26 Comb Gesamt Eng

Documentation
Unit type: Comb. LO CW module

Customer: Caterpillar International Power Systems
Order number: 7224521_26, 7224541_46, 7224561_66
Ktr. number: 265136, 265135, 265134
PowerStation: Kabul
Establish date of the documentation: 16.01.2008

Caterpillar International Power System
Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
DIRECTORY
Delivery date
2008

1

DIRECTORY:

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

Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
General
Delivery date
2008

2

1. General

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

Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
Annex components
Delivery date
2008

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

pcs pos.no. title type DN PN supplier

1 FV01 butterfly valve, EPDM, CuAl-disc 22.0130125G1 125 16 ARI
1 header 200 16 mas
1 FK01 angle-thermometer (0-100 C), Tt=100mm 3503011 1/2" WIKA
1 FV03 vent ball valve with locking device Art.No. V1-316-299-015LD 1/2" 25 Valvetek

1 FK02
glycerin vac. pressure gauge (d=100, -0.1 to +
0.15 MPa) 7201871 1/2" 25 WIKA
1 dumping pipe 5-422-K POELL
1 pressure gauge and test valve 007200090015 1/2" 250 Doden
1 FP03 LT cooling water pump LUBL100M180 100 4 Edur
1 E-Motor 30 kW Edur
1 FV05 non-return valve RK 41150 150 16 HTI
1 FK03
glycerin vac. pressure gauge (d=100, 0 to + 1.0
MPa) 7162140 1/2" 10 WIKA
1 FK17
0.15 MPa) 7201871 1/2" 25 WIKA
1 FP04 LT cooling water pump LUBL100M180 100 4 Edur
1 FK18
MPa) 7162140 1/2" 10 WIKA

1 header 200 16 mas

Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
Annex components
Delivery date
2008

4


1 FV09 ball valve V3NBC-316-025 25 25 Valve-tek
1 FV08 orifice, DN125, d = 100 mm manufacturer 125 16 mas


1 FR03 LT cooling water temp. control valve 431412Hd 125 16 kfm
1 FV13 orifice damko SPB DN125 125 16 damko
1 FV14 ball valve with locking device Art.No. V1-316-299-015LD 1/2" 25 Valvetek
1 FK06 straight-thermometer (0-100 C), Tt=100mm 3205371 1/2" WIKA
1 LH01 lube oil cooler
NT 150S HV, 147 Pl,
1.4301, 0,5, NBR,B-
10,S235-JRG2, CAT Gelb 150 16
GEA
ECO
1 FV15 ball valve with locking device Art.No. V1-316-299-015LD 1/2" 25 Valvetek

1 FV31 orifice damko SPB DN150 150 16 damko
1 FK08 straight-thermometer (0-100 C), Tt=40mm 1/2" WIKA
1 FR01 HT cooling water temp. control valve 431412Hd 125 16 kfm
1 FV17 orifice, DN125, d = 80 mm manufacturer 125 16 mas
1 header 200 16 mas


1 FK10
0.9 MPa) 7233323 1/2" 10 WIKA
1 FP01 HT cooling water pump LUBL100M185 100 4 Edur

Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
Annex components
Delivery date
2008

5


1 FK11
MPa) 7162140 1/2" 10 WIKA

1 FK19
0.9 MPa) 7233323 1/2" 10 WIKA
1 FP02 HT cooling water pump LUBL100M185 100 4 Edur
1 FK20
MPa) 7162140 1/2" 10 WIKA

1 header 200 16 mas

1 FK14
0.9 MPa) 7233323 1/2" 25 WIKA
1 FP05 cooling water preh. pump
TP 40-160/2 AE-F-A-
AUUE 40 6 Grundfos
1 FH03
cooling water preheater, 42 kW, 2 steps 28 kW
and 14 kW EH-W20/L=1000 40 16 Aalborg
1 FV25 ball valve n/c V1-316-299-015-LD 1/2'' 25 Valve-tek
1 FV29 ball valve n/c V1-316-299-015-LD 1/2'' 25 Valve-tek
1 FV28 savety valve, opening pressure 6 bar 4373.2604 1/2" Leser

Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
Annex components
Delivery date
2008

6


1 electric step thermostat, TempSwitch2000 0628-017 1/4" Barksdale
1 connection box 907-0357 Barksdale
1 FK15
MPa) 7162140 1/2" 10 WIKA
1 dumping pipe 5-422-U POELL
1 FK16 angle-thermometer (0-100 C), Tt=63mm 1/2" 16 WIKA

1 LV07 butterfly valve, Viton, CuAl-disc 22.0130080G1 80 16 ARI
1 LF01 strainer 2 mm 4-A-15796 80 16 HTI
1 LK07
0.15 MPa) 7201871 1/2" 25 WIKA
1 LP01 lube oil prelubricating pump Bfk 40,0 S GL 80 5 Trik
1 E-Motor 22 kW Trik
1 LK08
MPa) 7162140 1/2" 10 WIKA
1 LV11 non-return valve RK 4180 80 16 HTI
1 LV10 3-way valve (manual) R35LH444 80 16 HTI
1 LV09 non-return valve RK 4180 80 16 HTI

1 LK01 angle-thermometer (0-100 C), Tt=100mm 3503011 1/2" WIKA
1 LK02
MPa) 7162140 1/2" 10 WIKA
1 LF02 Automatic filter , 30 micron 6.46 150 16 Boll&Kirch
1 LK03 straight-thermometer (0-100 C), Tt=100mm 3205371 1/2" WIKA
1 LV03 ball valve with locking device Art.No. V1-316-299-015LD 1/2" 25 Valvetek

Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
Annex components
Delivery date
2008

7


1 LV04 ball valve with locking device Art.No. V1-316-299-015LD 1/2" 25 Valvetek
1 LK04 straight-thermometer (0-100 C), Tt=100mm 3205371 1/2" WIKA
1 LR01 lube oil temp. control valve 431415He 150 16 kfm
1 LF03 lube oil duplex filter, 80 micron 2.05.5.265.750 125 16 Boll&Kirch
1 ball valve n/c V1-316-299-015-LD 1/2'' 25 Valve-tek
1 ball valve n/c V1-316-299-015-LD 1/2'' 25 Valve-tek
1 LI08 temperature sensor, PT100, Sensycon 06023-92-0 1/2" 16 ABB
1 LK05 angle-thermometer (0-100 C), Tt=100mm 3503011 1/2" WIKA
1 LK06
MPa) 7162140 1/2" 10 WIKA
1 dumping pipe 5-422-U POELL

Customer
Kabul
System type
Comb. LO CW module
Documentation
Order Number
7224521_26
7224541_46
7224561_66
Manufacturer
m a s GmbH
Annex components
Delivery date
2008

8

3. Annex components

CW preheating pump 21 pages
Lube oil prelubricating pump 11 pages
LT CW temp. Control valve 03 pages
Duplexfilter 2.05.5 25 pages

LT/HT CW pump 16 pages
CW preheater 06 pages
Lube oil cooler 59 pages

Non return valve 13 pages
Pressure gauge 02 pages
Thermometer 04 pages
Pressure gauge valve and test 01 pages

Ball valve 06 pages
Safety valve 18 pages
Electric step thermostat 02 pages
2/3 way valve manuel operation 01 page

Butterfly valve 14 pages
Orifice 02 pages
Strainer 01 page
LO temp. Control valve 03 pages

Electrical diagrams 07 pages

FP05
CW preheating
pump

1
CONTENTS
Page
1. General 4
2. Delivery and handling 4
2.1 Delivery 4
2.2 Handling 4
3. Applications 5
3.1 Pumped liquids 5
4. Installation 5
4.1 Pipework 6
4.2 Terminal box positions 7
4.3 Base plate 7
4.4 Frost protection 7
5. Electrical connection 7
5.1 Frequency converter operation 7
6. Start-up 7
6.1 Priming 7
6.2 Checking the direction of rotation 8
6.3 Starting 8
6.4 Frequency of starts and stops 8
7. Maintenance and service 8
7.1 Pump 8
7.2 Motor 8
7.3 Service 8
7.4 Shaft adjustment 9
7.5 Blanking flanges 9
8. Technical data 10
8.1 Ambient temperature 10
8.2 Liquid temperature 10
8.3 Operating pressure/test pressure 10
8.4 Inlet pressure 10
8.5 Enclosure class 10
8.6 Electrical data 10
8.7 Sound pressure level 10
8.8 Environment 10
9. Fault finding chart 11
10. Disposal 12
Before beginning installation procedures,
these installation and operating instruc-
tions should be studied carefully. The in-
stallation and operation should also be in
accordance with local regulations and ac-
cepted codes of good practice.
1. General
These instructions apply to the pump types TP and
TPD fitted with GRUNDFOS motors, type MG, MMG,
or motors, type MEZ 63. If the pump is fitted with an-
other motor make, please note that the motor data
may differ from the data stated in these instructions.
2. Delivery and handling
2.1 Delivery
The pump is delivered from the factory in a carton
with a wooden bottom, which is specially designed
for transport by fork-lift truck or a similar vehicle.
Lifting eyes for motors of 4 kW and up are supplied
with the pump.
2.2 Handling
Pumps fitted with motors smaller than 4 kW should
be lifted by means of nylon straps, see fig. 1.
Fig. 1
The lifting eyes fitted to large pump motors
can be used for lifting the pump head (mo-
tor, motor stool and impeller). The lifting
eyes must not be used for lifting the entire
pump.
TPD: The centrally positioned thread of
the pump housing must not be used for
lifting purposes as the thread is placed be-
low the centre of gravity of the pump.
T
M
0
2

5
4
9
9

3
3
0
2
T
M
0
2

5
5
0
0

3
3
0
2
TP
TPD
2
Pumps fitted with motors of 4 kW and up should be
lifted by means of nylon straps and shackles, see
fig. 2.
Fig. 2
3. Applications
The pumps are designed to circulate hot or cold wa-
ter in for instance
heating systems,
district heating plants,
central heating systems for blocks of flats,
air-conditioning systems and
cooling systems
in housing, institutional and industrial applications.
In addition, the pump range is used for liquid transfer
and water supply in for instance
washing systems,
domestic hot water systems and
industrial systems in general.
To ensure optimum operation, the dimensioning
range of the system must fall within the performance
range of the pump.
3.1 Pumped liquids
Thin, clean, non-aggressive and non-explosive liq-
uids, not containing solid particles or fibres that may
attack the pump mechanically or chemically.
Examples:
central heating system water (it is recommended
that the water meets the requirements of ac-
cepted standards on water quality in heating sys-
tems, e.g. the German standard VDI 2035),
cooling liquids,
domestic hot water,
industrial liquids,
softened water.
The pumping of liquids with a density and/or kine-
matic viscosity higher than that of water will cause
a considerable pressure drop,
a drop in hydraulic performance,
a rise in power consumption.
In such cases, the pump should be fitted with a big-
ger motor. If in doubt, contact GRUNDFOS.
The EPDM O-rings fitted as standard are primarily
suitable for water.
If the water contains mineral/synthetic oils or chemi-
cals or if other liquids than water are pumped, the
O-rings should be chosen accordingly.
4. Installation
When installing pumps with oval bolt holes in the
pump flange (PN 6/10), washers must be used as
shown in fig. 3.
Fig. 3
The pump should be sited in a well ventilated, but
frost-free position.
Arrows on the pump housing show the direction of
flow of liquid through the pump.
Pumps with motors up to 7.5 kW can be installed in
horizontal or vertical pipework.
Pumps with motors of 7.5 kW and up may only be in-
stalled in horizontal pipework with the motor in verti-
cal position.
Note: The motor must never fall below the horizontal
plane.
T
M
0
2

5
5
0
1

3
3
0
2
T
M
0
2

5
5
0
2

3
3
0
2
TP
TPD
When pumping hot liquids, care should be
taken to ensure that persons cannot acci-
dentally come into contact with hot sur-
faces.
T
M
0
1

0
6
8
3

1
9
9
7
Installation
Pump
Washer
3
For inspection and motor/pump head removal, the
following clearance is required above the motor:
300 mm for motors up to and including 4.0 kW.
1 metre for motors of 5.5 kW and up.
See fig. 4.
Fig. 4
Twin-head pumps installed in horizontal pipes must
be fitted with an automatic air vent in the upper part
of the pump housing, see fig. 5.
The automatic air vent is not supplied with the pump.
Fig. 5
If the liquid temperature falls below the ambient tem-
perature, condensation may form in the motor during
inactivity. In this case, it must be ensured that the
drain hole in the motor flange, see fig. 6, is open and
points downwards.
Fig. 6
If twin-head pumps are used for pumping liquids with
a temperature below 0C/32F, condensed water
may freeze and cause the coupling to get stuck. The
problem can be remedied by installing heating ele-
ments. Whenever possible (pumps with motors
smaller than 7.5 kW), the pump should be installed
with the motor shaft in horizontal position, see fig. 5.
Note: The technical data in section 8 must be ob-
served.
4.1 Pipework
Isolating valves should be fitted either side of the
pump to avoid draining the system if the pump needs
to be cleaned or repaired.
The pump is suitable for pipeline mounting, provided
that the pipework is adequately supported either side
of the pump. TP 25-50, 25-90, 32-50, 32-90, 40-50
and 40-90 are designed for pipeline mounting only.
For pumps with motors of 7.5 kW and up, it is advis-
able to mount the pump on a concrete pedestal and
to install vibration dampers, see fig. 7. This may also
be relevant for smaller motors.
Fig. 7
A: Expansion joint
B: Concrete pedestal
C: Vibration damper
When installing the pipes, it must be ensured that the
pump housing is not stressed by the pipework.
The suction and discharge pipes must be of an ade-
quate size, taking the pump inlet pressure into ac-
count.
To avoid sediment build-up, do not fit the pump at
the lowest point of the system.
Install the pipes so that air locks are avoided, espe-
cially on the suction side of the pump, see fig. 8.
Fig. 8
Note: The pump is not allowed to run against a
closed discharge valve as this will cause an increase
in temperature/formation of steam in the pump which
may cause damage to the pump.
If there is any danger of the pump running against a
closed discharge valve, a minimum liquid flow
through the pump should be ensured by connecting
a bypass/a drain to the discharge pipe. The drain
can for instance be connected to a tank. A minimum
flow rate equal to 10% of the flow rate at maximum
efficiency is needed at all times. Flow rate and head
at maximum efficiency are stated on the pump name-
plate.
T
M
0
0

3
7
3
3

2
8
0
2

T
M
0
0

9
8
3
4

0
4
9
7

T
M
0
0

9
8
3
1

3
2
0
2
5.5 - kW 0.25 - 4.0 kW
1 m 300 mm
0.25 - 4.0 kW 5.5 kW and up
Drain hole
T
M
0
2

4
9
9
3

3
2
0
2

T
M
0
0

2
2
6
3

0
1
9
5

A
B
C
4
4.2 Terminal box positions
The terminal box can be turned to any of four posi-
tions, in 90 steps.
Change the terminal box position as follows:
1. If necessary, remove the coupling guards using a
screwdriver. Do not remove the coupling.
2. Remove the screws securing the motor to the
pump.
3. Turn the motor to the required position.
4. Replace and tighten the screws.
5. Replace the coupling guards.
4.3 Base plate
Single-head pumps (apart from TP 25-50, 25-90,
32-50, 32-90, 40-50 and 40-90) have two tapped
holes in the bottom of the pump housing which can
be used for fitting a GRUNDFOS base plate to the
pump. The base plate is available as an optional ex-
tra.
Twin-head pumps have four tapped holes in the bot-
tom of the pump housing. For some twin-head
pumps, a base plate consisting of two halves is avail-
able.
Base plates with dimensions are shown on page
131.
4.4 Frost protection
Pumps which are not being used during periods of
frost should be drained to avoid damage.
5. Electrical connection
The electrical connection should be carried out in ac-
cordance with local regulations.
The operating voltage and frequency are marked on
the pump nameplate. Make sure that the motor is
suitable for the electricity supply on which it will be
used.
Single-phase standard motors incorporate a thermal
switch and require no additional motor protection.
Three-phase motors must be connected to a motor
starter.
Motors of 3 kW and up incorporate thermistors
(PTC). The thermistors are designed according to
DIN 44 082.
The electrical connection should be carried out as
shown in the diagram inside the terminal box cover.
The motors of twin-head pumps are to be connected
separately.
Note: Do not start the pump until it has been filled
with liquid and vented.
5.1 Frequency converter operation
All three-phase motors can be connected to a fre-
quency converter.
Depending on the frequency converter type, this may
cause increased acoustic noise from the motor. Fur-
thermore, it may cause the motor to be exposed to
detrimental voltage peaks.
Note: Motors types MEZ 63, MG 71 and MG 80 for
supply voltages up to and including 440 V (see motor
nameplate) must be protected against voltage peaks
higher than 650 V between the supply terminals.
It is recommended to protect all other motors against
voltage peaks higher than 850 V.
The above disturbances, i.e. both increased acoustic
noise and detrimental voltage peaks, can be elimi-
nated by fitting an LC filter between the frequency
converter and the motor.
For further information, please contact the frequency
converter supplier or GRUNDFOS.
5.1.1 Other motor makes than GRUNDFOS
Contact GRUNDFOS or the motor manufacturer.
6. Start-up
Note: Do not start the pump until it has been filled
with liquid and vented. To ensure correct venting, the
vent screw should point upwards.
6.1 Priming
Closed systems or open systems where the liq-
uid level is above the pump inlet:
1. Close the discharge isolating valve and loosen
the air vent screw in the motor stool, see fig. 9.
2. Slowly open the isolating valve in the suction pipe
until a steady stream of liquid runs out of the vent
hole.
3. Tighten the air vent screw and completely open
the isolating valve(s).
Open systems where the liquid level is below the
pump inlet:
The suction pipe and the pump must be filled with
liquid and vented before the pump is started.
1. Close the discharge isolating valve and open the
isolating valve in the suction pipe.
2. Loosen the air vent screw, see fig. 9.
3. Remove the plug from one of the pump flanges,
depending on the pump location.
4. Pour liquid through the priming port until the suc-
tion pipe and the pump are filled with liquid.
5. Replace the plug and tighten securely.
Before starting work on the pump, make
sure that the electricity supply has been
switched off and that it cannot be acciden-
tally switched on.
Before removing the terminal box cover
and before any removal/dismantling of the
pump, make sure that the electricity supply
has been switched off.
The pump must be connected to an exter-
nal mains switch with a minimum contact
gap of 3 mm in all poles.
Pay attention to the direction of the vent
hole and take care to ensure that the es-
caping water does not cause injury to per-
sons or damage to the motor or other
components.
In hot-water installations, special attention
should be paid to the risk of injury caused
by scalding hot water.
5
6. Tighten the air vent screw.
The suction pipe can to some extent be filled with liq-
uid and vented before it is connected to the pump.
A priming device can also be installed before the
pump.
Fig. 9
6.2 Checking the direction of rotation
Do not start the pump to check the direction of rota-
tion until it has been filled with liquid.
Note: The direction of rotation should not be
checked with the motor alone, as an adjustment of
the shaft position is required when the coupling has
been removed.
The correct direction of rotation is shown by arrows
on the motor fan cover or on the pump housing.
6.3 Starting
1. Before starting the pump, completely open the
isolating valve on the suction side of the pump
and leave the discharge isolating valve almost
closed.
2. Start the pump.
3. Vent the pump during starting by loosening the
air vent screw in the motor stool, see fig. 9, until a
steady stream of liquid runs out of the vent hole.
4. When the piping system has been filled with liq-
uid, slowly open the discharge isolating valve un-
til it is completely open.
6.4 Frequency of starts and stops
Maximum 100 starts per hour.
On twin-head pumps, the duty and standby pumps
should be alternated on a regular basis, i.e. once
a week, to ensure an even distribution of the oper-
ating hours on both pumps.
Pump change can be effected either manually or
automatically by installing a suitable pump control-
ler.
If twin-head pumps are used for pumping domes-
tic hot water, the duty and standby pumps should
be alternated on a regular basis, i.e. once a day,
to avoid blocking of the standby pump due to de-
posits (calcareous deposits, etc.).
Automatic pump change is recommended.
7. Maintenance and service
7.1 Pump
The pump is maintenance-free.
If the pump is to be drained for a long period of inac-
tivity, inject a few drops of silicone oil on the shaft
between the motor stool and the coupling. This will
prevent the shaft seal faces from sticking.
7.2 Motor
The motor should be checked at regular intervals. It
is important to keep the motor clean in order to en-
sure adequate ventilation. If the pump is installed in
a dusty environment, the pump must he cleaned and
checked regularly.
Lubrication:
The bearings of motors up to 11 kW are greased for
life and require no lubrication.
The bearings of motors of 11 kW and up must be
greased in accordance with the indications on the
motor nameplate.
The motor should be lubricated with a lithium-based
grease meeting the following specifications:
NLGI grade 2 or 3.
Viscosity of basic oil: 70 to 150 cSt at 40C
(~ +104F).
Temperature range: 30C (~ 22F) to 140C
(~ +284F) during continuous operation.
7.3 Service
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 ac-
cept the pump for service.
Possible costs of returning the pump are paid by the
customer.
T
M
0
0

9
8
3
2

3
2
0
2
Pay attention to the direction of the vent
hole and take care to ensure that the es-
caping water does not cause injury to per-
sons or damage to the motor or other
components.
In hot-water installations, special attention
should be paid to the risk of injury caused
by scalding hot water.
Vent screw
Before starting work on the pump, make
sure that the electricity supply has been
switched off and that it cannot be acciden-
tally switched on.
If the pump has been used for a liquid
which is injurious to health or toxic, the
pump will be classified as contaminated.
6
7.4 Shaft adjustment
If the motor has been removed during installation or
for repair of the pump, the pump shaft must be ad-
justed after the motor has been replaced.
7.4.1 Pumps with two-part coupling
Make sure that the shaft pin is fitted in the pump
shaft.
Adjust the pump shaft as follows:
1. Remove the coupling guards using a screwdriver.
2. Fit the hexagon socket head screws in the cou-
pling and leave loose.
3. Raise the coupling and the pump shaft as far as
possible (towards the motor) by means of a
screwdriver or a similar tool so that the pump and
motor shafts touch each other, see fig. 10.
Fig. 10
4. Tighten the hexagon socket head screws in the
coupling to 5 Nm (0.5 kpm).
5. Check that the gaps either side of the coupling
halves are equal.
6. Tighten the screws two and two (one side at a
time), see fig. 11, to the torque stated below.
7. Fit the coupling guards.
Fig. 11
7.4.2 Pumps with integral shaft/coupling
For pumps with integral shaft/coupling, it is advisable
not to remove the motor. If the motor has been re-
moved, it is necessary to remove the motor stool in
order to refit the motor correctly. Otherwise the shaft
seal may be damaged.
7.5 Blanking flanges
For twin-head pumps, a blanking flange with a pump
housing gasket is available, see fig. 12.
Fig. 12
If one pump requires service, the blanking flange is
fitted to allow the other pump to continue operating.
T
M
0
0

6
4
1
5

3
6
9
5
Hexagon socket
head screw
Torque
M6 x 20 13 Nm (1.3 kpm)
M8 x 25 31 Nm (3.1 kpm)
T
M
0
0

