира се пробката за пълнене и помпата бавно се пълни.
смукателната се отваря.
3 4
Вижте правилната посока на въртене на капака на мотора. Включете помпата и проверете правилността на посоката на
въртене.
5 6
Обезвъздушете през обезвъздушителния вентил като Продължете да обезвъздушавате като отваряте крана на
същевременно малко отворете крана на напорната страна. напорната страна повече.
7 8
Затворете обезвъздушителния вентил, когато от него протече За повече информация виж страница 25.
флуид. Отворете изцяло крана на напорната страна.
CZ Uvedení do provozu
1 2
Uzavřete uzavírací armaturu na výtlačné straně čerpadla Z hlavy čerpadla vyšroubujte plnicí zátku a do čerpadla pomalu
a otevřete uzavírací armaturu na sací straně čerpadla. nalévejte kapalinu.
Plnící zátku vrat’te na své místo a pevně utáhněte.
3 4
Podle šipky na krytu ventilátoru motoru čerpadla zjistěte směr Zapněte čerpadlo a zkontrolujte, zda směr otáčení odpovídá směru
otáčení hřídele čerpadla. uvedenému na krytu ventilátoru motoru.
5 6
Čerpadlo odvzdušněte pomocí odvzdušňovacího ventilu Pokračujte v odvzdušňování čerpadla. Současně otevřete poněkud
umístěného ve hlavě čerpadla. Současně mírně pootevřete více uzavírací armaturu na výtlačné straně čerpadla.
uzavírací armaturu na výtlačné straně čerpadla.
7 8
Odvzdušňovací ventil uzavřete, jakmile jím začne vytékat kapalina Další informace viz str. 37.
bez vzduchu. Otevřete naplno uzavírací armaturu na výtlačné
straně čerpadla tak, abyste dosáhli pracovního bodu čerpadla.
DK Idriftsætning
1 2
Luk afspærringsventilen på pumpens afgangsside og åbn Afmontér spædeproppen i topstykket og spæd pumpen langsomt.
afspærringsventilen på pumpens tilgangsside. Montér derefter spædeproppen igen.
3 4
Se pumpens korrekte omdrejningsretning på motorens Start pumpen og kontrollér pumpens omdrejningsretning.
ventilatorskærm.
5 6
Udluft pumpen på udluftningsventilen, som er placeret i topstykket. Fortsæt med at udlufte pumpen. Åbn samtidig afspærringsventilen
Åbn samtidig afspærringsventilen på pumpens afgangsside lidt. på pumpens afgangsside lidt mere.
7 8
Luk udluftningsventilen, når der løber en jævn væskestrøm ud af For yderligere information, se side 49.
den. Åbn afspærringsventilen på pumpens afgangsside helt.
DE Inbetriebnahme
35
Declaration of conformity 2
Declaration of conformity
GB: EC declaration of conformity BG: EC декларация за съответствие

We, Grundfos, declare under our sole responsibility that the products Ние, фирма Grundfos, заявяваме с пълна отговорност, че продуктите
CR, CRI and CRN, to which this declaration relates, are in conformity CR, CRI и CRN, за които се отнася настоящата декларация,
with these Council directives on the approximation of the laws of the отговарят на следните указания на Съвета за уеднаквяване на
EC member states: правните разпоредби на държавите членки на ЕС:
— Machinery Directive (2006/42/EC). — Директива за машините (2006/42/EC).
Standard used: EN 809:1998, A1:2009. Приложени стандарти: EN 809:1998, A1:2009.
— EMC Directive (2004/108/EC). — Директива за електромагнитна съвместимост (2004/108/EC).
— Ecodesign Directive (2009/125/EC). — Директива за екодизайн (2009/125/EC).
Electric motors: Електродвигатели:
Commission Regulation No 640/2009. Наредба No 640/2009 на Европейската комисия.
Applies only to three-phase Grundfos motors marked IE2 or IE3. Отнася се само за трифазни електродвигатели на Grundfos,
See motor nameplate. маркирани с IE2 или IE3. Вижте табелата с данни на двигателя.
Standard used: EN 60034-30:2009. Приложен стандарт: EN 60034-30:2009.
— Ecodesign Directive (2009/125/EC). — Директива за екодизайн (2009/125/EC).
Water pumps: Водни помпи:
Commission Regulation No 547/2012. Наредба No 547/2012 на Европейската комисия.
Applies only to water pumps marked with the minimum efficiency Отнася се само за водни помпи, маркирани с минималният
index MEI. See pump nameplate. индекс за ефективност MEI. Вижте табелата с данни на помпата.
This EC declaration of conformity is only valid when published as part of Тази ЕС декларация за съответствие е валидна само когато е
the Grundfos installation and operating instructions публикувана като част от инструкциите за монтаж и експлоатация на
(publication number 96462123 0914). Grundfos (номер на публикацията 96462123 0914).
CZ: ES prohlášení o shodě DK: EF-overensstemmelseserklæring

My firma Grundfos prohlašujeme na svou plnou odpovědnost, že výrobky Vi, Grundfos, erklærer under ansvar at produkterne CR, CRI og CRN
CR, CRI a CRN, na něž se toto prohlášení vztahuje, jsou v souladu som denne erklæring omhandler, er i overensstemmelse med disse af
s ustanoveními směrnice Rady pro sblížení právních předpisů členských Rådets direktiver om indbyrdes tilnærmelse til EF-medlemsstaternes
států Evropského společenství v oblastech: lovgivning:
— Směrnice pro strojní zařízení (2006/42/ES). — Maskindirektivet (2006/42/EF).
Použité normy: EN 809:1998, A1:2009. Anvendte standarder: EN 809:1998, A1:2009.
— Směrnice pro elektromagnetickou kompatibilitu (EMC) — EMC-direktivet (2004/108/EF).
(2004/108/ES). — Ecodesigndirektivet (2009/125/EF).
— Směrnice o ekodesignu (2009/125/ES). Elektriske motorer:
Elektrické motory: Kommissionens forordning nr. 640/2009.
Nařízení Komise č. 640/2009. Gælder kun 3-fasede Grundfos-motorer der er mærket IE2 eller IE3.
Platí pouze pro třífázové motory Grundfos označené IE2 nebo IE3. Se motorens typeskilt.
Viz typový štítek motoru. Anvendt standard: EN 60034-30:2009.
Použitá norma: EN 60034-30:2009. — Ecodesigndirektivet (2009/125/EF).
— Směrnice o ekodesignu (2009/125/ES). Vandpumper:
Vodní čerpadla: Kommissionens forordning nr. 547/2012.
Nařízení Komise č. 547/2012. Gælder kun vandpumper der er mærket med
Vztahuje se pouze na vodní čerpadla označená minimální účinností mindsteeffektivitetsindekset MEI. Se pumpens typeskilt.
index MEI. Viz typový štítek čerpadla. Denne EF-overensstemmelseserklæring er kun gyldig når den publiceres
Toto ES prohlášení o shodě je platné pouze tehdy, pokud je zveřejněno som en del af Grundfos-monterings- og driftsinstruktionen
jako součást instalačních a provozních návodů Grundfos (publikationsnummer 96462123 0914).
(publikace číslo 96462123 0914).
DE: EG-Konformitätserklärung EE: EL vastavusdeklaratsioon

Wir, Grundfos, erklären in alleiniger Verantwortung, dass die Produkte Meie, Grundfos, deklareerime enda ainuvastutusel, et tooted CR, CRI ja
CR, CRI und CRN, auf die sich diese Erklärung bezieht, mit den CRN, mille kohta käesolev juhend käib, on vastavuses EÜ Nõukogu
folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften direktiividega EMÜ liikmesriikide seaduste ühitamise kohta, mis
der EU-Mitgliedsstaaten übereinstimmen: käsitlevad:
— Maschinenrichtlinie (2006/42/EG). — Masinate ohutus (2006/42/EC).
Normen, die verwendet wurden: EN 809:1998, A1:2009. Kasutatud standardid: EN 809:1998, A1:2009.
— EMV-Richtlinie (2004/108/EG). — Elektromagnetiline ühilduvus (EMC direktiiv) (2004/108/EC).
— ErP-Richtlinie (2009/125/EG). — Ökodisaini direktiiv (2009/125/EC).
Elektromotoren: Elektrimootorid:
Verordnung der Europäischen Kommission Nr. 640/2009. Komisjoni regulatsioon nr 640/2009.
Gilt nur für dreiphasige Motoren von Grundfos mit der Kennzeich- Kehtib ainult IE2- või IE3-märgisega Grundfosi kolmefaasiliste
nung IE2 bzw. IE3. Siehe Typenschild des Motors. mootorite kohta. Vaata mootori sildilt.
Norm, die verwendet wurde: EN 60034-30:2009. Kasutatud standard: EN 60034-30:2009.
— ErP-Richtlinie (2009/125/EG). — Ökodisaini direktiiv (2009/125/EC).
Wasserpumpen: Veepumbad:
Verordnung der Europäischen Kommission Nr. 547/2012. Komisjoni regulatsioon nr 547/2012.
Gilt nur für Pumpen, für die der Mindesteffizienzindex (MEI) Kehtiv ainult veepumpadele, mis on märgitud miinimum kasuteguri
anzugeben ist. Siehe Typenschild der Pumpe. indeksiga MEI. Vaata pumba silti.
Diese EG-Konformitätserklärung gilt nur, wenn sie in Verbindung mit der Käesolev EL-i vastavusdeklaratsioon kehtib ainult siis, kui see
Grundfos Montage- und Betriebsanleitung avaldatakse Grundfosi paigaldus- ja kasutusjuhendi
(Veröffentlichungsnummer 96462123 0914) veröffentlicht wird. (avaldamisnumber 96462123 0914) osana.
42
GR: ∆ήλωση συμμόρφωσης EC ES: Declaración CE de conformidad
Εμείς, η Grundfos, δηλώνουμε με αποκλειστικά δική μας ευθύνη ότι Nosotros, Grundfos, declaramos bajo nuestra entera responsabilidad
τα προϊόντα CR, CRI και CRN στα οποία αναφέρεται η παρούσα δήλωση, que los productos CR, CRI y CRN, a los cuales se refiere esta
συμμορφώνονται με τις εξής Οδηγίες του Συμβουλίου περί προσέγγισης declaración, están conformes con las Directivas del Consejo en la
των νομοθεσιών των κρατών μελών της ΕΕ: aproximación de las leyes de las Estados Miembros del EM:
— Οδηγία για μηχανήματα (2006/42/EC). — Directiva de Maquinaria (2006/42/CE).
Πρότυπα που χρησιμοποιήθηκαν: EN 809:1998, A1:2009. Normas aplicadas: EN 809:1998, A1:2009.
— Οδηγία Ηλεκτρομαγνητικής Συμβατότητας (EMC) (2004/108/EC). — Directiva EMC (2004/108/CE).
— Οδηγία Οικολογικού Σχεδιασμού (2009/125/ΕC). — Directiva sobre diseño ecológico (2009/125/CE).
Ηλεκτρικοί κινητήρες: Motores eléctricos:
Ρύθμιση πρώτης εκκίνησης Νο 640/2009. Reglamento de la Comisión Nº 640/2009.
Ισχύει μόνο σε τριφασικούς κινητήρες της Grundfos με σήμανση Válido sólo para motores trifásicos Grundfos pertenecientes a las
ΙΕ2 ή ΙΕ3. Βλέπε πινακίδα κινητήρα. categorías IE2 e IE3. Véase la placa de características del motor.
Πρότυπο που χρησιμοποιήθηκε: EN 60034-30:2009. Norma aplicada: EN 60034-30:2009.
— Οδηγία Οικολογικού Σχεδιασμού (2009/125/EC). — Directiva sobre diseño ecológico (2009/125/CE).
Αντλίες νερού: Bombas de agua:
Ρύθμιση πρώτης εκκίνησης Νο 547/2012. Reglamento de la Comisión Nº 547/2012.
Ισχύει μόνο για αντλίες νερού που φέρουν τον ελάχιστο δείκτη Aplicable únicamente a las bombas de agua marcadas con el índice
απόδοσης ΜΕΙ. Βλέπε πινακίδα αντλίας. de eficiencia mínima (IEM). Véase la placa de características de la
Αυτή η δήλωση συμμόρφωσης EC ισχύει μόνον όταν συνοδεύει τις bomba.
οδηγίες εγκατάστασης και λειτουργίας της Grundfos Esta declaración CE de conformidad sólo es válida cuando se publique
(κωδικός εντύπου 96462123 0914). como parte de las instrucciones de instalación y funcionamiento de
Grundfos (número de publicación 96462123 0914).
FR: Déclaration de conformité CE HR: EZ izjava o usklađenosti

Nous, Grundfos, déclarons sous notre seule responsabilité, que les Mi, Grundfos, izjavljujemo pod vlastitom odgovornošću da je proizvod
produits CR, CRI et CRN, auxquels se réfère cette déclaration, sont CR, CRI i CRN, na koji se ova izjava odnosi, u skladu s direktivama ovog
conformes aux Directives du Conseil concernant le rapprochement Vijeća o usklađivanju zakona država članica EU:
des législations des Etats membres CE relatives aux normes énoncées — Direktiva za strojeve (2006/42/EZ).
ci-dessous : Korištene norme: EN 809:1998, A1:2009.
— Directive Machines (2006/42/CE). — Direktiva za elektromagnetsku kompatibilnost (2004/108/EZ).
Normes utilisées : EN 809:1998, A1:2009. — Direktiva o ekološkoj izvedbi (2009/125/EZ).
— Directive Compatibilité Electromagnétique CEM (2004/108/CE). Električni motori:
— Directive sur l'éco-conception (2009/125/CE). Uredba Komisije No 640/2009.
Moteurs électriques : Odnosi se samo na trofazne Grundfos motore s oznakama IE2 ili
Règlement de la Commission Nº 640/2009. IE3. Pogledajte natpisnu pločicu motora.
S'applique uniquement aux moteurs triphasés Grundfos marqués Korištena norma: EN 60034-30:2009.
IE2 ou IE3. Voir plaque signalétique du moteur. — Direktiva o ekološkoj izvedbi (2009/125/EZ).
Norme utilisée: EN 60034-30:2009. Crpke za vodu:
— Directive sur l'éco-conception (2009/125/CE). Uredba Komisije No 547/2012.
Pompes à eau : Odnosi se samo na crpke za vodu označene s indeksom minimalne
Règlement de la Commission Nº 547/2012. učinkovitosti MEI. Pogledajte natpisnu pločicu crpke.
S'applique uniquement aux pompes à eau marquées de l'indice de Ova EZ izjava o usklađnosti važeća je jedino kada je izdana kao dio
performance minimum IEM. Voir plaque signalétique de la pompe. Grundfos montažnih i pogonskih uputa (broj izdanja 96462123 0914).
Cette déclaration de conformité CE est uniquement valide lors de sa
publication dans la notice d'installation et de fonctionnement Grundfos
(numéro de publication 96462123 0914).
IT: Dichiarazione di conformità CE KZ: EO сəйкестік туралы мəлімдеме

Grundfos dichiara sotto la sua esclusiva responsabilità che i prodotti Біз, Grundfos компаниясы, барлық жауапкершілікпен, осы
CR, CRI e CRN, ai quali si riferisce questa dichiarazione, sono conformi мəлімдемеге қатысты болатын CR, CRI жəне CRN бұйымдары ЕО
alle seguenti direttive del Consiglio riguardanti il riavvicinamento delle мүше елдерінің заң шығарушы жарлықтарын үндестіру туралы мына
legislazioni degli Stati membri CE: Еуроодақ Кеңесінің жарлықтарына сəйкес келетіндігін мəлімдейміз:
— Direttiva Macchine (2006/42/CE). — Механикалық құрылғылар (2006/42/EC).
Norme applicate: EN 809:1998, A1:2009. Қолданылған стандарттар: EN 809:1998, A1:2009.
— Direttiva EMC (2004/108/CE). — Электр магнитті үйлесімділік (2004/108/EC).
— Direttiva Ecodesign (2009/125/CE). — Қоршаған ортаны қорғауға арналған нұсқау (2009/125/EC).
Motori elettrici: Электр қозғалтқыш:
Regolamento CE n. 640/2009. Еуропалық комиссия регламенті 640/2009.
Applicabile solo ai motori trifase Grundfos contrassegnati IE2 o IE3. IE2 немесе IE3 белгіленген үш фазалы Grundfos моторларына
Vedere la targhetta di identificazione del motore. ғана қолданылады. Қозғалтқыштың техникалық деректері бар
Norma applicata: EN 60034-30:2009. фирмалық тақташаны қараңыз.
— Direttiva Ecodesign (2009/125/CE). Қолданылған стандарт: EN 60034-30:2009.
Pompe per acqua: — Қоршаған ортаны қорғауға арналған нұсқау (2009/125/EC).
Regolamento CE n. 547/2012. Су сорғылар:
Applicabile solo a pompe per acqua con l'indice di efficienza minimo Еуропалық комиссия регламенті 547/2012.
MEI. Vedere la targhetta di identificazione della pompa. Тек минималды тиімділік көрсіткішіпен МТК белгіленген су
Questa dichiarazione di conformità CE è valida solo quando pubblicata сорғыларына арналған. Сорғыдағы фирмалық тақтайшаны
come parte delle istruzioni di installazione e funzionamento Grundfos қараңыз.
(pubblicazione numero 96462123 0914). Бұл EO сəйкестік туралы мəлімдеме тек ғана Грундфос
компаниясының орнату жəне пайдалану нұсқасының бөлімі ретінде
жарамды (баспаға шыққан нөмірі 96462123 0914).
43
LT: EB atitikties deklaracija HU: EK megfelelőségi nyilatkozat

Mes, Grundfos, su visa atsakomybe pareiškiame, kad gaminiai CR, CRI Mi, a Grundfos, egyedüli felelősséggel kijelentjük, hogy a CR, CRI és
ir CRN, kuriems skirta ši deklaracija, atitinka šias Tarybos Direktyvas dėl CRN termékek, amelyekre jelen nyilatkozik vonatkozik, megfelelnek az
Europos Ekonominės Bendrijos šalių narių įstatymų suderinimo: Európai Unió tagállamainak jogi irányelveit összehangoló tanács alábbi
— Mašinų direktyva (2006/42/EB). előírásainak:
Taikomi standartai: EN 809:1998, A1:2009. — Gépek (2006/42/EK).
— EMS direktyva (2004/108/EB). Alkalmazott szabványok: EN 809:1998, A1:2009.
— Ekologinio projektavimo direktyva (2009/125/EB). — EMC Direktíva (2004/108/EK).
Elektros varikliai: — Környezetbarát tervezésre vonatkozó irányelv (2009/125/EK).
Komisijos reglamentas Nr. 640/2009. Villamos motorok:
Taikoma tik trifaziams Grundfos varikliams, pažymėtiems Az Európai Bizottság 640/2009. számú rendelete.
IE2 arba IE3. Žr. variklio vardinę plokštelę. Csak az IE2 vagy IE3 jelzésű háromfázisú Grundfos motorokra
Taikomas standartas: EN 60034-30:2009. vonatkozik. Lásd a motor adattábláját.
— Ekologinio projektavimo direktyva (2009/125/EB). Alkalmazott szabvány: EN 60034-30:2009.
Vandens siurbliai: — Környezetbarát tervezésre vonatkozó irányelv (2009/125/EK).
Komisijos reglamentas Nr. 547/2012. Víz szivattyúk:
Galioja tik vandens siurbliams, ant kurių nurodytas minimalus Az Európai Bizottság 547/2012. számú rendelete.
efektyvumo koeficientas MEI. Žr. siurblio vardinę plokštelę. Csak a MEI minimum hatásfok index-el jelölt víz szivattyúkra
Ši EB atitikties deklaracija galioja tik tuo atveju, kai yra pateikta kaip vonatkozik. Lásd a szivattyú adattábláján.
"Grundfos" įrengimo ir naudojimo instrukcijos Ez az EK megfelelőségi nyilatkozat kizárólag akkor érvényes, ha
(leidinio numeris 96462123 0914) dalis. Grundfos telepítési és üzemeltetési utasítás
(kiadvány szám 96462123 0914) részeként kerül kiadásra.
NL: EC overeenkomstigheidsverklaring UA: Декларація відповідності ЄС

Wij, Grundfos, verklaren geheel onder eigen verantwoordelijkheid dat Компанія Grundfos заявляє про свою виключну відповідальність
de producten CR, CRI en CRN waarop deze verklaring betrekking heeft, за те, що продукти CR, CRI та CRN, на які поширюється дана
in overeenstemming zijn met de Richtlijnen van de Raad in zake de декларація, відповідають таким рекомендаціям Ради з уніфікації
onderlinge aanpassing van de wetgeving van de EG Lidstaten правових норм країн - членів ЄС:
betreffende: — Механічні прилади (2006/42/ЄС).
— Machine Richtlijn (2006/42/EC). Стандарти, що застосовувалися: EN 809:1998, A1:2009.
Gebruikte normen: EN 809:1998, A1:2009. — Електромагнітна сумісність (2004/108/ЄС).
— EMC Richtlijn (2004/108/EC). — Директива з екодизайну (2009/125/ЄС).
— Ecodesign Richtlijn (2009/125/EC). Електродвигуни:
Elektromotoren: Регламент Комісії № 640/2009.
Verordening (EG) Nr. 640/2009 van de Commissie. Застосовується тільки до трифазних електродвигунів Grundfos,
Geldt alleen voor de driefase elektromotoren van Grundfos, aange- позначених IE2 або IE3. Дивіться паспортну табличку
duid met IE2 of IE3. Zie het typeplaatje van de motor. електродвигуна.
Gebruikte norm: EN 60034-30:2009. Стандарти, що застосовувалися: EN 60034-30:2009.
— Ecodesign Richtlijn (2009/125/EC). — Директива з екодизайну (2009/125/ЄС).
Waterpompen: Насоси для води:
Verordening (EG) Nr. 547/2012 van de Commissie. Регламент Комісії № 547/2012.
Is alleen van toepassing op waterpompen die gekenmerkt worden Стосується тільки насосів для води, що відзначені мінімальним
door de minimale efficiëntie index MEI. Zie het typeplaatje van de показником ефективності МЕІ. Дивіться паспортну табличку на
pomp. насосі.
Deze EC overeenkomstigheidsverklaring is alleen geldig wanneer deze Ця декларація відповідності ЄС дійсна тільки в тому випадку, якщо
gepubliceerd is als onderdeel van de Grundfos installatie- en публікується як частина інструкцій Grundfos з монтажу та
bedieningsinstructies (publicatienummer 96462123 0914). експлуатації (номер публікації 96462123 0914).
PL: Deklaracja zgodności WE PT: Declaração de conformidade CE

My, Grundfos, oświadczamy z pełną odpowiedzialnością, że nasze A Grundfos declara sob sua única responsabilidade que os produtos
wyroby CR, CRI oraz CRN, których deklaracja niniejsza dotyczy, są CR, CRI e CRN, aos quais diz respeito esta declaração, estão em
zgodne z następującymi wytycznymi Rady d/s ujednolicenia przepisów conformidade com as seguintes Directivas do Conselho sobre
prawnych krajów członkowskich WE: a aproximação das legislações dos Estados Membros da CE:
— Dyrektywa Maszynowa (2006/42/WE). — Directiva Máquinas (2006/42/CE).
Zastosowane normy: EN 809:1998, A1:2009. Normas utilizadas: EN 809:1998, A1:2009.
— Dyrektywa EMC (2004/108/WE). — Directiva EMC (compatibilidade electromagnética) (2004/108/CE).
— Dyrektywa Ekoprojektowa (2009/125/WE). — Directiva de Concepção Ecológica (2009/125/CE).
Silniki elektryczne: Motores eléctricos:
Rozporządzenie komisji nr 640/2009. Regulamento da Comissão No 640/2009.
Dotyczy tylko trójfazowych silników firmy Grundfos z oznaczeniami Aplica-se apenas a motores trifásicos Grundfos assinalados como
IE2 lub IE3. Patrz tabliczka znamionowa silnika. IE2 ou IE3. Ver a chapa de características do motor.
Zastosowana norma: EN 60034-30:2009. Norma utilizada: EN 60034-30:2009.
— Dyrektywa Ekoprojektowa (2009/125/WE). — Directiva de Concepção Ecológica (2009/125/CE).
Pompy do wody: Bombas de água:
Rozporządzenie komisji nr 547/2012. Regulamento da Comissão No 547/2012.
Dotyczy tylko pomp do tłoczenia wody z minimalnym indeksem Aplica-se apenas a bombas de água registadas com o índice de
sprawności MEI. Patrz tabliczka znamionowa pompy. eficiência mínimo MEI. Ver a chapa de características da bomba.
Deklaracja zgodności WE jest ważna tylko i wyłącznie wtedy kiedy jest Esta declaração de conformidade CE é apenas válida quando publicada
opublikowana przez firmę Grundfos i umieszczona w instrukcji montażu como parte das instruções de instalação e funcionamento Grundfos
i eksploatacji (numer publikacji 96462123 0914). (número de publicação 96462123 0914).
44
RU: Декларация о соответствии ЕС RO: Declaraţie de conformitate CE
Мы, компания Grundfos, со всей ответственностью заявляем, Noi, Grundfos, declarăm pe propria răspundere că produsele CR, CRI şi
что изделия CR, CRI и CRN, к которым относится настоящая CRN, la care se referă această declaraţie, sunt în conformitate cu aceste
декларация, соответствуют следующим Директивам Совета Directive de Consiliu asupra armonizării legilor Statelor Membre CE:
Евросоюза об унификации законодательных предписаний — Directiva Utilaje (2006/42/CE).
стран-членов ЕС: Standarde utilizate: EN 809:1998, A1:2009.
— Механические устройства (2006/42/ЕС). — Directiva EMC (2004/108/CE).
Применявшиеся стандарты: EN 809:1998, A1:2009. — Directiva Ecodesign (2009/125/CE).
— Электромагнитная совместимость (2004/108/EC). Motoare electrice:
— Директива по экологическому проектированию Regulamentul Comisiei nr. 640/2009.
энергопотребляющей продукции (2009/125/EC). Se aplică numai motoarelor trifazate Grundfos cu marca IE2 sau IE3.
Электродвигатели: Vezi plăcuţa de identificare a motorului.
Регламент Комиссии ЕС № 640/2009. Standard utilizat: EN 60034-30:2009.
Применяется только к трехфазным электродвигателям Grundfos, — Directiva Ecodesign (2009/125/CE).
обозначенным IE2 или IE3. См. шильдик с техническими Pompe de apa:
данными двигателя. Regulamentul Comisiei nr. 547/2012.
Применявшийся стандарт: EN 60034-30:2009. Se aplica numai pompelor de apa cu marca de eficienta minima
— Директива по экологическому проектированию index MEI. Vezi plăcuţa de identificare a pompei.
энергопотребляющей продукции (2009/125/EC). Această declarație de conformitate CE este valabilă numai când este
Насосы для перекачивания воды: publicată ca parte a instrucțiunilor Grundfos de instalare şi utilizare
Регламент Комиссии ЕС № 547/2012. (număr publicație 96462123 0914).
Применимо только к насосам для перекачивания воды,
промаркированным показателем минимальной эффективности
MEI. См. фирменную табличку насоса.
Данная декларация о соответствии ЕС имеет силу только в случае
публикации в составе инструкции по монтажу и эксплуатации на
продукцию производства компании Grundfos
(номер публикации 96462123 0914).
SK: Prehlásenie o konformite ES SI: ES izjava o skladnosti

My firma Grundfos prehlasujeme na svoju plnú zodpovednost’, že výrobky V Grundfosu s polno odgovornostjo izjavljamo, da so naši izdelki
CR, CRI a CRN, na ktoré sa toto prehlásenie vzt’ahuje, sú v súlade CR, CRI in CRN, na katere se ta izjava nanaša, v skladu z naslednjimi
s ustanovením smernice Rady pre zblíženie právnych predpisov direktivami Sveta o približevanju zakonodaje za izenačevanje pravnih
členských štátov Európskeho spoločenstva v oblastiach: predpisov držav članic ES:
— Smernica pre strojové zariadenie (2006/42/EC). — Direktiva o strojih (2006/42/ES).
Použité normy: EN 809:1998, A1:2009. Uporabljeni normi: EN 809:1998, A1:2009.
— Smernica pre elektromagnetickú kompatibilitu (2004/108/EC). — Direktiva o elektromagnetni združljivosti (EMC) (2004/108/ES).
— Smernica o ekodizajne (2009/125/ES). — Eco-design direktiva (2009/125/ES).
Elektromotory: Električni motorji:
Nariadenie Komisie č. 640/2009. Uredba Komisije št. 640/2009.
Platné iba pre trojfázové motory Grundfos, označené ako IE2 alebo Se nanaša samo na trofazne motorje Grundfos z oznako IE2 ali IE3.
IE3. Viď typový štítok motora. Glejte tipsko ploščico motorja.
Použitá norma: EN 60034-30:2009. Uporabljena norma: EN 60034-30:2009.
— Smernica o ekodizajne (2009/125/ES). — Eco-design direktiva (2009/125/ES).
Čerpadlá na vodu: Vodne črpalke:
Nariadenie Komisie č. 547/2012. Uredba Komisije št. 547/2012.
Vzťahuje sa iba na čerpadlá pre vodu označené minimálnym Velja le za vodne črpalke označene z indeksom minimalne
indexom energetickej účinnosti MEI. Viď typový štítok čerpadla. učinkovitosti MEI. Glejte tipsko ploščico črpalke.
Toto prehlásenie o konformite ES je platné iba vtedy, ak je zverejnené ES izjava o skladnosti velja samo kadar je izdana kot del Grundfos
ako súčasť montážnych a prevádzkových pokynov Grundfos instalacije in navodil delovanja (publikacija številka 96462123 0914).
(publikácia číslo 96462123 0914).
RS: EC deklaracija o konformitetu FI: EY-vaatimustenmukaisuusvakuutus

Mi, Grundfos, izjavljujemo pod vlastitom odgovornošću da je proizvod Me, Grundfos, vakuutamme omalla vastuullamme, että tuotteet CR, CRI
CR, CRI i CRN, na koji se ova izjava odnosi, u skladu sa direktivama ja CRN, joita tämä vakuutus koskee, ovat EY:n jäsenvaltioiden
Saveta za usklađivanje zakona država članica EU: lainsäädännön yhdenmukaistamiseen tähtäävien Euroopan neuvoston
— Direktiva za mašine (2006/42/EC). direktiivien vaatimusten mukaisia seuraavasti:
Korišćeni standardi: EN 809:1998, A1:2009. — Konedirektiivi (2006/42/EY).
— EMC direktiva (2004/108/EC). Sovellettavat standardit: EN 809:1998, A1:2009.
— Direktiva o ekološkom projektovanju (2009/125/EC). — EMC-direktiivi (2004/108/EY).
Električni motori: — Ekologista suunnittelua koskeva direktiivi (2009/125/EY).
Uredba komisije br. 640/2009. Sähkömoottorit:
Važi samo za trofazne Grundfos motore označene sa IE2 ili IE3. Komission asetus nro 640/2009.
Pogledajte natpisnu pločicu motora. Koskee vain Grundfosin IE2- tai IE3-merkittyjä 3-vaihemoottoreita.
Korišćen standard: EN 60034-30:2009. Katso moottorin arvokilvestä.
— Direktiva o ekološkom projektovanju (2009/125/EC). Sovellettu standardi: EN 60034-30:2009.
Pumpe za vodu: — Ekologista suunnittelua koskeva direktiivi (2009/125/EY).
Uredba Komisije br. 547/2012. Vesipumput:
Odnosi se samo na pumpe za vodu označene sa indeksom Komission asetus nro 547/2012.
minimalne efikasnosti MEI. Pogledajte natpisnu pločicu pumpe. Koskee vain vesipumppuja, jotka on merkitty
Ova EC deklaracija o usaglašenosti važeća je jedino kada je izdata kao minimihyötysuhdeindeksillä MEI. Katso pumpun tyyppikilvestä.
deo Grundfos uputstava za instalaciju i rad (broj izdanja 96462123 Tämä EY-vaatimustenmukaisuusvakuutus on voimassa vain, kun se
0914). julkaistaan osana Grundfosin asennus- ja käyttöohjeita
(julkaisun numero 96462123 0914).
45
SE: EG-försäkran om överensstämmelse TR: EC uygunluk bildirgesi

Vi, Grundfos, försäkrar under ansvar att produkterna CR, CRI och CRN, Grundfos olarak bu beyannameye konu olan CR, CRI ve CRN
som omfattas av denna försäkran, är i överensstämmelse med rådets ürünlerinin, AB Üyesi Ülkelerin kanunlarını birbirine yaklaştırma üzerine
direktiv om inbördes närmande till EU-medlemsstaternas lagstiftning, Konsey Direktifleriyle uyumlu olduğunun yalnızca bizim sorumluluğumuz
avseende: altında olduğunu beyan ederiz:
— Maskindirektivet (2006/42/EG). — Makineler Yönetmeliği (2006/42/EC).
Tillämpade standarder: EN 809:1998, A1:2009. Kullanılan standartlar: EN 809:1998, A1:2009.
— EMC-direktivet (2004/108/EG). — EMC Diretifi (2004/108/EC).
— Ekodesigndirektivet (2009/125/EG). — Çevreye duyarlı tasarım (Ecodesign) Direktifi (2009/125/EC).
Elektriska motorer: Elektrikli motorlar:
Kommissionens förordning nr. 640/2009. 640/2009 sayılı Komisyon Yönetmeliği.
Gäller endast trefas Grundfos-motorer märkta med IE2 eller IE3. Sadece IE2 veya IE3 işaretli trifaze Grundfos motorlar için geçerlidir.
Se motorns typskylt. Motor bilgi etiketine bakınız.
Tillämpad standard: EN 60034-30:2009. Kullanılan standart: EN 60034-30:2009.
— Ekodesigndirektivet (2009/125/EG). — Çevreye duyarlı tasarım (Ecodesign) Direktifi (2009/125/EC).
Vattenpumpar: Devirdaim su pompaları:
Kommissionens förordning nr. 547/2012. 547/2012 sayılı Komisyon Yönetmeliği.
Avser endast vattenpumpar markerade med min. effektivitetsindex Yalnızca Minimum Enerji Verimlilik Endeksine (MEI) dahil olan olan
(MEI). Se pumpens typskylt. devirdaim su pompaları için geçerlidir. Pompanın bilgi etiketine
Denna EG-försäkran om överensstämmelse är endast giltig när den bakın.
publiceras som en del av Grundfos monterings- och driftsinstruktion İşbu EC uygunluk bildirgesi, yalnızca Grundfos kurulum ve çalıştırma
(publikation nummer 96462123 0914). talimatlarının (basım numarası 96462123 0914) bir parçası olarak
basıldığı takdirde geçerlilik kazanmaktadır.
Bjerringbro, 15th November 2012
Svend Aage Kaae

Technical Director
Grundfos Holding A/S
Poul Due Jensens Vej 7
8850 Bjerringbro, Denmark
Person authorised to compile technical file and

empowered to sign the EC declaration of conformity.
Декларация о соответствии на территории РФ

Насосы центробежные вертикальные многоступенчатые CR, CRI и
CRN сертифицированы на соответствие требованиям Технического
регламента о безопасности машин и оборудования
(Постановление правительства РФ от 15.09.2009 №753).
Сертификат соответствия:
№ C-RU.АЯ56.В.04045, срок действия до 11.07.2017г.
№ C-DK.АЯ56.B.03740, срок действия до 27.05.2017г.
Изделия, произведенные в России, изготавливаются в соответствии
c ТУ 3631-001-59379130-2005.
Истра, 15 ноября 2012 г.
Касаткина В. В.
Руководитель отдела качества,
экологии и охраны труда
ООО Грундфос Истра, Россия
143581, Московская область,
Истринский район,
дер. Лешково, д.188
46
ECM: 1142070
96462123 0914
www.grundfos.com
The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. © Copyright Grundfos Holding A/S
1 2 3 4
A 17.5.2017 FIRAPTA ORIFICE PLATE ADDED
GENERAL TOLERANCE FOR TERMINAL POINTS: 20 MM

NOTE!
THE SLIDING SUPPORTS AND FIXED POINTS OF THE PIPELINES
TO BE DESIGNED SO THAT THE MASS FORCES AND THERMAL
EXPANSIONS ARE COMPENSATED.
B
957
250
C
A B
R D
FOR CUSTOMER APPROVAL

Alfa Laval Aalborg Oy
20.4.2017
E
R INSTRUMENT AIR D10
B WATER TO FEED WATER TANK DN32 16
A MAKE-UP WATER IN DN32 16
Pos Connection Note Size PN
Date/Drawn
Termonotre 93 MW dual fuel power plant 10.4.2017/FIRAPTA
Date/Checked
21.4.2017/POS
Date/Approved
MAKE-UP WATER CONTROL UNIT 21.4.2017/
Main dimensions Weight/kg Scale F
57,1 kg 1:10
Rauma, Finland
A4 5514-7M A 1 /1
1 2 3 4
A 17.5.2017 FIRAPTA ORIFICE PLATE ADDED
A
7 17 13 15 16
16
15
11 10
13
17 B
12
C
16 15 13 17 3 6 17 13 15 16
2 4 2 14 15 16 17
D
17 9FLANGE GASKET DN32 PN10-40 EN1514-1 GRAPHITE 35205180283RA 0,2
16 48Washer 16 DIN 126 FE-ZN HOT 30903920199RA 0,5
15 24HEXAGONAL NUT M16 DIN 934 / 8 FE-ZN HOT 30803800199RA 0,8
14 4HEXAGONAL SCREW M16 x 140 DIN 931 / 8.8 FE-ZN HOT 30103520409RA 1,0
13 20HEXAGONAL SCREW M16 x 60 DIN 931 / 8.8 FE-ZN HOT 30103520360RA 2,7
12 1Neck Flange DN32 PN40 EN 1092-1:11/B P250GH 20505740171RA 1,9
11 1 PREFABRICATED PIPE dwg:5514-178 6,7
10 1 PREFABRICATED PIPE dwg:5514-177 7,5
7 1GLOBE VALVE DN32 PN16 FWT001.V017 60107200192RA 6,8
5 1 SPEED RESTRICTOR FOR ACTUATOR FWT001.V015.1 60007380164RA 5,2
4 1BALL VALVE WITH PNEUMATIC ACTUATOR DN32 PN40 FWT001.V015 60007360171RA 15,2
E
2 1 ORIFICE PLATE RAA 901.V005 20506140157RA 0,3
1 1 AIR SET WITH METAL TANK MOUNTED TO GT 1/4'' FWT001.A002 80007800276RA 0,0
ACTUATOR
Date/Drawn
Thermonotre 93MW, Colombia 17.5.2017/FIRAPTA
Date/Checked
Date/Approved
MAKE-UP WATER CONTROL UNIT 17.5.2017/MJ
Assembly Weight/kg Scale F
62,4 kg 1:10
Rauma, Finland
A4 5514-48A A 1 /1
1 2 3 4 5 6 7 8 9 10 11 12
A 18.05.2017 FIRAAPO Manhole & switches moved. Updated level transmitter connection.
B 27.06.2017 FIRASHN FIRAAKI CON. C2 changed
A A
B B
A A
C C
B B
C2
D D
H
E C1 E
F F
A-A ( 1:20 )
C
G G
Fx Fy Fz Mx My Mz
Max. Loads (kN) Max. Moments (kNm) 21.4.2017/FIRATAA
5514, Termonorte, Colombia
ALLOWABLE FORCES AND MOMENTS Hyundai Heavy Industries 21.4.2017/FIRAPON
H B-B ( 1:20 ) - Not to be subjected to any fluctuating loads. H
C ( 1:5 ) - All loads are only static (+-).
LFO-2 /
- Forces given in the table are not allowed Main dimensions 538,9 kg 1:20
to be exceeded.
the mass forces and thermal expansions
are compensated. A2 5514-22M B 1 /1
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8
A 27.06.2017 FIRASHN FIRAAKI POS. 40 added.

B 6.7.2017 FIRAAPO FIRAPON Added chemical anchors with stud bolts.
A A
10 11
21
20 2 22
B 18 14 20 B
15 17 18
1 19 15
3
4 14 17 19
C C
22 20 16 12 8 6 7 20 18 13
D D
22
20
18
15
5
E E
9
12
16
20 5514, TERMONORTE 93 MW DFPP 6.7.2017/FIRAAPO
Hyundai Heavy Industries Co Ltd 6.6.2017/KSO

22 LFO-2 7.6.2017/MJÄ
F Assembly F
539,4 kg 1:25
A3 5514-29A B 1 /1
1 2 3 4 5 6 7 8

LFO-day tank (Atmospheric) Maintenance - 1/3
CONTENT:
1. GENERAL ........................................................................................................................... 2
2. MAINTENANCE INSTRUCTIONS FOR LFO-DAY TANK ................................................... 2
2.2Manual water cleaning .................................................................................................... 2
2.5 Tightness test ................................................................................................................ 3
2.6 Emptying of LFO-day tank ............................................................................................. 3

Maintenance / LFO-day tank (Atmospheric) - - 2/3
1. GENERAL
This part describes how to maintain the LFO-day Tank. In case any major problems
2. MAINTENANCE INSTRUCTIONS FOR LFO-DAY TANK
Note!
2.2 Manual water cleaning
Note!

Maintenance / LFO-day tank (Atmospheric) - - 3/3
2.5 Tightness test
Note!
vessel is implemented.
2.6 Emptying of LFO-day tank
Ref.: Maintenance Card, “Emptying of atmospheric LFO-day tank”.
Note!
Before LFO-day tank’s manhole is opened, make sure that it is complete empty and
until maintenance actions to the inside of LFO-day tank, the temperature of all steel
Storing of a cold LFO-day tank partly filled with oil is not allowed because of the risk of
Storing of LFO-day tank shall be made by taking into consideration instructions about

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A 19.4.2017 FIRATAA Pumps changed

B 26.4.2017 FIRATAA G1 changed, top view added
A C 17.5.2017 FIRAAPO Tank unit updated. Changed A1 and F1 pipe sizes and connection A
D 13.6.2017 FIRAAPO Added markings for X12 and C1. Updated connection text for F2.
C
L
A1
B B
A2
F1
C C
X11
D Aa Ad D
X12
E E
F2
B
C1
E C4
F F
C2
C3
B B
G G
UNIT ASSEMBLY TO THE FOUNDATION BED:

H 1. WITH CHEMICAL ANCHOR BOLTS SUPPLIED BY ALFA LAVAL. H
2. UNIT LEGS ARE FILLET WELDED AROUND TO THE FOUNDATION PLATES.
FOUNDATION BED IS TO BE MIN. 100 MM WIDER AND 100 MM LONGER THAN UNIT FRAME.
FOUNDATION PLATE IS TO BE MIN. 50 MM WIDER AND 50 MM LONGER THAN UNIT LEG.
FOUNDATION PLATES ARE TO BE BOLTED OR MOULDED TO THE FOUNDATION BED.
DURING INSTALLATION STAGE, THERMAL EXPANSIONS ARE TO BE TAKEN INTO THE CONSIDERATION;
SEE ALFA LAVAL AALBORG GENERAL INSTRUCTIONS.
DELIVERY AND DESIGN FOR THE FOUNDATION BED AND PLATES IS OUT OF
ALFA LAVAL AALBORG SCOPE OF SUPPLY.
NOTE !
J INSTRUMENTS (VALVES AND FITTINGS) ARE SHOWN AS SPACE AND SERVICE J
RESERVATION PURPOSE ONLY. EXACT DIMENSIONS ARE TO BE CHECKED
FROM RELATED INSTRUMENT CATALOGUES.
MOST OF INSTRUMENTS ARE DELIVERED LOOSE.
K K
L L
Hyundai Heavy Industries 11.4.2017/FIRAPOS
5514 TERMONORTE 93 MW, COLOMBIA 11.4.2017/FIRAMJA

CONDENSATE TANK UNIT C-1 11.4.2017/FIRAMJA
M Main dimensions 885,9 kg 1:10
M
B-B ( 1:10 )
A1 5514-4M D 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
65 61 57 44 40 1 31 45 57 61 A 27.06.2017 FIRASHN POS. 80 and 81 added.

B
B 6.7.2017 FIRAAPO Added chemical anchors with stud bolts. POS. 41.
A A
20 47 57 61 68
67 61 57 25
21 30 36 37 62
B 63 60 50 7 B
59
C 36 22 62 C
33 55
A A 48
63 60 50 8
71
60 56 42 4 71 68 61 57 44 38
32
D 32 33 D
32 26 6 5
62 36 9 B ( 1:15 )
23 23 24 29 62
32 53 69
54
41
2 3
E 58 E
52 52
70
57 57
61 61
F F
G G
64
64 61 64
61 61 57 61 30
H 57 57 44 57
H
46 34
43 39 44
64
19 17 35 26
61
28 49 56 60
57
J 44 J
27
11
10 62
K 66 61 51 26 14 K
18
43
66 61 51 26 15
57 27
61 A-A ( 1:15 )
L 32 26 12 16 26 L
64
46 44
32 26 13 57 57
5514 Termonorte 93 MW, COLOMBIA 11.5.2017/JJN
61 61 26 Hyundai Heavy Industries 15.6.2017/FIRAAKI

Condensate tank C-1 15.6.2017/FIRAPOS
M Assembly 885,2 kg 1:15
M
A1 5514-32A B 1 /1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Condensate tank Maintenance - 1/3
CONTENT:
1. GENERAL ........................................................................................................................... 2
2. MAINTENANCE INSTRUCTIONS FOR CONDENSATE TANK .......................................... 2
2.1 Water sampling and analyzing .................................................................................................... 2
2.2 Visual checking of operation ....................................................................................................... 2
2.3 Manual water cleaning................................................................................................................ 2
2.4 Inspection of instruments............................................................................................................ 3
2.5 Internal inspection of wearing and corrosion ............................................................................... 3
2.6 Tightness test ............................................................................................................................. 3
2.7 Emptying of condensate tank ..................................................................................................... 3
2.8 Electrical safety test ................................................................................................................... 3

Maintenance / Condensate tank - - 2/3
1. GENERAL
This part describes how to maintain the Condensate Tank. In case any major problems
2. MAINTENANCE INSTRUCTIONS FOR CONDENSATE TANK
2.1 Water sampling and analyzing
Note!
See above note.
Note!
2.3Manual water cleaning

Maintenance / Condensate tank - - 3/3
Note!
2.6 Tightness test
Note!
2.7 Emptying of condensate tank
Ref.: Maintenance Card, “Emptying of atmospheric tank”.
Note!
Before feed water tank’s manhole is opened, make sure that it is complete empty and
until maintenance actions to the inside of feed water tank, the temperature of all steel
Storing of a cold condensate tank partly filled with water is not allowed because of the
risk of corrosion and/or frozen.
Storing of feed water tank shall be made by taking into consideration instructions about


O
WASTE HEAT RECOVERY
K
1-7 Operation
2-1 Maintenance

INSTRUCTION
MANUAL
2-4 Feed Water Tank

O
INSTRUMENTS 2-7 Burner O
K
MW
2-10 Pumps
2-12 LFO Tank

B
3
B
4 Electrical
4
Customer's Ref: BOOK 3 INSTRUMENTS

1 How to find information of instruments
2 Components of enclosure 10000
3 Components of enclosure 20000
CONTENTS OF
CHAPTER 3.1
INSTRUMENT
INFORMATION
3.1 Instrument Information

INFORMATION FOR INSTRUMENTS

Information for instrumentation Information 1/1
HOW TO FIND INFORMATION FOR INSTRUMENTS?
All instruments (valves, manometers, actuators etc.) are identified between the main flow diagram and component list as a such way:
∂ the device where related instrument belongs is named with a device code, as example device code for feed water control unit is RBB 021
∂ thus all instruments for this unit are identified with a part code where related device code is indicated and secondly instrument number, as
example RBB 021 V001
∂ further information for instrument can be found as follows; read related standard/enclosure number and find right instrument brochure end of this
O&M book. Detailed information from brochure is found according to type/brand number and other information based on component list
Part Part Material no. Qty Component Type Standard NP/ Oper.flow/ Nom.t./ Range Power Supplier Notes
Nbr Code Certificate Description Brand Enclosure NS Oper. press. Oper.t. Voltage
1 RBB 021 7 CLOSING VALVE, NON-RETURN 16/
V001 feed water controlling Z26 111 616 10169 40 13 bar (g) 135 °C

1 10001 FABA
2 10002 Safety Valve
3 10009 Ball Valve ALFA20R
4 10011 Globe valve STOBU
5 10035 Ball valve ALFA 10
6 10063 Strainer
7 10098 Zesa 22.012
8 10100 Level gauge DS
CONTENTS OF 9 10113 Non-return valve RK 76

CHAPTER 3.1.2
10 10120 Steam trap BK 45
11 10128 ALFA 68
Control valve ALFA 10 GT 5R + 6519

12 10134
COMPONENTS BÜRKERT
OF ENCLOSURE 13 10151 Oil detector ORGS 11-2
10000 14 10165 Control valve 23.470 + Premio
15 10166 Level controller NRR 2-40
16 10168 Level electrode NRG 26-40
17 10174 NRGT 26-1
18 10203 Temperature regulator Temptrol
19 10241 Non-return valve RK86/86A
20 10249 Float Switch
21 10303 Magnetic level indication BNA
22 10308 Float valve NV98
23 10310 Conductive electrode NRG 16-4
24 10311 Level switch NRS 1-53
3.1.2 Components of Enclosure 10000

Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Enclosure 10001
Technology for the Future.

GERMAN QUALITY VALVES
Enclosure 10002
ARI-SAFE
Safety valve
Full lift safety valve / Standard safety valve
ARI-SAFE
Full lift safety valve D/G
Standard safety valve F
• Type-test approved acc. to
DIN EN ISO 4126 / AD2000-A2
• TÜV · SV · . . -663 · D/G Figure 901-912
• TÜV · SV · . . -663 · F Figure 901/911 Fig. 901 902 911 912
• Further approvals: see inside Page 2
ARI-SAFE
Standard safety valve
for the heating technology
• Type-test approved acc. to TRD 721
• TÜV · SV · . . -688 · D/G/H Figure 903
• TÜV · SV · . . -688 · D Figure 904 Fig. 903 904
Page 6
ARI-SAFE-P
Fig. 900 Fig. 940
Standard safety valve D/G/F
• TÜV · SV · . . -811 · D/G Figure 921-924
• TÜV · SV · . . -811 · F Figure 921/923 Fig. 921 922 923 924
Page 12
ARI-SAFE-TC
Full lift safety valve D/G
Standard safety valve F
• TÜV · SV · . . -995 · D/G Figure 941-943
Fig. 941 942 943
• TÜV · SV · . . -995 · F Figure 941/943
Page 16
ARI-SAFE-TC
Standard safety valve
for the heating technology
• Type-test approved acc. to TRD 721
• TÜV · SV · . . -997 · D/G/H Figure 945
• TÜV · SV · . . -997 · D Figure 946 Fig. 920 Fig. 950/960
Fig. 945 946
Page 20
ARI-SAFE-TCP
Standard safety valve D/G/F
• TÜV · SV · . . -1041 · D/G Figure 961-963
• TÜV · SV · . . -1041 · F Figure 961/963 Fig. 961 962 963
Page 24
ARI-SAFE-TCS Features:
Standard safety valve D/G/F • Direct loaded with spring
• Type-test approved acc. to • Wear resistant seat/disc
DIN EN ISO 4126 / AD2000-A2 • Precision disc alignment and guide
• TÜV · SV · . . -1041 · D/G Figure 951-953 • Possible with soft seal disc
• TÜV · SV · . . -1041 · F Figure 951/953 • Possible with EPDM bellow
Fig. 951 952 953
FOR HORIZONTAL APPLICATION • Possible with stainless steel bellow
Page 28
• ARI-SAFE-TC/TCP/TCS:
All common thread types
Edition 02/13 - Data subject to alteration Data sheet 900001 englisch (english)
Enclosure 10002
ARI-SAFE
Fig. 901 / 902 / 911 / 912
ARI-SAFE - Full lift safety valve D/G, Standard safety valve F
Figure Nominal pressure Material Nominal diameter

12.901 / 902 / 911 / 912 PN16/16 EN-JL1040 DN20/32 - 150/250
25.901 / 902 / 911 / 912 PN40/16 EN-JS1049 DN20/32 - 100/150
35.901 / 902 / 911 / 912 PN40/16 1.0619+N DN20/32 - 150/250
55.901 / 911 PN40/16 1.4408 DN20/32 - 100/150
Flange holes/-
Figure Temperature range Flange
thickness tolerances
12.901 / 902 / 911 / 912 -10°C to +300°C DIN EN 1092-2 DIN 2533/2533
25.901 / 902 / 911 / 912 -10°C to +350°C DIN EN 1092-2 DIN 28607/28605
35.901 / 902 / 911 / 912 -10°C to +450°C DIN EN 1092-1 DIN 2545/2543
55.901 / 911 -60°C to +400°C DIN EN 1092-1 DIN 2545/2543
Type-test approval
Full lift safety valve: TÜV · SV · . . -663 · D/G (Fig. 901/902/911/912)
Standard safety valve: TÜV · SV · . . -663 · F (Fig. 901/911)
Set gauge pressure refer to „Capacity“.
Requirement
Acc. to EN ISO 4126-1, VdTÜV-leaflet 100, AD2000-A2, TRD 421,
material selection observe TRB 801 No. 45!!
Construction
Safety valve, spring loaded, direct loaded
Sizing
For steam, air and water see capacity tables,
calculation acc. to EN ISO 4126-1, TRD 421 and AD2000-A2.
Fig. ... .901 Fig. ... .902 Details required
closed lifting device open lifting device
• Medium gasform: Mass flow (kg/h), molar mass (kg/kmol), temperature (°C), set gauge
pressure (bar), back gauge pressure (bar)
• Medium liquid: Mass flow (kg/h), density (kg/m3), viscosity, temperature (°C), Set gauge
Order data:
ARI-SAFE-Safety valve,
Figure ..., DN .../..., PN ..., Material ..., Set gauge pressure ...bar
Selection of possible applications
Chemical Industry, processing industry, plant manufacturing
(other applications on request)
Selection of possible flow media
EN-JL1040, EN-JS1049 1.0619+N: Steam, neutral gases, vapours and liquids
1.4408: Steam, aggressive gases, vapours and liquids
(other flow media on request)
without metal bellow with metal bellow
Superimposed back no backpressure allowed on request

pressure
Built up back pressure max. 10% from set pressure (gauge) on request
(higher on request)
Fig. ... .911 Fig. ... .912

gastight cap open lifting device
Edition 02/13 - Data subject to alteration

Enclosure 10002 ARI-SAFE
Fig. 901 / 902 / 911 / 912
Dimensions and weights
DN1/DN2 (mm) 20/32 25/40 32/50 40/65 50/80 65/100 80/125 100/150 125/200 150/250
d0 (mm) 18 22,5 29 36 45 58,5 72 90 106 125
A0 (mm2) 254 398 661 1018 1590 2688 4072 6362 8825 12272
l (mm) 85 100 110 115 120 140 160 180 200 225
l1 (mm) 95 105 115 140 150 170 195 220 250 285
H (mm) 270 280 330 390 435 545 610 690 845 890
H (Bellow design) (mm) 310 335 390 445 500 620 690 770 -- --
X (mm) 150 150 200 250 300 350 400 500 500 500
Drainhole with plug 1) (inch) G 1/4“ G 3/8“
Weight (kg) 8,5 10 14 20 28 40 53 80 125 165
Weight (Bellow design) (kg) 9,5 11,5 16 22,5 32 47 59 90 -- --
Standard-flange dimensions refer to page 34.
1) Standard for EN-JL1040, EN-JS1049 1.0619+N, optional at 1.4408
Spring ranges: Standard design (barg) Spring ranges: Bellow design (barg)
DN20 DN25 - 50 DN65 DN80 DN100 DN125 DN150 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100
0,2 - 0,5 0,2 - 0,5 0,2 - 0,5 0,2 - 0,5 0,2 - 0,5 0,2 - 0,4 0,2 - 0,5 3 - 3,7 2,5 - 3,3 2,5 - 3,2 2,6 - 3,6 2,8 - 3,4 2,5 - 3,7 2,5 - 3,3 2,5 - 3,5
> 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,4 - 0,75 > 0,5 - 1 > 3,7 - 4,6 > 3,3 - 4,6 > 3,2 - > 3,6 - 4,5 > 3,4 - 4,5 > 3,7 - 4,6 > 3,3 - 4,5 > 3,5 - 4,2
> 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 0,75 - 1,1 > 1 - 1,5 > 4,6 - 6,3 > 4,6 - 5,4 > 4 - 5,5 > 4,5 - 5,6 > 4,5 - 8,4 > 4,6 - 5,9 > 4,5 - 5,8 > 4,2 - 4,9
> 1,5 - 2,5 > 1,5 - 2 > 1,5 - 2 > 1,5 - 2 > 1,5 - 2 > 1,1 - 1,5 > 1,5 - 1,9 > 6,3 - 8,4 > 5,4 - 7 > 5,5 - 6,4 > 5,6 - 7,5 > 8,4 - 10 > 5,9 - 8 > 5,8 - 7,5 > 4,9 - 5,6
> 2,5 - 4,5 > 2 - 2,7 > 2 - 2,7 > 2 - 2,7 > 2 - 2,5 > 1,5 - 1,9 > 1,9 - 2,3 > 8,4 - 10,2 > 7 - 9 > 6,4 - 7,9 > 7,5 - 10 > 10 - 11,5 > 8 - 10 > 7,5 - 8,9 > 5,6 - 7
> 4,5 - 8,5 > 2,7 - 3,6 > 2,7 - 3,6 > 2,7 - 3,6 > 2,5 - 3 > 1,9 - 2,5 > 2,3 - 2,7 > 10,2 - 13 > 9 - 11,7 > 7,9 - 11,5 > 10 - 12,5 > 11,5 - 16 > 10 - 18 > 8,9 - 10,5 > 7 - 8
> 8,5 - 19 > 3,6 - 5 > 3,6 - 5 > 3,6 - 5 > 3 - 3,6 > 2,5 - 2,95 > 2,7 - 3,3 > 13 - 17 > 11,7 - 16 > 11,5 - 18,5 > 12,5 - 16 > 16 - 18,5 > 10,5 - 13 > 8 - 9,3
> 19 - 28 >5-9 >5-9 >5-9 > 3,6 - 5 >3-4 > 3,3 - 4,1 > 17 - 27,5 > 16 - 22 > 18,5 - 25,0 > 16 - 22 > 18,5 - 23 > 13 - 14 > 9,3 - 11,5
> 28 - 35 > 9 - 16 > 9 - 16 > 9 - 14 >5-9 > 4 - 5,7 > 4,1 - 5,5 > 22 - 30,0 > 11,5 - 13
> 35 - 40 > 16 - 22 > 16 - 22 > 14 - 19 > 9 - 14 > 5,7 - 8,2 > 5,5 - 7,4 Design with bellow as standard valve (only Fig. 901/911)
> 22 - 28 > 22 - 28 > 19 - 25 > 14 - 19 > 8,2 - 12 > 7,4 - 11
> 28 - 34 > 19 - 24 > 12 - 17 > 11 - 16
> 34 - 40 2) > 17 - 24 > 16 - 21
> 24 - 27 > 21 - 26
2) not possible for DN32
Certified coefficient of discharge Kdr (Values for D/G variable: DN20-100 < 3,5 bar, DN125-150 < 4,0 bar)
Kdr DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150
D/G 0,74 0,7
F 0,54 0,48 0,45
Parts
Pos. Description Fig. 12.901/902/911/912 Fig. 25.901/902/911/912 Fig. 35.901/902/911/912 Fig. 55.901/911
1 Body EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N GX5CrNiMo19-11-2, 1.4408
2 Seat X6CrNiMoTi17-12-2, 1.4571
3 Studs 25CrMo4, 1.7218 A4 - 70
4 Spindle guide X20Cr13+QT, 1.4021+QT X6CrNiMoTi17-12-2, 1.4571
8 Hexagon nut C35E, 1.1181 A4
11 Bonnet, closed EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
12 Disc unit X39CrMo17-1+QT, 1.4122+QT X6CrNiMoTi17-12-2, 1.4571
14 Spindle * X20Cr13+QT, 1.4021+QT X6CrNiMoTi17-12-2, 1.4571
17 Adjusting screw X20Cr13+QT, 1.4021+QT X2CrNiMo17-12-2, 1.4404
28 Cap, closed EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
29 Cap, open EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
30 Cap, gastight EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
35 Lift fork EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
36 Lever, closed EN-GJS-400-18U-LT, EN-JS1049 X6CrNiMoTi17-12-2, 1.4571
37 Spring * FDSiCr / 51CrV4, 1.8159 X10CrNi18-8, 1.4310
41 Lever, open EN-GJS-400-18U-LT, EN-JS1049 --
42 Bonnet, open EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 --
43 Bellow (optional) EPDM
55 Bellow unit (optional) X6CrNiMoTi17-12-2, 1.4571
70 Balanced piston (optional) X6CrNiMoTi17-12-2, 1.4571
* Spare parts
Information / restriction of technical rules need to be observed!
ARI-Valves of EN-JL1040 are not allowed to be operated in systems acc. to TRD 110.
A production allowance acc. to TRB 801 No. 45 exists (acc. to TRB 801 No. 45 EN-JL1040 is not allowed.)

Enclosure 10002
ARI-SAFE
Capacity Fig. 901 / 902 / 911 / 912
Capacity saturated steam / air incl. 10% overpressure
Set gauge pressure I Saturated steam (kg/h) II Air 0°C and 1.013 bara (Nm3/h)
DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150
bar
I II I II I II I II I II I II I II I II I II I II
0,2 81 95 126 148 210 246 324 380 506 594 855 1003 1295 1520 2024 2375 2510 2945 3490 4100
0,4 120 143 185 223 307 370 473 570 739 891 1250 1505 1890 2280 2960 3565 3630 4380 5050 6090
0,5 132 161 207 252 344 419 529 646 827 1009 1400 1705 2120 2585 3310 4035 4070 4970 5660 6910
0,6 147 182 230 284 383 472 590 728 923 1135 1560 1920 2360 2910 3690 4545 4470 5520 6220 7675
0,8 174 218 272 341 453 567 698 873 1090 1365 1840 2305 2790 3490 4360 5460 5240 6555 7280 9115
1 203 255 317 398 526 661 811 1019 1270 1590 2140 2690 3245 4075 5070 6370 6030 7575 8385 10530
1,5 272 344 425 538 707 894 1090 1378 1700 2150 2875 3640 4355 5510 6800 8610 8050 10195 11200 14180
2 305 388 477 607 792 1008 1220 1550 1900 2425 3220 4100 4880 6210 7625 9700 10125 12890 14080 17920
2,5 366 468 572 731 950 1215 1460 1870 2285 2925 3865 4945 5855 7490 9145 11700 11990 15330 16660 21300
3 424 544 662 850 1100 1410 1695 2175 2645 3400 4475 5750 6775 8700 10600 13600 13880 17840 19300 24800
4 535 692 837 1080 1390 1800 2140 2770 3350 4330 5650 7310 8570 11080 13400 17300 17550 22725 24400 31600
5 640 834 1000 1300 1665 2160 2565 3330 4000 5210 6770 8800 10260 13340 16000 20840 21000 27350 29250 38000
6 745 975 1165 1520 1940 2530 2990 3900 4665 6090 7890 10300 11950 15600 18650 24370 24500 31900 34050 44400
7 850 1115 1330 1745 2210 2900 3400 4465 5320 6970 9000 11790 13600 17860 21300 27900 27900 36600 38800 50900
8 957 1255 1495 1965 2485 3260 3820 5030 5980 7860 10100 13280 15300 20100 23900 31430 31350 41200 43600 57300
9 1060 1395 1660 2185 2755 3630 4245 5590 6630 8740 11200 14770 16950 22370 26500 34960 34800 45800 48400 63800
10 1165 1540 1820 2400 3025 3990 4665 6150 7290 9610 12300 16250 18650 24600 29150 38500 38250 50500 53200 70200
11 1270 1680 1985 2625 3300 4360 5080 6720 7940 10500 13400 17750 20300 26900 31750 42000 41600 55100 58000 76600
12 1375 1820 2150 2845 3570 4730 5500 7290 8590 11380 14500 19240 22000 29150 34350 45500 45100 59700 62700 83100
13 1480 1960 2310 3070 3840 5090 5920 7850 9250 12270 15600 20730 23650 31400 37000 49000 48500 64400 67500 89500
14 1580 2100 2475 3290 4110 5460 6340 8400 9900 13150 16700 22200 25350 33650 39600 52600 52000 69000 72300 96000
15 1690 2245 2640 3500 4385 5830 6760 8980 10550 14030 17800 23700 27000 35900 42200 56100 55400 73600 77000 102400
16 1790 2385 2800 3725 4655 6190 7170 9540 11200 14900 18950 25200 28700 38200 44800 59600 58800 78200 81800 108800
17 1900 2530 2965 3950 4930 6560 7590 10100 11850 15800 20050 26700 30350 40400 47400 63100 62200 82900 86600 115300
18 2000 2670 3130 4170 5200 6920 8010 10670 12500 16650 21150 28100 32050 42700 50100 66700 65700 87500 91400 121700
2100 2800 3295 4390 5470 7300 8430 11240 13150 17550 22250 29600 33700 44900 52700 70200 69100 92100 96200 128100
← max. set pressure stainless steel version
19
20 2210 2950 3460 4610 5750 7660 8850 11800 13800 18400 23350 31150 35400 47200 55300 73700 72600 96800 101000 134600
21 2320 3090 3620 4830 6020 8020 9250 12370 14500 19300 24500 32650 37100 49400 57900 77300 76000 101400 105800 141000
22 2420 3230 3790 5050 6290 8390 9700 12930 15150 20200 25600 34150 38800 51700 60600 80800 79500 106000 110900 147500
24 2635 3515 4120 5490 6840 9120 10500 14060 16450 21970 27850 37100 42100 56200 65900 87900 86500 115300 120600 160400
25 2740 3655 4280 5710 7120 9490 10950 14620 17100 22850 28950 38600 43800 58500 90200 120000 125500 166900
26 2850 3800 4450 5930 7390 9850 11350 15190 17800 23730 30050 40100 93700 124600 130300 173300
28 3060 4080 4780 6370 7950 10600 12250 16320 19100 25500 32300 43100
30 3270 4360 5120 6810 8500 11320 13100 17450 20450 27250
TÜV · SV · . . -663 · D/G
32 3490 4640 5450 7250 9060 12050 13950 18570 21800 29000
Calculation acc. to TRD 421 and AD2000-A2
34 4925 7700 12790 19700 30800
DN125, DN150 higher pressures on request
40 5770 9030 23810 36100

Capacity Fig. 901 / 911
Capacity water incl. 10% overpressure
Gauge press. Water 20°C (t/h)
bar DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150
0,2 3,28 5,13 8,53 13,1 20,5 30,8 46,7 73,0 94,9 132,0
0,5 5,19 8,12 13,5 20,8 32,5 48,8 73,9 115,0 150,0 209,0
1 7,35 11,5 19,1 29,4 45,9 69,0 104,0 163,0 212,0 295,0
2 10,4 16,2 27,0 41,6 64,9 97,5 148,0 231,0 300,0 417,0
3 12,7 19,9 33,0 50,9 79,5 119,0 181,0 283,0 368,0 511,0
4 14,7 22,9 38,1 58,7 91,8 138,0 209,0 326,0 424,0 590,0
5 16,4 25,7 42,6 65,5 102,0 154,0 233,0 365,0 474,0 660,0
6 18,0 28,1 46,7 72,0 112,0 169,0 256,0 400,0 520,0 723,0
7 19,4 30,4 50,4 77,7 121,0 182,0 276,0 432,0 562,0 781,0
8 20,8 32,5 53,9 83,1 130,0 195,0 295,0 461,0 600,0 835,0
9 22,0 34,4 57,2 88,1 138,0 207,0 313,0 490,0 637,0 885,0
10 23,2 36,3 60,3 92,9 145,0 218,0 330,0 516,0 671,0 933,0
11 24,4 38,0 63,2 97,4 152,0 229,0 346,0 540,0 703,0 977,0
12 25,4 39,7 66,0 102,0 159,0 239,0 362,0 565,0 735,0 1022,0
13 26,5 41,4 68,7 106,0 165,0 249,0 376,0 587,0 764,0 1062,0
14 27,5 42,9 71,3 110,0 172,0 258,0 391,0 611,0 794,0 1104,0
16 29,4 45,9 76,3 117,0 184,0 276,0 418,0 653,0 849,0 1181,0
18 31,2 48,7 80,9 125,0 195,0 293,0 443,0 692,0 900,0 1252,0
19 32,0 49,9 82,9 128,0 200,0 300,0 454,0 710,0 923,0 1284,0
32,8 51,3 85,3 131,0 205,0 308,0 467,0 730,0 949,0 1320,0
20
21 33,7 52,6 87,4 135,0 210,0 316,0 479,0 748,0 973,0 1350,0
24 36,0 56,2 93,4 144,0 225,0 338,0 512,0 800,0 1040,0 1443,0
25 36,7 57,4 95,3 147,0 229,0 345,0 522,0 1059,0 1473,0
26 37,4 58,5 97,2 150,0 234,0 352,0 1080,0 1502,0
27 38,2 59,6 99,0 153,0 238,0 358,0 1100,0
28 38,9 60,7 101,0 155,0 243,0 365,0
30 40,2 62,9 104,0 161,0 251,0
32 41,5 64,8 108,0 166,0 259,0

TÜV · SV · . . -663 · F
34 42,8 66,9 111,0 171,0 268,0
40 46,4 72,5 185,4 289,7

Enclosure 10002
ARI-SAFE
Fig. 903
ARI-SAFE - Heating-safety valve

12.903 PN16/16 EN-JL1040 DN20/32 - 150/250
Flange holes/-
12.903 -10°C to +120°C DIN EN 1092-2 DIN 2533/2533
Type-test approval
spring loaded: TÜV · SV · . . -688 · D/G/H
Requirement
Acc. to TRD 721 Part 6, material selection observe TRD!
(EN-JL1040 max. 10 bar; >10 bar 25.903 EN-JS1049 or 35.903 1.0619+N)
Application
Acc. to DIN EN 12828 Heating systems in buildings
Constructions
Standard safety valve, spring loaded, direct loaded metal seat with EPDM insert, EPDM-bellow,
closed spring bonnet with control hole, open lifting device, stainless steel seat and spindle
Sizing
Acc. to TRD Part 6.2.5 (see capacity-tables Figure 903)
Order data:
Heating facilities
Fig. .. .903 Warm water, hot water
EPDM-disc, soft seal insert; EPDM-bellow
(Design DN 20 - 100) (Design DN 125 - 150)

Fig. 903
DN1/DN2 (mm) 20/32 25/40 32/50 40/65 50/80 65/100 80/125 100/150 125/200 150/250
d0 (mm) 18 22,5 29 36 45 58,5 72 90 106 125
A0 (mm2) 254 398 661 1018 1590 2688 4072 6362 8825 12272
l (mm) 85 100 110 115 120 140 160 180 200 225
l1 (mm) 95 105 115 140 150 170 195 220 250 285
H (mm) 270 280 330 390 435 545 610 690 845 890
X (mm) 150 150 200 250 300 350 400 500 500 500
Drainhole with plug (optional) (inch) G 1/4“ G 3/8“
Weight (kg) 8,5 9,5 13,5 20 26 39 53 82 125 165
Spring ranges (barg)

DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN125 DN150
0,2 - 0,5 > 0,2 - 0,5 > 0,2 - 0,5 > 0,2 - 0,5 > 0,2 - 0,5 0,2 - 0,5 0,2 - 0,5 0,2 - 0,5 0,2 - 0,4 0,2 - 0,5
> 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,5 - 1 > 0,4 - 0,75 0,5 - 1
> 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 1 - 1,5 > 0,75 - 1,1 1 - 1,5
> 1,5 - 2,5 > 1,5 - 2 > 1,5 - 2 > 1,5 - 2 > 1,5 - 2 > 1,5 - 2 > 1,5 - 2 > 1,5 - 2 > 1,11 - 1,5 1,5 - 1,9
> 2,5 - 4,5 > 2 - 2,7 > 2 - 2,7 > 2 - 2,7 > 2 - 2,7 > 2 - 2,7 > 2 - 2,7 > 2 - 2,5 > 1,5 - 1,9 1,9 - 2,3
> 4,5 - 8,5 > 2,7 - 3,6 > 2,7 - 3,6 > 2,7 - 3,6 > 2,7 - 3,6 > 2,7 - 3,6 > 2,7 - 3,6 > 2,5 - 3 > 1,9 - 2,5 2,3 - 2,7
> 8,5 - 19 > 3,6 - 5 > 3,6 - 5 > 3,6 - 5 > 3,6 - 5 > 3,6 - 5 > 3,6 - 5 > 3 - 3,6 > 2,5 - 2,95 2,7 - 3,3
> 19 - 28 >5-9 >5-9 >5-9 >5-9 >5-9 >5-9 > 3,6 - 5 > 2,95 - 4 3,3 - 4,1
> 28 - 35 > 9 - 16 > 9 - 16 > 9 - 16 > 9 - 16 > 9 - 16 > 9 - 14 >5-9 > 4 - 5,7 4,1 - 5,5
> 35 - 40 > 16 - 22 > 16 - 22 > 16 - 22 > 16 - 22 > 16 - 22 > 14 - 19 > 9 - 14 > 5,7 - 8,2 5,5 - 7,4
> 22 - 28 > 22 - 28 > 22 - 28 > 22 - 28 > 22 - 28 > 19 - 25 > 14 - 19 > 8,2 - 12 7,4 - 11
> 28 - 34 > 28 - 34 > 28 - 34 > 28 - 34 > 19 - 24 > 12 - 17 11 - 16
> 17 - 24 16 - 21
> 24 - 27 21 - 26
Parts
Pos. Description Fig. 12.903
1 Body EN-GJL-250 , EN-JL1040
2 Seat X20Cr13+QT, 1.4021+QT
3 Studs 25CrMo4, 1.7218
4 Spindle guide X20Cr13+QT, 1.4021+QT
8 Hexagon nut C35E, 1.1181
11 Bonnet, closed EN-GJL-250 , EN-JL1040
12 Disc unit X20Cr13+QT, 1.4021+QT / EPDM
14 Spindle * X20Cr13+QT, 1.4021+QT
17 Adjusting screw X20Cr13+QT, 1.4021+QT
29 Cap, open EN-GJL-250 , EN-JL1040
37 Spring * FDSiCr / 51CrV4, 1.8159
41 Lever, open EN-GJS-400-18U-LT, EN-JS1049
43 Bellow EPDM
* Spare parts
The engineer, designing a system or a plant, is responsible for the selection of the correct valve.

Enclosure 10002
ARI-SAFE
Capacity Fig. 903
Capacity saturated steam incl. 10% overpressure
Saturated steam (kg/h) Heating capacity (kW)
Set gauge Capa- Inlet diameter
pressure in city
bar
kg/h 203 317 526 811 1270 2140 3245 5070 6030 8385
1,0
kW 124 193 321 495 774 1310 1980 3095 3680 5120
kg/h 272 425 707 1090 1700 2875 4355 6800 8050 11200
1,5
kW 164 257 427 658 1030 1740 2630 4110 4870 6770
kg/h 305 477 792 1220 1900 3220 4880 7625 10125 14080
2,0
kW 183 285 474 731 1140 1930 2920 4570 6060 8430
kg/h 366 572 950 1460 2285 3865 5855 9145 11990 16660
2,5
kW 217 340 565 870 1360 2300 3480 5440 7120 9900
kg/h 424 662 1100 1695 2645 4475 6775 10600 13880 19300
3,0
kW 250 391 649 1000 1560 2640 4000 6250 8190 11400
kg/h 482 754 1250 1930 3015 5100 7720 12050 15600 21700
3,5
kW 283 442 735 1130 1770 2990 4530 7070 9150 12700
kg/h 535 837 1390 2140 3350 5650 8570 13400 17550 24400
4,0
kW 312 488 810 1250 1950 3300 5000 7800 10200 14200
kg/h 588 920 1530 2355 3680 6215 9410 14710 19300 26850
4,5
kW 341 533 885 1360 2130 3600 5460 8520 11100 15600
kg/h 640 1000 1665 2565 4000 6770 10260 16000 21000 29250
5,0
kW 370 578 960 1480 2310 3900 5910 9240 12100 16900
kg/h 694 1085 1800 2775 4340 7330 11100 17350 22770 31660
5,5
kW 398 622 1030 1590 2490 4200 6370 9950 13000 18200
kg/h 745 1165 1940 2990 4665 7890 11950 18650 24500 34050
6,0
kW 426 666 1100 1700 2660 4500 6820 10600 14000 19400
kg/h 800 1250 2075 3200 4995 8440 12790 20000 26220 36450
6,5
kW 454 709 1180 1810 2840 4790 7260 11300 14900 20700
kg/h 850 1330 2210 3400 5320 9000 13600 21300 27900 38800
7,0
kW 481 752 1250 1930 3000 5080 7700 12000 15800 22000
kg/h 904 1415 2345 3615 5650 9550 14470 22600 29660 41250
7,5
kW 509 795 1320 2030 3180 5370 8140 12700 16700 23200
kg/h 957 1495 2485 3820 5980 10100 15300 23900 31350 43600
8,0
kW 536 837 1390 2140 3350 5660 8580 13400 17600 24500
kg/h 1060 1660 2755 4245 6630 11200 16950 26500 34800 48400
9,0
kW 590 921 1530 2360 3685 6230 9435 14740 19340 26900
kg/h 1165 1820 3025 4665 7290 12300 18650 29150 38250 53200
10,0
kW 643 1000 1670 2570 4010 6790 10300 16000 21100 29300
kg/h 1270 1985 3300 5080 7940 13400 20300 31750 41600 58000
11,0
kW 695 1085 1800 2780 4340 7340 11100 17400 22800 31700
kg/h 1375 2150 3570 5500 8590 14500 22000 34350 45100 62700
12,0
kW 745 1165 1940 2990 4670 7890 12000 18700 24500 34000
kg/h 1480 2310 3840 5920 9250 15600 23650 37000 48500 67500
13,0
kW 798 1250 2070 3190 4990 8430 12800 20000 26200 36400
kg/h 1580 2475 4110 6340 9900 16700 25350 39600 52000 72300
14,0
kW 850 1325 2200 3390 5300 8970 13600 21200 27900 38700
kg/h 1690 2640 4385 6760 10550 17800 27000 42200 55400 77000
15,0
kW 900 1405 2330 3590 5620 9500 14400 22500 29500 41000
kg/h 1790 2800 4655 7170 11200 18950 28700 44800 58800 81800
16,0
kW 950 1480 2460 3790 5930 10000 15200 23700 31100 43300
Calculated acc. to TRD 721 Part 6 and AD2000-A2

Capacity Fig. 903
Capacity water
Set gauge pressure in bar Water 20°C (kg/h)
bar DN 20 DN 25
1 7300 11500
2 10400 16000
3 12700 20000
4 14700 23000
5 16400 25500
6 18000 28000
7 19400 30500
8 21000 32500
9 22000 34500
10 23000 36500
11 24500 38000
12 25500 40000
13 26500 41500
14 27500 42500
15 28000 44000
16 29500 46000
Sizing: 1 l/h =^ 1 kW
Sizing safety valves for the volume flow of water expansion
(DIN 4751 p2 - item 8.1)

Enclosure 10002
ARI-SAFE
Fig. 904
ARI-SAFE - Low pressure steam - safety valve

12.904 PN16/16 EN-JL1040 DN20/32 - 150/250
Flange holes/-
12.904 -10°C to +120°C DIN EN 1092-2 DIN 2533/2533
Type-test approval
Low pressure steam - safety valve: TÜV · SV · . . -688 · D
Requirement
Acc. to TRD 721 Part 5
Application
For low pressure steamgenerators up to 1 bar, DIN 4750 and
DIN EN 12828 Heating systems in buildings
Construction
Standard safety valve, spring loaded, direct loaded, EPDM-bellow, closed bonnet with control
hole, open lifting device, stainless steel seat and spindle
Sizing
refer to „Capacity“.
Order data:
Heating facilities
Fig. .. .904 Selection of possible flow media
Steam
Metal seal;
EPDM-bellow
(Design DN 20 - 100) (Design DN 125 - 150)
10 Edition 02/13 - Data subject to alteration

Fig. 904
DN (mm) 20/32 25/40 32/50 40/65 50/80 65/100 80/125 100/150 125/200 150/250
d0 (mm) 18 22,5 29 36 45 58,5 72 90 106 125
A0 (mm2) 254 398 661 1018 1590 2688 4072 6362 8825 12272
l (mm) 85 100 110 115 120 140 160 180 200 225
l1 (mm) 95 105 115 140 150 170 195 220 250 285
H (mm) 270 280 330 390 435 545 610 690 845 890
X (mm) 150 150 200 250 300 350 400 500 500 500
Drainhole with plug G 1/4“ G 3/8“
(inch)
(optional)
Weight (kg) 8,5 9,5 13,5 20 26 39 53 82 125 165
Capacity Saturated steam

Set Saturated steam (kg/h)
gauge
Capa- Inlet diameter
pres-
city
sure in
bar
0,2 kg/h 72 113 187 289 451 763 1155 1805 2241 3116
0,3 kg/h 92 144 239 368 575 972 1472 2300 2867 3986
0,4 kg/h 110 172 286 440 688 1163 1762 2753 3380 4700
0,5 kg/h 125 196 325 501 783 1325 2006 3135 3858 5365
0,6 kg/h 142 223 370 569 889 1503 2277 3557 4317 6004
0,7 kg/h 158 248 412 634 990 1675 2537 3964 4748 6603
0,8 kg/h 173 271 450 693 1082 1830 2772 4331 5201 7233
0,9 kg/h 179 292 485 746 1166 1971 2986 4666 5616 7809
1,0 kg/h 203 317 526 811 1270 2140 3245 5070 6030 8385
Conversionrates: 1 kW = 860 kcal/h* = 0,86 Mcal/h* = 3,6 MJ/h * not lawful units
1 Mcal/h* = 1000 kcal/h* = 1,163 kW
Parts
1 Body EN-GJL-250 , EN-JL1040
3 Studs 25CrMo4, 1.7218
11 Bonnet, closed EN-GJL-250 , EN-JL1040
12 Disc unit X39CrMo17-1+QT, 1.4122+QT
29 Cap, open EN-GJL-250 , EN-JL1040
37 Spring * FDSiCr / 51CrV4, 1.8159
43 Bellow EPDM
* Spare parts
Edition 02/13 - Data subject to alteration 11

Enclosure 10002
ARI-SAFE-P
Fig. 921 / 922 / 923 / 924
ARI-SAFE-P - Standard safety valve D/G/F

12.921 / 922 / 923 / 924 PN16 EN-JL1040 DN15 - 100
35.921 / 922 / 923 / 924 PN40 1.0619+N DN15 - 100
55.921 / 923 PN40 1.4408 DN15 - 100
Flange holes/-
12.921 / 922 / 923 / 924 -10°C to +300°C DIN EN 1092-2 DIN 2533
35.921 / 922 / 923 / 924 -10°C to +450°C DIN EN 1092-1 DIN 2545
55.921 / 923 -60°C to +400°C DIN EN 1092-1 DIN 2545
Type-test approval
Standard safety valve: TÜV · SV · . . -811 · D/G (Fig. 921/922/923/924)
Requirement
Acc. to EN ISO 4126-1, VdTÜV-leaflet 100, AD2000-A2, TRD 421,
material selection observe TRB 801 No. 45!
Construction
Sizing
Details required
Fig. ... .921 Fig. ... .922 pressure (bar), back gauge pressure (bar)
closed lifting device open lifting device • Medium liquid: Mass flow (kg/h), density (kg/m3), viscosity, temperature (°C), set gauge
Order data:
ARI-SAFE-P - Safety valve,
Figure ....., DN ..., PN .. , Material ........, Set gauge pressure .... bar
EN-JL1040, 1.0619+N: Steam, neutral gases, vapours and liquids

pressure
(higher on request)
Fig. ... .923 Fig. ... .924

gastight cap open lifting device

Enclosure 10002 ARI-SAFE-P
Fig. 921 / 922 / 923 / 924
DN (mm) 15 20 25 32 40 50 65 80 100
d0 (mm) 12 12 15 18 20 29 36 44 55
A0 (mm2) 113 113 177 254 314 661 1018 1520 2376
l (mm) 90 95 100 105 115 125 145 155 175
H (mm) 260 260 270 285 290 290 340 400 450
H (Bellow design) (mm) 285 285 300 325 330 345 400 455 515
X (mm) 130 130 130 150 150 150 200 250 300
Weight (kg) 5 5 5,5 8 9,5 11,5 15,5 20,5 33
Weight (Bellow design) (kg) 5,4 5,4 6 9 10,5 12,8 17,5 23 37
DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100 DN15 DN20 DN25 DN32 DN40 DN50 DN65 DN80 DN100
0,3 - 0,5 0,3 - 0,5 0,2 - 0,6 0,2 - 0,55 0,2 - 0,4 0,2 - 0,4 0,2 - 0,5 0,2 - 0,6 0,2 - 0,5 4-5 3 - 5,5 3 - 4,8 3 - 4,5 3 - 4,5 3 - 3,5 3 - 3,5 3 - 3,5 3 - 4,5
> 0,5 - 1 > 0,5 - 1 > 0,6 - 1,1 > 0,55 - 0,8 > 0,4 - 0,6 > 0,4 - 0,6 > 0,5 - 1,2 > 0,6 - 1,2 > 0,5 - 1,1 >5-6 > 5,5 - 8 > 4,8 - 6 > 4,5 - 8 > 4,5 - 5,7 > 3,5 - 5 > 3,5 - 4,3 > 3,5 - 4,9 > 4,5 - 6,5
> 1 - 1,4 > 1 - 1,4 > 1,1 - 2 > 0,8 - 1,2 > 0,6 - 1,1 > 0,6 - 1,2 > 1,2 - 2 > 1,2 - 2,1 > 1,1 - 1,7 >6-9 > 8 - 12 >6-8 > 8 - 11 > 5,7 - 10 >5-7 > 4,3 - 5,9 > 5,9 - 7 > 6,5 - 10
> 1,4 - 1,9 > 1,4 - 1,9 > 2 - 2,7 > 1,2 - 2 > 1,1 - 1,8 > 1,2 - 1,8 > 2 - 2,7 > 2,1 - 2,6 > 1,7 - 2,4 > 9 - 14 > 12 - 21 > 8 - 12,5 > 11 - 14,5 > 10 - 16 > 7 - 10,5 > 6,9 - 7,5 > 7 - 9 > 10 - 18
> 1,9 - 2,5 > 1,9 - 2,5 > 2,7 - 3,7 > 2 - 3,3 > 1,8 - 2,7 > 1,8 - 2,5 > 2,7 - 3,4 > 2,6 - 3,2 > 2,4 - 3,1 > 14 - 26 > 21 - 27,5 > 12,5 - 16 > 14,5 - 21 > 16 - 22 > 10,5 - 15,5> 7,5 - 8,8 > 9 - 11 > 18 - 35
> 2,5 - 3,5 > 2,5 - 3,5 > 3,7 - 5 > 3,3 - 5,2 > 2,7 - 4,3 > 2,5 - 3,2 > 3,4 - 4,5 > 3,2 - 4,2 > 3,1 - 4 > 26 - 30 > 27,5 - 40 > 16 - 20,5 > 21 - 40 > 22 - 31 > 15,5 - 20 > 8,8 - 14 > 11 - 14,7
> 3,5 - 5 > 3,5 - 4 >5-8 > 5,2 - 8 > 4,3 - 6 > 3,2 - 4,5 > 4,5 - 5,5 > 4,2 - 5,5 > 4 - 5 > 30 - 40 > 20,5 - 30 > 31 - 40 > 20 - 40 > 14 - 21 > 14,7 - 18,8
>5-7 > 4 - 5,5 > 8 - 10,5 > 8 - 11,5 >6-9 > 4,5 - 8,5 > 5,5 - 6,8 > 5,5 - 6,5 > 5 - 8 > 30 - 40 > 21 - 30 > 18,8 - 35
> 7 - 10 > 5,5 - 7 > 10,5 - 15 > 11,5 - 16,5> 9 - 12 > 8,5 - 13 > 6,8 - 8,5 > 6,5 - 9 > 8 - 11 > 30 - 40
> 10 - 16 > 7 - 10,5 > 15 - 23 > 16,5 - 22 > 12 - 17 > 13 - 17 > 8,5 - 14 > 9 - 12 > 11 - 17,5 Design with bellow as standard valve (only Fig. 921/923)
> 16 - 25 > 10,5 - 17 > 23 - 35 > 22 - 30 > 17 - 30 > 17 - 23 > 14 - 23 > 12 - 16,5 > 17,5 - 27,5
> 25 - 33 > 17 - 25 > 35,1 - 40 > 30 - 40 > 30 - 40 > 23 - 34 > 23 - 34 > 16,5 - 20 > 27,5 - 40
> 33 - 40 > 25 - 37 > 34 - 40 > 34 - 40 > 20 - 33
> 37 - 40 > 33 - 40
Certified coefficient of discharge Kdr (Values for D/G variable: < 3 bar)
Kdr DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100
D/G 0,37 0,34 0,37 0,34 0,37 0,34
F 0,26 0,23 0,26 0,23 0,26 0,23
Parts
Pos. Description Fig. 12.921/922/923/924 Fig. 35.921/922/923/924 Fig. 55.921/922
1 Body EN-GJL-250 , EN-JL1040 GP240GH+N, 1.0619+N GX5CrNiMo19-11-2, 1.4408
3 Studs 25CrMo4, 1.7218 A4 - 70
4 Spindle guide X20Cr13+QT, 1.4021+QT X6CrNiMoTi17-12-2, 1.4571
8 Hexagon nut C35E, 1.1181 A4
11 Bonnet, closed EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
28 Cap, closed EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
29 Cap, open EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
30 Cap, gastight EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
36 Lever, closed EN-GJS-400-18U-LT, EN-JS1049 X6CrNiMoTi17-12-2, 1.4571
37 Spring * FDSiCr / 51CrV4, 1.8159 X10CrNi18-8, 1.4310
42 Bonnet, open EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 --
* Spare parts

Enclosure 10002
ARI-SAFE-P
Capacity Fig. 921 / 922 / 923 / 924
Capacity saturated steam / air incl. 10% overpressure
Set gauge pressure I Saturated steam (kg/h) II Air 0°C and 1.013 bara (Nm3/h)
DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100
bar
I II I II I II I II I II I II I II I II I II
0,2 -- -- -- -- 23 27 33 38 44 51 85 100 142 167 195 229 305 358
0,3 20 24 20 24 28 34 41 49 56 67 107 128 182 217 247 294 386 460
0,4 23 28 23 28 34 41 48 58 65 78 126 152 209 252 290 349 450 546
0,5 27 32 27 32 39 47 55 68 74 90 144 176 239 292 332 405 520 632
0,6 30 37 30 37 43 53 62 77 82 102 162 199 267 330 372 459 580 717
0,8 36 45 36 45 51 63 73 91 100 125 189 237 323 404 435 545 680 852
1 41 52 41 52 58 73 84 106 114 144 218 274 370 466 500 631 785 986
2 68 86 68 86 97 123 139 178 188 240 362 461 610 777 830 1061 1300 1657
3 95 123 95 123 137 176 197 253 265 340 510 658 860 1103 1180 1514 1840 2365
4 119 154 119 154 171 221 246 318 330 428 640 826 1070 1385 1470 1902 2300 2970
5 142 185 142 185 205 266 295 383 396 515 765 995 1280 1665 1760 2290 2750 3580
6 166 217 166 217 238 311 343 448 460 602 890 1165 1495 1950 2050 2680 3200 4180
7 189 248 189 248 272 356 391 513 525 689 1015 1330 1700 2230 2340 3065 3650 4790
8 213 279 213 279 305 401 440 577 590 776 1140 1500 1910 2515 2630 3450 4100 5390
9 236 311 236 311 340 446 490 642 655 863 1265 1670 2120 2800 2910 3840 4550 6000
10 259 342 259 342 370 491 535 707 720 950 1390 1835 2330 3080 3200 4225 5000 6600
12 306 405 306 405 440 581 630 837 850 1125 1640 2170 2750 3645 3780 5000 5900 7800
14 352 468 352 468 505 671 730 967 980 1300 1890 2510 3170 4200 4350 5780 6800 9000
16 400 530 400 530 570 761 825 1096 1105 1475 2140 2845 3590 4770 4920 6550 7700 10200
18 445 593 445 593 640 851 920 1226 1235 1645 2390 3180 4000 5340 5500 7320 8600 11450
20 490 656 490 656 705 941 1020 1356 1365 1820 2640 3520 4430 5900 6080 8100 9500 12650
22 540 718 540 718 770 1031 1110 1485 1495 1995 2890 3855 4850 6465 6660 8870 10400 13850
24 585 781 585 781 840 1121 1210 1615 1630 2170 3140 4190 5270 7030 7240 9650 11300 15100
25 609 812 609 812 875 1167 1260 1680 1690 2250 3270 4360 5480 7310 7530 10040 11760 15680
26 630 844 630 844 910 1211 1310 1745 1760 2340 3400 4530 5700 7595 7820 10400 12200 16300
28 680 907 680 907 975 1302 1405 1875 1890 2520 3650 4860 6120 8160 8400 11200 13100 17500
30 730 969 730 969 1045 1390 1505 2000 2020 2690 3900 5200 6550 8720 8990 12000 14000 18700
32 775 1032 775 1032 1110 1480 1600 2130 2150 2870 4160 5540 6980 9290 9580 12750 15000 19900
35 1126 1126 1620 2330 3130 6040 10130 13900 21700
36 1155 1155 1665 2390 3215 6220 10420 14300 22360
40 1283 1283 1840 2650 3560 6880 11500 15850 24700
Stainless steel version max. 24 bar for saturated steam.

Enclosure 10002 ARI-SAFE-P
Capacity Fig. 921 / 922 / 923 / 924
Gauge press. Water 20°C (t/h)
bar DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100
0,2 -- -- 0,97 1,4 1,95 3,63 6,33 8,36 13,06
0,3 0,84 0,84 1,16 1,67 2,33 4,30 7,46 9,80 15,22
0,5 1,11 1,11 1,54 2,21 3,09 5,74 10,0 13,22 20,6
1 1,57 1,57 2,17 3,13 4,37 8,12 14,15 18,69 29,2
2 2,22 2,22 3,07 4,42 6,17 11,48 20,0 26,4 41,3
3 2,72 2,72 3,76 5,42 7,56 14,07 24,5 32,4 50,6
4 3,14 3,14 4,35 6,26 8,73 16,24 28,3 37,4 58,4
5 3,51 3,51 4,86 7,0 9,76 18,16 31,6 41,8 65,3
6 3,85 3,85 5,32 7,66 10,69 19,89 34,6 45,8 71,6
7 4,16 4,16 5,75 8,28 11,55 21,5 37,4 49,5 77,3
8 4,45 4,45 6,14 8,85 12,35 23,0 40,0 52,9 82,6
9 4,72 4,72 6,52 9,39 13,1 24,4 42,4 56,1 87,6
10 4,97 4,97 6,87 9,89 13,81 25,7 44,7 59,1 92,4
12 5,44 5,44 7,53 10,84 15,12 28,1 49,0 64,8 100,2
14 5,88 5,88 8,13 11,71 16,34 30,4 52,9 69,9 109,3
16 6,29 6,29 8,69 12,51 17,46 32,5 56,6 74,8 116,8
18 6,67 6,67 9,22 13,27 18,52 34,4 60,0 79,3 123,9
20 7,03 7,03 9,72 14,0 19,53 36,3 63,3 83,6 130,6

22 7,37 7,37 10,19 14,7 20,5 38,1 66,3 87,7 137,0
24 7,7 7,7 10,64 15,33 21,4 39,8 69,3 91,6 143,1
25 7,86 7,86 10,86 15,64 21,8 40,6 70,7 93,3 146,0
26 8,0 8,0 11,06 15,92 22,2 41,3 72,0 95,1 148,6
28 8,3 8,3 11,47 16,52 23,1 42,9 74,7 98,7 154,2
30 8,6 8,6 11,88 17,1 23,9 44,4 77,3 102,2 159,7
35 9,28 9,28 12,83 18,47 25,8 47,9 83,5 110,4 172,5
36 9,4 9,4 13,0 18,7 26,1 48,7 84,7 111,9 174,9
40 9,92 9,92 13,71 19,75 27,6 51,3 89,3 118,0 184,4

Enclosure 10002
ARI-SAFE-TC
Fig. 941 / 942 / 943
ARI-SAFE-TC - Full lift safety valve D/G, Standard safety valve F

25.941 / 942 / 943 PN40 EN-JS1049 DN15 - 25
55.941 / 943 PN40 1.4408 DN15 - 25
Figure Temperature range Thread
25.941 / 942 / 943 -10°C to +350°C DIN ISO 228 Part 1
55.941 / 943 -60°C to +400°C DIN ISO 228 Part 1
Type-test approval
Full lift safety valve: TÜV · SV · . . -995 · D/G (Fig. 941/942/943)
Requirement
Acc. to EN ISO 4126-1, VdTÜV-leaflet 100, AD2000-A2, TRD 421
Construction
Sizing
Details required
Order data:
ARI-SAFE-TC - Safety valve,
Figure ....., DN ... / ..., PN .. / .., Material ........, Set gauge pressure .... bar
Fig. ... .941 Fig. ... .942
closed lifting device open lifting device Chemical Industry, processing industry, plant manufacturing
EN-JL1040, 1.0619+N: Steam, neutral gases, vapours and liquids

pressure
(higher on request)
Fig. ... .943

gastight cap

Enclosure 10002 ARI-SAFE-TC
Fig. 941 / 942 / 943
DN (mm) 15 20 25 25
G (inch) 1/2“ x 3/4“ 3/4“ x 1“ 1“ x 1 1/4“ 1“ x 1 1/2“
d0 (mm) 12 15 18 18
A0 (mm2) 113 177 254 254
GE (inch) 1/2“ 3/4“ 1“ 1“
GA (inch) 3/4“ 1“ 1 1/4“ 1 1/2“
b (mm) 15 16 18 18
l (mm) 50 50 50 50
l1 (mm) 53 55 58 58
H (mm) 260 260 260 260
H (Bellow design) (mm) 295 295 300 300
X (mm) 120 120 120 120
Weight (kg) 3,5 3,5 3,8 3,8
Weight (Bellow design) (kg) 4,4 4,4 4,7 4,7
DN15 DN20 DN25 DN15 DN20 DN25
0,3 - 0,6 0,3 - 0,48 0,2 - 0,4 5,7 - 6,5 4 - 5,7 4 - 5,4
> 0,6 - 0,9 > 0,48 - 0,68 > 0,4 - 0,88 > 6,5 - 8 > 5,7 - 7 > 5,4 - 6,4
> 0,9 - 1,35 > 0,68 - 1,35 > 0,88 - 1,5 > 8 - 9,3 > 7 - 9,9 > 6,4 - 7,4
> 1,35 - 2,2 > 1,35 - 2,1 > 1,5 - 2,1 > 9,3 - 11 > 9,9 - 14 > 7,4 - 8,4
> 2,2 - 3,3 > 2,1 - 3 > 2,1 - 2,6 > 11 - 15 > 14 - 21 > 8,4 - 10,4
> 3,3 - 4,5 >3-4 > 2,6 - 3,2 > 15 - 19 > 21 - 28,9 > 10,4 - 13,4
> 4,5 - 5,5 > 4 - 5,5 > 3,2 - 4,2 > 19 - 29 > 28,9 - 40 > 13,4 - 16,4
> 5,5 - 6,7 > 5,5 - 7,7 > 4,2 - 6,2 > 29 - 40 > 16,4 - 20,4
> 6,7 - 8,2 > 7,7 - 11,4 > 6,2 - 8 > 20,4 - 28
> 8,2 - 11 > 11,4 - 15 > 8 - 10 Design with bellow as standard valve (only Fig. 941/943)
> 11 - 13 > 15 - 20 > 10 - 15,5
> 13 - 18,5 > 20 - 28 > 15,5 - 18
> 18,5 - 32,4 > 28 - 35 > 18 - 29,9
> 32,4 - 40 > 35 - 40 > 29,9 - 40
Certified coefficient of discharge Kdr (Values for D/G variable: < 3,5 bar)
Kdr 15 20 25
D/G 0,64 0,60 0,75
F 0,45 0,42 0,53
Parts
Pos. Description Fig. 25.941/942/943 Fig. 55.941/943
1 Body EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
2 Screwed seat X6CrNiMoTi17-12-2, 1.4571
11 Bonnet, closed EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
28 Cap, closed EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMo19-11-2, 1.4408
36 Lever, closed EN-GJS-400-18U-LT, EN-JS1049
37 Spring * FDSiCr X10CrNi18-8, 1.4310
61 Coupling X6CrNiMoTi17-12-2, 1.4571
* Spare parts

Enclosure 10002
ARI-SAFE-TC
Capacity Fig. 941 / 942 / 943
Capacity saturated steam / air / water incl. 10% overpressure
Set gauge pressure I Saturated steam (kg/h) II Air 0°C and 1.013 bara (Nm3/h) III Water 20°C (t/h)
DN 15 DN 20 DN 25 DN 25
Inlet
G1/2“ G3/4“ G1“ G1“
Male
Outlet
bar G3/4“ G1“ G1 1/4“ G1 1/2“
Female
do
12 15 18 18
(mm)
I II III I II III I II III I II III
0,2 75 88 3,22 75 88 3,22
0,3 35 41 1,49 47 56 2,17 94 112 3,94 94 112 3,94
0,5 46 57 1,92 65 79 2,80 124 151 5,10 124 151 5,10
1 72 91 2,72 103 129 3,96 188 237 7,19 188 237 7,19
2 120 153 3,85 172 219 5,60 320 405 10,17 320 405 10,17
3 162 209 4,71 238 305 6,86 430 552 12,46 430 552 12,46
4 206 266 5,44 300 390 7,92 545 702 14,39 545 702 14,39
5 246 320 6,08 360 469 8,85 650 845 16,10 650 845 16,10
6 285 375 6,66 420 549 9,70 755 988 17,62 755 988 17,62
7 325 429 7,20 480 628 10,47 860 1130 19,04 860 1130 19,04
8 370 483 7,69 540 708 11,20 970 1275 20,30 970 1275 20,30
9 410 537 8,16 600 787 11,88 1075 1415 21,60 1075 1415 21,60
10 450 592 8,60 655 867 12,52 1180 1560 22,70 1180 1560 22,70
11 490 646 9,02 715 946 13,13 1290 1705 23,80 1290 1705 23,80
12 530 700 9,42 775 1026 13,72 1395 1845 24,90 1395 1845 24,90
13 570 754 9,81 835 1105 14,27 1500 1990 25,90 1500 1990 25,90
14 610 809 10,18 890 1185 14,81 1605 2130 26,90 1605 2130 26,90
15 650 863 10,54 950 1265 15,33 1710 2275 27,90 1710 2275 27,90
16 690 917 10,88 1010 1345 15,84 1820 2420 28,80 1820 2420 28,80
17 730 971 11,22 1070 1420 16,32 1925 2560 29,70 1925 2560 29,70
18 770 1025 11,54 1130 1500 16,80 2030 2705 30,50 2030 2705 30,50
19 810 1080 11,86 1190 1580 17,26 2135 2850 31,40 2135 2850 31,40
20 850 1135 12,17 1245 1660 17,71 2245 2990 32,20 2245 2990 32,20
22 930 1240 12,76 1365 1820 18,57 2455 3275 33,70 2455 3275 33,70
24 1015 1350 13,33 1485 1980 19,40 2670 3560 35,20 2670 3560 35,20
26 1095 1460 13,87 1600 2140 20,20 2885 3850 36,70 2885 3850 36,70
28 1175 1570 14,40 1725 2300 20,90 3100 4135 38,10 3100 4135 38,10
30 1260 1675 14,90 1845 2455 21,70 3320 4420 39,40 3320 4420 39,40
32 1340 1785 15,39 1965 2615 22,40 3535 4705 40,70 3535 4705 40,70
34 1895 15,86 2775 23,10 4990 41,90 4990 41,90
36 2000 16,28 2940 23,8 5270 43,1 5270 43,1
40 2220 17,21 3250 25,00 5850 45,50 5850 45,50
Stainless steel version max. 24 bar for saturated steam.

Notes

Enclosure 10002
ARI-SAFE-TC
Fig. 945 / 946
ARI-SAFE-TC - Heating-safety valve 945, Low pressure steam - safety valve 946

25.945 PN40 EN-JS1049 DN15 - 25
25.945 -10°C to +120°C DIN ISO 228 Part 1
Type-test approval
spring loaded: TÜV · SV · . . -997 · D/G/H (Fig. 945)
Requirement
Acc. to TRD 721 Part 6
Application
Acc. to DIN EN 12828 Heating systems in buildings
Construction
Standard safety valve, spring loaded, direct loaded disc with EPDM insert, EPDM-bellow,
closed spring bonnet with control hole, open lifting device, stainless steel seat and spindle
Sizing
Acc. to TRD 721 Part 6.2.5, refer to „Capacity“.
Order data:

25.946 PN40 EN-JS1049 DN15 - 25
25.946 -10°C to +120°C DIN ISO 228 Part 1
Type-test approval
Low pressure steam - safety valve: TÜV · SV · . . -997 · D (Fig. 946)
Requirement
Acc. toTRD 721 Part 5
Fig. ... .945 Application
For low pressure steamgenerators up to 1 bar, DIN 4750 and
DIN EN 12828 Heating systems in buildings
Construction
Standard safety valve, spring-/weight loaded, direct loaded with EPDM-bellow, closed bonnet
with control hole, open lifting device, stainless steel seat and spindle
Sizing
refer to „Capacity“
Order data:
Figure ..., DN ... / ..., PN .. / ..., Material ..., Set gauge pressure ...bar
Heating facilities
Fig. ... .945 Selection of possible flow media
EPDM-disc, soft seal insert; EPDM-bellow Warm water, hot water
Fig. ... .946

Disc metal seat, EPDM-Bellows seal

Fig. 945 / 946
DN (mm) 15 20 25 25
G (inch) 1/2“ x 3/4“ 3/4“ x 1“ 1“ x 1 1/4“ 1“ x 1 1/2“
d0 (mm) 12 15 18 18
A0 (mm2) 113 177 254 254
GE (inch) 1/2“ 3/4“ 1“ 1“
GA (inch) 3/4“ 1“ 1 1/4“ 1 1/2“
b (mm) 15 16 18 18
l (mm) 50 50 50 50
l1 (mm) 53 55 58 58
H (mm) 260 260 260 260
X (mm) 120 120 120 120
Weight (kg) 3,5 3,5 3,8 3,8
Spring ranges: Standard design (barg)

DN15 DN20 DN25
0,3 - 0,6 0,3 - 0,48 0,2 - 0,4
> 0,6 - 0,9 > 0,48 - 0,68 > 0,4 - 0,88
> 0,9 - 1,35 > 0,68 - 1,35 > 0,88 - 1,5
> 1,35 - 2,2 > 1,35 - 2,1 > 1,5 - 2,1
> 2,22 - 3,3 > 2,1 - 3 > 2,1 - 2,6
> 3,3 - 4,5 >3-4 > 2,6 - 3,2
> 4,5 - 5,5 > 4 - 5,5 > 3,2 - 4,2
> 5,5 - 6,7 > 5,5 - 7,7 > 4,2 - 6,2
> 6,7 - 8,2 > 7,7 - 11,4 > 6,2 - 8
> 8,2 - 11 > 11,4 - 15 > 8 - 10
> 11 - 13 > 15 - 16 > 10 - 15,5
> 13 - 16 > 15,5 - 16
Parts
Pos. Description Fig. 25.945/946
1 Body EN-GJS-400-18U-LT, EN-JS1049
2 Screwed seat X6CrNiMoTi17-12-2, 1.4571
11 Bonnet, closed EN-GJS-400-18U-LT, EN-JS1049
12 Disc unit X6CrNiMoTi17-12-2, 1.4571
29 Cap, open EN-GJS-400-18U-LT, EN-JS1049
37 Spring * FDSiCr
* Spare parts

Enclosure 10002
ARI-SAFE
Fig. 945 Capacity saturated steam incl. 10% overpressure
Saturated steam (kg/h), Heating capacity (kW)
Set gauge pressure in bar Capacity Inlet diameter
DN 15 DN 20 DN 25
kg/h 72 103 188
1,0
kW 44 63 115
kg/h 97 136 254
1,5
kW 58 82 154
kg/h 120 172 320
2,0
kW 72 103 191
kg/h 142 205 376
2,5
kW 85 122 224
kg/h 162 238 430
3,0
kW 96 140 253
kg/h 185 272 489
3,5
kW 109 159 287
kg/h 206 300 545
4,0
kW 120 176 316
kg/h 226 331 596
4,5
kW 131 192 346
kg/h 246 360 650
5,0
kW 142 208 375
kg/h 267 391 703
5,5
kW 153 224 403
kg/h 285 420 755
6,0
kW 164 240 432
kg/h 307 450 810
6,5
kW 174 256 460
kg/h 325 480 860
7,0
kW 185 271 488
kg/h 348 509 917
7,5
kW 195 286 516
kg/h 370 540 970
8,0
kW 206 302 543
kg/h 410 600 1075
9,0
kW 227 332 598
kg/h 450 655 1180
10,0
kW 247 362 651
kg/h 490 715 1290
11,0
kW 267 391 705
kg/h 530 775 1395
12,0
kW 287 421 757
kg/h 570 835 1500
13,0
kW 307 449 809
kg/h 610 890 1605
14,0
kW 326 478 860
kg/h 650 950 1710
15,0
kW 346 506 911
kg/h 690 1010 1820
16,0
kW 365 534 962
Calculated acc. to TRD 721 Part 6 and AD2000-A2

Fig. 946 Capacity saturated steam incl. 10% overpressure
Saturated steam (kg/h)
Set gauge pressure in bar Capacity Inlet diameter
DN 15 DN 20 DN 25
0,2 kg/h -- -- 67
0,3 kg/h 32 43 86
0,4 kg/h 38 53 103
0,5 kg/h 44 62 117
0,6 kg/h 50 71 133
0,7 kg/h 56 78 146
0,8 kg/h 62 86 163
0,9 kg/h 67 95 175
1,0 kg/h 72 103 188
Conversionrates:
1 kW = 860 kcal/h* = 0,86 Mcal/h* = 3,6 MJ/h
1 Mcal/h* = 1000 kcal/h* = 1,163 kW
* not lawful units

Gauge press. Water 20°C (kg/h)
Inlet diameter
bar
DN 20 DN 25 DN 32
1 2700 3900 7000
2 3800 5600 10000
3 4700 6800 12400
4 5400 7900 14300
5 6000 8800 16000
6 6600 9700 17600
7 7200 10400 19000
8 7600 11200 20300
9 8100 11800 21600
10 8600 12500 22700
11 9000 13000 23800
12 9400 13700 24900
13 9800 14200 25900
14 10000 14800 26900
15 10500 15300 27900
16 10800 15800 28800

Sizing: 1 l/h =^ 1 kW
Sizing safety valves for the volume flow of water expansion
(DIN 4751 p2 - item 8.1)

Enclosure 10002
ARI-SAFE-TCP
Fig. 961 / 962 / 963
ARI-SAFE-TCP - Standard safety valve D/G/F

67.961 / 962 / 963 PN100 1.4581/EN-JS1049 DN15 - 25
57.961 / 963 PN100 1.4581 DN15 - 25
67.961 / 962 / 963 -10°C to +300°C DIN ISO 228 Part 1
57.961 / 963 -60°C to +300°C DIN ISO 228 Part 1
Type-test approval
Standard safety valve: TÜV · SV · . . -1041 · D/G(Fig. 961/962/963)
Requirement
Acc. to EN ISO 4126-1, VdTÜV-leaflet 100, AD2000-A2
Construction
Sizing
Details required
Order data:
ARI-SAFE-TCP - Safety valve,
Fig. ... .961 Fig. ... .962 Figure ....., DN ... / ..., PN .. / .., Material ........, Set gauge pressure .... bar
1.4581/EN-JS1049: Steam, neutral gases, vapours and liquids
without metal bellow
Superimposed back no backpressure allowed

pressure
Built up back pressure max. 10% from set pressure (gauge) (higher on request)
Fig. ... .963

gastight cap alternative with lever

Enclosure 10002 ARI-SAFE-TCP
Fig. 961 / 962 / 963
DN (mm) 15 20 25
G (inch) 1/2“ x 1/2“ 1/2“ x 3/4“ 3/4“ x 1/2“ 3/4“ x 3/4“ 3/4“ x 1“ 1“ x 1“
d0 (mm) 12 12 12 12 12 12
A0 (mm2) 113 113 113 113 113 113
GE (inch) 1/2“ 1/2“ 3/4“ 3/4“ 3/4“ 1“
GA (inch) 1/2“ 3/4“ 1/2“ 3/4“ 1“ 1“
b (mm) 15 15 16 16 16 18
l (mm) 42 47 42 47 50 50
l1 (mm) 34 34 34 34 34 34
H (mm) 189 189 189 189 189 189
X (mm) 100 100 100 100 100 100
Weight (kg) 1,2 1,2 1,2 1,2 1,2 1,2
Further connections on request.

DN15 DN20 DN25
0,2 - 0,25 0,2 - 0,25 0,2 - 0,25
> 0,25 - 0,5 > 0,25 - 0,5 > 0,25 - 0,5
> 0,5 - 1 > 0,5 - 1 > 0,5 - 1
> 1 - 1,4 > 1 - 1,4 > 1 - 1,4
> 1,4 - 2,95 > 1,4 - 2,95 > 1,4 - 2,95
> 2,95 - 4,9 > 2,95 - 4,9 > 2,95 - 4,9
> 4,9 - 12 > 4,9 - 12 > 4,9 - 12
> 12 - 20 > 12 - 20 > 12 - 20
> 20 - 27 > 20 - 27 > 20 - 27
> 27 - 35 > 27 - 35 > 27 - 35
> 35 - 45 > 35 - 45 > 35 - 45
> 45 - 59 > 45 - 59 > 45 - 59
> 59 - 100 > 59 - 100 > 59 - 100
Kdr 15 20 25
D/G 0,30
F 0,23
Parts
1 Body GX5CrNiMoN19-11-2, 1.4581
4 Spindle guide X6CrNiMoTi17-12-2, 1.4571
11 Bonnet, closed EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMoN19-11-2, 1.4581
14 Spindle * X6CrNiMoTi17-12-2, 1.4571
17 Adjusting screw X2CrNiMo17-12-2, 1.4404
27 O-ring FPM
28 Cap, closed GX5CrNiMoN19-11-2, 1.4581
29 Cap, open GX5CrNiMoN19-11-2, 1.4581
30 Cap, gastight EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMoN19-11-2, 1.4581
36 Lever, closed (optional) EN AC-4420 (Al)
66 O-ring FPM
67 Lift button X6CrNiMoTi17-12-2, 1.4571
* Spare parts

Enclosure 10002
ARI-SAFE-TCP
Capacity Fig. 961 / 962 / 963
I Saturated steam (kg/h) II Air 0°C and 1.013 bara (Nm3/h) III Water 20°C (t/h)
DN 15 DN 20 DN 25
G1/2“ x G1/2“ G3/4“ x G1/2“ G1“ x G1“
Set gauge
pressure G1/2“ x G3/4“ G3/4“ x G3/4“
in bar
G3/4“ x G1“
do (mm) 12 12 12
I II III I II III I II III
0,2 14 16 0,62 14 16 0,62 14 16 0,62
0,5 24 29 0,98 24 29 0,98 24 29 0,98
1 35 44 1,39 35 44 1,39 35 44 1,39
2 56 71 1,97 56 71 1,97 56 71 1,97
3 75 96 2,41 75 96 2,41 75 96 2,41
4 96 125 2,78 96 125 2,78 96 125 2,78
5 116 150 3,11 116 150 3,11 116 150 3,11
6 135 176 3,41 135 176 3,41 135 176 3,41
7 153 201 3,68 153 201 3,68 153 201 3,68
8 172 227 3,93 172 227 3,93 172 227 3,93
9 191 252 4,17 191 252 4,17 191 252 4,17
10 210 277 4,40 210 277 4,40 210 277 4,40
11 229 303 4,61 229 303 4,61 229 303 4,61
12 248 328 4,82 248 328 4,82 248 328 4,82
13 267 354 5,01 267 354 5,01 267 354 5,01
14 286 379 5,20 286 379 5,20 286 379 5,20
15 304 405 5,39 304 405 5,39 304 405 5,39
16 323 430 5,56 323 430 5,56 323 430 5,56
17 342 455 5,73 342 455 5,73 342 455 5,73
18 361 481 5,90 361 481 5,90 361 481 5,90
19 380 506 6,06 380 506 6,06 380 506 6,06
20 399 532 6,22 399 532 6,22 399 532 6,22
25 494 659 6,95 494 659 6,95 494 659 6,95
30 590 786 7,62 590 786 7,62 590 786 7,62
686 913 8,23 686 913 8,23 686 913 8,23
35
40 784 1040 8,79 784 1040 8,79 784 1040 8,79
45 883 1165 9,33 883 1165 9,33 883 1165 9,33
50 983 1295 9,83 983 1295 9,83 983 1295 9,83
55 1085 1420 10,31 1085 1420 10,31 1085 1420 10,31
60 1185 1550 10,77 1185 1550 10,77 1185 1550 10,77
65 1290 1675 11,21 1290 1675 11,21 1290 1675 11,21
70 1400 1800 11,63 1400 1800 11,63 1400 1800 11,63
75 1500 1930 12,04 1500 1930 12,04 1500 1930 12,04
80 2055 12,44 2055 12,44 2055 12,44
85 2185 12,82 2185 12,82 2185 12,82
90 2310 13,19 2310 13,19 2310 13,19
95 2438 13,5 2438 13,5 2438 13,5
100 2565 13,76 2565 13,76 2565 13,76

Enclosure 10002 ARI-SAFE-TCP
Notes

Enclosure 10002
ARI-SAFE-TCS
Fig. 951 / 952 / 953
ARI-SAFE-TCS - Standard safety valve D/G/F

67.951 / 952 / 953 PN100 1.4581/EN-JS1049 DN15 - 25
57.951 / 953 PN100 1.4581 DN15 - 25
FOR HORIZONTAL APPLICATION 67.951 / 952 / 953 -10°C to +300°C DIN ISO 228 Part 1
57.951 / 953 -60°C to +300°C DIN ISO 228 Part 1
Type-test approval
Standard safety valve: TÜV · SV · . . -1041 · D/G (Fig. 951/952/953)
Requirement
Acc. to EN ISO 4126-1, VdTÜV-leaflet 100, AD2000-A2
Construction
Sizing
calculation acc. to EN ISO 4126-1, TRD 421 and AD2000-A2
Details required
Order data:
ARI-SAFE-TCP - Safety valve,
1.4581/EN-JS1049: Steam, neutral gases, vapours and liquids
Fig. ... .951 Fig. ... .952 (other flow media on request)
Fig. ... .953

gastight cap alternative with lever

Enclosure 10002 ARI-SAFE-TCS
Fig. 951 / 952 / 953
DN (mm) 15 20 25
G (inch) 1/2“ x 1/2“ 1/2“ x 3/4“ 3/4“ x 1/2“ 3/4“ x 3/4“ 3/4“ x 1“ 1“ x 1“
d0 (mm) 12 12 12 12 12 12
A0 (mm2) 113 113 113 113 113 113
GE (inch) 1/2“ 1/2“ 3/4“ 3/4“ 3/4“ 1“
GA (inch) 1/2“ 3/4“ 1/2“ 3/4“ 1“ 1“
b (mm) 15 15 16 16 16 18
l (mm) 42 47 42 47 50 50
l1 (mm) 34 34 34 34 34 34
H (mm) 189 189 189 189 189 189
X (mm) 100 100 100 100 100 100
Weight (kg) 1,2 1,2 1,2 1,2 1,2 1,2
Further connections on request.

DN15 DN20 DN25
0,5 0,5 0,5
> 0,5 - 1 > 0,5 - 1 > 0,5 - 1
> 1 - 1,4 > 1 - 1,4 > 1 - 1,4
> 1,4 - 2,95 > 1,4 - 2,95 > 1,4 - 2,95
> 2,95 - 4,9 > 2,95 - 4,9 > 2,95 - 4,9
> 4,9 - 12 > 4,9 - 12 > 4,9 - 12
> 12 - 20 > 12 - 20 > 12 - 20
> 20 - 27 > 20 - 27 > 20 - 27
> 27 - 35 > 27 - 35 > 27 - 35
> 35 - 45 > 35 - 45 > 35 - 45
> 45 - 59 > 45 - 59 > 45 - 59
> 59 - 100 > 59 - 100 > 59 - 100
Kdr 15 20 25
D/G 0,26
F 0,19
Parts
1 Body GX5CrNiMoN19-11-2, 1.4581
11 Bonnet, closed EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMoN19-11-2, 1.4581
14 Spindle * X6CrNiMoTi17-12-2, 1.4571
17 Adjusting screw X2CrNiMo17-12-2, 1.4404
27 O-ring FPM
28 Cap, closed GX5CrNiMoN19-11-2, 1.4581
28 Cap, open GX5CrNiMoN19-11-2, 1.4581
28 Cap, gastight EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMoN19-11-2, 1.4581
36 Lever, closed (optional) EN AC-4420 (Al)
63 Guide bush X6CrNiMoTi17-12-2, 1.4571
66 O-ring FPM
67 Lift button X6CrNiMoTi17-12-2, 1.4571
* Spare parts

Enclosure 10002
ARI-SAFE-TCS
Capacity Fig. 951 / 952 / 953
I Saturated steam (kg/h) II Air 0°C and 1.013 bara (Nm3/h) III Water 20°C (t/h)
DN 15 DN 20 DN 25
G1/2“ x G1/2“ G3/4“ x G1/2“ G1“ x G1“
Set gauge
pressure G1/2“ x G3/4“ G3/4“ x G3/4“
in bar
G3/4“ x G1“
do (mm) 12 12 12
I II III I II III I II III
0,5 20 24 0,81 20 24 0,81 20 24 0,81
1 30 37 1,15 30 37 1,15 30 37 1,15
2 48 62 1,62 48 62 1,62 48 62 1,62
3 68 86 1,99 68 86 1,99 68 86 1,99
4 84 108 2,30 84 108 2,30 84 108 2,30
5 100 130 2,57 100 130 2,57 100 130 2,57
6 117 152 2,81 117 152 2,81 117 152 2,81
7 133 174 3,04 133 174 3,04 133 174 3,04
8 149 196 3,25 149 196 3,25 149 196 3,25
9 166 218 3,45 166 218 3,45 166 218 3,45
10 182 240 3,63 182 240 3,63 182 240 3,63
11 198 262 3,81 198 262 3,81 198 262 3,81
12 215 284 3,98 215 284 3,98 215 284 3,98
13 231 306 4,14 231 306 4,14 231 306 4,14
14 247 328 4,3 247 328 4,3 247 328 4,3
15 264 351 4,45 264 351 4,45 264 351 4,45
16 280 373 4,59 280 373 4,59 280 373 4,59
17 297 395 4,74 297 395 4,74 297 395 4,74
18 313 417 4,87 313 417 4,87 313 417 4,87
19 329 439 5,01 329 439 5,01 329 439 5,01
20 346 461 5,14 346 461 5,14 346 461 5,14
25 428 571 5,74 428 571 5,74 428 571 5,74
30 512 681 6,29 512 681 6,29 512 681 6,29
595 791 6,80 595 791 6,80 595 791 6,80
35
40 680 901 7,26 680 901 7,26 680 901 7,26
45 765 1010 7,71 765 1010 7,71 765 1010 7,71
50 852 1120 8,12 852 1120 8,12 852 1120 8,12
55 940 1230 8,52 940 1230 8,52 940 1230 8,52
60 1030 1340 8,90 1030 1340 8,90 1030 1340 8,90
65 1120 1450 9,26 1120 1450 9,26 1120 1450 9,26
70 1200 1560 9,61 1200 1560 9,61 1200 1560 9,61
75 1300 1675 9,95 1300 1675 9,95 1300 1675 9,95
80 1785 10,27 1785 10,27 1785 10,27
85 1895 10,59 1895 10,59 1895 10,59
90 2005 10,90 2005 10,90 2005 10,90
95 2110 11,16 2110 11,16 2110 11,16
100 2220 11,36 2220 11,36 2220 11,36
From 0,5 - 4,9 bar, adjustment - horizontal.

Enclosure 10002 ARI-SAFE-TCS
Notes

Enclosure 10002
ARI-SAFE
Safety valve approvals
SAFE- TCS/
SAFE SAFE-P SAFE-TC
TCP
Fig. 900 Fig. 920 Fig. 940
Fig. 950 / 960
Fig. 951-953
Fig. 901-912 Fig. 903 Fig. 904 Fig. 921-924 Fig. 941-943 Fig. 945 Fig. 946
Fig. 961-963
Pressure equipment directive PED 97/23/
EG X X X X X X X X
Module H1, B+D
BV Bureau Veritas X -- -- X X -- -- --
Frankreich / France
DNV Det Norske Veritas X -- -- X X -- -- --

Norwegen / Norway
GL X -- -- X X -- -- X
Germanischer Lloyd
LROS (LRS) X -- -- X X -- -- --
Lloyds Register of Shipping
SELO (SQLO) X X X X X X X X
China / Chine
ASME Code X -- -- -- -- -- -- --
Section VIII-Division 1 (UV-stamp)
Canada Registration X -- -- -- -- -- -- --
(UV-stamp)
GOST-R X X X X X X X X
Russland / Russia
RMROS (RS) X X X X X X X X
Russian Maritime Register of Shipping
Promatomnadzor X X X X X X X X
White russia (Rep. of Belarus)
Prombezpeka X X X X X X X X
Ukraine
Rostechnadzor (Gosgortechnadsor) X X X X X X X X
Russland / Russia
Single approvals
Arbejdstilsynet X X X X X X X X
Danish emploment protection
ABS X X X X X X X X
American Bureau of Shipping
AIB Vincotte X X X X X X X X
Belgien / Belgium
IBR X -- -- X X -- -- --
Indien Boiler Regulations
ISPESL X X X X X X X X
Italien / Italy
RINA X -- -- X X -- -- --
Italien / Italy
Stoomwezen X X X X X X X X
Niederlande / Netherlands
NK X X X X X X X X
Japan
UDT X X X X X X X X
Polen / Poland

Enclosure 10002
ARI-myValve
Calculator
myValve - Calculator
Contents: Module ARI-Safety valves SAFE-Calcuation
- Sizing of valve-size with given capacity, temperature, set pressure and back pressure;
- Calculation acc. to SAFE DIN EN, AD2000, ASME VIII, API520
Media: Integrated media-databank (more than 160 media) with conditions:

- Vapours / gases
- Steam (saturated and superheated)
- Liquids
Special features: - Project administration of the calculation and product data incl. spare part drawings relating to the project and tag number
- Direct output or calculation and product data in PDF format
- Product data could be taken for a direct order
- SI- and ANSI-units with direct conversion to another databank
- Settings with over pressure or absolute pressure
- All ARI valves are integrated in a databank
- Direct access relating to the product on data sheets, operating instructions, pressure-temperature-diagram,
controller characteristics, spare part drawings and CAD-symbols on the website.
- Operation in company networks possible (no complex installations on individually PC‘s necessary)
- Extensive catalogue extending over several product groups
System Requirements: Windows operating systems, Linux, etc.

Enclosure 10002
ARI-SAFE
Flange dimensions / Pressure-temperature-ratings
Standard-flange dimensions SAFE Fig. 901-912, 903, 904 Flange holes / -thickness tolerances acc. to DIN 2533/2544/2545
DN1 / DN2 (mm) 20 / 32 25 / 40 32 / 50 40 / 65 50 / 80 65 / 100 80 / 125 100 / 150 125 / 200 150 / 250
PN16 DIN 2533 (mm) 220 250 285
ØD1 PN40 DIN 28607 (mm) 105 115 140 150 165 185 200
235 270 300
PN40 DIN 2545 (mm)
PN16 DIN 2533 (mm)
ØD2 PN16 DIN 28605 (mm) 140 150 165 185 200 220 250 285 340 405
PN16 DIN 2543 (mm)
EN-JL1040 (mm) 16 16 18 18 20 20 22 24 26 26
EN-JS1049 (mm) 18 18 18 19 20 22 24 24 -- --
b1
1.0619+N (mm) 20 20 20 21 22 24 26 28 31 34
1.4408 (mm) 16 16 18 19 20 22 22 23 -- --
EN-JL1040 (mm) 18 18 20 20 22 24 26 26 30 32
EN-JS1049 (mm) 19 19 20 20 20 20 22 22 -- --
b2
1.0619+N (mm) 19 19 20 20 20 20 22 22 27 29
1.4408 (mm) 15 16 17 17 17 17 19 19 -- --
Flanges acc. to DIN EN 1092-1 / -2, Flangeholes/-thickness tolerances acc. to DIN, raised face, facing acc. to DIN 2526 form C
Standard-flange dimensions SAFE-P Fig. 921-924 Flange holes / -thickness tolerances acc. to DIN 2533/2544/2545
DN (mm) 15 20 25 32 40 50 65 80 100
PN16 DIN 2533 (mm) 220
ØD 105 115 140 150 165 185 200
PN40 DIN 2545 (mm) 235
EN-JL1040 (mm) 16 16 18 18 20 20 22 24
b 1.0619+N (mm) 18 18 18 18 20 20 22 24
1.4408 (mm) 18 18 18 18 20 20 22 24
Flanges acc. to DIN EN 1092-1 / -2, Flangeholes/-thickness tolerances acc. to DIN, raised face, facing acc. to DIN 2526 form C
Standard-flangeholes Flange holes / -thickness tolerances acc. to DIN 2533/2544/2545
DN (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250
ØK (mm) 75 85 100 110 125 145 160 180 210 240 295 355
PN16
n x Ød (mm) 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 12x22 12x26
ØK (mm) 75 85 100 110 125 145 160 190 220 250 -- --

PN40
n x Ød (mm) 4x14 4x14 4x18 4x18 4x18 8x18 8x18 8x22 8x26 8x26 -- --
Pressure-temperature-ratings acc. to DIN EN 1092-2

Material -60°C to <-10°C* -10°C to 120°C 150°C 200°C 250°C 300°C 350°C 400°C 450°C
EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6 -- -- --
EN-JS1049 40 (bar) on request 40 38,8 36,8 34,8 32 28 -- --
Pressure-temperature-ratings acc. to manufacturers standard

1.0619+N 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 13,1

1.4408 40 (bar) 40 40 36,3 33,7 31,8 29,7 28,5 27,4 --
1.4581 100 (bar) 50 100 98 93,3 88,5 83,3 80,4 78 --
Intermediate values for max. permissible operational pressures can be determined by linear interpolation of the given temperature / pressure chart.
* Studs and nuts made of A4-70 (at temperatures below -10°C)
Dimensions in mm
Weights in kg
Pressures in barg (gauge)
1 bar =^ 105 Pa =^ 0,1 MPa
Kvs in m3/h

Enclosure 10002
ARI-SAFE
Special design
Soft sealing disc: WEDI
EPDM -35 °C to +150 °C Abbreviation E
Viton (FPM) -25 °C to +180 °C Abbreviation V
Neoprene (CR) -30 °C to +125 °C Abbreviation N
(Fig. 950/960 WEDI max. 40 bar)
Bellows seal EPDM (max. +120 °C)

Disc: Metal sealing
or soft sealing
Soft sealing disc WEDI / Bellows seal EPDM
Bellow - stainless steel

(Test: german TA-Luft TÜV-Test-No.. 922-960324)
Balanced stainless steel-bellow with balanced piston (Only for closed version!)
Parts
Pos. Description

special design / accessories
Body material DN1 x DN2 A B Ø S H
1.0619+N 50 x 80 176 70 155

14 12
1.4408 65 x 100 212 90 175
EN-JL1040 80 x 125 245 130 205
EN-JS1049
18 16
1.0619+N 100 x 150 295 165 230
1.4408
EN-JL1040 125 x 200 318 183 20 260

22
1.0619+N 150 x 250 360 200 22 295
Proximity switch Support tongues
Lock bushing Test gag Rupture disc
Seat 1.4571 / Stellite No. 21

Disc 1.4571 / Stellite No. 6
Heating jacket and removable lifting aid Removable lifting aid Chemical-version 1.4571

ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock,
Tel. +49 52 07 / 994-0, Telefax +49 52 07 / 994-158 or 159 Internet: http://www.ari-armaturen.com E-mail: [email protected]

Enclosure 10002
Operating and installation instructions

Safety valves SAFE
SAFE SAFE-P
(Series 900) (Series 920)
SAFE-TC SAFE-TCP/TCS
(Series 940) Contents (Series 960/950)
1.0 General information on operating 7.0 Care and maintenance.................................11
instructions ..................................................... 2 7.1 Setting instructions ................................................11
2.0 Notes on possible dangers........................... 2 7.1.1 Removing the cap ........................................11
2.1 Significance of symbols ..........................................2 7.1.2 Changing the set pressure
2.2 Explanatory notes on safety information .................2 “without” spring change .............................. 12
7.1.3 Changing the set pressure
3.0 Storage and transport .................................. 3 “with” spring change ................................... 12
4.0 Description..................................................... 3 7.2 Representation .................................................... 14
4.1 Scope of applications ..............................................3
8.0 Troubleshooting .......................................... 15
4.2 Operating principles ................................................3
9.0 Troubleshooting table ............................... 15
4.3 Diagram...................................................................4
4.3.1 Parts list ..........................................................5
10.0 Dismantling the valve or the top part ..... 17
4.4 Technical data - remarks .........................................6
11.0 Warranty / Guarantee ................................ 17
4.5 Marking .................................................................7
12.0 EC declaration of conformity ................... 18
5.0 Installation...................................................... 8
5.1 General notes on installation...................................8
6.0 Putting the valve into operation................. 10
Rev. 0040401000 1210 englisch

SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS
1.0 General information on operating instructions

These operating instructions provide information on mounting and maintaining the fittings.
Please contact the supplier or the manufacturer in case of problems which cannot be
solved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.
The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
ATTENTION !
... Warning of general danger.
Non-compliance with operating instructions is dangerous!

Read the operating instructions before installation, operation,
maintenance or disassembly and adhere to them strictly.
2.2 Explanatory notes on safety information

In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and maintenance instructions as well as technical data (in the operating instructions,
product documentation and on the device itself) must also be complied with to the fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.
Page 2 Rev. 0040401000 1210

3.0 Storage and transport

ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
4.0 Description
4.1 Scope of applications
Safety valves are used to protect pressurised systems.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed
these requirements, e.g. aggressive or abrasive media, the operator should
state the higher requirements when ordering
- Valves made from grey cast iron are not authorised for use in systems subject
to TRD 110.
- When media in Fluid Group 1 are used, seal exteriors must be designed so that
they pose no danger to humans or the environment.
- Open safety valves (open bonnet / open cap) are not permissible for fluids,
dusty atmospheres, open air use or for any Group 1 fluids in accordance with
Pressure Equipment Directive 97/23/EC.
The information complies to the Pressure Equipment Directive 97/23/EC.
It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles
Safety valves are safety devices designed to prevent the pressure in any pressurised
system from exceeding the maximum permissible pressure by more than the permissible
tolerance of, usually +10%.
Rev. 0040401000 1210 Page 3

4.3 Diagram
Fig. 901 Fig. 921 Fig. 941 Fig. 961
fig. 1
Fig. 902 / 912 / 903 / 904 / 922 / 924 / 945 / 946
WEDI Bellow
Lever Disc series 950 Bellow series 940

Fig. 951/952; 961/962
fig. 2
Page 4 Rev. 0040401000 1210

4.3.1 Parts list
Pos. Description Pos. Description

1 Body 32 Hex. nut
2 Seat (not changeable) 33 Lift bolt
2 Screwed seat (SAFE-TC) 34 Screw
3 Stud 35 Lift fork
4 Spindle guide 36 Lifting lever
7 Gasket 37 Spring
8 Hex. nut 38 Screw
9 Lift limitation ring 39 Bolt
10 Spindle ring 40 Split pin
11 Bonnet, closed 41 Lever open
12 Disc unit 42 Bonnet, open
13 Lifting aid 43 Bellow
14 Spindle 44 Ring
15 Gasket 45 Ring
16 Spring type straight pin 47 Ball
17 Adjusting screw 48 Retaining ring
18 Ball 55 Bellow unit
19 Spindle cap 59 Protective rim
20 Parallel pin 60 Spacer
21 Lock nut 61 Coupling
22 Hex. head screw 62 Weight
23 Lead seal 63 Guide bush
25 Snap ring 65 Coupling
26 Spring plate 66 O-Ring
27 Gasket 67 Lift button
28 Cap, closed 68 Spring type straight pin
29 Cap open 70 Balanced piston
31 Ring
Refer to the data sheet for information about materials.
Rev. 0040401000 1210 Page 5

4.4 Technical data - remarks
for
- Principal dimensions
- Pressure-temperature-ratings, etc. refer to datasheet.
Series 900: DN 20/32 - DN 150/250, 1”x2“ - 6”x10”

EN-JL1040, EN-JS1049, 1.0619+N, 1.4408, SA 216 WCB
PN 16/16, PN 40/16, ANSI 150/150, ANSI 300/150
Approval acc. to:
Figure 901, 902, 911, - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
912 TRD 421.
Application letter D/G and F
- ASME Code Section VIII-Division 1 (UV-Stamp)
Figure 903, 904, 990 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D (for Figure 904, 990)
Series 920: DN 15 - DN 100

EN-JL1040, 1.0619+N, 1.4408
PN 16, PN 40
Approval acc. to:
Figure 921-924 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Series 940: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4408
PN 40
Approval acc. to:
Figure 941-943 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Figure 945-946 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D
Series 950/960: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4581
PN 100
Approval acc. to:
Figure 951-953 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2.
Figure 961-963 Application letter D/G and F
Accessories: Stainless steel bellow for back-pressure compensation;

elastomer bellow; soft sealing disc; lock bush; proximity switch;
heating jacket; test gag; rupture disc; support tongues;
removable lifting aid
Page 6 Rev. 0040401000 1210

4.5 Marking
Fig.-No./Type Type-test
Safety valve (TÜV) approved No. Kdr CE-marking
Manufacturer d0
Notified
body
Approval
Set pressure Adjusting services
Serial-No.
Soft sealed disc: Year of manufacture

E = EPDM -35°C up to 150°C
V = Viton (FPM) -25°C up to 180°C
N = Neoprene -30°C up to 125°C
NB-stamp
Safety valve (ASME) Size (inch) UV-stamp CE-marking
Manufacturer
Notified
body
Fig.-No./Type
Capacity
Fig. 3: Set pressure
Units:
Type test plates SCFM = air
lb/hr = steam
gal/min = water
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
Set pressure
Mechanic No.
BA/BQ
Logo of external approvals
Fig. 4: Body (outlet)

Series with thread connections are marked on the body.
Rev. 0040401000 1210 Page 7

5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governing
installation work:
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Connecting bolts for pipe flanges should be mounted preferably from the
counter flange side (hexagon nuts from the valve side).
At DN15-32: If valves should be mounted directly to valves, the upper flange
connecting bolts should be preferably executed with studs and hexagon nuts on
both sides.
- Valve mountings such as actuators, handwheels, bonnets must not be used to
See data sheet for weights.
- The blow-off line shall be sufficiently large to ensure that the internal back-
pressure while blowing-off does not exceed 10% (on reqest max. 15%) of the
set pressure. (Exception: safety valves with metallic bellow for back-pressure
compensation).
- If back pressure exceeds 10% (on request max. 15%) of set pressure, the
safety valve must be fitted with a metallic bellow seal for back pressure
compensation. The maximum back pressure must be specified by the
manufacturer. If necessary a leak detector should be provided to monitor the
back pressure compensating metallic bellow seal, but the leak detector must
not block ventilation.
- The ventilation hole in the bonnet of safety valves with a metallic bellow seal
must remain open as a matter of principle, although in the case of Group I fluids
(PED 97/23/EC) a non-isolatable pipeline must be connected to remove the
medium safely (without back pressure if the bellow seal is damaged. Ventilation
must not be blocked by any leak detector used.
- No pipe sections or screws must protrude into the spring bonnet through the
inspection connection. Blockage hazard!
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow with or without a
rupture disk.
- Safety valves shall be installed with upright spindle, not series 950 when
marked, “Einbau nur horizontal (Installation only horizontal)”, then they must be
installed horizontally.
Page 8 Rev. 0040401000 1210
- Flange gaskets shall be fitted concentrically and not restrict the flow cross
section.
- Keep the shaft of the spindle-unit free from paint (open bonnet / cap).
- Blow-off lines shall be laid with gradient.
- The ratio pao/po shall be taken into account when dimensioning the system.
- Safety valves shall be equipped with support tongues to absorb high reaction
forces.
- Pressure losses in the line to the safety valve shall not exceed 3%.
- Ensure that adequate drip pans are used if setting media in Fluid Group
pursuant to PED 97/23/EC.
- Planners / construction companies or operators are responsible for positioning and
installing products.
- The valves are designed for application, not influenced from weather.
- For application outside or in adverse environments like corrosion-promoting conditions
(sea water, chemical vapours, etc.), special constructions or protective measures are
recommended.
- Refer to appropriate TRD 421, AD2000-A2, DIN, ASME Code rules for piping and
installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before
installation.
- Water shall be drained from the safety valve and blow-off line via the blow-off line
(drainage points always at the lowest point).
Support
Bellow
Drip pan
Drainage Drainage at lowest point
fig. 5
Rev. 0040401000 1210 Page 9

6.0 Putting the valve into operation

ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
- Before putting the valve into operation, check material, pressure, temperature,
direction of flow and also check that the data of the valve are correct for the
plant
(refer to type test plate)
- Remove any test gag from cap and close opening with stopper.
- Remove protective caps and lever lock before putting the valve into operation
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow without a rupture
disk. (Note point 5 “Installation”).
- When operating without a blow-off line, medium may spurt from the valve outlet.
Injury hazard!
- Blowing off may generate loud flow noise.
- Medium may be discharged from the ventilation or inspection hole in the spring
bonnet (safety valves with stainless steel bellows and heating valves)
Injury hazard!
- Hot vapour may be discharged if the spring bonnet is open.
Before putting a new plant into operation or restarting a plant after repairs or
modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
Page 10 Rev. 0040401000 1210

7.0 Care and maintenance

Maintenance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- Too frequent lifting for test purposes can increase wear of the sealing surfaces!
- The safety valve must be lifted from time to time in line with current regulations
(by ≥ 85% from the set pressure) to ensure that the valve works correctly.
(The intervals at which this must be done depends on various factors so that no
generally applicable interval can be specified)
- Original parts only should be fitted as spares as a matter of policy.
- In safety valves with an open spring bonnet there is a danger of being crushed
between the spring windings during lifting and setting.
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due
to particles between the seat and disc.
- If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been
damaged.
This can only be rectified at our works or by an authorised contractor.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be
returned to the original position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- The manufacturer accepts guarantee liabilities only if tampering by third parties is
prevented.
7.1 Setting instructions
ATTENTION !
The following work must only be carried out by authorised specialist workshops
or at the operator’s own responsibility with monitoring by an independent agency
(e.g. TÜV).
7.1.1 Removing the cap
ATTENTION !
If there is back pressure or during setting/lifting, medium may be discharged from
the open bonnet, or into the adjusting screw area if the bonnet is closed.
ATTENTION !
When changing to the cap without lifting device (series 911, 923, 943), the
spindel cap (pos. 19) must be removed.
Open caps
- Remove slit pin (pos. 40), bolt (pos. 39).
- Extract lifting lever (pos. 41).
- Remove screw (pos. 38).
- Unscrew cap (pos. 29).
Closed caps
- Press lifting lever (pos. 36) towards bonnet (pos. 11) and against stop.
- Unscrew cap (pos. 28).
Rev. 0040401000 1210 Page 11

Closed cap series 960/950
- Remove spring type straight pin (pos. 68)
- Remove lift button (pos. 67) or lifting lever (pos. 36)
- Unscrew cap (pos. 28)
7.1.2 Changing the set pressure “without” spring change
ATTENTION !
- When changing the set pressure in a pressurised system bear in mind vapour
discharge if bonnet is open, in adjusting screw area if bonnet is closed.
- Note spring setting range.
- Check the spring range.
- Spindle (pos. 14) must be held fast by all alterations.
- Loosen lock nut (pos. 21).
- Turn adjusting screw (pos. 17) clockwise to increase and anticlockwise to reduce the set
pressure.
- Secure spring setting by tightening lock nut (pos. 21).
- Assemble lifting device.
7.1.3 Changing the set pressure “with” spring change
ATTENTION !
- Depressurise the system before dismantling or opening the safety valve.
- For removing the cap refer to 7.1.1.

- Extract parallel pin (pos. 20) and lift off the spindle cap (pos. 19).
- Slacken locknut (pos. 21) and relieve spring (pos. 37) by turning adjusting screw (pos. 17)
anticlockwise.
- Unscrew nuts (pos. 8) at flange connection and remove bonnet (pos. 11/42).
Fig. 940: loosen coupling (pos. 61)
Fig. 950/960: loosen bonnet (pos. 11)
ATTENTION !
- With higher set pressures, the two nuts (pos. 8) on the longer studs (pos. 3)
must be removed last and simultaneously!
- Remove top spring-plate (pos. 26) and spring (pos. 37).
- Extract spindle (pos. 14) with disc (pos. 12/12a), guide plate (pos. 4/4a) and bottom
spring-plate (pos. 26).
- Clean seat (pos. 2) and disc (pos. 12).
- Insert spindle (pos. 14) with disc (pos. 12), guide plate (pos. 4), spring-plate (pos. 26) and
different spring (pos. 37).
Page 12 Rev. 0040401000 1210

- when carrying out any adjustment work hold the spindle (pos. 14) firm to prevent it
twisting.
ATTENTION !
- Torques must be observed:
M10 16-25 Nm screw joint BR940 100 Nm
M12 30-40 Nm screwed seat BR940 180 Nm
M16 70-90 Nm bonnet BR950/960 60 Nm
M20 150-175 Nm
- Check spring marking in accordance with manufacturer’s data.

- Note spring setting range.
- Change seals.
- Fit bonnet (pos. 11/42) and reset the set pressure; make sure spring setting range is
appropriate.
- Secure spring setting by means of lock nut (pos. 21).
- Assemble lifting device.
- If necessary, replace both spring plates (pos. 26) and use longer studs (pos. 3) when
fitting a spring for a higher set pressure.
- Further information obtainable from the manufacturer.
Only for series 900

ATTENTION !
When changing the set pressure and fitting a new spring, note that safety valves
with set pressures between 0.2 and 1.5 bar have a greater lift.
Therefore:
Set pressure in the range Spring change only in
the range
0.2 to 1.5 bar 0.2 to 1.5 bar
> 1.5 bar > 1.5 bar
Only for series 950:

ATTENTION !
Safety valves for horizontal application, must also to be set in a
horizontal position (≤ 4.9 bar).
Rev. 0040401000 1210 Page 13

7.2 Representation
SAFE-TCS
SAFE-TCP
SAFE-TC
Bellow
Closed cap
Open cap
fig. 6
Page 14 Rev. 0040401000 1210

8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
-
It is essential that the safety regulations are observed when identifying faults.
If malfunctions cannot be eliminate with the help of the following table

“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
9.0 Troubleshooting table

ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work!
- read point 6.0 before restarting the plant !
Fault Possible cause Corrective measures

Safety valve does not Flange covers not removed. Remove flange covers.
respond,
Test gag still in place. Remove test gag.
no flow
Spring blocked. Remove pipe or screw projecting into
bonnet through inspection connection.
Set pressure too high. Reset (point 8.1) or replace the safety
valve.
Stainless steel bellow defective, Replace the safety valve.
no back-pressure compensation.
Back-pressure not taken into account. Reset (point 8.1) or, if necessary,
replace the safety valve.
The use of a stainless steel bellow to
compensate for back-pressure should
be considered.
Medium viscous or sticky Use bellow / heating jacket. Insert
rupture disc upstream if necessary.
The valves and piping must be Heating !

protected against freezing and
solidifying media.
Stem cannot be lifted. Pressure less than 85% of set It must be possible to lift the spindle at
pressure. over 85% of the set pressure.
Safety valve seat leaking. Working pressure higher than 90% of Working pressure must be less than
set pressure. 90% of the set pressure.
At low pressures: lever not in neutral Press lever into neutral position
position with closed cap. (towards bonnet).
Safety valve flattering. Refer to separate point “Flattering”.
Medium contaminated; foreign body Raise spindle briefly or, if necessary,
between seat and disc. replace safety valve.
Use of a soft sealing disc should be
considered.
Rev. 0040401000 1210 Page 15


Flange broken. Damage during transport. Replace safety valve.
Flange bolts not evenly tightened. Replace safety valve.
Transfer of forces such as bending or Install free of tension.
torsional forces.
Pressure surges. Safety valve not installed at highest Install safety valve at highest point.
point.
Valve drainage inadequate or not fitted. Install drainage system a required by
regulations.
Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screw
above cap, Figure 990).
Spring corroded by medium and Replace safety valve.
broken. In the case of vapour, select open cap
or bonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. Replace safety valve.
liquids) emerging from valve. Select design with closed bonnet and
cap.
Install a guard if necessary.
Injury from vapour discharge Install a guard if necessary
(open bonnet / cap)
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or
radius in connection socket. Select
larger line if necessary.
Poor welding (root pass), gaskets at Change conditions.
inlet and outlet flanges too small or not
concentric.
Safety valve capacity too high. Install smaller safety valve.
Burner capacity too low. Install smaller safety valve.
Blow-off line too long or diameter too Use larger diameter or back-pressure
small. compensation by stainless steel
bellow.
Inlet and/or outlet socket too small. Install with dimensions larger than DN
of inlet and outlet lines.
Back-pressure higher than 10%. Install stainless steel bellow for
pressure compensation.
Capacity too low. Safety valves not applied unsuitable for Select and install suitable safety
plant conditions. valves.
Safety valve not applied in line with Adjust conditions.
current DIN, AD, TRD, etc. rules.
Page 16 Rev. 0040401000 1210

10.0 Dismantling the valve or the top part

ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic
media.
11.0 Warranty / Guarantee

The extent and period of warranty cover are specified in the "Standard Terms and
Conditions of Albert Richter GmbH & Co. KG“ valid at the time of delivery or, by way of
departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under
conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist
appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.
The manufacturer will accept warranty liability only if there has been no third party
tampering.

ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: [email protected]
Rev. 0040401000 1210 Page 17

12.0 EC declaration of conformity

ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, D-33756 Schloß Holte-Stukenbrock
EC declaration of conformity
as defined by
the Pressure Equipment Directive 97/23/EC
Herewith we declare,
that according to the above mentioned Pressure Equipment Directive (PED) the below listed
products comply and have been approved according to Module H1 and also EC type test according
to module B+D through Lloyd´s Register Quality Assurance GmbH (BS-No. 0525),
Am Sandtorkai 41, D-20457 Hamburg.
Certificate-No: 50003/2
Safety valves Safety valves

SAFE series 900 SAFE-P series 920
Type 901,911,912,902,903,904,990 Type 921,922,923,924
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
AD 2000 Code of Practice A2 AD 2000 Code of Practice A2
- Cast iron with spher. graphite - Cast steel
- Cast steel TRD 421, TRD 721
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
ASME Code Section VIII-Div. 1
Safety valves Safety valves
SAFE-TC series 940 SAFE-TCP/TCS series 950/960
Type 941,942,943,945,946 Type 951,952,953,961,962,963
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
- Cast iron with spher. graphite - Cast iron with spher. graphite
- Cast steel - Cast steel
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
Schloß Holte-Stukenbrock, 11.01.2010
...................................................
(Brechmann, Managing director)
Page 18 Rev. 0040401000 1210

Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
Enclosure 10009
OPERATING AND MAINTENANCE MANUAL Rev.2
VALVES A20 R/T
Sheet 1 of 5
OPERATING AND MAINTENANCE MANUAL

ALFA WAFER VALVES
Models ALFA 20R/T
INDICE PAG.
0. Technical Data 2
1. Trasportation, handling and storage 3
2. Mounting 3
3. Maintenance 3
4. Testing 3
5. How to order spare parts 3
6. Warnings and use limitations 4
Enclosure 10009
VALVES A20 R/T
Sheet 2 of 5
0. Technical Data
0.1 MANUFACTURER ALFA VALVOLE S.r.l. - V.le del Lavoro 19

20010 CASOREZZO (MI) – ITALY
Tel. 02-90296206 - Fax. 02-90296292

e-mail [email protected]
0.2 ALLOWED USE AND LIMITS
Service ON-OFF
Fluids liquids e gases Group 1 (dangerous) in accordance to the EC Directive 97/23/CE NOT UNSTABLE
Tightness limits on brand new valve
Hydrostatic Body Test Zero Leakage

Hydrostatic Seat Test Zero Leakage
Pneumatic Seat Test ( 6 bar Air) Zero Leakage
Model ALFA 20R/T ALFA 20R/T

BS 5351 ASME B16.34
800 Lb 1500 Lb
Nominal Diameters DN 32-50 DN 32-50

Seat Max. Working
64 255
Pressure at Amb.Temp. (bar)
Body Max. Working
138 255
Pressure at Amb.Temp. (bar)
Max. Working
8 230
Pressure at Max.Temp. (bar)
Max. Working
200ºC 150ºC
Temperature
Min. Working -29ºC for A105
Temperature -40ºC for A350LF2
-40ºC stainless steel bodies
Max.simultaneous Working Please contact ALFA VALVOLE Technical Dept.
conditions
Body Test (bar)
207 383
Pressure
0.3 SPECIFIC DESIGN PROCEDURES
- END CONNECTIONS Screwed ANSI/ASME B1.20.1 or GAS UNI ISO 228/1a

Socket Weld ANSI B16.11 / Butt Weld ANSI B16.25
- FIRE SAFETY BS6755 Part 2
- BODY THICKNESS ASME VIII Div.1 – BS 5351
- SCREWED CONNECTION ASME B16.34
- SIMULTANEOUS LOADS Pressure, Bending, Axial Loads
- WIND LOADS Negligible
- EARTHQUAKE LOADS Not Applicable, according to ASME III Div.1 Subsect.NB
- FATIGUE from Atmospheric to Service Pressure Cycles Not Applicable, according to ASME III Div.1 Subsect.NB
- FATIGUE from Service Pressure Fluctuation Not Applicable, according to ASME III Div.1 Subsect.NB
- MAX. LIFE in service hours Function of actual simultaneous working conditions and fluids but anyway not
longer than :
- 100.000 hours with periodical inspections (see also para 6.6);
- 1500 cycles from Atmospheric to Pressure at Max. Working Temperature for
carbon steel bodies;
- 13000 cycles from Atmospheric to Pressure at Max. Working Temperature for
stainless steel bodies;
- 50000 operations of opening/closing the valve on ideal liquid service
- 5000 operations of opening/closing the valve on ideal gas service
- AVAILABLE CORROSION OVERTHICKNESS 4 mm min. (carbon steel valves only)

Enclosure 10009
VALVES A20 R/T
Sheet 3 of 5
1. TRANSPORT, HANDLING AND STORAGE
1.1 Transport and handling
The valves must be transported and handled maintaining the ball in the open position.
DO NOT remove the protection caps from the ends until the valve is to be mounted in line.
1.2 Storage
The valves with bodies in carbon steel and stainless steel must both be stored with the ball in the OPEN position in a
location which is dry and free from fumes, gas or corrosive vapours.
For long storage periods it is advisable to cover the external surface with a layer of protective wax (Tectyl) or close the
valves in polythene bags.
2. MOUNTING
2.1 All ALFA valves are bi-directional and supplied ready to use.
They can be mounted with the stem orientated in any direction.
ATTENTION : remove the protective caps from the valve ends before mounting in the line and ensure that
the body closure is on the side of the fluid entrance.
3. MAINTENANCE
3.1 A general control of the valve is advisable every 2 Years of functioning or every 5.000 cycles of opening and closing.
The execution of eventual intervention must follow the procedure illustrated on the attached card.
4. TESTING
4.1 Before carrying out any test ensure, effecting at least one complete stroke of opening and closing, that there are no
problems in the movement of the ball.
4.2 The valve must be tested using the following procedure:
a) Place the ball in a semi-open position

b) Pressurise the body with water of a pressure 1,5 times the maximum operating pressure at ambient temperature
indicated in the table found at point 0.2
c) Verify that there are no leaks from the body seals
d) Release the pressure
e) Close the valve
f) Pressurise the first seat with water at a pressure 1,1 times the maximum operating pressure at ambient temperature
g) Verify that there are no leaks from the end opposite to that pressurised
h) Release the pressure
i) Pressurise the second seat (if present) with water at a pressure 1,1 times the maximum operating pressure at ambient
temperature indicated in the table found at point 0.2
j) Verify that there are no leaks from the end opposite to that pressurised
k) Release the pressure and drain the valve completely of any water
l) Repeat the tests described in points f) and i) using air at 6 bar verifying that there are no leaks from the end opposite to
that pressurised
WARNING : during the test the valve must be firmly blocked on the test rig so as to avoid possibile danger to
personnel caused by the pressure.
ALFA VALVOLE declines all responsibility regarding damage to things or people following to tests
carried out in accordance with the above procedure
5. HOW TO ORDER SPARE PARTS
5.1 The user must precise, when ordering spare parts:

Valve model
Nominal diameter
Pressure class
Identification number or name of the part to be substituted (ref. card attached)
Construction material of the spare part (or of the original part)
Original order number or serial number of the valve
Enclosure 10009
VALVES A20 R/T
Sheet 4 of 5
6. WARNINGS AND USE LIMITATIONS
6.1 The valves here described are intended for use with clean fluids (without solid particles) or slightly abrasive.
WARNING : Their use with abrasive fluids can determine a rapid decline of the valve tightness whilst operating;
the presence of solids or the use with hardening fluids or which leave deposits which harden can cause a
quick reduction of the tightness and the operability.
6.2 The valves here described are suitable for ON-OFF services on NOT dangerous liquids or gases NOT UNSTABLE.
6.3 The user must provide adequate methods to eliminate risks associated with the temperature of the external surface of the
valve in operation.
6.4 The valves must be used within the maximum and minimum values of temperature and pressure above indicated.
For further details about maximum allowable pressure/temperature combinations please contact ALFA VALVOLE technical
departement.
WARNING : the user must provide suitable means against the exceeding of the operating limits.
6.5 Before carrying out any intervention on the valve verify that there is no pressure left in the body cavity by carrying out a
complete opening and closing.
WARNING : entrapped pressure will be relieved from both valve ends.
6.6 Quick closure of the valve against high speed flows can cause overstressing of the seats due to “water hammer”, which can
determine reduction of valve tightness.
WARNING : the user must provide suitable means against the effects of “water hammers”.
6.7 The maximum number of operating hours can be influenced by the real operating conditions.
WARNING : the user must evaluate the minimum time between inspections, basing on actual operating conditions, in
particular in relation to the degree of corrosion/year used in the piping design with reference to the corrosion overthickness
shwed in para.0.3 of this manual.
Time between inspections should not be longer than 2 years or 5000 full open and close strokes.
6.8 During welding of Socket Weld valves to the pipe system it is possible to heat excessively the valve seats.
WARNING : the user must evaluate the best system to reduce valve seat heating.
Body temperature should not be more than 150°C.
Valve should be in OPEN position during the welding.
6.9 The valve can be assembled to the pipe line with the stem in every possible position.
6.10 This model is designed for manual operation only with the use of a lever.
WARNING : different valve operators are not allowed.
6.11 WARNING : If not differently agreed with Customer ALFA A20R and A20T are not suitable for use as end pipe valves
if additional permanent closure member (for example a blind plug) with drain and vent ports is not provided.
Enclosure 10009
VALVES A20 R/T
Sheet 5 of 5
ARI-STOBU® PN16-40
Enclosure 10011 Stuffing box valve
Stop valve with gland seal - metallic sealing
ARI-STOBU® -
Straight through with flanges
• TRB 801 Annex II No. 45 (except EN-JL1040) Grey cast iron
• German TA-Luft TÜV-Test-No. 922-9204866 SG iron
(optional)
Fig. 006/306 Page 2
ARI-STOBU® -
• Test approvals TÜ.A/TÜV.AR.187-00
• TRB 801 Annex II No. 45
• German TA-Luft TÜV-Test-No. 922-9204866 Cast steel
(optional) Fig. 006/306 Page 3
ARI-STOBU® -
• German TA-Luft TÜV-Test-No. 922-9204866 Forged steel
(optional) Fig. 006 Page 4
ARI-STOBU® -
Fig. 006
• German TA-Luft TÜV-Test-No. 922-9204866 Stainless steel
(optional)
Fig. 006 Page 5
ARI-STOBU - ®
Straight through with butt weld ends

• German TA-Luft TÜV-Test-No. 922-9204866 Forged steel
ARI-STOBU - ®
Straight through with butt weld ends

• German TA-Luft TÜV-Test-No. 922-9204866 Cast steel
ARI-STOBU® -
Y-pattern with flanges
• German TA-Luft TÜV-Test-No. 922-9204866 Stainless steel
(optional)
Fig. 009 Page 8
Features:
• Proven technology
ARI-STOBU - ®
• Solid plug made of stainless material
Angle pattern with flanges
• Solid stem made of stainless material
• TRB 801 Annex II No. 45 (except EN-JL1040) Grey cast iron • Solid seat made of stainless material
• German TA-Luft TÜV-Test-No. 922-9204866 SG iron
(optional) • Stem with roll hardened thread
Fig. 007/307 Page 9 • Burnished stem
ARI-STOBU® - • High-tensile gland packing
• Favourable zeta-values also for small nominal diameters
Angle pattern with flanges
In cast steel, forged steel and stainless steel:
• Bonnet top with threaded bushing
Cast steel • Pivot mounted bolts
• German TA-Luft TÜV-Test-No. 922-9204866
(optional) Fig. 007/307 Page 10
ARI-STOBU® PN16-25
Enclosure 10011 Fig. 006 / 306
Stop valve - straight through with flanges and gland seal (Grey cast iron, SG iron)

12.006 PN16 EN-JL1040 DN15-300
12.306 PN16 EN-JL1040 DN15-300
22.006 PN16 EN-JS1049 DN15-350
22.306 PN16 EN-JS1049 DN15-350
23.006 PN25 EN-JS1049 DN15-150
23.306 PN25 EN-JS1049 DN15-150
Fig. 306: Trim made of RG/MS:
CuZn35Ni3Mn2AlPb, CW710R code number 02
CuSn10-Cu, CC480K code number 03
(max. operating temperature: 180°C, code number acc. to DIN 86251)
Test:
• DN15-300 optional: German TA-Luft TÜV-Test-No. 922-9204866 (refer to page 16)
At high differential pressures a balancing plug is necessary!
(not possible at Fig. 306, observe max. differential pressure!)
(refer to page 13)
Industry, power stations, flue gas purification plant, vapour facilities, recycling facilities,
shipbuilding, general plant manufacturing
Steam, gases, liquids, etc.
Parts
Pos. Description Fig. 12.006 Fig. 12.306 Fig. 22./23.006 Fig. 22./23.306
1 Body EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT
1.2 Seat ring X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code
number 03 number 03
2 Bonnet EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT
3 Plug * DN ≤200: CuZn35Ni3Mn2AlPb, DN ≤200: CuZn35Ni3Mn2AlPb,
X20Cr13+QT, 1.4021+QT CW710R code number 02 X20Cr13+QT, 1.4021+QT CW710R code number 02
DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code
number 03 number 03
4 Stem * X20Cr13+QT, 1.4021+QT CuSn8, CW453K X20Cr13+QT, 1.4021+QT CuSn8, CW453K
(burnished) code number 03 (burnished) code number 03
(burnished) (burnished)
5 Handwheel EN-JL1040, EN-GJL-250 (FE 13 epoxy-coating)
6 Packing ring * Pure graphite
7 Hexagon bolt 5.6 --
7 Stud -- 25CrMo4, 1.7218
8 Hexagon nut -- C35E, 1.1181
9 Gasket * Pure graphite (CrNi laminated with graphite)
* Spare part
Operating instructions can be ordered by phone +49 (0)5207 / 994-0 or fax +49 (0)5207 / 994-158 or -159.
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850 980
H (mm) 185 185 205 205 230 230 270 305 355 395 450 570 685 770 860
ØC (mm) 120 120 140 140 160 160 180 200 225 250 400 520 520 520 640
Travel (mm) 9 9 13 13 21 19 28 32 36 52 56 73 80 110 116
Kvs-value (m3/h) 4,2 7,4 12 19 31 47 77 120 188 288 410 725 1145 1635 2220
Zeta-value -- 4,6 4,7 4,3 4,6 4,3 4,5 4,8 4,5 4,5 4,7 4,8 4,9 4,8 4,8 4,9
Zeta-value ... range of tolerance for Kvs-values acc. to VDI/VDE 2173 Standard-flange dimensions refer to page 15
Face-to-face dimension FTF series 1 according to DIN EN 558
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350
12.006 / 306 (kg) 3,5 4 5 6,8 9,3 12,2 18 24,5 35 55 77 145 243 341 --
22.006 / 306 (kg) 3,9 4,3 5,4 7 9,5 12,9 18,4 24,5 36 56 78 122 247 336 451
23.006 / 306 (kg) 3,9 4,3 5,4 7 9,5 12,9 18,4 24,5 36 56 78 -- -- -- --

ARI-STOBU® PN25-40
Stop valve - straight through with flanges and gland seal (Cast steel)

34.006 PN25 1.0619+N 15-500
34.306 PN25 1.0619+N 15-500
35.006 PN40 1.0619+N 15-500
35.306 PN40 1.0619+N 15-500
Fig. 306: Trim made of RG/MS
(max. operating temperature: 180°C, code number acc. to DIN 86251)
Test:
• 34.006 DN15-400: Test approvals TÜ.A/TÜV.AR.187-00
• DN15-300 optional: German TA-Luft TÜV-Test-No. 922-9204866 (refer to p.16)
(refer to page 13)
Parts
Pos. Description Fig. 34./35.006 Fig. 34./35.306
1 Body GP240GH+N, 1.0619+N
1.2 Seat ring DN ≤50: X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code number 03
DN >50: G19 9 Nb Si, 1.4551
2 Bonnet GP240GH+N, 1.0619+N
3 Plug * DN ≤200: X20Cr13+QT, 1.4021+QT CuZn35Ni3Mn2AlPb, CW710R code number 02
DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code number 03 2)
4 Stem * X20Cr13+QT, 1.4021+QT (burnished) CuSn8, CW453K
code number 03 (burnished)
7 Stud 25CrMo4, 1.7218
10 Insert nuts 11SMn30+C, 1.0715+C
* Ersatzteil
A production allowance acc. to TRB 801 No. 45 exists
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850 980 1100 1350 *
H (mm) 185 185 205 205 230 230 270 305 355 395 450 570 685 770 860 865 995
ØC (mm) 120 120 140 140 160 160 180 200 225 250 400 520 520 520 640 640 640
Travel (mm) 9 9 13 13 21 19 28 32 36 52 56 73 80 110 116 126 181
Kvs-value (m3/h) 4,2 7,4 12 19 31 47 77 120 188 288 410 725 1145 1635 2220 3180 4530
Zeta-value -- 4,6 4,7 4,3 4,6 4,3 4,5 4,8 4,5 4,5 4,7 4,8 4,9 4,8 4,8 4,9 3,4 4,9
Zeta-value ... range of tolerance for Kvs-values acc. to VDI/VDE 2173 * acc. to manufacturers standard
Standard-flange dimensions refer to page 15
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
34.006 / 306 (kg) 4,4 5,4 6,3 7 10,5 13,8 21 27,5 40 61 84 160 265 377 510 780 1095
35.006 / 306 (kg) 4,8 5,4 7,1 8 11,5 13,5 23,5 28 39,5 61 84 170 283 414 557 857 1150

ARI-STOBU® PN40
Enclosure 10011 Fig. 006
Stop valve - straight through with flanges and gland seal (Forged steel)

45.006 PN40 1.0460 15-50
Test:
• optional: German TA-Luft TÜV-Test-No. 922-9204866 (refer to page 16)
Parts
1 Body P250 GH, 1.0460
1.2 Seat ring G19 9 Nb Si, 1.4551
2 Bonnet P250 GH, 1.0460
3 Plug * X20Cr13+QT, 1.4021+QT
4 Stem * X20Cr13+QT, 1.4021+QT (burnished)
7 Stud 25CrMo4, 1.7218
* Ersatzteil
Dimensions
DN 15 20 25 32 40 50
L (mm) 130 150 160 180 200 230
H (mm) 201 203 223 229 236 237
ØC (mm) 120 120 140 140 160 160
Travel (mm) 9 9 13 13 21 19
Kvs-value (m3/h) 3,3 5,8 9,2 15 23,3 36
Zeta-value -- 7,4 7,6 7,4 7,4 7,5 7,7
Weights
Figure-No. DN 15 20 25 32 40 50
45.006 (kg) 4,3 5 6 7 10 13

ARI-STOBU® PN16-40
Stop valve - straight through with flanges and gland seal (Stainless steel)

52.006 PN16 1.4408 15-200
54.006 PN25 1.4408 200
55.006 PN40 1.4408 15-150
Test:
(refer to page 13)
Recycling facilities, chemical industry, hospital technology, process water installations,
installations with aggressive media
Process water, aggressive media, etc.
Parts
Pos. Description Fig. 52./54./55.006
1 Body GX5CrNiMo19-11-2, 1.4408
2 Bonnet GX5CrNiMo19-11-2, 1.4408
3 Plug * X6CrNiMoTi17-12-2, 1.4571
4 Stem * X6CrNiMoTi17-12-2, 1.4571
7 Stud A4-70
8 Hexagon nut A4
10 Insert nuts X5CrNiMo17-12-2, 1.4401
* Ersatzteil
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600
H (mm) 185 185 205 205 230 230 270 305 355 395 450 570
ØC (mm) 120 120 140 140 160 160 180 200 225 250 400 520
Travel (mm) 9 9 13 13 21 19 28 32 36 52 56 73
Kvs-value (m3/h) 4,2 7,4 12 19 31 47 77 120 188 288 410 725
Zeta-value -- 4,6 4,7 4,3 4,6 4,3 4,5 4,8 4,5 4,5 4,7 4,8 4,9
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200
52./54./55.006 (kg) 4,8 5,4 7,1 8 11,5 13,5 23,5 28 39,5 61 84 170

ARI-STOBU® PN40
Stop valve - straight through with butt weld ends and gland seal (Forged steel)

45.005 PN40 1.0460 15-50
DN65-300 refer to Fig. 35.005 (1.0619+N)
Butt weld ends according to DIN EN 12627 - 4 (refer to page 12)
Test:
Parts
1 Body P250 GH, 1.0460
1.2 Seat ring G19 9 Nb Si, 1.4551
2 Bonnet P250 GH, 1.0460
3 Plug * X20Cr13+QT, 1.4021+QT
7 Stud 25CrMo4, 1.7218
* Ersatzteil
Dimensions
DN 15 20 25 32 40 50
L (mm) 130 150 160 180 200 230
H (mm) 205 205 225 230 235 235
ØC (mm) 120 120 140 140 160 160
Travel (mm) 9 9 13 13 21 19
Kvs-value (m3/h) 3,3 5,8 9,2 15 23,3 36
Zeta-value -- 7,4 7,6 7,4 7,4 7,5 7,7
Zeta-value ... range of tolerance for Kvs-values acc. to VDI/VDE 2173
Face-to-face dimension ETE series 1 according to DIN EN 12982
Weights
Figure-No. DN 15 20 25 32 40 50
45.005 (kg) 2,9 3 3,5 3,5 6,2 7,8

ARI-STOBU® PN40
Stop valve - straight through with butt weld ends and gland seal (Cast steel)

35.005 PN40 1.0619+N 65-300
DN15-50 refer to Fig. 45.005 (1.0460)
alternative: DN 65-200 with shoed ends of P235GH
Test:
(refer to page 13)
alternative
Parts
1 Body GP240GH+N, 1.0619+N
1.2 Seat ring G19 9 Nb Si, 1.4551
3 Plug * DN ≤200: X20Cr13+QT, 1.4021+QT
DN >200: P265 GH, 1.0425
7 Stud 25CrMo4, 1.7218
* Ersatzteil
Dimensions
DN 65 80 100 125 150 200 250 300
L (mm) 290 310 350 400 480 600 730 850
H (mm) 270 305 355 395 450 570 685 770
ØC (mm) 180 200 225 250 400 520 520 520
Travel (mm) 28 32 36 52 56 73 80 110
Kvs-value (m3/h) 77 120 188 288 410 725 1145 1635
Zeta-value -- 4,8 4,5 4,5 4,7 4,8 4,9 4,8 4,8
Face-to-face dimension ETE series 1 according to DIN EN 12982
Weights
Figure-No. DN 65 80 100 125 150 200 250 300
35.005 (kg) 16 21 28 45 66 143 228 345

ARI-STOBU® PN16-40
Stop valve - Y-pattern with flanges and gland seal (Stainless steel)

52.009 PN16 1.4408 15-200
54.009 PN25 1.4408 15-200
55.009 PN40 1.4408 15-200
Test:
(refer to page 13)
Parts
1 Body GX5CrNiMo19-11-2, 1.4408
2 Bonnet GX5CrNiMo19-11-2, 1.4408
3 Plug * X6CrNiMoTi17-12-2, 1.4571
4 Stem * X6CrNiMoTi17-12-2, 1.4571
7 Stud A4-70
8 Hexagon nut A4
10 Insert nuts X5CrNiMo17-12-2, 1.4401
* Ersatzteil
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600
H2 (mm) 200 200 225 225 245 250 285 320 415 435 505 640
B (mm) 80 70 85 70 70 45 30 65 75 80 75 130
ØC (mm) 120 120 140 140 160 160 180 200 225 250 400 520
Travel (mm) 9 9 13 13 21 19 28 32 36 52 56 73
Kvs-value (m3/h) 5,8 8,6 13 20 42 59 90 127 205 310 445 800
Zeta-value -- 2,4 3,5 3,7 4,2 2,3 2,9 3,5 4,1 3,8 4,1 4,1 4
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200
52./54./55.009 (kg) 4 4,6 6 7,6 9,4 11,6 16,5 23,2 35 43 72 141

ARI-STOBU® PN16
Stop valve - angle pattern with flanges and gland seal (Grey cast iron, SG iron)

12.007 PN16 EN-JL1040 DN15-300
12.307 PN16 EN-JL1040 DN15-300
22.007 PN16 EN-JS1049 DN15-500
22.307 PN16 EN-JS1049 DN15-500
(max. operating temperature: 180°C, code number acc. to DIN 86251
Test:
• DN15-300 optional: German TA-Luft TÜV-Test-No. 922-9204866 (refer to page 16)
(refer to page 13)
Parts
Pos. Description Fig. 12.007 Fig. 12.307 Fig. 22.007 Fig. 22.307
1 Body EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT
1.2 Seat ring X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code
number 03 number 03
2 Bonnet EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT
3 Plug * DN ≤200: CuZn35Ni3Mn2AlPb, DN ≤200: CuZn35Ni3Mn2AlPb,
X20Cr13+QT, 1.4021+QT CW710R code number 02 X20Cr13+QT, 1.4021+QT CW710R code number 02
DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code
number 03 number 03
4 Stem * X20Cr13+QT, 1.4021+QT CuSn8, CW453K X20Cr13+QT, 1.4021+QT CuSn8, CW453K
(burnished) code number 03 (burnished) code number 03
(burnished) (burnished)
7 Hexagon bolt 5.6 --
7 Stud -- 25CrMo4, 1.7218
8 Hexagon nut -- C35E, 1.1181
* Ersatzteil
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
l (mm) 90 95 100 105 115 125 145 155 175 200 225 275 325 375 425 475 525 *
H1 (mm) 185 185 200 200 215 215 245 280 320 360 415 495 575 655 735 740 840
ØC (mm) 120 120 140 140 160 160 180 200 225 250 400 520 520 520 640 640 640
Travel (mm) 9 9 13 13 21 19 28 32 36 52 56 73 80 110 116 126 181
Kvs-value (m3/h) 5,2 9,2 15 24 37 58 96 150 235 360 510 905 1430 2040 2775 3975 5660
Zeta-value -- 3 3 2,8 2,9 3 3 3,1 2,9 2,9 3 3,1 3,1 3,1 3,1 3,1 2,6 3,1
Face-to-face dimension CTF series 8 according to DIN EN 558
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
12.007 / 307 (kg) 3,9 4,5 5,5 6,6 9,1 11,5 17,1 22,4 32 46 67 126 184 270 -- -- --
22.007 / 307 (kg) 4 4,5 5,6 6,6 9,2 11,6 17 22,6 33 46 68 100 204 270 398 570 885

ARI-STOBU® PN25-40
Stop valve - angle pattern with flanges and gland seal (Cast steel)

34.007 PN25 1.0619+N 15-500
34.307 PN25 1.0619+N 15-500
35.007 PN40 1.0619+N 15-500
35.307 PN40 1.0619+N 15-500
(max. operating temperature: 180°C, code number acc. to DIN 86251
Test:
• DN15-300 optional: German TA-Luft TÜV-Test-No. 922-9204866 (refer to p.16)
(refer to page 13)
Parts
Pos. Description Fig. 34./35.007 Fig. 34./35.307
1 Body GP240GH+N, 1.0619+N
1.2 Seat ring DN ≤50: X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code number 03
DN >50: G19 9 Nb Si, 1.4551
3 Plug * DN ≤200: X20Cr13+QT, 1.4021+QT CuZn35Ni3Mn2AlPb, CW710R code number 02
DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code number 03
4 Stem * X20Cr13+QT, 1.4021+QT (burnished) CuSn8, CW453K code number 03 (burnished)
7 Stud 25CrMo4, 1.7218
* Ersatzteil
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
l (mm) 90 95 100 105 115 125 145 155 175 200 225 275 325 375 425 475 525 *
H1 (mm) 185 185 200 200 215 215 245 280 320 360 415 495 575 655 735 740 840
ØC (mm) 120 120 140 140 160 160 180 200 225 250 400 520 520 520 640 640 640
Travel (mm) 9 9 13 13 21 19 28 32 36 52 56 73 80 110 116 126 181
Kvs-value (m3/h) 5,2 9,2 15 24 37 58 96 150 235 360 510 905 1430 2040 2775 3975 5660
Zeta-value -- 3 3 2,8 2,9 3 3 3,1 2,9 2,9 3 3,1 3,1 3,1 3,1 3,1 2,6 3,1
Face-to-face dimension CTF series 8 according to DIN EN 558
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
34.007 / 307 (kg) 5,2 7,2 7,4 8,4 12,4 13,6 20 25 34 53 70 138 170 290 383 690 963
35.007 / 307 (kg) 5,2 7,2 7,4 8,4 12,4 13,6 20 25 34 53 70 148 188 327 430 767 1018

ARI-STOBU® PN16-40
Enclosure 10011 Notes

ARI-STOBU® PN16-40
Enclosure 10011 Valves with butt weld ends
L = Face-to-face dimension
Edge shaping acc. to DIN EN 25817
Butt weld ends according to DIN EN 12627 - 4

DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850 980 1100
ØA (mm) 22 28 35 44 50 62 77 91 117 144 172 223 278 329 362 413
ØB (mm) 17,3 22,3 28,5 37,2 43,1 53,9 68,9 80,9 104,3 130,7 157,1 204,9 257 307,9 338 384,4
Ødi (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250 300 330 375
R (mm) 3 3 3 3 3 3 3 3 3 3 3 5 5 5 5 5
L1 (mm) 10 10 10 10 10 10 10 12 14 18 20 20 25 33 45 45
Ød3 (mm) 21,3 26,9 33,7 42,4 48,3 60,3 76,1 88,9 114,3 139,7 168,3 219,1 273,0 323,9 355,6 406,4
s1 (mm) 2 2,3 2,6 2,6 2,6 3,2 3,6 4 5 4,5 5,6 7,1 8 8 8,8 11
Shoed ends made of P235GH (Pipe connection =^ welding neck flanges)

DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
Ød (mm) -- -- -- -- -- -- 76,1 88,9 114,3 139,7 168,3 219,1 -- -- -- --
Øs (mm) -- -- -- -- -- -- 2,9 3,2 3,6 4,0 4,5 6,3 -- -- -- --
Face-to-face dimension ETE series 1 according to DIN EN 12982.
Butt weld ends according to DIN EN 12627 - 4.
Weld joint according to DIN EN 29692 code numer 1.3.3.
The material used for ARI valves with butt weld ends are:
GP240GH+N, 1.0619+N acc. to DIN EN 10213-2,
P250GH, 1.0460 acc. to DIN EN 10222-2.
The material used for ARI valves with shoed ends (DN 65-200) P235GH according to DIN EN 10216-2.
Based on our experience we recommend electric welding process for connecting valves or strainers with tubes or with each other
Lime based electrodes with an appropriate composite material should be used as filler material for welding.
Gas welding should be avoided.
Because of the different material compositions and wall thickness of the steam traps and the pipe gas welding shall not be applied. Quenching cracks and coarse grain
structure may develop..

ARI-STOBU® PN16-40
Enclosure 10011 Plug design
Regulating plug with soft seal

Max. operating temperature 200°C at PTFE + 25%
Regulating plug carbon
(for max. permissible ΔP refer to: Flow diagram) (for max. permissible ΔP refer to: Flow diagram)
Screw down non-return plug with re-setting spring -

max. differential pressure, refer to table of pressure
balancing plugs,
Set pressure 0,1 bar
(Design for special applications refer to page 14)
Flow values (Kvs and Zeta) refer to data sheet „Check
Plug with marginal seat valves“.
Flow direction
Valves with balancing plugs have to be installed with medium flowing over the plug (3) as indicated by flow direction arrow on valve body and the stem is vertically upright.
Working principles:
When the valve is closed, anticlockwise rotation of the hand wheel lifts the pilot plug (3.1) off the larger balancing plug (3).
This allows the medium to pass through the plug and equalizes the pressure of the medium under the plug (3). After the pressures have been equalized within the values
stated in the table, the valve can be opened by turning the valve further with normal manual force.
Balancing plugs are fully effective only in closed systems.
The pressures of the medium on either side of the plug can not be equalized if the medium is discharged into open air.
A bypass line or some other arrangement is necessary if too much time is required for pressure equalization owing to the volume in the piping system.
ARI-stop valves with differential pressures exceeding the following pressures, have to be fitted with pressure balancing plugs
DN 125 150 200 250 300 350 400 500
max. differential pressure (ΔP) (bar) 25 21 14 9 6 4,5 3,5 1,5

ARI-STOBU® PN16-40
Enclosure 10011 Special design / Accessories
DN ØC2 Weight
(mm) (mm) (kg)
15-32 180 1,5
40-100 250 3
125-200 365 5
250-500 520 13
Limit switch Handwheel operated by impact force
DN ØC2 Weight
(mm) (mm) (kg)
15-32 180 2,5
40-80 220 7
100-150 260 8,9
200-400 300 11
Chain wheel Position indicator with locking device
Flow direction
Hole and stem with a

precise tolerance
Screw down non-return plug with re-setting spring and plug damper
In special applications, like high flow turbulences, stuffing box valves with damper should be used with execution
„screw down non-return plug “:
- if stuffing box valves with loose plug are mounted directly by centrifuged pumps;
- behind pressure reduction stations;
- behind pipe elbows;
- in compact plants;
- if expansion joints are missing;
- if the pump is not mounted on a damper;
- if there is no flow stabilizing pipe dimension;
- if there is no start-up bypass line;
- when choosen valve diameter to large.
Working principle
The precise tolerance between stem and plug hole prevents an abrupt displacement of medium out of the plug.
Stem extension (please specify height in your order)

ARI-STOBU® PN16-40
Enclosure 10011 Flange dimensions / Pressure-temperature-ratings
Standard-flange dimensions Flanges acc. to DIN EN 1092-1/-2 (Flangeholes / -thickness tol. acc. to DIN 2533/2544/2545)
DN (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
PN6 ØD (mm) 80 90 100 120 130 140 160 190 210 240 265 320 -- -- -- -- --
PN6 ØK (mm) 55 65 75 90 100 110 130 150 170 200 225 280 -- -- -- -- --
PN6 n x Ød (mm) 4x11 4x11 4x11 4x14 4x14 4x14 4x14 4x18 4x18 8x18 8x18 8x18 -- -- -- -- --
PN16 ØD (mm) 95 105 115 140 150 165 185 200 220 250 285 340 405 460 520 580 715
PN16 ØK (mm) 65 75 85 100 110 125 145 160 180 210 240 295 355 410 470 525 650
PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 12x22 12x26 12x26 16x26 16x30 20x33
PN25 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 360 425 485 555 620 730
PN25 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 310 370 430 490 550 660
PN40 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 375 450 515 580 660 755
PN40 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 320 385 480 510 585 670

EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6 -- -- --
EN-JS1049 16 (bar) on request 16 15,5 14,7 13,9 12,8 11,2 -- --
EN-JS1049 25 (bar) on request 25 24,3 23 21,8 20 17,5 -- --

1.0619+N 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 8,2
1.0619+N 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 13,1
1.0460 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 10
1.0460 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 16

1.4408 16 (bar) 16 16 14,5 13,4 12,7 11,8 11,4 10,9 --
1.4408 25 (bar) 25 25 22,7 21 19,8 18,5 17,8 17,1 --
1.4408 40 (bar) 40 40 36,3 33,7 31,8 29,7 28,5 27,4 --
Please indicate when ordering

- Figure-No.
- Nominal pressure
Dimensions in mm
- Nominal diameter
Weights in kg
- Special design / accessories
1 bar =^ 105 Pa =^ 0,1 MPa
Example:
Kvs in m3/h
Figure 35.006; nominal pressure PN40; nominal diameter DN100; with regulating plug, position indicator with locking device..

ARI-STOBU® PN16-40
Enclosure 10011 Testing German TA-Luft
Testing German „TA-Luft“ optional at DN15-300 (TÜV-Test-No. 922-9204866)
with not spring-loaded stuffing box
Grey cast iron and SG iron Cast steel, Forged steel, Stainless steel
with spring-loaded stuffing box
Grey cast iron and SG iron Cast steel, Forged steel, Stainless steel


Enclosure 10011

Stop valve with gland seal
STOBU® PN16-160
Contents
1.0 General information on operating 5.4 Installing valves with limit switches ........................ 8
instructions ..................................................... 2 6.0 Putting the valve into operation .................. 8
2.0 Notes on possible dangers........................... 2 7.0 Care and maintenance.................................. 9
2.1 Significance of symbols ..........................................2 8.0 Troubleshooting .......................................... 10
2.2 Explanatory notes on safety information .................2 9.0 Troubleshooting table .................................11
3.0 Storage and transport .................................. 2 10.0 Dismantling the valve or the top part ..... 12
4.0 Description..................................................... 3 11.0 Warranty / Guarantee ................................ 12
4.1 Scope of applications ..............................................3 12.0 EC declaration of conformity ................... 13
4.3 Diagram...................................................................4
4.4 Technical data - remarks .........................................5
4.5 Marking ...................................................................5
5.0 Installation...................................................... 6
5.1 General notes on installation...................................6
5.2 Installing valves with butt weld ends .......................7
5.3 Installing valves with balancing plugs ...................7
Rev. 0040102000 0711 englisch

Enclosure 10011
STOBU®

and repair.
ATTENTION ! Warning of general danger.
...

Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
to property.

ATTENTION !
- At -20°C to +65°C.
Page 2 Rev. 0040102000 0711
Enclosure 10011
STOBU®
4.0 Description
Valves are used for „shut-off and/or throttling of media“.
ATTENTION !
state the higher requirements when ordering.
to TRD 110.

The valve is closed by turning the hand wheel clockwise (valve plug/seating function).
ATTENTION !
Do not use tools to increase the torque on the hand wheel.
The valve stem is sealed by a bellow and an outer safety stuffing box.
Tighten the stuffing box if required.
Rev. 0040102000 0711 Page 3

Enclosure 10011
STOBU®
4.3 Diagram
rotated
view
rotated
view
rotated
rotated view
view
fig. 1: STOBU straight through PN40 fig. 2: STOBU angle pattern PN40
1.0619+N 1.0619+N
rotated
view
rotated view
rotated
view
rotated view
fig. 3: STOBU straight through PN16/25 fig. 4: STOBU-straight through PN40

EN-JL1040 / EN-JS1049 butt weld ends 1.0619+N
Page 4 Rev. 0040102000 0711

Enclosure 10011
STOBU®
rotated view rotated view

rotated view rotated view
fig. 5: STOBU-DG PN63-160 fig. 6: STOBU-DG SE PN63-160

1.0460 / 1.7335 1.0460 / 1.5415 / 1.7335
Refer to the data sheet for information about materials with designations and figure
numbers.

for
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Manufacturer Address of manufacturer:
Typ Type refer to item 11.0 Warranty / Guarantee
Bj. Year of manufacture

PS max. allowable pressure
TS max. allowable temperature
According to the Pressure Equipment Directive table 6, annex II, valves without safety
function are only allowed to bear the CE-marking DN32 onwards.
Rev. 0040102000 0711 Page 5

Enclosure 10011
STOBU®
5.0 Installation
installation work:
ATTENTION !
- The interior of valve and pipeline must be free from foreign particles.
- Steam line systems should be designed to prevent water accumulation.
avoided.
both sides.
- Valves can be installed with the stem pointing in any direction, but the prefered
stem position is vertical.
- Valves should be installed upside down only, if the medium being handled is
clean.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Lockable stop valves must be installed in such a way that the stem is vertical
and the flow agent enters under the taper. If the valves are installed in pipelines
in positions other than specified, they must be fitted with a closing spring.
- Design with loose plug
A plug damper should be used in critical applications, immediately downstream
of pumps, compressors, etc., where severe turbulence and pulsating pressure
surges may occur.
Through the damper function of the loose plug, the negative influence of
pressure shocks and high turbulences, are not transferred onto the valve.
recommended.
Page 6 Rev. 0040102000 0711

Enclosure 10011
STOBU®
5.2 Installing valves with butt weld ends
Please note that only qualified persons using appropriate equipment and working in
accordance with technical rules are allowed to install fittings by welding.
The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
The valves must be welded in closed position.
5.3 Installing valves with balancing plugs

ATTENTION !
ARI stop valves must be equipped with pressure balancing plugs if the
differential pressures listed in the table below are exceeded in the closed state.
Valves with pressure balancing plugs should be installed so that the pressure of
the medium acts on the plug (pos. 3) and the stem is vertically upright.
ATTENTION !
Note direction of flow.
fig. 7
Valves with pressure balancing plugs have to be installed with medium flowing over the
plug (pos. 3) as indicated by flow direction arrow on valve body.
Working principles:
When the valve is closed, anticlockwise rotation of the hand wheel lifts the pilot plug
(pos. 3.1) off the larger balancing plug (pos. 3). This allows the medium to pass through the
plug and equalizes the pressure of the medium under the plug (pos. 3). After the pressures
have been equalized within the values stated in the table below, the valve can be opened
by turning the valve further.
Balancing plug DN 125 150 200 250 300 350 400 500
Pressure difference ΔP 25 bar 21 bar 14 bar 9 bar 6 bar 4,5 bar 3,5 bar 1,5 bar
- Pressure balancing plugs are fully effective only in closed line section.
Rev. 0040102000 0711 Page 7

Enclosure 10011
STOBU®
- The pressures of the medium on either side of the plug cannot be equalized if the medium
is discharged into “open air”.
- If adequate pressure equalisation cannot be achieved using a pressure balancing plug,
other design solutions must be used instead (e.g. a bypass line).
5.4 Installing valves with limit switches

The valves with limit switches must be connected up as shown in the plans of the plant on
the basis of their working principles.
ATTENTION !
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) media
Affix warning notice or protective insulation as appropriate.
- All works has been completed.
When putting the valve into operation, the tightness of the stuffing box seal (pos. 6) must be
checked.
If the valve stem / stem unit (pos. 4) leaks, gradually tighten the stuffing box seal (pos. 6)
evenly in increments by means of the hexagon nuts (pos. 19) until leaking stops (refer also
to item 7.0 Care and maintenance).
Page 8 Rev. 0040102000 0711

Enclosure 10011
STOBU®

Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
fig. 8: Pattern with hinged bolts

- Observe safety instructions!
- Keep the stem well greased!
- Lubricant: e.g. Klüberpaste HEL 46-450 (at valves for oxygen: Klüberalfa YV93-302)
to order at: Klüber Lubrication München KG, Postfach 701047, D-81310 München
or a lubricant wich is suitable for the application.
ATTENTION !
Pay attention, that the lubricant is suitable for the media.
- If the valve stem / stem unit (pos. 4) leaks, gradually tighten the stuffing box seal (pos. 6)
evenly in increments by means of the hex. nuts (pos. 19) until leaking stops.
ATTENTION !
- Retighten the stuffing box packing if required and re-pack it in good time.
- For safety reasons we recommend that valves only be repacked when
depressurised.
- Refer to point 10.0 and 11.0 before dismantling the valve.
- Replace stuffing box packings only after the system has cooled down and the pressure in
the plant has been relieved.
In the case of corrosive or aggressive mediums, drain and ventilate the valve before
replacing the packing.
Rev. 0040102000 0711 Page 9

Enclosure 10011
STOBU®
- Valve service life can be improved by leakage checks.
- When cutting the new packing (pos. 6) from

the roll, make sure that the ends are cut with
a slant
fig. 9: Split packing ring (pos. 6)

Mounting of the bonnet:
- Before reassembling the unit, remember that the bearing surface must be cleaned and a
new gaskets (pos. 9) must be inserted.
- Set the cover in place
- Tighten the hexagon nuts (hexagon screws for valves of cast iron) evenly crosswise.
- Tightening torque‘s for hexagon nuts / screws:
hexagon nuts / Torque

PN DN
hexagon screws (Nm)
16 - 40 15 - 32 M 10 15-30
40 - 65 M 12 35-50
80 - 100 M 16 75-100
125 - 150 M 16 80-120
200 M 20 150-200
250 - 400 M 24 340-410
500 M 27 340-410
63 - 160 10 - 25 M 16 50
32 - 50 M 20 150
8.0 Troubleshooting
Instructions.
ATTENTION !
-

Page 10 Rev. 0040102000 0711

Enclosure 10011
STOBU®

ATTENTION !

No flow Valve closed. Open valve.
Flange covers not removed. Remove flange covers.
(pos. 25; fig.1 - 2) (pos. 25; fig.1 - 2)
Little flow Valve not sufficiently open. Open valve.
Dirt sieve clogged. Clean / replace sieve.
Piping system clogged. Check piping system.
Valve difficult to move or Stem (pos. 4) dry (fig. 8) Grease stem (pos. 4) (fig. 8)
cannot be opened (Lubricant: see page 9)
Stuffing box too tight (pos. 6; fig. 1-4) Slacken hex. nuts of stuffing box gland
(pos. 15) slightly, but not sufficiently to
cause leakage (fig. 1-4)
Wrong direction of rotation Turn in correct direction (anticlockwise
to open valve).
Valve stem leaking Stuffing box gland (pos. 15) slack Tighten stuffing box gland (pos. 15)
(fig.1 - 6). until leakage stops.
-Hex. nut (fig.1 - 6).
If necessary, renew packing in stuffing
box seal (pos. 6). Observe warnings
(fig. 8)!
Leakage across valve Valve not properly closed. Pull hand wheel tight without tools.
seat. Seat (pos. 1.2) / plug (pos. 3 / 4.1) Replaced valve, consult supplier/man-
damaged by foreign particles. ufacturer.
(fig.1 - 6).
Pressure difference too high. Use a valve with balancing plug
(see point 5.3).
Medium contaminated Clean valve.
(suspended solids). Install dirt screen upstream of valve.
Valve with throttling plug + Locking device has been tightened. Release locking device.
position indicator + lock-
ing device cannot be
opened.
Rattling / banging Nominal diameter of the valve in com- Choose smaller nominal diameter
of the plug design with pliance to the flow rate is to big Use a plug damper execution: see
„loose plug“ medium
- high flow turbulences; Alter the system
- the valve with loose plug is mounted Use a plug damper execution: see
directly by a centrifuged pump; medium
- behind pressure reduction stations;
- behind pipe elbows;
- in compact plants;
- expansion joints are missing;
- the pump is not mounted on a
damper;
- there is no flow stabilizing pipe length;
- there is no start-up bypass line
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
valve and piping. Mating flanges not properly aligned.
Rev. 0040102000 0711 Page 11

Enclosure 10011
STOBU®

ATTENTION !
media.

appointed by us.

Page 12 Rev. 0040102000 0711

Enclosure 10011
STOBU®

EC declaration of conformity acc. to Pressure Equipment Directive 97/23/EC
Herewith we declare:

that the below listed products are meeting the following requirements.
Description of the products:
Stop valve with gland seal ARI-STOBU®

Nominal Nominal Certificate-
Type Fluid group Module Applied standards
pressure diamter No.:
005 PN16-40 DN 15-300 I H
006 PN16-40 DN 15-500 I H
DIN 3840
007 PN16-40 DN 15-500 I H AD 2000 leaflet A4
50003/1
009 PN16-40 DN 15-200 I H (EN-JS1049, 1.0619+N,
1.0460, 1.4408)
306 PN16-40 DN 15-500 I H
307 PN16-40 DN 15-500 I H
005 PN 63-160 DN 10 -50 I A1 DIN EN 12516-2

-- AD 2000 leaflet A4
006 PN 63-160 DN 10 -50 I A1 (1.0460, 1.5415, 1.7335)
Name and adress of the authorizing, monitoring, notified body:
Lloyd’s Register Quality Assurance GmbH

Am Sandtorkai 41, D-20457 Hamburg
No. of the notified body:
0525
...................................................
Rev. 0040102000 0711 Page 13

Enclosure 10011
STOBU®
Page 14 Rev. 0040102000 0711

10035
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10035

ALFA WAFER BALL VALVES
Models ALFA 10N / 10NF / 103 / 10HP
INDEX PAGE
0. Technical Data 2
1. Transportation, handling and storage 3
2. Assembly instructions 3
3. Maintenance 3
4. Testing 4
7. Trouble shooting 6
8. Maintenance card 7
Translation from the original maintenance manual in Italian language

10035
0. TECHNICAL DATA
0.1 MANUFACTURER ALFA VALVOLE S.r.l.

V.le del Lavoro 19 - 20010 CASOREZZO (MI) – ITALY
Ph. +39-0290296206
Fax. +39-0290296292

Operators involved in the storage, mounting, use and/or maintenance of our products are requested to have sufficient skill and
experience in such a kind of equipments. It’s user responsibility to guarantee this skill is met.
Service : ON-OFF and deviation of liquids e gases ( A103 type valves, only )
Fluids : liquids e gases Group 1 (dangerous), not unstable, according to the EC Directive 97/23/EC “PED” – Category III
Use in potentially explosive atmospheres : II 2 GD c T6 X according to the EC Directive 94/9/EC “ATEX”
Minimum guaranteed tightness limits on brand new valve :

Emissions to atmosphere on request, according to TA-LUFT and/or ISO 15848-1 requirements
Hydrostatic Body Test (1,5 x Maximum working pressure at room temperature ) Zero Leakage
Hydrostatic Seat Test (1,1 x Maximum working pressure at room temperature) Zero Leakage
Pneumatic Seat Test (Air , 6 bar ) Zero Leakage
“Fire Safe” features : on request, according to ISO 10497 / API 607 / API 6FA / BS 6755 , ( A103 type valves , excluded ).
ALFA 10N ALFA 10N ALFA 10N

ALFA 10HP
Model ALFA 10NF ALFA 10NF ALFA 10NF
ALFA 103
ALFA 103 ALFA 103 ALFA 103
PN63
PN10-16
Class PN25- 40 ANSI 300 PN100
ANSI 150
ANSI 600
DN10÷200 DN10÷200 DN 15÷200 DN10÷100
Nominal Diameters
(ALFA103 DN15÷150) (ALFA103 DN15÷150) (ALFA103 DN15÷150) (ALFA103 DN15÷100)
63 PN63
Maximum working 10 PN10 25 PN25 100 PN100
pressure at room 63 DN>80
51
temperature 16 PN16 102 A.600
(bar) 40 PN40
20 A.150 63 DN>80
63 PN63
80 PN100
Maximum working 8 8 15 63 DN>80
pressure at maximum 80 A.600
temperature 63 DN>80
(bar) Pressure values between room temperature and maximum temperature vary depending of
characteristics of used seats/seals materials.
Please contact ALFA VALVOLE Technical Dept. for more information.
200ºC DN10÷50
90ºC DN10÷50
Maximum working 180ºC DN65-80
temperature 160ºC DN100÷150
70ºC DN65÷100
120ºC DN200
-29ºC** for carbon steel A105 / A216 WCB valve bodies
with impact test verification when
Minimum working and for carbon steel A350 LF2 / A352 LCB valve
-40ºC** TR* ≤ 21°C
room temperature bodies
-40ºC** for stainless steel valve bodies without impact test verification
Maximum simultaneous
Please contact ALFA VALVOLE Technical Dept.
working conditions
*TR = design temperature, for impact test verification, according to I.S.P.E.S.L. Code Case M Table M.14.2 and
EN 13445 standard.
The body thickness is assigned so that the design temperature, for impact test verification according to I.S.P.E.S.L.
Code Case M Table M.14.2 and EN 13445 standard, are above 21 ° C.
** Other restrictions imposed from the material of the seat ring, the gasket material and the nominal diameter of the
valve will be indicated on the nameplate attached to the valve body.
Table of nominal dimensions of valves

DN 10 15 20 25 32 40 50 65 80 100 125 150 200
Ø” 3/8” 1/2” 3/4” 1” 1.1/4” 1.1/2” 2” 2.1/2” 3” 4” 5” 6” 8”
10035
END CONNECTIONS Flanged ANSI/DIN/UNI/EN with blind or straight screwed holes

BODY THICKNESS ASME VIII Div.1 – ASME B16.34 – DIN 3840
BOLTING DESIGN ASME VIII Div.1 – ASME B16.34 (Split Body only)
SCREWED CONNECTION DESIGN ASME B16.34 (Screwed Connector only)
FLANGE DESIGN ASME VIII Div.1 (Split Body only)
SIMULTANEOUS LOADS Pressure, Bending, Axial Loads from piping
WIND LOADS Negligible, according to ASME III Div.1 Subsect.NB
EARTHQUAKE LOADS Negligible, according to ASME III Div.1 Subsect.NB
Negligible, according to ASME III Div.1 Subsect.NB
FATIGUE from On-Off starting cycles
(see the maximum number of operating hours)
FATIGUE from service pressure Negligible, according to ASME III Div.1 Subsect.NB
fluctuation (see the maximum number of operating hours)
Function of actual simultaneous working conditions and fluids but anyway not
longer than :
MAXIMUM LIFE IN SERVICE HOURS 100.000 ( see para 3.1 for recommended periodical inspections);
50.000 operations of opening/closing of the valve ( liquid service )
5.000 operations of opening/closing of the valve ( gas service )
AVAILABLE CORROSION
1.5 mm min. (carbon steel valves only)
OVERTHICKNESS
ANTISTATIC FEATURES according to API 6D app. B5
1.1 TRANSPORT AND HANDLING
Valves must be transported and handled maintaining the ball in the open position.
Avoid impacts against obstacles that may damage the stem or the auxiliary connections (drains, sealant injectors, vents).
1.2 STORAGE
Valves with carbon steel or stainless steel bodies must both be stored with ball in the OPEN position and in a location dry
and free from fumes, gas or corrosive vapours.
2. ASSEMBLY INSTRUCTIONS
2.1 All valves are bi-directional ( A103 type valves , excluded ) and supplied ready to use.
Valves can be placed with stem oriented to any direction.
ATTENTION : remove the protective caps from the valve ends before connection to pipeline or the cap from the inlet side
of the fluid.
Ensure that all auxiliary connections, if any, (lubricators, drains, vents) are free of damage and properly tightened.
ATTENTION : connect electric and pneumatic or hydraulic actuators power supplies only after assembling the valve to the
piping.
3. MAINTENANCE
3.1 A general control of the valve is advisable every 2 years of functioning or every 5.000 opening and closing cycles.
3.1.1 Remove electric and pneumatic or hydraulic actuators power supplies before removing the valve from piping or before
any maintenance or cleaning adjustment.
ATTENTION : check absence of electric and pneumatic or hydraulic actuators power supplies before disconnecting.
In occurrence of dirty fluids interception, more frequent periodic checks are recommended, please contact ALFA
VALVOLE Technical Dept for further information.
ATTENTION : it’s user's responsibility to maintain the safety features of the product and of their components in case of
maintenance / repair on their own.
10035
4. TESTING
4.1 Before carrying out of any test, to verify there are no problems in the movement of the ball, make at least one complete
stroke of opening and closing.
4.2 Valve must be tested using the following procedure:

b) Pressurise the valve body, by water, with a pressure 1,5 times the maximum operating pressure at room temperature
( see table at para 0.2 )
e) Close the valve
f) Pressurise the first seat with water at a pressure 1,1 times the maximum operating pressure at room temperature
( see table at para 0.2 )
i) Pressurise the second seat (if present) with water at a pressure 1,1 times the maximum operating pressure at room
temperature ( see table at para 0.2 )
l) Repeat the tests described in points f) and i) using air at 6 bar and verifying that there are no leaks from the end
opposite to that pressurised
WARNING : during the test, valve must be firmly blocked on the test rig to avoid any possible danger to personnel
caused by the pressure.
carried out in accordance with the above procedure.
ATTENTION : while considering the above information sufficient for proper execution of the maintenance of the valve,
ALFA VALVOLE not give any warranty on the outcome of the intervention, not extended warranty, unless
the action is performed by ALFA VALVOLE personnel at its workshops.
5.1 User must specifies, when ordering spare parts:

Valve model
Nominal diameter
Pressure class
Identification number or name of the part to be substituted (ref. attached card)
Material of the spare part (or of the original part)
6.1 Here described valves are intended for use with clean or slightly abrasive fluids (without solid particles).
ATTENTION : their use with abrasive fluids can cause the rapid decay of the sealing characteristics of the valve during
operation;
any presence of solids or the use with hardening fluids which harden can cause a quick reduction of the tightness and of
the operability.
6.2 User must provide adequate methods to eliminate risks associated with the temperature of the external surface of the
valve during operations.
ATTENTION : User must evaluate the valve body surface temperature when the outside ambient has potentially explosive
conditions.
It is not possible to identify the body surface temperature in accordance to the Directive 94/9/EC “ATEX” because it is a
function of handled fluid temperature (surface temperature of valve body tends to reach the temperature of intercepted
fluid).
User must provide appropriate methods to reduce the surface temperature of the valve body when the temperature of the
intercepted fluid exceeds T6 limit.
During services with fluids at room temperature and in the presence of repeated maneuvers, at intervals not greater than 1
operation every 10 seconds, the valves do not exceed 60 ° C (T6 class temperature, according to EN 13463-1).
6.3 Valves must be used within maximum and minimum values of temperature and pressure above indicated or in nameplate.
For further details about maximum allowable pressure/temperature combinations please contact ALFA VALVOLE
technical department.
10035
ATTENTION : User must provide suitable means against the exceeding of the operating limits.
6.4 Before carrying out of any intervention on ball valve, verify that there is no pressure in the body cavity by carrying out a
complete opening and closing cycle.
6.5 ATTENTION : before removing any service connection such as drain plugs, vents, sealant injectors or stem, make sure of
the absence of pressure inside the body cavity of the valve.
The removal, even if accidental, of drain plugs, vents or sealant injectors may cause a dangerous sudden discharge of
pressure to the atmosphere and the expulsion of the organ itself.
Before carrying out this operation however, we recommend the use of personal safety equipment.
6.6 Before doing any intervention, ensure that no dangerous residue is contained in the valve body.
The valves must be completely drained and cleaned in the cavity around the ball before any intervention.
WARNING : any entrapped residue will be expelled from the ends of the valve.
6.7 ATTENTION : when installing the valve, User must ensure the same equipotential electrical level between valve and
piping system in order to prevent electric shock.
6.8 ATTENTION : when used in a potentially explosive area, for the purposes of Directive 94/9/EC "ATEX", User must provide
appropriate means to avoid impacts of metal parts against the valve body during assembly, service time and maintenance.
6.9 Quick closure of the valve against high speed flows can cause overstressing of the seats due to “water hammer”, which
can determine reduction of valve tightness.
ATTENTION : User must provide suitable means against the effects of “water hammers”.
ATTENTION : User must evaluate the minimum time between inspections, basing on actual operating conditions, in
( see para.0.3 of this manual ).
Time between inspections should not be longer than 2 years or 5.000 full open and close strokes.
6.11 ATTENTION : the user must carry out periodic inspections in order to eliminate any accumulation of powder greater than
5 mm in correspondence with the sliding surfaces of the stem/valve body and actuator pinion /actuator body.
6.12 ATTENTION : the functioning of valves complete with actuators is not guaranteed in the event of an earthquake due to
possible misalignment of connection between valve stem and actuator pinion.
Valve and actuator assembly is calculated for a maximum earthquake magnitude incrementing 40% the dead weight of
actuator and valve cover.
6.13 ATTENTION : assembling of actuators for valve operation different to that supplied is not allowed without previous
approval from the manufacturer.
6.14 Actuators, any type, are not suitable to resist against external fire conditions.
ATTENTION : actuators fire-safe properties can be obtained by use of fire-protection boxes enabling, to avoid system
(valve+actuators) malfunctions.
6.15 ATTENTION : cabling of actuators and electrical accessories should be realized after valve mounting to piping system
and according to the specifications showed in the relevant use and maintenance manuals.
6.16 ATTENTION : the user must establish an appropriate control program to verify the integrity of the lubricating grease in the
manual gears, if installed.
6.17 ATTENTION : split body type valves are suitable for resisting to reduced axial forces from piping system.
If necessary, require maximum values of allowed axial loads from ALFA VALVOLE technical department.
6.18 ATTENTION : valves can be used as end-type valves only by specific customer request and for working pressures not
exceeding 77% of the stated maximum working pressure at room temperature.
10035
7. TROUBLE SHOOTING
Malfunction Possible cause Action

Leakage through the Ball surface damage Replace the ball
valve
Seat damage Replace the seats or try with injection of
sealant grease (trunnion mounted
construction only)
Not complete closure Check Open/Close limits and settings
Ball movement not regular Dirt between ball and seats Flush the inside, operating the valve 5 times
(actuated valves)
Dirt between ball and body Flush the inside, operating the valve 5 times
cavities
Not sufficient air supply flow Confirm working conditions are as per
request
Not sufficient air discharge Include quick exhaust valve
Valve torque too high Seat damage Replace the seats
Dirt between ball and seats Flush the inside operating the valve 5 times
Dirt between ball and body Flush the inside operating the valve 5 times
cavities
Excessive Pressure or Confirm working conditions are as per
Temperature request
Stem leakage Stem nuts loose Tighten stem nuts
Damaged stem seal surfaces Replace stem
Damaged stem seals Replace stem seal or try with injection of
sealant grease (trunnion mounted
construction only)
Body seal leakage Gasket damage Replace gaskets
Excessive Pressure or Confirm working conditions are as per
Temperature request
Excessive load from piping Verify piping system architetture
system
Excessive valve noise Error in valve sizing Confirm valve sizing
Not complete opening Check Open/Close limits and settings
Fail in valve movement solenoid valve fail Confirm power supply
after electrical input Replace the solenoid
(actuated valves)
Fail in limit switch signal Uncorrect settings Check Open/Close settings
Limit switch is broken Replace limit switch
Uncorrect power supply Confirm working conditions are as per
request
10035
10063
ARI-Strainer
Strainer - Screen and supporting basket made of stainless steel
ARI-Strainer -
• TRB 801 Annex II No. 45 (except EN-JL1040) Grey cast
• German TA - Luft TÜV-Test-No. 922-9204866 iron
SG iron
Cast steel
Fig. 050 Page 2
ARI-Strainer -
• German TA - Luft TÜV-Test-No. 922-9204866
Stainless
steel
Fig. 050
Fig. 059 Page 3
ARI-Strainer -
Y-pattern with butt weld ends
• German TA - Luft TÜV-Test-No. 922-9204866
Cast steel
Fig. 080 Page 4
Features:
• Screen and supporting basket made of stainless steel
• Screen from DN50 with reinforced ring
• Screen from DN150 with supporting basket
• Precise guidance of screen in cover and body
10063 ARI-Strainer
Fig. 050
Strainer - Y-pattern with flanges (Grey cast iron, SG iron, Cast steel)

10.050 PN6 EN-JL1040 DN15-200
12.050 PN16 EN-JL1040 DN15-300
22.050 PN16 EN-JS1049 DN15-300
23.050 PN25 EN-JS1049 DN15-150
34.050 PN25 1.0619+N DN15-200
35.050 PN40 1.0619+N DN15-200
A supporting basket is necessary, with higher differential pressures, dependent on
clogging-up (DN >125 standard)
Test: • German TA - Luft TÜV-Test-No. 922-9204866
Parts
Pos. Description Fig. 10./12.050 Fig. 22./23.050 Fig. 34./35.050
1 Body EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT GP240GH+N, 1.0619+N
2 Cover DN ≤150: EN-JL1040, EN-GJL-250 DN ≤65: EN-JS1049, EN-GJS-400- DN ≤65: P250 GH, 1.0460
DN >150: P265 GH, 1.0425 18U-LT DN >65: P265 GH, 1.0425
DN >65: P265 GH, 1.0425
3 Screen * X5CrNi18-10, 1.4301
3.1 Supporting basket DN >125: X5CrNi18-10, 1.4301
4 Stud 25CrMo4, 1.7218
* Spare part
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850
H (mm) 90 100 115 125 150 160 180 215 235 275 305 390 540 680
H1 (mm) 135 150 180 205 235 250 285 330 365 425 480 610 915 1110
B (mm) 10 10 25 35 45 45 25 40 55 65 50 80 230 350
l1 (mm) 56 68 82 98 114 119 134 149 169 199 224 284 434 555
Ød1 (mm) 23 28 36 42 50 61,5 78,5 89,5 109,5 137,5 160 210 258 308
on request
Standard screen mesh width (mm) 1 1 1 1 1 1 1,25 1,25 1,6 1,6 1,6 1,6 1,6 1,6 possible in straight
Kvs-value 1) (m3/h) 6,9 10,8 17,8 26,1 36,7 61 98,6 146 234 376 394 652 1225 1873 through form
Zeta-value -- 1,7 2,2 2 2,5 3 2,7 2,9 3,1 2,9 2,8 5,2 6 4,2 3,7
Fine screen mesh width (mm) 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25
Kvs-value 1) (m3/h) 6,2 10,1 16,8 24,3 32,9 49,5 80,3 115 189 303 405 590 1231 1883
Zeta-value -- 2,1 2,5 2,2 2,8 3,8 4,1 4,4 4,9 4,4 4,5 4,9 7,3 4,1 3,6
Ratio of the free screen surface area to the area of
10 8,4 8,3 7,1 6,8 5,2 4,4 3,7 2,8 2,7 2,4 2,3 2,7 2,9
the nominal diameters.
1)
Kvs-values based upon clean screen !
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
10.050 (kg) 2,5 3 4,5 5,5 7 9 13 19 26 38 54 110 -- --
12.050 (kg) 3 4 5 7 9 12 16 21 30 43 61 121 154 335 on request
22.050 (kg) 3,5 4 5,5 7 9 12 16 21 28 41 58 115 154 335 possible in straight
23.050 (kg) 3,5 4 5,5 7 9 12 16 21 32 47 64 -- -- -- through form
34./35.050 (kg) 4 5 6 8 10 13 19 24,5 35 51 71 144 -- --

10063 ARI-Strainer
Fig. 059
Strainer - Y-pattern with flanges (Stainless steel)

52.059 PN16 1.4408 DN15-200
54.059 PN25 1.4408 DN15-200
55.059 PN40 1.4408 DN15-200
Parts
1 Body GX5CrNiMo19-11-2, 1.4408
2 Cover X6CrNiMoTi17-12-2, 1.4571
3 Screen * X6CrNiMoTi17-12-2, 1.4571
3.1 Supporting basket DN >125: X6CrNiMoTi17-12-2, 1.4571
4 Stud A4-70
5 Hexagon nut A4
* Spare part
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600
H2 (mm) 94 94 102 102 123 126 148 170 202 285 320 417
H3 (mm) 130 138 150 143 166 172 206 234 282 388 443 585
l2 (mm) 48 48 57 57 68 70 85 97 112 138 169 230
Ød2 (mm) 25 25 31 36 46 55,5 69,5 85,5 105,5 131,5 159 210
Standard screen mesh width (mm) 1 1 1 1 1 1 1,25 1,25 1,6 1,6 1,6 1,6
on request
Kvs-value 1) (m3/h) 6,9 10,8 17,8 26,1 36,7 61 98,6 146 234 376 394 652
Zeta-value -- 1,7 2,2 2 2,5 3 2,7 2,9 3,1 2,9 2,8 5,2 6
Fine screen mesh width (mm) 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25
Kvs-value 1) (m3/h) 6,2 10,1 16,8 24,3 32,9 49,5 80,3 115 189 303 405 590
Zeta-value -- 2,1 2,5 2,2 2,8 3,8 4,1 4,4 4,9 4,4 4,5 4,9 7,3
10 8,4 8,3 7,1 6,8 5,2 4,4 3,7 2,8 2,7 2,4 2,3
1)
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
52./54./55.059 (kg) 4 5 6 8 10 13 19 24,5 35,0 51 71 144 on request

10063 ARI-Strainer
Fig. 080
Strainer - Y-pattern with butt weld ends (Cast steel)

35.080 PN40 1.0619+N DN15-300
Parts
Pos. Description Fig. 34./35.080
1 Body GP240GH+N, 1.0619+N
2 Cover DN ≤100: P250 GH, 1.0460
DN >100: P265 GH, 1.0425
3 Screen * X5CrNi18-10, 1.4301
3.1 Supporting basket DN >125: X5CrNi18-10, 1.4301
4 Stud 25CrMo4, 1.7218
* Spare part
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850
H (mm) 90 100 115 125 150 160 180 215 235 275 305 390 540 680
H1 (mm) 135 150 180 205 235 250 285 330 365 425 480 610 915 1110
B (mm) 10 10 25 35 45 45 25 40 55 65 50 80 230 350
l1 (mm) 56 68 82 98 114 119 134 149 169 199 224 284 283 317
Ød1 (mm) 23 28 36 42 50 61,5 78,5 89,5 109,5 137,5 160 210 260 314
Standard screen mesh width (mm) 1 1 1 1 1 1 1,25 1,25 1,6 1,6 1,6 1,6 1,6 1,6
Kvs-value 1) (m3/h) 6,9 10,8 17,8 26,1 36,7 61 98,6 146 234 376 394 652 1225 1873
Zeta-value -- 1,7 2,2 2 2,5 3 2,7 2,9 3,1 2,9 2,8 5,2 6 4,2 3,7
Fine screen mesh width (mm) 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25
Kvs-value 1) (m3/h) 6,2 10,1 16,8 24,3 32,9 49,5 80,3 115 189 303 405 590 1231 1883
Zeta-value -- 2,1 2,5 2,2 2,8 3,8 4,1 4,4 4,9 4,4 4,5 4,9 7,3 4,1 3,6
10 8,4 8,3 7,1 6,8 5,2 4,4 3,7 2,8 2,7 2,4 2,3 2,7 2,9
1)
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300
35.080 (kg) 2,5 3 3,5 4 5,5 7,5 12 15 23,5 33 49 106 135 240

10063 ARI-Strainer
Valves with butt weld ends / special design / accessories
L = Face-to-face dimension
Butt weld ends according to DIN EN 12627 - 4

DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850 980 1100
ØA (mm) 22 28 35 44 50 62 77 91 117 144 172 223 278 329 362 413
ØB (mm) 17,3 22,3 28,5 37,2 43,1 53,9 68,9 80,9 104,3 130,7 157,1 204,9 257,0 307,9 338,0 384,4
Ødi (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250 300 330 375
R (mm) 3 3 3 3 3 3 3 3 3 3 3 5 5 5 5 5
L1 (mm) 10 10 10 10 10 10 10 12 14 18 20 20 25 33 45 45
Ød3 (mm) 21,3 26,9 33,7 42,4 48,3 60,3 76,1 88,9 114,3 139,7 168,3 219,1 273,0 323,9 355,6 406,4
s1 (mm) 2,0 2,3 2,6 2,6 2,6 3,2 2,9 4,0 5,0 4,5 5,6 7,1 8,0 8,0 8,8 11,0
Face-to-face dimension ETE series 1 according to DIN EN 12982.

Butt weld ends according to DIN EN 12627 - 4.
Weld joint according to DIN EN 29692 code numer 1.3.3.
GP240GH+N, 1.0619+N acc. to DIN EN 10213-2.
Based on our experience we recommend electric welding process for connecting valves or strainers with tubes or with each other .
Lime based electrodes with an appropriate composite material should be used as filler material for welding.
Gas welding should be avoided.
Because of the different material compositions and wall thickness of the steam traps and the pipe gas welding shall not be applied. Quenching cracks and coarse grain
structure may develop.
Only DN15: view on the cover flange

(not for stainless steel)
DN G
(mm) (inch)
15-20 3/8
25-32 3/4
40-80 1
100-150 1 1/2
200-300 2
350-500 on request
Pos. Description Fig. 10./12.22./23./34./35.050; Fig. 52./54./55.059;

34./35.080
8 Drain screw C35E, 1.1181 A4
9 Sealing ring St Aramid
Drain screw

10063 ARI-Strainer
Flange dimensions / Pressure-temperature-ratings
DN (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250 300
PN6 ØD (mm) 80 90 100 120 130 140 160 190 210 240 265 320 -- --
PN6 ØK (mm) 55 65 75 90 100 110 130 150 170 200 225 280 -- --
PN6 n x Ød (mm) 4x11 4x11 4x11 4x14 4x14 4x14 4x14 4x18 4x18 8x18 8x18 8x18 -- --
PN16 ØD (mm) 95 105 115 140 150 165 185 200 220 250 285 340 405 460
PN16 ØK (mm) 65 75 85 100 110 125 145 160 180 210 240 295 355 410
PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 12x22 12x26 12x26
PN25 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 360 425 485
PN25 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 310 370 430
PN40 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 375 450 515
PN40 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 320 385 480

EN-JL1040 6 (bar) -- 6 5,4 4,8 4,2 3,6 -- -- --
EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6 -- -- --

1.0619+N 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 8,2
1.0619+N 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 13,1
1.0460 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 10
1.0460 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 16

1.4408 16 (bar) 16 16 14,5 13,4 12,7 11,8 11,4 10,9 --
1.4408 25 (bar) 25 25 22,7 21 19,8 18,5 17,8 17,1 --
1.4408 40 (bar) 40 40 36,3 33,7 31,8 29,7 28,5 27,4 --

- Figure-No.
- Nominal pressure
Dimensions in mm
- Nominal diameter
Weights in kg
1 bar =^ 105 Pa =^ 0,1 MPa
Example:
Kvs in m3/h
Figure 35050; nominal pressure PN40; nominal diameter DN100; with drain screw.


10063 ARI-Y-Strainer
Flow diagram
DN15-40 Standard screen

DN mesh width Zeta-value Kv-value
15 1,0 1,7 6,9
20 1,0 2,2 10,8
25 1,0 2 17,8
32 1,0 2,5 26,1
40 1,0 3 36,7
→ Volume flow rate in m3 / h (water)
→ Kv-value in m3 / h
→ ∆p in bar
Pressure drop in Pascal (10 Pascal 1mm WS (1mm WS = 9,8066 Pa) 1bar = 0,1MPa = 105Pa

50 1,0 2,7 61
65 1,25 2,9 98,6
80 1,25 3,1 146
100 1,6 2,9 234
125 1,6 2,8 376
→ ∆p in bar
Flow diagram

150 1,6 5,2 394
200 1,6 5,6 652
250 1,6 4,2 1225
300 1,6 3,7 1873
→ ∆p in bar
DN15-40 Fine screen

15 1 +0,25 2,1 6,2
20 1 +0,25 2,5 10,1
25 1 +0,25 2,2 16,8
32 1 +0,25 2,8 24,3
40 1 +0,25 3,8 32,9
→ ∆p in bar

Flow diagram
DN50-125 Fine screen

50 1 +0,25 4,1 49,5
65 1,25 +0,25 4,4 80,3
80 1,25 +0,25 4,9 115
100 1,6 +0,25 4,5 189
125 1,6 +0,25 4,2 303
→ ∆p in bar
DN150-300 Fine screen

150 1,6 +0,25 4,9 405
200 1,6 +0,25 7,3 590
250 1,6 +0,25 4,1 1231
300 1,6 +0,25 3,6 1883
→ ∆p in bar

Flow diagram


10063 ARI-Strainer PN63-160
ARI-Strainer - Screen of stainless steel

DN 10 - 50
ARI-Strainer -
• TRB 801 Annex II No. 45 Cast steel
Forged steel
High temp.
Steel
Fig. 050 Page 2
ARI-Strainer -
Straight through with butt weld ends Fig. 050
• TRB 801 Annex II No. 45 Cast steel
Forged steel
High temp.
Steel
Fig. 080 Page 3
Features:
• Screen of stainless steel
• Screen from DN50 with reinforced ring
• Precise guidance of screen in cover and body
Edition 06/12 - Data subject to alteration - Regularly updated data on www.ari-armaturen.com! Data sheet 050003 englisch (english)
10063 ARI-Strainer 050 PN63-160 / DN10-50
Technical data
Strainer - straight through with flanges (Forged steel, High temperature steel)

48.050....40 PN63-160 1.0460 DN10-40
46.050....40 PN63 1.0460 DN50
48.050....40 PN100-160 1.0460 DN50
88.050....81 PN63-160 1.7335 DN10-40

86.050....81 PN63 1.7335 DN50
88.050....81 PN100-160 1.7335 DN50
Parts
Pos. Sp.p. Description Fig. 46./48.050....40 Fig. 86./88.050....81
1 Body P250 GH, 1.0460 13CrMo4-5, 1.7335
2 Cover P250 GH, 1.0460 13CrMo4-5, 1.7335
3 x Screen X6CrNiMoTi17-12-2, 1.4571
4 Stud 21CrMoV 5-7, 1.7709
5 Hexagon nut 21CrMoV 5-7, 1.7709
6 x Gasket Pure graphite (CrNi laminated with graphite)
└ Spare parts
DN 10 15 20 25 32 40 50
Face-to-face dimension FTF series 2 acc. to DIN EN 558 Standard-flange dimensions refer to page 6
L (mm) 210 210 230 230 260 260 300
Dimensions
H (mm) 105 105 105 105 145 145 160
H1 (mm) 150 150 150 150 200 200 220
l (mm) 56 56 56 56 68 68 70
Ød1 (mm) 31 31 31 31 46 46 56
Standard screen Mesh width (mm) 1 1 1 1 1 1 1
Ratio of the free screen surface area to the area of the 30 13 8 5 5 3 2,7
nominal diameters.
Weights
46./86.050 (kg) -- -- -- -- -- -- 23,3
48./88.050 (kg) 6,8 7 8,6 9,6 16 18 23,5

Operating and installation instructions can be downloaded at www.ari-armaturen.com.
Resistance and fitness must be verified (or contact the manufacturer for information).
Edition 06/12 - Data subject to alteration - Regularly updated data on www.ari-armaturen.com!
10063 ARI-Strainer 080 PN63-160 / DN10-50
Technical data
Strainer - straight through with butt weld ends (Forged steel, High temperature steel)

48.080....40 PN160 1.0460 DN10-50
88.080....81 PN160 1.7335 DN10-50
Butt weld ends according to DIN EN 12627 (refer to page 4)
Parts
Pos. Sp.p. Description Fig. 48.080....40 Fig. 88.080....81
1 Body P250 GH, 1.0460 13CrMo4-5, 1.7335
2 Cover P250 GH, 1.0460 13CrMo4-5, 1.7335
3 x Screen X6CrNiMoTi17-12-2, 1.4571
4 Stud 21CrMoV 5-7, 1.7709
5 Hexagon nut 21CrMoV 5-7, 1.7709
6 x Gasket Pure graphite (CrNi laminated with graphite)
└ Spare parts
DN 10 15 20 25 32 40 50
Face-to-face dimension ETE series 65 acc. to DIN EN 12982

L (mm) 150 150 150 160 180 210 250
Dimensions
H (mm) 105 105 105 105 145 145 160
H1 (mm) 150 150 150 150 200 200 220
l (mm) 56 56 56 56 68 68 70
Ød1 (mm) 31 31 31 31 46 46 56
Standard screen Mesh width (mm) 1 1 1 1 1 1 1
Ratio of the free screen surface area to the area of the 30 13 8 5 5 3 2,7
nominal diameters.
Weights
48.080 / 88.080 (kg) 4,6 4,6 4,6 4,7 10,2 10,2 12,7

Operating and installation instructions can be downloaded at www.ari-armaturen.com.
Resistance and fitness must be verified (or contact the manufacturer for information).
10063 ARI-Strainer 050/080 PN63-160 / DN10-50
Pressure-temperature-ratings / Standard-flange dimensions / Valves with butt weld ends
Intermediate values for max. permissible operational pressures can be determined by linear interpolation
Pressure-temperature-ratings of the given temperature / pressure chart.
acc. to manufacturers standard -10°C to 50°C 120°C 150°C 200°C 250°C 300°C 350°C 400°C 450°C
PN 63 (bar) 63 63 58 50 45 40 36 32 24
1.0460 PN 100 (bar) 100 100 90 80 70 60 56 50 38
PN 160 (bar) 160 160 145 130 112 96 90 80 60
acc. to manufacturers standard -10°C to 250°C 300°C 350°C 400°C 450°C 500°C 520°C 530°C 540°C 550°C
PN 63 (bar) 63 63 61 58 56 47 32 25 20 15
1.7335 PN 100 (bar) 100 100 95 91 87 74 49 38 31 24
PN 160 (bar) 160 160 153 146 139 118 79 62 46 35
DN 10 15 20 25 32 40 50
Standard-flange dimensions Flanges according to DIN 2501, Facing acc. to DIN 2526 Form E (Flange holes / -thickness tolerances acc. to DIN 2546/2547/2548)
ØD (mm) 100 105 130 140 155 170 180
PN63 ØK (mm) 70 75 90 100 110 125 135
n x Ød (mm) 4 x 14 4 x 14 4 x 18 4 x 18 4 x 22 4 x 22 4 x 22
ØD (mm) 100 105 130 140 155 170 195
PN100 ØK (mm) 70 75 90 100 110 125 145
n x Ød (mm) 4 x 14 4 x 14 4 x 18 4 x 18 4 x 22 4 x 22 4 x 26
ØD (mm) 100 105 130 140 155 170 195
PN160 ØK (mm) 70 75 90 100 110 125 145
n x Ød (mm) 4 x 14 4 x 14 4 x 18 4 x 18 4 x 22 4 x 22 4 x 26
Valves with butt weld ends

L = Face-to-face dimension Ød3 / s1 = corresponding pipe dimension
DN 10 15 20 25 32 40 50
Butt weld ends according to DIN EN 12627

L (mm) 150 150 150 160 180 210 250
ØA (mm)
ØB (mm)
PN63
Ød3 (mm)
s1 (mm)
on request
ØA (mm)
ØB (mm)
PN100
Ød3 (mm)
s1 (mm)
ØA (mm) 18 22 28 35 44 50 62
ØB (mm) 13,2 17,3 22,3 27,3 35,2 41,1 52,3
PN160
Ød3 (mm) 17,2 21,3 26,9 33,7 42,4 48,3 60,3
s1 (mm) 2 2 2,3 3,2 3,6 3,6 4
Face-to-face dimension ETE series 65 acc. to DIN EN 12982.
P250GH, 1.0460 acc. to DIN EN 10222-2
13CrMo4-5, 1.7335 acc. to DIN EN 10222-2
Please indicate when ordering:

- Figure-No.
- Nominal pressure Dimensions in mm
- Nominal diameter Weights in kg
- Special design / accessories 1 bar =^ 105 Pa =^ 0,1 MPa
Example: Kvs in m3/h
Figure 46.050; Nominal pressure PN63;
Nominal diameter DN50.


10063

Strainer
Contents
1.0 General information on operating 6.0 Putting the valve into operation ..................6
instructions ................................................... 2 7.0 Care and maintenance..................................6
2.0 Notes on possible dangers.......................... 2 8.0 Troubleshooting ............................................7
2.1 Significance of symbols ........................................2 9.0 Troubleshooting table ..................................7
2.2 Explanatory notes on safety information ...............2 10.0 Dismantling the valve or the top part .......8
3.0 Storage and transport ................................. 2 11.0 Warranty / Guarantee ..................................8
4.0 Description .................................................... 3 12.0 EC declaration of conformity .....................9
4.1 Scope of applications ............................................3
4.2 Operating principles ..............................................3
4.3 Diagram.................................................................4
4.4 Technical data - remarks .......................................4
4.5 Marking .................................................................5
5.0 Installation..................................................... 5
5.1 General notes on installation.................................5
5.2 Installing valves with butt weld ends .....................6
Rev. 0040101000 0410 englisch

10063 Operating and installation instructions
Strainer

and repair.
ATTENTION !

to property.

ATTENTION !
- At -20°C to +65°C.
Page 2 Rev. 0040101000 0410

Strainer
4.0 Description
Strainers are used for "cleanin flowing mediums“.
ATTENTION !
to TRD 110.

The medium flows through the strainer screen in the direction shown on the strainer and is
thereby cleaned.
Rev. 0040101000 0410 Page 3

Strainer
4.3 Diagram
rotated
rotated view
view
fig. 1: Strainer - Y fig. 2: Strainer - Y SE
rotated
view
fig. 3: Strainer - Y (1.4408)

Refer to the data sheet for information about materials with designations and figure
numbers.

for
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
Page 4 Rev. 0040101000 0410

Strainer
4.5 Marking
CE-marking
0525 Notified body
Typ Type refer to item 11.0 Warranty / Guarantee
5.0 Installation
installation work:
ATTENTION !
- Note installation position with reference to flow direction, see mark on valve.
- Lay pipelines so that damaging transverse, bending and torsional forces are avoided.
both sides.
- Leave sufficient space to remove the screen basket during installation in
pipelines.
- Installation position:
a) The screen basket should never be at the top, otherwise the dirt will
fall back into the pipe.
b) If water hammer is possible due to condensation in steam lines,
never install the trap with the screen basket at the bottom, but install
it so that it is horizontal.
- Install compensators to compensate for thermal expansion of the piping.
Rev. 0040101000 0410 Page 5

Strainer
recommended.
5.2 Installing valves with butt weld ends

Please note that only qualified persons using appropriate equipment and working in
accordance with technical rules are allowed to install fittings by welding.
The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
ATTENTION !

The strainer screens must be cleaned regularly. Maintenance and maintenance-intervals
have to be defined by the operator and depends on the degree of dirt accumulation in the
system.
- If necessary, the strainer can be fitted with an additional start-up filter (e.g. filter with
supporting basket) to start up the system.
- Flush the plant thoroughly before starting it.
- The strainer requires little maintenance.
ATTENTION !
Refer to point 10.0 before opening the strainer.
- Contaminated strainers in suction-lines will result cavitation and damage the
pumps.
- Before reassembling the unit, remember that the bearing surface must be cleaned and a
new gasket (pos. 6) must be inserted.
- Set the strainer cover (pos. 2) in place.
- Tighten the hexagon nuts (pos. 4) evenly crosswise.
Page 6 Rev. 0040101000 0410

Strainer
Tightening torque‘s for hexagon nuts / bolts:
hexagon nuts / Torque
DN
bolts (Nm)
15- 32 M 10 20-35
40 M 12 20-35
50- 65 M 12 60-80
80-150 M 16 100-125
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
8.0 Troubleshooting
Instructions.
ATTENTION !
-


ATTENTION !

No flow Flange covers have not been removed Remove flange covers
(7, Fig. 3) (7, Fig. 3)
Flow too low strainer clogged. Clean/replace screen.
Piping clogged. Check piping system.
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
unit and piping Mating flanges not properly aligned.
Rev. 0040101000 0410 Page 7

Strainer

ATTENTION !
media.

Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of
appointed by us.

Page 8 Rev. 0040101000 0410

Strainer

EG-Konformitätserklärung
im Sinne der
EG-Druckgeräterichtlinie 97/23/EG und
Hiermit erklären wir,
dass gemäß der oben genannten Druckgeräterichtlinie die nachfolgend aufgelisteten Pro-
dukte ausgeführt sind und nach Diagramm 6, Anhang II, Modul H der Druckgeräterichtlinie
von Lloyd´s Register Quality Assurance GmbH (BS-Nr. 0525), Am Sandtorkai 41,
D-20457 Hamburg, geprüft wurden.
Zertifikat-Nr: 50003/1
Schmutzfänger
Typ 050, 059, 080
Angewendete Normen:
DIN 3840
AD 2000 Merkblatt A4
- Gusseisen mit Kugelgraphit
- Stahlguss
- Schmiedestahl
Schloß Holte-Stukenbrock, den 11.01.2010
..................................................
(Brechmann, Geschäftsführer)
Rev. 0040101000 0410 Page 9

ARI-ZESA® / ARI-GESA® / THEA®
Enclosure 10098 Butterfly valves
ARI-ZESA® - Fig. 012 - Free of maintenance butterfly valve with elongated eyelets - soft sealed
ARI-GESA® - Fig. 013 - Free of maintenance butterfly valve with threaded eyelets - soft sealed
ARI-ZESA® / ARI-GESA®
with notch lever
Page 6
with lock lever
• With angle positioning
• With variable adjustment
Page 6
THEA®
ARI-ZESA® / ARI-GESA® Fig. 012 - ARI-ZESA® THErmo-Appliance
with worm gear

• Self-locking
Page 6
with electric rotary actuator rotork
•F or short time duty S 2-5 Min.
(periodic duty S3 30% duty cycle)
• 230V 50Hz
• Enclosure IP 67
Page 7
with electric rotary actuator Deufra
• Type of operation, on/off S4 30% (or controlS4 50% )
• 230V 50Hz (400V 50Hz)
Fig. 013 - ARI-GESA®
• Enclosure IP 67
Page 8
Features:
• Soft sealing
with electric rotary actuator Auma • Maintenance-free
• For temporary service S 2-15 min. (or control S4 25%) • Good flow characteristic due to excellent Zeta-values
• 400V 50Hz (230V 50Hz) • Seat materials EPDM / NBR / FPM
• Enclosure IP 67 • Double sealing of the stem
Page 9
• Stainless steel disc
ARI-ZESA® / ARI-GESA® • Complete insulation possible according to the german
„Energy saving order - EnEV“
with pneumatic rotary actuator
• Dew point barrier
AIR-TORQUE / bar
• Centrical disc bearing
• Function: double acting
• Nodular iron body
• Function: single acting, spring closes (opens)
• EPDM with DIN DVGW Reg. drinking water
• Actuating pressure 6 bar (=0,6 MPa) Page 10 / 11 (DW-6201BR0244)
ARI-ZESA®:
ARI-ZESA® / ARI-GESA® • Wafer type
ARI-GESA®:
with integrated Thermo - Appliance
• Lug type
• Cold (-20 up to +40°C) or warm (0 up to +120°C)
• As a pipe-end valve
• With lever
• Pipeline one-side detachable
• Precision class 1,0
Page 12
ARI-ZESA®
Butterfly valve with elongated eyelets (SG iron)

20.012 PN6 EN-JS1030 DN25-300
21.012 PN10 EN-JS1030 DN25-500
22.012 PN16 EN-JS1030 DN25-500
Disc: 1.4581
Stem: • 1.4021+QT
• 1.4571
Seat: • EPDM -10 °C to +130 °C
• NBR -10 °C to +80 °C
• FPM - 10 °C to + 150 °C (not for hot water useable)
max. gauge press.: 16 bar (DN25-150)
10 bar (DN200-500)
Actuation • Notch lever
arrangement: • Lock lever
(refer to page 6-11) • Worm gear
• Electric actuator
• Pneumatic actuator
Test:
Sealing leakage test EN 12266-1 Leakage rate A (DIN 3230 T3 Leakage rate 1)
DVGW-Registration EPDM for water Reg.-No. DW-6201BR0244,
acc. to DIN EN 1074-1/-2
incl. desinfection inspection,
DVGW VP646 and DVGW W270 for drinking water

Cold -and cooling water installations, Heating installations, Drinking water and domestic
water, Waste water, Swimming pool-installations, Power stations, Gas installations,
Shipbuilding, etc.
Cold water, warm water, hot water, drinking water, process water, etc.
Parts
1 Body EN-GJS-400-15, EN-JS1030
2 Seat EPDM 73 / NBR 73 / FPM 73
3 Disc GX5CrNiMoN19-11-2, 1.4581
4 Pivot X20Cr13+QT, 1.4021+QT X6CrNiMoTi17 12 2, 1.4571
5 Stem X20Cr13+QT, 1.4021+QT X6CrNiMoTi17 12 2, 1.4571
6 Taper pin X6CrNiMoTi17 12 2, 1.4571
8 Insulating cap * PA 6
9 Gasket * CU
10 Hexagon head screw plug * 5.8-A2G
11 O-ring * EPDM 73 / NBR 73 / FPM 73
* Spare part
DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
L (mm) 33 33 33 43 46 46 52 56 56 60 68 78 78 102 127
H (mm) 128 128 134 140 150 158 179 196 212 246 273 302 358 407 495
E (mm) 58 58 66 69 81 100 109 124 140 167 203 232 258 287 354
l (mm) 15 15 15 15 15 15 15 18 18 18 24 24 26 42 42
SW (mm) 11 11 11 11 11 11 11 17 17 17 22 22 22 30 30
Kvs-value (m3/h) 26 26,5 49,6 116 259 377 763 1030 1790 3460 5070 7430 10320 13290 21180
Zeta-value -- 0,93 2,4 1,7 0,75 0,43 0,46 0,27 0,37 0,25 0,21 0,24 0,23 0,23 0,23 0,22
Weights (kg) 1,4 1,4 1,6 2 2,6 3,2 4 4,6 8,6 12,6 19,4 29,4 43,9 67,7 111
Face-to-face dimension FTF series 20 acc. to DIN EN 558-1

ARI-ZESA®
Enclosure 10098 Construction / Installation variations / Flange dimensions
DN25-65 DN80-100 DN125-150
DN200 DN250-300 DN350-500
Pressure-temperature-ratings
Material PN -10°C to 120°C 130°C 150°C
EN-JS1049 16 bar 16 15,8 15,5
of the given temperature / pressure chart.
Welding neck flanges

PN 6 / PN 10 / PN 16
DIN EN 1092-1 / 11 / B1
(for slip-on-flanges acc. to DIN EN 1092-1 use ZIVA)
Hexagon screw
DIN EN ISO 4016 W.-Nr. 4.6
Hexagon nut
ZESA®-Wafer-type-valve DIN EN ISO 4034 W.-Nr. 5
Standard-flange dimensions / Hexagon screw (Quantity, Thread, Length)

DN 25 1) 32 1) 40 50 65 80 100 125 150 200 250 300 350 400 500
PN6 ØK (mm) 75 90 100 110 130 150 170 200 225 280 335 395
PN6 n x Ød1 (mm) 4x11 4x14 4x14 4x14 4x14 4x18 4x18 8x18 8x18 8x18 8x18 8x22
PN6 Quantity (pcs.) 4 4 4 4 4 4 4 8 8 8 12 12 -- on request
PN6 Thread M10 M12 M12 M12 M12 M16 M16 M16 M16 M16 M16 M20
PN6 Length (mm) 80 80 80 90 90 100 110 120 120 130 140 160
PN10 ØK (mm) 85 100 110 125 145 160 180 210 240 295 350 400 460 515 620
PN10 n x Ød1 (mm) 4x18 4x18 4x18 4x18 4x18 4x18 4x18 8x18 8x22 8x22 8x22 8x22 4x22 4x28 4x28
PN10 Quantity (pcs.) 4 4 4 4 4 8 8 8 8 8 12 12 16 16 20
PN10 Thread M12 M16 M16 M16 M16 M16 M16 M16 M20 M20 M20 M20 M20 M24 M24
PN10 Length (mm) 90 90 90 100 110 110 120 130 130 140 150 160 160 200 220
PN16 ØK (mm) 85 100 110 125 145 160 180 210 240 295 355 410 470 525 650
PN16 n x Ød1 (mm) 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 12x22 12x26 12x26 16x26 16x30 20x33
PN16 Quantity (pcs.) 4 4 4 4 4 8 8 8 8 12 12 12 16 16 20
PN16 Length (mm) 90 90 90 100 110 110 120 130 130 140 160 170 180 220 260
1) DN 25/32 suitable for flanges PN16 / DN 20

ARI-GESA®
Butterfly valve with threaded eyelets (SG iron)

21.013 PN10 EN-JS1030 DN25-500
22.013 PN16 EN-JS1030 DN25-500
Washer: 1.4581
Stem: • 1.4021+QT
• 1.4571
Seat: • EPDM -10 °C to +130 °C
• NBR -10 °C to +80 °C
• FPM - 10 °C to + 150 °C (not for hot water useable)
max. gauge press.: 16 bar (DN25-150)
10 bar (DN200-500)
Actuation • Notch lever
arrangement: • Lock lever
(refer to page 6-11) • Worm gear
• Electric actuator
• Pneumatic actuator
Test:
Sealing leakage test DIN EN 12266-1 Leakage rate A
(DIN 3230 T3 Leakage rate 1)
DVGW-Registration EPDM for water Reg.-No. DW-6201BR0244,
acc. to DIN EN 1074-1/-2
incl. desinfection inspection,
DVGW VP646 and DVGW W270 for drinking water
Cold -and cooling water installations, Heating installations, Drinking water and domestic
water, Waste water, Swimming pool-installations, Power stations, Gas installations,
Shipbuilding, etc.
Cold water, warm water, hot water, drinking water, process water, etc.
Parts
1 Body EN-GJS-400-15, EN-JS1030
2 Seat EPDM 73 / NBR 73 / FPM 73
3 Disc GX5CrNiMoN19-11-2, 1.4581
4 Pivot X20Cr13+QT, 1.4021+QT X6CrNiMoTi17 12 2, 1.4571
5 Stem X20Cr13+QT, 1.4021+QT X6CrNiMoTi17 12 2, 1.4571
6 Taper pin X6CrNiMoTi17 12 2, 1.4571
9 Gasket * CU
10 Hexagon head screw plug * 5.8-A2G
11 O-ring * EPDM 73 / NBR 73 / FPM 73
14 Parallel bush P1
* Spare part
DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
L (mm) 33 33 33 43 46 46 52 56 56 60 68 78 78 102 127
H (mm) 128 128 134 140 150 158 179 196 212 246 273 302 358 407 495
E (mm) 58 58 66 69 81 100 109 124 140 167 203 232 258 287 354
l (mm) 15 15 15 15 15 15 15 18 18 18 24 24 26 42 42
SW (mm) 11 11 11 11 11 11 11 17 17 17 22 22 22 30 30
Kvs-value (m3/h) 26 26,5 49,6 116 259 377 763 1030 1790 3460 5070 7430 10320 13290 21180
Zeta-value -- 0,93 2,4 1,7 0,75 0,43 0,46 0,27 0,37 0,25 0,21 0,24 0,23 0,23 0,23 0,22
Weights (kg) 1,8 18 2 2,8 3,2 4,8 6,2 8,8 11 15,6 24,8 36 55,6 85 146
Face-to-face dimension FTF series 20 acc. to DIN EN 558-1

ARI-GESA®
Enclosure 10098 Construction / Installation variations / Flange dimensions
DN25-65 DN80-150 DN200
DN250-300 DN350-500
Pressure-temperature-ratings
Material PN -10°C to 120°C 130°C 150°C
EN-JS1049 16 bar 16 15,8 15,5
of the given temperature / pressure chart.
GESA®-Wafer-type-valve GESA®-Pipe-end-valve
welding neck flanges welding neck flanges
PN 10 / PN 16 PN 10 / PN 16
DIN EN 1092-1 / 11 / B1 DIN EN 1092-1 / 11 / B1
(for slip-on-flanges acc. to DIN EN 1092-1 use ZIVA) (for slip-on-flanges acc. to DIN EN 1092-1 use ZIVA)
Hexagon screw Hexagon screw
DIN EN ISO 4016 W.-Nr. 4.6 DIN EN ISO 4016 W.-Nr. 4.6
When used on end of line applications, a safety precaution (blind flange, etc.) is recommended.
To ensure the seat tightness, a blind or counter flange is necessary.
The installation between, to above deviating flanges, is not or under special care possible. Please consult us.
For all installation, modification or maintenance work, please observe regulations in force and the ARI-operating instructions.
Standard-flange dimensions / Hexagon screw (Quantity, Thread, Length)

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
PN10 ØK (mm) 85 100 110 125 145 160 180 210 240 295 350 400 460 515 620
PN10 nxM (mm) 4xM12 4xM16 4xM16 4xM16 4xM16 8xM16 8xM16 8xM16 8xM20 8xM20 12xM20 12xM20 16xM20 16xM24 20xM24
PN10 Quantity (pcs.) 8 8 8 8 8 16 16 16 16 16 24 24 32 32 40
PN10 Length (mm) 30 30 30 35 35 40 40 45 45 50 55 55 60 70 85
PN16 ØK (mm) 85 100 110 125 145 160 180 210 240 295 355 410 470 525 650
PN16 n x Ød1 (mm) 4xM12 4xM16 4xM16 4xM16 4xM16 8xM16 8xM16 8xM16 8xM20 12xM20 12xM24 12xM24 16xM24 16xM27 20xM30
PN16 Quantity (pcs.) 8 8 8 8 8 16 16 16 16 24 24 24 32 32 40
PN16 Length (mm) 30 30 30 35 35 40 40 45 45 50 55 60 60 75 100

Enclosure 10098 Notch lever / Lock lever / Worm gear
with lever
Notch lever
For diameters larger than DN 125 we recommend using a gear mechanism. Gear
recommended for inaccessible installation (see below).
(till valve center)

Lock lever
• Cap convertable for lock lever
• Variable adjustment (with 0 - 90° angle positioning) (With variable adjustment)
(till valve center)
For diameters larger than DN 125 we recommend using a gear mechanism. Gear
recommended for inaccessible installation (see below).
Worm gear
• Self-locking
Stop screw
Lock nut
Position indicator
(till valve center)
The SHUT-position can be adjusted to ±5° by a locking screw.
Parts
Pos. Description Fig. 20./21./22.012; 21./22.013
7 Lever cap * PA 6
20 Hexagon nut * 5-A2B
21 Pan head screw * 8.8-A2B
50 Notch lever DC01, 1.0330 (surface treatment)
50 Clamp lever DC01, 1.0330 (surface treatment)
50 Worm gear
* Spare part

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
H1 (mm) 187 187 193 199 209 217 238 263 279 313 -- -- -- -- --
P1 (mm) 184 184 184 184 184 184 184 273 273 273 -- -- -- -- --
H2 (mm) 217 217 223 229 239 247 268 285 301 335 428 457 513 603 691
P2 (mm) 152 152 152 152 152 152 152 152 152 152 278 278 278 320 320
ØC (mm) 125 125 125 125 125 125 125 125 125 125 250 250 250 315 315
Type of gear SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE10 SE10 SE10 SE12 SE12
ZESA® with lever (kg) 1,8 1,8 2,0 2,4 3,0 3,6 4,4 7,4 9,4 13,4 -- -- -- -- --
GESA® with lever (kg) 2,2 2,2 2,4 3,2 3,6 5,2 6,6 9,6 11,8 14,9/16,4 -- -- -- -- --
ZESA® with gear (kg) 3,3 3,3 3,5 3,9 4,5 5,1 5,9 8,5 10,5 14,5 24,4 34,4 49 75,6 120
GESA® with gear (kg) 3,7 3,7 3,9 4,7 5,1 6,7 8,1 10,7 12,9 16/17,8 29,8 41 61 97 157

Enclosure 10098 rotork
Butterfly valve with electric rotary actuator Type: rotork
rotork
Electric rotary actuator
• for short time duty S 2-5 Min.
(Periodic duty S3 30% duty cicle, max. 60 c/h,
max. modulating torque = ca. 50% rated torque)
• 230V 50Hz
• Enclosure IP 67
• Temperature guard in the motor
• Travel switch
• Accessories:
- Potentiometer (1000 Ohm)
- Positioner 4-20 mA
- Position-transmitter 4-20 mA
- Heating
• Voltages:
12VDC/VAC, 24VDC/VAC, 110V
other voltages on request
For connection refer to terminal connection in the operating instructions of the

actuator !

DN 25 32 40 50 65 80 100 125 150 200
H1 (mm) 278 278 284 290 300 308 379 451 467 501
P1 (mm) 35 35 35 35 35 35 54 82 82 82
P2 (mm) 80 80 80 80 80 80 54 118 118 118
P3 (mm) 54 54 54 54 54 54 54 100 100 100
P4 (mm) 54 54 54 54 54 54 54 230 230 230
Type of actuator ROM-1 ROM-A ROM-2 ROM-3
Operating time (s) 13 24 17 26
ZESA® (kg) 3,3 3,3 3,5 4 4,4 5 6,9 16 17,7 22,1
GESA® (kg) 3,7 3,7 4 4,7 5,2 6,8 9,3 18,5 20 25

Enclosure 10098 Deufra
Butterfly valve with electric rotary actuator Type: Deufra
Deufra
• Type of operation on/off S4 30% (optional: for control S4 50%)
• 230V 50Hz (400V 50Hz (not at OA3))
• Enclosure IP 67
• Heating
• Accessories:
- Travel switch
- Potentiometer
- Valve positioner 0-10V / 4-20mA
- Position-transmitter
• Special actuators:
- Reset to start on failure Type FQ
Other voltages on request

actuator !

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
H1 (mm) 352 352 358 364 374 382 403 420 436 470 453 527 585 620 708
h (mm) 53 53 53 53 53 53 53 53 53 53 100 100 100 86 86
ØC (mm) 60 60 60 60 60 60 60 60 60 100 160 250 250 250 250
P1 (mm) 90 90 90 90 90 90 90 90 90 98 167 169 169 172 172
P2 (mm) 160 160 160 160 160 160 202 202 202 260 312 340 340 392 392
P3 (mm) 65 65 65 65 65 65 65 65 65 65 89 89 89 133 133
P4 (mm) 125 125 125 125 125 125 125 125 125 125 226 226 226 284 284
Type of actuator OA3 OA6 OA8 OA15 AS25 AS50 BS100
Operating time (s) 6 6 6 15 10 30 30
ZESA® (kg) 7,1 7,1 7,3 7,8 8,2 8,8 9,9 13,4 14,8 18,9 37,4 45,5 61 100 141
GESA® (kg) 7,5 7,5 7,8 8,5 9 10,6 12,2 15,8 17,2 21,1/21,8 43 54 74 121 181

Enclosure 10098 Auma
Butterfly valve with electric rotary actuator Type: Auma
Auma
• for temporary service S 2-15 min. (or control S4 25%)
• 400V 50Hz (230V 50Hz)
• Enclosure IP 67
• Heating
• Accessories:
- Travel switch
- Potentiometer
- Auma Matic
- Valve positioner 0-10V / 4-20mA
- Position-transmitter
Other voltages on request

actuator !

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
H1 (mm) 403 403 409 415 425 433 454 471 487 521 548 593 651 722 810
h (mm) 82 82 82 82 82 82 82 82 82 82 82 88 88 102 102
ØC (mm) 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160
P1 (mm) 195 195 195 195 195 195 195 195 195 195 195 205 205 205 205
P2 (mm) 291 291 291 291 291 291 291 291 291 291 291 301 301 301 301
P3 (mm) 58 58 58 58 58 58 58 58 58 58 58 75 75 75 75
P4 (mm) 191 191 191 191 191 191 191 191 191 191 191 216 216 233 233
Type of actuator SG05 SG07 SG10 SG12
Operating time (s) 16 16 16 32
ZESA® (kg) 19,9 19,9 21,1 20,6 21 21,6 22,4 24,6 26 30,5 38,4 53,5 69 99 140
GESA® (kg) 20,3 20,3 20,6 21,3 21,8 23,4 24,8 27 28,4 32,1/33,4 44,5 62 82 120 180

Enclosure 10098 AIR TORQUE
Butterfly valve with pneumatic rotary actuator Type: AIR TORQUE
AIR TORQUE
Pneumatic rotary actuator
single acting, Spring closes on air failure (opens)
• Actuating pressure 6 bar (=0,6 MPa)
• Position indicator
• Accessories:
- Limit switch open / close
- Solenoid valve
- Exhaust silencer with throttling function
- Valve positioner
Other actuating pressures on request

actuator !

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
H1 (mm) 233 233 239 245 255 263 301 331 347 393 448 509 567 635 792
double acting
P1 (mm) 159 159 159 159 159 159 211 248 248 269 315 409 409 438 543
P2 (mm) 83 83 83 83 83 83 95 106 106 123 141 172 172 187 222
Type of actuator DR30 DR60 DR100 DR150 DR220 DR450 DR600 DR1200
ZESA® (kg) 3 3 3,2 3,7 4,1 4,7 6,6 10 11,4 18,6 27,8 43 59 90 147
GESA® (kg) 3,4 3,4 3,7 4,4 4,9 6,5 9 12,4 13,8 19,5/21 33,9 51,5 72 111 187
H1 (mm) 233 233 239 245 272 293 326 371 399 453 500 597 655 758 877
single acting
P1 (mm) 159 159 159 159 211 248 269 315 345 409 438 543 543 621 684
P2 (mm) 83 83 83 83 95 106 123 141 152 172 187 222 222 262 330
2000 3000
Type of actuator (closes) 30SC6 60SC6 100SC6 150SC6 220SC6 300SC6 450SC6 600SC6 1200SC6
SC6 SC6
1200 2000
Type of actuator (opens) 30SO5 60SO5 100SO5 150SO5 220SO5 450SO5 900SO5
SO5 SO5
ZESA® (kg) 3,1 3,1 3,3 3,8 5,7 7,5 10,4 16 20,2 30,2 43,4 73,6 89 134 213
GESA® (kg) 3,5 3,5 3,8 4,5 6,5 9,3 12,8 18,4 22,6 32,2/33,7 49,5 82,1 102 155 253
Solenoid valve: Accessories: Limit switch in housing

for control of double acting actuators
5/2 - way
Solenoid valve: Accessories: Solenoid valve

for control of single acting actuators
3/2 - way

Enclosure 10098 bar
Butterfly valve with pneumatic rotary actuator Type: bar
bar
single acting, Spring closes on air failure (opens)
• Actuating pressure 6 bar (=0,6 MPa)
• Accessories:
- Limit switch open / close
- Solenoid valve
- Exhaust silencer with throttling function
- Position indicator
- Valve positioner
Other actuating pressures on request

actuator !

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
H1 (mm) 232 232 238 244 254 276 297 343 359 416 443 530 588 637 782
double acting
P1 (mm) 127 127 127 127 127 140 140 209 209 222 292 337 337 377 462
P2 (mm) 72 72 72 72 72 82 82 108 108 120 120 172 172 172 224
Type of actuator GTD 58/90 GTD 68/90 GTD 98/90 GTD GTD GTD GTD GTD
110/90 115/90 143/90 163/90 210/90
ZESA® (kg) 2,3 2,3 2,5 3 3,4 4,5 5,4 9,6 11 17,3 26,5 42,9 58,5 86,5 143
GESA® (kg) 2,7 2,7 3 3,7 4,2 6,3 7,7 12 13,4 19,3/20,2 32,6 51,4 71,5 107,5 183
H1 (mm) 246 246 252 258 280 296 349 366 382 436 501 587 645 741 829
single acting
P1 (mm) 140 140 140 140 161 182 222 222 292 298 337 462 462 603 603
P2 (mm) 82 82 82 82 94 100 120 120 120 137 172 224 224 272 272
Type of actuator (closes) GTE 68/90 GTE GTE GTE GTE GTE GTE GTE GTE 210/90 GTE 250/90
78/90 88/90 98/90 110/90 115/90 127/90 143/90
Type of actuator (opens) GTE 68/90 GTE GTE GTE 110/90 GTE GTE GTE GTE 210/90 GTE 250/90
78/90 88/90 115/90 127/90 143/90
ZESA® (kg) 3 3 3,2 3,7 4,9 6 9,8 12,4 16 22,8 37,5 66,8 82 136 177
GESA® (kg) 3,4 3,4 3,7 4,5 5,6 7,8 12,2 14,8 18,4 24,8/25,7 43,6 75,3 95 157 217
Solenoid valve: Accessories: Limit switch in housing Accessories: Limit switch

for control of double acting actuators
5/2 - way
Solenoid valve: Accessories: Solenoid valve

for control of single acting actuators
3/2 - way

Enclosure 10098 THErmo-Appliance / Actuator flange connection
THEA® - integrated THErmo-Appliance
Standard thermometer ranges

- cold (-20 to +40°C)
- warm (0 to +120°C)
• Indication: precision class 1,0 (thermometer adjusted to ARI-THEA)
Diameter range: DN 25 / 32 - DN 40
DN 50 - DN 80
DN 100
DN 125 - DN 200
Order data:
Thermo-Appliance with range ................,
for diameter range .........
Indicator installed by insertion into the bore hole of the lever and the stem -
convertible on site.
Actuator flange connection

DN25-200 DN250-500
Double „D“ 2-flat SW 4-square SW
DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500

Connection ISO5211 F 05 F 07 F 10 F 14
Double „D“ 2-flat SW (mm) 11 d11 17 d11 -- --
4-square SW (mm) -- -- 22 d11 30 d11 1)
Ød (mm) 7 9 11 18
ØD1 (mm) 65 90 125 175
ØD2 (mm) 35 H10 55 H10 70 H10 100 H10
ØD3 (mm) 50 70 102 140
ØD4 (mm) 12,9 19,7 -- --
l (mm) 15 18 24 40
t (mm) 3 3 3 4
1) different from EN ISO5211

- Figure-No. - Stem / disc material Please indicate in your order, if
- Nominal pressure - Actuation arrangement the valves are to be installed in
hazardous areas (ATEX). Dimensions in mm
- Nominal diameter - Special design / accessories
- Soft seal seat material Weights in kg
Example: 1 bar =^ 105 Pa =^ 0,1 MPa
Figure 22.012; Nominal pressure PN16; Nominal diameter DN100; Seat of EPDM, Stem / disc of 1.4581/1.4021, Kvs in m3/h
with notch lever and integrated Thermo-Indication (-20 to 40°C).
Capacity chart / Difference between disc outside-diameter and face-to-face
Enclosure 10098
Kvs-value and Zeta-value
DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
Kvs-value (m3/h) 26 26,5 49,6 116 259 377 763 1030 1790 3460 5070 7430 10320 13290 21180
Zeta-value -- 0,93 2,4 1,7 0,75 0,43 0,46 0,27 0,37 0,25 0,21 0,24 0,23 0,23 0,23 0,22
opening angle disc
close open
indication - lever
Difference between disc outside-diameter and face-to-face

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
B (mm) -- -- 5 5 11 18 25 36 48 71 91 112 132 147 188
D (mm) -- -- 26 29 49 68 88 115 142 194 243 292 333 383 486

Enclosure 10098 Actuator selection
DN 25-50 65 80 100 125 150 200 250 300 350 400 500
Connection-Flange ISO 5211 F 05 F 07 F 10 F 14
Double „D“ 2-flat SW (mm) 11 d11 17 d11 -- --

30 d11
4-square SW (mm) -- -- 22 d11 different from EN ISO5211
notch lever
Size I II --
Manual actuation
clamp lever
Size I II --
worm gear
Type SE07 SE10 SE12
rotork (230V 50Hz)
Type ROM-1 ROM-A ROM-2 ROM-3 --

Deufra (230V 50Hz)
Type OA3 OA6 OA8 OA15 AS25 AS50 BS100
Auma (400V 50Hz)
Type SG05 SG07 SG10 SG12
AIR TORQUE
double acting
Type DR30 DR60 DR100 DR150 DR220 DR450 DR600 DR1200

spring closes
2000 3000
Type 30SC6 60SC6 100SC6 150SC6 220SC6 300SC6 450SC6 600SC6 1200SC6
SC6 SC6
single acting
spring opens
1200 2000
Type 30SO5 60SO5 100SO5 150SO5 220SO5 450SO5 900SO5
SO5 SO5
bar
double acting
GTD GTD GTD GTD

Type GTD58/90 GTD68/90 GTD98/90 GTD143/90
110/90 115/90 163/90 210/90
spring closes
GTE GTE GTE GTE GTE GTE GTE GTE

Type GTE210/90-10 GTE250/90-8
68/90-12 78/90-10 88/90-10 98/90-12 110/90-12 115/90-12 127/90-12 143/90-12
single acting
spring opens
GTE GTE GTE GTE GTE GTE GTE

Type GTE210/90-8 GTE250/90-6
68/90-8 78/90-8 88/90-8 110/90-8 115/90-6 127/90-8 143/90-8


Enclosure 10098

Butterfly valves
BR 012 - ZESA ® BR 013 - GESA ®
BR 014 - ZIVA ®-Z BR 015 - ZIVA ®-G

Contents
1.0 General information on operating 5.4 Retrofitting the THErmo-Appliance
instructions ..................................................... 2 (ZESA THEA / GESA THEA) ................................. 9
2.0 Notes on possible dangers........................... 2 5.5 Converting or retrofitting lever
(ZIVA-Z / ZIVA-G) ................................................. 10
2.1 Significance of symbols ..........................................2
2.2 Explanatory notes on safety information .................2 6.0 Putting the valve into operation .................11
3.0 Storage and transport .................................. 2 7.0 Care and maintenance.................................11
7.1 Changing seat and O-ring seal
4.0 Description..................................................... 3
(ZIVA-Z / ZIVA-G) ................................................. 12
4.1 Scope of applications .............................................3
8.0 Troubleshooting .......................................... 13
4.3 Diagram - assembly ................................................49.0 Troubleshooting table ................................ 13
4.4 Technical data - remarks .........................................6 10.0 Dismantling the valve or the top part ..... 14
11.0 Warranty / Guarantee ................................ 14
4.5 Marking ...................................................................6
5.0 Installation...................................................... 7 12.0 EC declaration of conformity ................... 15
5.1 General remarks on installation ..............................7
5.2 Installation of accessories .......................................7
5.3 Conversion from notch lever to lock lever ...............8
Rev. 0040201000 0511 englisch

Enclosure 10098
ZESA® / GESA® / ZIVA®-Z / ZIVA®-G

and repair.
ATTENTION !

Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to property.

ATTENTION !
- At -20°C to +65°C.
Page 2 Rev. 0040201000 0511

Enclosure 10098
4.0 Description
Butterfly valves are used for “interruption or restriction of the flow of liquids and gases”.
ATTENTION !
to TRD 110.

The valve is closed by turning the disc shaft clockwise.
The shaft moves through 90°.
Rev. 0040201000 0511 Page 3

Enclosure 10098
4.3 Diagram - assembly
rotated view
Material designation:
EP = EPDM or
NBR or
FPM
fig. 1: Butterfly valve ZESA® / GESA®
Material designation:
EP = EPDM or
NBR or
FPM
Bild 2: Butterfly valve ZIVA®-Z / ZIVA®-G

Refer to the data sheet for information about materials with designations and figure numbers.
Page 4 Rev. 0040201000 0511

Enclosure 10098
Actuation arrangements
fig. 3: Notch lever ZESA® / GESA®

- The detent pin of the lower lever must be fully disengaged to move the lever.
fig. 4: Lock lever ZESA® / GESA®

- The star knob screw must be slackened before and tightened again after moving the
lever.
fig. 5: Notch lever ZIVA®-Z / ZIVA®-G

- The detent pin of the lower lever must be fully disengaged to move the lever.
Rev. 0040201000 0511 Page 5

Enclosure 10098
Position indicator
Lock nut
fig. 6: Worm gear ZESA®/GESA® and ZIVA®-Z/ ZIVA®-G

- Gear type (actuation by hand wheel, clockwise for closing).
The CLOSE-position can be adjusted by ± 5° by a stop screw.
The stop screws are self-sealing and self-locking (refer to Fig. 7).
- Refer to separate operating and maintenance manual for drive (electric or pneumatic).

for
- Pressure-temperature-ratings, etc. refer to data sheet.
4.5 Marking
CE-marking
0525 Notified body
refer to item 11.0 Warranty / Guarantee
Typ Type
Page 6 Rev. 0040201000 0511

Enclosure 10098
5.0 Installation
5.1 General remarks on installation
installation work:
ATTENTION !
- The direction of flow need not be taken into account.
avoided.
- Flooding of the butterfly valve is not permissible.
- The shaft can be in any position except for DN350 up to DN600 (horizontal
shaft preferably).
- No gaskets required between flanges, flexible gaskets are not allowed.
- The butterfly valve must be installed in open position if possible, but the disc
should not protrude beyond the housing.
- Large actuators with horizontal application must be supported.
- Avoid damage to the rubber sheathing during handling, storage and installation.
- Do not heat the valve (e.g. by welding, grinding, etc.) above its service
temperature (refer to data sheets).
- Protect actuators from excessive ambient temperatures
(refer to operating instructions for actuator).
- If the butterfly valve is in operation as a pipeend valve, regard DIN EN 294
point 5.

recommended.
- The valves are not permitted for subsurface installation.
5.2 Installation of accessories

Optional accessories (e.g. limit switches) supplies with valves must be fitted as required for
their functions as shown in the plants of the plant.
Rev. 0040201000 0511 Page 7

Enclosure 10098
5.3 Conversion from notch lever to lock lever
window
fig. 7
The notch lever cap (pos. 7) can be used for the conversion.
- Set notch lever (pos. 50) to notch position 4.
- Slacken socket screw (pos. 50.2 / SW 5 of 6 mm AF).
- Remove notch lever (pos. 50).
ATTENTION !
The position of the valve disc is not positively located!
- Dismantle notch lever cap (pos. 7) and use a screwdriver to break out the window.
- Put the cap, with the nut (pos. 19) in it, in place and tighten it.
- Set the lock lever (pos. 50.1) in position as shown in the diagram.
- Tighten the socket screw (pos. 50.2).
- Insert star knob screw (pos. 60) through the hole at the end of the lock lever (pos. 50.1)
and screw into the hex. nut (pos. 19).
If the lock lever must be on the same side as the original notch lever, the notch lever cap
must be turned through 180°.
For the angle limit stop, an additional nut can be placed in the cap for a locking screw.
Page 8 Rev. 0040201000 0511

Enclosure 10098
5.4 Retrofitting the THErmo-Appliance (ZESA®THEA / GESA®THEA)
fig. 8
- Remove sticker from the hole in the lever (pos. 50).
- Insert the THEA temperature indicator (pos. 58) into the hole down to the stop.
Rev. 0040201000 0511 Page 9

Enclosure 10098
5.5 Converting or retrofitting lever (ZIVA®-Z / ZIVA®-G)

Retrofit in butterfly valve with free shaft end:
fig. 9
ATTENTION !
- Do not remove shaft blowout protection (pos. 26) under pressure.
(see point 10.0 Dismantling the valve or the top part)
- The valve disc is not fixed in position without an actuating element!
- Slacken setscrew (pos. 50.1),

- Mount notch lever (pos. 50) on shaft end together with the notch disc (pos. 16)
(notch lever aligned with notch disc),
- Turn notch lever (pos. 50) until drillings in notch disc (pos. 16) and body are aligned,
- Assemble and tighten cheese-head screw (pos. 21) and nut (pos. 20),
- Tighten set screw (pos. 50.1).
Page 10 Rev. 0040201000 0511

Enclosure 10098

ATTENTION !

Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- It is advisable to actuate the valve at least once a month.
- When used as an end-blockage, a safety precaution (e.g. plug-in disc, blind
flange etc.) is demanded by maintenance works.
Rev. 0040201000 0511 Page 11

Enclosure 10098
7.1 Changing seat and O-ring seal
(ZIVA®-Z / ZIVA®-G)
fig. 10
- Observe safety instructions
- Grease seat (pos. 2) when changing
Lubricant: e.g. Berusoft 30 valve grease
obtainable from: Carl Bechem GmbH, Weststrasse 120, D-58089 Hagen
or a lubricant suitable for this application.
ATTENTION!
- Always ensure that the lubricant is compatible with the medium.
- It is not safe to replace the O-ring seal (pos. 11) until the system has cooled
down and the plant is pressureless.
- For safety reasons we recommend that the O-ring seal (pos. 11) only be
changed when disassembled.
- Prior to disassembling the butterfly valve note points 10.0 and 11.0.
- When the butterfly valve is activated there is a crushing hazard between valve
disc and body.
- Maintenance work inside the pipeline (large nominal diameters) should only be
carried out when the butterfly valve is safely deactivated (disconnect actuator
from power supply).
Page 12 Rev. 0040201000 0511

Enclosure 10098
8.0 Troubleshooting
Instructions.
ATTENTION !
-


ATTENTION !

No flow Valve closed. Open valve.
Little flow Valve not sufficiently open. Open valve.
Strainer sieve clogged. Clean / replace sieve.
Valve is impossible or diffi- Service conditions (e.g. medium, tem- Replace valve. Consult supplier or
cult to open or close perature) outside permissible limits. manufacturer.
Power failure. Check power supply.
Wrong direction of rotation. Turn in correct direction

(clockwise for opening).
Valve leaking Not properly closed. Close valve properly or readjust limit
switch/stop screw.
Pressure difference too high. Check plant.
Medium contaminated. Clean valve.

Install strainer sieve upstream of valve.
Lining/collars (Fig. 1-2, item 2) or valve Replace valve. Consult supplier or

disc (Fig. 1-2, item 3) damaged by for- manufacturer.
eign bodies or medium
Valve with locking device Locking device tightened. Slacken locking device.
cannot be opened
Rev. 0040201000 0511 Page 13

Enclosure 10098

ATTENTION !
media.

appointed by us.

Page 14 Rev. 0040201000 0511

Enclosure 10098

as defined by
that according to the above mentioned Pressure Equipment Directive (PED) the below
listed products comply and have been approved according to table 6, annex II, module H
through Lloyd´s Register Quality Assurance GmbH (BS-Nr. 0525), Am Sandtorkai 41,
D-20457 Hamburg.
Certificate-No: 50003/1
Butterfly valves ZESA® / GESA®
Type 012, 013
Butterfly valves ZIVA®-Z / ZIVA®-G

Type 014, 015
Applied standards:
DIN 3840
...................................................
Rev. 0040201000 0511 Page 15

Enclosure 10100
Technical data
Service conditions
Max Pressure: PN25 and PN40
Max Temperature: 280/300°C (According to DIN 7081 for glasses, see page 1.69)
View
GLASS LEVEL GAUGE Standard: adjustable on 360° in the installation phase
REFLEX TYPE
Distance (Centre-to-centre)
PN25 and PN40 / Class 150 Standard: see below table (Distance adjustable - 0 mm / + 10 mm)
Option: On request intermediate distances and over 3.000 mm
DS LG - RBR GR18 Materials (Standard)
Execution: CS/CS SS/CS
Gauge body & cocks body: ASTM A105 AISI 316L
Code: DS LG RBR…-… /40/RF-GR18/…/…-M…-CS/CS Cocks trim: AISI 303 AISI 316
Non-wetted parts: Carbon steel galvanized Carbon steel galvanized
Gaskets
Standard: grahite/copper Option: graphite/AISI 316 or PTFE/AISI316
Shut-off cocks
Type DS GR18: cylindrical plug type - Straight type - Quick 90° closing
Type DS MT18: cylindrical plug type with monolithic body - Straight type - Quick 90° closing
(see page 1.47) Centre-to-centre distance M = B + 115 mm or 140 mm
Handling: lever operated with PP handle (Standard: right; Option: left)
Process connections:
Standard flanges: UNI PN40 DN15-20-25 ANSI#150-300-600/RF DN ½“ - ¾“ - 1“
Standard threaded unions: BSP-M ½” - ¾” NPT-M ½” - ¾”
Options: further connections types or direct connections to the process without shut-off cocks
(see page 1.49)
Vent: Standard: blind Option: see page 1.50
Drain: Standard: cock type D12 threaded ½” Option: see page 1.50
Glasses
Reflex - Borosilicate glass, “extra hard” and thermally pre-stressed - According to DIN 7081
Standard: fitted with type A (see page 1.69) Option: type B (see page 1.69)
Accessories
See from page 1.55
Weights
Housing type DS RBR: see below table
Cocks type DS GR18: Kg. 7,4 approx. (with flanges UNI DN20 PN40)
Tightening torque of housing screws

Standard: 40 Nm
Spare parts
Housing type DS RBR: see from page 1.69 (drawing with components and parts list see page 1.61)
Cocks type DS GR18: see from page 1.72 (drawing with components and parts list see pag. 1.66)
CODE TYPE BODY DISTANCE SL DISTANCE HL VISIBLE GLASS WEIGHT

Length Pipes L = 57 Pipes L = 72 Length Length Housing
[mm] -0/+10 mm -0/+10 mm [mm] [mm] [Kg]
x No. el B M = B+105 M = B+130 VL x No. elements
11 1x1 130 235 260 95 115x1 2,4

12 2x1 155 260 285 120 140x1 2,8
13 3x1 180 285 310 145 165x1 3,3
14 4x1 205 310 335 170 190x1 3,8
15 5x1 235 340 365 200 220x1 4,3
16 6x1 265 370 395 230 250x1 4,9
17 7x1 295 400 425 260 280x1 5,4
18 8x1 335 440 465 300 320x1 6,1
19 9x1 360 465 490 320 340x1 6,6
24 4x2 410 515 540 375 190x2 7,5
25 5x2 470 575 600 435 220x2 8,5
26 6x2 530 635 660 495 250x2 9,7
27 7x2 590 695 720 555 280x2 10,7
28 8x2 670 775 800 635 320x2 12,1
29 9x2 720 825 850 680 340x2 13,1
36 6x3 795 900 925 760 250x3 14,4
37 7x3 885 990 1015 850 280x3 15,9
38 8x3 1005 1110 1145 970 320x3 18,0
39 9x3 1080 1185 1210 1040 340x3 19,5
47 7x4 1180 1285 1310 1145 280x4 21,2
48 8x4 1340 1445 1470 1305 320x4 24,0
49 9x4 1440 1545 1570 1400 340x4 26,0
57 7x5 1475 1580 1605 1440 280x5 26,5
58 8x5 1675 1780 1805 1640 320x5 30,0
59 9x5 1800 1905 1930 1760 340x5 32,5
68 8x6 2010 2115 2140 1975 320x6 35,9
69 9x6 2160 2265 2290 2120 340x6 38,9
78 8x7 2345 2450 2475 2310 320x7 41,9
79 9x7 2520 2625 2650 2480 340x7 45,4
88 8x8 2680 2785 2810 2645 320x8 47,9
89 9x8 2880 2985 3010 2840 340x8 51,9
Tab. RBR
Rev.0 Specifications and design can be subject to change without notice 1.7
Enclosure 10100
Enclosure 10100
GLASS LEVEL GAUGES

with reflex or transparent glasses
INSTALLATION & OPERATION MANUAL

Enclosure 10100
2/9
Rev. 01
Instructions for installation use and maintenance March 2013
1 PARTICULARS AND PURPOSE OF INSTRUCTIONS

The instructions in this manual are intended to illustrate and explain the operational directions to
be followed to install, uninstall, use and properly maintain glass level gauges and related
accessories.
These instructions should be made available to the person responsible for installation, use,
maintenance and dismantling.
2 CHARACTERISTICS DATA/ EQUIPMENT OPTIONS
Description: Single/multiple glass level gauge with reflex glasses

Single/multiple glass level gauge with transparent glasses
Centre to centre distance: Variable – Fixed
Material: Carbon steel – Stainless steel – Special on request
Type of glasses: (Reflex – Transparent) Borosilicate DIN 7081
Connections: Flanged – Threaded – Weld on
Shut-off valves: Shut-off cocks – Monolithic shut-off cocks

Globe valves – Push button valves
Accessories: • Safety ball

• Pusher
• Cocks Handle lock
• Illuminator
• Calibrated scale
• Minimum level arrow
• Non frosting extension
• Continuous reading
• Remote control
• Weight closing for handles
• Mica or PCTFE protection
• Further particulars on request
Operating limits and conditions
Compatibility with the fluid, maximum pressure and maximum temperature permitted, must be
evaluated/discussed with the Manufacturer in advance.
Operating limits and maximum conditions are detailed in each product’s data sheet which can be
viewed on our website. In case of doubts, please call our technical service.
DIESSE S.r.l. Fluid Control - Via dell’ Artigianato 10/12, Origgio (VA) - ITALIA
Enclosure 10100
3/9
Rev. 01
ACCESSORIES
SAFETY BALL
The Diesse level gauges can be equipped with a safety ball lower and/or upper (in stainless
steel 316) positioned inside the valves, which stops the fluid flow in case glass breakage
occurs. The breakage is anyway improbable if the operations are carried out in the proper
way. If the crystal breaks, the safety ball prevent the tank from emptying.
(Warning: their capacity could be compromised due to foreign bodies generated during use
of the equipment).
PUSHER
To re-position the safety balls and enable the normal flow of the fluid, on request it’s available
a pusher in stainless steel. (Only for valve type DS GR18).
COCKS HANDLE COCK

The cocks handle lock can be supplied on all cocks or only on shut-off cocks handle, on drain
or vent cocks.
CALIBRATED SCALE
The calibrated scale (millimiters) is in stainless steel, the values are engraved and black
coloured. The standard indication correspond to the centre-to-centre distance of the level
gauge.
On request other materials and graduations can be supplied.
MINIMUM LEVEL ARROW

To mark the minimum level of the fluid which must be maintained inside the tank, a minimum
level arrow in stainless steel can be fixed on the level gauge. On request to enable its
regulation along the full visible length it is possible to fix the arrow on a small rail.
NON FROSTING EXTENSION

On request an acrilic transparent resin slab can be supplied to be positioned on the level
gauge glass (both for reflex and tranparent one) to avoid the frost formation on the external
surface of the glass to facilitate the fluid level reading.
The non-frosting extension is recommended when the fluid reach a temperature < 0°C
CONTINUOUS READING
The execution of a multiple level gauge involves a discontinuity in reading due to short dark
area as a result of the two elements joint.
If a continuous reading of the fluid level is necessary, a special type can be supplied.
REMOTE CONTROL
In case of level gauge installed in a high position which does not enable an easy shut-off cocks
opening/closure, the handles can be equipped with a remote control device. Cable or chains
are not supplied by the manufacturer.
WEIGHT CLOSING FOR HANDLES

This device is supplied to ensure that the shut-off cocks remain closed even in case of the
operator absence.
ILLUMINATOR
The visibility of the transparent level gauges can be improved by the installation of an illumination
lamp positioned on the back side of the instrument.
The lamp light is directed at the level gauge by a borosilicate or plexiglas diffuser.
Enclosure 10100
4/9
Rev. 01
The illuminator provided as an accessory to the gauge is ATEX certified by the manufacturer. In
the cases where the model is supplied with an illuminator, documentation is provided by
separate attachment.
PRELIMINARY/WARNINGS:
On receiving the material, before proceeding with installation and during such installation, make
sure:
1. that the product has not been damaged during transport;
2. that the model and the temperature and pressure ratings are as required;
3. that the material is compatible with both the process fluid as well as with the
ambient/atmosphere in which it is to be installed;
4. in the models provided with an illuminator, that the information included on the product
identification label/plate is compatible with the power supply.
3. LIMITS OF RESPONSIBILITY
The manufacturer does not accept responsibility in any case where the above preliminary
instructions are not respected and/or the equipment is placed in an operating condition
that fails to respect the requirements set forth in this manual.
The installation and use of the gauge must guarantee not only its own safety but that of
people and buildings; the purchaser/user is responsible for this safety and must proceed as
above specified.
4. USE OF THE TOOL
While it is the responsibility of the user to verify that the fluid contained in the tank or
container is compatible with materials used for the construction of the equipment, for any
doubt or further explanation please contact the manufacturer.
The equipment must be used exclusively for displaying the level reached by fluid in a tank or
container in which the pressure and temperature do not exceed the limits set by the
manufacturer.
The level reached by the fluid inside a container or tank, either open-air or closed and in
which the pressure above the fluid surface is equal to or greater than atmospheric pressure,
is indicated by the height of the fluid in the gauge.
The user can request that the manufacturer add a visual indicator (for example graduated
scales) in order to improve the interpretation of the indications of the level gauge.
4.1 Improper Use
Improper use is any use which is different from that expressly intended and in particular
its utilisation in the following conditions:
• failure to respect or use contrary to current safety regulations;
• failure to respect the limitations set by the manufacturer, particularly with regard to
the maximum temperatures and pressures permissible;
• incorrect mounting and installation of the equipment;
• failure to purification waters (such failure could cause the erosion of glasses);
• incorrect installation after maintenance work;
Enclosure 10100
5/9
Rev. 01
• Total or partial non-observance of the prescribed maintenance;

• modifications or interventions on the equipment which have not been previously
discussed with and authorised by the manufacturer;
• use of replacemant parts either not from or of a type not recommended by the
manufacturer;
• partial or total non observance of the instructions;
• use of the equipment by untrained personnel;
• exceptional events such as earthquakes, floods, wilful or accidental blows and other
actions that could have caused not immediately perceptible damage to the
equipment;
• maintenance activity with parts under pressure;
• connection of a number of elements beyond those furnished by the manufacturer.
5 CRITERIA FOR MOUNTING AND DISMOUNTING THE EQUIPMENT

For the assembly and disassembly of the equipment, two people with good technical
knowledge of maintenance are envisioned. During the activities, operators must wear
appropriate individual personal protective means, and all necessary precautions must be
taken to avoid accidents.
5.1 Mounting of equipment with grinded pipes
a) Insert the grinded pipes in the support of the upper and lower taps and lightly
tighten the sealing caps.
b) Verify that the connections to the process are perfectly in line with each other
and the junctions are not damaged.
c) Position the connections in alignment with the tank junctions, making sure to
place a gasket, of material suitable for the type of fluid contained in the tank,
between the surfaces.
d) Place the screws in position for connection, making sure to start with mounting
those farther down, and tighten with sufficient torque to ensure a secure
connection without damaging the material.
e) Place the level, rotating it on its vertical axis, in the angular position best adapted
for visual requirements.
f) Tighten the sealing caps.
g) Verify the need to leave the shut-off valves closed during the first stages of start-
up, in order to avoid dangerous “head butts” to the crystals and to their grip.
h) During the first hours of use, if small losses of fluid are noted, gently tighten the
sealing cap, screws and holding nuts.
5.2 Mounting of the instrument with fixed centre to centre distance
a) Position the connections in alignment with the tank attachments making sure to
place a gasket, of material suitable for the type of fluid contained in the tank,
between the surfaces.
b) Verify that the connections are perfectly aligned on the axis between them and
that the attachments are not damaged.
c) Place the screws in position for connection, making sure to start with mounting
those farther down, and tighten with sufficient torque to ensure a secure
connection without damaging the material.
Enclosure 10100
6/9
Rev. 01
d) Verify the need to leave the shut-off valves closed during the first stages of start-
up, in order to avoid dangerous “head butts” to the crystals and to their grip.
e) During the first hours of use, if small losses of fluid are noted, gently tighten the
sealing cap, screws and holding nuts.
5.3 Mounting the equipment with illuminators
Particular attention must be paid during the installation of the illuminator (in the
models where included): see the appropriate instructions issued with the product.
5.4 Dismounting
a) Shut down and empty the installation.
b) Wait until the temperature of the equipment reaches one that will not harm the
operators (room temperature).
c) Then complete emptying the gauge.
d) Unscrew the screws and nuts that join connections to the tank (starting with the
lower connections) and remove the gauge, carefully evaluating its weight.
e) Make sure that the equipment is restarted only after the security operating
conditions have been reinstated.
6 MAINTENANCE
The gauge is designed so that dismounting is possible solely by means of specific tools in order
to freely open its parts.
Bear in mind that:
• It is the responsibility of the user to proceed with maintenance operations and to read
carefully the above details on risks; it is advisable to contact the manufacturer for the best
way to proceed.
• It is the responsibility of the user to institute appropriate schedules of maintenance,

determining the frequency of the same based on his own needs/use of the equipment.
the recommended maintenance operations are:
a) Cleaning the glass to keep visibility of the level better.

Warning: before effecting maintenance, wait until the insturment has reached room
temperature.
Use non-abrasive products and in any case products that are compatible with the
material of the glasses (borosilicate). Never use solvents.
b) Regular cleaning of the equipments, through verification of the state of the filtres so as to
avoid foreign bodies which can damage the apparatus.
c) For verification of the tightness of threaded parts (to guarantee constant tightness):
lightly tighten the seal cap and the screws/nuts in several stages (for the level:
commence with the centre and alternate on the two sides).
Tightening torque of housing screw: please refer to the data sheets of each product
available on the DIESSE website.
Eventual evidence of internal or external corrosion indicates ambiental conditions adverse

to/incompatible with the construction material of the apparatus. It is the responsibility of the user
to determine the cause of the problem.
Enclosure 10100
7/9
Rev. 01
7 SPARE PARTS
Spare parts that can be ordered are designated in the current catalogue available on the
website.
INSTRUCTIONS FOR THE REMOVAL AND REPLACEMENT OF GLASSES AND GASKETS
Assumptions:
o The glass and gaskets replacement requires such specific devices and tools that the
operation by personnel not specifically trained to do so is not advised.
o The level gauge is designed so that dismounting is possible solely by means of specific tools
in order to avoid any involuntary opening of its parts.
If the buyer decides to proceed with its own personnel and tools for maintenance operations,
such as the replacement of the glass and/or the gaskets, it is IMPORTANT:
o That two people with good technical knowledge of maintenance are envisioned.
o The customer contact the manufacturer to decide the proper parts and get instrucions.
o To carefully read the instructions reported in the use and maintenance manual provided
with the instrument.
o The operators wear appropriate individual personal protective means and all necessary
precautions must be taken to avoid accidents.
Before starting any maintenance operation, it is important to wait until the temperature of the
equipment reaches the room temperature.
Before level gauge dismounting be sure that the instrument is not under pressure:
1) Unscrew the tightening bolts and nuts and be sure that when it is opened no parts fall.
2) Remove all gaskets residues from the housing. Use non-abrasive products and in any case
products that are could incise the glass housing (any incision will affect the glass sealing).
3) Carefully clean all components by non-abrasive products.
Mounting:
1) Insert the sealing gasket in the housing, put the glass over (if it’s a reflex type the prismatic
surface must be in contact with the fluid) and then the cushion gasket; in case of a
transparent type, if foreseen, insert the mica shields (or the one in PCTFE) between the
sealing gaskets and the glass (it must perfectly adhere to the glass surface in contact with
the fluid).
2) Position the cover avoiding any movement of glass and gasket, even slighly.
3) Proceed by tightening the fitting screws in the cross sequence shown on the instruction
provided with the glass. The tightening torque is mentioned on every products data sheet.
Before restarting the equipment:

Leave the shut-off valves closed in order to avoid dangerous “head butts” to the glasses and
their seal.
During start up:
If small leakage of fluid are noted, gently tighten the stuffing box, the screws and sealing nuts.
8 DISPOSAL
To dispose of the component parts of the apparatus, observe the current related laws.
Enclosure 10100
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Rev. 01
DECLARATION OF CONFORMITY
We declare that the product is state-of-the-art construction and has been subjected to control
testing as defined by quality control procedures in force in the company.
We declare that, given the construction and use characteristics, level gauges covered by this
manual fall under the provisions of Article 3 par. 3 D. LGS No. 93 of 25.02.2000 and that, therefore,
the CE Mark cannot be affixed.
---------------------------------------------------------------------------------
TECHNICAL ASSISTANCE
For any need our technical service can be contacted at the addresses below. To ensure better
service please indicate the following:
• Type gauge
• Date of purchase/of installation of the instrument
• Operating conditions (fluid, pressure and temperature of use)
Our technical department will assess the extent of the problem and try to resolve any difficulties
where possible. Whenever repairs appear necessary, the manufacturer will reach agreement on
method and time of such repairs. Shipping by client to the manufacturers is at the client’s
expense.
For products covered by guarantee

The technical service will effect tests and determine the repairs necessary. If these are found to
be the responsibility of the manufacturer, the latter will repair/replace at no charge to the client.
If from analysis of the product it is ascertained that there are no manufacturing defects, and it is
revealed as the client's responsibility for misuse, the manufacturer will charge the customer all
the costs involved.
For products no longer covered by guarantee: the cost of repairs will be debited to purchaser
based on prior agreement (including the cost of any replacement parts).
Manufacturer:
DIESSE S.r.l. Fluid Control

Via dell’Artigianato, 10/12
21040 ORIGGIO (VA) - ITALY
Phone: +39 02 96731337

Fax: +39 02 06731683
Website: www.dssrl.it
Enclosure 10100
9/9
Rev. 01
GUARANTEE
The guarantee for the gauge is for 12 months from the date of purchase and can be extended
by the manufacturer on the basis of type and characteristics of the product purchased.
It covers eventual manufacturing defects or materials, excluding the parts subject to normal
usage such as the gaskets and glasses.
The responsibility of the manufacturer is limited to the reparation or substitution of the product.
The manufacturer is therefore not responsible for eventual damage to other products, structures,
personnel directly or indirectly connected to the improper use/installation of the product.
The guarantee is not applicable to disassembled products, repaired or mishandled without the
authorisation on behalf of the manufacturer. For any problem, therefore, contact the
manufacturer directly in order to evaluate and determine any eventual manufacturing defects.
In particular, the guarantee is not valid in the following cases:
• The user omitted controls prior to installation, in detail:
a) Verification that the data shown on the product label correspond to the requisite
product.
b) Verification that the material is both compatible with the fluid of the process and with the
ambient/atmosphere in which it is installed.
c) Careful verification that during transport the product has not been damaged.
• Repairs by personnel not authorised by the manufacturer.
• Damages caused by fire, short circuits and natural disasters.
• Inappropriate handling/installation executed differently from those indicated in the manual

furnished with the product of installation-use and maintenance.
• Fluid non-compatible with the materials used in the construction of the product.
• Temperature and pressure during use different from that indicated on the offer /order.
• Use of non-original spare parts.
• Accidental shocks.
• Cleaning of the installation either not effected or not effected correctly (presence of
foreign bodies/scales on the installation).
Water equipment purification not effected (with the consequence of glass erosion).
Enclosure 10100
Enclosure 10100
Enlosure 10113
Issue Date: 3/09
GESTRA Steam Systems Product Range A2
DISCO Non-Return Valves RK 76

RK 76 for Flanges PN 6/10/16/25/40, DN 15-100
ASME Class 150/300
Description
Wafer-type non-return (check) valve for sandwiching between flanges. Valve with spring for installation in any position.
Without spring only for vertical lines with upward flow. Self-centering valve body ensures accurate installation. Application
for liquids, gases and vapours. Please observe the classification according to the Pressure Equipment Directive (PED).
Pressure / Temperature Rating

RK 76 DIN, EN, ASME B16.5, Class 300
Design
[°C] –10 20 100 200 300
49.6 49.6 42.3 35.8 31.6 metal-to-metal (standard)
DN 15 – 100
[bar] g metal-to-metal DN 15-100
49.6 49.6 42.3 35.8 31.6
with Nimonic® springs
Valve disc gasket tmin [°C] tmax [°C] Application Leakage rate
Metal-to-metal
– 10 300 Liquids, gases, vapours DIN EN 12266, Class D
RK 76, DN 15-100
PTFE*) – 190 250 Corrosive fluids DIN EN 12266, Class D
EPDM*) – 40 150 Water, condensate, vapours DIN EN 12266, Class A
FPM*) – 25 200 Mineral oils, gases, air DIN EN 12266, Class A
Please check the chemical suitability of the valve for the application in question or, if in doubt, consult us.
*) Observe pressure/temperature limits of the equipment!
End Connections
∅D
DIN ASME BS 10 1) JIS
EN 1092-1 B 16.1 Class 125 FF B2238
Table D, E, F, H, J
PN 10/16/25/40 B 16.5 Class 150 / 300 RF 10K
1) Table D, E, DN 65, DN 80: Select DN one size smaller.
Dimensions
[mm] 15 20 25 32 40 50 65 80 100
Valve size L
[Inch] ½ ¾ 1 1¼ 1½ 2 2½ 3 4
Face-to-face
[mm] L 2) 16 19 22 28 31.5 40 46 50 60
dimensions
∅D PN 6-40 45 55 65 75 85 98 118 134 154
Weight [kg] 0.18 0.30 0.45 0.70 0.90 1.50 2.10 3.40 5.20
2) Short ^ DIN 3202-3, series K4)
overall length according to EN 558-1, series 49 (=
Materials
DN 15–100 DIN / EN ASTM Category
Body, seat and
RK 76 1.4107 ASTM A217 CA15 Chromium steel
guide ribs
Valve disc, spring retainer Austenitic stainless steel
1.4571
Spring Austenitic stainless steel
Spiral centering ring 1.4310 Chromium steel
DISCO Non-Return Valves Pressure Drop Chart ρ Enlosure 10113
V̇w = V̇ ·
RK 76 The curves given in the chart are valid for water at 20 °C.
To read the pressure drop for other fluids the equivalent
1000
for Flanges PN 6/10/16/25/40, water volume flowrate must be calculated and used in V̇w = Equivalent water volume flow
in l/s or m³/h
DN 15-100, ASME Class 150/300 the graph.
ρ = Density of fluid
The values indicated in the chart are applicable to
spring-loaded valves with horizontal flow. With vertical (operating condition) in kg/m³
flow insignificant deviations occur only within the range V̇ = Volume of fluid
Opening Pressures of partial opening. operating condition) in [l/s] or [m³/h]
Differential pressures at zero volume flowrate
Partial opening = Full opening =
DN Opening pressures [mbar] instable range stable range
[Lmp.
Direction of flow in valve [Imp gal/min] [m3/h]
without Gal/min.] [m3/h] [l/s] DN
spring
with springs 400 100 30
300 100
r r q o 20
200 80
15 2.5 10 7.5 5
20 2.5 10 7.5 5 65
10
25 2.5 10 7.5 5 100 50
32 3.5 12 8.5 5 6
40 4.0 13 9 5 60 40
50 4.5 14 9.5 5 4 32
65 5.0 15 10 5 40 10 3
5.5 16 10.5 5 30
80 2 25
100 6.5 18 11.5 5 20
On request at extra charge, special springs for opening 1 20
pressures: 10
Between 5 and 1000 mbar for DN 15 – 50 mm, 0,6
between 5 and 700 mbar for DN 65 and 80. 6 15
0,4
4 1 0,3
3
0,2
2
0,1
1
0,06
0,6
0,04
0,4 0,03
0,1
0,3
0,02
Volume flow Vw
Enquiry Specification 0,2

.
GESTRA DISCO Non-return valve type RK 76, wafer design

with extremely short overall length to EN 558-1, table 11, 0,01 [bar]
series 49. Body with spiral centering ring. 0,1 0,01 0,02 0,03 0,04 0,06 0,1 0,2 0,3 0,4 0,5
Broad sealing surfaces at body inlet and outlet. Designed
[psi]
in accordance with PED 97/28/EC.
0,1 0,2 0,3 0,4 0,6 1 2 3 4 5 6 7
Type: RK 76
Pressure drop ∆ρ
Connection: Wafer design for sandwiching
between flanges
Nominal size: DN 15 / DN 20 / DN 25 / DN 32 /
DN 40 / DN 50 / DN 65 / DN 80 /
DN 100 When ordering please state: PED (Pressure Equipment Directive)
Pressure: PN 6 / PN 10 / PN 16 / PN 25 / PN 40 / Fluid, flowrate, service pressure and temperature, standard The equipment complies with the requirements of the
CL 125 FF / CL 150 / CL 300 RF of pipe flange. Pressure Equipment Directive 97/23/CE. Applicable with
Seating surface: metal-to-metal / PTFE / EPDM / FPM The following test certificates can be issued on re- fluids of group 1 and 2. With CE marking (apart from
Certificates: Test certificate to quest, at extra cost: equipment that is excluded from the scope of the PED
EN 10204, 2.1 / 2.2 / 3.1. according to section 3.3). For more information refer to
In accordance with EN 10204-2.1, -2.2 and 3.1
our PED Declaration of Conformity.
All inspection requirements have to be stated with the
Please note: order. After supply of the equipment certificates can no
The selected non-return valve must ensure that the longer be established. Charges and extent of the above ATEX (Atmosphère Explosible)
minimum volume flowrate keeps the valve disk in the open mentioned certificates as well as the different tests con The equipment does not have its own potential source of
position (see Pressure Drop Chart / stable range). Valve firmed therein are listed in our price list “Test and In ignition and is therefore excluded from the scope of the
construction is very robust, but they are not recommended spection Charges for Standard Equipment”. ATEX Directive 94/9/CE.
for use on compressors or where pulsating flow exists. If in For other tests and inspections than those listed above, Applicable in Ex zones 0, 1, 2, 20, 21, 22 (1999/92/CE).
doubt please consult us and we will carry out the pressure please consult us. The equipment does not bear an Ex marking. For more
drop calculation and select a suitable valve. information refer to our ATEX Declaration of Manufacturer.
Supply in accordance with our general terms

of business.
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Münchener Str. 77, D-28215 Bremen
Telephone 0049 (0) 421 35 03 - 0, Fax 0049 (0) 421 35 03-393
E-Mail [email protected], Internet www.gestra.de
810294-03/309cm · 2007 GESTRA AG · Bremen · Printed in Germany

Enclosure 10113
RK... D

Betriebsanleitung
Rückschlagventile RK
 Installation Instructions
808519-07 Non-Return Valves RK
F Instructions de montage et de mise en service
Clapets de retenue RK
E Instrucciones de montaje y servicio
Válvulas de retención RK
I Manuale di Istruzioni
Valvole di non ritorno RK
 Инструкция по эксплуатации
Обратные клапаны RK
 Gebruiksaanwijzing
Terugslagkleppen RK
Sicherheitshinweis Enclosure 10113
D
Das Gerät darf nur von geeigneten und unterwiesenen Personen montiert und in Betrieb
genommen werden. Wartungs- und Umrüstarbeiten dürfen nur von beauftragten
Beschäftigten vorgenommen werden, die eine spezielle Unterweisung erhalten haben.
Bestimmungsgemäßer Gebrauch D
Einsatz in Rohrleitungen zum Verhindern des Rückfließens von Medien innerhalb der
zulässigen Druck- und Temperaturgrenzen unter Beachtung der chemischen und
korrosiven Einflüsse auf das Druckgerät.
Die Medienbeständigkeit der Armatur muss für die Einsatzbedingungen geprüft werden.
Achtung D
Das Typenschild kennzeichnet die technischen Eigenschaften des Gerätes.
Ein Gerät ohne gerätespezifisches Typenschild darf nicht in Betrieb
genommen oder betrieben werden!
Gefahr Enclosure 10113
D
Die Armatur steht während des Betriebs unter Druck!
Wenn Flanschverbindungen oder Verschlussschrauben gelöst werden,
strömen heißes Wasser, Dampf, ätzende Flüssigkeiten oder toxische Gase
aus. Schwere Verbrühungen und Verbrennungen am ganzen Körper sind
möglich! Schwere Vergiftungen sind möglich!
Montage- oder Wartungsarbeiten nur in drucklosem Zustand durchführen!
Die Armatur ist während des Betriebs heiß oder tiefkalt!
Schwere Verbrennungen an Händen und Armen sind möglich.
Montage- oder Wartungsarbeiten nur bei Raumtemperatur durchführen!
Scharfkantige Innenteile können Schnittverletzungen an den Händen
verursachen!
Beim Wechseln der Armatur Arbeitshandschuhe tragen!
ATEX (Atmosphère Explosible) D

Die Geräte weisen keine potenzielle Zündquelle auf und fallen daher nicht unter die
Explosionsschutz-Richtlinie 94/9/EG.
Einsetzbar in Ex-Zonen 0, 1, 2, 20, 21, 22 (1999/92/EG).
Die Geräte erhalten keine Ex-Kennzeichnung.
Technische Daten Enclosure 10113
D
Einsatzgrenzen siehe Kennzeichnung bzw. Typenschildangaben (Druckklasse PN/Class,
Werkstoffnummer, Aufkleber für Weichdichtung, Federwerkstoff).
Reduzierte Temperaturgrenzen bei Verwendung von elastischen Dichtungen und bei
einigen Federwerkstoffen beachten.
Type PN / CL DN PMA / TMA [bar] / [°C]
RK 70 6 /- 15 - 100 6 / -30 0,5 / 130
RK 70 6 /- 125 - 200 6 / -10 0,5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49,6 / -10 31,6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36,9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34,5 / 400
RK 86A 40 / 300 15 - 200 49,6 / -200 24 / 550
Technische Daten Fortsetzung Enclosure 10113
D
Type PN / CL DN PMA / TMA [bar] / [°C]
RK 16A 40 / 300 15 - 100 49,6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49,6 / -200 29,3 / 400
RK 26A 40 / 300 15 - 100 49,6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110,8 / 550
RK 49 160 / – 80 - 200 160 / -10 55,3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44,2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70,2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112,4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175,6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224,7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280,9 / 500
RK 29A – / 400 15 - 200 66,2 / -200 37,6 / 500
RK 29A – / 600 15 - 200 99,3 / -200 56,6 / 500
RK 29A – / 900 15 - 200 148,9 / -200 84,7 / 500
RK 29A – / 1500 15 - 200 248,2 / -200 140,9 / 500
RK 29A – / 2500 15 - 200 413,7 / -200 235 / 500
Systembeschreibung Enclosure 10113
D
Rückschlagventile RK mit Spiralring-Zentrierung oder Gehäuse-Zentrierung. Für Ventile
mit Schließfeder ist die Einbaulage beliebig. Ventile ohne Schließfeder nur in vertikale
Leitungen mit Strömungsrichtung von unten nach oben montieren.
1 Rückschlagventile mit Spiral-Zentrierung
2 Rückschlagventile mit Gehäuse-Zentriernocken
3 Rückschlagventile mit Gehäuse-Zentrierung
4 Position der Führungsleisten in horizontaler Leitung
Einbau Enclosure 10113
D
TOP
1 2 3 4
Typenschild / Kennzeichnung Enclosure 10113
D
Typ: RK ...
DN:... Typ: RK ...
PN:... DN:...
.......... PN:...
..........
Typ: RK ... Typ: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Konformitätserklärung Enclosure 10113
D
Für die Geräte RK... erklären wir die Konformität mit folgender europäischer Richtlinie:
 Druckgeräte-Richtlinie 97/23/EG vom 29.05.1997, soweit die Geräte nicht unter die
Ausnahmeregel nach Artikel 3.3 fallen.
 Angewandtes Konformitätsbewertungsverfahren: Anhang III, Modul H, überprüft
durch die benannte Stelle 0525.
Bei einer nicht mit uns abgestimmten Änderung des Gerätes verliert diese Erklärung ihre
Gültigkeit.
Bremen, den 11. 02.2005
GESTRA AG
Dipl.-Ing. Uwe Bledschun Dipl.-Ing. Lars Bohl

Leiter Konstruktion Qualitätsbeauftragter
Safety Note Enclosure 10113

The equipment must only be installed and commissioned by qualified and adequately
trained personnel. Maintenance and retrofitting must only be performed by entrusted
personnel who – through adequate training – have achieved a recognized level of
competence.
Usage for the intended purpose 

The non-return valves RK are automatic-stop check valves and designed for use in
pipes in order to prevent the backflow of fluid. The admissible pressure and temperature
ratings as well as the chemical and corrosive influences of the fluid on the pressure
equipment must be taken into account. Check the chemical resistance and suitability of
the valve for the operating conditions in question.
Attention 
The name plate specifies the technical characteristics of the equipment.
Do not commission or operate a device without a name plate!
Danger Enclosure 10113

The valve is under pressure during operation.
When loosening flanged connections or sealing plugs, hot water, steam,
corrosive fluids or toxic gases may escape. This presents the risk of severe
burns and scalds to the whole body or severe cases or poisoning.
Installation and maintenance work should only be carried out when the
system is depressurized.
The valve becomes hot or extremely cold during operation. This presents
the risk of severe burns to hands and arms. Installation and maintenance
work should only be carried out at room temperatures.
Sharp edges on internals present a danger of cuts to hands. Always wear
industrial gloves for installation and maintenance work.
ATEX Directive 94/9/EC, 1999/92/EC 

The equipment does not have its own potential source of ignition and is therefore not
subject to the Directive 94/9/EC.
The equipment can be used in the following explosive zones: 0, 1, 2, 20, 21 and 22.
The equipment does not require an Ex marking.
Technical Data Enclosure 10113

For pressure ratings see marking or name plate (pressure class PN/Class, material
number, sticker for soft seal, spring material)
Observe lower temperature ratings for equipment with elastic seals and certain spring
materials.
Typ PN / CL DN PMA / TMA [bar] / [°C]

RK 70 6 /- 15 - 100 6 / -30 0.5 / 130
RK 70 6 /- 125 - 200 6 / -10 0.5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49.6 / -10 31.6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36.9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34.5 / 400
RK 86A 40 / 300 15 - 200 49.6 / -200 24 / 550
Technical Data – continued – Enclosure 10113

RK 16A 40 / 300 15 - 100 49.6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49.6 / -200 29.3 / 400
RK 26A 40 / 300 15 - 100 49.6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110.8 / 550
RK 49 160 / – 80 - 200 160 / -10 55.3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44.2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70.2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112.4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175.6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224.7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280.9 / 500
RK 29A – / 400 15 - 200 66.2 / -200 37.6 / 500
RK 29A – / 600 15 - 200 99.3 / -200 56.6 / 500
RK 29A – / 900 15 - 200 148.9 / -200 84.7 / 500
RK 29A – / 1500 15 - 200 248.2 / -200 140.9 / 500
RK 29A – / 2500 15 - 200 413.7 / -200 235 / 500
Description Enclosure 10113

Non-return valve RK with spiral centering ring or self-centering body. Installation in any
position. Exception: Valves without spring can only be installed in vertical lines with
upward flow.
1 Non-return valve with spiral centering ring
2 Non-return valve with body centering cams
3 Non-return valve with self-centering body
4 Position of guide ribs (horizontal installation)
Installation Enclosure 10113

TOP
1 2 3 4
Name Plate / Marking Enclosure 10113

Type: RK ...
DN:... Type: RK ...
PN:... DN:...
.......... PN:...
..........
Type: RK ... Type: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02
Declaration of Conformity Enclosure 10113

We hereby declare that the pressure equipment RK... conforms to the following European
Directive:
n Pressure Equipment Directive (PED) 97/23/EC of 29 May 1997 (except for equipment
excluded from the scope of the PED according to section 3.3).
n Applied conformity assessment procedure: Annex III, Module H, verified by the
Notified Body 0525.
This declaration is no longer valid if modifications are made to the equipment without
consultation with us.
Bremen, 11th February 2005
GESTRA AG
Head of the Design Dept. Quality Assurance Manager

Uwe Bledschun Lars Bohl
(Academically qualified engineer) (Academically qualified engineer)
Enclosure 10113
GESTRA AG
Postfach 10 54 60, D-28054 Bremen
Telefon 0049 (0) 421 / 35 03 - 0
Telefax 0049 (0) 421 / 35 03 - 393
E-Mail [email protected]
Internet www.gestra.de
808519-07/1106cs · 1999 GESTRA AG · Bremen · Printed in Germany

Enclosure 10120
Data Sheet 810436-03
Issue Date: 03/11
Steam Traps
BK 45, BK 45-U, BK 45-LT, BK 46
PN 40
DN 15, 20, 25 (½", ¾", 1")
Description
When the plant is started up, the trap is fully open. Cold condensate and air are discharged. With rising temperature, the Duo
(bimetallic) stainless steel plates bend and pull the stage nozzle into the closing position.
The orifice is then closed immediately below the saturation temperature. Thermodynamic processes taking place in the
stage-nozzle chamber support the closing procedure.
The trap provides automatic air-venting at start-up and during operation. BK 45 and BK 46 can also be used for thermal
air-venting in steam systems.
BK 4... with flanges
Pressure /Temperature Ratings & End Connections

BK 45, BK 45-U, flanged PN 40, EN 1092-1
PMA (max. allowable pressure) [bar]g 40.0 33.3 27.6 25.7 23.8 13.1
TMA (max. allowable temperature) [°C] 20 200 300 350 400 450
Δ PMX (admissible differential pressure) [bar] 22
Based on EN 1092-1
BK 45, BK 45-U, flanged Class 150, ASME B16.5

TMA (max. allowable temperature) [°C] –29/38 200 300 350 400 425
Based on ASME B16.5, ASME B16.34
BK 45, BK 45-U, flanged Class 300, ASME B16.5, butt-weld ends EN 12627, socket-weld ends EN 12760,
socket-weld ends Class 3000, ASME B16.11, screwed sockets G, ISO 228-1, screwed sockets NPT, ASME B16.11
BK 45-LT, flanged Class 150, ASME B16.5

TMA (max. allowable temperature) [°C] –46 200 300 350 400 425
BK 45-LT, flanged Class 300, ASME B16.5, butt-weld ends EN 12627, socket-weld ends EN 12760,
TMA (max. allowable temperature) [°C] –46 200 300 350 400 425
BK 46, flanged PN 40, EN 1092-1

TMA (max. allowable temperature) [°C] 20 250 300 350 400 450
Based on EN 1759-1
BK 46, flanged Class 150, ASME B16.5

Based on EN 1759-1
BK 46, flanged Class 300, ASME B16.5, butt-weld ends EN 12627, socket-weld ends EN 12760,
PMA (zulässiger Betriebsdruck) [bar]g 51.7 44.2 35.0 32.9 30.9 29.8
TMA (zulässige Temperatur) [°C] –10/50 200 300 350 400 450
Δ PMX (zulässiger Differenzdruck) [bar] 32
Based on EN 1759-1
Materials Component Parts Enclosure 10120
Type BK 45, BK 45-U
BK 45, BK 45-U, BK 45-LT BK 46
Designation DIN / EN ASME
Body and cover 1.0460 A105
1
Hexagon-head cap screws 1.7225 A193 B7
2
Gasket Graphite/CrNi
Regulator with Duo steel plates Stainless steel
Other internals High-grade steels 3
Type BK 45-LT
Designation ASME
Body and cover SA350 LF2
Hexagon-head cap screws A193 B7
4
Regulator with Duo steel plates Stainless steel 5
Other internals High-grade steels
6
Type BK 46
Designation DIN / EN ASME equivalent* 7
Body and cover 1.5415 A182 F1
Hexagon-head cap screws 1.7225 A193 B7
Regulator with Duo steel plates Stainless steel
Other internals High grade steels
*) ASTM material similar to EN material. Observe different physical and chemical properties!
8
9
Key
1 Hexagon-head screw M 10 x 25
2 Name plate
3 Cover
4 Thermovit regulator
5 Bushing (interference fitted, no spare part)
6 Gasket 40 x 48 x 2
7 Body
8 Strainer
9 Gasket A 24 x 29
0 Sealing plug
Spare parts list see page 3
Dimensions Weights and dimensions for traps with flanged ends Enclosure 10120
L Flanged EN 1092-1 ASME B 16.5 ASME B 16.5
Type to
96 PN 40 Class 150 Class 300
Withdrawal 15 20 25 15 20 25 15 20 25
distance DN
1/ " 3/ " 1" 1/ " 3/ " 1" 1/ " 3/ " 1"
2 4 2 4 2 4
70 BK 45, BK 45-U,
D [mm] 95 105 115 88.9 98.4 107.9 95.2 117.5 123.8
BK 45-LT, BK 46
L [mm] 150 150 160 150 150 160 150 150 160
[kg] 3.7 4.3 4.8 3.7 4.3 4.8 3.7 4.3 4.8
Weights and dimensions for traps with butt-weld ends

88
Butt-weld ends EN 12627 ASME B 16.25

Type to Edge form to ISO 9692, code number 1.3 ASME B 36.10
15 20 25 15 20 25
D DN
1/ " 3/ " 1" 1/ " 3/ " 1"
2 4 2 4
BK 45, BK 45-U,
for pipe 21.3 x 2.0 26.9 x 2.3 33.7 x 2.6 21.3 x 2.8 26.7 x 2.9 33.4 x 3.4
BK 45-LT, BK 46
L [mm] 200 200 200 200 200 200
70
[kg] 2.5 2.5 2.5 2.5 2.5 2.5

Butt-weld ends for other pipe sizes available on request.
Withdrawal distance 30
Weights and dimensions for traps with socket-weld ends
Socket-weld
Type ends to DIN EN 12760, ASME B 16.11 Class 3000
96
15 20 25
DN
1/ " 3/ " 1"
2 4
BK 45, BK 45-U,
Withdrawal
distance
BK 45-LT, BK 46 L [mm] 95 95 95
70
[kg] 2.2 2.1 2.0
Weights and dimensions for traps with screwed sockets

Screwed sockets
Type to BSP: ISO 228-1, NPT: ASME B 16.11
88
15 20 25
DN
1/ " 3/ " 1"
2 4
BK 45, BK 45-U,
BK 45-LT, BK 46 L [mm] 95 95 95
[kg] 2.2 2.1 2.0
70
Withdrawal
distance
30
Spare Parts
Stock code Stock code Stock code
Item Designation
BK 45, BK 45-LT BK 45-U BK 46
4 4 /6 Thermovit regulator, gasket 375 234 375235 375464
890 Strainer set, cpl. 375 113 375 113 375113

6
6 Gasket*) 40 x 48 x 2, graphite 375 159 375 159 375159
9 Gasket*) A 24 x 29, stainless steel 375 162 375 162 375162

*) Minimum purchasing quantity 50 pcs. For smaller quantities please contact your local dealer.
8 9
0
Steam Traps Capacity Chart for BK 45, BK 45-U, BK 45-LT Enclosure 10120
BK 45, BK 45-U, BK 45-LT, BK 46
PN 40 2
DN 15, 20, 25 (½", ¾", 1")
Capacity Charts
The charts show the maximum capacities for hot and cold
condensate. 1
Curve 1
Indicates the max. capacity of hot condensate that steam
traps BK 45 and BK 46 with standard regulator can discharge
with virtually no banking-up.
The BK 45-U (undercooling) discharges the condensate
when it is approx. 30 K (degC) below saturation temperature
(banking-up of condensate).
Curve 2
Discharge capacity for cold condensate at 20 °C.
Specification Text
GESTRA Steam trap, DN 15 / DN 20 / DN 25
Condensate flowrate
Type: BK 45 (1.0460)
Type: BK 45-U (1.0460, 30 K undercooling)
Type: BK 45-LT (SA350 LF2)
Type: BK 46 (1.5415)
End connection: Flanged / socket-weld ends /
butt-weld ends / screwed sockets
Nominal size: DN 15 / 20 / 25 / ½"/¾"/1"
Pressure rating: PN 40 / CL 150 / CL 300
7
Regulator: Standard, Δt approx. 15 K
(BK 45, BK 46) Differential pressure
U = Undercooling, Δt approx. 30 K
(only BK 45-U) Capacity Chart for BK 46
Inspection & Certification 2

Documentation regarding material tests and in-house exami-
nation with test report EN10204-2.2 or inspection certificate
EN10204-3.1 available at extra cost. All inspection require-
ments have to be stated with the enquiry or order. After
supply of the equipment certification cannot be established.
Charges and extent of the above mentioned test certificates
as well as the different tests confirmed therein are listed in
our Price List “Test and Inspection Charges for Standard 1
Equipment”. For other tests and inspections than those listed
above, please consult us.
PED (Pressure Equipment Directive)

The equipment fulfills the requirements of the Pressure Equip-
ment Directive PED 97/23/EC. For use with fluids of group 2.
The equipment is excluded from the scope of the PED according
to section 3.3 and must not bear a CE marking.
ATEX (Atmosphère Explosible)

The equipment does not have ist own potential source of igni-
tion and is therefore not subject to the ATEX Directive 94/9/
EC. Applicable in Ex zones 0, 1, 2, 20, 21, 22 (1999/92/EC).
Condensate flowrate
The equipment is not Ex marked.
Supply in accordance with our general 7

terms of business. Differential pressure
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Tel. 0049 (0) 421 35 03 - 0, Fax 0049 (0) 421 35 03-393
E-mail [email protected], Web www.gestra.de
810436-03/03-2011cm (804138-02) · GESTRA AG · Bremen · Printed in Germany

Enclosure 10120
Steam Trap
BK 45
BK 45-U
BK 45-LT
BK 46
Original Installation Instructions

810437-07
Enclosure 10120
Contents
Preface ...............................................................................................................................................3
Availability.............................................................................................................................................3
Text layout ............................................................................................................................................3
Safety..................................................................................................................................................3
Usage for the intended purpose..............................................................................................................3
Basic safety notes .................................................................................................................................4
Typographic features of safety notes.......................................................................................................5
Description .........................................................................................................................................6
Scope of supply and equipment specification ..........................................................................................6
Purpose and function.............................................................................................................................7
Storing and transporting the equipment...........................................................................................8
Storing the equipment ...........................................................................................................................8
Transporting the equipment ...................................................................................................................8
Mounting and connecting the equipment .........................................................................................9
Preparing installation .............................................................................................................................9
Connecting the equipment .....................................................................................................................9
Operation ..........................................................................................................................................10
After operation .................................................................................................................................10
Removing external dirt deposits............................................................................................................11
Maintaining equipment ........................................................................................................................11
Servicing equipment and installing spare parts ......................................................................................11
Troubleshooting ...............................................................................................................................14
Putting equipment out of operation ................................................................................................17
Removing harmful substances..............................................................................................................17
Removing equipment ...........................................................................................................................17
Re-using equipment after storage.........................................................................................................18
Disposing of equipment .......................................................................................................................18
Technical data..................................................................................................................................19
Dimensions and weights ......................................................................................................................19
Pressure & temperature ratings............................................................................................................20
Manufacturer's Declaration.............................................................................................................23
Enclosure 10120
Preface Text layout

This installation & operating manual will help you Certain text elements of this installation & operating
use the following types of equipment safely and manual feature a specific typographic design. You
efficiently for their intended purpose. can easily distinguish the following text elements:
BK 45 Standard text
BK 45-U Cross-reference
BK 45-LT Listing
BK 46 Sub-items in listings
These steam traps will be called equipment in this ¾ Steps for action.
document.
Here you will find additional useful
This installation & operating manual is intended for information and tips serving to assist you
anyone commissioning, using, operating, servicing, in using the equipment to its fullest
cleaning or disposing of this equipment and, in potential.
particular, for professional after-sales service
technicians, qualified personnel and authorised and
trained staff. Safety
All of these persons must read and understand the
content of this installtion & operating manual.
Usage for the intended purpose
Following the instructions given in this installation &
operating manual helps avoiding danger and The following thermostatic/thermodynamic steam
increases the reliability and service life of the traps are installed in steam lines:
equipment. Please note that in addition to the BK 45
instructions given in this installation & operating BK 45-U
manual you must also observe all locally applicable
BK 45-LT
rules and regulations concerning the prevention of
accidents as well as approved safety guidelines for BK 46
good professional practice.
This equipment is designed for discharging
condensed water or air-venting pipes.
Availability
The equipment must only be used within the
Keep this installation & operating manual together allowable pressure and temperature limits and only
with the plant documentation for future reference. if the chemical and corrosive influences on the
Make sure that this installation & operating manual equipment are taken into account.
is available to the operator.
Correct use includes compliance with the
The installation & operating manual is part of the instructions given in this installation & operating
equipment. Please hand over this installation & manual, in particular obedience to all safety
operating manual when selling the equipment or instructions.
passing it on.
Any other use of the equipment is considered to be
improper.
Note that the equipment is also used incorrectly if
the materials of the equipment are not suitable for
the fluid.
3
Enclosure 10120
Basic safety notes Risk of minor injuries
Sharp edges on internals present the danger of
Risk of severe injuries cuts to hands. Always wear industrial gloves
The equipment is under pressure and hot during when servicing the equipment.
operation. Before carrying out any work on the If the support of the equipment during
equipment make sure that the following installation is insufficient the equipment might
requirements are met: fall down, thereby causing bruises or injuries.
The pipes must be depressurized (0 bar). Make sure the equipment is safely held in place
The fluid must be completely removed from during installation and cannot fall down. Wear
the pipes and the equipment. protective safety footwear.
During work on the equipment the Risk of property damage or malfunctions
installation must be switched off and
Malfunctions will occur if the equipment is
protected against unauthorised or
installed in a wrong position or with the flow
unintended activation.
arrow pointing in the opposite direction of the
The pipes and the equipment must have fluid flow. This may result in damage to the
cooled down to room temperature (approx. equipment or the installation. Make sure that
20 °C). the flow arrow on the equipment body matches
If the equipment is used in contaminated areas the indicated direction of the fluid flow in the
there is a risk of severe injuries or death caused pipe.
by harmful substances in or on the equipment. If the material is unsuitable for the fluid,
Before working on the equipment make sure increased wear may occur and fluid may
that it is completely decontaminated. Always escape. Make sure that the material is suitable
wear the protective clothing prescribed for for the fluid used in your installation.
contaminated areas when working on the
equipment.
The equipment must only be used with fluids
that do not attack the material and the gaskets
and sealings of the equipment. Otherwise leaks
may occur and hot or toxic fluid could escape.
The equipment and its component parts must
only be mounted or removed by qualified
personnel. A qualified person must be
acquainted with and experienced in the
following:
Making pipe connections.
Working with dangerous (contaminated, hot
or pressurized) fluids.
4
Enclosure 10120
Typographic features of safety
notes
Danger note
DANGER
Notes with the heading DANGER warn
against imminent dangerous situations that
can lead to death or serious injuries.
WARNING
Notes with the heading WARNING warn
against possibly dangerous situations that
could lead to death or serious injuries.
CAUTION
Notes with the heading CAUTION warn
against dangerous situations that could
lead to minor or moderate injuries.
Information on environmental and property

damage
Attention!
This note warns against situations that
may lead to environmental and/or property
damage.
5
Enclosure 10120
Description
Scope of supply and equipment

specification
Scope of supply
Our equipment is delivered packed and ready for
assembly.
Equipment specification
No. Designation No. Designation

1 Name plate 6 Body
2 Plug 7 Flow arrow
3 Cover 8 Strainer
4 Thermovit regulator 9 Gasket
5 Cover gasket 10 Sealing plug
6
Enclosure 10120
Optional extras The following items are indicated on the equipment
body:
The following add-on equipment is available:
Material
Blow-off valve
Quarter and year of manufacturing
Ultrasonic test device VAPOPHONE ®
Direction of flow
Continuous condensate monitoring equipment
PED (Pressure Equipment Directive)

End connections
The equipment fulfills the requirements of the
The equipment is available with the following end
Pressure Equipment Directive PED 97/23/EC and
connections:
can be used for the following fluids:
Flanges
Fluids of group 2
Butt-weld ends
Socket-weld ends The equipment is excluded from the scope of the
PED according to section 3.3 and must not bear a
Screwed sockets CE marking.
Name plate
ATEX
The following items are indicated on the name
plate: ¾ Please observe the following notes if the
equipment is to be used in explosion-risk areas:
Type designation
The equipment can be used in zones
Code letter for opening temperature of
(surrounding atmosphere acc. to Directive
Thermovit regulator (only if different from
1999/92/EC) 0, 1, 2, 20, 21 and 22 (ATEX
standard value)
Directive 94/9/EC).
Nominal size
Pressure rating The equipment does not have its own potential
source of ignition and is therefore not subject to the
Max. admissible design pressure ATEX Directive 94/9/EC.
Max. admissible design temperature The equipment is not Ex marked.
Max. service temperature at the corresponding
service pressure
Purpose and function
Max. differential pressure
Manufacturer Purpose
This equipment is designed for discharging
condensed water or air-venting steam lines.
Function of the Thermovit controller

The equipment is fitted with a Thermovit regulator
that regulates the flow of the fluid. The Thermovit
regulator is screwed into the body.
The Thermovit regulator consists of a stack of
several bimetallic plates. As the fluid temperature
rises the plates deflect, thereby moving the stage
nozzle. The orifice is being closed.
7
Enclosure 10120
When the installation is cold the Thermovit regulator Storing the equipment
is open.
Please observe the following items when storing the
equipment:
Do not store the equipment for more than 12
months.
Use the supplied sealing plugs or other suitable
seal caps in order to seal off all openings of the
equipment.
Protect the sealing surfaces and contact areas
against mechanical damage.
Protect the equipment and all components
against hard shocks and impacts.
Store the equipment only in closed rooms that
The Thermovit regulator of the BK 45 is available for meet the following environmental conditions:
two different opening temperatures:
Air humidity below 50 %, not condensing
Standard adjustment approx. 15 K undercooling
Indoor air: clean, salt-free and non-corrosive
Special adjustment approx. 30 K undercooling
(code letter of opening temperature "U" Temperature 5–40 °C.
indicated on name plate) ¾ Make sure that all these requirements are
The Thermovit regulator of the BK 46 is adjusted always met when storing the equipment.
before leaving the factory to close with approx.15 K ¾ Please contact the manufacturer if you cannot
undercooling. comply with the recommended storage
conditions.
Storing and transporting the Transporting the equipment

equipment ¾ Meet the requirements for storage also when
transporting the equipment.
Attention! ¾ Prior to transport seal off connections with
Equipment can be damaged if stored or sealing plugs.
transported improperly.
¾ Close all openings with the sealing If you do not have the sealing plugs
plugs or covers supplied with the supplied with the equipment use
equipment or use similar sealing appropriate seal caps to seal off the
covers. connections.
¾ Protect the equipment against ¾ For short distances (only a few metres) you can
moisture and corrosive atmospheres. transport the equipment unpacked.
¾ Please contact the manufacturer if the ¾ When transporting the equipment over larger
specified transport and/or storage distances use the original packaging.
requirements cannot be met. ¾ If you do not have the original packaging use a
box that protects the equipment adequately
against corrosion and physical damage.
8
Enclosure 10120
For a short period of time the equipment Connecting the equipment
may be transported even if the
temperature is below 0 °C, provided that DANGER
the equipment is completely empty and Incorrectly connected equipment can
dry. cause fatal accidents or severe injuries.
¾ Make sure that only qualified skilled
personnel connect the equipment to
Mounting and connecting the pipes.
equipment ¾ Make sure that the flow arrow on the
equipment body matches the direction
of flow in the pipe.
Preparing installation
¾ Take the equipment out of the transport Specialist personnel must be highly qualified and
packaging. fully experienced in making pipe connectinons for
¾ Check the equipment for transport damage. the respective type of end connection.
¾ Contact the manufacturer if you detect any kind
of shipping damage. Attention!
When supplied by the factory, the connections may Equipment will be damaged if the end
be sealed off with sealing plugs. connections are undersized.
¾ Make sure that the connections are
¾ Remove sealing plugs before mounting the strong and rigid enough to support the
equipment. weight of the equipment and to
¾ Keep the sealing plugs and the packing for withstand the forces that occur during
further use. operation.
To allow easy access for routine servicing and

DANGER
exchanging components observe the indicated
Personnel working on pipes are exposed to withdrawal distances and allow for clearances to
safety risks and may suffer severe injuries, adjacent installation parts.
burns, poisoning or even loss of life.
For more information see chapter "Dimensions and
¾ Make sure that no hot or hazardous
weights" on page 19.
fluid is in the equipment or the pipes.
¾ Make sure that the installation is ¾ Make sure that the pipe system of the plant is
switched off and protected against clean.
unauthorised or unintended activation.
¾ Make sure that the equipment and the
pipes have cooled down to room
temperatures.
¾ Drain pipes until they are empty.