6
4
1
6

3
6
9
5

T
M
0
0

6
3
6
0

3
4
9
5
7
8. Technical data
8.1 Ambient temperature
Maximum +40C (~ +104F).
8.2 Liquid temperature
25C (~ 13F) up to +140C (~ +288F).
The maximum liquid temperature depends on the
mechanical shaft seal type and the pump type.
Depending on the cast-iron version and the pump
application, the maximum liquid temperature may be
limited by local regulations and laws.
The maximum liquid temperature is marked on the
pump nameplate.
Note: If the pump is operating with liquids at high
temperatures, the life of the shaft seal may be re-
duced. It may be necessary to replace the shaft seal
more often.
8.3 Operating pressure/test pressure
The pressure test has been made with water con-
taining anti-corrosive additives at a temperature of
+20C (~ +68F).
8.4 Inlet pressure
To ensure optimum and quiet pump operation, the
inlet pressure (system pressure) must be adjusted
correctly. See table on page 124.
For the calculation of specific inlet pressures, con-
tact the local GRUNDFOS company or see the data
booklet for TP(D)/TPE(D), if at hand.
8.5 Enclosure class
Closed drain hole in motor: IP 55.
Open drain hole in motor: IP 44.
(Drain hole, see fig. 6.)
8.6 Electrical data
See motor nameplate.
8.7 Sound pressure level
Pumps with single-phase motors:
The sound pressure level of the pump is lower than
70 dB(A).
Pumps with three-phase motors:
See table on page 130.
8.8 Environment
Non-aggressive and non-explosive atmosphere.
Relative air humidity: Maximum 95%.
Pressure
stage
Operating
pressure
Test
pressure
bar MPa bar MPa
PN 6 6 0.6 10 1.0
PN 6/
PN 10
10 1.0 15 1.5
PN 16 16 1.6 24 2.4
8
9. Fault finding chart
* In twin-head pump installations, the standby pump will often rotate slowly.
Before removing the terminal box cover and before removal/dismantling of the pump, make sure that
the electricity supply has been switched off and that it cannot be accidentally switched on.
Fault Cause
1. Motor does not run when
started.
a) Supply failure.
b) Fuses blown.
c) Motor starter overload has tripped out.
d) Main contacts in motor starter are not making contact or the coil is
faulty.
e) Control circuit fuses are defective.
f) Motor is defective.
2. Motor starter overload trips
out immediately when supply
is switched on.
a) Supply failure.
b) Contacts in motor starter overload are faulty.
c) Cable connection is loose or faulty.
d) Motor winding is defective.
e) Pump mechanically blocked.
f) Overload setting too low.
3. Motor starter overload trips
out occasionally.
a) Overload setting too low.
b) Supply voltage periodically too low or too high.
c) Differential pressure across pump too low.
4. Motor starter has not tripped
out but the pump does not
run.
a) Check the electricity supply.
b) Check fuses.
c) Check main contacts in motor starter and coil.
d) Check the control circuit.
5. Pump capacity not constant. a) Pump inlet pressure is too low.
b) Suction pipe/pump partly blocked by impurities.
c) Pump draws in air.
6. Pump runs but gives no water. a) Suction pipe/pump blocked by impurities.
b) Foot or non-return valve blocked in closed position.
c) Leakage in suction pipe.
d) Air in suction pipe or pump.
e) Motor rotates in the wrong direction.
7. Pump runs backwards when
switched off.*
a) Leakage in suction pipe.
b) Foot or non-return valve defective.
c) Foot or non-return valve blocked in open or partly open position.
8. Leakage in shaft seal. a) Pump shaft position is incorrect.
b) Shaft seal is defective.
9. Noise. a) Pump is cavitating.
b) Pump does not rotate freely (frictional resistance) because of incorrect
pump shaft position.
c) Frequency converter operation:
- See section 5.1 Frequency converter operation.
- Resonance in the installation.
d) Foreign bodies in the pump.
10. Pump runs constantly
(applies only to pumps with
automatic start/stop).
a) Stop pressure is too high in relation to the required quantity of water.
b) The water consumption is larger than anticipated.
c) Leakage in discharge pipe.
d) The direction of rotation of the pump is incorrect.
e) Pipes, valves or strainer blocked by impurities.
f) Pump controller, if used, is defective.
11. Period of operation is too long
(applies only to pumps with
automatic start/stop).
a) Stop pressure is too high in relation to the required quantity of water.
b) Pipes, valves or strainer blocked by impurities.
c) Pump partly blocked or furred up.
d) The water consumption is larger than anticipated.
e) Leakage in discharge pipe.
9
10. Disposal
Disposal of this product or parts of it must be carried
out according to the following guidelines:
1. Use the local public or private waste collection
service.
2. In case such waste collection service does not
exist or cannot handle the materials used in the
product, please deliver the product or any haz-
ardous materials from it to your nearest GRUND-
FOS company or service workshop.
Subject to alterations.
10
GB: Inlet pressure stated in bar relative pressure (pressure gauge value measured on the suction side of the
pump)
D: Zulaufdruck in bar Relativdruck (Manometerdruck auf der Saugseite der Pumpe gemessen)
PL: Cinienie na krcu ssawnym pompy wyraone w barach (mierzone manometrem na stronie
ssawnej pompy)
CZ: Tlak na sn vyjden v barech je relativn tlak (hodnota na manometru men na sac stran
erpadla)
F: Pression dentre indique en bar (valeur mesure laide dun manomtre plac sur le ct aspiration
de la pompe)
I: Pressione di aspirazione indicata in bar (valore misurato con un manometro posto sul lato aspirazione
della pompa)
E: Presin de aspiracin indicada en bar como presin relativa (valor del manmetro medido en la aspira-
cin de la bomba)
P: Presso de entrada com a presso relativa apresentada em bar (ponto de medida na parte de aspirao
da bomba)
GR: bar (
)
NL: Inlaatdruk weergegeven in bar relatieve druk (drukopnemer waarde, gemeten aan de zuigkant van de
pomp)
S: Tilloppstrycket angivet i bar relativt tryck (manometervrde mtt p pumpens sugsida)
SF: Tulopaine ilmoitettuna baareina on suhteellinen paine (painemittarin lukema mitattu pumpun imupuo-
lella)
DK: Tillbstrykket angivet i bar relativt tryk (manometervrdi mlt p pumpens sugeside)
50 Hz, 2-pole
Pump type p [bar]
50 Hz, 2-pole 20C 60C 90C 110C 120C 140C
TP 25-50R/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 25-90R/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-50R/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-90R/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-60/2 0.1 0.1 0.2 1.0 1.5 3.2
TP(D) 32-120/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 32-150/2 0.1 0.3 0.8 1.6 2.1 3.8
TP(D) 32-180/2 0.5 0.7 1.2 2.0 2.5 4.2
TP(D) 32-230/2 0.7 0.9 1.4 2.2 2.7 4.4
TP(D) 32-200/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-250/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-320/2 0.1 0.1 0.6 1.4 1.9 3.6
TP(D) 32-380/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 32-460/2 0.1 0.2 0.7 1.4 2.0 3.7
TP(D) 32-580/2 0.2 0.4 0.9 1.6 2.2 3.9
TP 40-50/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-90/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-60/2 0.1 0.1 0.5 1.2 1.8 3.5
TP(D) 40-120/2 0.1 0.1 0.4 1.2 1.7 3.4
TP(D) 40-180/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 40-190/2 0.1 0.3 0.8 1.6 2.1 3.8
11
TP(D) 40-230/2 0.7 0.9 1.4 2.2 2.7 4.4
TP(D) 40-270/2 0.7 0.9 1.4 2.2 2.7 4.4
TP(D) 40-240/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-300/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-360/2 0.2 0.4 0.9 1.6 2.2 3.9
TP(D) 40-470/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-580/2 0.2 0.4 0.9 1.6 2.2 3.9
TP(D) 50-60/2 0.1 0.1 0.4 1.1 1.7 3.4
TP(D) 50-120/2 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 50-180/2 0.1 0.2 0.7 1.4 2.0 3.7
TP(D) 50-160/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-190/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-240/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-290/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-360/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-430/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-440/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-570/2 0.1 0.3 0.8 1.6 2.1 3.8
TP(D) 50-710/2 0.6 0.8 1.3 2.0 2.6 4.3
TP(D) 50-830/2 0.5 0.7 1.2 2.0 2.5 4.2
TP(D) 50-960/2 1.0 1.2 1.7 2.5 3.0 4.7
TP(D) 65-60/2 0.1 0.3 0.8 1.5 2.1 3.8
TP(D) 65-120/2 0.5 0.7 1.2 2.0 2.5 4.2
TP(D) 65-180/2 0.3 0.5 1.0 1.8 2.3 4.0
TP(D) 65-190/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-230/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-260/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-340/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-410/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-460/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-550/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-660/2 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-720/2 0.1 0.1 0.6 1.3 1.9 3.6
TP(D) 65-930/2 0.6 0.8 1.3 2.0 2.6 4.3
TP(D) 80-120/2 1.2 1.4 1.9 2.7 3.2 4.9
TP(D) 100-120/2 1.9 2.1 2.6 3.4 3.9 5.6
Pump type p [bar]
50 Hz, 2-pole 20C 60C 90C 110C 120C 140C
12
50 Hz, 4-pole
Pump type p [bar]
50 Hz, 4-pole 20C 60C 90C 110C 120C 140C
TP(D) 32-30/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-40/4 0.1 0.1 0.1 0.9 1.4 3.1
TP(D) 32-60/4 0.1 0.1 0.3 1.1 1.6 3.3
TP(D) 32-80/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-100/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 32-120/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-30/4 0.1 0.1 0.2 0.9 1.5 3.2
TP(D) 40-60/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-90/4 0.1 0.1 0.3 1.0 1.6 3.3
TP(D) 40-100/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 40-160/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-30/4 0.1 0.1 0.1 0.9 1.4 3.1
TP(D) 50-60/4 0.1 0.1 0.2 0.9 1.5 3.2
TP(D) 50-90/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-110/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-160/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 50-230/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-30/4 0.1 0.2 0.7 1.5 2.0 3.7
TP(D) 65-60/4 0.2 0.4 0.9 1.6 2.2 3.9
TP(D) 65-90/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-110/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-150/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-170/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 65-240/4 0.1 0.1 0.1 0.8 1.4 3.1
TP(D) 80-30/4 0.8 1.0 1.5 2.2 2.8 4.5
TP(D) 80-60/4 0.8 1.0 1.5 2.3 2.8 4.5
TP(D) 100-30/4 0.8 1.0 1.5 2.2 2.8 4.5
TP(D) 100-60/4 0.6 0.8 1.3 2.0 2.6 4.3
13
60 Hz, 2-pole
Pump type p [bar]
60 Hz, 2-pole 20C 60C 90C 110C 120C 140C
TP 32-80/2 0.4 0.4 0.4 1.2 1.7 3.4
TP 32-160/2 0.4 0.6 1.1 1.9 2.4 4.1
TP 32-220/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 32-260/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 32-330/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 32-300/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-360/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-450/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-550/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-680/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-820/2 0.5 0.7 1.2 1.9 2.5 4.2
TP 40-80/2 0.1 0.3 0.8 1.6 2.1 3.8
TP 40-160/2 0.1 0.2 0.7 1.5 2.0 3.7
TP 40-240/2 0.4 0.6 1.1 1.9 2.4 4.1
TP 40-270/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 40-330/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 40-390/2 0.7 0.9 1.4 2.2 2.7 4.4
TP 40-370/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-450/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-550/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-740/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-850/2 0.1 0.1 0.6 1.4 1.9 3.6
TP 40-930/2 0.3 0.5 1.0 1.7 2.3 4.0
TP 50-80/2 0.1 0.1 0.6 1.4 1.9 3.6
TP 50-160/2 0.4 0.6 1.1 1.9 2.4 4.1
TP 50-240/2 0.3 0.5 1.0 1.8 2.3 4.0
TP 50-250/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-300/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-350/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-410/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-440/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-540/2 0.1 0.2 0.7 1.4 2.0 3.7
TP 50-720/2 0.1 0.3 0.8 1.6 2.1 3.8
TP 50-790/2 0.5 0.7 1.2 1.9 2.5 4.2
TP 50-880/2 0.8 1.0 1.5 2.2 2.8 4.5
TP 50-1050/2 1.1 1.3 1.8 2.6 3.1 4.8
TP 65-80/2 0.6 0.8 1.3 2.1 2.6 4.3
TP 65-160/2 1.1 1.3 1.8 2.6 3.1 4.8
TP 65-240/2 0.9 1.1 1.6 2.4 2.9 4.6
TP 65-220/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-260/2 0.1 0.1 0.1 0.8 1.4 3.1
14
TP 65-340/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-390/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-480/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-540/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-630/2 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-740/2 0.1 0.1 0.6 1.3 1.9 3.6
TP 65-910/2 0.1 0.2 0.7 1.5 2.0 3.7
TP 65-1050/2 0.1 0.2 0.7 1.5 2.0 3.7
TP 80-160/2 2.1 2.3 2.8 3.6 4.1 5.8
Pump type p [bar]
60 Hz, 2-pole 20C 60C 90C 110C 120C 140C
15
60 Hz, 4-pole
Pump type p [bar]
60 Hz, 4-pole 20C 60C 90C 110C 120C 140C
TP 32-40/4 0.1 0.1 0.1 0.9 1.4 3.1
TP 32-80/4 0.1 0.1 0.5 1.3 1.8 3.5
TP 32-120/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-140/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 32-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-40/4 0.1 0.1 0.3 1.1 1.6 3.3
TP 40-80/4 0.1 0.1 0.2 1.0 1.5 3.2
TP 40-120/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-160/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 40-220/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-40/4 0.1 0.1 0.3 1.1 1.6 3.3
TP 50-80/4 0.1 0.1 0.3 1.1 1.6 3.3
TP 50-110/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-120/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-140/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-240/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-270/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 50-340/4 0.1 0.2 0.7 1.4 2.0 3.7
TP 65-40/4 0.4 0.6 1.1 1.9 2.4 4.1
TP 65-80/4 0.7 0.9 1.4 2.2 2.7 4.4
TP 65-130/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-150/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-190/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-230/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-310/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 65-330/4 0.1 0.1 0.1 0.8 1.4 3.1
TP 80-40/4 1.5 1.7 2.2 3.0 3.5 5.2
TP 80-80/4 1.6 1.8 2.3 3.1 3.6 5.3
TP 100-40/4 1.4 1.6 2.1 2.9 3.4 5.1
TP 100-80/4 1.2 1.4 1.9 2.7 3.2 4.9
16
Maximum sound pressure level
Three-phase motors
[kW]
50 Hz
[dB(A)]
60 Hz
[dB(A)]
2-pole 4-pole 2-pole 4-pole
0.12 <70 <70 <70 <70
0.18 <70 <70 <70 <70
0.25 <70 41.2 <70 45.0
0.37 56.2 44.8 57.0 45.0
0.55 56.6 41.8 56.0 45.0
0.75 56.3 41.5 57.0 49.0
1.1 59.0 50.0 63.0 53.0
1.5 58.0 50.0 64.0 53.0
2.2 60.0 52.0 65.0 55.0
3.0 59.0 52.0 64.0 55.0
4.0 63.0 54.0 68.0 57.0
5.5 63.0 58.0 67.0 62.0
7.5 68.0 58.0 73.0 62.0
11.0 65.0 60.0 69.0 64.0
15.0 65.0 60.0 69.0 64.0
18.5 66.0 61.0 70.0 65.0
22.0 68.0 61.0 72.0 65.0
30.0 69.0 62.0 73.0 66.0
37.0 69.0 65.0 73.0 69.0
17
Fig. A
Fig. B
Fig. C
235
195
120
200
8
0
1
9
5
1
6
0
2x14
2x14
2x18
4x14
2x18
35
T
M
0
0

9
8
3
5

0
4
9
7
235
195
144
9
6
1
9
5
2x18
4x14
2x14
35
T
M
0
0

3
7
5
5

5
0
9
7
2x18
2x14
175
300
330
4
7
6
7
3
5
T
M

0
2

5
3
3
6

2
6
0
2
Denmark
GRUNDFOS DK A/S
Poul Due Jensens Vej 7A
DK-8850 Bjerringbro
Tlf.: +45-87 50 50 50
Telefax: +45-87 50 51 51
Argentina
Bombas GRUNDFOS de Argentina
S.A.
Ruta Panamericana km. 37.500
Lote 34A
1619 - Garin
Pcia. de Buenos Aires
Phone: +54-3327 414 444
Telefax: +54-3327 411 111
Australia
GRUNDFOS Pumps Pty. Ltd.
P.O. Box 2040
Regency Park
South Australia 5942
Phone: +61-8-8461-4611
Telefax: +61-8-8340 0155
Austria
GRUNDFOS Pumpen Vertrieb
Ges.m.b.H.
Grundfosstrae 2
A-5082 Grdig/Salzburg
Tel.: +43-6246-883-0
Telefax: +43-6246-883-30
Belgium
N.V. GRUNDFOS Bellux S.A.
Boomsesteenweg 81-83
B-2630 Aartselaar
Tl.: +32-3-870 7300
Tlcopie: +32-3-870 7301
Brazil
GRUNDFOS do Brasil Ltda.
Rua Tomazina 106
CEP 83325 - 040
Pinhais - PR
Phone: +55-41 668 3555
Telefax: +55-41 668 3554
Canada
GRUNDFOS Canada Inc.
2941 Brighton Road
Oakville, Ontario
L6H 6C9
Phone: +1-905 829 9533
Telefax: +1-905 829 9512
China
GRUNDFOS Pumps (Shanghai) Co.
Ltd.
22 Floor, Xin Hua Lian Building
755-775 Huai Hai Rd, (M)
Shanghai 200020
PRC
Phone: +86-512-67 61 11 80
Telefax: +86-512-67 61 81 67
Czech Republic
GRUNDFOS s.r.o.
Cajkovskho 21
779 00 Olomouc
Phone: +420-68-5716 111
Telefax: +420-68-543 8908
Finland
OY GRUNDFOS Pumput AB
Mestarintie 11
Piispankyl
FIN-01730 Vantaa (Helsinki)
Phone: +358-9 878 9150
Telefax: +358-9 878 91550
France
Pompes GRUNDFOS Distribution
S.A.
Parc dActivits de Chesnes
57, rue de Malacombe
F-38290 St. Quentin Fallavier
(Lyon)
Tl.: +33-4 74 82 15 15
Tlcopie: +33-4 74 94 10 51
Germany
GRUNDFOS GMBH
Schlterstr. 33
40699 Erkrath
Tel.: +49-(0) 211 929 69-0
Telefax: +49-(0) 211 929 69-3799
e-mail: infoservice@grundfos.de
Service in Deutschland:
e-mail: kundendienst@grund-
fos.de
Greece
GRUNDFOS Hellas A.E.B.E.
20th km. Athinon-Markopoulou
Av.
P.O. Box 71
GR-19002 Peania
Phone: +0030-210-66 83 400
Telefax: +0030-210-66 46 273
Hong Kong
GRUNDFOS Pumps (Hong Kong)
Ltd.
Unit 1, Ground floor
Siu Wai Industrial Centre
29-33 Wing Hong Street &
68 King Lam Street, Cheung Sha
Wan
Kowloon
Phone: +852-27861706/27861741
Telefax: +852-27858664
Hungary
GRUNDFOS Hungria Kft.
Park u. 8
H-2045 Trkbalint,
Phone: +36-34 520 100
Telefax: +36-34 520 200
India
GRUNDFOS Pumps India Private
Limited
Flat A, Ground Floor
61/62 Chamiers Aptmt
Chamiers Road
Chennai 600 028
Phone: +91-44 432 3487
Telefax: +91-44 432 3489
Indonesia
PT GRUNDFOS Pompa
Jl. Rawa Sumur III, Blok III / CC-1
Kawasan Industri, Pulogadung
Jakarta 13930
Phone: +62-21-460 6909
Telefax: +62-21-460 6910/460
6901
Ireland
GRUNDFOS (Ireland) Ltd.
Unit 34, Stillorgan Industrial Park
Blackrock
County Dublin
Phone: +353-1-2954926
Telefax: +353-1-2954739
Italy
GRUNDFOS Pompe Italia S.r.l.
Via Gran Sasso 4
I-20060 Truccazzano (Milano)
Tel.: +39-02-95838112
Telefax: +39-02-95309290/
95838461
Japan
GRUNDFOS Pumps K.K.
1-2-3, Shin Miyakoda
Hamamatsu City
Shizuoka pref. 431-21
Phone: +81-53-428 4760
Telefax: +81-53-484 1014
Korea
GRUNDFOS Pumps Korea Ltd.
2nd Fl., Dong Shin Building
994-3 Daechi-dong, Kangnam-Ku
Seoul 135-280
Phone: +82-2-5317 600
Telefax: +82-2-5633 725
Malaysia
GRUNDFOS Pumps Sdn. Bhd.
7 Jalan Peguam U1/25
Glenmarie Industrial Park
40150 Shah Alam
Selangor
Phone: +60-3-5569 2922
Telefax: +60-3-5569 2866
Mexico
Bombas GRUNDFOS de Mexico
S.A. de C.V.
Boulevard TLC No. 15
Parque Industrial Stiva Aerop-
uerto
Apodaca, N.L. 66600
Mexico
Phone: +52-81-8144 4000
Telefax: +52-81-8144 4010
Netherlands
GRUNDFOS Nederland B.V.
Postbus 104
NL-1380 AC Weesp
Tel.: +31-294-492 211
Telefax: +31-294-492244/492299
New Zealand
GRUNDFOS Pumps NZ Ltd.
17 Beatrice Tinsley Crescent
North Harbour Industrial Estate
Albany, Auckland
Phone: +64-9-415 3240
Telefax: +64-9-415 3250
Norway
GRUNDFOS Pumper A/S
Strmsveien 344
Postboks 235, Leirdal
N-1011 Oslo
Tlf.: +47-22 90 47 00
Telefax: +47-22 32 21 50
Poland
GRUNDFOS Pompy Sp. z o.o.
ul. Klonowa 23
Baranowo k. Poznania
PL-62-081 Przezmierowo
Phone: +48-61-650 13 00
Telefax: +48-61-650 13 50
Portugal
Bombas GRUNDFOS Portugal, S.A.
Rua Calvet de Magalhes, 241
Apartado 1079
P-2780 Pao de Arcos
Tel.: +351-21-440 76 00
Telefax: +351-21-440 76 90
Russia
OOO GRUNDFOS
Shkolnaya 39
RUS-109544 Moscow
Phone: +7-095 564 88 00, +7-095
737 30 00
Telefax: +7-095 564 88 11, +7-
095 737 75 36
e-mail: grundfos.moscow@grund-
fos.com
Singapore
GRUNDFOS (Singapore) Pte. Ltd.
24 Tuas West Road
Jurong Town
Singapore 638381
Phone: +65-6865 1222
Telefax: +65-6861 8402
Spain
Bombas GRUNDFOS Espaa S.A.
Camino de la Fuentecilla, s/n
E-28110 Algete (Madrid)
Tel.: +34-91-848 8800
Telefax: +34-91-628 0465
Sweden
GRUNDFOS AB
Box 63, Angeredsvinkeln 9
S-424 22 Angered
Tel.: +46-771-32 23 00
Telefax: +46-31 331 94 60
Switzerland
GRUNDFOS Pumpen AG
Bruggacherstrasse 10
CH-8117 Fllanden/ZH
Tel.: +41-1-806 8111
Telefax: +41-1-806 8115
Taiwan
GRUNDFOS Pumps (Taiwan) Ltd.
14, Min-Yu Road
Tunglo Industrial Park
Tunglo, Miao-Li County
Taiwan, R.O.C.
Phone: +886-37-98 05 57
Telefax: +886-37-98 05 70
Thailand
GRUNDFOS (Thailand) Ltd.
947/168 Moo 12, Bangna-Trad Rd.,
K.M. 3,
Bangna, Phrakanong
Bangkok 10260
Phone: +66-2-744 1785 ... 91
Telefax: +66-2-744 1775 ... 6
Turkey
GRUNDFOS POMPA SAN. ve TIC.
LTD. STI
Bulgurlu Caddesi no. 32
TR-81190 skdar Istanbul
Phone: +90 - 216-4280 306
Telefax: +90 - 216-3279 988
United Arab Emirates
GRUNDFOS Gulf Distribution
P.O. Box 16768
Jebel Ali Free Zone
Dubai
Phone: +971-4- 8815 166
Telefax: +971-4-8815 136
United Kingdom
GRUNDFOS Pumps Ltd.
Grovebury Road
Leighton Buzzard/Beds. LU7 8TL
Phone: +44-1525-850000
Telefax: +44-1525-850011
U.S.A.
GRUNDFOS Pumps Corporation
17100 West 118th Terrace
Olathe, Kansas 66061
Phone: +1-913-227-3400
Telefax: +1-913-227-3500
Addresses revised 04.11.2002
96 40 49 99 1102
74
Repl. 96 40 49 99 0902
Being responsible is our foundation
Thinking ahead makes it possible
Innovation is the essence
Declaration of Conformity
We GRUNDFOS declare under our sole responsibility that the products
TP and TPD, to which this declaration relates, are in conformity with the
Council Directives on the approximation of the laws of the EEC Member
States relating to
Machinery (98/37/EEC).
Standard used: EN 292.
Electromagnetic compatibility (89/336/EEC).
Standards used: EN 61 000-6-2 and EN 61 000-6-3.
Electrical equipment designed for use within certain voltage limits
(73/23/EEC).
Standards used: EN 60 335-1 and EN 60 335-2-51.
Konformittserklrung
Wir GRUNDFOS erklren in alleiniger Verantwortung, da die Produkte
TP und TPD, auf die sich diese Erklrung bezieht, mit den folgenden
Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EG-Mit-
gliedstaaten bereinstimmen:
Maschinen (98/37/EWG).
Norm, die verwendet wurde: EN 292.
Elektromagnetische Vertrglichkeit (89/336/EWG).
Normen, die verwendet wurden: EN 61 000-6-2 und EN 61 000-6-3.
Elektrische Betriebsmittel zur Verwendung innerhalb bestimmter Span-
nungsgrenzen (73/23/EWG).
Normen, die verwendet wurden: EN 60 335-1 und EN 60 335-2-51.
Deklaracja zgodnoci
My, GRUNDFOS, owiadczamy z pen odpowiedzialnoci, e
nasze wyroby TP oraz TPD, ktrych deklaracja niniejsza
dotyczy, s zgodne z nastpujcymi wytycznymi Rady d/s
ujednolicenia przepisw prawnych krajw czonkowskich EWG:
maszyny (98/37/EWG),
zastosowana norma: EN 292.
zgodno elektromagnetyczna (89/336/EWG),
zastosowane normy: EN 61 000-6-2 i EN 61 000-6-3.
wyposaenie elektryczne do stosowania w okrelonym
zakresie napi (73/23/EWG),
zastosowane normy: EN 60 335-1 i EN 60 335-2-51.
Prohlen o konformit
My firma GRUNDFOS prohlaujeme na svou plnou
odpovdnost, e vrobky TP a TPD na n se toto prohlen
vztahuje, jsou v souladu s ustanovenmi smrnice Rady pro
sbl en prvnch pedpis lenskch stt Evropskho
spoleenstv v oblastech:
strojrenstv (98/37/EWG),
pou it norma: EN 292.
elektromagnetick kompatibilita (89/336/EWG),
pou it normy: EN 61 000-6-2 a EN 61 000-6-3.
provozovn spotebi v toleranci napt (73/23/EWG),
pou it normy: EN 60 335-1 a EN 60 335-2-51.
Dclaration de Conformit
Nous GRUNDFOS dclarons sous notre seule responsabilit que les pro-
duits TP et TPD auxquels se rfre cette dclaration sont conformes aux
Directives du Conseil concernant le rapprochement des lgislations des
Etats membres CEE relatives
Machines (98/37/CEE).
Standard utilis: EN 292.
Compatibilit lectromagntique (89/336/CEE).
Standards utiliss: EN 61 000-6-2 et EN 61 000-6-3.
Matriel lectrique destin employer dans certaines limites de tension
(73/23/CEE).
Standards utiliss: EN 60 335-1 et EN 60 335-2-51.
Dichiarazione di Conformit
Noi GRUNDFOS dichiariamo sotto la nostra esclusiva responsabilit che
i prodotti TP e TPD ai quali questa dichiarazione se riferisce sono con-
formi alle Direttive del Consiglio concernente il ravvicinamento delle
legislazioni degli Stati membri CEE relative a
Macchine (98/37/CEE).
Standard usato: EN 292.
Compatibilit elettromagnetica (89/336/CEE).
Standard usati: EN 61 000-6-2 e EN 61 000-6-3.
Materiale elettrico destinato ad essere utilizzato entro certi limiti di ten-
sione (73/23/CEE).
Standard usati: EN 60 335-1 e EN 60 335-2-51.
Declaracin de Conformidad
Nosotros GRUNDFOS declaramos bajo nuestra nica responsabilidad
que los productos TP y TPD a los cuales se refiere esta declaracin son
conformes con las Directivas del Consejo relativas a la aproximacin de
las legislaciones de los Estados Miembros de la CEE sobre
Mquinas (98/37/CEE).
Norma aplicada: EN 292.
Compatibilidad electromagntica (89/336/CEE).
Normas aplicadas: EN 61 000-6-2 y EN 61 000-6-3.
Material elctrico destinado a utilizarse con determinadas lmites de
tensin (73/23/CEE).
Normas aplicadas: EN 60 335-1 y EN 60 335-2-51.
Declarao de Conformidade
Ns GRUNDFOS declaramos sob nossa nica responsabilidade que os
produtos TP e TPD aos quais se refere esta declarao esto em confor-
midade com as Directivas do Conselho das Comunidades Europeias
relativas aproximao das legislaes dos Estados Membros respeitan-
tes
Mquinas (98/37/CEE).
Norma utilizada: EN 292.
Compatibilidade electromagntica (89/336/CEE).
Normas utilizadas: EN 61 000-6-2 e EN 61 000-6-3.
Material elctrico destinado a ser utilizado dentro de certos limites de
tenso (73/23/CEE).
Normas utilizadas: EN 60 335-1 e EN 60 335-2-51.

GRUNDFOS
TP TPD
M

(98/37/EEC).
: EN 292.
(89/336/EEC).
: EN 61 000-6-2 EN 61 000-6-3.

(73/23/EEC).
: EN 60 335-1 EN 60 335-2-51.
Overeenkomstigheidsverklaring
Wij GRUNDFOS verklaren geheel onder eigen verantwoordelijkheid dat
de produkten TP en TPD waarop deze verklaring betrekking heeft in over-
eenstemming zijn met de Richtlijnen van de Raad inzake de onderlinge
aanpassing van de wetgevingen van de Lid-Staten betreffende
Machines (98/37/EEG).
Norm: EN 292.
Elektromagnetische compatibiliteit (89/336/EEG).
Normen: EN 61 000-6-2 en EN 61 000-6-3.
Elektrisch materiaal bestemd voor gebruik binnen bepaalde spannings-
grenzen (73/23/EEG).
Normen: EN 60 335-1 en EN 60 335-2-51.
Frskran om verensstmmelse
Vi GRUNDFOS frskrar under ansvar, att produkterna TP och TPD, som
omfattas av denna frskran, r i verensstmmelse med Rdets Direktiv
om inbrdes nrmande till EU-medlemsstaternas lagstiftning, avseende
Maskinell utrustning (98/37/EC).
Anvnd standard: EN 292.
Elektromagnetisk kompatibilitet (89/336/EC).
Anvnda standarder: EN 61 000-6-2 och EN 61 000-6-3.
Elektrisk material avsedd fr anvndning inom vissa spnningsgrnser
(73/23/EC).
Anvnda standarder: EN 60 335-1 och EN 60 335-2-51.
Vastaavuusvakuutus
Me GRUNDFOS vakuutamme yksin vastuullisesti, ett tuotteet TP ja TPD,
jota tm vakuutus koskee, noudattavat direktiivej jotka ksittelevt EY:n
jsenvaltioiden koneellisia laitteita koskevien lakien yhdenmukaisuutta
seur.:
Koneet (98/37/EY).
Kytetty standardi: EN 292.
Elektromagneettinen vastaavuus (89/336/EY).
Kytetyt standardit: EN 61 000-6-2 ja EN 61 000-6-3.
Mrttyjen jnniterajoitusten puitteissa kytettvt shkiset laitteet
(73/23/EY).
Kytetyt standardit: EN 60 335-1 ja EN 60 335-2-51.
Overensstemmelseserklring
Vi GRUNDFOS erklrer under ansvar, at produkterne TP og TPD, som
denne erklring omhandler, er i overensstemmelse med Rdets direktiver
om indbyrdes tilnrmelse til EF medlemsstaternes lovgivning om
Maskiner (98/37/EF).
Anvendt standard: EN 292.
Elektromagnetisk kompatibilitet (89/336/EF).
Anvendte standarder: EN 61 000-6-2 og EN 61 000-6-3.
Elektrisk materiel bestemt til anvendelse inden for visse spndings-
grnser (73/23/EF).
Anvendte standarder: EN 60 335-1 og EN 60 335-2-51.
Bjerringbro, 1st September 2002
Svend Aage Kaae
Technical Manager

LP01

LO Pump

Sheet:1
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

Sheet:2
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

Contents

1. Technical data and description

1.1. Technical data Sheet 3

1.2. Brief description Sheet 3

2. Operation Sheet 4

3. Maintenance

3.1. Mechanical seal Sheet 5

4. Spare parts list

4.1. Sectional drawing Sheet 8
4.2. List of parts Sheet 9

Sheet:3
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

1. Technical data and description

1.1 Technical Data

Capacity m/h 30,0

Delivery head bar 5,0

Speed rpm 1450

Necessary power kW 15,1

Motor power kW 18,5

Medium SAE 40

Temperature of medium -

Viscosity of medium -

Inside diameter of suction pipe - mm 80

Inside diameter of pressure pipe - mm 80

1.2 Brief Description

The gear pumps of this type are pumps with inside bearings and control
valve. The pumps are delivered with mechanical seal ready for use.

Sheet:4
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

2. Operation

Fill up the pump before the first starting !

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

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

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

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

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

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

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

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

Note: The axial face seal should only be changed by specialist
personnel. Also all other repairs to the pump should be carried
out by specialists only.

3.1 Mechanical seal

Work sequence:

1. Removing the axial face seal :

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

1.4 Pull axial face seal out towards the front.

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

2. Fitting the new axial face seal :

Sheet:6
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

Important information:
Fitting a new axial face seal is to be carried out with extreme care, as
the counter ring and the sliding ring are extremely fragile !

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

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

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

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

First Use :

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

Should these instructions be ignored, this will lead to destruction of
the axial face seal and the warranty becomes invalid.

Sheet:7
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

Sheet:8
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

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

Item Description / Notes Piece Standard no.
1 Housing 1
2 Bearing plate driving side 1
3 Bearing plate end side 1
4 Driving shaft with gear 1
5 Driven shaft with gear 1
8 Packing 2
10 Bearing bushing 2
13 Overflow housing 1
14 Valve piston 1
15 Setting screw 1
16 Counter nut 1
17 Valve spring 1
18 Packing 1
19 Cap nut 1
20 Valve bush 1
21 Disk 1
22 Screw 1
23 Hexagon nut 1
24 Overflow pipe 1
25 Pipe connection 2
26 Mechanical Seal 1
27 Mechanical seal cover 1
28 O-Ring 1
29 Hexagonal screw 1
30 Copper ring 1

Sheet:9
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

Sheet:10
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

Sheet:11
TRIK
PUMPEN
KIEL
BfK 40,0 S GL

EC Declaration of Conformity
according to EC-Machinery Directive 98/3 T lF,C
Annex II A
The manufacturer TRIK-Pumpen GmbH
Braunstrasse 14- 18
24145 Ki el -Wel l see
Germany
decl are herewi th that the fol l owi ng descri bed pump
gear pump type: AfK 2,5 GL
gear pump type: BfliK 25,0 S
gear pump type: BfK 25,0 GL
gear pump type: BfK 40,0 GL
diaphragm pump type: TA 0,25
compressed air diaphragm pump type: E 5 ll2"
compl i es wi th the fol l owi ng EG-di recti ve
Machinery Directive (93144EEC, Annex I No 1).
Appl i ed harmoni sed standards i n parti cul ar:
EN 809, EN 292 T1, EN 292T2, EN 60034, EN 60204_T1
Ki el august 30, 2007
Manfred Lindholm/Technical Dept.

FR01/2 LR01

LT/CW/LO
temp. Control
valve

Installation and operating manual B 4 E
for motor control valves
_______________________________________________________________________
technische nderungen vorbehalten 4BA-E.DOC / 0209504

Installation:

The mounting site should be easily accessible and have sufficient clearance for maintenance
and for removing the actuator. Ensure that the pipe line axes are flush and connection flanges
are parallel. Provide suitable measures to absorb possible tensile and pressure forces.
Clean pipelines thoroughly prior to installing the control valves in order to avoid damage through
residual installation material, welding beads or forging scale. If possible, provide a dirt trap
in front of each control valve.
Installation position should be vertical to horizontal. Ensure that the installation direction is
correct (directional arrows of the flow on the valve housing). Observe a 10 x DN spacing
to flanges, elbows, etc., to avoid an impaired valve function.
Observe the ambient temperature limits (-20...+60C), if necessary, provide a drive heater
at lower temperatures, and for higher temperatures insulate the pipeline, provide conductive
plates or cooling possibilities.
Retighten the screws of all flange connections (also lid and connection piece flanges) prior
to commissioning/start-up and following initial heat-up.

Electrical connection:

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

Maintenance:

Following the initial temperature and pressure load, retighten the screws of all flange connections
(also lid and connection piece flanges), the valve cone should be located in the centre).
Attention! Never loosen the lid and flange screws as long as the fittings are subjected
to pressure and temperature.
Protect valve spindle against soiling, if necessary, clean and grease lightly in order to protect
stuffing boxes and deflector hoods against increased wear.
Retighten stuffing box seals slightly in the event of leaks.
No further maintenance work is required for fittings with deflector hoods or bellows.
Undertake maintenance on the drive in accordance with the corresponding information in the
separate operating manual.
Motor control valve in three way form 431 ...Ha/b/c/d E
PN 16 / 25, GGG-40.3
_______________________________________________________________________
data subject to alteration 431HAD-E / 0309504

Body: GGG-40.3, three way form,
for water and steam, as mixing valve,
(diverted purpose restricted,
see page 038 990)
Pressure range: PN 16, PN 25
Flanges acc. to DIN,
Spindle sealing: spring-loaded PTFE-V-ring unit
for media temperatures up to 250C
alternatively: graphite-packing
Internal parts: stainless steel
Flow characteristic: linear
Leakage: acc. to VDI/VDE 2174
Actuator: with integrated manual emergency
and load dependent limit switches
Thrust: 1,2 kN / 6,6 W (appendix ..a)
2,0 kN / 6,6 W (appendix ..b)
4,5 kN / 32 W (appendix ..c)
6,0 kN / 33 W (appendix ..d)
Power supply: 230V / 50Hz
alternatively: 230V / 60Hz (appendix ..a/B/C/D)
Protection class: IP65
Accessories, special designs:
Add. signal switches load dependent
Add. signal switches travel dependent
Feedback potentiometer
Integrated positioner
Other voltages (on request)
Other positioning speed (on request)
Reduced kvs-values (on request)
Order text:
Motor control valve PN . ., DN . .
in three way form with PTFE-V-ring unit,
Power supply . . ., List-No. 431 . . . H .
Max. operating pressure:
by: 120 200 250 C
PN 16 16 13 13 bar
PN 25 25 20 18 bar
DN List-No. Kvs Stroke Pos. speed Closing pressure (bar)
PN 16 PN 25 m/h mm sec 1,2 kN 2,0 kN 4,5 kN 6,0 kN
15 431 400H. 431 500H. 4,0 20 50 23,0 25,0
20 431 401H. 431 501H. 6,3 20 50 23,0 25,0
25 431 402H. 431 502H. 10 20 50 14,6 25,0
32 431 403H. 431 503H. 16 20 50 8,5 17,3 25,0
40 431 404H. 431 504H. 25 20 50 5,0 10,8 25,0
50 431 405H. 431 505H. 40 20 50 2,8 6,6 18,4 25,0
65 431 406H. 431 506H. 63 30 75 1,2 3,4 10,5 14,8
80 431 408H. 431 508H. 100 30 75 2,0 6,8 9,6
100 431 410H. 431 510H. 160 30 75 1,1 4,1 6,0
125 431 412H. 431 512H. 230 35 88 2,5 3,7
150 431 415H. 431 515H. 330 40 100 1,6 2,4
Motor control valve in three way form 431 ...Ha/b/c/d E
PN 16 / 25, GGG-40.3
_______________________________________________________________________
data subject to alteration 431HAD-E / 0309504

Aktuator type:
1,2 kN: 4eh1-25
2,0 kN: 4eh2-25(B)
4,5 kN: 4eh4-25(C)
6,0 kN: 4eh6-25(D)
Cap nut
Bonnet
Hand wheel
Coupling
with plate
Spindle
Coupling
Mounting rod
PTFE-V-ring-unit
Spindle
Plug
Valve body type: vg31...
DN 15 20 25 32 40 50 65 80 100 125 150
Height H 536 550 544 551 556 559 602 602 610 765 780
Stud lenght H1 65 70 75 80 90 100 120 130 150 200 210
Immersion lenght L 130 150 160 180 200 230 290 310 350 400 480
Weight kg 15 16 17 20 21 24 39 43 57 98 128
Electrical wiring: Accessories (optionaly):
Limit switches Signal switches
load dependent load dependent
for valve position Signal switches Potentiometer for valve position
OPEN CLOSED travel dependent OPEN CLOSED
L on 11= Straightway opens
L on 14= Straightway closes
M
1 2 3 10 11 12 13 14 15 19 20 21 22 23 24 25 26 27
N
34 35 36 37 38 39
H
180
145
L
Space required
to remove
the bonnet
15
42
H1
A AB
B
C E - K o n f o r mi t t s e r k l r u n g
C E D e c l a r a t i o n o f c o n f o r mi t y
Q\QMH\DGR-KONF_ERKLRUNG mit Unterschrift.DOC / 008528

Konfirmittserklrung gem
EG-Richtlinie 97/23/EG
(Druckgerterichtlinie)
Die Firma: KFM Regelungstechnik GmbH
Planckstr. 2
32052 Herford
erklrt, da die Produkte Regelventile
als druckhaltende Ausrstungsteile
Type / Baureihe: 3...
4...
5...
6...
mit der Richtlinie97/23/EG bereinstimmen und
folgendem Konfirmittsbewertungsverfahren
unterzogen wurden:
Kategorie II, Modul A1
Angewandte Normen:
TRD, AD2000
Die berwachung erfolgt durch den:
TV CERT-Zertifizierungsstelle
fr Druckgerte
der TV NORD GRUPPE
Bttcherstr. 11
33609 Bielefeld
Declaration of conformity in accordance with
EMC directive 97/23/EEC
The company: KFM Regelungstechnik GmbH
Planckstr. 2
32052 Herford
declares, that the products Control valves
as pressureholding parts
type / model: 3...
4...
5...
6...
comply with directive 97/23/EEC and following
conformity assurance system is used:
Category II, Module A1
Applicable standards:
TRD, AD2000
Surveillance is done by:
TV CERT-Zertifizierungsstelle
fr Druckgerte
der TV NORD GRUPPE
Bttcherstr. 11
33609 Bielefeld
Herford, den 13.01.03 Reinhard Schildmann, Geschftsfhrer

Duplexfilter 2.05.5

LF 03

DESCRIPTION AND OPERATING INSTRUCTIONS

FOR THE DUPLEX FILTER

Contents:

1. Type sheet

2. Spare parts drawing and spare parts list

3. Description and Operating Instructions for the duplex filter

4. Description and Operating Instructions for the filter element cleaning

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

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

D
G
G
120C
D e
e
G

E R S A T Z T E I L L I S T E T Y P 2.05.5 UND 2.05.5.4
SPARE PART LIST LISTE DES PIECES DE RECHANGE

Typenschlssel:
2.05.5 = Doppelfilter duplex filter Filtre doubles
G = Gehusedurchmesser cabin diameter diamtre du corps
Q = Filtereinsatzlnge length of the filter element longueur du panier
DN = Anschluflansche connection flanges brides dsires

Pos.
Nr.
Bezeichnung
designation
dsignation
Gr. 265.500
NW/NS/DS
100
St. Gr. 265.750
NW/NS/DS
100
St. Gr. 265.500
NW/NS/DS
125
St. Gr. 265.750
NW/NS/DS
125
St. Gr. 340.500
NW/NS/DS
150
St. Gr. 340.750
NW/NS/DS
150
St.

3

Verschluschraube
screw plug
vis

2000193

2

2000193

2

2000193

2

2000193

2

2000193

2

2000193

2

4

Dichtung
gasket
joint

3274855

2

3274855

2

3274855

2

3274855

2

3274855

2

3274855

2

6

O-Ring (Viton)
O-Ring
O-Ring (Perbunan)
3030183

3040131

2

3030183

3040131

2

3030183

3040131

2

3030183

3040131

2

3030184

3040135

2

3030184

3040135

2

7

Verschluschraube
screw plug
vis

2000189

2

2000189

2

2000189

2

2000189

2

2000189

2

2000189

2

8

Dichtung
gasket
joint

3270004

2

3270004

2

3270004

2

3270004

2

3270004

2

3270004

2

9

Stiftschraube
stud bolt
vis

2009088

12

2009088

12

2009088

12

2009088

12

2000009

12

2000009

12

10

Mutter
nut
crou

2100007

12

2100007

12

2100007

12

2100007

12

2100008

12

2100008

12

12

Siebeinsatz
filter element
lment filtrant
Fabr.Nr.
Filtertyp
Fabr.No.
Filtertype
Fabr.No.
Type de Filtre
Fabr.Nr.
Filtertyp
Fabr.No.
Filtertype
Fabr.No.
Type de Filtre

Pos.
Nr.
Bezeichnung
designation
dsignation
Gr. 265.500
NW/NS/DS
100
St. Gr. 265.750
NW/NS/DS
100
St. Gr. 265.500
NW/NS/DS
125
St. Gr. 265.750
NW/NS/DS
125
St. Gr. 340.500
NW/NS/DS
150
St. Gr. 340.750
NW/NS/DS
150
St.

13

Anker
bolt
vis
WN 5.1.91

WN 5.1.92

2
WN 5.1.94

WN 5.1.95

2
WN 5.1.91

WN 5.1.92

2
WN 5.1.94

WN 5.1.95

2
WN 5.1.91

WN 5.1.92
WN 5.1.94

WN 5.1.95

2

13 a

Stiftschraube
stud bolt
vis
2000104 (1)

2004950 (2)

2
2003830 (1)

2000968 (2)

2
2000104 (1)

2004950 (2)

2
2003830 (1)

2000968 (2)

2
2003830 (1)

2000968 (2)

2
2003830 (1)

2000968 (2)

2

14

Mutter
nut
crou

2100035

2

2100035

2

2100035

2

2100035

2

2100035

2

2100035

2

16

Druckausgleich
equalization of pressure
equilibrage de pression

0202001

1

0202001

1

0203221

1

0203221

1

0203221

1

0203221

1

18

Verschluschraube
screw plug
vis

2002885

1

2002885

1

2002885

1

2002885

1

2002885

1

2002885

1

19

Dichtung
gasket
joint

3270002

1

3270002

1

3270002

1

3270002

1

3270002

1

3270002

1

20
Dichtung
gasket
joint

3540022

2

3540022

2

3540022

2

3540022

2

3540017

2

3540017

2

21

Stiftschraube
stud bolt
vis

2009088

12

2009088

12

2009088

12

2009088

12

2009088

12

2009088

12

22
Mutter
nut
crou

2100007

12

2100007

12

2100007

12

2100007

12

2100007

12

2100007

12

23

Kken
cock
robinet

4-17977

1

4-17977

1

4-17957

1

4-17957

1

4-17643

1

4-17643

1

24

Sotef-Dichtung
sotef-gasket
sotef-joint

3420011

1

3420011

1

3420011

1

3420011

1

3420011

1

3420011

1
Pos. 13 + 13a = Bei Mantelsieb (1) und Gewebeeinsteckkerzeneinsatz (2) zustzlich.
These itemsare supplementary by multimantle element (1) and filter-candle-element (2)
En supplment avec panier manteaux (1) et cartouches (2) filtrantes

Pos.
Nr.
Bezeichnung
designation
dsignation
Gr. 265.500
NW/NS/DS
100
St. Gr. 265.750
NW/NS/DS
100
St. Gr. 265.500
NW/NS/DS
125
St. Gr. 265.750
NW/NS/DS
125
St. Gr. 340.500
NW/NS/DS
150
St. Gr. 340.750
NW/NS/DS
150
St.

25

O-Ring (Viton)
O-Ring
O-Ring (Perbunan)
3030178

3040124

1
3030178

3040124

1
3030180

3040164

1
3030180

3040164

1
3030182

3040129

1
3030182

3040129

1

28

O-Ring (Viton)
O-Ring
O-Ring (Perbunan)
3030080

3040163

2
3030080

3040163

2
3030083

3040127

2
3030083

3040127

2
3032130

3040130

2
3032130

3040130

2

29

Stiftschraube
stud bolt
vis

2009088

8

2009088

8

2009088

8

2009088

8

2000008

8

2000008

8

30

Mutter
nut
crou

2100007

8

2100007

8

2100007

8

2100007

8

2100008

8

2100008

8

31

Hahnschlssel
reversing handle
cl

8650481

1

8650481

1

8650481

1

8650481

1

8650481

1

8650481

1

32

Differenzdruckanzeiger
diff.pressure indicator
indicator de difference
de pression
Typ
Druck
Type
Pressure
Type
Pression
Typ
Druck
Type
Pressure
Type
Pression

33

Verschluschraube
screw plug
vis

2002885

2

2002885

2

2002885

2

2002885

2

2002885

2

2002885

2

34
Dichtung
gasket
joint

3270002

2

3270002

2

3270002

2

3270002

2

3270002

2

3270002

2

41

Dichtung
gasket
joint

3380049

2

3380049

2

3380049

2

3380049

2

3380049

2

3380049

2

42
Stiftschraube
stud bolt
vis

2000001

4

2000001

4

2000001

4

2000001

4

2000001

4

2000001

4

43

Mutter
nut
crou

2100004

4

2100004

4

2100004

4

2100004

4

2100004

4

2100004

4

Pos.
Nr.
Bezeichnung
designation
dsignation
Gr. 420.500
NW/NS/DS
200
St. Gr. 420.750
NW/NS/DS
200
St. Gr. 420.750
NW/NS/DS
250
St. Gr. 520.750
NW/NS/DS
250
St.

3

Verschluschraube
screw plug
vis

2000193

2

2000193

2

2000193

2

2000193

2

4

Dichtung
gasket
joint

3274855

2

3274855

2

3274855

2

3274855

2

6

O-Ring (Viton)
O-Ring
O-Ring (Perbunan)
3034406

3040151

2

3034406

3040151

2

3034406

3040151

2

3031074

3040155

2

7

Verschluschraube
screw plug
vis

2000189

2

2000189

2

2000189

2

2000189

2

8

Dichtung
gasket
joint

3270004

2

3270004

2

3270004

2

3270004

2

9

Stiftschraube
stud bolt
vis

2000011

16

2000011

16

2000011

16

2009094

24

10

Mutter
nut
crou

2100008

16

2100008

16

2100008

16

2100009

24

12

Siebeinsatz
filter element
lment filtrant
Fabr.Nr.
Filtertyp
Fabr.No.
Filtertype
Fabr.No.
Type de Filtre
Fabr.Nr.
Filtertyp

13

Anker
bolt
vis
WN 5.1.92

WN 5.1.98

2
WN 5.1.94

WN 5.1.95

2
WN 5.1.94

WN 6.1.95

2
WN 5.1.95
4-7094 (2)

2

13 a

Stiftschraube
stud bolt
vis
2004950 (1)

2008279 (2)

2
2000102 (1)

2004950 (2)

2
2000102 (1)

2004950 (2)

2

7203893

2

14

Mutter
nut
crou

2100035

2

2100035

2

2100035

2

2100035

2

Pos. 13 + 13a = Bei Mantelsieb (1) und Gewebeeinsteckkerzeneinsatz (2) zustzlich / These itemsare supplementary by multimantle element (1) and
filter-candle-element (2)
En supplment avec panier manteaux (1) et cartouches (2) filtrantes

Pos.
Nr.
Bezeichnung
designation
dsignation
Gr. 420.500
NW/NS/DS
200
St. Gr. 420.750
NW/NS/DS
200
St. Gr. 420.750
NW/NS/DS
250
St. Gr. 520.750
NW/NS/DS
250
St.

16

Druckausgleich
equalization of pressure
equilibrage de pression

0203221

1

0203221

1

0203568

1

0203568

1

18

Verschluschraube
screw plug
vis

2002885

1

2002885

1

2002885

1

2002885

1

19

Dichtung
gasket
joint

3270002

1

3270002

1

3270002

1

3270002

1

20
Dichtung
gasket
joint

3540024

2

3540024

2

3540028

2

3540028

2

21

Stiftschraube
stud bolt
vis

2000009

16

2000009

16

2000101

20

2000101

20

22
Mutter
nut
crou

2100008

16

2100008

16

2100009

20

2100009

20

23

Kken
cock
robinet

3-19029

1

3-19029

1

3-21142

1

3-21142

1

24

Sotef-Dichtung
sotef-gasket
sotef-joint

3420011

1

3420011

1

3420013

1

3420013

1

25

O-Ring (Viton)
O-Ring
O-Ring (Perbunan)
3033860

3040132

1
3033860

3040132

1
3030185

3040136

1
3030185

3040136

1

28

O-Ring (Viton)
O-Ring
O-Ring (Perbunan)
3031065

3040133

2
3031065

3040133

2
3031066

3050256

2
3031066

3050256

2

29

Stiftschraube
stud bolt
vis

2000009

12

2000009

12

2000010

16

2000010

16

30

Mutter
nut
crou

2100008

12

2100008

12

2100008

16

2100008

16

Pos.
Nr.
Bezeichnung
designation
dsignation
Gr. 420.500
NW/NS/DS
200
St. Gr. 420.750
NW/NS/DS
200
St. Gr. 420.750
NW/NS/DS
250
St. Gr. 520.750
NW/NS/DS
250
St.

31

Hahnschlssel
reversing handle
cl
WN 48-1

8650055

1
WN 48-1

8650055

1
WN 48-1

8650481

1
WN 48-1

8650481

1

32

Differenzdruckanzeiger
diff.pressure indicator
indicator de difference
de pression
Typ
Druck
Type
Pressure
Type
Pression
Typ
Druck

33

Verschluschraube
screw plug
vis

2002885

2

2002885

2

2002885

2

2002885

2

34
Dichtung
gasket
joint

3270002

2

3270002

2

3270002

2

3270002

2

41

Dichtung
gasket
joint

3380049

2

3380045

2

3380045

2

3380045

2

42
Stiftschraube
stud bolt
vis

2000001

4

2000001

4

2000001

4

2000003

4

43

Mutter
nut
crou

2100004

4

2100004

4

2100004

4

2100005

4

45

Passfeder
parallel keys
ressort d'adjustage

2400004

1

2400004

1

46

Stirnzahnrad
spur wheel
pignon

2700015

1

2700015

1

47

Ritzelwelle
pinion shaft
arbre de pignon

5600131

1

5600131

1

49

Schraube
screw
vis

2000155

4

2000155

4

INSTALLATION AND OPERATING INSTRUCTIONS FOR

BOLL DUPLEX FILTERS

1. Description

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

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

2. Installation

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

Heated filters with shut-off devices:
- Special equipment needed for heatable filters -

Heating of the filter serves to offset the heating loss at the filter during the filtration process
or before start-up of the plant to heat the liquid in the filter.
According to the AD Information Sheets, the filter housings
are only rated for internal overpressure. Additional external
forces and moments at the connection flanges of the filter
are to be avoided (possibly support feed lines).
a) Steam-heated filters:
Safety valves for the filter chamber set to operate at the
relief pressure which is 10 % above the max. admissible
operating pressure of the filter housing.

b) Electrically heated filters:
Thermostats which cut off the power supply to the
heating element at a max. admissible temperature of
150 C in the filter chamber and one safety valve per
filter pot.
It is imperative for the pressure equalising cock to only
remain closed in the cleaning phase so that there is no
inadmissible pressure build-up through the thermal
expansion of the medium in the isolated chamber.

3. Start-up

3.1 Pressure filters (> 0.1 bar pressure in the filter)
Set the change-over device to the mid-position, both chambers in service, pressure
equalising cock open.
Open air vents of both chambers (with venting screws only about 1 turn).
Start plant up slowly.
Close air vents when the air has escaped and the liquid has started to emerge.
Isolate one filter chamber by operating the change-over device, leave the pressure
equalising cock open; while one of the filter chambers is being used for filtering, the
isolated chamber is on stand-by until the admissible differential pressure has built up
as a result of clogging.
At a differential pressure of 0.8 bar in filter meshes or 2 bar in micro-cartridge filters
change over to the clean filter chamber as follows:

Cleaning

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

In smaller duplex filters without pressure compensation the
heat expansion of the medium is so low that there is no
risk to the components.

3.2 Suction filters (< 0.1 bar pressure in filter)

Recommended container filling for suction filters
drain
filling line

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

Dismantle the housing cover from the isolated filter half.
Drain liquid down to the strainer base.
Remove filter element vertically upwards.
Clean filter element (see operating instructions "Strainer cleaning"). Renew
disposable elements and install in the filter.
Fill filter housing (see Fig.).
Before mounting the cover, check that the seal is in perfect condition and seated
properly.
It is imperative to renew seals which have become hardened and deformed.
Close air vent.
The cleaned filter half is ready on stand-by. This procedure is to be repeated from
section as and when required.

Air may be drawn in if the level drops.
It is not permitted to fill the filter against the
indicated flow direction of the filter elements.

4. Servicing:
Servicing of the duplex filter comprises checking and, if necessary, renew the
seals and filter elements. If the filter is provided with rust-inhibiting paint, touch up or
repaint as and when required.
When filtering cooling water or media which may cause sedimentation on the
change-over device, it is advisable to activate the change-over device as often as
possible and at regular intervals in order to prevent clogging.

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

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

General

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

Operation of the valve
The marking engraved in the cock neck
indicates the direction of flow and thus shows
which filter chamber is in operation (see Fig. 2).
Before changing over from one filter chamber to
the other, a check is to be made to see whether
the pressure equalisation cock (16) is open.
Then turn the segmental cock completely to the
right or left using the lever (31).
In the central position both filter chambers are in
operation (see Fig. 2).

After change-over and before the filter chambers are opened, the pressure equalisation cock must
be closed again. After the filter chambers have been filled, the cock housing (17) is to be vented
using the venting screw (18).

1. Dismantling and installation of the segmental cock (for DN 100 - DN 200)
1.1 Drain medium as described in the operating instructions for duplex filters.
1.2 Undo venting screw (18).
1.3 Undo the cock housing cover (15) with the hexagon nut (30) and lift off.
1.4 Remove segmental cock and check seals (24, 25 + 28) as well as cocks and cock
housing bore for damage.
Grind down any scoring on the cock and bore. Replace O-rings.
1.5 After cleaning the cock housing and segmental cock, introduce the latter back into the
housing together with the oiled and mounted seals (24, 25 + 28).
1.6 Move segmental cock (23) into the central position.
1.7 The dowel pin (27) must be firmly seated in the cock housing. Close the cock housing
cover with seal (28) again. The dowel pin governs the position of the cover and thus the
stop of the segmental cock (23). Mount hexagon nut (30).

1.8 Fill up filters as described in the operating instructions for duplex filters. Close vent (18)
when the medium emerges free of bubbles.
It is imperative to read the operating instructions "BA Duplex Filters"
for this work.
This position guarantees the perfect stop of the segmental cock.

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

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

BOLL & KIRCH assumes no liability for any faults due to improper use of the product.

Cleaning / Maintenance of Filter-Candles in Insert Assembly

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

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

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

Optionally, a spring-loaded magnet-candle (8) can be fitted in the insert
peripherally between filter candles.
Where the requisite flow-rate has been met with a complement of candles less than
the maximum that can be accommodated, the unused sockets are factory-sealed
with plugs.

2. Cleaning of the insert and its candles
2.1 Submerge the candle-insert complete in a tank of suitable cleaning fluid, with the
openends of the candles facing upwards. Loose particles will be removed and
settle-out during the soaking period, which should not exceed 4 hours.
Remove insert from the tank and insert BOLL Cleaning-gun Type 5.01 (11) with
active airsupply, carefully and sequentially into each candle, moving the Gun
throughout each candle's length to blowthrough the candles from inside to out.
2.2 Put the assembly once more in fresh cleaning-fluid and then allow to drain.
Blow through again with the Cleaning-gun. (With some cleaning-fluids the cleaning
effect is improved by rinsing with hot or cold water before blowing-through for the
second time).
Stand the candle-assembly upside-down to allow cleaning-fluid and/or water to
drain. (If the candles are only lightly-contaminated an alternative cleaning
procedure is to rinse the insert-assembly complete with its candles by gently
rotating/moving it up-and-down in the cleaning-bath).
2.3 From time-to-time, inspect each candle for damage, replacing with new one(s)
where necessary (see also Para. 3.4 and 3.5).
2.4 Dirt-laden fluid remaining in the filter-housing(s) should be voided via the drain-
plug(s).
2.5 Close and secure drain(s): put back the insert (make sure candle-seals (5) are in
place):
secure filter chamber-cover(s): re-fill and air-vent housing(s) (see the Filter's
Operating manual).
2.6 For heavy contamination the same cleaning-sequence can be followed but using
highpressure cleaning at 60 bars. The cleaing-fluid can be water; or water in
solution with a cleaning-agent (e.g. BOLL CLEAN 2000 concentrate) but with either
cleaning-liquid the temperature should not exceed 60 C.

3. Cleaning Obstinate Contamination from the Filter-candles
3.1 If the candles are heavily contaminated (e.g. by gum-deposition, incrustation, tar-
residues, fibres, ferritic fragments) the candles should be removed from the insert
and cleaned individually.
The BOLL High-pressure Cleaning-trolley 5.04 is strongly recommended (see 4.3).
Its Rotary Spray-nozzle is highly effective in candle-cleaning; and its Flat-nozzle
will handle other parts of the insert-assembly.
If you do not have a Cleaning-trolley then follow the procedure in 3.2 etc.
3.2 Remove base-plate (10); carefully lift off the protective outer mantle (9). Remove
candles by pressing downwards and lifting out at an angle. Remove the candle-
seals (5). (See Fig. 3)
3.3 Put the obstinately-contaminated candles to soak in a cleaning-fluid tank, say for
maximum 4 hours.

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

By this means most of the contaminant will be washed-off. Dirt-particles equivalent
to the pore-size of the mesh which sometimes can be found entrapped in the mesh
are pushed through and safely rinsed away.

Do not lay the candles across one another - this can damage the
meshes.
When using high-pressure cleaning, ensure the nozzle is at all
times held clear of the mesh in order to avoid damage/displace-
ment of the mesh-filaments.

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

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

BOLL & KIRCH assumes no liability for any mistakes by any misuse of the product.
As cleaning fluid, either water alone; or water in solution with a
cleaning-agent (e.g. BOLL CLEAN 2000 concentrate) may be
used: but always at a temperature not exceeding 60 .