¾ Switch the installation off and protect it against
unauthorised or unintended re-activation.
9
Enclosure 10120
¾ Preferred installation of the equipment with the
strainer insert hanging downwards.
After operation
Other installation orientations of the
strainer are possible in exceptional cases. DANGER
If the equipment is used in contaminated
Attention! areas there is a risk of severe injuries or
Any installation position where the strainer death caused by harmful substances in or
insert does not point downwards may on the equipment.
impair the correct function of the ¾ Only qualified personnel are allowed to
equipment. perform work on contaminated
¾ Please consult the factory with equipment.
installation details if the equipment ¾ Always wear the protective clothing
cannot be installed in your installation prescribed for contaminated areas
with the strainer hanging downwards. when working on the equipment.
¾ Make sure that the equipment is
¾ Make sure that the equipment is free from
completely decontaminated before
foreign matter.
carrying out any service work.
¾ Mount the equipment in the desired installation
¾ Follow the pertinent instructions for
position.
handling the hazardous substances in
¾ Make sure that the equipment is safely mounted question.
and that all connections are made correctly.
Attention! Attention!
Frost damage may occur when the
Malfunctions may occur if the equipment
installation is shut down.
or condensate line is insulated.
¾ Drain the equipment if ambient
¾ Make sure that the heat generated by
temperatures below 0 °C (frost) are to
the equipment or the condensate line
be expected.
is dissipated.
Operation
You can check the equipment for correct operation
using the GESTRA ultrasonic measuring unit
VAPOPHONE®.
¾ For more details refer to the installation &
operating manual of the ultrasonic measuring
unit.
Continuous steam trap monitoring is recommended
for critical applications.
¾ For more details refer to the installation &
operating manual of the continuous steam trap
monitoring unit.
10
Enclosure 10120
Removing external dirt deposits
¾ To remove dirt deposits rinse the equipment
with fresh water and wipe it with a clean, lint-
free cloth.
¾ To remove any persistent residues use a
cleaning agent that is suitable for the material
and carefully wipe the equipment with a clean,
lint-free cloth.
Maintaining equipment
The equipment is maintenance-free.
Servicing equipment and installing

spare parts
You may exchange the following component parts
in case of wear or damage:
Thermovit regulator
Strainer
Cover gasket
Gasket
11
Enclosure 10120
Spare Parts
No. Designation Stock code #

BK45, BK 45-U BK 46
BK 45-LT
4 Thermovit regulator 375234 375235 375464
8, 9, 10 Strainer with sealing plug and gasket 375113 375113 375113
5 Cover gasket*) 375159 375159 375159
9 Gasket 375162 375162 375162
*) Minimum purchasing quantity 50 items. Contact your local dealer for smaller quantities.
12
Enclosure 10120
¾ Put the cover gasket into the body.
Removing Thermovit regulator
¾ Put the cover onto the body.
To clean the Thermovit regulator and, if necessary,
¾ Tighten the screws alternately and in several
replace it with a new one proceed as follows:
steps with a torque of 25 Nm.
¾ Use a 16 mm open-end spanner (US: wrench) to
unscrew the two screws from the body.
Removing and cleaning the strainer
¾ Lift the cover off the body.
To remove and, if required, clean or replace the
¾ Remove the cover gasket. strainer proceed as follows:
¾ Use a 22 mm open-end spanner (US: wrench) to ¾ Use a 30 mm open-end spanner (US: wrench) to
unscrew the Thermovit regulator from the body. unscrew the sealing plug from the body.
¾ Remove the gasket.
Cleaning Thermovit regulator
¾ Take out the strainer.
¾ Clean the Thermovit regulator with fresh water
and a clean lint-free cloth. ¾ Clean the sealing plug, the gasket and the
strainer with fresh water and a clean lint-free
¾ Clean gasket seating surfaces.
cloth.
¾ Clean gasket seating surfaces.
Checking the component parts for damage
¾ Check the removed parts for visible signs of
Checking the component parts for damage
wear or damage.
¾ Check the removed parts for visible signs of
¾ Discard and replace any damaged part.
wear or damage.
¾ Discard and replace any damaged part.
Installing Thermovit regulator
To fit the Thermovit regulator proceed as follows: Mounting the strainer
¾ Apply heat-resistant lubricant to the following
To remove the strainer proceed as follows:
surfaces:
¾ Apply heat-resistant lubricant to the thread of
all threads the sealing plug.
the seating surface of the nozzle insert ¾ If the gasket is damaged replace it with a new
the seating surface of the cover one.
¾ Put the gasket onto the sealing plug.
¾ Use a 22 mm open-end spanner (US: wrench) to
screw the Thermovit regulator into the body and ¾ Insert the strainer into the sealing plug.
tighten with a torque of 90 Nm. ¾ Use a 30 mm open-end spanner (US: wrench) to
¾ If the cover gasket is damaged replace it with a screw the sealing plug into the body and tighten
new one. with a torque of 75 Nm.
13
Enclosure 10120
Troubleshooting
Feature Cause Remedy
The steam trap is cold or only The shut-off valves for Open the shut-off valves.
hand-hot. condensate inlet or outlet are
closed.
The condensate inlet or outlet Clean the pipes.
is dirt clogged. Clean the equipment.
The steam trap is blowing off The Thermovit regulator is Clean the Thermovit regulator.
live steam. contaminated. Clean the strainer and the equipment.
There are dirt deposits in the Replace the Thermovit regulator with a
equipment. new one.
The Thermovit regulator is Replace the Thermovit regulator with a
worn down. new one.
The seat is leaking.
The bypass is open. Close the bypass.
14
Enclosure 10120
Insufficient condensate The shut-off valves for Open the shut-off valves.
discharge. condensate inlet or outlet are
Insufficient thermal output of closed.
the user. The condensate inlet or outlet Clean the pipes.
is dirt clogged. Clean the equipment.
Replace the Thermovit regulator with a
new one.
Steam pressure and Use a different steam trap type.
condensate flowrate fluctuate Contact the manufacturer to find out
considerably. which trap type is the most suitable for
The pressure upstream of the your application.
steam trap is too low for the
used trap type.
The steam trap is undersized. Use a steam trap with a larger
condensate discharge capacity.
The differential pressure is too Increase the steam pressure.
small. Lower the pressure in the condensate
line.
Check the size of the condensate line.
Install a steam trap with a larger
condensate discharge capacity, a pump
steam trap or a condensate return unit.
The pressure upstream of the Use a different steam trap type.
steam trap is too low. Contact the manufacturer to find out
The pressure in the condensate which trap type is the most suitable for
line is too high. your application.
The distance between the drain Install the steam trap approx. 1 - 2 m
point and the steam trap is too away from the drain point.
small. Lay the condensate line with a gradient
so that the condensate is free to fall
towards the steam trap.
The condensate line does not Lay the condensate line with a gradient
have a slight fall from the the so that the condensate is free to fall
drain point towards the steam towards the steam trap.
trap. Change the orientation of the condensate
The condensate is lifted line.
upstream of the steam trap.
The condensate temperature is If the steam trap or the condensate line
higher than the service is insulated remove the insulation.
temperature of the steam trap. Use a different steam trap type.
15
Enclosure 10120
The Thermovit regulator does Contact the manufacturer to find out
not open or only with a time which trap type is the most suitable for
delay. your application.
Insufficient deaeration. Provide additional deaeration.
Use a different steam trap type.
Contact the manufacturer to find out
which trap type is the most suitable for
your application.
Fluid escapes (equipment is The end connections are Seal off the end connections (e. g.
leaking). untight. flanged or screwed ends).
A gasket of the body is Replace the gasket with a new one.
defective.
The body has been damaged Check the resistance of the material for
by corrosion or erosion. the fluid used.
Use a steam trap made from a material
that is suitable for the fluid used.
The equipment has been Replace the equipment with a new one.
damaged by frost. When shutting down the installation
make sure that the condensate lines and
the steam trap are completely drained.
The equipment has been Replace the equipment with a new one.
damaged by waterhammer. Take appropriate measures to protect the
equipment against waterhammer, e. g.
by installing suitable non-return valves.
¾ If faults occur that are not listed above or cannot

be corrected, please contact our Technical
Service or authorized agency in your country.
16
Enclosure 10120
¾ For the disposal of all residues observe the
pertinent legal regulations concerning waste
Putting equipment out of disposal.
operation
Removing equipment
Removing harmful substances
DANGER
DANGER
Personnel working on pipes are exposed to
If the equipment is used in contaminated safety risks and may suffer severe injuries,
areas there is a risk of severe injuries or burns, poisoning or even loss of life.
death caused by harmful substances in or
¾ Make sure that no hot or hazardous
on the equipment.
fluid is in the equipment or the pipes.
¾ Only qualified personnel are allowed to
¾ Make sure that the installation is
perform work on contaminated
switched off and protected against
equipment.
unauthorised or unintended activation.
¾ Always wear the protective clothing
¾ Make sure that the equipment and the
prescribed for contaminated areas
pipes have cooled down to room
when working on the equipment.
temperatures.
¾ Make sure that the equipment is
completely decontaminated before
carrying out any service work. CAUTION
¾ Follow the pertinent instructions for Danger of bruising if the equipment falls
handling the hazardous substances in down.
question. ¾ When removing the equipment make
sure the it is safely held in place and
Qualified personnel must have extensive experience cannot fall down.
with and a working knowledge of:
pertinent rules and regulations concerning Suitable measurements are for instance:
handling hazardous substances Equipment that is not too heavy may be
special regulations for handling the hazardous supported by a second person.
substances encountered on site For heavy equipment use suitable lifting
using the required personal protective equipment of sufficient strength.
equipment (PPE) and clothing
¾ Detach the end connections of the equipment
from the pipes.
Attention!
¾ Put the equipment onto a suitable base.
Environmental damage may be caused by
¾ Store the equipment as described in section
poisonous fluid residues.
"Storing the equipment" on page 8.
¾ Before disposing of the equipment
make sure that it is clean and free of
fluid residues.
¾ For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
¾ Remove all residues from the equipment.
17
Enclosure 10120
BK 45-LT
Re-using equipment after storage Component ASME
Observe the following instructions if you want to Body and cover SA 350 LF2
remove the equipment and use it again somewhere
else: Screws A193 B7
Make sure that the equipment is free of any Gasket Graphite/CrNi
fluid residues.
Thermovit regulator Stainless steel
Make sure that all connections are in good
condition and leak-free. Other internals High grade steels
If necessary re-work welded connections in
BK 46
order to ensure that they are in good working
condition. Component DIN / EN ASTM
equivalent*
¾ Use the equipment only for its intended purpose
Body and cover 1.5415 A182 F1
and the service conditions for which it was
specified. Screws 1.7225 A193 B7
Disposing of equipment
Attention! Other internals High grade steels
Environmental damage may be caused by * Physical and chemical properties comply with
poisonous fluid residues. DIN grade. ASTM nearest equivalent grade is
¾ Before disposing of the equipment stated for guidance only.
make sure that it is clean and free of
fluid residues.
¾ For the disposal of all materials
observe the pertinent legal regulations
concerning waste disposal.
The equipment is made from the following

materials:
BK 45, BK 45-U
Component DIN / EN ASME
Body and cover 1.0460 A105
Screws 1.7225 A193 B7
Other internals High grade steels
18
Enclosure 10120
Technical data

All types
Height [mm] 158
Width of cover [mm] 96
Space required for removing 70
cover [mm]
Space required for removing 30
sealing plug [mm]
Equipment with flanged ends
EN 1092-1 ASME B 16.5 ASME B 16.5
PN 40 Class 150 Class 300
Nominal size DN 15 20 25 15 20 25 15 20 25
1/2“ 3/4“ 1“ 1/2“ 3/4“ 1“ 1/2“ 3/4“ 1“
Overall length 150 160 150 160 150 160
[mm]
Diameter of flange 95 105 115 88.9 98.4 107.9 95.2 117.5 123.8
[mm]
Weight [kg] 3.7 4.3 4.8 3.7 4.3 4.8 3.7 4.3 4.8
Equipment with butt-weld ends

EN 12627 ASME B 16.25
Edge form to ISO 9692, ASME B 36.10
code number 1.3
Nominal size DN 15 20 25 15 20 25
1/2“ 3/4“ 1“ 1/2“ 3/4“ 1“
For pipe 21.3 × 2.0 26.9 × 2.3 33.7 × 2.6 21.3 × 2.8 26.7 × 2.9 33.4 × 3.4
Overall length [mm] 200
Weight [kg] 2.5
19
Enclosure 10120
Equipment with socket-weld and butt-weld ends
Socket-weld ends to DIN EN 12760, ASME B 16.11 Class 3000
Butt-weld ends to G: ISO 228-1, NPT: ASME B 16.11
Nominal size DN 15 20 25
1/2“ 3/4“ 1“
Overall length [mm] 95
Weight [kg] 2.2 2.1 2.0
Pressure & temperature ratings

BK 45 and BK 45-U
Max. differential pressure Δ PMX: 22 bar
End connection Flanged PN 40, EN 1092-1

p (pressure) [bar] 40.0 33.3 27.6 25.7 23.8 13.1
T (temperature) [°C] 20 200 300 350 400 450
Based on EN 1092-1
End connection Flanged Class 150, ASME B16.5

p (pressure) [bar] 19.6 13.8 10.2 8.4 6.5 5.5
T (temperature) [°C] –29/38 200 300 350 400 425
End connection Flanged to Class 300, ASME B16.5,

Butt-weld ends to EN 12627,
Socket-weld ends to EN 12760,
Socket-weld ends to Class 3000, ASME B16.11,
Screwed sockets to G, ISO 228-1,
Screwed sockets to NPT, ASME B16.11
p (pressure) [bar] 51.1 43.8 39.8 37.6 34.7 28.8
T (temperature) [°C] –29/38 200 300 350 400 425
20
Enclosure 10120
BK 45-LT

p (pressure) [bar] 19.6 13.8 10.2 8.4 6.5 5.5
T (temperature) [°C] -46 200 300 350 400 425

p (pressure) [bar] 51.1 43.8 39.8 37.6 34.7 28.8
T (temperature) [°C] -46 200 300 350 400 425
BK 46
End connection Flanged PN 40, EN 1092-1

p (pressure) [bar] 40.0 39.0 34.2 32.3 29.9 27.6
T (temperature) [°C] 20 250 300 350 400 450
Based on EN 1092-1

p (pressure) [bar] 20.0 14.0 10.2 8.4 6.5 4.7
T (temperature) [°C] -10/50 200 300 350 400 450
Based on EN 1759-1
21
Enclosure 10120
p (pressure) [bar] 51.7 44.2 35.0 32.9 30.9 29.8
T (temperature) [°C] -10/50 200 300 350 400 450
Based on EN 1759-1
22
Enclosure 10120
Manufacturer's Declaration
For more information on the Conformity
Assessment according to European rules refer to
our Declaration of Conformity or our Declaration by
Manufacturer.
To download the current Declaration of Conformity
or Declaration by Manufacturer go to
www.gestra.en/documents or contact:
Manufacturer GESTRA AG
P. O. Box 10 54 60,
D-28054 Bremen
Telephone +49 (0) 421 35 03 0
Fax +49 (0) 421 35 03 393
E mail [email protected]
This declaration is no longer valid if modifications

are made to the equipment without consultation
with us.
23
Enclosure 10120
Agencies all over the world: www.gestra.de
Great Britain South Africa

Flowserve GB Limited Flowserve SA (Pty) Ltd.
Abex Road Unit No. 1
Newbury, Berkshire RG14 5EY Director Road
Tel. 0044 16 35 / 46 99 90 Spartan Extension 2
Fax 0044 16 35 / 3 60 34 Kempton Park 1613
E-Mail [email protected] P.O.Box 9279
Web www.flowserve.com Edenglen 1613
Tel. 0027 11 / 9 23 73 00
Fax 0027 11 / 9 74 64 20
Web www.flowserve.com
Singapore USA
Flowserve Pte. Ltd. Flowserve GESTRA U.S.
12 Tuas Avenue 20 2341 Ampere Drive
Singapore 638824 Louisville, KY 40299
Tel. 0065 / 68 79 89 00 Tel. 001 502 / 267 - 2205
Fax 0065 / 68 62 49 40 001 502 / 267 - 2206
E-Mail [email protected] Fax 001 502 / 266 - 5397
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Telephone 0049 (0) 421 / 35 03 - 0
Fax 0049 (0) 421 / 35 03 - 393
810437-07/12-2010kx_mm (808837-01) © GESTRA AG Bremen Printed in Germany
24
BALL VALVES full bore
ALFA 68S.B. DN 15-250 DIN 3202 F4/F5 PN 10/40
_____________________________________________________________________________
OY KONWELL AB Hankasuontie 11 A 00390 HELSINKI Puh. (09) 8946 480 Fax (09) 548 1129 e-mail [email protected]
OY KONWELL AB Hankasuontie 11 A 00390 HELSINKI Puh. (09) 8946 480 Fax (09) 548 1129 e-mail [email protected]
OPERATING AND MAINTENANCE MANUAL MM6X Rev.3
SPLIT BODY FLOATING BALL VALVES
Pag 1 di 6

ALFA SPLIT BODY FLOATING BALL VALVES
Models ALFA 60 / 64 / 68 / 606 / 609 / 615 / 625 / 50 / 54 / 58 / 506
Index Page
0. Technical Data 2
2. Mounting 3
3. Maintenance 3
4. Testing 3
Pag 2 di 6
0. Technical Data

V.le del Lavoro 19
20010 CASOREZZO (MI) – ITALY
Tel. 02-90296206
Fax. 02-90296292
Service ON-OFF
Fluids liquids e gases Group 1 (dangerous) in accordance to the EC Directive 97/23/CE

Emissions to atmosphere 1x10-4 mbar l/s m (acc.to TA-LUFT requirements)
Modello ALFA 64 ALFA 60 ALFA 606 ALFA 54 ALFA 50 ALFA 506

ALFA 68 DN≤80 ALFA 68 DN>80 ALFA 58 DN<100 ALFA 58 DN≥100
PN10-16-25-40 PN25-40 PN63-100 PN10-16-25-40 PN25-40 PN63-100

ANSI150 ANSI300 ANSI600 ANSI150 ANSI300 ANSI600
Nominal DN 32-250 DN 32-150 DN 32-150 DN 50 - 300 DN 50 - 300 DN 50 - 150
Diameters
Max. Working PN10 Æ 10 PN10 Æ 10
PN63 Æ 64
(bar) PN16 Æ 16 PN16 Æ 16
51 DN ≥ 150
Pressure at PN25 Æ 25 PN25 Æ 25 PN63 Æ 64
PN100 Æ 100
Amb.Temp. 20 DN ≥ 150 PN25 Æ 25 20 DN ≥ 200 PN25 Æ 25 PN100 Æ 100
64 DN ≥ 100
PN40 PN40 Æ 40 PN40 PN40 Æ 40 64 DN ≥ 150
51 DN ≥ 150
40 DN ≤ 80 A.300 Æ 51 40 DN ≤ 80 A.300 Æ 51 A.600 Æ 102
A.600 Æ 102
25 DN ≥ 100 25 DN ≥ 150 64 DN ≥ 150
64 DN ≥ 100
20 DN ≥ 150 20 DN ≥ 200
51 DN ≥ 150
A.150 Æ 20 A.150 Æ 20
Design PN10 Æ 10 PN10 Æ 10
Pressure (bar) PN16 Æ 16 PN25 Æ 25 PN63 Æ 64 PN16 Æ 16 PN25 Æ 25 PN63 Æ 64
at Amb.Temp. PN25 Æ 25 PN40 Æ 40 PN100 Æ 100 PN25 Æ 25 PN40 Æ 40 PN100 Æ 100
PN40 Æ 40 A.300 Æ 51 A.600 Æ 102 PN40 Æ 40 A.300 Æ 51 A.600 Æ 102
A.150 Æ 20 A.150 Æ 20
Max. Working 80 80
(bar) (64 per PN63) (64 per PN63)
8 8 8 8
Pressure at 64 DN ≥ 100 64 DN ≥ 100
Max.Temp. 51 DN ≥ 150 51 DN ≥ 150
Max. Working 1½” - 2” 200ºC 1½”- 2” 200ºC fino 3” 200ºC fino 3” 200ºC
Temperature 2½ “-3” 180ºC 2½ “-3” 180ºC 1½” - 2” 90ºC 4 “-6” 180ºC 4 “-6” 180ºC Fino 3” 90ºC
4” - 6” 160ºC 4” - 6” 160ºC 2½ “-4” 70ºC 8” - 10” 160ºC 8” - 10” 160ºC 4” – 6” 70ºC
8” - 10” 120ºC 12” 120ºC 12” 120ºC
Min. Working -29ºC for A105 / A216WCB
Temperature -40ºC for A350LF2 Classe 2 / A352LCB
-40ºC stainless steel bodies
Max.simultaneous Please contact ALFA VALVOLE Technical Dept.
Working
conditions
Pag 3 di 6
- END CONNECTIONS Flanged to ANSI/DIN/UNI/EN, BW or Screwed

- BODY THICKNESS ASME VIII Div.1 – ASME B16.34 – DIN 3840
- BOLTING DESIGN ASME VIII Div.1 – ASME B16.34
- FLANGE DESIGN ASME VIII Div.1
- WIND/EARTHQUAKE LOADS Not Applicable, according to ASME III Div.1 Subsect.NB
- FATIGUE from Atmospheric to Service Pressure Cycles 17500 cycles minimum, according to ASME III Div.1
Subsect.NB
- FATIGUE from Service Pressure Fluctuation Negligible
- MAX. LIFE in service hours Function of actual simultaneous working conditions and fluids but anyway not
longer than (ideal conditions):
- 50000 operations of opening/closing of the valve
- AVAILABLE CORROSION OVERTHICKNESS 2 mm min. (carbon steel valves only)
1.2 Storage
2. MOUNTING
3. MAINTENANCE
Pag 4 di 6
4. TESTING

e) Close the valve
that pressurised

Valve model and Nominal Diameter
Pressure class
Pag 5 di 6
valve in operation.
departement.
6.6 Il The maximum number of operating hours can be influenced by the real operating conditions.
shwed in para.0.3 of this manual.
6.7 WARNING : the functioning of valves complete with actuators is not guaranteed in the event of an earthquake.
6.8 WARNING : the mounting of actuators for valve operation different to that supplied is not allowed without previous
6.9 WARNING : the valves with split body bolted construction are suitable for resisting reduced axial forces from the
piping system.
Please request the maximum values of axial loads allowed, if necessary, from the Technical Office of ALFA VALVOLE.
6.10 WARNING : reduced port valves are suitable for resisting reduced bendino moments from the piping system.
Please request the maximum values of bending moments allowed, if necessary, from the Technical Office of ALFA
VALVOLE.
6.11 WARNING : reduced port valves will have concentrated erosion at the area of valve port reduction.
the user must evaluate the minimum time between inspections, basing on actual operating conditions, to verify any damage
in those areas due to erosion.
6.12 WARNING :the valves of ALFA A6X serie and A5X serie are suitable for use as sole means of isolation to
atmosphere under specific Customer request only and for working pressures up to 77% of the maximum working pressure
at ambient temperature as detailed in para 0.2 above
Pag 6 di 6
VALVES A10N/10NF/103/10HP
Sheet 1 of 6

ALFA WAFER VALVES
Models ALFA 10N / 10NF / 103 / 10HP
INDICE PAG.
0. Technical Data 2
2. Mounting 3
3. Maintenance 3
4. Testing 3
4 Modification of Tab.0.2 with A103 01/09/04 Ing.M.Orzali

Rev. Descrizione Data Elaborato Verificato Approvato
Sheet 2 of 6
0. Technical Data
V.le del Lavoro 19 - 20010 CASOREZZO (MI) – ITALY
Tel. 02-90296206
Fax. 02-90296292
Service ON-OFF
Fluids liquids e gases Group 1 (dangerous) in accordance to the EC Directive 97/23/CE – Category III
II 2 GD c T6 X in accordance to the Directive 94/9/CE

Emissions to atmosphere 1x10-4 mbar l/s m (acc.to TA-LUFT requirements)
Modello ALFA 10N ALFA 10N ALFA 10N ALFA 10HP

ALFA 10NF ALFA 10NF ALFA 10NF ALFA 103
ALFA 103 ALFA 103 ALFA 103 PN64
PN10-16-20 ANSI PN25-40 PN100
150 ANSI 300 ANSI 600
Nominal Diameters DN 32-200 DN 100-200 DN 32-150 DN32-150
ALFA103 DN 32-150 ALFA103 DN 32-150 ALFA103 DN 32-100
Max. Working (bar) 40 DN≤80 40 51 102
Pressure at Amb.Temp. 20 DN>80 64 DN>80
Max. Working (bar) 80
8 8 15
Pressure at Max.Temp. 64 DN>80
Max. Working
1¼” - 2” 200ºC
Temperature 1¼” - 2” 200ºC
2½ “- 3” 180ºC 1¼” - 2” 90ºC
4” - 6” 160ºC 2½ “-3” 180ºC
4” - 6” 160ºC 2½ “-6” 70ºC
8” 120ºC 4” - 6” 160ºC
8” 120ºC
Min. Working -29ºC per A105 / A216WCB
Temperature -19ºC per A105 / A216WCB for ALFA 103 only
-40ºC per A350LF2 Classe 2 / A352LCB
-40ºC corpi in acciaio inox
-19ºC corpi in acciaio inox for ALFA 103 only
Max.simultaneous
Please contact ALFA VALVOLE Technical Dept.
Working conditions
Body Test Pressure 1,5 x Max.Working Pressare at Ambient Temperature
Seat Test Pressure 1,1 x Max.Working Pressare at Ambient Temperature
- END CONNECTIONS Flanged with blind or straight screwed holes

- BODY THICKNESS ASME VIII Div.1 – ASME B16.34 – DIN 3840
- BOLTING DESIGN ASME VIII Div.1 – ASME B16.34 (Split Body only)
- SCREWED CONNECTION ASME B16.34 (Screwed Connector only)
- FLANGE DESIGN ASME VIII Div.1 (Split Body only)
- WIND/EARTHQUAKE LOADS Not Applicable, according to ASME III Div.1 Subsect.NB
- FATIGUE from Atmospheric to Negligible, according to ASME III Div.1 Subsect.NB
Service Pressure Cycles
- FATIGUE from Service Pressure Negligible, according to ASME III Div.1 Subsect.NB
Fluctuation
- MAX. LIFE in service hours Function of actual simultaneous working conditions and fluids but anyway not longer than :
- 1500 cycles from Atmospheric to Max. Working Pressure for carbon steel
bodies;
- 13000 cycles from Atmospheric to Max. Working Pressure for stainless steel
bodies;
- 50000 operations of opening/closing of the valve
- AVAILABLE CORROSION OVERTHICKNESS 1.5 mm min. (carbon steel valves only)

- ANTISTATIC devices according to BS 5142 A.2
Sheet 3 of 6
1.2 Storage
2. MOUNTING
3. MAINTENANCE
WARNING : the user must guarantee the safety and protection features when maintenance/refurbishing the products or
their components
4. TESTING

e) Close the valve
that pressurised

Valve model
Nominal diameter
Pressure class
Sheet 4 of 6
valve in operation.
It is not possible to identify the body surface temperature in accordance to the Directive 94/9/CE “ATEX” resulting a
function of the temperature of handled fluid.
With ambient temperature services the valves will not be heated more than 60°C (Temperature Class T6 in accordance to
EN 13463-1) when operations are not higher than 1 stroke every 3 sec.
Otherwise, the body surface temperature will reach the handled fluid temperature.
WARNING : the user must evaluate the body surface temperature when the outside ambient has potentially explosive
conditions and not to operate the valves with more than 1 stroke every 3 sec.
departement.
Drain and clean body cavities before any further intervention.
particular in relation to the degree of corrosion/year used in the piping design with reference to the corrosion
overthickness shwed in para.0.3 of this manual.
6.7 WARNING : the functioning of valves complete with actuators is not guaranteed in the event of an earthquake.
6.8 WARNING : the mounting of actuators for valve operation different to that supplied is not allowed without previous
6.9 Actuators are not suitable to resist against external fire conditions.
WARNING : fire-safe properties of actuators can be obtained by the use of fire-protection boxes enabling to avoid
system (valve +actuators) malfunctions.
6.10 WARNING : cabling of actuators and electrical accessories should be realized after valve mounting to piping system
and in accordance to the specifications showed in the relevant use and maintenance manuals..
The user l must provide suitable means for piping system ground and to guarantee the equipotentiality between
valves and piping system during assembling and dismantling.
6.11 WARNING : the grease or lubricator content of manual gears must be periodically (at least yearly) verified.
6.12 WARNING : the valves with split body bolted construction are suitable for resisting reduced axial forces from the
piping.
Request the maximum values of axial loads allowed, if necessary, from the Technical Office of ALFA VALVOLE.
Sheet 5 of 6
6. WARNINGS AND USE LIMITATIONS (cont.d)
6.13 WARNING : A10, A10HP e A103 valves can be used as sole means of insulation of piping pressure only against
specific customer request and for working pressures not exceeding 77% of the stated maximum working pressure
at ambient temperature.
6.14 WARNING : user should provide for periodical cleaning of those areas prone to dust accumulation to avoid dust
deposits bigger than 5 mm.
Sheet 6 of 6
6518/6519
3/2-, 5/2- and 5/3-way Solenoid

Valves for process pneumatics
Type
6518
standard
• High flow-rate capacity
• Reduced power consumption
• Single or manifold mounting
Type 6519
standard • Standard-, EEx m and EEx i versions
• Threaded port G 1/4” or NAMUR flange
Type 6518/6519 can be combined with...
Type 2508 Type 1078 Type 2511/12 Type 8600 Type 2012 Type 2030
Cable plug Timer unit ASI cable plug Dosing control Single-seat Diaphragm valve
globe valve
The Type 6518 is a servo-assisted 3/2-way

General technical data
valve and the Type 6519 is a 5/2 or 5/3-way
Orifice
valve. Together, they form a product line. The
Type 6518 DN 8
valves can be used individually or in blocks.
Type 6519 DN 6, 8 and 9
The valves work without a continuous air Body material
consumption and are used for the pneumatic Type 6518 Polyamide, reinforced
control of double or single-acting actuators. A Type 6519 Polyamide (5/2-way), aluminium (5/3-way)
solenoid valve Type 6014 is used as a pilot. Thread insert material Brass or stainless steel
The use of high quality materials makes it Seal material
possible to use these valves in the open air and Type 6518 NBR and PUR
under chemical atmospheres. The product line Type 6519 NBR, NBR and PUR
contains units with Ex-Approvals and NAMUR Pneumatic connection
flange interface. Supply ports 1,3,5 Threaded port G1/4, can also be flanged
Service ports 2 and 4 Threaded port G1/4 or NAMUR flange
Valves with circuit function C, D and H monos-
Electrical connection Tag connectors acc. to DIN EN 175301-803
table are certified acc. IEC 61508 as SIL2.
(previously DIN 43650) Form A
Content Operating voltage 24 V DC
24/110/230 V, 50-60 Hz
6518/19 standard p. 2
Voltage tolerance ±10%
6518/6519 EEx m p. 3
Media Lubricated or non-lubricated compressed air, neutral
6518/6519 EEx i p. 4 gases. Technical vacuum on request
6519 NAMUR standard p. 5 Media temperature -10 to +50°C
Ambient temperature
6519 NAMUR EEx m p. 6
Standard version -25 to +55° C
6519 NAMUR EEx i p. 7 EEx m version -25 to +50° C
EEx i version -25 to +55° C
Manifold assembly with p. 8
pneumatic modules MP07 Ambient conditions Open air, chemical atmosphere
Protection class IP 65 with cable plug
Accessories p. 10
Installation As required, preferably with actuator upright
Dimensions p. 11
I &URTHERôVERSIONSôONôREQUEST
Approvals
FM-Ex
EC Gas Appliances Directive www.burkert.com p. 1/16
6518/6519
Type 6518/6519 standard (with tag connector acc. to DIN EN 175301-803 Form A, without cable plug)
Technical data
Orifice DN 8.0 and 9.0
Body materials
Type 6518
Pilot valve and main Polyamide, reinforced
valve Type 6519
Pilot valve Polyamide
Main valve 5/2-way; polyamide, 5/3-way; aluminium
Type 6518 Thread insert material Brass (stainless steel on request)
standard Type 6519 Seal materials NBR, NBR and PUR
standard
Pneumatic connection
Supply ports 1,3,5 Threaded port G 1/4, can also be flanged
Service ports 2 and 4 Threaded port G 1/4 (on request NPT 1/4)
Electrical connection Tag connector acc. to DIN EN 175301-803 Form A
Type 6518 and the Type 6519 together form a product
(previously DIN 43650)
line. Both types can be mounted on a pneumatic module.
Protection class IP65 with cable plug
The valve width of 32 mm allows high flow rates. Operating voltage 24 V/DC, 24/110/230 V, 50-60 Hz
A solenoid valve Type 6014 is used as a pilot.
The valves can be used individually or in blocks. Power consumption coil 2 W (100% continuous rating)
Power consumption
Ambient temperature -25 to +55°C
Inrush Hold (hot coil) Media Lubricated or non-lubricated compressed air, neutral gases
AC [VA] AC [VA/W] DC [W] on request Technical vacuum
11 6/2 2 Environmental Open air, chemical atmosphere
conditions
1)
Response times
1)
Measured at valve outlet at 6 bar and +20°C acc. to ISO 12238.
Opening 20 [ms] Opening: Pressure rise 0 to 90%
Closing 40 [ms] Closing: Pressure drop 100 to 10%
Ordering chart valves with manual override (without manual override on request)
connection
air1) [l/min]
Weight [g]
power [W]
frequency
QNn value
threaded
Pressure
Voltage/
Nominal
function
material
Item no.
range2)
Orifice
Circuit
[V/Hz]
[mm]
body
[bar]
Seal
Port
port
Type 6518 standard – thread insert material brass, threaded port 1 and 3 can also be flanged; without cable plug (see Accessories p. 10)
C 2 8.0 NBR and G 1/4 1300 2-8 370 2 024/DC 132 457
12 10 PUR 024/50-60 132 458
1 3 (polyamide)
3/2-way valve, servo-assisted, in 110/50-60 132 459
de-energized position port 2 exhausted 230/50-60 132 460
D 2 8.0 NBR and G 1/4 1300 2-8 370 2 024/DC 132 461
12
10 PUR 024/50-60 132 462
1 3 (polyamide)
3/2-way valve, servo-assisted, in de- 110/50-60 132 463
energized position port 2 pressurized 230/50-60 132 464
Type 6519 standard – thread insert material brass, threaded port 1, 3 and 5 can also be flanged; without cable plug (see Accessories p. 10)
H 4 2 8.0 NBR and G 1/4 1300 2-8 450 2 024/DC 132 465
12 PUR
024/50-60 132 466
5 3 (polyamide)
1
5/2-way valve, servo-assisted, in de- 110/50-60 132 467
energized position port 2 pressurized, 230/50-60 132 468
port 4 exhausted
L 4 2 9.0 NBR G 1/4 1300 3-10 720 2 024/DC 132 469
14 12 (aluminium) 024/50-60 132 470
5 3
1 110/50-60 132 471
5/3-way valve, servo-assisted, in middle
position all ports locked 230/50-60 132 472
N 4 2 9.0 NBR G 1/4 1300 3-10 720 2 024/DC 132 473
14 12 (aluminium) 024/50-60 132 474
5 3
1 110/50-60 132 475
position ports 2 and 4 exhausted 230/50-60 132 476
1) Flow rate: QNn value air [l/min]: Measured at +20°C, 6 bar pressure at valve inlet, 1 bar pressure difference
2) Pressure values [bar]: Gauge pressures with respect to the prevailing atmospheric pressure
Manifold assembly see page 8 Accessories see page 10 Dimensions see page 11
p. 2/16
6518/6519
Type 6518/6519 EEx m (with moulded cable, 3 m long, terminal box on request)
Technical data
Orifice DN 8.0 and 9.0
Body materials
Type 6518
Pilot valve and main Polyamide, reinforced
valve Type 6519
Pilot valve Polyamide
Main valve 5/2-way; polyamide, 5/3-way; aluminium
Thread insert material Brass (stainless steel on request)
Seal materials NBR, NBR and PUR
Supply ports 1,3,5 Threaded port G 1/4, can also be flanged
Type 6518/19 EEx m, Service ports 2 and 4 Threaded port G 1/4 (on request NPT 1/4)
block assembly Electrical connection Moulded cable, 3 m (non-detachable),
Terminal box on request
Protection class IP65
The approval EEx m is achieved by the mounting of an Approval II 2G EEx m II T 5 PTB 00 ATEX 2129X
approved push-over coil. The cable connection and the II 2DIP 65T 100°C
cable are non-detachable and sealed together with the Operating voltage 24/110/230 V/UC
valve. The valves can be used individually or in blocks. Voltage tolerance ±10%
Power consumption coil 3 W (100% continuous rating)
1)
Response times
Opening 20 [ms] Ambient temperature -25 to +50°C
Closing 50 [ms] Media Lubricated or non-lubricated compressed air, neutral gases
on request technical vacuum
1)
Environmental conditions Open air, chemical atmosphere
Opening: Pressure rise 0 to 90%,
Closing: Pressure drop 100 to 10% For use in zone 1, 2, 21 and 22
connection
Weight [g]
power [W]
frequency
QNn value
threaded
Pressure
Voltage/
Nominal
function
material
Item no.
air 1) [l/
range2)
Orifice
Circuit
[V/Hz]
[mm]
body
[bar]
Seal
min]
Port
port
Type 6518 EEx m – thread insert material brass, threaded port 1 and 3 can also be flanged; with moulded cable, 3 m long 3)
C 2 8.0 NBR G 1/4 1300 2-8 600 3 024/UC 134 716
12 10 and 110/UC 134 717
1 3 PUR
230/UC 134 718
3/2-way valve, servo-assisted, in (polyamide)
de-energized position port 2 exhausted
D 2 8.0 NBR G 1/4 1300 2-8 600 3 024/UC 134 719
12
10 and 110/UC 134 720
1 3 PUR
230/UC 134 721
3/2-way valve, servo-assisted, in de- (polyamide)
energized position port 2 pressurized
Type 6519 EEx m – thread insert material brass, threaded port 1, 3 and 5 can also be flanged; with moulded cable, 3 m long 4)
H 4 2 8.0 NBR G 1/4 1300 2-8 700 3 024/UC 134 722
12 and 110/UC 134 723
5 3 PUR
1 230/UC 134 724
5/2-way valve, servo-assisted, in de- (polyamide)
energized position port 2 pressurized,
port 4 exhausted
L 4 2 9.0 NBR G 1/4 1300 3-10 1,100 3 024/UC 134 725
14 12 (aluminium) 110/UC 134 726
5 3
1 230/UC 134 727
position all ports locked
N 4 2 9.0 NBR G 1/4 1300 3-10 1,100 3 024/UC 134 728
14 12 (aluminium) 110/UC 134 729
5 3
1 230/UC 134 730
position ports 2 and 4 exhausted
1) Flow rate: QNn value air [l/min]: Measured at +20°C, 6 bar pressure at valve inlet, 1 bar pressure difference 2) Pressure values [bar]: Gauge pressures with respect to the prevailing atmospheric pressure
3) Versions with terminal box on request 4) Circuit function H (5/2-way) as impulse version on request
Manifold assembly see page 8 Accessories see page 10 Dimensions see page 13
p. 3/16
6518/6519
Type 6518/6519 EEx i (with tag connector acc. to DIN EN 175301-803 Form A, without cable plug)
Technical data
Orifice DN 8.0
Body materials
Pilot valve Stainless steel 1.4305 or brass
Main valve Polyamide, glass-fibre reinforced
Thread insert material Stainless steel or brass, nickel-plated
Seal materials FPM, NBR and PUR
Supply ports 1,3,5 Threaded port G 1/4
Service ports 2 and 4 Threaded port G 1/4
(previously DIN 43650) for cable plug Type 2508 (see
Type 6518 EEx i Type 6519 EEx i Accessories). Ensure correct polarity!
The intrinsically-safe Type 6518 EEx i and 6519 EEx i Media Lubricated or non-lubricated compressed air,
valves consist of an intrinsically-safe pilot control and a instrument air, nitrogen
pneumatic amplifier. The diaphragm-controlled valve seats Environmental conditions Open air, chemical atmosphere
work with very low friction, ensuring reliable switching of
For use in zone 1, 2, 21 and 22
the valve, even after long shutdown periods.
1)
Response times
1)
Opening 75 [ms]
Closing 115 [ms] Closing: Pressure drop 100 to 10%
Note Electrical data - Coil AC10 EEx i

These units may only be used in explosive atmospheres in Approval II 2G EEx ia IIC T6 PTB 01 ATEX 2101
the manner approved by the Federal Institute of Physics and II 2D Ex ia D21 T 80°C
Technology (PTB), i.e., the permissible maximum electrical Functional values for the
values must be complied with. Suitable barriers and isolating valve switching function1) at +20°C at +55°C
modules are available for this. Minimum switching current 29 mA 29 mA
Nominal resistance of the coil 310 Ω 360 Ω
Barrier/
Minimum terminal voltage 9.0 V 10.4 V
PLC isolating
component Permissible maximum
values acc. to certificate
The valve is intended for operation on 24 VDC outputs via the of conformity
intermediate switching of a corresponding intrinsically-safe Ui 35 V
operating resource (isolating module or barrier). Ii 0.9 A
If required, request the “Recommended Barrier and Isolating Pi 1.1 W
1)
Module” data sheet. With high-impedance coil on request
Ordering chart valves without manual override (with manual override and high-impedance coil on request)
connection
QNn value
pilot valve
Weight [g]
threaded
Pressure
function
material
material
material
Item no.
Pilot air
range 2)
Orifice
Circuit
[l/min]
thread
insert
Body
[mm]
body
[bar]
Seal
air 1)
Port
port
Type 6518 EEx i without cable plug (see accessories page10)

C 2 St. st. 145 111
NBR St. st.
12 10 brass, nickel
and 1.4305 144 486
1 3 8.0 G 1/4 1300 2-8 580 plated
PUR
3/2-way valve, servo-assisted, in de- (polyamide) brass, nickel
brass 147 253
energized position port 2 exhausted plated
Type 6519 EEx i without cable plug (see accessories page10)
H 4 2
St. st. 144 484
12 NBR St. st.
5 3 and 1.4305 brass, nickel
1 8.0 G 1/4 1300 2-8 670 144 485
5/2-way valve, servo-assisted, PUR plated
in de-energized position port 2 (polyamide) brass, nickel
pressurized, port 4 exhausted brass 147 252
plated
Accessories see page 10 Dimensions see page 14
p. 4/16
6518/6519
Type 6519 NAMUR standard (with tag connector acc. to DIN EN 175301-803 Form A, without cable plug)
Technical data
Orifice DN 6.0
Body materials
Pilot valve and main valve Polyamide (PA)
Thread insert material Brass, nickel-plated or stainless steel
Seal material NBR and PUR
Service ports 2 and 4 NAMUR flange
Type 6519
NAMUR standard
Operating voltage 24/110/230 V/UC (direct or universal current)
Duty cycle 100 % continuous rating
The valve bodies of Type 6519 NAMUR are identical
with the EEx m variants. The difference is in the coils, Ambient temperature -25 to +55°C
which are laid out and approved in different ways. By Media Compressed air, nitrogen, instrument air
changing the coil on the valve body, it is possible to Environmental conditions Slightly aggressive, also open air
easily convert from Non-Ex operation to Ex operation
(or vice versa). The coils are designed to be push-over Power consumption Response times 1)
and can be locked in 4 x 90° displaced positions and Opening 20 [ms]

be positioned any where in-between. Inrush Hold (hot coil)
Closing 40 [ms]
AC [VA] AC [VA/W] DC [W] 1)
11 6/2 2
Closing: Pressure drop 100 to 10%
without cable plug (see accessories page10)
consumption
connection
Weight [g]
1)
frequency
QNn value
threaded
Pressure
Voltage/
function
material
material
Item no.
Thread
range3)
Orifice
Circuit
[l/min]
Power
[V/Hz]
insert
[mm]
body
[bar]
Seal
air 2)
Port
port
[W]
C 42 024/DC 131 425

12
315
NBR 024/50-60 131 426
3/2-way valve with exhaust recycling, and stainless 110/50-60 131 427
6.0 G 1/4 900 2-8 460 2
in de-energized position port 2 fed PUR steel
back internally
230/50-60 131 428
or
42 024/DC 131 421

H
12 NBR 024/50-60 131 422
513 brass,
and
6.0 nickel- G 1/4 900 2-8 460 2 110/50-60 131 423
PUR
5/2-way valve, servo-assisted, in de- plated
energized position pressure port 1 con- 230/50-60 131 424
nected to port 2, output 4 exhausted
1) If the connectors are from stainless steel, the mounting screws will also be from stainless steel
All valves can be operated in circuit function C as well as in circuit function H. By replacing the adapter
plate that comes with the valves, the change between the two circuit functions can be set up.
p. 5/16
6518/6519
Type 6519 NAMUR EEx m (with moulded cable) or EEx me (with terminal box)
Technical data
Orifice DN 6.0
Body materials
Pilot valve and main valve Polyamide (PA)
Thread insert material Brass, nickel-plated or stainless steel
Seal material NBR and PUR
Service ports 2 and 4 NAMUR flange
Type 6519 NAMUR EEx m Protection class IP65 with cable plug
Approval II 2G EEx m II T 5 PTB 00 ATEX 2129X
II 2DIP 65T 100°C
Type 6519 NAMUR EEx m NAMUR valve for process plants
Operating voltage 24/110/230 V/UC (direct or universal current)
switches reliably, even when fully restricted. The valve made
out of premium polyamide can be operated either as a 5/2 Voltage tolerance ±10%
or a 3/2-way version through different mounting plates. The Duty cycle 100% continuous rating
solenoid valve Type 6014 with a coil approved for use in Ambient temperature -25 to +55°C
hazardous areas is connected as a pilot. The NAMUR flange
Media Lubricated or non-lubricated compressed air, nitrogen,
interface allows easy assembly on different pneumatic ac-
instrument air
tuators on the spot.
Environmental Slightly aggressive, also open air
The valve bodies are identical with the Type 6519 NAMUR conditions
standard version. The difference between the valves is in
1)
the coils, which are laid out and approved in different ways. Response times
By changing the coil on the valve body, it is possible to eas- Opening 20 [ms]
ily convert from Non-Ex operation to Ex operation (or vice Closing 40 [ms]
versa). Both coil versions (with moulded cable or with ter- 1)
minal box) are designed to be push-over and can be locked
in 4 x 90° displaced positions and be positioned any where Closing: Pressure drop 100 to 10%
in-between.
Thread insert
consumption
range 3) [bar]
Orifice [mm]
connection
QNn value
Weight [g]
material 1)
frequency
threaded
Pressure
Voltage/
function
material
Item no.
Circuit
[l/min]
Power
[V/Hz]
body
Seal
air 2)
Port
port
[W]
Version acc. to EEx m, with 3 m long moulded cable

42
C 024/UC 131 631
12 stainless
315 G 1/4 900 2-8 650 3 110/UC 131 632
steel
NBR 230/UC 131 633
3/2-way valve, with exhaust air 6.0 and
024/UC 131 627
return, in de-energized position PUR brass,
port 2 exhausted internally nickel- G 1/4 900 2-8 650 3 110/UC 131 628
plated
or 230/UC 131 629
Version acc. to EEx me, with terminal box without fuse (see Accessories p. 10)
H
42 024/UC 139 067
12 stainless
G 1/4 900 2-8 690 3 110/UC 139 068
513 steel
NBR 230/UC 139 069
5/2-way valve, servo-assisted, 6.0 and
in de-energized position pressure PUR 024/UC 427 978
brass,
port 1 connected to port 2, port 4
nickel- G 1/4 900 2-8 690 3 110/UC 139 065
exhausted
plated
230/UC 139 066
1) If the connectors are from stainless steel, the mounting screws will also be from stainless steel
3) Pressure values [bar]: Gauge pressures with respect to the prevailing atmospheric pressure.
All valves can be operated in circuit function C as well as in circuit function H. By replacing the adapter plate that comes with the valves, the change between the
two circuit functions can be set up.
p. 6/16
6518/6519
Type 6519 NAMUR EEx i (with tag connector acc. to DIN EN 175301-803 Form A, without cable plug)
Technical data
Orifice DN 6.0
Body materials
Pilot valve Stainless steel 1.4305 or brass
Main valve Polyamide, glass-fibre reinforced
Thread insert material Stainless steel or brass, nickel-plated
Seal materials FPM, NBR and PUR
Service ports 2 and 4 NAMUR flange acc. to VDI/VDE 3845
Type 6519 (previously DIN 43650) for cable plug Type 2508 (see
NAMUR EEx ia
Accessories). Ensure correct polarity!
The Type 6519 NAMUR EEx i valve is used for the pneu- Media Lubricated or non-lubricated compressed air,
matic control of double or single-acting actuators with a instrument air, nitrogen
NAMUR adapter plate flange. The circuit function can easily
Environmental conditions Open air, chemical atmosphere
be changed using an adapter plate. In the 3/2-way function,
feedback of the exhaust air takes place in the spring area 1)
1)
Response times [ms]
of the armature drive. The diaphragm-controlled valve seats Opening: Pressure rise 0 to 90%,
work with very low friction, ensuring reliable switching of the Opening 75 Closing: Pressure drop 100 to 10%
valve even after long shutdown periods and at ambient tem- Closing 115
peratures below 0 °C. The valves work without a continuous
air consumption. Electrical data
Approval II 2G EEx ia IIC T6 PTB 01 ATEX 2101
Note
II 2D Ex ia D21 T 80°C
The units may only be used in explosive atmospheres in the
manner approved by the Federal Institute of Physics and Functional values for valve
Technology (PTB), i.e., the permissible maximum electrical switching function 1) at +20°C at +55°C
values must be complied with. Suitable barriers and isolat- Minimum switching current 29 mA 29 mA
ing modules are available for this. Nominal resistance of the coil 310 Ω 360 Ω
Barrier/ Minimum terminal voltage 9.0 V 10.4 V
PLC isolating Permissible maximum
component
values acc. to certificate
of conformity
The valve is intended for operation on 24 VDC outputs via Ui 35 V
the intermediate switching of a corresponding intrinsically- Ii 0.9 A
safe operating resource (isolating module or barrier). Pi 1.1 W
If required, request the “Recommended Barrier and Isolating 1)
With high-impedance coil on request
Module” data sheet.
Ordering chart valves without manual override (with manual override and high-impedance coil on request)
without cable plug (see accessories page10)
connection
air1) [l/min]
for control
pilot valve
Weight [g]
QNn value
threaded
Pressure
Material
function
material
material
Item no.
air bush
range2)
Orifice
Circuit
Body
[mm]
body
[bar]
Seal
Port
port
42
C
12 St. st. 144 482
315 St. st.
1.4305
3/2-way valve, with exhaust air return, in de- brass,
NBR 144 483
energized position port 2 exhausted internally nickel-plated
and
or 42
6.0 G 1/4 900 2-8 670
PUR
H (polyamide)
12
513 brass,
brass 147 244
5/2-way valve, servo-assisted, in de-ener- nickel-plated
gized position pressure port 1 connected to
port 2, port 4 exhausted
2) Pressure values [bar]: Gauge pressures with respect to the prevailing atmospheric pressure.
All valves can be operated in circuit function C as well as in circuit function H. By replacing the adapter plate that comes with the valves, the change
between the two circuit functions can be set up. All valves have mounting plates and tag connectors acc. to DIN EN 175301-803 Form A
(previously DIN 43650) and are supplied without cable plug (see Accessories p. 10)

p. 7/16
6518/6519
Pneumatic modules Type MP07
Single modules or pre-mounted blocks are available.
Example of a complete valve block
Connector module,
Pneumatic basic Pneumatic intermediate supply module: supply channel pushed
left
module, 3 valves through for additional pressure supply
or
Connector module, right: supply channel closed off, thereby several
operational pressures possible in a single block
Pneumatic
basic module,
2 valves
Connector module,
right
Supply ports
3(R)
1(P)
Covering plate for 3/2- 5(S)

way valves (to cover up
unused ports)
Note when ordering complete valve blocks:

Please list the modules in the block assembly from right to left, as shown in the ordering example.
Valves with NAMUR Flange. Ex i coil or Ex versions with terminal boxes are not suitable for block mounting.
Ordering example for Type 6518 with Type MP07

Item no.
Unit
No.
1 Connector module right, G1/2 635 331

1 Pneumatic basic module, 2 valves 635 319
1 Pneumatic basic module, 3 valves 635 343
1 Connector module left, G1/2 635 324
5 Valves 132 457
Ordering chart for Type MP07 pneumatic modules

Item no.
Version
Connector module right G1/2 635 331

Intermediate supply module 637 505
Pneumatic basic module, 2 valves universal (for 3/2-, 5/2- and 5/3-way) 635 319
Pneumatic basic module, 3 valves universal (for 3/2-, 5/2- and 5/3-way) 635 343
Connector module left G1/2 635 324
Covering plate for 5/2- and 5/3-way (to cover unused valve positions) 635 335
Covering plate for 3/2-way (to cover unused connections) 635 337
p. 8/16
6518/6519
Type MP07 pneumatic modules, continued
Dimensions Type MP07 pneumatic modules [mm]

Manifold assembly either wall-mounted or standard mounting DIN rail 50022 or 50023
101.5
59 + (n x 33) 65
5/3, 5/3 - Impulse

55 5/2
42
ø 5.5
35
15
3 3
182
1 1
102.5
115
124.8
120
249
108
24
58
100
92
82
57.5
48
5 5
G 1/2
G 1/8 6
10
33 NPT 1/2
NPT 1/8 8
G 1/4 55
NPT 1/4
46
n x 33 52
87 + (n x 33) 90
110 + (n x 33)
n=no. of valves, maximal 12
Valve assembly on pneumatic modules Type MP05 using the supplied M4 screws
p. 9/16
6518/6519
Accessories
Cable plug Type 2508 acc. to DIN EN 175301-803 Form A Fixing screw
The delivery of a cable plug includes the flat seal and the fixing screw. For other cable plug
versions acc. to DIN EN 175301-803 Form A (previously DIN 43650) with
integrated circuitry, see datasheet Type 2508. Flat seal
Dimensions Type 2508 [mm]
18 46
27,5
18
18
1,5
M3
28
Ordering chart cable plug Type 2508
Circuitry Voltage Item no.
For standard version 6518/19

Fixing screw in steel (galvanised and chrome-plated)
without circuitry 0 - 250 V 008 376
with LED 12 - 24 V 008 360
with LED and varistor 12 - 24 V 008 367
with LED and varistor 200 - 240 V 008 369
For EEx i version 6519
Fixing screw in stainless steel 1.4404 and blue compression gland nut
without circuitry 0 - 250 V 438 574
for further versions see datasheet 2508
Ordering chart further Accessories
Accessory Feature Item no.

Cap nut
Cap nut in stainless steel for
additional protection of the exhaust air 649 554
channel from the penetration of damp
Blanking plug G 1/8 780 141

G 1/4 780 142
G 1/2 780 144
Silencer G 1/8 005 305
G 1/4 005 064
G 1/2 005 062
Labelling plate 64 pieces 635 416
Semi-delay fuse for 6519 NAMUR EEx m
Voltage [V] Max. current [mA] Item no.
24 V 315 mA 153 733

110 V 50 mA 153 716
230 V 32 mA 153 715
p. 10/16
6518/6519
Dimensions [mm]
Standard versions
Type 6518
3/2-way valve, circuit function C and D
45
Manual
G 1/8 SW 14
override
12
11
10
138.5
G1/4 / NPT 1/4

G1/4 / NPT1/4
112.5
8 - 4.3 deep
ø4.3
8 - 4.3 deep
69.5
76
12
28.5
Ø 4.3
25.5
25.5
13.5
8
3 24
24 43
32 53
Type 6519
5/2-way valve, circuit function H
G 1/8 SW 14 Manual
override
12
11
57.4
10
G1/4 / NPT1/4
8 - 4.3 deep
175.7 *
G1/4 / NPT1/4
Ø 4.3
8 - 4.3 deep
150
28.5
114
107.5
36
Ø 4.3
48
24
3 - 3 tief
26.5
39.5
24
3
24 43
32 53
* Mounting length with 2 magnetic coils 249 mm
p. 11/16
6518/6519
Dimensions [mm]
Standard versions
Type 6519
5/3-way valve, circuit function L and N
G 1/8 45
12
11
11
10
G1/4 / NPT1/4
G1/4 / NPT1/4
Ø 4.3
124.8
28.5
249
196.4
36
112
48
24
26.5
44
11 - 3 tief
11 - 3 tief
Ø 4.5
24
26 G1/8
32
p. 12/16
6518/6519
Dimensions [mm]
EEx m/me versions
Type 6518
3/2-way valve, circuit function C and D
with moulded cable, 3 m long (EEx m) with terminal box (EEx me)
60 82
Version without cable plug

G 1/8 45 29.8
45
61
A (T5 = 32 mm)
(T6 = 40 mm)
11
119
78
188.5
G 1/4 / NPT 1/4
G 1/4 / NPT 1/4

138.5
ø 4.3
ø 4.3
12
12
ø 4.3
ø 4.3
25.5
25.5
25.5
25.5
24 43 24 13.5 43
13.5
32 53 32 53
Type 6519
5/2-way valve, circuit function H, L and N
60 82
Version without cable plug

45 29.8
61
G 1/8 45
A (T5 = 32 mm)
(T6 = 40 mm)
119
11
78
G 1/4 / NPT 1/4
G 1/4 / NPT 1/4
225.7
175.7
ø 4.3
ø 4.3
36
36
ø 4.3
ø 4.3
24
24
51.3
51.3
43 43
39.5
39.5
24 53 24 53
32 32
p. 13/16
6518/6519
Dimensions [mm]
EEx i versions
Type 6518
3/2-way valve, circuit function C
G 1/8 29 51
11
40
G 1/4 / NPT 1/4
136
107.5
12
ø 4.3
25.5
25.5
13.5
ø 4.3 24 43
32
53
Type 6519
5/2-way valve, circuit function H
G 1/8 29 51
11
40
G 1/4 / NPT 1/4
8 - 4.3 deep
173.5
14
2
ø 4.3
107.5
36
24
4
ø 4.3
39.5
24 43
32
53
p. 14/16
6518/6519
Dimensions [mm]
NAMUR standard version
Type 6519
3/2-way valve, circuit function C or 5/2-way valve, circuit function H
NAMUR EEx m/me versions
Type 6519
C
37.3 60
Pg 13.5
G 1/8
61
29.8 D G 1/8
E
119
D
11.2
11.2
78
C
G 1/4 / NPT 1/4
G 1/4 / NPT 1/4

B
B
A
A
3 3
3/2 3/2
24
24
48
1
48
1
5/2 5/2
51.5
51.5
51.5
51.5
5 5
32 4 4 32
37 32 32 37
53 53
A B C D E A B C D
T5 coil 164.5 57.5 41.0 45.0 32 T5 coil 164.5 57.5 82 32
T6 coil 164.9 57.9 41.4 51.0 40 T6 coil 164.9 57.9 88 40
p. 15/16
6518/6519
Dimensions [mm]
NAMUR EEx i version
Type 6519
G 1/8 29 51
11
G 1/4 / NPT 1/4
40
173.5
3
2
1
48
24
5
51.5
51.5
32
53
37
To find your nearest Bürkert facility, click on the orange box www.burkert.com
In case of special application conditions, We reserve the right to make technical changes without notice.
please consult for advice. © Christian Bürkert GmbH & Co. KG 1307/4_EU-en_00891764
p. 16/16
Operating Instructions Type 6519
o 4V
r 2(example):
2 V
ge 1 Body with ly
Design: Marking
3- and 5-way solenoid valve, internally piloted
Vo l t a a lid Material
v n
UR AL up=ply oAluminium
PA = Polyamide
L /
U rs
Seal Materials and Fluids handled:
See Table 1.
2 p owe Seal Material
s
Fluid and Ambient Temperature: clas PB = NBR and PUR
For Hazardous Locations Div. 1 (T4 rated) NBR = NBR
Max. Ambient Temperature 104 °F (40 °C)
Max. Fluid Temperature 140 °F (60 °C) Circuit function
C = 3-way, Normally Closed
For Hazardous Locations Div. 1 (T6 rated) D = 3-way, Normally Open
Max. Ambient Temperature 104 °F (40 °C) H = 5-way
Max. Fluid Temperature 140 °F (60 °C) L = 5-way
N = 5-way
For Intrinsically Safe Apparatus for use in Class I, II and III,
Division 1 Hazardous Locations.
Max. Ambient Temperature 140 °F (60 °C)
Max. Fluid Temperature 140 °F (60 °C)
For Hazardous Locations Div. 2 and Ordinary Locations:

See Table 1.
Pressure Range:
Maximum inlet pressure see label on valve.
Installation: Item No.

Before installing valve ensure that piping etc. is free of foreign
matter (metal shavings, pipe sealing materials, welding scale Voltage / Frequency / Power Consumption
etc.). Installation as required but preferable with coil uppermost.
Installation in this position tends to prevent foreign matter Maximum Pressure
remaining in core tube (increased life). Do not put any loads on
coil unit. Approvals
The valve is either approved as
PTFE tape is recommended for sealing ports. Mounting is General Purpose valve for Hazardous Locations
accomplished by means of four M4 x 8 mm tapped holes Class I, Division 1, Group A, B, C, D
located on the valve underside. Letters on valve body indicate Class II, Division 1, Group E, F, G
pressure port, exhaust and outlet of the valve. Class III, Division 1 and 2
Operating Temperature T 4
or
General Purpose valve for Hazardous Locations
Class I, Division 1, Group A, B, C, D
Class II, Division 1, Group E, F, G
Class III, Division 1 and 2
or
Intrinsically Safe Apparatus for Hazardous Locations
Class II, Division 1, Group E, F, G
or
FM approved as
Operating Instructions 0605/09_EN-EN_00894148
Nonincendive for Hazardous Locations

Class II, Division 2, Group F, G
UL listed for General Purpose
CSA approved for General Purpose
See label on the valve.
Table 1 Seal Materials

Fluid Temperatures [°F] PB Buna “N”
NBR
Air Fluid Temp. - 10 to +140 - 10 to +140
Ambient - 10 to +140 - 10 to +140
Operating Instructions
Wiring Diagram For this product to be considered UL-listed and CSA approved
for General Purpose and FM approved for Hazardous Locations
Division 2, it must be in conjunction with the type 2509 cable plug
Electrical Connection Type 2509 connector (Electrically Operated Valves Parts, YSYI2).
The connector and gasket must be assembled to the valve with the
screw provided after the connection of the wire leads. This valve
and connector assembly is delivered together and is to be used as
one unit.
For valves to be used in Intrinsically Safe Applications the positive

pole is identified by a “+” on the pin or wire No. 1 has to be con-
nected to the “+”.
See Control Drawing for the Rules of Interconnection.
Power*
Warning:
Ground (green dot) All valves to be used in Intrinsically Safe Applications must be
clearly marked as Intrinsically Safe Apparatus.
Trouble-Shooting:
Check port connections, minimum operating pressure differential
Power* if required and supply voltage. Ensure pilot hole in piston is clear
and pilot bore in the valve outlet is not abstracted. If core does not
pull in, check for short circuit, coil burn-out or foreign matter im-
peding core movement. A jammed or missing core causes the coil
* Orientation is not important to overheat in the case of AC supply.
Warning:
These products are designed to operate in a wide variety of ap-
Electrical Connection: plications, it is the user’s responsibility to select a model that is
Ensure supply voltage/frequency corresponds with that on label. appropriate for the application. This product is designed to be
Voltage tolerance is ± 10 %. installed only by suitably qualified and trained personnel.
Available Electrical Connections see “Marking”. Specifications should not be exceeded under any circumstances.
Wiring diagram see above.
The torque for the terminal screw on type 2509 is 0,5 Nm
(4,4 lbf-in.).
Changes made to this product will render any applicable warranty

null and avoid.
Specifications subject to change without notice.
Any questions? Please call Bürkert Contromatic Technical Service

at (949) 223 31 00.
Germany
Contact address:
Bürkert Fluid Control Systems
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
International
Contact addresses can be found on the Internet at:
www.burkert.com Bürkert Company Locations

ATTUATORI EUROPE
PNEUMATIC ACTUATORS AND ACCESSORIES
Pneumatische Stellantriebe,
Typen GTK, GTW, GTX
pneumatic actuators
type GTK, GTW, GTX
CE, ATEX, GOST, SIL3

ATTUATORI EUROPE
Technische Daten / technical data

Bauform Design
Pneumatisch betätigter Doppelkolben-Schwenkantrieb in doppelt- und Single or double acting pneumatic twin piston actuator (rack and pinion).
einfachwirkender (federrückstellender) Ausführung.
Schwenkwinkel Standard angles

90°, 120°, 180° und 240°. Weitere Sonderschwenkwinkel sowie Rotation 90°, 120°, 180° and 240°. Customized angles available as well as
3-Positions-Antriebe lieferbar. three position versions.
Einstellbereich Stroke adjustment

Typ GTW: 0°-Position von -25° bis +5°, 90°-Position von -5° bis +5° Type GTW: 0°-Position from -25° to +5°, 90°-Position from -5° to +5°
Typ GTK, GTX: 90°-Position von -5° bis +5° Type GTK, GTX: 90°-Position from -5° to +5°
Drehmomente Torques
5 bis 8000 Nm 5 to 8000 Nm
Steuerdruck Air pressure

2 bis 10 bar 2 to 10 bar
Steuermedium Supply
2 Gefilterte Luft nach PNEUROP/ISO Klasse 4, weitere Medien auf Anfrage. Filtered air PNEUROP/ISO class 4, other fluids on request.
Werkstoffe Materials
Gehäuse: Aluminium eloxiert ASTM 6083, UNI 4522, weitere auf Anfrage Body: Anodized aluminium ASTM 6063, UNI 10681, additional versions on request
Deckel: Aluminium UNI 5076, epoxysharz-beschichtet End caps: Aluminium UNI EN1706, EN AC-46100, epoxy coated.
Kolben: Aluminium UNI 5076 Pistons: Aluminium UNI 5076
Ritzel: Hartvernickelter Stahl AISI SAE 11L37 - ASTM B 656 oder Edelstahl. Pinion: Nickel plated steel AISI SAE 11L37 - ASTM B 656, stainless steel optional
Lagerung: Gleitfreudiger Kunststoff Bearing pad: Technopolymer
Dichtungen: NBR, alternativ Viton oder Silikon. Seals: NBR, alternativ Viton or Silicone
Temperaturbereich Temperature range

Standardversion: Von -50°C bis +70°C (NBR) Standard: From -50°C to +70°C (NBR)
Sonderversionen: Von -15°C bis + 160°C (Viton) oder -30° bis +200° (Silikon) Special versions: From -15°C to + 160°C (Viton) or -30° to +200° (Silicone)
Mechanische Schnittstellen Mechanical interface

ISO 5211, NAMUR VDI/VDE 3845 ISO 5211, NAMUR VDI/VDE 3845
D R E HMOMENT [Nm] - D O P P E LT W I R K E N D E S T E L L A N T R I EBE / TOR QUE [Nm] - DOUBLE ACTING ACTUATORS

Grösse Pneumatisches Drehmoment [Nm] / Pneumatic torque [Nm]
size 2 bar 2,5 bar 3 bar 3,5 bar 4 bar 4,5 bar 5 bar 5,6 bar 6 bar 6,5 bar 7 bar 8 bar 9 bar 10 bar
43, 44 4,7 5,8 7,0 8,2 9,4 10,5 11,7 13,1 14,0 15,2 16,4 18,7 21,0 23,4
52 7,8 9,7 11,7 13,6 15,6 17,5 19,5 21,8 23,4 25,3 27,3 31,2 35,1 39,0
63 11,6 14,5 17,4 20,3 23,2 26,1 29,0 32,5 34,8 37,7 40,6 46,4 52,2 58,0
75 20,0 25,0 30,0 35,0 40,0 45,0 50,0 56,0 60,0 65,0 70,0 80,0 90,0 100,0
83 29,0 36,2 43,5 50,7 58,0 65,2 72,5 81,2 87,0 94,2 101,5 116,0 130,5 145,0
92 40,0 50,0 60,0 70,0 80,0 90,0 100,0 112,0 120,0 130,0 140,0 160,0 180,0 200,0
110 58,0 72,5 87,0 101,5 116,0 130,5 145,0 162,4 174,0 188,5 203,0 232,0 261,0 290,0
118 86,0 107,5 129,0 150,5 172,0 193,5 215,0 240,8 258,0 279,5 301,0 344,0 387,0 430,0
127 116,0 145,0 174,0 203,0 232,0 261,0 290,0 324,8 348,0 377,0 406,0 464,0 522,0 580,0
143 186,0 232,5 279,0 325,5 372,0 418,5 465,0 520,8 558,0 604,5 651,0 744,0 837,0 930,0
160 230,0 287,5 345,0 402,5 460,0 517,5 575,0 644,0 690,0 747,5 805,0 920,0 1035 1150
190 400,0 500,0 600,0 700,0 800,0 900,0 1000 1120 1200 1300 1400 1600 1800 2000
210 480,0 600,0 720,0 840,0 959,9 1080 1200 1344 1440 1560 1680 1920 2160 2400
254 920,0 1150 1380 1610 1840 2070 2300 2576 2760 2990 3220 3680 4140 4600
255 1160 1450 1740 2030 2320 2610 2900 3248 3480 3770 4060 4640 5220 5800
300, 300-F25 1600 2000 2400 2800 3200 3600 4000 4480 4800 5200 5600 6400 7200 8000
Pneumatischer Antrieb GT-Serie
Pneumatic actuator GT-series
DREHMOMENT [N m ] - E I N FAC H W I R K E N D E S T E L L A N T R I E B E / TOR QUE [Nm] - SINGLE ACTING ACTUATORS

Federmoment Pneumatisches Drehmoment
Springs
Federn
Spring torque Pneumatic torque 80 PSIG 100 PSIG

2 bar 3 bar 4 bar 5 bar 5,6 bar 6 bar 7 bar 8 bar 9 bar 10 bar
0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90°
2 1,68 2,53 2,97 2,09 5,31 4,43 7,64 6,77 9,98 9,11 11,39 10,51 12,32 11,45 14,66 13,79 17,00 16,12 19,34 18,46 21,68 20,80
43, 44
4 3,36 5,07 3,59 1,85 5,93 4,18 8,27 6,52 9,68 7,93 10,61 8,86 12,95 11,20 15,29 13,54 17,63 15,88 19,97 18,22
6 5,03 7,60 4,22 1,60 6,56 3,94 7,96 5,34 8,90 6,28 11,24 8,61 13,58 10,95 15,92 13,29 18,26 15,63
8 6,71 10,14 4,85 1,35 6,25 2,75 7,19 3,69 9,53 6,03 11,87 8,37 14,21 10,71 16,54 13,05
2 1,91 3,19 5,84 4,54 9,74 8,44 13,64 12,34 17,54 16,23 19,87 18,57 21,43 20,13 25,33 24,03 29,23 27,92 33,12 31,82 37,02 35,72
4 3,82 6,37 3,90 1,29 7,79 5,19 11,69 9,09 15,59 12,98 17,92 15,32 19,48 16,88 23,38 20,78 28,28 24,67 31,17 28,57 35,07 32,47
6 5,73 9,56 5,84 1,94 9,74 5,83 13,64 9,73 15,98 12,07 17,53 13,63 21,43 17,52 25,33 21,42 29,23 25,32 33,12 29,22
52
8 7,64 12,75 7,79 2,58 11,69 6,48 14,03 8,82 15,59 10,38 19,48 14,27 23,38 18,17 27,28 22,07 31,17 25,96
10 9,55 15,94 9,74 3,23 12,08 5,57 13,64 7,13 17,53 11,02 21,43 14,92 25,33 18,82 29,22 22,71
12 11,46 19,12 10,13 2,32 11,69 3,88 15,59 7,77 19,48 11,67 23,38 15,57 27,28 19,46
2 3,01 4,42 8,54 7,09 14,34 12,89 20,14 18,69 25,94 24,50 29,42 27,98 31,74 30,30 37,54 36,10 43,34 41,90 49,14 47,70 54,94 53,50
4 6,01 8,84 5,47 2,58 11,27 8,38 17,07 14,18 22,87 19,99 26,35 23,47 28,67 25,79 34,47 31,59 40,27 37,39 46,08 43,19 51,88 48,99
6 9,02 13,26 8,20 3,87 14,00 9,68 19,81 15,48 23,29 18,96 25,61 21,28 31,41 27,08 37,21 32,88 43,01 38,68 48,81 44,48
63
8 12,03 17,68 10,94 5,17 16,74 10,97 20,22 14,45 22,54 16,77 28,34 22,57 34,14 28,37 39,94 34,17 45,74 39,97
10 15,03 22,11 13,67 6,46 17,15 9,94 19,47 12,26 25,27 18,06 31,08 23,86 36,88 29,66 42,68 35,46
12 18,04 26,53 14,09 5,43 16,41 7,75 22,21 13,55 28,01 19,35 33,81 25,15 39,61 30,95
2 5,24 7,96 14,65 11,87 24,65 21,87 34,65 31,87 44,65 41,87 50,65 47,87 54,64 51,87 64,64 61,86 74,64 71,86 84,64 81,86 94,64 91,86
4 10,48 15,93 9,31 3,75 19,31 13,75 29,31 23,75 39,30 33,75 45,30 39,74 49,30 43,74 59,30 53,74 69,30 63,74 79,30 73,74 89,29 83,74
6 15,71 23,89 13,96 5,63 23,96 15,63 33,96 25,62 39,96 31,62 43,96 35,62 53,96 45,62 63,95 55,62 73,95 65,62 83,95 75,61
75
8 20,95 31,85 18,62 7,50 28,62 17,50 34,62 23,50 38,62 27,50 48,61 37,50 58,61 47,50 68,61 57,49 78,61 67,49
10 26,19 39,81 23,27 9,38 29,27 15,38 33,27 19,38 43,27 29,38 53,27 39,37 63,27 49,37 73,26 59,37
12 31,43 47,78 17,93 1,26 23,93 7,26 27,93 11,26 37,93 21,25 47,93 31,25 57,92 41,25 67,92 51,25
2 7,23 11,19 21,62 17,58 36,12 32,07 50,62 46,57 65,11 61,07 73,81 69,77 79,61 75,56 94,11 90,06 108,6 104,6 123,1 119,1 137,6 133,6
4 14,46 22,39 14,25 6,16 28,75 20,65 43,24 35,15 57,74 49,65 66,44 58,35 72,24 64,15 86,73 78,64 101,2 93,14 115,7 107,6 130,2 122,1
83
6 21,68 33,58 21,37 9,24 35,87 23,73 50,37 38,23 59,07 46,93 64,86 52,73 79,36 67,23 93,86 81,72 108,4 96,22 122,9 110,7
8 28,91 44,78 28,50 12,31 42,99 26,81 51,69 35,51 57,49 41,31 71,99 55,81 86,49 70,30 101,0 84,80 115,5 99,30
10 36,14 55,97 35,62 15,39 44,32 24,09 50,12 29,89 64,62 44,39 79,11 58,89 93,61 73,36 108,1 87,88
12 43,37 67,17 28,25 3,98 36,95 12,67 42,75 18,47 57,24 32,97 71,74 47,47 86,24 61,96 100,7 76,46
2 9,10 14,34 30,72 25,37 50,73 45,38 70,73 65,38 90,73 85,38 102,7 97,39 110,7 105,4 130,7 125,4 150,7 145,4 170,7 165,4 190,7 185,4
4 18,20 28,69 21,44 10,74 41,44 30,75 61,45 50,75 81,45 70,75 93,45 82,75 101,5 90,76 121,5 110,8 141,5 130,8 161,5 150,8 181,5 170,8
6 27,31 43,03 32,16 16,12 52,16 36,12 72,16 56,12 84,17 68,12 92,17 76,12 112,2 96,13 132,2 116,1 152,2 136,1 172,2 156,1
92
8 36,41 57,38 42,88 21,49 62,88 41,49 74,88 53,49 82,88 61,49 102,9 81,50 122,9 101,5 142,9 121,5 162,9 141,5
10 45,51 71,72 33,59 6,86 53,60 26,86 65,60 38,86 73,60 46,86 93,60 66,86 113,6 86,87 133,6 106,9 153,6 126,9
12 54,61 86,07
4 31,61 47,42 25,8

44,31 12,23 56,31 24,23 64,32 32,23 84,32 52,23
2 15,81 23,71 41,9 33,8 70,9 62,8 99,9 91,8 128,9 120,8 146,3 138,2 157,9 149,8 186,9 178,8
9,6 54,8 38,6 83,8 67,6 112,8 96,6 130,2 114,1 141,8 125,7 170,8 154,7
104,3 72,24
215,9 207,8
199,8 183,7
124,3 92,24
244,9 236,8
228,8 212,7
144,3 112,2
273,9 265,8
257,8 241,7
3
110
6 47,42 71,13 38,6 14,5 67,6 43,5 96,6 72,5 114,1 89,9 125,7 101,5 154,7 130,5 183,7 159,5 212,7 188,5 241,7 217,5
8 63,22 94,84 51,5 19,3 80,5 48,3 97,9 65,7 109,5 77,3 138,5 106,3 167,5 135,3 196,5 164,3 225,5 193,3
10 79,03 118,5 64,4 24,1 81,8 41,5 93,4 53,1 122,4 82,1 151,4 111,1 180,4 140,1 209,4 169,1
12 94,84 142,3 65,7 17,3 77,3 28,9 106,3 57,9 135,3 86,9 164,3 115,9 193,3 144,9
2 21,25 36,46 64,3 48,8 107,3 91,8 150,3 134,8 193,3 177,8 219,1 203,6 236,3 220,8 279,3 263,8 322,3 306,8 365,3 349,8 408,3 392,8
4 42,50 72,92 42,7 11,6 85,7 54,6 128,7 97,6 171,7 140,6 197,5 166,4 214,7 183,6 257,7 226,6 300,7 269,6 343,7 312,6 386,7 355,6
118
6 63,75 109,4 64,0 17,4 107,0 60,4 150,0 103,4 175,8 129,2 193,0 146,4 236,0 189,4 279,0 232,4 322,0 275,4 365,0 318,4
8 84,99 145,8 85,3 23,3 128,3 66,3 154,1 92,1 171,3 109,3 214,3 152,3 257,3 195,3 300,3 238,3 343,3 281,3
10 106,2 182,3 106,6 29,1 132,4 54,9 149,6 72,1 192,6 115,1 235,6 158,1 278,6 201,1 321,6 244,1
12 127,5 218,7 110,8 17,7 128,0 34,9 171,0 77,9 214,0 120,9 257,0 163,9 300,0 206,9
2 29,94 48,78 85,5 66,2 143,5 124,2 201,5 182,2 259,5 240,2 294,2 275,0 317,4 298,2 375,4 356,2 433,4 414,2 491,4 472,2 549,4 530,2
4 59,88 97,57 54,9 16,5 112,9 74,5 170,9 132,5 228,9 190,5 263,7 225,3 286,9 248,5 344,9 306,5 402,9 364,5 460,9 422,5 518,9 480,5
127
6 89,82 146,3 82,4 24,7 140,4 82,7 198,4 140,7 233,2 175,5 256,4 198,7 314,4 256,7 372,4 314,7 430,4 372,7 488,4 430,7
8 119,8 195,1 109,8 33,0 167,8 91,0 202,6 125,8 225,8 149,0 283,8 206,9 341,8 264,9 399,8 322,9 457,8 380,9
10 149,7 243,9 137,3 41,2 172,1 76,0 195,3 99,2 253,3 157,2 311,3 215,2 369,3 273,2 427,3 331,2
12 179,6 292,7 141,6 26,2 164,8 49,4 222,8 107,4 280,8 165,4 338,8 223,4 396,8 281,4
2 48,1 68,9 137,0 115,7 230,0 208,7 323,0 301,7 416,0 394,7 471,8 450,5 509,0 487,7 602,0 580,7 695,0 673,7 788,0 766,7 881,0 859,8
4 96,1 137,8 87,9 45,5 181,0 138,5 274,0 231,5 367,0 324,5 422,8 380,3 460,0 417,5 553,0 510,5 646,0 603,5 739,0 696,5 832,0 789,5
143
6 144,2 206,7 131,9 68,2 224,9 161,2 317,9 254,2 373,7 310,0 410,9 347,2 503,9 440,2 596,9 533,2 689,9 626,2 782,9 719,2
8 192,3 275,6 175,9 90,9 268,9 183,9 324,7 239,7 361,9 276,9 454,9 369,9 547,9 462,9 640.9 555,9 733,9 648,9
10 240,3 344,4 126,9 20,7 219,9 113,7 275,7 169,5 312,9 206,7 405,9 299,7 498,9 392,7 591,9 485,7 684,9 578,7
12 288,4 413,3 170,8 43,4 226,6 99,2 263,8 136,4 356,8 229,4 449,8 322,4 542,9 415,4 635,9 508,4
2 55,9 83,0 172,4 144,5 287,4 259,5 402,5 374,5 517,5 489,5 586,5 558,5 632,5 604,5 747,5 719,5 862,5 834,5 977,5 949,5 1092 1065
4 111,8 166,0 114,9 59,0 229,9 174,0 344,9 289,0 459,9 404,0 528,9 473,0 574,9 519,0 689,9 634,1 804,9 749,1 919,9 864,1 1035 979,1
160
6 167,6 249,0 172,3 88,6 287,3 203,6 402,3 318,6 471,3 387,6 517,3 433,6 632,3 548,6 747,3 663,6 862,3 778,6 977,3 893,6
8 223,5 332,0 229,8 118,1 344,8 233,1 413,8 302,1 459,8 348,1 574,8 463,1 689,8 578,1 804,8 693,1 919,8 808,1
10 279,4 415,0 172,2 32,6 287,2 147,6 356,2 216,6 402,2 262,6 517,2 377,6 632,2 492,6 747,2 607,6 862,2 722,6
12 335,3 498,0 229,7 62,1 298,7 131,1 344,7 177,1 459,7 292,1 574,7 407,1 689,7 522,1 804,7 637,1
2 106,2 133,9 290,6 262,1 490,6 462,1 690,6 662,1 890,6 862,1 1011 982,1 1091 1062 1291 1262 1491 1462 1691 1662 1891 1862
4 212,5 267,8 181,2 124,2 381,2 324,2 581,2 524,2 781,2 724,2 901,2 844,2 981,2 924,2 1181 1124 1381 1324 1581 1524 1781 1724
190
6 318,7 401,7 271,8 186,3 471,8 386,3 671,8 586,3 791,8 706,3 871,8 786,3 1072 986,3 1272 1186 1472 1386 1672 1586
8 424,9 535,6 162,4 48,4 362,4 248,4 562,4 448,4 682,4 568,4 762,4 648,4 962,4 848,4 1162 1048 1362 1248 1562 1448
10 531,2 669,5 253,0 110,5 453,0 310,5 573,0 430,5 653,0 510,5 853,0 710,5 1053 910,5 1253 1111 1453 1311
12 637,4 803,4 343,5 172,6 463,6 292,6 543,6 372,6 743,6 572,6 943,6 772,6 1144 972,6 1344 1173
2 114,2 160,7 362,4 314,5 602,3 554,5 842,3 794,5 1082 1034 1226 1178 1322 1274 1562 1514 1802 1754 2042 1994 2282 2234
4 228,4 321,3 244,7 149,0 484,7 389,0 724,7 629,0 964,7 868,9 1109 1016 1205 1109 1445 1349 1685 1589 1925 1829 2165 2069
210
6 342,6 482,0 367,1 223,5 607,1 463,5 847,1 703,5 991,1 847,4 1097 943,4 1327 1183 1567 1423 1807 1663 2047 1903
8 456,8 642,7 249,5 58,0 489,5 298,0 729,4 538,0 873,4 682,0 969,4 777,9 1209 1018 1449 1258 1689 1498 1929 1738
10 571,0 803,4 371,8 132,5 611,8 372,5 755,8 516,5 851,8 612,5 1092 852,4 1332 1092 1572 1332 1812 1572
12 685,2 964,0 494,2 207,0 638,2 351,0 734,2 447,0 974,2 686,9 1214 926,9 1454 1167 1694 1407
2 238,1 321,3 674,8 589,1 1135 1049 1595 1509 2055 1969 2331 2245 2515 2429 2975 2889 3435 3349 3895 3809 4355 4269
4 476,3 642,7 429,5 258,1 889,6 718,2 1350 1178 1810 1638 2086 1914 2270 2098 2730 2558 3190 3018 3650 3478 4110 3938
254
6 714,4 964,0 644,3 387,2 1104 847,2 1564 1307 1840 1583 2024 1767 2484 2227 2945 2687 3405 3147 3865 3607
8 952,5 1285 859,1 516,2 1319 976 1595 1252 1779 1436 2239 1896 2699 2356 3159 2816 3619 3276
10 1191 1607 613,8 185,2 1074 645 1350 921,0 1534 1105 1994 1565 2454 2025 2914 2485 3374 2945
12 1429 1928 829,0 314 1105 590,0 1289 774,0 1749 1234 2209 1694 2669 2154 3129 2614
2 272,2 406,1 880 742 1460 1322 2040 1902 2620 2482 2968 2830 3200 3062 3780 3642 4360 4222 4940 4802 5520 5382
4 544,4 812,2 599 323 1179 903 1759 1484 2339 2064 2687 2412 2919 2644 3499 3224 4079 3804 4659 4384 5239 4964
6 816,6 1218 899 485 1479 1065 2059 1645 2407 1993 2639 2225 3219 2805 3799 3385 4379 3965 4959 4545
255
8 1089 1624 1199 647 1779 1227 2127 1575 2359 1807 2939 2387 3519 2967 4099 3547 4679 4127
10 1361 2031 918 229 1498 809 1846 1157 2078 1389 2658 1969 3238 2549 3818 3129 4398 3709
12 1633 2437 1218 390 1566 738 1798 970 2378 1550 2958 2130 3538 2710 4118 3290
2 272 406 1320 1182 2120 1982 2920 2782 3720 3582 4200 4062 4520 4382 5320 5182 6120 5982 6920 6782 7720 7582
300, 300-F25
4 544 812 1039 763 1839 1563 2639 2363 3439 3163 3919 3643 4239 3963 5039 4763 5839 5563 6639 6363 7439 7163
6 817 1218 759 345 1559 1145 2359 1945 3159 2745 3639 3225 3959 3545 4759 4345 5559 5145 6359 5945 7159 6745
8 1089 1624 1278 727 2078 1527 2878 2327 3358 2807 3678 3127 4479 3927 5279 4727 6079 5527 6879 6327
10 1361 2031 998 309 1798 1109 2598 1909 3078 2389 3398 2709 4198 3509 4998 4309 5798 5109 6598 5909
12 1633 2437 1518 690 2318 1490 2798 1970 3118 2290 3918 3090 4718 3890 5518 4690 6318 5490
14 1906 2843 1237 272 2037 1072 2517 1552 2837 1872 3637 2672 4437 3472 5237 4272 6037 5072
16 2178 3249 1757 654 2237 1134 2557 1454 3357 2254 4157 3054 4957 3854 5757 4654
ATTUATORI EUROPE
Grösse 43 bis 92 = 1/8“, Grösse 110 bis 300-F25 = 1/4“ NAMUR

M.5 x 8 (NAMUR) Ch. Size 43 to 92 = 1/8“, size 110 to 300-F25 = 1/4“ NAMUR
Montagevarianten / Assembling versions
(20)
30
8-kant 2-flach Ritzel Kolben Richtung Version
32
star double D Pinion Piston direction version
24
 A
H
"L"
Luftanschluss nach NAMUR  B
Air connection according NAMUR
 C
(S) Schnittstelle - Rückmeldung: Grösse 43 bis 127 = 30 x 80, Grösse 143 bis 300-F25 = 30 x 130 NAMUR

(S) Feedback interface: Size 43 to 127 = 30 x 80, size 143 to 300-F25 = 30 x 130 according NAMUR
D
M.5 x 8 (NAMUR) (S) ISO F ch.q
(S)
ch.q
B
Grösse Abmessungen [mm] Luftverbrauch [N.lt] Gewicht (2) [kg]

Size Dimensions [mm] Air consumption [N.lt] Weight (2) [kg]
L H B Ch Ch.q ISO F
90° 120° 180° 90° 120° 180° 90°(1) 90° 120° 180° 90°(1)
43 116 - - 65 61,5 10 11 F03/F05 0,18 - - 0,10 0,60 - - 0,66
44 116 - - 65 61,5 10 11 F04 0,18 - - 0,10 0,60 - - 0,66
52 133 151 195 74 68,5 10 14 F03/F05 0,25 0,28 0,46 0,13 0,90 1,10 1,30 1,00
63 137 155 200 88 80 10 14 F05/F07 0,40 0,45 0,74 0,21 1,45 1,70 2,00 1,62
75 161 183 237 100 92,5 10 17 F05/F07 0,60 0,68 1,12 0,32 2,10 2,46 2,90 2,45
83 180 205 268 100 92,5 10 17 F05/F07 0,88 1,00 1,63 0,45 2,50 2,95 3,50 2,95
92 209 239 310 117 110,5 14 17 F05/F07 1,20 1,35 2,25 0,62 3,40 4,00 4,60 4,00
110 221 251 322 140 120 14 22 F07/F10 1,90 2,15 3,52 0,98 5,20 6,10 7,20 6,20
118 291 341 421 140 120 20 22 F07/F10 2,70 3,05 5,00 1,40 7,10 8,00 9,70 8,35
127 298 348 448 160 137 20 22 F07/F10 3,65 4,10 6,80 2,00 9,00 10,0 12,5 10,7
143 332 - - 198 172 20 27 F10/F12 4,60 - - 2,50 12,42 - - 15,78
160 374 436 562 198 172 28 27 F10/F12 7,00 8,00 13,0 3,60 16,4 18,8 26,0 21,1
190 422 - - 255 224 28 36 F14 12,5 - - 6,50 27,95 - - 37,75
210 464 540 692 255 224 32 36 F14 15,0 17,0 21,5 8,00 31,8 37,4 49,2 39,6
254 603 705 905 302 272 32 46 F16 27,0 31,5 41,0 14,0 55,5 66,5 79,0 70,6
255 683 809 - 302 272 32 46 F16 32,0 38,0 - 17,0 69,2 77,0 - 84,3
300 683 - - 360 360 32 46 F16 46,0 - - 25,0 92,0 - - 107,1
300-F25 683 - - 391,5 360 32 55 F25 46,0 - - 25,0 99,0 - - 114,0
(1) Einfachwirkender Antrieb mit 8 Federn (Grösse 43, 44), mit 12 Federn (Grösse 52 bis 300-F25) / (1) Spring return with 8 springs (size 43, 44), with 12 springs (size 52 to 300-F25)
(2) Gewichtsangaben für Antriebe mit Ritzelhöhe 30mm / (2) Weights refferred to protrusion shafts 30mm
(3) Mechanische Schnittstellen gemäß ISO 5211 - DIN 3337 NAMUR VDI/VDE 3845 / (3) Mechanical interfaces according ISO 5211 - DIN 3337 NAMUR VDI/VDE 3845
Pneumatischer Antrieb GT-Serie
Pneumatic actuator GT-series
9 4 10 11 12 5 6 8 2
16 15 14 13 2 8 6 5 7 3 1 19 18
7 26 25 14 15 17
0° 0° 0° 0°
-25° +5°
20
-5° -5°
21 90° 90°
+5° +5°
-5°
22 120°
26 +5° -5° +5°
23 180°
25 24 GTW GTK, GTX
5
Ersatzteilliste / Spare parts list

Pos. Beschreibung Description Menge Ersatzteilset / Spare parts set
Q.ty Set 1,5 Set 2 Set 3 Set 4 Set 6 Set 7 Set 8
1 Gehäuse Actuator body 1 - - - - - - -

2 Seitendeckel Actuator end cap 2 1 - - - - - -
3 Kolben ohne Durchgangsbohrung Blind piston 1 - 1 - - - - -
4 Kolben mit Durchgangsbohrung Drilled piston 1 - - 1 - - - -
5 O-Ring-Kolben Piston sealing O-Ring 2 - 1 1 - - 2 -
6 Führungsring-Kolben Piston guide ring 2 - 1 1 - - - 2
7 Gleitelement-Kolben Piston guide skate 2 - 7 1 - - - 2
8 O-Ring-Gehäusedeckel End cap sealing O-Ring 2 1 - - - - 2 -
9 Innere Hubeinstellschraube Internal travel stop rod 1 - - - - - - -
10 O-Ring für innere Hubeinstellschraube Internal travel stop rod sealing O-Ring 1 - - 1 - - - -
11 Gleithülse für innere Hubeinstellschraube Internal stop rod guide bush 1 - - 1 - - - -
12 Scheibe-Hubeinstellschraube-Innen Rod guide bush stop washer 1 - - - - - - -
13 Äussere Hubeinstellschraube External travel stop screw 1 - - - - 1 - -
14 O-Ring für äussere Hubeinstellschraube Stop sealing O-Ring 2 - - - - 1 2 -
15 O-Ring-Scheibe O-Ring stop washer 2 - - - - 1 - -
16 Kontermutter-Hubeinstellschraube aussen External stop nut 1 - - - - 1 - -
17 Kontermutter-Hubeisntellschraube innen Internal stop nut (yellow) 1 - - - - - - -
18 Seegering Pinion stop circlips 1 - - - 1 - - -
19 Anlaufscheibe Upper pinion washer 1 - - - 1 - - -
20 O-Ring-Ritzel-oben Upper pinion O-Ring sealing 1 - - - 1 - 1 -
21 Führungsring-Ritzel-oben Upper pinion guide ring 1 - - - 1 - - 1
22 Ritzel Pinion 1 - - - 1 - - -
23 Führungsring-Ritzel-unten Lower pinion guide ring 1 - - - 1 - - 1
24 O-Ring-Ritzel-unten Lower pinion O-Ring sealing 1 - - - 1 - 24 -
25 Schrauben-Seitendeckel End cap screws 8 4 - - - - - -
26 Rückstellfedern Spring cartridges 0 - 12 - - - - - - -
Set1,4 = S e i te n d e c k el , k o m p l et t / Ca p, co m p l e te
Set 2 = Ko l b e n o h n e D u rc h g a n g s b o h ru n g, k o m p l et t / B l i n d p i s to n , co m p le te
Set 3 = Ko l b e n m i t D u rc h g a n g s b o h ru n g, k o m p l et t / D r i l l e d p i s to n k it, co m p le te
S et 4 = R i t ze l , k o m p l et t / Sh a f t co m p l e te
S et 6 = I n n ere H u b e i n s tel l s c h ra u b e, k o m p l et t / E x te r n a l s to p k i t, co m pl e te
S et 7 = D i c ht u n g s s at z / S e a l k i t
S et 8 = Ve r s c h l e i ß te i l s at z / G u i d e k i t
© G.T. ATTUATORI EUROPE GmbH, 04/2009, DEU/ENG - Pneumatische Stellantriebe, Änderungen vorbehalten.
G.T. ATTUATORI EUROPE GmbH
Robert-Koch-Str. 12
D-53501 Grafschaft-Gelsdorf
Telefon / phone: +49 (0) 22 25 - 8 39 35 - 0

Telefax / fax: +49 (0) 22 25 - 8 39 35 - 29
email: [email protected]
Internet: www.gteurope.com
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Limit switch boxes Solenoid valves Assembling accessories
ATTUATORI EUROPE
WARRANTY
G.T. Attuatori S.r.l. guarantees its pneumatic actuators for one year from the date of delivery.
The warranty covers any defects in materials manufactured by us.
Under this warranty, G.T. Attuatori S.r.l. will either repair or replace any part, ex works.
The warranty is null and void in the following cases:
- Incorrect installation of the product;

- Use of the product for purposes other than those for which it is designed;
G.T. Attuatori S.r.l. does not recognise any other warranty, voiced or implied, outside the above indicated.
In the same way, G.T. Attuatori S.r.l. declines any responsibility for direct or indirect damages, of any type or nature, deriving
from its products or their use.
INSTRUCTION MANUAL
Pneumatic pinion actuators and racks
SERIES GTKB, GTXB, GTWB
EC EXAMINATION CERTIFICATE TYPE no. CESI 07 ATEX 049 X
1.0 INTRODUCTION
2.0 STORAGE
3.0 OPERATIONAL FEATURES
4.0 ACTUATORS INSTALLATION
5.0 DISASSEMBLY PROCEDURE
6.0 MBLY PROCEDURE
7.0 SPRING CARTRIDGES INSTALLATION
8.0 FCCW TO FCW CONVERSION
9.0 ACTUATOR SIZING
10.0 AIR TO AIR ACTUATORS
11.0 SPRING RETURN ACTUATORS
1.0 INTRODUCTION
Conceived for the installation on valves of
The actuators of the GTK SLS and GTX single limit stop series and GTK DLS and GTW double limit stop series with possibility
of adjustment of the rotation both in opening that in closing are manufactured to operate with a maximum pressure of 10
Bar., and tested for an operational life up to 1 million of manoeuvres.
The greasing performed during the assemblage guarantees a correct lubrication of the actuators for at least 500.000
manoeuvres.
in two styles:
- DOUBLE ACTING: Available with rotation of 90°. (**)

- (**) On request are available for 120°, 135° and 180°
- SPRING RETURN: Available with rotation of 90°.
The DOUBLE AC
of the unique patented G.T. Attuatori spring cartridges.
2.0 STORAGE
All Attuatori actuators are factory lubricated.
The actuator ports are plugged to prevent liquids or other materials from entering the actuator during shipment.
If the actuators have to be stored for a long period of time before installation, the units should be stroked periodically to
prevent the seals from setting.
(Note: the plugs must be removed in order to stroke actuators).
Storage should be indoors and the units should be protected against humidity and other harmful elements.
3.0 OPERATION CHARACTERISTICS

The actuators have simple operational characteristics:
C-1D and 1E-1F-1G-1H )
- Port A (2) is connected to the interior cavity between the pistons
The pinions of actuators have, as standard, a polygonal bottom female key, that allow the assembling on valves stem, or
On request, bottom pinion female key may be done at double D or cylindrical with one or two keyways:
Polygonal key Double D key Keyways

key
The ports are NAMUR standard, for easy solenoid valve connection, directly on the bodies of GTK52 DLS through GTW.300.
AIR TO AIR ACTUATORS
We see that by pressurizing port B and allowing air to exhaust trough port A we have the
normally closed position for the actuator, as in A and 1.B.
By inverting the pressurization from B to A and the exhaust from A to B, the position for the actuator. pinion will rotate in
the counter clockwise direction and we’ll see the open position of the actuator, as in and 1.D.
SPRING RETURN ACTUATORS
In the case of SPRING RETURN actuators, with pressure on port A and the port B connected to the exhaust, we get the
open position for the actuator, in the case of air failure the springs will close the actuator satisfying the conditions shown
in E and 1.G.
Although the actuators typically operate, counter clockwise to open and clockwise to close, it is possible to reverse this
stile of operation.
Figures 1.G and 1.H show the same spring return actuator with the piston orientation changed to convert the actuator from
a fail clockwise to a fail counter clockwise unit (as described in Section 8.0: FCCW to FCW conversion).
4.0 ACTUATORS INSTALLATION

The actuators are designed to be easy installed. The actuators come with one or more ISO 5211 (DIN 3337) standard
bottom mounting pattern, selon the model, for direct assembling to the valves to be drived or to the coupling, when necessary.
On top face of actuators there is a namur standard mounting pattern for easy installation of accessories for position survey
and/or control devices (Microswitches box, Positioners, etc ).
FOR ACTUATORS INSTALLATION PLEASE FOLLOW THESE STEPS:

4.1 - I
NOTE.: If actuator is an AIR TO AIR type check and see if pinion is in the normal position, or rather in the position necessary
to get the valve closed.
4.2 - Make sure valve is in normal position before proceeding. Figure 3 describes the correct normal position of all
actuators (Including spring return types with FCW, assembling A and FCCW assembling C, applications).
4.3 - Install mounting bracket on to valve and hand tighten all fasteners. Be sure not to fully torque bolts until entire
assembly is correctly aligned and installed.
4.4 - Place coupling on valve stem, if necessary, and position actuator on mounting brackets. Aligned valve and actuator
assembly so as to eliminate shear force on system.
Rotate the actuator to open direction (normally counter clockwise) as regards to the valve until to eliminate all torsional play
in closing direction, just to get correct closing valve position in corrispondence of actuator closing position (piston close
to piston, A and 1C table 3).
Rotate the actuator to open direction (normally counter clockwise) as regards to the valve until to eliminate all torsional play
in closing direction, just to get correct closing valve position in correspondence of actuator closing position (piston close
to piston, A and 1C table 3).
4.5 - Actuate unit pneumatically several times to ensure that coupling is not binding.
If unit does not function properly, disassemble fixture and actuator coupling, and repeat steps from 4.1 through 4.5.
If problem persist contact your local G.T. Attuatori representative.
4.6 - After all mounting procedures are completed, it is necessary to set travel stops, to ensure proper rotation.
NEVER ADJUST TRAVEL STOP SCREWS

WHILE PRESSURE IS PRESENT INSIDE THE ACTUATOR
4.7 - External travel stops, placed on left side of actuator GTK SLS e GTK, allow for a range of about -5° to +5° com-
pared with open position. If a larger range is necessary, consult directly G.T. Attuatori people for information on extended
limit stops screws.
Loosen both sealing nuts. Torque travel stops until they contact the pistons.
Be sure not to alter the valve and actuator position while setting the travel stops.
Torque the sealing nuts until secure.
Retest actuator to assure that there are no end cap air leaks.
4.8 - Internal travel stops, placed on right side of actuator GTK DLS e GTW series, allow for a range of about -25° to
+5° compared with open position.
Loosen the nut of internal (right side) adjusting screw, then move by hand the actuator connected to the valve, in closing
direction of the valve, up to desired closing degree. (I
to follow the valve manufacturer instruction sheet to get proper valve closing value)
Screw in counter-clockwise direction the adjusting screw up to go in touch with the piston inside the actuator, without to
4.9 - Re-check the actuator to be sure that there are no end cap air leaks on travel stops area.
5.0 DISASSEMBLY PROCEDURE

5.1 - Drawing with itemised component and recommended spare parts
5.2 - Disconnect all electrical and air supplies from the actuator.
CAUTION
NEVER DISASSEMBLE AN ACTUATOR THAT
IS UNDER PRESSURE
5.3 - Remove actuator from mounting bracket and coupling (when present).
Disassemble accessories as: limit switches, micro switches box and positioner (if present), and place in clean environment.
5.4 - Double limit stop R
nut on right side of the actuator and screw in clockwise direction the internal travel stop rod in order to make free right end
cap to be removed. For single limit stop R
5.5 - Remove O-Rings from end caps.
NOTE: unless actuator has not been in service it will be better to replace the O-Ring set. (See table 2A)
5.6 - Rotate pinion in Counter Clockwise direction (NOTE: if unit is a FCCW, assembling C, rotation will be in opposite
direction) until pistons are far enough from cylinder to be removed by hand (S
I NOTE: be
sure not to scar the surface of pistons).
Remove both pistons noting the orientation of them, so during reassembly the pistons will be replaced in the same orientation.
CAUTION
NEVER USE COMPRESSED AIR TO PULL OUT
THE PISTONS FROM THE ACTUATOR BODY
5.7 - Remove snap ring and delrin washer from top of pinion. Place the actuator between two blocks of wood so that the
pinion is free to be removed through the bottom of the actuator body.
Using a rubber mallet, lightly tap the top of the pinion. When the pinion is loose from the body remove the pinion through
the bottom (S
The O-Rings and guide kits are listed in the table 2A and 2B.
Quantity / Menge
Part. N. Quantité / Количество
Teil Nr. Quantità GB Description D Beschreibung F Description RUS Описание I Descrizione
No детали
DLS GTW SLS GTX
1 1 1 Actuator body Gehäuse Stellantrieb Corps actionneur Корпус привода Corpo attuatore
2 2 2 Actuator end cap Kopf Stellantrieb Tête d’actionneur Крышка привода Testata attuatore
3 1 1 Blind piston Blindkolben (Standard Kolben) Piston aveugle (Piston standard*) Поршень с заглушкой (стандартный) Pistone cieco (Pistone standard •)
4 1 1 Drilled piston Gelochter Kolben (Standard Kolben) Piston troué (Piston standard*) Поршень с отверстием (стандартный) Pistone forato (Pistone standard •)
5 2 2 Piston sealing O-Ring O-Dichtungsring Kolben O-Ring tenue piston Уплотнительное кольцо поршня O-Ring tenuta pistone
6 2 2 Piston guide ring Führungsring Kolben Anneau guide piston Направляющее кольцо поршня Anello guida pistone
7 2 2 Piston guide skate Führungsgleitschuh Kolben Glissière guide piston Направляющая опора поршня Pattino guida pistone
8 2 2 End cap sealing O-Ring O-Dichtungsring Kopf O-Ring de tenue de tête Уплотнительное кольцо крышки O-Ring tenuta testata
9 1 - Internal travel stop rod Stab Innenregler Tige de registre interne Упорный стержень внутреннего регулировочного винта Asta di registro inerno
10 1 - Internal stop rod sealing O-Ring O-Dichtungsring Kolbenstopp O-Ring tenue arrêt piston Уплотнительное стопорное кольцо поршня O-Ring tenuta ferma pistone
11 1 - Internal stop rod guide bush Führungsbuchse Kolbenstopp Douille de guide arrêt piston Направляющая втулка упорного стрежня поршня Bussola guida ferma pistone
12 1 - Rod guide bush stop washer Ring Führungsbuchse Stopp Anneau d’arrêt douille de guide Стопорное кольцо направляющей втулки Anello ferma bussola guida
13 1 2 External travel stop screw Außenregler Stift Vis sans tête de registre externe Внешний регулировочный винт Grano di registro esterno
14 2 2 Stop sealing O-Ring O-Dichtungsring Regler O-Ring tenue registres Уплотнительное кольцо регулировочных винтов O-Ring tenuta registri
15 2 2 O-Ring stop washer Unterlegscheibe O-Dichtungsring Regler Rondelle ferme O-Ring registres Прижимная шайба регулировочных винтов Rondella premi O-Ring registri
16 1 1 External stop nut Schraubenmutter Außenregler Ecrou ferme registre externe Стопорная гайка внешнего регулировочного винта Dado ferma registro esterno
17 1 1 Internal stop nut (yellow) (raw•) Schraubenmutter Innenregler (gelb) (roh•) Ecrou ferme registre interne (jaune) (brut•) Стопорная гайка внутреннего регулировочного винта (желтая•) Dado ferma registro interno (giallo) (grezzo•)
18 1 1 Pinion stop circlips Elastischer Ring Ritzelstopp Anneau élastique ferme pignon Эластичное стопорное кольцо вала Anello elastico ferma pignone
19 1 1 Upper pinion washer Obere Unterlegscheibe Ritzel Rondelle supérieure pignon Верхняя шайба вала Rondella superiore pignone
20 1 1 Upper pinion O-Ring sealing Oberer O-Dichtungsring Ritzel O-Ring supérieur tenue pignon Верхнее уплотнительное кольцо вала O-Ring superiore tenuta pignone
21 1 1 Upper pinion guide ring Oberer Führungsring Ritzel Anneau supérieur guide pignon Верхнее кольцо направляющей вала Anello superiore guida pignone
22 1 1 Pinion Ritzel Pignon Вал Pignone
23 1 1 Lower pinion guide ring Unterer Führungsring Ritzel Anneau inférieur guide pignon Нижнее кольцо направляющей вала Anello inferiore guida pignone
24 1 1 Lower pinion O-Ring sealing Unterer O-Dichtungsring Ritzel O-Ring inférieur tenue pignon Нижнее уплотнительное кольцо вала O-Ring inferiore tenuta pignone
25 8 8 End caps screws Befestigungsschrauben Köpfe Vis serrage têtes Стопорные винты крышки Viti ferma testate
26 0÷12 0÷12 Spring cartridges Federeinsätze Cartouche ressort Пружинный блок Cartuccia molla
Tab. / Таб. 2A: O-RINGS SERIES / SERIE O-RINGE / SÉRIE O-RINGS / СЕРИЯ УПЛОТНИТЕЛЬНЫХ КОЛЕЦ / SERIE O-RINGS
Part. N. / Teil Nr. Quantity / Menge / Quantité /
Количество / Quantità
GB Description D Beschreibung F Description RUS Описание I Descrizione
No детали
5 2 O-Ring Piston O-Ring Kolben O-Ring Piston Уплотнительное кольцо поршня O-Ring Pistone
8 2 O-Ring End Cap O-Ring Kopf O-Ring Testata Уплотнительное кольцо крышки O-Ring Testata
20 1 O-Ring Upper Pinion Oberer O-Ring Ritzel O-Ring supérieur Pignon Верхнее уплотнительное кольцо вала O-Ring superiore Pignone
24 1 O-Ring Lower Pinion Unterer O-Ring Ritzel O-Ring inférieur Pignon Нижнее уплотнительное кольцо вала O-Ring inferiore Pignone
14 2 O-Ring Travel Stop Screws O-Ring Reglerstifte O-Ring Vises sans tête de registre Уплотнительное кольцо регулировочных винтов O-Ring Grani di registro
Tab. / Таб. 2B: GUIDE SERIES / SERIE FÜHRUNGEN / SERIE GUIDES / СЕРИЯ НАПРАВЛЮЩИХ ОПОР / SERIE GUIDE
Part. N. / Teil Nr. Quantity / Menge / Quantité /
Количество / Quantità
GB Description D Beschreibung F Description RUS Описание I Descrizione
No детали
7 2 Piston guide skates Führungsgleitschuhe Kolben Glissières-guide Piston Направляющая опора поршня Pattini-guida Pistone
6 2 Piston guide rings Führungsringe Kolben Anneaux guide Piston Направляющие кольца поршня Anelli-guida Pistone
21 1 Upper Pinion guide rings Oberer Führungsring Ritzel Anneau guide supérieur Pignon Верхнее направляющее кольцо вала Anello-guida superiore Pignone
23 1 Lower Pinion guide rings Unterer Führungsring Ritzel Anneau guide inférieur Pignon Нижнее направляющее кольцо вала Anello-guida inferiore Pignone
19 1 Upper Pinion washer Obere Unterlegscheibe Ritzel Rondelle supérieure Pignon Верхняя шайба вала Rondella superiore Pignone
Double effect Actuators / Stellantriebe mit Doppelwirkung / Actionneurs à effet double /
Приводы двойного действия / Attuatori a doppio effetto
Assembly A = closing clockwise / Montage A= Schließen im Uhrzeigersinn /

Fig. / Abb. / Рис. Montage A = fermeture dans le sens des aiguilles d’une montre /
1a - 1b - 1c - 1d Сборка А – закрытие по часовой стрелке / Montaggio A = chiusura in senso orario
Top view of sectioned

DOUBLE EFFECT GT Actuators,
closing clockwise, assembly A
assembly C
Ansicht von oben: Stellantriebe

mit DOPPELWIRKUNG im Schnitt,
mit Schließen im Uhrzeigersinn,
Montage A (ab. 1A), und mit
Schließen entgegen dem
Uhrzeigersinn, Montage C (Abb. 1C). A B A B
1a Closed / Position geschlossen / Position fermée / 1b Open / Position offen / Position ouverte /
Vues d’en-haut d’actionneurs GT Закрытая позиция / Posizione chiusa Открытая позиция / Posizione aperta
à EFFET DOUBLE sectionnés,
avec fermeture dans le sens des
aiguilles d’une montre,
montage A
fermeture en sens contraire des
montage C
Вид сверху на привод GT

двойного действия в разрезе - с
закрытием по часовой стрелке -
сборка А (Рис.1А), и закрытием
против часовой стрелки
- сборка С (Рис. 1С)
A B A B
Viste da sopra di attuatori GT 1c Closed / Position geschlossen / Position fermée / 1d Open / Position offen / Position ouverte /
a DOPPIO EFFETTO sezionati, Закрытая позиция / Posizione chiusa Открытая позиция / Posizione aperta
con chiusura in senso orario,
montaggio A
chiusura in senso anti-orario,
Assembly C = closing anti-clockwise / MONTAGE C = Schließen entgegen dem Uhrzeigersinn /
montaggio C
Montage C = fermeture dans le sens contraire des aiguilles d’une montre /
Сборка С = закрытие против часовой стрелки / Montaggio C = chiusura in senso antiorario
Simple effect Actuators / Stellantriebe mit Heinfakwirkung / Actionneurs à effet simple /

Приводы простого действия / Attuatori a semplice effetto
Assembly A = closing clockwise / Montage A= Schließen im Uhrzeigersinn /

Fig. / Abb. / Рис. Montage A = fermeture dans le sens des aiguilles d’une montre /
1e - 1f - 1g - 1h Сборка А – закрытие по часовой стрелке / Montaggio A = chiusura in senso orario
Top view of sectioned

SIMPLE EFFECT GT Actuators,
closing clockwise, assembly A
assembly C
Ansicht von oben: Stellantriebe

mit EINFACHWIRKUNG im Schnitt,
mit Schließen im Uhrzeigersinn,
Montage A (Ab.1A), und mit
Schließen entgegen dem
Uhrzeigersinn, Montage C (Abb. 1C). A B A B
1e Closed / Position geschlossen / Position fermée / 1f Open / Position offen / Position ouverte /
Vues d’en-haut d’actionneurs GT Закрытая позиция / Posizione chiusa Открытая позиция / Posizione aperta
à EFFET SIMPLE sectionnés,
avec fermeture dans le sens des
montage A
fermeture en sens contraire des
montage C
Вид сверху на привод GT с

возвратной пружиной в разрезе – с
закрытием по часовой стрелке, –
сборка А (Рис.1А), и закрытием
против часовой стрелки
– сборка С (Рис. 1С)
A B A B
Viste da sopra di attuatori GT 1g Closed / Position geschlossen / Position fermée / 1h Open / Position offen / Position ouverte /
a SEMPLICE EFFETTO sezionati, Закрытая позиция / Posizione chiusa Открытая позиция / Posizione aperta
con chiusura in senso orario,
montaggio A
chiusura in senso anti-orario,
Assembly C = closing anti-clockwise / MONTAGE C = Schließen entgegen dem Uhrzeigersinn /
montaggio C
Montage C = fermeture dans le sens contraire des aiguilles d’une montre /
Сборка С = закрытие против часовой стрелки / Montaggio C = chiusura in senso antiorario
Fig. / Abb. / Рис. 2
Lower view of GT Actuator

with assembly holes
complying with ISO norm
Ansicht von unten eines

Fig. / Abb. / Рис. GT Stellantriebs
mit den Montagelochungen
2 gemäß ISO Norm
Vue inférieure
d’un actionneur GT avec
selon la norme ISO
Вид снизу на привод GT с

монтажными отверстиями,
изготовленными
по стандарту ISO
Vista inferiore di un
ISO dimension B attuatore con i fori
ISO Abmessung B di montaggio a norma ISO
ISO dimension B
ISO размер В
ISO dimensione B
ISO dimension A
ISO Abmessung A
ISO dimension A
ISO размер A
ISO dimensione A
Tab. / Таб. 1 TYPE / TYP / ТИП / TIPO

Dimens./ Размер A Dimens./ Размер B
ISO Ø mm. ISO Ø mm.
GTK. 52DLS F03 36 F05 50
GTK. 63DLS F05 50 F07 70
GTK. 75DLS F05 50 F07 70
GTK. 83DLS F05 50 F07 70
GTK. 92DLS F05 50 F07 70
GTW.110 F07 70 F10 102
GTW.118 F07 70 F10 102
GTW.127 F07 70 F10 102
GTW.143 F10 102 F12 125
GTW.160 F10 102 F12 125
GTW.190-210 F14 140
GTW.254-255-300 F16 165
Upper view of GT Actuator with assembly

holes complying with ISO norm
Ansicht von oben eines
GT Stellantriebs mit den
Montagelochungen gemäß ISO Norm
Vue supérieure d’un actionneur GT
avec les de montage selon
la norme ISO
Вид сверху на привод GT с
монтажными отверстиями,
изготовленными по стандарту ISO
Vista superiore di un
attuatore GT con i fori
di montaggio a norma ISO
(VDI VDE 3845)

- Assembly zone of end-run kit, Switch
Box and Positioners
- Mo Sets Endschalter,
Switch Boxen und Positionierer
- de montage
Zone des kits de
de course, des Switch Box et
des Positionneurs
Fig. / Abb. / Рис. - установки

Место комплекта
конечного выключателя,
3 распределительной коробки и
позиционеров
- Zona di montaggio dei kit di corsa,
degli Switch Box e dei Posizionatori
INSTRUCTION MANUAL
Pneumatic pinion actuators and racks GB
SERIES GTK DLS, GTW - GTK SLS, GTX
6.0 ASSEMBLY PROCEDURE

6.1 - Inspect all wear surfaces for excessive wear or possible damage
CAUTION
FOR LOW END HIGH TEMPERATURE SERVICE, SPECIAL GREASE IS REQUIRED.
PLEASE CONTACT GT ATTUATORI
6.2 - Make sure all metallic parts are clean and free of any nicks or burrs.
6.3 - Lubricate the inside bore of the cylinder body, O-Rings seats, pistons and pinion wear surfaces with MOBILUX EP 2
compatible grease, suitable for use from -20°C through + 130°C, high temperature actuators with special grease -20°C to 160°C.
CAUTION
BE SURE THAT ALL PARTS ARE STILL WITHIN FACTORY SET
TOLERANCES BEFORE ASSEMBLY
NOTE: All O-Rings should be replaced as a matter of service policy if the actuator has been in service.
6.4 - Install wear surface skates and bearings on pistons and pinion, and install O-Rings on pistons, pinions and end caps.
6.5 - Insert pinion into actuator body. Install pinion washer and snap ring (seeger).
6.6 - Insert pistons into cylinder body until the pistons begin to mesh with the pinion Make sure that the pistons are symme-
trically placed inside the cylinder body In we see that the pistons are at the mating position and are symmetrical.
This is very important. Infact, if the pistons are not tracking properly remove and reinsert them.
NOTE: Be sure that tooth engagement is even on both pistons.
6.7 - Apply equal pressure on each piston until they are fully engaged with pinion.
Rotate pinion until actuator is fully closed.
6.8 - Check the top of pinion for correct orientation. If the indicator-drive milling is perpendicular to the cylinder body
then proceed to the next part 6.9.
If the pinion is incorrectly positioned , then proceed to part 6.8b.
6.8b - Turn actuator up on its side. Rotate pinion counter clockwise until both pistons disengage from pinion. Rotate pinion
with a wrench to correct position. Apply light pressure to pistons until pinion and pistons engage.
Close actuator and check for correct pinion orientation, as at section 6. (Repeat this step as many times as necessary to get
the correct orientation).
6.9 - In case of SPRING RETURN actuator insert cartridge springs. (For information on the loading of springs refer to section
7.0).
6.10 - Double limit stop To reassemble the left cap in correct way for GT
with his point lined up to the external face of the same cap, then to reassemble the same right cap. For the single limit stop
replace end caps,being sure to position them in correct way for GTW series
NOTE: Torque screws in alternating order to ensure that the O-Ring seats properly.
6.11 - End cap screws should be torqued, in alternating order, to the factory standard. Refer to below table 3 for correct
CAUTION:
NEVER GIVE COMPRESSED AIR TO THE ACTUATOR BEFORE TO CHECK VERY WELL
IF PINION IS FIXED BY SNAP RING SEEG
AND END CAPS WELL CLOSED WITH TIGHTENED SCREWS
6.12 - Pressurize right port on actuator body to test for air leaks. Leaks can occur around pinion and between end cap and
body mating surfaces.
If an air leak is found near the end cap, remove end cap and check for proper O-Ring seating.
If O-Ring appear to be in good condition, repeat the step 6.11.
Pressurize left port on actuator to test for pinion air leaks. If an air leak develops near the pinion and body mating areas,
remove the pinion from the body, as at point 5.6 taking well care that pistons do not change position inside the actuator
body, during this operation.
Inspect upper and/or lower pinion O-Rings, selon where the leak is found If O-Rings appear in good condition, verify for
burrs into O-Ring grooves. Clean very well and reinsert O-Rings in their seats. Insert pinion into actuator body in the same
orientation as before, taking well care not to move pistons. If pistons are moved repeat steps from point 6.5. Install pinion
washer and snap ring.
Begin test again as described in this section.
If the problem persist contact your local G.T. Attuatori representative.
Fig. / Abb. / Рис. 7a
indicates the numbered slots for the spring cartridges.
Die Abbildung zeigt den linken Kolben und dessen
Frontalansicht mit Angabe der nummerierten Sitze
für die Federeinsätze.
et sont indiquées les logements numérotés pour les

cartouches-ressort
Показан левый поршень и его фронтальный вид с
обозначенными номерами гнезд пружинных блоков.
indicate le sedi numerate per le cartucce-molla.

Fig. / Abb. / Рис.
7a
Fig. / Abb. / Рис. 7b
indicates the numbered slot for the spring cartridges.

Die Abbildung zeigt den rechten Kolben und dessen
Frontalansicht mit Angabe der nummerierten Sitze für
die Federeinsätze.
indiquées les logements numérotés pour les cartouches

ressort
Показан правый поршень и его фронтальный вид с
обозначенными номерами гнезд пружинных блоков.
indicate le sedi numerate per le cartucce-molla.
7b
Fig. / Abb. / Рис. 6-8 GTX - GTW only / Nur GTX - GTW /Seulement GTX - GTW /
Только для серий GTX -GTW / Solo GTX - GTW
facing upwards and part B facing downwards.

Die Abbildung zeigt den internen Teil eines Kopfes, wie er auf dem Gehäuse des Stellantriebs montiert wird, mit Teil A nach
oben und Teil B nach unten. Warnung: mit umgekehrt montierten Köpfen funktioniert der Stellantrieb nicht.
tournée vers le haut et la partie B tournée vers le bas. Attention: si les TESTATE sont montées à l’envers, l’actionneur
ne fonctionne pas.
Показан вид на крышку изнутри, как она должна быть установлена на корпусе привода: стороной А сверху, стороной
В снизу. Внимание: с перевернутыми крышками привод функционировать не может.
verso il basso. Attenzione: con le testate montate capovolte l’attuatore non funziona.
UP UP
A A
B B
Fig. / Abb. / Рис. Fig. / Abb. / Рис.
6 8
Tab. / Таб. 7
Mark of conformity to pertinent European Directives
Kennzeichnung nach anwendbaren Europäischen Richtlinieni
Marquage de conformité aux Directives européennes applicables
Маркировка в соответствии с применяемыми Европейскими директивами
Marcatura di conformità alle Direttive Europee applicabili
Mark of conformity with Directive.94/9/CE..and relative technical norms

Kennzeichnung lt. Richtlinie 94/9/EG und einschlägigen technischen Normen
Marquage de conformité à la Directive 94/9/CE et aux normes techniques relatives
Маркировка в соответствии с директивой 94/9/СЕ и связанными с ней техническими нормами
Marcatura di conformità alla Direttiva 94/9/CE ed alle relative norme tecniche
II Group II (Surface) /
Группа II (Поверхность)
/
2 Category 2 apparatus / Gerät von Kategorie 2 / Appareil de catégorie 2

Механизм категории 2 / Apparato di categoria 2
Explosive Atmosphäre mit Präsenz von Gas, Dampf, Nebel und Staub.
GD Atmosphère explosive avec présence de gaz, nuées vapeurs et poussières
Взрывоопасная среда с примесями газов, паров и пыли
Atmosfera esplosiva con presenza di gas, nebbie vapori e polveri.
Explosive Atmosphäre mit Präsenz von Gas, Nebel, Dampf.

G Atmosphère explosive avec présence de gaz, nuées vapeurs
Взрывоопасная среда с примесями газов, паров
Atmosfera esplosiva con presenza di gas, nebbie, vapori.
T4, T3, T2 Temperature class / Temperaturklasse / Classe de température

Класс температуры / Classe di temperatura
Air temperature
Umwelttemperatur
Température ambiante -60°C + 70° C ; -20°C +70°C;-57°C + 160°C; -15°C +160°C ; -30°C +200°C
Температура окружающей среды
Temperatura ambiente
Tab. / Таб. 8
Danger Zone Equipment category with directive ATEX 94/9EC
Gefahrenbereich Kategorie des Geräts mit Richtlinie ATX 94/9/EG
Zone dangereuse Catégorie de l’appareil avec la directive ATEX 94/9/CE
Опасная среда атегория установки в соответствии с директивой ATEX 94/9/CE
Area pericolosa Categoria dell’apparecchiatura con la direttiva ATEX 94/9/CE
Zone / Зона / Zona 1 GD
Gas, steam, vapour and dust 0,1,2/20,21/22
Gas, Nebel, Dampf und Staub
Zone / Зона / Zona 2 GD
Gaz, nuées, vapeurs et poussièresi 1,2/21,22
Газ, пары, пыльi
Gas, nebbie, vapori e polveri Zone / Зона / Zona
3 GD
2/22

9a N Fig. / Abb. / Рис. 9b N

7.0 CARTRIDGE SPRINGS INSTALLATION
The DOUBLE ACTING to a SPRING RETURN actuator type,
The actuators can accept up to 6 cartridge springs in each end cap, also if very rarely they are less than 2.
T
during the closing and opening portions of the cycle.
Review sections 11, 12 and 13 on actuator sizing, for correct procedures in selecting spring combinations.
7.1 - Drive the actuator in closed position (S E and 1.G).
7.2 - Double limit stop R
nut on right side of the actuator and screw in clockwise direction the internal adjustment screw in order to make free right
end cap to be removed. For the single limit stop R
7.3 - As it is not possible to see the rack position with pistons assembled into actuator body, refer to mark present
in one of springs seats of the piston, corresponding to which there is the rack on the other side of the piston. (S
7A and 7B: that seat is numbered 1).
7.4 - Fixed the number of cartridge springs to put in each cap, insert them according to A and 7B.
( Example: Model GTWN.110x90.NP22A. K4 has 4 cartridge springs per end cap).
When reassemble the end caps pay attention not to overturn them. looking at the O-Ring, be sure to place end caps
with A on the top and B on the bottom for GTX and GTW series.
8.0 FCW TO FCCW CONVERSION

The actuators typically comes from the factory as Fail Clock-wise (FCW) units, that is Mounting A, that allows infact
FCW operation.
In the event that the need of the actuator changes from FCW to a Fail Counter Clock-wise (FCCW) actuator, that is Mounting
C,
8.1 - R e m o v e e n d c a p s , p i s t o n s a n d t h e p i n i o n a s d e s c r i b e d i n t h e d i s a s s e m b l y p r o c e d u r e .
(Section 5.0).
Prior to reassembly rotate both pistons 180° along the long axis of the piston. (S
Upon rotation of pistons, reassembly can be accomplished by following the reassembly instruction in Section 6.0, Parts
6.1 to 6.12 of this manual.
REMEMBER: IN CASE OF SPRING RETU

CARTRIDGE SPRINGS BEFORE END CAPS ASSEMBLING
ACCORDINGLY WITH TABLE 3, SPRING ORIENTATION CHART
REPLACE CARTRIDGE SPRINGS IF NECESSARY
8.2 - After this procedure has been accomplished, you should be able to put air into the right air port and move the actuator
to the normal position. (If the actuator is not already in the normal position)
wise direction when returning in its normal position.

Logically, in the case of SPRING RETURN type, the return in normal position by counter clock-wise rotation will happen just
when the air will be put to the exhaust from left air port.
9.0 ACTUATOR SIZING

Prior to actuate sizing it is important to get certain information. Key numbers to get are as follows:
• - Torque required to open the valve.
• - Torque required to close the valve.
• - Actuator air pressure.
O SPRING RETURN actuator. ( NOTE: DOUBLE

ACTING actuators have a constant torque throughout their entire stroke ).
When determining the air supply pressure it is important that you use the minimum air pressure that the actuator will
experience and not the average air supply pressure.
If an actuator is supplied by a lower air pressure than it is sized for, failure or improper performances can occur.
10.0 AIR TO AIR ACTUATORS

10.1 - Select the largest torque (opening or closing torque ) and, increase that number of 10%.
(NOTE: Adding 10% is done to ensure an acceptable factor of safety).
The data published in the sizing table indicates average capacity for that given pressure and allow to choose correct
actuator size.
11.0 SPRING RETURN ACTUATOR

11.1 - Increase both your valve closing torque and your valve opening torque by 20%. (Again this will provide an acceptable
factor of safety).
11.2 - Using SPRING RETURN actuators sizing table, look in the column that corresponds to the supply pressure you have
selected. Move down the chart until you have found a torque which is larger than the torque determined for your application.
After you have found the correct value, move across the table horizontally to determine the correct actuator. (See example
table 5)
NOTE: THE VALVE CLOSING TORQUE CORRESPONDS TO

THE SPRINGS 0° COLUMN
AND THE VALVE OPENING TORQUE CORRESPONDS TO
THE ACTUATOR AIR PRESSURE COLUMN
Enclosure 10151
GESTRA Steam Systems
ORGS 111 EN
English
ORGS 112
Installation & Operating Instructions
810801-04
Oil Detector & Alarm
ORGS 11-1, ORGS 112
1
Enclosure 10151
Contents
Page
Important notes
Usage for the intended purpose................................................................................................................4

Function...................................................................................................................................................4
Safety note...............................................................................................................................................4
Directives and standards
Approvals for Marine Applications............................................................................................................5

LV (Low Voltage) Directive and EMC (Electromagnetic Compatibility).........................................................5
ATEX (Atmosphère Explosible)..................................................................................................................5
Note on the Declaration of Conformity / Manufacturer's Declaration . ..................................................5
Design.....................................................................................................................................................5
Technical data
ORGS 112...............................................................................................................................................6
Name plate/marking................................................................................................................................8
Installation
Installation requirements..........................................................................................................................9
Examples of installation.........................................................................................................................10
Dimensions ORGS 11-1..........................................................................................................................11
Key........................................................................................................................................................11
Dimensions ORGS 11-2..........................................................................................................................12
ORGS 112.............................................................................................................................................13
Tools......................................................................................................................................................13
Key........................................................................................................................................................13
Electrical connection
ORGS 111.............................................................................................................................................14
Connection of measuring electrode ORGS 111......................................................................................15
Connecting ORGS 11-1 .........................................................................................................................15
Key........................................................................................................................................................15
Tools......................................................................................................................................................15
Wiring diagram for oil detector & alarm ORGS 11-1................................................................................16
Connecting oil detector & alarm ORGS 11-1 with supply voltage 24 / 115 / 230 V AC.............................16
Basic settings
Factory setting.......................................................................................................................................17
Selecting the measuring range...............................................................................................................17
2
Enclosure 10151
Contents - continued -
Page
Commissioning procedure
Applying supply voltage.........................................................................................................................18

Operating valves....................................................................................................................................18
Operation
Normal operation, oil alarm....................................................................................................................18
Troubleshooting
Safety note.............................................................................................................................................19
Indication, diagnosis and remedy...........................................................................................................19
Exchanging the electronic module..........................................................................................................20
Spare parts list.......................................................................................................................................20
Removing and disposing of measuring electrode ORGS 11-1
Safety note.............................................................................................................................................21
Removing and disposing of measuring electrode ORGS 11-1.................................................................21
3
Enclosure 10151
Important notes
Use oil detector & alarm ORGS 112 only for signalling ingress of oil in cooling water systems.
Function
The oil detector & alarm ORGS 112 is an equipment unit consisting of the measuring electrode
ORGS 11-1 and a measuring pot.
The measuring electrode ORGS 11-1 is a compact-type system that comprises the measuring
electrode and an electronic module integrated in the terminal box. The electrode operation is based on
the conductive measuring principle using the electrical conductivity of the water for signalling water
level. The electronic module detects whether the electrode rods are submerged or exposed and, in the
event of ingress of oil, deactivates the output contacts.
A water sample, taken from the cooling water system downstream of the location at the highest point
where ingress of oil might occur, is fed from below into the measuring pot of the ORGS 11-2. If the
water is contaminated with oil, the oil droplets - due to their lower density - ascend and accumulate on
top of the water and, consequently, the electrode rods are now submerged in this oil film.
Oil is not electrically conductive, which means that no current can flow between the electrode rods of
the measuring electrode. In this case the oil detector & alarm will signal ingress of oil and trigger an
alarm.
The amount of oil necessary to signal ingress of oil depends on the design of the measuring pot and
the length of the electrode rods. The measuring pot is matched to the electrode such that ingress of oil
is signalled when the oil content limit of approx. 50 ml is reached.
The equipment can detect all substances that are insoluble in water, not emulsified and lighter than
water. In addition, the equipment can also detect all liquids with a conductivity value below the
adjusted response sensitivity.
Safety note
The equipment must only be installed and commissioned by qualified and competent staff.
Retrofitting and maintenance work must only be performed by qualified staff who - through adequate
training - have achieved a recognised level of competence.
Danger
When loosening the measuring electrodes hot cooling water may escape.
This presents the risk of severe scalding all over the body!
Do not remove the measuring electrode ORGS 111 unless the boiler pressure is verified
to be zero.
The terminal strip of the measuring electrode ORGS 111 is live during operation!
This presents the danger of electric shock!
Cut off power supply before mounting or removing the housing cover!
Attention
The name plate specifies the technical features of the equipment. Do not commission or
operate any item of equipment that does not bear its specific name plate.
4
Enclosure 10151
Approvals for Marine Applications
The equipment is approved for marine applications.
LV (Low Voltage) Directive and EMC (Electromagnetic Compatibility)
The equipment meets the requirements of the Low Voltage Directive 2006/95/EC and the
EMC Directive 2004/108/EC.
According to the European Directive 94/9/EC the equipment must not be used in explosion-risk areas.
Note on the Declaration of Conformity / Manufacturer's Declaration
For details on the conformity of our equipment according to the European Directives see our Declaration
of Conformity or our Declaration of Manufacturer.
The current Declaration of Conformity / Declaration of Manufacturer are available in the Internet under
www.gestra.de documents or can be requested from us.
Attention
 Rust preventing oils, which are for instance emulsified in the cooling water, will not
raise an alarm!
Design
ORGS 112:
Equipment module with three isolating valves and rapid-action deaerator, ready for connection. Fig. 4
ORGS 111 :
Measuring electrode as spare part for equipment module ORGS 112 Fig. 3
5
Enclosure 10151
Technical data
ORGS 112
Oil detector & alarm ORGS 112 (equipment unit)

Service pressure
6 bar
Service temperature
110 °C
Flow velocity
100 l/h to 300 l/h, recommended 200 l/h
Pressure drop ∆pv
0.06 bar (under test conditions)
Alarm
Raised when approx. 50 ml oil has accumulated
Water inlet, drain
Ball valve with EOconnection 15 L
Water outlet
Ball valve with EOconnection 12 L
Weight
approx. 7.4 kg
Measuring electrode ORGS 111 (component of ORGS 112)

Mechanical connection
Screwed G 1 A, ISO 228
Materials
Screw-in body: 1.4571, X6CrNiMoTi17-12-2
Electrode rods: 1.4571, X6CrNiMoTi17-12-2
Insulating sheath: PTFE
Terminal box: 3.2161 G AlSi8Cu3
Supply voltage
230 V +/- 10 %, 50/60 Hz
115 V +/- 10 %, 50/60 Hz
24 V +/- 10 %, 50/60 Hz (optional)
Power consumption
5 VA
Fuse
external slow-blow 0.5 A
internal thermal fuse Tmax = 102 °C
Response sensitivity
Range 1: 10 µS/cm
Range 2: 0.5 μS/cm
Code-switch selectable
Electrode voltage
10 Vpp
6
Enclosure 10151
Technical data - continued -
ORGS 111 - continued -
Outputs for control circuit

2 volt-free change-over contacts,
8 A 250 V AC / 30 V DC cos ϕ = 1
De-energizing delay: 3 sec.
Provide inductive loads with RC combinations according to manufacturer's specification to ensure
interference suppression.
Indicators and adjusters
2 red LEDs indicating "Electrode submerged" and "Output relay energized" (no ingress of oil)
1 four-pole code switch for selecting the response sensitivity
2 cable gland with integrated cable clamp M20 x 1.5
1 five-pole screw-type terminal strip, detachable, conductor size 1.5 mm2
Protection
IP 65 to DIN EN 60529
Max. admissible ambient temperature
Max. 70 °C
Storage and transport temperature
– 40 up to + 80 °C
Certification
Marine applications BV 17515-B0 BV
GL 17106-00 HH;
LR 07-20031 (E1)
Scope of supply
ORGS 112
1 Oil detector & alarm ORGS 112, PN 6
1 Measuring electrode ORGS 11-1 (mounted)
2 Sealing plugs for cable entry
1 Installation manual
7
Enclosure 10151
Name plate/marking
Safety note
Equipment designation
Pressure rating,
End connection,
Material number
Pressure/temperature range
Power rating
GL 17106-00HH CE Marking
Type approval no.
Disposal note
Spare part specification
Manufacturer
Fig. 1
8
Enclosure 10151
Installation
Installation requirements
The water sample taken from the cooling water system must flow continuously through the oil
detector & alarm ORGS 112. We recommend a flowrate of 200 l/h.
The sampling of the cooling water should take place downstream of a potential oil leak at the
highest point and, if possible, in a horizontal line. Since the oil flows in the upper part of the pipe we
recommend the installation of a welding saddle according to DIN 2618 for collecting the oil droplets.
The line leading to the measuring pot of the ORGS 112 should be vertically ascending, running
directly into the bottom part of the measuring pot. Avoid any narrow parts in the supply line since
they could give rise to undesired emulsification of the oil.
If space is a consideration and the measuring pot has to be installed at a lower point than the main
cooling line make sure that the line leading to the measuring pot features sufficiently sized bends in
order to prevent emulsification.
To achieve the recommended flowrate of approx. 200 l/h provide the main cooling water line with a
standard orifice plate in order to throttle the flow velocity between the water sampling location and
its re-entry point.
The pressure drop ∆pv across the measuring pot is 0.06 bar.
The pressure drops of the connecting lines depend on the design and layout of the installation and
must be ascertained individually. The calculated resistance coefficient ζ can be used to determine
the opening ratio and, consequently, the required diameter "d" for the opening of the standard orifice
plate.
For more information on the sizing and layout of fluid dynamic systems please refer to the
corresponding technical literature and relevant standards.
9
Enclosure 10151
Installation - continued -
Examples of installation
1 3
6 5
4
7
Cooling 8
water cycle
Fig. 2
6 2
1 3
5
9
7 4
Cooling
water cycle
8
Fig. 3
10
Enclosure 10151
Dimensions ORGS 11-1
173
140
GESTRA
336
b = 70
∅ 42
G1 A
ISO 228
50
96
15
Fig. 4
Key
1 Oil detector & alarm ORGS 11-2 (equipment unit) 6 Cooling water inlet DN 15
(outside ∅ 20 mm)
2 Automatic rapid-action deaerator
7 Standard orifice plate
3 Cooling water outlet (ball valve DN 12 L, PN 500)
8 Cooling water outlet DN 12
4 Drain (ball valve DN 15 L, PN 500) (outside ∅ 16 mm)
5 Cooling water inlet (ball valve DN 15 L, PN 500) 9 Main engine, diesel fuel, oil cooler, etc.
11
Enclosure 10151
Dimensions ORGS 11-2
f
0
e 85
5
60
a
23
59
90
~ 845
~ 685
R8 a
45
15
45 d
8.5
70
331
8
a
210
19 11
270
b
c
Fig. 5 ~ 160
12
Enclosure 10151
ORGS 112
1. Use support flanges a to install the oil detector ORGS 112 in a suitable place.
2. Connect the supply line, the return line and the drain line with the progressive ring fitting of the ball
valves in a pressure-tight manner.
3. Close ball valve b and open ball valves c and d. If the cooling water line is under pressure the
rapid-action deaerator e will vent the ORGS 112.
Note
 Please refer to the examples of installation on page 10, Fig. 2, Fig. 3

 Fig. 2 Recommended installation for an optimum arrangement of the measuring pot.
 Fig. 3 Recommended installation if the measuring pot must be mounted at a lower point
Tools
 Open-end spanner A. F. 22, DIN 3110, ISO 3318

Key
0 Measuring electrode ORGS 111 c Cooling water inlet (ball valve DN 15 L, PN 500)
a Support flange d Cooling water outlet (ball valve DN 12 L, PN 500)
b Drain (ball valve DN 15 L, PN 500) e Rapid-action deaerator
f Sealing plug with lateral vent hole
13
Enclosure 10151
ORGS 111
GESTRA
g i h i
Fig. 6
q 10µS/cm
o
p q 0,5µS/cm
s
t
u
j l k
m 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Fig. 7
14
Enclosure 10151
Electrical connection - continued -
Connection of measuring electrode ORGS 111
A self-locking fixing nut j connects the terminal box to the electrode part. Before establishing the
electrical connection you can turn the terminal box through max. +/– 180° into the desired direction
(cable gland).
Connecting ORGS 11-1
1. Unscrew cover screws g and remove cover h. Fig. 6

2. Detach terminal strip n from circuit board.
3. Strip off approx. 40 mm of cable insulation coating and remove approx. 5 mm of conductor end
insulation.
4. Loosen cable glands i. If the equipment is supplied with 24 V pull control cable through one of the
cable glands. Seal off the unused cable gland (protection IP 65). If the equipment is supplied with
115 / 230 V pull the power cable through the right cable gland and the control cable through the left.
5. Connect the individual cables according to the wiring diagram to the terminal strip n.
6. Re-attach terminal strip n to circuit board.
7. Tighten cable glands i.
7. Mount cover h and fasten cover screws g.
Attention
 The following relocations of cables with basic insulation are not permissible:
Mains and control cables in low voltage areas.
Key
g Cover screws (cross recess head screws M4) o LED "Oil alarm"
h Body cover p LED "Oil alarm"
i Cable glands M 20 x 1.5 q LED without function
j Fixing nut for terminal box
r LED without function
k Thermal fuse TMAX 102 °C
s Code switch for measuring range
l Terminal strip for thermal fuse t Fixing screws for electronic module (4x)
m Connection of functional earth u Electronic module
n Terminal strip
Tools
 Screwdriver, size 1
 Screwdriver, size 2.5, completely insulated according to DIN VDE 0680-1
15
Enclosure 10151
Wiring diagram for oil detector & alarm ORGS 11-1
T
1 2
Alarm
ON
10µS/cm
1 2 34 0,5µS/cm
1 2
1 2 3 4 5 6 7 8 9
115V
230(24)V
PE
N L L
Netz
Main Oil
Secteur
Red Alarm
Fig. 8 Relays shown in power-off (alarm) position, LEDs 1 and 2 not illuminated!
Connecting oil detector & alarm ORGS 11-1 with supply voltage 24 / 115 / 230 V AC
Provide the oil detector & alarm with an external slow-blow fuse 0.5 A. To connect the supply voltage
and the output contacts use multi-core control cables with a min. conductor size 1.5 mm2,
e. g. LiYCY .. x 1.5 mm2.
16
Enclosure 10151
Basic settings
Factory setting
The oil detector & alarm features the following factory set default values:
 Measuring range ≥ 10 µS/cm
Selecting the measuring range
The measuring range can be switch-selected between ≥ 0.5 µ S/cm and ≥ 10 µS/cm by means of a
code switch s (toggle switch white):
1. Undo the cover screws g and take off the housing cover h. Fig. 6
Code switch 1 – 4 OFF Measuring range ≥ 0.5 µS/cm.
Code switch 1 – 4 ON Measuring range ≥ 10 µS/cm.
Attention
 Do not damage the electronic components when setting the code switch!
 Do not use a pencil to set the code switch!
17
Enclosure 10151
Danger
The terminal strip of the oil detector & alarm is live during operation.
Use only a completely insulated screwdriver according to VDE 0680 for setting the
measuring points.
Applying supply voltage

2. Please check that the oil detector & alarm is wired in accordance with the wiring diagram
(Fig. 8 page 16) and switch on mains voltage.
Operating valves
3. Close ball valve b and open ball valves c and d. If the cooling water line is under pressure the
rapid-action deaerator e will vent the ORGS 112.
4. If the measuring pot is vented and completely filled with cooling water the red LEDs f and g are
illuminated.
Operation
Normal operation, oil alarm
1. Under certain conditions air or gases that have been dissolved in the cooling water can accumulate
in the upper part of the measuring pot. The rapid-action deaerator e will automatically vent the
measuring pot during normal operation.
2. If oil accumulates in the upper part of the measuring pot and the electrode rods of the measuring
electrode are completely covered with oil, an oil alarm will be raised and the LEDs o and p
extinguish.
3. If an oil alarm has been triggered although there is no oil in the cooling water system, please refer
to the troubleshooting notes on page 19.
18
Enclosure 10151
Troubleshooting
Safety note
Danger
The terminal strip of the measuring electrode ORGS 111 is live during operation!
Indication, diagnosis and remedy
Attention
Before carrying out the fault diagnosis please check:

Supply voltage:
Is the oil detector & alarm supplied with the mains voltage specified on the name plate?
Wiring:
Is the wiring in accordance with the wiring diagram?
Indication of malfunctions
Oil alarm raised but no oil in cooling water system
Error Remedy
Power failure. Switch on supply voltage. Check all electrical connections.
Air or gases that have been dissolved in the cooling

Check rapid-action deaerator and replace it if necessary .
water have accumulated in the measuring pot.
The electrical conductivity is ≤ 10 μS/cm. Set code switch s to 0.5 μS/cm.See Basic Settings
Discard and replace defective thermal fuse. Stock code

Thermal fuse k defective. no. 052433.Check ambient temperature, make sure that it
does not exceed 70° C.
Clean seating surfaces and screw in the oil detector &
alarm together with the joint ring 33 x 39, form D, DIN 7603
The earth connection to the vessel is interrupted.
(made from 1.4301), bright annealed. Do not insulate the
electrode with hemp or PTFE tape!
The electronic module is faulty. Replace electronic module.
19
Enclosure 10151
Troubleshooting - continued -
Exchanging the electronic module

2. Pull electrode wires from terminal lugs on circuit board. Remove the terminal strip n.
3. Unscrew the fixing screws t for the electronic module u and remove the module. The module is
available as spare part..
4. Install the new electronic module in reverse order.
Spare parts list
Stock code # Stock code #

Item Designation
ORGS 11-1 ORGS 11-2
u Electronic module NRV 1-43 321 321
k Thermal fuse Tmax 102 °C 052 433
Note
When ordering spare parts please state the material number indicated on the name plate.
20
Enclosure 10151
Safety note
Danger
When loosening the measuring electrodes hot cooling water may escape.
Do not remove the measuring electrode ORGS 111 unless the boiler pressure is verified
to be zero.
The terminal strip of the measuring electrode ORGS 111 is live during operation! This
presents the danger of electric shock!
1. Close ball valves c and d.

2. Switch off supply voltage.
2. Undo cover screws g and remove the housing lid h.
3. Detach the connecting wires from the terminals n and pull wires out of the cable gland.
4. Before removing the equipment make sure that is is neither hot nor under pressure.
For the disposal of the measuring electrode observe the pertinent legal regulations concerning waste
disposal.
If faults occur that are not listed above or cannot be corrected, please contact our service centre or
authorized agency in your country.
21
Enclosure 10151
For your Notes
22
Enclosure 10151
For your Notes
23
Enclosure 10151
GESTRA
Agencies all over the world:

www.gestra.com

Fax 0044 16 35 / 3 60 34 Kempton Park 1613
E-Mail [email protected] Tel. 0027 11 / 9 23 73 00
Web www.flowserve.com Fax 0027 11 / 9 74 64 20
Singapore
Flowserve Pte. Ltd. USA
12 Tuas Avenue 20
Singapore 63882 Flowserve GESTRA U.S.
Tel. 0065 / 68 79 89 00 2341 Ampere Drive
Fax 0065 / 68 62 49 40 Louisville, KY 40299
E-Mail [email protected] Tel. 001 502 / 267-22 05
Web www.gestra.com Fax 001 502 / 266-53 97
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Tel. 0049 (0) 421 / 35 03 - 0
Fax 0049 (0) 421 / 35 03 - 393
E-mail [email protected]
Web www.gestra.com

24
ARI-STEVI® 470 / 471
10165 with electric and pneumatic actuators
Control valve - straight through with flanges and shaft guided plug
DN 15 - 150

Electric actuator ARI-PREMIO
• Enclosure IP 65
• 2 torque switches
• Handwheel
• Additional devices available, e.g. potentiometer
Page 2 Fig. 470

Electric actuator AUMA SAR
• Electric multiturn actuator capable of high
closing pressures
• Enclosure IP 67
• 2 travel switches
• Handwheel
• Overheating protection for motor as standard
• Explosion proof version available
Page 6

Pneumatic actuator ARI-DP
• Reversible pneumatic actuator
• Actuator with rolling diaphragm
• Air supply pressure max. 6 bar
• Stem protection by bellow
• Maintenance-free O-ring sealing
• Assembly of additional devices acc. to
DIN IEC 60534‑6
Fig. 471
Page 14
Features:
• Compact design
• Precision guided stem
• Burnished stem
• Tapered seat ring
• Replaceable seat and plug
• Screwed seat ring
• Kvs-values reducible up to 6 times
• Rangeability 50 : 1
• Post guided plug
• Spring loaded PTFE-V ring packing unit
• Two-ply bellows seal as standard
• Travel indicator
10165 Electric actuator ARI-PREMIO
Control valve straight through with electric actuator ARI-PREMIO

12.470 / 12.471 PN16 EN-JL1040 DN15-150
22.470 / 22.471 PN16 EN-JS1049 DN15-150
23.470 / 23.471 PN25 EN-JS1049 DN15-150
34.470 / 34.471 PN25 1.0619+N DN15-150
35.470 / 35.471 PN40 1.0619+N DN15-150
Other materials and versions on request.
Stem sealing
Fig. 470: • PTFE-V-ring unit -10°C up to +220°C
• PTFE-packing -10°C up to +250°C
• Pure graphite-packing -10°C up to +450°C
Fig. 471: • Stainless steel bellows seal with safety stuffing box -60°C up to +450°C
Plug design
standard: • Parabolic plug, metal seat
optional:
• Parabolic plug with PTFE soft seat (max. 200°C)
• V-port plug, metal seat
• Perforated plug, metal seat
• Parabolic pressure balanced plug (or perforated plug), metal seat;
Material of piston seal:
PTFE with stainless steel spring (max. 200°C)
Guiding
• Parabolic plug: post guiding
• Perforated / V-port plug: post and port guiding
Flow characteristic
• Equal percentage or linear
(from Kvs 100 modified equal percentage)
(Miniature-Kvs-values ≤ 0,63 only equal percentage)
Rangeability
Fig. 470 • 50 : 1 on parabolic plug
• 30 : 1 on perforated plug / V-port plug
Shut off class (seat / plug leakage classes)
• Metal seat - Leakage class IV acc. to DIN EN 1349 or IEC 60534-4
• Soft seat - Leakage class VI acc. to DIN EN 1349 or IEC 60534-4
(from Kvs 1,0)
Closing pressures refer to page 4-5.
Technical data for actuator refer to data sheet.

Industrial installations, processing technology, plant manufacturing, etc.
Fig. 470: Cooling water, cooling brine, warm water, hot water, steam, gas, etc.
Fig. 471: Refrigerant, cooling water, warm water, hot water, thermal oil, steam, gas, etc.
Fig. 471

10165 Electric actuator ARI-PREMIO
DN 15 20 25 32 40 50 65 80 100 125 150
L (mm) 130 150 160 180 200 230 290 310 350 400 480
Fig. 470 H (mm) 584 584 587 587 618 618 614 647 649 726 731
PN16/25 (kg) 12,2 13,1 13,9 15,4 20,2 21,9 26,4 36,4 50 71 98
ARI-PREMIO 2,2 kN
PN40 (kg) 12,8 13,9 14,9 16,9 21,9 23,9 29,4 40,9 57 82 114
PN16/25 (kg) 13,3 14,2 15 16,5 21,3 23 27,5 37,5 52 73 100
ARI-PREMIO 5 kN
PN40 (kg) 13,9 15 16 18 23 25 30,5 42 58 84 116
H (mm) -- -- -- -- 768 768 764 797 799 874 879
ARI-PREMIO 12 kN PN16/25 (kg) -- -- -- -- 25,3 27 31,5 41,5 56 77 104
ARI-PREMIO 15 kN PN40 (kg) -- -- -- -- 27 29 34,5 46 62 88 120
Fig. 471 H (mm) 741 741 744 744 829 829 838 847 877 1052 1058
PN16/25 (kg) 14,3 15,2 15,8 17,3 23,4 25,7 35,1 43,9 58 86 112
ARI-PREMIO 2,2 kN
PN40 (kg) 15,2 16,9 16,8 18,4 24 26,5 36,9 45,9 62 95 120
PN16/25 (kg) 15,4 16,3 16,9 18,4 24,5 26,8 36,2 44,2 60 87 113
ARI-PREMIO 5 kN
PN40 (kg) 16,3 17,2 17,9 19,5 25,1 27,6 38 47 63 96 121
H (mm) -- -- -- -- 979 979 988 997 1027 1200 1206
ARI-PREMIO 12 kN PN16/25 (kg) -- -- -- -- 28,5 30,8 40,2 48,2 64 91 117
ARI-PREMIO 15 kN PN40 (kg) -- -- -- -- 29,1 31,6 42 51 67 100 125
Parts
Fig. 12.470 Fig. 22.470 / Fig. 23.470 Fig. 34.470 / Fig. 35.470
Pos. Description
1 Body EN-GJL-250 , EN-JL1040 EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N
2 Seat ring * X20Cr13+QT, 1.4021+QT
3 Plug * X20Cr13+QT, 1.4021+QT
4 Straight pin * X10CrNi18-8, 1.4310
5 Stem * X20Cr13+QT, 1.4021+QT
6 Mounting bonnet EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N
7 Guide bushing X20Cr13+QT, 1.4021+QT (hardened)
9 Studs 25CrMo4, 1.7218
10 Hexagon nuts C35E, 1.1181
11 V-ring unit * PTFE
13 Washer * X5CrNi18-10, 1.4301
14 Spring * X10CrNi18-8, 1.4310
15 Strip * PTFE25%C
17 Scraper * PTFE
18 Stem guiding * X8CrNiS18-9, 1.4305
19 Packing box flange P250GH, 1.0460
20 Studs (refer to page 24) A4-70
21 Hexagon nuts (refer to page 24) A4
22.1 Bellows housing EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N
22.2 Mounting bonnet EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N
22.3 Stem- / Bellows unit * X20Cr13+QT, 1.4021+QT / X6CrNiTi18-10, 1.4541
22.4 Guide bushing X20Cr13+QT, 1.4021+QT (hardened)
22.6 Gasket * Pure graphite (CrNi laminated with graphite)
22.7 Studs 25CrMo4, 1.7218
22.8 Hexagon nuts C35E, 1.1181
22.10 Packing ring * Pure graphite
22.12 Washer * X5CrNi18-10, 1.4301
22.17 Screw joint * X8CrNiS18-9, 1.4305
* Spare parts

10165 Closing pressures: Electric actuator ARI-PREMIO
max. permissible closing pressures on flow-to-open P2 = 0
Observe restrictions by Pressure-temperature-ratings, refer to page 23.
DN 15 20 25 32 40
Seat-Ø (mm) 18 22 25 32 40
Standard 3)
Kvs-value 4 6,3 10 16 25
Kvs-value
Travel (mm) 20 20 20 20 30
Seat-Ø (mm) 3 5 12 3 5 12 18 3 5 12 18 22 22 25 25 32
0,25/ 2,5/ 0,25/ 2,5/ 0,25/ 2,5/
Reduced Kvs- 0,63/ 0,63/ 0,63/
Kvs-value 0,16/ 1,6/ 0,16/ 1,6/ 4 0,16/ 1,6/ 4 6,3 6,3 10 10 16
values 0,4 0,4 0,4
0,1 1 0,1 1 0,1 1
Travel (mm) 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
Max. differential Parabolic plug 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 30

pressure drop (bar) V-port plug
I. 40 40 40 40 40 40 40 40 40 40 40 40 40 40 35,9 40 35,9 21,6 35,2 21,1 13,2

Closing pressure
II. 40 40 40 40 40 40 40 40 40 40 40 40 40 40 33,7 40 33,7 20,2 32,1 19,2 11,9
Actuator 1) (bar)
ARI-PREMIO III. 33,3 33 32 31,1 33,3 33 32 31,1 30,5 31,8 31,5 30,5 29,6 29,1 28,6 29,1 28,6 18 28,6 18 11,2
2,2 kN Operating time 2) (s)
(Op. speed 0,38 53 53 53 53 53 79
mm/s)
I. 40 40 40 40 40 34,6
Closing pressure
Actuator 1) II. 40 40 40 40 40 33,4
(bar)
ARI-PREMIO III. 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 32,6
5 kN Operating time 2) (s)
(Op. speed 0,38 53 53 53 53 53 79
mm/s)
I. 40
Closing pressure
Actuator 1) II. 40
(bar)
ARI-PREMIO III. 40
(Op. speed 0,38 79
mm/s)
I. Fig. 470: PTFE-V-ring unit; II. Fig. 470: PTFE- / Pure graphite-packing; III. Fig. 471: Bellows seal
1) otor voltage: 230V 50Hz

M
Other voltages: 24V 50/60Hz; 115V 50/60Hz; 230V 60Hz
Technical data for actuator refer to data sheet ARI-PREMIO.
2) Indicated operating times with 50Hz.
3) Not for perforated plug (presentation ref. to page 24) acc. to Selection STEVI, refer to techn. annex.

10165 Closing pressures: Electric actuator ARI-PREMIO
(Observe regulations, refer to page 23. Plug design acc. to „Selection STEVI“, refer to techn. annex.)
DN 50 65 80 100 125 150
Seat-Ø (mm) 50 65 80 100 125 150
Standard 3)
Kvs-value 40 63 100 160 250 400
Kvs-value
Travel (mm) 30 30 30 30 50 50
Seat-Ø (mm) 32 40 40 50 50 65 65 80 80 100 100 125
Reduced Kvs-
Kvs-value 16 25 25 40 40 63 63 100 100 160 160 250
values
Travel (mm) 20 30 30 30 30 30 30 30 30 30 30 50
Max. differential Parabolic plug 40 30 30 30 30 15 30 15 8 15 8 4 8 4 2 4 2 2
pressure drop (bar) V-port plug 30 30 30 30 30 25 30 25 15 25 15 15
I. 21,1 13,2 8,1 13,2 8,1 4,5 8 4,4 2,7 4,4 2,7 1,5 2,7 1,5 1,5
Closing pressure
II. 19,2 11,9 7,3 11,9 7,3 4 7,1 3,9 2,3 3,9 2,3 1,3 2,3 1,3 1,3
Actuator 1) (bar)
III. 18 11,2 6,8 11,2 6,8 3,7 6,8 3,7 2,2 3,7 2,2 1,2 1,9 1 1
ARI-PREMIO
2,2 kN Operating time 2) (s)
(Op. speed 0,38 53 79 79 79 79 79 79
mm/s)
I. 40 34,6 21,9 34,6 21,9 12,7 21,8 12,6 8,2 12,6 8,2 5 8,2 5 3,1 5 3,1 2
Closing pressure
Actuator 1) II. 40 33,4 21,1 33,4 21,1 12,2 20,9 12,1 7,8 12,1 7,8 4,8 7,8 4,8 2,9 4,8 2,9 1,9
(bar)
ARI-PREMIO III. 40 32,6 20,6 32,6 20,6 11,9 20,6 11,9 7,7 11,9 7,7 4,7 7,4 4,5 2,8 4,5 2,8 1,8
(Op. speed 0,38 53 79 79 79 79 79 132 79 132
mm/s)
I. 40 40 40 40 33,3 40 33,2 21,8 33,2 21,8 13,8 21,8 13,8 8,7 13,8 8,7 5,9
Closing pressure
Actuator 1) II. 40 40 40 40 32,8 40 32,7 21,5 32,7 21,5 13,6 21,5 13,6 8,6 13,6 8,6 5,8
(bar)
ARI-PREMIO III. 40 40 40 40 32,5 40 32,5 21,3 32,5 21,3 13,5 21 13,3 8,4 13,3 8,4 5,7
(Op. speed 0,38 79 79 79 79 79 132 79 132
mm/s)
I. 40 40 27,7 40 27,7 17,6 27,7 17,6 11,1 17,6 11,1 7,6
Closing pressure
Actuator 1) II. 40 40 27,3 40 27,3 17,3 27,3 17,3 11 17,3 11 7,5
(bar)
ARI-PREMIO III. 40 40 27,2 40 27,2 17,3 26,9 17,1 10,8 17,1 10,8 7,4
(Op. speed 0,38 79 79 79 79 132 79 132
mm/s)
1) otor voltage: 230V 50Hz

M
Other voltages: 24V 50/60Hz; 115V 50/60Hz; 230V 60Hz
Technical data for actuator refer to data sheet ARI-PREMIO.

10165 Electric actuator AUMA SAR (MATIC)
Control valve straight through with electric actuator AUMA

12.470 / 12.471 PN16 EN-JL1040 DN15-150
22.470 / 22.471 PN16 EN-JS1049 DN15-150
23.470 / 23.471 PN25 EN-JS1049 DN15-150
34.470 / 34.471 PN25 1.0619+N DN15-150
35.470 / 35.471 PN40 1.0619+N DN15-150
Stem sealing
Plug design
optional:
Guiding • Parabolic plug: post guiding
Flow characteristic
Rangeability
• 50 : 1 on parabolic plug
Fig. 470 Shut off class (seat / plug leakage classes)

(from Kvs 1,0)
Closing pressures refer to page 7.

Fig. 471

DN 40 50 65 80 100 125 150
L (mm) 200 230 290 310 350 400 480
Fig. 470 H (mm) 658 658 654 687 689 744 749
AUMA SAR 07.2 PN16/25 (kg) 41,1 44,3 48,8 58,8 73 94 121
AUMA SAR 07.6 PN40 (kg) 42,8 46,3 51,8 63,3 79 105 137
H (mm) -- -- -- 699 701 756 761
PN16/25 (kg) -- -- -- 63,3 77 98 125
AUMA SAR 10.2
PN40 (kg) -- -- -- 67,8 84 109 141
Fig. 471 H (mm) 869 869 878 887 917 1070 1076
AUMA SAR 07.2 PN16/25 (kg) 45,8 48,1 57,5 65,5 81 108 134
AUMA SAR 07.6 PN40 (kg) 46,4 48,9 59,3 68,3 84 118 142
H (mm) -- -- -- 899 929 1082 1088
PN16/25 (kg) -- -- -- 70 85 113 139
AUMA SAR 10.2
PN40 (kg) -- -- -- 72,8 89 122 147
Standard-flange dimensions refer to page 23. (For version with AUMA SAR Ex other heights.)
Parts
Pos. Description
3 Plug * X20Cr13+QT, 1.4021+QT
5 Stem * X20Cr13+QT, 1.4021+QT
9 Studs 25CrMo4, 1.7218
13 Washer * X5CrNi18-10, 1.4301
14 Spring * X10CrNi18-8, 1.4310
15 Strip * PTFE25%C
17 Scraper * PTFE
22.7 Studs 25CrMo4, 1.7218
22.12 Washer * X5CrNi18-10, 1.4301
* Spare parts

10165 Closing pressures: Electric actuator AUMA SAR (MATIC)
Fig. 470
DN 40 50 65 80 100 125 150
Seat-Ø (mm) 40 50 65 80 100 125 150
Standard 4)
Kvs-value 25 40 63 100 160 250 400
Kvs-value
Travel (mm) 30 30 30 30 30 50 50
Seat-Ø (mm) 25 32 32 40 40 50 50 65 65 80 80 100 100 125
Reduced
Kvs-value 10 16 16 25 25 40 40 63 63 100 100 160 160 250
Kvs-values
Travel (mm) 20 20 20 30 30 30 30 30 30 30 30 30 30 50
Max. differential Parabolic plug 30 30 30 1530 30 30 15 8 15 8 4 8 4 2 4 2 2
Actuator 1) Closing pressure shut off 40 40 40 40 40 40 40 40 40 40 40 30,6 40 30,6 19,4
(bar) I./II.
AUMA controlling 3) 40 40 40 40 40 37,6 40 37,6 22 37,4 21,9 14,3 21,9 14,3 9
SAR 07.2 Torque (Nm) 15 15 20 15 20 30 20 30 30
Output drive
Operating time 2) (s) 54 56 54 56 56 56 56
Form A
TR 20 x 4 - LH Output drive (rpm) 5,6 8 5,6 8 8 8 8
Actuator 1) Closing pressure shut off 40 40 40 40 40 40 40 40 27,5 40 27,5 17,5 27,5 17,5 12
(bar) I./II.
AUMA controlling 3) 40 40 31,5 40 31,3 20,6 31,3 20,6 13 20,6 13 8,2 13 8,2 5,6
SAR 07.6 Torque (Nm) 30 30 40 30 40 60 40 60 60 60
Output drive
Operating time 2) (s) 64 64 64 64 64 55 64 55
Form A
TR 26 x 5 - LH Output drive (rpm) 5,6 5,6 5,6 5,6 5,6 11 5,6 11
Actuator 1) Closing pressure shut off 40 40 40 40 40 40 40 29,8 40 29,8 20,7
(bar) I./II.
AUMA controlling 3) 40 40 40 40 27,5 40 27,5 17,5 27,5 17,5 12
SAR 10.2 Torque (Nm) 60 60 90 60 90 100 90 100
Output drive
Operating time 2) (s) 64 64 64 55 64 55
Form A
TR 26 x 5 - LH Output drive (rpm) 5,6 5,6 5,6 11 5,6 11
I. Fig. 470: PTFE-V-ring unit; II. Fig. 470: PTFE- / Pure graphite-packing
Fig. 471
DN 40 50 65 80 100 125 150
Seat-Ø (mm) 40 50 65 80 100 125 150
Standard 4)
Kvs-value 25 40 63 100 160 250 400
Kvs-value
Travel (mm) 30 30 30 30 30 50 50
Seat-Ø (mm) 25 32 32 40 40 50 65 50 65 80 80 100 100 125
Reduced
Kvs-value 10 16 16 25 25 40 63 40 63 100 100 160 160 250
Kvs-values
Travel (mm) 20 20 20 30 30 30 30 30 30 30 30 30 30 50
Max. differential Parabolic plug 30 30 30 30
15 30 15 8 30 15 8 4 8 4 2 4 2 2
Actuator 1) Closing pressure shut off 40 40 40 40 40 40 40 40 40 40 40 30,4 40 30,4 19,4
(bar) III.
AUMA controlling 3) 40 40 40 40 40 37,1 40 37,1 21,7 37,1 21,7 14,2 21,7 14,2 8,9
SAR 07.2 Torque (Nm) 15 15 20 15 20 30 20 30 30
Output drive
Operating time 2) (s) 54 56 54 56 56 56 56
Form A
TR 20 x 4 - LH Output drive (rpm) 5,6 8 5,6 8 8 8 8
Actuator 1) Closing pressure shut off 40 40 40 40 40 40 40 40 27,4 40 27,2 17,3 27,2 17,3 11,9
(bar) III.
AUMA controlling 3) 40 40 31,2 40 31,2 20,4 31,2 20,4 12,9 20,1 12,7 8,0 12,7 8,0 5,5
SAR 07.6 Torque (Nm) 30 30 40 30 40 60 40 60 60 60
Output drive
Operating time 2) (s) 64 64 64 64 64 55 64 55
Form A
TR 26 x 5 - LH Output drive (rpm) 5,6 5,6 5,6 5,6 5,6 11 5,6 11
Actuator 1) Closing pressure shut off 40 40 40 40 32,2 40 40 29,7 40 29,7 20,5
(bar) III.
AUMA controlling 3) 40 40 40 40 27,4 40 27,2 17,3 27,2 17,3 11,9
SAR 10.2 Torque (Nm) 60 60 70 60 90 100 90 100
Output drive
Operating time 2) (s) 64 64 64 55 64 55
Form A
TR 26 x 5 - LH Output drive (rpm) 5,6 5,6 5,6 11 5,6 11
III. Fig. 471: Bellows seal
1) otor voltage: 400V 50Hz 3~

M
(Other voltages on request)
Technical data for actuator refer to price list.
3) Restrictions through max. permissible torque of the actuator at controlling operation.

10165 Notes

Control valve straight through with electric actuator AUMA

12.470 PN16 EN-JL1040 DN125v-150v
22.470 PN16 EN-JS1049 DN125v-150v
23.470 PN25 EN-JS1049 DN125v-150v
34.470 PN25 1.0619+N DN125v-150v
35.470 PN40 1.0619+N DN125v-150v
Fig. 471 with SAR14.2 on request
Stem sealing
Fig. 470: • PTFE-packing -10°C up to +250°C
Fig. 471: • Stainless steel-bellow (on request)
Plug design
optional:
Guiding
Flow characteristic
Rangeability
Fig. 470
(from Kvs 1,0)

Cooling water, cooling brine, warm water, hot water, steam, gas, etc.

DN 125v 150v
L (mm) 400 480
Fig. 470 H (mm) 858 888
PN16/25 (kg) 132 159
AUMA SAR 14.2
PN40 (kg) 147 176
Standard-flange dimensions refer to page 23. (For version with AUMA SAR Ex other heights.)
Parts
Pos. Description
3 Plug * X20Cr13+QT, 1.4021+QT
5 Stem * X20Cr13+QT, 1.4021+QT
9 Studs 25CrMo4, 1.7218
13 Washer * X5CrNi18-10, 1.4301
20 Studs A4-70
21 Hexagon nuts A4
24 Stuffing box housing EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N
26 Packing ring * PTFE or Pure graphite
* Spare parts

10165 Closing pressures: Electric actuator AUMA SAR (MATIC)
Fig. 470
DN 125v 150v
Seat-Ø (mm) 125 150
Standard 4)
Kvs-value 250 400
Kvs-value
Travel (mm) 50 50
Seat-Ø (mm) 80 100 100 125
Reduced Kvs-
Kvs-value 100 160 160 250
values
Travel (mm) 30 30 30 50
Max. differential Parabolic plug 8 4 2 4 2 2
pressure drop
(bar) V-port plug 30 25 15 25 15 15
Actuator 1) Closing pressure shut off 40 40 40 40 40 40
(bar) II.
AUMA controlling 3) 40 40 28,9 40 28,9 20
SAR 14.2 Torque (Nm) 120 175 120 175 250
Output drive
Operating time 2) (s) 38 63 38 63
Form A
TR 30 x 6 - LH Output drive (rpm) 8 8
II. Fig. 470: PTFE- / Pure graphite-packing
1) otor voltage: 400V 50Hz 3~

M
(Other voltages on request)
Technical data for actuator refer to price list.
3) Restrictions through max. permissible torque of the actuator at controlling operation.

10165 Notes

10165 Pneumatic actuator ARI-DP
Control valve straight through with pneumatic actuator DP

12.470 / 12.471 PN16 EN-JL1040 DN15-150
22.470 / 22.471 PN16 EN-JS1049 DN15-150
23.470 / 23.471 PN25 EN-JS1049 DN15-150
34.470 / 34.471 PN25 1.0619+N DN15-150
35.470 / 35.471 PN40 1.0619+N DN15-150
Stem sealing
Plug design
optional:
Guiding
Flow characteristic
Fig. 470 Rangeability
(from Kvs 1,0)

Top mounted handwheel

Actuator DP32 DP33 DP34
Fig. 471 Ø D1 (mm) 225 300 400
H1 (mm) 270 284 442
Weight (kg) 5 8 17
Technical data for actuator refer to data sheet DP32-34Tri.

DN 15 20 25 32 40 50 65 80 100 125 150
L (mm) 130 150 160 180 200 230 290 310 350 400 480
DP32 ØA (mm) 250
H (mm) 470 470 473 473 504 504 489 522 524 579 584
Fig. 470 PN16/25 (kg) 15,8 16,7 17,5 19 23,8 25,5 30 40 54 75 102
PN40 (kg) 16,4 17,5 18,5 20,5 25,5 27,5 33 44,5 61 86 118
H (mm) 627 627 630 630 715 715 713 722 752 905 911
Fig. 471 PN16/25 (kg) 17,9 18,8 19,4 20,9 27 29,3 38,7 46,7 62 90 115
PN40 (kg) 18,8 19,7 20,4 22 27,6 30,1 40,5 49,5 66 99 123
DP33 ØA (mm) 300
H (mm) 525 525 528 528 559 559 555 588 590 645 650
Fig. 470 PN16/25 (kg) 21,8 22,7 23,5 25 29,8 31,5 36 46 60 81 108
PN40 (kg) 22,4 23,5 24,5 26,5 31,5 33,5 39 50,5 67 92 124
H (mm) 682 682 685 685 770 770 779 788 818 971 977
Fig. 471 PN16/25 (kg) 23,9 24,8 25,4 26,9 33 35,5 44,7 52,7 68 96 121
PN40 (kg) 24,8 25,7 26,4 28 33,6 36,1 46,5 55,5 72 105 129
DP34 ØA (mm) -- -- -- -- 405
H (mm) -- -- -- -- 694 694 690 723 725 780 785
Fig. 470 PN16/25 (kg) -- -- -- -- 59,8 61,5 66 76 90 111 138
PN40 (kg) -- -- -- -- 61,5 63,5 69 80,5 97 122 154
H (mm) -- -- -- -- 905 905 914 923 953 1106 1112
Fig. 471 PN16/25 (kg) -- -- -- -- 63 65,3 74,7 82,7 98 126 151
PN40 (kg) -- -- -- -- 63,6 66,1 76,5 85,5 102 135 159
Parts
Pos. Description
3 Plug * X20Cr13+QT, 1.4021+QT
5 Stem * X20Cr13+QT, 1.4021+QT
9 Studs 25CrMo4, 1.7218
13 Washer * X5CrNi18-10, 1.4301
14 Spring * X10CrNi18-8, 1.4310
15 Strip * PTFE25%C
17 Scraper * PTFE
22.7 Studs 25CrMo4, 1.7218
22.12 Washer * X5CrNi18-10, 1.4301
* Spare parts

10165 Closing pressures: Pneumatic actuator ARI-DP
Spring closes on air failure
DN 15 20 25 32 40
3)
Seat-Ø (mm) 18 22 25 32 40
Standard
Kvs-value 4 6,3 10 16 25
Kvs-value
Travel (mm) 20 20 20 20 30
Seat-Ø (mm) 3 5 12 3 5 12 18 3 5 12 18 22 22 25 25 32
0,25/ 2,5/ 0,25/ 2,5/ 0,25/ 2,5/
Reduced Kvs- 0,63/ 0,63/ 0,63/
Kvs-value 0,16/ 1,6 0,16/ 1,6 4 0,16/ 1,6 4 6,3 6,3 10 10 16
values 0,4 0,4 0,4
0,1 1 0,1 1 0,1 1
Travel (mm) 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
I. 30,6 29,2 21,2 8,1 30,6 29,2 21,2 8,1 4,8 30,6 29,2 21,2 8,1 4,8 3,3 4,8 3,3 1,3 2,5
0,2-1,0 1,2 II. 20 18,6 11,9 3,8 20 18,6 11,9 3,8 1,8 20 18,6 11,9 3,8 1,8 1 1,8 1
III. 2,3 2 1 2,3 2 1
I. 40 40 40 25,8 40 40 40 25,8 16,8 40 40 40 25,8 16,8 12,6 16,812,6 7,1 11,9 6,7 3,8
Air supply pressure min. (bar)
0,4-1,2 1,4 II. 40 40 40 21,4 40 40 40 21,4 13,8 40 40 40 21,4 13,8 10,3 13,810,3 5,7 8,8 4,8 2,6
III. 11,2 10,9 9,9 9 11,2 10,9 9,9 9 8,4 9,7 9,4 8,4 7,5 7 6,5 7 6,5 3,6 6,5 3,6 1,8
Spring range (bar)
I. 40 40 40 40 40 31,4 40 31,418,7 30,6 18,3 11,3

Actuator
DP32
0,8-2,4 2,7 II. 40 40 37,8 40 37,8 29,1 37,829,117,3 27,5 16,4 10,1
III. 28,9 28,6 27,6 26,7 28,9 28,6 27,6 26,7 26,227,5 27,2 26,2 25,3 24,7 24,3 24,724,315,2 24,3 15,2 9,3
I. 40 40 39 40 38,6
1,5-2,5 2,8 II. 40 40 40 40 40 37,6 40 36,7
III. 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 35,5 40 35,5
I. 40 40
2,0-3,3 3,6 II. 40 40
III. 40 40
I. 40 c) 40 c) 40 c) 18,6c) 40 c) 40 c) 40 c) 18,6c) 11,9c) 40 c) 40 c) 40 c) 18,6c) 11,9c) 8,8 c) 11,9c) 8,8 c) 4,8 c) 8 a) 4,3 a) 2,3 a)
0,2-1,0 1,2 II. 40 c) 40 c) 34,4c) 14,2c) 40 c) 40 c) 34,4c) 14,2c) 8,9 c) 40 c) 40 c) 34,4c) 14,2c) 8,9 c) 6,5 c) 8,9 c) 6,5 c) 3,4 c) 5 a) 2,4 a) 1,1 a)
III. 7,5 a) 7,2 a) 6,2 a) 5,4 a) 7,5 a) 7,2 a) 6,2 a) 5,4 a) 4,8 a) 6,1 a) 5,8 a) 4,8 a) 3,9 a) 3,3 a) 2,9 a) 3,3 a) 2,9 a) 1,2 a) 2,9 a) 1,2 a)
I. 40 c) 40 c) 31 c) 40 c) 31 c) 23,7c) 31 c) 23,7c) 14 c) 22,9a) 13,5a) 8,3 a)
0,4-1,2 1,4 II. 40 c) 40 c) 40 c) 40 c) 28 c) 40 c) 40 c) 28 c) 21,4c) 28 c) 21,4c) 12,6c) 19,9a) 11,6a) 7 a)

III. 21,7a) 21,4a) 20,4a) 19,5a) 21,7a) 21,4a) 20,4a) 19,5a) 18,9a) 20,2a) 19,9a) 18,9a) 18 a) 17,5a) 17 a) 17,5a) 17 a) 10,5a) 17 a) 10,5a) 6,3 a)
Spring range (bar)
I. 40 a) 40 a) 40 a) 40 a) 40 a) 32,5a) 40 32 20,2
Actuator
DP33
0,8-2,4 2,7 II. 40 a) 40 a) 40 a) 40 a) 40 a) 31,1a) 40 30,1 19

III. 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 28,9 40 28,9 18,2
I. (40 a)) (40) 40
1,5-3,0 3,3
II. (40 a)) (40) 39,9
(1,7-2,7) (3,1)
III. (40) (40) 39,1
I.
2,0-4,0 4,5 II. 40
III. 40
I. 8,3 e)
0,2-1,0 1,2 II. 7,1 e)
III. 6,4 e)
I. 20,4d)
0,4-1,2 1,4 II. 19,1d)
III. 18,4d)
I. 40 b)
0,8-2,4 2,7 II. 40 b)

III. 40 b)
Spring range (bar)
I.
Actuator
DP34
1,5-3,0 3,3 II.

III.
I.
2,1-3,0 3,3 II.
III. 3) Notfor perforated plug (presentation ref. to page
I.
24) acc. to Selection STEVI, refer to techn.
2,0-4,0 4,5 II. annex.
III.
I.
2,4-3,6 4 II.
III.
Air supply pressure max. of pneumatic actuators DP: max. permissible 6 bar
Air supply pressure max. limit of control valve: max. permissible a) 5 bar b) 4,5 bar c) 4 bar d) 3,5 bar e) 3 bar

DN 50 65 80 100 125 150
3)
Seat-Ø (mm) 50 65 80 100 125 150
Standard
Kvs-value 40 63 100 160 250 400
Kvs-value
Travel (mm) 30 30 30 30 50 50
Seat-Ø (mm) 32 40 40 50 50 65 65 80 80 100 100 125
Reduced Kvs-
Kvs-value 16 25 25 40 40 63 63 100 100 160 160 250
values
Travel (mm) 20 30 30 30 30 30 30 30 30 30 30 50
I.
0,2-1,0 1,2 II.
III.
I. 6,7 3,8 2,1 3,8 2,1 2
0,4-1,2 1,4 II. 4,8 2,6 1,3 2,6 1,3 1,1

III. 3,6 1,8 1,8
Spring range (bar)
I. 18,3 11,3 6,9 11,3 6,9 3,8 6,8 3,7 2,2 3,7 2,2 1,2 2,2 1,2 1,2
Actuator
DP32
0,8-2,4 2,7 II. 16,4 10,1 6,1 10,1 6,1 3,3 5,9 3,2 1,9 3,2 1,9 1 1,9 1 1
III. 15,2 9,3 5,6 9,3 5,6 3 5,6 3 1,8 3 1,8 1,5
I. 38,6
1,5-2,5 2,8 II. 36,7
III. 35,5
I. 40
2,0-3,3 3,6 II. 40
III. 40
I. 4,3 a) 2,3 a) 1,1 a) 2,3 a) 1,1 a) 1
0,2-1,0 1,2 II. 2,4 a) 1,1 a) 1,1 a)
III. 1,2 a)
I. 13,5 a) 8,3 a) 4,9 a) 8,3 a) 4,9 a) 2,6 a) 4,8 2,5 1,4 2,5 1,4 1,4
0,4-1,2 1,4 II. 11,6 a) 7 a) 4,1 a) 7 a) 4,1 a) 2,1 a) 3,9 2 1,1 2 1,1 1,1
III. 10,5 a) 6,3 a) 3,7 a) 6,3 a) 3,7 a) 1,8 a) 3,7 1,8 1 1,8 1
Spring range (bar)
I. 32 20,2 12,6 20,2 12,6 7,2 12,5 7,1 4,5 7,1 4,5 2,7 4,5 2,7 2,7
Actuator
DP33
0,8-2,4 2,7 II. 30,1 19 11,8 19 11,8 6,7 11,6 6,6 4,1 6,6 4,1 2,5 4,1 2,5 2,5
III. 28,9 18,2 11,3 18,2 11,3 6,4 11,3 6,4 4 6,4 4 2,4 3,7 2,2 2,2
I. (40) 40 26,1 40 26,1 15,2 26 15,1 9,8 15,1 9,8 6,1 9,8 6,1 6,1
1,5-3,0 3,3
II. (40) 39,9 25,3 39,9 25,3 14,7 25,1 14,6 9,5 14,6 9,5 5,9 9,5 5,9 5,9
(1,7-2,7) (3,1)
III. (40) 39,1 24,8 39,1 24,8 14,4 24,8 14,4 9,3 14,4 9,3 5,8 9 5,6 5,6
I. 35,7 35,7 20,9 35,6 20,9 13,6 20,9 13,6 8,5 13,6 8,5 8,5
2,0-4,0 4,5 II. 40 34,9 40 34,9 20,5 34,7 20,4 13,3 20,4 13,3 8,3 13,3 8,3 8,3
III. 40 34,4 40 34,4 20,2 34,4 20,2 13,1 20,2 13,1 8,2 12,9 8,1 8,1
I. 8,3 e) 5 e) 8,3 e) 5 e) 2,6 e) 4,9 2,6 1,5 2,6 1,5 1,5
0,2-1,0 1,2 II. 7,1 e) 4,2 e) 7,1 e) 4,2 e) 2,1 e) 4 2 1,1 2 1,1 1,1
III. 6,4 e) 3,7 e) 6,4 e) 3,7 e) 1,9 e) 3,7 b) 1,9 b) 1 b) 1,9 b) 1 b)
I. 20,4d) 12,7d) 20,4d) 12,7d) 7,2 d) 12,6 7,2 4,5 7,2 4,5 2,7 4,5 2,7 1,6 2,7 1,6 1
0,4-1,2 1,4 II. 19,1d) 11,9d) 19,1d) 11,9d) 6,8 d) 11,7 6,6 4,2 6,6 4,2 2,5 4,2 2,5 1,4 2,5 1,4
III. 18,4d) 11,4d) 18,4d) 11,4d) 6,5 d) 11,4b) 6,5 b) 4,1 b) 6,5 b) 4,1 b) 2,4 b) 3,8 2,2 1,3 2,2 1,3
I. 40 b) 28,2b) 40 b) 28,2b) 16,5b) 28,1 16,4 10,6 16,4 10,6 6,6 10,6 6,6 4,1 6,6 4,1 2,7
0,8-2,4 2,7 II. 40 b) 27,4b) 40 b) 27,4b) 16 b) 27,2 15,9 10,3 15,9 10,3 6,4 10,3 6,4 4 6,4 4 2,6
III. 40 b) 26,9b) 40 b) 26,9b) 15,7b) 26,9 15,7 10,2 15,7 10,2 6,3 9,9 6,2 3,8 6,2 3,8 2,5
Spring range (bar)
I. 8,5 8,5 5,8

Actuator
DP34
1,5-3,0 3,3 II. 8,4 8,4 5,7

III. 8,2 8,2 5,6
I. 40 a) 40 a) 40 a) 40 40 30,5 40 30,5 19,4 30,5 19,4 19,4
2,1-3,0 3,3 II. 40 a) 40 a) 40 a) 40 40 30,2 40 30,2 19,2 30,2 19,2 19,2
III. 40 a) 40 a) 40 a) 40 40 30,1 40 30,1 19,1 29,8 18,9 18,9
I. 11,7 11,7 8
2,0-4,0 4,5 II. 11,5 11,5 7,9
III. 11,4 11,4 7,8
I. 35,1 35,1 22,4 35,1 22,4 22,4
2,4-3,6 4 II. 34,8 34,8 22,2 34,8 22,2 22,2
III. 34,7 34,7 22,1 34,4 21,9 21,9

Spring opens on air failure
DN 15 20 25 32 40
Seat-Ø (mm) 18 22 25 32 40
Standard 3)
Kvs-value 4 6,3 10 16 25
Kvs-value
Travel (mm) 20 20 20 20 30
Seat-Ø (mm) 3 5 12 3 5 12 18 3 5 12 18 22 22 25 25 32
0,25/ 2,5/ 0,25/ 2,5/ 0,25/ 2,5/
Reduced 0,63/ 0,63/ 0,63/
Kvs-value 0,16/ 1,6 0,16/ 1,6 4 0,16/ 1,6 4 6,3 6,3 10 10 16
Kvs-values 0,4 0,4 0,4
0,1 1 0,1 1 0,1 1
Travel (mm) 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
I. 40 40 40 25,8 40 40 40 25,8 16,8 40 40 40 25,8 16,8 12,6 16,8 12,6 7,1 11,9 6,7 3,8
1,4 II. 40 40 40 21,4 40 40 40 21,4 13,8 40 40 40 21,4 13,8 10,3 13,8 10,3 5,7 8,8 4,8 2,6
III. 11,2 10,9 9,9 9 11,2 10,9 9,8 9 8,4 9,7 9,4 8,4 7,5 7 6,5 7 6,5 3,6 6,5 3,6 1,8
I. 40 40 40 40 40 40 40 40 24,5 40 24,1 15,1
2 II. 40 40 40 40 40 38,4 40 38,4 23,1 36,9 22,2 13,8
III. 37,8 37,5 36,5 35,6 37,8 37,5 36,5 35,6 35 36,3 36,1 35 34,2 33,6 33,2 33,6 33,2 21 33,2 21 13,1
I. 40 40 33,8
3 II. 40 40 40 40 40 32,6
Actuator
III. 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 40 31,8
DP32
I. 40
4 II. 40
III. 40
I.
5 II.
III.
I.
6 II.
III.
I. 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 31 d) 40 d) 40 d) 40 d) 40 d) 31 d) 23,7d) 31 d) 23,7d) 14 d) 22,9d) 13,5d) 8,3 d)
1,4 II. 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 28,2d) 40 d) 40 d) 40 d) 40 d) 28 d) 21,4d) 28 d) 21,4d) 12,6d) 19,9d) 11,6d) 7 d)
III. 21,7d) 21,4d) 20,4d) 19,5d) 21,7d) 21,4d) 20,4d) 19,5d) 18,9d) 20,2d) 19,9d) 18,9d) 18,2d) 17,5d) 17 d) 17,5d) 17 d) 10,5d) 17 d) 10,5d) 6,3 d)
I. 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 26,2d)
2 II. 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 39,3d) 24,9d)
III. 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 40 d) 38,2d) 40 d) 38,2d) 24,2d)
I. 40 d)
3 II. 40 d) 40 d)
Actuator
III. 40 d) 40 d) 40 d)
DP33
I.
4 II.
III.
I.
5 II.
III.
I.
6 II.
III.
I. 20,4e)
1,4 II. 19,1e)
III. 18,4e)
I. 40 e)
2 II. 40 e)
III. 40 e)
I.
3 II.
Actuator
III.
DP34
I.
4 II.
III.
I.
5 II. 3) Not for perforated plug (presentation ref. to
III. page 24) acc. to Selection STEVI, refer to techn.
I. annex.
6 II.
III.

DN 50 65 80 100 125 150
Seat-Ø (mm) 50 65 80 100 125 150
Standard 3)
Kvs-value 40 63 100 160 250 400
Kvs-value
Travel (mm) 30 30 30 30 50 50
Seat-Ø (mm) 32 40 40 50 50 65 65 80 80 100 100 125
Reduced
Kvs-value 16 25 25 40 40 63 63 100 100 160 160 250
Kvs-values
Travel (mm) 20 30 30 30 30 30 30 30 30 30 30 50
I. 6,7 3,8 2,1 3,8 2,1 2
1,4 II. 4,8 2,6 1,3 2,6 1,3 1,1
III. 3,6 1,8 1,8
I. 24,1 15,1 9,3 15,1 9,3 5,2 9,2 5,1 3,2 5,1 3,2 1,8 3,2 1,8 1,8
2 II. 22,2 13,8 8,5 13,8 8,5 4,7 8,3 4,6 2,8 4,6 2,8 1,6 2,8 1,6 1,6
III. 21 13,1 8 13,1 8 4,4 8 4,4 2,7 4,4 2,7 1,5 2,4 1,4 1,4
I. 40 33,8 21,4 33,8 21,4 12,4 21,3 12,4 8 12,4 8 4,9 8 4,9 4,9
3 II. 40 32,6 20,6 32,6 20,6 11,9 20,4 11,8 7,6 11,8 7,6 4,7 7,6 4,7 4,7
Actuator
III. 40 31,8 20,1 31,8 20,1 11,6 20,1 11,6 7,5 11,6 7,5 4,6 7,2 4,4 4,4
DP32
I. 40 33,5 40 33,5 19,6 33,4 19,6 12,7 19,6 12,7 8 12,7 8 8

4 II. 40 32,7 40 32,7 19,1 32,5 19 12,4 19 12,4 7,8 12,4 7,8 7,8
III. 40 32,2 40 32,2 18,9 32,2 18,9 12,3 18,9 12,3 7,7 12 7,5 7,5
I. 40 40 26,8 40 26,8 17,5 26,8 17,5 11,1 17,5 11,1 11,1
5 II. 40 40 26,4 40 26,2 17,2 26,2 17,2 10,8 17,2 10,8 10,8
III. 40 40 26,1 40 26,1 17 26,1 17 10,8 16,8 10,6 10,6
I. 34 34 22,3 34 22,3 14,1 22,3 14,1 14,1
6 II. 33,6 33,4 21,9 33,4 21,9 13,9 21,9 13,9 13,9
III. 33,3 33,3 21,8 33,3 21,8 13,8 21,5 13,6 13,6
I. 13,5 d) 8,3 d) 4,9 d) 8,3 d) 4,9 d) 2,6 d) 4,8 d) 2,5 d) 1,4 d) 2,5 d) 1,4 d) 1,4 d)
1,4 II. 11,6 d) 7 d) 4,1 d) 7 d) 4,1 d) 2,1 d) 3,9 d) 2 d) 1,1 d) 2 d) 1,1 d) 1,1 d)
III. 10,5 d) 6,3 d) 3,7 d) 6,3 d) 3,7 d) 1,8 d) 3,7 d) 1,8 d) 1 d) 1,8 d) 1 d)
I. 40 d) 26,2 d) 16,5 d) 26,2 d) 16,5 d) 9,5 d) 16,4 d) 9,4 d) 6 d) 9,4 d) 6 d) 3,7 d) 6 d) 3,7 d) 3,7 d)
2 II. 39,3 d) 24,9 d) 15,7 d) 24,9 d) 15,7 d) 9 d) 15,5 d) 8,9 d) 5,7 d) 8,9 d) 5,7 d) 3,4 d) 5,7 d) 3,4 d) 3,4 d)
III. 38,2 d) 24,2 d) 15,2 d) 24,2 d) 15,2 d) 8,7 d) 15,2 d) 8,7 d) 5,5 d) 8,7 d) 5,5 d) 3,4 d) 5,2 d) 3,2 d) 3,2 d)
I. 40 d) 35,7 d) 40 d) 35,7 d) 20,9 d) 35,6 d) 20,9 d) 13,6 d) 20,9 d) 13,6 d) 8,5 d) 13,6 d) 8,5 d) 8,5 d)
3 II. 40 d) 40 d) 34,9 d) 40 d) 34,9 d) 20,5 d) 34,7 d) 20,4 d) 13,3 d) 20,4 d) 13,3 d) 8,3 d) 13,3 d) 8,3 d) 8,3 d)
Actuator
III. 40 d) 40 d) 34,4 d) 40 d) 34,4 d) 20,2 d) 34,4 d) 20,2 d) 13,1 d) 20,2 d) 13,1 d) 8,2 d) 12,9 d) 8,1 d) 8,1 d)
DP33
I. 40 a) 40 a) 32,4 a) 40 32,4 21,2 32,4 21,2 13,4 21,2 13,4 13,4

4 II. 40 a) 40 a) 31,9 a) 40 31,8 20,9 31,8 20,9 13,2 20,9 13,2 13,2
III. 40 a) 40 a) 31,6 a) 40 31,6 20,7 31,6 20,7 13,1 20,5 12,9 12,9
I. 40 a) 40 28,8 40 28,8 18,3 28,8 18,3 18,3
5 II. 40 a) 40 28,5 40 28,5 18,1 28,5 18,1 18,1
III. 40 a) 40 28,4 40 28,4 18 28,1 17,8 17,8
I. 36,4 36,4 23,2 36,4 23,2 23,2
6 II. 36,1 36,1 23 36,1 23 23
III. 36 36 22,9 35,7 22,7 22,7
I. 20,4 e) 12,7 e) 20,4 e) 12,7 e) 7,2 e) 12,6 7,2 4,5 7,2 4,5 2,7 4,5 2,7 1,6 2,7 1,6 1
1,4 II. 19,1 e) 11,9 e) 19,1 e) 11,9 e) 6,8 e) 11,7 6,6 4,2 6,6 4,2 2,5 4,2 2,5 1,4 2,5 1,4
III. 18,4 e) 11,4 e) 18,4 e) 11,4 e) 6,5 e) 11,4 b) 6,5 b) 4,1 b) 6,5 b) 4,1 b) 2,4 b) 3,8 2,2 1,3 2,2 1,3
I. 40 e) 36 e) 40 e) 36 e) 21,1 e) 35,9 21 13,7 21 13,7 8,6 13,7 8,6 5,4 8,6 5,4 3,6
2 II. 40 e) 35,2 e) 40 e) 35,2 e) 20,6 e) 35 20,5 13,4 20,5 13,4 8,4 13,4 8,4 5,2 8,4 5,2 3,5
III. 40 e) 34,7 e) 40 e) 34,7 e) 20,3 e) 34,7 b) 20,3 b) 13,2 b) 20,3 b) 13,2 b) 8,3 b) 12,9 8,1 5,1 8,1 5,1 3,4
I. 40 e) 40 e) 40 e) 40 40 29 40 29 18,4 29 18,4 11,7 18,4 11,7 8

3 II. 40 e) 40 e) 40 e) 40 40 28,7 40 28,7 18,2 28,7 18,2 11,5 18,2 11,5 7,9
Actuator
III. 40 e) 40 e) 40 e) 40 b) 40 b) 28,5 b) 40 b) 28,5 b) 18,1 b) 28,3 18 11,4 18 11,4 7,8

DP34
I. 40 40 28,3 40 28,3 18 28,3 18 12,4

4 II. 40 40 28,1 40 28,1 17,9 28,1 17,9 12,3
III. 40 b) 40 b) 28 b) 40 27,8 17,7 27,8 17,7 12,2
I. 3) Not for perforated plug (presentation ref. to 38,1 38,1 24,3 38,1 24,3 16,8
5 II. page 24) acc. to Selection STEVI, refer to techn. 37,9 37,9 24,2 37,9 24,2 16,7
III. annex. 37,6 24 37,6 24 16,6
I. 40 40 30,6 40 30,6 21,2
6 II. 40 40 30,5 40 30,5 21,1
III. 40 30,3 40 30,3 21

Control valve straight through with pneumatic actuator DP

12.470 / 12.471 PN16 EN-JL1040 DN125v-150v
22.470 / 22.471 PN16 EN-JS1049 DN125v-150v
23.470 / 23.471 PN25 EN-JS1049 DN125v-150v
34.470 / 34.471 PN25 1.0619+N DN125v-150v
35.470 / 35.471 PN40 1.0619+N DN125v-150v
Stem sealing
Fig. 470: • PTFE-packing -10°C up to +250°C
Plug design
optional:
Guiding
Flow characteristic • Equal percentage or linear
Rangeability
Fig. 470
(from Kvs 1,0)

til valve center
til valve center
DP34Tri DP35
Top mounted handwheel
Actuator DP34T DP34Tri
Ø D1 (mm) 400 400
H1 (mm) 635 635
Weight (kg) 41 41
Fig. 471 Technical data for actuator refer to data sheet DP32-34Tri.

DN 125v 150v
L (mm) 400 480
DP34 ØA (mm) 405
T H (mm) 1021 1051
Fig. 470 PN16 (kg) 181 210
PN25/40 (kg) 192 225
H (mm) 1468 1498
Fig. 471 PN16 (kg) 204 232
PN25/40 (kg) 227 256
DP34 ØA (mm) 405
Tri H (mm) 1243 1273
Fig. 470 PN16 (kg) 216 243
PN25/40 (kg) 227 259
H (mm) 1690 1720
Fig. 471 PN16 (kg) 234 260
PN25/40 (kg) 261 290
DP35 ØA (mm) 755
H (mm) 1124 1154
Fig. 470 PN16/25 (kg) 387 414
PN40 (kg) 398 430
Face-to-face dimension FTF series 1 according to DIN EN 558.
Parts
Pos. Description
2 Seat ring X20Cr13+QT, 1.4021+QT
3 Plug * X20Cr13+QT, 1.4021+QT
5 Stem * X20Cr13+QT, 1.4021+QT
9 Studs 25CrMo4, 1.7218
13 Washer * X5CrNi18-10, 1.4301
20 Studs A4-70
21 Hexagon nuts A4
22.7 Studs 25CrMo4, 1.7218
22.9 Straight pin St
22.12 Washer * X5CrNi18-10, 1.4301
22.13 Stuffing box housing EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N
22.15 Packing follower X20Cr13+QT, 1.4021+QT
22.16 Sleeve nut X8CrNiS18-9, 1.4305
24 Stuffing box housing EN-GJS-400-18U-LT, EN-JS1049 GP240GH+N, 1.0619+N
29 Adapter flange EN-GJS-400-18U-LT, EN-JS1049
30 Hexagon socket head screw 8.8 - A2B
35 Stem adapter * X20Cr13+QT, 1.4021+QT
38 Studs 25CrMo4, 1.7218
* Spare parts

DN 125v 150v
Seat-Ø (mm) 125 150
Standard 3)
Kvs-value 250 400
Kvs-value
Travel (mm) 50 50
Seat-Ø (mm) 80 100 100 125
Reduced Kvs-values 3) Kvs-value 100 160 160 250
Travel (mm) 30 30 30 50
pressure drop (bar) V-port plug 30 25 15 25 15 15
II. 3,7 b) 2,2 b) 1,2 b) 2,2 b) 1,2 b)
0,2-1,0 1,5
III. 3,7 e) 2,2 e) 1,3 e) 2,2 e) 1,3 e)
II. 9,8 b) 6,1 b) 3,8 b) 6,1 b) 3,8 b) 2,5 b)
0,4-1,2 1,7
III. 9,9 d) 6,2 d) 3,8 d) 6,2 d) 3,8 d) 2,5 d)
II. 22,1 14 8,8 14 8,8 6
0,8-2,4 2,9
III. 22,1 b) 14 b) 8,8 b) 14 b) 8,8 b) 6 b)
Actuator
II. 17,7 17,7 12,2

DP34T
1,5-3,0 3,5
III. 17,7 a) 17,7 a) 12,2 a)
II. 40 39,6 39,6
2,1-3,0 3,5
III. 40 a) 39,6 a) 39,6 a)
II. 24 24 16,6
2,0-4,0 4,5
III. 24 24 16,6
II. 40 40
2,4-3,6 4,1
III.
II. 6,8 d) 4,1 d) 2,5 d) 4,1 d) 2,5 d) 1,6 d)
0,2-1,0 1,5
III. 6,8 f) 4,2 f) 2,5 f) 4,2 f) 2,5 f) 1,6 f)
II. 16 d) 10,1 d) 6,3 d) 10,1 d) 6,3 d) 4,3 d)
0,4-1,2 1,7
III. 16 f) 10,1 f) 6,3 f) 10,1 f) 6,3 f) 4,3 f)
Actuator
DP34Tri
II. 34,3 b) 21,9 b) 13,9 b) 21,9 b) 13,9 b) 9,5 b)

0,8-2,4 2,9
III. 34,4 d) 21,9 d) 13,9 d) 21,9 d) 13,9 d) 9,6 d)
II. 27,1 a) 27,1 a) 18,8 a)
1,5-3,0 3,5
III. 27,2 b) 27,2 b) 18,8 b)
2,1-3,0 3,5 II. 40 a) 40 a) 40 a)
2,0-4,0 4,5 II. 36,6 a) 36,6 a) 25,4 a)
Actuator
DP35
1,8-3,8 4,3 II. 40 40 40
II. Fig. 470 PTFE- / Pure graphite-packing; III. Fig. 471: Bellows seal
DN 125v 150v
Seat-Ø (mm) 125 150
Standard 3)
Kvs-value 250 400
Kvs-value
Travel (mm) 50 50
Seat-Ø (mm) 80 100 100 125
Reduced Kvs-
Kvs-value 100 160 160 250
values 3)
Travel (mm) 30 30 30 50
pressure drop (bar) V-port plug 30 25 15 25 15 15
II. 12,9 b) 8,1 b) 5 b) 8,1 b) 5 b) 3,4 b)
1,5
III. 12,9 e) 8,1 e) 5,1 e) 8,1 e) 5,1 e) 3,4 e)
Air supply pressure min.
II. 28,2 b) 17,9 b) 11,3 b) 17,9 b) 11,3 b) 7,8 b)

Actuator
2
DP34T
III. 28,3 e) 18 e) 11,4 e) 18 e) 11,4 e) 7,8 e)

II. 40 b) 37,6 b) 24 b) 37,6 b) 24 b) 16,6 b)
3
III. 40 e) 37,6 e) 24 e) 37,6 e) 24 e) 16,6 e)
(bar)
4 II. 40 b) 36,6 b) 40 b) 36,6 b) 25,4 b)

II. Fig. 470 PTFE- / Pure graphite-packing; III. Fig. 471: Bellows seal
Air supply pressure max. of pneumatic actuators DP: max. permissible 6 bar (DP34Tri: max. zul. 5 bar)
Air supply pressure max. limit of control valve: max. permissible a) 5 bar b) 4,5 bar c) 4 bar d) 3,5 bar e) 3 bar f) 2,5 bar

10165 Flange dimensions / Pressure-temperature-ratings
DN 15 20 25 32 40 50 65 80 100 125 150

PN16 ØD (mm) 95 105 115 140 150 165 185 200 220 250 285
PN16 ØK (mm) 65 75 85 100 110 125 145 160 180 210 240
PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22
PN25 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300
PN25 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250
PN40 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300
PN40 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250

EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6 -- -- --

1.0619+N 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 8,2
1.0619+N 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 13,1
* Valve with extended bonnet, studs and nuts made of A4-70 (at temperatures below -10°C)

- Figure-No.
- Nominal diameter
- Nominal pressure
- Body material
- Plug design
- Kvs-value
- Flow characteristic
- Stem sealing
Dimensions in mm
- Actuator
Weights in kg
Pressures in barg (gauge)
Example:
1 bar =^ 105 Pa =^ 0,1 MPa
Figure 35.470; nominal diameter DN 100; nominal pressure PN 40; body material 1.0619+N; parabolic plug; kvs 160; equal
Kvs in m3/h
percentage; PTFE-V-ring unit; ARI-PREMIO 5 kN.

10165 Constructions
Stem sealing
Spring loaded PTFE-V ring packing unit PTFE-/ Pure graphite-packing

Pos. Description
13 Washer * X5CrNi18-10, 1.4301
20 Studs A4-70
21 Hexagon nuts A4
25 Distance bush * X20Cr13+QT, 1.4021+QT
28 Packing follower * X20Cr13+QT, 1.4021+QT
* Spare part Bellows seal with safety stuffing box
Plug design
Parabolic plug with post guiding Parabolic plug with PTFE soft seat and post guiding V-port plug with post and port guiding
Perforated plug with post and port guiding Parabolic pressure balanced plug Perforated pressure balanced plug
low direction for gas and steam to reduce the
F low direction for gas and steam to reduce the
F
sound level sound level
low direction for liquids to reduce the
F low direction for liquids to reduce the
F
cavitation cavitation


ARI-PREMIO®
10165 Electric thrust actuator
Electric actuator ARI-PREMIO
Electric thrust actuator

ARI-PREMIO®
2,2 - 5 kN
Page 2
Electric thrust actuator

ARI-PREMIO®
12 - 15 kN
Page 4
Features
• Handwheel
• Operative ambient temperatures -20°C up to +70°C
• Enclosure IP 65
• Travel indicator
Edition 03/13 - Data subject to alteration - Regularly updated data on www.ari-armaturen.com! Data sheet 000001 englisch (english)
ARI-PREMIO® 2,2 - 5 kN
Electric actuator ARI-PREMIO 2,2 - 5 kN
Synchronous motor
115V AC - 230 V AC
BLDC motor
24 V AC/DC

50.1 Gearbox 50.31 Spindle safety feature
50.2/3 Cable gland 2 x M16x1,5 50.32 Torsion safety feature
50.4 Sealing plug 1 x M16x1,5 50.33 Slide
50.6 Hood 50.34 Bellow
50.7 Hood seal 50.40 Synchronous motor, complete
50.10 Column 50.40.3 Capacitor
50.11 Spring washer 50.42 Board support, cpl. (incl. circuit board)
50.12 Handwheel 50.45 Shift lever
50.14 Yoke 50.48 Connector, 3-pole (standard)
50.16 Washer DIN 128-A10 50.57 Cylinder screw DIN EN ISO 4762 - M4x10
50.17 Hexagon screw DIN EN ISO 4017 - M10x40 50.58 Protective conductor terminal
50.19 T-head bolt DIN 261-M12x40 50.59 Cylinder screw DIN EN ISO 4762 - M4x6
50.20 Washer DIN EN ISO 7089 50.87 Threaded bush
50.21 Washer DIN 128 - A12 50.128 Flange nut Seal lock M6
50.22 Hexagon nut DIN EN ISO 4032 - M12 50.174 Platine AC/DC
50.23 Lift dial 50.175 BLDC motor
50.27 Coupling 50.176 Distance bolt M4x45
50.30 Driving spindle 50.177 Cylinder screw M4x18

ARI-PREMIO® 2,2 - 5 kN
10165 Technical data
Technical data
Type ARI-PREMIO 2,2 kN ARI-PREMIO 5 kN
Thrust force kN 2,2 kN 5,0 kN
Operating speed mm/s 0,38 mm/s 0,38 mm/s 1,0 mm/s
Travel distance max. mm 50 mm
Duty classification
S3 80% ED / max. 1200 c/h S3 50% ED / max. 1200 c/h
in accordance with EN 60034-1/A11
Motor voltage V - Hz 230 V - 50 Hz / 60 Hz 1) 230 V - 50/60 Hz 1)
Motor type Synchronous motor
Power consumption VA 21 33 75
Torque switch 2 pcs., fixed wiring switching capacity 10 A, 250 V~
Travel switch 1 pcs., fixed wiring switching capacity 10 A, 250 V~ (Options trip slide necessary!)
Enclosure EN 60529 IP 65
Max. storage temperature °C -40 °C ... +85 °C
Max. permissible ambient -20 °C ... +70 °C
°C
temperature (For outdoor use and sub-zero temperatures, a heating is recommended!)
Hand operating device Yes (always running)
Operation 3-step
Max. cable cross section mm2 3-step input: 2,5 mm2
Mounting position Any, except: motor not hanging downwards
Gear lubricant Klüber / Isoflex Topas NB152
Weight kg 5,4 kg 6,0 kg 6,5 kg
Accessories refer to page
Additional voltage / frequencies

Synchronous motor
115 V - 50/60 Hz 1) 115 V - 50/60 Hz 1)
Motor voltage V - Hz
3~400 V - 50/60 Hz 1) 3~400 V - 50/60 Hz 1)
Duty classification 24 V - 230 V: S3 80% ED / max. 1200 c/h
S3 50% ED / max. 1200 c/h
in accordance with EN 60034-1/A11 400 V : S3 50% ED / max. 1200 c/h
Power consumption refer to nameplate or on request
BLDC motor (Brushless DC motor)

Motor voltage V - Hz 24V - AC/DC
Duty classification
S3 80% ED / max. 1200 c/h
1) Control speed and power consumption are 20% higher at frequency of 60 Hz.
ARI-PREMIO® 12 - 15 kN
Electric actuator ARI-PREMIO 12 - 15 kN
Synchronous motor
115V AC - 230 V AC
BLDC motor
24 V AC/DC

50.1 Gearbox 50.40 Synchronous motor, complete
50.2 Cable gland 2 x M16 x 1,5 / 1 x M20 x 1,5 50.40.3 Capacitor
50.6 Hood 50.41 Cylinder screw DIN EN ISO 4762-M4 - 18
50.7 Hood seal 50.42 Board support, cpl. (incl. circuit board)
50.8 Counter-sunk screw DIN EN ISO 10642 - M5x20 50.45 Shift lever
50.9 Gasket DIN EN ISO 7089 - 5,3 50.57 Cylinder screw DIN EN ISO 4762 - M4x10
50.10 Column 50.58 Protective conductor terminal
50.11 Spring washer 50.59 Cylinder screw DIN EN ISO 4762 - M4x6
50.12 Handwheel (engageable) 50.87 Threaded bush
50.24 Distance column 50.96 O-ring DIN 3771 - 4x1,8
50.25 Hexagon nut DIN EN ISO 4032 - M12 50.101 Connector, 8-pole
50.26 2-ear clamp 50.110 Gear cap
50.27 Coupling 50.115 O-ring
50.30 Driving spindle 50.119 Fan wheel
50.31 Spindle safety feature 50.174 Board AC/DC
50.32 Torsion safety feature 50.175 BLDC motor
50.34 Bellow 50.176 Distance bolt M4x45
50.35 Grub screw DIN ISO 4766 - M6 50.177 Cylinder screw M4x18

ARI-PREMIO® 12 - 15 kN
Technical data
Type ARI-PREMIO 12 kN ARI-PREMIO 15 kN
Travel distance max. mm 80 mm
Duty classification
S3 50% ED / max. 1200 c/h
Motor voltage V - Hz 230 V - 50 Hz
Motor type Synchronous motor
Torque switch 2 pcs., fixed wiring, switching capacity 16A, 250V~
Travel switch 1 pcs., fixed wiring switching capacity 16A, 250V~ (Options trip slide necessary!)
Enclosure EN 60529 IP 65
Max. storage temperature °C -40 °C ... +85 °C
Max. permissible ambient -20 °C ... +70 °C
°C
temperature (For outdoor use and sub-zero temperatures, a heating is recommended.)
Hand operating device Yes (engageable)
Operation 3-step
Max. cable cross section mm2 3-step input: 2,5 mm2
Mounting position Any, except: motor not hanging downwards
Gear lubricant Molyduval Valenzia H2
Weight kg 10,5 kg
Accessories refer to page
Additional voltage / frequencies

Synchronous motor
24 V - 50 Hz / 24 V - 60 Hz 1)
115 V - 50 Hz / 115 V - 60 Hz 1)
Motor voltage V - Hz
230 V - 60 Hz 1)
3~400 V - 50 Hz / 3~400 V - 60 Hz 1)
Duty classification
S3 50% ED / max. 1200 c/h
Power consumption refer to nameplate or on request
BLDC motor (Brushless DC motor)

Motor voltage V - Hz 24V - AC/DC
Duty classification
S3 80% ED / max. 1200 c/h
1) Control speed and power consumption are 20% higher at frequency of 60 Hz.
ARI-PREMIO®
10165 Accessories
Accessories
Type ARI-PREMIO 2,2 kN - 15 kN
Trip slide Required for acutating ...
- the travel switch S3 / retracting spindle
(the travel swith S3 is in the basic version of the actuator already available)
- the potentiometer
- the additional travel switches S4 / S5
Additional intermediate position Type Standard - 2 piece, zero potential, switching capacity 10 A, 250 V~
switches S4, S5
Type low voltage - 2 pieces, zero potential, with gold contacts, switching capacity max. 0,1 A, 4-30 V
(for low switching capacities and at
aggressive atmosphere gold contacts
should be used)
Potentiometer Conductive - 500, 1000, 2000, 5000 Ohm; 1 Watt (at +70 °C)
(max. 2 only) - Wiper current max. 0,01 mA / recommended 0,002 mA
Wire - 100, 200 Ohm; 0,5 Watt (at +70 °C)
(max. 2 only) - Wiper current max. 35 mA / recommended 0,02 mA
TÜV-approved potentiometer - TÜV tested conductive plastic for use as a sensor for position feedback of control
(max. 2 only) devices in electronic systems for controlling and monitoring of fuel, air and gas
streams in combustion plants
- 5000 Ohm (standard)
Options trip slide necessary !
- or optional: 100, 200, 500, 1000 Ohm; 1 Watt (at +70 °C)
- Wiper current max. 0,01 mA / recommended 0,002 mA
- No retrofitting possible!
Electronic position controller Type ES11 - Input signals 0(2)...10V or 0 (4)...20mA;
(for controling the actuator with an analog - galvanically separation between power supply and control signal
control signal) - including potentiometers (note max. number of potentiometers))
Type PREMIO-Plus - Input signals: 3-point, 0-10V or 4-20mA;
(refer to seperate data sheet / - self-adaptation;
operating instructions)
- Optional position feedback;
- galvanically separation between power supply and control signal
Electronic position indicator RI21 - analogue output for position-feetback 0(4)...20mA changeable to 0(2)-10V,
(for position feedback with an analog (only for AC) invertable; galvanically separation between power supply and control signal
control signal) - active
- including potentiometers (note max. number of potentiometers))
RI32 - analogue output for position-feetback 2... 10V; 4... 20 mA
- compact design; 2 (passive) or 4 wire technology (active)
- Power supply: 24V AC/DC
- including potentiometers (note max. number of potentiometers))
Heating Heating resistor - (automatic switching circuit) 230 VAC, 115VAC, 24VAC/DC, 15 Watt
Connection board Type Standard PA - zero potential, switching capacity 10A, 250V~
2 Torque- and 1 Travel switch, all switch - (At 12/15kN already possible with the standard version)
contacts are guided on terminals Type low voltage NA - zero potential, with gold contacts, switching capacity max. 0,1 A, 4-30 V
(for low switching capacities and at aggressive
atmosphere gold contacts should be used)
(Process-) controller Type - Mounted in the actuator
Processcontroller dTRON 316 - 3-point stepping controller with 2 solid state relay outputs outputs for direct control of
the PREMIO actuators with a 3-point signal;
- for resistance thermometers and thermocouples (provided by the customer) or
standard signals,
- Pre-configured for temperature control::
control range from -200°C up to +850°C (resistance thermometer)
- Not compatible for use with the ES11!
Special voltage 24 V AC/DC

Board support for pole-changing - For the control of the BLDC motor with pole-changing (2-wire technology).
- By reversing the polarity of the supply voltage, the motor rotation direction is changed (ON/ OFF)
Special voltage 3~400 V
Integrated reversing contactor - Only 1 electronic module possible !
- At 2,2 kN - 5kN is no electronic in the actuator possible!

ARI-PREMIO®
10165 Accessories
Intermediate position switch Potentiometer

50.42 Board support 50.42 Board support
50.50 Trip slide 50.67 Potentiometer
50.52 Setting spindle for switch S4 50.68 Connecting cable
50.53 Setting spindle for switch S5 50.69 Self-tapping screw
50.61.2 Travel switch S4 50.70 Pinch spring
50.61.3 Travel switch S5 50.71 Slide block
50.62 Connector, 6-pole 50.73 Pinion
50.74 Connector, 3-pole
Electronic position controller ES11

Motor type BLDC motor Synchronous motor
24V - DC 24V - AC 24V - AC 115 V - AC 230 V - AC
Operating voltage UB
-- 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz
Operating current
IB 150 mA 40 mA 20 mA
without load
Input control signal YU 0 (2) .... 10 V DC - (RI = 30 kOhm)
Input control signal YI 0 (4) .... 20 mA DC - (RI = 125 Ohm)
0 .... 10 kOhm, recommended 0 .... 1 kOhm
Potentiometer input RP
(Potentiometer can be used only as a voltage divider)
3-point-Output UA 24 V - DC 24 V - AC 115 V - AC 230 V - AC
Three-step switching current IS 4 A max.
Electronic position indicator RI21

Operating voltage UB 24 V - AC 50/60 Hz 115 V - AC 50/60 Hz 230 V - AC 50/60 Hz
Operating current without load IB 150 mA 40 mA 20 mA
Output control signal YU 0 (2) .... 10 V DC - (load resistance > 1 kOhm) active
Output control signal YI 0 (4) .... 20 mA DC - (load resistance max. 800 Ohm) active
Potentiometer input RP 0 .... 1 kOhm
Electronic position indicator RI32

Operating voltage UB 24V - DC/AC 50/60 Hz
Output control signal YU 2 .... 10 V DC active
4 .... 20 mA DC - (load resistance max. 500 Ohm)
Output control signal YI
passive or active
Potentiometer input RP 100 Ohm .... 20 kOhm
Board support for pole-changing for 24 V DC

To control the 24V-AC/DC PREMIO-actuators with a 3-point 24V-DC signal or by pole-changing
Comparison: DC 3-point (standard) DC pole-changing
Opening
retracting stem
Closing
extending stem

ARI-PREMIO®
10165 Integrated temperature controller dTRON 316
Integrated temperature controller dTRON 316
Features
• programmable analogue input
• 2 auto-tune methods
• Program function with 8 program sections or slope-function
• 2 Timer functions
• 4 limit-comparators
• Interlock for keyboard and level
• 4 programmable setpionts, two parameter sets
• 4 digit resolution (max. 2 decimal places)
• Controller characteristic P, PD, PI or PID
• Actual value input by usual temperature sensors (see in table)
• 2 relay outputs 230V/3A (shutter)
• 1 three-step output for actuator motor (by solid state relay 4A)
• 2 combinable binary inputs / binary outputs
Block structure Function in the ARI-PREMIO-thrust actuator
Analogue input 2 relay
Binary input or Logical output Temperature

sensor
Binary input or Logical output
3-point-step output for

actuator motor
Input thermocouples Input resistance thermometer

Description Measuring range Description Type of connection Measuring range
Fe-CuNi „L“ -200 ...+900°C Pt 100 (standard) 2-wire / 3-wire / 4-wire -200...+850°C
Fe-CuNi „J“ DIN EN 60584 -200 ...+1200°C Pt 500 2-wire / 3-wire / 4-wire -200...+850°C
Cu-CuNi „U“ -200 ...+600°C Pt 1000 2-wire / 3-wire / 4-wire -200...+850°C
Cu-CuNi „T“ DIN EN 60584 -200 ...+400°C KTY11-6 2-wire -50...+150°C
NiCr-Ni „K“ DIN EN 60584 -200 ...+1372°C Sensor output resistance:
NiCr-CuNi „E“ DIN EN 60584 -200 ...+1000°C max. 30Ohm each circuit at 3- and 4-wire connection
NiCrSi-NiSi „N“ DIN EN 60584 -100 ...+1300°C Measurement current: approx. 250µA
Pt10Rh-Pt „S“ DIN EN 60584 0 ........+1768°C Circuit acjustment:
- at 3- and 4-wire connection not necessary.
Pt13Rh-Pt „R“ DIN EN 60584 0 ........+1768°C
- at 2-wire connection a circuit acjustment can be done with sofware by correcting
Pt30Rh-Pt6Rh „B“ DIN EN 60584 0 ........+1820°C the actual value.
W5Re-W26Re „C“ 0 ........+2320°C
W3Re-W25Re „D“ 0 ........+2495°C
W3Re-W26Re 0 ........+2400°C
Input standardized active current or voltage signals

Description Measuring range
Voltage 0 (2) ... 10V, input resistance Re > 100kOhm
Current 0 (4) ... 20mA, voltage drop ≤ 1,5 V

standard Accessories
only
input resistance thermometer Teletrans- Thermo- Current Voltage

mitter element 0(4)...20mA 0(2)...10V
Binary input Binary input logic 12V alter-

native to binary
inputs bin1 and
bin2
power
supply
230V/3A Binary output (Out1)

10165

Output to the actuator voltage
and power supply voltage are
equal
Options PA
(only 2,2 - 5 kN)
Wire connections of the different valve types

HZ Heating resistor
3-way valve 3-way valve
Straight through valve with mixing plug with diverting plug DE Torque switch
Travel switch for limiting the travel distance in opening
WE (S3)
direction
closed A - AB open AB - B open RI21 Electronic position indicator
open B - AB open AB - A open ES11 Electronic position controller
NA Low-voltage connection board, zero potential
PA Standard-voltage connection board, zero potential
POT Potentiometer
WE Travel switch, zero potential
TTR Electronic temperature controller dTRON316

Wiring diagram
ARI-PREMIO® 2,2 - 15 kN Standard
10
only

Straight through valve with mixing plug with diverting plug
closed A - AB open AB - B open
open B - AB open AB - A open
For external reversing contactor connect at L1, L2, L3.

L1, L2, L3 - actuator spindle drives in
L3, L2, L1 - actuator spindle drives out
In all external reversing circuits the torque switches S1 and S2/S3
have to be used to switch off the actuator motor.
Attention:
10165
Please check the operating direction of the actuator !

only
HZ Heating resistor
DE Torque switch
Travel switch for limiting the travel distance in opening
WE (S3)
direction
RI21 Electronic position indicator
ES11 Electronic position controller
NA Low-voltage connection board, zero potential
POT Potentiometer
Reversing
contactor extern TTR Electronic temperature controller dTRON316
WS Reversing contactor
TS Temperature switch (motor)

Wiring diagram
ARI-PREMIO® 2,2 - 15 kN Accessories
only
Wire connections of the

different valve types
Straight through valve
closed
open
3-way valve
with mixing plug
A - AB open
B - AB open
3-way valve
with diverting plug
AB - B open
AB - A open
10165

Board support for pole-changing for 24 V DC (Connector X37/X38) Two-wire connection
(current loop)
4....20 mA
24 V DC
Output
24 V DC
Attention !
Do not connect terminal 2 and 3. Four-wire connection
4....20 mA
By a potential shift the position indicator 24 V DC and AC
Input
RI32 could be destroyed.
24 V DC
DC 3-point DC pole-changing
(standard)
retracting
Four-wire connection
spindle
2....10 V
24V DC and AC
extending
spindle
Wiring diagram
ARI-PREMIO® 2,2 - 15 kN 24V-AC/DC
11
ARI-PREMIO®
10165 Dimensions
2,2 - 5 kN
A (mm) 165
B (mm) 150
C (mm) 50
Ø D1 (mm) 90
X (mm) 150
2,2 - 5 kN 2,2 - 5 kN H (mm) 447 480
Nominal travel max. 30 mm Nominal travel > 30 mm - 50 mm h (Nominal travel) (mm) max. 30 max. 50
12 - 15 kN
A (mm) 202
B (mm) 176
C (mm) 97
Ø D1 (mm) 130
X (mm) 200
H (mm) 622 637 652
12 - 15 kN h (Nominal travel) (mm) max. 50 max. 65 max. 80
Nominal travel max. 80 mm L (Column) (mm) 256 271 286

12 Edition 03/13 - Data subject to alteration - Regularly updated data on www.ari-armaturen.com!

10165
Straight through control valves - STEVI® 470 / 471
Series 470 Series 471

Contents
1.0 General information on operating 7.0 Care and maintenance................................... 8
instructions ..................................................... 2 7.1 Replacement of stem sealings ............................... 8
2.0 Notes on possible dangers............................ 2 7.1.1 PTFE V-ring unit design .................................... 8
2.1 Significance of symbols ..........................................2 7.1.2 Stuffing box packing design ............................... 9
7.1.3 Bellows seal design ........................................ 10
2.2 Explanatory notes on safety information .................2
7.2 Replacement of internal parts .............................. 12
3.0 Storage and transport ................................... 2 7.2.1 Replacement of plug and stem ...................... 12
4.0 Description...................................................... 3 7.2.2 Replacement of seals of
4.1 Scope of applications ..............................................3 pressure balanced plugs ............................... 12
4.2 Operating principles ................................................3 7.2.3 Replacement of the seat ring........................... 13
7.3 Tightening torques................................................ 13
4.3 Diagram ..................................................................4
4.3.1 Plug design ........................................................57.3.1 Tightening torques for nuts .............................. 13
7.3.2 Tightening torques for seat rings ..................... 13
4.4 Technical data .........................................................5
4.5 Marking ...................................................................5 8.0 Troubleshooting ........................................... 13
5.0 Installation....................................................... 6 9.0 Troubleshooting table ................................ 14
5.1 General notes on installation...................................6 10.0 Dismantling the valve or the top part ...... 15
5.2 Requirements at the place of installation ................7 11.0 Warranty / Guarantee ................................. 15
5.3 Installation instructions concerning actuators .........7 12.0 EC declaration of conformity .................... 16
6.0 Putting the valve into operation.................... 8
Rev. 0040305000 0410 englisch

10165 control valves - STEVI® 470 / 471
Straight through

and repair.
ATTENTION !

to property.

ATTENTION !
- At -20°C to +65°C.
Page 2 Rev. 0040305000 0410

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4.0 Description
Valves are used for „controlling the flow of liquids, gases and vapours in chemical and other
processing plants and for plant engineering“.
ATTENTION !
to TRD 110.

ARI control valves are especially suitable for actuation by pneumatic or electrical actuators.
Four plug types are available to suit the various applications:
Parabolic plug (standard pattern)
Perforated plug
V-port plug
Pressure balanced plug
The flow through control valves is always against the closing direction.
In the case of control valves with perforated plugs, gases and vapours flow against the
closing directions, but liquids flow through in the closing direction. If a pneumatic actuator is
to be used on a straight-way valve with a perforated plug with the fluid moving in the closing
direction, a higher closing force will be needed. This is to prevent vibration as the plug
approaches the closed position.
If the forces generated by the actuators are too low, arrangements should be made to
relieve the pressure as far as this is compatible with service conditions.
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4.3 Diagram
Fig. 1: Series 470 DN15-150 Fig. 2: Series 471 DN15-150
Fig. 3: Series 470 DN125v-150v Fig. 4: Series 471 DN125v-150v
Page 4 Rev. 0040305000 0410

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4.3.1 Plug design
Fig. 5: Perforated plug Fig. 6: V-port plug
(Pressure balanced plug refer to Fig. 17)
4.4 Technical data

for
4.5 Marking
Nominal diameter Manufacturer
Type-Number CE-marking
Flow Nominal pressure
characteristic Notified body
Kvs-value
Plug Customer-specific
design information
Serial-No. Stem sealing
Material of Year of manufacture clear speech
internal parts (1. and 2. position)
Fig. 7
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
According to the Pressure Equipment Directive table 6, annex II valves without safety
Rev. 0040305000 0410 Page 5

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5.0 Installation
The following items should be taken into account besides the general principles governing
installation work:
ATTENTION !
avoided.
both sides.
Refer to data sheet for weights.
- Keep the thread and shaft of the stem free from paint.
- Strainers or filters should be installed before the valves.

recommended.
Page 6 Rev. 0040305000 0410

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5.2 Requirements at the place of installation
The place of installation should be easily accessible and provide ample space for
maintenance and removing the actuator. Stop valves should be installed before and after
the control valve to enable maintenance working without draining the piping system. The
valve should preferably installed vertically with the actuator at the top. Inclined or horizontal
installation without supports is permissible only with light actuators.
For this installation position, the two distance columns (or joke) have to be above each
other in the vertical plane.
Fig. 8: Pipeline vertically Fig. 9: Pipeline horizontally

Permissible actuator weights for valves with unsupported horizontal stems:
20 kg for DN 15 - 32
25 kg for DN 40 - 65
35 kg for DN 80-100
40 kg for DN 125-150
55 kg for DN125v-150v
The pipes must be lagged to protect the actuators from excessive heat. Sufficient space
must be left for the maintenance of the stem packing.
To ensure that the control valves function correctly, the pipe run should be straight for at
least 2 x n.d. upstream and 6 x n.d. downstream of the valve.
5.3 Installation instructions concerning actuators

Normally, control valves are supplied complete with actuator fitted.
It is not permitted to mantle / dismantle actuators with valves operating and service
conditions (temperature and pressure). The actuators must be assemble as describe in the
operating instructions during conversion and maintenance.
During assembly work, the plug is not be turned on its seating at closing pressure.
ATTENTION !
Care must be taken with the bellow type valves when actuators are mounted or
removed. (Hold the valve-stem against turning with an open-end wrench!)
When retrofitting actuators, the maximum permissible force for valve actuation must be
taken into account.
The maximum permissible actuation forces are:
Series 470 Series 471
12 kN for DN 15- 32 18 kN for DN 15-65
18 kN for DN 40-65 29 kN for DN 80-100
40 kN for DN 80-150 37 kN for DN 125-150/125v-150v
59 kN for DN 125v-150v
Rev. 0040305000 0410 Page 7

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ATTENTION !
Maintenance and maintenance intervals have to be defined by the operator according to
the service conditions.
7.1 Replacement of stem sealings

7.1.1 PTFE V-ring unit design
PTFE V-ring unit (pos. 11) consisting of: 1 backing ring
4 sealing rings
1 cover ring
Owing to the installed compression spring (pos. 14), this
stem packing is self-adjusting. If the stem starts leaking, the
ring pack is worn out and must be replaced.
Replacement of PTFE V-ring unit:
ATTENTION !
Refer to item 10.0 and 11.0 before
dismantling the valve.
- Remove actuator.
(Refer to operating instructions for actuator!)
- When replacing PTFE V-ring unit (pos. 11), make sure that
the parts are installed in the correct order and positions
(refer to Fig. 10).
Damaged stems must also be replaced (refer to item 7.2 for
instructions) since a new ring pack will soon start leaking
again if the stem is damaged.
Fig. 10: V-ring unit
DN15-150
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7.1.2 Stuffing box packing design
The stuffing box packing (pos. 26) requires maintenance.
If leaks develop, immediately tighten the hexagon nuts (pos. 21) gradually until the packing
(pos. 26) stops leaking.
The service life of stuffing box packings (pos. 26) can be increased by checking regularly
leakage.
If leaks can no longer be stopped by tightening the nuts (pos. 21), a new packing ring
(pos. 26) must be inserted into the gland.
Replacement of stuffing box packing:
ATTENTION !
Refer to item 10.0 and 11.0 before dismantling the valve.
- Remove actuator. (Refer to operating instructions for actuator!)
- Insert the new packing ring (pos. 26) as shown in Fig. 11 and Fig. 12.
Fig. 11: Stuffing box packing DN15-150 Fig. 12: Stuffing box packing DN125v-150v
If a split packing ring is used, cut with a chamfer

as shown in Fig. 13.
Fig. 13: Split packing ring

Damaged stems must also be replaced (refer to item 7.2 for instructions) since a new ring
pack will soon start leaking again if the stem is damaged.
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7.1.3 Bellows seal design
If the stem leaks the bellows seal (pos. 22.2) is
defective. The leak can initially be stopped by
tightening the screw joint (pos. 22.17)
respectively the sleeve nut (pos. 22.16).
Stem and bellows (pos. 20.3) can only be
replaced together.
Replacement of bellows seal:
ATTENTION !
- Remove actuator.
(Refer to operating instructions for actuator!)
DN15-150
- Loose nuts (pos. 10).
- Detach bellows assembly (pos. 22).
- Slacken screw joint (pos. 22.17) by about one
turn.
- Press stem-/bellows unit (pos. 22.3) down.
- Drive pin (pos. 4) out with a drift.
- Unscrew plug (pos. 3).
- Loose nuts (pos. 22.8).
- Detach mounting bonnet (pos. 22.2).
- Extract stem-/bellows unit (pos. 22.3) from
the bellows housing (pos. 22.1).
Fig. 14: Series 471 DN 15-150
- Bolt new parts together and drill them.
- Replace 2 gaskets (pos. 22.6) and 1 gasket
(pos. 8).
- Assemble in reverse order.
ATTENTION at DN125-150!
- Ensure that the torsion lock is
correctly positioned when inserting
new stem/bellows unit. Introduce the
grooved pin (pos. 20.9) into the
torsion lock groove.
Make sure it runs smoothly!
- Secure with nuts (pos. 10 and 22.8) and tighten them crosswise.
(For tightening torques refer to item 7.3.1)
- Tighten screw joint (pos. 22.17) resp. sleeve nut (pos. 22.16) gradually up to tightness of
the stuffing box packing (pos. 22.10).
Page 10 Rev. 0040305000 0410

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DN125v-150v
- Detach bellows assembly (pos. 22) incl. stuffing
box housing (pos. 24).
- Slacken sleeve nut (pos. 22.16) by about one
turn.
- Lift bellows housing (pos. 22.1).
- Drive spring pin (pos. 36) out with a drift.
- Unscrew stem adapter (pos. 35) with plug
(pos. 3).
- Loose nuts (pos. 22.8).
- Detach stuffing box housing (pos. 22.13).
- Extract stem/bellows-unit (pos. 22.3) from the
bellows housing (pos. 22.1).
- Bolt new parts together and drill them.
- Replace 2 gaskets (pos. 22.6), 1 gasket
(pos. 37) and 1 gasket (pos. 8).
ATTENTION !
- Ensure that the torsion lock is
correctly positioned when inserting
new stem/bellows unit. Introduce the
grooved pin (pos. 20.9) into the
torsion lock groove.
Make sure it runs smoothly!
- Secure with nuts (pos. 10, 39 and 22.8) and
tighten them crosswise.
Fig. 15: Series 471
(For tightening torques refer to item 7.3.1)
DN125v-150v
- Tighten sleeve nut (pos. 22.16) gradually up to
tightness of the stuffing box packing (pos. 22.10).
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7.2 Replacement of internal parts
7.2.1 Replacement of plug and stem
ATTENTION !
Series 470
- Detach the mounting bonnet (pos. 6) resp. stuffing box
housing (pos. 24).
- Slacken nuts (pos. 21) by about 2-3 turns.
- Extract plug (pos. 3) and stem (pos. 5).
- Drive pin (pos. 4) out with a drift.
- Unscrew plug (pos. 3).
- Bolt new parts togethe, drill and pin them.
- Replace the gasket (pos. 8).
- Assemble in reverse order
- Secure with nuts (pos. 10) and tighten them crosswise.
(For tightening torques refer to item 7.3.1) Fig. 16: Series 470
Series 471:
For replacement of plug and stem with bellows sealing (Series 470) refer to item 7.1.3.
7.2.2 Replacement of seals of pressure balanced plugs
ATTENTION !
- Remove plug as described in item 7.2.1.
- Prise worn piston seal (pos. 34) out of groove in
plug with suitable tool (e.g. screwdriver).
- Insert new piston seal (pos. 34), taking care that it
is in the correct position (refer to Fig. 17).
- Replace guide ring (pos. 33).
- Clean sliding surface of guide bush (pos. 32);
smooth with fine abrasive if necessary.
- Replace 2 gaskets (pos. 8).
- Secure with nuts (pos. 10) and tighten them
crosswise.
(For tightening torques refer to item 7.3.1) Fig. 17: Pressure balanced plug
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7.2.3 Replacement of the seat ring
ATTENTION !
- Detach valve top part.
- Unscrew seat ring (pos. 2) with a special wrench (can be obtained from the manufacturer).
- Clean thread and sealing taper in body (pos. 1) and apply with suitable lubricant.
- Replace respectively recondition seat ring (pos. 2).
- Install seat ring (pos. 2). (For tightening torques refer to item 7.3.2.)
- Replace gasket (pos. 8).
- Assemble valve top part.
- Secure with nuts (pos. 11) and tighten them crosswise.
(For tightening torques refer to item 7.3.1.)
7.3 Tightening torques

7.3.1 Tightening torques for nuts
M 10 = 15-30 Nm
M 12 = 35-50 Nm
M 16 = 75-100 Nm
M 20 = 80-120 Nm
7.3.2 Tightening torques for seat rings

DN 15/ 20 = 100 Nm
DN 25/ 32 = 150 Nm
DN 40/ 50 = 350 Nm
DN 65 = 480 Nm
DN 80 = 660 Nm
DN100 = 980 Nm
DN125 / 125v = 1450 Nm
DN150 / 150v = 2000 Nm
DN200 = 4200 Nm
! Refer to operating instructions for actuator concerned for
installing actuators !
8.0 Troubleshooting
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-

“9.0 Troubleshooting table”, the supplier or manufacturer should be consulted.
Rev. 0040305000 0410 Page 13

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ATTENTION !
- refer to item 10.0 and 11.0 prior to dismantling and repair work!
- refer to item 6.0 before restarting the plant !

No flow Valve closed. Open valve (using actuator).
Flange covers not removed. Remove flange covers.
Little flow Valve not sufficiently open. Open valve (using actuator).
Dirt sieve clogged. Clean / replace sieve.
Kvs value of valve unsuitable. Fit valve with higher Kvs value.
Valve stem moves in jerks. Stuffing box sealing too tight (for valves Slacken stuffing box gland or hex. nut
with graphite packings). (pos. 21) slightly.
Valve must nor start leaking!
Valve plug slightly seized owing to Clean internals, smooth rough spots.
solid dirt particles.
Valve stem or plug cannot be Seating and plug clogged with dirt; Clean seating and plug with suitable
moved. especially with V-port and perforated solvent.
plugs.
Valve plug seized in seating or guide Replace plug and seating; use parts
owing to deposits or dirt in medium. made from different material if neces-
sary.
Valve stem leaking. PTFE V-ring unit damaged or worn. Replace ring pack; refer to item 7.1.1
Stuffing box gland too slack in valves Tighten or repack stuffing box gland or
with stuffing box packings. nuts (pos. 21); refer to item 7.1.2
Bellows defective in valves with bellow Replace bellows unit;
seal. refer to item 7.1.3
Leakage too high when Sealing surfaces of plug eroded or Replace plug; refer to item 7.2
valve is closed. worn.
Sealing edge of seating damages or Replace seating; refer to item 7.2,
worn. fit dirt sieve if necessary.
Piston sealing ring worn (pressure- Replace sealing ring;
relieved valves). refer to item 7.2.2
Seating and/or plug dirty. Clean internals of valve;
fit strainer if necessary.
Pneumatic actuator not completely Vent actuator air chamber completely.
vented; spring force not fully effective.
Actuator not powerful enough. Install more powerful actuator.
Check service data.
Page 14 Rev. 0040305000 0410

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ATTENTION !
media.

appointed by us.

Rev. 0040305000 0410 Page 15

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as defined by
that according to the above mentioned Pressure Equipment Directive (PED) the below listed prod-
ucts comply and have been approved according to table 6, annex II, module H or module H1 (with
safety function: also EC type test according to module B+D) through Lloyd´s Register Quality Assur-
ance GmbH (BS-No. 0525), Am Sandtorkai 41, D-20457 Hamburg.
Module H, Certificate-No: 50003/1
Straight through stop and control valves
Type 405, 460, 440, 441, 445, 446, 470, 471, 422, 462, 425, 426, 480
Applied standard:
DIN EN 60534 part 1
VDI/VDE 3844 sheet 1
DIN 3840
AD 2000 leaflet A4
- Cast iron with spheroidal graphite
- Cast steel
- Forged steel
Module H1, Certificate-No: 50003/2

Straight through control valves with safety function
Type 440, 441
Applied standard:
DIN EN 60534 part 1
VDI/VDE 3844 sheet 1
DIN 3840
AD 2000 leaflet A4
- Cast steel
- Forged steel
...................................................
Page 16 Rev. 0040305000 0410

10165
Operating and Installation Instructions

Thrust actuator ARI-PREMIO
Contents
1.0 General information on operating instructions...................................................................................... 3
2.0 Notes on possible dangers ...................................................................................................................... 3
2.1 Significance of symbols .................................................................................................................... 3
2.2 Explanatory notes on safety information............................................................................................ 4
3.0 Storage and transport............................................................................................................................... 4
4.0 Description ................................................................................................................................................ 5
4.1 Field of application ............................................................................................................................. 5
4.2 Method of functioning......................................................................................................................... 5
4.3 Diagram ............................................................................................................................................. 6
4.3.1 ARI-PREMIO 2,2 - 5 kN............................................................................................................ 6
4.3.2 ARI-PREMIO 12 - 15 kN........................................................................................................... 7
4.3.3 Parts list .................................................................................................................................... 8
4.4 Technical data .................................................................................................................................... 9
4.5 Dimensions ...................................................................................................................................... 12
5.0 Installation .............................................................................................................................................. 13
5.1 General installation data .................................................................................................................. 13
5.2 Manual operation ............................................................................................................................. 15
5.2.1 ARI-PREMIO 2.2 - 5 kN ......................................................................................................... 15
5.2.2 ARI-PREMIO 12 - 15 kN ........................................................................................................ 16
Rev. 0040501000 4511 englisch

10165
5.3 Installation instructions for mounting to valves ................................................................................ 17
5.3.1 Mounting for valve-lift up to 30 mm (yoke version) ................................................................. 17
5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version) .............................................. 19
5.4 Electrical connection ........................................................................................................................ 21
5.4.1 Wiring diagram ARI-PREMIO 2.2 - 5 kN................................................................................. 21
5.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN................................................................................ 22
5.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor ....................................... 22
5.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor ............................................ 23
5.4.3 Connection ............................................................................................................................. 24
5.5 Options and settings ....................................................................................................................... 25
5.5.1 Torque and travel switches ..................................................................................................... 25
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN) ....................................................................... 25
5.5.3 Travel switch ........................................................................................................................... 26
5.5.3.1 Installation of additional travel switches ................................................................................... 27
5.5.3.2 Installation of trip slide and setting of the travel switch (S3) .................................................... 29
5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25) .................................................... 30
5.5.4 Potentiometers........................................................................................................................ 31
5.5.4.1 Installing the potentiometer ...................................................................................................... 31
5.5.4.2 Setting the potentiometer ......................................................................................................... 33
5.5.5 Error-proof potentiometer for single-channel, error-proof position feedback ......................... 34
5.5.5.1 Setting the potentiometer on conductive plastic basis ............................................................. 34
5.5.6 Heating ................................................................................................................................... 36
5.5.6.1 Installation of heating ............................................................................................................... 36
5.5.7 Electronic position indicator RI21 ........................................................................................... 37
5.5.8 Electronic position controller ES11 ......................................................................................... 37
5.5.9 Electronic position indicator (RI21) and position controller (ES11) together in the actuator ... 38
5.5.10 Integrated temperature controller dTRON 316 ..................................................................... 39
5.5.10.1 Installation of the dTRON 316................................................................................................ 39
5.5.11 Integrated reversing contactor .............................................................................................. 40
5.5.11.1 Installing the reversing contactor............................................................................................ 40
5.5.11.2 Electrical connection with ES11 or dTRON 316 ..................................................................... 40
5.5.12 Phase control relay ............................................................................................................... 41
5.5.12.1 Installing the phase control relay............................................................................................ 41
5.5.14 Electronic position indicator RI32 ......................................................................................... 46
5.5.14.1 Useful range of the linear motion potentiometer ................................................................... 46
5.5.14.2 Installing the RI32 electronic position indicator in the PREMIO ............................................. 46
5.5.14.3 Electronic position indicator (RI32) and position controller (ES11)
together in the actuator ........................................................................................................................ 47
5.5.14.4 Technical data - Position indicator RI32 ................................................................................. 48
5.5.14.5 Potentiometer installation ...................................................................................................... 48
5.5.14.6 Wiring diagram ...................................................................................................................... 49
5.5.14.7 Connection conditions............................................................................................................ 49
5.5.14.8 Setting zero point and slope span.......................................................................................... 50
6.0 Putting the actuator into operation ...................................................................................................... 51
7.0 Care and maintenance............................................................................................................................ 51
8.0 Troubleshooting ...................................................................................................................................... 51
9.0 Troubleshooting table ............................................................................................................................ 52
10.0 Dismantlement of thrust actuator ....................................................................................................... 53
11.0 Warranty / Guarantee ............................................................................................................................ 53
12.0 EC declaration of conformity ............................................................................................................... 54
10165 Thrust actuator ARI-PREMIO

and repair.
ATTENTION !
ATTENTION !
... Warning of dangerous voltage.
Exposed to injury!
Don’t touch the turning handwheel when the motor is running.
Exposed to injury!
Don’t put your hand into the up or downwards moving
appliance.
Danger when not observing the operating and installation

instructions!
Before installing, operating, maintenance or dismantling read
and observe the instructions.
Danger though voltage!

Before dismantling the hood, switch of the electrical source
and secure against turning on again.
0040501000 4511 Page 3


to property.

ATTENTION !
- Valve mountings such as drives, handwheels, hoods must not be used to take
external forces, e.g. they are not designed for use as climbing aids, or as
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
See “4.4 Technical data” for weights.
- At -20° to +70°C dry, free from dirt.

- Do not unpack thrust drive or setting equipment assembly prior to installation.
- Protect against external force (impact, vibration etc.).
- Do not soil or damage type identification plate and wiring diagram on the controller.
Page 4 0040501000 4511

4.0 Description
4.1 Field of application
ARI-PREMIO linear thrust actuators are employed to actuate control or shut-off valves
requiring a nominal linear stroke distance of up to 80 mm and thrust from 2.2 kN to 15 kN.
The thrust actuators are set to the thrust forces specified in the technical data. If supplied
with the valve, the lift of the thrust actuator will be set to the stroke distance of the valve.
Selection of the proper actuator version in alignment with the corresponding fitting as well
as use of the thrust actuator in accordance with the specified technical data is the
responsibility of the systems engineer.
See data sheet for areas of application, application limits and potential.
Any use of the thrust actuator beyond the specified technical data or improper use of the
actuator is deemed to be not for the intended purpose.
The ambient conditions have to be conform to the actual electromagnetic compatibility
directives. Additional the compatibility to this directives has to be maintained in case of
expansion or other changing of the ambient conditions.
4.2 Method of functioning

The thrust actuator, fitted with a yoke or columns, is mounted to the valve.
Transfer of force is effected via a coupling safeguarded against torsion.
The torsion safeguarding feature also serves as a lift indicator.
The lift settings can be read off on a lift dial attached to the yoke or between the 2-ear
clamps mounted to the column.
The electrical components are accommodated separately from the gearbox underneath a
sealed hood, thus being protected against operating and environmental effects.
Following removal of the hood, easy access is provided to the switchgear and indicating
feature.
The rotary motion of the motor is transmitted to the spindle nut by means of spur gear.
The drive spindle, which is safeguarded against torsion, screws its way into the spindle nut
and thus performs a pull or push motion depending on the sense of rotation.
In the final positions of the valve, the spindle nut is pressed against a set of springs so as to
produce closing force.
The motor is switched-off by means of two load-dependent switches and one stroke-
dependent switch. For the function of the stroke-dependent travel switch (S3), an optionally
available trip slide is necessary. The load-dependent switches will also switch-off the motor
if foreign bodies have lodged themselves between the valve seat and cone.
The load-dependent switches serve to protect the valve and thrust actuator against
damage.
0040501000 4511 Page 5

4.3 Diagram
4.3.1 ARI-PREMIO 2,2 - 5 kN
Yoke Version Column Version
Fig. 1
Page 6 0040501000 4511

4.3.2 ARI-PREMIO 12 - 15 kN
Fig. 2
0040501000 4511 Page 7

4.3.3 Parts list
Pos. Designation Pos. Designation

50.1 Gearbox 50.30 Driving spindle
50.1.1 Gearbox cover plate 50.31 Spindle safety feature
Cable gland 50.32 Torsion safety feature
2.2 - 5kN: 2 x M16x1,5 50.34 Bellow
50.2
12 - 15kN: 2 x M16x1,5 /
1 x M20x1,5 50.35 Grub screw DIN ISO 4766 - M6
50.4 Sealing plug 1 x M16x1,5 50.36 Set collar
50.6 Hood 50.37 Grub screw DIN 913-M3x5
50.7 Hood seal 50.40 Synchronous motor, complete
50.8 Counter-sunk screw DIN EN ISO 50.40.3 Motor capacitor
10642 - M5x20
50.9 Sealing washer DIN EN ISO 7089 50.41 Head cap screw
DIN EN ISO 4762-M4 - 18
50.10 Column 50.42 Board support
50.11 Conical spring washer 50.43 Standard board
50.12 Handwheel 50.43.1 Directional switch (valve – up) S3
50.12.1 Turning handle of handwheel 50.43.2 Torque switch
50.14 Yoke 50.45 Shift lever
50.15 Flange 50.46 Washer
50.16 Spring washer DIN 128-A10 50.47 Wiring diagram sticker, standard
50.17 Hexagon head screw 50.48 Connector, 3-pole (standard)
DIN EN ISO 4017 - M10x40
50.18 Hexagon head screw 50.57 Head cap screw
DIN EN 24017-M10x55 DIN EN ISO 4762 - M4x10
50.19 T-head bolt DIN 261-M12x40 50.58 Protective conductor terminal
50.20 Washer DIN EN ISO 7089 50.59 Head cap screw
50.21 Spring washer DIN 128-A12 50.87 Threaded bush
50.22 Hexagon nut DIN EN ISO 4032 - M12 50.96 O-ring DIN 3771 – 4 x 1.8
50.23 Lift dial 50.101 Connector, 8-pole
50.24 Distance column 50.110 Gear cap
50.25 Hexagon nut DIN 980-V-M16 50.115 O-ring DIN 3771 - 52x2.5
50.26 2-ear clamp (stroke indicator) 50.119 Fan wheel
50.27 Coupling 50.128 Collar nut Seal lock M6
Page 8 0040501000 4511

4.4 Technical data

Type ARI-PREMIO
Thrust force kN 2,2 5,0 12,0 15,0
Stroke distance max. mm 50 80
Duty classification acc. to EN 60034-1 S3 80% DC / max.1200 c/h S3 50% DC / max. 1200 c/h
Control speed mm/sec. 0,38 0,38 1,0 0,38 0,79 0,38
1)
Motor voltage 230V - 50Hz / 60Hz 230V - 50Hz
Power consumption W 21 33 75 69 85 69
For power consumption of other voltages and frequencies refer to type plate or on
request.
Torque switch 2 pcs., permanently wired, 2 pcs., permanently wired
switching capacity 10A, 250V~ switching capacity 16A, 250V~
Travel switch 2) 1 pcs., permanently wired, 1 pcs.,
switching capacity 10A, 250V~ permanently wired
switching capacity 16A, 250V~
Enclosure IEC 60529 IP 65
Max. storage temperature -40 °C ... +85 °C
Max. permissible ambient temperature -20 °C ... +70 °C
For operation outside or at freezing temperature a heating is recommended.
Handwheel Yes (rotating during operation) Yes (engageable)
Mounting position Any. Exception: motor must not be suspended downwards
Gear lubricant Molyduval
Klüber Isoflex Topas NB152
Valenzia H2
Weight kg 5.4 6 6.5 10.5
1) Control speed and power consumption are 20% higher at frequency of 60 Hz
2)
Option trip slide necessary
Additional voltages / frequencies

Type ARI-PREMIO
Thrust force kN 2,2 5,0 12,0 15,0
Control speed mm/sec. 0,38 0,38 1,0 0,38 0,79 0,38
Voltages 24V - 50Hz / 24V - 60Hz 1)
24V - 50/60Hz 1) 24V - 50Hz
24V - DC 2)
24V - DC 2) 24V - 60Hz 1)
24V - DC 2) 115V - 50Hz / 115V - 60Hz 1)
115V - 50/60Hz 1)
3~400V - 50/60Hz 1)3) 115V - 50/60Hz 230V - 60Hz 1)
3~400V - 50Hz / 3~400V - 60Hz 1)
1)
Control speed and power consumption are 20% higher at frequency of 60 Hz
2)
further information / technical data for DC-version refer to item 5.5.14 Electronic position indicator RI32
3)
S3 50%ED / max 1200 c/h
0040501000 4511 Page 9

Accessories
Trip slide Necessary for operation:
- for actuating travel switch S3 / retracting spindle
(the travel switch S3 exists already in the standard version of the actuator)
- for potentiometer
- for additional position switches S4 / S5
Additional intermediate Type Standard - 2 pcs., zero potential, switching capacity 10A, 250V~
position switches - 2 pcs., zero potential, with gold contacts,
S4, S5 4)5) Type Low-voltage
switching capacity max. 0,1A, 4-30V
Conductive plastic
- 500, 1000, 2000, 5000 ohm; 1 W
(max. 2 pcs.)
Wire (max. 2 pcs.) - 100, 200 ohm; 1 W
- Only in conjunction with RI22
Contactless (max. 1 pc.)
- Feedback signal corresponds to RI22
Potentiometer 4) - TÜV-approved conductive plastic potentiometer, suitable as a
position feedback sensor for control devices in electronic systems
TÐúV-approved used to regulate and monitor fuel, air and exhaust gas streams in
potentiometer combustion plants
(max. 2 pcs.) - 5000 ohm
- Or optionally: 100, 200, 500, 1000 ohm; 1.5 W
- Not suitable for retrofitting!
- Control signals 0(2)...10V or 0(4)...20mA; electrical isolation
between mains voltage and control signal
Type ES11
Electronic - Incl. potentiometer
position controller 4) (note the maximum number of potentiometers)
(for controlling actuator with - Control signals: 3-step, 0-10V or 4-20mA
analogue control signal) Type PREMIO-Plus
- Automatic initialisation
(see separate data sheet /
- Optional position feedback
operating instructions)
- Electrical isolation between mains voltage and control signal
- Analogue output for position feedback 0(4)...20mA, optional
switching to 0(2)-10V, output can be inverted; electrical isolation
between mains voltage and position feedback signal
RI22
- Optional display for indicating position feedback signal in mA or V
Electronic - Incl. potentiometer
position indicator 4) (note the maximum number of potentiometers)
(for position feedback with - Analogue output for position feedback
analogue control signal) 2...10V; 4...20 mA
- Compact design; 2 or 4-wire circuit
RI32
- Power supply: 24V AC/DC
- Incl. potentiometer
(note the maximum number of potentiometers)
- (With automatic switching circuit)
Heating Heating resistor
230V AC, 115V AC, 24V AC, 15W
- Zero potential, switching capacity 10A, 250V~
Type Standard PA
- (Also possible with standard version for operation at 12/15kN)
Connection board 4)
- Zero potential, with gold contacts,
Type Low-voltage NA
max. switching capacity 0.1A, 4-30V
Page 10 0040501000 4511

- Built into actuator

- 3-state stepper controller with 2 solid state relay outputs for direct
control of PREMIO actuators with a 3-step signal
Type - Compatible with resistance thermometers and thermocouples
Process controller Process controller (provided by customer), or standardized active current or voltage
dTRON 316 signals,
- Preconfigured for temperature control:
Control range: -200°C to +850°C (resistance thermometer)
- Not compatible for use with the ES11!
Integrated
-Only 1 electronic module possible!
400V 3~ Acessories reversing contactor
Phase control relay -Only in addition with integrated reversing contactor!
4)
Option trip slide necessary
5)
Gold contacts should be used for low switching capacities and aggressive atmosphere
0040501000 4511 Page 11

Fig. 3
Page 12
Clearance required for
removal of hood
4.5 Dimensions

removal of hood
removal of hood
10165
0040501000 4511
X L h
236 602 max. 30 mm
256 622 max. 50 mm
271 637 max. 65 mm
286 652 max. 80 mm
ARI-PREMIO 2,2 - 5 kN ARI-PREMIO 2,2 - 5 kN ARI-PREMIO 12 - 15 kN

Nominal stroke max. 30 mm Nominal stroke > 30 mm - 50 mm Nominal stroke max. 80 mm
5.0 Installation
ATTENTION !
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supervision of a
qualified electrician in compliance with regional electrical safety requirements
and regulations.
- Valve mountings such as drives, handwheels, hoods must not be used to take
external forces, e.g. they are not designed for use as climbing aids, or as
Non-compliance may lead to death, injury or damage to property due to
persons falling or parts being dropped.
- Actuator components which rotate or move during operation are coloured red.
Crushing and injury hazard!
5.1 General installation data

- In addition to general installation guidelines, the following points are required to be
observed:
- Planners / construction firms and operators are responsible for positioning and installing
the products.
ATTENTION !
- A voltage is induced in the thrust actuator motor. This induction voltage may be
higher than the operating voltage.
- For this reason relays and electronic load relays for thrust actuator control
require a protective circuit. The contacts of unprotected relays may stick after a
while.
- This may result in reversed directions of rotation or defective switch-off
Recommended safety circuit for relays and electronic load relays:

Connect a varistor or RC module parallel to each relay point.
Varistor S10K385 to S10K460
RC module 100 Ohm / 100nF
Where relay points and electronic load relays are particularly sensitive a coil should be
connected in series additionally to each relay point.
Recommended coil:
Toroidal coil 2mH / 2A
- Contactors of 16A and upwards do not need a safety circuit.
- Check thrust actuator for damage prior to fitting.
Damaged parts must be replaced by original spares.
- Existing operating instructions for valve.
- Complete valve with crossarm.
- Valve cone approximately in mid lift position - on no account supported inside a seat!
- Electrical installation in accordance with current regional regulations.
- Conductor cross-section selected to correspond to the given drive power and existing line
length.
0040501000 4511 Page 13

- Mains fuse rating max. 6A.
- Circuit breakers in the plant to cut off the mains supply to the actuator.
- Conformity of technical data on thrust actuator with field conditions.
- Mains voltage in accordance with data specified on rating plate of thrust actuator.
- Thrust actuator complete with yoke or distance columns and coupling parts intended for
mounting to the corresponding valve.
- Ease of access to installation site.
- Adequate clearance space above the thrust actuator for removing the hood
(refer to point 4.5 Dimensions).
- Install where there is protection against high-energy heat radiation.
- The ambient temperature must be between -20°C and +70°C.

If installed outdoors, the thrust actuator must be provided with an additional cover to protect
against
- rain,
- direct insulation,
- dust.
In case of widely fluctuating ambient temperatures, high atmospheric humidity and
temperatures below the freezing point, your are recommended to install a heating resistor
to minimise condensation buildup in the actuator.
- Thrust actuator mountable in any position except in downward suspended position.
If installed with a horizontal connecting rod, the thrust actuator must be mounted so both
yoke legs or columns are on top of one another in the vertical plane (see Fig. 4 ).
Correct Incorrect
Fig. 4
Page 14 0040501000 4511

5.2 Manual operation

5.2.1 ARI-PREMIO 2.2 - 5 kN
ATTENTION !
- The handwheel always rotates during motor-driven operation (running
indicator). Never activate manual operation while the motor is running.
Injury hazard!
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator! Since the
handwheel always follows during motor-driven operation (running indication),
never operate by hand while the motor is running - potential injury hazards!
With the motor in the stationary state, the thrust actuator can be run in the retracted and
extended state with the handwheel firmly meshed with the gear.
Proceed as follows:
- Swing out lever (pos. 50.12.1) from handwheel (pos. 50.12).
- Turning in clockwise direction --> extending spindle.
- Turning in counter-clockwise direction --> retracting spindle.
retracting spindle extending spindle
Fig. 5
0040501000 4511 Page 15

5.2.2 ARI-PREMIO 12 - 15 kN
ATTENTION !
- Do not attempt to engage manual operation until the motor has stopped.
Switching over while the motor is running may damage the thrust actuator.
- In the manual operating mode pay careful attention in the final positions that the
handwheel is only turned to the point where the torque switch trips (audible
click) as otherwise damage will be caused to the thrust actuator!
With the motor in the stationary state, the thrust actuator can be run in the retracted and
extended state with the engageable handwheel.
Proceed as follows:
- Fold the turning handle out of the handwheel (A)
- Turn the handwheel slightly and push in the engaging button for manual mode (B)
--> the button engages
- Turning in clockwise direction --> extending spindle
- Turning in counter-clockwise direction --> retracting spindle
The motor is no longer in mesh when the handwheel is engaged. The handwheel is
automatically disengaged when the motor starts and the motor is once more in mesh.
Engaging button
for manual mode
retracting
extending
Fig. 6
ATTENTION !
When changing the motor, it’s necessary to
observe for a correct function of the manual
operating device, that the head-cap screw
M4x18 is screwed in the right place.
Page 16 0040501000 4511

5.3 Installation instructions for mounting to valves

5.3.1 Mounting for valve-lift up to 30 mm (yoke version)
turn
Hexagon nut Hexagon nut

Valve spindle Valve spindle
Fig. 7
To mount the thrust actuator to a valve having a nominal lift of up to 30mm, proceed
as follows:
- Screw coupling (pos. 50.27) out of torsion safety feature (pos. 50.32) of thrust
actuator (not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A: - Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (pos. 50.27) over valve spindle.
- Screw threaded bush (pos. 50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
ATTENTION !
Setting dimension (Y) and fitting-projection (X) are measured with
inserted valve spindle. This means for
- 2-way valves at closed valve,
- 3-way valves with mixing plug at closed way B,
- 3-way valves with diverting plug at closed way A
After measuring put the valve plug back in the mid lift position!
- Setting dimension (Y) for fitting-projection (X) 60 and 83mm = 102mm.
Fig. C: - Place thrust actuator (pos. 50) on valve.
- Mount thrust actuator (pos. 50) on fitting with two T-head bolts (pos. 50.19), two
washers (pos. 50.20), two spring washers (pos. 50.21), two hexagon nuts
(pos. 50.22).
Fig. D/E: - Swing out handwheel lever (pos. 50.12.1) and use it to move out the thrust
actuator until the driving spindle (pos. 50.30) comes to rest on the threaded
bush (pos. 50.87).
0040501000 4511 Page 17

Fig. F: - Screw the coupling (pos. 50.27) firmly into the torsion safety feature
(pos. 50.32) and secure in place using grub screw M6 (pos. 50.35).
- Run valve to lowest position.
- Clip lift dial (pos. 50.23) onto yoke in such a way that top edge of torsion safety
feature is in alignment with tip of arrow mark on lift dial.
- Run valve to both final positions and check to ensure that these are safely
reached
- Carry out electrical connection (see point 5.4).
- Set travel switch S3 (see point 5.5.3.2).
Page 18 0040501000 4511

5.3.2 Mounting for valve lift over 30 mm to 80 mm (column version)
turn
Hexagon nut Hexagon nut

Valve spindle
Valve spindle
Fig. 8
To mount the thrust actuator to a valve having a nominal lift of over 30mm to 50mm,
proceed as follows:
- Screw coupling (pos. 50.27) out of torsion safety feature (pos. 50.32) of thrust
actuator
(not illustrated).
- Position valve cone approximately in mid lift position.
Fig. A: - Turn flat hexagon nut if not present on valve spindle.
Fig. A-B: - Slip coupling (pos. 50.27) over valve spindle.
- Screw threaded bush (pos. 50.87) matching the valve onto the valve spindle in
accordance with setting dimension (Y) and lock with hexagon nut.
ATTENTION !
Setting dimension (Y) and fitting-projection (X) are measured with
inserted valve spindle. This means for
- 2-way valves at closed valve,
- 3-way valves with mixing plug at closed way B,
- 3-way valves with diverting plug at closed way A
After measuring put the valve plug back in the mid lift position!
- Setting dimension (Y) for fitting-projection (X) 83mm = 102mm.
- Setting dimension (Y) for fitting-projection (X) 98mm = 116mm.
0040501000 4511 Page 19

Fig. C: - Slip 2-ear clamp (pos. 50.26) onto a distance column (pos. 50.24) press on
very lightly.
- Screw distance column with 2-ear clamps on opposite side of handwheel into
the flange in such a way that one of the 2-ear clamps is situated above the
torsion safety feature (pos. 50.32) and the other below.
- Screw the other distance column into the flange likewise.
- Place thrust actuator (pos. 50) with distance columns onto valve and fix into
position with two self-locking hexagon nuts (pos. 50.25).
Fig. D/E: - Fold out turning handle of handwheel (pos. 50.12.1), slightly turn the
handwheel and press in the engaging button for manual mode (only 12 - 15 kN)
(button engages). Having done this, move out the thrust actuator until driving
spindle (pos. 50.30) comes into contact with threaded bush (pos. 50.87).
Fig. F: - Screw coupling (pos. 50.27) firmly into torsion safety feature (pos. 50.32) and
secure using grub screw M6 (pos. 50.35).
- Move the valve to the lowest position.
- Press 2-ear clamps (pos. 50.26) into position according to the stroke so they
cannot slip, with the bottom clamp in the lowest valve position located directly
below torsion safety feature (pos. 50.32) and the top clamp in the highest valve
position located directly above the torsion safety feature.
- Move the valve to both travel positions and check that it reaches them reliably.
- Fold turning handle of handwheel (pos. 50.12.1) back in.
- Make the electrical connection (see point “5.4 Electrical connection”). The
engaging button for manual mode (only 12 - 15 kN) disengages when the
motor starts up.
- Set standard travel switch S3 (see point 5.5.3.2).
Page 20 0040501000 4511

standard accessories
Fig. 9
Trip cam as
accessories trip slide
Tele- Thermo- Current Voltage

Input resistance thermometer
transmitter element 0(4)...20mA 0(2)...10V
Binary input Binary output Logic 12V

alternativ to
binary inputs
bin1 and bin2
5.4 Electrical connection
power
supply
230V/3A Binary outpu t (Out2)

5.4.1 Wiring diagram ARI-PREMIO 2.2 - 5 kN
10165
Output to the actuator

Voltage and power
0040501000 4511
supply voltage are equal
Wire connections of the different valve types HZ Heating resistor

Straight through valve with mixing plug with diverting plug DE Torque switch
A-AB open AB-B open

WE Travel switch for traveling the stroke distance
closed
(S3) in retracting direction
open B-AB open AB-A open
RI 21 Electronic position indicator
Option NA: ES 11 Electronic position controller

same design but no RC circuit NA Low-voltage connection board, zero potential
and switches with gold contacts
Standard-voltage connection board,
(Switching capacity 0.1A, 4-30VDC) PA zero potential
POT Potentiometer
TTR Electronic temperature-controller dTRON 316
Page 21
Standard Accessories
Fig. 10
Page 22
Trip cam Tele- Thermo- Current Voltage
Input resistance thermometer
accessories trip slide transmitter element 0(4)...20mA 0(2)...10V
Binary input Binary output Logic 12V

alternativ to
binary inputs
bin1 and bin2
power
supply
230V/3A Binary outpu t (Out2)
Option NA
same design as Standard but no RC
circuit and switches with gold contacts
(Switching capacity 0.1A, 4-30V) Output to the actuator
Wire connections of the different valve types Voltage and power
3-way valve 3-way valve supply voltage are equal
5.4.2 Wiring diagram ARI-PREMIO 12 - 15 kN
Standard
10165
closed A-AB open AB-B open
0040501000 4511
open B-AB open AB-A open HZ Heating resistor
DE Torque switch
WE Travel switch for traveling the travel
(S3) distance in retracting direction
RI 21 Electronic position indicator
External reversing contactor: ES 11 Electronic position controller
L1, L2, L3 - actuator spindle drives in
L3, L2, L1 - actuator spindle drives out Low-voltage connection board,
NA
In all external reversing circuits the torque zero potential
switches S1 and S2 have to be used to POT Potentiometer
switch-off the actuator motor.
5.4.2.1 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ without reversing contactor
external TTR Temperature-controller dTRON 316

reversing Please check the operating direction
contactor of the actuator ! WS Reversing contactor
PR Phase control relay
TR Temperature switch motor
Accessories WS + PR
Fig. 11
3-step input signal Connect 3 phases L1, L2, L3 only here
closed A-AB open AB-B open
Accessories WS
open B-AB open AB-A open
10165
0040501000 4511
5.4.2.2 ARI-PREMIO 12 - 15 kN 1 Ph~ / 3 Ph~ with reversing contactor
3-step input signal Connect 3 phases L1, L2, L3 only here
Please check the operating direction

of the actuator !
Page 23
5.4.3 Connection
ATTENTION !
- Work on electrical systems or equipment must only be carried out by qualified
electricians or by trained individuals under the guidance and supervision of a
qualified electrician in compliance with regional electrical requirement and
regulations.
- When connecting the thrust actuator the supply line must be disconnected from
the mains (not live) during connection work. It must be impossible to switch the
power on unintentionally while the mains are disconnected in this way. Failure
to comply may result in death, serious injury or substantial damage to property.
To connect the thrust actuator up to the electrical power supply, proceed as follows:
- Run the thrust actuator a few mm out of the lower final position applying the manual mode.
- Loosen collar nut / countersunk screw on hood, carefully remove hood in upward
direction.
- Remove blind plug fom the cable connection.
- Insert the connection line through this cable inlet until sufficient conductor length is
available up to the corresponding terminals; then tighten the cable connection until the
connecting cable is clamped in place inside it.
- Strip connecting cable approx. 1-1.5 cm above cable inlet.
- Strip the individual conductors approx. 5mm away from the end and fit with conductor end
sleeves.
- Connect protective conductor of connecting cable up to protective conductor terminal of
thrust actuator.
- Connect neutral N/MP conductor of connecting cable up to terminal 1/N of thrust-actuator
terminal strip.
- Connect pulse line for move-out connecting rod up to terminal 11 of thrust-actuator
terminal strip.
- Connect pulse line for move-in connecting rod up to terminal 14 of thrust-actuator terminal
strip.
- Place hood on carefully from above and mount firmly onto thrust actuator with collar nut /
countersunk screw and rubber gasket.
- Connect supply line to mains and run thrust actuator to each of the final positions so as to
check whether the final-position travel switches effect switching off, also checking to see
whether the direction of movement on the thrust actuator corresponds to the desired
direction.
- If the directions of movement are contrary to those desired, the pulse lines governing the
move-in and move-out connecting rod will need to be exchanged.
Page 24 0040501000 4511

5.5 Options and settings

ATTENTION !
- The thrust actuator may only be operated for a short time without the hood for
unavoidable setting operations to the potentiometers, travel switches and the
electrical options. While these operations are in progress, the thrust actuator
has hazardous, live, uninsulated parts exposed as well as moving and rotating
parts.
- Improper execution of the setting operations or lack of care may cause death,
grievous bodily injury or substantial property damage.
- Operation of the thrust actuator without the hood for any purpose other than
that described above is strictly prohibited.
5.5.1 Torque and travel switches

The thrust actuators are equipped with a load-dependent travel switch for the retracting
direction (S1), a load-dependent travel switch for the extending direction (S2) and a stroke-
dependent travel switch for the retracting direction (S3).
The load-dependent travel switches (S1, S2) switch-off the motor as soon as the factory-set
thrust force is attained.
ATTENTION !
- The settings of the load-dependent travel switches must on no account
whatsoever be changed!
- For the function of the stroke-dependent travel switch (S3), an optionally
available trip slide is necessary.
The stroke-dependent travel switch (S3) switches off the motor as soon as the lift or stroke
is attained. If the thrust actuator is supplied on a straight through valve, the stroke-
dependent travel switch S3 is set in such a way that the motor of the thrust actuator is
switched off as soon as the maximum valve-lift is attained.
If the thrust actuator is supplied on a three-way valve, the trip cam belonging to travel
switch S3 is set in the retracting direction in the trip slide to such a downward extent that the
upper final position of the valve is attained prior to travel switch S3 being reached, thus
causing the load-dependent travel switch S2 to switch-off the motor.
For this function, all three switches reveal interlock-controlled circuitry on the board.
If the standard travel switches are to be integrated directly into the facility control system,
the standard board can be replaced by optional boards PA or NA (only 2.2-5kN).
5.5.2 Connection boards PA or NA (only 2.2 - 5 kN)

On connection boards PA or NA, the standard travel switches S11/S21, S12/S22 and S13/
S23 do not reveal interlock-controlled circuitry and can be integrated individually into the
facility control system.
The 3 contacts on each of the switches S11/S21, S12/S22 and S13/S23, designed as
double-throw contacts, are - in the case of these boards - brought out on terminals 40-48
and can be freely connected.
The switches on the PA optional board (standard-voltage connection board) are designed
for switching capacities of up to 10A, 250V AC.
The switches on the NA optional board (low-voltage connection board) are designed for
switching capacities of up to 0.1A, 4-30V (gold contacts).
0040501000 4511 Page 25

The optional boards may only be installed at the factory due to the switching points of the
load-dependent switches having to be reset following installation of these boards!
ATTENTION !
- When using optional boards PA or NA, it must be warranted - due to the
operator’s individual circuitry- that, when switching the load-dependent travel
switches S11/21, S12/S22 and S13/S23 the motor of the thrust actuator comes
to a standstill without delay.
This function is not provided for on the optional boards PA and NA in the
supplied state!
5.5.3 Travel switch

The thrust actuators can be equipped with an additional stroke-switch board containing two
travel switches (double-throw contact S4 and S5).
These switches can be set on infinitely variable lines over the entire stroke distance in both
lift directions and integrated at will into the facility control system (no interlock-controlled
circuitry).
The maximum switching capacity of the switches (see point “4.4 Technical data”) must not
be exceeded.
For low voltage (see point “4.4 Technical data”), the additional travel switches are supplied
with gold contacts (option: low-voltage travel switch).
NOTE !
- The internal torque switches (S1 and S2) are not switched synchronously to the
additional limit switches (S4 and S5) in the end position!
As construction continues, the actuator travels at the end-position into a plate spring
package and thus builts the actuators force. There is no travel further on, so the additional
limit switches signalise the end position already, before the actuator has built the actuator
force.
Only after the actuating force has been reached, the motor will be switched-off by the
internal torque switch.
CONCLUSION !
- If the motor is switched-off by the additional limit switches S4 or S5, then the
actuator builds no force. The valve does not close tightly!
In order to switch-off the motor by limit switches S4 and S5 in the end position,
- either the motor has to be provided with a release delay from min. 10 s after the additional
limit switches were switched,
- or the torque switches have ot be queried directly. For this, the optional PA-connection
board is required. Please observe notes at „5.5.2 Connection boards PA or NA (only 2.2 -
5 kN)“ .
Page 26 0040501000 4511

5.5.3.1 Installation of additional travel switches
To install additional travel switches, proceed as follows.
- Switch-off mains voltage and safeguard to prevent it from being switched back on again
accidentally.
- Loosen collar nut / countersunk screw on hood, carefully remove hood.
- Disconnect motor plug and mains connection plug from board.
- Carefully ease open the lock washer (pos. 50.56) (open ends) with a screw driver while
pulling the trip slide (pos. 50.50) upwards from the board support.
- Remove trip slide (pos. 50.50) from board support by pulling upwards.
- Loosen head cap screws (pos. 50.57) on board support and remove this from gearbox
(only necessary on 5kN thrust actuator).
- Insert stroke-switch board (pos. 50.61) in board support (pos. 50.42) and fix in place using
the supplied screws (pos. 50.44).
- Mount board support loosely on gearbox cover plate with two head cap screws (pos.
50.57) (only necessary on 5kN).
- Push trip slide (pos. 50.50) back into board support (pos. 50.42) from above and onto the
guide spindle (pos. 50.38).
- Align board support (pos. 50.42) on gearbox cover plate in such a way that the guide
spindle (pos. 50.38) is centrally situated in the borehole of the trip slide (pos. 50.50); then
screw down tightly on gearbox cover plate (only necessary on 5kN).
- Mount the trip slide (pos. 50.50) so that the spring (pos. 50.56) clips into the groove of the
guide spindle (pos. 50.38).
- Insert 6-pole connector (pos. 50.62) in jack strip of stroke-switch board.
- Proceed to strip the connecting cable that has been led in through the cable inlet and
fastened, and connect the individual conductors to the terminal strip in accordance with
the desired circuitry and the wiring diagram.
- Set switch points on travel switches in accordance with section 5.5.3.3 Setting the
additional travel switches (S4/S5 and S24/S25)
- Insert motor connection plug in jack strip (pos. 50.43.4) provided for the purpose.
- Insert mains connection plug in jack strip (pos. 50.43.3) provided for the purpose.
0040501000 4511 Page 27

- Carefully place hood onto gearbox and mount firmly on thrust actuator with collar nut /
rubber gasket and countersunk screw.
Fig. 12 Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

50.38 Guide spindle 50.52 Setting spindle for switch S4
50.42 Board support 50.53 Setting spindle for switch S5
50.43.3 Jack strip for mains connection 50.54 Trip cam
50.43.4 Jack strip for motor connection 50.56 Spring
50.44 Self-tapping screw 50.57 Head cap screws DIN EN ISO 4762 -
M4x10
50.50 Trip slide (option) 50.61 Stroke-switch board
50.51 Setting spindle for switch S3 50.62 Connector, 6-pole
(option: travel switch)
Page 28 0040501000 4511

5.5.3.2 Installation of trip slide and setting of the travel switch (S3)
To retrofit guide spindle and trip slide for the travel switch, proceed as follows:
accidentally.
- Disconnect motor plug and mains connection plug from board.
- Screw the hexagon nut M5 (pos. 50.39) approx. 6mm on the guide spindle (pos. 50.38)
- Screw the guide spindle in accordance with setting dimension E=50mm into the drive
spindle (pos. 50.30) and counters with the hexagon nut M5.
- Lubricate trip slide (pos. 50.50) at the bearing surface ends with grease
- Push trip slide (pos. 50.50) into board support (pos. 50.42) from above and onto the guide
spindle (pos. 50.38).
- Mount the trip slide (pos. 50.50) so that the guide spindle (pos. 50.38) is centrally situated
in the borehole of the trip slide and the spring (pos. 50.56) clips into the groove of the
guide spindle.
- Insert motor connection plug in jack strip (pos. 50.43.4) provided for the purpose.
- Insert mains connection plug in jack strip (pos. 50.43.3) provided for the purpose.
- Carefully place hood onto gearbox and mount firmly on thrust actuator with collar nut /
Groove for spring
Fig. 13: Spindle and trip slide installation

50.30 Drive spindle 50.51 Setting spindle for switch S3
50.38 Guide spindle 50.52 Setting spindle for switch S4
50.39 Hexagon nut DIN EN ISO 4034 - M5 50.53 Setting spindle for switch S5
50.42 Board support 50.54 Trip cam
50.50 Trip slide 50.56 Spring PREMIO for trip slide
0040501000 4511 Page 29

Installing the thrust actuator on a straight through valve, the travel switch S3 needs
to be set as follows:
- Move valve out of the lowest position so as to run valve-lift to up position.
- Using a screw driver, proceed to turn setting spindle for switch S3 (pos. 50.51) until the trip
cam (pos. 50.54) arriving from below trips the switch (audible click).
- Run thrust actuator briefly in extending direction and then in retracting direction once
more, checking to see whether the thrust actuator is switched off at the desired point
(nominal lift).
- If need be, correct the setting as described.
Installing the thrust actuator on a three-way valve, the travel switch S3 needs to be
set as follows:
- Run valve in both final positions and check in each final position whether the valve
switches off via the load-dependent switch.
- Carry out a check in the top final position the see whether, after switching off the thrust
actuator, the trip cam (pos. 50.54) of the travel switch S3 is situated below switch S3 and
has not tripped the latter. If the trip cam (pos. 50.54) is situated above the travel switch S3
or trips the same, the setting spindle governing the travel switch S3 (pos. 50.51) needs to
be turned until the trip cam is situated below travel switch S3 without tripping it.
- Run the thrust actuator in both final positions once more and check whether thrust
actuator switches off in both final positions via the load-dependent switches.
- If need be, correct the setting as described above.
5.5.3.3 Setting the additional travel switches (S4/S5 and S24/S25)

The two additional travel switches can be freely set in both lift directions for indicating
certain valve positions.
To do this, proceed as follows:
- Run valve to desired position due to be indicated by the corresponding switch.
- Proceed to turn the setting spindle belonging to the appurtenant switch until the switch is
tripped (audible click).
- Run thrust actuator briefly in both directions, checking and, if need be, correcting the
setting.
The actuating feature on the travel switches is designed in such a way that both travel
switches can be overrun in both directions.
Standard design:
For that reason, care should be taken on additional travel switches to see that the actuating
state of the switches remains active only for a short time while the thrust actuator continues
to run and that switching back takes place afterwards.
The actuating state of the travel switches remains in force over a lift of 4 mm.
Special design:
At additional travel switches with extended switch levers, the actuating state of the travel
switches remains in force over a lift of 49 mm.
Page 30 0040501000 4511

5.5.4 Potentiometers
The potentiometers are used for electrical position acknowledgement on the facility control
system or for the options - electronic position controller ES11 or electronic position indicator
RI21
A maximum of 2 potentiometers can be installed (= 1 double potentiometer).
The potentiometers can be supplied with different resistance values
(see point „4.4 Technical data“).
For the electronic position controller ES11 and the electronic position indicator RI21 use
must be made solely of 1000 ohm potentiometers.
Conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by
means of transmission determined in respect of each valve-lift between the toothed rack on
the trip slide and the pinion on the potentiometer shaft.
Use must only be made of the pinion specified for the valve-lift.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer
is assembled and set ready for operation.
To achieve optimal electromagnetic compatibility it is recommended to use shielded cables
for connecting potentiometers or standardized active current or voltage signals.
5.5.4.1 Installing the potentiometer
If retrofitting the potentiometer, proceed as follows:
accidentally.
- Insert the potentiometer into the guide in the way that the pinion (pos. 50.73) of the
potentiometer meshes with the gear stick of the trip slide.
- With a valve lift up to 30 mm, hook spiral spring (pos. 50.70) into the left-hand window of
board support (pos. 50.42) above the potentiometer guide, insert into the guide between
the slide block and the potentiometer guide and hook into the cut-out below the
potentiometer.
With a valve lift between 30 mm and 50mm, hook spiral spring (pos. 50.70) into the right-
hand window (for 12 - 15kN middle window) above the potentiometer guide, insert into the
guide between the slide block and the potentiometer guide and hook into the cut-out
below the potentiometer.
With a valve lift between 50 mm and 65 mm, hook spiral spring (pos. 50.70) into the
middle window in board support (pos. 50.42) above the potentiometer guide, insert into
the guide between the slide block and the potentiometer guide and hook into the cut-out
below the potentiometer.
- Check to see whether pinion (pos. 50.73) is pressed into toothed rack by spiral spring
(pos. 50.70) and is positioned free from backlash.
- If this is not the case, remove spiral spring (pos. 50.70), readjust by bending a little, and
place back in position again.
- Screw jack strip of connecting cable (pos. 50.68) to board support (pos. 50.42) with two
self-tapping screws (pos. 50.69) (single potentiometer connectors 25-27).
- Insert additional 3-pole connector (pos. 50.74) in jack strip of connecting cable
(pos. 50.68).
- Set potentiometer (see point 5.5.4.2).
- Place hood carefully onto thrust actuator and fasten it on the actuator with collar nut /
0040501000 4511 Page 31

Fig. 14: Switchgear and indicating feature ARI-PREMIO 2.2 - 5 kN

50.42 Board support 50.68 Connecting cable for option:
potentiometer
50.46 Washer 50.69 Self-tapping screw
50.47 Circuit-diagram sticker 50.70 Spiral spring (option:
potentiometer)
50.67.1 Hexagon nut 50.71 Slide block (option: potentiometer)
50.67.2 Tooth lock washer 50.73 Pinion (selection depends on
valve-lift 20, 30, 50, 65 or 80 mm)
50.67.3 Potentiometer 50.74 Connector, 3-pole
(option: potentiometer)
Page 32 0040501000 4511

5.5.4.2 Setting the potentiometer
To set the potentiometer, proceed as follows:
- Move thrust actuator to extended position.
accidentally.
- Turn potentiometer shaft in counter-clockwise direction until reaching the travel stop.
This places the potentiometer in the initial position (approx. 0 ohm).
- For checking purposes, the resistance of the potentiometer needs to be measured using
an ohmmeter.
- Measure resistance on potentiometer 1 between terminals 25 and 26.
- In this position of the actuator, the measured value should be approx. 0 ohm.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.
- The resistance values thus measured need to be taken into account for the settings to the
0040501000 4511 Page 33

5.5.5 Error-proof potentiometer for single-channel, error-proof position feedback
The TÜV certified potentiometer on conductive plastic basis is used for single-channel,
error-proof position feedback in connection with error-proof, electronic group monitoring
systems for the regulation of fuel -, air and exhaust gas streams.
A maximum of 2 potentiometers can be installed (=1 double potentiometer).
The potentiometers can be supplied with different resistance values (see point „4.4
Technical data“).
For the electronic position controller ES11 use must be made solely with 1000 ohm
potentiometers
The conversion of the relevant valve-lift to the potentiometer angle of rotation is effected by
the transmission between the toothed rack on the trip slide and the pinion on the
potentiometer shaft.
The pinion and the potentiometer shaft are firmly connected.
If the thrust actuator is supplied with the valve and built-in potentiometer, the potentiometer
is assembled and set ready for operation.
The potentiometer is with the options „Heating“ and “position indicator RI21“ not
combinably.
To use for the electromagnetic compatibility, shielded lines are recommended for
potentiometers and electrical unit signals.
Don`t lay signal lines parallel to the main line!
ATTENTION !
- In order to achieve as high a life span as possible with maximum accuracy,
potentiometers on conductive plastic basis are not as adjustable pre-resistors
to begin but as read-free voltage dividers!
- An additional installation of the option „Error-proof potentiometer“ is not
permitted for safety reasons.
5.5.5.1 Setting the potentiometer on conductive plastic basis

To set the potentiometer, proceed as follows:
- Move thrust actuator to extended position.
accidentally.
- For checking purposes, the resistance of the potentiometer needs to be measured using
an ohmmeter.
- Loose the potentiometer by unscrewing the 2 screws and remove it incl. pinion from the
toothed rack.
- Turn potentiometer shaft (angle of rotation mech. 360°, electr. 320° without stop) and by
means of ohmmeter bring the potentiometer in initial position (approx. 0 Ohm).
- Bring the potentiomter and the pinion back in contact with the toothed rack and fasten the
screws.
- Subsequently, the screws are to be provided again with locking lacquer.
- Run thrust actuator to upper final position and read off corresponding resistance value on
ohmmeter.
Page 34 0040501000 4511

- The resistance values thus measured need to be taken into account for the settings to the
Fig. 15: Error-proof potentiometer ARI-PREMIO 2,2 - 5 kN

50.38 Guide spindle 50.81 Head cap screw
50.39 Hexagon nut 50.120 Lever
50.42 Board support 50.121 Metal sheet
50.50 Trip slide (option) 50.122 Tension spring
50.67 TÜV-approved potentiometer 50.123 Pan-head screw
50.71 Slide block (option: potentiometer) 50.124 Straight pin, slotted
50.73 Pinion (travel 50 mm) 50.125 Hexagon nut M4, self-locking
50.74 3-pole connector 50.126 Hexagon nut M5, self-locking nut
(option: potentiometer)
0040501000 4511 Page 35

5.5.6 Heating
A heating resistor should be fitted as a means of protection against the formation of
condensation water in cases involving widely varying ambient temperatures, high
atmospheric humidity (outdoor use) and temperatures below the freezing point. The heating
resistor is self-regulating so that a continuous supply of current merely needs to be
connected up.
5.5.6.1 Installation of heating
On principle, the heating can be combined with all options. It is completely mounted on a
holding bracket.
If electronic system ES11 or RI21 is already installed, unscrew the electronic system from
the holding bracket, remove it, install the heating and attach the electronic system to the
holding bracket for the heating.
To install the heating proceed as follows:
accidentally.
- Using the supplied screws, mount complete heating (on holding bracket) at the point on
the gearbox cover plate provided for the purpose. (Fig. 17).
- Lead continuous-current cable (mains voltage = rated voltage of heating) through cable
inlet into thrust actuator and fix in place with inlet.
- Strip continuous-current cable approx. 1-1,5 cm above cable inlet.
- Strip individual conductors approx. 5mm away from the end and provide with conductor
end sleeves.
- Lay the individual conductors in such a way that they do not come into contact with
moving parts.
- Connect the individual conductors up to the connection terminal block in accordance with
the wiring diagram.
Mounting thread M3 Mounting thread M3

for heating resistor for thermal circuit breaker
Mounting thread M4
for options ES11 and RI21
Mounting thread M3
for jack strip
Fig. 16: Heating installation ARI-PREMIO 2.2-15 kN

50.83.1 Holding bracket 50.83.4 Jack strip
(Option: heating)
50.83.2 Head cap screw DIN 84-M3x8 50.83.6 Connector, 2-pole
50.83.3 Thermal circuit breaker 50.83.10 Heating resistor
Page 36 0040501000 4511

5.5.7 Electronic position indicator RI21
The electronic position indicator RI21 converts the resistance of the 1000 ohm
potentiometer corresponding to the lift into an optional output control signal 0 (2) ...10V DC
or 0 (4) ...20mA DC. For installing and setting the electronic position indicator RI21 the
operating instructions applicable to this unit must be observed in the appropriate valid
version. The corresponding operating instructions are supplied with each unit.
5.5.8 Electronic position controller ES11

The electronic position controller ES11 converts continuous input control signals 0 (2)
...10V DC or 0 (4) ...20mA into a 3-point output signal for the motor, in which case
interrogation of the valve position takes place via a 1000 ohm potentiometer. For installing
and setting the electronic position controller ES11 the operating instructions applicable to
this unit must be observed in the appropriate valid version. The corresponding operating
instructions are supplied with each unit.
Fig. 17: Installing RI21 / ES11 / heating ARI-PREMIO 2.2 - 5 kN

50.78/79 Option ES11 or RI21 50.82 Head cap screw
50.80 Holding bracket 50.83 Heating
50.81 Head cap screw
0040501000 4511 Page 37

5.5.9 Electronic position indicator (RI21) and position controller (ES11) together in
the actuator
The electronic position indicator RI21 and the electronic position controller ES11 can be
build-in together in the ARI-PREMIO (Except: 5 kN 24V 1,0/1,2 mm/s; 12 kN 24V;
15 kN 24V).
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI21 and ES11 proceed as follows:
accidentally.
- Mount RI21 and ES11 with mounting kit according to Fig. 18.
Fig. 18: Installing RI21 / ES11 at the same time as ARI-PREMIO 2.2 – 5 kN

50.67 Potentiometer 50.82 Head cap screw
50.78/79 Option ES11 or RI21 50.106 Metal sheet ES11 and RI21
50.81 Head cap screw 50.108 Distance bold
Page 38 0040501000 4511

5.5.10 Integrated temperature controller dTRON 316
The integrated temperature controller controls temperatures, which are measured by input-
connected temperature sensors, to a manual given setpoint by means of a three-step
output connected with the actuator.
5.5.10.1 Installation of the dTRON 316

The dTRON 316 can be mounted in the ARI-PREMIO as a complete unit with a mounting
kit.
It cannot be combined with ES11.
To install the dTRON 316 proceed as follows:
In addition to “5.4.3 Connection”, the electrical connection of the dTRON 316 has to be
done in the following way:
- Mount the temperature controller on the gear plate by using the specific installation kit
(Fig. 19).
- Plug in the connector X2 of the dTRON 316 to the plug-in connector X1 (1/N, 11, 14) of the
actuator terminal.
- Connect the signal input and the individual wanted additional functions according the
wiring diagram to the dTRON 316.
- Connect the power supply L1 and N to the dTRON 316.
- For changing the working direction to heating signal = extending driving spindle, just
change the wires on the connectors 11 and 14.
Pos. Designation
50.97 Temperature controller dTRON 316
50.98 Fixing bracket (option dTRON)
50.99 Holding bracket (option dTRON)
50.100 Self-locking nut (option dTRON)
Fig. 19: Installing dTRON 316 ARI-PREMIO 2.2 – 5 kN
0040501000 4511 Page 39

5.5.11 Integrated reversing contactor
The integrated reversing contactor is actuated using a 3-step input signal.
The reversing contactor swaps over phases L1, L2 and L3 to achieve the desired direction
of rotation of the three-phase motor.
5.5.11.1 Installing the reversing contactor

The reversing contactor can be mounted in the ARI-PREMIO as a complete unit using a
mounting kit.
The reversing contactor can only be combined with one of the ES11, RI21 or temperature
controller options. It is also possible to install the heating and the phase control relay.
Proceed as follows to install the reversing contactor:
Switch-off the mains voltage and take measures to prevent it being switched back on
inadvertently.
ATTENTION !
- When the reversing contactor is installed without a phase control relay, the
thrust actuator may be damaged if phases L1, L2 and L3 are wrongly
connected!
The electrical connection procedure as described in „5.4.3 Connection“ is supplemented by

the following steps:
- Use the mounting kit to attach the reversing contactor to the gear plate (Fig. 20).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in
Fig. 11.
- Wire up as shown in the table in fig. 10 if you are connecting the reversing contactor
without a phase control relay.
- Refer to “5.5.12 Phase control relay” regarding connecting with a phase control relay.
5.5.11.2 Electrical connection with ES11 or dTRON 316

Modify the 3P output cable of the ES11 or the dTRON 316 as follows:
- Remove plug X25.
- Strip off the outer cable insulation down to about 18 cm.
- Connect the individual conductors as follows:
Black (L↑) - S2/14
Brown (L↓) - S1/11
Blue (1/N) - K1/A2, K2/A2
Page 40 0040501000 4511

5.5.12 Phase control relay
The phase control relay monitors phases L1, L2 and L3 in the mains input supply. The
reversing contactor is only activated by the phase control relay providing phases L1, L2 and
L3 are connected correctly. This protects the thrust actuator.
5.5.12.1 Installing the phase control relay

The phase control relay is installed in the ARI-PREMIO next to the reversing contactor. It is
only possible to use the phase control relay in conjunction with the reversing contactor. It
cannot be combined with the dTRON 316 temperature controller in the actuator.
Proceed as follows to install the phase control relay:
Switch-off the mains voltage and take measures to prevent it being switched back on
inadvertently.
The electrical connection procedure as described in „5.4.3 Connection“ and „5.5.11
Integrated reversing contactor“ is supplemented by the following steps:
- Attach the phase control relay next to the reversing contactor (Fig. 20).
- Connect the three-phase connection L1, L2, L3 and the 3-step input signal as shown in
Fig. 10.
Pos. Designation
DIN EN ISO 4762 - M4 x 10
50.59 Head cap screw DIN EN ISO 4762 - M4 x 6
50.81 Head cap screw DIN EN ISO 4762 - M4 x 8
50.102 Reversing contactor
50.103 Fixing plate (option reversing contactor)
50.105 Phase control relay
50.107 Bracket (option phase control relay)
Fig. 20: Installing reversing contactor and phase control relay ARI-PREMIO 12 – 15 kN
0040501000 4511 Page 41

5.5.13 DC module
5.5.13.1 Fitting the DC module to ARI-PREMIO
Space for 2 electronic systems:

- ES11 24V DC
- RI22 24V DC
3-point connection
for 24V DC Connection for 24V
DC mains voltage
Motor control
Fig. 21: PREMIO 2.2-5kN Fig. 22: PREMIO 2.2-5kN

3-step control with position indicator / controller
About the BLDC motor:

- Brushless DC motor, also referred to as a BLDC, BL or EC (electronically commutated)
motor
- Conventional DC motors have carbon brushes. Carbon brushes are subject to wear and
cause high-frequency interference owing to the "coal fire".
- As the name implies, BLDC motors work without carbon brushes. The traditional
drawbacks no longer apply; the motors are non-wearing and no disturbances are
produced. The coils are electronically controlled, which means an electronic control
system is required. In many cases, this is already integrated in the motor.
Page 42 0040501000 4511

5.5.13.2 Optional board support for pole changing
There are several ways of telling a DC
actuator which direction it should travel in.
The most widespread method is three-step
control – our standard technology.
As with the AC variants, the driving spindle
is extended or retracted by means of the DC 3-step DC pole changing
Open
energised terminal. Spindle retracted
If 24V DC voltage is present at terminals 1 or

and 11, for example, the spindle is moved in;
if there is voltage at terminals 1 and 14, it is
moved out.
DC 3-step DC pole changing
Close
In older plants or with older actuators as well Spindle extended
as with our DC module, the direction of
motor rotation is normally changed with the or
help of a pole changing device. Here, power

is applied to terminals 11 and 14. The
actuator extends or retracts the driving
spindle according to the polarity of the
supply voltage. Fig. 23: Pole changing and 3-step control
compared
This method of control can be implemented
with the optional board support for pole
changing (Fig. 24). An electronic system
that converts the signals for this purpose is
mounted on the board in addition to the
travel switches. Thanks to the optional
board support for pole changing, the
actuator can now be operated both with a
three-step signal and with pole changing.
Fig. 24
NOTE !
- The optional board support for pole changing should always be used you
are not sure whether three-step or pole changing control is required! The
support is suitable for both types of control.
0040501000 4511 Page 43

5.5.13.3 Technical data – DC module
Type PREMIO-24V DC
Thrust force kN 2.2 5 12 15
Travel distance mm 50 80
Duty classification in accordance with S3 80% DC 1200 c/h
EN 60034
Control speed mm/s 0.38 1.00 0.38 0.79 0.38
Supply voltage 24V DC ± 10% BLDC motor
Power consumption VA 7 14 30 Max. 72
Protection to DIN 60529 IP65
Storage temperature °C -40°C ... +85°C
Max. permissible ambient °C -20°C ... +70°C
temperature
Handwheel Yes (rotating during operation) Yes (engageable)
Operation: 3-step: 24V DC/AC or 90 to 253V AC
Pole changing for 24V DC (with optional board support)
Max. conductor cross-sections Supply voltage: 2.5mm²
3-step input: 2.5mm²
Control signals: 2.5mm²
Mounting position Any, exception: the motor must not be suspended downwards
Gear lubricant Klüber Isoflex Tobas NB152 Molyduval Valenzia H2
Weight kg 5.4 6 10.5
Accessories
Electronic position controller Type ES11 - For control with 0(2)...10V or 0(4)...20mA;
electrical isolation between mains voltage and control signal
Electronic position indicator Type RI22 - Analogue output for position feedback 0(4)...20mA, optional
switching to 0(2)-10V, output can be inverted; electrical isolation
between mains voltage and position feedback signal
- Optional display (for indicating position feedback signal in mA or V)
Potentiometer Conductive plastic 500, 1000, 2000, 5000 ohm; 1 W
max. 2 pcs.
Wire‚ Äö 100, 200 ohm; 1 W
max. 2 pcs.
Contactless Only in conjunction with RI22
max. 1 pc. Feedback signal corresponds to RI22
Board support for pole changing at For 3-step control with pole changing (two-wire circuit). The direction of motor rotation is
24V DC changed by reversing the supply voltage
2 additional intermediate position Standard Zero potential, switching capacity 10A, 250V~
switches S4, S5
Information: Low-voltage Zero potential, with gold contacts, max. switching capacity 0.1A,
Gold contacts should be used for low 4-30V
switching capacities and aggressive
atmosphere.
Battery-operated emergency reset - Mounted to the outside of the actuator
(available from 2012 approx.) - In the event of a power failure, the actuator is moved into a defined end position (extending
or retracting) by battery power
- Battery capacity after one year without recharging: > 85%
- Sufficient battery capacity for at least 5 runs
Page 44 0040501000 4511

Standard Accessories 5.5.13.4 Wiring diagram – DC module
10165
0040501000 4511
Fig. 25: Wiring diagram ARI-PREMIO 2.2-5 kN – DC module
Pole changing option (X1/X2 connector)
Wire connections for the different valve types
Open DC 3-step DC pole changing
Spindle retracted 3-way valve 3-way valve
Straight-through valve with mixing plug with diverting plug
or
Closed A-AB open AB-B open
DC 3-step DC pole changing Open B-AB open AB-A open

Close
Spindle extended
or
Page 45
5.5.14 Electronic position indicator RI32
The RI32 electronic indicator transforms a resistance change into a 4...20mA or 2...10V
standardised control signal.
The RI32 position indicator can be operated by 24V DC voltage or 24V AC voltage.
It is possible to link into a current loop without an additional power supply.
5.5.14.1 Useful range of the linear motion

potentiometer
Linear motion potentiometers R1 or R2 are
connected in a three-conductor connection.
Here the RI32 position indicator is also suitable
for conductive plastic potentiometers.
adjustable
The diagram on the right will help when zero point setting range
adjusting the RI32 position indicator to the
stroke distance of the linear motion
potentiometer.
It is important that the mechanical stroke
distance of the control actuator is smaller than adjustable
slope span setting range
the stroke distance of the linear motion
potentiometer.
Fig. 26: Linear motion potentiometer
5.5.14.2 Installing the RI32 electronic position indicator in the PREMIO

- The RI32 position indicator is fitted to the ARI-PREMIO as illustrated.
- Screw fixing bracket (pos. 50.98) to gearbox cover plate with head cap screw (pos. 50.81).
- Then fit position indicator (pos. 50.121) to fixing bracket (pos. 50.98) with the head cap
screws (pos. 50.59) and washers (pos. 50.122).
Fig. 27: Option RI32 ARI-PREMIO 2,2 - 5 kN

50.59 Head cap screw M4 x 6 50.98 Fixing bracket
50.67 Potentiometer 50.121 Position indicator RI32
50.81 Head cap screw 50.122 Washer 4.3
Page 46 0040501000 4511

5.5.14.3 Electronic position indicator (RI32) and position controller (ES11)
together in the actuator
The electronic position indicator RI32 and the electronic position controller ES11 can be
build-in together in the ARI-PREMIO (Except: 5 kN 24V 1,0/1,2 mm/s).
It must be used a double potentiometer with 1000/1000 Ohm.
To install the RI32 and ES11 proceed as follows:
accidentally.
- Mount RI32 and ES11 with mounting kit according to Fig. 28.
Fig. 28: Installing RI32 / ES11 at the same time as ARI-PREMIO 2.2 – 5 kN

50.67 Potentiometer 50.82 Head cap screw
50.78 Option ES11 or RI21 50.121 Option RI32
0040501000 4511 Page 47

5.5.14.4 Technical data - Position indicator RI32
Type RI 32 Position indicator
Supply voltage V 24V DC / AC 50...60Hz
Potentiometer input Ω 1 kOhm ... 10 kOhm three-conductor connection, suitable for
conductive plastic potentiometer
Control signal output, V 2...10 V DC with (control signal output with supply voltage
voltage internal electrical connection)
Control signal output, mA 4...20 mA DC (load max. 500 W)
current (control output signal with supply voltage internal electrical
connection)
Measuring current at μA max. 800 μA
potentiometer arm
Linearity error % ± 0,2 % measurement range
Temperature coefficient %/K 0,04 %/K
Auxiliary energy inflow %/V 0,02 %/V
Protection type EN 60529 IP40 (terminals IP20)
Max. ambient temperature °C -40 °C...+85 °C
Humidity % 95 % r.F., no dewing
Weight g ca. 35 g
Dimensions mm Ø x depth 44 x 38
Connection / installation RI 32 Position indicator

Electrical connection using screw terminals max 2,5 mm2
Built into thrust actuator in ARI-PREMIO all versions
5.5.14.5 Potentiometer installation
ATTENTION !
When installing the potentiometer please note point „5.5.4 Potentiometer“ in
these Operating Instructions.
Plug Ra, Rb, Rc connector from potentiometer cable of RI32 position indicator into
pin strip 25, 26, 27 or 28, 29, 30 of the ARI-PREMIO.
Page 48 0040501000 4511

5.5.14.6 Wiring diagram
Attention:
Do not connect terminal 2 and
terminal 3.
With a potential shift, the position
indicator RI32 might be destroyed.
Potentiometer connection optionally

or with R1 or R2 potentiometers
from 100 Ohm to 20 kOhm
Two-wire connection
(current loop)
4...20mA
24V DC
4...20mA
24V DC and AC
2...10V
24V DC and AC
Fig. 29
5.5.14.7 Connection conditions

The electrical connections are joined to position indicator RI32 by series disconnect
terminals. The connection to the potentiometer is made by a cable.
Position indicator RI32 is connected by a potentiometer (R1 or R2) built into the ARI-
PREMIO.
When the valve is shut approx. 0 ohm are applied between Rb and Rc.
Appropriate conductor cross-sections for terminal connections are 0.2 to 2.5 mm2.
To achieve electromagnetic compatibility is recommended that shielded conductors be
used for longer routings.
Please request technical information direct from ARI-Armaturen.
0040501000 4511 Page 49

5.5.14.8 Setting zero point and slope span
The 4...20mA or 2...10V output control signal is adjusted to the potentiometer stroke by
miniature potentiometers S (slope) and N (zero).
Zero point setting

- The zero point setting is always made before the slope span setting.
- Potentiometer must be at approximately 0 Ω.
- Before measuring resistance, isolate the potentiometer from the RI32 position indicator
and reconnect after measuring.
- Resistance measurement at the potentiometer cable between Rb and Rc.
- Make the connection in accordance with the wiring diagram.
- Zero point setting is made at the zero point setscrew marked N.
- Adjust zero point setscrew N so that the desired minimum control signal value is applied to
the meter.
- Rotate zero point setscrew N to the right to increase the output signal, rotate to the left
to reduce it (a slip clutch engages after 12 rotations)
For example:
- Current output ........minimum value ......... = 4 mA
- Voltage output ........minimum value ......... = 2 V
Slope span setting

The slope span setting is made after the zero point setting.
- Before measuring resistance, isolate the potentiometer from the RI32 position indicator
and reconnect after measuring.
- Resistance measurement at potentiometer cable between Rb and Rc.
- Adjustment of resistance range to control signal output range is set at the slope span
setscrew marked S.
- The meter from the zero point setting stays in the same measurement range for the slope
span setting.
- Adjust the slope span setscrew S so that the desired maximum control signal value is
applied to the meter.
- Rotate slope span setscrew S to the right to increase the output signal, rotate to the left
to reduce it (a slip clutch engages after 12 rotations).
For example:
- Current output ........maximum value ........= 20 mA
- Voltage output ........maximum value ........= 10 V
Page 50 0040501000 4511

6.0 Putting the actuator into operation

ATTENTION !
- Actuator components which rotate or move during operation are coloured red.
Crushing or injury hazard!
- all works has been completed!
- Regional safety instructions must be observed as a matter of policy.
- hood of thrust actuator assembled.
When placing into service proceed as follows:
- Using the handwheel, run the thrust actuator to approximately mid lift position.
- Apply brief pulses to the thrust actuator for each direction of movement and check
whether the directions of movement correspond to those desired. If this is not the case,
the pulse lines governing the retracting and extending action must be exchanged on the
thrust actuator.
- Run thrust actuator to the final position in each direction of movement and check whether
it switches off automatically and whether all externally moving parts are able to move
freely.
- If failing to function properly, check all installation and setting work previously carried out,
correcting if necessary, and afterwards place into service once again.
The thrust actuator requires very little maintenance. Accordingly maintenance in specified
intervals is not necessary.
Depending on the conditions governing use, the maintenance and maintenance-intervals
have to be defined by the operator.
The thrust actuator must not be cleaned with high-pressure equipment or aggressive
solvents or detergents injurious to health or highly inflammable.
During and after cleaning, an inspection should be carried out of the sealing points on the
thrust actuator.
If there is any sign of lubricant escaping or dirt having accumulated, the sealing elements
must be repaired.
8.0 Troubleshooting
Instructions.
ATTENTION !
- It is essential that the safety regulations are observed when identifying faults.
-

0040501000 4511 Page 51


ATTENTION !
Fault Possible Causes Remedy

Thrust actuator fails to move Power failure Ascertain and eliminate cause
Fuse has blown Replace fuse
Thrust actuator not properly Rectify connection on thrust
connected actuator in accordance with wiring
diagram
Short circuit due to: Ascertain exact cause,
- moisture - Dry the thrust actuator and
eliminate leakage
- wrong connection - Rectify connection on thrust
actuator in accordance with
wiring diagram
- motor has burned out - Check whether the mains voltage
agrees with the voltage specified
on the rating plate. Have motor
changed.
Connector contacts not plugged in/ Insert connector firmly in jack strip
not properly plugged into jack strip thus affected
(Only for 12 - 15 kN) Unscrew the motor mounting
Handwheel is still engaged and screw closest to the cable feed-
does not disengage when the through. (Manual release of the
motor starts up handwheel disengagement
mechanism.)
Thrust actuator alternates Motor operating capacitor Have motor operating capacitor
between clockwise and defective replaced
counter-clockwise rotation
Thrust actuator fails to run to Load-dependent travel switches Remove thrust actuator and send
final positions and also out of to factory for repair
produces chatter
/ defective
Voltage drop due to excessively Lay connecting cables in
long connecting cables or accordance with requisite output
inadequate conductor cross-
section
Mains fluctuations beyond Arrange for "clean" mains system
permissible tolerance travels within requisite tolerances
System pressure too high Reduce system pressure
Periodic failure on thrust Loose connection on feedline Tighten connections on terminal
actuator strips
Thrust actuator is switched off Travel switch S3 not set Set travel switch S3 in accordance
in retracting direction prior to corresponding to use with operating instructions
load-dependent switch (three-
way valve)
Page 52 0040501000 4511

10.0 Dismantlement of thrust actuator

ATTENTION !
- The supply line for connecting up the thrust actuator must be in the dead state
i.e. disconnected while dismantlement work is being carried out. After being
disconnected, the mains power must be prevented from being switched back
on again accidentally.
- The system must be run down (depressurised state) as the valve cone is not
held without the thrust actuator and would thus be conducted by the system
pressure.
- Valve plug approximately in mid lift position - on no account supported inside a
seat!
To dismantle the thrust actuator proceed as follows:
- Disconnect all cables led into thrust actuator from outside and remove from thrust
actuator.
- Place hood on carefully from above and fix in place with collar nut / countersunk screw
and rubber gasket.
- Loosen grub screw inside torsion safety feature; screw coupling out of torsion safety
feature.
- Loosen clamping bolts connecting the thrust actuator to the fitting.
- Remove thrust actuator from valve.
appointed by us.