COVER SECURING DEVICE FOR DOUBLE FILTERS

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

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

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

1. Establish on the circuit diagram
(5) with chamber is switched off.

2. Unscrew the venting screw of this
chamber (4) to the point where the
cover plate (2) can swivel over the
cover screws (3)

3. Loosen cover screws (3) and remove
cover (1).

4. Assemble in reverse order

5. For sieve cleaning and
commissioning, see Sieve Cleaning
Operating Instructions and Double
Filter Operating Instructions.
Check seals items 6 and 7
for damage.

MAX. TEMPERATURE 150C

LF02

Automatic
filter

DESCRIPTION AND OPERATING INSTRUCTIONS
FOR BACK-FLUSHING FILTER TYPE 6.46
Order No.
LIST OF CONTENTS
1. Type sheet
2. General notes on the automatic filter
3. Installation of the filter
Installation drawings Z39347 + Z39349
4. Commissioning
5. Filtration phase
Filtration phase Z39293 sheet 1
6. Back-flushing phase
Back-flushing phase Z39293 sheet 2
7. Functioning of the overflow valves
Overflow valves Z39293 sheet 3
8. Maintenance
9. Filter candle inspection and cleaning
10. Technical information BOLL CLEAN 2000
11. Sources of faults and their remedy
12. Spare parts drawing for type 6.46
13. Spare parts list for type 6.46
14. Type sheet differential pressure contact indicator
15. Spare parts drawing for the differential pressure indicator
BOLL & KIRCH assumes no liability for any mistakes by improper use of the product.
We reserve the right to change this description without prior notice!
2. General notes on the automatic filter
The back-flushing filter type 6.46 is suitable for filtering oils with a viscosity of max.
50 cSt. and an operating pressure of min. 3 bar to max. 10 bar.
The filter works with permanent back-flushing using its own process fluid; the back-
flushed fluid is fed back into the circulation tank or the oil trough again.
No external power is required to operate the automatic filter.
The function of the automatic filter is to protect the bearings, journals and shafts in
the engine from noxious impurities in the oil.
Treating the lubricating oil, i.e. removing the solids discharge, is carried out by a
separator, a centrifuge, a bypass filter or the attached flushing oil treatment unit.
The filter can be mounted both vertically and horizontally directly on the engine or
on the base frame.
In order to satisfy the different requirements of the engine manufacturers, the filter
type 6.46 can be combined with a wide variety of engine attachments.
The back-flushing Filter type 6.46 satisfies the safety standard
for ships' main propulsion units. It is registered by GL, LRS
and other ship classification bodies.
The filter type 6.46 mainly consists of the following:
- the housing with the inlet and outlet flanges
- the filter element with the appropriate number of filter candles, depending on the
nominal width
- the excess pressure safety devices
- the downstream second filter stage [protective filter (8)]
- the entire flushing facility
- the gear unit including drive turbine.
3. Installation of the filter
Care must be taken during installation of the filter to ensure that clean pipes are
connected to the filter inlet and the filter outlet without any strain.
The inlet and outlet of the filter are marked.
The flushing oil line is to be at least as large as specified in the information sheet.
This line is to be laid without any shut-off device but with a gradient and vented to
prevent any build-up in the pipe.
The potential-free contacts of the differential pressure indicator (24) installed (see
"Differential pressure indicator, section 14) must be wired to monitor the degree of
contamination of the filter elements (7) and the protective filter (8).
The filter housings are only designed for internal overpressure in
accordance with the AD Information Sheets. Additional external
forces and moments at the filter connection flanges are to be
avoided (possibly by supporting the supply lines).
When installing the filters, make sure that any oil or fuel which
leaks due to improper handling cannot result in a fire or injury.
4. Commissioning
4.1 Check to see whether all connections have been made properly.
4.2 Check to see whether the ball cocks in the control line to the differential pressure
indicator are open.
4.3 The following must be observed before switching on the pump:
- Close shut-off device in the bypass line
- Open shut-off device at the filter outlet
- Only partially open the shut-off device at the filter inlet and, after switching on
the pump (to prevent pressure surges), slowly open it fully.
4.4 If the pressure downstream of the filter is less than 2 bar, the shut-off device
downstream of the filter is to be regulated until the appropriate operating pressure
has built up.
4.5 The rotary motion of the flushing facility can now be seen at the visible shaft end in
the filter cover.
If there is an inadmissible rise in the differential pressure during
commissioning (with new plants poss. greater initial
contamination) in spite of perfect back-flushing, a signal is
emitted via the differential pressure indicator. The Filter must be
taken out of service (open the bypass line and close the shut-off
devices on the Filter). Dismantle the Filter element completely
and clean the Filter candles individually (oberserve section 9
"Filter candle inspection and cleaning").
5. Filtration phase
(see drawing Z39293 sheet 1 or Z101308 sheet 1 )
The fluid to be filtered passes through the inlet flange and turbine (14) to the bottom
end of the filter candles (7); a partial stream of about 50% is passed through the
central connection tube (4) to the top end of the filter candles (7). This means that
the fluid flows through the filter candles (7) at both ends from the inside outwards
and most of the dirt particles are retained in the inside of the filter candles (7).
The fluid filtered in this way now passes through the protective filter (8) to the filter
outlet.
6. Back-flushing phase
(see drawing Z39293 sheet 2 or Z101308 sheet 2)
The back-flushing filter type 6.46 operates as a continuous flushing filter and
does not require any external power to drive the back-flushing facility.
The flow energy drives the turbine (14) installed in the inlet flange. The high speed
of the turbine (14) is reduced by the worm gear unit (13) and gear (15) to the lower
speed required for turning the flushing arm (3).
The individual filter candles (7) are now connected successively to the atmosphere
by means of the continuously rotating flushing arm (3), the flushing bush (17) and
nozzle (21).
The pressure gradient thus produced (operating pressure to atmosphere)
results in an extremely efficient cleaning action.
The unfiltered fluid passes through the optimally designed bores of the top cover
plate (9) into the individual filter candles (7) from above. The resultant turbulent
stream in the longitudinal direction of the filter candles (7) (cross-flow back-flushing)
and the counter-flow back-flushing through the filter candles (7) result in a
particularly effective and lasting back-flushing action.
This newly developed cross-flow back-flushing feature in conjunction with
the time-tested counter-flow back-flushing principle means that the pressure
drop at the filter remains constant for a longer period.
Counter flow back-flushing:
The lower pressure in the interior of the filter candles (7) during
the back-flushing operation (connected with the atmosphere)
and the higher pressure (operating pressure) outside the filter
candles (7) produce a counter-flow through the mesh from the
clean filter side through the dirty filter side to the atmosphere.
7. Functioning of the overflow valves
Should for any reason the filter candles (7) (first filter stage) no longer be
adequately cleaned, the overflow valves (19) are opened at a differential pressure
of 2 bar upwards and some of the fluid is filtered through the protective filter (8)
(second filter stage).
However, before this situation arises, the installed differential pressure indicator
(24) emits a differential pressure warning (first contact). The cause must now be
localised and remedied.
If this warning is not heeded, an alarm is emitted by the second contact of the
differential pressure indicator (24).
The overflow valves are closed under normal operating conditions, even
during start-up at lower fluid temperatures.
The filter may only be operated in this emergency condition for a
short time (opened overflow valves and differential pressure
warning). Prolonged operation in this mode can result in
damage to downstream components.
8. Maintenance
Section 9 - Filter candle inspection and cleaning - must also be observed.
Even with automatic filters inspections and maintenance must be performed at
regular intervals.
It is extremely important to remember that in spite of constant back-flushing the
mesh may become clogged over the course of time, depending on the quality of the
fluid and whether a bypass treatment unit installed.
In order to maintain trouble-free operation, the following aspects are to be observed
during maintenance:
8.1 The filter must be switched off for all maintenance work.
8.2 Check filter and connections for leaks.
8.3 Conduct visual inspection of all filter candles (7) once a year.
Should a higher differential pressure occur beforehand, all the
filter candles (7) and the protective filter (8) must be checked
and, if necessary, cleaned.
Observe section 9 "filter candle inspection and cleaning".
A highly contaminated protective filter (8) is a sign of
prolonged operation with defective or clogged filter candles (7)
and thus (from a differential pressure of 2 bar upwards)
opened overflow valves (19).
It is imperative to check these components.
8.4 Check the ease of movement of the worm gear unit (13), the turbine (14)
including gear (15) with flushing arm (3).
To this end the cover (34) or the screw plug (34) must be removed. Now check
the ease of movement with a suitable spanner (on the hexagon of the worm
gear unit).
If movement is sluggish, refer to section "Sources of faults and their remedy".
8.5 Replace the dyn. loaded seals (66) as and when required.
It is advisable to replace all static seals during an overhaul.
9. Filter candle inspection and cleaning
9.1 Open bypass line.
9.2 Close shut-off devices at the filter inlet and outlet.
9.3 Now drain the filter from the drain screw.
9.4 Pull the entire filter element incl. flushing arm (3) and gear (15) out of the
housing.
9.5 Remove the upper cover plate (9).
9.6 The filter candles (7) can now be pushed out from below or pulled out from
above.
9.7 Place the filter candles (7) in the cold cleaner BOLL CLEAN 2000, max.
soaking time 24 hours.
9.8 After immersing the filter candles (7), clean them from the outside inwards
using high pressure.
Make sure that the exposed gear (15) is not damaged.
It must be ensured that the filter candles are cleaned at a
pressure of max. 60 bar and at a minimum distance of the
cleaning nozzle of 20 cm. Otherwise, damage to the mesh is
possible.
In our experience it is only possible to achieve an almost 100
% cleaning effect by hand with the high-pressure cleaning unit
type 5.04 using BOLL CLEAN 2000.
Refer to the separate description "Filter cleaning unit type
5.04".
9.9 If operating an engine on heavy fuel
If operating an engine on diesel oil
9.10 Now push the entire filter element into the housing.
By slightly turning the flushing shaft (10), the gear (15) is forced into the drive
pinion of the gear unit (13).
Now re-assemble the filter in the reverse sequence to that described
under points 9.1 - 9.9.
Defective filter candles (7) must not be used again.
Before installation of the entire filter element, the ease of motion
of the flushing facility must be checked.
The flushing arm (3) must not grind against the bottom filter
plate (5).
If operating on diesel oil, the filter elements must be checked
after 4 years at the latest and any damaged ones must be
replaced.
We recommend the general replacement of all filter elements
after 6 years.
If operating on heavy fuel, the filter elements must be checked
after 2 years at the latest and any damaged ones must be
replaced.
We recommend the general replacement of all filter elements
after 4 years.
10. Technical information BOLL CLEAN 2000
Solvent-free cold cleaner
Product description
BOLL CLEAN 2000 is a liquid cleaning and degreasing agent for a wide range of
applications. It can be used for virtually all cleaning and degreasing work.
BOLL CLEAN 2000 is miscible with any water - even sea water.
BOLL CLEAN 2000 cleans quickly and thoroughly and is extremely economical.
Even mixed with water in concentration ranges of 1:50, it exhibits good cleaning and
degreasing properties. When BOLL CLEAN 2000 is used, no safety precautions are
needed. BOLL CLEAN 2000 exhibits these outstanding properties without having
the disadvantages of solvent cleaners.
BOLL CLEAN 2000 is non-flammable
does not need to be identified
does not have a pungent smell
is a non-irritant
is physiologically safe
is biodegradable
Federal Office of the Environment Reg. No. 04860019
BOLL CLEAN 2000 can become cold or hot during storage but can be readily used
again at normal temperature.
Field of application
BOLL CLEAN 2000 is suitable for cleaning and degreasing all metals, plastics,
highly adhesive paints etc. It removes oil, wax, grease, rust and numerous other
kinds of dirt.
BOLL CLEAN 2000 is used, for example, in the automobile, engine, aviation, oil (for
drilling equipment), food and drinks, and metalworking industries, in overhauling
and machine workshops, shipping, diesel and electric locomotives, and in electricity
works for cleaning the generators.
Mesh contaminated with heavy oil
Filters contaminated with heavy oil must be soaked in a commercially available
solvent. After being soaked, the filters are cleaned in the BOLL & KIRCH cleaning
unit type 5.04 with BOLL CLEAN 2000 and a high-pressure pump.
Instructions for use
The use of BOLL CLEAN 2000 does not involve any specific cleaning method.
BOLL CLEAN 2000 can be employed in an immersion bath, in a spraying plant, in a
steam jet cleaner or using a manual application process with a cloth, brush or
sponge, depending on the circumstances.
It can be used either cold or warm.
BOLL CLEAN 2000 is miscible with water - even sea water.
Concentration for cleaning mesh: 1:2.5
Temperature: up to max. 60C
The concentration depends on the type and thickness of the adhering material to be
removed. When used in a concentration of 1:30 and more, rinsing is not necessary.
No visible film remains on the surface.
11. Sources of faults and their remedy
Fault Cause Reasons and remedy
Viscosity too high Wait for normal operating conditions
High volume of dirt Check bypass treatment unit for
operability
Filter candles clogged Clean candles
Flushing volume too low Check flow control device in outlet
and sludge discharge line for
clogging
Shaft end does not turn Turbine jammed
Remove parts jammed between
turbine and wall
p rises Gear unit defective
Check for ease of movement
(as per section 8 "Maintenance")
Replace gear unit if necessary
Flushing arm (3) jammed, Remove
any foreign matter
Operating pressure < 2 bar
Run for prolonged period at higher
pressure 5-6 bar and thus eliminate
the blockage
Oil quantity too low / Increase oil
quantity
UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE
19044 ALT 03 17.12.03 1
ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME
IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME
0000 0629044 6.46 NW150 RUECKSP. 19044 03 1.000 ST
BACK FLUSHING FILTER
................................................................................
ZUSAMMENSTELLUNG : Z42564
ASSEMBLY DRAWING
MASSBLATT : TYP6.46
DIMENSION PAGE
AUSLEGUNGSUEBERDRUCK: 10 BAR / 100 GRD C
DESIGN PRESSURE
.
................................................................................
********************
................................................................................
0001 6521235 GEHAEUSE 1.000 ST
HOUSING
................................................................................
0002 6022216 DECKEL 1.000 ST
COVER
................................................................................
0003 6551249 SPUELARM 1.000 ST
FLUSHING CANAL
................................................................................
0004 5151255 VERBINDUNGSROHR 1.000 ST
JOINING TUBE
................................................................................
0005 5101245 SIEBPLATTE (UNTEN) 1.000 ST
SIEVE PLATE
................................................................................
0006 5101246 SIEBPLATTE (OBEN) 1.000 ST
SIEVE PLATE
................................................................................
0007 1345456 FILTERKERZE 66.000 ST
FILTER ELEMENT
................................................................................
0008 5709913 SCHUTZSIEB 1.000 ST
SIEVE
................................................................................
0008 7108807 LOCHBLECHZUSCHNITT 1.000 ST
PLATE BLANK
................................................................................
0009 5108372 ABDECKPLATTE 1.000 ST
PLATE
................................................................................
0010 5300219 SPUELARMWELLE 1.000 ST
FLUSHING CANAL SHAFT
................................................................................
0011 6853849 TURBINENGEHAEUSE 1.000 ST
TURBINE HOUSING
................................................................................
/ 2
19044 ALT 03 17.12.03 2
0012 5301235 FLANSCHBEFESTIGUNG 1.000 ST
FLANGE FASTENING
................................................................................
0013 2709131 SCHNECKENGETR.KURZ A 1.000 ST
GEAR
................................................................................
0014 2784402 FLUEGEL MIT NABE 1.000 ST
TURBINE WING WITH WH
................................................................................
0015 2705519 ZAHNRAD 1.000 ST
TOOTHED WHEEL
................................................................................
0016 5300723 BEFESTIGUNGSBUCHSE 1.000 ST
BUSH
................................................................................
0017 5060722 SPUELBUCHSE 1.000 ST
BUSH
................................................................................
0018 0209130 UEBERSTROEMVENTIL 6.46 D=34 19130 10.000 ST
VALVE
................................................................................
0021 5004689 DUESE 1.000 ST
NOZZLE
................................................................................
0022 2310058 DRUCKFEDER 1.000 ST
PRESSURE SPRING
................................................................................
0023 2703600 RILLENKUGELLAGER 2.000 ST
DEEP GROOVE BALL BEA
................................................................................
0024 0550001 4.36.2 P = 0.8 DDA 09322 08 1.000 ST
PRESSURE DIFFERENT.CONTACT INDICATOR
................................................................................
0025 2000257 ZYL.-SCHRAUBE 1.000 ST
SLOTTED CHEESE HEAD
................................................................................
0026 2301130 STECKKERBSTIFT 1.000 ST
PIN
................................................................................
0027 2300010 SPANNSTIFT 1.000 ST
SPRING TYPE STRAIGHT
................................................................................
0028 2560063 WINKELKUGELHAHN 2.000 ST
ANGLE BALL COCK
................................................................................
0030 2009089 STIFTSCHRAUBE 16.000 ST
STUD
................................................................................
0031 2100007 SECHSKANTMUTTER 16.000 ST
HEXAGON NUT
................................................................................
/ 3
19044 ALT 03 17.12.03 3
0033 2000190 VERSCHLUSSCHRAUBE 1.000 ST
HEXAGON HEAD SCREW P
................................................................................
................................................................................
................................................................................
0037 2000142 ZYL.-SCHRAUBE 6.000 ST
SLOTTED CHESSE HEAD
................................................................................
0038 2000121 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0039 2000121 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0040 2000143 ZYL.-SCHRAUBE 1.000 ST
SLOTTED CHESSE HEAD
................................................................................
0041 2003658 STIFTSCHRAUBE 1.000 ST
BOLT
................................................................................
0042 2000122 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0043 2000154 ZYL.-SCHRAUBE 4.000 ST
HEXAGON SOCKET HEAD
................................................................................
0044 2000121 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0045 2000121 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0046 2200005 SCHEIBE 3.000 ST
DISK
................................................................................
0047 5008712 SCHEIBE 1.000 ST
DISC
................................................................................
0048 2200007 SCHEIBE 1.000 ST
WASHER
................................................................................
0049 2200009 SCHEIBE 4.000 ST
DISK
................................................................................
0050 2001635 SECHSKANTSCHRAUBE 4.000 ST
HEXAGON SCREW
................................................................................
/ 4
19044 ALT 03 17.12.03 4
0051 6024503 BODENBEF. 1.000 ST
BOTTOM FASTENING
................................................................................
0052 5708316 BEFESTIGUNGSBLECH 1.000 ST
PLATE
................................................................................
0053 2000122 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
HEXAGON NUT
................................................................................
0055 2500024 VERSCHRAUB. 3.000 ST
SCREWING
................................................................................
0056 2500025 VERSCHRAUB. 1.000 ST
SCREWING
................................................................................
0057 7300002 PRAEZ.-ROHR NBK 1.000 M
TUBE
................................................................................
0058 3040115 O-RING 1.000 ST
GASKET
................................................................................
0060 3040154 O-RING 1.000 ST
GASKET
................................................................................
0061 3040021 O-RING 1.000 ST
GASKET
................................................................................
0062 3040021 O-RING 2.000 ST
GASKET
................................................................................
0063 3040023 O-RING 66.000 ST
GASKET
................................................................................
0064 3140003 RUNDSCHNURRING 66.000 ST
ROUND CORD RING
................................................................................
0065 3031743 O-RING 1.000 ST
GASKET
................................................................................
0066 3040115 O-RING 1.000 ST
GASKET
................................................................................
0068 3290012 DICHTRING 1.000 ST
GASKET
................................................................................
0069 3270002 DICHTRING 1.000 ST
GASKET
................................................................................
/ 5
19044 ALT 03 17.12.03 5
0070 3332814 FLACHDICHTUNG 1.000 ST
GASKET
................................................................................
0071 3048235 O-RING 1.000 ST
GASKET
................................................................................
0075 2209799 FEDERRING 3.000 ST
SPRING RING
................................................................................
0076 2000122 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
HEXAGON NUT
................................................................................
0078 3270005 DICHTRING 1.000 ST
SEAL
................................................................................
0079 2000115 ZYL.-SCHRAUBE 1.000 ST
HEXAGON SOCKET HEAD
................................................................................
0080 9400997 SCHILD "EIN/IN 1.000 ST
LABEL " IN "
................................................................................
0080 9407569 SCHILD "AUS/OU 1.000 ST
LABEL " OUT "
................................................................................
0080 9402913 TYPENSCHILD WN26 1.000 ST
NAME PLATE
................................................................................
0081 3529686 ANZEIGEBUCHSE 1.000 ST
INDICATION BUSH
................................................................................
0082 5209684 SPANNRING 1.000 ST
TENSION RING
................................................................................
0083 4707080 SCHAUGLAS 1.000 ST
INSPECTION GLAS
................................................................................
0085 2311117 WELLENFEDER 1.000 ST
SPRING
................................................................................
QUALITY MANAGEMENT
FORMBLATT / FORM SHEET
EG-KONFORMITTSERKLRUNG
DECLARATION OF CONFORMITY
Document
FB-8-79
Part
8
Revision
00
Page
1/1
Ausgestellt in bereinstimmung mit der Maschinen-Richtlinie 98/37/EG Anhang V /
Issued in accordance with the Machinery Directive 98/37/EC Annex V
Hersteller / Manufacturer
Boll & Kirch Filterbau GmbH
Siemensstrasse 10-14
D- 50170 Kerpen
Wir erklren hiermit, dass das/die nachstehend beschriebene(n) Produkt(e) in bereinstimmung mit
der Maschinen-Richtlinie 98/37/EG Anhang V hergestellt wurden:
We herewith declare, that the undernoted item(s) have been manufactured in compliance with the
Machinery Directive 98/37/EC Annex V:
Bezeichnung: /
designation:
Automatikfilter / Automatic-filter
Typ: /
type:
6.18 / 6.19 / 6.46 / 6.48 / 6.61 / 6.62 / 6.64
Angewandte nationale Normen / Applied national Standards
Bei elektrischen Anbauteilen entsprechen diese folgenden Richtlinien /
Electrical assembly parts are in accordance to following Standards
Niederspannungs-Richtlinie 73/23/EWG / Low Voltage Directive 73/23/EEC
Elektromagnetische Vertrglichkeit 89/336/EWG / EMC Directive 89/336/EEC
Bescheinigung erstellt durch / Certificate written by : F. Rohm
07.02.07
Datum / Hersteller-Unterschrift:
Date / Manufacturer's signature
Angaben zum Unterzeichner:
Details of the undersigned
H. Anders Produktionsleiter / Production Manager
maschinelles Dokument / electronic document

FP01-4

LT/HT CW
Pumps

Operating Instruction
Type LTU/LUB

Type
Serial No.

EDUR-Pumpenfabrik
Eduard Redlien GmbH & Co. KG
Postfach 1949 D-24018 Kiel
Tel. (+431) 689868 Fax (+431) 6898800
E-mail: info@edur.de http://www.edur.de

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2
Contents
1 Security 3
1.1 Identification of Safety Instructions in the
Operating Manual 3
1.2 Qualification and Training of Operating
Personnel 3
1.3 Hazards in the Event of Non-Compliance
with the Safety Instructions 3
1.4 Compliance with Regulations Pertaining to
Safety at Work 4
1.5 Safety Instructions relevant for Operation 4
1.6 Safety Instructions relevant for Maintenance,
Inspection and Assembly Work 4
1.7 Unauthorized Alterations and Production of
Spare Parts 4
1.8 Unauthorized Modes of Operation 4
2 Transport and Intermediate Storage 4
2.1 Transport 4
2.2 Intermediate Storage 5
2.2.1 Internal Preservation 5
2.2.2 Preservation Control 5
2.2.3 Removal of Preservation 5
3 Description 5
3.1 Design 5
3.2 Place of Operation 6
3.3 Connected Loads 6
3.4 Direction 6
3.5 Coupling Protection 6
3.6 Piping 6
3.6.1 General Remarks 7
3.6.2 Suction Pipeline 7
3.6.3 Pressure Pipeline 7
3.6.4 Additional Connections 7
4 Starting Operation/ Stopping Operation 7
4.1 Preparations for Initial 7
4.2 Initial Starting 7
4.3 Restarting 7
4.4 Stopping Operation 7
5 Service/Maintenance 7
5.1 Supervision of Operation 7
5.1.1 Mechanical Seal 7
5.2 Maintenance 7
5.2.1 Preparation 7
5.2.2 Dismounting 7
5.2.2.1 Pump 7
5.2.2.2 Dismounting of Mechanical Seal 7
5.2.2.3 Motor 7
5.2.3 Mounting 7
5.2.3.1 General Remarks 7
5.2.3.2 Mounting of the Motor 7
5.2.3.3 Mounting of Mechanical Seal 8
6 Disturbance 9
7 Pump View and list of Spare Parts 10
7.1 LUB 65 LUB 80 10
7.2 LUBL 65 LUBL 80 LUBL 100 11
7.3 LTU 12

3
General
The most important operational data are
mentioned on the type label. The sound
pressure L
pA
following VDI-guidelines 3743 sheet 1
depending on the nominal pump power input P
will be seen from the diagram underneath.
Fig. Noise emission
The actual sound level ascertained at place of
installation will possibly differ considerably from
these values due to the operating conditions and
the conditions of installation.
1 Security
This operating manual gives basic instructions
which are to be observed during installation,
operation and maintenance of the pump. it is
therefore imperative that this manual be read by
the responsible personnel/operator prior to
assembly and commissioning. It is always to be
kept available at the installation site.
It is not only the general safety instructions
contained under this main heading safety that are
to be observed but also the specific information
provided under the other main headings.
1.1 Identification of Safety
Instructions in the Operating
Manual
Safety instructions given in this manual
non-compliance with which would affect safety are
identified by the following symbol:
see DIN 4844-W9
or where electrical safety is involved, with
see DIN 4844-W8
Instructions non-compliance with which would
give rise to malfunctioning of the machinery are
identify by the word
It is imperative that signs affixed to the machine,
e. g.
- arrow indicating the direction of rotation
- symbols indicating fluid connections
be observed and kept legible.
1.2 Qualification and Training of
Operating Personnel
The personnel responsible for operation,
maintenance, inspection and assembly must be
adequately qualified. Scope of responsibility and
supervision of the personnel must be exactly
defined by the plant operator. If the staff does not
have the necessary knowledge, they must be
trained and instructed, which may be performed
by the machine manufacturer or supplier on
behalf of the plant operator. Moreover the plant
operator is to make sure that the contents of the
operating manual are fully understood by the
personnel.
1.3 Hazards in the Event of
Non-Compliance with the Safety
Instructions
Non-compliance with the safety instructions may
produce a risk to the personnel as well as to the
environment and the machine and results in a
loss of any right to claim damages.
For example, non-compliance may involve the
following hazards:
- Failure of important functions of the
machine/plant
- Failure of specified procedures of
maintenance and repair
- Exposure of people to electrical, mechanical
and chemical hazards
- Endangering the environment owing to
hazardous substances being released
CAUTION

4
1.4 Compliance with Regulations
Pertaining to Safety at Work
When operating the pump, the safety instructions
contained in this manual, the relevant national
accident prevention regulations and any other
service and safety instructions issued by the plant
operator are to be observed.
1.5 Safety Instructions relevant for
Operation
- If hot or cold machine components involve
hazards, they must be guarded against
accidental contact.
- Guards for moving parts (e.g. coupling)
must not be removed from the machine
while in operation.
- Any leakage of hazardous (e.g. explosive,
toxic, hot) fluids (e.g. from the shaft seal)
must be drained away so as to prevent any
risk occurring to persons or the environment.
Statutory regulations are to be complied
with.
- Hazards resulting from electricity are to be
precluded (see, for example, the
VDE Specifications and the bye-laws of the
local power supply utilities).
1.6 Safety Instructions relevant for
Maintenance, Inspection and
Assembly Work
It shall be the plant operator's responsibility to
ensure that all maintenance, inspection and
assembly work is performed by authorized and
qualified personnel who have adequately
familiarized themselves with the subject matter by
studying this manual in detail.
Any work on the machine shall only be performed
when it is at a standstill, it being imperative that
the procedure for shutting down the machine
described in this manual be followed.
Pumps and pumps units which convey hazardous
media must be decontaminated.
On completion of work all safety and protective
facilities must be re-installed and made operative
again.
Prior to restarting the machine, the instructions
listed under Initial commissioning are to be
observed.
1.7 Unauthorized Alterations and
Production of Spare Parts
Any modifications may be made to the machine
only after consultation with the manufacturer.
Using spare parts and accessories authorised by
the manufacturer is in the interest of safety. Use
of other parts may exempt the manufacturer from
any liability.
1.8 Unauthorized Modes of
Operation
The reliability of the machine delivered will be only
guaranteed if it is used in the manner intended, in
accordance with our order documentation,
especially with the order confirmation.
The limit values specified in the data sheet must
under no circumstances be exceeded.
2 Transport and Intermediate Storage
2.1 Transport
When transporting the complete pump unit by
crane, mount the ropes as shown in the figure.
The crane facility and the ropes
must be of sufficient capacity.
The ring loop of the motor must not be used for
transport of the complete pump unit.
Fig. 2.1a Pumps of structural form LUB