0040501000 4511 Page 53


as defined by
Directive about electromagnetic compatibility 2004/108/EEC and the
EG-Low voltage directive 2006/95/EEC

Mergelheide 56-60, 33756 Schloß Holte-Stukenbrock
that the supplied model of

electric thrust actuator ARI-PREMIO
in the delivered version complies with the following regulations:
- Directive about electromagnetic compatibility 2004/108/EEC

Applied harmonized standards:
DIN EN 61000-6-1/3; DIN EN 61000-6-2/4
- EG-Low voltage directive 2006/95/EEC
Applied harmonized standards:
EN 60204-1; EN 60335-1; EN 60730-1; DIN EN 60730-2-14
........................................................
Page 54 0040501000 4511

10166
Issue Date: 10/06
GESTRA Steam Systems Product Range B1
Level Controller NRR 2-40

Type NRR 2-40
With CAN-Bus
System Description CAN Bus

Use level controller type NRR 2-40 in combination with All level and temperature switches, controllers and elec-
level electrode type NRG 26-40 for level control and trodes are interconnected by means of a CAN bus. The data
monitoring. The level controller has the following func- exchange is effected by means of a CAN bus according to
tions: DIN ISO 11898 using the CANopen protocol. Every item
■ Two level limit values with one switchpoint each of equipment features an electronic address (Node ID).
(high-level alarm, low-level alarm) The four-core bus cable serves as power supply and data
highway for high-speed data exchange.
■ Three-position or modulating control within a
predefined proportional band NRR 2-40 is configured at our works and ready for service
with other GESTRA components.
■ Water level is maintained within the control band
defined by the two preset limits NRR 2-40 can be used straight away without having to
set the node ID.
The NRR 2-40 features optional outputs for standard
signals 4 – 20 mA.
Technical Data
The level data are transferred from the electrode to the
Type approval no.
level controller or an additional system component via a
TÜV . WR · 03-399
CAN data bus. The controller and the electrode use the
CANopen protocol. Input
Interface for CAN bus to DIN ISO 11898,
Function CANopen protocol
Feedback potentiometer 1000 Ω.
At regular intervals the level electrode NRG 26-40 sends
a data telegram to the level controller NRR 2-40. The data Output
are transferred via a CAN bus to DIN ISO 11898 using Power supply 24 V DC, conditionally short-circuit
the CANopen protocol. The transmitted data are then protected.
evaluated and allocated to the respective control range Analogue output 4 – 20 mA, load 500 Ω for display of
and switchpoints. Optionally a standard signal 4 – 20 mA actual value (option).
is established for external level indication or, when used 4 volt-free relay contacts.
for modulating control, for the manipulated variable Y. A Max. contact rating with switching voltages of 24 V AC,
relay de-energizing delay can be set manually with the 115 V AC and 230 V AC:
control terminal and display unit URB 1. 4 A ohmic, 0.75 A inductive at cos ϕ 0.5
Max. contact rating with a switching voltage of
To guarantee the correct functioning and safety of the
24 V DC: 4 A.
system the data transmitting cycle of the level con
Contact material: silver, hard-gold plated
troller is constantly monitored. When the CAN bus line
is interrupted the level switch sends a visual signal to Interference suppression
indicate a malfunction and the relays 1 and 4 will be Provide contactor with external RC combination
instantaneously de-energized (fail safe position). (100 Ω-47 nF) or according to the specification of the
valve manufacturer.
Design Analogue control output for manipulated variable
4 – 20 mA, max. load 500 Ω (option).
NRR 2-40 b
Enclosure of insulating material with terminals for installa- Relay de-energizing delay
tion in control cabinets. The terminals are externally acces- Output “min”, “max” 3s (set at the factory).
sible. Clipping onto a 35 mm standardized supporting rail
(DIN EN 50022). External dimensions: 100 x 73 x 118. P.T.O.
Important Note
Note that screened multi-core twisted-pair control cable is required, e. g. UNITRONIC® BUS CAN 2 x 2 x ...2 or
RE-2YCYV-fl 2 x 2 x ...2. The bus lines in the control cabinet must be used up to the control devices.
The baud rate (data transfer rate) dictates the cable length between the bus nodes and the total power consumption
of the sensor dictates the conductor size.
Number of pairs
S8 S9 S 10 Baud rate Cable length and conductor size [mm2]
OFF ON OFF 250 kBit/s 125 m
2 x 2 x 0.34
Factory setting
ON ON OFF 125 kBit/s 250 m 2 x 2 x 0.5
OFF OFF ON 100 kBit/s 335 m 2 x 2 x 0.75
ON OFF ON 50 kBit/s 500 m
on request, dependent on
OFF ON ON 20 kBit/s 1000 m bus configuration
ON ON ON 10 kBit/s 1000 m
The baud rate is set via a code switch. Reduce baud rate if cable is longer than specified in the table. Make sure that
all bus nodes have the same settings.
To protect the switching contacts fuse circuit with 2.5 A (anti-surge fuse) or according to TRD regulations (1.0 A for
72 hrs operation).
Level Controller Dimensions 10166
Type NRR 2-40 100
With CAN-Bus
Technical Data – continued –

Indicators and adjustors
1 red LED for switchpoint “high level”
1 red LED for switchpoint “low level”
73
2 green LEDs for deviation
“Xw low level” and “Xw high level”
1 green LED “Power”
1 red LED “Bus fault”
1 ten-pole code switch for node ID and baud rate 8
11
4 pushbuttons
Control response
P-controller as continuous or three-position stepping
controller
Proportional band Xp
1 % to 100 % Wiring Diagram
Position feedback Yp Three-position stepping controller
0 Ω to 1000 Ω L N LCLOSED LOPEN
Switching range (dead band) XSh
3% L
Supply voltage
MAX MIN
230 V +/– 10 %, 50/60 Hz
115 V +/– 10 %, 50/60 Hz (option)
24 V +/– 10 %, 50/60 Hz (option)
Power consumption
5 VA
Protection
Enclosure: IP 40 to DIN EN 60529 Actuator
Terminal strip: IP 20 to DIN EN 60529
Admissible ambient temperature Feedback potentiometer
1000 Ω
0 °C to 55 °C
Enclosure material Fill control
Front panel: polycarbonate, grey = valve CLOSED
= valve OPEN
Enclosure: polycarbonate, black
Optional output
Weight Potentiometer
for actual value
Discharge control
Approx. 0.8 kg = valve CLOSED
4 – 20 mA
= valve OPEN
Order and Enquiry Specification Terminating resistor

120 Ω
GESTRA Level Controller type NRR 2-40 CANopen
Mains voltage ..............V
Continuous L N Relay Relay Relay Relay
Ancillary Units controller 1 2 3 4
■ Capacitance level electrode type NRG 26-40
CANopen
MAX MIN
■ Control terminal and display unit type URB 1
CANopen
Optional output for actual value

4 – 20 mA
Analogue control output
Supply in accordance with our general terms manipulated variable Y, 4 – 20 mA
of business. (option)
Terminating resistor 120 Ω
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Telephone +49 (0) 421 35 03 - 0, Fax +49 (0) 421 35 03-393

10166
NRR 240 EN
English

81036905
Level Controller NRR 2-40
1
10166
Contents
Page
Important Notes
Usage for the intended purpose...............................................................................................................5

Safety note..............................................................................................................................................5
Danger....................................................................................................................................................5
Attention..................................................................................................................................................5
LV (Low Voltage) Directive and EMC (Electromagnetic Compatibility)........................................................5
Explanatory Notes
Scope of supply.......................................................................................................................................6
Description..............................................................................................................................................6
Function..................................................................................................................................................6
System components................................................................................................................................6
Design.....................................................................................................................................................6
Technical Data
NRR 240................................................................................................................................................7
Corrosion resistance................................................................................................................................8
Name plate / marking..............................................................................................................................8
Dimensions..............................................................................................................................................9
Design
NRR 240..............................................................................................................................................10
Key........................................................................................................................................................12
Functional Elements
NRR 240..............................................................................................................................................11
Key........................................................................................................................................................12
Installation
NRR 240..............................................................................................................................................12
Tools......................................................................................................................................................12
Example of Installation...........................................................................................................................13
Key........................................................................................................................................................12
2
10166
Contents – continued –
Page
Electrical Connection
Control cable.........................................................................................................................................14
Note......................................................................................................................................................15
CAN bus voltage supply.........................................................................................................................15
Attention . .............................................................................................................................................15
Wiring diagram................................................................................................................................ 16, 17
Key........................................................................................................................................................18
CAN bus wiring diagram........................................................................................................................19
Attention................................................................................................................................................19
Note......................................................................................................................................................20
Tools......................................................................................................................................................20
Basic Settings
Bus cable..............................................................................................................................................20
Node ID.................................................................................................................................................21
Factory setting.......................................................................................................................................22
Function of the controller.......................................................................................................................22
Establishing / changing node ID.............................................................................................................23
Attention................................................................................................................................................23
Code switch settings..............................................................................................................................23
Dead band.............................................................................................................................................24
Establishing / changing the dead band............................................................................................. 24, 25
Commissioning Procedure
Using operating device URB for parameter setting.................................................................................26

NRR 2-40..............................................................................................................................................26
Measuring range....................................................................................................................................26
Setting measuring range.................................................................................................................. 26, 27
Switchpoints and proportional range......................................................................................................28
Establishing switchpoints and proportional range...........................................................................29 – 31
Calibrating the feedback potentiometer of an external control valve.......................................................31
Attention................................................................................................................................................31
Operation
NRR 2-40..............................................................................................................................................32
3
10166
Contents – continued –
Page
Test
NRR 2-40..............................................................................................................................................32
Alarm
NRR 2-40..............................................................................................................................................33
MAX alarm.............................................................................................................................................33
MIN alarm..............................................................................................................................................33
Operational malfunctions
Fault finding list for troubleshooting.......................................................................................................34
System Malfunctions
Danger..................................................................................................................................................35
NRR 2-40..............................................................................................................................................35
Danger..................................................................................................................................................36
Systematic malfunction analysis............................................................................................................36
System malfunction 1............................................................................................................................37
Decommissioning
Danger..................................................................................................................................................39
Disposal................................................................................................................................................39
Annex
Note on the Declaration of Conformity / Declaration by the Manufacturer ..............................................39
4
10166
Important Notes
Use the level controller NRR 2-40 only in conjunction with GESTRA level electrode NRG 26-40 for
c ontrolling liquid levels of conductive fluids.
Safety note
The equipment must only be installed and commissioned by qualified and competent staff. Retrofitting
and maintenance work must only be performed by qualified staff who – through adequate training –
have achieved a recognised level of competence.
Danger
The terminal strips of the equipment are live during operation.

This presents the danger of electric shock.
Cut off power supply before mounting or removing the terminal strips and the housing
cover.
Attention
The name plate specifies the technical features of the equipment. Note that any piece of
equipment without its specific name plate must neither be commissioned nor operated.
The level controller NRR 2-40 meets the requirements of the Low Voltage Directive 2006/95/EC
and the EMC Directive 2004/108/EC.
According to the European Directive 94/9/EC the equipment must not be used in potentially explosive
areas.
5
10166
Explanatory Notes
Scope of supply
NRR 2-40
1 Level controller NRR 2-40 plug-in unit in plastic case with box terminals
1 Terminating resistor 120 Ω
1 Installation & operating manual
Description
The level controller NRR 2-40 in conjunction with level electrode NRG 26-40 is designed for level
control and monitoring. The level controller features the following functions:
n Two level limit values with one switchpoint each (high-level alarm, low-level alarm).
n Three-position or modulating control within a predefined proportional band.
n Water level is maintained within the defined control band of the electrode.
The NRR 2-40 features an optional output for a standard signal 4 – 20 mA.
The level data are transferred from the level electrode NRG 26-40 to the level controller or an additional
system component via a CAN data bus.
Function
At regular intervals the level electrode NRG 26-40 sends a data telegram to the level controller
NRR 2-40. The data are transferred via a CAN bus to DIN ISO 11898 using the CANopen protocol. The
transmitted measuring data are then evaluated and allocated to the manually adjusted switchpoints.
Optionally a standard signal 4 – 20 mA is established for external level indication. A relay de-energizing
delay can be set manually with the control terminal and display unit URB 1. To guarantee the correct
functioning and safety of the system the data transmitting cycle is constantly monitored by the level
controller. If the CAN bus line is interrupted the level controller sends a visual signal to indicate a
malfunction and the relays 1 and 4 will be instantaneously de-energized. (fail safe position).
GESTRA's control terminal & display units URB enable advanced features such as adjustable energizing
and de-energizing delays of the output relays (1 to 25sec.)
System components
NRG 26-40
Level electrode NRG 26-40, PN 40
Design
NRR 2-40
Enclosure of insulating material with terminals for installation in control cabinets.
The terminals are externally accessible.
Clipping onto a 35 mm standardized supporting rail (DIN EN 50022).
External dimensions: 73 x 100 x 118
6
10166
Technical Data
NRR 240
Type approval no.

NRR 2-40: TÜV . XX-399
Input/Output
Interface for CAN bus to DIN ISO 11898 CANopen.
Feedback potentiometer 1000 Ω.
Output voltage supply for electrodes
Power supply 24 V DC, short-circuit protected.
Analog output 4-20 mA, load 500 Ω for indication of actual value (optional).
Analog control output for manipulated variable, 4-20 mA, max. load 500 Ω (optional).
4 volt-free relay contacts. Max. contact rating with switching voltages of 24 V AC, 115 V AC and 230 V
AC: 4 A resistive, 0.75 A inductive at cos ϕ 0.5.
Max. contact rating with a switching voltage of 24 V DC: 4 A. Contact material: silver, hard-gold plated.
Interference suppression
Provide contactor with an external RC combination (100 Ω / 47 nF).
Relay de-energizing delay
Output “MIN”, “MAX” 3s
1 red LED for switchpoint “MAX”
1 red LED for switchpoint “MIN”
2 green LEDs for “Opening control valve” and “Closing control valve”
One green LED “Power”
1 red LED “Bus malfunction”
1 ten-pole code switch for setting node ID and baud rate
4 pushbuttons
Proportional range Xp
1 % to 100 %
Valve position feedback
0 Ω to 1000 Ω (only when used as three-position stepping controller)
Switching range (dead band Xsh
0 % (factory setting) up to 15 %
Mains voltage
230 V +/– 10 %, 50/60 Hz
115 V +/– 10 %, 50/60 Hz (optional)
Power consumption
10 VA
Protection
Housing: IP 40 to DIN ISO 60529
Terminal strip: IP 20 to DIN ISO 60529
Admissible ambient temperature
0 °C to 55 °C
Body material
Front panel: polycarbonate, grey
Housing: polycarbonate, black
Weight
approx. 0.8 kg
7
10166
Corrosion resistance
If the equipment is used for the intended purpose, its safety is not impaired by corrosion.
Name plate / marking
Steuergerät
Betriebsanleitung control device NRR 2 - 40 b
beachten appareille de commande
See installation 230 V 50 / 60 Hz 10 VA
instructions
Voir instructions de
115 V IP 40 (IP20)
montage Tmax = 55 °C (131 °F)
24 V
18-36 V DC
IN / OUT: CAN-Bus Node ID:___ ___ ___
- CL S CH +
1 2 3 4 5 9 10 11 12 16 17
S S
L N
24V + -
CAN-BUS
DC
TÜV · WR · 09-399 M
250 V ~ T 2,5 A
GESTRA AG VS.-Nr.:XX
Mat.Nr.:
Münchener Str. 77, D-28215 Bremen 391768
Fig. 1
8
10166
Dimensions
100
73
8
11
Fig. 2
9
10166
Design
NRR 240
9
0
Fig. 3
10
10166
Functional Elements
NRR 240
Fig. 4 7 6 5 4 3 2
Fig. 5 8
11
10166
Design / Functional Elements / Installation
Key
1 Status LED Alarm Malfunction

LED 1 Switchpoint 1 MAX alarm Multifunction
LED 2 Closing control valve Not assigned Multifunction
LED 3 Opening control valve Not assigned Multifunction
LED 4 Switchpoint 4 MIN alarm Multifunction
2 LED Bus status
3 LED Power
4 Enter / Test
5 Increase button
6 Increase button
7 Program button
8 Code switch, 10 poles
9 Terminal strip
0 Screws for terminal strip
a Body
b Supporting rail TS 35 x 15 DIN EN 50022
Installation
NRR 240
Mounting on supporting rail

1. Clip control unit onto the supporting rail.
Supporting rail TS 35 x 15, DIN EN 50022.
2. Align level controller. Fig. 7
Tools
n Screwdriver (5.5 / 100)
12
10166
Installation – continued –
Example of Installation
9 0
Fig. 6
20 20
Fig. 7
13
10166
Control cable
NRS, NRR, LRR, TRS, URB 1

To wire the equipment, multi-core twisted-pair control cable must be used for the bus line, e. g. UNI-
TRONIC® BUS CAN 2 x 2 x ... mm2 or RE-2YCYV-fl 2 x 2 x ... mm2.
Control cable assemblies (2 x 2 x 0.32 mm² cable with plug and connector) of various lengths are avail-
able as add-on equipment.
NRG, LRG, EF, URZ, TRV, URB 2
The equipment is fitted with sensor plug-in connectors (5 poles, A-coded). For connecting the bus
devices control cable assemblies (with plug and socket) of various lengths are available as add-on
equipment.
Note that the recommended control cables are not UV-resistant and must be protected by a UV-resistant
plastic tube or cable duct if the equipment is installed outdoors (except for URB 2).
The baud rate (data transfer rate) dictates the cable length and size between the bus nodes. The total
power consumption must also be taken into consideration when selecting the conductor size. The total
power consumption is obtained from the number of bus nodes.
If the cable length between the steam boiler and the control cabinet exceeds 15 m, we recommend that
you fit a branching box that is resistant to electromagnetic interference (stock code 1501214) and use a
control cable with a larger conductor size for the distance to the control cabinet.
Number of pairs
S8 S9 S 10 Baud rate Cable length
and conductor size [mm2]
2 x 2 x 0.32
Factory setting
on request, depending on
OFF ON ON 20 kBit/s 1000 m
bus configuration
Set baud rate via code switch 8. Make sure that all bus nodes feature the same settings.
UNITRONIC® is a registered trademark of LAPP Kabelwerke GmbH, Stuttgart.
14
10166
Electrical Connection – continued –
Note
n The specified max. baud rates and cable lengths are based on empirical values
o btained by GESTRA. In certain cases it may be necessary to reduce the baud rate in
order to ensure operational safety.
n The type and design of the data cable has a strong influence on the electromag-
netic compatibility (EMC) of the equipment. Take special care when connecting the
equipment.
n If you do not use the control cable assemblies connect the connectors and jacks for
the control cables as indicated in the assignment diagram for sensor plug-in unions.
CAN bus voltage supply
To ensure the troublefree operation of the CAN bus system make sure that the voltage supply for all bus
devices is sufficient.
Please use the following table to check the voltage supply of your bus system.
Control units with Qty. x Power output per item = Sum

voltage supply x 6W = W
Please enter data. Sum 1 = W
Sensor, transmitter, control Qty. x Power consumption per item = Sum
units, operating & display unit
URB 1 x 3W = W
Operating & Display Unit
URB 2 x 5W = W
If sum 2 exceeds sum 1 supply the CAN bus with 24 V DC coming from a separate and stabilized safety
power supply unit (e. g. SITOP Smart 24 V 2.5 A) .
The power supply unit must be electrically isolated from dangerous contact voltages and must meet at
least the requirements on double or reinforced isolation acc. to DIN EN 50178 or DIN 61010-1 or
DIN EN 60730-1 or DIN EN 60950 (safe isolation).
The power supply unit must be provided with an overcurrent protective device in accordance with
EN 61010-1.
Attention
If a safety power supply unit (e. g. SITOP smart, 24 V, 2.5 A) is used for the voltage supply
of the CAN bus do not tap the supply voltage from the terminals 1 and 5 of the GESTRA
control devices.
SITOP smart is a registered trademark of Siemens AG, Munich
15
10166
Wiring diagram
f
d
e g
l h
k j
l
Fig. 8
NRR 2-40 as 3-position stepping controller
m
Fig. 9
Valve actuator n 1000 Ω
16
10166
Wiring diagram
d
e g
l h
k
l i
Fig. 10
NRR 2-40 as continuous controller
17
10166
Key
d Mains supply
e MAX limit contact (MAX alarm)
f Activation control of valve actuator
Fill control: = Valve CLOSED 23
= Valve OPEN 25
Discharge control: = Valve OPEN 23
= Valve CLOSED 25
e MIN limit contact (MIN alarm)
h Actual value output 4-20 mA (optional)
i Controller output, analogue, manipulated variable Y, 4-20 mA
j Input for feedback potentiometer 1000 Ω
k Terminating resistor 120 Ω, RES 1 or RES 2
l CAN bus line, twisted pair control cable
m Valve actuator
n Feedback potentiometer 1000 Ω for actuator
18
10166
CAN bus wiring diagram
URB 2 NRS, NRR, LRR, NRG, LRG, TRV

CEP
TRS, URB 1 EF, URZ
RES 2 RES 1
Fig. 11
Attention
n Wire equipment in series. Star-type wiring is not permitted!

n Link screens of control cables such that electrical continuity is ensured and connect
them once to the central earthing point (CEP). If equipotential bonding currents are
to be expected, for instance in outdoor installations, make sure that the screen is
separated from the central earthing point (CEP).
n To protect the switching contacts fuse circuit with T 2.5 A or according to TRD
regulations (1.0 A for 72 h operation).
n If two or more system components are connected in a CAN bus system, provide the
first and the last device with a terminating resistor of 120 Ω, Fig. 11
n Do not interrupt the CAN bus network during operation with one or more system
components!
If the CAN bus network is interrupted the safety circuit will be opened.
If the control unit has to be replaced, detach terminal strips 9.
Fig. 3
Before taking the CAN bus line from the terminal strip, make sure that all connected
system components are out of service.
19
10166
Note
n Link screen only to terminal 3, ensure electrical continuity and connect it once to the
central earthing point (CEP).
n The loop resistance must be below 10 Ω.
n The rated voltage is indicated on the name plate.
n When switching off inductive loads, voltage spikes are produced that may impair the
operation of control and measuring systems. Provide connected contactors with RC
combinations, e. g. 0.1 µF/100 Ω.
n Even in correctly wired systems high frequency interference caused by the installation
can lead to system outages and malfunction alarms. For more information please refer
to the fault-finding list in the section Malfunctions – Troubleshooting.
Tools
n Screwdriver for slotted screws, size 2.5, completely insulated according to VDE 0680
Basic Settings
Bus cable
All devices (level, conductivity) are interconnected via CAN bus. The CANopen protocol is used for the
data exchange between the equipment groups. All devices have an electronic address – the node ID.
The four-core bus cable serves as power supply and data highway for high-speed data exchange.
The CAN address (node ID) can be set between 1 – 123.
The equipment has already been configured at our works for operation with other GESTRA components
and can be used straight away without having to set the node ID.
If several identical systems are to communicate in a CAN bus network, set a different node ID for
each system (e. g. limiter, controller, etc).
If the length of the CAN bus cable exceeds 125 m change the settings of the code switch 8,
Fig. 15. Note that the baud rate setting must be identical for all bus-based equipment!
For more information on switch positions see Basic Settings Switch positions.
20
10166
Basic Settings – continued –
Node ID
Water level limiter

NRS 1-40 NRG 16-40 (1) NRG 16-40 (2) Reserved Reserved
X X+1 X+2 X+3 X+4
1 2 3 Factory setting
Safety system for steam boilers with superheater
NRS 1-40.1 NRG 16-40 (1) NRG 16-40 (2) TRV 5-40 Limiter 4
X X+1 X+2 X+3 X+4
1 2 3 4 Factory setting
Safety system (e. g. hot-water generating units)
NRS 1-40.1 NRG 16-40 (1) NRG 16-40 (2) Limiter 3 Limiter 4
X X+1 X+2 X+3 X+4
1 2 Factory setting
NRS 1-40.2 TRV 5-40 (1) TRV 5-40 (2) Limiter 3 Limiter 4
X X+1 X+2 X+3 X+4
6 7 8 9 10 Factory setting
TRS 5-40 (1) TRS 5-40 (2)
X + 1 + 90 X + 2 + 90
97 98
High level alarm
NRS 1-41 NRG 16-41 Reserved Reserved Reserved
X X+1 X+2 X+3 X+4
Further components
SRL 40
X = (sensor: level limiter // hi alarm) + 2 Factory setting
ORT 6
98 Factory setting
On-off level control
Reserved NRS 1-42 NRG 16-42
X–1 X X+1
Modulating level control
URZ 40 NRS 2-40 NRR 2-40 NRG 26-40 Reserved
X–2 X–1 X X+1 X+2
Automatic continous blowdown control
EF 1-40 Reserved LRR 1-40 LRG 1-4... Reserved
X–2 X–1 X X+1 X+2
Control unit
URB 1, URB 2
60 Factory setting
21
10166
Factory setting
The level controller features the following factory set default values:
n Baud rate: 250 kb/s n Relay de-energizing delay, switchpoint 1: 1s
n Proportional range XP: 20 % n Relay de-energizing delay, switchpoint 4: 1s
n Node ID: 40 n Relay de-energizing delay, switchpoint 1: 3s
n Switchpoint 1: 80 % n Relay de-energizing delay, switchpoint 4: 3s
n Switchpoint 4: 20 %
n Dead band: 0 %
100 %
1/80 %
2/60 %
20 %
3/40 %
4/20 %
0%
Fig. 12
Function of the controller
The controller NRR 2-40 is specially designed for level control in steam boilers and feedwater
deaerators. The NRR 2-40 is a proportional controller with steady-state deviation.
The positive and negative deviation lies within the proportional band (XP) preselected by the user.
If is possible to control electric and pneumatic (optional) actuators.
The control of electric actuators is effected by an analogue signal which, in combination with an ac-
tive position feedback coming from the valve, is converted in the controller into a three-position step-
ping signal. The control pulses for the electric actuator are transmitted by the relay integrated in the
controller.
The control of pneumatic valve actuators is effected by an analogue signal 4 – 20 mA. The analogue
signal is transmitted directly from the proportional controller to the positioner of the pneumatic control
valve, which means that an active position acknowledgement is not possible.
XP-Werte:
XP > large permanent deviation, valve reacts sluggishly.
XP < no permanent deviation, valve may be hunting, recommended XP value 20 % to 60 %.
22
10166
Establishing / changing node ID
If several identical systems are to communicate in a CAN bus network, allocate a different node ID for
each system (e. g. limiter, controller, etc). In most cases it is sufficient to commission the equipment
with the default factory settings.
To set the code switch 8 remove the lower terminal strip 9.
Attention
n We recommend that you commission the CAN bus devices with the default factory
setting.
n Do not use a node ID for more than one piece of equipment in the CAN bus system.
Code switch settings
8 8
Node ID 40 Node ID 75
S 1 OFF 1 S 1 ON 1
S 2 OFF 2 S 2 ON 2
S 3 OFF 4 S 3 OFF 4
S 4 ON 8 S 4 ON 8
S 5 OFF 16 S 5 OFF 16
S 6 ON 32 S 6 OFF 32
S 7 OFF 64 S 7 ON 64
Fig. 13 (Factory setting) Fig. 14 (Example 1)
S 8 S 9 S 0 Baud rate Cable length

ON ON OFF 125 kBit/s 250 m
Fig. 15 (Factory setting 250 kBit/s)
23
10166
Dead band
To prevent oscillation or repeated activation-deactivation cycles of the controlled system, a deadband

can be defined for the septpoint “W”.
The setpoint is defined by the proportional range which is limited by the switchpoints 2 and 3. To set
the code switch 8 remove the terminal strip 9.
S 1 S2 S3 S4 S5 S6 S7 S8 S9 S10 Deadband
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 0%
OFF OFF OFF OFF OFF OFF OFF ON OFF OFF 1%
OFF OFF OFF OFF OFF OFF OFF OFF ON OFF 2%
OFF OFF OFF OFF OFF OFF OFF ON ON OFF 3%
OFF OFF OFF OFF OFF OFF OFF OFF OFF ON 5%
OFF OFF OFF OFF OFF OFF OFF ON OFF ON 7%
OFF OFF OFF OFF OFF OFF OFF OFF ON ON 10 %
OFF OFF OFF OFF OFF OFF OFF ON ON ON 15 %
Fig. 16
Establishing / changing the dead band
Write down the node ID and baud rate settings.

Node ID in this example: 40
Baud rate in this example: 250 kBit/s
Switch off mains voltage.

The four status LEDs go out.
The LED “Power” goes out.
24
10166
Establishing / changing the dead band – continued –
To set the dead band refer to Fig. 16.

Dead band in this example: 2 %
Apply mains voltage. 1 MAX GESTRA

The four status LEDs are flashing rapidly. 2 +
XW
NRR 2-40
If the LED “Power” is alight, the adjustment was 3
W
MIN
-
1
P
2 3 4
E
successful. 4
Test
If the LED “Bus status” above the LED “Power” is

alight, repeat the adjustment procedure.
Switch off mains voltage.

The four status LEDs go out.
The LED “Power” goes out.
Write down the node ID and baud rate settings.

Node ID in this example: 40
Baud rate in this example: 250 kBit/s

XW
NRR 2-40
The LED “Power” is illuminated. 3
W
MIN
-
1
P
2 3 4
E
The system is ready for operation.
4
Test
25
10166
Commissioning Procedure
Using operating device URB... for parameter setting
When using the operating device URB ... all parameters can be set via its user interface.
NRR 2-40

XW
NRR 2-40
The LED “Power” is illuminated. 3
W
MIN
-
1
P
2 3 4
E
The system test takes 2 seconds.
4
Test
Measuring range
A Desired measuring range [mm]

B Max. measuring range
C Lower measuring point NRG 26-40
37
Establish the appropriate measuring

range A for your level monitoring
sytem.
B
A
C
Fig. 17
26
Setting measuring range
Press button for 3 sec.

Lower liquid level until the lower limit
of the control range A is reached.
If necessary first use button to

adjust the upper limit of the control
range.
26
10166
Commissioning – continued –
Setting measuring range – continued –
Press button briefly.

Attention:
In the event of a system malfunction, the LED(s)
“Bus status” and/or “Power” will be flashing
rapidly when in program mode. Quit program
mode and analyse the system malfunction
(see pages 36 – 39)

The min. limit of the control range
is now saved.

Raise the liquid level in the
vessel until the maximum
limit of the control range A is
reached.
Press button briefly. Wait for 30 sec.

before continuing the procedure.
To compensate for transient fluctuations
of the water level a filter is installed in the
preamplifier of the electrode. If the setting
is confirmed too quickly an incorrect
100 % will be saved.
Press button twice briefly.

The max. limit of the control range
is now saved. The NRR 2-40 is now
again in operating mode.
27
10166
Switchpoints and proportional range
NRG 26-40
1
2
3
A
4
Fig. 18 You can establish two switchpoints and the proportional band XP within the
control range.
80 % 90 %
70 %
20 %
50 % 45 %
10 %
35 %
20 % 10 %
Fig. 19 (example) Fig. 20 (example)
28
10166
Establishing switchpoints and proportional range

Raise or lower the liquid level in the vessel
to the desired value.
Use button if you first want to establish
a different switchpoint or the proportional
band.

Lower or raise the liquid level until switch-
point 4 within the control range is reached.
Attention:
In the event of a system malfunction, the
LED(s) “Bus status” and/or “Power” will be
flashing rapidly when in program mode.

Switchpoint 4 is now saved.

The lower limit of the proportional band XP
(switchpoint 3) is now selected.

Lower or raise the liquid level until switchpoint
3 within the control range is reached.
Example:
Liquid level switchpoint 3 = 40 % and
liquid level switchpoint 2 = 60 % make an
XP value (60 % – 40 %) = 20 %.
The setpoint is 50 %.
29
10166
Establishing switchpoints and proportional range – continued –


The upper limit of the proportional band XP
(switchpoint 2) is now selected.

Lower or raise the liquid level until switchpoint 2
within the control range is reached.
Example:
Liquid level switchpoint 3 = 40 % and
liquid level switchpoint 2 = 60 %
make an XP value of 20 %


Switchpoint 1 is now selected.
30
10166
Establishing switchpoints and proportional range – continued –

Lower or raise the liquid level until switchpoint 1
within the control range is reached.
Press button twice briefly.

The NRR 2-40 is now again in operating
mode.
Calibrating the feedback potentiometer of an external control valve
The feedback potentiometer of an external control valve with electric actuator has to be calibrated
manually before commissioning.
1. Ascertain the total resistance of the feedback potentiometer.
2. Set the control valve manually to mid-position.
3. Adjust manually the position of the feedback potentiometer until the partial resistance values of the
measured total resistance are equal.
1000 Ω +/– tolerance
Mean value
Fig. 21 0Ω
Attention
n For the GESTRA level controller NRR 2-40 a 1000 Ω feedback potentiometer in an external
control valve is required!
n If the terminals for the feedback potentiometer are not wired or the feedback potentiometer
is defective the NRR 2-40 will work as two-position controller!
n Use the control and display units URB 1 and URB 2 for semi-automatic calibration of
the feedback potentiometer of an external control valve without measurement of the
resistance value. If you use the URB 1 or URB 2 please refer to the operating manual for
more information.
31
10166
Operation
NRR 2-40
Normal operation, controller is working.

The green LEDs 2 and 3 are flashing when the
external control valve is being opened or closed.
All LEDs go out once the setpoint is reached.
The LED “Power” is illuminated.
Test
NRR 2-40

The test mode (relay test) remains active for 5
seconds.
Hold down button .

LED 4 goes out.
A MIN alarm is simulated for
switchpoint 4.
Hold down button .

LED 1 goes out.
A MAX alarm is simulated for
switchpoint 1.
32
10166
Alarm
NRR 2-40
The are two alarm conditions:

n MAX alarm
n MIN alarm
MAX alarm
LED 1 is flashing rapidly.

LED 1 is illuminated after the de-energizing flashing illuminated
delay has been elapsed.
MIN alarm
LED 4 is flashing rapidly.

flashing illuminated
LED 4 is illuminated after the de-energizing
delay has been elapsed.
33
10166
Operational malfunctions
Fault finding list for troubleshooting

Equipment does not work – no function
Fault: LED “Power ON” is not illuminated.
Remedy: Switch on mains voltage. Wire equipment according to the wiring diagram.
Equipment is not working – a malfunction is indicated
Fault: In spite of correct wiring and commissioning of the equipment an error message is indicated.
Remedy: The error message is caused by the high-frequency interference coming from the system.
For the interference suppression of the voltage supply we supply hinged-shell ferrite rings,
stock code # 147253.
The 230 V supply lines should be looped five to ten times through the ferrite ring. If sev-
eral controllers are used in one system, they can be fed from the interference suppressed
supply lines.
For the interference suppression of the bus line we supply hinged-shell ferrite rings, stock
code # 147254. The hinged-shell ferrite rings are clamped onto the bus lines near the
terminal strip of the control unit.
Equipment does not work accurately

Fault: Incorrect function at analogue output. The connected actual value indicator shows
incorrect readings.
Remedy: Correct the switchpoint settings.
Correct the control range setting of the electrode.
Fault: Switchpoints and the indicated actual value drift steadily towards 100 %
Remedy: Dirt has deposited on the electrode rod. Remove the level electrode and clean the
electrode rod.
Fault: MAX level is signalled although the water level is below the MAX limit.
Remedy: Dirt has deposited on the electrode rod. Clean the electrode rod.
Sealing / insulation of level electrode defective. Replace level electrode.
Fault: Liquid level below MIN switchpoint but no switching function.

Remedy: Check the installation of the level electrode. Maybe there is no vent hole in the protection
tube. If electrode is installed in external level pot: Open the isolating valves.
Fault: Level exceeds MAX switchpoint but there is no indication.

Remedy: Level switch defective. Replace equipment.
The equipment is working as two-position (on-off) controller
Fault: The feedback potentiometer is defective or not connected.
Remedy: Wire equipment according to the wiring diagram. Check feedback potentiometer.
If faults occur that are not listed above or cannot be corrected, please contact our service centre
or authorized agency in your country.
34
10166
System Malfunctions
Danger
The terminal strip of the equipment is live during operation.
cover.
NRR 2-40
Malfunctions occur if CAN bus components have been mounted, wired or configured incorrectly or
if electronic component parts are defective, or in the event of excessive heat in the equipment or
electrical interference in the supply system.
There are four types of malfunctions that might occur in the controller and the measuring sensor.
n Max. admissible temperature in electrode terminal box exceeded
n No or faulty communication between controller and measuring sensor
n Malfunction in CAN bus
n Failure of 24 V power supply unit built in controller or external PSU.
35
10166
System malfunctions – continued –
Danger
The terminal strip of the equipment is live during operation.

This presents the risk of severe cases of electric shock! Cut off power supply
to the equipment before mounting or removing the terminal strips and the housing cover.
Systematic malfunction analysis
The sources of malfunctions occuring in CAN bus systems operating with several bus-based stations
must be analysed systematically since faulty components or incorrect settings can give rise to negative
interactions with intact bus devices in the CAN bus system. These unwanted interactions can cause
error messages in fully functional bus devices, which will make fault detection even more difficult.
We recommend the following systematic fault finding procedure:
Step 1 (Start)
Detach terminal strips
of all bus-based
sensors!
Level electrode
Conductivity electrode
Pressure sensor
Temperature sensor etc.
Test Step 2
Use Plug in terminal strip
fault-finding list of the sensor
to eliminate the fault(s)! of the system
Check next system
e. g. NRS ...
Final test and
− Have all faults been NRG ... (sensor)
eliminated?
System fault Step 3 System O.K.

Use Apply mains voltage Detach terminal
fault-finding list to bus devices of the strips between
to identify the fault(s)! system BUS nodes
e. g. NRS ... of the system
Cut off power supply to and NRG ... e. g. NRS ...
the equipment! and NRG ... !
36
10166
System malfunction 1
LEDs 1 – 4 are flashing slowly. LEDs are flashing slowly
MIN / MAX alarm. 1 MAX
+
GESTRA
NRR 2-40
2
XW
1 2 3 4
P E
W
3 -
MIN
4
Test
Fault: The admissible temperature in the electrode terminal box is exceeded!

Remedy: Insulate the electrode flange against thermal radiation.
As soon as the temperature falls below the max. admissible limit, the equipment automatically switches
back to normal operating mode.
LEDs are flashing rapidly
LEDs 1 and 4 are flashing rapidly.
GESTRA
MIN / MAX alarm.
1 MAX
2 + NRR 2-40
XW
1 2 3 4
P E
W
3 -
MIN
4
Test
Fault: The CAN bus line between the devices is interrupted.

Remedy: Check wiring and terminals. Restart system.
Fault : The node IDs are wrong.

Remedy: Establish node IDs as specified in section “Basic Settings”.
Cut off power supply and restart system after 5 sec.
37
10166
LED bus status is flashing slowly 1 MAX GESTRA

2 + NRR 2-40
XW
1 2 3 4
P E
W
3 -
MIN
4
Test
LED is flashing slowly
Fault: A malfunction in the CAN bus has occurred.

Remedy: Restart system.
LED bus status is flashing slowly 1 MAX GESTRA

NRR 2-40
MIN / MAX alarm. 2 +
XW
1 2 3 4
P E
W
3 -
MIN
4
Test
Fault: The data transfer in the CAN bus is interrupted!

Remedy: The wiring of the bus lines must be in accordance with the wiring diagram (observe polarity).
As specified in the wiring diagram provide the end-of-line bus devices with 120 Ω
terminating resistors.
Cut off power supply and restart system.
Fault: The baud rate setting(s) of at least one bus device is not correct.
Remedy: Check the baud rate settings of all bus-based devices.
The baud rates must be identical!
Fault: The total length of the bus line does not correspond to the baud rate setting!
Remedy: Check the baud rate settings of all bus-based devices.
38
10166
LED Power is flashing slowly. MAX GESTRA

1
2 + NRR 2-40
XW
1 2 3 4
P E
W
3 -
MIN
4
Test
Fault: The power supply unit is overloaded! The power supply unit may have been misused for
supplying power to other components.
Remedy: Check the load of the power supply unit. Use the power supply unit only for the voltage
supply of the bus-based equipment.
Cut off power supply and restart system.
Fault: The power supply unit is defective.

Remedy: Replace power supply unit.
Decommissioning
Danger
The equipment is live during operation.

cover.
Disposal
Dismantle the equipment and separate the waste materials, using the material specification as a
reference.
Electronic components (circuit boards) must be disposed of separately.
For the disposal of the equipment observe the pertinent legal regulations concerning waste disposal.
Annex
Note on the Declaration of Conformity / Declaration by the Manufacturer
For details on the conformity of our equipment according to the European Directives see our
Declaration of Conformity or our Declaration of Manufacturer.
The current Declaration of Conformity / Declaration of Manufacturer are available in the Internet under
www.gestra./de/documents or can be requested from us.
39
10166
GESTRA

www.gestra.de

Fax 0044 16 35 / 3 60 34 Kempton Park 1613
Singapore
12 Tuas Avenue 20
Tel. 0065 / 68 79 89 00 2341 Ampere Drive
GESTRA AG
P. O. Box10 54 60, D-28054 Bremen
Tel. 0049 (0) 421 / 35 03 - 0
Fax 0049 (0) 421 / 35 03 - 393
Web www.gestra.de

40
10168
Issue Date: 11/09
GESTRA Steam Systems Product Range B
Level Electrode NRG 26-40

With CAN Bus, CANopen Protocol
Type NRG 26-40
System Description Technical Data

The level electrode NRG 26-40 works according to the Type Approval N°
capacitance measurement principle. The NRG 26-40 is TÜV · WR · 04-399 GESTRA Steam Systems
used for signalling different levels in conductive and non- Max. service pressure
conductive liquids: 32 barg at 238 °C
■ Water level maintained within the control band defined Connections
by two preset limits. Screwed ¾" BSP, EN ISO 228-1
GESTRA
Use level electrode NRG 26-40 in combination with level Materials NRG 26-40
switch type NRS 2-40 or further system components. The Case Die cast aluminium 3.2161(G AlSi8Cu3)
level data are transferred to the level switch or another Stem S. S. 1.4571 (X6CrNiMoTi17-12-2)
system component via the CAN data bus. The controller Measuring electrodes S. S. 1.4401 (X5CrNiMo17-12-2)
and the electrode use the CANopen protocol. Electrode insulation PTFE
Length supplied
Function 300 mm to 2000 mm
The principle of capacitance measurement is applied to Supply voltage
determine the level. The electrode rod and the vessel wall 18 – 36 V DC
form the plates of a capacitor. If the level of the dielectric
Current consumption
located between these two capacitor plates changes, the
65 mA
current which flows through the plates changes proporti-
onally to the level. A dielectric is by definition an insulating Fuse
substance, which excludes many liquids such as water. In Thermal fuse Tmax = 80 °C
order to receive a useful measuring result the measuring Hysteresis
rod, which is submerged to varying depths in the liquid, -2 K
must be completely insulated. After the calibration of the
zero point /measuring range (0 %/100 %) the level can be Data exchange
read off from a remote display unit. The level measuring CAN bus acc. to DIN ISO 11898,
range can be changed during operation. CANopen protocol
At regular intervals the level electrode NRG 26-40 sends Indicators and adjustors B
a data signal to the level switch NRS 2-40 or level con- 1 green LED for indication “Can bus communication”
troller NRR 2-40. The data transfer is effected by means 1 red LED “Bus fault”
of a CAN bus according to DIN ISO 11898 using the CAN 1 10-pole code switch for node ID and baud rate settings
open protocol.
Design
NRG 26-40 screwed ¾" BSP EN ISO 228-1 P.T.O.
Wiring INDUSTRIAL CONTROL

EQUIPMENT
Note that screened multi-core twisted-pair control cable is required, e. g. UNITRONIC® BUS CAN 2 x 2 x ... mm2 or 26NX
RE-2YCYV-fl 2 x 2 x ... mm2.
Prefabricated control cable (with connector and coupler) of various lengths for connecting the equipment are
available as accessories. The baud rate (data transfer rate) dictates the cable length between the bus nodes and
the total power consumption of the sensor dictates the conductor size.
Number of pairs
OFF ON OFF 250 kBit/s 125 m Wiring Diagram
2 x 2 x 0.34
Factory setting Code switch
NO
1 2 3 4 5 6 7 8 9 0
OFF OFF ON 100 kBit/s 335 m 2 x 2 x 0.75 Electrode rod 1

NRG 26-40
1 2 3 4 5
on request, dependent on
OFF ON ON 20 kBit/s 1000 m _
bus configuration CL S CH +
CL C H S
24V DC
The baud rate is set via a code switch. Reduce baud rate if cable is longer than specified in the table above. Make
sure that all bus nodes feature the same settings.
CAN - Bus
To protect the switching contacts fuse circuit with 2.5 A (anti-surge fuse) or according to TRD regulations (1.0 A for
72 hrs operation). Terminating resistor 120 Ω e.g. UNITRONIC®
Paired cable BUS CAN 2 x 2 x ...2
When a max. cable length of more than 125 m (up to 1000 m) is desired, make sure to modify the baud rate
accordingly.
Level Electrode Dimensions 10168
MAX 70 °C
With CAN Bus, CANopen Protocol 173
Type NRG 26-40
%
MAX 95 %
140
GESTRA
Electric connection NRG 26-40
M 12 sensor connector, 5 poles, A-coded, IP 65

M 12 sensor jack, 5 poles, A-coded
Protection b = 70
337.5
70 °C
Weight J K
approx. 2.5 kg 1373 1300
1477 1400
Order and Enquiry Specification
1583 1500
GESTRA Level electrode type NRG 26-40
CANopen
1688 1600
1794 1700
Associated Level Switch/ ¾" BSP to EN ISO 228-1
37
1899 1800
Level Controller 1004 1900
 Level switch type NRS 2-40 CANopen 1110 1000
 Level controller type NRR 2-40 CANopen 1214 1100
J K
Ancillary Equipment L 1319 1200
 Visual display unit type URB 1, URB 2 1423 1300
1528 1400
Key
26
1636 1500
A Flange PN 40, DN 50 (2"), DIN ISO 2527 2156 2000
Flange PN 40, DN 100 (4"), DIN ISO 2527
B For the approval of the boiler standpipe
with connecting flange the relevant Fig. 1 NRG 26-40
regulations must be considered.
¾" BSP ¾" BSP
C Vent hole
A
1 A
D High water (HW) DN 50 B
E Electrode rod d = 15 mm
≤ 20
F Protection tube DN 80 mm DN 20
∅ 20
G Electrode distance
C
D
20
H Low water (LW) D

I Reducer K-88.9 x 3.2 – 42.4 x 2.6 W
J Max. length of installation at 238 °C E
K Measuring range F
ME
L Adjustable control range G E

H
≥ 10

According to the European Directive 94/9/EC the ≤ 90 ° I
equipment must not be used in explosion-risk areas. ∅ 20 H
≤ 20
DN 20
DN 20
Supply in accordance with our general terms Fig. 2 Protection tube for installation
of business. of electrode inside the boiler Fig. 3 External measuring pot
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Telephone 0049 (0) 421 35 03 - 0, Fax 0049 (0) 421 35 03-393

10168
GESTRA
NRG 26-40 EN
English
Installation Instructions 810274-04

Level Electrode NRG 26-40
1
10168
Contents
Page
Important Notes
Usage for the intended purpose...............................................................................................................4

Safety note..............................................................................................................................................4
Danger....................................................................................................................................................4
Attention..................................................................................................................................................4
Explanatory Notes
Scope of supply.......................................................................................................................................4
Description..............................................................................................................................................5
Function..................................................................................................................................................5
System components................................................................................................................................5
Design.....................................................................................................................................................5
Technical Data
NRG 26-40..............................................................................................................................................6
Corrosion resistance................................................................................................................................7
Sizing......................................................................................................................................................7
Name plate / marking..............................................................................................................................7
Dimensions ............................................................................................................................................8
Design
NRG 26-40..............................................................................................................................................9
Key........................................................................................................................................................11
Functional Elements
NRG 26-40............................................................................................................................................10
Key........................................................................................................................................................11
Installation
NRG 26-40............................................................................................................................................12
Attention................................................................................................................................................12
Note......................................................................................................................................................12
Tools......................................................................................................................................................12
Examples of Installation ........................................................................................................................13
Key........................................................................................................................................................14
Aligning terminal box.............................................................................................................................15

Note......................................................................................................................................................15
Control cable.........................................................................................................................................15
2
10168
Page
Electrical Connection - continued -
Note......................................................................................................................................................16
CAN bus voltage supply.........................................................................................................................16
Attention................................................................................................................................................16
Wiring diagram......................................................................................................................................17
Wiring diagram for the sensor plug-in connections................................................................................18
Key........................................................................................................................................................18
Wiring diagram for CAN bus...................................................................................................................19
Attention................................................................................................................................................19
Note......................................................................................................................................................20
Tools......................................................................................................................................................20
Basic Settings
Bus cable..............................................................................................................................................20
Node ID.................................................................................................................................................21
Factory setting.......................................................................................................................................22
Establishing / changing node ID.............................................................................................................22
Attention................................................................................................................................................22
Measuring ranges..................................................................................................................................24
Key........................................................................................................................................................24
Commissioning
Checking electrical connection..............................................................................................................25

Applying mains voltage..........................................................................................................................25
Operation
Level electrode with CAN bus................................................................................................................26

Note......................................................................................................................................................26
Setting the attenuation of the level controller.........................................................................................26
Malfunctions
Fault finding list for troubleshooting................................................................................................. 27, 28
Decommissioning
Danger..................................................................................................................................................29
Disposal................................................................................................................................................29
Annex
Declaration of Conformity......................................................................................................................30
3
10168
Important Notes
Use level electrode NRG 26-40 only in conjunction with switching controller NRS 2-40 or level controller
NRR 2-40 for signalling levels in electrically conductive or non-conductive liquids.
Safety note
Retrofitting and maintenance work must only be performed by qualified staff who – through adequate
training – have achieved a recognised level of competence.
Danger
When loosening the electrode steam or hot water might escape!

It is therefore essential not to dismantle the level electrode unless the boiler pressure is
verified to be 0 bar.
The level electrode becomes hot during operation.
This presents the risk of severe burns to hands and arms.
Before carrying out installation and maintenance work make sure that the valve is cold.
If the internal ceramic insulation breaks, hot steam can escape through the lateral
vent hole in the electrode body.
Do not stay near the electrode during operation.
Attention
The name plate specifies the technical features of the equipment. Note that any item of
equipment without its specific name plate must neither be commissioned nor operated.

According to the European Directive 94/9/EC the equipment must not be used in potentially explosive
areas.
Explanatory Notes
Scope of supply
NRG 26-40
1 Level electrode NRG 26-40
1 Joint ring D 27 x 32 DIN 7603, stainless steel 1.4301, bright annealed
4
10168
Explanatory Notes - continued -
Description
The level electrode NRG 26-40 works according to the capacitance measurement principle.
The NRG 26-40 is used for signalling different levels in conductive and non-conductive liquids:
■ Water level maintained within the control band defined by two preset limits
Use level electrode NRG 26-40 in combination with level switch NRS 2-40 or further system compo-
nents. The level data are transferred to the level switch or another component via the CAN data bus,
using the CANopen protocol.
Function
The principle of capacitance measurement is applied to determine the level. The electrode rod and
the vessel wall form a capacitor. If the level of the dielectric located between the two capacitor plates
changes, the current which flows through the plates changes proportionally to the level. A dielectric
is defined as an insulating substance, which excludes many liquids such as water. In order to receive
a useful measuring result the measuring rod, which is completely submerged in the liquid, must be
completely insulated. After calibration of the zero point/measuring range (0 % –100 %) of the control
unit, the level can be read off from a remote display unit. The level measuring range can be changed
during operation.
At regular intervals the level electrode NRG 26-40 sends a data telegram to the level switch NRS 2-40
or level controller NRR 2-40. The data transfer is effected by means of a CAN bus according to DIN ISO
11898 using the CANopen protocol.
System components
NRS 2-40
Digial switching controller for level electrode NRG 26-40.
Functions: Four liquid levels with one switchpoint each, MAX alarm, MIN alarm, pump ON, pump OFF
with one switchpoint each, liquid level continuously within the predefined control band of the electrode.
Data exchange: CAN bus to ISO 11898 via CANopen protocol.
NRR 2-40
Digial level controller for level electrode NRG 26-40.
Functions: Four liquid levels with one switchpoint each, MAX alarm, MIN alarm, pump ON, pump OFF
with one switchpoint each, liquid level continuously within the predefined control band of the electrode.
Data exchange: CAN bus to ISO 11898 via CANopen protocol.
URB 1, URB 2
Operating & display unit.
Functions: Parameterization and visual indication via LCD display.
Data exchange: CAN bus to DIN ISO 11898 via CANopen protocol.
Design
NRG 26-40:
Screwed design ¾" to EN ISO 228-1. Fig. 2
5
10168
Technical Data
NRG 26-40
Type approval
TÜV · WR · XX-399 (see name plate)
Service pressure
32 bar g at 238 °C
Screwed ¾" to EN ISO 228-1
Materials
Case 3.2161 G AlSi8Cu3
Rod 1.4571 CrNiMoTi17-12-2
Measuring electrode 1.4571 CrNiMoTi17-12-2
Electrode insulation PTFE
Length supplied / measuring range
see Fig. 2
Supply voltage
18 – 36 V DC
Power consumption
65 mA
Fuse
Thermal fuse Tmax = 80 °C
Hysteresis
–2 K
Data exchange
CAN bus to DIN ISO 11898, CANopen protocol
Attenuation of signal output
19 seconds
1 10-pole code switch for node ID and Baud rate setting
1 green LED “Communication CAN bus”
1 red LED “Malfunction in bus”
M 12 sensor connector, 5 poles, A coded,
M 12 sensor jack, 5 poles, A coded
Protection
70 °C
Weight
Approx. 2.5 kg
6
10168
Technical Data - continued -
Corrosion resistance
If the unit is used for the intended purpose, its safety is not impaired by corrosion.
Sizing
The body must not be subjected to sharp increases in pressure. Welds and flanges are designed to
withstand dynamic loading (bending and alternative stress). The dimensional allowances for corrosion
and anti-corrosive additives reflect the latest state of technology.
Name plate / marking
Equipment
designation
Fig. 1
7
10168
Technical Data - continued -
Dimensions
173
140
337 .5
Width: 70 mm
A B
1373 1300
1477 1400
37
¾" to EN ISO 228-1 1583 1500

1688 1600
1794 1700
1899 1800
1004 1900
A B 1110 1000
C
1214 1100
1319 1200
D 1423 1300
1528 1400
26
1636 1500
2156 2000
Fig. 2
8
10168
Design
NRG 26-40
1
4 2
Fig. 3
∅ 33
¾" to DIN 228

N 10
N1
0.5
Fig. 4
9
10168
Functional Elements
NRG 26-40
5 6 7 6
Fig. 5
9
0
§
" !
Fig. 6
10
10168
Design / Functional Elements - continued -
Key
1 Thermal insulation, provided on site, d = 20 mm (outside of thermal insulation of steam boiler)
2 Seating surface
3 Joint ring D 27 x 32 DIN 7603, stainless steel 1.4301, bright annealed
4 Electrode thread ¾" to EN ISO 228-1
5 Housing screws M 4
6 M 12 sensor connector, 5poles, A coded, M 12 sensor jack, 5poles, A coded
7 Housing cover
8 Code switch, 10 poles
9 Green LED “CAN bus communciation”
0 Red LED “Malfunction in bus”
! Terminal strip
" PE connection
§ Nut
A Max. length of installation at 238 °C
B Measuring range
C Adjustable control range
D Lower measuring point
11
10168
Installation
NRG 26-40
1. Check seating surfaces of threads or flange provided on vessel or boiler standpipe. Fig. 4
2. Place joint ring 3 onto seating surface 2 of the electrode. Fig. 3
3. Apply a light smear of silicone grease (e.g. Molykote® 111) to electrode thread 4.
4. Screw level electrode into threads or flange provided on vesssel and tighten with a 41 mm open-
end spanner. The torque required when cold is 160 Nm.
5. When mounting two electrodes in one flange install the first electrode as described under item 4.
Before installing the second electrode loosen nut §, unscrew PE connection and remove cable
connectors from circuit board. Screw electrode in place. Slightly tighten nut §.
Install PE connection " and fix cable connectors.
Attention
 The seating surfaces of the standpipe or the flange provided on the vessel must be
accurately machined, see Fig. 4.
 Do not bend electrode tip when mounting
 Use only the supplied joint ring (of stainless steel 1.4301) D 33 x 39 DIN 7603.
 Do not lag electrode body above the hexgonal section.
 Do not insulate electrode thread with hemp or PTFE tape.
Note
 For the approval of the boiler standpipe the relevant regulations must be considered.
 Refer to page 13 for four typical installation examples.
Tools
 Open-end spanner A. F. 19 mm
Molykote® 111 is a registered trademark of DOW Corning Corp., Midland Michigan, USA
12
10168
Examples of Installation
¾" ¾"
$ $
DN 50
% DN 50 %
∅ 20
a &
≤ 1500
≥10
20
∅ 20
&
/
20
( (
) )
b b
≥10
≤ 90° c ≤ 90° c
∅ 20
∅ 20
Fig. 7 Fig. 8
¾"
¾" ¾" $
$
% DN 20 ≥ 20
≤ 3000
/
DN 100 (
24.5 24.5
=
Centre distance
∅ 20
20
& ≥10 a
/ (
b
d b
≤ 90°
≥ 20
∅ 20 DN 20
Fig. 9 DN 20
Fig. 10
13
10168
Key
$ Flange PN 40, DN 50, DIN 2527

Flange PN 40, DN 100, DIN 2527
%
For the approval of the boiler standpipe with connecting flange the relevant regulations must
be considered.
&
Vent hole Provide vent hole as close to the boiler wall as possible!
/
High water HW
(
Electrode rod d = 15 mm
)
Protection tube DN 80
=
Protection tube DN 100
a
Electrode distance ≥ 14 mm
b
Low water LW
c
Reducer DIN 2616-2, K - 88.9 x 3.2 - 42.4 x 2.6 W
d
Reducer DIN 2616-2, K-114.3 x 3.6 - 48.3 x 2.9 W
14
10168
Aligning terminal box
1. Unscrew screws 5 and remove housing cover 7. Fig. 5

2. Loosen nuts § with 19 mm spanner. Do not remove them! Fig. 6
The electrode terminal box can now be turned through +/– 180°.
3. Turn electrode terminal box into desired position (+/– 180°).
4. Tighten nuts § with a torque of 25 Nm.
5. Set node ID (see “Basic Settings”, “Configuring level electrode”).
6. Re-attach housing cover 7 and fix it with screws 7.
Note
 Wire the control cable according to the wiring diagram with connector and coupler.
Control cable
NRS, NRR, LRR, TRS, URB 1

To wire the equipment, multi-core twisted-pair control cable must be used for the bus line, e. g.
UNITRONIC® BUS CAN 2 x 2 x ... mm2 or RE-2YCYV-fl 2 x 2 x ... mm2.
Control cable assemblies (2 x 2 x 0.32 mm² cable with plug and connector) of various lengths are
available as add-on equipment.
NRG, LRG, EF, URZ, TRV, URB 2
The equipment is fitted with sensor plug-in connectors (5 poles, A-coded). For connecting the bus
devices control cable assemblies (with plug and connector) of various lengths are available as add-on
equipment.
Note that the recommended control cables are not UV-resistant and must be protected by a
UV-resistant plastic tube or cable duct if the equipment is installed outdoors (except for URB 2).
The baud rate (data transfer rate) dictates the cable length and size between the bus nodes. The total
power consumption must also be taken into consideration when selecting the conductor size. The
total power consumption is obtained from the number of bus nodes. If the cable length between the
steam boiler and the control cabinet exceeds 15 m, we recommend that you fit a branching box that is
resistant to electromagnetic interference (stock code 1501214) and use a control cable with a larger
conductor size for the distance to the control cabinet.
Number of pairs
2 x 2 x 0.34
Factory setting
on request, depending on
bus configuration
Set baud rate via code switch 8. Make sure that all bus nodes feature the same settings.
UNITRONIC® is a registered trademark of LAPP Kabelwerke GmbH, Stuttgart.
15
10168
Note
 The max. baud rates and cable lengths indicated above are based on empirical values
obtained by GESTRA. In certain cases it may be necessary to reduce the baud rate in
order to ensure operational safety.
 The type and design of the data cable has a strong influence on the electromagnetic
compatibility (EMC) of the equipment. Take special care when connecting the equip-
ment.
 If you do not use the control cable assemblies connect the connectors and jacks for
the control cables as indicated in the assignment diagram for sensor plug-in unions.
CAN bus voltage supply
To ensure the troublefree operation of the CAN bus system make sure that the voltage supply for all bus
devices is sufficient.
Please use the following table to check the voltage supply of your bus system.
Control units with Qty. x Power output per item = Sum

voltage supply x 6W = W
Sensor, transmitter, control Qty. x Power consumption per item = Sum
units, operating & display unit
URB 1 x 3W = W
Operating & display unit
URB 2 x 5W = W
If sum 2 exceeds sum 1 supply the CAN bus with 24 V DC coming from a separate and stabilized safety
power supply unit (e. g. SITOP Smart 24 V 2.5 A).
The power supply unit must be electrically isolated from dangerous contact voltages and must meet at
least the requirements on double or reinforced isolation acc. to DIN EN 50178 or DIN 61010-1 or
DIN EN 60730-1 or DIN EN 60950 (safe isolation).
The power supply unit must be provided with an overcurrent protective device in accordance with
EN 61010-1.
Attention
If a safety power supply unit (e. g. SITOP smart, 24 V, 2.5 A) is used for the voltage supply
of the CAN bus do not tap the supply voltage from the terminals 1 and 5 of the GESTRA
control devices.
SITOP smart is a registered trademark of Siemens AG, Munich
16
10168
Wiring diagram
f
e
f
Fig. 11
17
10168
Wiring diagram for the sensor plug-in connections
120 Ω 120 Ω
Fig. 12 e ij g 31 h
j ih g j
31 j e
Fig. 13 RES 1 Fig. 14 RES 2
Key
e
Terminating resistor 120 Ω, RES 1 or RES 2
f
CAN bus line, twisted pair control cable
g
Pin 1: Screen
h
Pin 2: Power supply 24 V DC+ (red)
i
Pin 3: Power supply 24 V DC– (black)
j
Pin 4: CAN data line CH (white)
u Pin 5: CAN data line CL (blue)
18
10168
CAN bus wiring diagram
URB 2 NRS, NRR, LRR, NRG, LRG, TRV

CEP
TRS, URB 1 EF, URZ
RES 2 RES 1
Fig. 15
Attention
 Wire equipment in series. Star-type wiring is not permitted!

 Link screens of control cables such that electrical continuity is ensured and connect
them once to the central earthing point (CEP). If equipotential bonding currents are
to be expected, for instance in outdoor installations, make sure that the screen is
separated from the central earthing point (CEP).
 To protect the switching contacts fuse circuit with T 2.5 A or according to TRD
regulations (1.0 A for 72 h operation).
 If two or more system components are connected in a CAN bus system, provide the
first and the last device with a terminating resistor of 120 Ω, Fig. 13, Fig. 14
 Note that in a CAN bus network only one water-level limiting system may be used.
 Do not interrupt the CAN bus network during operation with one or more system
components!
If the CAN bus network is interrupted the saftey circuit will be opened.
Before taking the CAN bus line from the terminal strip, make sure that all connected
system components are out of service.
19
10168
Note
 The loop resistance must be below 10 Ω.

 The rated voltage is indicated on the name plate.
 When switching off inductive loads, voltage spikes are produced that may impair the
operation of control and measuring systems. Provide connected contactors with RC
combinations, e. g. 0.1 µF/100 Ω.
 Even in correctly wired systems high frequency interference caused by the installation
can lead to system outages and malfunction alarms. For more information please refer
to the fault-finding list in the section Troubleshooting.
Tools
 Screwdriver for cross head screws, size 1

 Screwdriver for slotted screws, size 2.5, completely insulated according to VDE 0680
Basic Settings
Bus cable
All devices (level, conductivity) are interconnected via CAN bus. The CANopen protocol is used for the
data exchange between the equipment groups. All devices have an electronic address – the node ID.
The four-core bus cable serves as power supply and data highway for high-speed data exchange.
The CAN address (node ID) can be set between 1 - 99.
The control unit NRS 1-40 has already been configured at our works for operation with other GESTRA
components and can be used straight away without having to set the node ID.
If several identical systems are to communicate in a CAN bus network, set a different node ID
for each system (e. g. limiter, controller, etc).
If the length of the CAN bus cable exceeds 125 m change the settings of the code switch 8.
For more information on switch positions see Basic Settings / Switch positions.
20
10168
Basic Settings - continued -
Node ID
Water level limiter

NRS 1-40 NRG 16-40 (1) NRG 16-40 (2) Reserved Reserved
X X+1 X+2 X+3 X+4
Safety system for steam boilers with superheater
NRS 1-40.1 NRG 16-40 (1) NRG 16-40 (2) TRV 5-40 Limiter 4
X X+1 X+2 X+3 X+4
1 2 3 4 Factory setting
NRS 1-40.1 NRG 16-40 (1) NRG 16-40 (2) Limiter 3 Limiter 4
X X+1 X+2 X+3 X+4
1 2 Factory setting
NRS 1-40.2 TRV 5-40 (1) TRV 5-40 (2) Limiter 3 Limiter 4
X X+1 X+2 X+3 X+4
TRS 5-40 (1) TRS 5-40 (2)
X + 1 + 90 X + 2 + 90
97 98
High level alarm
NRS 1-41 NRG 16-41 Reserved Reserved Reserved
X X+1 X+2 X+3 X+4
Further components
SRL 40
X = (sensor: level limiter // hi alarm) + 2 Factory setting
ORT 6
98 Factory setting
On-off level control
Reserved NRS 1-42 NRG 16-42
X–1 X X+1
Modulating level control
URZ 40 NRS 2-40 NRR 2-40 NRG 26-40 Reserved
X–2 X–1 X X+1 X+2
Automatic continous blowdown control
EF 1-40 Reserved LRR 1-40 LRG 1-4... Reserved
X–2 X–1 X X+1 X+2
Control unit
URB 1, URB 2
60 Factory setting
21
10168
Factory setting
The level electrode features the following factory set default values:
 Baud rate: 250 kB/s
 Measuring sensitivity: 10 µS/cm
 Node ID: 041
Establishing / changing node ID
If several identical systems are to communicate in a CAN bus network, set a different node ID for each
system (e. g. limiter, controller, etc).
1. Unscrew screws 5 and take off housing cover 7.
2. Set code switch 8 as requested. Please observe the table “Code switch settings” on page 23.
Attention
 We recommend that you commission the CAN bus devices with the default factory
setting.
 Do not use a node ID for more than one piece of equipment in the CAN bus system.
22
10168
8 8
Node ID 41 Node ID 71
S 1 ON 1 S 1 ON 1
S 2 OFF 2 S 2 ON 2
S 3 OFF 4 S 3 ON 4
S 4 ON 8 S 4 OFF 8
S 5 OFF 16 S 5 OFF 16
S 6 ON 32 S 6 OFF 32
S 7 OFF 64 S 7 ON 64
Fig. 16 (Factory setting) Fig. 17 (Example 1)
S8 S9 S0 Baud rate Cable length

ON ON OFF 125 kBit/s 250 m
Fig. 18 (Factory setting 250 kBit/s)
23
10168
Measuring ranges
37
B
C
D
Fig. 19
26
Key
B
Measuring range at 25 °C
C
Adjustable control range [mm]
D
Lower measuring point
24
10168
Commissioning
Checking electrical connection
Check that the electrode NRG 26-40 is connected to the level switch NRS 2-40 or the level controller
NRR 2-40 according to the wiring diagram. Fig. 11, Fig. 15
Applying mains voltage
Apply mains voltage to the control unit NRS 2-40 or the level controller NRR 2-40.
25
10168
Operation
Level electrode with CAN bus
Use in conjunction with level switch NRS 2-40 in steam and pressurised hot water plants in accordance
with TRD 401, TRD 602, TRD 604, EN 12952, EN 12953 or according to other national regulations.
Note
 To analyse and eliminate malfunctions refer to section “Fault finding list for trouble-
shooting” on pages 27 – 28.
Setting the attenuation of the level controller
If the liquid level varies considerably for a short time during operation change the attenuation of the
level signal. The default factory setting for the attenuation is 19 seconds.
1. Unscrew screws 5 and take off housing cover 7.
2. Write down the node ID and baud rate settings. Unplug the CAN bus connector.
3. Set code switch 8 S 1 to ON and S 2 to S 7 to OFF.
S1 S2 S3 S4 S5 S6 S7
ON OFF OFF OFF OFF OFF OFF
4. Set the desired attenuation via code switches S8 to S10.

S8 S9 S 10 Attenuation [s]
OFF OFF OFF 3
ON OFF OFF 5
OFF ON OFF 7
ON ON OFF 9
OFF OFF ON 15
ON OFF ON 19*)
OFF ON ON 25
ON ON ON 29
*) Factory settings
5. Plug in the CAN bus connector.

Green LED 1 illuminated: The new attenuation setting has been accepted.
Red LED 2 illuminated: New attenuation setting has not been accepted. Repeat the setting or
replace the electronic circuit board.
6. Unplug the CAN bus connector. Set the original node ID and baud rate.
Plug in the CAN bus connector. The level electrode NRG 26-40 works now with the new attenuation
setting.
26
10168
Malfunctions
Fault finding list for troubleshooting
Equipment does not work – no function
Fault: The thermal fuse has been triggered.

Remedy: The ambient temperature must not exceed 70 °C.
Fault: In spite of correct wiring and commissioning of the equipment an error message is
indicated.
Remedy: The error message is caused by the high-frequency interference coming from the
system. For interference suppression we supply ferrite rings, stock code # 147253.
The 230 V supply lines should be looped five to ten times through the ferrite ring.
If several controllers are used in one system, they can be fed from the interference
suppressed supply lines. For the interference suppression of the bus line we supply
hinged-shell ferrite rings, stock code # 147254. The hinged-shell ferrite rings are
clamped onto the bus line close to the terminal strip of the controller and next to the
housing cover of the level electrode.
Fault: LED “Power” is not illuminated.

Remedy: Apply mains voltage. Connect electrode according to wiring diagram.
Fault: The electrode body does not have earth connection to the boiler.
Remedy: Clean sealing surfaces and insert metal joint ring D 33x39 to DIN 7603,
made from 1.4301. Do not insulate level electrode with hemp or PTFE tape!
Fault: LED 9 is not flashing. No data exchange.

Remedy: Check level switch/controller. Connect electrode according to wiring diagram.
Equipment does not work correctly
Fault: The vent hole in the protection tube does not exist, is obstructed or flooded.
Remedy: Check protection tube and, if necessary, provide vent hole.
Fault: The electrode was installed without a protection tube.

The protection tube serves as reference electrode.
Remedy: Install a protection tube.
Fault: The desired zero point of the control range is outside of the measuring range
of the electrode. The electrode is too short.
Remedy: Replace level electrode. Select suitable electrode length.
Fault: The electrode rod is covered with dirt deposits.

Remedy: Remove level electrode and clean the electrode tip with a wet cloth.
Fault: The internal insulation of the electrode rod is damaged.

Remedy: Replace level electrode.
27
10168
Malfunctions - continued -
Fault finding list for troubleshooting - continued -
Fault: The isolating valves of the external measuring pot (optional extra) are closed.
Remedy: Open isolating valves.
Fault: The level electrode responds too sluggishly to changes in the liquid level.
Remedy: Correct the attenuation setting.
If faults occur that are not listed above or cannot be corrected, please contact our service centre
or authorized agency in your country.
28
10168
Decommissioning
Danger
Risk of severe burns and scalds to the whole body!

Before installing the level electrode make sure that the vessel or the external pot are
depressurised (0 bar) and cooled down to room temperature (20 °C).
Disposal
Dismantle the level electrode and separate the waste materials, using the specifications in the table
“Materials” as a reference.
Electronic component parts such as the circuit board must be disposed of separately!
For the disposal of the level electrode observe the pertinent legal regulations concerning waste
disposal.
29
10168
Annex
We hereby declare that the equipment NRG 26-40 conforms to the following European guidelines:
 Low Voltage Directive 73/23/eec version 93/68/eec
 EMC Directive 89/336/EC version 93/68/EC
 ATEX Directive 94/9/EC of 23 March 1994
This declaration is no longer valid if modifications are made to the equipment without consultation
with us.
Bremen, 3rd January 2005

GESTRA AG
Dipl.-Ing. Uwe Bledschun Dipl.-Ing. Lars Bohl

(Academically qualified engineer) (Academically qualified engineer)
Head of Design Dept. Quality Assurance Manager
30
10168
For your notes
31
10168
GESTRA

www.gestra.de

Fax 0044 16 35 / 3 60 34 Kempton Park 1613
Singapore
12 Tuas Avenue 20
Tel. 0065 / 68 79 89 00 2341 Ampere Drive
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Telephone +49 (0) 421 35 03 - 0
Fax +49 (0) 421 35 03 - 393

32
Enclosure 10174
Issue Date: 03/13
Level Monitoring
NRGT 26-1
NRGT 26-1S For Marine Applications
GESTRA
Description Technical data

The level transmitter NRGT 26-1 / NRGT 26-1 S is a compact- Service pressure
type system consisting of a level measuring electrode and a PN 40, 32 bar at 238°C
level transmitter integrated in the terminal box. Mechanical connection
The level transmitters NRGT 261 and NRGT 261S are NRGT 2661: Screwed G ¾ A, ISO 228
used for continuous level monitoring in steam boilers and NRGT 2661S: Flange DN 50, PN 40, DIN EN 1092-01
(pressurized) hot-water installations or in condensate and Materials
feedwater tanks. Screw-in body: 1.4571, X6CrNiMoTi17-12-2
In conjunction with the level switch NRS 2-.. and the level Electrode rod insulation: PTFE
controller NRR 2-.. the transmitter can be used as water Terminal box: 3.2161 G AlSi8Cu3
level controller with MIN/MAX alarm. NRGT 26-1S: Flange 1.0460 P250GH
The level transmitter can be used in combination with the NRGT 26-1S: Spacer disc: PTFE
following level switches and controllers: NRS 2-50, NRS 2-51, Length of installation / measuring range
NRR 2-50, NRR 2-51, NRR 2-52 and NRR 2-53.
NRGT 26-1 NRGT 26-1S
Function Length of instal- Measuring Length of instal- Measuring

lation at 238° C range lation at 238° C range
The level transmitter works according to the capacitance
measurement principle and translates the level changes 373 300 316 275
into a level-dependent current signal of 4-20 mA, with 477 400 420 375
the length of the electrode rod determining the measuring 583 500 526 475
range.
688 600 631 575
NRGT 26-1 The level transmitter is installed inside steam boilers, ves- 794 700 737 675
sels or in an external level pot. If the equipment is installed
inside the boiler or vessel, a protection tube provided on 899 800 842 775
side ensures correct functioning. 1004 900 947 875
The level transmitter can be installed together with one 1110 1000 1053 975
GESTRA level electrode for water level limiting or for high-
1214 1100 1157 1075

level alarm in a single protection tube or an external level 1319 1200 1262 1175
pot.
GESTRA
1423 1300 1366 1275
The level transmitter can be used in electrically conductive
and non-conductive fluids. 1528 1400 1471 1375
1636 1500 1579 1475
Directives and standards 2156 2000 2099 1975
VdTÜV Bulletin "Water Monitoring 100" Weight
The level transmitter NRGT 26-1 is type approved acc. NRGT 2661: approx. 1.8 kg
to VdTÜV Bulletin "Wasserstand 100" if used in combi- NRGT 2661S: approx. 8.0 kg
nation with the following level switches / controllers:
NRS 2-50, NRS 2-51, NRR 2-50, NRR 2-51, NRR 2-52 Electronic circuit board
and NRR 2-53. Supply voltage
24 V AC/DC
The VdTÜV Bulletin "Wasserstand (= Water Level) 100" AC +/– 20%
specifies the requirements made on water level control and DC +10 / –45%
D limiting equipment for boilers. 115 V +/– 10%, 50/60 Hz (option)
Approvals for Marine Applications 230 V +/– 10 %, 50/60 Hz (option)
The level transmitter NRGT 26-1S is approved for marine Power consumption
applications. 3 VA at 24 V DC
LV (Low Voltage) Directive and EMC 5 VA at 24, 115, 230 V AC
(Electromagnetic Compatibility) Fuse
The level transmitter NRGT 26-1 meets the requirements of External slow-blow 0.5 A
the Low Voltage Directive 2006/95/EC and the EMC Direc- Internal thermal fuse Tmax = 102°C
tive 2004/108/EC.
Sensitivity of response
F ATEX (Atmosphère Explosible) Range 1: Water ≥ 0.5 µS/cm
According to the European Directive 94/9/EC the equipment Range 2: Water ≥ 20 µS/cm
must not be used in potentially explosive areas. Range 3: Fuel oil EL εr 2,3
NRGT 26-1S Output
Actual value 4 – 20 mA, level proportional. Electrically
insulated, max. load 500 Ω
Enclosure 10174 173 173
Level Monitoring Dimensions
NRGT 26-1
NRGT 26-1S
GESTRA Steam Systems GESTRA Steam Systems
140
140
For Marine Applications GESTRA GESTRA
Technical data - continued - b = 68 b = 68

Indicators and adjusters
336
336
2 red LEDs for signallling "Level 0 %" or "Level 100"
within the measuring range,
1 green LED for signalling “Level between 0 % and 100
%” of measuring range.
1 code switch for selecting the measuring range.
2 adjustable resistors for small-percentage adjustment of
the measuring range.
2 terminal lugs for voltage measurement. 5 5
41 mm A. F.
Electrical connection Screwed G ¾ A, ISO 228
6
37
2 cable glands with integral
cable clamp M20 x 1.5 NRGT 26-1 NRGT 26-1S
Screw-type terminal strip with 2 and 3 terminals, 1 2 3 4
detachable, conductor size 1.5 mm2 ∅ 48.5
373 300 316 275
Protection 12
IP 65 to DIN EN 60529 477 400 420 375 7
583 500 526 475 3 4
Max. 70 °C 688 600 631 575
8
26
794 700 737 675

– 40 to + 80 °C 899 800 842 775
Approvals: 1004 900 947 875
NRGT 26-1 ∅ 42.5
TÜV type approvals acc. to VdTÜV Bulletin "Wasserstand 1110 1000 1053 975
100": Requirements made on water level limiting & control 1214 1100 1157 1075 NRGT 26-1S
equipment. 1319 1200 1262 1175
Type approval no. TÜV · WR · 12-391, 12-425, 12-426, 12-427
1423 1300 1366 1275
Marine applications: DNV A-12022, KR HMB 06190-MS002,
NK TA11016M, BV 10617/CO, CCS HBT 0742 1062-1, RINA 1528 1400 1471 1375
ELE 407609CS, GL 992499-96 HH, LR 98/20074 (E2) 1636 1500 1579 1475
2156 2000 2099 1975
Important Notes
Installation Electrical connection
 The level transmitter NRGT 26-1 can be installed together
with one GESTRA level electrode for water level limiting or
for high-level alarm in a single protection tube or external
level pot (inside diameter 100 m). If the level limiting Thermal
DC
electrode is installed inside the vessel, it must be at least fuse
40 mm away from the upper vent hole. Supply
 The level transmitter shall be installed vertically.
 Do not cut the electrode rod.
 NRGT 26-.., 24 V AC/DC: An external slow-blow fuse 0.5
A must be provided for the level transmitter. To connect Earthing
S1 Disconnecting switch
the equipment use screened multi-core control cable with 420 mA screw
a min. conductor size 0.5 mm2, e. g. LiYCY 4 x 0.5 mm2, Max. load in housing F1 Fuse
max. length 100 m. 500 Ω
+ – 24V AC/DC
For the power supply of the level transmitter use a safety (L) (N) optional 115/230 V AC
power supply unit (PSU), e.g. Siemens SITOP PSU100C
24V/0.6A, which must provide a level of isolation against
voltages that at least meets the requirements for double Important Notes Key
or reinforced insulation as per DIN EN 50178 or DIN EN Electrical connection
61010-1 or DIN EN 60730-1 or DIN EN 60950 (electrically 1 + 3 Max. length of installation at 238 °C
 Any item of equipment that you want to connect to the
protective separation).
terminals for the actual-value output 4 - 20 mA must be 2 + 4 Measuring range
 NRGT 26-.., 115/230 V AC: An external slow-blow fuse
0.5 A must be provided for the level transmitter. To connect
certified to have at least double or reinforced isolation 5 Thermal insulation, provided on site, d = 20 mm
according to DIN EN 50178 or DIN EN 61010-1 or DIN (outside of thermal insulation of steam boiler)
the voltage supply use a multi-core control cable with a EN 60730-1 or DIN EN 60950 (safe electrical isolation)
min. conductor size 0.5 mm2. To connect the actual value between the current loop and live parts of the equipment 6 Flange DN 50, PN 40, DIN EN 1092-01
output use screened multi-core control cable with a min. that are not supplied with safety extra-low voltage (SELV).
conductor size 0.5 mm2, e. g. LiYCY 2 x 0.5 mm2, max. 7 Protection tube
 Make sure that the connecting cable is segregated and
length: 100 m. 8 Spacer disc
runs separately from power cables. Please observe the
Install a disconnector for all poles. Make sure it is easily max. load of 500 ohm.
accessible and in the close proximity of the equipment
(EN 61010-1).
Mark this disconnecting switch as isolating device for the
level transmitter.
Enclosure 10174
Level Monitoring Examples of installation
NRGT 26-1
G¾ G¾
NRGT 26-1S
b b
For Marine Applications c 2
DN 50 DN 50 c
Order & Enquiry Specification
≤ 3000
GESTRA Level transmitter NRGT 26-1
PN 40, screwed G ¾
i d
20
Length of installation.........................................mm e
∅ 20
∅ 20
Supply voltage ....................................................... d
20
Fluid ..................................................................... e
GESTRA Level transmitter NRGT 26-1S f f
PN 40, DN 50 g g
Length of installation.........................................mm
Supply voltage .......................................................
Fluid ..................................................................... k k
≥ 10
Associated switch / controller, ≤ 90° l ≤ 90° l
∅ 20
associated power supply unit ∅ 20
 Level switch NRS 2-50, NRS 2-51 Fig. 5 Protection tube (provided on site) for installation Fig. 6 Protection tube (provided on site)
 Level controller NRR 2-50, NRR 2-51 inside the boiler for installation inside the boiler
 Level controller NRR 2-52, NRR 2-53
 Power supply unit SITOP PSU100C 24V/0,6A G¾ G¾ G¾
Key b b
b Flange PN 40, DN 50, DIN EN 1092-01 c
190
(for one electrode)
≤ 20
Flange PN 40, DN 100, DIN EN 1092-01 DN 20
≤ 3000
(for electrode combination)
c For the approval of the boiler standpipe with connecting
DN 100 f e
flange the relevant regulations must be considered.
24.5 24,5
h
d j
≥ 14
Vent hole
n
Centre distance
Provide vent hole as close to the boiler wall as possible! i
e High water HW d 4 e
f
∅20
20
f Electrode rod
g Protection tube DN 80 k
(in France according to AFAQ ≥ DN 100)
≤ 90° m k
h Protection tube DN 100
≤ 20
∅ 20
i Distance between electrode rod and protection tube DN 20
≥ 14 mm Fig. 7 Protection tube (provided on site) for installation
inside the boiler and in combination with other
j Distance between electrode tip (NRG 1..-50 or GESTRA equipment
NRG 1...-51) ≥ 14 mm (creepage distances and
clearances)
k Low water LW DN 20
l Reducer DIN 2616-2, K-88.9 x 3.2-42.4 x 2.6 W Fig. 8 External level pot
m Reducer DIN 2616-2, K-114.3 x 3.6-48.3 x 2.9 W
n Level pot ≥ DN 80
.
Supply in accordance with our general terms of business.
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Tel. 0049 (0) 421 / 35 03-0, Fax 0049 (0) 421 / 35 03-393
E-mail [email protected], Web www.gestra.com
810194-07/03-2013cm (804071-09)· GESTRA AG · Bremen · Printed in Germany

Enclosure 10174
GESTRA
NRGT 26-1 EN
English
NRGT 26-1S
810213-09
Level Transmitter
NRGT 26-1, NRGT 26-1S
1
Enclosure 10174
Contents
Page
Important notes
Usage for the intended purpose................................................................................................................4

Function...................................................................................................................................................4
Safety note...............................................................................................................................................4
VdTÜV Bulletin "Water Monitoring 100"....................................................................................................5

Approvals for Marine Applications............................................................................................................5
LV (Low Voltage) Directive and EMC (Electromagnetic Compatibility).........................................................5
Note on the Declaration of Conformity / Declaration by the Manufacturer . .........................................5
Technical data
NRGT 26-1, NRGT 26-1S..........................................................................................................................6

Scope of supply .........................................................................................................................................................................................................7
Name plate/marking................................................................................................................................8
Installation
Dimensions NRGT 26-1, NRGT 26-1S.....................................................................................................10

NRGT 26-1.............................................................................................................................................11
NRGT 26-1S...........................................................................................................................................11
Key........................................................................................................................................................11
Tools......................................................................................................................................................11
NRGT 26-1.............................................................................................................................................12
Key........................................................................................................................................................13
NRGT 26-1, NRGT 26-1S........................................................................................................................14

Connection of level transmitter...............................................................................................................15
Connecting the NRGT 26-1, NRGT 26-1S................................................................................................15
Key........................................................................................................................................................15
Tools......................................................................................................................................................15
Wiring diagram for level transmitter NRGT 26-1, NRGT 26-1S................................................................16
Connecting level transmitter NRGT 26-.. with supply voltage 24 V AC/DC...............................................16
Connecting level transmitter NRGT 26-.. with supply voltage 115 / 230 V AC..........................................16
Actual value output................................................................................................................................16
2
Enclosure 10174
Page
Basic settings
Factory setting NRGT 26-1.....................................................................................................................17

Factory setting NRGT 26-1S...................................................................................................................17
Establishing active measuring range (control range)...............................................................................17
Applying supply voltage.........................................................................................................................18

Adjusting lower end of measuring range ...............................................................................................18
Adjusting upper end of measuring range................................................................................................18
Troubleshooting
Indication, diagnosis and remedy...........................................................................................................19

Replacing electronic circuit board .........................................................................................................20
Maintenance
Safety note.............................................................................................................................................21
Cleaning the electrode rod.....................................................................................................................21
Removing and disposing of the level transmitter
Removing and disposing of level transmitter NRGT 26-1, NRGT 26-1S...................................................21
3
Enclosure 10174
Important notes
The level transmitters NRGT 261 and NRGT 261S are used for continuous level monitoring in steam
boilers and (pressurized) hot-water installations or in condensate and feedwater tanks.
In conjunction with the level switch NRS 2-.. and the level controller NRR 2-.. the transmitter can be
used as water level controller with MIN/MAX alarm.
The level transmitter is designed for use in conjunction with the following level switches/controllers:
NRS 2-50, NRS 2-51, NRR 2-50, NRR 2-51, NRR 2-52 and NRR 2-53.
The level transmitter can be used in electrically conductive and non-conductive fluids.
Function
The level transmitter NRGT 26-1 is a compact-type system consisting of a level measuring electrode
and electronic circuit board integrated in the terminal box.
The level transmitter NRGT 26-1 works according to the capacitance measurement principle and
translates the level changes into a level-dependent current signal of 4-20 mA, with the length of the
electrode rod determining the measuring range.
The level transmitter is installed inside steam boilers, vessels or in an external level pot. If the elec-
trode is installed inside the boiler or vessel, a protection tube provided on side ensures correct func-
tioning (see section Examples of installation (page 12).
The level transmitter can be installed together with one GESTRA level electrode for water level limiting
or for high-level alarm in a single protection tube or an external level pot.
Safety note
The equipment must only be installed, wired and commissioned by qualified and competent staff.
Danger
When loosening the level transmitter steam or hot water might escape!
It is therefore essential not to dismantle the level transmitter unless the boiler pressure is
The level transmitter becomes hot during operation.
Risk of severe burns to hands and arms.
Before carrying out installation and maintenance work make sure that the equipment is
cold.
The terminal strip of the level transmitter is live during operation.
Attention
The name plate specifies the technical features of the equipment. Do not commission or
operate any item of equipment that does not bear its specific name plate.
4
Enclosure 10174
VdTÜV Bulletin "Water Monitoring 100"

The level transmitter NRGT 26-1 is type approved acc. to VdTÜV Bulletin "Water Level 100" if used in
combination with the following level switches / controllers: NRS 2-50, NRS 2-51, NRR 2-50, NRR 2-51,
NRR 2-52 and NRR 2-53.
The VdTÜV Bulletin "Wasserstand (=Water Level) 100" specifies the requirements made on water level
control and limiting equipment for boilers.
Approvals for Marine Applications
The level transmitter NRGT 26-1S is approved for marine applications.
The level transmitter NRGT 26-1 meets the requirements of the Low Voltage Directive 2006/95/EC and
the EMC Directive 2004/108/EC.
According to the European Directive 94/9/EC the equipment must not be used in explosion risk areas.
Note on the Declaration of Conformity / Declaration by the Manufacturer
For details on the conformity of our equipment according to the European Directives see our Declaration
of Conformity or our Declaration of Manufacturer.
The current Declaration of Conformity and Declaration of Manufacturer are available in the Internet under
www.gestra.com documents or can be requested from us.
5
Enclosure 10174
Technical data
Service pressure
PN 40, 32 bar at 238°C
NRGT 26-1: Screwed G ¾ A, ISO 228
NRGT 26-1S: Flange DN 50, PN 40, DIN EN 1092-01
Materials
Screw-in body: 1.4571, X6CrNiMoTi17-12-2
Electrode rod insulation: PTFE
Terminal box: 3.2161 G AlSi8Cu3
NRGT 26-1S: Flange 1.0460 P250GH
NRGT 26-1S: Spacer disc: PTFE
NRGT 26-1
Length of installation 373 477 583 688 794 899 1004 1110
at 238°C
Measuring range 300 400 500 600 700 800 900 1000
Length of installation 1214 1319 1423 1528 1636 2156

at 238°C
Measuring range 1100 1200 1300 1400 1500 2000
NRGT 26-1S
Length of installation 316 420 526 631 737 842 947 1053
at 238°C
Measuring range 275 420 526 575 675 737 875 975
Length of installation 1157 1262 1366 1471 1579 2099

at 238°C
Measuring range 1075 1175 1275 1375 1475 1975
Weight
NRGT 26-1: approx. 1.8 kg
NRGT 26-1S: approx. 8.0 kg
Electronic circuit board
Supply voltage
24 V AC/DC
AC +/– 20%
DC +10 / –45%
115 V +/– 10%, 50/60 Hz (option)
230 V +/– 10 %, 50/60 Hz (option)
Power consumption
3 VA at 24 V DC
5 VA at 24, 115, 230 V AC
6
Enclosure 10174
NRGT 26-1, NRGT 26-1S - continued -
Fuse
external slow-blow 0.5 A
internal thermal fuse Tmax = 102°C
Sensitivity of response
Range 1: Water ≥ 20 µS/cm
Range 2: Water ≥ 0.5 µS/cm
Range 3: Fuel oil EL εr 2,3
Output
Actual value 4 – 20 mA, level proportional. Electrically insulated, max. load 500 Ω
Indicators and adjusters
2 red LEDs for signalling "Level 0 %" or "Level 100" within the measuring range
1 green LED for signalling “Level between 0 % and 100 %” of measuring range
1 code switch for setting the measuring range
2 adjustable resistors for small-percentage adjustment of the measuring range
2 terminal lugs for voltage measurement
2 cable glands with integral cable clamp M20 x 1.5
Screw-type terminal strip with 2 and 3 terminals, detachable, conductor size 1.5 mm2
Protection
Max. 70 °C
– 40 to + 80 °C
Approvals:
TÜV certificate VdTÜV Bulletin "Water Level 100"
Requirements made on water level limiting & control equipment.
Type approval no. TÜV . WR . 12-391, 12-425, 12-426, 12-427
(see name plate)
Marine applications DNV A-12022, KR HMB 06190-MS002, NK TA11016M, BV 10617/CO
CCS HBT 0742 1062-1, RINA ELE 407609CS, GL 992499-96 HH;
LR 98/20074 (E2)
Scope of supply
NRGT 26-1
1 Level transmitter NRGT 26-1
1 Joint ring 27 x 32, form D, DIN 7603, 1.4301, bright annealed
NRGT 26-1S (for marine applications)

1 Level transmitter NRGT 26-1S with flange DN 50, PN 40, DIN EN 1092-01
7
Enclosure 10174
Name plate/marking
Safety note
Equipment designation,
PN 40
pressure rating
PN 40
End connection,
material number
32 bar (464psi)
238°C (460°F)
Pressure/temperature rating
Tamb
70°C IP 65
(158°F)
Power rating
Measuring range
Actual value output
Type approval no.
CE Marking
Manufacturer Münchener Str. 77

D-28215 Bremen
Disposal note
Spare part specification
Fig. 1
8
Enclosure 10174
Installation
Note
 The level transmitter NRGT 26-1 can be installed together with one GESTRA level elec-
trode for water level limiting or for high-level alarm in a single protection tube or exter-
nal level pot (inside diameter 100 m). Fig. 5 - 8. If the level limiting electrode is installed
inside the vessel, it must be at least 40 mm away from the upper vent hole.
 For the approval of the boiler standpipe the relevant regulations must be considered.
 Refer to page 12 for typical installation examples.
Attention
 The level transmitter shall be installed vertically.

 The seating surfaces of the standpipe or the flange provided on the vessel must be
accurately machined, see Fig. 4.
 Do not bend electrode tip when mounting.
 Do not subject electrode to physical shocks.
 Use only the supplied joint ring.
NRGT 26-1: 27 x 32, form D, DIN 7603, 1.4301, bright annealed
 Do not lag transmitter body above the hexagonal section.
 Do not insulate transmitter thread with hemp or PTFE tape!
 Do not apply conductive paste or grease to the transmitter thread!
 Make sure that the air distance between the electrode tips and earth (flange, vessel
wall) is not less than 14 mm. Fig. 5 - 8
 Observe the minimum withdrawal distance when installing the transmitter!
 Observe the specified tightening torque.
 Do not cut the electrode rod.
9
Enclosure 10174
Dimensions NRGT 26-1, NRGT 26-1S
173 173
GESTRA Steam Systems GESTRA Steam Systems
140
140
GESTRA GESTRA
b = 68 b = 68
336
336
a a
7 7
8
37
Screwed G ¾ A, 6
62
ISO 228
5
∅48.5
1 2
4 9
NRGT 26-1 NRGT 26-1S
3
1 2 3 4
26
373 300 316 275 0

477 400 420 375
583 500 526 475
688 600 631 575
Fig. 2 794 700 737 675 ∅ 42.5
Ra 12.5
NRGT 26-1 899 800 842 775 Fig. 3

1004 900 947 875 NRGT 26-1S
1110 1000 1053 975 ∅ 33
Screwed G ¾ A,
1214 1100 1157 1075
0.5
ISO 228
1319 1200 1262 1175 Ra 3.2
1423 1300 1366 1275
1528 1400 1471 1375
1636 1500 1579 1475
2156 2000 2099 1975 Fig. 4
10
Enclosure 10174
NRGT 26-1
1. Check seating surfaces. Fig. 4

2. Place supplied joint ring 5 onto seating surface of the threaded standpipe or flange. Fig. 4
3. Apply a light smear of heat resistant silicone grease (e.g. WINIX® 2150) to electrode thread 6.
4. Screw level transmitter into threaded standpipe or flange and tighten with an open-end spanner
A. F. 41 mm. The torque required when cold is 160 Nm.
NRGT 26-1S
1. Check seating surfaces and place joint ring onto the connecting standpipe.
2. Put flange 8 with level transmitter onto connecting standpipe and bolt them together.
Tighten bolts in diagonally opposite pairs.
Key
1 + 3 Max. length of installation at 238 °C

2 + 4 Measuring range
5 Joint ring 27 x 32, form D, DIN 7603, 1.4301, bright annealed
6 Thread G ¾ A to ISO 228 of transmitter
7 Thermal insulation, provided on site, d = 20 mm (outside of thermal insulation of steam boiler)
8 Flange DN 50, PN 40, DIN EN 1092-01
9 Protection tube
0 Spacer disc
a Cable glands
Tools

11
Enclosure 10174
NRGT 26-1
G¾ G¾
b b
DN 50 c DN 50
2
c
i d
≤ 3000
20
∅ 20
∅ 20
20
e
f f
g g
k k
≥ 10
≤ 90° l ≤ 90° l
∅ 20
∅ 20
Fig. 5 Protection tube (provided on site) for installation Fig. 6 Protection tube (provided on site)
inside the boiler for installation inside the boiler
G¾ G¾ G¾
b b
c
190
≤ 20
≤ 3000
DN 20
DN 100 f e
24.5 24,5
h
j
≥ 14
Centre distance
i n
d e
∅20
f
20
k
≤ 90°
m k
≤ 20
∅ 20 DN 20
Fig. 7 Protection tube (provided on site) for installation
inside the boiler and in combination with other
GESTRA equipment
Fig. 8 External level pot

DN 20
12
Enclosure 10174
Examples of installation - continued -
Key
b Flange PN 40, DN 50, DIN EN 1092-01 (for one electrode)

Flange PN 40, DN 100, DIN EN 1092-01 (for electrode combination)
c For the approval of the boiler standpipe with connecting flange the relevant regulations
must be considered.
d Vent hole Provide vent hole as close to the boiler wall as possible!
e High water HW
f Electrode rod
g Protection tube DN 80 (in France according to AFAQ ≥ DN 100)
h Protection tube DN 100
i Distance between electrode rod and protection tube ≥ 14 mm
j Distance between electrode tip (NRG 1..-50 or NRG 1...-51) ≥ 14 mm (creepage distances
and clearances)
k Low water NW
l Reducer DIN 2616-2, K-88.9x3.2-42.4 x 2.6 W
m Reducer DIN 2616-2, K-114.3x3.6-48.3 x 2.9 W
n Level pot ≥ DN 80
.
13
Enclosure 10174
GESTRA
o q
t
r s u v
Fig. 9
23
4 56
9 1
0
78
w x
D
A z
C y
1 2 3 4 5
Fig. 10 Shown without cover plate
14
Enclosure 10174
Connection of level transmitter
A self-locking fixing nut B connects the terminal box to the electrode part. Before establishing the
electrical connection you can turn the terminal box through max. +/- 180° into the desired direction
(cable gland).
Connecting the NRGT 26-1, NRGT 26-1S
1. Unscrew housing screws o and remove housing cover p. Fig. 9

2. Remove terminal strips z and A from circuit board.
3. Strip off approx. 40 mm of cable insulation coating and remove approx. 5 mm of conductor end
insulation.
4. Loosen cable glands q. If the equipment is supplied with 24 V pull control cable through one of the
cable glands. Seal off the unused cable gland (protection IP 65). If the equipment is supplied with
115 / 230 V pull the power cable through the right cable gland and the control cable through the left.
5. Connect the individual cables according to the wiring diagram to terminal strip z and A.
6. Attach terminal strips z and A to the circuit board.
7. Tighten cable glands q.
7. Mount cover p and fasten cover screws o.
Attention
n The following relocations of cables with basic insulation are not permissible:
Mains and control cables in low voltage areas.
Key
o Cover screws (cross-recess head M4) w Potentiometer for lower measuring point
p Cover x Potentiometer for upper measuring point
q Cable glands M 20 x 1.5 y Thermal fuse TMAX 102 °C
r Selector switch for measuring range z Terminal strip for supply voltage
s LED "Level 0 %" A Terminal strip for actual-value output
t LED "Level > 0 %, < 100 % B Connection for functional earth
u LED "Level 100 %" C Fixing nut for terminal box
v Terminal lugs for voltage measurement D Fixing screw for electronic circuit board
(between 0 - 7 V, level proportional)
Tools
n Screwdriver, size 1
n Screwdriver, size 2.5, completely insulated according to DIN VDE 068001
15
Enclosure 10174
Wiring diagram for level transmitter NRGT 26-1, NRGT 26-1S
NRGT 26-1
NRGT 26-1S
DC
Supply Thermal
fuse
Earthing
screw S1 Disconnecting switch
420 mA in housing
F1 Fuse
max. load. PE
500 Ω
+ – 24V AC/DC
Fig. 11 (L) (N) optional 115/230 V AC
Connecting level transmitter NRGT 26-.. with supply voltage 24 V AC/DC
An external slow-blow fuse 0.5 A must be provided for the level transmitter. For the connection use
screened multi-core control cable with a min. conductor size 0.5 mm2, e. g. LiYCY 4 x 0.5 mm2, max.
length 100 m.
For the power supply of the level transmitter use a safety power supply unit (PSU), e.g. Siemens SITOP
PSU100C 24V/0.6A, which must provide a level of isolation against voltages that at least meets the
requirements for double or reinforced insulation as per DIN EN 50178 or DIN EN 61010-1 or
DIN EN 60730-1 or DIN EN 60950 (electrically protective separation).
Connecting level transmitter NRGT 26-.. with supply voltage 115 / 230 V AC
An external slow-blow fuse 0.5 A must be provided for the level transmitter. To connect the
voltage supply use a multi-core control cable with a min. conductor size 0.5 mm2. To connect the
actual value output use screened multi-core control cable with a min. conductor size 0.5 mm2,
e. g. LiYCY 2 x 0.5 mm2, max. length: 100 m.
Install a disconnector for all poles. Make sure it is easily accessible and in the close proximity of the
equipment (EN 61010-1). Mark this disconnecting switch as isolating device for the level transmitter.
Actual value output
Any item of equipment that you want to connect to the terminals for the actual-value output 4 - 20 mA
must be certified to have at least double or reinforced isolation according to DIN EN 50178 or
DIN EN 61010-1 or DIN EN 60730-1 or DIN EN 60950 (safe electrical isolation) between the current
loop and live parts of the equipment that are not supplied with safety extra-low voltage (SELV).
Make sure that the connecting cable is segregated and runs separately from power cables. Please
observe the max. load of 500 ohm.
16
Enclosure 10174
Basic settings
Factory setting NRGT 26-1

The level transmitter features the following factory set default values:
n Measuring range1300 mm: Switch r position 4, water ≥ 20 µS/cm
n Measuring range 1400 mm to 1700 mm: Switch r position 4, water ≥ 20 µS/cm
Factory setting NRGT 26-1S

The level transmitter features the following factory set default values:
n Measuring range1275 mm: Switch r position 4, water ≥ 20 µS/cm
Establishing active measuring range (control range)

Within the measuring range of the transmitter you can establish the active control range.
Use switch r to establish the length of the active measuring range. Switch r see Fig. 10.
X Selected (active) measuring range [mm] X 5 6 7

100 4 3 3
2 4 Measuring range [mm] = xxx % see Fig. 2 and 3
200 4 3 3
E Lower end of measuring range, adjustable
300 4 3 3
F Upper end of measuring range, adjustable
400 4 4 3
5 Water, conductivity ≥ 20 µS/cm 500 3
4 4
6 Water, conductivity ≥ 25 µS/cm 600 4 4 3
7 Fuel oil EL, dielectric constant εr 2,3 700 4 4 3
800 4 4 3
900 4 5 3
1000 4 5 3
1100 4 5 3
37
r 1200 4 5 3
F 1300 4 5 3
1400 4 5 3
1500 4 5 3
2 4 1600 5 5 3
X
1700 5 6 3
1800 5 6 4
Fig. 12 Lower measuring point 1900 5 6 4
E
26
2000 5 6 4
Attention
n If X is clearly smaller than 2 4 set switch r one step back.
17
Enclosure 10174
Danger
The terminal strip of the level transmitter is live during operation.
Use only a completely insulated screwdriver according to VDE 0680 for setting the
measuring points.
Applying supply voltage
Please check that the level transmitter is wired in accordance with the wiring diagram (Fig. 11
page 16) and switch on mains voltage. When the electrode tip is exposed the LED is illuminated s.
Fig. 10
Adjusting lower end of measuring range

1. Unscrew cover screws o and remove cover p. Fig. 9
2. Lower liquid level until the lower end of the measuring range is reached.
3. Raise the pressure in the steam boiler or vessel until the service pressure is reached.
4. Turn potentiometer w to the left until the red LED s lights up.
5. Turn potentiometer w to the right until only the green LED t lights up.
The lower end of the measuring range is now adjusted.
Adjusting upper end of measuring range

1. Fill tank and wait for 30 seconds (internal attenuation).
2. Turn potentiometer x to the right until only the red LED u lights up.
3. Turn potentiometer x to the left until the green LED t lights up.
4. Turn potentiometer x to the right until the green LED t goes out.
The upper end of the measuring range is now adjusted.
5. Mount cover p and fasten cover screws o.
Note
n When adjusting the measuring range when the system is cold, the adjusted measuring
points will shift with rising temperature as a result of the longitudinal expansion of the
electrode rod. Correct the settings accordingly.
n If a higher accuracy (for 0 % = 4 mA and 100 % = 20 mA) than ± 0.5 mA is required,
measure the level-proportional current at terminals 1 ü and 2 ä in order to establish
more accurate settings.
18
Enclosure 10174
Troubleshooting
Indication, diagnosis and remedy
Attention
Before carrying out the fault diagnosis please check:

Supply voltage:
Is the level transmitter supplied with the mains voltage specified on the name plate?
Wiring:
Is the wiring in accordance with the wiring diagram?
Malfunctions
Equipment does not work accurately
Error Remedy
The transmitter was installed without a protection
tube. The protection tube is required because it serves Install a protection tube.
as reference electrode.
The vent hole in the protection tube does not exist, is
Check protection tube and, if necessary, provide vent hole.
obstructed or flooded.
The isolating valves of the external level pot (optional)
Open isolating valve.
are closed.
The desired lower measuring point is outside the
measuring range of the transmitter. Install a sufficiently long level transmitter.
The transmitter is too short.
The adjustment of the measuring range is wrong. Correct switch r settings.

See Basic Settings
Remove level transmitter and clean the electrode tip with
The electrode rod is covered with dirt deposits.
a wet cloth.
The transmitter is defective. Actual value output
Replace level transmitter.
(terminals 1 and 2) > 20 mA. Fig. 11
Equipment fails to work

Error Remedy
Switch on supply voltage.
Power failure.
Check all electrical connections.
Discard and replace defective thermal fuse. Stock code
Thermal fuse y defective. # 052433.Check ambient temperature, make sure that it
does not exceed 70° C.
Clean seating surfaces and screw in the level transmit-
ter together with the joint ring 27 x 32, form D, DIN 7603
The earth connection to the vessel is interrupted.
(made from 1.4301), bright annealed. Do not insulate the
level transmitter with hemp or PTFE tape!
Electronic circuit board defective Exchange the electronic insert.
19
Enclosure 10174
Troubleshooting - continued -
Replacing electronic circuit board
1. Unscrew cover screws o and remove housing cover p.

2. Pull electrode wires from terminal lugs on circuit board. Detach terminals strips z A.
3. Undo the functional earth B connection.
4. Unscrew the fixing screws D for the electronic circuit board and take out the circuit board.
The circuit board is available as spare part.
Stock code # NRGT 26-1 NRGT 26-1S
321317 230 V AC
321340 115 V AC
321354 24 V AC/DC
321319 230 V AC
321342 115 V AC
321355 24 V AC/DC
5. Install the new electronic circuit board in reverse order.
Note
When ordering spare parts please state the material number indicated on the name plate.
After replacing the electronic circuit board please re-commission the equipment.
20
Enclosure 10174
Maintenance
Safety note
The equipment must only be installed, wired and commissioned by qualified and competent staff.
Danger
When loosening the level transmitter steam or hot water might escape!
It is therefore essential not to dismantle the level transmitter unless the boiler pressure is
The level transmitter becomes hot during operation.
Risk of severe burns to hands and arms.
Before carrying out installation and maintenance work make sure that the equipment is
cold.
Cleaning the electrode rod
The equipment may only be installed and removed by qualified personnel. Observe note in chapter
"Installation" on page 11.
Before cleaning the electrode rod decommission and remove the level transmitter.
Clean the electrode rod with a wet cloth.
Removing and disposing of the level transmitter
Removing and disposing of level transmitter NRGT 26-1, NRGT 26-1S
1. Switch off supply voltage.

2. Unscrew cover screws o and remove housing cover p.
3. Disconnect the connecting wires from the terminal strips z A and pull wires out of the cable gland.
4. Before removing the equipment make sure that is is neither hot nor under pressure.
For the disposal of the level transmitter observe the pertinent legal regulations concerning waste
disposal.
If faults occur that are not listed above or cannot be corrected, please contact our service centre or
authorized agency in your country.
21
Enclosure 10174
For your Notes
22
Enclosure 10174
For your Notes
23
Enclosure 10174
GESTRA

www.gestra.com

Fax 0044 16 35 / 3 60 34 Kempton Park 1613
Singapore
12 Tuas Avenue 20
Tel. 0065 / 68 79 89 00 2341 Ampere Drive
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Tel. 0049 (0) 421 / 35 03-0
Fax 0049 (0) 421 / 35 03-393
Web www.gestra.com
810213-09/05-2013cm (808437-13) ·GESTRA AG · Bremen · Printed in Germany

24
ARI-TEMPTROL®
10203 Temperature reglator
Temperature reglator
DN 15 - 100
ARI-TEMPTROL®
Thermal closing valve
straight through with flanges
Fig. 771 Fig. 772 Page 2

Fig. 771
ARI-TEMPTROL® LCG
straight through with screwed sockets
without balanced bellow
Fig. 771....2..1 Fig. 771/772....2..1
SA105
Page 4
ARI-TEMPTROL® Fig. 775

Thermal opening valve
Fig. 775
Page 6
ARI-TEMPTROL® LCG
straight through with screwed sockets Fig. 773
Fig. 775....2..1
Page 8
IN EN
p ro v a l acc. to D /TW911
p
• TÜV-a Reg.-No. TR910
14597 /
gh
ARI-TEMPTROL® ed throu
• Approv ischen Lloyd
Thermal mixing/diverting valve German
3-way form with flanges
Features:
• Self-operating (no auxilary power required)
• Reliable, low maintenance operation
• Over-temperature safety device
ARI-TEMPTROL® LCG • Valves pressure balanced with stainless
steel bellows
Thermal mixing/diverting valve • 3 thermal controller sizes for optimal
3-way form with screwed sockets without selection of proportional range
balanced bellow • Thermal sensors with different time
constants
Fig. 773....2..1 • Exact and easy adjustment
Page 12
• Setting range is adjustable
• Sensor pocket
• Manual control device
ARI-TEMPTROL®
10203 Thermal closing valve
Thermal closing valve straight through with flanges

12.771 / 12.772 PN16 EN-JL1040 DN15-100
22.771 / 22.772 PN16 EN-JS1049 DN15-100
23.771 / 23.772 PN25 EN-JS1049 DN15-100
35.771 / 35.772 PN40 1.0619+N DN15-100
55.771 / 55.772 PN40 1.4408 DN15-100

Industrial heating and ventilation systems, residential applications, marked-warehouses,
ship building, cooling systems, etc..
Fluids, air and steam
Construction LC without balanced bellow

12.771....1..1
PN16 EN-JL1040 DN15-50
12.772....1..1
Fig. ...771 max. 150°C
Fig. 12.771....1..1 max. 130°C
Fig. 12.772....1..1 with cooling spacer max. 250°C
Fig. ...772 with cooling spacer max. 300°C

ARI-TEMPTROL®
DN 15 20 25 32 40 50 65 80 100
L (mm) 130 150 160 180 200 230 290 310 350
Fig. 771 H (mm) 160 160 195 195 215 255 260 320 340
Weight (kg) 3,4 4,2 5,3 6,9 8,8 12,4 23 29 38
Fig. 772 H (mm) 305 305 340 340 360 400 405 455 485
Weight (kg) 4,3 5,1 6,3 7,9 9,7 13,3 24 30 39
Fig. 771...1..1 (LC) H (mm) 125 125 125 125 130 135 -- -- --
Weight (kg) 2,5 3,5 5 6 8 10 -- -- --
Fig. 772...1..1 (LC) H (mm) 270 270 270 270 275 280 -- -- --
Weight (kg) 3,5 4,5 6 7 9 11 -- -- --

Kvs-value
DN 15 20 25 32 40 50 65 80 100
Standard Kvs-values (m3/h) 4,0 6,3 10,0 16,0 22,0 32,0 50,0 70,0 80,0
Travel (mm) 7,5 7,5 8 9,5 9,5 11,5 14 15 15
Reduced Kvs-values (m3/h) 0,4 1,0 -- -- -- -- -- -- -- --
Travel (mm) 5 5 -- -- -- -- -- -- -- --
Leakage rate IV acc. to DIN EN 1349 (≤ 0,01% from the nominal flow)
Max. differential pressure drop Δp

DN 15 20 25 32 40 50 65 80 100
Fig. 771
Straight through (bar) 16 16 16 16 12 9 9 9 9
Fig. 772
Fig. 771...1..1 (LC)
Straight through (bar) 9,3 9,3 5,6 4,1 2,3 1,5 -- -- --
Fig. 772...1..1 (LC)
Pressure balancing of the actuator needed: P1 > Δp (e.g. P1=12 bar, Δp=9 bar). For pressure balancing use manual control device (Type 9900390011).
Parts
Pos. Description Fig. 12.771 Fig. 22./23.771 Fig. 35.771 Fig. 55.771
Fig. 12.772 Fig. 22./23.772 Fig. 35.772 Fig. 55.772
EN-JS1049, GX5CrNiMo19-11-2,
1 Body EN-JL1040, EN-GJL-250 GP240GH+N, 1.0619+N
EN-GJS-400-18U-LT 1.4408
2 Seat X6CrNiTi18-10, 1.4541
3 Cylinder screw A2-70
5 Guide bushing X6CrNiTi18-10, 1.4541
7 Gasket * Graphite
X6CrNiMoTi17-12-2,
11 Hood EN-JS1049, EN-GJS-400-18U-LT
1.4571
14 Spindle unit * X6CrNiTi18-10, 1.4541
19 Pressure piece X6CrNiTi18-10, 1.4541
21 Hexagon nut A2-70
28 Cooling spacer EN-JS1049, EN-GJS-400-18U-LT X6CrNiTi18-10, 1.4541
37 Spring * X12CrNi17-7, 1.4310
55 Balanced bellow * X6CrNiTi18-10, 1.4541
* Spare part


ARI-TEMPTROL® LCG
Thermal closing valve straight through with screwed sockets without balanced bellow

72.771....2..1 PN16 CC491K G1/2” - G1”

Liquids and Luft

45.771....2..1
PN40 SA105 G1/2” - G2”
45.772....2..1
Fig. 72.771....2..1 max. 130°C Fig. 45.771....2..1 max. 130°C

ARI-TEMPTROL® LCG

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Ø G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
L (mm) 80 90 110 120 130 150
L1 (mm) 128 138 166 -- -- --
Fig. 771....2..1 H (mm) 283 283 289 -- -- --
H1 (mm) 55 55 55 -- -- --
H3 (mm) 65 65 66 -- -- --
Weight (kg) 2,9 3,1 3,7 -- -- --
Fig. 45.771....2..1 H (mm) 127 127 131 138 138 140
Weight (kg) 2,5 3,5 5 6 8 10
Fig. 45.772....2..1 H (mm) 272 272 276 283 283 285
Weight (kg) 3,5 4,5 6 7 9 11
Kvs-value
DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Kvs-value (m3/h) 4,0 6,3 10,0 -- -- --
Fig. 72.771....2..1
Travel (mm) 7,5 7,5 8 -- -- --
Fig. 45.771....2..1 Kvs-value (m3/h) 3,1 5,5 8,6 12,8 20 26
Fig. 45.772....2..1 Travel (mm) 7,5 7,5 8 9,5 9,5 11,5

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Fig. 72.771....2..1 Straight through (bar) 9,3 9,3 5,6 -- -- --
Fig. 45.771....2..1
Straight through (bar) 9,3 9,3 5,6 4,1 2,3 1,5
Fig. 45.772....2..1
Pressure balancing of the actuator needed: P1 > Δp (e.g. P1=12 bar, Δp=9,3 bar). For pressure balancing use manual control device (Type 9900390011).
Parts
Pos. Description Fig. 72.771....2..1 Fig. 45.771....2..1 / Fig. 45.772....2..1
1 Body CuSn5Zn5Pb5-C, CC491K SA105
1.2 Seat -- X6CrNiTi18-10, 1.4541
3 Cylinder screw A4-70 A2-70
4 Plug * CuZn39Pb3, CW614N --
5 Guide bushing -- X6CrNiTi18-10, 1.4541
6 O-ring * EPDM --
7 Gasket * -- Graphite
8.1 Screw joint CuZn39Pb3, CW614N --
8.2 Retaining ring CuSn8, CW453K --
8.3 O-ring * EPDM --
8.4 Bushing PTFE --
8.5 Washer CuZn37, CW508L --
11 Hood CuZn39Pb3, CW614N EN-JS1049, EN-GJS-400-18U-LT
13 Sealing ring Centellen --
14 Stem / Spindle unit * X6CrNiMoTi17-12-2, 1.4571 X6CrNiTi18-10, 1.4541
15 Sleeve nut TMP / chrom. --
16 Blind plate S235JR, 1.0037 --
21 Hexagon nut A2 A2-70
28 Cooling spacer -- EN-JS1049, EN-GJS-400-18U-LT
35 Spring plate X6CrNiTi18-10, 1.4541 --
36 Spring plate X6CrNiMoTi17-12-2, 1.4571 --
37 Spring * X10CrNi18-8, 1.4310
* Spare parts
A production allowance acc. to TRB 801 No. 45 exists.

ARI-TEMPTROL®
10203 Thermal opening valve
Thermal opening valve straight through with flanges

12.775 PN16 EN-JL1040 DN15-100
22.775 PN16 EN-JS1049 DN15-100
23.775 PN25 EN-JS1049 DN15-100
35.775 PN40 1.0619+N DN15-100
55.775 PN40 1.4408 DN15-100


12.775....1..1 PN16 EN-JL1040 DN15-50
Fig. ...775 max. 150°C (> 150°C on request)
Fig. 12.775....1..1 max. 130°C (> 130°C on request)

ARI-TEMPTROL®
DN 15 20 25 32 40 50 65 80 100
L (mm) 130 150 160 180 200 230 290 310 350
Fig. 775 H (mm) 195 195 200 225 245 280 300 365 385
Weight (kg) 5,4 6,8 9,1 11,9 17 19,5 30 37 46
Fig. 775....1..1 (LC) H (mm) 125 125 130 155 160 160 -- -- --
Weight (kg) 4,5 6 8 10,5 15 17 -- -- --

Kvs-value
DN 15 20 25 32 40 50 65 80 100
Travel (mm) 7,5 7,5 8 9,5 9,5 11,5 14 15 15
Reduced Kvs-values (m3/h) 1,0 -- -- -- -- -- -- -- --
Travel (mm) 5 -- -- -- -- -- -- -- --

DN 15 20 25 32 40 50 65 80 100
A AB
Fig. 775 (bar) 12 4 4 4 4 4 4 4 4
Straight through
A AB
Fig. 775....1..1 (LC) (bar) 3 3 2,5 1,5 1 0,5 -- -- --
Straight through
Parts
EN-GJS-400-18U-LT 1.4408
1.2 Seat X20Cr13+QT, 1.4021+QT X6CrNiMoTi17-12-2, 1.4571
4 Plug guiding X20Cr13+QT, 1.4021+QT X6CrNiTi18-10, 1.4541
5 Guide bushing X20Cr13+QT, 1.4021+QT X6CrNiTi18-10, 1.4541
7 Gasket * Graphite
11 Hood EN-JS1049, EN-GJS-400-18U-LT X6CrNiMoTi17-12-2, 1.4571
14 Spindle unit * X20Cr13+QT, 1.4021+QT / X6CrNiTi18-10, 1.4541 X6CrNiTi18-10, 1.4541
23 Hexagon nut C35E, 1.1181 -A2B A4-70
24 Hexagon screw 5.6-A2B A4-70
25 Flange S235JR, 1.0037 X6CrNiTi18-10, 1.4541
26 Gasket * Graphite (with CrNi-Streckmetalleinlage)
37 Spring * X12CrNi17-7, 1.4310
* Spare part


ARI-TEMPTROL® LCG
Thermal opening valve straight through with screwed sockets without balanced bellow

72.775....2..1 PN16 CC491K G1/2” - G2”

Fig. 72.775....2..1 max. 130°C

ARI-TEMPTROL® LCG

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Ø G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
L (mm) 80 90 110 120 130 150
L1 (mm) 128 138 166 186 199 223
Fig. H (mm) 283 283 289 293 302 302
775....2..1
H1 (mm) 55 55 55 55 60 65
H2 (mm) 79 79 83 88 95 102
Weight (kg) 2,4 2,6 3,2 4,1 4,7 6,3

Kvs-value
DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Kvs-value (m3/h) 4,0 6,3 10,0 16,0 25,0 40,0
Travel (mm) 14 14 14 14 14 14

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
A AB
(bar) 3 3 2,5 1,5 1 0,5
Straight through
Parts
1 Body CuSn5Zn5Pb5-C, CC491K
4 Plug * CuZn39Pb3, CW614N
6 O-ring * EPDM
8.1 Screw joint CuZn39Pb3, CW614N
8.2 Retaining ring CuSn8, CW453K
8.3 O-ring * EPDM
8.4 Bushing PTFE
8.5 Washer CuZn37, CW508L
8.6 O-ring * EPDM
11 Hood CuZn39Pb3, CW614N
13 Sealing ring Centellen
14 Stem * X6CrNiMoTi17-12-2, 1.4571
15 Sleeve nut TMP / chrom.
16 Blind plate S235JR, 1.0037
17 Retaining ring FSt
18 O-ring * EPDM
21 Hexagon nut A2
22 Washer A2
35 Spring plate X6CrNiTi18-10, 1.4541
36 Spring plate X6CrNiMoTi17-12-2, 1.4571
37 Spring * X10CrNi18-8, 1.4310
* Spare parts

ARI-TEMPTROL®
10203 Thermal mixing/diverting valve
Thermal mixing/diverting valve in 3-way form with flanges

12.773 / 12.774 PN16 EN-JL1040 DN15-100
22.773 / 22.774 PN16 EN-JS1049 DN15-100
23.773 / 23.774 PN25 EN-JS1049 DN15-100
35.773 / 35.774 PN40 1.0619+N DN15-100
55.773 / 55.774 PN40 1.4408 DN15-100

Mixing function Diverting function

Fig. ...773 max. 150°C 12.773....1..1
PN16 EN-JL1040 DN15-50
12.774....1..1
Fig. 12.773....1..1 max. 150°C

ARI-TEMPTROL®

DN 15 20 25 32 40 50 65 80 100
L (mm) 130 150 160 180 200 230 290 310 350
Fig. 773 H (mm) 195 195 200 225 245 280 300 365 385
Weight (kg) 4,4 5,8 7,6 9,9 14,5 16,5 25 31 38
Fig. 774 H (mm) 340 340 345 370 390 425 445 510 530
Weight (kg) 5,4 6,8 8,6 10,9 15,5 17,5 26 32 39
Fig. 773....1..1 H (mm) 125 125 130 155 160 160 -- -- --
(LC) (kg) 3,5 5 6,5 8,5 12,5 14 -- -- --
Weight
Fig. 774....1..1 H (mm) 270 270 275 300 305 305 -- -- --
(LC) (kg) 4,5 6 7,5 9,5 13,5 15 -- -- --
Weight
Kvs-value
DN 15 20 25 32 40 50 65 80 100
Travel (mm) 7,5 7,5 8 9,5 9,5 11,5 14 15 15
Travel (mm) 5 -- -- -- -- -- -- -- --

DN 15 20 25 32 40 50 65 80 100
pB > pA (Δp = pB - pA) (bar) 12 16 16 16 12 9 9 9 9
pA > pB (Δp = pA - pB) (bar) 12 4 4 4 4 4 4 4 4

Fig. 773 Mixing function
Fig. 774
pAB > pB
(bar) 12 4 4 4 3 1,5 0,7 0,25 0,15
pAB > pA
Diverting function
pAB > pB
(bar) 3 3 2,5 1,5 1 0,5 -- -- --
pAB > pA
Fig. 773....1..1 (LC) Mixing function
Fig. 774....1..1 (LC)
(bar) 3 3 2,5 1,5 1 0,5 -- -- --
Diverting function
Parts
Fig. 12.774 Fig. 22./23.774 Fig. 35.774 Fig. 55.774
EN-GJS-400-18U-LT 1.4408
7 Gasket * Graphite
37 Spring * X12CrNi17-7, 1.4310
* Spare part

ARI-TEMPTROL® LCG
Thermal mixing/diverting valve in 3-way form with screwed sockets without balanced bellow

72.773....2..1 PN16 CC491K G1/2” - G2”

Fig. 72.773....2..1 max. 130°C

ARI-TEMPTROL® LCG

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Ø G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
L (mm) 80 90 110 120 130 150
L1 (mm) 128 138 166 186 199 223
Fig. 773 H (mm) 136 136 142 146 155 155
H1 (mm) 55 55 55 55 60 65
H2 (mm) 79 79 83 88 95 102
Weight (kg) 2,4 2,6 3,2 4,1 4,7 6,3

Kvs-value
DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Standard Kvs-values (m3/h) 4,0 6,3 10,0 16,0 25,0 40,0
Travel (mm) 14 14 14 14 14 14

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
(bar) 3 3 2,5 1,5 1 0,5

Mixing function
(bar) 3 3 2,5 1,5 1 0,5

Diverting function
Parts
4 Plug CuZn39Pb3, CW614N
6 O-ring * EPDM
8.3 O-ring * EPDM
8.4 Bushing PTFE
8.6 O-ring * EPDM
14 Stem * X6CrNiMoTi17-12-2, 1.4571
18 O-ring * EPDM
21 Hexagon nut A2
22 Washer A2
37 Spring * X10CrNi18-8, 1.4310
* Spare parts

ARI-TEMPTROL®
10203 Application / Kvs-value / Selecting the controller
Application / Operating principle
Thermal control devices are used to regulate temperature of fluids, air and steam. You will find them in industrial heating and ventilation systems, in residential applications, in
marked-warehouses, ship building and also in cooling systems.
The ARI-Temperature Regulator (TEMPTROL) works on the principle of thermal expansion. For operation no extra energy is needed, self acting. Changes in temperature lead
to changes in fluid volume in the capillary tube, which means a certain stroke in the actuator onto the valve spindle. The excess temperature protector prevents an unnecessary
load on the controller when the temperature is to high on the thermal sensor. The setting range can be adjusted precisely with the adjusting knob to the required temperature
value. If a manual control device is fitted, the stroke position is shown and the valve can be operated manually. With thermal detectors acc. to DIN EN 14597, the intended
value can only be adjusted with tools.
Ambient temperature: max. 70°C for indicator unit (DIN EN 14597 T70)
Operating principle:
Thermal closing valve: - closes with rising temperature
Thermal opening valve: - opens with rising temperature

- reduces or closes inlet B with rising temperature
Thermo-3-way mixing valve: (at mixing function, the warmer medium must be put into inlet B)
Thermo-3-way diverting valve: - reduces resp. closes output B with rising temperature
Selecting the valve

To select the nominal diameter it is necessary to know the Kvs-value.
This can be done using the calculation program „MyValve“ (Module „ARI-Temperature reglator TEMPTROL-Calculation“).
The following data is needed
- Medium
- Temperature
- Flow capacity (Q)
- Upstream pressure (p1)
- Downstream pressure (p2)
Then the thermal controller with the next highest Kvs-value is selected (see table). With „MyValve“ you can also calculate the velocities in the piping, before and behind the
valve, and if necessary select the right piping size.
For selecting a valve, the pressure-temperature-ratings must be observed (see page 15), also the corrosive aspect.
If at thermal opening valves and at thermal mixing/diverting valves Δ p > P1 , then a perforated plug is recommended.
2
Selecting the controller

The following must be observed:
- Type selecting acc. to the used medium
(rod sensor, spiral sensor for gas, spiral sensor for liquids, with thread or flange).
- The temperature range.
- Installation place of thermal sensor, set point adjusting unit and valve (length of capillary tubes)..
Then the thermal controller is selected using the recommended proportional range (see page 17).
The proportional range shows by which temperature alteration on the thermal sensor, the valve needs from open to closed position. Preferably use the range between 10 and
15 K. It is also possible to use the other ranges, if the calculation of the control loop finds this necessary. We strongly advise that you check the systems transient response.

ARI-TEMPTROL®
Standard-flange dimensions Flanges acc. to DIN EN 1092-2 (Flange holes / -thickness tolerances acc. to DIN)
DN (mm) 15 20 25 32 40 50 65 80 100
PN16 ØD (mm) 95 105 115 140 150 165 185 200 220
PN16 ØK (mm) 65 75 85 100 110 125 145 160 180
PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18
PN25 ØD (mm) 95 105 115 140 150 165 185 200 235
PN25 ØK (mm) 65 75 85 100 110 125 145 160 190
PN40 ØD (mm) 95 105 115 140 150 165 185 200 235
PN40 ØK (mm) 65 75 85 100 110 125 145 160 190

Material -60°C to <-10°C* -10°C to 120°C 150°C 200°C 250°C 300°C
EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6
EN-JS1049 16 (bar) on request 16 15,5 14,7 13,9 12,8
EN-JS1049 25 (bar) on request 25 24,3 23 21,8 20

Material -60°C to <-10°C* -10°C bis120°C 150°C 200°C 250°C 300°C
1.0619+N 40 (bar) 30 40 38,1 35 32 28
SA105 40 (bar) 30 40 38,1 35 32 28
DN100 max. 26 bar

1.4408 40 (bar) 40 40 36,3 33,7 31,8 29,7
DN100 max. 26 bar

Material -10°C to 20°C 100°C 130°C
CC491K 16 (bar) 16 16 16

- Figure-No. - Kvs-value
- Nominal diameter - ΔP Dimensions in mm
- Nominal pressure - Medium Weights in kg
- Body material Ordering data for controller: refer to Seiite 16. Pressures in barg (gauge)
Figure 22.772; Nominal diameter DN25; Nominal pressure PN16; Body material EN-JS1049; Kvs 10, ΔP 3 bar, Water. Kvs in m3/h

ARI-TEMPTROL®
10203 Thermal controller / detector - Types
Type
Temperature Time constant
Thermal Size range Temperature sensor version
Thermal detector without sensor pocket
controller
9900386011 9900387611 I Temperature sensor and

-20 ... +50°C
setpoint adjusting knob in
0 ... +70°C
9900386021 9900387621 II one unit.
+30 ... +100°C
Stainless steel 1.4541
+60 ... +130°C
9900386031 9900387631 III (optional sensor pocket)
75 s 2)
measured with water
9900386041 9900387641 I (flow rate 0,2 - 0,3 m/s)
rod sensor, nickel-plated brass

9900386051 9900387651 II
(optional sensor pocket)
9900386061 9900387661 III
9900386071 9900387671 I
Spiral sensor for gas, Copper

9900386081 9900387681 II
blank with flange
-20 ... +50°C
9900386091 9900387691 III 0 ... +70°C 80 s
+30 ... +100°C measured with air
9900386101 9900387701 I +60 ... +130°C (flow rate 3m/s)
+130 ... +200°C
Spiral sensor for gas Copper
9900386111 9900387711 II
blank with bracket
9900386121 9900387721 III
9900386131 9900387731 I
80 s 2) Rod sensor, Stainless steel
9900386141 9900387741 II measured with water 1.4541
(flow rate 0,2 - 0,3 m/s) (optional sensor pocket)
9900386151 9900387751 III
9900386311 9900387911 I
-20 ... +50°C
0 ... +70°C Spiral sensor for liquids and
9900386321 9900387921 II
+30 ... +100°C gas, nickel-plated copper
+60 ... +130°C
9900386331 9900387931 III 15 s
measured with water
9900386341 9900387941 I (flow rate 0,2 - 0,3 m/s)
-20 ... +50°C
0 ... +70°C
Spiral sensor for liquids and
9900386351 9900387951 II +30 ... +100°C
gas, Stainless steel 1.4541
+60 ... +130°C
9900386361 9900387961 III +130 ... + 200°C
9900387461 I
75 s 3) rod sensor, nickel-plated brass
+35 ... +105°C Flow temperature sensor (optional sensor pocket)
9900387471 I
trend scale measured with water outdoor rod sensor, stainl. st.
(flow rate 0,2 - 0,3 m/s) 1.4541 (with bracket)
9900387481 III
V1 : V2 = 1 : 2,5 1)
9900387491 I
80 s Spiral sensor for gas, Copper
+10 ... +50°C Air intake temperature sensor blank with flange outdoor rod
9900387501 II
trend scale measured with air sensor, stainl. st. 1.4541
(flow rate 3m/s) (with bracket)
9900387511 III
V1 : V2 = 1,8 : 1 1)
9900387581 I
9900387591 II
9900387601 III
V1 : V2 = 1 : 1,9 1)
1) V1 = Volume of controlled volume sensor 2) with brass sensor pocket: 100 s 3) with brass sensor pocket: 125 s
V2 = Volume of outside temperature sensor with stainless steel sensor pocket: 115 s with stainless steel sensor pocket: 145 s

ARI-TEMPTROL®
10203 Thermal controller / detector - Technical data
Proportional range (Combination controller with valve in Kelvin) 1)
DN 15 20 25 32 40 50 65 80 100
Controller size l 10 10 15 15 17 20 20 24 37 39 39
Controller size lI 7,5 7,5 10 10 12 13 13 16 27 29 29

Controller size lII 5 5 6,5 6,5 7,5 8,5 8,5 10 20 21 21
Proportional range Fig. 773 LCG Thermal mixing valve / Fig. 775 LCG Thermal opening valve (Combination controller with valve in Kelvin) 1)
DN 15 20 25 32 40 50
G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
Controller size l 29 29 29 29 29 29
Controller size lI 19 19 19 19 19 19
Controller size lII 12 12 12 12 12 12
= recommended combinations
1) The proportional range determines at what change in sensor temperature the valve will move from totally open to totally closed.
Setting diagrams
(only for temperature regulators with two temperature sensors and trend scale)
Outdoor temperature Outdoor temperature

Setting range +35°C to +105°C Setting range +30°C to +90°C
Type 9900387461 ... 481 Type 9900387581 ... 601
Adjusting knob
trend scale
(only type 9900387461 ... 601)
Body
Indicator unit
Setting range +10°C to +50°C Outdoor temperature

Type 9900387491 ... 511

- Thermal controller / detector (Type-No.)
- Temperature range
Please indicate in your order, if
- Length of capillary tube (refer to page 19: L1 ... L4) the valves are to be installed in
- Top mounted handwheel hazardous areas (ATEX)
- Sensor pocket
Example:
Type 9900386041; temperature range 0...70°C; length of capillary pipe 4m + 4m., Top mounted handwheel, Sensor pocket 990038600Z31

ARI-TEMPTROL®
Type 9900386041 ... 061

Type 9900387641 ... 661
Type 9900386011 ... 031 Type 9900386071 ... 091

Type 9900387611 ... 631 Type 9900387671 ... 691
Type 9900386101 ... 121 Type 9900386131 ... 151 Type 9900386311 ... 361
Type 9900387701 ... 721 Type 9900387731 ... 751 Type 9900387911 ... 961
Type 9900387461 ... 481

Type 9900387581 ... 601 Type 9900387491 ... 511

ARI-TEMPTROL®
Type h1 h2 t1 t2 t3 L1 L2 L3 L4 Weight
Thermal (mm) (mm) (mm) (mm) (mm) (m) (m) (m) (m) (kg)
Thermal detector
controller
9900386011 9900387611 269 339 1,8
9900386021 9900387621 347 557 2,4,8,16 3
9900386031 9900387631 347 857 3,3
9900386041 9900387641 240 239 256 3,2
9900386051 9900387651 318 389 390 3,5
9900386061 9900387661 318 559 600 4
9900386071 9900387671 240 239 151 3,2
9900386081 9900387681 318 389 207 4,2
9900386091 9900387691 318 559 305 4,5
9900386101 9900387701 240 239 184 3
9900386111 9900387711 318 389 240 4
9900386121 9900387721 318 559 338 4,2
2,4,8,16 1) 2,4,8,16 1)
9900386131 9900387731 240 239 256 3,2
9900386141 9900387741 318 389 390 3,5
9900386151 9900387751 318 559 600 4
9900386311 9900387911 240 239 266 3,5
9900386321 9900387921 318 389 394 4,5
9900386331 9900387931 318 559 598 5
9900386341 9900387941 240 239 266 3,5
9900386351 9900387951 318 389 394 4,5
9900386361 9900387961 318 559 598 5
9900387461 240 201 239 257 708 4,4
9900387471 318 201 389 391 1078 5,1
9900387481 318 477 559 601 839 7
9900387491 240 201 239 207 257 5
9900387501 318 201 389 305 384 2,4,8,16 1) 2,4,8,16 1) 2,4,8,16 1) 0,8 5,8
9900387511 318 477 559 477 585 7,3
9900387581 240 201 239 257 542 4,2
9900387591 318 201 389 391 824 4,8
9900387601 318 477 559 601 642 6,5
1) max. permissible length (L1+L2+...) = 24 m
Parts
Pos. Description *
50.1 Thermal sensor Constructions refer to page16
50.2 Screw joint X6CrNiMoTi17-12-2, 1.4571
50.3 Sleeve nut X6CrNiMoTi17-12-2, 1.4571
50.11 Pipe Al (painted)
50.13 Indicator unit ABS (Plastic)
50.15 Capillary tube Cu (tin plated)
50.16 Actuator X6CrNiTi18-10, 1.4541
* Spare part (cpl. unit)

ARI-TEMPTROL®
10203 Accessories
Manual control device Type 9900390011

• Installed as an accessory between controller and valve.
• Allows valve to be operated independently of the controller.
• Valve position indicator (pin) plus two movable wire set rings mark the max. positions
(totally open and totally closed) (Pos. 60.3).
• Enables a pressure relif of the actuator.
Function:
The spindle of the manual control device transfers the travel of the actuator onto the valve.
The valve and manual control device is sealed metal to metal.
The spindle is sealed with an o-ring and PTFE-strip band.
Parts
Pos. Description * Type 9900390011
60.1 Sealing unit CuZn39Pb3, CW614
60.2 Position tube 11SMn30+C, 1.0715+C
60.3 Retaining ring (Travel indicator) X12CrNi17-7, 1.4310
60.4 Ground unit CuZn39Pb3, CW614N
60.5 Adjusting ring CuZn39Pb3, CW614N
60.9 Ball grip Plastic
60.14 Sleeve nut St Fe/Zn 12C
Sensor pocket
A sensor pocket eliminates the need to empty the system when replacing the temperature sensor.
Technical data
Construction Brass Stainless steel
Material CW508L, CuZn37 X6CrNiTi18-10, 1.4541
max. pressure (bar) 25 40
max. Temperature (°C) 130 250

Type
L Weight
Thermal Thermal Sensor pocket Sensor pocket (mm) (kg)
controller detector Brass Stainless steel
9900386011 9900387611 990038600Z22 990038600Z32 344 0,5
9900386021 9900387621 990038600Z24 990038600Z34 562 0,7
9900386031 9900387631 990038600Z26 990038600Z36 862 1,0
9900386041 9900387641 990038600Z21 990038600Z31 262 0,4
9900386051 9900387651 990038600Z23 990038600Z33 396 0,6
9900386061 9900387661 990038600Z25 990038600Z35 606 0,8
9900386131 9900387731 990038600Z21 990038600Z31 262 0,4
9900386141 9900387741 990038600Z23 990038600Z33 396 0,6
9900386151 9900387751 990038600Z25 990038600Z35 606 0,8
Steam injector BR 651

• Steam injector without moving parts
• Direct condensation of steam for heating water (acc. to PED 97/23/EC fluid group 2)
• The released heat of condensation of the vapor is transferred directly to the water
• Installation position horizontally
(Further informations about the accessories can be found in the appropriate data sheets.)
Fig. 651....2 Fig. 651....4


10203

Temperature regulator TEMPTROL®
Fig. 771/772
Fig. 775 Fig. 773/774

Thermal opening valve Thermal mixing/diverting valve
Contents
1.0 General information on operating instructions....2 5.3 Installation instructions concerning actuators
(Connection of valve with thermal controller) .................9
2.0 Notes on possible dangers ....................................2
5.4 Manual control device .....................................................10
2.1 Significance of symbols ................................................... 2
5.5 Strainer ........................................................................... 11
2.2 Explanatory notes on safety information .......................... 2
6.0 Putting the valve into operation...........................11
3.0 Storage and transport ............................................3
6.1 Setting range...................................................................12
4.0 Description ..............................................................3 6.1.1 Controller....................................................................12
4.1 Scope of applications ....................................................... 3 6.1.2 Detector......................................................................13
4.2 Operating principles ......................................................... 4 6.2 Setting correction ............................................................13
4.3 Diagram ........................................................................... 4 7.0 Care and maintenance ......................................... 13
4.3.1 Parts ............................................................................ 4
8.0 Troubleshooting ................................................... 14
4.4 Technical data - remarks .................................................. 5
4.5 Marking ............................................................................ 6 9.0 Troubleshooting table ......................................... 14
5.0 Installation ...............................................................7 10.0 Dismantling the valve or the top part .............. 15
5.1 General notes on installation............................................ 7 11.0 Warranty / Guarantee ......................................... 15
5.2 Requirements at the place of installation ......................... 8 12.0 EC declaration of conformity ............................ 16
5.2.1 Thermo controller with 2 temperature sensors ............ 8
5.2.2 Selection of temperature sensor- Location.................. 9
Rev. 0040702000 3310 englisch

10203 TEMPTROL®

and repair.

ATTENTION !


Information marked with the above symbol and “ATTENTION !” describe practices, a failure
to property.
Page 2 Rev. 0040702000 3310

10203 TEMPTROL®

ATTENTION !
- Valve mountings such as actuator, capillary tube, bonnets, temperature sensors
must not be exposed to external forces, e.g. they are not designed for use as
climbing aids, or as connecting points for lifting gear.
Refer to catalogue sheet for weights.
- At -20°C to +65°C.
4.0 Description
Temperature regulators are used for „regulating the temperature of fluids, air or steam used
in heating and ventilation systems for industrial or residential applications, ocean going
vessels and also in cooling systems“ and complies to type of operating mode 2B acc. to
DIN EN 14597.
ATTENTION !
to TRD 110.
Rev. 0040702000 3310 Page 3

10203 TEMPTROL®

The temperature regulator TEMPTROL® is a self acting proportional controller for
temperature of fluid, gas and vapour media of Fluid Group I pursuant to Pressure
Equipment Directive 97/23/EC. No auxiliary energy is needed.
The temperature regulator is a combination of controller and valve and is working acc. to
the principle liquid expansion by changing temperatures.
- Thermal closing valves reduce the flow with rising sensor temperature (heating
application).
- Thermal opening valves raise the flow with rising sensor temperature (cooling
application).
- Thermal mixing valves mix 2 flows (inlet A and inlet B to outlet AB).
- Thermal diverting valves divert one flow into 2 flows (AB to A and B).
Mixing/diverting valves open inlet A and closes inlet B with rising temperature.
Valves are available in several materials for specific media e.g. heating water, steam,
thermal oil, coolant water (other media available on request).
- Thermal detectors acc. to DIN EN 14597 can only be adjusted to the intended value with
tools.
4.3 Diagram
4.3.1 Parts
Pos. Designation
11 Bonnet (valve)
50.1 Sensor
50.4 Set-point indicator
50.13 Indicator unit
50.15 Capillary tube
50.16 Actuator
60 Manual control device
(accessory)
Fig. 1: : Illustration of closing valve Fig. 771

with controller type 990038604 and manual
control device
(for other controller types refert to data sheet)
Page 4 Rev. 0040702000 3310

10203 TEMPTROL®

for example
Valve
Nominal diameter: DN 15 - DN 100
Pressure class: PN 16 / 25 / 40
Body material: EN-JL1040, EN-JS1049, 1.0619+N, 1.4408, CC491K, SA105
Temperature - valve: acc. to pressure-temperature table refer to data sheet:
max. 150 °C without cooling spacer (Fig. 771, 775, 773)
max. 300 °C with cooling spacer (Fig. 772, 774, 776)
Disc seal: Metal
Thermal controller / Detector

Setting range: -20 ... +50°C
0 ... +70°C
+30 ... +100°C
+60 ... +130°C
+130 ... +200°C
Excess temperature: for short time max. 30K
Ambient temperature: max. +70°C for indicator unit (DIN EN 14597 „T70“)
Sensor pocket Brass Stainless steel

Pressure: max. 25 bar max. 40 bar
Temperature: max. 130 °C max. 250 °C
Approval TÜV-certified acc. to DIN EN 14597

Reg. No. TR91006 / TW91106
For all necessary project planning data, refer to data sheet (acc. to DIN EN 14597
table BX); e.g. Kvs-value, lengths of sensor pocket, max. operating ranges pressure/
temperature, etc.
Rev. 0040702000 3310 Page 5

10203 TEMPTROL®
4.5 Marking
Manufacturer Nominal diameter
Figure-Number /
Type-Number
Kvs-value
Nominal pressure
max. perm.
differential pressure
CE-marking
max. perm. pressure

Serial-No.
Year of manufacture no code
(1. and 2. position) max. perm. temperature
Fig. 2: Valve
min. temperature Figure-Number / min. temperature Figure-Number /

Type-Number Type-Number
max. temperature max. temperature
Manufacturer Manufacturer
max. ambient max. ambient

DIN-Register-No. DIN-Register-No.
Serial-No. temperature Serial-No. temperature
Year of manufacture no code Year of manufacture no code
(1. and 2. position) (1. and 2. position)
Fig. 3: Thermo controller Fig. 4: Detector
- Address of manufacturer:
refer to item 12.0 EC declaration of conformity
Page 6 Rev. 0040702000 3310

10203 TEMPTROL®
5.0 Installation
installation work:
Refer to data sheet for necessary resp. relevant data for correct installation;
e.g. dimensions, connections, max. operating limits, etc.
ATTENTION !
media.
avoided.
both sides.
recommended.
- Valve and controller/detector are delivered separately.
- Before installing the temperature regulator, rinse and clean the system otherwise the
seat / disc will be damaged and the control hole will be blocked.
- Centre packings between the flanges.
Rev. 0040702000 3310 Page 7

10203 TEMPTROL®
- Flow direction:
- Thermal closing valves:
The flow direction must correspond with the arrow on the valve body.
- Thermal opening valves (Inlet B closed):
Flow direction for thermal openting valves is preferably from A to B.
Inlet B must be closed with a blind flange.
(Flow direction from AB to A is possible, but not recommended, because oncoming
flow goes contrary the usual flow direction onto the plug.
- Thermal mixing/diverting valves: Mixing function
When installing 3-way valves, it is important to distinguish between
mixing and diverting of flow.
- Mixing:
The flow media inlets are A and B (the warmer medium should
enter inlet B).
- Diverting:
The medium enters through inlet AB and exits out of outlets A and B.
Diverting
In order to assure proper regulation, the pressures of both partial
flows (inflow for mixing or outflow for diverting) must be of equal
magnitude.
Please note, that with rising sensor temperature, inlet B (mixing) or
outlet B (diverting) are throttled.
The flow direction must correspond with the arrow on the valve
body.
maintenance and removing the actuator and extracting the temperature sensor out of the
piping or tank. Install a stop valve upstream and downstream of the temperature regulator
to enable repair and maintenance work, without emptying the system. Also a strainer
should exist in front of the control valve (refer to point 5.5), to exclude wear between seat
and disc.
Insert thermometer to control the medium temperature. The piping diameters before and
behind the valve must ensure, that the allowed flow velocities are not exceeded.
- When insulating, the bonnet, actuator, capillary tube and temperature sensor must stay
free.
- The capillary tube of the temperature regulator must be installed in such a way that no
large temperature alterations and vibrations occur. The max. distance between the tube
holders is 250 mm. The min. bending radius is 50 mm. The connecting pipe is part of a
hydraulic system. It must not be disconnected or damaged.
- Temperature sensors (pos. 50.1) can be installed in systems with sensor pockets. The
sensor pocket enables easy installation, when a change is necessary the system must not
be emptied. Note the longer time constant!
- Installation with actuator hanging.
5.2.1 Thermo controller with 2 temperature sensors
- The first temperature controller (pos. 50.1a) (a bar sensor for liquids or a spiral sensor for
air) measures the external temperature (regulating variable).
- The second temperature controller (pos. 50.1b) (a bar sensor) measures the external
temperature (command variable). It should be mounted outside wall - north side away
form the sun, 2m above ground and protected from wind.
Page 8 Rev. 0040702000 3310

10203 TEMPTROL®
- The influence of the external temperature on the controlled temperature is possible due to
the difference in volume between the first sensor (regulating variable) and the second
sensor (command variable).
- The set point indicator has a trend scale with a middle mark (refer to setting diagrams in
the data sheet).
5.2.2 Selection of temperature sensor- Location
- The temperature sensor (pos. 50.1) must be completely immersed.
Care should be taken to assure adequate circulation.
- At low flow rates, we recommend installing the temperature sensor (pos. 50.1) horizontally
(for example in boilers at 2/3 height).
- The control thermometer should be installed near the location from temperature sensor.
- In pipelines, a threaded coupler must be welded into the pipe and the temperature sensor
mounted against the flow direction.
- When installing the temperature sensor (pos. 50.1) directly, be sure the connection is free
of leaks (gasket is included).
- Room temperature sensors should not be exposed to interference such as drafts, sunlight
and other sources of heat.
(Connection of valve with thermal controller)
ATTENTION !
- It is not permitted to mantle / dismantle actuators with valves operating and in
service conditions (temperature and pressure) (refer to item 10.0).
-
Construction
- Set point of the thermal controller/detector, turn to maximum. Hold the set point indicator
with the other hand.
- Connect the actuator (pos. 50.16) (ca. 100 Nm) through the connecting nut to the valve
(pos. 11). (Attention: The actuator must not turn whilst connecting, because the capillary
tube (pos. 50.15) will be damaged!).
- The actuator (pos. 50.16) seals the valve interior only metallic; not extra gasket is allowed!
Dismantling
- Loosen the connecting nut of the actuator (pos. 50.16). (Attention: The actuator must not
turn, because the capillary tube (pos. 50.15) will be damaged!).
ATTENTION !
- When loosening the actuator, dangerous media can escape
(hot condensate, steam)
-
Rev. 0040702000 3310 Page 9

10203 TEMPTROL®
5.4 Manual control device
Pos. Designation
11 Bonnet (valve)
50.16 Actuator
50.17 Connecting nut (actuator)
60.3 Securing ring
Fig. 5 60.5 Adjusting ring
60.11 Pin
60.14 Connecting nut
- The manual control device is installed between the valve (pos. 11) and the actuator
(pos. 50.16) of the thermal control valve (Fig. 5).
- Note, that here also the sealing is only metallic, no extra gasket!
- The connecting nut (pos. 60.14) is fastened with about 100 Nm to the valve (pos. 11), the
actuator (pos. 50.16) with about 50 Nm to the manual control device.
In the following, a setting example is shown for a closing valve:
- Turn the adjusting ring (pos. 60.5) clockwise till the valve (pos. 11) is closed (mechanical
endpoint). The upper securing ring (pos. 60.3) is put in line with the notch of the pin
(pos. 60.11).
- Now turn the adjusting ring (pos. 60.5) anti-clockwise, till the valve (pos. 11) is full open
(max. flow). The bottom securing ring (pos. 60.3) is put in line with the notch of the
indicator pin (pos. 60.11). In the system you can then see the lift over the open and closed
position between the securing rings (pos. 60.3).
- Note, that when working the adjusting ring (pos. 60.5) must be in the opening position of
the valve; closed valve can’t be opened through the thermal controller!
Page 10 Rev. 0040702000 3310

10203 TEMPTROL®
5.5 Strainer
ATTENTION !
Install a strainer before the temperature regulator with the sieve sideways (with
the medium steam) to avoid the collection of condensate.
-
The strainer must be cleaned from time to time.

ATTENTION !
- Putting into operation only through expert personnel.
- To avoid a to higher temperature on the sensor, firstly adjust to the max. range
of the setting range.
The operation is then as follows:

- After installation, valve and piping must be filled over the return line. If this is not possible,
slowly open (half open) the stop valve before the control valve, and carefully without
pressure surges, fill the piping. Then slowly fully open the stop valve.
- Any leakage tests may be conducted only when the valve is not closed.
Otherwise, internal valve components could be damaged.
Rev. 0040702000 3310 Page 11

10203 TEMPTROL®
6.1 Setting range

6.1.1 Controller
Fig. 6: Setting range

Body screw
- The temperature setting is done through turning the setting ring (pos. 50.13). The body
(pos. 50.5) must be held fast; it is not allowed to turn.
- Setting of higher ranges is allowed without any restrictions.
- Setting for lower ranges when installed, is only allowed in small steps smaller 30 K.
Between the steps, the temperature regulation (system dependent about 15 min.) must be
waited for.
- When alterations larger than 30 K are done, the excess temperature indicator can
respond.
This can be seen when the setting ring (pos. 50.13) has moved upwards from the body
(Fig. 7) (pos. 50.5). In this case, the temperature regulation must be waited for, before
further alterations are done. Excess responses from the indicator shortens the lifetime
from the thermal controller!
Fig. 7: Excess temperature indicator
- After the temperature regulation in the system has been fulfilled, the actual temperature
can be seen on the control manometer.
- If both values which have been set are reached, then the procedure is ended.
- If the values are not correct, then a correction must be done on the set point indicator. The
set point must be altered to the actual value (see point 6.2).
Page 12 Rev. 0040702000 3310

10203 TEMPTROL®
6.1.2 Detector
Procedure see point 6.1.1, but instead of the alteration of the setting ring, the intended
setting is done with 11-box spanner or 8-key wrench.
Before you must remove the black ring (Pos. 50.13, Fig. 6) through pulling off, and then
push on after setting.
6.2 Setting correction
Fig. 8: Setting correction

Body screw
- Loosen the body screw (M4).

- The correction is done through turning the body (pos. 50.5) till the setting is equal to the
actual temperature (actual value on control manometer). The setting ring (pos. 50.13)
(tools with detector) must be held; it is not allowed to turn.
- Set to the needed value.
(Turn the setting ring (pos. 50.13) (tools with detector) - Hold body (pos. 50.5)).
- After the temperature regulation in the system had been fulfilled, read again the actual
temperature.
- If both values are the same, the procedure is ended.
- If the value has not been successfully reached, repeat the setting correction.
- When the correction is done, turn the body (pos. 50.5) so far, that the setting range can be
seen, then fasten the screw.

the requirements.
Rev. 0040702000 3310 Page 13

10203 TEMPTROL®
8.0 Troubleshooting
Instructions.
ATTENTION !
-

ATTENTION !
- read item 10.0 and 11.0 prior to dismantling and repair work !
- read item 5.0 and 6.0 before restarting the plant !

No flow Valve closed Bring manual control device in com-
(manual control device) plete open position
Flange covers not removed Remove flange covers
Flow to small Valve not sufficiently open Bring manual control device in com-
Dirt sieve clogged Clean / replace sieve
Piping system clogged Check piping system
Thermal closing valve: Leaky capillary tube system Change the thermal control device
Flow to large, no temper-
mounted against the allowed flow Mount valve in the correct flow direc-
ature regulation possible
direction tion
Thermal opening valve: Leaky capillary tube system Change the thermal control device
Flow to small, no temper-
direction tion
Thermal mixing/diverting Leaky capillary tube system Change the thermal control device
valve:
no or inadequate mixing
direction tion
or diverting function
Page 14 Rev. 0040702000 3310

10203 TEMPTROL®

ATTENTION !
media.

appointed by us.

Rev. 0040702000 3310 Page 15

10203 TEMPTROL®

AWH Armaturenwerk Halle GmbH,
Turmstrasse 118, D-06110 Halle/Saale
acc. to
ucts comply and have been approved according to module A diagram 6 (art. 3, annex II).
Bodies from pressure bearing equipment without safety function.
Category I (fluid group 1)
Temperature regulator
TEMPTROL®
Type 771, 772, 773, 774, 775, 776
in connection with
controller / detector / manual control device / sensor pocket
(Article 3, paragraph 3 acc. to „sound engineering practice“)
Type 990038601 to 990038636
Type 990038746 to 990038796
Type 990039001
Type 990038600Z22 to 990038600Z36
Applied standard:
DIN 3840 (DIN EN 12516)
DIN EN 14597
AD 2000 leaflet A4
- Cast steel, Forged steel
- Stainless steel
- Brass
.................................................
Page 16 Rev. 0040702000 3310

ARI-TEMPTROL®
10203 Temperature reglator
Temperature reglator
DN 15 - 100
ARI-TEMPTROL®

Fig. 771
ARI-TEMPTROL® LCG
straight through with screwed sockets
Fig. 771....2..1 Fig. 771/772....2..1
SA105
Page 4
ARI-TEMPTROL® Fig. 775

Fig. 775
Page 6
ARI-TEMPTROL® LCG
straight through with screwed sockets Fig. 773
Fig. 775....2..1
Page 8
IN EN
p ro v a l acc. to D /TW911
p
• TÜV-a Reg.-No. TR910
14597 /
gh
ARI-TEMPTROL® ed throu
• Approv ischen Lloyd
Thermal mixing/diverting valve German
3-way form with flanges
Features:
• Self-operating (no auxilary power required)
• Reliable, low maintenance operation
• Over-temperature safety device
ARI-TEMPTROL® LCG • Valves pressure balanced with stainless
steel bellows
Thermal mixing/diverting valve • 3 thermal controller sizes for optimal
3-way form with screwed sockets without selection of proportional range
balanced bellow • Thermal sensors with different time
constants
Fig. 773....2..1 • Exact and easy adjustment
Page 12
• Setting range is adjustable
• Sensor pocket
• Manual control device
ARI-TEMPTROL®
Thermal closing valve straight through with flanges

12.771 / 12.772 PN16 EN-JL1040 DN15-100
22.771 / 22.772 PN16 EN-JS1049 DN15-100
23.771 / 23.772 PN25 EN-JS1049 DN15-100
35.771 / 35.772 PN40 1.0619+N DN15-100
55.771 / 55.772 PN40 1.4408 DN15-100


12.771....1..1
PN16 EN-JL1040 DN15-50
12.772....1..1
Fig. ...771 max. 150°C
Fig. 12.771....1..1 max. 130°C

ARI-TEMPTROL®
DN 15 20 25 32 40 50 65 80 100
L (mm) 130 150 160 180 200 230 290 310 350
Fig. 771 H (mm) 160 160 195 195 215 255 260 320 340
Weight (kg) 3,4 4,2 5,3 6,9 8,8 12,4 23 29 38
Fig. 772 H (mm) 305 305 340 340 360 400 405 455 485
Weight (kg) 4,3 5,1 6,3 7,9 9,7 13,3 24 30 39
Fig. 771...1..1 (LC) H (mm) 125 125 125 125 130 135 -- -- --
Weight (kg) 2,5 3,5 5 6 8 10 -- -- --
Fig. 772...1..1 (LC) H (mm) 270 270 270 270 275 280 -- -- --
Weight (kg) 3,5 4,5 6 7 9 11 -- -- --

Kvs-value
DN 15 20 25 32 40 50 65 80 100
Travel (mm) 7,5 7,5 8 9,5 9,5 11,5 14 15 15
Reduced Kvs-values (m3/h) 0,4 1,0 -- -- -- -- -- -- -- --
Travel (mm) 5 5 -- -- -- -- -- -- -- --

DN 15 20 25 32 40 50 65 80 100
Fig. 771
Straight through (bar) 16 16 16 16 12 9 9 9 9
Fig. 772
Fig. 771...1..1 (LC)
Straight through (bar) 9,3 9,3 5,6 4,1 2,3 1,5 -- -- --
Fig. 772...1..1 (LC)
Parts
Fig. 12.772 Fig. 22./23.772 Fig. 35.772 Fig. 55.772
EN-GJS-400-18U-LT 1.4408
2 Seat X6CrNiTi18-10, 1.4541
5 Guide bushing X6CrNiTi18-10, 1.4541
7 Gasket * Graphite
X6CrNiMoTi17-12-2,
11 Hood EN-JS1049, EN-GJS-400-18U-LT
1.4571
14 Spindle unit * X6CrNiTi18-10, 1.4541
37 Spring * X12CrNi17-7, 1.4310
* Spare part


ARI-TEMPTROL® LCG
Thermal closing valve straight through with screwed sockets without balanced bellow

72.771....2..1 PN16 CC491K G1/2” - G1”

Liquids and Luft

45.771....2..1
PN40 SA105 G1/2” - G2”
45.772....2..1
Fig. 72.771....2..1 max. 130°C Fig. 45.771....2..1 max. 130°C

ARI-TEMPTROL® LCG

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Ø G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
L (mm) 80 90 110 120 130 150
L1 (mm) 128 138 166 -- -- --
Fig. 771....2..1 H (mm) 283 283 289 -- -- --
H1 (mm) 55 55 55 -- -- --
H3 (mm) 65 65 66 -- -- --
Weight (kg) 2,9 3,1 3,7 -- -- --
Fig. 45.771....2..1 H (mm) 127 127 131 138 138 140
Weight (kg) 2,5 3,5 5 6 8 10
Fig. 45.772....2..1 H (mm) 272 272 276 283 283 285
Weight (kg) 3,5 4,5 6 7 9 11
Kvs-value
DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Kvs-value (m3/h) 4,0 6,3 10,0 -- -- --
Fig. 72.771....2..1
Travel (mm) 7,5 7,5 8 -- -- --
Fig. 45.771....2..1 Kvs-value (m3/h) 3,1 5,5 8,6 12,8 20 26
Fig. 45.772....2..1 Travel (mm) 7,5 7,5 8 9,5 9,5 11,5

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Fig. 72.771....2..1 Straight through (bar) 9,3 9,3 5,6 -- -- --
Fig. 45.771....2..1
Straight through (bar) 9,3 9,3 5,6 4,1 2,3 1,5
Fig. 45.772....2..1
Pressure balancing of the actuator needed: P1 > Δp (e.g. P1=12 bar, Δp=9,3 bar). For pressure balancing use manual control device (Type 9900390011).
Parts
Pos. Description Fig. 72.771....2..1 Fig. 45.771....2..1 / Fig. 45.772....2..1
1 Body CuSn5Zn5Pb5-C, CC491K SA105
1.2 Seat -- X6CrNiTi18-10, 1.4541
3 Cylinder screw A4-70 A2-70
4 Plug * CuZn39Pb3, CW614N --
5 Guide bushing -- X6CrNiTi18-10, 1.4541
6 O-ring * EPDM --
7 Gasket * -- Graphite
8.1 Screw joint CuZn39Pb3, CW614N --
8.2 Retaining ring CuSn8, CW453K --
8.4 Bushing PTFE --
8.5 Washer CuZn37, CW508L --
11 Hood CuZn39Pb3, CW614N EN-JS1049, EN-GJS-400-18U-LT
13 Sealing ring Centellen --
14 Stem / Spindle unit * X6CrNiMoTi17-12-2, 1.4571 X6CrNiTi18-10, 1.4541
15 Sleeve nut TMP / chrom. --
16 Blind plate S235JR, 1.0037 --
21 Hexagon nut A2 A2-70
28 Cooling spacer -- EN-JS1049, EN-GJS-400-18U-LT
35 Spring plate X6CrNiTi18-10, 1.4541 --
36 Spring plate X6CrNiMoTi17-12-2, 1.4571 --
37 Spring * X10CrNi18-8, 1.4310
* Spare parts

ARI-TEMPTROL®
Thermal opening valve straight through with flanges

12.775 PN16 EN-JL1040 DN15-100
22.775 PN16 EN-JS1049 DN15-100
23.775 PN25 EN-JS1049 DN15-100
35.775 PN40 1.0619+N DN15-100
55.775 PN40 1.4408 DN15-100


12.775....1..1 PN16 EN-JL1040 DN15-50
Fig. ...775 max. 150°C (> 150°C on request)
Fig. 12.775....1..1 max. 130°C (> 130°C on request)

ARI-TEMPTROL®
DN 15 20 25 32 40 50 65 80 100
L (mm) 130 150 160 180 200 230 290 310 350
Fig. 775 H (mm) 195 195 200 225 245 280 300 365 385
Weight (kg) 5,4 6,8 9,1 11,9 17 19,5 30 37 46
Fig. 775....1..1 (LC) H (mm) 125 125 130 155 160 160 -- -- --
Weight (kg) 4,5 6 8 10,5 15 17 -- -- --

Kvs-value
DN 15 20 25 32 40 50 65 80 100
Travel (mm) 7,5 7,5 8 9,5 9,5 11,5 14 15 15
Travel (mm) 5 -- -- -- -- -- -- -- --

DN 15 20 25 32 40 50 65 80 100
A AB
Fig. 775 (bar) 12 4 4 4 4 4 4 4 4
Straight through
A AB
Fig. 775....1..1 (LC) (bar) 3 3 2,5 1,5 1 0,5 -- -- --
Straight through
Parts
EN-GJS-400-18U-LT 1.4408
7 Gasket * Graphite
23 Hexagon nut C35E, 1.1181 -A2B A4-70
24 Hexagon screw 5.6-A2B A4-70
25 Flange S235JR, 1.0037 X6CrNiTi18-10, 1.4541
26 Gasket * Graphite (with CrNi-Streckmetalleinlage)
37 Spring * X12CrNi17-7, 1.4310
* Spare part


ARI-TEMPTROL® LCG
Thermal opening valve straight through with screwed sockets without balanced bellow

72.775....2..1 PN16 CC491K G1/2” - G2”

Fig. 72.775....2..1 max. 130°C

ARI-TEMPTROL® LCG

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Ø G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
L (mm) 80 90 110 120 130 150
L1 (mm) 128 138 166 186 199 223
Fig. H (mm) 283 283 289 293 302 302
775....2..1
H1 (mm) 55 55 55 55 60 65
H2 (mm) 79 79 83 88 95 102
Weight (kg) 2,4 2,6 3,2 4,1 4,7 6,3

Kvs-value
DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Kvs-value (m3/h) 4,0 6,3 10,0 16,0 25,0 40,0
Travel (mm) 14 14 14 14 14 14

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
A AB
(bar) 3 3 2,5 1,5 1 0,5
Straight through
Parts
4 Plug * CuZn39Pb3, CW614N
6 O-ring * EPDM
8.3 O-ring * EPDM
8.4 Bushing PTFE
8.6 O-ring * EPDM
14 Stem * X6CrNiMoTi17-12-2, 1.4571
16 Blind plate S235JR, 1.0037
18 O-ring * EPDM
21 Hexagon nut A2
22 Washer A2
37 Spring * X10CrNi18-8, 1.4310
* Spare parts

ARI-TEMPTROL®
Thermal mixing/diverting valve in 3-way form with flanges

12.773 / 12.774 PN16 EN-JL1040 DN15-100
22.773 / 22.774 PN16 EN-JS1049 DN15-100
23.773 / 23.774 PN25 EN-JS1049 DN15-100
35.773 / 35.774 PN40 1.0619+N DN15-100
55.773 / 55.774 PN40 1.4408 DN15-100

Mixing function Diverting function

Fig. ...773 max. 150°C 12.773....1..1
PN16 EN-JL1040 DN15-50
12.774....1..1
Fig. 12.773....1..1 max. 150°C

ARI-TEMPTROL®

DN 15 20 25 32 40 50 65 80 100
L (mm) 130 150 160 180 200 230 290 310 350
Fig. 773 H (mm) 195 195 200 225 245 280 300 365 385
Weight (kg) 4,4 5,8 7,6 9,9 14,5 16,5 25 31 38
Fig. 774 H (mm) 340 340 345 370 390 425 445 510 530
Weight (kg) 5,4 6,8 8,6 10,9 15,5 17,5 26 32 39
Fig. 773....1..1 H (mm) 125 125 130 155 160 160 -- -- --
(LC) (kg) 3,5 5 6,5 8,5 12,5 14 -- -- --
Weight
Fig. 774....1..1 H (mm) 270 270 275 300 305 305 -- -- --
(LC) (kg) 4,5 6 7,5 9,5 13,5 15 -- -- --
Weight
Kvs-value
DN 15 20 25 32 40 50 65 80 100
Travel (mm) 7,5 7,5 8 9,5 9,5 11,5 14 15 15
Travel (mm) 5 -- -- -- -- -- -- -- --

DN 15 20 25 32 40 50 65 80 100
pB > pA (Δp = pB - pA) (bar) 12 16 16 16 12 9 9 9 9
pA > pB (Δp = pA - pB) (bar) 12 4 4 4 4 4 4 4 4

Fig. 773 Mixing function
Fig. 774
pAB > pB
(bar) 12 4 4 4 3 1,5 0,7 0,25 0,15
pAB > pA
Diverting function
pAB > pB
(bar) 3 3 2,5 1,5 1 0,5 -- -- --
pAB > pA
Fig. 773....1..1 (LC) Mixing function
Fig. 774....1..1 (LC)
(bar) 3 3 2,5 1,5 1 0,5 -- -- --
Diverting function
Parts
Fig. 12.774 Fig. 22./23.774 Fig. 35.774 Fig. 55.774
EN-GJS-400-18U-LT 1.4408
7 Gasket * Graphite
37 Spring * X12CrNi17-7, 1.4310
* Spare part

ARI-TEMPTROL® LCG
Thermal mixing/diverting valve in 3-way form with screwed sockets without balanced bellow

72.773....2..1 PN16 CC491K G1/2” - G2”

Fig. 72.773....2..1 max. 130°C

ARI-TEMPTROL® LCG

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Ø G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
L (mm) 80 90 110 120 130 150
L1 (mm) 128 138 166 186 199 223
Fig. 773 H (mm) 136 136 142 146 155 155
H1 (mm) 55 55 55 55 60 65
H2 (mm) 79 79 83 88 95 102
Weight (kg) 2,4 2,6 3,2 4,1 4,7 6,3

Kvs-value
DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
Standard Kvs-values (m3/h) 4,0 6,3 10,0 16,0 25,0 40,0
Travel (mm) 14 14 14 14 14 14

DN 15 20 25 32 40 50
Ø G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
(bar) 3 3 2,5 1,5 1 0,5

Mixing function
(bar) 3 3 2,5 1,5 1 0,5

Diverting function
Parts
4 Plug CuZn39Pb3, CW614N
6 O-ring * EPDM
8.3 O-ring * EPDM
8.4 Bushing PTFE
8.6 O-ring * EPDM
14 Stem * X6CrNiMoTi17-12-2, 1.4571
18 O-ring * EPDM
21 Hexagon nut A2
22 Washer A2
37 Spring * X10CrNi18-8, 1.4310
* Spare parts

ARI-TEMPTROL®
10203 Application / Kvs-value / Selecting the controller
Application / Operating principle
Thermal control devices are used to regulate temperature of fluids, air and steam. You will find them in industrial heating and ventilation systems, in residential applications, in
marked-warehouses, ship building and also in cooling systems.
The ARI-Temperature Regulator (TEMPTROL) works on the principle of thermal expansion. For operation no extra energy is needed, self acting. Changes in temperature lead
to changes in fluid volume in the capillary tube, which means a certain stroke in the actuator onto the valve spindle. The excess temperature protector prevents an unnecessary
load on the controller when the temperature is to high on the thermal sensor. The setting range can be adjusted precisely with the adjusting knob to the required temperature
value. If a manual control device is fitted, the stroke position is shown and the valve can be operated manually. With thermal detectors acc. to DIN EN 14597, the intended
value can only be adjusted with tools.
Ambient temperature: max. 70°C for indicator unit (DIN EN 14597 T70)
Operating principle:
Thermal closing valve: - closes with rising temperature
Thermal opening valve: - opens with rising temperature

- reduces or closes inlet B with rising temperature
Thermo-3-way mixing valve: (at mixing function, the warmer medium must be put into inlet B)
Thermo-3-way diverting valve: - reduces resp. closes output B with rising temperature
Selecting the valve

To select the nominal diameter it is necessary to know the Kvs-value.
This can be done using the calculation program „MyValve“ (Module „ARI-Temperature reglator TEMPTROL-Calculation“).
The following data is needed
- Medium
- Temperature
- Flow capacity (Q)
- Upstream pressure (p1)
- Downstream pressure (p2)
Then the thermal controller with the next highest Kvs-value is selected (see table). With „MyValve“ you can also calculate the velocities in the piping, before and behind the
valve, and if necessary select the right piping size.
For selecting a valve, the pressure-temperature-ratings must be observed (see page 15), also the corrosive aspect.
If at thermal opening valves and at thermal mixing/diverting valves Δ p > P1 , then a perforated plug is recommended.
2
Selecting the controller

The following must be observed:
- Type selecting acc. to the used medium
(rod sensor, spiral sensor for gas, spiral sensor for liquids, with thread or flange).
- The temperature range.
- Installation place of thermal sensor, set point adjusting unit and valve (length of capillary tubes)..
Then the thermal controller is selected using the recommended proportional range (see page 17).
The proportional range shows by which temperature alteration on the thermal sensor, the valve needs from open to closed position. Preferably use the range between 10 and
15 K. It is also possible to use the other ranges, if the calculation of the control loop finds this necessary. We strongly advise that you check the systems transient response.

ARI-TEMPTROL®
Standard-flange dimensions Flanges acc. to DIN EN 1092-2 (Flange holes / -thickness tolerances acc. to DIN)
DN (mm) 15 20 25 32 40 50 65 80 100
PN16 ØD (mm) 95 105 115 140 150 165 185 200 220
PN16 ØK (mm) 65 75 85 100 110 125 145 160 180
PN25 ØD (mm) 95 105 115 140 150 165 185 200 235
PN25 ØK (mm) 65 75 85 100 110 125 145 160 190
PN40 ØD (mm) 95 105 115 140 150 165 185 200 235
PN40 ØK (mm) 65 75 85 100 110 125 145 160 190

EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6
EN-JS1049 16 (bar) on request 16 15,5 14,7 13,9 12,8
EN-JS1049 25 (bar) on request 25 24,3 23 21,8 20

Material -60°C to <-10°C* -10°C bis120°C 150°C 200°C 250°C 300°C
1.0619+N 40 (bar) 30 40 38,1 35 32 28
SA105 40 (bar) 30 40 38,1 35 32 28
DN100 max. 26 bar

1.4408 40 (bar) 40 40 36,3 33,7 31,8 29,7
DN100 max. 26 bar

Material -10°C to 20°C 100°C 130°C
CC491K 16 (bar) 16 16 16

- Figure-No. - Kvs-value
- Nominal diameter - ΔP Dimensions in mm
- Nominal pressure - Medium Weights in kg
- Body material Ordering data for controller: refer to Seiite 16. Pressures in barg (gauge)
Figure 22.772; Nominal diameter DN25; Nominal pressure PN16; Body material EN-JS1049; Kvs 10, ΔP 3 bar, Water. Kvs in m3/h

ARI-TEMPTROL®
10203 Thermal controller / detector - Types
Type
Temperature Time constant
Thermal Size range Temperature sensor version
Thermal detector without sensor pocket
controller
9900386011 9900387611 I Temperature sensor and

-20 ... +50°C
setpoint adjusting knob in
0 ... +70°C
9900386021 9900387621 II one unit.
+30 ... +100°C
Stainless steel 1.4541
+60 ... +130°C
9900386031 9900387631 III (optional sensor pocket)
75 s 2)
measured with water
9900386041 9900387641 I (flow rate 0,2 - 0,3 m/s)
rod sensor, nickel-plated brass

9900386051 9900387651 II
(optional sensor pocket)
9900386061 9900387661 III
9900386071 9900387671 I
Spiral sensor for gas, Copper

9900386081 9900387681 II
blank with flange
-20 ... +50°C
9900386091 9900387691 III 0 ... +70°C 80 s
+30 ... +100°C measured with air
9900386101 9900387701 I +60 ... +130°C (flow rate 3m/s)
+130 ... +200°C
Spiral sensor for gas Copper
9900386111 9900387711 II
blank with bracket
9900386121 9900387721 III
9900386131 9900387731 I
80 s 2) Rod sensor, Stainless steel
9900386141 9900387741 II measured with water 1.4541
(flow rate 0,2 - 0,3 m/s) (optional sensor pocket)
9900386151 9900387751 III
9900386311 9900387911 I
-20 ... +50°C
0 ... +70°C Spiral sensor for liquids and
9900386321 9900387921 II
+30 ... +100°C gas, nickel-plated copper
+60 ... +130°C
9900386331 9900387931 III 15 s
measured with water
9900386341 9900387941 I (flow rate 0,2 - 0,3 m/s)
-20 ... +50°C
0 ... +70°C
Spiral sensor for liquids and
9900386351 9900387951 II +30 ... +100°C
gas, Stainless steel 1.4541
+60 ... +130°C
9900386361 9900387961 III +130 ... + 200°C
9900387461 I
9900387471 I
9900387481 III
V1 : V2 = 1 : 2,5 1)
9900387491 I
80 s Spiral sensor for gas, Copper
+10 ... +50°C Air intake temperature sensor blank with flange outdoor rod
9900387501 II
trend scale measured with air sensor, stainl. st. 1.4541
(flow rate 3m/s) (with bracket)
9900387511 III
V1 : V2 = 1,8 : 1 1)
9900387581 I
9900387591 II
9900387601 III
V1 : V2 = 1 : 1,9 1)
1) V1 = Volume of controlled volume sensor 2) with brass sensor pocket: 100 s 3) with brass sensor pocket: 125 s
V2 = Volume of outside temperature sensor with stainless steel sensor pocket: 115 s with stainless steel sensor pocket: 145 s

ARI-TEMPTROL®
Proportional range (Combination controller with valve in Kelvin) 1)
DN 15 20 25 32 40 50 65 80 100
Controller size l 10 10 15 15 17 20 20 24 37 39 39
Controller size lI 7,5 7,5 10 10 12 13 13 16 27 29 29

Controller size lII 5 5 6,5 6,5 7,5 8,5 8,5 10 20 21 21
Proportional range Fig. 773 LCG Thermal mixing valve / Fig. 775 LCG Thermal opening valve (Combination controller with valve in Kelvin) 1)
DN 15 20 25 32 40 50
G1 1/2“ 3/4“ 1“ 1 1/4“ 1 1/2“ 2“
G2 1 1/8“ 1 1/4“ 1 1/2“ 2“ 2 1/4“ 2 3/4“
Controller size l 29 29 29 29 29 29
Controller size lI 19 19 19 19 19 19
Controller size lII 12 12 12 12 12 12
= recommended combinations
1) The proportional range determines at what change in sensor temperature the valve will move from totally open to totally closed.
Setting diagrams
(only for temperature regulators with two temperature sensors and trend scale)
Outdoor temperature Outdoor temperature

Setting range +35°C to +105°C Setting range +30°C to +90°C
Type 9900387461 ... 481 Type 9900387581 ... 601
Adjusting knob
trend scale
(only type 9900387461 ... 601)
Body
Indicator unit
Setting range +10°C to +50°C Outdoor temperature

Type 9900387491 ... 511

- Thermal controller / detector (Type-No.)
- Temperature range
Please indicate in your order, if
- Length of capillary tube (refer to page 19: L1 ... L4) the valves are to be installed in
- Top mounted handwheel hazardous areas (ATEX)
- Sensor pocket
Example:
Type 9900386041; temperature range 0...70°C; length of capillary pipe 4m + 4m., Top mounted handwheel, Sensor pocket 990038600Z31

ARI-TEMPTROL®
Type 9900386041 ... 061

Type 9900387641 ... 661
Type 9900386011 ... 031 Type 9900386071 ... 091

Type 9900387611 ... 631 Type 9900387671 ... 691
Type 9900386101 ... 121 Type 9900386131 ... 151 Type 9900386311 ... 361
Type 9900387701 ... 721 Type 9900387731 ... 751 Type 9900387911 ... 961
Type 9900387461 ... 481

Type 9900387581 ... 601 Type 9900387491 ... 511

ARI-TEMPTROL®
Type h1 h2 t1 t2 t3 L1 L2 L3 L4 Weight
Thermal (mm) (mm) (mm) (mm) (mm) (m) (m) (m) (m) (kg)
Thermal detector
controller
9900386011 9900387611 269 339 1,8
9900386021 9900387621 347 557 2,4,8,16 3
9900386031 9900387631 347 857 3,3
9900386041 9900387641 240 239 256 3,2
9900386051 9900387651 318 389 390 3,5
9900386061 9900387661 318 559 600 4
9900386071 9900387671 240 239 151 3,2
9900386081 9900387681 318 389 207 4,2
9900386091 9900387691 318 559 305 4,5
9900386101 9900387701 240 239 184 3
9900386111 9900387711 318 389 240 4
9900386121 9900387721 318 559 338 4,2
2,4,8,16 1) 2,4,8,16 1)
9900386131 9900387731 240 239 256 3,2
9900386141 9900387741 318 389 390 3,5
9900386151 9900387751 318 559 600 4
9900386311 9900387911 240 239 266 3,5
9900386321 9900387921 318 389 394 4,5
9900386331 9900387931 318 559 598 5
9900386341 9900387941 240 239 266 3,5
9900386351 9900387951 318 389 394 4,5
9900386361 9900387961 318 559 598 5
9900387461 240 201 239 257 708 4,4
9900387471 318 201 389 391 1078 5,1
9900387481 318 477 559 601 839 7
9900387491 240 201 239 207 257 5
9900387501 318 201 389 305 384 2,4,8,16 1) 2,4,8,16 1) 2,4,8,16 1) 0,8 5,8
9900387511 318 477 559 477 585 7,3
9900387581 240 201 239 257 542 4,2
9900387591 318 201 389 391 824 4,8
9900387601 318 477 559 601 642 6,5
1) max. permissible length (L1+L2+...) = 24 m
Parts
Pos. Description *
50.1 Thermal sensor Constructions refer to page16
50.2 Screw joint X6CrNiMoTi17-12-2, 1.4571
50.11 Pipe Al (painted)
50.13 Indicator unit ABS (Plastic)
50.15 Capillary tube Cu (tin plated)
50.16 Actuator X6CrNiTi18-10, 1.4541

ARI-TEMPTROL®
10203 Accessories
Manual control device Type 9900390011

• Installed as an accessory between controller and valve.
• Allows valve to be operated independently of the controller.
• Valve position indicator (pin) plus two movable wire set rings mark the max. positions
(totally open and totally closed) (Pos. 60.3).
• Enables a pressure relif of the actuator.
Function:
The spindle of the manual control device transfers the travel of the actuator onto the valve.
The valve and manual control device is sealed metal to metal.
The spindle is sealed with an o-ring and PTFE-strip band.
Parts
Pos. Description * Type 9900390011
60.1 Sealing unit CuZn39Pb3, CW614
60.2 Position tube 11SMn30+C, 1.0715+C
60.3 Retaining ring (Travel indicator) X12CrNi17-7, 1.4310
60.4 Ground unit CuZn39Pb3, CW614N
60.5 Adjusting ring CuZn39Pb3, CW614N
60.9 Ball grip Plastic
60.14 Sleeve nut St Fe/Zn 12C
Sensor pocket
A sensor pocket eliminates the need to empty the system when replacing the temperature sensor.
Technical data
Construction Brass Stainless steel
Material CW508L, CuZn37 X6CrNiTi18-10, 1.4541
max. pressure (bar) 25 40
max. Temperature (°C) 130 250

Type
L Weight
Thermal Thermal Sensor pocket Sensor pocket (mm) (kg)
controller detector Brass Stainless steel
9900386011 9900387611 990038600Z22 990038600Z32 344 0,5
9900386021 9900387621 990038600Z24 990038600Z34 562 0,7
9900386031 9900387631 990038600Z26 990038600Z36 862 1,0
9900386041 9900387641 990038600Z21 990038600Z31 262 0,4
9900386051 9900387651 990038600Z23 990038600Z33 396 0,6
9900386061 9900387661 990038600Z25 990038600Z35 606 0,8
9900386131 9900387731 990038600Z21 990038600Z31 262 0,4
9900386141 9900387741 990038600Z23 990038600Z33 396 0,6
9900386151 9900387751 990038600Z25 990038600Z35 606 0,8
Steam injector BR 651

• Direct condensation of steam for heating water (acc. to PED 97/23/EC fluid group 2)
(Further informations about the accessories can be found in the appropriate data sheets.)
Fig. 651....2 Fig. 651....4


10203

Temperature regulator TEMPTROL®
Fig. 771/772
Fig. 775 Fig. 773/774

Thermal opening valve Thermal mixing/diverting valve
Contents
1.0 General information on operating instructions....2 5.3 Installation instructions concerning actuators
(Connection of valve with thermal controller) .................9
2.0 Notes on possible dangers ....................................2
5.4 Manual control device .....................................................10
2.1 Significance of symbols ................................................... 2
5.5 Strainer ........................................................................... 11
2.2 Explanatory notes on safety information .......................... 2
6.0 Putting the valve into operation...........................11
3.0 Storage and transport ............................................3
6.1 Setting range...................................................................12
4.0 Description ..............................................................3 6.1.1 Controller....................................................................12
4.1 Scope of applications ....................................................... 3 6.1.2 Detector......................................................................13
4.2 Operating principles ......................................................... 4 6.2 Setting correction ............................................................13
4.3 Diagram ........................................................................... 4 7.0 Care and maintenance ......................................... 13
4.3.1 Parts ............................................................................ 4
8.0 Troubleshooting ................................................... 14
4.4 Technical data - remarks .................................................. 5
4.5 Marking ............................................................................ 6 9.0 Troubleshooting table ......................................... 14
5.0 Installation ...............................................................7 10.0 Dismantling the valve or the top part .............. 15
5.1 General notes on installation............................................ 7 11.0 Warranty / Guarantee ......................................... 15
5.2 Requirements at the place of installation ......................... 8 12.0 EC declaration of conformity ............................ 16
5.2.1 Thermo controller with 2 temperature sensors ............ 8
5.2.2 Selection of temperature sensor- Location.................. 9
Rev. 0040702000 3310 englisch

10203 TEMPTROL®

and repair.

ATTENTION !


Information marked with the above symbol and “ATTENTION !” describe practices, a failure
to property.
Page 2 Rev. 0040702000 3310

10203 TEMPTROL®

ATTENTION !
Refer to catalogue sheet for weights.
- At -20°C to +65°C.
4.0 Description
Temperature regulators are used for „regulating the temperature of fluids, air or steam used
in heating and ventilation systems for industrial or residential applications, ocean going
vessels and also in cooling systems“ and complies to type of operating mode 2B acc. to
DIN EN 14597.
ATTENTION !
to TRD 110.
Rev. 0040702000 3310 Page 3

10203 TEMPTROL®

The temperature regulator TEMPTROL® is a self acting proportional controller for
temperature of fluid, gas and vapour media of Fluid Group I pursuant to Pressure
Equipment Directive 97/23/EC. No auxiliary energy is needed.
The temperature regulator is a combination of controller and valve and is working acc. to
the principle liquid expansion by changing temperatures.
- Thermal closing valves reduce the flow with rising sensor temperature (heating
application).
- Thermal opening valves raise the flow with rising sensor temperature (cooling
application).
- Thermal mixing valves mix 2 flows (inlet A and inlet B to outlet AB).
- Thermal diverting valves divert one flow into 2 flows (AB to A and B).
Mixing/diverting valves open inlet A and closes inlet B with rising temperature.
Valves are available in several materials for specific media e.g. heating water, steam,
thermal oil, coolant water (other media available on request).
- Thermal detectors acc. to DIN EN 14597 can only be adjusted to the intended value with
tools.
4.3 Diagram
4.3.1 Parts
Pos. Designation
11 Bonnet (valve)
50.1 Sensor
50.4 Set-point indicator
50.13 Indicator unit
50.15 Capillary tube
50.16 Actuator
60 Manual control device
(accessory)
Fig. 1: : Illustration of closing valve Fig. 771

with controller type 990038604 and manual
control device
(for other controller types refert to data sheet)
Page 4 Rev. 0040702000 3310

10203 TEMPTROL®

for example
Valve
Nominal diameter: DN 15 - DN 100
Pressure class: PN 16 / 25 / 40
Body material: EN-JL1040, EN-JS1049, 1.0619+N, 1.4408, CC491K, SA105
Temperature - valve: acc. to pressure-temperature table refer to data sheet:
max. 150 °C without cooling spacer (Fig. 771, 775, 773)
max. 300 °C with cooling spacer (Fig. 772, 774, 776)
Disc seal: Metal
Thermal controller / Detector

Setting range: -20 ... +50°C
0 ... +70°C
+30 ... +100°C
+60 ... +130°C
+130 ... +200°C
Excess temperature: for short time max. 30K
Ambient temperature: max. +70°C for indicator unit (DIN EN 14597 „T70“)
Sensor pocket Brass Stainless steel

Pressure: max. 25 bar max. 40 bar
Temperature: max. 130 °C max. 250 °C
Approval TÜV-certified acc. to DIN EN 14597

Reg. No. TR91006 / TW91106
For all necessary project planning data, refer to data sheet (acc. to DIN EN 14597
table BX); e.g. Kvs-value, lengths of sensor pocket, max. operating ranges pressure/
temperature, etc.
Rev. 0040702000 3310 Page 5

10203 TEMPTROL®
4.5 Marking
Manufacturer Nominal diameter
Figure-Number /
Type-Number
Kvs-value
Nominal pressure
max. perm.
differential pressure
CE-marking
max. perm. pressure

Serial-No.
Year of manufacture no code
(1. and 2. position) max. perm. temperature
Fig. 2: Valve
min. temperature Figure-Number / min. temperature Figure-Number /

Type-Number Type-Number
max. temperature max. temperature
Manufacturer Manufacturer
max. ambient max. ambient

DIN-Register-No. DIN-Register-No.
Serial-No. temperature Serial-No. temperature
Year of manufacture no code Year of manufacture no code
(1. and 2. position) (1. and 2. position)
Fig. 3: Thermo controller Fig. 4: Detector
- Address of manufacturer:
refer to item 12.0 EC declaration of conformity
Page 6 Rev. 0040702000 3310

10203 TEMPTROL®
5.0 Installation
installation work:
Refer to data sheet for necessary resp. relevant data for correct installation;
e.g. dimensions, connections, max. operating limits, etc.
ATTENTION !
media.
avoided.
both sides.
recommended.
- Valve and controller/detector are delivered separately.
- Before installing the temperature regulator, rinse and clean the system otherwise the
seat / disc will be damaged and the control hole will be blocked.
- Centre packings between the flanges.
Rev. 0040702000 3310 Page 7

10203 TEMPTROL®
- Flow direction:
- Thermal closing valves:
The flow direction must correspond with the arrow on the valve body.
- Thermal opening valves (Inlet B closed):
Flow direction for thermal openting valves is preferably from A to B.
Inlet B must be closed with a blind flange.
(Flow direction from AB to A is possible, but not recommended, because oncoming
flow goes contrary the usual flow direction onto the plug.
- Thermal mixing/diverting valves: Mixing function
When installing 3-way valves, it is important to distinguish between
mixing and diverting of flow.
- Mixing:
The flow media inlets are A and B (the warmer medium should
enter inlet B).
- Diverting:
The medium enters through inlet AB and exits out of outlets A and B.
Diverting
In order to assure proper regulation, the pressures of both partial
flows (inflow for mixing or outflow for diverting) must be of equal
magnitude.
Please note, that with rising sensor temperature, inlet B (mixing) or
outlet B (diverting) are throttled.
The flow direction must correspond with the arrow on the valve
body.
maintenance and removing the actuator and extracting the temperature sensor out of the
piping or tank. Install a stop valve upstream and downstream of the temperature regulator
to enable repair and maintenance work, without emptying the system. Also a strainer
should exist in front of the control valve (refer to point 5.5), to exclude wear between seat
and disc.
Insert thermometer to control the medium temperature. The piping diameters before and
behind the valve must ensure, that the allowed flow velocities are not exceeded.
- When insulating, the bonnet, actuator, capillary tube and temperature sensor must stay
free.
- The capillary tube of the temperature regulator must be installed in such a way that no
large temperature alterations and vibrations occur. The max. distance between the tube
holders is 250 mm. The min. bending radius is 50 mm. The connecting pipe is part of a
hydraulic system. It must not be disconnected or damaged.
- Temperature sensors (pos. 50.1) can be installed in systems with sensor pockets. The
sensor pocket enables easy installation, when a change is necessary the system must not
be emptied. Note the longer time constant!
- Installation with actuator hanging.
5.2.1 Thermo controller with 2 temperature sensors
- The first temperature controller (pos. 50.1a) (a bar sensor for liquids or a spiral sensor for
air) measures the external temperature (regulating variable).
- The second temperature controller (pos. 50.1b) (a bar sensor) measures the external
temperature (command variable). It should be mounted outside wall - north side away
form the sun, 2m above ground and protected from wind.
Page 8 Rev. 0040702000 3310

10203 TEMPTROL®
- The influence of the external temperature on the controlled temperature is possible due to
the difference in volume between the first sensor (regulating variable) and the second
sensor (command variable).
- The set point indicator has a trend scale with a middle mark (refer to setting diagrams in
the data sheet).
5.2.2 Selection of temperature sensor- Location
- The temperature sensor (pos. 50.1) must be completely immersed.
Care should be taken to assure adequate circulation.
- At low flow rates, we recommend installing the temperature sensor (pos. 50.1) horizontally
(for example in boilers at 2/3 height).
- The control thermometer should be installed near the location from temperature sensor.
- In pipelines, a threaded coupler must be welded into the pipe and the temperature sensor
mounted against the flow direction.
- When installing the temperature sensor (pos. 50.1) directly, be sure the connection is free
of leaks (gasket is included).
- Room temperature sensors should not be exposed to interference such as drafts, sunlight
and other sources of heat.
(Connection of valve with thermal controller)
ATTENTION !
- It is not permitted to mantle / dismantle actuators with valves operating and in
service conditions (temperature and pressure) (refer to item 10.0).
-
Construction
- Set point of the thermal controller/detector, turn to maximum. Hold the set point indicator
with the other hand.
- Connect the actuator (pos. 50.16) (ca. 100 Nm) through the connecting nut to the valve
(pos. 11). (Attention: The actuator must not turn whilst connecting, because the capillary
tube (pos. 50.15) will be damaged!).
- The actuator (pos. 50.16) seals the valve interior only metallic; not extra gasket is allowed!
Dismantling
- Loosen the connecting nut of the actuator (pos. 50.16). (Attention: The actuator must not
turn, because the capillary tube (pos. 50.15) will be damaged!).
ATTENTION !
- When loosening the actuator, dangerous media can escape
(hot condensate, steam)
-
Rev. 0040702000 3310 Page 9

10203 TEMPTROL®
5.4 Manual control device
Pos. Designation
11 Bonnet (valve)
50.16 Actuator
50.17 Connecting nut (actuator)
60.3 Securing ring
Fig. 5 60.5 Adjusting ring
60.11 Pin
60.14 Connecting nut
- The manual control device is installed between the valve (pos. 11) and the actuator
(pos. 50.16) of the thermal control valve (Fig. 5).
- Note, that here also the sealing is only metallic, no extra gasket!
- The connecting nut (pos. 60.14) is fastened with about 100 Nm to the valve (pos. 11), the
actuator (pos. 50.16) with about 50 Nm to the manual control device.
In the following, a setting example is shown for a closing valve:
- Turn the adjusting ring (pos. 60.5) clockwise till the valve (pos. 11) is closed (mechanical
endpoint). The upper securing ring (pos. 60.3) is put in line with the notch of the pin
(pos. 60.11).
- Now turn the adjusting ring (pos. 60.5) anti-clockwise, till the valve (pos. 11) is full open
(max. flow). The bottom securing ring (pos. 60.3) is put in line with the notch of the
indicator pin (pos. 60.11). In the system you can then see the lift over the open and closed
position between the securing rings (pos. 60.3).
- Note, that when working the adjusting ring (pos. 60.5) must be in the opening position of
the valve; closed valve can’t be opened through the thermal controller!
Page 10 Rev. 0040702000 3310

10203 TEMPTROL®
5.5 Strainer
ATTENTION !
Install a strainer before the temperature regulator with the sieve sideways (with
the medium steam) to avoid the collection of condensate.
-
The strainer must be cleaned from time to time.

ATTENTION !
- Putting into operation only through expert personnel.
- To avoid a to higher temperature on the sensor, firstly adjust to the max. range
of the setting range.
The operation is then as follows:

- After installation, valve and piping must be filled over the return line. If this is not possible,
slowly open (half open) the stop valve before the control valve, and carefully without
pressure surges, fill the piping. Then slowly fully open the stop valve.
- Any leakage tests may be conducted only when the valve is not closed.
Otherwise, internal valve components could be damaged.
Rev. 0040702000 3310 Page 11

10203 TEMPTROL®
6.1 Setting range

6.1.1 Controller
Fig. 6: Setting range

Body screw
- The temperature setting is done through turning the setting ring (pos. 50.13). The body
(pos. 50.5) must be held fast; it is not allowed to turn.
- Setting of higher ranges is allowed without any restrictions.
- Setting for lower ranges when installed, is only allowed in small steps smaller 30 K.
Between the steps, the temperature regulation (system dependent about 15 min.) must be
waited for.
- When alterations larger than 30 K are done, the excess temperature indicator can
respond.
This can be seen when the setting ring (pos. 50.13) has moved upwards from the body
(Fig. 7) (pos. 50.5). In this case, the temperature regulation must be waited for, before
further alterations are done. Excess responses from the indicator shortens the lifetime
from the thermal controller!
Fig. 7: Excess temperature indicator
- After the temperature regulation in the system has been fulfilled, the actual temperature
can be seen on the control manometer.
- If both values which have been set are reached, then the procedure is ended.
- If the values are not correct, then a correction must be done on the set point indicator. The
set point must be altered to the actual value (see point 6.2).
Page 12 Rev. 0040702000 3310

10203 TEMPTROL®
6.1.2 Detector
Procedure see point 6.1.1, but instead of the alteration of the setting ring, the intended
setting is done with 11-box spanner or 8-key wrench.
Before you must remove the black ring (Pos. 50.13, Fig. 6) through pulling off, and then
push on after setting.
6.2 Setting correction
Fig. 8: Setting correction

Body screw
- Loosen the body screw (M4).

- The correction is done through turning the body (pos. 50.5) till the setting is equal to the
actual temperature (actual value on control manometer). The setting ring (pos. 50.13)
(tools with detector) must be held; it is not allowed to turn.
- Set to the needed value.
(Turn the setting ring (pos. 50.13) (tools with detector) - Hold body (pos. 50.5)).
- After the temperature regulation in the system had been fulfilled, read again the actual
temperature.
- If both values are the same, the procedure is ended.
- If the value has not been successfully reached, repeat the setting correction.
- When the correction is done, turn the body (pos. 50.5) so far, that the setting range can be
seen, then fasten the screw.

the requirements.
Rev. 0040702000 3310 Page 13

10203 TEMPTROL®
8.0 Troubleshooting
Instructions.
ATTENTION !
-

ATTENTION !
- read item 10.0 and 11.0 prior to dismantling and repair work !
- read item 5.0 and 6.0 before restarting the plant !

No flow Valve closed Bring manual control device in com-
Flange covers not removed Remove flange covers
Flow to small Valve not sufficiently open Bring manual control device in com-
Dirt sieve clogged Clean / replace sieve
Piping system clogged Check piping system
Thermal closing valve: Leaky capillary tube system Change the thermal control device
Flow to large, no temper-
direction tion
Thermal opening valve: Leaky capillary tube system Change the thermal control device
Flow to small, no temper-
direction tion
Thermal mixing/diverting Leaky capillary tube system Change the thermal control device
valve:
no or inadequate mixing
direction tion
or diverting function
Page 14 Rev. 0040702000 3310

10203 TEMPTROL®

ATTENTION !
media.

appointed by us.

Rev. 0040702000 3310 Page 15

10203 TEMPTROL®

AWH Armaturenwerk Halle GmbH,
Turmstrasse 118, D-06110 Halle/Saale
acc. to
ucts comply and have been approved according to module A diagram 6 (art. 3, annex II).
Bodies from pressure bearing equipment without safety function.
Category I (fluid group 1)
Temperature regulator
TEMPTROL®
Type 771, 772, 773, 774, 775, 776
in connection with
controller / detector / manual control device / sensor pocket
(Article 3, paragraph 3 acc. to „sound engineering practice“)
Type 990038601 to 990038636
Type 990038746 to 990038796
Type 990039001
Type 990038600Z22 to 990038600Z36
Applied standard:
DIN 3840 (DIN EN 12516)
DIN EN 14597
AD 2000 leaflet A4
- Cast steel, Forged steel
- Stainless steel
- Brass
.................................................
Page 16 Rev. 0040702000 3310

10241
Issue Date: 10/06
GESTRA Steam Systems Product Range A2
Non-Return Valve RK 86, RK 86A

RK 86, 86A for Flanges PN 10/16/25/40, DN 15-200
ASME Class 125/150/300
Description
Wafer-type non-return (check) valve for sandwiching between flanges. Valve with spring for installation in any position.
Without spring only for vertical lines with upward flow. Self-centering valve body. Application for liquids, gases and
vapours (observe classification according to PED).
Pressure/Temperature Rating
RK 86 DIN, EN, ASME B16.5, Class 300 Design
[°C] – 200 –10 20 100 200 300 350 400 500 550
DN 15 – 100 51 51 46.4 43.9 38.9 metal-to-metal (standard)
[bar] g 51 51 46.4 43.9 38.9 36.9 metal-to-metal with Nimonic®-springs
DN 125 – 200 51 51 46.4 43.9 38.9 metal-to-metal (standard) DN 15-100 mm (½ – 4")
[bar] g 51 51 46.4 43.9 38.9 36.9 34.5 metal-to-metal with Nimonic®-springs Standard design fitted with M8 antistatic connection
RK 86 A DIN, EN, ASME B16.5, Class 300 Design

[°C] – 200 –10 20 100 200 300 350 400 500 550
DN 15 – 200 49.6 49.6 49.6 42.3 35.8 31.6 metal-to-metal (standard)
[bar] g 49.6 49.6 49.6 42.3 35.8 31.6 30.4 29.3 27.3 24.0 metal-to-metal with Nimonic®-springs
Valve seat sealing tmin [°C] tmax [°C] Application Leakage rate
metal-to-metal RK 86, DN 15-100 –10 350 Liquids, gases, steam DIN 3230-3, BN 2, BO 3
metal-to-metal RK 86, DN 125-200 –10 400 Liquids, gases, steam DIN 3230-3, BN 2, BO 3
metal-to-metal RK 86A, DN 15-200 –200 550 Liquids, gases, steam DIN 3230-3, BN 2, BO 3
PTFE –190 250 Aggressive fluids DIN 3230-3, BN 2, BO 3
EPDM –40 150 Water, condensate, steam DIN 3230-3, BN 1, BO 1 DN 125-200 mm (5 – 8")
FPM –25 200 Mineral oils, gases, air DIN 3230-3, BN 1, BO 1 Standard design fitted with M8 antistatic connection
Chemical resistance see GESTRA Database “Chemical Resistance”
End Connections
DIN 1) ASME BS 10 3) JIS 4)
EN 1092-1 B 16.1 Class 125 FF B2238
Table D, E, F, H, J
PN 10/16/25/40 2) B 16.5 Class 150 /300 RF 10K
1) DN 125–200 mm (5–8"): On request form D or E acc. to EN 1092. 2) DN 15–100 mm (½–4") also suitable for PN 6.
3) For installation between flanges DN 15 mm (½"), BS 10, table H and J, please use RK 86/86A, DN 20 mm (¾").
4) As standard for installation between Fl. JIS 10K (except DN 80 mm). When ordering please indicate nominal size (reworking required).
Dimensions
Nominal [mm] 15 20 25 32 40 50 65 80 100 125 150 200
sizes [inch] ½ ¾ 1 1¼ 1½ 2 2½ 3 4 5 6 8
Dimensions L 5) 16 19 22 28 31.5 40 46 50 60 90 106 140
[mm] Zmin 44 53 64 73 83 96 110 128 151
Zmax 67 76 82 93 104 118 136 158 186 L
PN 10/16 194 220 275
PN 25 194 226 286
∅D PN 40 194 226 293 n
Z mi
Class 125/150 194 220 275
Class 300 216 251 308
Weight [kg] 0.27 0.38 0.52 0.8 1.12 1.78 2.43 3.37 5.34 11 14 25
5) Short overall length according to EN 558-1, series 49 ( DIN 3202, part 3, series K4)
Materials
DN 15 – 100 (¼ – 4") DIN /EN ASTM Category
Body, seat and RK 86 1.4317 A 743-CA 6-NM Chromium steel
guide ribs RK 86 A 1.4408 A 351CF8M Stainless steel Zmax
Valve disc, spring retainer Stainless steel
1.4571
Spring Stainless steel
DN 125 – 200 (5 – 8") DIN /EN ASTM Category

RK 86 1.0619 A 216 WCB Cast steel (carbon steel)
Body hard faced seat 1.4502
RK 86 A 1.4408 A351CF8M Stainless steel
Valve cone RK 86 1.4006 A 182F6 Chromium steel
∅D
Guide RK 86 1.4107 Chromium steel

Guide RK 86 A 1.4408 Stainless steel
Valve cone RK 86 A 1.4571 A 182F316 Stainless steel
Spring RK 86 and 86A 1.4571 Stainless steel
*) For the use in hygienic installations, foodstuff industry, pharmaceutical industry and similar applications please order RK 86 A
in pickled design. L
10241
Non-Return Valve Pressure Drop Chart ρ
VV̇w = V̇ ·
RK 86, 86A for Flanges The curves given in the chart are valid for water at 20 °C. 1000
To read the pressure drop for other fluids the equivalent
PN 10/16/25/40, DN 15-200 water volume flowrate must be calculated and used in VV̇w = Equivalent water volume flow
the graph. in l/s or m³/h
ASME Class 125/150/300 ρ = Density of fluid
The values indicated in the chart are applicable to spring-
assisted valves with horizontal flow. With vertical flow (operating condition) in kg/m³
insignificant deviations occur only within the range of V̇ = Volume of fluid
Opening pressures partial opening. (operating condition) in l/s or m³/h
Differential pressures at zero volume flow
DN Opening pressures in mbar
Direction of flow
without
with springs
springs
r r q o
15 2.5 10 7.5 5
20 2.5 10 7.5 5
25 2.5 10 7.5 5
32 3.5 12 8.5 5
40 4.0 13 9 5
50 4.5 14 9.5 5
65 5.0 15 10 5
80 5.5 16 10.5 5
100 6.5 18 11.5 5
125 12.5 35 22.5 10
150 14.0 38 24.0 10
200 13.5 37 23.5 10
1 mbar = 0.0145 psi = 100 mm w.g. = 0.4 in w.g.
On request at extra charge, special springs for opening
pressures:
Between 5 and 1000 mbar for DN 15 –50 mm (½ – 2"),
between 5 and 700 mbar for DN 65 and 80 mm (2½, 3"),
between 5 and 500 mbar for DN 100–200 mm (4 – 8").
Enquiry Specification
GESTRA DISCO Non-return valve type RK 86 / RK 86A for
flanges PN 10/16/25/40.
Wafer design with extremely short overall length to EN
558-1, series 49.
Suitable for fitting between pipe flanges to DIN/EN, BS and
ASME. Self-centering valve body (DN 15 – DN 100). The
valve disc rests on two of the four guide ribs, independently
of the flange standard. Broad sealing surfaces. Installation
in any position. Connection for electrostatic discharge line
as standard. Stronger springs for other opening pressures
are also available on request. Metal-to-metal or soft (EPDM,
FPM) seats. Design in accordance with PED 97/23/EC, with
CE marking. Specification of nominal pressure, size, body
materials etc. in accordance with EN 19.
Please note:
The selected non return valve must ensure that the
minimum volume flowrate keeps the valve disk in the open
position (see Pressure Drop Chart / stable range). Valve When ordering please state: PED (Pressure Equipment Directive)
construction is very robust, but they are not recommended
for use on compressors or where pulsating flow exists. If in Fluid, flowrate, service pressure and temperature, standard The equipment complies with the requirements of the
doubt please consult us and we will carry out the pressure of pipe flange. Pressure Equipment Directive 97/23/CE. Applicable with
drop calculation and select a suitable valve. The following test certificates can be issued on request, fluids of group 1 and 2. With CE marking (apart from
at extra cost: equipment that is excluded from the scope of the PED
according to section 3.3). For more information refer to
In accordance with EN 10204-2.1, -2.2, 3.1 and 3.2. our PED Declaration of Conformity.
All inspection requirements have to be stated with the
order. After supply of the equipment certificates can no
longer be established. Charges and extent of the above
mentioned certificates as well as the different tests The equipment does not have its own potential source of
confirmed therein are listed in our price list “Test and ignition and is therefore excluded from the scope of the
Inspection Charges for Standard Equipment”. A
ATEX Directive 94/9/EC. Applicable in Ex zones 0, 1, 2,
20, 21, 22 (1999/92/EC). The equipment does not bear
Supply in accordance with our general terms For other tests and inspections than those listed above,
an Ex marking. For more information refer to our ATEX
of business. please consult us.
Declaration of Manufacturer.
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Telephone +49 (0) 421 35 03 - 0, Fax +49 (0) 421 35 03-393
E-Mail gestra.ag@flowserve.com, Internet www.gestra.de

Safety Note 1
10241
The equipment must only be installed and commissioned by qualified and adequately
trained personnel. Maintenance and retrofitting must only be performed by entrusted
personnel who – through adequate training – have achieved a recognized level of
competence.
Usage for the intended purpose 1

The non-return valves RK are automatic-stop check valves and designed for use in
pipes in order to prevent the backflow of fluid. The admissible pressure and temperature
ratings as well as the chemical and corrosive influences of the fluid on the pressure
equipment must be taken into account. Check the chemical resistance and suitability of
the valve for the operating conditions in question.
Attention 1
The name plate specifies the technical characteristics of the equipment.
Do not commission or operate a device without a name plate!
Danger 1
10241
The valve is under pressure during operation.
When loosening flanged connections or sealing plugs, hot water, steam,
corrosive fluids or toxic gases may escape. This presents the risk of severe
burns and scalds to the whole body or severe cases or poisoning.
Installation and maintenance work should only be carried out when the
system is depressurized.
The valve becomes hot or extremely cold during operation. This presents
the risk of severe burns to hands and arms. Installation and maintenance
work should only be carried out at room temperatures.
Sharp edges on internals present a danger of cuts to hands. Always wear
industrial gloves for installation and maintenance work.
ATEX Directive 94/9/EC, 1999/92/EC 1

The equipment does not have its own potential source of ignition and is therefore not
subject to the Directive 94/9/EC.
The equipment can be used in the following explosive zones: 0, 1, 2, 20, 21 and 22.
The equipment does not require an Ex marking.
Technical Data 1
10241
For pressure ratings see marking or name plate (pressure class PN/Class, material
number, sticker for soft seal, spring material)
Observe lower temperature ratings for equipment with elastic seals and certain spring
materials.

RK 70 6 /- 15 - 100 6 / -30 0.5 / 130
RK 70 6 /- 125 - 200 6 / -10 0.5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49.6 / -10 31.6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36.9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34.5 / 400
RK 86A 40 / 300 15 - 200 49.6 / -200 24 / 550
Technical Data – continued – 1
10241
RK 16A 40 / 300 15 - 100 49.6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49.6 / -200 29.3 / 400
RK 26A 40 / 300 15 - 100 49.6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110.8 / 550
RK 49 160 / – 80 - 200 160 / -10 55.3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44.2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70.2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112.4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175.6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224.7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280.9 / 500
RK 29A – / 400 15 - 200 66.2 / -200 37.6 / 500
RK 29A – / 600 15 - 200 99.3 / -200 56.6 / 500
RK 29A – / 900 15 - 200 148.9 / -200 84.7 / 500
RK 29A – / 1500 15 - 200 248.2 / -200 140.9 / 500
RK 29A – / 2500 15 - 200 413.7 / -200 235 / 500
Description 1
10241
Non-return valve RK with spiral centering ring or self-centering body. Installation in any
position. Exception: Valves without spring can only be installed in vertical lines with
upward flow.
1 Non-return valve with spiral centering ring
2 Non-return valve with body centering cams
3 Non-return valve with self-centering body
4 Position of guide ribs (horizontal installation)
Installation 1
10241
TOP
1 2 3 4
Name Plate / Marking 1
10241
Type: RK ...
DN:... Type: RK ...
PN:... DN:...
.......... PN:...
..........
Type: RK ... Type: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02 X 2002
1 X 2002
02
Declaration of Conformity 1
10241
We hereby declare that the pressure equipment RK... conforms to the following European
Directive:
Q Pressure Equipment Directive (PED) 97/23/EC of 29 May 1997 (except for equipment
excluded from the scope of the PED according to section 3.3).
Q Applied conformity assessment procedure: Annex III, Module H, verified by the
Notified Body 0525.
This declaration is no longer valid if modifications are made to the equipment without
consultation with us.
Bremen, 11th February 2005
GESTRA AG
Head of the Design Dept. Quality Assurance Manager

Uwe Bledschun Lars Bohl
(Academically qualified engineer) (Academically qualified engineer)
Enclosure no. 10249
Level Measurement
Float Switches with Permanent Magnet

For Horizontal Installation
Model HIF
KSR KUEBLER AG Data Sheet HIF
Applications
Level measurement for almost all liquid media

Pump/level control
Chemical industry, petrochemical industry, natural gas,
offshore, shipbuilding, machine building, power genera-
ting equipment, power stations
Process water and drinking water treatment, food and
beverage industry
Special Features
Large scope of application due to the simple, proven

functional principle
For harsh operating conditions, long service life
Operating limits:
- Operating temperature: T = -196 ... +300 °C
- Working pressure: P = vacuum to 100 bar
- Limit S. G.: ρ ≥ 400 kg/m3
Wide variety of different electrical connections and
materials
Explosion-protected versions
Float Switches with Permanent Magnet,
for horizontal installation, Model HIF
Fig. top: Stainless steel version
Fig. bottom: Plastic version
Description
In addition to the various applications for KSR KUEBLER By using a magnet and reed contact the switching opera-
AG‘s float switches for vertical installation, the horizontal tion is non-contact, free from wear and needs no power
KSR KUEBLER AG float switches likewise offer innumer- supply.
able possibilities to monitor and/or switch levels in order to
indicate minimum/maximum levels. The float switch is simple to mount and maintenance-free,
so the costs of mounting, commissioning and operation are
The float is attached to a supported, swivelling lever and low.
moves with the level of the medium being measured. By
means of a permanent magnet, fixed to the other end of the
lever, when a preset switch point is reached, a reed contact
(inert gas contact) within the contact pipe is energised.
KSR KUEBLER AG Data Sheet HIF ∙ 01/2013 Page 1 of 6
Data Sheets showing similar devices:

Float Switches with Permanent Magnet, vertical installation; Model RSM; see data sheet RSM
Float Switches with Permanent Magnet, lateral mounting; Model RSB; see data sheet RSB
Enclosure no. 10249
Further special features
Process connection, contact tube and float made of

stainless steel 1.4571 or plastic
Universal signal processing:
connection direct to a PLC is possible,
NAMUR connection, signal amplification / contact
protection relays
Works independently of foaming, conductivity,
dielectricity, pressure, vacuum, temperature, steam,
condensation, blistering, boiling effects and vibrations
Exact repeatability of the switch points
Float switches with permanent magnets qualify as
passive electrical equipment in accordance with DIN IEC
60 079-11 and can be installed in 'Zone 1' hazardous
areas without certification, so long as the equipment
is operated in a certified intrinsically safe circuit with a
minimum explosion protection of EEx ib
Options
Customer-specific solutions
Process connection, contact tube material and float
made of titanium or Hastelloy (other materials on
request)
Page 2 of 6 KSR KUEBLER AG Data Sheet HIF ∙ 01/2013

Enclosure no. 10249
Standard version
Process connection, contact tube and float made of stainless steel 1.4571
Example
Terminal box
Float Model V44HI Float Model T52/1HI Float Model ZVSS43/100HI

Electrical connection Terminal box  Stainless steel
Raised Terminal Box  without (60 mm with high temperature version)
Process connection Mounting flange  DIN DN 50 ... DN 200, PN 6 ... PN 100
 ANSI 2" ... 8", Class 150 ... 600
Contact tube
Insertion length L 190 ... 1090 mm 250 ... 1150 mm
Contact tube length KL 100 ... 1000 mm
Float material Stainless steel 1.4571 Titanium 3.7035 Stainless steel 1.4571
Float
Diameter 44 mm 52 mm 43 mm
Length 52 mm 52 mm 100 mm
Max. working pressure 16 bar 100 bar 20 bar
Min. specific gravity 600 kg/m³
Temperature range
standard -40 ... +200 °C
Option:  High temperature version: +100 ... +350 °C
Option:  Low temperature version: -196 ... +40 °C
Switch function Change-over U (initiator SJ 3.5-SN) - at increasing level
Max. number of contacts 1xU
Contact rating 230 V AC; 40 VA; 1 A 230 V DC; 20 W; 0.5 A Please observe contact protection measures (see page 6)!
Attention: Versions without protective earth conductor - operation only at safety extra-low voltage
e.g. KSR KUEBLER AG contact protection relay or external earthing
Mounting position Horizontal ± 30°
Ingress protection IP 65 per EN 60 529 / lEC 529
Connection diagrams
1 switch point 1 switch point 1 switch point
Wiring for operation with a PLC Initiator equivalent circuit
blue (1) per EN 60 947-5-6
blue (1)
brown (2) 22 Ohm blue (1) 10 K
brown (2) 1K
black (3) brown (2)
black (3) 10 K
black (3)

Enclosure no. 10249
Plastic version
Process connection, contact tube and float made of polypropylene
Example
Terminal box
Float Model PP44HI

Electrical connection Terminal box  Polypropylene 80 x 82 x 55 mm
Process connection Mounting flange  DIN DN 50 ... DN 125, PN 10, form A
 ANSI 2" ... 5", Class 150 FF
Contact tube
Insertion length L 176 mm
Contact tube length KL 111 mm
Float material  Polypropylene
Float
Diameter 44 mm
Length 52 mm
Max. working pressure 3 bar
Temperature range -10 ... +80 °C
Contact rating 230 V AC; 40 VA; 1 A 230 V DC; 20 W; 0.5 A Please observe contact protection measures (see page 6)!
Attention: Versions without protective earth conductor - operation only at safety extra-low voltage
e.g. KSR KUEBLER AG contact protection relay or external earthing
Connection diagrams
1 switch point 1 switch point

Initiator equivalent circuit
blue (1) per EN 60 947-5-6
brown (2) blue (1) 10 K
1K
black (3) brown (2)
10 K
black (3)

Enclosure no. 10249
Explosion-protected version, intrinsically safe

II 1/2G EEx ia IIC T3-T6 KEMA 01 ATEX 1053X
II 2D T80 °C IP6X
Process connection, contact tube and float made of stainless steel 1.4571
Example
Terminal box
Float Model V44HI Float Model T52/1HI Float Model ZVSS43/100HI

Electrical connection Terminal box  Stainless steel
Process connection Mounting flange  DIN DN 50 ... DN 200, PN 6 ... PN 100
 ANSI 2" ... 8", Class 150 ... 600
Contact tube
Insertion length L 190 ... 1090 mm 250 ... 1150 mm
Contact tube length KL 100 ... 1000 mm
Float material Stainless steel 1.4571 Titanium 3.7035 Stainless steel 1.4571
Float
Diameter 44 mm 52 mm 43 mm
Length 52 mm 52 mm 100 mm
Max. working pressure 16 bar 100 bar 20 bar
Temperature class T2 T3 T4 T5 T6
Process temperature Max. 180 °C 160 °C 108 °C 80 °C 65 °C
Ambient temperature
at terminal box Max. 80 °C 80 °C 80 °C 80 °C 60 °C
Contact rating Only for connection to a certified intrinsically safe circuit with Umax 36 V, Imax 100 mA
Connection diagrams
1 switch point 1 switch point 1 switch point

Wiring for operation with a PLC Initiator equivalent circuit
blue (1) per EN 60 947-5-6
blue (1)
brown (2) 22 Ohm blue (1) 10 K
brown (2) 1K
black (3) brown (2)
black (3) 10 K
black (3)

Enclosure no. 10249
Contact protection measures

To ensure reliable operation of sensors with reed switches and highest possible service life,
we recommend using one of the following circuits.
Inductive load AC Surge current S1

measurement
S1 with oscilloscope C RE
RC modules depending
Example: 24 V DC
R
24 - 230V AC on operating voltage
see table C = 0.33 µF/24 V DC RM
C
Inductive load DC I (A)

without current limitation
I (A) not
S1
+
4 allowed
43
Shunt diode with current limitation
24 - 250V DC
e.g. 1N4007 32
21
– allowed
1
3-10
3-10 t (μs)
µ
Current limitation with capacitive load Protective RC modules t (μs)
e.g. PLC, DCS and cables > 50 m RC modules are, depending on the operating voltage,
to be used exclusively according to the table below.
D
S1 RS
+ Rs = 22 Ohm
C1 (47 Ohm with
24 V DC D
10 VA contacts)
C1= internal capacitance D = Ø 16 mm - Ø 25 mm
SPS
L
– L = 26 mm - 58 mm
L
wire
200
For inert gas contacts from 10 ... 40 VA

Current limitation with electronic timers
200
Capacitance Resistance Voltage

0.33 µF 100 Ohm 24 V AC
S1 RS
0.33 µF 220 Ohm 48 V AC
+ Rs = 220 Ohm
C1 0.33 µF 470 Ohm 115 V AC
230 V AC 230 V AC) 0.33 µF 1500 Ohm 230 V AC
Zeit- C1= internal capacitance
– relais For inert gas contacts from 40 ... 100 VA
Capacitance Resistance Voltage
0.33 µF 47 Ohm 24 V AC
0.33 µF 100 Ohm 48 V AC
0.33 µF 470 Ohm 115 V AC
0.33 µF 1000 Ohm 230 V AC
Other types than the RC modules specified here might
lead to destruction of the reed contact.
Model / Version / Electrical connection / Process connection / Contact tube (insertion length L, contact tube length KL) /
Options
Modifications may take place and materials specified may be replaced by others without prior notice.
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
112456 REV 01/2013 GB
KSR KUEBLER Niveau-Messtechnik AG

Heinrich-Kuebler-Platz 1
69439 Zwingenberg, Germany
Tel. (+49) 6262 87-0
Fax (+49) 6263 8799
www.ksr-kuebler.com
Enclosure no. 10249
Montage- und Betriebsanleitung

Mounting and operating instruction
Montage et mode d´ emploi
Bitte zur künftigen Verwendung aufbewahren

Please retain for future usage
Veuillez conserver pour un usage futur
Schwimmer - Magnetschalter
Magnetic operated float switches
Interrupteurs magnètiques à flotteur
Rev.4 / 04.12.2002 Irrtümer und Änderungen vorbehalten

Enclosure no. 10249
Enclosure no. 10249
Folgende Symbole werden in dieser Betriebsanleitung verwendet:

The following symboles are be used in this manual:
Les symboles suivant sont utilisès dans ce manuel:
Warnhinweis.
Hinweise zur fachgerechten Montage und den
bestimmungsgemäßen Betrieb des Schwimmer - Magnetschalters.
Eine Nichtbeachtung kann zu Fehlfunktionen oder der Zerstörung
der Reedkontakte führen.
Warning
Instructions for proper installation and use of magnetic float
switches. Disregard may lead to malfunction or destruction of reed
contacts.
Signal d’avertissement
Instructions qui permettet le montage et l’utilisation correctes des
régulateurs de niveau á flotteur. Un mépris de ces instructions
peut conduire au mauvais fonctionnement ou á la detruction des
contacts à lame souple.
Gefahrenhinweis
Hinweise zur Vermeidung von Personen- oder Sachschäden.
Danger
Instructions to avoid personal or property damage.
Signal de danger
Instructions qui permettet d’éviter de porter atteinte á des
personnes ou á des biens.
Hinweise zur elektrischen Installation

Angaben für eine fachgerechte elektrische Installation.
Electrical installations
Instructions for proper electrical installation.
Installation électrique
Indications qui permettet une installation électrique correcte.
-1-
Enclosure no. 10249
Funktionsbescheibung
Schwimmer - Magnetschalter arbeiten nach dem Schwimmer-
prinzip mit magnetischer Übertragung. Ein im Gleitrohr (5) bzw.
Kontaktrohr (8) eingebauter Reedkontakt wird durch das Ma-
gnetfeld eines Permanentmagneten bei Erreichen eines vorge-
gebenen Schaltpunktes betätigt. Der Permanentmagnet befindet
sich in einem Schwimmer (7), der seine Höhenlage mit dem Pegel
des zu überwachenden Mediums verändert. Der Schaltzustand
des Reedkontaktes kann durch eine nachgeschaltete
Steuereinrichtung ausgewertet und weiterverarbeitet werden.
Die Anzahl und Anordnung der Schwimmer ist abhängig von der
Anzahl der vorgegebenen Schaltpunkte, deren Kontaktfunktion
sowie dem Abstand der Schaltpunkte.
Einsatzbereich
Schwimmer - Magnetschalter sind ausschließlich zur Füll-
standssteuerung bzw. -überwachung von flüssigen Medien zu
verwenden.
Die Flüssigkeiten dürfen keine starke Verschmutzungen oder
Grobteile aufweisen und nicht zum Auskristallisieren neigen. Es ist
sicherzustellen, daß die medienberührenden Werkstoffe des
Schalters (Schwimmer, Gleitrohr) gegen das zu überwachende
Medium ausreichend beständig sind.
Montage
Ausführungen für vertikalen Einbau (Fig. 1)

• KSR Schwimmer - Magnetschalter entsprechend der Ausfüh-
rung (Flansch o. Gewinde [3]) einbauen.
• Bei Flanschausführungen sind die zum Flansch passenden
Schrauben und Muttern zu verwenden. Zum Abdichten ist eine
geeignete Dichtung (4) vorzusehen.
• Es ist auf korrekte Einbaulage zu achten. (Max. Abweichung
aus der vertikalen ± 30° ).
• Bei Einbauöffnungen die kleiner als der Durchmesser des
Schwimmers sind, ist der Schwimmer (7) vor dem Einbau des
Schalters abzunehmen.
• Die Position der Stellringe (6) ist vor dem Abnehmen zu mar-
kieren (z.B. mit einem wasserfesten Stift).
• Sofern die Schwimmer nicht gekennzeichnet sind, ist die Ein-
baulage entsprechend zu kennzeichnen (z.B. "Oben")
• Nach dem Einbau des Schwimmer - Magnetschalters ist der
Schwimmer im Inneren des Tanks wieder aufzusetzen
(Einbaulage beachten!).
• Die Stellringe (6) sind anschließend an den markierten Stellen
wieder zu befestigen.
• Die Anzahl der Schwimmer sowie die Position der Stellringe
sind vom Maß und der Anzahl der Schaltpunkte abhängig.
-2-
Enclosure no. 10249
Ausführungen für horizontalen Einbau (Fig. 2)

Schwimmer - Magnetschalter für horizontale Einbaulage sind ge-
mäß Fig.2 einzubauen.
Bei Flanschausführungen sind die zum Flansch passenden
Schrauben und Muttern zu verwenden. Zum Abdichten ist eine
geeignete Dichtung (4) vorzusehen. Es ist auf korrekte Einbaulage
zu achten. (Der Schwimmer muß im unbetätigten Zustand nach
unten gekippt sein). Beim Einbau in Stutzen muß gewährleistet
sein, daß der Schwimmer in seiner Kippbewegung nicht
beeinträchtigt wird.
Beim Einbau in ferromagnetische Stutzen wird die Funktions-

fähigkeit des Schalters beeinträchtigt.
Gefahr von Sachschäden durch fehlerhaftes Schaltverhalten des
Reedkontaktes.
Der Schwimmerschalter ist so einbauen, daß sich das Kontaktrohr
außerhalb eines ferromagnetischen Stutzens befindet.
Elektrischer Anschluß
Der elektrische Anschluß ist entsprechend den im Errichtungsland

geltenden Errichtungsbestimmungen durchzuführen und darf nur
von Fachpersonal durchgeführt werden.
Zur Erhöhung der Lebensdauer der Kontakte wird der Betrieb an
einem Kontaktschutzrelais empfohlen.
Der elektrische Anschluß ist entsprechend dem jeweiligen am

Schalter angebrachten Anschlußschema vorzunehmen.
(Ausführungen mit nur einem Öffner oder Schließerkontakt
enthalten kein Anschlußschema.)
Die Kabeldurchführung (2) am Anschlußgehäuse (1) ist abzu-
dichten.
-3-
Enclosure no. 10249
Der Betrieb der Schwimmer - Magnetschalter an induktiver oder

kapazitiver Last kann eine Zerstörung des Reedkontaktes zur
Folge haben. Dies kann zu einer Fehlfunktion der nachgeschal-
teten Steuerung und zu Personen- oder Sachschäden führen.
Bei induktiver Belastung sind die Schwimmer - Magnetschalter
durch Beschaltung mit einem RC Glied gem. Anhang bzw. einer
Freilaufdiode zu schützen.
Induktive Last an Induktive Last an

Wechselspannung Gleichspannung
S1 S1
+
R RC-Glieder je nach Freilaufdiode
24 - 230V AC Betriebsspannung 24 - 250V DC z.B. 1N4007
siehe Tabelle
C
-
Bei kapazitiver Belastung, Leitungslängen über 50m oder dem An-

schluß an Prozeßleitsystemen mit kapazitivem Eingang ist zur Be-
grenzung des Spitzenstromes ein Schutzwiderstand von 22Ω bzw.
47Ω (bei 10VA-Kontakten) in Serie zu schalten.
Bei Anschluß an elektronische Zeitrelais muß ein Widerstand von
220 Ohm in Serie geschaltet werden.
Strombegrenzung bei Strombegrenzung bei
kapazitiver Last elektronischen Zeitrelais
z.B. SPS, PLS und Leitungen >50m
S1 Rs S1 Rs
+ Rs = 22 Ohm Rs = 220 Ohm
C1 (47Ω bei Kontakten 230V AC
24V DC C1 (230V AC)
bis 10VA) Zeit-
- SPS C1 = innere Kapazität C1 = innere Kapazität
relais
Eine Überlastung des Schwimmer - Magnetschalters kann eine

Zerstörung des eingebauten Reedkontaktes zur Folge haben. Dies
kann zu einer Fehlfunktion der nachgeschalteten Steuerung und
zu Personen- oder Sachschäden führen. Die im Kapitel
"Technische Daten" und im KSR-Typenblatt 1003 angegebenen
Maximalwerte für die Schaltleistung sind einzuhalten.
Spitzenstrommessung mit Oszilloscope
S1 I (A)
ohne Strombegrenzung
C RE 4
24V DC 3
mit Strombegrenzung
2
RM
nicht zul. Bereich
1
zul. Bereich
Beispiel: C = 0,33µF/230V AC 3-10 t (µs)
Bei Schwimmer - Magnetschaltern mit Anschlußkabel ohne

Schutzleiteranschluß kann der Schalter im Fehlerfall spannungs-
führend sein. Bei Berührung können schwere Körperschäden oder
tödliche Verletzungen auftreten. Diese Schalter dürfen nur an
Schutzkleinspannung nach VDE0100 betrieben werden (z.B. an
einem KSR Kontakt-schutzrelais) oder sind so zu montieren, daß
der Schwim-mer - Magnetschalter mit dem Potentialausgleich elek-
trisch verbunden ist.
-4-
Enclosure no. 10249
Inbetriebnahme / Funktionsprüfung
Versorgungsspannung der angeschlossenen Steuerungsein-
richtung einschalten, Behälter füllen und die Schaltpunkte des
Schwimmer - Magnetschalters auf Funktion prüfen. Die Funk-
tionsprüfung kann auch manuell bei ausgebautem Schalter erfol-
gen.
Es ist sicherzustellen, daß durch die Funktionsprüfung keine

unbeabsichtigten Prozeßabläufe eingeleitet werden.
Wartung
Schwimmer - Magnetschalter arbeiten bei bestimmungsgemäßem
Gebrauch wartungs- und verschleißfrei.
Bei extremen Einsatzbedingungen sollte der Schalter im Rahmen
der durchzuführenden Revisionen einer Sichtkontrolle unterzogen
werden.
Hinweise
Beim Betrieb im Ex - Bereich der Zone 1 oder 2 sind die
Reedkontakte an eigensicheren Stromkreisen zu betreiben.
Schwimmerschalter aus Kunststoff dürfen nicht im Ex - Bereich

der Zone 1 oder 2 eingesetzt werden.
Schwimmerschalter nicht in unmittelbarer Nähe von starken

elektromagnetischen Feldern bzw. in unmittelbarer Nähe von
Einrichtungen, die durch Magnetfelder beeinflußt werden können,
betreiben (Abstand min. 1m).
Die Schaltpunkte der Schwimmer - Magnetschalter können nicht

verstellt werden.
Schwimmer - Magnetschalter nur in Medien einsetzen gegen die

der Werkstoff des Gleitrohres und des Schwimmers beständig ist
Die Schalter dürfen keinen starken mechanischen Belastungen

(Stoß, Verbiegen, Vibrationen) ausgesetzt werden.
-5-
Enclosure no. 10249
Technische Daten
Kontaktfunktion :Öffner / Schließer
Max. Spannung :250V AC / DC
Schaltstrom :2A AC / 1A DC
Schaltleistung :100 VA, cosϕ >0,7 / 50 W
Kontaktfunktion :Umschalter
Max. Spannung :250V AC / DC
Schaltstrom :1A AC / 0,5A DC
Schaltleistung :40 VA, cosϕ > 0,7 / 20 W
Mini Schwimmerschalter
Kontaktfunktion :Öffner / Schließer

Spannung :250V AC / DC
Schaltstrom :0,5A AC / 0,25A DC
Schaltleistung :10 VA , cosϕ > 0,7 / 5 W
-6-
Enclosure no. 10249
Functional Description
Magnet-operated float switches operate according to the float
principle with magnetic transmission. A reed contact built into the
slip pipe (5) or contact pipe (8) is activated by the magnetic field of
a permanent magnet on reaching a preset switching point. The
permanent magnet is located in a float (7) which changes its
height with the level of the medium being monitored. The switching
state of the reed contact can be evaluated and processed by a se-
ries-connected control unit.
The number and arrangement of the floats depends on the
number of preset switching points, their contacting function and
the distance apart of the switching points.
Area of Application
Magnet-operated float switches are used exclusively for level
control and monitoring of liquid media.
The liquids may not be heavily contaminated and should not have
a tendency to crystallize. Make sure that the materials of the
switch (float, slip pipe) which come into contact with the medium
being monitored are suitably resistant.
Assembly
Versions for vertical installation (Fig. 1)
• Install KSR magnet-operated float switches according to their
type (flange or thread [3]).
• Use the screws and nuts suitable for the flange for flange
types. Fit a suitable gasket (4) for sealing. Make sure it is
installed in the right position. (Max. deviation from the vertical ±
30°).
• The float (7) must be removed before installation in openings
with a diameter smaller than the diameter of the float.
• Mark the position of the set collars (6) before removing.
• If top and bottom of the floats are not already marked, please
do so now.
• Replace the float inside the tank after installing the magnet-
operated float switch.
• Then fix the set collars (6) back in the same position.
• The number of floats and position of stop rings are dependent
on the switching positions and number of switch points.
Versions for horizontal installation (Fig. 2)

Magnet-operated float switches for horizontal operation must be
installed as shown in fig. 2.
Use the screws and nuts suitable for the flange for flange types.
Fit a suitable gasket (4) for sealing. Make sure it is installed in the
right position. (The float must be tilted downwards in the
unactivated state). When installing in the union, make sure that the
tilting of the float is not affected.
-7-
Enclosure no. 10249
When mounted inside ferromagnetic surroundings the function

could be restrained. This may cause a malfunktion and harm to
goods.
The magnet operated float switch must be mounted outside
ferromagnetic surroundings.
All cabling and electrical connections must be carried out in ac-
cordance with the regulations applicable in the country where the
equipment is installed and by personnel qualified to do.
Operation on a contact protection relay is recommended to
prolong the life of the contacts.
The electrical connection is made according to the wiring

diagram printed on the switch.
(Types with only one normally closed or normally open contact
contain no wiring diagram.)
The cable bushing (2) in the connection enclosure (1) must be
sealed.
Use of magnetic float switches with inductive or capacitive load

may lead to the destruction of the reed switch. This may cause a
malfuction to the control circuitry and harm to persons or goods.
With inductive load, magnetic switches have to be connected to a
RC Network (acc. to appendix).
Inductive Load AC Inductive Load DC
S1 S1
+
R RC-Modules Shunt diode
24 - 230V AC acc. to table 24 - 250V DC e.g. 1N4007
C
-
-8-
Enclosure no. 10249
With capacitive load, connecting cables longer than 50m or

connection to a PLC with capacitive input circuit, a 22Ω resp. 47Ω
(10 VA contacts) resistor is required to be connected in series to
limit current spikes. A 220Ω resistor shall be used when connected
to an electronic timer.
Current limitation with Current limitation with

capacitive load electronic timers
e.g. PLC and cables > 50m
S1 Rs S1 Rs
+ Rs = 220 Ohm
C1 Rs = 22 Ohm (230V AC)
24V DC 230V AC C1
C1 = internal C1 = internal
- SPS timer
capacitance capacitance
Overloading the magnetic float switches may lead to the de-

struction of the reed switch, which may cause a malfunktion to the
control circuitry and harm to persons or goods. The maximum
switch capacity values given in the chapter "Technical data" and
the Technical bulletin 1003 must not be exceeded.
Current measurement with oscilloscope

S1 I (A)
without current limitation
C RE 4
24V DC 3
with current limitation
2
RM not allowed
1
allowed
Example: C = 0,33µF/230V AC 3-10

t (µs)
Magnetic float switches with connecting cable including no

protective earth may be live under fault conditions. Touching
the housing may cause harm to persons or even be lethal.
These switches must only be used with protective low voltage
acc. to VDE 0100 ( f. e. use a KSR contact protection relay) or
have to be mounted in such way, that the switch is earthed.
Commissioning / Function Test

Switch on the power supply to the connected control unit. Fill
the vessel and check the function of the switching points of the
magnet-operated float switch.
The function test can also be conducted manually on the removed
switch.
Note
Make sure that the function test does not accidentally set any
processes in motion.
-9-
Enclosure no. 10249
Maintenance
The magnet-operated float switches operate free of maintenance
and wear when used properly.
The switch must be eye-checked within the scope of the
necessary inspections under extreme operating conditions.
Notes
The reed contacts must be operated on intrinsically safe circuits
when operating in "e" areas of zone 1 or 2.
Float switches made of plastic may not be used in the "e" areas of
zone 1 or 2.
Do not operate float switches in the immediate vicinity of strong

electromagnetic fields (distance away at least 1m).
The switching points of the magnet-operated float switches cannot

be adjusted.
Magnet-operated float switches can only be used in media to

which the material of the slip pipe and the float is resistant.
The switches may not be exposed to heavy mechanical stresses

(shock, bending, vibrations).
Technical data
Switching behaviour :Norm close / Norm open
Max. voltage :250V AC / DC
Max. current :2A AC / 1A DC
Max. power :100 VA, cosϕ >0,7 / 50 W
Switching behaviour :change over

Max. current :1A AC / 0,5A DC
Max. power :40 VA, cosϕ > 0,7 / 20 W
Magnet operated Mini Float Switches
Switching behaviour :Norm close / Norm open

Max. current :0,5A AC / 0,25A DC
Max. power :10 VA , cosϕ > 0,7 / 5 W
- 10 -
Enclosure no. 10249
Description fonctionnelle
Les interrupteurs magnétiques à flotteur fonctionnent suivant le
principe des flotteurs à transfert magnétique. Un contact Reed
logé dans le tube de glissement (5) ou dans un tube de contact (8)
est actionné par le champ magnétique d'un aimant permanent
lorsqu'un point de commutation prédéterminé est atteint. L'aimant
permanent est monté dans un flotteur (7) qui change sa position
en hauteur avec le niveau du milieu à surveiller. L'état de
commutation du contact Reed peut être évalué et traité par un
dispositif de commande monté en aval à circuit de courant de
commande à sécurité intrinsèque.
Le nombre et la disposition des flotteurs dépendent du nombre de
points de commutation prédéterminés et de leur fonction de
contact ainsi que de l'écart des points de commutation.
Domaine d'application
Les interrupteurs magnétiques à flotteur servent exclusivement à
commander ou à surveiller le niveau de remplissage de milieux
liquides.
Les liquides à surveiller ne doivent pas contenir de fortes
pollutions ou de particules grossières et ne doivent pas avoir
tendance à se cristalliser. Il faut s'assurer que les matériaux de
l'interrupteur (flotteur, tube de glissement) au contact du milieu
résistent suffisamment au milieu à surveiller.
Montage
Exécutions pour un montage à la verticale (fig. 1)
• Monter les interrupteurs magnétiques à flotteur KSR con-
formément à l'exécution (bride ou filetage [3]).
• Pour les exécutions à bride, il convient d'utiliser les vis et les
écrous adaptés à la bride. Pour étouper, il convient de prévoir
un joint adéquat (4).
• Veiller à ce que la position de montage soit correcte. (Ecart
maximal par rapport à la verticale ± 30° ).
• En présence d'ouvertures de montage plus petites que le dia-
mètre du flotteur, il convient d'enlever le flotteur (7) avant le
montage de l'interrupteur.
• Dans la mesure où les flotteurs ne portent pas de marquage, la
position de montage adéquate (par exemple en „haut“) doit
être indiquée.
• Il convient de marquer la position des bagues de réglage (6)
avant l'enlèvement.
• Après avoir monté l'interrupteur magnétique à flotteur, il
convient de replacer le flotteur à l'intérieur du réservoir.
• Les bagues de réglage (6) doivent être ensuite fixées de
nouveau au même endroit.
• Le nombre de flotteurs ainsi que la position des anneaux de
règlage dèpendent de la position et du nombre des contacts.
- 11 -
Enclosure no. 10249
Exécutions pour un montage à l'horizontale (fig. 2)

Les interrupteurs magnétiques à flotteur destinés à un mon-tage à
l'horizontale doivent être montés conformément à la figure 2.
Pour les exécutions à bride, il convient d'utiliser les vis et les
écrous adaptés à la bride. Pour étouper, il convient de prévoir un
joint adéquat (4). Veiller à ce que la position de montage soit
correcte. (Le flotteur doit être basculé vers le bas à l'état non
actionné).
Pour un montage dans des tubulures, il faut assurer que le flotteur
ne soit pas gêné dans son mouvement de basculement
Le montage dans des tubes ferromagnétiques entraîne un

mauvais fonctionnement du commutateur. Danger de dommages
matériels en raison de mauvaises commutations du contact reed.
Le commutateur du flotteur doit être monté de telle sorte que la
tubulure de contact se trouve à l'extérieur d'un tube ferroma-
gnétique.
Raccordement électrique
Il faut respecter les dispositions relatives aux installations
électriques en vigueur dans le pays d'exécution. Seul le personnel
spécialisé est autorisé à travailler sur les installations électriques.
Pour augmenter la durée de vie des contacts, nous recom-
mandons le fonctionnement avec un relais de protection des
contacts.
Le raccordement électrique doit être réalisé conformément au

schéma des connexions apposé sur l'interrupteur.
(Les exécutions avec un seul contact d'ouverture ou de fermeture
n'ont pas de schéma des connexions.)
- 12 -
Enclosure no. 10249
Il convient de s'en tenir aux prescriptions en vigueur pour les

installations électriques dans le pays d'installation.
Il convient d'étouper le passe-câble (2) sur le boîtier de
raccordement (1).
L'utilisation des interrupteurs magnétiques á flotteur sous charge

inductive ou capacitive peut provoquer la destruction du contact
reed. Ceci peut entraîner le mauvais fonctionnement de la com-
mande située en aval ainsi que des dommages corporels ou
matériels.
Sous charge inductive, les interrupteurs magnétiques doivent être
protégés par un circuit RC (voir annexe) ou par une diode de
dérivation.
Charge inductive sous tension Charge inductive sous tension

alternative alternative
S1 S1
+
R Circuits RC selon
Diode de dérivation
24 á 230V AC tension d’alimentation 24 à 250V DC p. ex. 1N4007
(voir tableau)
C
-
En cas de charge capacitive, de conduites de plus de 50 m de

long ou de raccord à des systèmes d'automatisme industriel à
entrée capacitive, il faut monter en série une résistance protectrice
de 22 ohms ou de 47 ohms (avec des contacts de 10 VA) afin de
limiter de courant de crête. Une résistance de 220 Ohm montée
en série doit être utilisée lors d’un raccordement à un minuteur
éléctronique.
Limitation du courant pour Limitation du courant pour

charge capacitive minuteurs électroniques
p. ex. poste de commande programmable
ou câbles > 50 m
S1 Rs S1 Rs
+ Rs = 22 Ohm Rs = 220 Ohm
C1 (47 Ohm pour (230 V~)
24V DC contact de 10 VA) 230V AC C1
PCP C1 = capacité interne Minuteur C1 = capacité interne
-
Une surcharge du commutateur magnetique peut provoquer la

destruction du contact reed intégré. Ceci peut entraîner le mauvais
fonctionnement de la commande située en avai ainsi que des
dommages corporels ou matériels. Il faut respecter les valeurs
maximales de puissance de rupture indiquée dans le chapitre
"Données techniques" ainsi que dans la fiche technique KSR
1003.
- 13 -
Enclosure no. 10249
Mesure de pointe de courant à l’oscilloscope

S1 I (A)
sans limitation de courant
C RE 4
24 V= 3
avec limitation de courant
2
RM domaine interdit
1 domaine permis
Exemple: C = 0,33 µF / 24 V= 3 à 10
t (µs)
Avec des interrupteurs magnétiques á flotteur à boîtier

métallique sans prise de terre, le boîtier peut être sous ten-
sion en cas de perturbation. De graves lésions corporelles ou
des blessures mortelles sont possibles en cas de contact.
Ces commutateurs ne peuvent être utilisés qu'avec une
basse tension de protection selon VDE 0100 (KSR relais de
protection des contacts) ou bien doivent être montés de telle
sorte que le boîtier du interrupteur mag-nétique á flotteur soit
relié à une compensation de potentiel.
Mise en service / Contrôle fonctionnel

Mettre la tension d'alimentation du dispositif de commande
raccordé en circuit. Remplir le réservoir et vérifier le
fonctionnement des points de commutation de l'interrupteur
magnétique à flotteur.
Le contrôle fonctionnel peut aussi être réalisé manuellement
lorsque l'interrupteur est démonté. Ce faisant, il convient de veiller
à ce qu'aucun déroulement de processus ne soit involontairement
déclenché.
Avertissement!
Il faut s'assurer que le contrôle de fonctionnement ne déclenche
pas une étape de process involontaire.
Entretien
A condition d'être utilisés de manière conforme, les interrupteurs
magnétiques à flotteur fonctionnent sans usure et ne nécessitent
pas d'entretien.
En cas de conditions d'utilisation extrêmes, l'interrupteur devrait
être soumis à un contrôle visuel dans le cadre des révisions à
réaliser.
- 14 -
Enclosure no. 10249
Remarques
Pour une exploitation dans la zone explosive 1 ou 2, les contacts
Reed doivent être exploités sur des circuits de courant à sécurité
intrinsèque.
Les interrupteurs à flotteur en matière plastique n'ont pas le droit

d'être utilisés dans la zone explosive 1 ou 2.
Ne pas utiliser les interrupteurs à flotteur à proximité directe de

puissants champs électromagnétiques (distance minimale: 1m).
Ne pas changer le positionnement des bagues de réglage ou ne

pas les enlever du tube de glissement.
Les points de commutation des interrupteurs magnétiques à

flotteur ne peuvent pas être déréglés.
Les interrupteurs magnétiques à flotteur ont uniquement le droit
d'être utilisés dans des milieux contre lesquels le matériau du tube
de glissement et du flotteur est résistant.
Les interrupteurs n'ont pas le droit d'être soumis à de fortes

sollicitations mécaniques (chocs, torsion, vibration).
Caractéristiques techniques
Fonction de contact : :ouverture / fermeture
Tension commutée :250V AC / DC

Courant commuté :2A AC / 1A DC
Pouvoir de coupure :100 VA, cosϕ >0,7 / 50 W
Fonction de contact :inverseur

Courant commuté :1A AC / 0,5A DC
Pouvoir de coupure :40 VA, cosϕ > 0,7 / 20 W
Mini régulateurs de niveau
Fonction de contact : ouverture / fermeture

Courant commuté :0,5A AC / 0,25A DC
Pouvoir de coupure :10 VA , cosϕ > 0,7 / 5 W
- 15 -
Enclosure no. 10249
RC-Glieder zur Schutzbeschaltung

Protective RC-Modules
Circuits RC de protection de contacts
RC-Glieder sind, je nach Betriebsspannung, ausschließlich entsprechend

untenstehender Tabelle zu verwenden.
Andere als die hier aufgeführten RC-Glieder führen zur Zerstörung des
Reedschalters.
Please use RC-modules according to the table below. Rating of the switches and
supply voltage will determine the type to be used.
Other types might lead to destruction or lower service life of the reed contacts.
Selon la tension d’alimentation, les circuits RC de protection de contacts listés dans

le tableau ci-dessous doivent être utilisés.
L’utilisation d’autres circuits RC conduit à la destruction des contacts à lame
souple.
Für Schutzgaskontakte von 10-40VA Für Schutzgaskontakte von 40-100VA

For reed contacts 10-40VA For reed contacts 40-100VA
Pour contacts à lame souple de 10 à 40VA Pour contacts à lame souple de 40 à 100VA
Kapazität Widerstand Spannung Typ Kapazität Widerstand Spannung Typ
Capacitance Resistance Voltage Type Capacitance Resistance Voltage Type
Capacité Résistance Tension Type Capacité Résistance Tension Type
0,33 µF 100 Ohm 24 V~ A 3/24 0,33 µF 47 Ohm 24 V~ B 3/24
0,33 µF 220 Ohm 48 V~ A 3/48 0,33 µF 100 Ohm 48 V~ B 3/48
0,33 µF 470 Ohm 115 V~ A 3/115 0,33 µF 470 Ohm 115 V~ B 3/115
0,33 µF 1500 Ohm 230 V~ A 3/230 0,33 µF 1000 Ohm 230 V~ B 3/230
d d d
l
l
l
Litze wire
200
fils de
200
200
raccordement
d = von ø16mm- ø25mm d = OD 16mm - 25mm d = Ø 16 mm à 25 mm

l = von 26mm- 58mm l = 26mm - 58mm l = 26 mm à 58 mm
- 16 -
Enclosure no. 10249
1
2
3
4
max. 30°
Fig.1
7 8 4 3 2 1
Fig.2
- 17 -
Enclosure no. 10249
KSR KUEBLER AG Adressen
KSR KUEBLER Niveau-Messtechnik AG

Im Kohlstatterfeld 17 DE-69439 Zwingenberg/Neckar
Tel:[+49] 06263 870 Fax:[+49] 06263/87-99
http://www.ksr-kuebler.com e-Mail:[email protected]
KUBLER FRANCE S.A.

10, avenue d‘Alsace FR-68700 Cernay
Tel:[+33] 03 89 75 41 73 Fax: [+33] 03 89 75 53 14
KSR KUEBLER Level Measurement & Control Ltd.

Tan Capel, Betws Gwerfil Goch Corwen, Denbighshire LL21 9PU, GB
Tel:[+44] 1490 460 584 Fax:[+44] 1490 460 477
KSR H&H Measurement B.V.

Alphenseweg 4-h NL-5133 Riel / Niederlande
Tel:[+31] 13 533 96 88 Fax: [+31] 13 533 19 62
http://www.h-hm.com e-Mail: [email protected]
KSR KUEBLER Level Control Products of America Inc.

8349-M Arrowridge Blvd Charlotte, NC 28273 USA
Tel:[+1] 704 522 7663 Fax: [+1] 704 522 7616
http://www.ksr-usa.com e-Mail:[email protected]
SHANGHAI KSR KUEBLER Automation Instrument Co. LTD

No. 510 Yu Tang Road Industrial Zone Songjiang Shanghai 201613, P.R. China
Tel:[+86] 21 57745225 Fax: [+86] 21 67741420
http://www.ksr-kuebler.com e-Mail: [email protected]
KSR KUEBLER (SINGAPORE) Level Measurement & Control PTE LTD

21 Toh Guan Road East, #09-17 Toh Guan Centre Singapore 608609
Tel: [+65] 6316 7625 6 Fax.: [+65] 6316 7627
KSR KUEBLER Niveau-Messtechnik AG, D-69439 Zwingenberg

Tel. 06263 / 87-0 • Fax. 06263 / 87-99 • eMail: [email protected]. • Internet: www.ksr-kuebler.com
Enclosure 10303
1015
BYPASS LEVEL INDICATOR

Enclosure 10303
Bypass Level Indicator / Content
Table of content
Bypass Level Indicator / Content............................................................................................................................................................................................... 234

Bypass Level Indicator / Functional description.......................................................................................................................................................................... 235
Bypass Level Indicator / Type key.............................................................................................................................................................................................. 236
Bypass Level Indicator / Stainless steel PN 16........................................................................................................................................................................... 242
Bypass Level Indicator / Stainless steel PN 100 ........................................................................................................................................................................ 245
Bypass Level Indicator / Stainless steel PN 160......................................................................................................................................................................... 246
Bypass Level Indicator / Stainless steel PN 250-400................................................................................................................................................................. 247
Bypass Level Indicator / Stainless steel without process side connections................................................................................................................................. 248
Bypass Level Indicator / Stainless steel - Liquid gas design....................................................................................................................................................... 249
Bypass Level Indicator / Stainless steel with steam tracing system............................................................................................................................................ 250
Bypass Level Indicator /Stainless steel differential compensated ............................................................................................................................................... 251
Bypass Level Indicator / Titanium PN 16 - 40............................................................................................................................................................................ 252
Bypass Level Indicator / Alloy C PN 16 - 40............................................................................................................................................................................... 253
Bypass Level Indicator / PVC..................................................................................................................................................................................................... 254
Bypass Level Indicator / PVC..................................................................................................................................................................................................... 255
Bypass Level Indicator / Polypropylene...................................................................................................................................................................................... 256
Bypass Level Indicator / PVDF................................................................................................................................................................................................... 257
Bypass Level Indicator / Stainless steel - ECTFE coated............................................................................................................................................................ 258
Bypass Level Indicator / Stainless steel - PFA coated................................................................................................................................................................ 259
Bypass Chamber for guided wave radar ( GWR ) / ACS1........................................................................................................................................................... 260
Bypass Level Indicator for guided wave radar ( GWR ) / ACS2................................................................................................................................................... 261
Bypass Level Indicator / Cylindrical float PN 4........................................................................................................................................................................... 264
Bypass Level Indicator / Cylindrical float PN 4........................................................................................................................................................................... 265
Bypass Level Indicator / Cylindrical float PN 16......................................................................................................................................................................... 266
Bypass Level Indicator / Cylindrical float PN 63 - 320................................................................................................................................................................ 270
Bypass Level Indicator / Cylindrical float PN 63 - 320................................................................................................................................................................ 271
Bypass Level Indicator / Cylindrical float PN 16 / K74................................................................................................................................................................ 272
Bypass Level Indicator / Cylindrical float PN 40 / K74................................................................................................................................................................ 273
Bypass Level Indicator / Magnetic roller indicator....................................................................................................................................................................... 274
Bypass Level Indicator / Scale................................................................................................................................................................................................... 275
Bypass Level Indicator / Level transmitter.................................................................................................................................................................................. 276
Bypass Level Indicator / Magnetic switch.................................................................................................................................................................................. 282
1015

Bypass Level Indicator / Isolation / Heat tracing......................................................................................................................................................................... 290
Bypass Level Indicator / Isolation............................................................................................................................................................................................... 291
Bypass Level Indicator / Chamber end top................................................................................................................................................................................ 292
Bypass Level Indicator / Chamber end top................................................................................................................................................................................ 293
Bypass Level Indicator / Chamber end bottom.......................................................................................................................................................................... 294
Bypass Level Indicator / Chamber end bottom.......................................................................................................................................................................... 295
Bypass Level Indicator / Process connection............................................................................................................................................................................. 296
Bypass Level Indicator / Dampening spring / Support bracket................................................................................................................................................... 297
Heinrich Kübler AG
234 Ruessenstrasse 4 | CH-6341 Baar | Phone +41 (0)41 766 62 62 | Fax +41 (0)41 766 62 63 | E-Mail [email protected] | Internet www.kubler.ch
Enclosure 10303
Bypass Level Indicator / Functional description
Functional description
Bypass level indicators form an integral part of the pressure vessel. Via two process connections a
standpipe ( bypass ) is mounted to the side of a tank or vessel. Due to the direct connection the filling
level in the bypass will always correspond exactly to the filling level in the vessel
( communicating display ).
1015
In the bypassing pipe a cylindrical float with a built-in magnetic system

is contained. The concentrated magnetic field of the permanent magnet
corresponds exactly to the filling level of the liquid in the bypass.
In a contactless way the magnetic field transmits itSelf through the wall
of the standpipe onto externally mounted displaying, recording and
switching elements.
Design limits
Specific gravity: ≥ 350 kg/m3

Design pressure: -1 bar ... 300 bar
Design temperature: -196°C ... 400°C
Heinrich Kübler AG
Ruessenstrasse 4 | CH-6341 Baar | Phone +41 (0)41 766 62 62 | Fax +41 (0)41 766 62 63 | E-Mail [email protected] | Internet www.kubler.ch 235
Enclosure 10303
Bypass Level Indicator / Type key
Code 1
Key 1
…-
Version
BNA1 Bypass level indicator

BMG1 Bypass level indicator with Level transmitter
ACS1A1 Bypass complete solution for GWR system, chamber ≤ DN50 / 2“
ACS1B1 Bypass complete solution for GWR system, chamber DN65 / 2.5“
ACS1C1 Bypass complete solution for GWR system, chamber DN80 / 3“
ACS1D1 Bypass complete solution for GWR system, chamber ≥ DN100 / 4“
ACS21 Bypass complete solution for GWR system
Code 2
Key 1 ( for process connection flange ) Key 1 ( for process connection other )
…- …-
Flange connection Other process connection
FE1 Flange according to EN GM1 Female thread G

FA1 Flange according to ANSI NPTM1 Female thread NPT
F1 Flange according to … GN1 Male thread G
FS1 Flange according to drawing NPTN1 Male thread NPT
SE1 Welding stub end
OS1 Without process side connections ( Code 3 not applicable )
Code 3
Key 1.1 ( only for flange ) Key 1.2 ( only for flange ) Key 1.3 ( only for flange )
…/…/…- …/…/…- …/…/…-
Flange connection Flange connection Flange connection
… Flange nominal bore … Flange pressure rating … Flange facing
Code 3
Key 1 ( for process connection other )

…-
Size
… Threaded connection size

… Welding stub end size
1015
Example
Code 1 2 3 4 5 6 7 8
Key 1 - 1 - 1.1 / 1.2 / 1.3 - 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 - 1 - 1 - 1 / 2 / 3 - 1 -
Example BMG - FE - 25 / 16 / B1 - ALE / TP43B / V / K15 / EXIAG - DU - M… - V / 60 / 2 - -
Black = not possible according to Atex / Blue = possible according to Atex Exia / Blue1 = possible according to Atex Exia and Exd / Black1 = possible according to Atex Exd
Heinrich Kübler AG
Enclosure 10303
Code 4
Key 1 Key 2 Key 3

…/…/…/…/…/…/…/…- …/…/…/…/…/…/…/…- …/…/…/…/…/…/…/…-
Electrical connection level transmitter Control unit Level transmitter tube material quality
ALE Aluminium terminal box 64 x 58 x 34 mm TP43A1 TP5343A V1 Stainless steel

( only without control unit ) TP43B1 TP5343B Ex
ALF Aluminium terminal box 80 x 75 x 57 mm TD35A1 TD5335A
ALDA1 Aluminium terminal box Ø 95 x 84 mm TD35B1 TD5335D Ex
AVA Stainless steel terminal box Ø 82 x 110 mm TP50AP1 TP5350AP / PROFIBUS® PA
AVDA1 Stainless steel terminal box Ø 82 x 110 mm TP50BP1 TP5350BP Ex / PROFIBUS® PA
AVM Stainless steel terminal box Ø 50 x 117 mm TP50AF1 TP5350AF / FOUNDATIONTM Fieldbus
AVDM1 Stainless steel terminal box Ø 169 x 117 mm TP50BF1 TP5350BF Ex / FOUNDATIONTM Fieldbus
DAAVDM1 Stainless steel terminal box with TMT181A1 TMT181
LED display Ø 169 x 117 mm TMT181B1 TMT181 Ex
APA Polyester terminal box 80 x 75 x 55 mm ZMU1 XT42SI Ex
APB Polyester terminal box 80 x 75 x 55 mm / Exm TAMX1 Other control unit
ABA ABS terminal box 80 x 82 x 55 mm MST1 Magnetostrictive / 4 ... 20 mA
K Connection cable MSTB1 Magnetostrictive / 4 ... 20 mA / Ex
K68 Connection cable IP 68 ( ≥ G 3/8“ ) MSTH1 Magnetostrictive / HART®-Protocol
DAALA Aluminium terminal box with MSTHB1 Magnetostrictive / HART®-Protocol / Ex
LED display Ø 82 x 100 mm
DAAVDA1 Stainless steel terminal box with
LED display Ø 82 x 100 mm
Code 4
Key 4 Key 5 ( only for connection cable ) Key 6 ( only for connection cable )
…/…/…/…/…/…/…/…- …/…/…/…/…/…/…/…- … / … /… / … / … / … / … / … -
Accuracy Length of cable Connection cable
K51 Accuracy 5 mm / -30 ... 130°C … Length of cable in meter PVC1 PVC connection cable
K5HTF1 Accuracy 5 mm / -30 ... 200°C PVCB1 PVC connection cable with blue coating
K5HT1 Accuracy 5 mm / -40 ... 250°C SIL1 Silicone connection cable
K101 Accuracy 10 mm / -30 ... 130°C PUR1 PUR connection cable
K10HTF1 Accuracy 10 mm / -30 ... 200°C RAD1 Radox connection cable
K10HT1 Accuracy 10 mm / -40 ... 250°C
K151 Accuracy 15 mm / -30 ... 130°C
K15HTF1 Accuracy 15 mm / -30 ... 200°C
K15HT1 Accuracy 15 mm / -40 ... 250°C
K11 Accuracy 0.2 mm / -40 ... 125°C
K1HT1 Accuracy 0.2 mm / -40 ... 250°C
K1HHT1 Accuracy 0.2 mm / -40 ... 450°C
Code 4
Key 7 ( only for connection cable ) Key 8

…/…/…/…/…/…/…/…- …/…/…/…/…/…/…/…-
Connection cable option Approvals level transmitter 1015
KA1 Shielded EXIAG Acc. to Exia, atmosphere gas
KB1 Shielded / oil-resistant EXIAGD Acc. to Exia, atmosphere gas and dust
KC1 Shielded / oil-resistant / halogen-free EXDG1 Acc. to Exd, atmosphere gas
KD1 Oil-resistant EXDGD1 Acc. to Exd, atmosphere gas and dust
KE1 Oil-resistant / halogen-free EXIADG1 Acc. to Exia and Exd, atmosphere gas
KF1 Halogen-free EXIADGD1 Acc. to Exia and Exd, atmosphere gas and dust
Example
9 10 11 12 13
1 / 2 / 3 - 1 / 2 / 3 / 4 / 5 / 6 / 7 - 1 / 2 / 3 / 4 / 5 / 6 - 1 / 2 - 1 / 2 / 3
MRB / SA1 - 3 / BGU / N / 1 / PVCB / KA / EXIAG - ZVS / 250 / 20 / B152 - - EX / PED
Heinrich Kübler AG
Enclosure 10303
Code 5
Key 1
…-
Electrical connection position of the level transmitter
DO1 Electrical connection top mounted

DU1 Electrical connection bottom mounted
Code 6
Key 1
…-
Centre distance / Length of instrument
M…1 Centre distance in mm

L…1 Length of instrument in mm ( only for instrument without process side connections )
Code 7
Key 1 Key 2 Key 3

…/…/…- …/…/…- …/…/…-
Bypass chamber material quality Bypass chamber outside diameter Bypass chamber wall thickness
V1 Stainless steel 32 Ø 32.00 mm ( P ) …1 Bypass chamber wall thickness in mm

VP1 Stainless steel electropolished / Ra ca. 0,8μm 601 Ø 60.30 mm ( V / VP / TI / CS ) ( see the relevant catalog page or
( not attestable ) 611 Ø 60.33 mm ( V / VP / MO / HC / CS ) by calculation )
TI1 Titanium 63 Ø 63.00 mm ( P / PP / PF )
HC1 Alloy C 631 Ø 63.50 mm ( V / VP / VEEC / VPFA / VETF )
MO1 6Mo 731 Ø 73.03 mm ( V / VP / MO / TI / HC / CS )
CS1 Steel ( only ACS.. ) 761 Ø 76.10 mm ( V / VP )
VEEC1 Stainless steel ECTFE coated 881 Ø 88.90 mm ( V / VP / CS )
VPFA1 Stainless steel PFA coated 1141 Ø 114.30 mm ( V / VP / CS )
VETF1 Stainless steel ETFE coated
P PVC
PP Polypropylene
PF PVDF
Code 8
Key 1
…-
Bypass chamber additional design
HM761 Steam tracing system with outer tube Ø 76.10 x 2.00 mm

DK1 Differential compensated
ZK11 2-chamber system with G / BSP socket ( only for bypass level indicator ACS2 )
ZK21 2-chamber system with NPT socket ( only for bypass level indicator ACS2 )
1015
Example
Code 1 2 3 4 5 6 7 8
Key 1 - 1 - 1.1 / 1.2 / 1.3 - 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 - 1 - 1 - 1 / 2 / 3 - 1 -
Heinrich Kübler AG
Enclosure 10303
Code 9
Key 1 Key 2 Key 3

…/…/…- …/…/…- …/…/…-
Magnetic roller indicator Scale Mag. roller indicator sight extension
MRA Magnetic roller indicator MRA SAK Scale in Aluminium with adhesive foil PV1 Acryl glass extension
MRB1 Magnetic roller indicator MRB ( Ex ) SA01 Scale in Aluminium without engraving
MRAN Mag. roller indicator MRAN over-roll-protected SA11 Scale in Aluminium with engraving in %
MRBN1 Mag. roller indicator MRBN over-roll-prot. ( Ex ) SA21 Scale in Aluminium with engraving in cm
MRK1 Magnetic roller indicator MRK SA31 Scale in Aluminium with engraving in inch.
MRKN1 Magnetic roller indicator MRKN over-roll-prot. SA41 Scale in Aluminium with engraving acc. to customized table
MNA Magnetic roller indicator MNA SV01 Scale in Stainless steel without engraving
MNB1 Magnetic roller indicator MNB ( Ex ) SV11 Scale in Stainless steel with engraving in %
MNAN Magnetic roller indicator MNAN over-roll-prot. SV21 Scale in Stainless steel with engraving in cm
MNBN1 Mag. roller indicator MNBN over-roll-prot. ( Ex ) SV31 Scale in Stainless steel with engraving in inch.
MNAV Magnetic roller indicator MNAV SV41 Scale in Stainless steel with engraving acc. to customized table
MNBV1 Magnetic roller indicator MNBV ( Ex )
MNAVN Magnetic roller indicator MNAVN over-roll-protected
MNBVN1 Magnetic roller indicator MNBVN over-roll-prot. ( Ex )
MNKV1 Magnetic roller indicator MNKV
MNKVN1 Magnetic roller indicator MNKVN over-roll-protected
Code 10
Key 1 Key 2 Key 3

…/…/…/…/…/…/…- …/…/…/…/…/…/…- …/…/…/…/…/…/…-
Number of magnetic switches Magnetic switch Magnetic switch option
… Number of magnetic switches BGU Magnetic switch BGU R221 Switch protective circuit with
BGUD1 Magnetic switch BGU 22 ohm / 0.21 W resistor
BGUALE Magnetic switch BGUALE N1 Switch protective circuit according to
BGUASQ Magnetic switch BGUASQ NAMUR EN 60947
BGUASMA Magnetic switch BGUASMA
ALFU Magnetic switch ALFU
ALFI Magnetic switch ALFI ( inductive )
ALEU Magnetic switch ALEU
APAVU Magnetic switch APAVU
APBVU Magnetic switch APBVU
RU60 Magnetic switch RU60
RUV60 Magnetic switch RUV60
RUVD60 Magnetic switch RUVD60
RU73 Magnetic switch RU73 ( for chamber ≥ Ø 73 mm )
RUV73 Magnetic switch RUV73 ( for chamber ≥ Ø 73 mm )
RUVD73 Magnetic switch RUVD73 ( for chamber ≥ Ø 73 mm )
ALDAU1 Magnetic switch ALDAU
PS32 Magnetic switch PS32
PO32 Magnetic switch PO32
PU32 Magnetic switch PU32
PU32ASH Magnetic switch PU32ASH
1015
Code 10
Key 4 Key 5 Key 6

…/…/…/…/…/…/…- …/…/…/…/…/…/…- …/…/…/…/…/…/…-
Length of cable Connection cable Connection cable option
… Length of cable in meter PVC1 PVC connection cable KA1 Shielded

PVCB1 PVC connection cable with blue coating KB1 Shielded / oil-resistant
SIL1 Silicone connection cable KC1 Shielded / oil-resistant / halogen-free
PUR1 PUR connection cable KD1 Oil-resistant
RAD1 Radox connection cable KE1 Oil-resistant / halogen-free
KF1 Halogen-free
Example
9 10 11 12 13
1 / 2 / 3 - 1 / 2 / 3 / 4 / 5 / 6 / 7 - 1 / 2 / 3 / 4 / 5 / 6 - 1 / 2 - 1 / 2 / 3
Heinrich Kübler AG
Enclosure 10303
Code 10
Key 7
…/…/…/…/…/…/…-
Approvals magnetic switch
EXIAG Acc. to Exia, atmosphere gas

EXIAGD Acc. to Exia, atmosphere gas and dust
EXDG1 Acc. to Exd, atmosphere gas
EXDGD1 Acc. to Exd, atmosphere gas and dust
EXIADG1 Acc. to Exia and Exd, atmosphere gas
EXIADGD1 Acc. to Exia and Exd, atmosphere gas and dust
Code 11
Key 1 Key 2 Key 3

…/…/…- …/…/…- …/…/…-
Float Float length Magnetic system
ZVSS1 Float in Stainless steel … Acc. to float table on page 264 - 266 / 38 / 271 … Acc. to float table on page 264 - 266 / 38 / 271
ZVEECSSA1 Float in Stainless steel E-CTFE coated
ZVEECSSB1 Float in Stainless steel E-CTFE coated
ZVPFASSA1 Float in Stainless steel PFA coated
ZVPFASSB1 Float in Stainless steel PFA coated
ZTIKS11 Float in Titanium
ZPSS24 Float in PVC ( Page 254 )
ZPSS Float in PVC
ZPPSS Float in Polypropylene
ZPFSS Float in PVDF
Code 11 ( only protocol float )
Key 1 Key 2 Key 3

…/…/…/…/…/…- …/…/…/…/…/…/…- …/…/…/…/…/…/…-
Float Float length Design pressure
ZVS1 Float in Stainless steel … Acc. to float table on page 267 - 269 / 272 - 273 … Acc. to float table on page 267 - 269 / 272 - 273
ZTIS1 Float in Titanium
ZHCS1 Float in Alloy C
ZTIEECSA1 Float in Titanium E-CTFE coated ( on request )
ZTIEECSB1 Float in Titanium E-CTFE coated ( on request )
ZTIPFASA1 Float in Titanium PFA coated ( on request )
ZTIPFASB1 Float in Titanium PFA coated ( on request )
ZGS Float in Glass ( on request )
ZCES Float in Cevolite Eccolite ( on request )

1015
Key 4 Key 5 Key 6 ( only interface float )

…/…/…/…/…/…/…- …/…/…/…/…/…/…- …/…/…/…/…/…/…-
Design temperature Specific gravity 1 Specific gravity 2
… Acc. to float table on page 267 - 269 / 272 - 273 … Acc. to float table on page 267 - 269 / 272 - 273 … Acc. to protocol
Example
Code 1 2 3 4 5 6 7 8
Key 1 - 1 - 1.1 / 1.2 / 1.3 - 1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 - 1 - 1 - 1 / 2 / 3 - 1 -
Heinrich Kübler AG
Enclosure 10303
Key 7
…/…/…/…/…/…/…-
Magnetic system
… Acc. to float table on page 267 - 269 / 272 - 273
Code 12
Key 1 Key 2
…/…- …/…-
Instrument isolation Electrical heat tracing
AIT Armaflex isolation AIT H75A Electrical heat tracing 75°C

AHT Armaflex isolation AHT H75B Electrical heat tracing 75°C acc. to EExe
SW Rock-wool isolation H150A Electrical heat tracing 150°C
H150B Electrical heat tracing 150°C acc. to EExe
Code 13
Key 1 Key 2 Key 3

…/…/…- …/…/…- …/…/…-
Approvals / 1 Approvals / 2 Approvals / 3
EX Acc. to Ex PEDII1 Acc. to PED97/23/EC category II GL1 Approval 3A Sanitary Standard

PEDIV1 Acc. to PED97/23/EC category IV BV1 Approval Germanischer Lloyd
DNV1 Approval Bureau Veritas
ABS1 Approval American Bureau of Shipping
GOST1 Approval GOST
1015
Example
9 10 11 12 13
1 / 2 / 3 - 1 / 2 / 3 / 4 / 5 / 6 / 7 - 1 / 2 / 3 / 4 / 5 / 6 - 1 / 2 - 1 / 2 / 3
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Stainless steel PN 16
Type BNA-..-../../..-M..-V/6../..-MR..-Z..S/..
Material quality: 1.4404 / 1.4435 / 1.4571 ( 316L / 316Ti )

Centre distance M: 150 ... 25000 mm**
Specific gravity: ≥ 400 kg/m3 C = 150
~ 20
B = 90
Design
Chamber: Ø 60.30 x 2.00 mm

Ø 60.33 x 2.77 mm / NACE
Ø 63.50 x 2.00 mm
Process connection: Type key page 236
Chamber end top: Page 292 - 293
Chamber end bottom: Page 294 - 295
Float: Page 266 - 267
M = ...
Option magnetic roller indicator / Page 274
Aluminium or Stainless steel / Pocan -40°C ... 200°C

Aluminium or Stainless steel / Ceramic -40°C ... 400°C
Option scale / Page 275
Aluminium / Stainless steel With adhesive foil / Engraving / Blank
U = ...
Option magnetic switch / Page 282 - 289
Aluminium / Stainless steel -60°C ... 300°C
Option level transmitter / Page 276 - 280

~ 35
Accuracy / Reed contacts: 5 / 10 / 15 mm

Accuracy / Magnetostrictive: 0.2 mm
Control unit: - Programmable
- Hart-programmable / SIL2
- Profibus PA
- Fondation Fieldbus
Option electrical heat tracing / Page 290 0°
270° 90°
Holding temperature: ~10°C / Frost protection
180°
Option instrument isolation / Page 290 - 291

1015
Isolation: Armaflex isolation / Rock-wool isolation
Approvals / Certificates
ATEX*
II 1G2D/2GD c II 2GD c
Liquid temperature Ex max. 300°C
The bypass level indicator are based on a modular design and can be arranged individually.
Type key page 236 - 241
* = The approval is dependent on the equipment combination ** ATEX-design = if measuring range ≥ 4000 mm please choose different material quality for chamber and float
Heinrich Kübler AG
Enclosure 10303
Type BNA-..-../../..-M..-V/6../..-MR..-Z..S/..

Specific gravity: ≥ 480 kg/m3 C = 150
~ 20
B = 90
Design

Ø 60.33 x 2.77 mm / NACE
Ø 63.50 x 2.00 mm
Float: Page 268
M = ...

U = ...

~ 35

- Profibus PA
Option electrical heat tracing / Page 290

0°

270° 90°
180°

1015
ATEX*
Heinrich Kübler AG
Enclosure 10303
Type BNA-..-../../..-M..-V/6../..-MR..-Z..S/..

Centre distance M: 150 ... 25000 mm C = 150
~ 20
B = 90
Design

Ø 60.33 x 2.77 mm / NACE
Ø 60.30 x 3.00 mm
M = ...

U = ...
~ 50

- Profibus PA

0°
270° 90°
180°
1015
ATEX*
* = The approval is dependent on the equipment combination
Heinrich Kübler AG
Enclosure 10303
Type BNA-..-../../..-M..-V/../..-MR..-Z..S/..

~ 20
B = 90
Design
Chamber: Ø 60.33 x 2.77 mm / NACE
Ø 60.30 x 3.00 mm
Ø 73.03 x .. mm / NACE
Ø 76.10 x .. mm
M = ...

U = ...
~ 85

- Profibus PA

0°

270° 90°
180°

1015
ATEX*
Heinrich Kübler AG
Enclosure 10303
Type BNA-..-../../..-M..-V/7../..-MR..-Z..S/..

~ 30
B = 90
Design
Chamber: Ø 73.03 x .. mm / NACE

Ø 76.10 x .. mm
( .. wall thickness acc. to calculation )
M = ...

U = ...
~ 100

- Profibus PA

0°
270° 90°
Option instrument isolation / Page 290 - 291 180°

1015
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Stainless steel PN 250-400
Type BNA-..-../../..-M..-V/7../..-MR..-Z..S/..

~ 30
Design pressure: -1 bar ... 250 / 400 bar
B = 90
Design
Chamber: Ø 73.03 x .. mm / NACE

Ø 76.10 x .. mm
( .. wall thickness acc. to calculation )
M = ...
Float: Page 271

U = ...
~ 115

- Profibus PA

0°
270° 90°

1015
180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / without process side connections

Bypass Level Indicator / Stainless steel without process side connections
Type BNA-OS-L..-V/60/..-MR..-Z..S/..
~ 40
Length of instrument L: 150 ... 25000 mm**
90
Design

Ø 60.33 x 2.77 mm / NACE
Ø 63.50 x 2.00 mm
Process connection: -
A = ...
L = ...
U = ...
Option level transmitter / Page 276 - 280 ~ 50

- Profibus PA
- Fondation Fieldbus 0°
270° 90°
Option electrical heat tracing / Page 290 180°

1015
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Stainless steel - Liquid gas design
Type BNA-..-../../..-M..-V/88/..-MR..-Z..S/..
C = 180
~ 50
B = 180
Design

Ø 88.90 x 2.60 mm
Ø 88.90 x 3.05 mm / NACE
M = ...

U = ...

~ 70

- Profibus PA

0°
Option instrument isolation / Page 290 - 291 270° 90°

1015

180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / with steam tracing system

Bypass Level Indicator / Stainless steel with steam tracing system
Type BNA-..-../../..-M..-V/60/..-HM76-MR..-Z..S/..

Specific gravity: ≥ 460 kg/m3 C2 = 150 C1 = 150
B = 100
100
Design

Ø 60.33 x 2.77 mm / NACE
Ø 63.50 x 2.00 mm
M = ...

U = ...
~ 95
~ 35

- Profibus PA
0°
Steam tracing system

270° 90°
Steam tracing system chamber: Ø 76.10 x 2.00 mm

180°

1015
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / differential compensated

Bypass Level Indicator /Stainless steel differential compensated
Type BNA-..-../../..-M..-V/../..-DK-MR..-Z..S/..

Centre distance M: 150 ... 25000 mm** C = 150
~ 80
~ 80
Design
Ø 60.33 x 2.77 mm / NACE
B = 90
Ø 73.03 x .. mm / NACE
Ø 76.10 x .. mm
Chamber end top: Flanged connection with tube cap
Float: Acc. to protocol
M = ...

U = ...

~ 35

- Profibus PA
0°

1015
270° 90°
Isolation: Armaflex isolation / Rock-wool isolation 180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Titanium PN 16 - 40
Type BNA-..-../../..-M..-TI/60/2.77-MR..-Z..S/..
Material quality: Titanium

B = 90
Design

Float: Page 267 / 268
M = ...

U = ...
~ 50

- Profibus PA
Holding temperature: ~10°C / Frost protection 0°
270° 90°

1015
180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Alloy C PN 16 - 40
Type BNA-..-../../..-M..-HC/60/2.77-MR..-Z..S/..
Material quality: Alloy C

B = 90
Design

Float: Page 267 / 269
M = ...

U = ...
~ 50

- Profibus PA
270° 90°

1015
180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / PVC
Type BNA-..-../../..-M..-P/32/1.8-ZPSS/24/../M2
Material quality: PVC transparent

C = 100
Centre distance M: 200 ... 4000 mm
B = 140
Design

Chamber end top: Screwed connection
Chamber end bottom: Screwed connection
Float: ZPSS24/80/M2 ≥ 900 kg/m3
ZPSS24/120/M2 ≥ 600 kg/m3
M = ...
Option magnetic switch
PS32/…/…/PVC/…
Electrical connection: PVC connection cable

Function: Normally open
Switch behaviour: Bistable
Switching capacity: 230 V / 0.5 A / 40 VA
U = 140
PO32/…/…/PVC/…

Function: Normally closed
PU32/…/…/PVC/…

Function: Change over
Switch behaviour: Bistable 0°

270° 90°
PU32ASH/… 180°
Electrical connection: Connector Hirschmann DIN 43650

~ 80
1015
1 SWITCH POINT 70
BLUE 1 70
BROWN 3
20
BLACK 2
31. 4
31.4
40
40
YELLOW / GREEN 2
P..32/…/…/PVC/… PU32ASH/…
3
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / PVC
Type BNA-..-../../..-M..-P/63/3-MR..-ZPS/..
Material quality: PVC

C = 150
B = 280
Design

Float: Page 264
A = M - 220
M = ...
Aluminium / Stainless steel -60°C ... 300°C U = ...

- Profibus PA
0°
270° 90°
180° 1015
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Polypropylene
Type BNA-..-../../..-M..-PP/63/3.6-MR..-ZPPS/..
Material quality: Polypropylene

Design
B = 280

Float: Page 264
A = M - 210
M = ...

U = ...

- Profibus PA
0°
270° 90°
180°
1015
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / PVDF
Type BNA-..-../../..-M..-PF/63/3-MR..-ZPFS/..
Material quality: PVDF

B = 240
Design

Float: Page 265
A = M - 210
M = ...
U = ...

- Profibus PA
0°
270° 90°
180°
1015
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Stainless steel - ECTFE coated
Type BNA-..-../../..-M..-VEEC/63/2-MR..-ZVEECSSA/.../B152
Material quality: Stainless steel ECTFE coated

~ 25
B = 160
Design

Chamber end top: Flanged connection
Chamber end bottom: Flanged connection
Float: Page 266
M = ...

U = ...

~ 30

- Profibus PA
270° 90°

1015
180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Stainless steel - PFA coated
Type BNA-..-../../..-M..-VPFA/63/2-MR..-ZVPFASSA/.../B152
Material quality: Stainless steel PFA coated

~ 25
B = 160
Design

Chamber end top: Flanged connection
Chamber end bottom: Flanged connection
Float: Page 266
M = ...

U = ...

~ 30

- Profibus PA
270° 90°

1015
180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Chamber for guided wave radar ( GWR ) / ACS1..
Type ACS1..-..-../../..-M..-../../..
Material quality: Stainless steel

1.4404 / 1.4435 / 1.4571 ( 316L / 316Ti ) C = ...
Steel
1.0460 / 1.5415 / 1.5423
( A106Gr.B / A105/C21 / A234Gr.WPB )
B = 200
Titanium
Alloy C
Stainless steel ECTFE coated
Stainless steel PFA coated

Specific gravity: -
Design temperature:
- Stainless steel: -196°C ... 400°C
- Stahl: -30°C ... 400°C
- Titanium: -10°C ... 400°C
- Alloy C: -196°C ... 200°C
M = ...
- Stainless steel ECTFE coated: -78°C ... 150°C
- Stainless steel PFA coated: -100°C ... 250°C
Design
Chamber: Ø 60.30 x 2.00 mm C: 150 mm

Ø 60.33 x 2.77 mm C: 150 mm / NACE
Ø 73.03 x 3.05 mm C: 150 mm / NACE
Ø 88.90 x 2.00 mm C: 180 mm
Ø 88.90 x 3.05 mm C: 180 mm / NACE
Ø 114.30 x 2.00 mm C: 180 mm
A = 200
Ø 114.30 x 3.00 mm C: 180 mm
Ø 114.30 x 3.05 mm C: 180 mm / NACE
Chamber end top: -
Float: -
~ 15
C2
D
Isolation: Armaflex isolation / Rock-wool isolation 0°
270° 90°
1015
180° Optional with vent
Der Werkstoff Stahl hat keine GL / BV / DNV / ABS Zulassung.
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator for guided wave radar ( GWR ) / ACS2
Type ACS2-..-../../..-M..-V/../..-ZK..-MR..-Z..S/..

Centre distance M: 150 ... 25000 mm** C2 = 120 C1 = 150
B = 90
110
Design

Ø 60.33 x 2.77 mm / NACE
Ø 63.50 x 2.00 mm
M = ...


150
U = ...
Option level transmitter / Page 276 - 280 ~ 65

- Profibus PA

0°

270° 90°
180°

1015
ATEX*
Heinrich Kübler AG
Enclosure 10303
Type ACS3-..-../../..-M..-V/88/..-MR..-Z..S/..
C = 180
~ 50
B = 90
Design

Ø 88.90 x 3.05 mm / NACE

Chamber end top: -
M = ...

U = ...
~ 55
Accuracy / Reed contacts: 5 / 10 / 15 mm C2

- Profibus PA
D
270° 90° Optional with vent

1015
180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Type ACS4-..-../../..-M..-V/114/..-MR..-Z..S/..
Material quality: 1.4404 / 1.4435 / 1.4571 ( 316L / 316Ti ) C = 180

150
Design
B = 200
Ø 114.30 x 3.00 mm
Ø 114.30 x 3.05 mm / NACE
Chamber end top: -
M = ...

U = ...

~ 55
C2
- Profibus PA
D

0°
270° 90°
Optional with vent

1015
180°
ATEX*
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Cylindrical float PN 4
Cylindrical float PN 4 PVC
Float: ZPSS/.../B152
Diameter [ mm ]: 50
Design temperature [ °C ]: -15 ... 40
Design pressure [ bar ]: -1 ... 4
Distance U ( see bypass level indicator figure )
Distance U with float stop: Float length - 25 mm
Float ZPSS/.../B152
Length [ mm ] 150 200 250 300 350
Weight [ g ] 275 316 356 397 437
Float height above liquid [ mm ] Specific gravity of the liquid [ kg/m³ ]

0 0 - - - - -
10 10 - - - - -
20 20 - - - - -
30 30 1170 950 820 750 700
40 40 1270 1010 860 780 720
50 50 1400 1070 910 810 740
60 60 1560 1150 950 840 770
70 70 1750 1240 1010 880 790
80 80 2000 1340 1070 920 820
90 90 2330 1460 1130 960 860
100 100 2800 1610 1210 1010 890
Cylindrical float PN 4 PP
Float: ZPPSS/../B152
Diameter [ mm ]: 50
Float ZPPSS/.../B152
1015
Length [ mm ] 150 200 250 300 350

Weight [ g ] 246 279 311 344 376

0 0 - - - - -
10 10 - - - - -
20 20 - - - - -
30 30 1040 840 720 650 600
40 40 1140 890 750 670 620
50 50 1250 950 790 700 640
60 60 1390 1010 830 730 660
70 70 1570 1090 880 760 680
80 80 1790 1180 930 800 710
90 90 2090 1290 990 830 740
100 100 2510 1420 1060 880 770
50 ~ Position of the magnetic system
Heinrich Kübler AG
Enclosure 10303
Cylindrical float PN 4 PVDF
Float: ZPFSS/../B152
Diameter [ mm ]: 50
Float ZPFSS/../B152
Length [ mm ] 150 200 250 300 350
Weight [ g ] 278 319 360 401 442

0 0 - - - - -
10 10 - - - - -
20 20 - - - - -
30 30 1180 960 830 760 700
40 40 1290 1020 870 790 730
50 50 1420 1080 920 820 750
60 60 1570 1160 960 850 780
70 70 1770 1250 1020 890 800
80 80 2020 1350 1080 930 830
90 90 2360 1480 1150 970 870
100 100 2830 1620 1220 1020 900
1015
Heinrich Kübler AG
Enclosure 10303
Cylindrical float PN 16 Stainless steel 1.4571 ( 316Ti )
Float: ZVSS/.../B152
Diameter [ mm ]: 52
Design temperature [ °C ]: -40 ... 250 ( 300 )
Design pressure [ bar ]: -1 ... 20 ( 18,5 )

Distance U with dampening spring: Float length - 10 mm
Float ZVSS/.../B152
450 400 350 300 250 200 150 Length [ mm ]
472 440 399 362 327 297 253 Weight [ g ]
Specific gravity of the liquid [ kg/m³ ] Float height above liquid [ mm ]

- - - - - - - 0 0
- - - - - - - 10 10
- - - - - - - 20 20
600 640 680 720 800 950 1170 30 30
610 660 700 740 840 1010 1280 40 40
630 680 720 780 880 1080 1420 50 50
650 700 750 810 930 1160 1600 60 60
660 720 780 850 980 1260 1820 70 70
680 740 810 890 1050 1370 2110 80 80
700 770 840 930 1110 1500 2520 90 90
720 790 870 980 1190 1670 - 100 100
Cylindrical float PN 16 Stainless steel / ECTFE coated Stainless steel / PFA coated
Float: ZVEECSSA/.../B152 / ZVEECSSB/.../B152 ( Ex ) ZVPFASSA/.../B152 / ZVPFASSB/.../B152 ( Ex )

Diameter [ mm ]: 53 53
Design temperature [ °C ]: -40 ... 150 -40 ... 250
Design pressure [ bar ]: -1 ... 20 -1 ... 20
Distance U with float stop: Float length - 24 mm Float length - 24 mm

Distance U with dampening spring: Float length - 10 mm Float length - 10 mm
Float ZVEECSSA/.../B152 / ZVEECSSB/.../B152 (Ex) Float ZVPFASSA/.../B152 / ZVPFASSB/.../B152 (Ex)

1015
450 400 350 300 250 200 150 Length [ mm ] 150 200 250 300 350 400 450
545 505 456 410 367 329 277 Weight [ g ] 284 338 378 424 471 523 565
Specific gravity of the liquid [ kg/m³ ] Float height above liquid [ mm ] Specific gravity of the liquid [ kg/m³ ]
- - - - - - - 0 0 - - - - - - -
- - - - - - - 10 10 - - - - - - -
- - - - - - - 20 20 - - - - - - -
660 700 730 770 850 1000 1220 30 30 1260 1035 885 805 750 715 680
670 720 760 800 900 1070 1350 40 40 1385 1105 930 835 775 735 695
690 740 780 840 940 1140 1490 50 50 1535 1185 975 870 800 760 715
710 760 810 870 1000 1230 1680 60 60 1725 1275 1030 905 830 780 735
730 780 840 910 1050 1330 1910 70 70 1965 1375 1090 950 860 805 755
750 810 870 960 1120 1450 2220 80 80 2285 1500 1160 995 890 830 775
770 830 910 1000 1190 1590 2650 90 90 2730 1650 1235 1040 925 860 795
790 860 950 1060 1280 1770 - 100 100 - 1830 1325 1095 965 890 820
Heinrich Kübler AG
Enclosure 10303
Cylindrical float PN 16 Titanium Alloy C
Float: ZTIS/.../16/…/…/…/TR1 ZHCS/.../16/…/…/…/TR1

Diameter [ mm ]: 52 52
Design temperature [ °C ]: -30 ... 150 ( 200 ) -196 ... 200
Design pressure [ bar ]: -1 ... 16 ( 10 ) -1 ... 16
Distance U with float stop: Float length - 24 mm Float length - 24 mm

Distance U with dampening spring: Float length - 10 mm Float length - 10 mm
Float ZTIS/../16/…/…/…/TR1 Float ZHCS/../16/…/…/…/TR1

450 400 350 300 250 200 150 Length [ mm ] 150 200 250 300 350 400 450
474 430 381 338 289 245 197 Weight [ g ] 197 245 289 338 381 430 474
Specific gravity of the liquid [ kg/m³ ] Float height above liquid [ mm ] Specific gravity of the liquid [ kg/m³ ]
- - - - - - - 0 0 - - - - - - -
- - - - - - - 10 10 - - - - - - -
- - - - - - - 20 20 - - - - - - -
380 395 410 430 475 535 645 30 30 900 770 695 660 625 605 585
390 405 425 450 500 570 710 40 40 985 825 730 685 645 625 600
400 415 440 470 525 610 785 50 50 1095 880 770 710 665 640 615
410 430 455 490 555 655 885 60 60 1230 950 810 745 690 660 635
420 440 470 510 585 710 1005 70 70 1400 1025 855 775 715 680 650
435 455 490 535 625 775 1170 80 80 1625 1115 910 815 740 705 665
445 470 510 560 665 850 1400 90 90 1940 1225 970 855 770 725 685
460 485 530 590 710 945 1735 100 100 2410 1360 1040 900 805 750 705
1015
Heinrich Kübler AG
Enclosure 10303
Cylindrical float PN 40 Stainless steel 1.4571 ( 316Ti )
Float: ZVS/.../40/…/…/…/TR1
Diameter [ mm ]: 52

Float ZVS/../40/…/…/…/TR1
Length [ mm ] 150 200 250 300 350 400 450 500 550 600 650
Weight [ g ] 197 258 300 342 389 431 472 519 561 603 645

0 0 - - - - - - -
10 10 - - - - - - -
20 20 - - - - - - -
30 30 900 815 720 665 635 605 585 575 560 545 535
40 40 985 865 760 690 655 625 600 585 570 555 545
50 50 1095 930 795 720 680 640 615 600 580 565 555
60 60 1230 1000 840 750 705 660 630 610 595 580 565
70 70 1400 1080 890 785 730 680 645 625 605 590 575
80 80 1625 1175 945 825 755 705 665 640 620 600 585
90 90 1940 1290 1005 865 785 730 685 660 635 610 595
100 100 2410 1435 1080 910 820 755 705 675 645 625 605
Cylindrical float PN 40 Titanium
Float: ZTIS/.../40/…/…/…/TR1
Diameter [ mm ]: 52

Float ZTIS/../40/…/…/…/TR1
1015
Length [ mm ] 150 200 250 300 350 400 450 500 550 600 650
Weight [ g ] 175 219 258 298 337 376 420 460 499 538 578

0 0 - - - - - - - - - - -
10 10 - - - - - - - - - - -
20 20 - - - - - - - - - - -
30 30 775 670 600 560 535 515 505 490 480 475 465
40 40 850 715 630 585 550 530 515 505 490 480 475
50 50 945 765 665 610 570 545 530 515 500 490 480
60 60 1060 820 700 635 590 560 545 525 510 500 490
70 70 1205 890 740 665 610 575 560 540 520 510 500
80 80 1405 970 790 695 635 595 575 550 535 520 510
90 90 1675 1065 840 730 660 615 590 565 545 530 515
100 100 2080 1180 900 770 690 635 605 580 560 540 525
Heinrich Kübler AG
Enclosure 10303
Cylindrical float PN 40 Alloy C
Float: ZHCS/.../40/…/…/…/TR1
Diameter [ mm ]: 52

Float ZHCS/../40/…/…/…/TR1
Length [ mm ] 150 200 250 300 350 400 450 500 550 600 650
Weight [ g ] 216 264 313 361 414 463 511 565 613 661 710

0 0 - - - - - - -
10 10 - - - - - - -
20 20 - - - - - - -
30 30 985 830 755 705 675 650 630 625 610 600 590
40 40 1080 885 790 730 700 670 650 635 620 610 600
50 50 1200 950 830 760 725 690 665 650 635 620 610
60 60 1345 1020 875 795 750 710 680 665 650 635 620
70 70 1535 1105 930 830 775 735 700 680 660 645 635
80 80 1785 1205 985 870 805 755 720 700 675 660 645
90 90 2130 1320 1050 910 840 780 740 715 690 670 655
100 100 2640 1465 1125 960 870 810 760 735 705 685 670
1015
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Cylindrical float PN 63 - 320
Float: ZTIKS1/../TR1 for chamber: ≤ Ø 63.50 mm

Diameter [ mm ]: 52
Design temperature [ °C ]: -90 … 400 -90 … 350 -90 … 300 -90 … 250 -90 … 200 -90 … 150
Design pressure [ bar ]: -1 … 125 -1 … 135 -1 … 150 -1 … 155 -1 … 165 -1 … 175

Float ZTIKS1/../TR1
Anzahl Kugeln 3 4 5 6 7 8 9 10 11 12 13 14
Length [ mm ] 146 194 243 291 340 388 437 485 534 582 631 679
Weight [ g ] 134 159 184 209 234 258 283 308 333 358 382 407
0 0 - - - - - - - - - - - -
10 10 - - - - - - - - - - - -
20 20 - - - - - - - - - - - -
30 30 870 725 645 595 565 535 520 505 490 480 475 465
40 40 975 785 685 625 585 555 535 515 505 493 480 475
50 50 1025 810 705 640 595 565 540 525 510 497 485 478
60 60 1080 840 720 650 605 570 550 530 515 502 490 482
70 70 1240 915 770 685 635 595 565 545 525 515 500 492
80 80 1515 1035 840 735 670 620 590 565 545 530 515 505
90 90 1855 1155 905 780 700 645 610 580 560 540 525 515
100 100 2045 1215 935 800 715 655 620 590 565 545 530 520
Float: ZTIKS1/../TR2 for chamber: ≥ Ø 73.03 mm

Diameter [ mm ]: 52

Float ZTIKS1/../TR2
1015
Anzahl Kugeln 3 4 5 6 7 8 9 10 11 12 13 14
Length [ mm ] 146 194 243 291 340 388 437 485 534 582 631 679
Weight [ g ] 174 199 224 249 274 298 323 348 373 398 422 447
0 0 - - - - - - - - - - - -
10 10 - - - - - - - - - - - -
20 20 - - - - - - - - - - - -
30 30 1130 905 785 710 660 620 590 570 550 535 520 510
40 40 1265 980 835 745 685 640 610 585 565 550 533 520
50 50 1330 1015 855 760 700 650 615 590 570 555 537 525
60 60 1400 1050 880 775 710 660 625 600 575 560 542 530
70 70 1615 1150 940 820 740 685 645 615 590 570 555 540
80 80 1965 1295 1020 875 780 715 670 635 610 585 570 555
90 90 2410 1445 1105 925 820 745 695 655 625 600 580 565
100 100 2660 1520 1140 950 835 760 705 665 635 610 585 570
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Cylindrical float PN 63 - 320

Diameter [ mm ]: 52

Float ZTIKS2/../TR2
Anzahl Kugeln 3 4 5 6 7 8 9 10 11 12 13 14
Length [ mm ] 146 194 243 291 340 388 437 485 534 582 631 679
Weight [ g ] 204 239 274 308 343 378 412 447 482 516 551 586
0 0 - - - - - - - - - - - -
10 10 - - - - - - - - - - - -
20 20 - - - - - - - - - - - -
30 30 1325 1090 960 880 825 785 755 730 710 695 680 670
40 40 1480 1175 1020 920 860 815 775 750 730 710 695 685
50 50 1560 1215 1045 940 875 825 785 760 735 715 700 690
60 60 1645 1260 1075 960 890 840 795 770 745 725 710 695
70 70 1890 1380 1150 1010 930 870 825 790 765 740 725 710
80 80 2305 1555 1250 1080 980 910 855 820 785 760 740 725
90 90 2825 1735 1350 1145 1025 945 885 845 810 780 760 740
100 100 3115 1825 1395 1175 1050 965 900 855 820 790 765 745

Diameter [ mm ]: 62

Float ZTIKS4/../TR2
1015
Anzahl Kugeln 3 4 5 6 7 8 9 10 11 12 13 14 15
Length [ mm ] 180 240 300 360 420 480 540 600 660 720 780 840 900
Weight [ g ] 197 226 255 284 313 342 371 400 429 458 487 516 545
0 0 - - - - - - - - - - - -
10 10 - - - - - - - - - - - -
20 20 - - - - - - - - - - - -
30 30 696 570 500 456 426 404 386 374 362 350 345 339 333
40 40 770 614 530 478 442 418 398 382 370 360 352 345 338
50 50 838 650 554 496 456 428 406 390 378 366 357 349 343
60 60 872 666 564 500 462 432 410 394 380 368 359 351 345
70 70 906 684 576 512 468 438 414 398 382 370 361 353 347
80 80 1000 730 604 530 482 450 424 406 390 378 367 359 351
90 90 1162 800 646 558 504 466 438 418 400 386 375 366 357
100 100 1382 884 692 590 528 484 452 428 410 396 383 373 364
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Cylindrical float PN 16 / K74
Cylindrical float PN 16 for Bypass Level Indicator with steam tracing system Stainless steel 1.4571 ( 316Ti )
Float: ZVS/../16/…/…/…/K74
Diameter [ mm ]: 52

Float ZVS/../16/…/…/…/K74
Length [ mm ] 150 200 250 300 350 400 450 500 550 600 650
Weight [ g ] 279 321 358 400 437 479 516 553 595 632 674

0 0 - - - - - - -
10 10 - - - - - - -
20 20 - - - - - - -
30 30 1270 1010 860 780 715 675 640 610 590 575 560
40 40 1400 1080 905 810 740 695 655 625 605 585 570
50 50 1550 1155 950 845 765 715 670 640 615 595 580
60 60 1740 1240 1005 880 790 735 690 650 630 605 590
70 70 1985 1345 1060 920 820 760 705 670 640 615 600
80 80 2305 1465 1130 960 850 785 725 685 655 630 610
90 90 2750 1610 1200 1010 885 810 745 700 670 640 620
100 100 3410 1785 1285 1065 920 835 770 720 685 655 635
Cylindrical float PN 16 for Bypass Level Indicator with steam tracing system Titanium
Float: ZTIS/../16/…/…/…/K74
Diameter [ mm ]: 52

Float ZTIS/../16/…/…/…/K74
1015
Length [ mm ] 150 200 250 300 350 400 450 500 550 600 650
Weight [ g ] 251 281 310 340 369 399 433 462 489 521 550

0 0 - - - - - - - - - - -
10 10 - - - - - - - - - - -
20 20 - - - - - - - - - - -
30 30 1110 860 725 640 585 545 520 495 470 460 445
40 40 1220 915 760 665 605 560 530 505 480 465 450
50 50 1355 980 800 695 625 575 545 515 490 475 460
60 60 1520 1055 845 725 645 595 560 530 500 485 465
70 70 1730 1140 890 755 670 610 575 540 510 495 475
80 80 2015 1245 945 795 695 630 590 555 525 505 485
90 90 2405 1365 1010 830 725 655 610 570 535 515 490
100 100 2980 1515 1080 875 755 675 625 580 545 525 500
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Cylindrical float PN 40 / K74
Cylindrical float PN 40 for Bypass Level Indicator with steam tracing system Stainless steel 1.4571 ( 316Ti )
Float: ZVS/../40/…/…/…/K74
Diameter [ mm ]: 52

Float ZVS/../40/…/…/…/K74
Length [ mm ] 150 200 250 300 350 400 450 500 550 600 650
Weight [ g ] 298 359 401 443 490 532 573 620 662 704 746

0 0 - - - - - - -
10 10 - - - - - - -
20 20 - - - - - - -
30 30 1360 1130 965 860 800 750 710 685 660 640 620
40 40 1495 1205 1015 895 825 770 725 700 670 650 630
50 50 1655 1290 1065 935 855 795 745 715 685 660 640
60 60 1860 1390 1125 975 885 815 765 730 700 675 655
70 70 2120 1505 1190 1020 920 840 785 750 715 685 665
80 80 2460 1635 1265 1065 955 870 805 765 730 700 675
90 90 2935 1800 1345 1120 990 900 830 785 745 715 690
100 100 3640 1995 1440 1175 1035 930 855 805 765 730 700
Cylindrical float PN 40 for Bypass Level Indicator with steam tracing system Titanium
Float: ZTIS/../40/…/…/…/K74
Diameter [ mm ]: 52

Float ZTIS/../40/…/…/…/K74
1015
Length [ mm ] 150 200 250 300 350 400 450 500 550 600 650
Weight [ g ] 276 320 359 399 438 477 521 561 600 639 679

0 0 - - - - - - - - - - -
10 10 - - - - - - - - - - -
20 20 - - - - - - - - - - -
30 30 1220 975 835 755 695 650 625 600 580 560 550
40 40 1340 1040 880 785 715 670 640 615 590 570 555
50 50 1490 1115 925 815 740 690 655 625 600 580 565
60 60 1670 1200 975 850 770 710 675 640 615 595 575
70 70 1905 1300 1035 890 795 730 690 655 630 605 585
80 80 2215 1415 1095 930 825 755 710 675 640 615 595
90 90 2640 1555 1170 975 860 780 730 690 655 630 605
100 100 3280 1725 1250 1030 895 805 755 705 670 640 620
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Magnetic roller indicator
Type MRA / MRB / MRAN / MRBN

MRK / MRKN
Housing: Aluminium anodized

Ingress protection class: IP 67
20
MRA / MRB / MRAN / MRBN
Indication
- Material quality: Pocan
- Colour: White / Red
End part: Ryton, black
Sight cover - MRA / MRAN: Macrolon
L = M + 63
M = ...
- MRB / MRBN: Glass
Ambient temperature: -40°C ... 200°C
MRAN / MRBN ( over-roll-protected ): Roller rotation max. 180°
MRK / MRKN
Indication
- Material quality: Ceramic
- Colour: White / Blue
End part: Aluminium
20
Sight cover: Glass
MRKN ( over-roll-protected ): Roller rotation max. 180° 49
23
ATEX / GOST / GL / BV / DNV / ABS
Type MNAV / MNBVN / MNAVN / MNBVN

MNKV / MNKVN
Housing: Aluminium with Stainless steel covered

20
MNAV / MNBV / MNAVN / MNBVN
Indication
- Material quality: Pocan
- Colour: White / Red
End part: Ryton, black
Sight cover - MNAV / MNAVN: Macrolon
L = M + 63
M = ...
- MNBV / MNBVN: Glass

MNAVN / MNBVN ( over-roll-protected ): Roller rotation max. 180°
1015
MNKV / MNKVN
Indication
- Material quality: Ceramic
- Colour: White / Blue
End part: Aluminium
20
Sight cover: Glass

MNKVN ( over-roll-protected ): Roller rotation max. 180° 36
24
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Scale
Type SAK / SA.. / SV..
SAK
Scale: Adhesive foil ( black )

Angle profile: Aluminium
Scaling: in cm ( 0 cm .. 10 cm .. 20 cm .. 30 cm .. )
Width: 40 mm
L = M + 63
SA0 / SA1 / SA2 / SA3 / SA4
Scale: Engraved
Angle profile: Aluminium
Scaling: Blank / % / cm / inch. / ..
Width: 40 mm
SV0 / SV1 / SV2 / SV3 / SV4
Scale: Engraved
Angle profile: Stainless steel
Scaling: Blank / % / cm / inch. / .. 40
Width: 40 mm
20
Type Magnetic roller indicator

sight extension PV
Material quality: Acryl glass
Width: 35 mm
Depth: 67 mm
1015
Mounting: on magnetic roller indicator

67
44
ATEX / GOST / GL / BV / DNV / ABS 35
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Level transmitter
Connection diagram
BROWN 3 3
BLACK
BLACK
BLUE
- -
2 4 2 4
- BROWN - R0Ω
-
8 - 28 VDC 8 - 28 VDC BROWN
4 - 20 mA 4 - 20 mA
+ Rv
+ +
1 5 BLUE 1 5
+ mA + mA
+ - + - BLACK
6 6
without Control unit Control unit TP5343.. Control unit TD5335..
100% (20 mA)

0% (4 mA) 0% (4 mA)
3 100% (20 mA)
BLACK
2 4 LED (Cal/Err.)
- BROWN
BLACK
1
+ BROWN
2
1 5 BLUE BLUE
3
6
+ -
Bus + - + mA
4 - 20 mA + -
10 - 30 VDC
4 - 20 mA
+ + mA - -
12 - 30 VDC -
Control unit TP5350.. Control unit XT42SI Ex Control unit magnetostrictive
Some further data according to chapter Control Units 1011

SIL
C
IE
11
615 5
0 8 / 61
ATEX-Approval for accuracy K5.. / K10.. / K15..*
II 1/2G Ex ia c IIC T6 - T4 II 1/2G Ex ia c IIC T6 - T3 bzw. Ex d ia c IIC T6 - T4 II 2G Ex d c IIC T6 - T4

II 1/2G Ex d ia c IIC T6 - T4 II 2D Ex tD A21 c IP6* T80°C - T190°C bzw. T125
1015
Liquid temperature Exia max. 180°C / Exd max. 120°C

Type of protection intrinsic safety Ex ia IIC switch bzw. temperature switch Ii ≤ 100 mA
Type of protection intrinsic safety Ex ia IIC temperature probe Ui ≤ 28 V Ii ≤ 100 mA Pi ≤ 700 mW
Type of protection intrinsic safety Ex ia IIC with option /N ( NAMUR EN 60947 ) Ui ≤ 15 VDC Ii ≤ 60 mA
Type of protection „moulding“ UN ≤ 250 VDC/AC PSN ≤ 50 W/VA PFN ≤ 700 mW
Type of protection „moulding“ with option /N ( NAMUR EN 60947 ) UN ≤ 15 VDC IN ≤ 60 mA
Type of protection „moulding“ with option /R22 ( resistor ) UN ≤ 250 VDC/AC IN ≤ 100 mA
ATEX-Approval for accuracy K1..*
II 1/2G Ex ia c IIC T6 - T2 II 1G Ex ia IIC T4 - T2

II 1/2G Ex ia IIC T6 - T2 II 2G Ex d IIC T4
Type of protection intrinsic safety Ex ia IIC Ui ≤ 30 V Ii ≤ 200 mA Pi ≤ 1000 mW
Temperature class T6 T5 T4 - T2
Ambient temperature(Ta) -20°C ... 40°C -20°C ... 55°C -20°C ... 85°C
Liquid temperature(TF) -20°C ... 60°C -20°C ... 60°C -20°C ... 60°C
Heinrich Kübler AG
Enclosure 10303
Type ALF/../V/../..-M..
Electrical connection: Aluminium anodized

Cable entry: M20 x 1.5
Ingress protection class: IP 65 57 T = ... 75
Level transmitter tube material quality: Stainless steel
Mounting: T-shaped sliding block or tension strap
Minimum measures ( Liquid ≤ 200°C ): T: 27 mm / L1: 40 mm / Ub: 50 mm
80
Minimum measures ( Liquid > 200°C ): T: 100 mm / L1: 40 mm / Ub: 50 mm
L1 = ...
Accuracy 100 %
Accuracy: 5 / 10 / 15 mm
Ambient temperature
- K5 / K10 / K15: -30°C ... 130°C
L = Ub + M + L1
- K5HTF / K10HTF / K15HTF: -30°C ... 200°C
M = ...
- K5HT / K10HT / K15HT: -40°C ... 250°C
Option control unit / Page 276

- Profibus PA 0%
Ub = ...
14
Type ALDA/../V/../EXDG-M..
Electrical connection: Aluminium coated RAL 9006

Ingress protection class: IP 68 84 T = ... 97
Minimum measures ( Liquid ≤ 200°C ): T: 50 mm / L1: 40 mm / Ub: 50 mm 106
L1 = ...
Accuracy 100 %
Accuracy: 5 / 10 / 15 mm 1015
Ambient temperature
- K5 / K10 / K15: -30°C ... 120°C
- K5HTF / K10HTF / K15HTF: -30°C ... 120°C
L = Ub + M + L1
- K5HT / K10HT / K15HT: -40°C ... 120°C

M = ...

- Profibus PA 0%
Ub = ...
Approvals / Certificates 14
Heinrich Kübler AG
Enclosure 10303
Type DAALA/../V/..-M..
Electrical connection: Aluminium anodized

100 T = ... 20 74
Display: 4-digit LED display in red / Free scaling
Current input: 4 ... 20 mA
82
L1 = ...
100 %
Ambient temperature
- K5 / K10 / K15: -30°C ... 130°C
- K5HTF / K10HTF / K15HTF: -30°C ... 200°C
L = Ub + M + L1
- K5HT / K10HT / K15HT: -40°C ... 250°C
M = ...

- Profibus PA
0%
Ub = ...
ATEX / GOST
Type DAAVDA/../V/../EXIADG-M..
Electrical connection: Stainless steel electropolished

100 T = ... 20 74
Display: 4-digit LED display in red / Free scaling
Current input: 4 ... 20 mA
82
L1 = ...
100 %
1015
Ambient temperature
- K5 / K10 / K15: -30°C ... 130°C ( Exd 120°C )
- K5HTF / K10HTF / K15HTF: -30°C ... 180°C ( Exd 120°C )
L = Ub + M + L1
- K5HT / K10HT / K15HT: -40°C ... 180°C ( Exd 120°C )

M = ...

- Profibus PA
0%
Ub = ...
ATEX / GOST
Heinrich Kübler AG
Enclosure 10303
Type AVA/../V/..-M..
Electrical connection: Stainless steel A4 ( SS316 )

Cable entry: M20 x 1.5 110 T = ... 82
95
L1 = ...
100 %
Accuracy
Ambient temperature
- K5 / K10 / K15: -30°C ... 130°C
L = Ub + M + L1
- K5HTF / K10HTF / K15HTF: -30°C ... 200°C
M = ...
- K5HT / K10HT / K15HT: -40°C ... 250°C

0%
- Profibus PA
Ub = ...
14
Type AVM/../V/../..-M..
Electrical connection: Stainless steel A4 ( SS316 ) 46 18 50

112
Minimum measures: L1: 40 mm / Ub: 50 mm

L1 = ...
Accuracy
100 %
Accuracy: 0.2 mm 1015
Ambient temperature
- K1: -40 ... 125°C
- K1HT: -40 ... 250°C
- K1HHT: -40 ... 450°C
L = Ub + M + L1
M = ...
Control unit
- MST / MSTB: - Programmable

4 ... 20 mA, 10 ... 30 VDC
- MSTH / MSTHB: - Hart-programmable
4 ... 20 mA, 10 ... 30 VDC 0%
Ub = ...
12
ATEX / GOST / IECEX / SIL2
Heinrich Kübler AG
Enclosure 10303
Type AVDM/../V/../EXIADG-M..
Electrical connection: Stainless steel A4 ( SS316 ) 107 18 25 48

74
112
L1 = ...
100 %
Accuracy
Accuracy: 0.2 mm
Ambient temperature
- K1: ATEX temperature page 276
L = Ub + M + L1
M = ...
Control unit
- MSTB: - Programmable
4 ... 20 mA, 10 ... 30 VDC
- MSTHB: - Hart-programmable
4 ... 20 mA, 10 ... 30 VDC 0%
Ub = ...
12
Type DAAVDM/../V/../EXIADG-M..
Electrical connection: Stainless steel A4 ( SS316 ) 107 18 25 48

74
112

L1 = ...
100 %
Accuracy
1015
Accuracy: 0.2 mm
Ambient temperature
- K1: ATEX temperature page 276
L = Ub + M + L1
M = ...
Control unit
- MSTB: - Programmable
4 ... 20 mA, 10 ... 30 VDC
- MSTHB: - Hart-programmable
4 ... 20 mA, 10 ... 30 VDC 0%
Ub = ...
12
Heinrich Kübler AG
Enclosure 10303
Notes
1015
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Magnetic switch
Connection diagram
1 SWITCH POINT
1 SWITCH POINT 1 SWITCH POINT Protective circuit according to
recommended wiring EN 60 947-5-6
for PLC input
BLUE 1
BLUE 1 BLUE 1 10K

1K
BROWN 2 BROWN 2
BROWN 2
22 Ohm
BLACK 3 BLACK 3 10K
BLACK 3
Change over Change over Change over

with resistor with NAMUR EN 60947
SIL C
IE
11
615 5
0 8 / 61
ATEX*
II 2G Ex ia IIC T6 - T1 II 2G Ex d IIC T6 - T4
II 2D Ex tD A21 IP6* T80°C - T300°C II 2D Ex tD A21 IP6* T80°C - T120°C
1015
Liquid temperature Exia max. 180°C / Exd max. 120°C

Type of protection intrinsic safety Ex ia IIC switch bzw. temperature switch Ii ≤ 100 mA
Type of protection intrinsic safety Ex ia IIC temperature probe Ui ≤ 28 V Ii ≤ 100 mA Pi ≤ 700 mW
Type of protection intrinsic safety Ex ia IIC with option /N ( NAMUR EN 60947 ) Ui ≤ 15 VDC Ii ≤ 60 mA
Type of protection „moulding“ UN ≤ 250 VDC/AC PSN ≤ 50 W/VA PFN ≤ 700 mW
Type of protection „moulding“ with option /N ( NAMUR EN 60947 ) UN ≤ 15 VDC IN ≤ 60 mA
Type of protection „moulding“ with option /R22 ( resistor ) UN ≤ 250 VDC/AC IN ≤ 100 mA
Heinrich Kübler AG
Enclosure 10303
Type BGU/../../../..
BGU/../../../../EXIAG

Mounting: Right or left at the magnetic roller indicator
Ambient temperature / ATEX Exia:

- with PVC connection cable: -20°C ... 80°C / -20°C ... 80°C
25 30
- with Silikon connection cable: -60°C ... 180°C / -25°C ... 180°C
- with PUR connection cable: -40°C ... 80°C / -25°C ... 80°C
- with Radox connection cable: -35°C ... 120°C / -25°C ... 120°C
T-shaped
sliding block
Switch function
100
~ 120
Switching capacity / ATEX Exia: Exia 100 mA / Exia NAMUR 60 mA
Switch point
Switching hysteresis: 5 mm ... 7 mm
Options
- Switch option .. /R22: Resistor 22 Ohm / 0.21 W

- Switch option .. /N: NAMUR EN 60947
ATEX / GOST / GL / BV / DNV / ABS / SIL1
Type BGUD/../../../../EXDG

25 30
Ambient temperature:
- with PVC connection cable: -20°C ... 80°C
- with Silikon connection cable: -25°C ... 120°C
- with PUR connection cable: -25°C ... 80°C
- with Radox connection cable: -25°C ... 120°C T-shaped
sliding block
Switch function
100

1015
~ 130
Switching capacity: UN 250 V / PSN 50 W/VA / PFN 700 mW

- NAMUR EN 60947: UN 15 VDC / IN 60 mA Switch point
- with resistor: UN 250 V / IN 100 mA
Options

Heinrich Kübler AG
Enclosure 10303
Type BGUALE/..
BGUALE/../EXIAG

Ambient temperature / ATEX Exia: -40°C ... 130°C / -25°C ... 130°C
~ 60 ~ 60
25 30
Switch function T-shaped

sliding block
100
108
~ 130
Switching capacity: 230 V / 0.5 A / 40 VA Switch point
64
Options

Type BGUASQ/..
BGUASQ/../EXIAG

25 30
T-shaped
sliding block
Switch function
100

~ 135
1015
Switch point
Options

1
2
ATEX / GOST / SIL1
Heinrich Kübler AG
Enclosure 10303
Type BGUASMA/../../../..
BGUASMA/../../../../EXIAG

Connector: M12
Mounting: Right or left at the magnetic roller indicator 3
Ambient temperature: -25°C ... 90°C 2 1
25 30
Switch function

T-shaped
Switch behaviour: Bistable sliding block
100
~ 115
Options Switch point
ATEX / GOST / SIL1
Type RU60/../../../.. RU73/../../../..

RU60/../../../../EXIAG RU73/../../../../EXIAG

Mounting: Free positionable on the chamber
RU73.. ( for chamber ≥ Ø 73 mm )
- with Silikon connection cable: -40°C ... 180°C 22
- with Radox connection cable: -35°C ... 120°C
Switch point
Switch function
69

1015
82
~ 100

Options

Heinrich Kübler AG
Enclosure 10303
Type RUV60/../../../.. RUV73/../../../..