Fig. 2.1b Pumps of structural form LT
CAUTION

5
2.2 Intermediate Storage
On delivery, all pumps are preserved. Thus, they
can be stored for 6-12 months. If the storage time
is longer or the pumps are not in operation, they
must receive additional preservation on the inside.
The preservation means (please consult us)
depends on the used materials and conditions of
operation.
The storage room must be roofed and well
ventilated. Avoid temperatures below zero and
high humidity.
2.2.1 Internal Preservation
Close the suction branch securely. Fill the pump
with the preservation means and slowly turn the
rotor manually. Close the pressure branch
securely.
2.2.2 Preservation Control
Check the filling level of the pump and turn the
rotor by hand at regular intervals of 3 months.
Refill preservation means, if necessary.
2.2.3 Removal of Preservation
Prior to operation, the pump must be rinsed
thoroughly. In the case of additional preservation,
the preservation means on the inside must at first
be removed.
3 Description
3.1 Design
Horizontal and vertical, single-stage or multi-stage
ring section pumps, with or without an electric
drive unit, on a common bed-plate or unit-
construction pumps, available in different
construction materials, sizes and with different
shaft sealings.
3.2 Place of Operation
The pump unit must be freely accessible for the
purpose of supervision, servicing, maintenance,
mounting and dismounting.
Avoid using it in corrosive and very dusty
surroundings.
The limiting values of the electric drive unit with
regard to the insulation material class and the
types of protection must be observed.
For other drive units supplied, see the enclosed
separate operating instructions.
3.3 Connected Loads
Work must only be executed when
electricity is switched off. Make sure
that the system cannot be powered
on accidentally.
Prior to connecting the pump to
the power system, fill it with
pumped liquid. The pump must
by no means be operated without liquid!
The pump must be connected according to
international national requirements as well as
according to the requirements of the local mains
system. Voltage and frequency must correspond
to the winding of the electric drive. For details of
the respective winding, see the type label.
The motor must not be operated without motor
protection facility.
For motors with explosion protection, the range of
temperature of the motor indicated on the type
label must correspond to the range of the fuel
gas.
3.4 Direction
Switch on the motor briefly in order to check the
direction of rotation. The motor must not reach its
operational speed. The direction of rotation must
correspond to the arrow indicating the direction of
rotation on top of the pump. If the direction of
rotation is not correct, perform the relevant
modifications at the phase-sequence
3.5 Coupling Protection
The pump must not be operated if
coupling protection is not fitted. If this
coupling protection is not supplied by
the manufacturer, the operator of the pump must
supply it himself.
3.6 Piping
3.6.1 General Remarks
The nominal widths of the pipes must be at least
as wide as those of the pump connection joints.
For adapters, use extension angles of 8, if
possible.
The pipes must be gathered and secured right in
front of the pump so that their weight does not
affect the pump. The negative effects of variations
in temperature and occurring oscillation may be
reduced by installing a suitable bellow expansion
joint (see section 4.6).
Measuring equipment for supervision of the pump
operation is required.
CAUTION

6
Prior to operation, all parts in contact with liquids
must be thoroughly cleaned.
3.6.2 Suction Pipeline
The suction pipeline must be as short as possible.
Variations in diameter and additional piping must
be kept to a minimum. The suction pipeline
towards the pump must be rising, the inlet must
be descending to prevent an air pocket from being
formed. For non-self-priming pumps, installation
of a foot valve into the suction pipeline is
compulsory in order to avoid that, in case of a
standstill, the pump and the suction pipeline run
out of liquid during suction operation.
Contamination of the pumped liquid is to be
avoided by using a suction hose or a filter. By no
means must air penetrate through the liquid level
via the suction hose or dirt be whirled up from the
liquid pool. Clean the suction hose and filter
regularly.
To close the suction pipeline in the case of
mounting or maintenance work, a stop valve must
be provided near the pump. The stop valve must
not be used for adjustment and must be
completely open during operation.
3.6.3 Pressure Pipeline
For adjustment, repair and mounting of the pump,
a stop valve is to be provided near the pressure
joint.
3.6.4 Additional Connections
For the position and dimension of required
additional connections as e.g. for rinse, stop and
quench liquid, refer to the labels supplied with the
pump or to the drawings in the operating
instructions. The rinse, stop and quench liquids
must be checked at regular intervals.
Connections for ventilation and release of the
leakage liquid are also described in the drawings.
4 Starting Operation/ Stopping
Operation
4.1 Preparations for Initial
Prior to the start, the pump and the suction
pipeline must be drained of air and be completely
filled with the pumped liquid. The stop valve in the
suction or inlet pipeline must be completely open,
if there is one. For self-priming pumps, the pump
must only be completely drained of air and filled
with the pumped liquid.
4.2 Initial Starting
The pump must not be started until the outlet stop
valve is closed so as to avoid overload of the
motor. Immediately after reaching the operational
speed, slowly open the stop valve of the pressure
pipeline and adjust the operating point.
The pump must never be operated for
a longer period if the outlet stop valve
is closed. The pump unit will be
damaged if the pumped liquid exceeds the
permitted temperature.
4.3 Restarting
Do not restart the pump until the pump shaft
stands still.
Backflow of liquid must not result
in a change of direction of
rotation of the pump. If this is the case,
mechanical seals dependent on direction of
rotation may be damaged.
4.4 Stopping Operation
Close stop valve of the pressure pipeline. If there is
a backflow stop and sufficient counter pressure in
the pipeline, the stop valve can remain open.
Switch off the motor and observe that it slows down
smoothly. Close stop valve of the pressure pipeline.
If the pumped liquid reaches temperatures below
zero and/or if longer periods of standstill occur,
the pump must be drained completely and be
preserved (see section 2.2.1).
5 Service/Maintenance
5.1 Supervision of Operation
Ensure that the pump runs free of vibration and
smoothly
The pump must by no means be operated without
liquid.
There is only a minimal or invisible loss of leakage
(steam) if the mechanical seals function correctly.
Gland packings should drip slightly.
Do not operate the pump for a longer period with
a closed stop valve.
The maximum permitted environmental
temperature is 40
o
C. The storing temperature
measured at the motor or pump casing may
exceed the environmental temperature by 50
o
C. It
must not exceed 90
o
C. Only operate the pump at
a higher temperature with the manufacturer's
approval.
Installed pumps must be powered on and off
briefly once a week in order to guarantee that they
are ready for operation.
CAUTION

7
5.1.1 Mechanical Seal
The mechanical seals are maintenance-free. If
leakages occur after a longer period of operation,
replace the complete seal.
5.2 Maintenance
5.2.1 Preparation
In order to make sure that the pump
cannot be started, separate the power
cable from the motor. Secure the unit
against accidental switch-on.
Close the stop valve of the pressure and suction
pipelines. The pump casing must have reached
the environmental temperature and be drained of
liquid and pressure. In the case of pumps in
unit-construction with mounting flange, the
container must be drained completely.
5.2.2 Dismounting
By no means use force while dismounting the
pump.
Proceed as follows for the different pump types:
For fixed parts of the casings, impellers and
couplings, use appropriate dismounting facilities.
Impellers, which cannot easily be removed from
the shaft, can be pushed back from the shaft by
means of two hexagon screws.
5.2.2.1 Pump
The pump is always dismounted on the suction
side and with the shaft in a horizontal position.
Refer to enclosed drawings on page 10, 11 and
12 or in the supplementary sheet for the
dismounting sequence.
5.2.2.2 Dismounting of Mechanical Seal
In order to replace the mechanical seal, the pump
must be dismounted (see Fig. 5.2.2) first. After
that the pump must be dismantled before the seal
can be removed. Dismantle the pump in the
sequence shown in the exploded view diagrams,
pages 10,11 or 12. Remove impeller (230), casing
(108,117), key (940.1) and the circlip (932), pull
the delivery casing (107) off the shaft with the
mechanical seal (433).
5.2.2.3 Motor
For vertical pumps and unit-construction pumps, it
is not necessary to dismount the pump unit. The
pump can remain in the piping. First, remove the
coupling protection and loosen the hexagon
screws of the coupling. After having loosened the
hexagon screws at the motor flange, remove the
motor from the pump.
5.2.3 Mounting
5.2.3.1 General Remarks
Prior to mounting, all parts must be cleaned
thoroughly. Remove remaining parts of the seals.
Slight scratches and grooves on the shaft near
the shaft seal and on other sealing surfaces of the
casings are to be polished with linen. If this is not
possible, replace the parts. Gaskets must always
be renewed. Check O-rings for damage and
replace them, if necessary.
Mounting is effected in the reverse order of
dismounting. Heat up the coupling joints of rigid
couplings to approximately 250C prior to
mounting them onto the shaft.
In the case of flexible couplings,
the coupling half on the pump
shaft must be tightened thoroughly by means of
the shaft nut and/or the hexagon nut. If this is not
observed, the bearings will be damaged.
The starting torques for the tie bolts and locking
screws non lubricated condition are displayed in
fig. 6.2.3.1a.
thread M 10 M 12 M 14 M16 M20
torque
Nm
30 50 75 110
70*
120
* for pumps with more than 4 tie bolts
Abb. 6.2.3.1a Starting torque
5.2.3.2 Mounting of the Motor
For initial mounting of motor and pumps with rigid
coupling, first of all, remove the transport
safeguards of the lantern or of the intermediate
flange, then remove the motorside coupling half.
Subsequently, put this part onto the motor shaft.
This coupling half must be next to the motor shaft
collar. Tighten screws, join motor and pump
centrically without tilting them. Tighten screws
between motor and lantern or intermediate flange
and then coupling screws.
The inner parts of the pump will
be damaged if motor and pump
are connected and the
motorside or pumpside coupling half has been
installed incorrectly or not at all.
CAUTION
CAUTION

8
5.2.3.3 Mounting of Mechanical Seal
When mounting the mechanical seals, you must
proceed very carefully and with precision.
Do not touch the surfaces of the seal. Do not
damage the sealing parts. To facilitate the
mounting, moisten elastomer with low-surface
tension water.
Mechanical seals and sealingparts
with elastomer made of EP rubber
must by no means come in contact
with oil or grease.
The shape of spare mechanical seals may differ
from those of the installed mechanical seal.
However, the dimensions of the spare mechanical
seal are the same and for that reason it can be
replaced.
To avoid distortion of the counter-ring, mechanical
seals with doubled PTFE-wrapped sealing O rings
are additionally secured by a leading pin inside
the casing. The pin must be removed when
replacing the type of mechanical seals and when
using a type with different O-ring material.
For details of the individual types of mechanical
seals observe the following procedures.

For details of the individual types of mechanical
seals observe the following procedures.
1. Stressed mechanical seal independent of
direction of rotation with elastomer bellows
(fig. 6.2.3.3a)

Fig. 6.2.3.3a
Carefully press angle collar (1) together with
counter ring (2) into the counter ring fit.
Twist the rotating unit (3,4,5) onto the shaft
as far as the counter ring. Put on supporting
ring and mount circlip and/or push shaft
sleeve for mechanical seal onto the shaft.
2. Stressed mechanical seal dependent on
direction of rotation with conical springs
(fig. 6.2.3.3b)
Fig. 6.2.3.3b
Insert O Ring (1) into counter ring fit and
carefully press counter ring (2) into it. Push
mechanical seal (3) onto the shaft as far as
the counter ring. Press O Ring (4) into the
mechanical seal by means of the supporting
ring. The pivot of the pressure spring (6)
must be situated in the groove of the
mechanical seal ring. Put on locking
ring (7). Mount circlip and/or shaft sleeve for
mechanical seal.

9
6 Disturbance
To eliminate disturbance, the pump must have
reached the environmental temperature and must
be drained of air and pressure.
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The chart shows a list of potential errors and their possible causes. For
errors which are not listed here or which have other reasons, please
consult us.
Cause Elimination
z z
Pump and/or suction pipeline is not
completely drained of air/filled
Drain of air and fill
z z z z
Suction level too high, NPSH value of
the unit too high
Completely open stop slide in the suction
pipeline, check suction bag/footing valve, if
necessary, increase liquid level, if
necessary
z z z
Air inclusion in the pumped liquid too
high
Seal suction pipeline once again, check
suction bag, increase liquid level, if
necessary
z z z z
Formation of air bag in suction pipeline Change suction pipeline/attach drain valve
z z
Direction of rotation incorrect Check and change phase sequence, if
necessary
z
Rates of flow too low Readjust operating point
z z
Wear of inner parts Replace inner parts
z z z
Pump operates out of tolerance Readjust operating point
z
Shaft seal damaged Replace shaft seal
z
Stuffing box gland jammed or tightened
too heavily
Correct
z z z z
Air entry through shaft sealing on
suction side
Check liquid sealing or replace packing
z z
Speed too low Increase speed
1)

z z
Speed too high Reduce speed
1)

z
Connecting screws, seals Tighten connecting screws, replace seals
z z
Pump/motor not adjusted Replace defective parts, adjust pump/motor
z z z
Problems via piping Check pipe connections/pump
fasteners/bearing distance of pipe clips,
installation with oscillation absorbers
z
Insufficient, excessive or wrong
lubrication grease
Add, remove or change grease
2)

z
Incorrect coupling gap Readjust motor
z
Defective bearing Replace bearing
z z z z
Density/viscosity of pumped liquid
higher than indicated in the order
1)

z
Motor protection unit set incorrectly or
defective
Check motor protection unit, replace it, if
necessary
z
Impeller blocked Clean interior parts from particles and
impurities
1)
Please consult us
2)
Only pumps with lubricator
CAUTION
9

10

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BE7 20326_2 / 040811
14

BE7 20326_2 / 040811
15

BE7 20326_2 / 040811
16

13
As defined by machinery directive 98/37/EC Annex II A

Herewith we declare that the pump unit supplied with mounted electric drive
1)
complies with the following provisions applying to it
EC-machinery directive (98/37/EC, Annex I No. 1)
EC-low voltage directive (73/23/EEC)
Applied harmonized standards
EN 809 EN 953
EN 292-1 EN 60204-1 section 16
EN 292-2 EN 60034-5
EN 294
In case of a modification of the pump unit without being coordinated with us this declaration will not longer be
valid.
___________________
(QM-Supervisor)
1) other driving motor see separate declaration of conformity

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

Herewith we declare that the pump supplied without driving motor is intended to be incorporated into
machinery or assembled with other machinery to constitute machinery covered by this directive and must not
be put into service until the machinery into which it is to be incorporated has been declared in conformity with
the provisions of the directive, version 98/37/EC.
Applied harmonized standards
EN 809
EN 292-1
EN 292-2
In case of a modification of the pump without being coordinated with us this declaration will not longer be
valid.
___________________
(QM-Supervisor)

FH02

CW preheater

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

INSTRUCTIONS FOR ELECTRIC HEATER

Instruction Manual
for VESTA
TM
EH

Table of contents for instruction manual
1. General Description.........................................................................................1
2. Installation Space Requirements .....................................................................2
3. Storage.............................................................................................................2
4. Mounting and Installation ...............................................................................2
5. Connecting the Heater .....................................................................................3
6. Operation.........................................................................................................3
7. Maintenance and Cleaning..............................................................................4
8. Spare Parts.......................................................................................................6
Appendix:
- Spare Parts Drawing
- Dimensional Drawing
- Connection Diagram
- Electric Diagram (optional)
- Thermostats, working and safety (optional)

1. General Description
Aalborg Industries electrical heaters are of the flow through type. They are
manufactured with a heating capacity of 5 235 kW and a surface heat load
ranging from 1 to 3 W/cm
2
depending on the heated medium.
Other capacities can be manufactured at request.
All electric heaters can be delivered as immersion heaters with a capacity of 5 to
121 kW, or as outflow heaters with a capacity of 5 to 171 kW.
Aalborg Industries electrical heaters are primarily used for heating of fuel oil, lu-
brication oil or water.
Cable assembly box, terminal box, safety thermostat and control thermostat are
placed in the vessel extension.

The control thermostat (optional) is supplied as 1 to 8 steps corresponding to the
number of power groups specified.
The heaters are supplied with a inch socket for drain and safety valves.
Safety valve, thermometer, and pressure gauge may be mounted on a standard
outlet tube (optional).
All heaters have been hydrostatic pressure tested before delivery.
Aalborg Industries electrical heaters are type approved by all major classification
societies.
2. Installation Space Requirements
2.1. Space allowance
When mounting the heater sufficient space must be allowed for withdrawal of
the heating elements for cleaning, inspection or replacement purposes.
Please refer to dimensional drawing for withdrawal space requirements.
2.2. Installation surface
The heater must be placed on a level and stable surface.
3. Storage
3.1. Damp and humidity
Store the heater only in a dry storage room before installation. If the room is
damp the heater must be isolated with bags of silica gel. Saturated silica gel must
be replaced continuously. To avoid damage it is recommended the heater be
stored in the original packaging.
3.2. Hydrostatic testing
All Aalborg Industries heaters have undergone hydrostatic pressure testing be-
fore delivery. The testing fluid used contains a certain amount of corrosion pro-
tection (Castrol Rustilo Aqua 2); hence no further actions regarding storage are
required before installation.
3.3. Extended storage
When heaters are to be kept in storage for an extended period of time we rec-
ommend Castrol Rustilo Aqua 2 be used as protection against corrosion.
4. Mounting and Installation
The heater may be installed vertically or horizontally.
In case of vertical installation the terminal box and the medium outlet socket
must be top placed.

Instruction manual for heat exchanger type Vesta EH 2 / 6
Manufactured in Aalborg, Denmark
DEC 2000, rev. 2 torque values added
C:\Documents and Settings\hdu\Desktop\Manuals\Documents\Word\EH_manual_english.doc; Print Date: 07/11/2002 2:49 PM

In case of horizontal installation the outlet socket must be pointing upwards.
Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts in the holes and tighten up.
5. Connecting the Heater
5.1. Preparation and pipe connection of the heater
Remove all plugs and cover flanges before connecting the heater. Make sure
sand and other impurities are removed from all connections. Set up the pipe con-
nections and make sure that no forces are transferred to the heater.
5.2. Electrical connection of the heater
Set up the cable connections between the control panel and the connection box
mounted on the heater. Make sure that suitable cable glands are used to ensure
tight ducts.
6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securely
tightened and that the heater has been tested for earth faults with a resistance me-
ter before connected to the power supply.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.
6.2. Storage facilities without humidity control
If the heater has been stored in storage facilities without humidity control special
attention has to be paid before commissioning may continue.
Before applying full power load the heater must be conditioned to avoid short
circuits due to accumulated moisture in the heating elements. Apply a low volt-
age to the heater connections for reduced and slow heating of the elements. The
conditioning voltage should not exceed 25 % of the nominal voltage, please refer
to specification. Condition for minimum 1 hour and observe the heater for ab-
normal temperature rise or signs of short circuits. When the heater is conditioned
the main power supply may be applied.
6.3. Initial adjustment of thermostats
The safety thermostat must be set to maximum design temperature or 10 C
above normal working temperature.
The multistep working-thermostat (optional) must be adjusted to the required set
point. (See separate instruction).


The number of steps to be connected can be selected on the control panel.
6.4. Initial connecting to power supply
IMPORTANT: Full fluid flow through the heater must be established before
connecting to power supply.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.

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

Always use a torque wrench when tightening the flange bolts.
The heater must be carefully vented and carefully inspected for leakage during
the whole start-up period.
Make sure the power supply source and the design voltage on the heater and con-
trol panel (optional) are the same.
Switch on the power on the control panel main switch. The multistep thermostat
will automatically switch the individual step on and off.
6.5. Stopping the heater
IMPORTANT: When the heater is stopped (power switched off) after a period
of service it is very important to maintain fluid flow through the heater for at
least 10 minutes to remove the accumulated heat energy in the heating elements
(keep the pumps running).
Hence it is essential to make arrangements to maintain flow through the heater
also during emergency stops of the heater (keep the pumps running).
7. Maintenance and Cleaning
7.1. Mechanical maintenance
After every 2500 hours of operation the flange with heating elements must be
removed to check if deposits have gathered on the heating elements.


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

Always use a torque wrench when tightening the flange bolts.
The heater must be carefully vented and carefully inspected for leakage during
the whole start-up period.
Make sure the power supply source and the design voltage on the heater and con-
trol panel (optional) are the same.
Switch on the power on the control panel main switch. The multistep thermostat
will automatically switch the individual step on and off.
7.2. Thermostats and control panel
Once a year the thermostats must be checked for correct set point.
All circuit breakers must be checked once a year for correct functioning.
7.3. Checking heating elements
In order to check the elements an ampere meter may be connected in series with
each single heating element to check the current.
If a heating element is open circuit it must be replaced. It is important to make
sure that the element tube is perfectly cleaned and 100% dry before replacement
of the element. An insulating brick must be placed in the bottom of the element
tube before inserting the new element.


7.4. Checking the safety valves
Once every year the safety valves must be checked for correct set point.
8. Spare parts
When ordering spare parts please state the serial number of the heater (located on
the nameplate).
For spare parts and further information please contact Aalborg Industries.

LH01

LO cooler

Table of contents
Plate Heat Exchanger Revision: 28.06.2002
1
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 PHE safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Incorrect operating conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Permitted PHE operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Residual dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.1 User notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drawings and figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operator of the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PHE setter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.2 Safety notes in the text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Managers obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Intended purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Overview and description of the PHE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.1 Basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.4 HE plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.4.1 Chevron pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.4.2 Free Flow design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.4.3 Plate evaporator design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.5 HE plate gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8 Delivery, transport, and installation of the PHE . . . . . . . . . . . . . . . . . . . . . 24
8.1 Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2 Setting up the lying PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.3 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table of contents
2
8.3.1 Suspended with shackles at the fixed plate
and with sling attachment at the carrying beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.3.2 Suspended at transport eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.3.3 Suspended with sling attachment at the tightening device . . . . . . . . . . . . . . . . . . . 30
8.4 Installation of the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.4.1 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.4.2 Pipe assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.5 PHE disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9 Operation, start-up, and shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.3 Shutdown of the PHE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.3.1 Short-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.3.2 Long-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.1 Preparatory precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.2 Opening the PHE and removing the HE plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.3 Mounting the HE plates and closing the PHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.4 Cleaning the PHE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.4.1 Cleaning the HE plates of the closed PHE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CIP process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Backflushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.4.2 Cleaning the HE plates of an open PHE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Manually cleaning the HE plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Chemically cleaning the HE plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.5 Replacing HE gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.6 Replacing port rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.7 Maintaining the PHE frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.1 Impaired PHE performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.2 PHE leakages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12 Technical terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Preface
3
1 Preface
With GEA Ecoflex, you use the technical know how of one of the worldwide lea-
ding manufacturers of plate heat exchangers (PHE).
We would like to make the handling of the PHE as safe and simple as possible. For
this reason, these comprehensive operating instructions serve as your personal ad-
viser who explains everything understandably and clearly: structure, function, in-
stallation, operation, maintenance, troubleshooting, transport and repair.
We especially devote ourselves to the subject of safety, so that all possible dangers
or damages can be avoided from the start. For that reason alone, all employees
who deal with the PHE should be able to reach for these important operating in-
structions at all times.
In the clear table of contents, you will quickly find what you are looking for. If not,
look in the index with page references. In the same way all technical terms are in-
formatively explained. After all, no questions should remain open, and in the case
they do, your GEA Ecoflex agent or the central service department is glad to assist
you further.
Operating instructions for special applications supplement these general operating
instructions.
With this in mind, we wish you a problem-free operation with GEA Ecoflex plate
heat exchangers.
GEA Ecoflex GmbH
Voss-Str. 11/13
D-31157 Sarstedt
Phone: +49/5066/601-0
Fax: +49/5066/601-106
Internet: http://www.gea-ecoflex.de
PHE safety
4
2 PHE safety
2.1 General safety
This chapter advises you on general precautions for the proper handling of the
PHE and which dangers the user can encounter.
If the PHE is employed improperly or not according to the intended purpose, or if
the safety notes are not adhered to, dangers to persons and property can arise.
NOTE
Read this chapter attentively. It contains important information and obligations. It
concerns your health and the trouble-free operation of the PHE.
CAUTION
The operator is responsible for the safe operation of the PHE.
The following points must be adhered to:
Always adhere to the general, national, and operational safety regulations, for
example, wearing protective glasses, close-fitting protective clothing, and
safety shoes.
Always adhere to the safety notes in the individual chapters of these operating
instructions.
The PHE may only be operated in perfect condition. Each change on the PHE
must be immediately reported to the nearest available responsible superior.
Before beginning work with the PHE, operators must familiarize themselves
with the possible dangers.
Before each start of the PHE, ensure that all parts of the PHE are in perfect con-
dition and function correctly.
PHE safety
5
2.2 Incorrect operating conditions
Operation of the PHE is not permitted, whenever:
substantial faults or damages are present,
the maintenance is not regularly performed,
the operating conditions (e. g. inner pressure, temperature, media, external in-
fluences) are exceeded.
NOTE
GEA Ecoflex accepts no liability for damages caused by incorrect operating condi-
tions.
2.3 Permitted PHE operators
For operating the PHE each operator must:
be appropriately trained for the task to be performed,
be familiar with the work safety and accident prevention regulations,
be instructed in the handling of the PHE and
have read and understood these operating instructions.
Persons who are responsible for the set-up, assembly, start-up, maintenance or di-
sassembly of the PHE must have command of the necessary knowledge.
PHE safety
6
2.4 Residual dangers
Residual dangers can never be fully excluded. You can only prevent these dangers
through appropriate behaviour.
CAUTION
Danger of injury!
Heat exchanger (HE) Plates:
The thin HE plates are sharp edged.
When handling HE plates, always
wear suitable protective gloves.
Outside of the PHE
On the edges, threads, or similar
parts, there is a danger of injury. Al-
ways wear suitable protective gloves
when handling the outside of the
PHE.
Hazardous flow-through media
Hazardous flow-through media pre-
sent dangers of chemical burns, bur-
ning, or poisoning. Always wear
suitable protective clothing when
working on the PHE with hazardous
flow-through media.
Opening the PHE:
Before opening the PHE, ensure that
it is unpressurised and empty. When
opening the PHE, always ensure that
the HE plates do not unintendedly
loosen from the frame and tip over,
see chapter 10.2, page 42.
Also ensure that the pressure plate is
secured against unintended slippage
(e. g. on ships).
PHE safety
7
Transporting the PHE:
Before transporting the PHE, always
ensure that the hoisting gear are of
sufficient dimensions and securely
fixed.
Never step underneath suspended
loads.
Operating instructions
8
3 Operating instructions
3.1 Operating instructions
These operating instructions are the instructions of the manufacturer for the PHE
managers and for all persons who are responsible for the set-up, operation, main-
tenance and repair of the PHE.
These operating instructions are generally applicable to all bolted/gasketted (not
welded) PHEs manufactured and supplied by GEA Ecoflex.
3.1.1 User notes
Drawings and figures
The drawings in these operating instructions are exemplary. For reasons of clarity,
some drawings have been greatly simplified. The actual details depend on the in-
dividually delivered PHE. You find diagrams and dimensions of the delivered
PHE in the supplied technical documentation.
Operator of the PHE
The operator of the PHE is the person who the PHE manager entitles to operate the
PHE.
PHE setter
These operating instructions contain no details about special tools that are needed
for the setting up and operating the PHE.
Operating instructions
9
3.1.2 Safety notes in the text
In these operating instructions, the following symbols are used in order to draw
your attention to dangers in handling the PHE or give you information about
handling the PHE:
CAUTION
This symbol means danger to life and health of persons.
The following text explains the type of danger and its effects and gives instructions
for averting the danger. Not adhering to the instructions can have health effects up
to and including death.
ATTENTION
This symbol means danger to the PHE or its parts and the surroundings.
The following text explains the type of danger and its effects and gives instructions
for averting the danger. Not adhering to the instructions can cause substantial da-
mages to the PHE.
NOTE
This symbol appears above paragraphs that give you useful or important notes for
the correct handling of the PHE. This information helps you to avoid problems and
makes it easier to handle the PHE.
Managers obligations
10
4 Managers obligations
CAUTION
Danger of injury
In the case of hazardous media (acids or similar media), high pressures and high/
low temperatures in the PHE, there is a danger of injury during maintenance or
leakages. In this case, you absolutely must have a splash protector. This splash
protector may only be removed when the PHE reaches room pressure and room
temperature, or is empty.
As manager of the PHE, you must ensure that each operator who is responsible for
the set-up, operation, maintenance or repair of the PHE has read and understood,
from beginning to end, the parts of the operating instructions important for the
job.
The PHE is built according to state-of-the-art technology and is reliable in service.
Nevertheless, dangers from the PHE or damages to the PHE can arise if you do not
adhere to the following instructions:
These operating instructions must always be accessible to the operators ent-
rusted to work on the PHE.
Only operators who are instructed in the handling of the PHE and the basic
work safety and accident prevention regulations may work on the PHE. For
safety reasons, it is forbidden for other persons to be in the area of the PHE.
You must verify the safety-conscious work of the operator in regular intervals.
As manager you must ensure that:
the PHE remains in functional order.
no premature wear of certain PHE components due to unfavourable sur-
rounding conditions occurs.
Unfavourable surrounding conditions are for example, for
all maintenance/inspections are carried out in regular intervals.
sealing materials: aggressive gases and/or aggressive aerosols in
the surrounding air
effects of UV radiation (e.g. sunlight)
extreme surrounding temperatures
metallic components: aggressive gases and/or aggressive aerosols in
the surrounding air
humidity
Managers obligations
11
no changes, additions, or reconstructions to the PHE are carried out without
approval of the PHE manufacturer. A change can lead to the loss of the ope-
rating approval.
all even not here explicitly mentioned laws and regulations valid for the
PHE as well as the valid accident prevention regulations are adhered to.
Functional description
12
5 Functional description
A series of contoured plates with transfer ports forms a pack of flow channels in
the PHE. The heat exchange media flows through these flow channels in alternate
channels.
Usually a single-pass PHE is employed. In this single-pass PHE, all of the feed and
discharge pipes are connected to the fixed plate, that is, on one side.
Functional description
13
Close temperature differences between the media may demand multi-pass PHE. In
these multi-pass PHEs, the connection pipes are then attached to the fixed plate
and to the pressure plate, that is, on both sides.
Intended purpose
14
6 Intended purpose
This PHE has been specially designed and manufactured for your specified opera-
ting conditions concerning pressure, temperature, flow rates, and type and compo-
sition of the flow-through media.
If a change in the specified operating conditions becomes necessary, GEA Ecoflex
must be consulted. The PHE may only be operated under new operating conditi-
ons after GEA Ecoflex has examined, approved, and altered the PHE documenta-
tion, if necessary.
Usage according to the rules includes:
adhering to the valid national and international laws, decrees, regulations, di-
rectives and other rules for the installation site .
following all safety notes of these operating instructions.
adhering to regular inspection and maintenance work.
NOTE
GEA Ecoflex accepts no liability for damages caused by deviations from the speci-
fied operating conditions for the PHE.
Overview and description of the PHE
15
7 Overview and description of the PHE
7.1 Basic structure
The following figure represents the basic structure of a plate heat exchanger. The
actual design depends on the application.
1
2
3
4
5
6
7
8
9
No. Component No. Component
1 Carrying beam 4 Support column
2 Pipe connections 5 Pressure plate
3 Fixed plate 6 HE Plate
7 Guiding bar
8 Gasket
9 Tightening device
16
The plate pack consists of contoured
HE plates (1) and the corresponding
gaskets (2) of varying number and ar-
rangement.
7.2 Identification
Each GEA Ecoflex PHE is provided with a name plate. It is attached to the outside
of the PHEs fixed plate. Here you find details about:
plate heat exchanger type
serial no.
admissible working pressure [bar g]
admissible working temperature [ C]
test pressure [bar g]
volume [L]
net weight, year of construction
compression dimensions:
"a max." / "a min." [mm]
additional details [project specific]
1
2
17
Examples for the name plate design in conformity with the European Directive on
Pressure Equipment 97/23/EC.
Each PHE is supplied with a dimension sheet or, alternatively, an assembly dra-
wing, and a flow diagram.
The dimension sheet or the assembly drawing shows the external dimensions as
well as details of the type, size and position of the pipe connections.
The flow diagram shows the HE plate arrangement and the type, the HE plate ma-
terial, the plate thickness as well as the sealing material and the part numbers.
1 2
No. Component
1 PHE without CE index number
2 PHE with CE index number
18
7.3 Frames
GEA Ecoflex PHE are available in different application specific frame designs.
There are two basic designs, B and CD. The design B is especially employed for
longer plate packs.
Special stainless steel designs with intermediate elements for separating the indivi-
dual compartments are employed for the foodstuff and pharmaceutical industries.
The frames made of structural steel are given a weather-protective coating. The
tightening bolts and nuts are made of high-strength steel alloys and in some cases
galvanised.
The pipe connections can be attached to the fixed plate, to the pressure plate and
possibly to intermediate elements.
B CD
19
The pipe connections on the fixed and pressure plate are positioned as follows:
From an outside position looking
onto the fixed plate, the connec-
tions 1F-4F are numbered conse-
cutively anticlockwise.
From an outside position looking
onto the pressure plate, the con-
nections 1L-4L are numbered
consecutively clockwise.
In order to fulfill customer specific requirements, different connection types are
available.
20
As an alternative, the designs B and
CD can be cladded with stainless steel
and equipped with tightening bolts
made of stainless steel. They then
have the additional letter C (for clad-
ded) and frame designation BC and
CDC.
To some extent, these frames are
equipped with height-adjustable
threaded feet. In this case, the feet are
not anchored to the ground. Thrust
plates lie beneath the threaded feet.
These thrust plates are not part of the
standard equipment.
7.4 HE plates
NOTE
The selection of the HE plate material is determined by customer-specific opera-
ting conditions (among others pressure, temperature, media, operating mode). In a
few special applications, the media used typically erodes the material of the HE
plates. This can lead to a malfunction of the HE plates and to a mixing of the me-
dia.
The HE plates and gaskets are essential components of the PHE. GEA Ecoflex dis-
tinguishes between three product groups.
7.4.1 Chevron pattern
The HE plates of the series VARITHERM(VT), NT and LASER welded cassettes
(LWC) belong to this product group.
These HE plates have horizontal and vertical profiles, which are used individually
or combined. They are used for clean media with a low viscosity and also for high
working pressures.
The gaskets of this product group can be fixed with adhesive. Additionally, many
plate types allow adhesive-free fixing (LocIn, EcoLoc).
21
7.4.2 Free Flow design
The HE plates of the series FA (free flow) and the N40 plate belong to this group.
The special feature of this product group is the unrestricted broad flow cross sec-
tion between the HE plates. Highly viscose media or media containing solids re-
quire the use of this product group.
The gaskets of this product group are fixed with adhesive. The plate type N40 al-
lows adhesive-free fixing (LocIn).
7.4.3 Plate evaporator design
The HE plates of the series CT (Concitherm) form this product group.
Liquids are concentrated by evaporation using these plates ("evaporator").
The gaskets are fixed with adhesive. The plate type CT187 allows adhesive-free fi-
xing (LocIn). The plate type CT193 consists of LASER welded cassettes.
22
7.5 HE plate gaskets
CAUTION
Damages to persons and property !
The use of inadmissible pressures, temperatures and media can lead to an immedi-
ate failure of the gaskets and a grave endangerment of persons and the surroun-
dings. Therefore, never exceed the admissible operating parameters.
ATTENTION
Leakage!
The gaskets are wearing parts and sensitive to chemical, thermal and mechanical
damages. The selection of the gasket material and its properties is determined by
customer-specific operating conditions (pressure, temperature, media). Inadmis-
sible use can lead to a reduction of the service life. Elastomer gaskets are always
subject to the ageing process (e.g. embrittlement).
There are two basic groups of gaskets:
Gaskets made of elastomers, available in different materials and design types
(e. g. 2-eye gaskets and 4-eye start and/or end gaskets). The gaskets can, in
principle, be fixed with adhesive, also often without adhesive (LocIn, EcoLoc).
Gaskets made of mineral fibres ("hard gaskets"). They are principally fixed with
adhesive. Unlike gaskets made of elastomers, these gaskets made of mineral
fibres cannot compensate for large temperature differences (e. g. start-up and
shutdown). Therefore, leakages may occur during these operating phases.
23
All gaskets are designed to enable separating both media from each other at the
transfer ports by means of a double-gasket guidance system. In the event of any
leakage in this area, the leakage chamber formed in this way has the task of out-
wardly discharging the liquid via gaps in the sealing webs (leakage grooves) so
that any leakage immediately becomes apparent.
The materials of the gaskets are clearly marked by coded colours.
The storage of the gaskets must be done properly.
Never exceed the admissible parameters.
Delivery, transport, and installation of the PHE
24
8 Delivery, transport, and installation of
the PHE
CAUTION
Damages to persons and property!
Improper and careless handling of the
PHE can lead to danger to persons
and property. The PHE may never be
lifted underneath the plate pack, at
the connections or at the tightening
bolts.
25
8.1 Delivery
The fully assembled PHE is packed and delivered either lying on its side or up-
right, depending on the frame type.
If it is delivered lying on its side, the PHE is anchored by the back of the fixed plate
to solid planks. A forklift truck can pick the PHE up from beneath the planks and
transport it.
The PHE that is packed upright and to be transported upright is top heavy. To be
secured for transport, it is screwed to solid planks and must be unloaded and
transported in suspension, according to chapter 8.3 on page 29. In no case may the
device be lifted under the HE plate pack because this inevitably leads to a dama-
ging of the plate pack.
In the BC frame, the height-adjustable transport feet replace the ball feet. You find
the ball feet in an enclosed package with the PHE.
PHE parts are packed on pallets as well as in suitable cartons on pallets. Upon re-
quest, we will use special air freight, container and wood packages. You, as the
customer, are responsible for the disposal of the PHE packing material.
NOTE
If, in spite of the careful packaging, you should observe damage at delivery, you
must make a note of the extent and type of the damage on the consignment note
and obtain a receipt from the deliverer. Please report any possible damages to us
immediately.
8.2 Setting up the lying PHE
CAUTION
Danger to life!
There is always a danger that the PHE will tip over while righting it. Always
ensure that:
the hoisting gear are of sufficient dimensions,
the hoisting gear cannot come loose or slide off,
no swing movements to the side result when lifting the PHE,
the floor at the installation site is sufficiently large, level and able to support the
load.
26
ATTENTION
Damage to the PHE!
The connecting pieces can bend or
crack. Attach the hoisting gear
(slings) only as in the following.
When attaching the hoisting gear
(slings), make sure that they are
firmly seated.
Never use a chain or a steel rope, but
only slings.
Proceed as follows to set up the lying PHE:
1. Remove all of the fastening screws
and elements from the PHE and
from the pallet.
27
2. Attach a sling to the upper tighte-
ning nut on each side of the PHE.
Do not use a steel rope or
chain!
If the tightening nuts are not
accessible for attaching the
slings, slightly tip the PHE
with an additional sling (al-
ways attach the slings between
2 tightening nuts).
Then attach the slings around
the top tightening nuts.
3. Lift the PHE slowly from the pal-
let over its centre of gravity.
28
4. Slowly lower the PHE onto the
edge of the fixed plate or the feet
of the PHE. Align the PHE and
bring it to its final position at the
installation site.
5. Remove the slings and other aids.
Then anchor the PHE to the
ground.
; The PHE has been set up.
29
8.3 Transport
CAUTION
Danger to life! Damage to the PHE!
Before transporting the PHE always ensure that:
no swing movements to the side result when lifting the PHE,
the operating personnel keep a sufficiently large safety distance,
load.
The suspended transport always starts out from an upright position of the PHE.
8.3.1 Suspended with shackles at the fixed plate
and with sling attachment at the carrying beam
Proceed as follows:
1. Attach two suitable shackles in
both holes intended for that pur-
pose on the upper side of the fixed
plate.
2. Attach a sufficiently long sling to
the carrying beam directly behind
the pressure plate and to both
shackles.
Do not use steel ropes or
chains!
3. Slowly lift the PHE.
; The PHE can nowbe
transported away.
30
8.3.2 Suspended at transport eyes
Proceed as follows:
1. Attach the hoisting gear to both
transport eyes on the top side of
the carrying beam.
2. Slowly lift the PHE.
; The PHE can nowbe
transported away.
8.3.3 Suspended with sling attachment at the tightening device
Use this transport method only when the above-described fastening possibilities
are not available.
Proceed as follows:
1. Attach a sling around the top tigh-
tening bolts on each side of the
PHE.
Do not use steel ropes or
chains!
2. Slowly tilt the PHE until it reaches
a hanging position.
; The PHE can nowbe
transported away.
31
8.4 Installation of the PHE
CAUTION
Danger to life!
There is always a danger that the PHE will tip over during installation. Always
ensure that:
the operating personnel keep a sufficiently large safety distance,
load.
In case of outdoor installation, take precautions against freezing the flow-through
media in the PHE, if necessary.
8.4.1 Space requirements
Provide enough space around the
PHE. This facilitates access to the
PHE and necessary service tasks (e. g.
replacing individual plates, compres-
sing the plate pack).
The values for the necessary space gi-
ven in the adjacent figure are guide
values and are recommended by
GEA Ecoflex. They provide sufficient
space for accessing the PHE.
32
8.4.2 Pipe assembly
The PHEs from GEA Ecoflex are provided with different connection types accor-
ding to the purpose. Pay attention to the following points during pipe assembly:
ATTENTION
Damages to the pipe connections and to the PHE!
Make sure that no forces, moments, or vibrations that are too high are transferred
via the pipes onto the connections of the PHE. By request, you can obtain an over-
view of the admissible forces and moments for the PHE.
8.5 PHE disposal
As a customer, you are responsible for the disposal of the PHE packing materials.
By request, GEA Ecoflex takes on disposal of the PHE. For the cost of labour, the
PHE is disassembled, transported away and professionally disposed.
NOTE
If the PHE or its parts are contaminated, GEA Ecoflex cannot take on the disposal.
In this case, disposal of the PHE is the managers obligation.
Operation, start-up, and shutdown
33
9 Operation, start-up, and shutdown
CAUTION
Danger of injury!
Hazardous flow-through media (corrosive, poisonous, flammable, explosive etc.)
present dangers of chemical burns and burning. Inform yourself beforehand which
flow-through media are used and make sure that a protective covering is on hand.
ATTENTION
Environmental damages! Damage to the PHE!
When ecologically harmful flow-through media flow out, serious environmen-
tal damages are possible. Make sure that it is possible to empty the product and
that a drip tray for the entire PHE filling volume is on hand.
If the PHE is further compressed
below "a min.", the plates warp.
Make sure that the plate pack is
compressed to the necessary com-
pression dimension
"a min." < "a" < "a max.".
ATTENTION
Damages to the PHE!
Quick switching operations (e. g. from valves in the pipes connected to the
PHE) or operation-related events (e. g. spontaneous evaporations, condensa-
tion surges) can lead to high-pressure surges. Avoid high-pressure surges th-
rough the flow-through media in order to avoid damaging the PHE.
The PHE may only be tightened in its unpressurised state because otherwise it
may fall below the compression dimension "a min." (see the explanation for
"a min." in chapter 12 on page 56).
34
9.1 Start-up
Before start-up, visually inspect the PHE and make sure that:
the PHE is not operated with inadmissible flow-through media, pressures and
temperatures.
all pipe connections are firmly connected to the PHE.
all necessary PHE components are completely installed.
the plate pack is not compressed below compression dimension "a min." (see
name plate or flow diagram in chapter 7.2 on page 16). The HE plates could be
permanently damaged.
when restarting, no residues of previous processes (e. g. cleaning agents) are
present in the PHE.
all air is removed from the PHE.
pressure surges are avoided. The proper operation of the PHE could be endan-
gered. Flow-through media could escape.
; If all of these conditions are fulfilled, you can start operating the PHE.
NOTE
If faults occur during start-up of the PHE, see chapter 11, page 53.
35
9.2 Operation
CAUTION
Danger of injury! Damages to the PHE!
If the PHE is in operation when working on the PHE, there is a danger of injury or
a danger that the PHE will be damaged. Always shutdown the PHE first, before
you start maintaining or repairing it.
Visually inspect the PHE regularly during operation and make sure that:
the PHE is not operated with inadmissible flow-through media, pressures and
temperatures.
the minimum and maximum parameters given on the name plate are not ex-
ceeded. If the parameters are exceeded, the operating approval dissolves and
GEA Ecoflex accepts no liability for resulting damages.
pressure surges are avoided. The proper operation of the PHE could be endan-
gered. Flow-through media could escape.
NOTE
If faults occur during operation of the PHE, see chapter 11, page 53.
36
9.3 Shutdown of the PHE
9.3.1 Short-term shutdown
ATTENTION
Escape of environmentally hazardous flow-through media possible!
Flow-through media can be dangerous and environmentally hazardous. Make sure
that no flow-through media can escape during the shutdown period. In case of
outdoor installation, take precautions (e. g. emptying, heating) against freezing the
flow-through media in the PHE.
9.3.2 Long-term shutdown
ATTENTION
Premature component wear!
The components of the PHE can wear out prematurely due to unfavourable sur-
rounding conditions or due to flow-through media remaining in the PHE. If the
PHE is shutdown for a longer time period, the PHE must be depressurised and
completely emptied. Additionally, we recommend a basic cleaning and an approp-
riate storage until setting the PHE into operation again.
NOTE
You can obtain detailed information about storage conditions from your
GEA Ecoflex service department (see back cover).
Maintenance and repair
37
10 Maintenance and repair
10.1 Preparatory precautions
Before starting work, check the supplied documentation to see with which frame
type the PHE was delivered.
CAUTION
Danger of injury!
There is a danger of injury during maintenance and repair work on the PHE. For
this reason, always adhere to the following points:
Always wear suitable protective clothing.
If a pressurised or filled PHE is opened, the flow-through media can escape un-
controllably. This is a danger of injury for the operator and bystanders.
Before beginning maintenance or repair work, ensure that the PHE is empty
and has reached room pressure.
When using hot or very cold flow-through media there is a danger of burning,
or respectively, freezing. Before beginning maintenance or repair work, always
ensure that the PHE has reached room temperature.
Hazardous flow-through media (corrosive, poisonous, flammable, explosive
etc.) present an acute danger of injury for the operator and bystanders. Make
sure that the regulations for flow-through media are followed during all work.
Ensure that the pressure plate is secured against unintended slippage (e. g. on
ships).
The HE plates of the PHE can tip
out sideways and severely injure
persons. Always ensure when sus-
pending the HE plates and when
closing the PHE that the HE plates
do not unintentionally detach
from the frame and tip over.
For this reason, at least two per-
sons must work on a PHE with
CD frame.
38
ATTENTION
Danger of falling over during stacking!
The HE plates can fall over during unchecked stacking. Injuries and damaged HE
plates are the result. Never stack the plates higher than:
60 HE plates for Varitherm/NT
30 cassettes for LWC
30 HE plates for Free Flow/Concitherm/Safetytherm
39
Before opening the PHE you must carry out a few work steps. If necessary, remove
the connected pipes.
In general, you should proceed as follows:
Clean the guiding rail (for better
plate mobility).
Clean the threads of the tighte-
ning bolts (to remove the contami-
nation and prevent a fretting of
the nuts).
Apply a thin film of oil to the
thread.
40
To ensure that the plates are reas-
sembled in the right order, we ad-
vise painting a diagonal line
across the side of the plate pack.
Be sure to note the current "a" di-
mension.
NOTE
When removing the HE plates, document the order with the help of the flow dia-
gram.
The PHE frames are usually
equipped with four tightening de-
vices. In PHEs with more than
four tightening devices, as a rule
four longer tightening devices are
used. These only pretension the
HE plate pack (so-called preten-
sioning bolts).
41
The HE plates are mounted in different ways in the frame, depending on the frame
design of the PHE.
In CD frames, the HE plates rest on the bottom guiding bar and are guided by the
top.
In the CD frame, the plates are
guided by a top and a bottom gui-
ding bar.
In the B frames, the HE plates are suspended at the top carrying beam with a spe-
cial rail. The plates are hooked into the recess of the guiding rail and are guided by
the bottom guiding bar.
Top carrying beam with a guiding
rail and a guiding bar.
Top carrying beam without a gui-
ding rail.
VT NT
VT NT
42
10.2 Opening the PHE and removing the HE plates
NOTE
Before loosening/opening the PHE pay attention to the safety notes in
chapter 10.1, page 37 "Preparatory precautions".
Open the PHE as follows:
1. Release the nuts of the tightening devices on the pressure plate.
Release the tightening devices
evenly in small steps on alter-
nate sides (1-2-3-4) and diago-
nally (1-2 and 3-4), in order to
prevent overloading indivi-
dual tightening devices and
tilting the pressure plate.
Proceed similarly in the case of
frames with more than 4 tigh-
tening devices.
2. Remove the nuts.
3. Remove all tightening devices.
; The PHE is open.
NOTE
For the CD frame, we recommend leaving the top pretensioning pair (1-3) in the
frame as an additional safety precaution.
1
2
3
4
43
Remove the HE plates as follows:
1. In the B frame, slide the pressure
plate up to the end support co-
lumn.
In the CD frame, pull the pressure
plate back. A second operator se-
cures the plate pack against sli-
ding.
The individual HE plates are
now accessible.
.
2. For removal, swing the HE plate
out to the side and take it out of
the guiding rail of the carrying
beam.
In the case of some Varitherm
carrying beams, swinging is
only possible to one side.
44
10.3 Mounting the HE plates and closing the PHE
NOTE
Before mounting and closing the PHE, pay attention to the safety notes in
chapter 10.1, page 37 "Preparatory precautions".
ATTENTION
Damage to the HE plates!
Going below the compression dimen-
sion "a min" generally leads to da-
mage to the HE plates and possibly to
a malfunction of the PHE. Ensure that
the plate pack is only compressed to
the necessary dimension
"a min." < "a" < "a max.".
NOTE
When all the HE plates are correctly installed, the outside of the plate pack must
show a continuous honeycomb pattern.
You can also check that the plates are in the right order by means of the diagonal
line on the outside of the plate pack, which you painted before opening the PHE.
a
45
Proceed as follows:
1. Make sure that the gaskets and HE plates are free of foreign matter or contami-
nation.
If necessary, clean them with running water and a soft brush.
2. Check that the gaskets fit correctly in the grooves of the HE plates.
3. Clean the sealing faces of the frame gaskets.
4. For a PHE with a B frame: clean
the HE guiding rail at the carrying
beam and apply a thin layer of oil
to it.
5. Clean the threads of the tighte-
ning bolts as well as the tighte-
ning nuts and apply a thin layer of
grease to these.
6. Mount all the HE plates into the PHE frame in the correct order according to
the flow diagram.
Secure the plate pack in CD frames with the help of a second operator.
7. Determine the required compression dimension ("a" dimension).
The required compression dimension "a" is
in the case of a complete replacement of the gaskets: the "a max" printed on
the name plate.
provided that the HE plates are only cleaned and no gaskets are replaced:
the compression dimension written down before opening the PHE.
46
in case of a change in the number of HE plates: the new "a max"-dimension,
which matches the details on the supplied flow diagram and the supplied
modification plate at the name plate.
8. Tighten the tightening devices according to the procedure described in
chapter 10.2, page 42 "Opening the PHE and removing the HE plates" on alter-
nate sides and diagonally to the necessary compression dimension "a".
9. Carry out a leak test before restarting the PHE.
NOTE
The procedure for the occurrence of leakages is described in chapter 11 on page 53.
47
10.4 Cleaning the PHE
10.4.1 Cleaning the HE plates of the closed PHE
Deposits on the HE plates
impair the heat transfer between the flow-through media,
increase the pressure loss,
can cause or accelerate HE plate corrosion.
The particular PHE application determines
the necessity,
the type and
the frequency of a PHE cleaning.
CIP process
ATTENTION
Danger to persons and environment!
The use of aggressive cleaning agents presents poisoning, chemical burns, and bur-
ning dangers. Make sure that:
before the CIP process, you have been instructed in the use and have a good
command of all work steps.
during work with aggressive cleaning agents you always wear suitable protec-
tive clothing.
the cleaning agent you use is completely removed from the PHE after cleaning.
With CIP ("Cleaning in Place"), a cleaning agent flows through the PHE instead of
the flow-through media. Contaminants are removed by the cleaning solutions dis-
solving capacity, supported by the mechanical action of the turbulence.
ATTENTION
Damage to the PHE!
The improper use of CIP can damage the PHE. Pay attention to the notes on chemi-
cal cleaning of the HE plates in chapter 10.4.2, page 49 "Cleaning the HE plates of
an open PHE".
48
Backflushing
This process is used if the flow-through media contain coarse particles of contami-
nation and thus block the inlet channels. By briefly reversing the direction of flow,
the particles of contamination are removed from the PHE.
The direction of flow is reversed by
using a suitable pipe configuration
with the appropriate valves. If there is
a risk of the released particles of con-
tamination causing damage to the
PHE, preference should be given to
manual cleaning of the HE plates.
1F 2F
3F 4F
49
10.4.2 Cleaning the HE plates of an open PHE
Manually cleaning the HE plates
ATTENTION
Leakage!
At every cleaning, ensure that no particles can settle on or under the gaskets
because this leads to leakages.
Hard cleaning tools (e. g. brushes with metal bristles) can damage the metallic
surfaces of the HE plates and the surfaces of the gaskets. Damaged metal sur-
faces can lead to corrosion of the HE plates. Damaged gasket surfaces can lead
to leakages of the PHE when restarting it.
Never use hard cleaning tools.
Ensure that the stream of the high-pressure jet always directs face-on at the
gaskets in order to avoid loosening them.
In order to manually clean the HE plates, proceed as follows:
1. For coarse contamination, use a
high-pressure cleaner jet to loo-
sen the particles.
50
2. Wash each plate from both sides
with flowing, warm water and a
soft brush.
; The HE plates have been
manually cleaned.
Chemically cleaning the HE plates
ATTENTION
Leakage!
Chemical cleaning processes can attack the gaskets materials and create leaks. Al-
ways use cleaning agents that do not attack the gaskets materials. Choose a sui-
table temperature and do not let the cleaning agent take effect on the materials for
an unnecessarily long time.
NOTE
Always follow the safety instructions and recommendations of the cleaning
agent manufacturer. Only use chloride-free or low-chloride water with a low
hardness value for the cleaning liquid.
Chlorides in the medium reduce the corrosion resistance of chrome-nickel
steels and chrome-nickel-molybdenum steels (including Hastelloy, Incoloy and
Inconel). The intensity of the effect of the chlorides depends on the tempera-
ture, concentration and pH of the medium.
Stubborn contamination, such as coatings on the plate surface, which are not
released by the above-described processes, can be loosened by soaking in an
open chemical bath.
51
Choose a cleaning agent suitable for the type of contamination and for the pro-
perties of the HE plates and sealing materials.
You must obtain confirmation from the cleaning agent manufacturer that
the cleaning agents employed will not attack the HE plates or gasket mate-
rials. Clean the HE plates according to the cleaning agent manufacturers in-
structions.
Before reassembling the cleaned HE plates, always rinse them with sufficient
clean water. Remove foreign matter on the gaskets with a soft brush.
10.5 Replacing HE gaskets
You can find the fixing type of the gasket in the PHE technical documentation. The
gaskets can be either fixed with adhesive into the gasket grooves or pressed into
the grooves without adhesive.
We recommend that you always replace all gaskets at the same time. Use only ori-
ginal GEA Ecoflex gaskets.
NOTE
You can obtain detailed information about replacing gaskets from your
GEA Ecoflex service department (see back cover)
10.6 Replacing port rings
The type of port ring between the HE plate pack and the frame components de-
pends on the frame type.
NOTE
You can obtain detailed information about replacing port rings from your
GEA Ecoflex service department (see back cover)
52
10.7 Maintaining the PHE frame
ATTENTION
Loss of operating approval!
You must consult your GEA Ecoflex service department (see back cover) before
changing or replacing PHE frame components. Always use original PHE compon-
ents from GEA Ecoflex because otherwise loss of the operating approval for the
PHE follows.
Regularly carry out simple maintenance work, for example:
external cleaning,
greasing and
touch up varnish damage on the PHE frame.
NOTE
You can obtain detailed information about maintenance of the PHE frame from
your GEA Ecoflex service department (see back cover).
Troubleshooting
53
11 Troubleshooting
NOTE
On principle, you should reach an agreement with your GEA Ecoflex service de-
partment (see back cover) before repairing faults, in order to avoid improperly per-
formed work on the PHE and its consequences.
In the following you will find a few typical faults that can occur during operation
of a PHE.
11.1 Impaired PHE performance
Fault Cause Remedy
insufficient heat
transfer
deposits on the HE plates clean the HE plates
flow paths, media etc. chan-
ged from the design
have GEA Ecoflex examine the
design of the PHE with the
new operating data
too high-pressure
loss
flow impeded by blockage of
the flow channels of the distri-
butor
clean the HE plates
flow impeded by incorrect in-
stallation of the HE plates
check the installation order by
means of the flow diagram
flow paths, media etc. chan-
ged from the design
have GEA Ecoflex examine the
design of the PHE with the
new operating data
Troubleshooting
54
11.2 PHE leakages
Fault Cause Remedy
sealing fault bet-
ween the HE plates
false compression dimension
of the PHE
check the correct compression
dimension by means of the
data on the name plate
too high working pressures check the working pressures
by means of the data on the
name plate
too high/too low working tem-
peratures
check the working temperatu-
res by means of the data on the
name plate
gaskets fitted incorrectly open the PHE and correct the
gaskets position
gaskets are dirty open the PHE and clean the
gaskets
gaskets are defective open the PHE and replace the
gaskets
sealing fault bet-
ween HE plates and
frame, intermedi-
ate plates, interme-
diate elements
gaskets or port rings fitted in-
correctly
open the PHE, correct the posi-
tion of the gaskets or port rings
gaskets or port rings are dirty open the PHE, clean the gas-
kets or port rings
gaskets or port rings are defec-
tive
open the PHE, replace the gas-
kets or port rings
sealing fault bet-
ween pipe connec-
tion and frame plate
too high loads at the pipe con-
nection due to the pipe
reduce connection loads to the
admissible parameters
seal ring fitted incorrectly loosen the pipe connection and
correct the position of the seal
ring
seal ring is dirty loosen the pipe connection and
clean the seal ring
seal ring is defective loosen the pipe joint and re-
place the seal ring
flange connection is not suffi-
ciently tightened
check the seal ring and connec-
tion and tighten any loose bolts
damage to the HE
plates
over-tightened plate packs
(compression dimension less
than "a min")
replace defective HE plates
corrosion of the HE plate
material
check the design of the PHE
concerning flow-through me-
dia, consult GEA Ecoflex
Troubleshooting
55
damage to the start
or end HE plate
incorrect earthing during wel-
ding of special connections to
the open connecting pipes of
the PHE frame
replace defective HE plates
Fault Cause Remedy
Technical terms
56
12 Technical terms
Term Meaning
B frame An especially stable frame design, which also allows a
high number of HE plates.
backflushing A cleaning process in which the direction of flow is re-
gularly reversed. Reversing the direction of flow flus-
hes the particles of contamination from the PHE.
carrying beam The top component placed between the fixed plate and
support column upon which the HE plates and the
pressure plate are suspended.
Particularity:
In CD frames the carrying beam guides the HE plates.
CD frame A compact PHE frame design (compact design). The
number of HE plates that can be stacked is lower in a
CD frame than in the corresponding B frame.
CIP process (Cleaning in
Place)
A cleaning process in which the flow channels of the
closed PHE are flushed with specific cleaning soluti-
ons.
collector channel The flow channel which is created by the total passage
openings of the HE plates.
compression dimension
"a" dimension ("a max."/
"a min")
Dimension referring to the depressurised (!) PHE.
Tighten the HE plate pack placed between the frame
plates to this dimension. Going below the "a min" di-
mension can damage the HE plate pack. The tighte-
ning units adjust the compression dimension.
connection (pipe) The pipe connections intended for the fixed plate and,
if applicable, the pressure plate. The pipe connections
have different designs according to each application
(industrial design, rubber insert piece, metal liner,
flange connection etc.).
connection corner (pipe) Component of the intermediate element in the HE
plate pack. With this intermediate element, multi-stage
designs of a PHE are realised. The connection corners
allow the connection of additional pipes/media (espe-
cially for food applications).
distributor channel see "collector channel"
EcoLoc A fixing system without adhesive for gaskets of the
NT series.
fixed plate The basic component of the PHE frame. The fixed
plate is an unmovable frame plate. Normally, the pipes
are connected to this component.
Technical terms
57
flow-through media The term for the media that are responsible for the
heat transfer in the PHE.
frame plates The fixed plate and the pressure plate of the PHE
frame.
gasket of the HE plates An elemental component for sealing the flow channels
from each other and between the HE plates and the
surroundings or leakage chamber. There are gaskets
that are fixed to the HE plates with adhesive or wit-
hout adhesive (LocIn, EcoLoc).
guiding bar Component that guides the HE plates and the pressure
plate at the bottom.
Particularity:
In CD frames the HE plates rest on the bottom guiding
bar.
HE plate pack The collective term for all of the HE plates located bet-
ween the frame plates, including the gaskets.
HE plates The short form for the term Heat Exchanger plates. An
elemental component that keeps the flow-through me-
dia separated from each other and transfers the heat.
intermediate element A component placed within the HE plate pack. The in-
termediate element has pipe connections along the si-
des for multi-stage PHE designs.
intermediate plate A component placed within the HE plate pack. The in-
termediate plate has no pipe connections and is used
for special multi-pass PHE designs.
LocIn A fixing system without adhesive for some elastomer
gaskets.
metal liner A liner of the frame plates in the area of the pipe con-
nections. The material used depends on the applica-
tion (stainless steel, titanium, etc.).
multi-pass PHE A special design of the PHE with internal deflection of
the flow-through media. The construction of multi-
pass PHE always demands pipe connections to the
pressure plate.
multi-stage PHE A special design of the PHE with more than two flow-
through media (use of intermediate elements). With
this PHE design, complex heat transfer tasks are com-
bined in one PHE (heating and cooling, e.g. in the food
stuff industry).
name plate A label attached to the fixed plate of the PHE frame for
identification with the basic data of the PHE (stan-
dardly applied as a gummed label).
Term Meaning
Technical terms
58
PHE The short form of the term Plate Heat Exchanger.
pressure plate A movable frame plate suspended at the carrying
beam of the PHE frame. This frame plate compresses
the HE plate pack.
The pressure plate can have pipe connections.
rubber insert piece A liner of the frame plates (elastomer) in the area of
the pipe connections. It seals off the pipe connection
and the HE plate pack.
single-pass PHE The standard design of a PHE with two flow-through
media. Normally, the connections are placed on the
fixed plate.
splash protector A safety device attached to the HE plate pack.
GEA Ecoflex generally recommends attaching a splash
protector when using hazardous media.
support column A fixed component of a PHE frame to which the car-
rying beam and the guiding bar are fixed.
suspending (the pressure
plate)
Suspending the pressure plate at the carrying beam
(normally with a movable roller). The suspension
makes it possible to move the pressure plate on the
carrying beam.
tightening unit The frame component for compressing the HE plate
packs. It consists of tightening bolts, tightening nuts
and washers.
Term Meaning