RUV60/../../../../EXIAG RUV73/../../../../EXIAG
Housing: Stainless steel

RUV73.. ( for chamber ≥ Ø 73 mm )
22
Switch point
Switch function
69
82
~ 100
Options

Type RUVD60/../../../../EXDG
RUVD73/../../../../EXDG
Housing: Stainless steel

RUVD73.. ( for chamber ≥ Ø 73 mm )
Ambient temperature / ATEX Exia:
- with PVC connection cable: -20°C ... 80°C 22
Switch point
Switch function
69

82
1015

~ 110

- NAMUR EN 60947: UN 15 VDC / IN 60 mA
Options

Heinrich Kübler AG
Enclosure 10303
Type ALFU/..
ALFU/../EXIAG

80

- with 22 Ohm Resistor: -40°C ... 220°C
- with NAMUR EN 60947: -40°C ... 220°C
71
Switch function

Switch point
75
Options

~ 130
ATEX / GOST / SIL1
Type ALFI
ALFI/EXIAG
Housing: Aluminium coated RAL 9006

80
Ambient temperature / ATEX Exia: -40°C ... 100°C / -40°C ... 73°C
Power supply: 5.0 ... 25 VDC
Nominal voltage: 8.0 VDC ( Ri ~ 1 Ohm )
Self inductance: 100 mH
71
Self capacitance: 30 nF
Switch function 1015

Function: NAMUR normally closed Switch point
( Proximity switch )
75
Intrinsic safety data: Ui = 16 VDC

Ii = 25 mA
Pi = 34 mW
~ 130
ATEX / GOST / SIL1
Heinrich Kübler AG
Enclosure 10303
Type ALEU/..
ALEU/../EXIAG

~ 60 58
25 30
Switch function
Switch point
100
107
~ 130
64
Options

Type APAVU/..
APBVU/../EXIAG
Housing: Polyester / Stainless steel

83 80
24.5 29.5
Switch function
Switch point
1015
100
113

~ 140

75

Options

ATEX / GOST / SIL1
Heinrich Kübler AG
Enclosure 10303
Type ALDAU/../../../../EXDG
Housing: Aluminium coated RAL 9006


120 82
94 23.5
Switch function

125
~ 170
- NAMUR EN 60947: UN 15 VDC / IN 60 mA
Switch point
Options

ATEX / GOST / SIL1
1015
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Isolation / Heat tracing
Type AIT
AHT
Armaflex isolation AIT

C = ...
Material quality: Cellular plastic based on synthetic rubber
Fire behaviour: Self-extinguishing, not drippy, not flamable
B = ...
Nominal thickness: 32 mm
UV-resistance: No
Armaflex isolation AHT
Material quality: Cellular plastic based on synthetic rubber
Fire behaviour: Self-extinguishing, not drippy, not flamable
M = ...
Nominal thickness: 25 mm
UV-resistance: Yes
Type H..A
H..B
Self-regulating antifreeze heat tracing
U = ...
Type: H75A
H75B acc. to EExe / T4
Terminal box: GFK black with cable entry M25
Protective shell: Fluorpolymer
Power supply: 230V AC
Power output: 76 W/m at 10°C
( 32 mm Isolation necessary )
Steam-flushing: No
Approvals / Certificates: ATEX / DNV
Self-regulating antifreeze heat tracing

0°
Type: H150A
H150B acc. to EExe / T2 270° 90°
Terminal box: GFK black with cable entry M25

Protective shell: Fluorpolymer 180°
Power supply: 230V AC

Power output: 50 W/m at 10°C
( 32 mm Isolation necessary )
1015
Steam-flushing: Yes
Approvals / Certificates: ATEX / DNV
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Isolation
Type SW
Rock-wool isolation SW
C = ...
Material quality: Rock-woll with crome-nickel cover
( Removable )
B = ...
Nominal thickness: ~50 mm
UV-resistance: Yes
M = ...
U = ...
0°
270° 90°
180°
1015
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Chamber end top
Chamber end top
Z
Z
B
B
B
B
BA BB BC BD
Tube cap Tube plate Tube plate Tube plate

with vent plug G.. with vent plug NPT..
Z
OFF
Z
Z
ON
Y
B
B
B
BE BF BG BH
Tube plate Tube plate Tube plate Tube plate

with vent welding stub end with vent flange with vent ball valve with vent needle valve
Z
Z
Z
Z
B
B
B
BI BJ BK BL
Flanged connection Flanged connection Flanged connection Flanged connection

with vent plug G.. with vent plug NPT.. with vent welding stub end
1015
OFF
Z
Z
ON
Y
Y
B
B
B
BM BN BO
Flanged connection Flanged connection Flanged connection

with vent flange with vent ball valve with vent needle valve
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Chamber end top
Chamber end top
Z
Z
Z
B
B
B
B
BP BQ BR BS
Flanged connection EN/ANSI Flanged connection EN/ANSI Flanged connection EN/ANSI Flanged connection EN/ANSI
with vent plug G.. Z with vent plug NPT.. with vent welding stub end
OFF
Z
Z
ON
Y
Y
B
B
B
BT BU BV
Flanged connection EN/ANSI Flanged connection EN/ANSI Flanged connection EN/ANSI

with vent flange with vent ball valve with vent needle valve
Pressure rating 16 / 150# 40 / 300# 63 / 600# 160 / 1500# 250-400 / 2500#
B Y Z B Y Z B Y Z B Y Z B Y Z
Measure in ~ mm
Tube cap 90 - - 90 - - - - - - - - - - -
Tube plate 90 - - 90 - - 90 - - 90 - - 90 - -
Tube plate with vent plug G1/2 90 - 20 90 - 20 90 - 20 - - - - - -
Tube plate with vent plug NPT1/2 90 - 30 90 - 30 90 - 30 90 - 30 90 - 30
Tube plate with vent welding stub end 90 - 120 90 - 120 90 - 120 90 - 120 90 - 120
Tube plate with vent flange 90 - 120 90 - 120 90 - 120 90 - 120 90 - 120
Tube plate with vent ball valve G 90 180 55 90 180 55 90 180 55 - - - - - -
Tube plate with vent needle valve G 90 120 50 90 120 50 90 120 50 - - - - - -
1015
Flanged connection 120 - 30 120 - 30 - - - - - - - - -

Flanged connection with vent plug G1/2 120 - 35 120 - 35 - - - - - - - - -
Flanged connection with vent plug NPT1/2 120 - 65 120 - 65 - - - - - - - - -
Flanged connection with vent welding stub end 120 - 120 120 - 120 - - - - - - - - -
Flanged connection with vent flange 120 - 120 120 - 120 - - - - - - - - -
Flanged connection with vent ball valve G 120 180 55 120 180 55 - - - - - - - - -
Flanged connection with vent needle valve G 120 120 50 120 120 50 - - - - - - - - -
Flanged connection EN/ANSI 160 - 35 160 - 35 160 - 50 200 - 100 250 - 115
Flanged connection EN/ANSI with vent plug G1/2 160 - 35 160 - 35 160 - 50 - - - - - -
Flanged connection EN/ANSI with vent plug NPT1/2 160 - 65 160 - 65 160 - 70 200 - 100 250 - 115
Flanged connection EN/ANSI with vent welding stub end 160 - 120 160 - 120 160 - 120 200 - 120 250 - 120
Flanged connection EN/ANSI with vent flange 160 - 120 160 - 120 160 - 120 200 - 200 250 - 200
Flanged connection EN/ANSI with vent ball valve G 160 200 55 160 200 55 160 200 55 - - - - - -
Flanged connection EN/ANSI with vent needle valve G 160 120 50 160 120 50 160 120 50 - - - - - -
Flanged connection EN/ANSI with vent needle valve NPT 160 120 50 160 120 50 160 120 50 200 200 55 250 200 55
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Chamber end bottom
Chamber end bottom
U = ...
U = ...
U = ...
W
U = ...
W
W
UA UB UC UD
Tube plate Tube plate Tube plate Tube plate

with drain plug G.. with drain plug NPT.. with drain welding stub end
U = ...
U = ...
U = ...
V
ON
V
W
OFF
W
UE UF UG
Tube plate Tube plate Tube plate

with drain flange with drain ball valve with drain needle valve
U = ...
U = ...
U = ...
U = ...
W
W
W
W
UH UI UJ UK
Flanged connection Flanged connection Flanged connection Flanged connection

1015
U = ...
U = ...
U = ...
V
ON
V
W
OFF
W
UL UM UN
Flanged connection Flanged connection Flanged connection

Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Chamber end bottom
Chamber end bottom
U = ...
U = ...
U = ...
U = ...
W
W
W
W
UO UP UQ UR
Flanged connection EN/ANSI Flanged connection EN/ANSI Flanged connection EN/ANSI Flanged connection EN/ANSI
U = ...
U = ...
U = ...
V
ON
V
W
OFF
W
US UT UU
Flanged connection EN/ANSI Flanged connection EN/ANSI Flanged connection EN/ANSI

Pressure rating 16 / 150# 40 / 300# 63 / 600# 160 / 1500# 250-400 / 2500#
U V W U V W U V W U V W U V W
Measure in ~ mm
Tube plate ...S - - ...S - - ...S - - ...S - - ...S - -
Tube plate with drain plug G1/2 ... S
- 20 ...
S
- 20 ... S
- 20 ... S
- - ...S - -
Tube plate with drain plug NPT1/2 ...S - 30 ...S - 30 ...S - 30 ...S - 30 ...S - 30
Tube plate with drain welding stub end ...S - 120 ...S - 120 ...S - 120 ...S - 120 ...S - 120
Tube plate with drain flange ...S - 120 ...S - 120 ...S - 120 ...S - 120 ...S - 120
Tube plate with drain ball valve G ...S 180 55 ...S 180 55 ...S 180 55 - - - - - -
Tube plate with drain needle valve G ...S 120 50 ...S 120 50 ...S 120 50 - - - - - -
1015
Flanged connection ...S - 30 ...S - 30 - - - - - - - - -

Flanged connection with drain plug G1/2 ...S - 35 ...S - 35 - - - - - - - - -
Flanged connection with drain plug NPT1/2 ...S - 65 ...S - 65 - - - - - - - - -
Flanged connection with drain welding stub end ...S - 120 ...S - 120 - - - - - - - - -
Flanged connection with drain flange ...S - 120 ...S - 120 - - - - - - - - -
Flanged connection with drain ball valve G ...S 180 55 ...S 180 55 - - - - - - - - -
Flanged connection with drain needle valve G ...S 120 50 ...S 120 50 - - - - - - - - -
Flanged connection EN/ANSI ...S - 35 ...S - 35 ...S - 50 ...S - 100 ...S - 115
Flanged connection EN/ANSI with drain plug G1/2 ...S - 35 ...S - 35 ...S - 50 ...S - - ...S - -
Flanged connection EN/ANSI with drain plug NPT1/2 ...S - 65 ...S - 65 ...S - 70 ...S - 100 ...S - 115
Flanged connection EN/ANSI with drain welding stub end ...S - 120 ...S - 120 ...S - 120 ...S - 120 ...S - 120
Flanged connection EN/ANSI with drain flange ... S
- 120 ...
S
- 120 ... S
- 120 ... S
- 200 ...S - 200
Flanged connection EN/ANSI with drain ball valve G ...S 200 55 ...S 200 55 ...S 200 55 - - - - - -
Flanged connection EN/ANSI with drain needle valve G ...S 120 50 ...S 120 50 ...S 120 50 - - - - - -
Flanged connection EN/ANSI with drain needle valve NPT ...S 120 50 ...S 120 50 ...S 120 50 ...S 200 55 ...S 200 55
...S = Depending on the Float length
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Process connection
Process connection
C = 150 C = ... C = 150 C = 150
CA CB CC CD
Welding neck flange ( Standard ) Welding neck flange reduced Blind flange Female thread
C = 150 C = 150
CE CF
Male thread Welding stub end
Welding neck flange reduced DN50 to DN25 / 2“ to 1“
Pressure rating 16 / 150# 40 / 300# 63 / 600# 160 / 1500# 250-400 / 2500#
Standrohraussendurchmesser [ mm ] C [ mm ] C [ mm ] C [ mm ] C [ mm ] C [ mm ]
Ø 60.30 154 / 172 156 / 179 170 / 188 - -

Ø 63.50 155 / 174 158 / 180 172 / 190 - -
Ø 73.03 160 / 179 163 / 185 177 / 195 190 / 223 225 / 248
Ø 88.90 168 / 186 171 / 193 185 / 203 198 / 231 233 / 256
Ø 114.30 181 / 199 184 / 206 198 / 215 211 / 244 246 / 269
1015
Material quality / Process connection
Welding neck flange

Welding neck flange Blind flange Female thread Male thread Welding stub end
reduced
Stainless steel n n n n n n
Titanium n n n n n n
Alloy n n n n n n
PVC - - n - - -
PP - - n - - -
PVDF - - n - - -
E-CTFE coated n n n - - -
PFA coated n n n - - -
redundantes System n n n n n n
Bezugsgefäss n n n n n n
Heinrich Kübler AG
Enclosure 10303
Bypass Level Indicator / Dampening spring / Support bracket
Dampening spring
Dampening spring top Dampening spring bottom
Support bracket
50
17
100
60
Support bracket HE-4824

( recommended for M ≥ 2000 mm )
1015
Heinrich Kübler AG
Enclosure 10303
INSTALLATION AND
OPERATING INSTRUCTIONS
BYPASS- LEVEL INDICATOR

TYPE BNA / BMG
1. FUNCTIONAL DESCRIPTION: ________________________________________________________________ 2
2. APPLICATION: ____________________________________________________________________________ 2
3. ASSEMBLY:_______________________________________________________________________________ 2
4. HAZARD NOTICE:__________________________________________________________________________ 2
5. NOTICES:_________________________________________________________________________________ 2
6. NOTICES FOR EX-INSTRUMENT: _____________________________________________________________ 3
7. COMMISSIONING:__________________________________________________________________________ 3
8. MAGNETIC SWITCH / LIMITING VALUE: _______________________________________________________ 5

9. ELECTRICAL CONNECTION OF THE MAGNETIC SWITCH: ________________________________________ 5
10. CAUTION: ________________________________________________________________________________ 5
11. MAINTENANCE OF THE MAGNETIC SWITCH:___________________________________________________ 5
12. FUNCTIONAL TEST OF THE MAGNETIC SWITCH: _______________________________________________ 5
13. NOTES FOR MAGNETIC SWITCH: ____________________________________________________________ 6
14. NOMINAL DATA FOR EX-MAGNETIC SWITCH:__________________________________________________ 6
15. NOTICES FOR EX-MAGNETIC SWITCH:________________________________________________________ 7
16. LEVEL SENSOR:___________________________________________________________________________ 8

17. ELECTRICAL CONNECTION OF THE LEVEL SENSOR: ___________________________________________ 8
18. CAUTION: ________________________________________________________________________________ 8
19. MAINTENANCE OF THE LEVEL SENSOR: ______________________________________________________ 8
20. FUNCTIONAL TEST OF THE LEVEL SENSOR: __________________________________________________ 8
21. NOTES FOR LEVEL SENSOR:________________________________________________________________ 9
22. NOMINAL DATA FOR EX-LEVEL SENSOR: _____________________________________________________ 9
23. NOTICES FOR EX-LEVEL SENSOR: ___________________________________________________________ 9
HEINRICH KÜBLER AG KFG LEVEL AG

Ruessenstrasse 4, CH-6341 BAAR
Ruessenstrasse 4, CH-6341 BAAR
Tel. ++41(0)41 766 62 62
Tel. ++41(0)41 766 62 82
Fax ++41(0)41 766 62 63
Fax ++41(0)41 766 62 83
E-Mail: [email protected]
http://www.ksr-kubler.com
KÜBLER SVENSKA AB KÜBLER Afrika (Pty) Ltd. KÜBLER SUOMI OY

Box 649 P. O. Box 1292
PL225
Finntorpsvsvägen 5D 2040 Honeydew,
01301 Vantaa
131 21 Nacka South Africa
Tel. ++358 9-870 09 60
Tel. ++46 8-556 117 60 Tel. ++27 11 675-0616
Fax ++358 9-870 09 611
Fax ++46 8-718 43 77 Fax ++27 11 675-0619
E-Mail: [email protected] E-Mail: [email protected]
13.06.05 page 1 of 10 Bypass-e.doc

Enclosure 10303
1. FUNCTIONAL DESCRIPTION:
The bypass level indicator forms an integral part of a pressure vessel. A chamber is mounted on the side of a tank or
container by means of two process connections. This direct connection ensures that the level in the chamber corresponds
precisely to the level of the liquid in the tank or container (communicating pipes). Inside the bypass chamber is a cylindrical
float with a built-in magnetic system. The concentrated magnetic field produced by the permanent magnet gives a precise
reading for the level of liquid in the chamber. A signal is transmitted by the magnetic field through the wall of the chamber to
an externally mounted display, as well as to recording and switchgear elements.
2. APPLICATION:
The bypass level indicator is only to be exposed to liquids that allow the float to function reliably and to which the materials
used are resistant. Furthermore, the system should only be used for the specified parameters such as pressure, temperature
and density. In addition, no contamination, coarse particles and crystallization should be present. Excluded from these
requirements are units that are specifically suited for such applications and marked accordingly.
3. ASSEMBLY:
The bypass level indicator (acc. to page 4) is bolted onto the side of the container using a process flange (1) and a suitable
seal (2). The raised and flat faces as well as the gaskets have to be mechanically perfectly matched. The correct gasket
material has to be used for sealing according to the medium, pressure and temperature.
Remove the base flange (3) and insert the ZVS cylindrical float (4) into the bypass chamber with the inscripti-on "oben"
("top") at the top. Fit the seal (5) and seal the base flange again, tightening the bolts (6) firmly to secure it. Screw in the vent
and drain plugs (11), if existing.
If not installed by the factory, the magnetic roller display (7) will be mounted with two clamps onto the chamber (9). Further
the level sensor will be mounted onto the chamber or MRA-profile. The magnetic switches (10), depending on type, will be
mounted onto the MRA-profile or chamber at the required switching level.
4. HAZARD NOTICE:
It is not allowed to make a temporary installation if components or whole instruments are faulty or wrong, particularly
when components are missing.
Instruments and their accessory parts should not be used to secure lifting gear, to act as foot rests or any other
mechanical aids that could damage the installation.
Where there is a hazard or danger present, warning signs have to be displayed according to the local and national
standards. Any isolation device fitted must also comply with these standards.
The operators have to wear protection clothes according to the local circumstances and regulations. The operators have
to be trained and given instructions as well as to be in possession of the technical data.
The operator is responsible, to ensure that unauthorized persons do not have access to the installations or instruments
and these operations.
If passing the instruments and installations on to a third party, all documentation has to be included indicating the
correct mounting procedures, operational details and hazards.
Precautions are necessary for:
Heat radiation from outside on to the instruments.
Heat radiation from the instruments to the surroundings.
Electrical heating systems.
Exposure to medium, gas, mist or steam.
5. NOTICES:
The bypass level indicator must not be subjected to any mechanical loads, vibrations or shock influences. If these loads
exist, supporting or protecting elements have to be used.
Mechanical shocks are not allowed transmitted through the medium to the instrument.
For flammable or explosive mediums, instruments with 94/9/EG ATEX approvals have to be used.
The conditions of the environment have to be optimised so that all indicating instruments on-site can be read correctly
and positioned so that they may be seen in a normal field of view.
Disposal of instruments should be according to regional and national directions and guidelines.
By disposal it is possible that residues of the medium remain within the instrument.

Enclosure 10303
TRANSPORTATION SPECIFICATIONS:
These instruments should be packed with respect to the delicate nature of some of the parts. Outer packing such as wooden
cases should be marked with fragile or similar signs to help protect the instrument.
6. NOTICES FOR EX-INSTRUMENT:

The bypass level indicator is according to RL 94/9/EG (ATEX 95) annex I an instrument of the instrument group II
category 1G resp. 2G, which can be used acc. to RL 99/92/EG (ATEX 137) in the zones 0, 1 and 2 resp. 1 and 2 as well
as the gas groups IIA, IIB and IIC, which are explosion endangered by flammable substances in the area of the
temperature classes which values are resulting by the application of the media resp. the listed values in the separately
certificates of the installed KSR instruments.
Only the bypass chamber and the float of the bypass level indicator, type acc. to type key, may be used in the zone 0.
There these parts have to be included in the recurring pressure test of the installation.
The parts of the composition in the material of the components of the category 1G may not excess the following values:
< 10% for: Aluminium + Magnesium + Titanium + Zirconium, or
< 7.5% for: Magnesium + Titanium + Zirconium.
The allowed length of the bypass chamber is defined by suitable material matchings in terms of float: The max.length is
4m if both parts are made of stainless steel. A conductive plastic coated float can be used in all area acc. to the type
key.
The bypass level indicator is acc. to RL 94/9/EG (ATEX 95) annex I an instrument of the instrument group II category
2D, which may be used acc. to RL 99/92/EG (ATEX 137) in the zones 21 and 22 of flammable dusts.
The bypass level indicator resp. the components have to correspond to the protection rating IP6*.
The metal housing of the overtank level indicator has to be connected conductive with the potential compensation
system of the plant.
Canges at the instrument may be only done by the manufacturer.
NOTES FOR THE AREA OF USE

The wetted parts of the level indicator, that means the internal space of the bypass chamber, do not contain electrical
parts. They have been assessed therefore acc. to the appropriate norms for not electrical equipments.
The assessment by use as component, by mounting according to regulations of separately certified KSR-instruments,
does not show advanced hazards.
7. COMMISSIONING:
Fill the container and switch on the electrical control, where provided. Check the MNA or MRA magnetic roller display and
check the switching function of the magnetic switches to make sure that they are operating properly. Use a connecting cable
for the level sensor of at least 3 x 0.5 mm2. Route cable from measuring transducer (switchgear cabinet) to the bypass level
sensor and insert into the terminal box using a cable gland and seal it.
The level indicator is ready for operation.

Enclosure 10303
9 10
2 1
OBEN
6 6
3
11

Enclosure 10303
M
MAAG
GNNE
ETTIIC
CSSW
WIIT
TCCH
HFFO
ORRB
BNNA
A // B
BMMG
G
8. MAGNETIC SWITCH / LIMITING VALUE:
Limit levels are activated by magnetic switches.
The magnetic switches will be differentiated after different types corresponding to the range of applications and the technial
requirements.
All magnetic switches are bistable, i.e. they are switched over by the float's magnetic system as the level rises and falls.
9. ELECTRICAL CONNECTION OF THE MAGNETIC SWITCH:

The electrical connection must comply with the safety regulations for installing electrical systems and equipment that apply in
the country where the unit is installed and this work may only be undertaken by qualified personnel. The service life of the
switch can be increased considerably through the use of a contact protection relay.
As options, the magnetic switches can be provided with the following configurations:
Circuit for the operation Namur circuit acc. to EN 60947

on SPS with 22 resistance
10. CAUTION:
If the switch is connected to an inductive load, it may be damaged beyond repair. A protective circuit with an RC element or a
freewheeling diode should be provided.
If connected to a capacitive load, a protective resistor is to be connected in series to limit the peak current.
Electrical overloading may result in the switch being damaged irreparably. This may cause the control connected in the
outgoing circuit to malfunction and result in damage to property and injury to persons. Maximum electrical switching
capacities must be complied with.
If a fault is present on units with metal enclosures and connecting cables without a ground terminal, the units may be live and
thus cause damage to property or injury to persons. These units may only be operated on extra-low voltage or they must
have an additional ground connection. (> 50 V / max. 1A)
It is important that an adequate and correct power supply is used.
11. MAINTENANCE OF THE MAGNETIC SWITCH:

The units must be installed and commissioned in accordance with the generally accepted rules of engineering practice.
When in service the units do not require any maintenance, provided that the magnetic switch is designed for the ambient
conditions such as the temperature, protection rating and medium.
12. FUNCTIONAL TEST OF THE MAGNETIC SWITCH:

With the electrical connection between the switch and the control disconnected, a continuity tester is then connected and the
functionality of the switch is tested using a magnet. Bistable switches should be switched twice so that they are returned to
their initial position. Reconnect the electrical connection after the test has been completed.

Enclosure 10303
M
MAAG
GNNE
ETTIIC
CSSW
WIIT
TCCH
HFFO
ORRB
BNNA
A // B
BMMG
G
13. NOTES FOR MAGNETIC SWITCH:
Do not operate magnetic switches in close proximity to powerful electro-magnetic fields. Minimum clearance: 1 m.
The magnetic switches must not be subjected to any mechanical loads, vibrations or shock influences. If these loads
exist, support or protecting elements have to be used.
Mechanical shocks are not allowed transmitted through the medium to the instrument.
For flammable or expolsive mediums, instruments with 94/9/EG ATEX approvals have to be used.
and be positioned to be in a normal field of view.
Disposal of instruments should be in accordance with regional and national directions and guidelines.
These instruments should be packed with respect to the delicate nature of some of the parts. Outer packing, such as wooden
cases should be marked with fragile or similar signs to help protect the instrument.
14. NOMINAL DATA FOR EX-MAGNETIC SWITCH:

VERSION WITH "INTRINSIC SAFETY" PROTECTION RATING, ALSO WITH OPTION /R (PROTECTIVE RESISTOR)
Supply circuit:
For protection rating EEx ia IIC
only for connection to a certified intrinsically safe circuit.
Maximum current: Ii 100 mA
The effective self inductance and capacitance are negligible.
VERSION WITH OPTION /N (NAMUR CIRCUIT) WITH "INTRINSIC SECURITY" PROTECTION RATING
Supply circuit:
For protection rating EEx ia IIC.
only for connection to a certified intrinsically safe circuit.
Maximum current:
Ui 15 V
Ii 60mA
VERSION WITH PROTECTION RATING "EXPLOSION PROOF", ALSO WITH OPTION /R (PROTECTIVE RESISTOR)
Supply circuit:
Only for connection to a circuit with safe limitation of the electrical parameters to the following values:
Rated voltage: UN = 250 VDC/AC
Switching capacity: IN = 100 mA
VERSION WITH OPTION /N (NAMUR CIRCUIT) WITH "FLAMEPROOF ENCLOSURE" PROTECTION RATING
Supply circuit:
Rated voltage: UN = 15 VDC
Switching capacity: IN = 60 mA
If the instrument will be supplied without cable gland, it is only allowed to mount a cable gland which is according to norm EN
50018 (pressure die-cast EExd).

Enclosure 10303
M
MAAG
GNNE
ETTIIC
CSSW
WIIT
TCCH
HFFO
ORRB
BNNA
A // B
BMMG
G
15. NOTICES FOR EX-MAGNETIC SWITCH:

The magnetic switch is acc. to RL 94/9/EG (ATEX 95) annex I an instrument of the instrument group II category 2G,
which can be used acc. to RL 99/92/EG (ATEX 137) in the zones 1 and 2 as well as in the gas groups IIA, IIB and IIC,
which are explosion endangered by flammable substances in the area of the temperature classes T1 to T6 resp. the
listed values in the below-mentioned figures of the notices.
The requests acc. to EN 60079-14 have to be observed by the application.
The magnetic switch is acc. to RL 94/9/EG (ATEX 95) annex I an instrument of the instrument group II category 2D, that
can be used acc. to RL 99/92/EG (ATEX 137) in the zones 21 and 22 of flammable dusts.
The requests acc. to EN 50281-1-2 have to be observed by the application.
The magnetic switch resp. the components have to comply with the protection rating IP6*.
The assignment between the temperature classes resp. the surface temperature and the maximum ambient
temperature has to be taken from the following table.
ambient temperature
temperature classes /
EEx ia llC EEx d llC Eex m ll
surface temperature
Basis Option /N /R Basis Option /N /R Basis Option /N /R
T6 80°C 80°C 75°C 80°C 75°C 80°C 75°C
T5 95°C 95°C 90°C 95°C 90°C 95°C 90°C
T4 130°C 130°C 125°C 120°C 120°C --- ----
T3 190°C 190°C 185°C ---- ---- ---- ----
T2 290°C 290°C 220°C ---- ---- ---- ----
T1 300°C 300°C ---- ---- ---- ---- ----
The nominal value of the protective resistor of option /R is 22 . By deviant assembly the thermal capacity value Pv = R
* I2 = 0.25 W may not be exceeded. If need the instrument has to be marked with the allowed, reduced input current Ii
resp. IN. Alternatively the allowed ambient temperature can be reduced in steps of 0.25W about 5K at a time acc. to the
above table for the increasing of the thermal capacity value.
If temperatures in excess of 70°C occur at the cable lead-in or above 80°C at the wire terminations, only a verified heat-
resistant cable for the relevant temperature may be connected.
The magnetic switch (type according to type key) in the version with „explosion proof“ protection rating resp.
„compound-filled encapsulation“ is only for connection to an electric circuit with safe (external) delimitation of the
electrical parameters to the given values.
Magnetic switches with metal enclosures must be electrically bonded to the equipment's earth bonding system.
Equipment for use in hazardous locations is identified with a special rating plate containing all data relevant to explosion
protection.

Enclosure 10303
LLE
EVVE
ELL S
SEEN
NSSO
ORRF
FOOR
RBBM
MGG
16. LEVEL SENSOR:

Level sensors are used for the electrical continuous remote display of levels. The resistance measuring chain, which is
mounted outside the chamber, transmits the current level through the wall of the chamber using the magnetic system of the
float. The resistance is converted into a (0)4 - 20 mA analog signal by means of a transducer and the reading is output on a
digital or analog display.
17. ELECTRICAL CONNECTION OF THE LEVEL SENSOR:

The electrical connection must comply with the safety regulations for installing electrical systems and equipment that apply in
the country where the unit is installed and this work may only be undertaken by qualified personnel.
The level sensor is to be connected in the junction box in accordance with the connection plan. The level sensor is to be
wired with the electronic transmitter connected in the outgoing circuit.
2 brown
3 black
1 blue
high
blue 1
100%
R2
brown 2 Rl
R1
low
black 3
0%
The cable gland is to be sealed and the lid of the junction box is to be properly sealed.
Control unit:
Level sensors with integral head measuring transducers are to be connected in accordance with the connection plan in the
junction box. Information on terminal assignment can be found in the relevant connection plan. The connection data can be
found in the appropriate operating instructions.
18. CAUTION:
The operator has to guarantee that instruments that have an earth, will be earthed.
Instruments with a connection cable are not earthed and can be alive in case of error.
These instruments are only allowed to be operated with extra-low voltage.
Instrument cables must not be run in trunking or close proximity with power lines that have heavy switching functions.
Such power cables may cause switch damage from high-voltage spikes. Shielded connecting lines have to be used.
These lines have to be earthed one-side.
It is important that an adequate and correct power supply is used
19. MAINTENANCE OF THE LEVEL SENSOR:

The units must be installed and commissioned in accordance with the generally accepted rules of engineering practice.
When in service, the units do not require any maintenance providing that parameters such as the type of medium, density,
temperature and pressure are complied with.
20. FUNCTIONAL TEST OF THE LEVEL SENSOR:

The user is responsible for periodically carrying out a functional test or, at the very least, a visual check.
A functional test can be performed on the measuring chain with the sensor either removed or in situ. If the units are in situ, it
must be possible to fill the system.
1. Remove connecting cable.
2. Connect ohmmeter to two cores.
3. Move float manually or by filling the system from the min. to max.points.
4. The resistance reading displayed changes continuously as a function of the core colors connected.
BLACK-BROWN (R1) BLUE-BROWN (R2) BLACK-BLUE (Ri)
Resistance falls from the value of the overall

Resistance increases in proportion
resistance in inverse proportion to the height Display of overall resistance (Ri)
to the height of the float
of the float

Enclosure 10303
LLE
EVVE
ELL S
SEEN
NSSO
ORRF
FOOR
RBBM
MGG
21. NOTES FOR LEVEL SENSOR:
Do not operate level sensors in close proximity to powerful electromagnetic fields. (Minimum clearance: 1 m.)
Only use in conjunction with a suitable measuring transducer.
When used on safety barriers, the overall resistance of the reed measuring chain (Ri) must be between 1 k to 100 k
Ohms.
The level sensor must not be subjected to any mechanical loads, vibrations or shocks. If these loads exist, support or
protecting elements have to be used.
Mechanical shocks are not allowed transmitted through the medium on to the instrument.
For flammable or explosive mediums, instruments with 94/9/EG ATEX approvals have to be used.
and be positioned within a normal field of view.
Disposal of the instruments must be in accordance with the regional and national directions and guidelines.
These instruments should be packed with respect to the delicate nature of some of the parts. Outer packing, such as wooden
cases should be marked with fragile or similar signs to help protect the instruments.
22. NOMINAL DATA FOR EX-LEVEL SENSOR:

VERSIONS WITH «INTRINSIC SAFETY» PROTECTION RATING
Supply circuit as a passive n-terminal circuit:
For protection rating EEx ia IIC
only for connection to a certified intrinsically safe circuit
Maximum values:
Ui 30 V
Ii 150 mA
Supply circuit with separately certified integral measuring transducer:

For intrinsically safe protection rating EEx ia llC / EEx ib IIC
Only for connection to a certified intrinsically safe circuit.
Maximum current:
In accordance with the nominal data of the separately certified measuring transducer.
VERSION WITH "EXPLOSION PROOF" PROTECTION RATING

Supply circuit as a passive n-terminal circuit:
Rated voltage UN = 30 VDC/AC
Rated current IN = 150 mA
If the instrument is delivered without the cable gland, it is only allowed to mount a cable gland in accordance to the norm EN
50018 (pressure-proof encapsulation EExd).
23. NOTICES FOR EX-LEVEL SENSOR:

The level sensor is acc. to RL 94/9/EG (ATEX 95) annex I an instrument of the instrument group II category 1G resp.
2G, which can be used acc. to RL 99/92/EG (ATEX 137) in the zones 1 and 2 as well as the gas groups IIA, IIB and IIC,
which are explosion endangered by flammable substances in the area of the temperature classes T1 to T6 resp. the
listed values of the notices.
The requests acc. to EN 60079-14 have to be observed by the application.
The level sensor is acc. to RL 94/9/EG (ATEX 95) annex I an instrument of the instrument group II category 2D, which
can be used acc. to RL 99/92/EG (ATEX 137) in the zones 21 and 22 of flammable dusts.
The requests acc. to EN 50281-1-2 have to be observed by the application.
The level sensor resp. the components have to comply with the protection rating IP6*.

Enclosure 10303
LLE
EVVE
ELL S
SEEN
NSSO
ORRF
FOOR
RBBM
MGG
Amendments, completions as well as repair works at the measuring system (e.g. change of a control unit, terminal box) may
be done only by briefed qualified persons (acc. to ATEX 137). The operator is responsible, that the measuring system
correspond to the original design. The type label may not be changed.
The assignment between the temperature classes resp. the surface temperature and the maximum ambient
temperature has to be taken from the following table, incl. installation of temperature switches.
Temperature classes / Ambient temperature

surface temperature EEx ia/ib llC EEx d (ia/ib) llC
T6 80°C 80°C 80°C
T5 95°C 95°C 95°C
T4 130°C 130°C 120°C
T3 180°C 180°C
Separate certified control units, when installed, also have operational ambient temperature limits that have to be observed.
If temperatures in excess of 70°C occur at the cable gland or above 80°C at the wire terminations, only a verified heat-
resistant cable for the relevant temperature may be used. The cable gland must be suitable for this temperature.
Metallic or electrically conductive housings on level sensor must be earthed to the main equipment.
Equipment for use in hazardous locations is identified with a special rating plate containing all data relevant to explosion
protection.

Enclosure 10308
Float Valves
Float Valves for installation in tanks NV 98
Universal Valve
Technical Data
www.mankenberg.de | Tel. +49 (0) 451 - 8 79 75 0
Connection DN 40 - 80
Connection G 3/8A - 1 1/2A
Nominal Pressure PN 16
Operating Pressure 0 - 8 bar
Kvs-Value 0.5 - 82 m3/h
Temperature 130 °C
Medium liquids
Description
Float valves automatically control liquid levels in sealed or open
(non-pressurised) tanks and vessels without requiring external energy.
The float registers the liquid level and directly controls the valve via a
lever. A change in the liquid level immediately results in a changed flow
volume.
NV 98 is a float valve for horizontal installation inside a tank as inlet
valve with outlet at the bottom. This valve is made entirely of stainless
steel featuring excellent corrosion resistance. NV 98 R (spigot
connection) is fitted with a ball float, NV 98 F (flange connection) is
MANKENBERG GmbH | Spenglerstraße 99 | D-23556 Lübeck
fitted with a cylindrical float that is adjustable on its float bar. NV 98 FP

is fitted with a parallel float guide which prevents oscillation of the
float. The valve cone is fitted with a soft seal.
The following note applies to float valves fitted with float bars: If the
liquid level is below the float bar i.e. if the float points downwards, a illustration shows NV 98FP
guide for the float bar should be installed.
Kvs-Values [m3/h]
Standard pressure range nominal diameter G...A
bar 3/8 1/2 3/4 1 1 1/4 1 1/2
» all stainless steel construction
0-2 1.2 2.5 6 8 13.3 17.8
» NV 98 R with ball float SC 3
» NV 98 F with cylindrical float SC 8 0-4 1.2 2.5 3.5 6 7.9 13.3
» NV 98FP with cylindrical float SC 8 and float bar parallel guide 0-8 0.5 1.2 2.5 4 5 6.4
Options Kvs-Values [m3/h]

pressure range nominal diameter G...A
» various seal materials suitable for your medium bar 40 50 65 80
» special versions on request
0-8 20 32 50 82
Please state working pressure range when enquiring or ordering.
Pressure Ranges
Operating instructions, know how and safety instructions must be nom. diam. pressure range[bar]
observed. All the pressure has always been indicated as overpressure.
Page No. NV 98/2.1.151.1 - Standing 06.02.2015
G 3/8 - 1 0-2 0-4 0-8

We reserve the right to alter technical specifications without notice.
DN 40 - 80 0-8
Enclosure 10308
Float Valves
Float Valves for installation in tanks NV 98
Universal Valve
Materials
Dimensional Drawing
Body CrNiMo-steel
www.mankenberg.de | Tel. +49 (0) 451 - 8 79 75 0
Cone CrNiMo-steel
Seat CrNiMo-steel
Valve Seal G 3/8 FPM, G 1/2 - 1 1/2 EPDM
Float CrNiMo-steel
Dimensions [mm] NV 98 R
size nominal diameter G..A
3/8 1/2 3/4 1 1 1/4 1 1/2
A 40 40 40 45 47 47
B 60 60 60 65 72 77
C 85 85 85 90 96 101
D ø 60 ø 60 ø 60 ø 60 ø 60 ø 60
E 110 110 110 115 123 128
F 16 16 20 20 23 25
G 3/8 3/8 1/2 3/4 1 1 1/4
H 200 200 200 200 200 200
I 125 135 155 175 205 225
K ø 100 ø 110 ø 130 ø 150 ø 180 ø 200
MANKENBERG GmbH | Spenglerstraße 99 | D-23556 Lübeck
Weights [kg] NV 98 R
nominal diameter G ... A
3/8 1/2 3/4 1 1 1/4 1 1/2
0.9 0.9 1.4 1.5 2.7 3
Dimensions [mm] NV 98 F + NV 98 FP
size nominal diameter DN
40 50 65 80
A 85 95 95 110
B 60 75 75 80
C 105 125 125 140
D ø 70 ø 90 ø 90 ø 125
E 145 165 165 180
F ø 43 ø 53 ø 64 ø 80
H 330 330 440 530
I 975 970 965 965
K ø 280 ø 305 ø 340 ø 380
L 280 305 340 380
M 55 55 80 80
Page No. NV 98/2.1.151.2 - Standing 06.02.2015
Weights [kg] NV 98 F + NV 98 FP
nominal diameter DN
40 50 65 80
6.5 9.5 12.5 13.5
Customs Tariff Number

84818059
Special designs on request.

The pressure has always been indicated as overpressure.
Mankenberg reserves the right to alter or improve the designs or
specifications of the products described herein without notice.
Enclosure 10310

Issue Date: 06/14
Level Electrode
NRG 16-4
Description Technical Data

The level electrode NRG 16-4 in conjunction with level switch Operating pressure
NRS 1-.. is designed to signal a water level limit and used in PN 40, 32 bar at 238 °C
steam boiler plants and (pressurized) hot-water installations Mechanical connection
or in condensate and feedwater tanks, e. g. as water level Screwed G 3/8 A or G ¾ A to ISO 228
limiter with MIN/MAX alarm.
Materials
The level electrode can be used in combination with Screw-in body: 1.4571, X6CrNiMoTi17-12-2
the following level switches: NRS 1-52, NRS 1-53, Electrode rod: 1.4571, X6CrNiMoTi17-12-2
NRS 1-54 and NRS 1-55 or NRS 1-1, NRS 1-2, Insulation: PTFE
NRS 1-3 and NRS 1-5. Four-pole connector: polyamide (PA)
Lengths available
Function 500 mm, 1000 mm, 1500 mm
The electrode operation is based on the conductive measur- Electrical connection
ing principle using the electrical conductivity of the water Four-pole connector, cable gland M 16
for signalling water level. The length of the electrode rod
determines the switchpoint for the water level limit. Protection
IP 65 to EN 60529
The level electrode is installed inside steam boilers, vessels or
in an external level pot. If the electrode is installed inside the Ambient temperature
boiler or vessel, a protection tube provided on side ensures Max. 70 °C
NRG 16-4 with four-pole connector correct functioning. Weight
The level electrode can be installed together with one GESTRA approx. 0.5 kg
level electrode for water level limiting or for high-level alarm Approvals
in a single protection tube or external level pot. TÜV type approvals acc. to
VdTÜV Bulletin "Wasserstand 100": Requirements made
Directives and standards on water level limiting & control equipment.
Type approval no. TÜV · WR / WB · 08-302; 10-424
VdTÜV Bulletin "Wasserstand 100" (see name plate)
(= Water Level 100)
The level electrode NRG 16-4 in conjunction with UL/cUL (CSA) Approval: UL 508 and CSA C22.2
the following level switches is type approved accord- No. 14-13, Standards for Industrial Control Equipment.
ing to VdTÜV Bulletin "Wasserstand 100": NRS 1-52, File E243189.
NRS 1-53, NRS 1-54 and NRS 1-55 or NRS 1-1, NRS 1-2,
NRS 1-3 and NRS 1-5. Important Notes
The VdTÜV Bulletin "Wasserstand (=Water Level) 100" Installation
specifies the requirements made on water level control and The level electrode NRG 16-4 can be installed together with
limiting equipment for boilers. one GESTRA level electrode, one compact level switch or
ATEX (Atmosphère Explosible) transmitter in a single protection tube or external level pot
The equipment is a simple item of electrical equipment (inside diameter 100 m). If the level limiting electrode is
according to EN 60079-11 paragraph 5.7. installed inside the vessel, it must be at least 40 mm away
from the upper vent hole.
According to the European Directive 94/9/EC the equipment
must be equipped with approved Zener barriers if used The angle of inclination of the electrode must not exceed 45°,
in potentially explosive areas. Applicable in Ex zones 1, 2 with the length of the electrode rod being limited to 500 mm.
(1999/92/EC). The equipment does not bear an Ex marking. If installed outdoors the level electrode must be equipped
The suitability of the Zener barriers is certified in a separate with a GESTRA weather protection cover.
wiring diagram provided by the manufacturer. Electrical connection
UL/cUL (CSA) Approval To connect the level electrode use overall screened multi-
The equipment complies with the requirements of the follow- core control cable with a min. conductor size 0.5 mm2, e. g.
ing standards: UL 508 and CSA C22.2 No. 14-13, Standards LiYCY 4 x 0.5 mm2.
for Industrial Contro Equipment. File E243189. Connect the screen only once to the central earthing point
(CEP) in the control cabinet.
Enclosure 10310
Level Electrode Dimensions NRG 16-4

NRG 16-4
70

GESTRA Level electrode type NRG 16-4
Connection G ..., inspection ...............
Length supplied ...........................mm
Key
190
1 Thermal insulation, provided on site, d = 20 mm (outside
of thermal insulation of steam boiler)
2 Electrode thread G 3/8 A or G ¾ A to ISO 228
4 Flange PN 40, DN 50, DIN EN 1092-01
Flange PN 40, DN 100, DIN EN 1092-01 1
5 For the approval of the boiler standpipe with connecting
flange the relevant regulations must be considered.
6 Vent hole 2
≥ 30
500, 1000, 1500
C
7 Distance between electrode rod and protection tube ≥
14 mm
8 High water (HW)
≥ 50
9 Electrode rods ∅ = 5 mm
0 Protection tube ≥ DN 80
a Low water LW Fig. 1 NRG 16-4
b Reducer DIN 2616-2,
K-88.9 x 3.2-42.4 x 2.6 W
c Level pot ≥ DN 80
. 3
/8 /8
3
4
5
≤ 20
DN 20
DN 50
8
7 6
8 c
Centre distance
∅ 20
20
9
9
0 a
≤ 20
DN 20
a
≤ 90° b
∅20
DN 20
Fig. 2 Protection tube (provided on site) for installation Fig. 3 External level pot
inside the boiler
Supply in accordance with our general terms of business.
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen
Tel. 0049 (0) 421 35 03-0, Fax 0049 (0) 421 35 03-393
E-mail [email protected], Web www.gestra.com

Enclosure 10311

Issue Date: 10/13
Level Switch
NRS 1-53
Description Technical data

The level switch NRS 1-53 in conjunction with level electrodes Supply voltage
NRG 16-.. and ER 5. is used as limit switch, for instance as 24 VDC, + / –20 %, 0.1 A
water level limiter in steam boilers and (pressurized) hot-water Fuse
installations. The level switch detects and indicates two low external 0.5 A (semi-delay)
water levels (MIN 1, MIN 2).
Power consumption
The level switch can work with following level electrodes: 2 VA
NRG 10-52, NRG 16-52, NRG 16-4 and ER 5.-1.
Connection of level electrode
2 inputs for level electrode NRG 10-52, NRG 16-52,
Function NRG 16-4 and ER 5.-1,
The operation of the level switch NRS 1-53 is based on the 4 poles with screen.
conductive measuring principle using the electrical conduc- Response sensitivity
tivity of the water for signalling water level. The level switch (electrical conductivity of water at 25 °C)
is designed for different electrical conductivities and for >0.5 ...< 1000 µS/cm or >10 ...< 10 000 µS/cm
connecting two level electrodes. (switch-selectable).
NRS 1-53
The length of the associated electrode rod determines switch- Outputs
points for MIN 1/MIN 2 water level. 2 volt-free change-over contacts,
The level switch detects that the MIN1/MIN 2 water level is 8 A 250 V AC / 30 V DC cos ϕ = 1
reached when the corresponding electrode rods are exposed. De-energizing delay: 3 sec.
After the de-energizing delay has elapsed, the MIN 1/MIN 2 Provide inductive loads with RC combinations according
output contact is switched over. At the same time the MIN to manufacturer's specification to ensure interference
1/MIN 2 LED changes from green to red. suppression.
When the equipment is used as water level limiter, the safety Indicators and adjusters
circuit for the heating is opened by the output contacts. 1 pushbutton “Test” for simulating MIN 1/MIN 2 alarm,
The disconnection of the heating is interlocked in the external 2 red/green LEDs for indicating “Operating mode” and
safety circuit and can only be deactivated when the electrode MIN 1/MIN 2 alarm,
rods enter the water again. 1 green LED indicating “Power ON”,
A MIN 1/MIN 2 alarm can be simulated by pressing the 1 code switch with 4 poles for changing the sensitivity.
button “Test”. Housing
Housing material: base: polycarbonate, black;
Front: polycarbonate, grey.
Directives and standards Terminal strips separately detachable.
VdTÜV Bulletin “Wasserstand 100” (= Water Level 100) Fixing of enclosure: Mounting clip on supporting rail TH 35,
The level switch NRS 1-53 is certified acc. to VdTÜV EN 60715
Bulletin “Wasserstand 100” if used in combination with Electrical safety
the following level electrodes: NRG 10-52, NRG 16-52, Contamination class 2.
NRG 16-4 and ER 5.-1
Protection
The VdTÜV Bulletin “Wasserstand (=Water Level) 100” Housing: IP 40 to EN 60529
specifies the requirements made on water level control and Terminal strip: IP 20 to EN 60529
limiting equipment for boilers.
Weight
LV (Low Voltage) Directive and EMC Approx. 0.2 kg
(Electromagnetic Compatibility)
The equipment meets the requirements of the Low Voltage Ambient temperature
Directive 2006/95/EC and the EMC Directive 2004/108/EC. when system is switched on: 0 ... 55 °C,
during operation: –10 ... 55 °C
According to the European Directive 94/9/EC the equipment Transport temperature
must not be used in potentially explosive areas. –20 ... +80 °C (< 100 hours), defrosting time of the
de-energized equipment before it can be put into
Note: operation: 24 hours.
The level electrodes NRG 10-52, NRG 16-52, NRG 16-4
and ER 5.-1 are simple items of electrical equipment as Storage temperature
specified in EN 60079-11 section 5.7. According to the –20 ... +70 °C, defrosting time of the de-energized equip-
European Directive 94/9/EC the equipment must be equipment before it can be put into operation: 24 hours.
ped with approved Zener barriers if used in potentially ex- Relative humidity
plosive areas. Applicable in Ex zones 1, 2 (1999/92/EC). max. 95%, no moisture condensation
The equipment does not bear an Ex marking. The suitability Approvals
of the Zener barriers is certified in a separate wiring diagram Type approval no: TÜV · WR / WB · XX-XXX
provided by the manufacturer. (see name plate)
UL/cUL (CSA) Approval
The equipment meets the requirements of: UL 508 and CSA
C22.2 No. 14-13, Standards for Industrial Control Equipment.
File E243189.
Enclosure 10311
Level Switch Dimensions

NRS 1-53 46 120
Important Notes 1
The level switch NRS 1-53 is clipped onto the support rail
in the control cabinet.
The equipment is supplied with 24 V DC and fused with an
4 3
74
external semi-delay fuse 0.5 A.
The power supply unit must be electrically isolated from
dangerous contact voltages and must meet at least the re-
quirements on double or reinforced isolation according to one
of the following standards: DIN EN 50178, DIN EN 61010-1,
DIN EN 60730-1 or DIN EN 60950.
To prevent the welding together of contacts provide an
external slow-blow fuse T 2.5 A or 1.0 A (TRD 604, 72 hrs.
operation) for the output contacts. 2
Fig. 1 NRS 1-53
When used as water level limiter the level switch NRS 1-53
does not interlock automatically when the electrode rods
are exposed.
If an interlock function is required for the installation it must be
provided in the follow-up circuitry (safety circuit). The circuitry
must meet the requirements of the EN 50156.
When switching off inductive loads, voltage spikes are pro-
duced that may impair the operation of control systems.
Connected inductive loads must be provided with suppressors
such as RC combinations as specified by the manufacturer.
To connect the level electrode(s) use screened multi-core
control cable with a min. conductor size 0.5 mm2, e. g. LiYCY
3 x 0.5 mm2 , max. length: 100 m.
Make sure that connecting cables leading to the level
a 0
electrodes are segregated and run separately from power
cables.

Level switch type NRS 1-53
GESTRA SPECTORmodule
Output: 2 volt-free change-over contacts MIN alarm
De-energizing delay: 3 seconds
Supply voltage: 24 V DC, 2 VA 6 8 9
Fig. 2 5 7
Key
1 Upper terminal strip
Connecting several level electrodes
2 Lower terminal strip
3 Housing
4 Supporting rail type TH 35, EN 60715
5 Connection of supply voltage 24 V DC with fuse 0.5 A
(semi-delay), provided on site
6 Reference electrode or vessel used as functional earth
7 Electrode rod for MIN 2 9 9
8 Electrode rod for MIN 1
NRG 1.-52 b c
9 Central earthing point (CEP) in control cabinet
0 Output contact for MIN 1
MIN-1 MIN-1
a Output contact for MIN 2 MIN-2 MIN-2
b Level electrode NRG 10-52,
NRG 16-52, five pole connector
c Level electrode ER 5.. 4 pole connector
d Level electrode ER 5.. 5 pole connector
e Level electrode NRG 16-4
9 9
d e
Supply in accordance with our general terms of business. MIN-1 MIN-1

MIN-2 MIN-2
GESTRA AG
P. O. Box 10 54 60, D-28054 Bremen, Germany
Münchener Str. 77, D-28215 Bremen, Germany
Tel. 0049 (0) 421 / 35 03-0, Fax 0049 (0) 421 / 35 03-393
E-mail [email protected], Web www.gestra.de

1 20005 Oriface plate
2 20020 Pressure switch BCP
3 20021 Pressure transmitter MBS3100
4 20025 Pressure switch RT
5 20032 Pressure gauges, Model 232.50_233.50
6 20037 Bimetal thermometer, Model 54
Temperature control valve, self acting

7 20045
AVTA 15, 25
8 20071 Solenoid valve 0407
CONTENTS OF
9 20080 Steam injector 54.651
CHAPTER 3.1.3
Gauge valve with H-test connection
10 20086
DIN_16271
11 20089 Level transmitter Cerabar
12 20090 Gauge valve DIN 16720

COMPONENTS
OF ENCLOSURE 13 20092 Sample cooler NJ
20000 14 20134 Chemical dosing unit with Beta B pump
15 20149 Ball valve 20M-20C-1/4
16 20150 Non-return valve RHZ10LRED71
3.1.3 Components of Enclosure 20000

Enclosure 20020
Technical leaflet
Pressure switch type BCP
Introduction The BCP type is a series of dedicated pressure

switches for safety and pressure monitoring of
steam and hot water boilers.
The BCP incorporates a single-pole changeover

microswitch where the contact position depends
on the pressure in the connection port and the
range set value.
For installations, in which operation is particularly

critical for safety reason, the use of fail-safe control
is recommended.
Features Available as high and low pressure limiters as Direct mounting on pressure connection or
well as pressure controllers wall mounting by means of a bracket
Wide pressure range: Versions with automatic and manual resets
from low pressure BCP1 with narrow available
differential to high pressure BCP7 Screw adjustments made on top of housing
The fail-safe dual bellows enable premature Manual reset for pressure limiters possible
cut-out when fault occurs only by means of tools
DIN plug mounted on the top of control for easy Version with gold plated contact for electronic
electrical wiring devices
Single-pole changeover switch (SPDT), switch
+ alarm
Approvals CE-marked in accordance with EN 60947-4/-5 CE marked in accordance with PED 97/23/EC,
category IV, safety equipment, testing basis
pr EN12952-11 and EN12953-9.
Materials in contact with Bellows: stainless steel 1.436 (18/8)

media Pressure connection: nickel plated free cutting steel
Technical data Media Electrical connection

Steam, water, air Plug, DIN 43650, Pg 11
Ambient temperature Switch type

–20 to 70°C SPDT, snap action microswitches:
type A and type B
Media temperature
Up to 120°C Contact material:
(Above 120˚C a water-filled loop Type A: Silver/ gold (Au plated Ag)
must be installed) Type B: Silver (AgCdO)
Enclosure
IP 65
Action type acc. to EN 60730

Type BCP - 2B
Types BCPL/ BCPH - 2BDF
IC.PD.P10.M2.02-520B3129 © Danfoss A/S (AC-BNM /mr),11 - 2007

Enclosure 20020
Technical leaflet Pressure switch, type BCP
Technical data (continued) Contact load Expected electrical lifetime

BCP type A (silver/ gold contact) Min. 250 000 cycles under full contact load
Minimum:
4mA, 5V 1)
If used with current higher than 400mA the
Maximum: 1) gold will disappear and the unit can’t be used
2) AC-1: 6A, 250V
at a lower current again.
3)
AC-15: 1A, 250 V 2)
AC-1 Ohmic load, cosφ 1
4)
DC 13 10W, 250 V 3)
AC-15 inductive load like coil and contactors
with, cosφ 0.3
Contac load 4)
DC-13 Direct current load
BCP type B (silver contact)
Minimum:
500mA, 24V
2)
AC-1: 10A, 250V
3)
AC-15: 2A, 250V
4)
DC 13: 50W, 250V
Ordering High pressure limiters

Range Fixed Max. Max. test
Code no. Code no.
Differential operating pressure Pressure
Type Reset Contact Contact
avg. pressure connection
type A type B
[bar] [bar] [bar] [bar]
BCP1H 0.1 to 1.1 0.1 6 7 017B0030 017B0029

BCP2H 0 to 2.5 0.2 10 11 017B0034 017B0033
BCP3H 0 to 6 0.4 16 18 017B0038 017B0037
BCP4H 1 to 10 0.45 Man. 25 28 G½A 017B0042 017B0041
BCP5H 2 to 16 1.2 32 35 017B0046 017B0045
BCP6H 5 to 25 1.5 40 45 017B0050 017B0049
BCP7H 10 to 40 2.3 63 70 017B0054 017B0053
Low pressure limiters

Range Fixed Max. Max. test
Code no. Code no.
avg. pressure connection
type A type B
BCP2L 0 to 2.5 0.2 10 11 017B0058 017B0057

BCP3L 0 to 6 0.4 16 18 017B0062 017B0061
BCP4L 1 to 10 0.45 Man. 25 28 G½A 017B0066 017B0065
BCP5L 2 to 16 1.2 32 35 017B0070 017B0069
BCP6L 5 to 25 1.2 40 45 017B0074 017B0073
Pressure controllers
Range Adjust. Max. Max. test
Code no. Code no.
pressure connection
type A type B
BCP1 0.1 to 1.1 0.15 to 0.6 6 7 017B0002 017B0001

BCP2 0 to 2.5 0.4 to 1.0 10 11 017B0006 017B0005
BCP3 0 to 6 0.7 to 1.4 16 18 017B0010 017B0009
BCP4 1 to 10 1.0 to 2.5 Auto 25 28 G½A 017B0014 017B0013
BCP5 2 to 16 2.0 to 3.2 32 35 017B0018 017B0017
BCP6 5 to 25 2.5 to 4.0 40 45 017B0022 017B0021
BCP7 10 to 40 3.0 to 6.0 63 70 017B0026 017B0025
2 IC.PD.P10.M2.02-520B520B3129 © Danfoss A/S (AC-BNM /mr),11 - 2007

Enclosure 20020
Design and function

1. Main spindle
2. Main spring
3. Differential spindle
4. Differential spring
5. Reset spring
6. Activating arm
7. Bellows
8. Pressure connection
9. Reset push button
10. Differential knob
11. DIN plug
12. Microswitch
13. Michroswitch bracket
14. Range knob
Simplified drawing of BCP control
Reset
Version with automatic reset cut-in again Fail-safe bellows concept BCP6, BCP6H, BCP7,
automatically when the pressure falls to the set and BCP7H have a double bellows: an operating
point minus differential. Version with manual bellows (inner) and safety bellows (outer).
reset has to be cut in manually by means of tool.
1. Pressure connection
2. Regulating bellows
3. Safety bellows
Microswitch Note:
BCP is a microswitch based control with DIN plug. Ambient temperature influence
Such design enables easy electrical connection and All BCP pressure controls operate independently
makes control suitable for operation with modern of changes in ambient temperature around the
electronic systems, as PLC. control.
Silver/gold plated and silver contacts Therefore the settings for cut-out pressure and
Silver/gold plated contacts (type A) are used for low differential stay constant unless the permissible
currents and middle range of current, especially ambient temperature is exceeded.
in applications with PLC or other corresponding When system pressure exceeds the set value, the
electronic devices. Such contacts have also BCP will automatically stop the plant.
significantly lower emission of electromagnetic A rupture in the inner bellows cause the control
noises produced on contact break. EMC (Electro cut-out pressure to fall about 3 times less then the
Magnetic Compatibility) is an important parameter preset value, thus the system stops prematurely.
where electronic equipment is used. A gold plated A rupture in the outer bellows cause the control
contact has a silver layer under the gold and can cut-out pressure to fall about 3 bar under the preset
therefore also be used in the middle range of load. value, thus providing a fail-safe function.
The gold will disappear at loads above 0.4 A.
For loads higher then 0.5 A, contact type B is In other BCP types with single bellows assembly,
recommended. This contact Is mainly used in fail-safe function is satisfied by proofed 2 millions
application were the switch operate devices as cycles mechanical life time test.
coils, contactors and others which is in the high
current area.
© Danfoss A/S (AC-BNM /mr),11 - 2007 IC.PD.P10.M2.02-520B3129 3

Enclosure 20020
Setting Note: Low pressure limiters

Cut-in and cut-out pressures of the system Set cut-out pressure on RANGE scale. Limiter can
should always be checked with accurate only be reset manually by pressing (with tool)
pressure gauges. the reset button when pressure rises to cut-out
pressure plus differential or above it.
Pressure settings for controls (with automatic
reset) Note:
Set the cut-out pressure on RANGE scale and Pressure limiters have no differential scale.
differential on DIFF. scale. Restart pressure Fixed differential value is printed on the scale
is equal to cut-out pressure minus pre-set plate.
differential value.
Pressure controls with manual reset

High pressure limiters
Set cut-out pressure on the RANGE scale. Pressure
limiter can only be manually reset by pressing
reset button by means of tools when the pressure
is equal to or below the cut-out pressure minus
value of the differential.
Terminology Pressure limiters Maximum working pressure

Limiters are devices that, on reaching a fixed The maximum permissible pressure for safe
value interrupt and lock out the energy supply. functioning of the system or any of its
Manual unlocking is required before restart. components.
A limiter shall be such that a single fault in any
related part shall not lead to a loss of the safety Snap function
function. A specific contact force is maintained in micro-
switch until snap is initiated, therefore, contact
Note: bounce cannot occur as a result, for example, of
If a BCP pressure controller with automatic slight vibrations before cut-out.
reset is used as limiter, lockout must be realized These design features ensure that the cut-out
externally as a part of safety logic, e.g.: by point of the BCP control remains very accurate
external contactors and/ or relays according and completely independent of the magnitude
to requirements of standard prEN501156-1 for of the current load.
safety relevant hardware. External closure must
be interlocked, while loss of auxiliary energy Set point
must lead to closure. A predetermined value to which a control is
Resetting must not be automated; it has to be adjusted and at which it performs its intended
performed manually. function.
Resetting on fault must lead to a repeated
closure. Differential
When BCP limits, is for rising or falling The difference between pressure cut-out and
applications, the external safety logic must pressure cut-in.
change to fail-safe position.
Reset
Fail-safe control 1. Manual reset
A control is fail-safe if it has the capability to A unit with manual reset can only be restored to
remain in a safe condition or transition to a safe operational mode by activation of the external
condition when a fault occurs. reset button.
Note: 2. Automatic reset

If the system pressure exceeds MWP then A unit with automatic reset is restored to
accuracy of the control settings can be lost. operational mode automatically
Maximum test pressure

The maximum pressure applied in strength or
leakage tests on heating systems or components
thereof.
4 IC.PD.P10.M2.02-520B520B3129 © Danfoss A/S (AC-BNM /mr),11 - 2007

Enclosure 20020
Installation in steam To protect the pressure element against excessive

systems temperature of the media, above allowable 120°C
the insertion of water-filled loop is recommended.
Approx. weight: 0.5 kg

All BCP types except for BCP 1 and BCP 1H
BCP 1 and BCP1H
© Danfoss A/S (AC-BNM /mr),11 - 2007 IC.PD.P10.M2.02-520B3129 5

Enclosure 20021
Technical leaflet
Pressure transmitter for marine applications

Type MBS 3100 and MBS 3150
Features • Designed for use in severe maritime

environments
• All relevant marine approvals
• Enslosure and wetted parts of acid-resistant
stainless steel (AISI 316L)
• Pressure ranges in relative (gauge) or absolute
from 0 up to 600 bar
• Standard output signal: 4 - 20 mA
• A wide range of pressure connections
• Temperature compensated and laser calibrated
Description The compact ship approved pressure transmitter The flexible pressure transmitter programme
MBS 3100 is designed for use in almost all marine covers, absolute and gauge (relative) versions,
applications. measuring ranges from 0-1 to 0-600 bar and a
MBS 3150 with integrated pulse-snubber is de- wide range of pressure connections.
signed for use in marine applications with severe
medium influences like cavitation, liquid hammer Excellent vibration stability, robust construction,
or pressure peaks and offers a reliable pressure and a high degree of EMC/EMI protection equip
measurement, even under harsh the pressure transmitter to meet the most
environmental conditions. stringent industrial requirements.
Ordering Measuring range

Pressure connection Type no. Code no.
standard versions Pe1) [bar]
MBS 3100 0-4 MBS 3100 - 1611 - 6AB04 060G1367
Plug: Pg 11 (EN 175301-803) 0-6 MBS 3100 - 1811 - 6AB04 060G1368
Output signal: 4-20mA G 1/4 A 0 - 10 MBS 3100 - 2011 - 6AB04 060G1369
(EN 837) 0 - 16 MBS 3100 - 2211 - 6AB04 060G1370
0 - 25 MBS 3100 - 2411 - 6AB04 060G1371
0 - 40 MBS 3100 - 2611 - 6AB04 060G1372
0-4 MBS 3100 - 1611 - 6BB04 060G1463
0-6 MBS 3100 - 1811 - 6BB04 060G1464
G 1/4 A, O-ring 0 - 10 MBS 3100 - 2011 - 6BB04 060G1465
DIN 3852 0 - 16 MBS 3100 - 2211 - 6BB04 060G1466
0 - 25 MBS 3100 - 2411 - 6BB04 060G1467
0 - 40 MBS 3100 - 2611 - 6BB04 060G1468
-1 - 1.5 2) MBS 3100 - 8411 - 6AB08 060G5600
-1 - 5 2) MBS 3100 - 8711 - 6AB08 060G5601
0-4 MBS 3100 - 1611 - 6AB08 060G1469
G½A 0-6 MBS 3100 - 1811 - 6AB08 060G1470
(EN 837) 0 - 10 MBS 3100 - 2011 - 6AB08 060G1471
0 - 16 MBS 3100 - 2211 - 6AB08 060G1472
1)
Gauge/relative 0 - 25 MBS 3100 - 2411 - 6AB08 060G1473
2)
Sealed gauge 0 - 40 MBS 3100 - 2611 - 6AB08 060G3388
INDUSTRIAL CONTROLS IC.PD.P20.O3.02/520B2154

Enclosure 20021
Technical leaflet Pressure transmitter for marine applications, Types MBS 3100 and MBS 3150
Ordring Pressure Measuring range

standard versions connection Type no. Code no.
Pe1) [bar]
MBS 3150
G 1/4 A, O-ring 0-6 MBS 3150 - 1811 - 6BB04 060G1474
Plug: Pg 11 (EN 175 301-803 DIN 3852 0 - 10 MBS 3150 - 2011 - 6BB04 060G1475
Output signal: 4-20 mA
G½A 0-6 MBS 3150 - 1811 - 6AB08 060G1476
(EN 837) 0 - 10 MBS 3150 - 2011 - 6AB08 060G1477
1)
Gauge/relative
Technical data Performance (EN 60770)

±0.5% FS (typ.)
Accuracy (incl. non-linearity, ±1% FS (max.)
hysteresis and repeatability) For range -1 to xx bar ±1.5% FS (typ.)
±3% FS (max)
Non-linearity BFSL (conformity) ≤ ±0.5% FS
Hysteresis and repeatability ≤ ±0.1% FS
Thermal zero point shift ≤ ±0.1% FS/10K (typ.)
≤ ±0.2% FS/10K (max.)
Thermal sensitivity (span) shift ≤ ±0.1% FS/10K (typ.)
≤ ±0.2% FS/10K (max.)
Response time MBS 3100 < 4 ms
Response time MBS 3150 liquids with viscosity <100 Cst < 4 ms
Air and gases < 35 ms
Overload pressure (Static) 6 × FS (max. 1500 bar)
Burst pressure > 6 × FS (max. 2000 bar)
Durability, P: 10-90% FS >10×106 cycles
Electrical specifications
Nom. output signal (short circuit protected) 4 to 20 mA
Supply voltage (polarity protected) 9 to 32 V dc
Voltage dependency < 0.2 %FS/10V
Current limitation 28 mA (typ.)
Load [RL] (load connected to 0V)
Vsupply − 9 V
RL ≤ ________________ [Ω]
0.02 A
Environmental conditions
Medium temperature range −40 → +85°C
Ambient temperature range (depending on electrical connection) see page 4
Compensated temperature range 0 → +80°C
Transport temperature range −50 → +85°C
EMC - Emission EN 61000-6-3
EMC Immunity EN 61000-6-2
Insulation resistance > 100 MΩ at 100 V
Mains frequency test SEN 361503
15.9 mm-pp, 5 Hz-25 Hz
Vibration stability Sinusoidal IEC 60068-2-6
20 g, 25 Hz - 2 kHz
Random 7.5 grms, 5Hz-1kHz IEC 60068-2-34, IEC 60068-2-36
Shock 500 g / 1 ms IEC 60068 - 2 - 27
Shock resistance
Free fall IEC 60068 - 2 - 32
Enclosure (depending on electrical connection) see page 4
Mechanical characteristics
Wetted parts EN 10088-1 ; 1.4404 (AISI 316 L)
Enclosure EN 10088-1 ; 1.4404 (AISI 316 L)
Materials
Pressure connection see page 3
Electrical connections see page 4
Weight (depending on pressure connection and electrical connection) 0.2 - 0.3 kg
IC.PD.P20.O3.02/520B2154
Enclosure 20021
Ordering of special versions
Type
Pressure Connection
Standard..................... 0 0
With pulsesnupper 5 0 A B 0 4 ............ G ¼ A (EN 837), not MBS 3150!
G B 0 4 ............ DIN 3852 E - G ¼, Gasket: DIN 3869-14-NBR
A B 0 8 ............ G ½ A (EN 837)
Measuring range
-1-1.5 bar............................................. 8 4 A C 0 4 ............ ¼ - 18 NPT
-1-3 bar................................................ 8 5
-1-5 bar................................................ 8 7 Electrical connection
0-1 bar................................................... 1 0 Figures refer to plug and standard PIN configuration - see page 4
0-1.6 bar................................................ 1 2 ................................ Plug (EN 175301-803), GL, Pg 13.5
1
0-2.5 bar................................................ 1 4 ................................ Plug (EN 175301-803), Pg 9
5
0-4 bar................................................... 1 6 ................................ Plug (EN 175301-803), Pg 11
1 8
6
0-6 bar...................................................
0-10 bar................................................. 2 0
Output signal
0-16 bar................................................. 2 2
0-25 bar................................................. 2 4 1 ............................................ 4 - 20 mA
0-40 bar................................................. 2 6
0-60 bar................................................. 2 8 Prefered version
0-100 bar.............................................. 3 0
0-160 bar.............................................. 3 2
0-250 bar.............................................. 3 4
0-400 bar.............................................. 3 6
0-600 bar.............................................. 3 8
Pressure reference
Gauge (relative)..................................................... 1
Absolute................................................................... 2
Non-standard build-up combinations may be selected. However, minimum order quantities may apply.
Please contact your local Danfoss office for further information or request for other versions
Dimensions / Combinations
Type code 1 5 6
EN175301-803, Pg 13.5 EN 175301-803, Pg 9 EN175301-803, Pg11

G½A ¼ - 18 NPT G ¼ A (EN 837) DIN 3852-E-G ¼
(EN 837) Gasket:
DIN 3869-14
Type code AB08 AC04 AB04 GB04
IC.PD.P20.O3.02/520B2154
Enclosure 20021
Electrical connections
Type code, page 3
1 5 6
EN 175301-803, Pg 13.5 EN 175301-803, Pg 9 EN 175301-803, Pg 11
Ambient temperature
−40 → + 85 °C −40 → + 85 °C −40 → + 85 °C
Enclosure
IP 65 IP 65 IP 65
Materials
Glass filled polyamid, PA 6.6 Glass filled polyamid, PA 6.6 Glass filled polyamid, PA 6.6
Electrical connection, 4 - 20 mA output (2 wire)
Pin1: + supply Pin1: + supply Pin1: + supply
Pin 2: ÷ supply Pin 2: ÷ supply Pin 2: ÷ supply
Pin 3: Not used Pin 3: Not used Pin 3: Not used
Earth: Connected to MBS enclosure Earth: Connected to MBS enclosure Earth: Connected to MBS enclosure
MBS 3150 Application Media condition

Application and media Cavitation, liquid hammer and pressure peaks may Clogging of the nozzle may occour in liquids containing
conditions occour in hydraulic systems with changes in flow particles. Mounting the transmitter in an upright
velocity, e.g. fast closing of a valve or pump starts and position minimizes the risk of clogging, because the
stops. flow in the nozzle is restricted to the start-up period
The problem may occour on inlet and outlet side, even when the dead volume behind the nozzle orifice is
at rather low operating pressures. relatively big (0.3 mm). The media viscosity has only
little effect on the response time. Even at a viscosities
up to 100 cSt, the response time will not exceed 4 ms
Approvals • Lloyd’s Register of Shipping • Bureau Veritas

• Det Norske Veritas • Nippon Kaiji Kyokai
• Germanischer Lloyd • MRS, Maritime Register of Shipping
• RINA, Registro Italiano Navale • Korean Register of Shipping
• American Bureau of Shipping
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.
© Danfoss A/S 10-2007 DE-BD
IC.PD.P20.O3.02/520B2154
Enclosure 20025
Data sheet
Pressure switches
Type RT
Description Type RT pressure switches incorporate a pressure
controlled, single-pole changeover switch where
the contact position depends on the pressure in
the connection port and the set value. The RT series
consists of pressure switches, differential pressure
switches and pressure switches for neutral zone
regulation. These units are for general use within the
industrial and marine sectors.
The RT series also covers safety pressure switches for
steam boiler plant.
For installations in which operation is particularly
critical from safety and economic points of view,
the use of fail-safe pressure switches is recommended.
The use of gold-plated contacts is also recommended
in such installations, provided operation involves only
a few switching cycles or low signal currents and
voltages.
Contents Page
Description ...............................................................................................................................................................................1
Survey of types, pressure ranges ......................................................................................................................................1
Technical data and code nos. all types ...........................................................................................................................2
Approvals ..................................................................................................................................................................................3
Technical data and material in contact with medium ..............................................................................................4
Dimension and weight .........................................................................................................................................................5
Installation ................................................................................................................................................................................6
Function ....................................................................................................................................................................................7
Function description fail-safe, TÜV ..................................................................................................................................8
Pressure switch for liquid level control...........................................................................................................................8
Pressure switch with adjustable neutral zone .......................................................................................................... 10
Differential pressure switches......................................................................................................................................... 11
RT spare parts and accessories ....................................................................................................................................... 13
Pressure switches type RT

Range
0 5 10 15 20 25 30 bar pe Type
bar
−1 o 0 RT 121
0 o0.3 RT 113
0.1 o1.1 RT 112
0.2 o 3 RT 110
Standard pressure switches −0.8 o 5 RT 1, 1A
0.2 o 6 RT 200
1 o 10 RT 116
4 o 17 RT 5, 5A
10 o 30 RT 117
0.1 o 1.1 RT 112
0 o 2.5 RT 33B, RT 35 W
Pressure switches for steam plant 1 o 10 RT 30 AW/ AB/ AS
approved by Vd TÜV
1o 10 RT 116 W
2 o 10 RT 31 W/ B/ S
5 o 25 RT 19 W/ B/ S
5 o 25 RT 32 W/ B/ S
−0.8 o 5 RT 1 AL
Pressure switches with adjustable 0.2 o 3 RT 110 L
neutral zone 0.2 o 6 RT 200 L
4 o 17 RT 5 AL
10 o 30 RT 117 L
Δp = 0-0.9 bar Differential pressure switches −1 o 6 RT 266 AL
Δp = 0.1-1 bar −1 o 6 RT 263 AL
Δp = 0.1-1.5 bar −1 o 9 RT 262 AL/ A
Δp = 0.5-4 bar −1 o 18 RT 260 AL/ A
Δp = 0.5-6 bar −1 o 36 RT 260 A
Δp = 1-6 bar −1 o 36 RT 265 A
IC.PD.P10.B3.02 - 520B3058
Enclosure 20025
Data sheet Pressure switches, type RT
Technical data and code nos. When ordering, please state type and code The type designation for the letters below means:
number. A: Unit suitable for the medium ammonia
L: Unit with neutral zone
Pressure switches Preferred versions

Regulation Adjustable/ Max. Max. Pressure Code no.
range fixed operating test connection
(pe = mechanical pressure pressure ISO 228/1
effective differential PB p’
pressure)
Type
bar bar bar bar

−1 o 0 0.09 o 0.4 7 8 G⅜A 017-521566 RT 121
RT 113
0 o 0.3 0.01 o 0.05 0.4 0.5 G⅜A 017-519666 RT 113
for manual setting;
0.1 o 1.1 0.07 o 0.16 7 8 G⅜A 017-519166 017-519366 RT 112
cover with windows
0.1 o 1.1 0.07 7 8 G⅜A 017-519266 RT 112
0.2 o 3 0.08 o 0.25 7 8 G⅜A 017-529166 017-529266 RT 110
0.2 o 3 0.08 7 8 G⅜A 017-511066 RT 110
−0.8 o 5 0.5 o 1.6 22 25 7
/16-20 UNF 017-524566 RT 1
−0.8 o 5 0.5 22 25 7
/16-20 UNF 017-524666 RT 1
−0.8 o 5 0.5 o 1.6 22 25 G ⅜ A 1) 017-500166 RT 1A
−0.8 o 5 0.5 22 25 G ⅜ A 1) 017-500266 RT 1A
−0.8 o 5 1.3 o 2.4 22 25 G ⅜ A 1) 017-500766 RT 1A
0.2 o 6 0.25 o 1.2 22 25 G⅜A 017-523766 017-524066 RT 200
0.2 o 6 0.25 22 25 G⅜A 017-523866 017-523966 RT 200
1 o 10 0.3 o 1.3 22 25 G⅜A 017-520366 017-520066 RT 116
1 o 10 0.3 22 25 G⅜A 017-520466 017-519966 RT 116
4 o 17 1.2 o 4 22 28 G⅜A 017-525566 017-525366 RT 5
4 o 17 1.2 22 28 G⅜A 017-5094662) RT 5
4 o 17 1.2 o 4 22 28 G ⅜ A 1) 017-5046662) RT 5A
RT 116 4 o 17 1.2 22 28 G ⅜ A 1) 017-5047662) RT 5A
for tamper proof;
10 o 30 1o4 42 47 G ⅜ A 1) 017-529566 017-529666 RT 117
cap and blank cover 1)
Supplied with Ø 6/ Ø 10 mm weld nipple.
2)
With seal cap
Pressure switches with adjustable neutral zone

Regulation Mechanical Adjustable Max. Max. test
range differential neutral zone operating pressure Pressure
Code no. Type
(pe ) pressure, PB p’ connection
bar bar bar bar bar
−0.8 o 5 0.2 0.2 o 0.9 22 25 G ⅜ A 1) 017L003366 RT 1AL
0.2 o 0.08 0.08 o 0.2 7 8 G⅜A 017L001566 RT 110L
0.2 o 6 0.25 0.25 o 0.7 22 25 G⅜A 017L003266 RT 200L
4 o 17 0.35 0.35 o 1.4 22 25 G ⅜ A 1) 017L004066 RT 5AL
10 o 30 1 1 o 3.0 42 47 G⅜A 017L004266 RT 117L
1)
Supplied with Ø6/ Ø10 mm weld nipple
Differential pressure switches

Regulation Mechanical Adjustable Operation Max. Max. test Pressure
range differential neutral zone range operating pressure p’ connection
Code no. Type
Δp pressure, PB ISO 228/1
bar bar bar bar bar bar
0 o 0.9 0.05 0.05 o 0.23 −1 o6 7 8 G ⅜ A 1) 017D008166 RT 266AL
RT 262 A 0.1 o 1.0 0.05 0.05 o 0.23 −1 o6 7 8 G ⅜ A 1) 017D004566 RT 263AL
Differential pressure switch 0.1 o 1.5 0.1 0.1 o 0.33 −1 o9 11 13 G ⅜ A 1) 017D004366 RT 262AL
0.1 o 1.5 0.1 −1 o9 11 13 G ⅜ A 1) 017D002566 RT 262A
0 o 0.3 0.035 −1 o10 11 13 G ⅜ A 1) 017D0027662) RT 262A
0.5 o 4 0.3 0.3 o 0.9 −1 o18 22 25 G ⅜ A 1) 017D004866 RT 260AL
0.5 o 4 0.3 −1 o18 22 25 G ⅜ A 1) 017D002166 RT 260A
0.5 o 6 0.5 −1 o36 42 47 G ⅜ A 1) 017D002366 RT 260A
1.5 o 11 0.5 −1 o31 42 47 G⅜A 017D002466 RT 260A
1o6 0.5 −1 o36 42 47 G ⅜ A 1) 017D0072663) RT 265A
1)
Supplied with Ø 6/Ø 10 mm nipple. 2) Non-snap action contacts (see spare parts and accessories, contact system 017-018166)
3)
With SPST and SPDT contact system for alarm and cut off function at 0.8 and 1 bar
2 IC.PD.P10.B3.02 - 520B3058
Enclosure 20025
Technical data and ordering The designation letters mean: B: Safety units with external reset
A: Units suitable for the medium ammonia. S: Safety units with internal reset
W: Units for control purposes.
Pressure switches for steam plant, approved by Vd, TÜV Preferred versions
Regulation Adjustable/ Max. Max. Pressure Code no.
range fixed operating test connection
(pe = mechanical pressure pressure ISO 228/1
effective differential PB p’
pressure)
Type
bar bar bar bar
For rising pressure, approved acc. to PED

0.1 o 1.1 0.07 7 8 G ½A 017-528266 RT 112W
0 o 2.5 0.1 7 8 G ½A 017-528066 RT 35W
1 o 10 0.8 22 25 G ½A 017-518766 RT 30AW
1 o 10 0.4 22 25 G ½A 017-518866 RT 30AB
1 o 10 0.4 22 25 G ½A 017-518966 RT 30AS
5 o 25 1.2 42 47 G ½A 017-518166 RT 19W
5 o 25 1 42 47 G ½A 017-518266 RT 19B
5 o 25 1 42 47 G ½A 017-518366 RT 19S
For falling pressure

0 o 2.5 0.1 7 8 G ½A 017-526266 RT 33B
2 o 10 0.3 o 1 22 25 G ½A 017-526766 RT 31W
2 o 10 0.3 22 25 G ½A 017-526866 RT 31B
2 o 10 0.3 22 25 G ½A 017-526966 RT 31S
5 o 25 0.8 o 3 42 47 G ½A 017-524766 RT 32W
5 o 25 0.4 42 47 G ½A 017-524866 RT 32B
Pressure switch for low pressure steam plant (pressure monitoring)

0.1 o 1.1 0.07 o 0.16 7 7 G ½A 017-518466 RT 112
Approvals
RT 1 RT 1A RT 1AL RT 5 RT 30AW RT 31W RT 33B RT 110 RT 112 RT 113 RT 116 RT 117L RT 260A
RT 5A RT 30AB RT 31B RT 35W RT 117 RT 200L RT 262A
RT 121 RT 30AS RT 31S RT 112W RT 200 RT 265A
RT 19W RT 32W RT 260AL Approvals
RT 19B RT 32B RT 262AL
RT 19S RT 32S RT 263AL
RT 266AL
x x x x x x x x x x x x x CE marked acc. to EN 60947-4/-5
x x x x VD Tüv, Germany
x x x x Det Norske Veritas, Norway
x x x x Lloyds Register of Shipping, UK
x x x x x x Germanischer Lloyd, Germany
x x x x x Bureau Veritas, France
x x x x x x x x x x x x x Registro Italiano Navale, Italy
x x x x x x x x x x x x x RMRS, Russian Maritime Register of shipping
x x x x x x x Nippon Kaiji Kyokai, Japan
x x x x x x x x x x x x x CCC, China Compulsory Certificate
Note: in addition we refer to the certificates, the copies of which can be ordered from Danfoss
All RT are
x CE marked in accordance with EN 60947-4/-5 for sale in Europe
x Further, the RT 19 , RT 30, RT 35, and RT 112 series is CE markd in accordance with PED 97/23/EC, category IV, safety equipment.
IC.PD.P10.B3.02 - 520B3058 3
Enclosure 20025
Technical data Designation RT pressure switches

Ambient temperature In general −50 to 70°C ;
Diaphragm version −10 to 70°C
VD TÜV approved −40 to 70°C
Media temperature In general −40 to 100°C;
Diaphragm version −10 to 90°;
VD TÜV appr. -40 to 150°C, see page 6 (Steam plant)
Contact system
Single-pole changeover switch (SPDT)

Contact load Alternating current: Fig. 6
AC-1: 10A, 400 V
AC-3: 4A, 400 V
AC-15: 3A, 400 V
Contact material:
AgCdO Direct current:
DC-13: 12 W, 230 V
(see fig. 6)
Special contact system See “accessories” page 13
Cable entry 2 PG 13.5 for 6 - 14 mm diameter cables
Enclosure IP 66 acc. to IEC 529 and EN 60529. Units supplied with external reset.
IP 54. The thermostat housing is made of bakelite acc. to DIN 53470
Cover is made of polyamide.
Materials in contact with the medium
RT RT RT RT RT RT
RT RT RT RT RT RT
Material Part W .no. DIN RT 1 RT 1A RT 5 RT 5A 200/ 260A 262A/ 260AL 265A 263AL/
110 112 113 116 117 121
200 L 262 AL 266AL
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x x x x x x x x x x
Stainless steel 17/7 Spring 1.4568 17224 x x x x x
Brass Housing 2.0402 17660 x x x x x x x
Brass Bellows ring 2.0321 17660 x x x x x x x
Free-cutting steel Flare connection 1.0718 1651 x
Deep-drawn steel
(nick.plated surface) Housing 1.0338 1623 x x x x x x x x
Non-alli. carbon steel Weld connect. for

1.0402 1652 x x x x x x x
C 20 connection
Aluminium Gasket 3.0255 1712 x x x x x x x x
Case hardening steel Weld connection
1.0401 1652
C 15 Bellows connect.
Stainless steel Spring guide + screw 1.4305 17440
NBR rubber Diaphragm x
Deep-drawn steel Diaphragm housing
(surface DIN 50961 weld with welded 1.0338 1623 x
connection Fe/Zn 5C) connector
Spring thread Spring 1.1250 17223 x
Materials in contact with the medium Vd TÛV approved controls

RT 30AW
Material Part W.no. DIN RT 19W B,S RT 31W B,S RT 32W B,S RT 33B 35W RT 112 W RT 112
AB, AS
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x x
Stainless steel 17/7 Orifice 1.4305 17440 x x
Steel C 15 Connector 1.0401 1652 x x
Deep-drawn steel + Ni Bellows ring 1.0338 1623 x x x x x x
Stainless steel 17/7 Bellows spring 1.4568 17224 x x
Stainless steel Ring 1.4305 17440 x
Deep-drawn steel + Ni Housing 1.0338 1623 x x x x x x
Stainless steel Bellows connect. 1.4305 17440 x
Stainless, weldable
Connector 1.4301 17440 x x x x
free-cutting steel
Deep-drawn steel + Sn Spring guide 1.0338 1623 x
Brass Housing 2.0402 17660 x
Brass Bellows ring 2.0321 17660 x
4 IC.PD.P10.B3.02 - 520B3058
Enclosure 20025
Dimensions and weight
RT 5, 110, 112, 116, 117, 200

Special version with tamper
proof cap and blank cover
RT 13 RT 5, 110, 112, RT 5 RT 1A, 1AL

116, 117, 117L,
121, 200, 200L
RT 260A, 260AL RT 262A, 262AL, RT 5 RT 5A, 5AL

263AL
: External reset knob

only for RT...B
RT 30 AW, -B, -S L = 225

RT 19 W, -B, -S L = 228
RT 33 B, 35W L = 221
RT 112 W L = 210
RT 31 W-B, -S L = 212
RT 32 W-B, -S L = 212
Weight: approx. 1 kg
IC.PD.P10.B3.02 - 520B3058 5
Enclosure 20025
Installation RT units have two mounting holes which become Pressure connection
accessible when the front cover is removed. Units When fitting or removing pressure lines, the
fitted with switch 017-018166*) must be installed spanner flats on the pressure connection should
with the setting knob upwards. When installing be used to apply counter-torque.
differential pressure switches, the low pressure
Steam plant
side (marked LP) must be installed upwards. The
To protect the pressure element against tempera-
other pressure switches in the RT series can be
ture in excess to the maximum temperature of
installed in any position, expect that on plant
the medium 150°C (RT 113 90°C), the insertion of
subjected to severe vibrations it is advantageous
water-filled loop is recommended.
to have the screwed cable entry downwards.
Water systems
*) Contact system with snap-action contact. Water in the pressure element is not harmful, but
See spare parts and accessories, page 13. if frost is likely to occur a water-filled pressure
element may burst. To prevent this happening,
the pressure control can be allowed to operate
on an air cushion.
Media resistance
See table of materials in contact with the
medium. If seawater is involved, diaphragm
pressure switches types KPS 43, 45 and 47 are
recommended.
Pulsations
The pressure control must be connected in such
a way that the pressure element is affected by
pulsations as little as possible. A damping coil can
Fig. 1 Positioning of unit be inserted (see “Accessories”). With strongly
pulsating media, diaphragm pressure switches
types KPS 43, 45 and 47 can be advantageous.
Setting
5. Setting knob The range is set by using the setting knob (5)
9. Range scale while at the same time reading the scale (9). Tools
19. Differential setting
must be used to set pressure switches fitted with
disc
a seal cap.
In units having a fixed differential, the difference
between cut-in and cut-out pressures is of course
determined. On units having an adjustable
differential the front cover must be removed. The
differential disc (19) must be set in accordance
with the diaphragm.
Fig. 2
Selection of differential
To ensure that the plant functions properly, a
suitable differential pressure is necessary. 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 oscillations.
Differential scale values are guiding
Fig. 3 Obtainable differential disc scale
6 IC.PD.P10.B3.02 - 520B3058
Enclosure 20025
Function a. RT 19, RT 30, and pressure switches with max. I. Alarm for rising pressure given at the set
reset range value.
When the pressure exceeds the set range value, II. Alarm for falling pressure given at the set
contacts 1-4 make and contact 1-2 brake. The range value minus the differential.
contacts changeover to their initial position when Units with max. reset can only be reset at a
the pressure falls to the range value minus the pressure corresponding to the set range value
differential (see fig. 4). minus the differential, or a lower pressure.
Scale setting −−−

Mechanical differential
Fig. 4. Contact function, setting for rising pressure
b. All other RT pressure switches I. Alarm for falling pressure given at the set range
When the pressure falls to the set range value, value.
contacts 1-2 make and contacts 1-4 brake. The II. Alarm for rising pressure given at the set range
contacts changeover to their original position value plus the differential.
when the pressure again rises to the set range Units with min. reset can only be reset at a
plus the differential (see fig. 5). pressure corresponding to the set range value
plus the differential.

Fig. 5. Contact funktion, setting for falling pressure
Example 1 The range is 5-25 bar and the differential is fixed

An extra cooling water pump must start if the at approx. 1 bar. The range scale must be set at
cooling water pressure falls below 6 bar, and 17 bar. After cut-out of the burner, manual reset
must stop when the pressure exceeds 7 bar. is possible only when the pressure had fallen to
Choose an RT 116 with a range of 1-10 bar and an the setting of 17 bar minus the differential: in this
adjustable differential of 0.2-1.3 bar. case, 16 bar and below.
The start pressure of 6 bar must be set on the
range scale. The differential must be set as the
difference between the stop pressure (7 bar) and Example 3
the start pressure (6 bar) = 1 bar. According to fig. The min. permissible lubricating oil pressure for a
3, the differential setting disc must be set on 8. gear is 3 bar. Reset must not be possible until the
reason for oil pressure failure has been investigated.
Example 2 Choose an RT 200 with min. reset.
The burner on a steam boiler must cut out when The range value must be set while reading the
the pressure exceeds 17 bar. Automatic restart range scale. Manual reset is possible only when
must not occur. the pressure has reached 3.2 bar (the differential
Choose an RT 19B with external reset. If extra is fixed at 0.2 bar or higher).
safety is demanded, an RT 19S with internal max.
reset can be used.
IC.PD.P10.B3.02 - 520B3058 7
Enclosure 20025
Function description Fail-safe function for falling pressure

for RT units Fig. 5a shows a cross-section of a bellows element
TÜV approval for the RT 32W with fail-safe function for falling
pressure. On rising pressure the contact arm is
actuated to break the connection between
terminals 1 and 2.
On falling pressure the contact arm is actuated to
break the connection between terminals 1 and 4.
If a defect occurs in the bellows the setting spring
actuates the contact arm to break the connection
between terminals 1 and 4, as in the case of falling
pressure. This will occur irrespective of the pressure
on the bellows. Fig 5a
Fail-safe function for rising pressure
Fig. 5b shows a cross-section through a bellows
element for the RT 30W with fail-safe for rising
pressure. On rising pressure the contact arm is
actuated to break the connection between
terminals 1 and 2 . If a defect occurs in the inner
bellows the pressure is led to the outer bellows.
The outer bellows has an area three times as large
as the inner bellows. The connection between
terminals 1 and 2 becomes broken.
If a defect occurs in the outer bellows, there will be
atmospheric pressure in the gap between the two
bellows. This actuates the contact system to break
the connection between terminals 1 and 2. The
important factor with the double bellows design is
the vacuum between the two bellows, and that in Fig. 5b
case of bellows break, no media will leak into the
environment.
Pressure switches for liquid The RT 113 pressure switch can be used to control 3. Connection to the side of the tank with the RT 113
level control RT 113 the liquid level in open tanks. Fig. 6 shows in below the liquid level
principle, four different types of installation. Where possible, this form of connection should
be used. If an air-absorbing liquid like oil is
1. With air bell (see “Accessories”) involved, it is preferable to 1 and 2. The resulting
For control purpose, the air bell should be installed range setting is the distance from the liquid surface
20 to 40 mm below the lowest liquid level. In to the centre of the diaphragm housing.
addition, the tube between the RT 113 and the
air bell must be absolutely airtight. If only an 4. Connection in the tank with the RT 113 above the
indication is required, the bell can be placed 100 liquid level
mm below the max. level. The RT 113 must be set This method is for use with air-absorbing liquids
at 0 cm wg and the differential disc on 1. where connection type 3 is not possible. The
shortest horizontal tube length is determined as
2. Connection to the side of the tank with the RT 113 described in 2. A shut-off valve is installed
above the liquid level between the oil tank and water reservoir shown
The horizontal tube A must have a certain length so that impurities can be drained from the water
in relation to the vertical tube B in order to reservoir through a bottom drain plug. Fresh water
ensure reliable control. The length ofA can be can then be poured into the reservoir through a
found from fig. 7, using B and the range setting filling connector in its top.
pressure C.
8 IC.PD.P10.B3.02 - 520B3058
Enclosure 20025
Height from tank connector to pressure control
Min horizontal tube length
Fig. 6 Fig. 7
Application RT-L pressure switches are fitted with a switch

with an adjustable neutral zone. This enables the
units to be used for floating control.
The terminology involved is explained below.
Floating control
A form of discontinuous control where the
correcting element (e.g. valve, damper, or similar)
moves towards one extreme position at a rate
independent of the magnitude of the error when
the error exceeds a definit positive value, and
towards the opposite extreme position when the
error exceeds a definite negative value.
Hunting
Periodic variations of the controlled variable from
the fixed reference.
5. Setting knob
9. Range scale
Neutral zone
40. Neutral zone disc
The interval in the controlled variable in which
the correcting element does not respond
(see fig. 13).
The contact system in neutral zone units cannot

Fig. 8
be exchanged, as the contact system adjustment
is adjusted to the other parts of the unit.
IC.PD.P10.B3.02 - 520B3058 9
Enclosure 20025
Setting of neutral zone The range is set using the setting knob (5) fig. 8 The required neutral zone can be found in the
while reading the range scale (9). The pressure set diagram for the unit concerned. The position at
is the break pressure for contacts 1-4 (see fig. 13). which the neutral zone disc (40) must be set can
be read from the lower scale in the diagram. The
function can be seen in fig. 13.
Fig. 9 Fig. 10 Fig. 11 Fig. 12
Range setting
Inlet pressure
Differential (mechanical
differential) corresponds to the
least neutral zone setting.
a: The neutral zone.Inlet

pressure may vary within this
interval without resulting in a
make function 1-2 or 1-4.
Fig. 13
Example
Together with a VLT® static frequency converter, RT
200L neutral zone pressure switches can be used
for the infinite control of a pump in, for example, a
pressure boosting plant.
In this case, the pump must be up and down-regu-
lated at 32 and 25 m wg.
The RT 200L must be set using the setting knob (5) Pressure
fig. 8 page 9 at 3.5 bar (35 m wg) minus the fixed gauge
differential of 0.2 bar.
Signal lamp for
The range setting is 3.5 - 0.2 = 3.3 bar. falling and rising
Compressed
The neutral zone, 35 - 32 = 3 m wg, corresponding air pressure
to 0.3 bar, must be set on the neutral zone disc
(40) fig. 8 page 9. According to the diagram fig. 12
the disc setting is 1 or just over. A more accurate
setting can be obtained by using the test setup
Fig. 14
shown in fig. 14.
Test setup for setting the pressure control
10 IC.PD.P10.B3.02 - 520B3058
Enclosure 20025
Application Control and monitoring of pressure differentials between the counteracting bellows elements and
A differential pressure control is a pressure the set scale value. This unit is also available with
controlled switch that cuts in and cuts out the an adjustable neutral zone (like the RT-L which is
current dependent on the pressure differential described on page 10.)
Setting The setting disc (5) becomes accessible when the

front cover is removed. The differential pressure
is set by turning the disc with a screwdriver while
reading the scale (9).
For differential pressure switches with a changeover

contact system, the contact differential is given
as the differential pressure switches have a fixed
differential.
In units with an adjustable neutral zone, the
neutral zone disc must also be set. See diagram in
fig. 16.
5. Setting disc
9. Range scale
Note:
When installing, the low
pressure connection (LP)
must always be upwards
Fig. 15
Fig. 16
IC.PD.P10.B3.02 - 520B3058 11
Enclosure 20025
Function a. Units with changeover switch (SPDT) I. Contacts make when differential pressure falls
If the differential pressure falls below the set below the range scale setting.
value, contacts 1-2 make and contacts 1-4 break.
Contacts 1-2 break again and contacts 1-4 make II. Contacts make when pressure rises above the
when the differential pressure has risen to the set range scale setting plus the fixed mechanical
range value plus the fixed contact differential. differential.

Fig. 17 Contact function, setting of falling differential pressure
b. Units with adjustable neutral zone (SPDTNP) The contact function can be summed up as
If the differential pressure rises above the set value follows:
plus the differential, contacts 1-4 make.
If the pressure falls by the amount of the differential I. Setting disc set for falling differential pressure.
(which is fixed in this unit), contacts 1-4 break.
If the pressure falls to the neutral zone minus the II. Neutral zone disc set for rising differential
differential, contacts 1-2 make. When the differential pressure.
pressure rises again by an amount corresponding to
the differential, contacts 1-2 break again.
Range setting
Inlet pressure
Mechanical
differential
Differential
(mechanical
differential)
corresponds to
the least neutral
zone setting.
a: The neutral zone and inlet differential
pressure may vary within this interval
without resulting in a make function 1-2
or 1-4.
Fig. 18. Contact function, setting of neutral zone
Example 1 Example 2
When the differential pressure exceeds 1.3 bar, a The speed of a circulation pump must be controlled
filter needs cleaning. The static pressure over the to give a constant differential pressure of 10 m wg
filter is 10 bar. in a heating plant. The static plant pressure is 4 bar.
According to the ordering table on page 4, the The choice is an RT 262AL.
choice is an RT 260A (the RT 262A has a max. The differential disc (5) fig. 15 page 11, must be set
operating pressure on the low pressure side (LP) of at 1 bar (10 m wg) minus the fixed differential of 0.1
6 bar and is therefore not suitable for this applica- bar, i.e. 0.9 bar. The neutral zone disc is factory-set
tion). (marked in red).
Setting: Since a signal is required for rising differen-
tial pressure, the setting becomes 1.3-0.3 bar = 1.0
bar.
12 IC.PD.P10.B3.02 - 520B3058
Enclosure 20025
Spare parts and accessories

Version Symbol Description Contact rating Code no.
Single-pole changeover switch (SPDT) with

terminal board proof against leakate current
Standard 017-403066
Fitted in all standard versions of type RT1).
Snap action changeover contacts.
For manual reset of unit after contact

changeover on rising pressure Alternating current:
With max. reset 017-404266
AC-1 (ohmic): 10 A, 400 V
For units with max. reset. AC-3 (inductive): 4 A, 400 V
AC-14/15 (coil/transformer): 3 A, 400 V
For manual reset of units after contact
Blocked rotor: 28 A, 400 V
changeover on falling pressure.
Direct current:
With min. reset 017-404166
DC 13/14: 12 W, 230 V
For units with min. reset.
Alternating current
Single-pole changeover switch (SPDT) with gold
AC-1 (ohmic): 10 A, 400 V
plated (oxide-free) contact surfaces.
AC-3 (inductive): 2 A, 400 V
Increases cut-in reliability on alarm and monitoring
Standard AC-14/15 1 A, 400 V 017-424066
systems, etc.
Snap action changeover contacts.
Direct current:
Terminal board proof against leakage current.
DC-13/14: 12 W, 230 V
Alternating current:
Single-pole changeover switch that cuts in two
AC-1(ohmic): 10 A, 400 V
Cuts in two circuits circuits simultaneously on rising pressure.
AC-3 (inductive): 3 A, 400 V 017-403466
simultaneously Snap action changeover contacts.
AC-14/15 2 A, 400 V
Terminal board proof against leakage current.
Direct current:
DC-13/14: 12 W, 230 V
Single-pole changeover switch that cuts out two
Cuts out two circuits circuits simultaneously on rising pressure. * If current is led through contacts 2 and 017-403666
simultaneously Snap action changeover contacts. 4, i.e. terminals 2 and 4 connected but
Terminal board proof against leakage current. not 1, max. permissible load is increased
to 90 W, 220 V - - -.
With non-snap action Single-pole changeover with non-snap action Alternating or direct current:
017-018166
changeover contacts changeover gold plated (oxide-free) contacts. 25 VA, 24 V
1
) At load types with low currents/voltages contact failure The switch contacts are shown in the position they
may occure on the silver contacts because of oxidation. assume on falling pressure/temperature, i.e. after
In systems where such a contact failure is of great downward movement of the RT main spindle.
importance (alarm etc.), gold plated contacts are
The setting pointer of the control shows the scale value
recommended.
Contact systems for neutral zone units are not at which contact changeover occurs on falling pressure/
available as spare parts. Exchange not possible, as the temperature. An exception is switch no. 017-403066
contact system adjustment is adjusted to the other with max. reset where the setting pointer shows the
parts of the unit. scale value at which contact changeover occurs on
rising pressure.
Switches
Version Symbol Description Contact rating Code no.
For Alarm application
For manual reset of unit after contact changeover on Alternating current:
With min. manual
falling pressure. AC-1 (ohmic): 10 A, 400 V 017-404766
reset
Gold plated (oxide-free) contact surfaces AC-3 (inductive): 2 A, 400 V
Full load current: 2 A, 400 V
AC-14/15: 1 A, 400 V
Blocked rotor: 14A, 400 V
For manual reset of unit after contact changeover on Direct current

With max. reset rising pressure. DC-13/14: 12W, 230 V 017-404866
Gold plated (oxide-free) contact surfaces
For control application
max. 100 mA / 30 V a.c./ d.c.
min. 1 mA / 5 V a.c. / d.c.
IC.PD.P10.B3.02 - 520B3058 13
Enclosure 20025
Part Description Qty. Code no.
Covers: Polyamide With window 5 017-436166

Cover
Colour: Pale grey RAL 7035 Without window 5 017-436266
Replacement Pale grey Ral 7035

Setting knob 30 017-436366
Seal cap to replace setting knob so that Black 20 017-436066

Seal cap
Setting can only be altered with tools
Seal screws for

1 + 1 017-425166
cover and seal cap
For all RT pressure switches with damping coil or other longer connections
Clamping band 10 017-420466
L= 392 mm
Conncetor with Pipe thread ISO 228/1, G⅜ connector, nipple and AL washer (10 mm ext. 6.5 mm
5 017-436866
nipple int. diam.) for welding or brazing on to steel or copper tubing
Connector 7/16 - 20 UNF connector for ¼ copper tube, brass, span of jaws 16 10 011L1101
Reducer Pipe thread ISO 228/1, G½A u G⅜, steel, span of jaws 22 1 017-421966
Pipe thread ISO 228/1, G⅜ u ⅛ - 27 NPT with copper washer, brass,

Adaptor 1 060-333466
span of jaws 22
Pipe thread ISO 228/1, G⅜ A u ¼ - 18 NPT with copper washer, brass,

Adaptor 1 060-333566
span of jaws 22
Pipe thread ISO 228/1, G⅜ u ¼ - 18 NPT with copper washer, brass,

Adaptor 1 060-333666
span of jaws 22
Adaptor Pipe thread ISO 228/1, G⅜ A - G ¼ A, brass, span of jaws 17 1 060-324066
Adaptor Pipe thread ISO 228/1, G ⅜ A u R ⅜ (ISO 7/1) brass, span of jaws 17 1 060-324166
0.50 m
Damping coil with 7/16 - 20 UNF connectors. Reducer code no. 017-420566 is 060-019066
1.00 m
necessary if the damping coil is to be used with RT units having a pipe thread 060-019166
Damping coil 1.50 m 1
ISO 228/1, G⅜ connection. Damping coils with several lengths of capillary tubes 060-019266
2.00 m
are available. Please contact Danfoss. 060-019366
Pipe thread ISO 228/1, damping coils with G⅜ connector and 1.5 m copper
Damping coil 1 060-104766
capillary tube. Standard washers are supplied.
Armoured Pipe thread ISO 228/1, damping coil with G⅜ connector and 1 m copper
1 060-333366
damping coil capillary tube. Standard washers are supplied.
® Danfoss A/S 09-07/ AC-BNM/mr
Air bell, 62 mm diam. ext. u 204 mm length. Pipe thread ISO 228/1,
Air bell for liquid
G⅜ connector and nipple (10 mm o.d./ 6.5 mm i.d.) for welding or brazing on to 1 017-401366
level control RT 113
steel or copper tubing. The air bell is of brass CuZn 37, W.no. 2.0321.
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.
14 IC.PD.P10.B3.02-520B3058
Enclosure 20032 Mechanical
Pressure Measurement
Bourdon Tube Pressure Gauges

Stainless Steel Series
Model 232.50/233.50, without/with Liquid Filling
WIKA Data Sheet PM 02.02
Applications
 With liquid-filled case for applications with high dynamic
pressure pulsations or vibrations
 For gaseous and liquid aggressive media that are
not highly viscous or crystallising, also in aggressive
ambience
 Process industries: chemical/petro-chemical, power
stations, mining, on and offshore, environmental tech-
nology, machine building and plant construction
Special Features
 Excellent load-cycle stability and shock resistance

 All stainless steel construction
 German Lloyd, Gosstandart and DVGW approval
 Scale ranges up to 0 … 1600 bar
Bourdon Tube Pressure Gauge Model 232.50
Description Pressure limitation

NS 63: Steady: 3/4 x full scale value
Design Fluctuating: 2/3 x full scale value
EN 837-1 Short time: full scale value
Nominal size in mm NS 100, 160: Steady: full scale value
63, 100, 160 Fluctuating: 0.9 x full scale value
Short time: 1.3 x full scale value
Accuracy class
NG 63: 1.6 Operating temperature
NG 100, 160: 1.0 Ambient: -40 ... +60 °C without liquid filling
-20 ... +60 °C gauges with glycerine filling
Scale ranges
Medium: +200 °C maximum without liquid filling
NS 63: 0 ... 1 to 0 ... 1000 bar
+100 °C maximum with liquid filling
NS 100: 0 ... 0.6 to 0 ... 1000 bar
NS 160: 0 ... 0.6 to 0 ... 1600 bar Temperature effect
or all other equivalent vacuum or combined pressure and When the temperature of the measuring system deviates
vacuum ranges from the reference temperature (+20 °C):
max. ±0.4 %/10 K of full scale value
Ingress protection
IP 65 per EN 60 529 / lEC 529
WIKA Data Sheet PM 02.02 ∙ 02/2009 Page 1 of 2
Data Sheets showing similar devices:

Stainless steel series; model 232.30; see data sheet PM 02.04
Enclosure 20032
Standard version Options

Process connection  O ther process connection
Stainless steel 316L (NS 63: 1.4571),  A  ssembly on diaphragm seals see product review DS
lower mount (LM) or lower back mount (LBM) 1)  M  onel pressure system (model 26X.50, not with NS 160
NS 63: G ¼ B (male), 14 mm flats back connection)
NS 100, 160: G ½ B (male), 22 mm flats  Pressure system stainless steel 1.4571
 Surface or panel mounting flange, stainless steel
Pressure element  Panel mounting flange, stainless steel, polished
Stainless steel 316L,  Triangular bezel, stainless steel, polished, with clamp
< 100 bar: C-type  Ambient temperature -40 °C: silicon oil filling
≥ 100 bar: helical type  Switch contacts (see data sheet AC 08.01)
 Pressure gauge with electrical output signal,
Movement see Model PGT23.100/160, data sheet PV 12.04
Stainless steel  Version per ATEX Ex II 2 GD c
Dial
Standard version
Aluminium, white, black lettering,
NS 63 with pointer stop pin Lower mount (LM)
≤ 16 bar with compensating valve
> 16 bar without compensating valve
Pointer
Aluminium, black
1520806.03
Case
Stainless steel, with pressure relief in case top (NS 63) or in
case back (NS 100 and 160),
ranges ≤ 0 ... 16 bar with compensating valve to vent case
Window: Laminated safety glass (NS 63: Polycarbonate)
Bezel ring: Cam ring (bayonet type), stainless steel
Liquid filling (for Model 233.50): Glycerine 99.7 % Lower back mount (LBM) 1)
≤ 16 bar with compensating valve
1520814.03
> 16 bar without compensating valve
Special versions
Gauges for ammonia plants (NS 100 and 160)
With temperature scale for refrigerant R 717 (NH3) in °C,
scale ranges: -1 ... 0 ... 15 bar or -1 ... 0 ... 26 bar
Dimensions in mm
NS Dimensions in mm Weight in kg
a b b1 b2 D1 D2 e f G h±1 SW Model 232.50 Model 233.50
63 9.5 33 33 57 63 62 11.5 - 1) G¼B 54 14 0.16 0.20
100 15.5 49.5 49.5 83 101 99 17.5 30 G½B 87 22 0.60 0.90
160 15.5 49.5 3) 49.5 2) 83 2) 161 159 17.5 50 G½B 118 22 1.10 2.00
Process connection per EN 837-1 / 7.3 2) Plus 16 mm with pressure ranges ≥ 100 bar
1) NS 63: Centre back pressure entry (CBM) 3) Plus 16 mm with pressure range 1600 bar
Model / Nominal size / Scale range / Connection size / Connection location / Options
9019723 02/2009 GB
Page 2 of 2 WIKA Data Sheet PM 02.02 ∙ 02/2009
WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
www.wika.de
Enclosure 20037 Mechanical
Temperature Measurement
Bimetal Thermometers
Heavy Duty Series, Model 54
WIKA Data Sheet TM 54.01
Applications
 Plant, machinery, tank and apparatus construction
 Facility management
 With liquid damping also suitable for applications with
extreme vibrations
Special Features
 Universal application
 Case and stem of stainless steel
 Bimetal with zero-point adjustment on the rear of the case
 Approval Germanischer Lloyd (with feature liquid
damping, version axial or radial)
Fig. left: Bimetal Thermometer Model A5402

Fig. right: Bimetal Thermometer, Adjustable Stem and
Dial Model S5412
Description
This series of thermometers is designed for installation in

pipes, tanks, plants and machinery.
The stem and the case of the instrument are made from
stainless steel. Various insertion lengths and process
connections are available to optimally match the require-
ments of each process. Due to their high ingress protection
(IP 65) and liquid damping these thermometers can be used
in applications with extreme vibrations.
WIKA Data Sheet TM 54.01 ∙ 08/2009 Page 1 of 6

Enclosure 20037
Standard version
Temperature element Dial
Bimetal helix Aluminium, white, lettering black
Nominal sizes in mm Window

63, 80, 100, 160 Instrument glass
Design of connection Pointer

S Standard (male thread connection) Aluminium, black, adjustable pointer
1 Plain stem (without thread)
2 Male nut Pressure rating of stem
3 Union nut max. 25 bar, static
4 Compression fitting (sliding on stem)
5 Union nut with fitting Ambient temperature limit at the case
+60 °C max. (others on request)
Instrument version
A54XX back mount (axial) Ingress protection
R54XX lower mount (radial) IP 65 per EN 60 529 / IEC 529
S54XX back mount (adjustable stem and dial)
Accuracy class Options

Class 1 per DIN EN 13 190  Scale range °F, °C/°F (dual scale)
 Liquid damping to 250 °C max. (at stem)
Working range
 GL approval with feature liquid damping, not with adjust-
Normal (1 year): Measuring range (DIN EN 13 190)
able stem and dial or NS 160 (vibratory stress conditions
Short time (24 h max.): Scale range (DIN EN 13 190)
25 ... 200 Hz, 5 g)
Case and ring  Window of laminated safety glass or acrylic plastic
Stainless steel 1.4301  Stem Ø 6, 10 mm
 Ingress protection IP 66
Stem and process connection  Thermometers with electrical output signal (Data Sheet
Stainless steel 1.4571 TV15.01)
 Special temperature range or dial printing to customer
Elbow behind the case specifications (on request)
Aluminium, only with radial entry version  Explosion-protected version, see marking on the instrument
Scale range, measuring range 1) , error limit (DIN EN 13 190)

Scale graduation per WIKA standard
Scale range Measuring range 1) Scale spacing Error limit
in °C in °C in °C ± °C
-30 ... +50 -20 ... +40 0.5 1
-20 ... +60 -10 ... +50 0.5 1
0 ... 60 10 ... 50 0.5 1
0 ... 80 10 ... 70 0.5 1
0 ... 100 10 ... 90 1 1
0 ... 120 10 ... 110 1 2
0 ... 160 20 ... 140 1 2
0 ... 200 20 ... 180 2 2
0 ... 250 30 ... 220 2 2.5
0 ... 300 30 ... 270 2 5
0 ... 400 50 ... 350 5 5
0 ... 500 50 ... 450 5 5
1) The measuring range is limited by two triangular marks on the dial. Within this range the specified error limit applies per DIN EN 13
Models
Version Nominal size in mm Design
63 80 100 160 S 1 2 3 4 5
Model 54 axial A5400 A5401 A5402 A5403 x x x x x x
radial R5440 R5441 R5442 R5443 x x x x x x
Model 54, adjustable stem/dial S5410 S5411 S5412 S5413 - x x x x x
Page of 6 WIKA Data Sheet TM 54.01 ∙ 08/2009

Enclosure 20037
Design of connection
Design standard (male thread connection)

Standard stem lengths: l1 = 100, 160, 200, 250 mm
3073050.03 (G1)
Nominal size Process connection Dimensions in mm
NS G i SW d4 Ød
63, 80, 100, 160 G ½ B 14 27 26 8
G¾B 16 32 32 8
½ NPT 19 22 - 8
¾ NPT 20 30 - 8 Legend:
G Male thread
i Thread length
Ø d4 Diameter of the sealing collar
SW Flats
Ø d Stem diameter
Design 1, plain stem (without thread)

Standard stem lengths: I = 100, 140, 160, 200, 240, 290 mm
3073050.03 (G1)
The basis for design 4, compression fitting
Nominal size Dimensions in mm
NS d6 Ød
63, 80, 100, 160 18 8
Legend:
Ø d6 Plain diameter
Ø d Stem diameter
Design 2, male nut

Standard stem lengths: l1 = 140, 180, 230 mm
3073050.03 (G1)
NS G i SW Ød
63, 80, 100, 160 G ½ B 20 27 8
M18 x 1.5 12 24 8
Legend:
G Male thread
i Thread length incl. plain
SW Flats
Ø d Stem diameter
Design 3, union nut

3073050.X

NS G1 i SW Ød
63, 80, 100, 160 G ½ 8.5 27 8
G¾ 10.5 32 8
M20 x 1.5 13.5 32 8 Legend:
G1 Female thread
i Thread length
SW Flats
Ø d Stem diameter

Enclosure 20037
Design 4, compression fitting (sliding on stem)

Stem lengths: l1 = variable
3073050.Y
Length: L = l1 + 40 mm
NS G i SW d4 Ød
63, 80, 100, 160 G ½ B 14 27 26 8
Sealing ring
G¾B 16 32 32 8
½ NPT 19 22 - 8
¾ NPT 20 30 - 8 Legend:
G Male thread
i Thread length
SW Flats
Ø d Stem diameter
Design 5, union nut with fitting

3073050.Z
NS G i SW d4 Ød
63, 80, 100, 160 G ½ B 14 27 26 8
G¾B 16 32 32 8
½ NPT 19 22 - 8
Legend:
¾ NPT 20 30 - 8
G Male thread
i Thread length
SW Flats
Ø d Stem diameter

Enclosure 20037
Dimensions and location of stem

Back mount (axial) Lower mount (radial)
3280897.01
3280919.01
NS Dimensions in mm Weight in kg
b b1 b2 ØD Ød Ø d4 F R U
63 20 35 38 68 8 1) 26 47 0.20 0.30
80 20 35 38 77 8 1) 26 56 0.25 0.35
100 22 37 40 107 8 1) 26 66 0.35 0.45
160 25 40 43 161 8 1) 26 96 0.50 0.60
1) Option: Stem Ø 6, 10 mm R back mount
U lower mount
Adjustable stem and dial

3280854.01
NS Dimensions in mm Weight
b b3 ØD Ød F in kg
63 20 63 68 8 1) 66 0.35
80 20 63 77 8 1) 66 0.40
100 22 65 107 8 1) 66 0.50
160 25 68 161 8 1) 66 0.65
1) Option: Stem Ø 6, 10 mm

Enclosure 20037
Model / Nominal size / Scale range / Design of connection / Connection size / Length l, l1 / Options
08/2009 GB
WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
www.wika.de
Enclosure 20045
MAKING MODERN LIVING POSSIBLE
Thermostatic valve
AVTA
Technical brochure
Enclosure 20045
Technical brochure Thermostatic valve, type AVTA
2 IC.PD.500.A3.02 - 520B3728 ® Danfoss A/S 07-2009/ RA-MC/mr

Enclosure 20045
Contents Page
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Introduction AVTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
AVTA application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ordering AVTA with adsorption charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ordering AVTA with universal charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Ordering AVTA with mass charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Dimension and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
AVTA SS for aggressive media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Ordering AVTA in stainless steel with adsorption charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sensor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
® Danfoss A/S 07-2009/ RA-MC/mr IC.PD.500.A302 - 520B3728 3

Enclosure 20045
Features AVTA
• Insensitive to dirt
• Insensitive to water pressure
• Needs no power supply - self acting
• Opens on rising sensor temperature
• Differential pressure: 0 to 10 bar
• Max. working pressure: 16 bar
• Max. test pressure: 25 bar
• Max.pressure on sensor: 25 bar
• Stainless Steel version available
• The valves are pressure-relieved, i.e. the degree
of opening is not affected by differential
pressure Δp (pressure drop).
• The regulation range is defined for the point at
which the valve begins to open.
Introduction Thermostatic valves are used for the infinite, Because the valves constantly match flow
proportional regulation of flow quantity, quantity to demand, they are especially suitable
depending on the setting and the sensor for temperature regulation.
temperature. The required temperature is maintained constant
The Danfoss range of thermostatic valves with no overconsumption of:
includes a series of industrial products for both - cooling water in cooling systems,
refrigeration and heating regulation. The valves - hot water or steam in heating systems.
are self-acting, i.e. they operate without the The operating economy and efficiency
supply of auxiliary energy such as electricity or is maximized.
compressed air.
How it works
Thermostatic valves consist of three main elements:
- Setting section with knob, reference spring and setting

scale.
- Valve body with orifice, closing cone and sealing

elements.
- Hermetically sealed thermostatic element with sensor,

bellows and charge.
When the three elements are built together, the 1. A temperature-dependent pressure - charge
valve is installed and the sensor is located at the vapour pressure - builds up in the sensor.
point where the temperature is to be regulated, 2. This pressure is transferred to the valve via the
the function sequence is as follows: capillary tube and bellows and acts as an
opening or closing force.

Enclosure 20045
How it works (continued) 3. The knob on the setting section and the spring balance is re-established, or the valve is fully
exert a force that acts counter to the bellows. open or closed.
4. When balance is created between the two 6. On sensor temperature change, the flow
opposing forces, the valve spindle remains in quantity change is approximately proportional.
its position.
The illustrations show an AVTA cooling water
5. If the sensor temperature - or the settings - is valve, but the function principle applies to all
changed, the point of balance becomes types of thermostatic valves.
displaced and the valve spindle moves until
AVTA application AVTA thermostatic valves are widely used

for temperature regulation in many different
machines and installations where cooling is
required. AVTA always opens to admit flow on
rising sensor temperature. The valve can be
installed either in the cooling water flow line or
return line.
Standard version of thermostatic valve AVTA can
be used with fresh water or neutral brine.
• Typical application areas

• Injection moulding machines
• Compressors
• Vacuum pumps
• Dry cleaning machines
• Destillation plants
• Printing machines
• Hydraulic systems
• Rolles/ mills
• Biomass boilers
• Industrial lasers
• Steam sterilizers
• Medical equipment
• Food processing
1. Oil tank
2. Hydraulic machinery
3. Heat exchangers
4. Cooling water supply
5. Thermostatic valve AVTA

Enclosure 20045
Materials
No. Description Material
1 Spindle Brass W.no. 2.0401
2 Diaphragms Rubber - ethylene - propylene (EPDM).
3 Valve body and other metal parts Forged brass W.no. 2.0402
4 Valve cone Nitrile rubber (NBR)
5 Valve seat Stainless steel W.no. 1.4305/AISI 303
6 Sensor Copper W.no. 2.0090
7 Nitrile rubber (NBR)
Capillary tube gland
Brass W.no. 2.0321 / 2.0401
Charges Thermostatic valve AVTA with different types of charge
Universal charge Mass charge Adsorption charge
Ordering • Wide regulating range The charge consists of active carbon and CO2
AVTA with adsorption charge • Can be installed in any which is adsorbed on falling sensor temperature
position as far as orientation and thereby produce pressure changes in the
and - temperature are element.
concerned
• Withstands up to +130oC
sensor temperature
• Small sensor dimensions
- Ø 9,5 x 150 mm
• Max. pressure on sensor 25 bar.
Regulating Max. temp. kv value Capillary tube

Connection
range sensor (m3/h length Type Code no. 1)
ISO 228
[oC] [oC] at Δp = 1 bar) [m]
G 3/8 1.4 2.3 AVTA 10 003N1144
G 1/2 1.9 2.3 AVTA 15 003N0107
G 1/2 +10 o +80 130 1.9 2.3 armoured AVTA 15 003N2114
G 3/4 3.4 2.3 AVTA 20 003N0108
G1 5.5 2.3 AVTA 25 003N0109
Sensor installation
1) Code no. covers complete valve incl. cappillary tube gland.
Immersion pockets, see “Spare parts and accessories”, page 11-12.

Enclosure 20045
Ordering • Sensor dimensions Ø 18 x The charge is a mix of liquid and gas where the
AVTA with universal charge 210 mm liquid surface (regulating point) is always inside
• Sensor can be installed colder the sensor. Wich charge medium is used depends
or warmer than the valve on the regulation range.
• Sensors must be orientated
as shown in sketch below
• Max. pressure on sensor 25 bar.
kv value
Regulating Max.temp. Capillary tube
Connection
range sensor length Type Code no. 1)
ISO 228 (m3/h
[oC] [oC] [m]
at Δ p = 1 bar)
G 3/8 1.4 AVTA 10 003N1132
G 1/2 1.9 AVTA 15 003N2132
2.0
G 3/4 +0 o +30 57 3.4 AVTA 20 003N3132
G1 5.5 AVTA 25 003N4132
G1 5.5 2.0 armoured AVTA 25 003N4133
G 3/8 1.4 2.0 AVTA 10 003N1162
G 1/2 1.9 2.0 AVTA 15 003N2162
G 1/2 1.9 2.0 (armoured) AVTA 15 003N0041
Sensor installation G 3/4 3.4 2.0 AVTA 20 003N3162
G 3/4 +25 o +65 90 3.4 5.0 AVTA 20 003N3165
G 3/4 3.4 2.0 (armoured) AVTA 20 003N0031
G1 5.5 2.0 AVTA 25 003N4162
G1 5.5 2.0 (armoured) AVTA 25 003N0032
G1 5.5 5.0 AVTA 25 003N4165
G 3/8 1.4 2.0 AVTA 10 003N1182
G1/2 1.9 2.0 AVTA 15 003N2182
G 3/4 +50 o +90 125 3.4 2.0 AVTA 20 003N3182
G1 5.5 2.0 AVTA 25 003N4182
G1 5.5 3.0 AVTA 25 003N4183 2)

2) A Ø 2 mm bypass is drilled in the valve body.
Valve body with bypass
Ordering • Small sensor dimensions The Charge is a mix of liquid and gas. Due to
AVTA with mass charge - Ø 9,5 x 180 mm the volumetric conditions the sensor must be
• Short time constant installed warmer than the valve, since the liquid
• Sensor must always be installed Surface (regulation point) must be in the Sensor.
warmer than the valve
• Max. pressure on sensor 25 bar
kv value
Connection
ISO 228 (m3/h
[oC] [oC] [m]
atΔ p = 1 bar)
G 1/2 1.9 AVTA 15 003N0042
+0 o +30 57 2.0
G 3/4 3.4 AVTA 20 003N0043
G 1/2 1.9 2.0 AVTA15 003N0045
G 1/2 1.9 2.0 (armoured) AVTA 15 003N0299
G 1/2 +25 o +65 90 1.9 5.0 AVTA 15 003N0034
G 3/4 3.4 2.0 AVTA 20 003N0046
G1 5.5 2.0 AVTA 25 003N0047
Sensor installation

Enclosure 20045

Type H1 H2 L L1 a b Weight
[mm] [mm] [mm] [mm] [mm] [kg]
AVTA 10 240 133 72 14 G 3/8 27 1.45

AVTA 15 240 133 72 14 G 1/2 27 1.45
AVTA 20 240 133 90 16 G 3/4 32 1.50
AVTA 25 240 138 95 19 G1 41 1.65

Enclosure 20045
Features AVTA SS for aggressive media.

• Insensitive to dirt
• Insensitive to water pressure
• Needs no power supply - self acting
• Opens on rising sensor temperature
• Differential pressure: 0 to 10 bar
• Max. working pressure: 16 bar
• Max. test pressure: 25 bar
• Max. pressure on sensor: 25 bar
• The valves are pressure-relieved, i.e. the degree
of opening is not affected by differential
pressure Δ p (pressure drop).
• The regulation range is defined for the point at
which the valve begins to open.
Application AVTA SS for aggressive media.

A valve body in stainless steel means that the AVTA SS valves have an adsorption charge as
valve can be used for aggressive media in such standard.
applications as the marine sector and the For special request we have also AVTA SS with
chemical industry. mass and universal charges available.
Materials No. Description Material

1 Spindle Stainless steel W.no. 1.4539
2 Diaphragms Rubber - ethylene - propylene (EPDM).
3 Valve body Stainless steel W.no. 1.4581
4 Valve cone Nitrile rubber (NBR)
5 Sensor Copper W.no. 2.0090
6 Capillary tube gland Nitrile rubber (NBR),
Brass W.no. 2.0321 / 2.0401
Ordering • Wide regulating range The charge consists of active carbon and CO2
AVTA in stainless steel • Can be installed in any which is adsorbed on falling sensor temperature
with adsorption charge position as far as and thereby produce pressure changes in the
orientation and element.
temperature are
concerned
• Withstands up to +130oC
sensor temperature
• Small sensor dimensions
- Ø 9,5 x 150 mm
• Max. pressure on sensor
25 bar.
kv value
Connection
ISO 228 (m3/h
[oC] [oC] [m]
at Δp = 1 bar)
G 1/2 1.9 AVTA 15 003N2150
G 3/4 +10 to +80 130 3.4 2.3 AVTA 20 003N3150
G1 5.5 AVTA 25 003N4150

Sensor installation

Enclosure 20045
Dimensions

Type H1 H2 L a
[mm] [mm] [mm] ISO 228/1
AVTA 15 240 133 72 G 1/2
AVTA 20 240 133 90 G 3/4
AVTA 25 240 138 95 G1
Installation The valves can be installed in any position.

An arrow on the valve body indicates the
direction of flow.
AVTA valves are also marked so that the letters RA
can be read straightforwardly when the valve is
held as shown.
The installation of an FV filter ahead of the
valve is recommended.
Capillary tube
Install the capillary tube without sharp bends
(no ”kinks”). Relieve the capillary tube at the ends.
Relief is important where vibration might occur.
Note:
Where AVTA is used, the sensor must be able to
react to variations in cooling water temperature
on system start. Therefore a bypass line with a
shut-off valve might be necessary to ensure fl ow
at the sensor during start-up.
If a mounting bracket is used - see “Spare parts
and accessories” page 11-12 - it must always be
between valve body and setting section (see
illustration).
AVTA with mounting bracket

Enclosure 20045
Sensor installation If an immersion pocket is installed, the use of AVTA with mass charge (sensor Ø9.5 x 180 mm)
heat-conductive compound is recommended. must always have valve housing fitted in the inlet,
This will reduce reaction time. See “Spare parts where the regulated liquid is coldest (“sensor
and accessories”, page 11-12. warmer”).
Adsorption charge Mass charge Universal charge
Sensor Ø 9.5 x 150 mm Sensor Ø 9.5 x 180 mm Sensor Ø 18 x 210 mm

(Sensor warmer or colder) (Sensor warmer) (Sensor warmer or colder)
“Up” = upwards.
Accessories Designation Description Code no.

Brass for Ø 18 sensor R 3/4 003N0050
Immersion sensor Brass for Ø18 mm

003N0051
max. pressure 50 bar sensor 3/4 - 14 NPT
L = 220 mm 18/8 steel 1) for Ø 18, 3/4 - 14 NPT 003N0053
18/8 steel1) for Ø18 sensor R 3/4 003N0192
Immersion sensor Brass for Ø 9.5 sensor G 1/2 017-436766
max. pressure 50 bar
L = 182 mm 18/8 steel1) for Ø 9.5 sensor R 1/2 003N0196
Mounting bracket For AVTA 003N0388
5 gram tube 041E0110

Heat-conductive compound
0.8 kg 041E0111
For AVTA 10/15 003N0445
1 set of nitrile (NBR)
For AVTA 20 003N0446
diaphragm for mineral oil
For AVTA 25 003N0447
G 1/2 017-422066
G 3/4 003N0155
Capillary tube gland 003N0157
1/2 - 14 NPT
3/4 - 14 NPT 003N0056
Plastic hand knob For AVTA 003N0520
1) W. no. 1.4301

Enclosure 20045
Spare parts
Service elements for AVTA
Temperature range Capillary tube length Code no.

[oC] [m]
Adsorption charge - sensor Ø 9.5 x 160 mm +10 o +80 2.3 003N0278
2 003N0075
0 o +30
5 003N0077
2 003N0078
5 003N0080
Universal charge - sensor Ø 18 x 210 mm +25 o +65
2 (armoured) 003N0063
3 003N0079
2 003N0062
+50 o +90
3 003N0089
0 o +30 2 003N0066
Mass charge - sensor Ø9.5 x 190 mm 2 003N0091
+25 o +65
5 003N0068
Sizing When sizing and selecting thermostatic valves, it Valve size

is most important to ensure that the valve is able The following data are used when selcting valve
to give the necessary quantity of cooling water size:
at any time, irrespective of the load. Therefore, - Required cooling water flow, Q [m3/h]
to select a suitable size of valve it is necessary to - Temperature rise in cooling water, [Δt] (oC)
know the precise amount of cooling required. - Differential pressure across valve, [Δp] (bar).
On the other hand, to avoid the risk of unstable With fully open valve the differential pressure
regulation (hunting), the valve should not be should be around 50% of the total pressure drop
oversized. across the cooling system.
The type of charge must be selected on the basis The diagrams on page 10 are intended to make
of the temperature to be maintained, and on an valve sizing easier.
assessment of the characteristics of each type, as
described in the foregoing. Fig. 1 - Relation between heat quantity [kW]
and cooling water quantity
In general the aim should be to select the Fig. 2 - Graphs of kv values
smallest valve capable of giving the required flow. Fig. 3 - Valve operating range
Fig. 4 - Flow quantities as a function of
It is also recommended that the temperature pressure drop [Δp]
range be chosen so that the required sensor
temperature lies in the middle of the regulation
range.
To help fine-setting the valve, a thermometer

should be installed near the sensor.

Enclosure 20045
Example
A cooling water valve must be selected for the
temperature regulation of a vacuum pump.
Since direct regulation of the oil temperature is

required, an AVTA valve is suitable. The sensor
position is horizontal - and small dimensions are
desired.
Given data:
- Necessary cooling at full load 10 kW.
- Oil temperature to be maintained constant Fig.4
at +45oC
- Cooling water p1 = 3 bar
- Outlet p3 = 0 bar
The above considerations apply to both AVTA
p1+p3
- p2 = (guess) and FJVA types.
2
- Cooling water temperature t1 = +20oC Operating conditions and other product require-
- Outlet temperature t2 = +30oC ments in this example mean that a valve with
adsorption charge is the correct choice.
1. The graphs in fig. 1 can be used to find the The temperature range +10 o +80oC is in order.
necessary cooling water quantity at
Δt = 10oC (+30oC - +20oC) to 0.85 m3/h. The table at the top of page 3 shows AVTA
10, code no. 003N1144, or AVTA 15, code no.
The graphs in fig. 2 show the necessary kv value 003N0107. Both fulfil the requirements named.
for 0.85 m3/h with
In many applications, installation conditions
Δp = p1- p2 = 3 - 1.5 = 1.5 bar for 0.7 m3/h. make the use of sensor pockets advisable.
The columns in fig. 3 show that all four AVTA “Accessories” on page 11 gives the code nos. for
valves can be used, but in practice an AVTA 10 or sensor pockets for Ø 9.5 mm sensors in brass and
15 shall be selected, so the necessary water flow stainless steel: 017-436766 and 003N0196,
is in the middle of the regulating range. respectively.

Enclosure 20045
Sizing
Fig. 1 Fig. 2
Heating or cooling with water. Relation between water quantity and pressure drop across valve.
Example: Necessary cooling Example: Flow 0.85 m3/h with a pressure drop of 1.5 bar.
output 10 kW with Δ t = 10oC The kv value becomes 0.7 m3/h.
Required flow 0.85 m3/h.
bar
Pressure drop across valve
Fig. 3
Nomogram showing the
valve kv range. kv values are
always given for water flow
in m3/h with a pressure
drop Δ p of 1 bar. The
valve should be selected
so that the necessary kv Capacity with fully open valve m3/h
value lies in the middle of
the regulation range. Fig. 4
Example: AVTA 10 and 15 Valve flow quantity in fully open position, as
are the most suitable for a a function of pressure drop Δp.
kv value of 0.7

Enclosure 20045
Options • DZR brass

• Outer thread connecting
• Other lenghts of capillary tubes
• Armouring of capillary tubes
• Other combinations of sizes, materials and ranges
• NPT - connection, see separate datasheet for USA / Canada

Enclosure 20045

Enclosure 20071
0407
2/2-way Solenoid Valve

for neutral media up to +180°C,
G 1/2 - G 2, flange
• Servo-piston with forced lifting

• Switches without differential pressure
• Temperatures up to + 180°C
• For neutral media, incl. steam
• Push-over coil system
Type 0407 can be combined with...
Type 2508 Type 1078 Type 2511

Cable plug Timer unit ASI cable plug
The Type 0407 is a pilot controlled solenoid

Technical data
valve with servo-piston and forced valve lifting,
Orifice DN 13 - 50 mm
and is suitable for media temperatures up to
Body material Brass (grey cast iron on request)
+180°C. The valve opens without differential
pressure from zero bar, and is closed by its Coil material Epoxy
own media pressure and spring force without Coil insulation class H
power supply. Seal material PTFE/graphite
Media Neutral media such as hot water and steam
Media temperature -20 to +180 °C
Ambient temperature Max. +55 °C
Viscosity Max. 21 mm2/s
Duty cycle 100% continuous rating
Electrical connection Cable plug for Ø 7 mm cable, acc. to
DIN EN 175301-803 Form A (supplied as standard)
Protection class IP 65 with cable plug
Installation As required, preferably with actuator upright
Orifice Power consumption

DN Inrush Hold (hot coil)
[mm] AC [VA] AC [VA/W] UC [W]
13 - 40 100 35/14 –
50 – – 30
www.burkert.com p. 1/3
Enclosure 20071
0407
Materials
Coil Epoxy
Stopper 1.4105 Stainless Steel
Spring 1.4310 Stainless Steel
Plunger 1.4105 Stainless Steel
Plunger Seal PTFE
Cover Brass
Graphite Seal
Piston Seal PTFE

Valve body Brass
Piston Brass
Seal (seat) PTFE
Ordering chart for valves (other versions on request)

Brass body, with cable plug
Item no. per voltage/frequency [V/Hz]

connection
3)
Pressure
Kv value
function
[m3/h] 1)
230/UC
024/50
230/50
Orifice
Circuit
[bar] 2)
range
water
[mm]
Port
A 2/2-way valve NC Brass body, seal material PTFE/graphite

G 1/2 13 3.7 0 - 10 021 598 615 637 –
G 3/4 20 5.0 0 - 10 022 032 615 157 –
G1 25 10.0 0 - 10 021 620 615 638 –
G 1 1/4 32 16.0 0 - 10 085 385 064 919 –
G 1 1/2 40 16.0 0 - 10 085 392 085 394 –
G2 50 36.0 0 - 10 – – 085 402
1)
Measured at +20 °C, 1 bar2) pressure at valve inlet and free outlet.
2)
Pressure data [bar]: Overpressure with respect to atmospheric pressure
2)
With integrated rectifier in cable plug
I &URTHERôVERSIONSôONôREQUEST
Voltage
110/50, 24 V DC, non-standard voltages
Port connection
NPT- thread, flange body acc. to DIN 2501
Approvals
UL / CSA approval
p. 2/3
Enclosure 20071
0407
Dimensions [mm]
Threaded port Flange port acc. DIN 2501
DN D B E F G H J L
13 G 1/2 127 40 14 – 40 73 65
20 G 3/4 147 60 16 – 49 80.5 100
25 G1 157 70 18 – 49 80.5 115
32 G 1 1/4 186 85 20 – 49 80.5 126
40 G 1 1/2 195 85 22 – 49 80.5 126
50 G2 260 115 24 – 72 104.5 164
50 Flange 307.5 115 – 165 72 104.5 230
To find your nearest Bürkert facility, click on the orange box www.burkert.com
In case of special application conditions, Subject to alteration.

please consult for advice. © Christian Bürkert GmbH & Co. KG 0908/1_EU-en_00891630
p. 3/3
Enclosure 20080 CONA® 651
PN25
Steam injector (Stainless steel)

• Direct condensation of steam for heating water
Operating limits
Fig. 54.651 PN25 - 1.4301 / 1.4305
Operating pressure PS (bar-g) 17
Operating temperature TS (°C) 207
Types of connection
Internal thread ....2 Rp 1/2
and external thread R1 (acc. to DIN EN10226-1)
Fig.651....2 with internal thread (Rp 1/2) and external thread (R 1) Rp 1 up to 1 1/2 (acc. to DIN EN10226-1)
Butt weld ends ....4 acc. to DIN EN 12627
Capacity chart
Inlet pressure saturated steam (bar)
Fig.651....2 with internal thread (Rp 1 - Rp 1 1/2)
Steam flow capacity (kg/h)
Dimensions Types of connection

and Weights Internal thread Butt weld ends
(mm) DN15 DN25 DN40 DN25 DN40
Nominal diameter
(in) Rp 1/2“ Rp 1“ Rp 1 1/2“ Rp 1“ Rp 1 1/2“
L (mm) 200 87 112 87 112
External thread R (in) 1“ -- -- -- --
ØD1 (mm) 29 48 88 48 88
ØD2 (mm) -- 74 62 74 62
HEX (mm) 36 41 55 41 55
Weight approx. (kg) 0,4 1 2 1 3,4
Parts
Pos. Description Fig. 54.651....2 (1/2“) Fig. 54.651....2 (1“ - 1 1/2“) Fig. 54.651....4 (1“ - 1 1/2“)
1 Head, (cpl.) (X5CrNi18-10, 1.4301) X8CrNiS18-9, 1.4305
1.1 Head X5CrNi18-10, 1.4301 --
1.2 Pipe X5CrNi18-10, 1.4301 --
3 Nozzle -- X8CrNiS18-9, 1.4305 X5CrNi18-10, 1.4301
8 Grub screw -- A2

20086
Absperrventil für Druckmeßgeräte nach DIN 16271 401-71-A
Stand :05 / 04 Valve with test connection for pressure gauges 5.050
Absperrventil für Druckmeßgeräte nach DIN 16271 mit Prüfanschluß, Form A

Valve with test connection for pressure gauges
Bestell-Nr. Ausführung Prüfanschluß Anschluß d1 Anschluß d2 Gewicht kg

Order-No Version Test connection Thread d1 Thread d2 Weight kg
401-71-MS-PA Messing brass PA. M 20 x 1,5 Stud M 20 x 1,5 G 1/2 G 1/2 0,720
401-71-MS-FL Messing brass FL. 60 x 25 Flange 60 x 25 G 1/2 G 1/2 0,720
401-71-ST-PA Stahl Steel PA. M 20 x 1,5 Stud M 20 x 1,5 G 1/2 G 1/2 0,720
401-71-ST-FL Stahl Steel FL. 60 x 25 Flange 60 x 25 G 1/2 G 1/2 0,720
401-71-VA-PA Edelstahl Stainless steel PA. M 20 x 1,5 Stud M 20 x 1,5 G 1/2 G 1/2 0,720
401-71-VA-FL Edelstahl Stainless steel FL. 60 x 25 Flange 60 x 25 G 1/2 G 1/2 0,720
Einzelteile Werkstoff Tabelle

Components Index of Material
Ausführung Messing Ausführung Stahl Ausführung Edelstahl

Version brass Version steel Version stainless steel
Pos.1 Messing Brass Stahl Steel Edelstahl Stainless steel
Pos. 2 Stahl Steel Stahl Steel Edelstahl Stainless steel
Pos. 3 Edelstahl Stainless steel Edelstahl Stainless steel Edelstahl Stainless steel
Pos. 4 Preßstoff Plastic Preßstoff Plastic Preßstoff Plastic
Pos. 9 Messing Brass Stahl Steel Edelstahl Stainless steel
Ludwig Mohren KG Telefon / Phone 0049 (0)241 8877 - 0 E - Mail [email protected]

Telefax / Fax 0049 (0)241 8877 - 111 Homepage www.LudwigMohren.de
Enclosure 20089
Cerabar M PMC51, PMP51, PMP55

Process pressure measurement
Pressure transmitter with ceramic and metal sensors;
With analog electronics or communication via HART,
PROFIBUS PA or FOUNDATION Fieldbus

The Cerabar M pressure transmitter is used for the • Very good reproducibility and long-term stability
following measuring tasks: • High reference accuracy: up to ±0.15%,
• Absolute pressure and gauge pressure measurement in as PLATINUM version: ±0.075%
gases, steams or liquids in all areas of process • Turn down up to 100:1
engineering and process measurement technology • End-to-end modularity for differential pressure,
• Level, volume or mass measurements in liquids hydrostatics and pressure (Deltabar M – Deltapilot M –
• High process temperature Cerabar M), e.g.
– without diaphragm seals up to 130°C (266°F), for a – replaceable display
maximum of 60 minutes 150 °C (302 °F) – universal electronics
– with diaphragm seals up to 400°C (752°F) • Easy commissioning without the need for an operating
• High pressure up to 400 bar (6000 psi) tool
• International usage thanks to a wide range of approvals • Easy and safe menu-guided operation
– on-site via display module
– via 4 to 20 mA with HART
– via PROFIBUS PA
– via FOUNDATION Fieldbus
• Device versions compliant with ASME-BPE
• Used for process pressure monitoring up to SIL2,
certified to IEC 61508 Edition 2.0 and IEC 61511 by
TÜV NORD
TI00436P/00/EN/16.12
No. 71157149
Enclosure 20089 Cerabar M PMC51, PMP51, PMP55
Table of contents
Function and system design. . . . . . . . . . . . . . . . . . . . . 4 Total performance – PMP51 . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Device selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Total error - PMP51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Thermal change in the zero output and the output span –
Level measurement (level, volume and mass) . . . . . . . . . . . . . . . . 6 PMP51 and PMP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical differential pressure measurement with gauge pressure
sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operating conditions (installation) . . . . . . . . . . . . . . 26
System integration (except analog electronics) . . . . . . . . . . . . . . . . 6 General installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . 26
Communication protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Measuring arrangement for devices without diaphragm seal –
PMC51, PMP51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Measuring arrangement for devices with diaphragm seal
Measured variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – PMP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Measuring range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wall and pipe mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Explanation of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 "Separate housing" version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oxygen applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PWIS cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Ultrapure gas applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Applications with hydrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Signal range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Signal on alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Load - 4 to 20 mA analog and 4 to 20 mA HART . . . . . . . . . . . . 11 Operating conditions (environment) . . . . . . . . . . . . . 29
Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Ambient temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dead time, Time constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Storage temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dynamic behavior: current output (analog electronics) . . . . . . . . 12 Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dynamic behavior: current output (HART electronics) . . . . . . . . 12 Climate class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dynamic behavior: digital output (HART electronics) . . . . . . . . . 12 Vibration resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dynamic behavior: PROFIBUS PA . . . . . . . . . . . . . . . . . . . . . . . . 13 Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dynamic behavior: FOUNDATION Fieldbus . . . . . . . . . . . . . . . . 13 Overvoltage protection (optional) . . . . . . . . . . . . . . . . . . . . . . . . 30
Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Data of the FOUNDATION Fieldbus interface . . . . . . . . . . . . . . . 14 Operating conditions (process) . . . . . . . . . . . . . . . . . 31
Process temperature range PMC51 . . . . . . . . . . . . . . . . . . . . . . . 31
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Process temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Pressure specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Start-up current HART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Mechanical construction . . . . . . . . . . . . . . . . . . . . . . 33
Current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F31 aluminum housing dimensions . . . . . . . . . . . . . . . . . . . . . . 33
Cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F15 stainless steel housing dimensions (hygienic) . . . . . . . . . . . . 33
Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Process connections PMC51 (with ceramic process isolating
Residual ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 diaphragm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Influence of power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Process connections PMP51 (with metal process isolating
diaphragm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Performance characteristics – general . . . . . . . . . . . . 19 PMP55 basic device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Reference operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Process connections PMP55 (with diaphragm seal) . . . . . . . . . . . 50
Uncertainty of measurement for small absolute pressure ranges . . 19 Wall and pipe mounting with mounting bracket . . . . . . . . . . . . 67
Long-term stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Influence of orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Material (not wetted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Warm-up period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Material (wetted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Performance characteristics – ceramic process isolating Human interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Reference accuracy – PMC51 . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Onsite operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Total performance – PMC51 . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remote operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Total error - PMC51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hardware and software for onsite and remote operation . . . . . . . 76
Thermal change in the zero output and the output span –
PMC51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Planning instructions for diaphragm seal systems . . . 77
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Performance characteristics – metal process isolating Function and design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Diaphragm seal filling oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Reference accuracy – PMP51, PMP55 . . . . . . . . . . . . . . . . . . . . 23 Operating temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2 Endress+Hauser
Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Certificates and approvals . . . . . . . . . . . . . . . . . . . . . 81

CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Ex approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Suitability for hygienic processes . . . . . . . . . . . . . . . . . . . . . . . . 81
Functional safety SIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Pharma (CoC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CRN approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Pressure Equipment Directive (PED) . . . . . . . . . . . . . . . . . . . . . 81
Drinking water approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
North-American practice for installation of process seals . . . . . . . 82
Ordering information . . . . . . . . . . . . . . . . . . . . . . . . 83
PMC51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
PMC51 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PMC51 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
PMC51 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
PMP51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
PMP51 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
PMP51 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
PMP51 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
PMP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
PMP55 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
PMP55 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
PMP55 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
PMP55 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
PMP55 (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Brief Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Functional safety manual (SIL) . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Installation/Control Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 100
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Siphon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Welding necks and Weld-in tool flanges . . . . . . . . . . . . . . . . . . 102
Mounting bracket for wall and pipe mounting . . . . . . . . . . . . . 102
M12 connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Configuration data sheet (HART, PROFIBUS PA,

FOUNDATION Fieldbus electronics) . . . . . . . . . . . 103
Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Configuration data sheet (analog electronics) . . . . . 105

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3 Endress+Hauser

Device selection
Cerabar M – PMC51 PMP51 PMP55

Product family
P01-PMC51xxx-16-xx-xx-xx-000 P01-PMP51xxx-16-xx-xx-xx-000 P01-PMP55xxx-16-xx-xx-xx-000
With capacitive measuring cell and With piezoresistive measuring cell With diaphragm seal
ceramic process isolating diaphragm and metal welded process isolating
(Ceraphire®) diaphragm
Field of application – Gauge pressure and absolute pressure
– Level
Process connections – Thread – Thread – Wide range of diaphragm seals

– EN flanges DN 25 – DN 80 – EN flanges DN 25 – DN 80
– ANSI flanges 1" – 4" – ANSI flanges 1" – 4"
– JIS flanges 50 A – 100 A – JIS flanges 25 A – 100 A
– Flush-mounted hygienic connections – Prepared for diaphragm seal mount
– Flush-mounted hygienic
connections
Measuring ranges From –100/0 to 100 mbar (–1.5/0 to From –400/0 to 400 mbar (–6/0 to 6 psi)
1.5 psi) to –1/0 to 400 bar (–15/0 to 6000 psi)
to –1/0 to 40 bar (–15/0 to 600 psi)
OPL 1) Max. 60 bar (900 psi) Max. 600 bar (9000 psi)
Process temperature range –40 to +130 °C (–40 to +266°F) –40 to +125°C (–40 to +257°F) –70 to 400 °C (–94 to +752 °F)
For a maximum of 60 minutes: +150 °C For a maximum of 60 minutes: +150 depending on the filling oil
(+302 °F) °C (+302 °F)
Ambient temperature range – Without LCD display: -40 to +85°C (–40 to +185 °F)
– With LCD display: –20 to +70°C (–4 to +158°F) (extended temperature application range (-40 to 85°C (-40 to 185°F)) with
restrictions in optical properties such as display speed and contrast)
– Separate housing: –20 to +60°C (–4 to +140°F)
– Diaphragm seal systems depending on the version
Reference accuracy – Up to ±0.15% of the set span Up to ±0.15% of the set span
– PLATINUM version: up to ±0.075% of the set span
Supply voltage – 11.5 to 45 V DC (versions with plug-in connection 35 V DC)

– For intrinsically safe device versions: 11.5 to 30 V DC
Output 4 to 20 mA, 4 to 20 mA with superimposed HART protocol
Options – PMP51, PMP55: NACE-compliant materials

– PMC51, PMP51, PMP55: inspection certificate 2.2 or 3.1 or other certificates
– 3A approval and EHEDG approval
– Specific firmware versions
– Initial device settings
– Separate housing
– Broad range of accessories
Specialties – Metal-free measurement with PVDF – Process connections with minimum – Wide range of diaphragm seals
connection oil volume – For extreme medium temperatures
– Special cleaning of the transmitter to – Gas-tight, elastomer-free – Process connections with minimum
remove paint-wetting substances, for use oil volume
in paint shops – Completely welded versions
1) OPL = over pressure limit; depends on the lowest-rated element, with regard to pressure, of the selected components
4 Endress+Hauser
Cerabar M PMC51, PMP51, PMP55 Enclosure 20089
Measuring principle
Ceramic process isolating diaphragm used in PMC51 (Ceraphire®) Metal process isolating diaphragm used in PMP51 and PMP55
➀ ➁ ➂
➀
➁
➃ ➂
➃
p p
P01-PMC71xxx-03-xx-xx-xx-000 P01-PMP7xxxx-03-xx-xx-xx-000
Ceramic sensor Metal sensor

1 Air pressure (gauge pressure sensors) 1 Silicon measuring element, substrate
2 Ceramic substrate 2 Wheatstone bridge
3 Electrodes 3 Channel with fill fluid
4 Ceramic process isolating diaphragm 4 Metal process isolating diaphragm
Ceramic process isolating diaphragm used in PMC51 (Ceraphire®)

The ceramic sensor is a dry sensor, i.e. the process pressure acts directly on the robust ceramic process isolating
diaphragm and deflects it. A pressure-dependent change in capacitance is measured at the electrodes of the
ceramic substrate and the process isolating diaphragm. The measuring range is determined by the thickness of
the ceramic process isolating diaphragm.
Advantages:
• Guaranteed overload resistance up to 40 times the nominal pressure
• Thanks to ultrapure 99.9% ceramic (Ceraphire®, see also "www.endress.com/ceraphire")
– extremely high chemical stability, comparable with Alloy C
– less relaxation
– high mechanical stability
• Can be used in absolute vacuum
• Outstanding surface finish, Ra ≤0.3 μm (11.8 μin)
Metal process isolating diaphragm used in PMP51 and PMP55
PMP51
The operating pressure deflects the process isolating diaphragm and a fill fluid transfers the pressure to a
resistance bridge (semiconductor technology). The pressure-dependent change in the bridge output voltage is
measured and evaluated.
Advantages:
• Can be used for process pressure up to 400 bar (6000 psi)
• High long-term stability
• Significantly less thermal effect compared to diaphragm seal systems
PMP55
The operating pressure acts on the process isolating diaphragm of the diaphragm seal and is transferred to the
process isolating diaphragm of the sensor by a diaphragm seal fill fluid. The process isolating diaphragm is
deflected and a fill fluid transfers the pressure to a resistance bridge. The pressure-dependent change in the
bridge output voltage is measured and evaluated.
Advantages:
• Depending on the version, can be used for process pressure up to 400 bar (6000 psi) and simultaneous
extreme process temperatures
• High long-term stability
Endress+Hauser 5
Level measurement (level, Function and design

volume and mass)
p
h= r g
P01-PMx5xxxx-15-xx-xx-xx-000
Level measurement
h Height (level)
p Pressure
ρ Density of the medium
g Gravitation constant
Your benefits
• Choice of different level measuring modes in the device software
• Volume and mass measurements in any tank shapes by means of a freely programmable characteristic curve
• Choice of diverse level units
• Has a wide range of uses, even in the following cases:
– in the event of foam formation
– in tanks with agitators or screen fittings
– in the event of liquid gases
Electrical differential pressure

measurement with gauge
pressure sensors
Cerabar M
FXN 520
➀ ➀
Fieldgate Multidrop-Connector ➁
FXA520 FXN520
P01-PMX51xxx-14-xx-xx-xx-001
1 Shut-off valves
2 e.g. filter
In the example given, two Cerabar M devices (each with a gauge pressure sensor) are interconnected. The
pressure difference can thus be measured using two independent Cerabar M devices.
Caution!
If using intrinsically safe devices, strict compliance with the rules for interconnecting intrinsically safe circuits
as stipulated in IEC60079-14 (proof of intrinsic safety) is mandatory.
System integration (except The device can be fitted with a tag name and a preset bus address, see → ä 83 ff "Ordering information"
analog electronics) feature 895 "Identification:" version "Z1" and "Z2".
6 Endress+Hauser
Communication protocol • 4 to 20 mA without communication protocol (analog electronics)

• 4 to 20 mA with HART communication protocol
• PROFIBUS PA
– The Endress+Hauser devices meet the requirements of the FISCO model.
– Due to the low current consumption of 11 mA ± 1 mA, the following number of devices can be operated
on one bus segment if installing as per FISCO:
– up to 8 Cerabar M for Ex ia, CSA IS and FM IS applications
– up to 31 Cerabar M for all other applications, e.g. in non-hazardous areas, Ex nA, etc.
Further information on PROFIBUS PA can be found in Operating Instructions BA00034S "PROFIBUS DP/
PA: Guidelines for planning and commissioning" and in the PNO Guideline.
• FOUNDATION Fieldbus
– The Endress+Hauser devices meet the requirements of the FISCO model.
– Due to the low current consumption of 16 mA ± 1 mA, the following number of devices can be operated
on one bus segment if installing as per FISCO:
– up to 6 Cerabar M for Ex ia, CSA IS and FM IS applications
– up to 22 Cerabar M for all other applications, e.g. in non-hazardous areas, Ex nA, etc.
Further information on FOUNDATION Fieldbus, such as requirements for bus system components can be
found in Operating Instructions BA00013S "FOUNDATION Fieldbus Overview".
Endress+Hauser 7
Input
Measured variable • Analog electronics: Absolute pressure and gauge pressure
• HART electronics: Absolute pressure and gauge pressure, from which level (level, volume or mass) is derived
Measuring range PMC51 – with ceramic process isolating diaphragm (Ceraphire®) for gauge pressure
Nominal value Range limit Smallest MWP 2) OPL 3) Vacuum Version in

calibratable span resistance the order
(preset at the code4)
factory) 1)
lower (LRL) upper (URL)
[bar (psi)] [bar (psi)] [bar (psi)] [bar (psi)] [bar (psi)] [barabs (psiabs)]
100 mbar (1.5 psi) –0.1 (–1.5) +0.1 (+1.5) 0.01 (0.15) 2.7 (40.5) 4 (60) 0.7 (10.5) 1C
250 mbar (4 psi) –0.25 (–4) +0.25 (+4) 0.01 (0.15) 3.3 (49.5) 5 (75) 0.5 (7.5) 1E
400 mbar (6 psi) –0.4 (–6) +0.4 (+6) 0.02 (0.3) 5.3 (79.5) 8 (120) 0 1F
1 bar (15 psi) –1 (–15) +1 (+15) 0.05 (1) 6.7 (100.5) 10 (150) 0 1H
2 bar (30 psi) –1 (–15) +2 (+30) 0.1 (1.5) 12 (180) 18 (270) 0 1K

4 bar (60 psi) –1 (–15) +4 (+60) 0.2 (3) 16.7 (250.5) 25 (375) 0 1M
10 bar (150 psi) –1 (–15) +10 (+150) 0.5 (7.5) 26.7 (400.5) 40 (600) 0 1P
40 bar (600 psi) –1 (–15) +40 (+600) 2 (30) 40 (600) 60 (900) 0 1S
PMC51 – with ceramic process isolating diaphragm (Ceraphire®) for absolute pressure
Nominal value Range limit Smallest MWP 2) OPL 3) Vacuum Version in

calibratable span resistance the order
(preset at the code4)
factory)1)
[barabs (psiabs)] [barabs (psiabs)] [bar (psi)] [barabs (psiabs)] [barabs (psiabs)] [barabs (psiabs)]
100 mbar (15 psi) 0 +0.1 (+1.5) 0.01 (0.15) 2.7 (40.5) 4 (60) 0 2C
250 mbar (4 psi) 0 +0.25 (+4) 0.01 (0.15) 3.3 (49.5) 5 (75) 0 2E
400 mbar (6 psi) 0 +0.4 (+6) 0.02 (0.3) 5.3 (79.5) 8 (120) 0 2F
1 bar (15 psi) 0 +1 (+15) 0.05 (1) 6.7 (100.5) 10 (150) 0 2H
2 bar (30 psi) 0 +2 (+30) 0.1 (1.5) 12 (180) 18 (270) 0 2K
4 bar (60 psi) 0 +4 (+60) 0.2 (3) 16.7 (250.5) 25 (375) 0 2M
10 bar (150 psi) 0 +10 (+150) 0.5 (7.5) 26.7 (400.5) 40 (600) 0 2P
40 bar (600 psi) 0 +40 (+600) 2 (30) 40 (600) 60 (900) 0 2S
1) Recommended turn down: Max 10:1.

Factory calibration turn down: Max 20:1, higher on request or configurable in the device.
2) The MWP (maximum working pressure) for the measuring device depends on the lowest-rated element, with regard to pressure, of the selected components,
i.e. the process connection (→ ä 33 ff) has to be taken into consideration in addition to the measuring cell (→ see Table above). Pay attention to the pressure-
temperature dependence also. For the appropriate standards and other information, see → ä 32, "Pressure specifications" section.
3) OPL: over pressure limit depends on the lowest-rated element, with regard to pressure, of the selected components
4) Version in the order code → see also → ä 83 ff, feature 70 "Sensor range"
8 Endress+Hauser
PMP51 and PMP55 – metal process isolating diaphragm for gauge pressure
Nominal value Range limit Smallest MWP 2) OPL 3) Vacuum Version in the
calibratable span resistance 4) order code5)
(preset at the
Silicone oil/
factory) 1)
Inert oil
[bar (psi)] [bar (psi)] [bar (psi)] [bar (psi)] [bar (psi)] [barabs (psiabs)]
400 mbar (6 psi) –0.4 (–6) +0.4 (+6) 0.02 (0.3) 4 (60) 6 (90) 1F
1 bar (15 psi) –1 (–15) +1 (+15) 0.05 (1) 6.7 (100) 10 (150) 1H
2 bar (30 psi) –1 (–15) +2 (+30) 0.1 (1.5) 13.3 (200) 20 (300) 1K
4 bar (60 psi) –1 (–15) +4 (+60) 0.2 (3) 18.7 (280.5) 28 (420) 0.01/0.04 1M
10 bar (150 psi) –1 (–15) +10 (+150) 0.5 (7.5) 26.7 (400.5) 40 (600) (0.15/0.6) 1P
40 bar (600 psi) –1 (–15) +40 (+600) 2 (30) 100 (1500) 160 (2400) 1S
100 bar (1500 psi) –1 (–15) +100 (+1500) 5 (75) 100 (1500) 400 (6000) 1U
400 bar (6000 psi) –1 (–15) +400 (+6000) 20 (300) 400 (6000) 600 (9000) 1W
PMP51 and PMP55 – metal process isolating diaphragm for absolute pressure
Nominal value Range limit Smallest MWP 2) OPL 3) Vacuum Version in the
calibratable span resistance 4) order code 5)
(preset at the
factory) 1) Silicone oil/
Inert oil

[barabs (psiabs)] [barabs (psiabs)] [bar (psi)] [barabs (psiabs)] [barabs (psiabs)] [barabs (psiabs)]
400 mbar (6 psi) 0 +0.4 (+6) 0.02 (0.3) 4 (60) 6 (90) 2F
1 bar (15 psi) 0 +1 (+15) 0.05 (1) 6.7 (100) 10 (150) 2H

2 bar (30 psi) 0 +2 (+30) 0.1 (1.5) 13.3 (200) 20 (300) 2K
4 bar (60 psi) 0 +4 (+60) 0.2 (3) 18.7 (280.5) 28 (420) 0.01/0.04 2M
10 bar (150 psi) 0 +10 (+150) 0.5 (7.5) 26.7 (400.5) 40 (600) (0.15/0.6) 2P
40 bar (600 psi) 0 +40 (+600) 2 (30) 100 (1500) 160 (2400) 2S
100 bar (1500 psi) 0 +100 (+1500) 5 (75) 100 (1500) 400 (6000) 2U
400 bar (6000 psi) 0 +400 (+6000) 20 (300) 400 (6000) 600 (9000) 2W
1) Recommended turn down: Max 10:1.

Factory calibration turn down: Max 20:1, higher on request or configurable in the device.
2) The MWP (maximum working pressure) for the measuring device depends on the lowest-rated element, with regard to pressure, of the selected components,
i.e. the process connection (→ ä 33 ff) has to be taken into consideration in addition to the measuring cell (→ see Table above). Pay attention to the pressure-
temperature dependence also. For the appropriate standards and other information, see → ä 32, "Pressure specifications" section.
3) OPL: over pressure limit (= sensor overload limit)
4) The vacuum resistance applies to the measuring cell at reference conditions. The pressure and temperature application limits of the selected filling oil must
also be observed for the PMP55. → ä 78, "Diaphragm seal filling oils" section.
5) Version in the order code → ä 83 ff, feature 70 "Sensor range"
Endress+Hauser 9
Explanation of terms Explanation of terms: turn down (TD),

set span and span based on zero point
Case 1:
• ⏐Lower range value (LRV)⏐ ≤ ⏐Upper range value ➀=➁
(URV)⏐
LRL = LRV URV URL
Example:
• Lower range value (LRV) = 0 bar
0 bar 0.5 bar +1 bar
• Upper range value (URV) = 0.5 bar (7.5 psi)
• Nominal value (URL) = 1 bar (15 psi)
Turn down: ➂
• TD = URL / ⏐URV⏐ = 2:1
Set span: ➃=➄
• URV – LRV = 0.5 bar (7.5 psi)
This span is based on the zero point. Example: 1 bar (15 psi) measuring cell
Case 2:
• ⏐Lower range value (LRV)⏐ ≤ ⏐Upper range value ➀=➁
(URV)⏐
LRL LRV URV URL
Example:
• Lower range value (LRV) = 0 bar –1 bar 0 0.5 bar +1 bar
• Upper range value (URV) = 0.5 bar (7.5 psi)
Turn down: ➂
• TD = URL / ⏐URV⏐ = 2:1
➃
Set span:
• URV – LRV = 0.5 bar (7.5 psi) ➄
This span is based on the zero point. P01-PMx7xxxx-05-xx-xx-xx-007.
Example: 1 bar (15 psi) measuring cell
Case 3:
• ⏐Lower range value (LRV)⏐ ≥ ⏐Upper range value ➀=➁
(URV)⏐
LRL LRV URV URL
Example:
• Lower range value (LRV) = –0.6 bar (–9 psi)
–1 bar –0.6 bar 0 +1 bar
• Upper range value (URV) = 0 bar
Turn down: ➂
• TD = URL / ⏐LRV⏐ = 1.67:1
Set span:
➃
• URV – LRV = 0.6 bar (–9 psi) ➄
This span is based on the zero point. P01-PMx7xxxx-05-xx-xx-xx-008
Example: 1 bar (15 psi) measuring cell
1 Set span
2 Span based on zero point
3 Nominal value i upper range limit (URL)
4 Nominal measuring range
5 Sensor measuring range
LRL Lower range limit
URL Upper range limit
LRV Lower range value
URV Upper range value
10 Endress+Hauser
Output
Output signal • 4 to 20 mA analog, 2-wire
• 4 to 20 mA with superimposed digital communication protocol HART 6.0, 2-wire
• Digital communication signal PROFIBUS PA (Profile 3.02)
• Digital communication signal FOUNDATION Fieldbus
Signal range 4 to 20 mA analog, 4 to 20 mA HART: 3.8 to 20.5 mA
Signal on alarm As per NAMUR NE 43

• 4 to 20 mA Analog:
– Signal overshoot: > 20.5 mA
– Signal undershoot: < 3.8 mA
– Min Alarm (3.6 mA)
• 4 to 20 mA HART
Options:
– Max. alarm: can be set from 21 to 23 mA (factory setting: 22 mA)
– Hold measured value: last measured value is held
– Min. alarm: 3.6 mA
• PROFIBUS PA: can be set in the Analog Input block,
Options: Last Valid Out Value (factory setting), Fail-safe Value, Status Bad
• FOUNDATION Fieldbus: can be set in the Analog Input block,
Options: Last Good Value, Fail-safe Value (factory setting), Wrong Value
Load - 4 to 20 mA analog and

4 to 20 mA HART RLmax
[W]
1456
1239
804
➁
369
➀
11.5 20 30 40 45 U
[V]
U – 11.5 V
RLmax £
0.023 A
P01-xxxxxxxx-05-xx-xx-xx-002
Load diagram
1 Power supply 11.5 to 30 V DC for intrinsically safe device versions
2 Power supply 11.5 to 45 V DC (versions with plug-in connector 35 V DC) for other types of protection and for
uncertified device versions
RLmax Maximum load resistance
U Supply voltage
Note!
When operating via a handheld terminal or via a PC with an operating program, a minimum communication
resistance of 250 Ω must be taken into account.
Resolution • Current output: 1 μA

• Display HART: can be set (factory setting: presentation of the maximum accuracy of the transmitter)
Endress+Hauser 11
Dead time, Time constant

I
100 %
90 %
63 %
t1 t2 t
t3
Presentation of the dead time and the time constant
Dynamic behavior: Type Dead time (t1) [ms] Time constant T63 Time constant T90
current output (analog (= t2) [ms] (= t3) [ms]
electronics)
max. PMC51 60 40 50
max. PMP51 40 40 50
max. PMP55 PMP51 + influence of the diaphragm seal
Dynamic behavior: Type Dead time (t1) [ms] Time constant T63 Time constant T90
current output (HART (= t2) [ms] (= t3) [ms]
electronics)
max. PMC51 50 85 200
max. PMP51 70 80 185
Dynamic behavior: digital Type Dead time (t1) [ms] Dead time (t1) [ms] + Dead time (t1) [ms] +
output (HART electronics) Time constant T63 (= t2) [ms] Time constant T90 (= t3) [ms]
min. 210 295 360

PMC51
max. 1010 1095 1160
min. 210 285 345

PMP51
max. 1010 1085 1145
Reading cycle
• Acyclic: max. 3/s, typical 1/s (depends on command # and number of preambles)
• Cyclic (Burst): max. 3/s, typical 2/s
The Cerabar M commands the BURST MODE function for cyclic value transmission via the HART
communication protocol.
Cycle time (Update time)

Cyclic (Burst): min. 300 ms
Response time
• Acyclic: min. 330 ms, typical 590 ms (depends on command # and number of preambles)
• Cyclic (Burst): min. 160 ms, typical 350 ms (depends on command # and number of preambles)
12 Endress+Hauser
Dynamic behavior: Type Dead time (t1) [ms] Dead time (t1) [ms] + Dead time (t1) [ms] +
PROFIBUS PA Time constant T63 (= t2) [ms] Time constant T90 (= t3) [ms]
min. 85 170 235
PMC51
max. 1185 1270 1335
min. 85 160 220

PMP51
max. 1185 1260 1320
Reading cycle
• Cyclic: max. 30/s (dependent on the number and type of function blocks used in a closed-control loop)
• Acyclic: typical 25/s
Cycle time (update time)

min. 100 ms
The cycle time in a bus segment in cyclic data communication depends on the number of devices, on the
segment coupler used and on the internal PLC cycle time.
Response time
• Cyclic: approx. 8 to 13 ms (depends on Min. Slave Interval)
• Acyclic: approx. 23 to 35 ms (depends on Min. Slave Interval)
Dynamic behavior: Type Dead time (t1) [ms] Dead time (t1) [ms] + Dead time (t1) [ms] +
FOUNDATION Fieldbus Time constant T63 (= t2) [ms] Time constant T90 (= t3) [ms]
min. 95 180 245

PMC51
max. 1095 1180 1245
min. 95 170 230
PMP51
max. 1095 1170 1230
Reading cycle
• Cyclic: max. 10/s (dependent on the number and type of function blocks used in a closed-control loop)
• Acyclic: typical 5/s
Cycle time (update time)

Cyclic: min. 100 ms
Response time
• Cyclic: max. 20 ms (for standard bus parameter settings)
• Acyclic: typical 70 ms (for standard bus parameter settings)
Damping A damping affects all outputs (output signal, display).

• Via on-site display, handheld terminal or PC with operating program, continuous from 0...999 s
• Via DIP-switch on the electronic insert, switch position
"on" (= set value) and "off" (= damping switched off)
• Factory setting: 2 s
Endress+Hauser 13
Data of the FOUNDATION Basic data

Fieldbus interface
Device Type 0x1019
Device Revision 01 (hex)
DD Revision 0x01021
CFF Revision 0x000102
ITK Version 5.2.0
ITK Certification Driver No. IT067700

Link-Master (LAS) capable Yes
Link Master / Basic Device Yes; Factory setting: Basic Device

selectable
Number of VCRs 44
Number of Link Objects in VFD 50
Number of FB-Schedule Objects 40
Virtual communication references (VCRs)
Permanent Entries 44
Client VCRs 0
Server VCRs 5
Source VCRs 8
Sink VCRs 0
Subscriber VCRs 12
Publisher VCRs 19
Link settings
Slot time 4
Min. inter PDU delay 12
Max. response delay 40
Transducer Blocks
Block Content Output values
TRD1 Block Contains all parameters related to the measurement • Pressure or level (channel 1)
• Process temperature (channel 2)
• Measured pressure value (channel 3)
• Max. pressure (channel 4)
• Level before linearization (channel 5)
Diagnostic Block Contains diagnostic information Error code via DI channels
(channel 10 to 15)
Display Block Contains parameters to configure the onsite display No output values
14 Endress+Hauser
Function blocks
Block Content Number Execution time Functionality

of blocks
Resource Block The Resource Block contains all the data that 1 enhanced
uniquely identify the device. It is an electronic
version of a nameplate of the device.
Analog Input The AI Block receives the measuring data from the 2 25 ms enhanced
Block 1 Sensor Block, (selectable via a channel number) and
Analog Input makes the data available to other function blocks at
Block 2 its output. Enhancement: digital outputs for process
alarms, fail safe mode.
Digital Input This block contains the discrete data of the Diagnose 1 20 ms standard
Block Block (selectable via a channel number 10 to 15) and
provides them for other blocks at the output.
Digital Output This block converts the discrete input and thus 1 20 ms standard
Block initiates an action (selectable via a channel number)
in the DP Flow Block or in the im TRD1 Block.
Channel 20 resets the counter for max. pressure
transgressions value and Channel 21 resets the
Totalizer.
PID Block The PID Block serves as a proportional-integral- 1 40 ms standard
derivative controller and is used almost universally
for closed-loop-control in the field including cascade
and feedforward. Input IN can be indicated on the
display. The selection is performed in the Display
Block (DISPLAY_MAIN_LINE_CONTENT).
Arithmetic This block is designed to permit simple use of popular 1 35 ms standard

Block measurement math functions. The user does not have
to know how to write equations. The math algorithm
is selected by name, chosen by the user for the
function to be performed.
Input Selector The Input Selector Block facilitates the selection of up 1 30 ms standard
Block to four inputs and generates an output based on the
configured action. This block normally receives its
inputs from AI Blocks. The block performs maximum,
minimum, average and ‘first good’ signal selection.
Inputs IN1 to IN4 can be indicated on the display.
The selection is performed in the Display Block
(DISPLAY_MAIN_LINE_1_CONTENT).
Signal The Signal Characterizer Block has two sections, 1 40 ms standard

Characterizer each with an output that is a non-linear function of
Block the respective input. The non-linear function is
generated by a single look-up table with 21 arbitrary
x-y pairs.
Integrator The Integrator Block integrates a variable as a 1 35 ms standard

Block function of the time or accumulates the counts from a
Pulse Input Block. The block may be used as a
totalizer that counts up until reset or as a batch
totalizer that has a setpoint, where the integrated or
accumulated value is compared to pre-trip and trip
settings, generating a binary signal when the setpoint
is reached.
Additional function block information:

Instantiate Function Block YES
Number of instantiate blocks 20
Endress+Hauser 15
Power supply
Electrical connection Note!
• When using the measuring device in hazardous areas, installation must comply with the corresponding
national standards and regulations and the Safety Instructions or Installation or Control Drawings.
→ ä 99 ff, "Safety Instructions" and "Installation/Control Drawings" sections.
• According to IEC/EN61010 a suitable disconnector has to be installed for the device
• HART: Overvoltage protection HAW569-DA2B for the non-hazardous area, ATEX II 2 (1) Ex ia IIC and IEC
Ex ia can be ordered as an option (see "Ordering information" section).
• Protective circuits against reverse polarity, HF influences and overvoltage peaks are installed.
• The digital communication signal is transmitted to the bus via a 2-wire connection. The bus also provides
the power supply.
- +
6
2
5
3
P01-xMx5xxxx-04-xx-xx-xx-004
1 External grounding terminal
2 Internal grounding terminal
3 Supply voltage → ä 18
4 4...20 mA for HART devices
5 For HART and FOUNDATION Fieldbus devices: With a handheld terminal, all the parameters can be configured
anywhere along the bus line via menu operation.
6 Terminals
7 For HART devices: test terminals, see section "Taking 4 to 20 mA test signal"
4 to 20 mA Analog, 4 to 20 mA HART
Taking 4 to 20 mA test signal

A 4 to 20 mA test signal may be measured via the test terminals without interrupting the measurement.
PROFIBUS PA
For further information on the network structure and grounding, and for further bus system components such
as bus cables, see the relevant documentation, e.g. Operating Instructions BA00034S "PROFIBUS DP/PA:
Guidelines for planning and commissioning" and the PNO Guideline.
Cable specifications:
Use a twisted, shielded two-wire cable, preferably cable type A
Note!
For further information on the cable specifications, see Operating Instructions BA00034S
"PROFIBUS DP/PA: Guidelines for planning and commissioning", the PNO Guideline 2.092
16 Endress+Hauser
PROFIBUS PA User and Installation Guideline" and IEC 61158-2 (MBP).
FOUNDATION Fieldbus
The digital communication signal is transmitted to the bus via a 2-wire connection. The bus also provides the
power supply. For further information on the network structure and grounding and for further bus system
components such as bus cables, see the relevant documentation, e.g. Operating Instructions BA00013S
"FOUNDATION Fieldbus Overview" and the FOUNDATION Fieldbus Guideline.
Cable specifications:
Use a twisted, shielded two-wire cable, preferably cable type A
Note!
For further information on the cable specifications, see Operating Instructions BA00013S "FOUNDATION
Fieldbus Overview", FOUNDATION Fieldbus Guideline and IEC 61158-2 (MBP).
Devices with valve connector
+ –
– +
+ –
Left: electrical connection for devices with a valve connector

Right: view of the connector at the device
Material: PA 6.6
Devices with Harting plug Han7D
+
7
+ – – 8 6
1
2 5
3 4
Han7D
+ –
P01-xMD7xxxx-04-xx-xx-xx-000
Left: electrical connection for devices with Harting plug Han7D

Right: view of the plug connector at the device
Material: CuZn
Endress+Hauser 17
Devices with M12 plug
PIN assignment for M12 connector
PIN Meaning
1 Signal +
4 3 –
2 Not assigned
3 Signal –
1 + 2 nc
4 Earth
A0011175
Endress+Hauser offers the following accessories for devices with an M12 plug:
Plug-in jack M 12x1, straight
• Material: body PA; coupling nut CuZn, nickel-plated
• Degree of protection (fully locked): IP66/67
• Order number: 52006263
Plug-in jack M 12x1, elbowed
• Material: body PBT/PA; coupling nut GD-Zn, nickel-plated
Cable 4x0.34 mm² (20 AWG) with M12 socket, elbowed, screw plug, length 5 m (16 ft)
• Material: body PUR; coupling nut CuSn/Ni; cable PVC
Devices with 7/8" plug
PIN assignment for 7/8" connector
PIN Meaning
1 Signal –
1 – 3 nc
2 Signal +
3 Not assigned
2 + 4
4 Earth
A0011176
External thread: 7/8 - 16 UNC

• Material: housing / body CuZn, nickel-plated
• Protection: IP66/68
Cable gland
Approval Type Clamping area
Standard, II1/2G Exia, IS Plastic M20x1.5 5 to 10 mm (0.2 to 0.39 in)
ATEX II1/2D, II1/2GD Exia, II3G Ex nA Metal M20x1.5 (Ex e) 7 to 10.5 mm (0.28 to 0.41 in)
Terminals
For wire cross-sections of 0.5 to 2.5 mm² (20 to 14 AWG).
Supply voltage Note!

• When using the measuring device in hazardous areas, installation must comply with the corresponding
national standards and regulations and the Safety Instructions or Installation or Control Drawings.
• All explosion protection data are given in separate documentation which is available upon request. The
Ex documentation is supplied as standard with all devices approved for use in explosion hazardous areas.
18 Endress+Hauser
4 to 20 mA, 4 to 20 mA HART
Type of protection Supply voltage
• Intrinsically safe 11.5 ... 30 V DC
• Other types of protection 11.5 ... 45 V DC (Versions with plug-in connection 35 V DC)
• Devices without certificate
PROFIBUS PA
• Version for non-hazardous areas: 9 to 32 V DC
FOUNDATION Fieldbus
• Version for non-hazardous areas: 9 to 32 V DC
Start-up current HART 12 mA or 22 mA (selectable)
Current consumption • PROFIBUS PA: 11 mA ± 1 mA, switch-on current corresponds to IEC 61158-2, Clause 21
• FOUNDATION Fieldbus: 16 mA ± 1 mA, switch-on current corresponds to IEC 61158-2, Clause 21
Cable entry → ä 83 ff, feature 50 "Electrical connection".
Cable specification • Endress+Hauser recommends using twisted, shielded two-wire cables.

• Terminals for wire cross-sections 0.5 to 2.5 mm2 (20 to 14 AWG)
• Cable outer diameter: 5 to 9 mm (0.2 to 0.35 in) depends on the used cable gland (→ ä 18)
Residual ripple No influence on 4 to 20 mA signal up to ± 5 % residual ripple within the permitted voltage range [according to
HART hardware specification HCF_SPEC-54 (DIN IEC 60381-1)]
Influence of power supply ≤ 0.001% of URL/1 V
Performance characteristics – general

Reference operating • As per IEC 60770
conditions • Ambient temperature TA = constant, in the range of: +21 to +33°C (+70 to +91°F)
• Humidity ϕ = constant, in the range of: 5 to 80 % RH
• Ambient pressure pA = constant, in the range of: 860 to 1060 mbar (12.47 to 15.37 psi)
• Position of the measuring cell: constant, in range: ±1° horizontally
• Input of LOW SENSOR TRIM and HIGH SENSOR TRIM for lower range value and upper range value
• Span based on zero point
• Material of the process isolating diaphragm PMC51: Al2O3 (aluminum-oxide ceramic, Ceraphire®)
• Material of the process isolating diaphragm PMP51 and PMP55: AISI 316L
• Filling oil PMP51 and PMP55: silicone oil
• Supply voltage: 24 V DC ± 3 V DC
• Load with HART: 250 Ω
Uncertainty of measurement The smallest expanded uncertainty of measurement that can be returned by our standards is:
for small absolute pressure • 0.4% of the measured value in the range of 1 to 30 mbar
ranges • 1% of the measured value in the range < 1 mbar.
Endress+Hauser 19
Long-term stability PMC51 Measuring range Long-term stability of URL / 1 year
PMC51 with thread or flange ≤ 1 bar (15 psi) ±0.2 %
> 1 bar (15 psi) ±0.1 %
PMC51 with hygienic process ≤ 1 bar (15 psi) ±0.35 %

connection
> 1 bar (15 psi) ±0.2 %
PMP51 Long-term stability of URL / 1 year
Measuring range
≤ 1 bar (15 psi) ±0.25 %

> 1 bar to 10 bar (15 to 150 psi) ±0.1 %
40 bar (600 psi) ±0.1 %
100 bar (1500 psi) ±0.1 %
400 bar (6000 psi) ±0.1 %
Influence of orientation
3
90
°
➀
°
90
P01-PMD55xxx-17-xx-xx-xx-001
Measuring error in mbar (psi)

➀ Axis of the diaphragm perpendicular ➁ Diaphragm points up ➂ Diaphragm points down
PMC51 < +0.2 mbar (0.003 psi) < -0.2 mbar (0.003 psi)
PMP51 with process connections < +4 mbar (0.06 psi) < -4 mbar (0.06 psi)
Calibration position,
1/2" thread and silicone oil
no measuring error
PMP51 with process connections < +10 mbar (0.145 psi) < -10 mbar (0.145 psi)
> thread 1/2" and flanges This value is doubled for inert oil. This value is doubled for inert oil.
Note!
Position-dependent zero point shift can be corrected at the device. → ä 26, "General installation instructions"
section and → ä 79 ff, "Installation instructions" section.
Warm-up period • 4 to 20 mA analog: ≤1.5 s

• 4 to 20 mA HART: ≤5 s
• PROFIBUS PA: ≤8 s
• FOUNDATION Fieldbus: ≤20 s (after a TOTAL-reset ≤45 s)
20 Endress+Hauser
Performance characteristics – ceramic process isolating

diaphragm
Reference accuracy – PMC51 The reference accuracy comprises the non-linearity according to limit point setting, hysteresis and non-
reproducibility as per IEC 60770. The data refer to the calibrated span.
Gauge pressure sensors
Measuring cell Standard reference accuracy Platinum reference accuracy
• TD 1:1 to ≤ TD 10:1 = 0.15 % • TD 1:1 to ≤ TD 10:1 = ±0.075 %

100 mbar (1.5 psi)
• TD > 10:1 to TD 20:1 = 0.20 % • TD > 10:1 to TD 20:1 = ±0.015 x TD
250 mbar (4 psi), • TD 1:1 to ≤ TD 10:1 = 0.15 % • TD 1:1 to ≤ TD 10:1 = ±0.075 %

400 mbar (6 psi), • TD > 10:1 to TD 20:1 = 0.20 % • TD > 10:1 to TD 20:1 = ±0.1 %
1 bar (15 psi),
2 bar (30 psi),
4 bar (60 psi),
10 bar (150 psi)
• TD 1:1 to ≤ TD 10:1 = 0.15 % • TD 1:1 to ≤ TD 10:1 = ±0.075 %

40 bar (600 psi)
Absolute pressure sensors
Measuring cell Standard reference accuracy Platinum reference accuracy
• TD 1:1 to ≤ TD 10:1 = 0.15 % • TD 1:1 to TD 5:1 = ±0.075 %

100 mbar (1.5 psi)
• TD > 10:1 to TD 20:1 = ±0.0015 x TD • TD > 5:1 to TD 20:1 = ±0.0015 x TD
• TD 1:1 to ≤ TD 10:1 = 0.15 % • TD 1:1 to ≤ TD 10:1 = ±0.075 %

250 mbar (4 psi)
• TD > 10:1 to TD 20:1 = 0.20 % • TD > 10:1 to TD 13:1 = ±0.1 %
400 mbar (6 psi), • TD 1:1 to ≤ TD 10:1 = 0.15 % • TD 1:1 to ≤ TD 10:1 = ±0.075 %

1 bar (15 psi), • TD > 10:1 to TD 20:1 = 0.20 % • TD > 10:1 to TD 20:1 = ±0.1 %
2 bar (30 psi),
4 bar (60 psi),
10 bar (150 psi)
• TD 1:1 to ≤ TD 10:1 = 0.15 % • TD 1:1 to ≤ TD 10:1 = ±0.075 %

40 bar (600 psi)
Total performance – PMC51 The "Total performance" specification comprises the non-linearity including hysteresis, non-reproducibility as
well as the thermal change in the zero point. All specifications apply to the temperature range –10 to +60°C
(+14 to +140°F) and Turndown 1:1.
Signal output Measuring cell % URL
HART, PROFIBUS PA, 100 mbar (1.5 psi), 250 mbar (4 psi), 400 mbar (6 psi) ±0.575
FOUNDATION Field-
1 bar (15 psi), 2 bar (30 psi), 4 bar (60 psi), 10 bar (150 psi), 40 bar (600 psi) ±0.5
bus
100 mbar (1.5 psi), 250 mbar (4 psi), 400 mbar (6 psi) ±0.775
Analog (4 to 20 mA)
Endress+Hauser 21
Total error - PMC51 The total error comprises the long-term stability and the total performance. All specifications apply to the
temperature range –10 to +60°C (+14 to +140°F) and Turndown 1:1.
Signal output Measuring cell % URL
1 year
PMC51 with thread or flange HART, PROFIBUS PA, 100 mbar (1.5 psi), 250 mbar (4 psi), 400 mbar (6 psi) ±0.55
FOUNDATION Fieldbus 1 bar (15 psi), 2 bar (30 psi), 4 bar (60 psi), 10 bar (150 psi), 40 bar (600 psi) ±0.47
Analog (4 to 20 mA)
PMC51 with hygienic process HART, PROFIBUS PA, 100 mbar (1.5 psi), 250 mbar (4 psi), 400 mbar (6 psi) ±0.925
connection FOUNDATION Fieldbus 1 bar (15 psi), 2 bar (30 psi), 4 bar (60 psi), 10 bar (150 psi), 40 bar (600 psi) ±0.7
Analog (4 to 20 mA)
Thermal change in the zero PMC51 with thread or flange

output and the output span –
PMC51
Signal output Measuring cell % of the calibrated measuring span
–40 to -20°C –10 to +60°C –20 to +100°C

(–40 to –4°F) (+14 to +140°F) (–4 to +212°F)
100 mbar (1.5 psi), 250 mbar (4 psi), 400

HART, ±(0,6 + 0,45 x TD) ±0,2 + 0,275 x TD ±(0,4 + 0,425 x TD)
mbar (6 psi)
PROFIBUS PA, FOUNDATION
Fieldbus 1 bar (15 psi), 2 bar (30 psi), 4 bar (60 psi),
±0,5 + 0,35 x TD ±0,1 + 0,15 x TD ±(0,225 + 0,525 x TD)
10 bar (150 psi), 40 bar (600 psi)
100 mbar (1.5 psi), 250 mbar (4 psi), 400

±(0,6 + 0,45 x TD) ±0.4 + 0.275 x TD ±0.7 + 0.425 x TD
Analog mbar (6 psi)
(4 to 20 mA) 1 bar (15 psi), 2 bar (30 psi), 4 bar (60 psi),
±0,5 + 0,35 x TD ±0.3 + 0.15 x TD ±0.525 + 0.525 x TD
10 bar (150 psi), 40 bar (600 psi)
PMC51 with hygienic process connection
Signal output Measuring cell % of the calibrated measuring span
–10 to +60°C –20 to +130°C

(+14 to +140°F) (–4 to +266°F)
HART, 100 mbar (1.5 psi), 250 mbar (4 psi), 400

±(0,4 + 0,275 x TD) ±(0,7 + 0,425 x TD)
PROFIBUS PA, mbar (6 psi)
FOUNDATION 1 bar (15 psi), 2 bar (30 psi), 4 bar (60 psi),
Fieldbus ±(0,3 + 0,15 x TD) ±(0,525 + 0,525 x TD)
10 bar (150 psi), 40 bar (600 psi)
100 mbar (1.5 psi), 250 mbar (4 psi), 400

±(0,4 + 0,275 x TD) ±(0,7 + 0,425 x TD)
Analog mbar (6 psi)
(4 to 20 mA) 1 bar (15 psi), 2 bar (30 psi), 4 bar (60 psi),
±(0,3 + 0,15 x TD) ±(0,525 + 0,525 x TD)
10 bar (150 psi), 40 bar (600 psi)
22 Endress+Hauser
Performance characteristics – metal process isolating

diaphragm
Reference accuracy – The reference accuracy comprises the non-linearity according to limit point setting, hysteresisand non-
PMP51, PMP55 reproducibility as per IEC 60770. The data refer to the calibrated span.
Gauge pressure sensors/absolute pressure sensors

PMP51 and PMP55 without capillary
Measuring cell Standard reference accuracy Platinum reference accuracy 1)
• TD 1:1 = ±0.15 % Not available

• TD >1:1 to TD 20:1 = ±0.15 % x TD
400 mbar (6 psi) PMP51 with hygienic process connection: PMP51 with hygienic process connection:
• TD 1:1 = ±0.3 % • TD 1:1 = ±0.2 %
• TD >1:1 to TD 10:1 = ±0.3 % x TD • TD >1:1 to TD 10:1 = ±0.2 % x TD
• TD 1:1 to TD 5:1 = ±0.15 % • TD 1:1 to TD 2.5:1 = ±0.075 %
• TD >5:1 to TD 20:1 = ±0.03 % x TD • TD >2.5:1 to TD 20:1 = ±0.03 % x TD
1 bar (15 psi) PMP51 with hygienic process connection: PMP51 with hygienic process connection:
• TD 1:1 = ±0.3 % • TD 1:1 = ±0.2 %
• TD 1:1 to TD 10:1 = ±0.15 % • TD 1:1 to TD 5:1 = ±0.075 %

• TD 1:1 to TD ≤5:1: 0.15 % • TD 1:1 to TD ≤5:1: 0.075 %
• TD >5:1 to TD ≤10:1: 0.2 % • TD >5:1 to TD ≤10:1: 0.1 %
• TD 1:1 to TD 10:1 = ±0.15 % • TD 1:1 to TD 10:1 = ±0.075 %

• TD >10:1 to TD 20:1 = ±0.20 % • TD 10:1 to TD 20:1 = ±0.0075 % x TD
• TD 1:1 to TD ≤10:1: 0.15 % • TD 1:1 to TD ≤10:1: 0.075 %
• TD >10:1 to TD 20:1: ±0.2 % • TD >5:1 to TD 20:1: ±0.1 %
• TD 1:1 to TD 10:1 = ±0.15 % • TD 1:1 to TD 10:1 = ±0.075 %

• TD >10:1 to TD 20:1 = ±0.20 % • TD 10:1 to TD 20:1 = ±0.1 %
10 bar (150 psi),
• TD 1:1 to TD ≤10:1: 0.15 % • TD 1:1 to TD ≤10:1: 0.075 %
• TD >10:1 to TD 20:1: ±0.2 % • TD >5:1 to TD 20:1: ±0.1 %
• TD 1:1 to TD 10:1 = ±0.15 % • TD 1:1 to TD 10:1 = ±0.075 %

100 bar (1500 psi)
• TD >10:1 to TD 20:1 = ±0.20 % • TD 10:1 to TD 20:1 = ±0.0075 %
• TD 1:1 to TD 5:1 = ±0.15 % • TD 1:1 to TD 5:1 = ±0.15 %

400 bar (6000 psi)
• TD >5:1 to TD 20:1 = ±(0.03 % x TD) • TD >5:1 to TD 20:1 = ±(0.03 % x TD)
1) Only PMP51, PMP55 with direct diaphragm seal mounting
Endress+Hauser 23
Gauge pressure sensors/absolute pressure sensors

PMP55 with capillary
Measuring cell Standard reference accuracy Platinum reference accuracy 1)
• TD 1:1 = ±0.15 % Not available

400 mbar (6 psi)
• TD >1:1 to TD 20:1 = ±0.15 % x TD
• TD 1:1 to TD 3.75:1 = ±0.15 % • TD 1:1 to TD 2:1 = ±0.1 %

1 bar (15 psi)
• TD >3.75:1 to TD 20:1 = ±0.04 % x TD • TD >2:1 to TD 20:1 = ±0.04 % x TD
• TD 1:1 to TD 3.75:1 = ±0.15 % • TD 1:1 to TD 2.5:1 = ±0.1 %

2 bar (30 psi)
• TD >3.75:1 to TD 20:1 = ±0.04 % x TD • TD >2.5:1 to TD 20:1 = ±0.04 % x TD
• TD 1:1 to TD 10:1 = ±0.15 % • TD 1:1 to TD 10:1 = ±0.075 %

4 bar (60 psi)
10 bar (150 psi), • TD 1:1 to TD 10:1 = ±0.15 % • TD 1:1 to TD 10:1 = ±0.075 %

40 bar (600 psi) • TD >10:1 to TD 20:1 = ±0.20 % • TD 10:1 to TD 20:1 = ±0.1 %
• TD 1:1 to TD 10:1 = ±0.15 % • TD 1:1 to TD 10:1 = ±0.075 %

100 bar (1500 psi)
• TD 1:1 to TD 5:1 = ±0.15 % • TD 1:1 to TD 5:1 = ±0.15 %

400 bar (6000 psi)
• TD >5:1 to TD 20:1 = ±(0.03 % x TD) • TD >5:1 to TD 20:1 = ±(0.03 % x TD)
1) Only PMP51, PMP55 with direct diaphragm seal mounting
Total performance – PMP51 The "Total performance" specification comprises the non-linearity including hysteresis, non-reproducibility as
well as the thermal change in the zero point. All specifications apply to the temperature range –10 to +60°C
(+14 to +140°F) and Turndown 1:1.
Signal output Measuring cell PMP51 PMP51 with hygienic process PMP51 with gold/rhodium-coated
connection process isolating diaphragm
% of URL
400 mbar (6 psi) ±0.34 ±1.25

HART, 1 bar (15 psi) ±0.34 ±0.25 ±0.75
PROFIBUS PA,
FOUNDATION 2 bar (30 psi) ±0.25 ±0.45
Fieldbus
4 bar (60 psi) ±0.30 ±0.25 ±0.3
10 bar (150 psi), ±0.25

±0.25 ±0.25
40 bar (600 psi)
100 bar (1500 psi) ±0.25 - ±0.25
400 bar (6000 psi) ±0.4 - ±0.4
400 mbar (6 psi) ±0.54 ±1.25

1 bar (15 psi) ±0.34 ±0.54 ±0.75
Analog
2 bar (30 psi) ±0.45 ±0.45
(4 to 20 mA)
4 bar (60 psi) ±0.30 ±0.45 ±0.3
10 bar (150 psi), ±0.45

±0.25 ±0.25
40 bar (600 psi)
100 bar (1500 psi) ±0.25 - ±0.25
400 bar (6000 psi) ±0.4 - ±0.4
24 Endress+Hauser
Total error - PMP51 The total error comprises the long-term stability and the total performance. All specifications apply to the
temperature range –10 to +60°C (+14 to +140°F) and Turndown 1:1.
Signal output Measuring cell % of URL/year
HART, 400 mbar (6 psi) ±0.59

PROFIBUS PA,
FOUNDATION Fieldbus ≥1 bar to 40 bar (15 psi to 600 psi) ±0.35
≥40 bar to 100 bar (600 psi to 1500 psi) ±0.35
400 bar (6000 psi) ±0.5
Analog 400 mbar (6 psi) ±0.79

(4 to 20 mA)
400 bar (6000 psi) ±0.5
Thermal change in the zero Note!

output and the output span – When using a PMP55, the influence from the respective diaphragm seal must also be taken into account
PMP51 and PMP55 (→ ä 77 ff "Planning instructions for diaphragm seal systems").
PMP51 and PMP55 (basic device)
Measuring cell –10 to +60 °C –40 to –10°C, +60 to +85°C

(+14 to +140°F) (–40 to +14°F, +140 to +185°F)
% of the calibrated measuring span
400 mbar (6 psi), 1 bar (15 psi),

2 bar (30 psi), 4 bar (60 psi),
±(0.34 + 0.15 x TD) ±(0.4 + 0.25 x TD)
10 bar (150 psi), 40 bar (600 psi),
100 bar (1500 psi)
400 bar (6000 psi) ±(0.3 + 0.35 x TD) ±(0.3 + 0.7 x TD)
PMP51 with hygienic process connection
Signal output Measuring cell –10 to +60 °C –40 to –10°C, +60 to +125°C
(+14 to +140°F) (–40 to +14°F, +140 to +257°F)
% of the calibrated measuring span
Clamp ½" / 400 mbar (6 psi) ±(0.1 + 0.4 x TD) ±(0.8 + 1.5 x TD)
HART,
400 mbar (6 psi), 1 bar (15 psi) ±(0.1 + 0.25 x TD) ±(0.1 + 1.1 x TD)
PROFIBUS PA, FOUNDATION
Fieldbus 2 bar (30 psi), 4 bar (60 psi),
±(0.1 + 0.2 x TD) ±(0.1 + 0.5 x TD)
10 bar (150 psi), 40 bar (600 psi)
Clamp ½" / 400 mbar (6 psi) ±(0.3 + 0.4 x TD) ±(1.1 + 1.5 x TD)
Analog
400 mbar (6 psi), 1 bar (15 psi) ±(0.3 + 0.25 x TD) ±(0.4 + 1.1 x TD)
(4 to 20 mA)
2 bar (30 psi), 4 bar (60 psi),
±(0.3 + 0.2 x TD) ±(0.4 + 0.5 x TD)
10 bar (150 psi), 40 bar (600 psi)
Endress+Hauser 25
Operating conditions (installation)

General installation • The position-dependent zero point shift can be corrected:
instructions – directly at the device via operating keys on the electronic insert
– directly at the device via operating keys on the display (except analog electronics)
– via digital communication if the cover is not open (except analog electronics)
Note!
In hazardous areas, comply strictly with the safety instructions when the housing cover is closed and open.
• Endress+Hauser offers a mounting bracket for installing the device on pipes or walls.
See also → ä 26, "Wall and pipe mounting" section.
• Use flushing rings for flange and cell diaphragm seals if medium buildup or clogging can be expected at the
diaphragm seal connection. The flushing ring can be inserted between the process connection and the
diaphragm seal. Thanks to the two lateral flushing bore holes, material buildup in front of the process
isolating diaphragm can be rinsed away and the pressure chamber can be ventilated.
• To guarantee the leak-tightness of the transmitter, Endress+Hauser recommends that only genuine cable
glands be used (also available as spare parts).
Measuring arrangement for Cerabar M transmitters without diaphragm seals are mounted as per the norms for a manometer
devices without diaphragm (DIN EN 837-2). We recommend the use of shutoff devices and siphons. The orientation depends on the
seal – PMC51, PMP51 measuring application.
Pressure measurement in gases

• Mount Cerabar M with shutoff device above the tapping point so that any condensate can flow into the
process.
Pressure measurement in steams

• Mount Cerabar M with siphon above the tapping point.
• Fill the siphon with liquid before commissioning.
The siphon reduces the temperature to almost the ambient temperature.
Pressure measurement in liquids

• Mount Cerabar M with shutoff device below or at the same level as the tapping point.
Level measurement
• Mount Cerabar M below the lowest measuring point (zero point of the measurement).
• Do not mount the device at the following positions: In the filling curtain, in the tank outlet or at a point in
the container which could be affected by pressure pulses from an agitator or a pump.
• The calibration and functional test can be carried out more easily if you mount the device downstream of a
shutoff device.
Measuring arrangement for • → ä 77, "Planning instructions for diaphragm seal systems" section.
devices with diaphragm seal
– PMP55
Wall and pipe mounting For installing the device on pipes or walls, Endress+Hauser provides a mounting bracket which is included in
the scope of supply or can be ordered as a separate accessory (part no. 71102216).
For the dimensions, see → ä 67.
26 Endress+Hauser
"Separate housing" version With the "separate housing" version, you are able to mount the housing with the electronics insert at a distance
from the measuring point. This version allows for trouble-free measurement:
• Under particularly difficult measuring conditions (at installation locations that are cramped or difficult to
access)
• If extreme cleaning of the measuring point is required
• If the measuring point is exposed to vibrations
• For space-saving installations
You can choose between different cable versions:
• PE (2 m (6.6 ft), 5 m (16 ft) and 10 m (33 ft))
• FEP (5 m (16 ft)).
→ ä 83 ff, feature 600, "Separate housing".
For the dimensions, → ä 67.
➃
➂ IP xx
FEP cable: (see chapter
IP 69K “Ordering information”)
IP 66/68 NEMA 4/6P
PE cable:
IP 66/68 NEMA 4/6P
➀
➁
r ³ 120 mm
P01-PMx5xxxx-11-xx-xx-en-002
In the case of the "separate housing" version, the sensor is delivered with the process connection and cable ready
mounted. The housing and a mounting bracket are enclosed as separate units. The cable is provided with a socket at both
ends. These sockets are simply connected to the housing and the sensor.
1 Process connection with sensor
2 Cable, both ends are fitted with a socket
3 Mounting bracket provided, suitable for pipe and wall mounting (for pipes from 1 1/4" up to 2" diameter)
4 Housing with electronic insert
Degree of protection for the process connection and sensor with the use of
• FEP cable:
– IP 69K
– IP 66 NEMA 4/6P
– IP 68 (1.83 mH2O for 24 h) NEMA 4/6P
• PE cable:
– IP 66 NEMA 4/6P
– IP 68 (1.83 mH2O for 24 h) NEMA 4/6P
Technical data of the PE and FEP cable:
• Minimum bending radius: 120 mm (4.72 in)
• Cable extraction force: max. 450 N (101 lbf)
• Resistance to UV light
Use in hazardous area:
• Intrinsically safe installations (Ex ia/IS)
• FM/CSA IS: for Div.1 installation only
Reduction in installation height

If the separate housing is used, the mounting height of the process connection is reduced compared to the
dimensions of the standard version (see graphic).
Endress+Hauser 27
r ³ 120 mm r ³ 120 mm r ³ 120 mm
F31 F15
44
ø54.1
36
29
17
81
➀ ➀ ➀
Oxygen applications Oxygen and other gases can react explosively to oils, grease and plastics. As a result, the following are some of
the precautions that must be taken:
– All components of the system, such as measuring devices, must be cleaned in accordance with the BAM
(DIN 19247) requirements.
– Depending on the materials used, a certain maximum temperature and maximum pressure must not be
exceeded for oxygen applications.
The devices suitable for gaseous oxygen applications are listed in the following table with the specification pmax.
Ordering code for devices1) pmax for oxygen applications Tmax for
cleaned for oxygen applications oxygen
applications
PMC51 2) – devices with sensors, Over pressure limit (OPL) of sensor3), 4) 60°C (140°F)
nominal value < 10 bar (150 psi)
PMC51 2) – devices with sensors, 40 bar (600 psi) 60°C (140°F)

nominal value ≥ 10 bar (150 psi)
PMP51 PMP55 2) Depends on the lowest-rated element, with regard to 85°C (185°F)
pressure, of the selected components: over pressure limit
(OPL) of sensor 3, process connection (1.5 x PN) or fill fluid
(160 bar (2320 psi))
1) Only device, not accessory or enclosed accessory

2) Feature 570 "Service" version "HB"
3) → ä 83 ff "Ordering information", feature 70 "Sensor range"
4) PMC51 with PVDF thread or PVDF flange pmax = 15 bar (225 psi)
PWIS cleaning Special cleaning of the transmitter to remove paint-wetting substances, for use in paint shops
→ ä 86 feature 570 "Service", version "HC".
Ultrapure gas applications Endress+Hauser also provides devices which have been cleaned of oil and grease for special applications, such
as for ultrapure gas. No special restrictions regarding the process conditions apply to these devices.
→ ä 83 ff, "Ordering information PMC51", feature 570 "Service" version "HA".
→ ä 89 ff, "Ordering information PMP51", feature 570 "Service" version "HA".
Applications with hydrogen With regard to materials in which hydrogen formation takes place, hydrogen atoms can diffuse through the
metal process isolating diaphragm. This can result in incorrect measurement results.
Endress+Hauser offers process isolating diaphragms with a gold/rhodium coating for such instances.
→ ä 88 ff "Ordering information PMP51" and
→ ä 93 ff "Ordering information PMP55", feature 170 "Membrane Material" version "M".
28 Endress+Hauser
Operating conditions (environment)
Ambient temperature range Version PMC51 PMP51 PMP55
Without LCD display –40°C to +85°C (–40°F to +185°F)

1)
With LCD display –20°C to +70°C (–4°F to +158°F)
With M12 plug , elbowed –25°C to +85°C (–13°F to +185°F)
With separate housing –20°C to +60°C (–4°F to +140°F) ⎯

(installation without insulation)
Diaphragm seal systems ⎯ ⎯ → ä 77
1) Extended temperature application range (–40°C to +85°C (–40°F to +185°F)) with restrictions in optical properties
such as display speed and contrast
Note!
For high-temperature applications, either a PMP55 with a temperature isolator or with a capillary can be used.
If vibrations also occur in the application, Endress+Hauser recommends you use a PMP55 with a capillary. If
a PMP55 with a temperature isolator or capillary is used, we recommend a suitable bracket for mounting (see
"Wall and pipe mounting" section on → ä 26).
For devices for use in hazardous areas, see Safety Instructions, Installation or Control Drawing. (→ ä 99 ff,
"Safety Instructions" and "Installation/Control Drawings" sections)
Storage temperature range Version PMC51 PMP51 PMP55

Without LCD display –40°C to +90°C (–40°F to +194°F)
With LCD display –40°C to +85°C (–40°F to +185°F)
With M12 plug , elbowed –25°C to +85°C (–-13°F to +185°F)

With separate housing –40°C to +60°C (–40°F to +140°F) ⎯
Diaphragm seal systems ⎯ ⎯ → ä 77
Degree of protection • → ä 83 ff, feature 50 "Electrical connection".

• Separate housing (→ ä 27)
Climate class Class 4K4H (air temperature: –20 to 55°C (–4 to +131°F), relative humidity: 4 to 100%) satisfied as per
DIN EN 60721-3-4 (condensation possible).
Endress+Hauser 29
Vibration resistance Device/Additional Test standard Vibration resistance

option
Devices without mounting GL VI-7-2 guaranteed for

bracket • Part 7: Guidelines for the Performance of Type 3 to 18 Hz: ±4 mm (0.16 in);
Approvals 25 to 500 Hz: 5 g
• Chapter 2: Test Requirements for Electrical / in all 3 planes
Electronic Equipment and Systems
IEC 61298-3 guaranteed for

IEC 60068-2-6 10 to 60 Hz: ±0.35 mm (0.01 in);
60 to 2000 Hz: 2 g
in all 3 planes
Devices with mounting IEC 61298-3 guaranteed for
bracket IEC 60068-2-6 10 to 60 Hz: ±0.15 mm (0.01 in);
60 to 500 Hz: 2 g
in all 3 planes
Note!
For high-vibration applications, either a PMC51/PMP51 with a separate housing or a PMP55 with a capillary
can be used. We recommend a suitable bracket for mounting (see "Wall and pipe mounting" section on
→ ä 26).
Electromagnetic compatibility • Electromagnetic compatibility as per all the relevant requirements of the EN 61326 series and NAMUR
Recommendation EMC (NE21). Details can be found in the Declaration of Conformity (in the Download
area of "www.de.endress.com", "search area - Approvals and Certificates", "Manufact. Declaration").
• Maximum deviation: < 0.5 % of span
Overvoltage protection The device can be fitted with overvoltage protection, see → ä 83 ff "Ordering information" feature 610
(optional) "Accessory mounted:" version "NA". The overvoltage protection is mounted at the factory on the housing
thread (M20x1.5) for the cable gland and is approx. 70 mm (2.76 in) in length (take additional length into
account when installing). The device is connected as illustrated in the following graphic.
For details refer to TI001013KEN, XA01003KA3 and BA00304KA2.
Incoming
connection cables
+ Unit to be
➀ -
protected
+
Red +
➁ - Black -
Connection
cables
HAW569-DA2B
Shield grounding
➀ without
➁ direct
P01-xMx5xxxx-04-xx-xx-en-006
30 Endress+Hauser
Operating conditions (process)
Process temperature range

PMC51 Tp
°C
1 150
140
Ta
2 130
TP 120
110
3 100
...
20
10
Ta
0
-50 -40 -30 -20 -10-10 0 10 20 30 40 50 60 70 80 90 °C
-20
-30
-40
Ta = Ambient temperature; Tp = Process temperature; ➀, ➁ and ➂ see following chapter.
Process temperature limits PMC51 (with ceramic process isolating diaphragm)

• ➂: –40 to +100°C (–40 to +212°F) for threaded process connections or flange process connections
• ➁: –40 to +130°C (–40 to +266°F) for hygienic process connections
• ➀: For a maximum of 60 minutes: +150 °C (+302 °F)
• Observe the process temperature range of the seal. See also the following table.
Version for Seal Notes Process temperature range

feature 190 in
Thread or flange Hygienic process connection
the order code
A FKM Viton - -20 to +100°C (-4 to +212°F) -
A 1) FKM Viton cleaned for O2 application -5 to +60°C (+23 to +140°F) -
B FKM Viton FDA 2), 3A Class I, USP Class VI -5 to +100°C (+23 to +212°F) -5 to +150 °C (+23 to +302°F)
F NBR FDA 2) -10 to +100°C (-14 to +212°F) -
H NBR, Low temperature - -40 to +100°C (-40 to +212°F) -
G HNBR FDA 2), 3A Class I, KTW, AFNOR, BAM -25 to +100°C (-13 to +212°F) -20 to +125 °C (-4 to +257°F)
J EPDM 70 FDA 2) -40 to +100°C (-40 to +212°F) -
K EPDM 291 FDA 2), 3A Class II, USP Class VI, DVGW, - -15 to +150 °C (+5 to +302°F)
KTW, W270, WRAS, ACS, NSF61
L FFKM Kalrez 6375 - +5 to +100°C (+41 to +212°F) -
M FFKM Kalrez 7075 - +5 to +100°C (+41 to +212°F) -
N FFKM Kalrez 6221 FDA 2), USP Class VI -5 to +100°C (+23 to +212°F) -5 to +150 °C (+23 to +302°F)
2)
P Fluoroprene XP40 FDA , USP Class VI, 3A Class I +5 to +100°C (+41 to +212°F) +5 to +150 °C (+41 to +302°F)
2)
S VMQ Silicone FDA -35 to +85°C (-31 to +185°F) -20 to +85 °C (-4 to +185°F)
1) With feature 570 "Service", version "HB - Cleaned for oxygen service"
2) Suitable for foods FDA 21 CFR 177.2600
Endress+Hauser 31
Applications with jumps in temperature

Extreme jumps in temperature can result in temporary measuring errors. Temperature compensation takes
effect after several minutes. Internal temperature compensation is faster the smaller the jump in temperature
and the longer the time interval involved.
For further information please contact your local Endress+Hauser Sales Center.
PMP51 (with metal process isolating diaphragm)
Description Temperature operating range
Process connections with internal process isolating diaphragm -40 to +125°C (-40 to +257°F)
Process connections with flush-mounted process isolating diaphragm, -40 to +100°C (-40 to +212°F)
G 1 A, G 1 1/2 A, G 2 A, 1 NPT, 1 1/2 NPT, 2 NPT,
M 44 x 1.25, EN/DIN, ANSI and JIS flanges
Process connections with flush-mounted process isolating diaphragm, -20 to +85°C (-4 to +185°F)
G 1/2 A, M 20x1.5
Hygienic process connections –40 to +130 °C (–40 to +266 °F)

For a maximum of 60 minutes: +150 °C
(+302 °F)
PMP55 (with diaphragm seal)

• Depending on the diaphragm seal and filling oil from -70°C (-94°F) up to +400°C (+752°F). Observe the
temperature application limits → ä 77.
Note!
• Do not use diaphragm seals with 0.09 mm (0.0035 in) PTFE foil on AISI 316L for vacuum applications,
upper temperature limit +204°C (+399°F).
• For oxygen applications, observe → ä 28, "Oxygen applications" section.
Pressure specifications • The maximum pressure for the measuring device depends on the lowest-rated element with regard to
pressure.
See the following sections:
– → ä 8 ff, "Measuring range" section
– "Mechanical construction" section.
The MWP (maximum working pressure) is specified on the nameplate. This value refers to a reference
temperature of +20°C (68°F), or 100°F (38°C) for ANSI flanges, and may be applied to the device for an
unlimited time. Observe temperature dependency of the MWP.
• The pressure values permitted at higher temperatures can be found in the following standards:
– EN 1092-1: 2001 Tab. 18 1
– ASME B 16.5a – 1998 Tab. 2-2.2 F316
– ASME B 16.5a – 1998 Tab. 2.3.8 N10276
– JIS B 2220.
• The test pressure corresponds to the over pressure limit of the device (over pressure limit OPL =
1.5 x MWP 2) and may be applied for only a limited time period in order to avoid permanent damage.
• The Pressure Equipment Directive (EC Directive 97/23/EC) uses the abbreviation "PS". The abbreviation
"PS" corresponds to the MWP (maximum working pressure) of the measuring device.
• In the case of sensor range and process connection combinations where the OPL (over pressure limit) of the
process connection is smaller than the nominal value of the sensor, the device is set at the factory, at the
very maximum, to the OPL value of the process connection. If you want to use the entire sensor range, select
a process connection with a higher OPL value (1.5 x PN; PN = MWP).
• In oxygen applications, the values for "pmax and Tmax for oxygen applications" as per → ä 28, "Oxygen
applications" may not be exceeded.
• Avoid steam hammering!
Steam hammering can cause zero point drift.
Recommendation:
Residue (such as condensation or drops of water) can remain at the process isolating diaphragm after CIP
cleaning and lead to local steam hammering if immediately steam is introduced. In practice, drying the
process isolating diaphragm (e.g. by blowing off excess moisture) has proven to be a successful way of
avoiding steam hammering.
1) With regard to their stability-temperature property, the materials 1.4435 and 1.4404 are grouped together under 13EO
in EN 1092-1 Tab. 18. The chemical composition of the two materials can be identical.
2) The equation does not apply for PMP51 and PMP55 with a 40 bar (600 psi) - or a 100 bar (1500 psi) - measuring cell.
32 Endress+Hauser
F31 aluminum housing
115
dimensions
94
15
103
H
P01-F31xxxx-06-00-xx-xx-000
Front view, left-hand side view, top view

➀ The cover with viewing window is 15 mm (0.59 in) higher than the cover without viewing window.
→ For installation height H for housing with viewing window, see the specific process connection. Housing weight
→ ä 67
F15 stainless steel housing

dimensions (hygienic) 100
➀
19
H 76
P01-F15xxxx-06-00-xx-xx-000
Front view, top view.

➀ The cover with viewing window is 19 mm (0.75 in) higher than the cover without viewing window.
→ For installation height H for housing with viewing window, see the specific process connection. Housing weight
→ ä 67
Process connections PMC51 Thread, internal process isolating diaphragm

(with ceramic process
isolating diaphragm)
➀ G 1/2A ➁ G 1/2A G 1/4 ➂ G 1/2A 11.4 mm
H
ø8
17
17
17
20
20
20
13
ø3 G 1/4 ø11.4
3
ø6 ø17.5 ø17.5
G 1/2 G 1/2 G 1/2
P01-PMC71xxx-06-09-xx-xx-001
Process connections PMC51, thread ISO 228

Installation height H → ä 34.
1 Thread ISO 228 G 1/2 A EN 837;
Material version GCJ: AISI 316L, version GCC: Alloy C276
Version GCF: PVDF (max.: 15 bar (217.5 psi), –10 to +60 °C (+14 to +140 °F)), mount version"GCF" with a
mounting bracket only ( → ä 26); weight: 0.63 kg (1.39 lbs)
2 Thread ISO 228 G 1/2 A G 1/4 (female);
Material version GLJ: AISI 316L, version GLC: Alloy C276; weight: 0.63 kg(1.39 lbs)
3 Thread ISO 228 G 1/2 A hole 11.4 mm (0.45 in);
Material version GMJ: AISI 316L, version GMC: Alloy C276; weight: 0.63 kg(1.39 lbs)
Endress+Hauser 33
➀ 1/2 MNPT 1/4 FNPT ➁ 1/2 MNPT 11.4 mm ➂ 1/2 MNPT 3 mm ➃ 1/2 FNPT
H
25
25
25
25
ø11.4 ø11.4 ø3 1/2 NPT
1/4 NPT 1/2 NPT 1/2 NPT ø26.5
1/2 NPT
P01-PMC71xxx-06-09-xx-xx-002
Process connections PMC51, thread ANSI

1 Thread ANSI 1/2 MNPT 1/4 FNPT;
Material version RLJ: AISI 316L, version RLC: Alloy C276; weight: 0.63 kg (1.39 lbs)
2 Thread ANSI 1/2 MNPT hole 11.4 (0.45 in);
Material version RKJ: AISI 316L; version RKC: Alloy C276; weight: 0.63 kg (1.39 lbs)
3 Thread ANSI 1/2 MNPT hole 3 mm (0.12 in);
Material version RJF: PVDF (max.: 15 bar (225 psi), –10 to +60 °C (+14 to +140 °F)) mount with mounting bracket
only (→ ä 26); weight: 0.63 kg (1.39 lbs)
4 Thread ANSI FNPT 1/2
Material version R1J: AISI 316L, version R1C: Alloy C276; weight: 0.63 kg (1.39 lbs)
➀ G 1/2 ➁ R 1/2
H
H
13.2
ø8
20
23
3
ø3 ø11.4
ø5 R 1/2
G 1/2
P01-PMC71xxx-06-09-xx-xx-003
Process connections PMC51, thread JIS

1 Version GNJ: thread JIS B0202 G 1/2 (male), material: AISI 316L; weight: 0.63 kg (1.39 lbs)
2 Version GOJ: thread JIS B0203 R 1/2 (male), material: AISI 316L; Weight: 0.63 kg (1.39 lbs)
Installation height H for devices with threaded connection and internal process isolating diaphragm
F31 housing F15 housing
154 mm (6.06 in) 146 mm (5.75 in)
34 Endress+Hauser
Thread, flush-mounted process isolating diaphragm
➀ G 1 1/2 ➁ G2
SW 60 SW 60
60 AF 60 AF
H
H
33.5
28
30
25
G 1 1/2 G2
ø55 ø68
➂ 1 1/2 NPT ➃ 2 NPT ➄ M44x1.25

SW 60 SW 60 SW 60
60 AF 60 AF 60 AF
H
33.5
27
22
30
11
1 1/2 NPT 2 NPT ø40.5
ø68 M44x1.25
P01-PMC71xxx-06-09-xx-xx-005
Process connections PMC51,

→ Installation height, see table below.
1 Thread ISO 228 G 1 1/2 A;
Material version GVJ: AISI 316L; weight: 0.63 kg (1.39 lbs)
2 Thread ISO 228 G 2 A;
Material version GWJ: AISI 316L; weight: 0.63 kg (1.39 lbs)
3 Thread ANSI 1 1/2 MNPT;
Material version U7J: AISI 316L; weight: 0.63 kg (1.39 lbs)
4 Thread ANSI 2 MNPT;
5 Thread DIN 13 M 44x1.25;
Material version G4J: AISI 316L; weight: 0.63 kg (1.39 lbs)
Installation height H for devices with threaded connection and flush-mounted process isolating
diaphragm
201 mm (7.91 in) 193 mm (7.6 in)
Endress+Hauser 35
EN/DIN flanges, connection dimensions as per EN 1092-1/DIN 2527
g2
H
2
b
26 (1.024)
g
k
D
P01-PMC71xxx-06-09-xx-xx-006
Process connection PMC51, EN/DIN flange with raised face (flush-mounted process isolating diaphragm)
Flange Boltholes
Version Material Nominal Nominal Shape 1) Diameter Thickness Raised Quantity Diameter Hole Flange
diameter pressure face circle weight 2)
D b g g2 k

CNJ AISI 316L DN 25 PN 10-40 B1 (D) 115 18 68 4 14 85 1.4
CPJ AISI 316L DN 32 PN 10-40 B1 (D) 140 18 78 4 18 100 2.0
CQJ AISI 316L DN 40 PN 10-40 B1 (D) 150 18 88 4 18 110 2.4
CXJ AISI 316L DN 50 PN 10-40 B1 (D) 165 20 102 4 18 125 3.2

3)
CFF PVDF DN 50 PN 10-16 B1 (D) 165 18 102 4 18 125 2.9
4)
CRP ECTFE DN 50 PN 25-40 B1 (D) 165 20 102 4 18 125 3.2
CZJ AISI 316L DN 80 PN 10-40 B1 (D) 200 24 138 8 18 160 5.5
4)
CSP ECTFE DN 80 PN 25-40 B1 (D) 200 24 138 8 18 160 5.5
1) Designation as per DIN 2527 in brackets

2) Housing weight → ä 67
3) OPL.: 15 bar (225 psi)
Process temperature range: –10 to +60 °C (+14 to +140 °F)
4) ECTFE coating on AISI 316/316L (1.4404/1.4435). When operating in hazardous areas, avoid electrostatic charging of the plastic surfaces.
36 Endress+Hauser
ANSI flanges, connection dimensions as per ANSI B 16.5, raised face RF
g2
0.06
1.6
H
b
g
k
D
P01-PMC71xxx-06-09-xx-xx-007
Process connection PMC51, ANSI flange with raised face RF (flush-mounted process isolating diaphragm)
Flange Boltholes
Ver- Material Nominal Class Diameter Thickness Raised face Quantity Diameter Hole circle Flange
sion diameter weight 1)
D b g g2 k
[in] [lb./sq.in] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [kg]
ACJ AISI 316/316L 2) 1 150 4.25 / 108 0.56 / 14.2 2 / 50.8 4 0.62 / 15.7 3.12 / 79.2 0.9
2)
ANJ AISI 316/316L 1 300 4.88 / 123.9 0.69 / 17.2 2 / 50.8 4 0.75 / 19 3.5 / 88.9 1.4
2)
AEJ AISI 316/316L 1 1/2 150 5 / 127 0.69 / 17.5 2.88 / 73.2 4 0.62 / 15.7 3.88 / 98.6 1.0
AQJ AISI 316/316L 2) 1 1/2 300 6.12 / 155.4 0.81 / 20.6 2.88 / 73.2 4 0.88 / 22.4 4.5 / 114.3 2.6
2)
AFJ AISI 316/316L 2 150 6 / 152.4 0.75 / 19.1 3.62 / 91.9 4 0.75 / 19.1 4.75 / 120.7 2.4
3)
AFN ECTFE 2 150 6 / 152.4 0.75 / 19.1 3.62 / 91.9 4 0.75 / 19.1 4.75 / 120.7 2.4
AFF PVDF 4) 2 150 6 / 152.4 0.75 / 19.1 3.62 / 91.9 4 0.75 / 19.1 4.75 / 120.7 0.5
2)
ARJ AISI 316/316L 2 300 6.5 / 165.1 0.88 / 22.4 3.62 / 91.9 8 0.75 / 19.1 5 / 127 3.2
2)
AGJ AISI 316/316L 3 150 7.5 / 190.5 0.94 / 23.9 5 / 127 4 0.75 / 19.1 6 / 152.4 4.9
AGN ECTFE 3) 3 150 7.5 / 190.5 0.94 / 23.9 5 / 127 4 0.75 / 19.1 6 / 152.4 4.9
4)
AGF PVDF 3 150 7.5 / 190.5 0.94 / 23.9 5 / 127 4 0.75 / 19.1 6 / 152.4 0.9
2)
ASJ AISI 316/316L 3 300 8.25 / 209.5 1.12 / 28.6 5 / 127 8 0.88 / 22.4 6.62 / 168.1 6.8
AHJ AISI 316/316L 2) 4 150 9 / 228.6 0.94 / 23.9 6.19 / 157.2 8 0.75 / 19.1 7.5 / 190.5 7.1
3)
AHN ECTFE 4 150 9 / 228.6 0.94 / 23.9 6.19 / 157.2 8 0.75 / 19.1 7.5 / 190.5 7.1
2)
ATJ AISI 316/316L 4 300 10 / 254 1.25 / 31.8 6.19 / 157.2 8 0.88 / 22.4 7.88 / 200.2 11.6
2) Combination of AISI 316 for required pressure resistance and AISI 316L for required chemical resistance (dual rated)
3) ECTFE coating on AISI 316/316L (1.4404/1.4435). When operating in hazardous areas, avoid electrostatic charging of the plastic surfaces.
4) OPL.: 15 bar (225 psi)
Process temperature range: –10 to +60 °C (+14 to +140 °F)
Endress+Hauser 37
JIS flanges, connection dimensions as per JIS B 2220 BL, raised face RF
g2
H
2
b
g
k
D
P01-PMC71xxx-06-09-xx-xx-008
Process connection PMC51, JIS flange with raised face RF (flush-mounted process isolating diaphragm), material:
AISI 316L → Installation height H, see table below.
Flange Boltholes
Version Nominal Nominal Diameter Thickness Raised face Quantity Diameter Hole circle Flange
diameter pressure weight 1)
D b g g2 k

KFJ 50 A 10 K 155 16 96 4 19 120 2.0
KGJ 80 A 10 K 185 18 127 8 19 150 3.3
KHJ 100 A 10 K 210 18 151 8 19 175 4.4
1) Housing weight, see → ä 67
Installation height H for devices with flange

201 mm (7.91 in) 193 mm (7.6 in)
38 Endress+Hauser
Hygienic process connection, flush-mounted process isolating diaphragm
1 DIN11851 DN40 2 DIN11851 DN50

D4
K
D1
D2
K
(0.39) (0.3)
7.5
(0.43)
H
11
10
D3
D3
D2
D1
1
3 DIN11864 DN40
D4
K 4 DIN11864 DN50
D1
D2
K
H
(0.3)
7.5
D2
(0.43)
(0.39)
11
10
D3
D3
D1
5 Tri-Clamp 2" 6 Tri-Clamp 3"

D2 D2
K K
(0.28)
H
H
7
D3 D3
d d
D1 D1
mm (in)
P01-PMC51xxx-06-00-00-xx-000
Hygienic process connections, material: AISI 316L (1.4435)

Surface roughness of the surfaces in contact with the medium Ra 0.76 μm (30 μin). Diaphragm seal versions optionally in
conformity with ASME-BPE for use in biochemical processes, wetted surfaces Ra 0.38 μm (15 μin),
electropolished; to be ordered using feature 570 "Service", version "HK" in the order code.
Pos. Version Nominal Outer-∅ Outer-∅ Internal-∅ Outer-∅ Seal-∅ Hole circle Height Weight
pressure PN D1 D2 D3 D4 d K1) H [kg/lbs]
1 MZJ 25 56 (2.2) 48 (1.89) 38 (1.5) 60 (2.36) - 52 (2.05) 0.652 (1.44)
2 MRJ 25 68 (2.68) 61 (2.4) 42 (1.65) - - 52 (2.05) 0.276 (0.61)
3 NCJ 16 54.9 (2.16) 48 (1.89) 38 (1.5) 60 (2.36) - 52 (2.05) max. 220 0.656 (1.45)
4 NDJ 16 66.8 (2.63) 61 (2.4) 42 (1.65) - - 52 (2.05) (8.66) 0.288 (0.64)
5 TDJ 40 64 (2.52) 61 (2.4) 42 (1.65) - 56.5 (2.22) 52 (2.05) 0.171 (0.38)
6 TFJ 40 91 (3.58) 76.7 (3.02) 42 (1.65) - 83.5 (3.29) 52 (2.05) 0.539 (1.19)
mm (in)
1) 4 x M5 thread
Endress+Hauser 39
1 Varivent F DN25-32 2 Varivent N DN40-162
D2
K
D1
D2
K
H
(0.48)
(0.48)
H
12,3
12,3
D3 D3
D1
1
3 NEUMO BioControl 4 DRD DN50
D1
D1
k k
K 61 (2.4)
K
H
h
H
D3
D2
h
D3
D2
5 APV Inline
D1
k
ø59,5 (2.34)
K
H
h
D3
D2
mm (in)
P01-PMC51xxx-06-00-00-xx-001

Pos. Version Nominal Outer-∅ Outer-∅ Internal-∅ Hole circle Hole circle Height Height Weight
pressure PN D1 D2 D3 K k1) H h [kg/lbs]
1 TQJ 40 66 (2.6) 60 (2.36) 38 (1.5) 52 (2.05)2) - - 0.459 (1.01)
2 TRJ 40 84 (3.31) 75 (2.95) 42 (1.65) 52 (2.05)2) - - 0.426 (0.94)

max. 220
3 S4J 40 90 (3.54) 49.9 (1.96) 38 (1.5) 52 (2.05)2) 90 (3.54)3) 17 (0.67) 1.34 (2.95)
(8.66)
4 TIJ 25 105 (4.13) 65 (2.56) 42 (1.65) 52 (2.05)2) 84 (3.31)4) 16 (0.63) 0.619 (1.36)
5 TMJ 40 100 (3.94) 69 (2.72) 42 (1.65) 52 (2.05)2) 82 (3.23)5) 12.5 (0.49) 0.519 (1.14)
mm (in)
1) 4 x M5 thread
2) 4 x M5 thread
3) 4 x ∅9 (0.35); 4 screws DIN912 M8 x 45 are enclosed (material (A4-80))
4) 4 x ∅11.5 (0.45)
5) 6 x ∅8.6 (0.34) + 2 x M8 thread; 8 x 45° (=360)
40 Endress+Hauser
Universal adapter
b
H
a
3
➀
➁ ø43.5
(1.71)
mm (in)
P01-PMC51xxx-06-00-00-xx-002
Material: b = top section AISI 316L (1.4404), a = bottom section AISI 316L (1.4435); Endress+Hauser supplies the slotted
nut in stainless steel AISI 304 (DIN/EN material number 1.4301) or in AISI 304L (DIN/EN material number 1.4307)..
Ver- Process Material of the molded seal ➀ Material of the measuring cell seal ➁ Measuring cell seal approval Nominal Weight
sion connection (changeable) (not changeable) Pressure [kg/lbs]
approval at the ceramic sensor ➂ PN
UPJ EHEDG, 3A Silicone EPDM (Order version "K") FDA1) 3A Class II, USP Class VI.
(Spare part order no.: 52023572) DVGW, KTW, W270, WRAS,
ACS, NSF61 10 0.74 (1.63)
UNJ EHEDG EPDM EPDM (Order version "J") FDA1)
(Spare part order no.: 71100719)
1) Suitable for foods FDA 21 CFR 177.2600
Installation height H, devices with universal adapter

196 mm (7.72 in) 189 mm (7.44 in)
Endress+Hauser 41
Process connections PMP51 Thread, internal process isolating diaphragm

(with metal process isolating
diaphragm)
➀ G 1/2A ➁ G 1/2A G 1/4 ➂ G 1/2A 11.4 ➃ M 20x1.5

H
H
3.5
ø17.7
3
ø11.4 ø11.4
14
20
3
17
17
20
20
13 dM = ø17.5
2
ø3.2 G 1/4 ø17.5 M20x1.5
3
ø6 G 1/2 A ø23.6
ø17.5
ø17.5 ø26.5
G 1/2 A
G 1/2 A
Process connections PMP51, thread ISO and DIN

1 Thread ISO 228 G 1/2 A EN 837;
Material version GCJ: AISI 316L, version GCC: Alloy C276; weight: 0.6 kg (1.32 lbs)
2 Thread ISO 228 G 1/2 A G 1/4 (female);
Material version GLJ: AISI 316L, version GLC: Alloy C276; weight: 0.6 kg (1.32 lbs)
3 Thread ISO 228 G 1/2 A hole 11.4 mm (0.45 in);
Material version GMJ: AISI 316L, version GMC: Alloy C276; weight: 0.6 kg (1.32 lbs)
4 Thread DIN13 M20x1.5
Material version G1J: AISI 316L; weight 0.4 kg (0.88 lbs)
➀ 1/2 MNPT 1/4 FNPT ➁ 1/2 MNPT ➂ 1/2 FNPT

H
H
ø11.4
7
10
ø21.4 ø21.4
25
25
20
15
8
1/4 NPT ø11.4 1/2 NPT
1/2 NPT 1/2 NPT ø38
P01-PMP51xxx-06-09-xx-xx-001
Process connections PMP51, thread ANSI

1 Thread ANSI 1/2 MNPT 1/4 FNPT;
Material version RLJ: AISI 316L, version RLC: Alloy C276; weight: 0.6 kg (1.32 lbs)
2 Thread ANSI 1/2 MNPT hole: 400 bar (6000 psi) = 11.4 mm (0.45 in)
Material version RKJ: AISI 316L, version RKC: Alloy C276; weight: 0.6 kg (1.32 lbs)
3 Thread ANSI 1/2 FNPT;
Material version R1J: AISI 316L, version R1C: Alloy C276/2.4819; Weight: 0.7 kg (1.54 lbs)
Installation height H for devices with threaded connection and internal process isolating diaphragm

Height H 169 mm (6.65 in) 150 mm (5.91 in)
42 Endress+Hauser
➀ G 1/2A ➁ G 1A
H
H
3.5
ø30
3
3.5
ø18.4
18
14
2
2
dM = ø17.5 dM = ø28
G 1/2A ø30
ø23.6 G 1A
ø26.5 ø36
ø39
➂ G 1 1/2A ➃ G 2A
H
26 8
31
2
2
dM = ø28 dM = ø28
ø36 ø56.3
G 1 1/2A G2A
ø55 ø68
P01-PMx5xxxx-06-xx-xx-xx-001-package1
Thread ISO 228

1 Thread ISO 228 G 1/2 A DIN 3852 (viton seal included);
Material version GRJ: AISI 316L, version GRC: : Alloy C276; weight: 0.4 kg (0.88 lbs)
2 Thread ISO 228 G 1 A (viton seal included);
Material version GTJ: AISI 316L; weight: 0.7 kg (1.54 lbs)
3 Thread ISO 228 G 1 1/2 A
Material version GVJ: AISI 316L; weight: 1.1 kg (2.43 lbs)
4 Thread ISO 228 G 2 A
Material version GWJ: AISI 316L; weight: 1.5 kg (3.31 lbs)
Note!
Endress+Hauser offers a pressure sensor dummy for the welding neck with order number 52002643. Order
number for pressure sensor dummy: 52005082
– Welded neck
Order number: 52002643
AF 27
G½
21
Viton seal
13
G½
21
ø26
ø50
max. pressure resistance

100 bar
O-Ring 14 x 1.78
Viton or NBR
Version G0J: Thread ISO 228 G1/2; weight: 0.4 kg (0.88 lbs)
Endress+Hauser 43
m 1 MNPT n 1 1/2 MNPT o 2 MNPT
H
H
H
33.5
27
23
dM = ø28 dM = ø28 dM = ø28
1 NPT 1 1/2 NPT 2 NPT
P01-PMx5xxxx-06-xx-xx-xx-002-package1
Process connections PMP51 thread ANSI

Installation height H see following table.
1 Thread ANSI 1 MNPT;
2 Thread ANSI 1 1/2 MNPT;
3 Thread ANSI 2 MNPT
Installation height H for devices with threaded connection and flush-mounted process isolating
diaphragm
Description F31 housing F15 housing

G 1/2 163 mm (6.42 in) 148 mm (5.83 in)
G1 167 mm (6.57 in) 152 mm (5.98 in)
G 1 1/2 A 163 mm (6.42 in) 148 mm (5.83 in)
G2A 162 mm (6.38 in) 147 mm (5.79 in)
1 MNPT 162 mm (6.38 in) 147 mm (5.79 in)
1 1/2 MNPT 169 mm (6.65 in) 150 mm (5.91 in)
2 MNPT 199 mm (7.83 in) 144 mm (5.67 in)
M 20x1.5 163 mm (6.42 in) 148 mm (5.83 in)
44 Endress+Hauser
EN/DIN flanges, connection dimensions as per EN 1092-1/DIN 2527
h
H
g2
b
dM = ø28
60 (m)
g
k
D
P01-PMP71xxx-06-09-xx-xx-008
Process connection PMP51, EN/DIN flange with raised face, material AISI 316L
H: device height = height of device without flange h + flange thickness b
Height H → ä 46.
Flange 1) Boltholes
2)
Version Nominal Nominal Shape Dia- Thic- Raised Width of Quantity Diameter Hole circle Flange
diameter pressure meter kness face the raised weight 3)
face
D b g (m) g2 k
[mm] [mm] [mm] [mm] [mm] [mm] [kg]

CNJ DN 25 PN 10-40 B1 (D) 115 18 68 4) 4 4 14 85 1.2
4)
CPJ DN 32 PN 10-40 B1 (D) 140 18 78 9 4 18 100 1.9
4)
CQJ DN 40 PN 10-40 B1 (D) 150 18 88 14 4 18 110 2.2
CXJ DN 50 PN 25/40 B1 (D) 165 20 102 - 4 18 125 3.0
CZJ DN 80 PN 10-40 B1 (D) 200 24 138 - 8 18 160 5.5
1) The roughness of the surface in contact with the medium is Ra 0.8 μm (31.5 μin). Lower surface roughness available on request.
4) With these process connections the sealing surface is smaller than described in the standard. Due to a smaller sealing surface a special seal must be used.
Contact a seal manufacturer or your local Endress+Hauser Sales Center.
Endress+Hauser 45
h
H
g2
b
dM = ø28
60 (m)
g
k
D
P01-PMP71xxx-06-09-xx-xx-009
Process connection PMP51, ANSI flange with raised face RF (see table below)
H: device height = height of device without flange h + flange thickness b.. For height H → ä 46.
Flange 1) Boltholes
Ver- Material Nominal Class/ Diameter Thickness Diameter of Width of Quan Diameter Hole circle Flange
sion dia- Nominal raised face the raised tity weight 2)
meter pressure face
D b g (m) g2 k
[in] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [kg]
ANSI flanges
ANJ AISI 316/316L 3) 1 300 lb./sq.in 4.88 / 124 0.69 / 17.5 2.76 4) / 50.8 0.2 / 5 4 0.75 / 19.1 3.5 / 88.9 1.3
AEJ AISI 316/316L 3) 1 1/2 150 lb./sq.in 5 / 127 0.69 / 17.5 2.88 4) / 73.2 0.52 / 6.6 4 0.62 / 15.7 3.88 / 98.6 1.5
AQJ AISI 316/316L 3) 1 1/2 300 lb./sq.in 6.12 / 155.4 0.81 / 20.6 2.88 4) / 73.2 0.52 / 6.6 4 0.88 / 22.4 4.5 / 114.3 2.6
AFJ AISI 316/316L 3) 2 150 lb./sq.in 6 / 152.4 0.75 / 19.1 3.62 / 91.9 - 4 0.75 / 19.1 4.75 / 120.7 2.4
ARJ AISI 316/316L 3) 2 300 lb./sq.in 7.5 / 190.5 0.88 / 22.3 3.62 / 91.9 - 8 0.75 / 19.1 5 / 127 3.2
AGJ AISI 316/316L 3) 3 150 lb./sq.in 7.5 / 190.5 0.94 / 23.9 5 / 127 - 4 0.75 / 19.1 6 / 152.4 4.9
ASJ AISI 316/316L 3) 3 300 lb./sq.in 8.25 / 209.5 1.12 / 28.6 5 / 127 - 8 0.88 / 22.4 6.62 / 168.1 6.7
AHJ AISI 316/316L 3) 4 150 lb./sq.in 9 / 228.6 0.94 / 23.9 6.19 / 157.2 - 8 0.75 / 19.1 7.5 / 190.5 7.1
ATJ AISI 316/316L 3) 4 300 lb./sq.in 10 / 254 1.25 / 31.8 6.19 / 157.2 - 8 0.88 / 22.4 7.88 / 200.2 11.6
1) The roughness of the surface in contact with the medium is Ra 0.8 μm (31.5 μin). Lower surface roughness available on request.
3) Combination of AISI 316 for required pressure resistance and AISI 316L for required chemical resistance (dual rated)
4) With these process connections the sealing surface is smaller than described in the standard. Due to a smaller sealing surface a special seal must be used.
Contact a seal manufacturer or your local Endress+Hauser Sales Center.
Height H for devices with flange
46 Endress+Hauser
Hygienic process connection, flush-mounted process isolating diaphragm
1 2
H
H
dM dM
d d
D1 D1
3 4
H
H
m
m
dM dM
D1 D1
D3 D3
5 6
H
H
m
m
dM dM
D1 D1
D3 D3
P01-PMC51xxx-06-00-00-xx-000

Pos. Version Nominal Outer-∅ Outer-∅ Seal-∅ Membrane-∅ Height Height Weight
pressure PN D1 D3 d dM H m kg (lbs)
1 Clamp ½" TBJ 40 34 (1.34) - 27.5 (1.08) 17.2 (0.68) - 0.5 (1.10)
2 Clamp 1" TCJ 40 50.5 (1.99) - 43.5 (1.71) 21.65 (0.85) - 0.6 (1.32)
Clamp 1½" TJJ 40 50.5 (1.99) - 43.5 (1.71) 28 (1.10) - 0.6 (1.32)
Clamp 2" TDJ 40 64 (2.52) - 56.5 (2.22) 28 (1.10) - 0.7 (1.54)

3 DIN11851 B25 MXJ 40 43.4 (1.71) 63 (2.48) - 28 (1.10) 21 (0.83) 0.7 (1.54)
DIN11851 B32 MIJ 40 49.4 (1.94) 70 (2.76) - 28 (1.10) max. 165 (6.5) 21 (0.83) 0.8 (1.76)
4 DIN11851 B40 MZJ 40 55.4 (2.18) 78 (3.07) - 28 (1.10) 21 (0.83) 0.9 (1.98)
DIN11851 B50 MRJ 25 67.4 (2.65) 92 (3.62) - 28 (1.10) 22 (0.87) 1.1 (2.43)
5 SMS 1" T6J 25 35.5 (1.4) 51 (2.01) - 21.65 (0.85) 20 (0.79) 0.7 (1.54)
6 SMS 1½" T7J 25 55 (2.17) 74 (2.91) - 28 (1.10) 25 (0.98) 0.8 (1.76)

SMS 2" TXJ 25 65 (2.56) 84 (3.31) - 28 (1.10) 26 (1.02) 0.9 (1.98)
mm (in)
Endress+Hauser 47
7 10
H
dM dM
d D2
D2 k
D1 D1
15.5 (0.61)
8 11
H
dM H
D2 dM
D1 D2
D1
k
105 (4.13)
R
2 (0.08)
9 12
H
H
dM dM
D2 D2
k k
D1 D1
mm (in)
P01-PMC51xxx-06-00-00-xx-001

Pos. Version Nominal Outer-∅ Outer-∅ Hole circle-∅ Membran-∅ Height Weight
pressure PN D1 D2 k dM H kg (lbs)
7 Varivent B TPJ 40 52.7 (2.07) 31 (1.22) - 21.65 (0.85) 0.7 (1.54)
8 Varivent F TQJ 40 66 (2.6) 53 (2.09) - 28 (1.10) 0.9 (1.98)

Varivent N TRJ 40 84 (3.31) 71 (2.8) - 28 (1.10) 1.1 (2.43)
max. 165
9 Neumo D25 S1J 16 64 (2.52) 30.4 (1.2) 50 (1.97); 4 x, R 3,5 mm (0.14 in) 21.65 (0.85) 0.8 (1.76)
(6.5)
10 Neumo D50 S4J 16 89.5 (3.52) 49.9 (1.96) 70 (2.76); 4 x ø 9 mm (0.35 in) 28 (1.10) 1.2 (2.65)
11 DRD TIJ 25 64.5 (2.54) 52.5 (2.07) 84 (3.31); 4 x ø 11.5 mm (0.45 in) 28 (1.10) 1.0 (2.21)
12 APV Inline TMJ 10 99.5 (3.92) 69 (2.72) 82 (3.23); 6 x ø 8.6 mm (0.34 in) + 2 x M8 28 (1.10) 1.2 (2.65)
mm (in)
48 Endress+Hauser
Prepared for diaphragm seal mount
➀ ➁ ➂
h
ø2.5
5
ø7.95
P01-PMP71xxx-06-09-xx-xx-013
Version XSJ: prepared for diaphragm seal mount

1 Hole for fill fluid
2 Bearing
3 Setscrew with a hexagonal recess 4 mm (0.16 in)
PMP55 basic device
P01-PMP75xxx-06-09-xx-xx-012
PMP55 basic device with diaphragm seal

1 PMP55 basic device
2 Diaphragm seal, here e.g. flange diaphragm seal
Endress+Hauser 49
Process connections PMP55 Note!

(with diaphragm seal) • The weights of the diaphragm seals are given in the tables. See → ä 67 for the weight of the housing.
• The following drawings are schematic diagrams. In other words, the dimensions of a diaphragm seal supplied
may deviate from the dimensions given in this document.
• When using high-temperature oils the design can deviate significantly.
• Observe the information in the "Planning instructions for diaphragm seal systems" section → ä 77 ff.
• For further information please contact your local Endress+Hauser Sales Center.
Diaphragm seal cell structure (Pancake)
b
dM
P01-FMD78xxx-06-09-xx-xx-000
Process connection PMP55, material AISI 316L
Flange Diaphragm seal

Version Nominal Nominal Max. Thickness Max. diameter of the process Weight of two
diameter pressure 1) diameter isolating diaphragm diaphragm seals
D b dM
[mm] [mm] [mm] [kg]
UIJ DN 50 PN 16-400 102 20 59 2.6
UJJ DN 80 PN 16-400 138 20 89 4.6

UKJ DN 100 PN 16-400 162 20 89 6.2
[in] [lb/sq.in] [in (mm)] [in (mm)] [in (mm)] [kg]
ULJ 2 150-2500 4.01 (102) 0.79 (20) 2.32 (59) 2.6

UMJ 3 150-2500 5.35 (136) 0.79 (20) 3.50 (89) 4.6
URJ 4 150-2500 6.22 (158) 0.79 (20) 3.50 (89) 6.2
1) The specified nominal pressure applies to the diaphragm seal. The maximum pressure for the measuring device is
dependent on the lowest-rated element, with regard to pressure, of the selected components. See also → ä 32,
"Pressure specifications" section.
50 Endress+Hauser
SW SW
AF AF
h
x1
x1
dM dM
d1 NPT
G d2
d2
P01-PMP75xxx-06-09-xx-xx-003
Process connections PMP55, left: thread ISO 228, right: thread ANSI
Threaded connection Diaphragm seal
Ver- Material Thread Nomin Diamet Diamet Screw-in Across Max. Height Diaphra
sion al er er length flats diaphrag gm seal
pressur m weight
e diameter
PN d1 d2 x1 SW/AF dM h

GTJ G1 400 30 39 211) 41 30 19 0.4
GVJ G1 1/2 A 400 44 55 30 50 42 20 0.9
GWJ G2 400 56 68 30 65 50 20 1.9

U5J 316L 1 MNPT 400 - 48 28 41 24 37 0.6
U7J 1 1/2 0.9

400 - 60 30 41 36 20
MNPT
U8J 2 MNPT 400 - 78 30 65 38 35 1.8
1) 28 mm (1.1 in) in conjunction with high-temperature oil
Endress+Hauser 51
Pipe diaphragm seal (RDM) as per ISO2852
D
d2
L
P01-FMD78xxx-06-09-xx-xx-001
Process connection PMP55, material AISI 316L, surface roughness of the surfaces in contact with the medium Ra ≤ 0.8 μm
(31.5 μin) as standard. Lower surface roughness, see feature 570 "Service" version HK.
Version Nominal diameter Nominal Nominal diameter Diameter Diameter Height Face-to-face Diaphragm
pressure length seal weight
ISO2852 D [in] d2 [mm] h [mm] L [mm] [kg]
SBJ DN 25 PN40 1" 22.5 50.5 67 126 1.7
SCJ DN 38 PN40 1 1/2" 35.5 50.5 67 126 1.0
SDJ DN 51 PN40 2" 48.6 64 79 100 1.7
SIJ DN 10 PN40 3/4" 10.3 25 42 138.5 0.6
SJJ DN 16 PN40 3/4" 15.7 25 67 116 0.9
Pipe diaphragm seal (RDM) as per DIN 11851, Threaded adapter

h
G
D
P01-PMP55xxx-06-xx-xx-xx-000
Version Nominal diameter Nominal pressure Diameter Thread Height Face-to-face Diaphragm seal weight
length
DIN11851 D [in] G [mm] h [mm] L [mm] [kg]
SSJ DN 25 PN40 26 Rd 52 x 1/6 65 114 1.0
STJ DN 32 PN40 32 Rd 58 x 1/6 68 126 1.3
SUJ DN 40 PN40 38 Rd 65 x 1/6 75 146 1.9
SZJ DN 50 PN25 50 Rd 78 x 1/6 78 156 2.8
52 Endress+Hauser
Pipe diaphragm seal (RDM) as per DIN11864-1
G
d
L
Version Nominal diameter Nominal Diameter Thread Face-to-face Diaphragm

DIN11864-1 pressure length seal weight
d G L
[in] [mm] [mm] [kg]
VAJ DN 25 PN40 26 Rd 52 x 1/6 128 1.3

VCJ DN 40 PN40 38 Rd 65 x 1/6 160 2.0
VDJ DN 50 PN25 50 Rd 78 x 1/6 170 3.0
Aseptic screwed union, threaded connection, DIN 11864-1 Form A; pipe DIN 11866-A
20
30
dM
d
G
Threaded adapter Diaphragm seal
Version Nominal Nominal Diameter Thread Max. diaphragm Weight

diameter pressure diameter Diaphragm
seal
d G dM
[mm] [mm] [kg]
NCJ DN 40 55 Rd 65 x 1/6 35 1.5

PN 16
NDJ DN 50 67 Rd 78 x 1/6 45 2.3
Endress+Hauser 53
Aseptic flange connection, DIN 11864-2 Form A; pipe DIN 11866-1
10
30
dM
d
K
D
Collar flange Diaphragm seal
Version Nominal Nominal Hole circle Seal diameter Outer Max. Diaphragm
diameter pressure diameter diameter diaphragm seal
diameter weight
K d D dM
[mm] [mm] [mm] [mm] [kg]

NFJ DN 32 59 47.7 76 25 1.5
NXJ DN 40 PN 16 65 53.7 82 35 1.7
NZJ DN 50 77 65.7 94 45 2.2
Tri-Clamp ISO 2852

h
dM
C7
P01-FMD78xxx-06-09-xx-xx-005
Process connection PMP55, material: AISI 316L, surface roughness of the surfaces in contact with the medium
Ra ≤ 0.8 μm (31.5 μin) as standard. Lower surface roughness, see feature 570 "Service" version HK.
Version Nominal Nominal Nominal Diameter Max. Height Diaphragm

diameter diameter diameter diaphragm seal weight
ISO 2852 DIN 32676 diameter
[in] C7 [mm] dM [mm] h [mm] [kg]
TCJ DN 25 DN 25 1 50.5 24 37 0.32
TJJ 1) DN 38 DN 40 1 1/2 50.5 34 30 1.0

1)
TDJ DN 51 DN 50 2 64 48 30 1.1
TFJ DN 76.1 – 3 91 73 30 1.2
1) Diaphragm seal versions optionally in conformity with ASME-BPE for use in biochemical processes, wetted surfaces
Ra ≤ 0.38 μm (15 μin), electropolished; to be ordered using feature 570 "Service", version "HK" in the order code.
54 Endress+Hauser
Varivent N for pipes
30
H
dM max.
D
Process connection PMP55, material AISI 316, 3A, surface roughness of the surfaces in contact with the medium
Version Description Nominal Diameter Max. diaphragm Max. Diaphragm

pressure diameter installation seal weight
height
D dM H
[bar] [mm] [mm] [mm] [kg]
TQJ Type F for tubes

50 30 0.6
DN 25 - DN 32
PN 40 250
TRJ 1) Type N for tubes
68 64 0.8
DN 40 - DN 162
1) Diaphragm seal versions optionally in conformity with ASME-BPE for use in biochemical processes, wetted surfaces
Ra ≤ 0.38 μm (15 μin), electropolished; to be ordered using feature 570 "Service", version "HK" in the order code.
DRD DN50 (65 mm)

41
23.6
dM max. =50 4 x ø11.5

ø65–1.2
ø84
ø105
P01-FM78xxx-06-09-xx-xx-002
Process connection PMP55, surface roughness of the surfaces in contact with the medium Ra ≤ 0.8 μm (31.5 μin) as stand-
ard. Lower surface roughness, see feature 570 "Service" version HK.
Version Material Nominal Diaphragm

pressure seal weight
[kg]
TIJ AISI 316L PN 25 0.75
Endress+Hauser 55
SMS nozzles with coupling nut
h
m
f
dM
G
D
P01-PMP75xxx-06-09-xx-xx-009
Version Nominal Nominal Diamete Adapter Thread Height Height Max. Diaphrag
diameter pressure r height diaphrag m seal
m weight
diameter
D f G m h dM
[in] [bar] [mm] [mm] [mm] [mm] [mm] [kg]
T6J 1 PN 25 54 3.5 Rd 40 – 1/6 20 42.5 24 0.25

T7J 1 1/2 PN 25 74 4 Rd 60 – 1/6 25 57 36 0.65
TXJ 2 PN 25 84 4 Rd 70 – 1/6 26 62 48 1.05
APV-RJT nozzles with coupling nut

h
m
dM
G
D
P01-PMP75xxx-06-09-xx-xx-010
Version Nomina Nomina Diamet Adapter Thread Height Height Max. Diaphrag
l l er height diaphragm m seal
diamete pressur diameter weight
r e
PN D f G m h dM
T0J 1 PN 40 77 6.5 1 13/16 – 1/8" 22 42.6 21 0.45
T1J 1 1/2 PN 40 72 6.4 2 5/16 – 1/8" 22 42.6 28 0.75
T2J 2 PN 40 86 6.4 2 7/8 – 1/8" 22 42.6 38 1.2
56 Endress+Hauser
APV-ISS nozzles with coupling nut
f
m
SW/AF dM
G
D
P01-PMP75xxx-06-09-xx-xx-011
Versi Nomin Nomi Diamet Adapter Thread Height Across Height Max. Diaphra
on al nal er height flats diaphragm gm seal
diamet pressu seal weight
er re
D f G m AF h dM
T3J 1 PN 40 54.1 4 1 1/2" – 1/8" 30 46.8 50 24 0.4
T4J 1 1/2 PN 40 72 4 2" – 1/8" 30 62 50 34 0.6
T5J 2 PN 40 89 4 2 1/2" – 1/8" 30 77 50 45 1.1
Taper adapter with coupling nut, DIN 11851

H
30
f
m
dM
D
G
Process connection PMP55, material AISI 316L, 3A, surface roughness of the surfaces in contact with the medium
Taper adapter Slotted nut Diaphragm seal

Version Nomina Nomin Diameter Adapter Thread Height Max. Max. Diaphra
l al height diaphragm installat gm seal
diamete pressu diameter ion weight
r re height
D f G m dM H
MIJ DN 32 PN 40 50 10 Rd 58 x 1/6" 21 32 1.9
MZJ DN 40 PN 40 56 10 Rd 65 x 1/6" 21 38 2.0
MRJ DN 50 PN 25 68.5 11 Rd 78 x 1/6" 22 52 250 1.1
MSJ DN 65 PN 25 86 12 Rd 95 x 1/6" 35 66 2.0
MTJ DN 80 PN 25 100 12 Rd 110 x 1/4" 30 81 2.55
Endress+Hauser 57
NEUMO BioControl
d2
h
dM max.
d
d3
d1
D
Threaded adapter Diaphragm seal
Version Nominal Nomin Diamet Hole Diameter Diamet Height Max. Diaphrag
diameter al er circle er diaphragm m seal
pressu diamet diameter weight
re er
D d1 d2 d3 h dM
[mm] [mm] [mm] [mm] [mm] [mm] [kg]

S4J DN 50 PN 16 90 70 4x∅9 50 27 40 1.1
58 Endress+Hauser
EN/DIN flanges, connection dimensions as per EN 1092-1/DIN 2527 and DIN 2501-1
40
g2
dM
b
f
g
k
D
P01-PMP75xxx-06-09-xx-xx-002
Process connection PMP55, EN/DIN flange with flush-mounted process isolating diaphragm, material AISI 316L
Flanges Boltholes Diaphragm seal

1)
Version Nominal Nominal Shape Diameter Thick Raised face Quantity Diameter Hole Max. Diaphragm
diameter pressure ness circle diaphragm seal weight
diameter
D b g f g2 k dM
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg]
CNJ DN 25 PN 10-40 B1 (D) 115 18 66 3 4 14 85 32 2.1

QIJ DN 25 PN 63-160 B2 (E) 140 24 68 2 4 18 100 28 2.5
QJJ DN 25 PN 250 B2 (E) 150 28 68 2 4 22 105 28 3.7
QSJ DN 25 PN 400 B2 (E) 180 38 68 2 4 26 130 28 7.0

CPJ DN 32 PN 10-40 B1 (D) 140 18 77 2.6 4 18 100 34 1.9
CQJ DN 40 PN 10-40 B1 (D) 150 18 87 2.6 4 18 110 48 2.2
CXJ DN 50 PN 10-40 B1 (D) 165 20 102 3 4 18 125 59 3.0
PDJ DN 50 PN 63 B2 (E) 180 26 102 3 4 22 135 59 4.6
QOJ DN 50 PN 100-160 B2 (E) 195 30 102 3 4 26 145 59 6.2
QMJ DN 50 PN 250 B2 (E) 200 38 102 3 8 26 150 59 7.7
QVJ DN 50 PN 400 B2 (E) 235 52 102 3 8 30 180 59 14.7
CZJ DN 80 PN 10-40 B1 (D) 200 24 138 3.5 8 18 160 89 5.3
PPJ DN 80 PN 100 B2 (E) 230 32 138 4 8 24 180 89 8.9
PQJ DN 100 PN 100 B2 (E) 265 36 175 5 8 30 210 89 13.7
Endress+Hauser 59
EN/DIN flanges with extended diaphragm seal, connection dimensions as per EN 1092-1/DIN
2527 and DIN 2501-1
40
g2
b
L
f
dM
d3
g
k
D
P01-PMP75xxx-06-09-xx-xx-015
Process connection PMP55, EN/DIN flange with flush-mounted process isolating diaphragm, material AISI 316L
Flanges Boltholes Diaphragm seal
Version Nominal Nominal Shape 1) Diameter Thick Raised face Quantity Diameter Hole Max. Diaphragm
diameter pressure ness circle diaphragm seal weight
diameter
D b g f g2 k dM

FDJ 2) DN 50 PN 10-40 B1 (D) 165 20 102 3 4 18 125 47 2)
FEJ 2) DN 80 PN 10-40 B1 (D) 200 24 138 3.5 8 18 160 72 2)

2) Available with 50 mm (1.97 in), 100 mm (3.94 in) or 200 mm (7.87 in) extended diaphragm seal, for extended diaphragm seal diameter and weight see the
following table
Version Nominal Nominal Extended Extended Diaphragm

diameter pressure diaphragm seal diaphragm seal seal weight
length (L) diameter d3
[mm] [mm] [kg]
FDJ DN 50 PN 10-40 50 / 100 / 200 48.3 3.2 / 3.8 / 4.4

FEJ DN 80 PN 10-40 50 /100 / 200 76 6.2 / 6.7 / 7.8
60 Endress+Hauser
40
g2
400 – 2500 lb/sq.in

dM
b
150, 300 lb/sq.in
0.06 in (1.6 mm)
0.25 in (6.4 mm)

g
k
D
P01-PMP75xxx-06-09-xx-xx-001
Process connection PMP55, ANSI flange, material AISI 316/316L (Combination of AISI 316 for required pressure
resistance and AISI 316L for required chemical resistance (dual rated))
Flange Boltholes Diaphragm seal
Version Nominal Class Diameter Thickness Raised face Quantity Diameter Hole circle Max. Diaphrag
diameter diaphragm m seal
diameter weight
D b g g2 k dM
[in] [lb./sq.in] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [in] / [mm] [kg]
ACJ 1 150 4.25 /108 0.56 / 14.2 2 / 50.8 4 0.62 / 15.7 3.12 / 79.2 1.26 / 32 1.2
ANJ 1 300 4.88 / 124 0.69 / 17.5 2 / 50.8 4 0.75 / 19.1 3.5 / 88.9 1.26 / 32 1.3
A0J 1 400/600 4.88 / 124 0.69 / 17.5 2 / 50.8 4 0.75 / 19.1 3.5 / 88.9 1.26 / 32 1.4
A2J 1 900/1500 5.88 / 149.4 1.12 / 28.6 2 / 50.8 4 1 / 25.4 4 / 101.6 1.26 / 32 3.2
A4J 1 2500 6.25 / 158.8 1.38 / 35.1 2 / 50.8 4 1 / 25.4 4.25 / 108 1.26 / 32 4.6
AEJ 1 1/2 150 5 / 127 0.69 / 17.5 2.88 / 73.2 4 0.62 / 15.7 3.88 / 96.6 1.89 / 48 1.5
AQJ 1 1/2 300 6.12 / 155.4 0.81 / 20.6 2.88 / 73.2 4 0.88 / 22.4 4.5 / 114.3 1.89 / 48 2.6
AFJ 2 150 6 / 152.4 0.75 / 19.1 3.62 / 91.9 4 0.75 / 19.1 4.75 / 120.7 2.32 / 59 2.2
ARJ 2 300 6.5 / 165.1 0.88 / 22.4 3.62 / 91.9 8 0.75 / 19.1 5 / 127 2.32 / 59 3.4
A1J 2 400/600 6.5 / 165.1 1 / 25.4 3.62 / 91.9 8 0.75 / 19.1 5 / 127 2.32 / 59 4.3
A3J 2 900/1500 8.5 / 215.9 1.5 / 38.1 3.62 / 91.9 8 1 / 25.4 6.5 / 165.1 2.32 / 59 10.3
A5J 2 2500 9.25 / 235 2 / 50.8 3.62 / 91.9 8 1.12 / 28.6 6.75 / 171.5 2.32 / 59 15.8
AGJ 3 150 7.5 / 190.5 0.94 / 23.9 5 / 127 4 0.75 / 19.1 6 / 152.4 3.50 / 89 5.1
ASJ 3 300 8.25 / 209.5 1.12 / 28.6 5 / 127 8 0.75 / 19.1 6 / 152.4 3.50 / 89 7.0
AHJ 4 150 9 / 228.6 0.94 / 23.9 6.19 / 157.2 8 0.75 / 19.1 7.5 / 190.5 3.50 / 89 7.2
ATJ 4 300 10 / 254 1.25 / 31.8 6.19 / 157.2 8 0.88 / 22.4 7.88 / 200.2 3.50 / 89 11.7
Endress+Hauser 61
ANSI flanges with extended diaphragm seal, connection dimensions as per ANSI B 16.5, raised face
RF
40
g2
b
L
400 – 2500 lb/sq.in
150, 300 lb/sq.in
0.06 in (1.6 mm)
0.25 in (6.4 mm)

dM
d3
g
k
D
P01-PMP75xxx-06-09-xx-xx-016
Process connection PMP55, ANSI flange with extended diaphragm seal, material AISI 316/316L (Combination of AISI
316 for required pressure resistance and AISI 316L for required chemical resistance (dual rated))
Flange Boltholes Diaphragm seal
Version Nominal Class Dia- Thick- Raised face Quantity Diameter Hole circle Max. Diaphragm
diameter meter ness diaphragm seal weight
diameter
D b g g2 k dM
[in] [lb./ [in] / [in] / [in] / [in] / [in] / [in] / [kg]
sq.in] [mm] [mm] [mm] [mm] [mm] [mm]
1)
FMJ 1) 2 150 6 / 152.4 0.75 / 19.1 3.62 / 91.9 4 0.75 / 19.1 4.75 / 120.7 1.85 / 47
FNJ 1) 3 150 7.5 / 190.5 0.94 / 23.9 5 / 127 4 0.75 / 19.1 6 / 152.4 2.83 / 72 1)
FWJ 1) 3 300 8.25 / 209.5 1.12 / 28.6 5 / 127 8 0.88 / 22.4 6.62 / 168.1 2.83 / 72 1)
FOJ 1) 4 150 9 / 228.6 0.94 / 23.9 6.19 / 157.2 8 0.75 / 19.1 7.5 / 190.5 3.50 / 89 1)
FXJ 1) 4 300 10 / 254 1.25 / 31.8 6.19 / 157.2 8 0.88 / 22.4 7.88 / 200.2 3.50 / 89 1)
1) Available with 2 in, 4 in, 6 in or 8 in extended diaphragm seal, for extended diaphragm seal diameter and weight see the following table
Version Nominal Class Extended diaphragm seal length (L) Extended diaphragm seal Diaphragm
diameter diameter d3 seal weight
[in] [lb./sq.in] in (mm) in (mm) [kg]
FMJ 2 150 2 (50.8) / 4 (101.6) / 6 (152.4) / 8 (203.2) 1.9 (48.3) 3.0 / 3.4 / 3.9 / 4.4
FNJ 3 150 2 (50.8) / 4 (101.6) / 6 (152.4) / 8 (203.2) 2.99 (75.9) 6.0 / 6.6 / 7.1 / 7.8
FWJ 3 300 2 (50.8) / 4 (101.6) / 6 (152.4) / 8 (203.2) 2.99 (75.9) 7.9 / 8.5 / 9.0 / 9.6
FOJ 4 150 2 (50.8) / 4 (101.6) / 6 (152.4) / 8 (203.2) 3.7 (94) 8.6 / 9.9 / 11.2 / 12.4
FXJ 4 300 2 (50.8) / 4 (101.6) / 6 (152.4) / 8 (203.2) 3.7 (94) 13.1 / 14.4 / 15.7 / 16.9
62 Endress+Hauser
JIS flanges, connection dimensions as per JIS B 2220 BL, raised face RF
g2
40
b
dM
f
g
k
D
P01-PMP75xxx-06-09-xx-xx-000
Process connection PMP55, JIS flange with raised face RF, material AISI 316L
Flange 1) Boltholes Diaphragm seal
Vers Nominal Nominal Dia Thick Diameter Height Quan Dia Hole Max. Diaphra
ion diameter pressure meter ness of raised of tity meter circle diaphragm gm seal
face raised diameter weight2)
face
D b g f g2 k dM
KCJ 25 A 10 K 125 14 67 1 4 19 90 32 1.5

KEJ 40 A 10 K 140 16 81 2 4 19 105 48 2.0
KFJ 50 A 10 K 155 16 96 2 4 19 120 59 2.3
KGJ 80 A 10 K 185 18 127 2 8 19 150 89 3.3
KHJ 100 A 10 K 210 18 151 2 8 19 175 89 4.4
1) The roughness of the surface in contact with the medium, including the raised face of the flanges (all standards)
made of Hastelloy C, Monel or tantalum, is Ra 0.8 μm. Lower surface roughness available on request.
Endress+Hauser 63
Thread 1/2 NPT and 1 NPT, separator
ø118 ø118
76
94.5
26
19
44.5
12
27
1/2 NPT
15
SW 27
27 AF
ø30 1 NPT
SW 36
36 AF
ø52
P01-PMP75xxx-06-09-xx-xx-008
Process connection PMP55, version "UGJ" and "UHJ", threaded, material AISI 316L, seal Viton
Version Measuring range Description Nominal Diaphragm seal weight

pressure
[kg]
UGJ ≤ 250 bar 1/2 NPT PN 250 4.75
UHJ ≤ 250 bar 1 NPT PN 250 5.0
Thread ISO 228 G 1/2 A and ANSI 1/2 MNPT, separator
ø72.6 ø72.6
70
70
SW 30 SW 30
AF 30 AF 30
14
14
ø18.4
17
21.5
20
3
ø4 ø11.4
ø6 1/2 - 14 NPT
G 1/2A
P01-PMP75xxx-06-09-xx-xx-004
Process connection PMP55, version "UBJ" and "UCJ", welded, material AISI 316L

pressure
[kg]
UBJ ≤ 160 bar ISO 228 G 1/2 A PN 160 1.43
UCJ ≤ 160 bar ANSI 1/2 MNPT PN 160 1.43
64 Endress+Hauser
100 100
90
89
➀ ➀
SW22 SW22
22 AF 22 AF
6 1/2 NPT
G½
P01-PMP75xxx-06-09-xx-xx-013
Process connection PMP55, left version "UDJ" threaded, with threaded connection ISO 228 G 1/2 B, right version "UEJ"
with threaded connection ANSI 1/2 MNPT
1 PTFE seal as standard max. 260°C (500°F) (higher temperatures on request)

pressure
[kg]
UDJ ≤ 40 bar ISO 228 G 1/2 B PN 40 1.43
UEJ ≤ 40 bar ANSI 1/2 MNPT PN 40 1.43
ø115 ø115
84
92.5
SW 36 SW 36
19
SW 22
17
20
ø2.5
1/2 NPT
3
ø4
ø6
G 1/2A
P01-PMP75xxx-06-09-xx-xx-007
Process connection PMP55, version "UDJ" and "UEJ", threaded, with integrated seal lip, material AISI 316L

pressure
[kg]
UDJ > 40 bar ISO 228 G 1/2 A PN 400 4.75

UEJ > 40 bar ANSI 1/2 MNPT PN 400 4.75
Endress+Hauser 65
Universal adapter
b
H
a
ø43.5
Material: b = top section AISI 316L (1.4404), a = bottom section AISI 316L (1.4435);
Surface roughness of the surfaces in contact with the medium Ra ≤ 0.76 μm (30 μin) as standard. Lower surface roughness
available on request.
Process connection PMP55, version UPJ 1): universal adapter incl. silicone molded seal, EHEDG, 3A Class I,
FDA 21 CFR 177.2600, USP Plastic Class VI-70C; Order no.: 52023572
Installation height H, devices with universal adapter
Universal adapter 196 mm (7.72 in) 189 mm (7.44 in)
1) Endress+Hauser supplies these slotted nuts in stainless steel AISI 304 (DIN/EN material number 1.4301) or in AISI 304L (DIN/EN material number 1.4307).
66 Endress+Hauser
Wall and pipe mounting with

69
mounting bracket
➁
➀
127
112
52
122 140
158 175
70
86
63
➃
➂ 114
95
ø6
ø52
F31 housing dimensions. Housing weight → ä 67. ➀ Cover without viewing window. ➁ Cover with viewing window.
F15 housing dimensions. Housing weight → ä 67. ➂ Cover without viewing window. ➃ Cover with viewing window.
Weight Housing
F31 (aluminum) F15 (stainless Separate housing

steel)
With electronic insert and 1.1 kg (2.43 lbs) 0.8 kg (1.76 lbs)
local display Weight of housing + 0.5 kg (1.10 lbs).
With electronic insert without 1.0 kg (2.21 lbs) 0.7 kg (1.54 lbs) Weight of sensor + 0.5 kg (1.10 lbs).
local display
Process connections
• Process connections PMC51 (with ceramic process isolating diaphragm): → ä 33 ff
• Process connections PMP51 (with metal process isolating diaphragm): → ä 42 ff
• Process connections PMP55 (with diaphragm seal): → ä 50 ff
Endress+Hauser 67
Material (not wetted) Housing
16 1
14
13 15
6
9 8
3
5
10 4
12 11 7
P01-xMxx3xxx-14-xx-xx-xx-002
Item num- Component part Material

ber
F31 housing, RAL 5012 (blue) Die-cast aluminum with protective powder-coating on
1
polyester base
Cover, RAL 7035 (gray) Die-cast aluminum with protective powder-coating on
2
polyester base
3 Cover seal EPDM
4 Sight glass Mineral glass
5 Sight glass seal Silicone (VMQ)
6 External ground terminal AISI 304 (1.4301)
7 Nameplates Plastic film
8 Attachement for tie-on label AISI 304 (1.4301)/ AISI 316 (1.4401)
9 Pressure compensation filter PA6 GF10
10 Pressure compensation filter, O-ring Silicone (VMQ)
11 Sealing ring EPDM
12 Snap ring PC Plastic
13 Seal of cable gland and blind plug EPDM/NBR
14 Cable gland Polyamide (PA) or CuZn nickel-plated
15 Blind plug PBT-GF30 FR
for dust ignition-proof, Ex d, FM XP and CSA XP:
AISI 316L (1.4435)
16 Cover clamp Clamp AISI 316L (1.4435), screw A4
68 Endress+Hauser
14
1
7
6
2
3
5
13 12 11 10 9 8 4
P01-xMxx3xxx-14-xx-xx-xx-002
Item number Component part Material

1 F15 housing
AISI 316L (1.4404)
2 Cover
3 Cover seal Silicone with PTFE coating
4 Sight glass for non-hazardous area, ATEX Ex ia,
NEPSI Zone 0/1 Ex ia, IECEx Zone 0/1 Ex ia, FM Polycarbonate (PC)
NI, FM IS, CSA IS
4 Sight glass for ATEX 1/2 D, ATEX 1/3 D, ATEX 1
GD, ATEX 1/2 GD, ATEX 3 G, FM DIP, CSA dust Mineral glass
ignition-proof
5 Sight glass seal Silicone (VMQ)
6 External ground terminal AISI 304 (1.4301)
7 Attachement for tie-on label AISI 304 (1.4301)/ AISI 316 (1.4401)
8 Pressure compensation filter PA6 GF10
9 Pressure compensation filter, O-ring Silicone (VMQ)
10 Nameplates lasered
11 Cable gland Polyamide (PA), for dust ignition-proof: CuZn nickel-
plated
12 Seal of cable gland and blind plug NBR/Silicone/EPDM
13 Sealing ring EPDM
14 Screw A4-50
Endress+Hauser 69
Connecting parts
4 4
1
5
6
2 3
7
8
1 9
6
5
Item number Component part Material

1 Connection between the AISI 316L (1.4404)
housing and process connection
2 Mounting bracket Bracket AISI 304 (1.4301), AISI 304L (1.4306)
3 Screw and nuts A2-70
4 Half-shells: AISI 304L (1.4306)
5 Seal for cable from FKM, EPDM
separate housing
6 Gland for cable from separate AISI 316L (1.4404)
housing:
Screws: A2 or A4
7 PE cable for separate housing Abrasion-proof cable with strain-relief Dynema members; shielded using
aluminum-coated film; insulated with polyethylene (PE-LD), black;
copper wires, twisted, UV-resistant
8 FEP cable for separate housing Abrasion-proof cable; shielded using galvanized steel wire netting;
insulated with fluorinated ethylene propylene (FEP), black;
copper wires, twisted, UV-resistant
9 Process connection adapter for AISI 316L (1.4404)
separate housing
Filling oil
See "Ordering information" (→ ä 83)
Miscellaneous:
• Diaphragm seal capillary: AISI 316 Ti (1.4571)
• Protective hose for diaphragm seal capillary: AISI 304 (1.4301)
70 Endress+Hauser
Material (wetted) Note!

The wetted device components are listed in the "Mechanical construction" (→ ä 33 ff) and "Ordering
information" (→ ä 83 ff) sections.
TSE Certificate of Suitability (Transmissible Spongiform Encephalopathy)

The following applies to all process wetted device components:
• They do not contain any materials derived from animals.
• No auxiliaries or operating materials derived from animals are used in production or processing.
Process connections
• "Clamp connections" and "Hygienic process connections" (see also "Ordering information" section):
AISI 316L (DIN/EN material number 1.4435)
• Endress+Hauser supplies process connections with threaded connections and DIN/ EN flanges made of
stainless steel as per AISI 316L (DIN/EN material number 1.4404 (AISI 316) or 14435). With regard to their
stability-temperature property, the materials 1.4404 and 1.4435 are grouped together under 13E0 in EN
1092-1 Tab.18. The chemical composition of the two materials can be identical.
• Some process connections are also available in the material Alloy C276 (DIN/EN material number 2.4819).
See the information in the "Mechanical construction" section.
Process isolating diaphragm

• PMC51: Al2O3 aluminum-oxide ceramic, Ceraphire® (FDA 21 CFR 186.1256, USP
Class VI), ultrapure 99.9 % (→ see also www.endress.com/ceraphire)
• PMP51:
– AISI 316L (DIN/EN material number 1.4435)
– AISI 316L with gold-rhodium coating
– Alloy C276 (DIN/EN material number 2.4819)
• PMP55:
– AISI 316L (DIN/EN material number 1.4435)
– AISI 316L with gold-rhodium coating
– AISI 316L with 0.09 mm PTFE foil (not for vacuum applications)
– AISI 316L with 0.25 mm PTFE foil (not for vacuum applications)
– Alloy C276 (DIN/EN material number 2.4819)
– Monel
– Tantalum
Seals
See ordering information, → ä 83 ff
Endress+Hauser 71
Human interface
Operating elements Local display (optional) for devices with HART, PROFIBUS PA or FOUNDATION Fieldbus
electronics
A 4-line liquid crystal display (LCD) is used for display and operation. The local display shows measured values,
dialog texts as well as fault and notice messages in plain text, thereby supporting the user at every stage of
operation. The liquid crystal display of the device can be turned in 90° stages.
Depending on the orientation of the device, this makes it easy to operate the device and read the measured
values.
Functions:
• 8-digit measured value display including sign and decimal point, bar graph for 4 to 20 mA HART as current
display; or for PROFIBUS PA as graphic display of the standardized value of the AI Block; for FOUNDATION
Fieldbus as graphic display of the transducer output in relation to the set pressure range.
• Three keys for operation
• Simple and complete menu guidance as parameters are split into several levels and groups
• Each parameter is given a 3-digit ID number for easy navigation
• Possibility of configuring the display to suit individual requirements and preferences, such as language,
alternating display, contrast setting, display of other measured values such as sensor temperature etc.
• Comprehensive diagnostic functions (fault and warning message etc.)
Measured value display

Device tag Value
Header line Symbol

Main line
Information Unit
line
– + E
Bargraph
Operating keys Operating menu
Parameter with selection list

Direct
Access
Selection Code
options
Freely editable parameter
Value that
can be
edited
P01-Mxxxxxxx-07-xx-xx-en-002
72 Endress+Hauser
Local display (optional) for devices with analog electronics

A 4-line liquid crystal display (LCD) is used. The local display shows measured values, fault messages and notice
messages. The liquid crystal display of the device can be turned in 90° stages.
Depending on the orientation of the device, this makes it easy to operate the device and read the measured
values.
Functions:
• 8-digit measured value display including sign and decimal point, bar graph for 4 to 20 mA as current display.
• Diagnostic functions (fault and warning message etc.)
Measured value display

Value
F
F Symbol
Main line
Information Unit
line
Bargraph
P01-Mxxxxxxx-07-xx-xx-en-002
Operating keys and elements located on the electronic insert
➅ Display ➁ Display
Zero Zero
➄ ➂
➆ Span on ➀ Span on
off off
SW / Alarm min
SW / P2=High
delta p only
damping
damping
SW / Ö
on on
1 2 3 4 5 off 1 off
SW / Alarm min
SW / P2=High
damping
damping
SW / Ö
➀ ➁➂ ➃ ➃
P01-Mxxxxxxx-19-xx-xx-xx-001 P01-Mxxxxxxx-19-xx-xx-xx-010
HART electronic insert Analog electronic insert

1 DIP switch for locking/unlocking parameters 1 Operating keys for lower range value (zero), upper
relevant to the measured value range value (span), position zero adjustment or reset
2 DIP switch for switching damping on/off 2 Green LED to indicate successful operation
3 DIP switch for alarm current SW / Alarm Min 3 Slot for optional local display
(3.6 mA) 4 DIP switch for switching damping on/off
4 DIP switch only for Deltabar M
5 Slot for optional local display
6 Green LED to indicate successful operation
7 Operating keys for lower range value (zero), upper
range value (span), position zero adjustment or reset
Endress+Hauser 73
9
10 Zero
Display ➆ Zero
Display
➇ ➅
damp
not used
1
2
3
on ➇ TM on
delta p on:Ö off:SW 4
only on:P2=High off:SW 5 off FOUNDATION off
SW / P2=High
delta p only
on SW
simulation
damping
off HW
SW / Ö
Address
on ➅ ➆ on
1 2 3 4 5
SW / P2=High
off 1 2 3 4 5 off
SW / P2=High
Simulation
damping
damping
SW / Ö
SW / Ö
➀ ➁ ➂ ➃➄ ➀ ➁ ➂ ➃➄
P01-Mxxxxxxx-19-xx-xx-xx-013 P01-Mxxxxxxx-19-xx-xx-xx-014
PROFIBUS PA electronic insert FOUNDATION Fieldbus electronic insert

1 DIP switch for locking/unlocking parameters 1 DIP switch for locking/unlocking parameters
relevant to the measured value relevant to the measured value
2 DIP switch for switching damping on/off 2 DIP switch for switching damping on/off
3/4/5 Not used 3 DIP-switch for simulation mode
6 DIP-switch for hardware address 4/5 Not used
7 DIP-switch for bus address SW / HW 6 Slot for optional local display
8 Slot for optional local display 7 Green LED to indicate successful operation
9 Operating key for position zero adjustment (Zero) or 8 Operating key for position zero adjustment (Zero) or
reset reset
10 Green LED to indicate successful operation
Onsite operation
Function Operation without display with operating keys and DIP-switches on the electronic insert
Analog electronics HART PROFIBUS PA FOUNDATION Fieldbus
Position adjustment (zero point correction) X X X X

Setting lower range value and upper range value -
X X -- --
reference pressure present at the device
Device reset X X X X
Locking and unlocking parameters relevant to the

-- X X X
measured value
Value acceptance indicated by the green LED X X X X
Switching damping on and off X X X X
Function Operation via display (option)
Analog electronics HART PROFIBUS PA FOUNDATION Fieldbus
Position adjustment (zero point correction) -- X X X
Setting lower range value and upper range value -

-- X X X
reference pressure present at the device
Device reset -- X X X
Locking and unlocking parameters relevant to the

-- X X X
measured value
Value acceptance indicated by the green LED -- -- -- --
Switching damping on and off -- X X X
74 Endress+Hauser
Remote operation All software parameters are accessible depending on the position of the write protection switch on the device.
HART
Remote operation via:
• FieldCare (see "Hardware and software for onsite and remote operation" section → ä 76 ff) with
Commubox FXA195 (see "Hardware and software for onsite and remote operation" section → ä 76 ff)
• Field Xpert SFX100. Field Xpert is an industrial PDA with integrated 3.5" touchscreen from Endress+Hauser
based on Windows Mobile. It communicates via wireless with the optional VIATOR Bluetooth modem
connected to a HART device point-to-point or wireless via WiFi and Endress+Hauser’s Fieldgate FXA520.
Field Xpert also works as a stand-alone device for asset management applications. For details refer to
BA00060S/00/EN.
PROFIBUS PA
• FieldCare (see "Hardware and software for onsite and remote operation" section → ä 76 ff)
– Profiboard: For connecting a PC to PROFIBUS
– Proficard: For connecting a laptop to PROFIBUS
FOUNDATION Fieldbus
• FieldCare (see "Hardware and software for onsite and remote operation" → ä 76 ff)
– NI PCMCIA-FBUS series 2 to connect a laptop to FF.
• Use an FF-configuration program for example NI-FBUS Configurator, to
– connect devices with "FOUNDATION Fieldbus signal" into an FF-network
– set FF-specific parameters
Operation with NI-FBUS Configurator:
The NI-FBUS Configurator is an easy-to-use graphical environment for creating linkages, loops, and a
schedule based on the fieldbus concepts.
You can use the NI-FBUS Configurator to configure a fieldbus network as follows:
– Set block and device tags
– Set device addresses
– Create and edit function block control strategies (function block applications)
– Configure vendor-defined function and transducer blocks
– Create and edit schedules
– Read and write to function block control strategies (function block applications)
– Invoke Device Description (DD) methods
– Display DD menus
– Download a configuration
– Verify a configuration and compare it to a saved configuration
– Monitor a downloaded configuration
– Replace a virtual device by a real device
– Save and print a configuration
Note!
Endress+Hauser 75
Hardware and software for Commubox FXA195

onsite and remote operation
For intrinsically safe HART communication with FieldCare via the USB interface. For details refer to
TI00404F/00/EN.
Field Xpert SFX100

Compact, flexible and robust industry handheld terminal for remote parametrization and measured value
inspection via the HART current output (4-20mA).
For details refer to Operating Instructions BA00060S/04/EN.
FieldCare
FieldCare is an Endress+Hauser asset management tool based on FDT technology. With FieldCare, you can
configure all Endress+Hauser devices as well as devices from other manufacturers that support the FDT
standard.
FieldCare supports the following functions:
• Configuration of transmitters in offline and online mode
• Loading and saving device data (upload/download)
• Documentation of the measuring point
Connection options:
• HART via Commubox FXA195 and the USB port on a computer
• PROFIBUS PA via segment coupler and PROFIBUS interface card
• FOUNDATION Fieldbus via NI interface card
For further information ➝ www.endress.com
76 Endress+Hauser
Planning instructions for diaphragm seal systems

Note!
The performance and the permitted applications for a diaphragm seal system depend on the process isolating
diaphragm used, the filling oil, the coupling, the design and the process and ambient conditions at the place of
operation.
To help you select suitable diaphragm seal systems for your individual application,
Endress+Hauser provides a free "Applicator Sizing Diaphragm Seal" selection tool. This tool is available online
at "www.endress.com/applicator", or is available offline on a CD.
Applicator Sizing Diaphragm Seal PMP55-en
For further details, or for information on an optimum diaphragm seal solution, please contact your local
Endress+Hauser Sales Center.
Applications Diaphragm seal systems should be used if the process and the device need to be separated. Diaphragm seal
systems offer clear advantages in the following instances:
• In the case of extreme process temperatures
• For aggressive media
• If extreme measuring point cleaning is necessary, or in the event of very damp mounting locations
• If the measuring point is exposed to severe vibrations
• For mounting locations that are difficult to access
Function and design Diaphragm seals separate the measuring system from the process.
A diaphragm seal system consists of:
• A diaphragm seal
• A capillary tube or a temperature isolator if necessary
• Fill fluid
• A pressure transmitter
The process pressure acts via the process isolating diaphragm of a diaphragm seal on the liquid-filled system,
which transfers the process pressure to the sensor of the pressure transmitter.
Endress+Hauser delivers all diaphragm seal systems as welded versions. The system is hermetically sealed,
which ensures greater reliability.
The diaphragm seal determines the application range of the system on the basis of
• The diameter of the process isolating diaphragm
• The process isolating diaphragm: stiffness and material
• The design (oil volume)
Endress+Hauser 77
Diameter of the process isolating diaphragm

The greater the diameter of the process isolating diaphragm (less stiff), the smaller the temperature effect on
the measurement result.
Stiffness of the process isolating diaphragm

The stiffness depends on the diameter of the process isolating diaphragm, the material, any existing coating,
the thickness of the process isolating diaphragm and the shape. The thickness of the process isolating diaphragm
and the shape are determined by the design. The stiffness of a process isolating diaphragm of a diaphragm seal
influences the temperature application range and the measuring error caused by temperature effects.
Capillary
Capillaries with an internal diameter of 1 mm (0.04 in) are used as standard.
As a result of its length and internal diameter, the capillary tube influences the thermal change, the ambient
temperature application range and the response time of a diaphragm seal system.
Filling oil
When selecting the filling oil, the medium temperature and ambient temperature, as well as the process
pressure, are of crucial importance. Observe the temperatures and pressures during commissioning and
cleaning. A further selection criterion is the compatibility of the filling oil with the requirements of the medium.
For example, only filling oils that do not present a health hazard are used in the food industry, e.g. vegetable
oil or silicone oil. → See also the following section "Diaphragm seal filling oils".
The filling oil used influences the thermal change, the temperature application range of a diaphragm seal system
and the response time. A temperature change results in a volume change in the filling oil. The volume change
depends on the thermal expansion coefficient of the filling oil and on the volume of the fill fluid at calibration
temperature (constant in the range: +21 to +33°C (+70 to 91°F)).
For example, the filling oil expands in the event of a temperature increase. The additional volume presses
against the process isolating diaphragm of a diaphragm seal. The stiffer a process isolating diaphragm is, the
greater its return force, which counteracts a volume change and acts together with the process pressure on the
measuring cell, thus shifting the zero point.
Pressure transmitter
The pressure transmitter influences the temperature application range, the thermal change and the response
time as a result of its volume change. The volume change is the volume that has to be shifted in order to pass
through the complete measuring range.
Pressure transmitters from Endress+Hauser are optimized with regard to minimum volume change.
Diaphragm seal filling oils
Version1) Filling oil Permissible Permissible Density Viscosity Thermal Note

temperature range 2) at temperature range 2) at [g/cm3] / [mm²/s] / [cSt] expansion
0.05 bar (0.725 psi) pabs ≥ 1 bar (14.5 psi) [SGU] at 25°C (77°F) coefficient 3)
≤ pabs ≤ 1 bar (14.5 psi) [1/K]
1 Silicone oil –40 to +180°C –40 to +250°C 0.96 100 0.00096 Suitable for foods
(–40 to +356°F) (–40 to +482°F) FDA 21 CFR 175.105
2 Inert oil –40 to +80°C –40 to +175°C 1.87 27 0.000876 For ultrapure gas and
(–40 to +176°F) (–40 to +347°F) oxygen applications
4 Vegetable oil –10 to +120°C –10 to +200°C 0.94 9.5 0.00101 Suitable for foods
(+14 to +248°F) (+14 to +392°F) FDA 21 CFR 172.856
5 High- –10 to +200°C –10 to +400°C 1.07 37 0.0007 High temperatures

temperature oil (+14 to +392°F) (+14 to +752°F)
4)
6 Low- –70 to +80°C –70 to +180°C 0.92 4.4 0.00108 Low temperatures
temperature oil (–94 to +176°F) (–94 to +356°F)
1) Version for feature 180 in the order code (→ ä 93 ff)

2) Observe temperature limits of the device (→ ä 31) and of the system (→ ä 77).
3) Please refer to the "Applicator Sizing Diaphragm Seal" tool for the thermal change of the diaphragm seal and other important technical features.
4) When simultaneously applying the diaphragms seal at high process temperatures and low absolute pressures, Endress+Hauser recommends the vacuum
service (Feature 570 "Service" version "HG").
78 Endress+Hauser
Operating temperature range The operating temperature range of a diaphragm seal system depends on the fill fluid, capillary length and
internal diameter, process temperature and oil volume of the diaphragm seal.
The range of application can be extended by using a fill fluid with a smaller expansion coefficient and a shorter
capillary.
Installation instructions Diaphragm seal systems

• Endress+Hauser offer flushing rings as accessory to clean process isolating diaphragms without taking the
transmitters out of process.
• A diaphragm seal together with the transmitter form a closed, calibrated system, which is filled through
openings in the diaphragm seal and in the transmitter's measurement system. These openings are sealed and
must not be opened.
• In the case of devices with diaphragm seals and capillaries, the zero point shift caused by the hydrostatic
pressure of the filling liquid column in the capillaries must be taken into account when selecting the
measuring cell. If a measuring cell with a small measuring range is selected, a position adjustment can cause
range violation.
• For devices with a temperature isolator or capillary, a suitable fastening device (mounting bracket) is
recommended.
• When using diaphragm seal systems with a capillary, sufficient strain relief must be ensured in order to
prevent the capillary bending down (bending radius ≥ 100 mm (3.94 in)).
Capillary
In order to obtain more precise measurement results and to avoid a defect in the device, mount the capillaries
as follows:
• Vibration-free (in order to avoid additional pressure fluctuations)
• Not in the vicinity of heating or cooling lines
• Insulate if the ambient temperature is below or above the reference temperature
• With a bending radius of ≥ 100 mm (3.94 in).
Vacuum applications
For applications under vacuum, Endress+Hauser recommends mounting the pressure transmitter below the
diaphragm seal. This prevents vacuum loading of the diaphragm seal caused by the presence of fill fluid in the
capillary.
When the pressure transmitter is mounted above the diaphragm seal, the maximum height difference H1 in
accordance with the illustration below must not be exceeded. The maximum height difference depends on the
density of the filling oil and the smallest ever pressure that is permitted to occur at the diaphragm seal (empty
container), see illustration below right.
When simultaneously applying the diaphragm seal systems at high process temperatures and low absolute
pressures, Endress+Hauser recommends the vacuum service (Feature 570 "Service" version "HG").
12.0
Low temperature oil
10.0
Height difference H1 [m]
Vegetable oil
8.0
Silicone oil
6.0
High temperature
oil
H1 4.0
Inert oil
2.0
0.0
50 100 200 300 400 500 600 700 800 900 1000
Pressure at diaphragm seal [mbarabs]
Maximum installation height above the diaphragm seal for vacuum
Installation above the diaphragm seal
applications
Endress+Hauser 79
Thermal insulation
The PMP55 may only be insulated up to a certain height. The maximum permitted insulation height is
indicated on the devices and applies to an insulation material with a heat conductivity ≤ 0.04 W/(m x K) and
to the maximum permitted ambient and process temperature. The data were determined under the most
critical application "quiescent air".
l £ 0.04 W
m•K
TU
TP
Maximum permitted insulation height, here indicated on a PMP55 with a flange
Mounting with temperature isolator

Endress+Hauser recommends the use of temperature isolators in the event of constant extreme medium
temperatures which lead to the maximum permissible electronics temperature of +85°C (+185°F) being
exceeded.
Depending on the filling oil used, diaphragm seal systems with temperature isolators can be used for maximum
temperatures of up to 260 °C (+500 °F). → For the temperature application limits, see → ä 78, "Diaphragm
seal filling oils" section.
To minimize the influence of rising heat, Endress+Hauser recommends the device be mounted horizontally or
with the housing pointing downwards.
The additional installation height also brings about a maximum zero point shift of 21 mbar (0.315 psi) due to
the hydrostatic column in the temperature isolator. You can correct this zero point shift at the device.
max. 115
PMP55 with temperature isolator
80 Endress+Hauser

CE mark The device meets the legal requirements of the relevant EC directives.
Endress+Hauser confirms that the device has been successfully tested by applying the CE mark.
Ex approvals • ATEX
• IECEx
• FM
• CSA
• Also combinations of different approvals
All explosion protection data are given in separate documentation which is available upon request. The
Ex documentation is supplied as standard with all devices approved for use in explosion hazardous areas.
Suitability for hygienic The Cerabar M is suitable for use in hygienic processes.
processes Overview of suitable process connections → ä 33 ff.
Many versions meet the requirements of 3A-Sanitary Standard No. 74 and
are certified by the EHEDG.
Suitable fittings and seals must be used for hygienic design in accordance
with 3A and EHEDG specifications.
Note!
Gap-free connections can be cleaned
without residue using the usual cleaning methods. TYPE EL 74 -
February 2010
Functional safety SIL The Cerabar M with 4 to 20 mA output signal has been developed to assessed and certified by TÜV NORD
CERT as per IEC 61508 Edition 2.0 and IEC 61511. These devices can be used to monitor the process level
and pressure up to SIL 2. For a detailed description of the safety functions with Cerabar M, settings and
functional safety data, see the "Functional safety manual - Cerabar M" SD00347P. Ordering Information
→ ä 83 ff, feature 590 "Additional Approval:" version LA "SIL".
Pharma (CoC) Certificate of Compliance (CoC) (according to ASME BPE-2007)

See "Ordering information", → ä 83 ff, feature 590 "Additional Option:", option"LW".
CRN approvals Some device versions have CRN approval. For a CRN-approved device, a CRN-approved process connection
(→ ä 33 ff, "Process connection") has to be ordered with a CSA approval (→ ä 83 ff, feature 10 "Approval").
PMP55 devices with a capillary are not CRN-approved. These devices are fitted with a separate plate bearing
the registration number 0F10525.5C.
Pressure Equipment Directive The devices PMC51, PMP51 and PMP55 correspond to Article 3 (3) of the EC directive 97/23/EC (Pressure
(PED) Equipment Directive) and have been designed and manufactured according to good engineering practice.
The following also applies:
– PMP51/PMP55 with threaded connection and internal process isolating diaphragm PN > 200:
Suitable for stable gases in group 1, category I
– PMP55 with pipe diaphragm seal ≥ 1.5"/PN40:
Suitable for stable gases in group 1, category II
– PMP55 with separators PN400:
Suitable for stable gases in group 1, category I
Drinking water approval NSF 61 approval
Standards and guidelines DIN EN 60770 (IEC 60770):

Transmitters for use in industrial process control systems
Part 1: Methods for inspection and routine testing
DIN 16086:
Electrical pressure measuring instruments, pressure sensors, pressure transmitters, pressure measuring
instruments, concepts, specifications on data sheets
EN 61326 series:
EMC product family standard for electrical equipment for measurement, control and laboratory use.
Endress+Hauser 81
North-American practice for Endress+Hauser instruments are designed according to ANSI/ISA 12.27.01 either as single seal or dual seal
installation of process seals devices with annunciation, allowing the user to waive the use and save the cost of installing external secondary
process seals in the conduit as required by the process sealing sections of ANSI/NFPA 70 (NEC) and CSA 22.1
(CEC). These instruments comply with the North-American installation practice and provide a very safe and
cost-saving installation for pressurized applications with hazardous fluids.
Further information can be found in the control drawings of the relevant devices.
82 Endress+Hauser
PMC51 This overview does not mark options which are mutually exclusive.
10 Approval:
AA For non-hazardous areas
BA ATEX II 1/2G Ex ia IIC T6
BB ATEX II 1/2D Ex t IIIC
BD ATEX II 3G Ex nA IIC T6
BE ATEX II 2G Ex ia IIC T6
BF ATEX II 1/2D Ex ia IIIC
BG ATEX II 3G Ex ic IIC T6
B1 ATEX II 1/2G Ex ia IIC T6 + ATEX II 1/2D Ex iaD
8C ATEX II Ex ia + FM/CSA IS
ATEX II 1/2G Ex ia IIC T6+
FM/CSA IS Cl.I Div. 1 Gr. A-D
FM/CSA: zone0,1,2
IA IEC Ex ia IIC T6 Ga/Gb
IE IEC Ex ic IIC T6 Gc
IF IEC Ex ia IIIC Da/ Db
I1 IEC Ex ia IIC T6 Ga/Gb+Ex ia IIIC Da/Db
NA NEPSI Ex ia IIC T6
TA TIIS Ex ia IIC T4
CA CSA C/US IS Cl.I,II,III Div.1 Gr. A-G, CSA C/US IS Cl.I Div.2 Gr. A-D, Ex ia, C: Zone 0, 1, 2/US: Zone 0, 1, 2, 20, 21,
22
CD CSA General Purpose
FA FM IS Cl.I,II,III Div.1 Gr.A-G, AEx ia
FM NI Cl.I Div.2 Gr.A-D
FM IS: Zone 0,1,2,20,21,22/FM NI: Zone 2
FD FM NI Cl.I Div.2 Gr.A-D
99 Special version
20 Output:
1 4-20mA Analog
2 4-20mA HART
3 PROFIBUS PA
4 FOUNDATION Fieldbus
9 Special version
30 Display, operation:
1 LCD, push buttons on display electronics
2 W/o LCD, push buttons on electronics
9 Special version
40 Housing:
I F31 aluminum
J F31 aluminum, glass window
Q F15 Stainless Steel Hygiene
R F15 Stainless Steel Hygiene, glass window
S F15 Stainless Steel Hygiene, plastic window
Y Special version
50 Electrical connection:
A Gland M20, IP66/68 NEMA4X/6P
B Thread M20, IP66/68 NEMA4X/6P
C Thread G1/2, IP66/68 NEMA4X/6P
D Thread NPT1/2, IP66/68 NEMA4X/6P
I Connector M12, IP66/67, NEMA4X/6P
M Connector 7/8", IP66/68, NEMA4X/6P
P Connector Han7D, 90deg, IP65
S PE Cable 5m, IP66/68 NEMA4X/6P + pressure compensation via cable
V Valve connector ISO4400 M16, IP64
Y Special version
Endress+Hauser 83
PMC51 (continued) 70 Sensor range:

1C 100mbar/10kPa/1.5psi relative,
1mH2O/3ftH2O/40inH2O
Overload: 4bar/400kPa/60psi
1E 250mbar/25kPa/3.75psi relative,
2.5mH2O/7.5ftH2O/100inH2O
1F 400mbar/40kPa/6psi relative,
1H 1bar/100kPa/15psi relative,
Overload: 10bar/1MPa/150psi
1K 2bar/200kPa/30psi relative,
Overload: 18bar/1.8MPa/270psi
1M 4bar/400kPa/60psi relative,
1P 10bar/1MPa/150psi relative,
1S 40bar/4MPa/600psi relative,
400mH2O/1334ftH2O/16000inH2O
2C 100mbar/10kPa/1.5psi abs,
2E 250mbar/25kPa/3.75psi abs,
2.5mH2O/7.5ftH2O/100inH2O
2F 400mbar/40kPa/6psi abs,
2H 1bar/100kPa/15psi abs,
2K 2bar/200kPa/30psi abs,
20mH2O/67ftH2O/800inH2O abs
2M 4bar/400kPa/60psi abs,
2P 10bar/1MPa/150psi abs,
2S 40bar/4MPa/600psi abs,
99 Special version
80 Reference accuracy:
D Platinum
G Standard
Y Special version
90 Calibration; Unit:
A Sensor range; %
B Sensor range; mbar/bar
C Sensor range; kPa/MPa
D Sensor range; mm/mH2O
E Sensor range; inH2O/ftH2O
F Sensor range; psi
J Customized pressure; see additional spec.
K Customized level; see additional spec.
Y Special version
84 Endress+Hauser
PMC51 (continued) 110 Process connection:

ANSI flanges
ACJ 1" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AEJ 1-1/2" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AFF 2" 150lbs RF, PVDF, flange ANSI B16.5
AFJ 2" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AFN 2" 150lbs, ECTFE>316/316L, flange ANSI B16.5
AGF 3" 150lbs RF, PVDF, flange ANSI B16.5 (CRN)
AGJ 3" 150lbs RF, 316/316L, flange ANSI B16.5
AGN 3" 150lbs, ECTFE>316/316L, flange ANSI B16.5
AHJ 4" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AHN 4" 150lbs, ECTFE>316/316L, flange ANSI B16.5
ANJ 1" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AQJ 1-1/2" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
ARJ 2" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
ASJ 3" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
ATJ 4" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
EN flanges
CNJ DN25 PN10-40 B1, 316L, flange EN1092-1
CPJ DN32 PN10-40 B1, 316L, flange EN1092-1
CQJ DN40 PN10-40 B1, 316L, flange EN1092-1
CXJ DN50 PN10-40 B1, 316L, flange EN1092-1
CFF DN50 PN10/16 B1, PVDF, flange EN1092-1
CEF DN40 PN10/16 B1, PVDF, flange EN1092-1
CRP DN50 PN25/40, ECTFE>316L, flange EN1092-1
CZJ DN80 PN10-40 B1, 316L, flange EN1092-1
CSP DN80 PN25/40, ECTFE>316L, flange EN1092-1
JIS flanges
KFJ 10K 50 RF, 316L, flange JIS B2220
KGJ 10K 80 RF, 316L, flange JIS B2220
KHJ 10K 100 RF, 316L, flange JIS B2220
Threaded connection
GCC Thread ISO228 G1/2, AlloyC (CRN)
GCF Thread ISO228 G1/2, PVDF
GCJ Thread ISO228 G1/2, 316L (CRN)
GLC Thread ISO228 G1/2 G1/4 female, AlloyC (CRN)
GLJ Thread ISO228 G1/2 G1/4 female, 316L (CRN)
GMC Thread ISO228 G1/2 hole 11.4mm, AlloyC (CRN)
GMJ Thread ISO228 G1/2 hole 11.4mm, 316L (CRN)
GOJ Thread JIS B0203 R1/2 male, 316L
GNJ Thread JIS B0202 G1/2 male, 316L
GVJ Thread ISO228 G1-1/2, 316L, flush-mounted (CRN)
GWJ Thread ISO228 G2, 316L, flush-mounted (CRN)
G4J Thread DIN13 M44x1.25, 316L, flush-mounted
Threaded connection as per ANSI
RJF Thread ANSI MNPT1/2 hole 3mm, PVDF (CRN)
RKC Thread ANSI MNPT 1/2 hole, 11.4mm, Alloy C (CRN)
RKJ Thread ANSI MNPT1/2 hole 11.4mm, 316L (CRN)
RLC Thread ANSI MNPT1/2 FNPT1/4, AlloyC (CRN)
RLJ Thread ANSI MNPT1/2 FNPT1/4, 316L (CRN)
R1C Thread ANSI FNPT 1/2, Alloy C (CRN)
R1J Thread ANSI FNPT 1/2, 316L (CRN)
U7J Thread ANSI MNPT1-1/2, 316L, flush-mounted (CRN)
U8J Thread ANSI MNPT2, 316L, flush-mounted (CRN)
Hygienic process connections
MRJ DIN11851 DN50 PN25 slotted-nut, 316L, EHEDG, 3A with seal FDA (CRN)
MZJ DIN11851 DN40 PN25 slotted-nut, 316L, EHEDG, 3A with seal FDA (CRN)
NCJ DIN11864-1 A DN40 PN16 pipe DIN11866-A, slotted-nut, 316L, EHEDG, 3A with seal FDA
NDJ DIN11864-1 A DN50 PN16 pipe DIN11866-A, slotted-nut, 316L, EHEDG, 3A with seal FDA
TQJ Varivent F pipe DN25-32 PN40, 316L, EHEDG, 3A with seal FDA
TRJ Varivent N pipe DN40-162 PN40, 316L, EHEDG, 3A with seal FDA
S4J NEUMO BioControl D50 PN16, 316L, EHEDG, 3A with seal FDA
TIJ DRD DN50 65mm PN25, 316L
TMJ APV Inline DN50 PN40, 316L, 3A with seal FDA
UPJ Universaladapter 44mm 316L, incl. silicone molded seal, EHEDG, 3A with seal FDA
UNJ Universaladapter 44mm 316L, EPDM molded seal, EHEDG
TDJ Tri-Clamp ISO2852 DN40-51 (2"), 316L, DIN32676 DN50, EHEDG, 3A with seal FDA (CRN)
TFJ Tri-Clamp ISO2852 DN76.1 (3"), 316L, EHEDG, 3A with seal FDA (CRN)
Endress+Hauser 85
110 Process connection:

YYY Special version
PMC51 (continued) 190 Seal:

A FKM Viton
B FKM Viton, FDA, 3A Class I, USP Class VI
G HNBR, FDA, 3A Class I, KTW, AFNOR, BAM
F NBR
H NBR, Low temperature
J EPDM, FDA
K EPDM, FDA, 3A Class II, USP Class VI, DVGW, KTW, W270, WRAS, ACS, NSF61
L FFKM Kalrez 6375
M FFKM Kalrez 7075
N FFKM Kalrez 6221, FDA, USP Class VI
P Fluoroprene XP40, FDA, USP Class VI, 3A Class I
S VMQ Silicone, FDA
Y Special version
Additional ordering information (optional)

500 Additional Operating language:
AA English
AB German
AC French
AD Spanish
AE Italian
AF Dutch
AK Chinese simplified
AL Japanese
550 Calibration:
F1 Factory calibration certificate, 5-point
F2 DKD/DAkkS calibration certificate 10-point
570 Service:
HA Oil and grease removed 1)
HB Cleaned for oxygen service 1)
HC Cleaned from PWIS (PIWS = paint wetting impairment substances) 1)
IA Configured min alarm current
IB Configured HART Burst Mode PV
I9 Special version
580 Test, certificate:

JA EN10204-3.1 process connection material, inspection certificate
JB NACE MR0175 process connection
KB EN10204-3.1 material process conn. +Ra, Ra= surface roughness, dimensional check, inspection certificate
KD EN10204-3.1 helium leak test, inspection certificate
KE EN10204-3.1 pressure test, inspection certificate
K9 Special version,
590 Other approvals:

LW CoC-ASME BPE (CoC = Certificate of Compliance)
LA SIL
600 Separate housing:

MA Cable PE, 2m/80in + housing mounting bracket, wall/pipe, 304
MB Cable PE, 5m/200in + housing mounting bracket, wall/pipe, 304
MC Cable PE, 10m/400in + housing mounting bracket, wall/pipe, 304
MH Cable FEP, 5m/200in IP69K + housing mounting bracket, wall/pipe, 304
610 Accessory mounted:

NA Overvoltage protection
620 Accessory enclosed

PA Mounting bracket, wall/pipe, 304
P2 Shutoff valve (PZAV), see additional spec
-R1A1 PZAV-R1A1 Shutoff valve, G1/2, C22.8
-R1A2 PZAV-R1A2 Shutoff valve, G1/2, 316Ti
-R1D1 PZAV-R1D1 Shutoff valve, NPT1/2, C22.8
-R1D2 PZAV-R1D2 Shutoff valve, NPT1/2, 316Ti
-B1A2 PZAV-B1A2 Shutoff valve, G1/2, 316Ti, 3.1
86 Endress+Hauser

-B1D2 PZAV-B1D2 Shutoff valve, NPT1/2, 316Ti, 3.1
P4 Siphon (PZW), see additional spec
-RA21 PZW-RA21 Siphon G1/2 vertical, C22.8 (O-shape)
-RA22 PZW-RA22 Siphon G1/2 vertical, 316Ti (O-shape)
-RC11 PZW-RC11 Siphon G1/2 x weld. horiz. C22.8 (U-shape)
-RD11 PZW-RD11 Siphon NPT1/2 x weld. horiz. C22.8 (U-shape)
-BB22 PZW-BB22 Siphon NPT1/2 vertical, 316Ti, 3.1 (O-shape)
-BA22 PZW-BA22 Siphon NPT1/2x weld.vert.316Ti 3.1 (O-shape)
QJ Welding neck G1-1/2, 316L
QK Welding neck G1-1/2, 316L, 3.1, EN10204-3.1 material, inspection certificate
QL Weld-in tool adapter G1-1/2, brass
QP Weld-in flange DRD DN50 65mm, 316L
QR Weld-in fl. DRD DN50 65mm, 316L 3.1 EN10204-3.1 material, inspection certificate
QS Weld-in tool flange DRD DN50 65mm, Brass
QT Weld-in adapter Uni D65, 316L
QU Weld-in adapter Uni D65, 316L, 3.1 EN10204-3.1 material, inspection certificate
Q1 Weld-in tool adapter Uni D65/D85, Brass
Q2 Weld-in adapter Uni D85, 316L
Q3 Weld-in adapter Uni D85, 316L, 3.1 EN10204-3.1 material, inspection certificate
RA Adapter Uni > DIN11851 DN40, 316L, slotted-nut
RB Adapter Uni > DIN11851 DN50, 316L, slotted-nut
RC Adapter Uni > DRD DN50 65mm, 316L
RD Adapter Uni > Clamp 2", 316L
RE Adapter Uni > Clamp 3", 316L
RF Adapter Uni > Varivent N, 316L
RH Adapter Uni > Cherry Burell 2", 316L
R1 Adapter Uni > DIN11851 DN40, 316L, 3.1, slotted-nut, EN10204-3.1 material, inspection certificate
R2 Adapter Uni > DIN11851 DN50, 316L, 3.1, slotted-nut, EN10204-3.1 material, inspection certificate
R3 Adapter Uni > DRD DN50 65mm, 316L, 3.1 EN10204-3.1 material, inspection certificate
R4 Adapter Uni > Clamp 2", 316L, 3.1 EN10204-3.1 material, inspection certificate
R5 Adapter Uni > Clamp 3", 316L, 3.1 EN10204-3.1 material, inspection certificate
R6 Adapter Uni > Varivent, 316L, 3.1 EN10204-3.1 material, inspection certificate
R7 Adapter Uni > Cherry Burell, 316L, 3.1 EN10204-3.1 material, inspection certificate
RL Plug-in jack M12
RM Plug-in jack M12, 90deg
RN Plug-in jack M12, 90deg+5m cable
R9 Special version, TSP-no. to be spec.
850 Firmware version:

78 01.00.zz, HART, DevRev01
895 Identification:
Z1 Measuring point (TAG), see additional spec.
Z2 Bus address, see additional spec.
Endress+Hauser 87
PMP51 This overview does not mark options which are mutually exclusive.
10 Approval:
BC ATEX II 2G Ex d IIC T6
B2 ATEX II 1/2G Ex ia IIC T6 + ATEX II 2G Ex d IIC T6
8A ATEX II Ex ia/Ex d + FM/CSA IS + XP
ATEX II 2G Ex d IIC T6+
FM/CSA IS + XP Cl.I, II Div.1 Gr. A-G/B-G, zone 1,2
8B FM/CSA IS + XP Cl.I, II Div.1 Gr.A-D/B-G
FM IS/FM XP Cl.I, II Div.1 Gr.A-G+
CSA IS/XP Cl.I, II Div.1 Gr.A-G, zone 1,2
IB IEC Ex d IIC T6 Gb
ID IEC Ex t IIIC Da/Db
NB NEPSI Ex d IIC T6
CA CSA C/US IS Cl.I,II,III Div.1 Gr.A-G,
CSA C/US IS Cl.I Div.2 Gr.2 Gr.A-D, Ex ia, zone 0,1,2,20,21,22
CB CSA C/US XP Cl.I, II Div.1 Gr.B-G, Ex d (Conduit seal not required), zone 1,2
CC CSA C/US Cl.II, III Div.1 Gr.E-G, US: Zone 21,22
CD CSA General Purpose
C1 CSA C/US IS/XP Cl.I, II Div.1 Gr.A-G/B-G, Zone 1,2
FA FM IS Cl.I,II,III Div.1 Gr.A-G, AEx ia
FM NI Cl.I Div.2 Gr.A-D
FM IS: Zone 0,1,2,20,21,22/FM NI: Zone 2
FB FM XP Cl.I, II Div.1 Gr.A-D, AEx d (Factory sealed) zone 1,2
FC FM DIP Cl.II, III Div.1 Gr.A-D Zone 21,22
FD FM NI Cl.I Div.2 Gr.A-D, Zone 2
F1 FM IS/XP Cl.I, II Div.1 Gr.A-G, Zone 1,2
99 Special version
20 Output:
1 4-20mA Analog
2 4-20mA HART
3 PROFIBUS PA
4 FOUNDATION Fieldbus
9 Special version
30 Display, operation:
1 LCD, keys on display/electronics
2 Without LCD, keys on electronics
9 Special version
40 Housing:
I F31 aluminum
J F31 aluminum, glass window
Q F15 Stainless Steel Hygiene
R F15 Stainless Steel Hygiene, glass window
S F15 Stainless Steel Hygiene, plastic window
Y Special version
A Gland M20, IP66/68 NEMA4X/6P
B Thread M20, IP66/68 NEMA4X/6P
C Thread G1/2, IP66/68 NEMA4X/6P
D Thread NPT1/2, IP66/68 NEMA4X/6P
I Connector M12, IP66/67, NEMA4X/6P
M Connector 7/8", IP66/68, NEMA4X/6P
P Connector Han7D, 90deg, IP65
S PE Cable 5m, IP66/68 NEMA4X/6P + pressure compensation via cable
V Valve connector ISO4400 M16, IP64
88 Endress+Hauser
Y Special version
PMP51 (continued) 70 Sensor range:

1F 400mbar/40kPa/6psi relative,
1H 1bar/100kPa/15psi relative,
1K 2bar/200kPa/30psi relative,
1M 4bar/400kPa/60psi relative,
1P 10bar/1MPa/150psi relative,
1S 40bar/4MPa/600psi relative,
400mH2O/1334ftH2O/16000inH2O
1U 100bar/10MPa/1500psi relative,
1000mH2O/3330ftH2O/40000inH2O
1W 400bar/40MPa/6000psi relative,
4000mH2O/13340ftH2O/160000inH2O
2F 400mbar/40kPa/6psi abs,
2H 1bar/100kPa/15psi abs,
2K 2bar/200kPa/30psi abs,
2M 4bar/400kPa/60psi abs,
2P 10bar/1MPa/150psi abs,
2S 40bar/4MPa/600psi abs,
2U 100bar/10MPa/1500psi abs,
2W 400bar/40MPa/6000psi abs,
99 Special version
80 Reference accuracy:
D Platinum
G Standard
Y Special version
90 Calibration; Unit:
A Sensor range; %
B Sensor range; mbar/bar
C Sensor range; kPa/MPa
D Sensor range; mm/mH2O
E Sensor range; inH2O/ftH2O
F Sensor range; psi
J Customized pressure; see additional spec.
K Customized level; see additional spec.
Y Special version
Endress+Hauser 89
PMP51 (continued) 110 Process connection:

ANSI flanges
AEJ 1-1/2" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AFJ 2" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AGJ 3" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AHJ 4" 150lbs RF, 316/316L, flange ANSI B16.5 (CRN)
ANJ 1" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
AQJ 1-1/2" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
ARJ 2" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
ASJ 3" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
ATJ 4" 300lbs RF, 316/316L, flange ANSI B16.5 (CRN)
EN flanges
CNJ DN25 PN10-40 B1, 316L, flange EN1092-1
CPJ DN32 PN10-40 B1, 316L, flange EN1092-1
CQJ DN40 PN10-40 B1, 316L, flange EN1092-1
CXJ DN50 PN25/40 B1, 316L flange EN1092-1
CZJ DN80 PN25/40 B1, 316L, flange EN1092-1
Threaded connection
GCC Thread ISO228 G1/2, AlloyC
GCJ Thread ISO228 G1/2, 316L
GLC Thread ISO228 G1/2 G1/4 female, AlloyC
GLJ Thread ISO228 G1/2 G1/4 female, 316L
GMC Thread ISO228 G1/2 hole 11.4mm, AlloyC
GMJ Thread ISO228 G1/2 hole 11.4mm, 316L
GRC Thread ISO228 G1/2, AlloyC, flush-mounted
GRJ Thread ISO228 G1/2, 316L, flush-mounted
GTJ Thread ISO228 G1, 316L, flush-mounted
GVJ Thread ISO228 G1-1/2, 316L, flush-mounted
GWJ Thread ISO228 G2, 316L, flush-mounted
G0J Thread ISO228 G1/2 seal O-ring, fm= flush-mounted, 316L, adapter 52002643
G1J Thread DIN13 M20x1.5, 316L
Threaded connection as per ANSI
RKC Thread ANSI MNPT1/2 hole 11.4mm, AlloyC (CRN)
RKJ Thread ANSI MNPT1/2 hole 11.4mm, 316L (CRN)
RLC Thread ANSI MNPT1/2 FNPT1/4, AlloyC (CRN)
RLJ Thread ANSI MNPT1/2 FNPT1/4, 316L (CRN)
R1C Thread ANSI FNPT 1/2, Alloy C (CRN)
R1J Thread ANSI FNPT 1/2, 316L (CRN)
U7J Thread ANSI MNPT1-1/2, 316L, flush-mounted (CRN)
XSJ Prepared for diaphragm seal mount, 316L (CRN)
Hygienic connections
MXJ DIN11851 DN25 PN25 coupling nut, 316L, EHEDG, 3A
MIJ DIN11851 DN32 PN25 coupling nut, 316L, EHEDG, 3A
MZJ DIN11851 DN40 PN25 coupling nut, 316L, EHEDG, 3A
MRJ DIN11851 DN50 PN25 coupling nut, 316L, EHEDG, 3A
S1J NEUMO BioControl D25 PN16, 316L, EHEDG, 3A
S4J NEUMO BioControl D50 PN16, 316L, EHEDG, 3A
TBJ Clamp ISO2852 DN12-22 (1/2..3/4"), 316L, DIN32676 DN10-20, EHEDG, 3A, ASME-BPE
TCJ Tri-Clamp ISO2852 DN25 (1"), 316L, DIN32676 DN25, EHEDG, 3A, ASME-BPE
TJJ Tri-Clamp ISO2852 DN38 (1-1/2"), 316L, DIN32676 DN40, EHEDG, 3A, ASME-BPE
TDJ Tri-Clamp ISO2852 DN40-51 (2"), 316L, DIN32676 DN50, EHEDG, 3A
TIJ DRD DN50 65mm PN25, 316L
TMJ APV Inline DN50 PN40, 316L, 3A
TPJ Varivent B pipe DN10-15 PN40, 316L, EHEDG, 3A
TQJ Varivent F pipe DN25-32 PN40, 316L, EHEDG, 3A
TRJ Varivent N pipe DN40-162 PN40, 316L, EHEDG, 3A
T6J SMS 1" PN25, 316L, EHEDG, 3A
T7J SMS 1-1/2" PN25, 316L, EHEDG, 3A
TXJ SMS 2" PN25, 316L, EHEDG, 3A
YYY Special version
170 Material of the process isolating diaphragm:

A 316L
B AlloyC
M Rhodium>gold>316L
Y Special version
90 Endress+Hauser
180 Fill fluid:

1 Silicone oil
2 Inert oil
3 Synthetic oil, FDA
9 Special version
Additional ordering information (optional)

500 Additional Operating language:
AA English
AB German
AC French
AD Spanish
AE Italian
AF Dutch
AK Chinese simplified
AL Japanese
PMP51 (continued) 550 Calibration:

F1 Factory calibration certificate, 5-point
F2 DKD/DAkkS calibration certificate 10-point
570 Service:
HA Oil and grease removed 1)
HB Cleaned for oxygen service 1)
HC Cleaned from PWIS (PIWS = paint wetting impairment substances) 1)
IA Configured min alarm current
IB Configured HART Burst Mode PV
I9 Special version
580 Test, certificate:

JA EN10204-3.1 wetted material, inspection certificate
JB NACE MR0175 wetted
JF EN10204-3.1 AD2000 material wetted parts, excepting process membrane inspection certificate
KB EN10204-3.1 wetted material + Ra, Ra= surface roughness, dimensional check, inspection certificate
KD EN10204-3.1 helium leak test, inspection certificate
KE EN10204-3.1 pressure test, inspection certificate
KG EN10204-3.1 PMI test* (PMI = positive material identification), inspection certificate
* Meter body and process isolating diaphragm not included.
K9 Special version
590 Other approvals:

LW CoC-ASME BPE (CoC = Certificate of Compliance)
LA SIL
LR NSF potable water approval
600 Separate housing:

MA Cable PE, 2m/80in + housing mounting bracket, wall/pipe, 304
MB Cable PE, 5m/200in + housing mounting bracket, wall/pipe, 304
MC Cable PE, 10m/400in + housing mounting bracket, wall/pipe, 304
MH Cable FEP, 5m/200in IP69K + housing mounting bracket, wall/pipe, 304
610 Accessory mounted:

NA Overvoltage protection

PA Mounting bracket, wall/pipe, 304
P2 Shutoff valve (PZAV), see additional spec
-R1A1 PZAV-R1A1 Shutoff valve, G1/2, C22.8 (O-shape)
-R1A2 PZAV-R1A2 Shutoff valve, G1/2, 316Ti (O-shape)
-R1D1 PZAV-R1D1 Shutoff valve, NPT1/2, C22.8 (U-shape)
-R1D2 PZAV-R1D2 Shutoff valve, NPT1/2, 316Ti (U-shape)
-B1A2 PZAV-B1A2 Shutoff valve, G1/2, 316Ti, 3.1 (O-shape)
-B1D2 PZAV-B1D2 Shutoff valve, NPT1/2, 316Ti, 3.1 (O-shape)
P4 Siphon (PZW), see additional spec
-RA21 PZW-RA21 Siphon G1/2 vertical, C22.8
-RA22 PZW-RA22 Siphon G1/2 vertical, 316Ti
-RC11 PZW-RC11 Siphon G1/2 x weld. horiz. C22.8
-RD11 PZW-RD11 Siphon NPT1/2 x weld. horiz. C22.8
-BB22 PZW-BB22 Siphon NPT1/2 vertical, 316Ti, 3.1
Endress+Hauser 91

-BA22 PZW-BA22 Siphon NPT1/2x weld.vert.316Ti 3.1
QA Welding neck G1/2, 316L,
QB Welding neck G1/2, 316L, 3.1, EN10204-3.1 material, inspection certificate
QC Weld-in tool adapter G1/2, brass
QG Weld-in tool adapter G1, brass, metal sealing taper
QJ Welding neck G1-1/2, 316L
QK Welding neck G1-1/2, 316L, 3.1, EN10204-3.1 material, inspection certificate
QL Weld-in tool adapter G1-1/2, brass
RL Plug-in jack M12
RM Plug-in jack M12, 90deg
RN Plug-in jack M12, 90deg+5m cable
850 Firmware version:

78 01.00.zz, HART, DevRev01
895 Identification:
Z1 Measuring point (TAG), see additional spec.
Z2 Bus address, see additional spec.
92 Endress+Hauser
PMP55 This overview does not mark options which are mutually exclusive.
10 Approval:
BC ATEX II 2G Ex d IIC T6
B2 ATEX II 1/2G Ex ia IIC T6 + ATEX II 2G Ex d IIC T6
8A ATEX II Ex ia/Ex d + FM/CSA IS + XP
ATEX II 2G Ex d IIC T6+
FM/CSA IS + XP Cl.I, II Div.1 Gr. A-G/B-G, zone 1,2
8B FM/CSA IS + XP Cl.I, II Div.1 Gr.A-D/B-G
FM IS/FM XP Cl.I, II Div.1 Gr.A-G+
CSA IS/XP Cl.I, II Div.1 Gr.A-G, Zone 1,2
IB IEC Ex d IIC T6 Gb
ID IEC Ex t IIIC Da/Db
NB NEPSI Ex d IIC T6
CA CSA C/US IS Cl.I,II,III Div.1 Gr.A-G,

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1-1 Safety precautions

1-2 System description

1-3 Mainflow diagram / Component list

1-4 Technical Data Sheets B

1-8 General Instructions

1-9 Spare parts information

2-2 Exhaust Gas Boiler

2-5 Heat Recovery Container

BOOK 1/4 2-6 Auxiliary Boiler B

COLOMBIA 2-11 Control units

2-12 LFO Tank

2-13 Condensate tank

Customer's Ref: BOOK 1 GENERAL

REV. DATE MADE BY NOTES

Subject Group Ref. No. Page

1.1 PERSONNEL QUALIFICATION AND TRAINING ................................................................................................ 2

3. SAFETY ASPECTS IN CONNECTION TO STARTING THE SYSTEM ............................................. 3

4. SAFETY ASPECTS IN CONNECTION TO THE OPERATOR / USER............................................... 4

5. SAFETY ASPECTS IN CONNECTION TO THE MAINTENANCE .................................................... 4

6. SAFETY ASPECTS IN CONNECTION TO THE RELATED EQUIPMENT....................................... 5

7. SAFETY RISKS BECAUSE OF DIRTY EXHAUST GAS BOILER ..................................................... 5

8. SAFETY RISKS BECAUSE OF LOW WATER LEVEL (LACK OF WATER) ................................... 7

9. SAFETY RISKS BECAUSE OF HIGH PRESSURE AND TEMPERATURE ....................................... 7

10.SAFETY RISKS IF SAFETY DEVICE OPENS IN USE ........................................................................ 7

11.RISK OF ELECTRICAL SHOCK........................................................................................................... 8

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

1.1 Personnel qualification and training

1.2 Non-compliance with safety instructions and unauthorized

Neglect of the safety precautions, installation instructions, operational instructions,

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

2. SAFETY INSTRUCTIONS AND WARNINGS

WARNING - High Voltage!

WARNING – Hot surfaces!

3. SAFETY ASPECTS IN CONNECTION TO STARTING THE

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

4. SAFETY ASPECTS IN CONNECTION TO THE OPERATOR /

User safety factors during normal operation are for instance:

Safe use of equipment requires that checks and services recommended by

5. SAFETY ASPECTS IN CONNECTION TO THE MAINTENANCE

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

- Have a permission for fire / electric / maintenance work

6. SAFETY ASPECTS IN CONNECTION TO THE RELATED

- Sufficient lighting must be provided for working platforms.

Equipment, vessels, components or corresponding devices which are to be integrated

7. SAFETY RISKS BECAUSE OF DIRTY EXHAUST GAS BOILER

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

Action for prevention of soot fire:

4. Heavy smoke from engine. If an excessive amount of smoke is observed the

ALFA LAVAL AALBORG OY

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

8. SAFETY RISKS BECAUSE OF LOW WATER LEVEL (LACK OF

9. SAFETY RISKS BECAUSE OF HIGH PRESSURE AND

10. SAFETY RISKS IF SAFETY DEVICE OPENS IN USE

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

11. RISK OF ELECTRICAL SHOCK

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

Subject Group Ref. No. Page

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

© Copyright Alfa Laval Aalborg Oy www.alfalaval.com

3.2 Feed water tank