FV05

Non return
valve

RK 41
RK 44
RK 44s
RK 70
RK 71
Betriebsanleitung 808519-02
Rckschlagventile RK
Installation Instructions 808519-02
Non-Return Valves RK
Instructions de montage et
de mise en service 808519-02
Clapets de retenue RK
Instrucciones de montaje y
servicio 808519-02
Vlvulas de retencin RK
Manuale di Istruzioni 808519-02
Valvole di non ritorno RK
Important Safety Note

The valve must only be installed by qualified staff.
Qualified staff are those persons who through adequate training in
engineering, the use and application of safety equipment in accordance
with regulations concerning safety systems, and first aid & accident
prevention have achieved a recognised level of competence
appropriate to the installation and commissioning of this device.
The non-return valves RK are automatic-stop check valves used in
pipes to prevent a backflow of fluid within the admissible pressure/
temperature ratings.
Contact the Factory for specific recommendations concerning the
chemical resistance and suitability of the valve material in a given
application.
Proper Use
Danger
The valve is under pressure during operation.
When loosening flanged connections or sealing plugs, hot water,
steam, corrosive fluids or toxic gases may escape. This presents the
risk of severe burns and scalds to the whole body or severe cases of
poisoning.
Installation and maintenance work should only be carried out when the
system is depressurized.
The valve becomes hot or extremely cold during operation. This
presents the risk of severe burns to hands and arms. Installation and
maintenance work should only be carried out at room temperatures.
Sharp edges on internals present a danger of cuts to hands. Always
wear industrial gloves for installation and maintenance work.
Ratings pursuant to article 9 of the PED

1)
Fluid
gas
2 2 1 1
Use no yes no yes
Fluid group
1)
PED = Pressure Equipment Directive
Category
Nominal size DN
CE marking no
I
15-50 65-150 65-200
yes
RK 70 Type
all
RK 70 only DN 200
RK 44s only DN 65-100
all
Exception pursuant
to article 3.3
liquid
no
Exception pursuant
to article 3.3
None
125-200
no
RK 44s
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.
Non-return valve with spiral centering ring
Non-return valve with self-centering body
Position of guide ribs (horizontal installation)
Description
1
2
3
Installation

TOP
1 2 3
Technical Data

ts [C] 20 200 250
[F] 68 392 482
ps [barg] 16 14 13
[psig] 232 203 189
RK 41/44/44s DN 15-100
ts [C] 20 200 300
[F] 68 392 572
ps [barg] 16 14 13
[psig] 232 203 189
RK 41/44/44s DN 125-200
ts [C] 20 100 130
[F] 68 212 266
ps [barg] 6 1.5 0.5
[psig] 87 22 7
RK 70 DN 15-200
ts [C] 20 120 250
[F] 68 248 482
ps [barg] 16 16 13
[psig] 232 232 189
RK 71 DN 15-100
Max. service temperature for RK 44s with spring: 90C
For RK 44s without spring see table above.
For more information see data sheets.
Name Plate / Marking

Type: RK...
DN: ...
PN: ...
..........
Type: RK...
DN: ...
PN: ...
..........
1/02 2002
1
2002
02
808519-02/103cs 2000 GESTRA GmbH Bremen Printed in Germany
GESTRA GmbH
Postfach 10 54 60
D-28054 Bremen
Mnchener Str. 77
D-28215 Bremen
Tel. +49 (0) 421 35 03- 0
Fax +49 (0) 421 35 03- 393
E-mail gestra.gmbh@flowserve.com
Internet www.gestra.de
A Unit of Flowserve Corporation
Flowserve Flow Control (UK) Ltd.

Burrel Road, Haywards Heath
West Sussex RH 161 TL
Tel. 00 44 14 44 / 31 44 00
Fax 00 44 14 44 / 31 45 40
E-mail: sales@flowserve.com
GESTRA

www.gestra.de
Flowserve Portuguesa, Lda.

Av. Dr. Antunes Guimares, 1159
Porto 4100-082
Tel. 0 03 51 22 / 6 19 87 70
Fax 0 03 51 22 / 6 10 75 75
E-mail: gestra@gestra.pt
GESTRA ESPAOLA S.A

Luis Cabrera, 86-88
E-28002 Madrid
Tel. 00 34 91 / 5 152 032
Fax 00 34 91 / 4 136 747, 5 152 036
E-mail: gestra@gestra.es
Flowserve Flow Control S. A. S

10, Avenue du Centaure, BP 8263
F-95801 CERGY PONTOISE CEDEX
Tl. 0 03 31 / 34 43 26 60
Fax 0 03 31 / 34 43 26 87
E-mail: gnation@flowserve.com
ITALGESTRA s.r.l.
Via Carducci 125
l-20099 Sesto San Giovanni (MI)
Tel. 00 39 02 / 24 10 12.1
Fax 00 39 02 / 24 10 12.460
E-mail: info@italgestra.it
GESTRA GmbH
Mnchener Str. 77
D-28215 Bremen
Tel. +49 (0) 421 3503-0
Fax +49 (0) 421 3503-393
E-mail: gestra@flowserve.com

We hereby declare that the pressure equipment RK 41, 44, 44s,
DN 65-100, RK 71 PN 16, DN 65-100; RK 70 PN 6, DN 200, conform
to the following European Directive:
EC Pressure Equipment Directive (PED) No. 97/23 of 29 May 1997
GESTRA non-return valves are pressure equipment as defined in
article 1, section 2.1.4 of the PED.
Applied conformity assessment procedure: Module H as described in
Annex II and III.
This declaration is no longer valid if modifications are made to the
equipment without consultation with us.
Bremen, 27. 05. 2002
GESTRA GmbH
Academically qualified engineer
Uwe Bledschun
Head of the Design Dept.
Academically qualified engineer
Lars Bohl
Quality Assurance Representative

LK/FK02..

Pressure gauge

Pressure Gauges
Service intended
All stainless steel pressure gauge.
Suitable for corrosive environments and gaseous or liquid media
that will not obstruct the pressure system.
Design
EN 837-1
Nominal size
63, 100 and 160 mm
Accuracy class per EN 837-1 /6
63 mm: 1.6
100 and 160 mm: 1.0
Scale ranges per EN 837-1 /5
63 mm: 0 ... 1 to 0 ... 1000 bar
100 mm: 0 ... 0.6 to 0 ... 1000 bar
160 mm: 0 ... 0.6 to 0 ... 1600 bar
or other equivalent units of pressure or vacuum.
Working pressure
63 mm: Steady: of full scale value
Fluctuating: B of full scale value
Short time: full scale value
100 and 160 mm: Steady: full scale value
Fluctuating: 0.9 x full scale value
Short time: 1.3 x full scale value
Operating temperature
Ambient: -40 ... +60 C
Medium: +200 C maximum
Temperature effect
When temperature of the pressure element deviates from
reference temperature (+20 C):
max. 0.4 %/10 K of true scale value
Ingress protection
IP 65 per EN 60 529 / IEC 529
Standard features
Pressure connection
Material: stainless steel 1.4571
Threaded entry (radial or back) per EN 873-1 /7.3
63 mm: G B (male), 14 mm flats
100 and 160mm: G B (male), 22 mm flats
Pressure element
Material: stainless steel 1.4571
< 100 bar: C-type
100 bar: helical type
Movement
Stainless steel
Stainless Steel Series Model 232.50
Bourdon Tube Pressure Gauges
PM 02.02
Approval German Lloyd
Dial
White aluminium with black lettering,
63 mm with pointer stop pin.
Pointer
Black aluminium
Case
Natural finish stainless steel,
with pressure relief in case top (63 mm)
or in case back (100 and 160 mm).
Ranges 10 bar with compensating valve to vent case.
Window
Laminated safety glass
Bezel ring
Cam ring (bayonet type), natural finish stainless steel
Optional extras
- Other pressure connection
- 3-hole surface or panel mounting flange, stainless steel
- 3-hole panel mounting flange, stainless steel, polished
- Triangular bezel, stainless steel, with clamp
- Alarm contacts (see data sheet AE 08.01)
- Transmitter (model 232.30 with combined Transmitter model
89X.34, see data sheet PM 02.04 and AE 08.02)
Special versions
Ammonia gauges (100 and 160 mm)
Scale in C for refrigerant R 717 (NH
3
),
Pressure range: -1 ... 0 ... 15 bar or
-1 ... 0 ... 26 bar
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.
WIKA Alexander Wiegand GmbH & Co. KG
Alexander-Wiegand-Strae
.
63911 Klingenberg
( (0 93 72) 132- 0
.
Fax
(0 93 72) 132 - 406 / 414
http://www.wika.de
.
E-mail: info@wika.de
Nominal
size
Dimensions
[mm]
Weight
[kg]
a b b b D D e f G h 1 SW
63 9.5 33 33 57 63 62 11.5 - G B 54 14 0.16
100 15.5 49.5 49.5 83 101 99 17.5 30 G B 87 22 0.60
160 15.5 49.5 49.5 83 161 159 17.5 50 G B 118 22 1.10
Standard pressure entry with parallel thread and seating to EN 837-1 /7.3.
State:
Pressure gauge model / Nominal size / Scale range / Size and location of connection / Optional extras required
Dimensions
Standard version
100 mm, radial bottom pressure entry 100 mm, lower back pressur e entry
2 1 1 2
3) 2) 2)
W

8
6
3

G
B

1
5

1
2
.
0
0

C
M

9
0
1
9

7
2
3

P
r
i
n
t
e
d

i
n

G
e
r
m
a
n
y
1)
1) Centre back pressure entry
2) Plus 16 mm with pressure ranges 100 bar
3) Plus 16 mm with pressure range 1600 bar
1520 806.03 1520 814.03
10 bar with compensating valve
> 10 bar without compensating valve
10 bar with compensating valve
> 10 bar without compensating valve
Ordering information
Alexander-Wiegand-Strae 30
63911 Klingenberg Germany
Phone (+49) 93 72/132-0
Fax (+49) 93 72/132-406
E-Mail info@wika.de
www.wika.de
A. Hawlik
Leiter Logistikzentrum 2
Manager Production and Logistics
W. Hnerth
Leiter Qualittssicherung
Quality Assurance Manager
2
4
7
3
9
7
2

0
3
/
2
0
0
3
Konformittserklrung
Richtlinie 97 / 23 / EG
"Druckgerterichtlinie"
Wir erklren in alleiniger Verantwortung, dass
nachstehend genannte Produkte,
Druckmessgerte mit Rohrfeder,
gem gltigem Datenblatt mit der Richtlinie berein-
stimmen und dem Konformittsbewertungsverfahren
Modul H (Umfassende Qualittssicherung)
unterzogen wurden.
Directive 97 / 23 / EC
"Pressure Equipment Directive (PED)"
We declare under our sole responsibility,
that the products,
bourdon tube pressure gauges,
according to the current data sheet correspond with
the directive and were subjected to the conformity
assessment procedure Module H (full quality
assurance).
Dclaration de Conformit
Directive 97 / 23 / CE
"Directive Equipements sous Pression"
Nous dclarons sous notre propre responsabilit que,
les produits nomms ci-aprs
"manomtres tube manomtrique"
selon la fiche technique en vigueur, correspondent la
directive et ont t soumis au procd d'valuation de
conformit Module H (assurance de la qualit
globale).
*) fr maximal zulssigen Druck (PS) > 200 bar
Angewandte Norm:
EN 837-1 "Druckmessgerte mit Rohrfeder"
Die Bewertung und berwachung des Qualitts-
sicherungssystems erfolgt durch die benannte Stelle
TV Sddeutschland Bau und Betrieb GmbH
(Kennzeichen CE 0036).
*) for maximum allowable pressure PS > 200 bar
Applied standard:
EN 837-1 "Boudon tube pressure gauges"
Assessment and monitoring of the quality system
by notified body TV Sddeutschland Bau und
Betrieb GmbH (mark CE 0036).
*) pour pression maxi autorise (PS) > 200 bar
Norme utilise:
EN 837-1 "manomtres tube de Bourdon"
L'valuation et la surveillance du systme de gestion
de qualit sont effectues par le ci-nomm "TV
Sddeutschland Bau und Betrieb GmbH"
(numro d'immatriculation CE 0036).
WIKA- Daten-
Typ blatt *)
131.11 PM 01.05
131.12 PM 01.06
131.15 PM 01.07
212.20 PM 02.01
213.20 PM 02.01
232.50 PM 02.02
262.50 PM 02.02
233.50 PM 02.02
263.50 PM 02.02
232.30 PM 02.04
262.30 PM 02.04
233.30 PM 02.04
263.30 PM 02.04
211.11 PM 02.07
232.35 PM 02.11
212.53 PM 02.12
213.53 PM 02.12
WIKA- Daten-
Typ blatt *)
233.53 PM 02.12
232.36 PM 02.15
233.36 PM 02.15
231.11 PM 02.17
213.54 APM 23X.54
232.54 APM 23X.54
262.54 APM 23X.54
233.54 APM 23X.54
263.54 APM 23X.54
312.20 PM 03.01
311.11 PM 03.02
331.11 PM 03.02
341.11 PM 03.03
342.11 PM 03.03
332.11 PM 03.04
332.30 PM 03.05
333.30 PM 03.05
WIKA- Data-
Model sheet *)
131.11 PM 01.05
131.12 PM 01.06
131.15 PM 01.07
212.20 PM 02.01
213.20 PM 02.01
232.50 PM 02.02
262.50 PM 02.02
233.50 PM 02.02
263.50 PM 02.02
232.30 PM 02.04
262.30 PM 02.04
233.30 PM 02.04
263.30 PM 02.04
211.11 PM 02.07
232.35 PM 02.11
212.53 PM 02.12
213.53 PM 02.12
WIKA- Data-
Model sheet *)
233.53 PM 02.12
232.36 PM 02.15
233.36 PM 02.15
231.11 PM 02.17
213.54 APM 23X.54
232.54 APM 23X.54
262.54 APM 23X.54
233.54 APM 23X.54
263.54 APM 23X.54
312.20 PM 03.01
311.11 PM 03.02
331.11 PM 03.02
341.11 PM 03.03
342.11 PM 03.03
332.11 PM 03.04
332.30 PM 03.05
333.30 PM 03.05
WIKA- Fiche
Type technique *)
131.11 PM 01.05
131.12 PM 01.06
131.15 PM 01.07
212.20 PM 02.01
213.20 PM 02.01
232.50 PM 02.02
262.50 PM 02.02
233.50 PM 02.02
263.50 PM 02.02
232.30 PM 02.04
262.30 PM 02.04
233.30 PM 02.04
263.30 PM 02.04
211.11 PM 02.07
232.35 PM 02.11
212.53 PM 02.12
213.53 PM 02.12
WIKA- Fiche
Type technique *)
233.53 PM 02.12
232.36 PM 02.15
233.36 PM 02.15
231.11 PM 02.17
213.54 APM 23X.54
232.54 APM 23X.54
262.54 APM 23X.54
233.54 APM 23X.54
263.54 APM 23X.54
312.20 PM 03.01
311.11 PM 03.02
331.11 PM 03.02
341.11 PM 03.03
342.11 PM 03.03
332.11 PM 03.04
332.30 PM 03.05
333.30 PM 03.05
D GB F

LK/FK01

Thermometer

Thermometers
TM 32.02
V- Form Model 32
Machine Glass Thermometer
Service intended
Universal application in plant, machine, tank and apparatus construc-
tion as well as for central and large heating systems.
Measuring principle
Liquid expansion
Limit of error
DIN 16 195
Pressure rating of stem
6 bar maximum (without thermowell)
Stem
10 mm diameter
6.5 mm diameter with NS 200 x 36 with union nut M 24 x 1.5
Case
Aluminium, brass colour anodised
Lettering
printed with special ink, protected by anodised finish
Thermometer glass insert
Rod shape, prismatic capillaries
Nominal size
110, 150 and 200 mm
Approval German Lloyd*
* only straight design and 90 angle design
2
Nominal size 110 x 30 mm
Standard features
Design of connection
Connection E, male thread
Straight design ( DIN 16 181 )
Male thread
G A, M 20 x 1.5 (Form B to DIN )
G A, M 16 x 1.5 (Form B1 to DIN )
Male thread screwed into case
Length of stem l
1
= 30, 40, 63, 100, 160, 250 or 400 mm
Cu-alloy
90angle design ( DIN 16 182 )
Male thread
G A, M 20 x 1.5 (Form S to DIN )
G A, M 16 x 1.5 (Form S1 to DIN )
Male thread inserted into case, removable
Length of stem l
1
= 30, 40, 63, 100, 160, 250 or 400 mm
Cu-alloy
135angle design
Male thread
G A, M 20 x 1.5
G A, M 16 x 1.5
Length of stem l
1
= 30, 40, 63, 100, 160, 250 or 400 mm
Cu-alloy
Standard features
Straight design ( DIN 16 185)
Male thread
G A, M 20 x 1.5 (Form B to DIN )
G A, M 27 x 2
Length of stem l
1
= 63, 100, 160, 250 or 400 mm
Cu-alloy
90 angle design ( DIN 16 186 )
Male thread
G A, M 20 x 1.5 (Form S to DIN )
G A, M 27 x 2
Length of stem l
1
= 63, 100, 160, 250 or 400 mm
Cu-alloy
135 angle design
Male thread
G A, M 20 x 1.5
G A, M 27 x 2
Length of stem l
1
= 63, 100, 160, 250 or 400 mm
Cu-alloy
Scale ranges
Scale range
C
Scale
spacing
C
Limit of error
C
Thermometric
liquid
- 30 ... + 50 2
0 ... 60
1
1.5
0 ... 100
0 ... 120
2 2
0 ... 160 4 4
0 ... 200 5 5
blue, wetting
Models
Model Location of stem DIN
G 3200 straight DIN 16 181
W 3201 90 angle DIN 16 182
W 3202 135 angle -
Scale ranges
Scale range
C
Scale
spacing
C
Limit of error
C
Thermometric
liquid
- 60 ... + 40 2 red, wetting
- 30 ... + 50
2
0 ... 60
1
1.5
0 ... 100
0 ... 120
2
0 ... 160
0 ... 200
2
4
blue, wetting
Models
W 3211 90 angle DIN 16 186
W 3212 135 angle -
3
TM 32.02
Standard features
Male thread
G A, M 27 x 2 (Form B to DIN )
Length of stem l
1
= 63, 100, 160, 250 or 400 mm
Cu-alloy
Male thread
G A, M 20 x 1.5 (Form S1 to DIN )
G A, M 27 x 2 (Form S to DIN )
Length of stem l
1
= 63, 100, 160, 250 or 400 mm
Cu-alloy
135angle design
Male thread
G A, M 27 x 2 (Form B to DIN )
Length of stem l
1
= 63, 100, 160, 250 or 400 mm
Cu-alloy
Design of connection (of choise)
Connection no. 3, union nut
Union nut
G , M 20 x 1.5 (Form C1 to DIN )
G , M 27 x 2 (Form C to DIN )
M 24 x 1.5 (Form F to DIN )
Connection piece screwed into case, removable
Length of stem l
1
Form C1: l
1
= 89, 126, 186, 276 or 426 mm
Form C: l
1
= 93, 130, 190, 280 or 430 mm
Form F: l
1
= 155, 215, 275, 295, 355 or 415 mm
Union nut and connection piece in Cu-alloy, tube in St. 35 steel
Union nut
Connection piece inserted into case, removable
Length of stem l
1
Form C1: l
1
= 89, 126, 186, 276 or 426 mm
Form C: l
1
= 93, 130, 190, 280 or 430 mm
Form F: l
1
= 155, 215, 275, 295, 355 or 415 mm
Union nut
Connection piece screwed into case, removable
Length of stem l
1
Form C1: l
1
= 89, 126, 186, 276 or 426 mm
Form C: l
1
= 93, 130, 190, 280 or, 430 mm
Form F: l
1
= 155, 215, 275, 295, 355 or, 415 mm
Optional extras (for all nominal sizes)
- Dual scale F/C
- Other scale ranges
- Male thread made of other materials
- Thermowells per DIN (see data sheet TM 90.01)
made of Cu-alloy, steel, stainless steel or other materials
Scale ranges
Scale range
C
Scale
spacing
C
Limit of error
C
Thermometric
liquid
- 60 ... + 40 red, wetting
- 30 ... + 50
2
0 ... 60 1.5
0 ... 100
0 ... 120
1
2
0 ... 160
0 ... 200
2 4
blue, wetting
Models
W 3221 90 angle DIN 16 190
W 3222 135 angle DIN 16 191
Specifications and dimensions given in this leaflet are correct at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.
Alexander-Wiegand-Strae
.
63911 Klingenberg
( (0 93 72) 132 -0
.
Fax
(0 93 72) 132 -406 / 414
http://www.wika.de
.
E-Mail: info@wika.de
Dimensions in mm
Nominal
size
a
1
a
2
B d d
1
G G
1
H H
1
SW
Weight in kg
22 G 3/8 A
21 M 16 x 1.5
22
26 G A
110 44 20 30 10
25 M 20 x 1.5
- 110 130
27
0.250
26 G A
25 M 20 x 1.5
27
G A
150 46 21 36 10
32
M 27 x 2
- 150 170
32
0.300
26 G A G
25 M 20 x 1.5 M 20 x 1.5
27
G A G
10
32
M 27 x 2 M 27 x 2
200 46 21 36
6.5 - - M 24 x 1.5
200 220
32
0.350
Ordering information
State: Model / Nominal size / Scale range / Design and size of connection / Length of stem I
1
/ Optional extras required
3073 106.01
3073 114.01
Design of connection no. 3, union nut (only with nominal size 200)
( Basic connection for thermowells per DIN, Form CD, CE,CS )
3073 130.01
3073 181.01
Dimensions
Design of connection E, male thread
Straight 90 angle 135 angle
Straight 90 angle 135 angle
3073 092.01
3073 122.01
9
0
1
6
0
2
3

G
B

2
0

V
O
L

0
7
.
0
1

Pressure gauge and test valve

FK 02
LK 08....

LV/FV03

Ball valve

Operating, Assembly and Maintenance Recommendation
for Ball Valves

Index: Page

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

- 1 -

1. General:

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

2. Safety instructions:

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

3. Transport:

- Valves should be transported to the building site in a firm packing.
- Do not attach cranes or elevators to the handle or to any mounted drive to prevent damage.
- Check valves for any transport damage immediately upon delivery and report as necessary.
We assume no liability for transport damages that have not been duly reported.

- 2 -

4. Storage:

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

5. Functioning:

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

6. Installation:

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

- 3 -

7. Initial operation

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

8. Maintenance:

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

9. Troubleshooting:

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

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

- 4 -

FV28

Safety valve

Betriebsanleitung Operating instructions
Ausgabe Februar 2002 February 2002 edition
Instructions de service Instrucciones de servicio
Edition fvrier 2002 Edicin febrero 2002
Das Sicherheitsventil
NPS
Inlet
N
P
S
O
u
t
l
e
t
H
do
a
DN
Eintritt
b
D
N
A
u
s
t
r
i
t
t
1
5
7
8
60
56
55
54
12
9
16
18
40
Betriebsanl.A1 d(U1-17)+ U4 15.02.2002 9:20 Uhr Seite 1
E
18
NPS
Inlet
N
P
S
O
u
t
l
e
t
H
do
a
DN
Eintritt
b
D
N
A
u
s
t
r
i
t
t
1
5
7
8
60
56
55
54
12
9
16
18
40 Lifting device
Adjusting screw
Spring plate
Bonnet
Spindle
Spring
Stud bolt
Hexagonal nut
Seal
Guide
Plate
Seat
Body
Betriebsanl.A2 e(18-33) 15.02.2002 9:38 Uhr Seite 2
1 Contents
1 Contents 19
2 General 19
3 Testing/marking 19
4 Pressure 20
5 Function of the safety valve 20
6 Functional tightness of the safety valve 21
7 Medium 21
8 Temperature of the medium and
environmental temperature 22
9 Choice of spring 22
10 Safety valves with bellows 23
11 Safety valves built into installations 23
11.1 Open bonnet 23
11.2 Regular lifting operation 23
11.3 Forces acting on the safety valve 23
11.4 Connections 23
11.5 Orientation of safety valves 24
11.6 Flow-through 24
11.7 Condensation 24
11.8 Transfer of vibrations from the
installation 24
11.9 Discharge pipe 25
11.10 Unfavourable environmental conditions 25
11.11 Leaks caused by impurity 25
11.12 Protection during storage and
transportation 25
11.13 Corrosion protection 25
11.14 Maintenance 25
11.15 Identification of safety valves 25
11.16 Lever safety valves 25
12 Setting instructions for spring loaded safety
valves 26
12.1 Lifting device H3 26
12.2 Lifting device H4 26
12.3 Spring replacement 26
13 Handling 27
14 Supplementary loading system 27
15 Combined Safety Valve and Bursting Disc 28
16 Unexpected conditions 28
17 Product overview 28
18 Declarations of Conformity 30
2 General
The following general notes refer to directly
loaded and controlled safety valves (with supple-
mentary loading system).
In order for a safety valve to be able to fulfil the
purpose for which it is installed, all components
are manufactured to great precision. Only this
precision allows precise functioning. Safety
valves must therefore be handled with care.
Failure could endanger people, animals and
installations. Even a correctly functioning safety
valve can cause hazards, and this has to be taken
into account.
The following risks could ensue:
a.) The safety valve does not work correctly or is
dimensioned wrongly: the pressure equip-
ment bursts. Hazard caused through the
bursting itself and by the hot, poisonous and
aggressive medium.
b.) The safety valve operates correctly: medium
escapes: danger from hot, poisonous and
aggressive medium.
c.) The safety valves leaks: danger from hot,
poisonous and aggressive medium.
d.) Other dangers caused through the handling
of safety valves: these are, e. g., risk of injury
from sharp edges, heavy weight, ...).
In order to minimise the risks from these hazards,
the operating instructions must be adhered to at
all times. They have been developed through
practical experience and from the requirements
dictated by the regulations. As a rule these
regulations must always be adhered to with
priority over the recommendations given below.
Sets of rules:
Pressure Vessel and Steam Boiler Ordinance
TRD 421, 721,
TRB 403, 801 No. 45,
AD-Merkbltter,
Pressure Equipment Directive 97/23/EC,
ASME Code,
API 526, 520
and others
We are in possession of the appropriate product-
related certificates to certify that the sets of rules
are satisfied and therefore to certify safety.
LESER is certified pursuant to DIN EN ISO 9001
(quality management systems), pursuant to DIN
EN ISO 14000 (envi ronmental management
system) and Module D of the Pressure Equipment
Directive (quality assurance in production). This
ensures that all quality requirements and the
environment are complied with.
3 Testing/marking
After setting and testing, each safety valve is
sealed by LESER or by the expert of an official
acceptance organisation at the customers re-
quest (such as TV, Germanischer Lloyd, ...).
If the marking is brought up by means of an im-
pact stamp, etc., the safety valve may not be
damaged. Deformations may lead to leakage or
the destruction of the safety valve. An impact
stamp should not be used especially with thin
walls.
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19
Safety valves have a type test approval plate with
the following data:
- data of order
- technical data
- test pressure
- VdTV type test approval number
- CE marking and identification number of the
notified body
- further information such as the UV stamp with
safety valves approved by ASME
For safety valves without type test approval, only
the order data and technical data are included.
Further marks required are either cast in, or, for
safety valves with threaded connections, punch-
ed in. Safety valves with a heating jacket receive
a separate plate for the heating jacket.
If technical changes are made, it should always
be checked to see whether the identification has
to be adjusted. Only trained personnel may make
changes on valves and identifications (refer to
section 11.14).
4 Pressure
Definitions:
a.) Test pressure: the pressure that LESER sets
the safety valve at. There is ambient pressure
on the outlet side of the safety valve.
b.) Set pressure: the pressure at which the safety
valve responds to the plant.
c.) Opening pressure: the pressure where the
safety valve drains the recognised mass flow
(this may also be given as the difference from
the set pressure in % opening pressure
difference).
d.) Reseating pressure: the pressure where the
safety valve closes complete (this may also
be gi ven as the di fference from the set
pressure in % blow down).
e.) Operating pressure: the pressure that the
plant is constantly run with.
f.) Built-up back pressure: pressure built up on
the outlet side by flow losses when blowing
off.
g.) Superimposed back pressure: the pressure in
the discharge line when this is part of a
system with pressures greater than the am-
bient pressure.
h.) Back pressure: the total of built up and su-
perimposed back pressure.
Pressure shall be stated as overpressure [bar g or
psig] above ambient pressure.
If not stated otherwise, LESER always sets the
set pressure specified by the customer at ambi-
ent pressure on the outlet side (test pressure =
set pressure).
If there is a pressure on the outlet side (super-
imposed back pressure), this produces a force
exerted on the rear side of the disc. This in-
creases set pressure by exactly the value of this
pressure. If the superimposed back pressure is
constant, it is possible to set the differential
pressure by reducing the test pressure by the
back pressure (test pressure set pressure).
If there is no superimposed back pressure, the
set pressure drops. The back pressure provided
may not be exceeded because then it would also
fall below the set pressure.
The maximum pressure that a safety valve may
be operated with regardless of the test pressure
depends upon a number of factors. Among them
are:
- the selection of materials
- the medium temperature
- the design pressure
- the flange pressure stages
- miscellaneous
This should be taken into consideration when
selecting the safety valve.
The operational pressure must in the long-term
be a least 5 % below the reseating pressure.
Otherwise it cannot be guaranteed that the valve
will close securely after working (exception: if the
valve is fitted with an supplementary loading
system, refer to section 14).
5 Function of the safety valve
It is necessary to have a performance certificate
to ensure that it is possible to drain the required
mass flow from the safety valve if necessary.
Pipes going to the safety valves have to be fitted
in such a way as to prevent large hydrodynamic
losses, and the edges at the pipe inlet should be
at least chamfered but preferably rounded. The
notes on dimensioning given in the regulations,
standards and manufacturers information sheets
must be adhered to.
The functi on of safety val ves may onl y be
switched off with shut-off elements if it is ensured
that the appropriate pressure device is protected
against overpressure by other safety equipment
or is not in operation.
Flawless functioning is guaranteed to the built-up
back pressure on the outlet side of a maximum of
15 % of the test pressure minus the super-
imposed back pressure (if available).
Built-up and superimposed back pressures may
be compensated up to 35 % of the set pressure
with a stainless steel bellows specially designed
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20
for it because the force exerting itself on the rear
side of the disc is compensated for. The function
and set pressure remain constant. If it is not clear
whether the bel l ows compensates for back
pressure, LESER shoul d be contacted. The
application limits of the bellows for pressure and
temperature may not be exceeded (refer to
section 10).
If discharge lines have equipment that prevents
rainwater or foreign matter from penetrating, this
equipment may not obstruct the safety valves in
freely and completely blowing off.
The blow-off pipe has to be dimensioned using
the max. back pressure and the corresponding
temperature. It should be laid in a streamlined
fashi on and shoul d not be opposi te other
branches to ensure that it does not impair func-
tioning or cause damage to the safety valve. The
flowthrough and the functioning of safety valves
have also to be guaranteed if blow-off systems
have multiple uses.
During blowing-off, reaction forces work on the
safety valve itself, the pipes connected to it and
the fixed mounts. The size of the reactive force is
particularly important for the dimensioning of the
fixed mounts.
The following points have to be taken into con-
sideration:
- static, dynamic or thermal loads from the pipe
leading to or from the safety valve must not act
on the valve.
- Safety valves must be fixed as defined in the
drawing. Omitting or removing mounts can
result in damage if as a result excessively high
forces or tensions occur.
- Refer also to section 11.3.
6 Functional tightness of the safety valve
One has to expect a slight leakiness with all
safety valves with metallic seals. Persons, the
envi ronment and i nstal l ati ons must not be
endangered by the escaping medium.
Safety valves with soft seals seal much more
reliably than those with metallic seals. LESER
offers a range of elastomer materials for different
applications. The elastomers must be matched to
the medium and its pressure and temperature.
All LESER products are inspected for damage
and leaks. In order to prevent damage during
transportation all products are packed with
protectors on flange sealing surfaces, sealing lips
and threads. They should be removed before as-
sembly (refer to section 11.12).
Before mounting the valve in the installation it
must be visually inspected and then its tightness
shoul d be checked whi l e the i nstal l ati on i s
switched on.
Sealing surfaces are precisely machined. The
ti ghtness i s achi eved, e. g., by hardeni ng,
tempering, precise grinding and lapping. This
makes safety valves vulnerable to impact, so they
may develop leaks as a result of vibrations. The
following notes are to be observed:
- During transportation, fitting and operation
safety val ves must be protected from
vibrations.
- Safety valves must be transported with care.
E. g., the lever must never be used as a carrying
handl e and the safety val ve must not be
dropped.
The force between the seat and the disc falls as a
function of rising operating pressure. Therefore the
probability of leaks also rises when the operating
pressure is close to the set pressure (refer to
section 4). Damaged or contaminated sealing
surfaces in particular tend to develop leaks.
7 Medium
Any moving parts have to be protected from
abrasive/corrosive media as then the danger
develops of seizure or sticking. This can be done
by servicing the valve each time it has operated
or by the use of stainless steel/elastomer bellows.
The limits of application for the bellows have to
be observed.
The possibility of leaking sealing surfaces in the
case of abrasive media must be considered.
Dangerous media must not enter the environ-
ment. In doubt the safety valve must be replaced
after it has operated.
Soft sealing discs can compensate for minor
damage to the seat. In every case the limits of
application and medium consistency for the
elastomer material have to be observed.
The strength of individual components (e. g.,
body, spindle, spring, ...) can be decreased
through abrasion. This may lead to leaks or to the
pressure equipment bursting. If abrasive media
occur, shorter servi ce i nterval s shoul d be
observed.
The sealing surfaces must not stick together.
This can be prevented by:
- regular lifting operation (refer to section 11.2)
- heating or cooling to prevent the seat from
sticking
- other measures which prevent sticking.
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21
Corrosion damage to body components and
internal components cannot be spotted easily in
all cases. Therefore it must be ensured that the
media to be secured do not attack the materials
the safety valve is made from. If this possibility
cannot be excluded, monitoring and servicing
have to be adapted to this situation accordingly.
Special materials can be selected on request.
Lubricants based on mineral oils are used as an
aid during installation and without special pre-
cautions they will get in contact with the medium.
The following points have to be observed:
- Lubri cants/auxi l i ary medi a can reach the
medium and contaminate it or cause a chemical
reaction.
- Lubricants can be washed out and make the
dismantling of the safety valve more difficult.
- Safety val ves can be desi gned as oi l and
grease-free types. For these types the surfaces
are cleaned from all residues containing mineral
oil and specialist lubricants are used.
- Bellows prevent the contact of medium and
lubricant.
8 Temperature of the medium and
environmental temperature
Minimum and maximum temperatures are given
for LESER safety valves. They always refer to the
medium temperature that may simultaneously be
the ambient temperature. Therefore, the ambient
temperature has to be taken into consideration
under extreme climatic conditions such as in
Scandinavia.
It is necessary to observe the influence of the
medium temperatures on the maximum permitted
pressure. If expansion limits drop at higher
temperatures or if it tends to be brittle at low
temperatures, this lowers the maximum permitted
temperatures. Please observe the regulations in
the appropriate sets of rules and the manufac-
turers specifications.
If the safety valve is supposed to be insulated,
the bonnet and the cooling zones (if there are
any) have to be free to prevent the springs from
heating up impermissibly.
In case of setting the pressure of safety valves
and ambient temperatur, they can be adjusted for
working at an increased temperature by making
use of a correcti on factor. Thi s makes i t
unnecessary for the valve to be adjusted at the
i ncreased temperature, ( procedure: Col d
differential test pressure acc. to the LESER com-
pany standard LWN 001.78).
During the operation of safety valves, media can
freeze, which prevents opening and closing. This
can happen if the temperature falls below the
freezing point of the medium with media that
congeal i n col d the vi scosi ty may drop
significantly or if there are freezing vapours
contained in the medium. Icing-up is increased
by the expansion of gases as this causes the
temperature to fall further. If there is a danger of
icing, measures must be taken to ensure that the
safety valve works correctly.
Contact with hot or dangerously cold safety valve
surfaces must be prevented by appropriate
protective measures.
9 Choice of spring
The springs used by LESER are designed for
defined pressure ranges. The test pressure is
always the basis for selecting the spring (refer to
section 4). The functioning of the springs is
ensured if the spring is designed and used in
conformity with the sets of rules. When dismant-
ling the valves, the springs must not be swapped
as the functioning will be impaired if the wrong
spring is installed.
In extreme cases the spring will be fully com-
pressed (the turns touch each other) and then the
safety valve cannot work.
When changing the test pressure it must be
checked whether the spring/springs can be used
at the new pressure. This can be done by using
actual LESER spri ng tabl es. If they are not
available LESER has to be contacted. If the
spring does not permit the new test pressure it
must be replaced by a valid spring. Changed test
pressures always require that the whole safety
valve and its dimensioning are checked.
LESER spri ngs are marked unambi guousl y.
Springs which no longer can be identified or
damaged springs must not be used.
Spri ngs must not be reused i f i t cannot be
estimated how many load changes they have
experienced. This applies in particular to springs
from safety valves which have been exposed to
vibrations, as in this case the actual number of
l oad changes i s practi cal l y i mpossi bl e to
estimate.
The springs in LESER safety valves have been
coordinated with the material in the safety valve
with reference to the material. In unfavourable
cases, there may be influences leading increased
temperature or corrosion that make the following
actions necessary:
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22
Temperature influences:
As spring temperatures can depend on many
external conditions, no general temperature of
the medium can be specified as the limit of
application. They are always specific to the
installation and a judgement has to be made as
to which of the following measures need to be
taken:
- Using spring materials that are heat resistant or
tough at subzero temperatures
- Providing test pressure with a correction factor
to compensate for dropping set pressures at
higher temperatures (refer to section 8 for cold
adjustment)
- By the uti l i sati on of hi ghl y heat resi sti ng
materials in conjunction with cooling zones,
open bonnets and bellows, the effect of the
temperature on the spring is reduced.
Corrosion effects:
- Medium may get into the spring spaces if safety
valves do not have bellows. Corrosive/abrasive
media reduce the fatigue strength. This should
be taken into consideration with selecting,
designing and servicing.
- Spri ng materi al s wi th i ncreased corrosi on
resistance are possible (e. g., stainless steel,
Hastelloy, ...)
10 Safety valves with bellows
The pressure and temperature application limits
of bellows shall be complied with.
Defecti ve bel l ows are recogni sabl e by the
medium leaking out of the open bonnet or the
vent hole. Hazards from leaking medium must be
prevented.
Measures against leaking medium:
- Equi ppi ng the val ve wi th an i nspecti on
manometer and a drip container.
- In the case of open bonnets, the leaking of the
medium cannot be prevented if the bellows are
defective. Hazards have to be prevented, (e. g.,
by a sufficient safety distance, protective in-
stallations, utilisation only for harmless media).
Defective bellows must be replaced immediately
in order to secure the correct working of the
safety valve.
Stainless steel bellows for which the number of
load changes has been exceeded, or is unknown,
must be replaced. As a rule bellows should be
replaced whenever the valve is dismantled.
Moisture or dirt must not be allowed to enter into
the bonnet vi a the vent hol e. Appropri ate
protective measures (e. g., connections, pipes, ...)
must be taken.
11 Safety valves built into installations
11.1 Open bonnet
For open bonnets or lever valves, appropriate
measures must be taken to avoid contact with
movable parts (e. g., the spring) as otherwise
there is a danger of jamming. Medium can leak
out of the open bonnets or open spindle guides
of lever safety valves. It must be ensured that
l eaki ng medi um cannot cause hazards. A
sufficient safety distance has to be observed.
11.2 Regular lifting operation
Safety valves must be vented regularly in order
to check their functioning and to remove any
deposits. They can be opened if at least an
operating pressure of 85 % of the set press-
ure is present. Exceptions can only be allowed
if the functioning is checked regularly in a
di fferent way, e. g., by appropri ate short
servicing intervals. The valid regulations for the
application of safety valves have to be adhered
to.
After venting, the lever must move freely, i. e.
the lifting fork in the lifting device is not acting
on the spindle cap.
11.3 Forces acting on the safety valve
No high static, dynamic or thermal tensions
may be transmitted to the safety valves.
These can be caused by:
- Installation under tension (static)
- Reaction forces when blowing off (static)
- Vibrations (dynamic)
- Temperature expansion (thermal)
The following measures have to be taken:
- System must be able to expand
- Pipes of the installation must not be attached
in such a way that tensions are created.
- Utilisation of the safety valve brackets for
secure attachment to the installation.
- Preventing the installation from vibrating.
11.4 Connections
The connections/seals between the safety valve
and the plant shall be sufficiently sized. They
also have to be designed in accordance with
the sets of rules to prevent the connection from
failing (also refer to section 4 and 8 for this).
LESER is not responsible for the correct fitting
of seals for pipes leading into the valve and
pipes for blowing-off or other connections to
the safety valves. Therefore LESER will not
accept any liability for these.
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For the correct fitting one has to ensure that the
flange sealing surfaces are not damaged during
installation.
11.5 Orientation of safety valves
Confirmation by the TV Nord:
Directly-loaded safety valves are to be installed
in accordance with AD-A2 upright with respect
to the flow direction:
In addition AD-A2 requires that safety valves
must correspond to the state-of-the-art and be
suitable for the purpose for which they are
deployed.
Under the following conditions it is possible to
deviate from the upright installation direction,
and in our view it is also permissible.
E. g., the safety valves have been granted type
approval for horizontal installation and a note to
this effect is found in the VdTV-Merkblatt.
Adequate experience of installation in applica-
tions in an orientation other than upright is
available over an extended period. Therefore
this type of installation can be allowed after
discussion between operator, manufacturer and
the technical inspector who authorises the
installation. If applicable, additional measures
may need to be taken wi th regard to thi s
installation.
Therefore safety valves may, according to the
information provided above, be installed in
directions other than the one specified in AD-
A2.
If the conditions mentioned above have been
ful fi l l ed, the fol l owi ng poi nts have to be
observed when installing the valve in a direction
other than the upright direction.
- Drainage has to be built in, in order to prevent
medium or condensation from remaining in
parts which are important for the function of
the valve.
- The servicing has to be modified, e. g., the
functioning of the drainage has to be gua-
ranteed.
- LESER must be i nformed of the type of
installation in order to be able to agree to an
orientation deviating from upright.
11.6 Flow-through
The flow direction must be observed during
i nstal l ati on. I t can be recogni sed by the
following features:
Flow direction arrow on the body;
diagrams
- In the catalogue,
- In the operating instructions
- In the data sheets and
- In the installation instructions
11.7 Condensation
In the outlet chamber of safety valves or in
parts which are important to their functioning
(spring area, bellows area, ...) no medium or
condensation may remain as this might impair
the functioning of the safety valves.
The following points have to be observed:
- Drainage should always be carried out via the
blow-off pipe, which has to be laid sloping
downwards, downstream of the safety valve
so that it can drain itself (figure 3).
- Immediately downstream of the safety valve,
no upwards bend may be installed as then
correct drainage is not possible (figure 4).
- Bl ow-off pi pe must be provi ded wi th a
sufficiently large condensation drainage pipe,
which must be attached to the lowest point of
the pi pe. For pi pes l arger than nomi nal
diameter 40 the drainage pipe must be at
least of a nominal diameter 25. (In the case of
steam applications even larger diameters may
be necessary. In such cases the regulations
must be observed)
- LESER safety valves are not provided with a
drainage hole as the drainage must take place
via the blow-off pipe.
Excepti ons: Certai n regul ati ons requi re
drainage holes (e. g., on ships with varying
orientation on the water and indefinable pipe
slope). Safety valves which are intended for
such purposes are equipped with a drainage
hole. Such designs are only manufactured if
they are specifically ordered from LESER.
- It is possible to drill a drainage hole later at
the place intended for this purpose.
Caution: swarfs can cause damage which
may lead to leaks or to the failure of safety
valves.
- Drai nage pi pes must be l ai d sl opi ng
downwards and without waisting. It must be
possible to observe the outlet freely, any risks
the l eaki ng medi um may cause must be
prevented (e. g., through condensation steam
traps, drip container, filters, ...).
- Drainage holes without function must be
closed.
11.8 Transfer of vibrations from the installation
Any vibrations which might be transferred to the
safety valve must be prevented. Where this is
not possible the safety valve must be de-
coupled from the installation, e. g., via bellows,
pipe bends, ....
Pressure variations or surges in the medium
also can lead to dangerous vibrations of the
safety valve. This also has to be avoided.
Where the transfer of vibrations cannot be
prevented, damping systems can be built in,
e. g., o-ring dampers.
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11.9 Discharge pipe
When a safety valve is blowing off, in addition
to the general hazards from the medium, the
following hazards have to be expected
(refer to section 2):
- High flow rates
- High temperatures
- Noise emissions
In this context the following has to be observed:
- For steam or gases the blow-off pipe should
point upwards in order to allow blowing off
without danger.
- For liquids the blow-off pipe should point
downwards so that the medium can com-
pletely drained out of the blow-off chamber.
- The outlet flange of safety valves or the blow-
off pipe must point in such a direction that no
danger is caused by the medium blowing out.
These are the options:
- Blowing off into a container
- Safety valve and blowing-off pipes without
direct access
- Design with silencer
11.10 Unfavourable environmental conditions
All LESER safety valves which could corrode
are painted with a protective coating during
manufacture which protects the safety valve
during storage and transportation. In corrosive
environments a further corrosion protection is
required (refer to section 11.13). Under extreme
conditions, we recommend stainless steel
safety val ves. The suppl ementary l oadi ng
system may not be given a protective coating.
Media from outside (e. g., rain water or dirt/dust)
in the blowing-off pipe and near components
important for the operating (e. g., guides with
open bonnets) have to be avoided. By analogy,
the statements made in section 7 apply.
Simple preventive measures are possible:
- Protection of the blow-off chamber from
extraneous media and dirt
- Protection of the parts important to operating
from extraneous media and dirt.
11.11 Leaks caused by impurity
Impurities must not remain in the installation
(e. g., welding beads, sealing material such as
hemp/Teflon tape, screws, etc.). One option for
avoiding extraneous bodies in the system is to
rinse the system before commissioning.
In the case of leaks caused by contamination
between the sealing surfaces, the safety valve
can be vented to clean the surfaces. If this does
not remove the leak, one of the sealing surfaces
is probably damaged. In this case the safety
valve has to receive maintenance.
11.12 Protection during storage and transportation
All protective devices for transportation and
handling have to be removed before installing
the safety valve.
After installation, the protection for the lever
must be removed from the bonnet as otherwise
the safety valve cannot be vented. The lever
must move freely, i. e. it must be in its initial
position and the coupling at the spindle must
not be connected to the lever.
In the case of lever safety valves, the wooden
wedge, which protects the sealing surfaces
from damage during transportation, has to be
removed.
11.13 Corrosion protection
Moving parts and parts important to the oper-
ating must not be impaired. E. g., the blowing-
off chamber and the spindle guide must not be
varnished.
The additional load must not be coated with
protective paint (refer also to section 14).
11.14 Maintenance
Safety valves may only be serviced by skilled
staff.
LESER cannot speci fy the mai ntenance
intervals as they depend on many factors:
- Corrosive, aggressive and abrasive media
lead to rapid wear and shortened mainten-
ance intervals
- Frequent operating shortens the maintenance
intervals
- Maintenance intervals have to be agreed
between the operator, the inspector and the
manufacturer. Inspections must be carried out
at the time of the regular outside and inside
examinations of the pressure equipment.
11.15 Identification of safety valves
Before fitting safety valves the documentation
must be checked in order to ensure that the
correct valve has been selected for fitting.
11.16 Lever safety valves
The set pressure of l ever safety val ves i s
defined by the mass and the position of the
loading weights. It is not allowed to change
them.
Additional loading weights must not be added.
It is not allowed to use the lever to hang on any
parts, e. g., clothes, ...
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25
12 Setting instructions for spring loaded
safety valves
The following operating instructions only apply to
valves without additional equipment. If there is
additional equipment (such as O-ring dampers,
proximity switches, bellows, ...), please refer to
the corresponding assembly instructions.
12.1 Lifting device H3
Remove shaft (45).
Pull lever (43) out to the side.
Loosen hexagonal head screw (84).
Unscrew and remove lever cover (41).
Loosen lock nut (19).
1)
Turn adjusting screw (18) to the required set
pressure.
Pay attention to the admissible pressure range
of the spring!
Clockwise turning of adjusting screw increase
the spring tension, giving a higher set pressure.
Anti cl ockwi se turni ng of adj usti ng screw
reduces the spring tension, giving a lower set
pressure.
Reassemble in reverse order and lock at the set
pressure.
Figure 1
12.2 Lifting device H4
Loosen the spring cover (41) and simultan-
eously press the lever (43) in the direction of the
bonnet so that the lifting fork (44) comes free.
Remove the lever cover (41).
Loosen the lock nut (19).
1)
Turn adjusting screw (18) as described in
lifting device H3. Pay attention to the ad-
missible pressure range of the spring!
Reassemble in reverse order and lock at the set
pressure.
Figure 2
12.3 Spring replacement
The following items refer to the figures shown
on pages 3/40-3/42 of the LESER complete
catalogue.
1. Loosen the existing lead seal.
2. Press the lever (43) towards the middle until it
reaches the stop so that the lifting fork (44) no
longer holds the spindle cap (46).
3. Loosen and remove the lever cover (41).
4. Loosen the spindle cap (46) from the spindle (12),
remove the securing ring (91) and the pin (74).
5. Loosen the lock nut (19) of the adjusting screw
(18).
6.
1)
Turn the adjusting screw (18) anticlockwise to
remove all spring tension.
7. Remove the hex. nuts (56) from the flange of the
bonnet (9).
8. Lift off the bonnet (9).
9. Remove the uper spring plate (16).
10. Lift off the spring (54) and remove lower spring
plate (16) and split rings (14).
11. Remove spindle (12) with guide (8) and disc (7).
12. Carefully clean seat (5) and disc (7), and if re-
quired body internals.
13. Refit spindle (12) with guide (8) and disc (7).
14. Fit the split rings (14) into spindle groove and
retain with the securing ring (59); slip on lower
spring plate (16) to locate on split rings (14).
15. Replace spring (54).
16. Slip on the upper spring plate (16) onto the
spindle (12).
17. Align adjusting screw (18), and bonnet (9). over
the spindle (12) and refit.
18. Fit and tighten the hex. nuts (56).
19.
1)
Load the spring (54) to obtain the required set
pressure. Clockwise rotation of adjusting screw
(18) increases pressure. Anticlockwise rotation of
adjusting screw (18) reduces pressure.
20. Tighten the lock nut (19) onto the adjusting screw
(18).
21. Refit and secure spindle cap (46) by pin (74) and
securing ring (91).
22. Screw-on the lever cover (41).
23. Pull the lever (43) towards the middle so that the
lifting fork (44) is pushed under the spindle cap
(46).
24. Test spindle will lift correctly by pulling lever.
These instructions are applicable for relief valves,
safety valves and safety relief valves.
1)
Caution: During all work the spindle has to be
secured against twisting in order to prevent dam-
age to the sealing surfaces.
E
26
18
41
45
43
84
19
41
44
19
18
43

To be observed:
The pressure setting is wire-locked and sealed
against unauthorized alteration. The rules of
the TV, agreed by the manufacturer, require
the fitting of a type test approval plate stating
the correct valve data. The manufacturer
cannot be held responsible for any changes to
set pressure or other alterations after despatch
from our factory. I n case of necessary
modifications we recommend returning the
valve to our supervision of the TV or any
suitable inspecting authority.
13 Handling
There is a risk of injury from sharp edges and
burrs. For this reason all parts have to be handled
with caution.
There is a risk from safety valves falling over.
They always have to be secured adequately.
Duri ng di smantl i ng the spri ng must not be
tensed. Otherwise there is the danger of injury
from fl yi ng parts. Observe the i nstal l ati on
instructions for the relevant safety valves!
Before dismantling is must always be checked
whether there is, or could be, any, and if it is the
case which, medium there is inside the bonnet.
High risk of injury, chemical burns or poison-
ing if there is any remaining medium inside the
safety valve.
One should use conventional high quality tools in
order or minimise the risks arising from bad
quality or mismatched tools. Any necessary
special tools are indicated in the installation
instructions
Safety val ves may onl y be di smantl ed and
assembled by skilled staff.
The training can be carried out:
- In the workshop by experienced staff
- At LESER in training seminars
- By means of LESER documentation, e. g., vi-
deos, operation instructions, catalogues, insta-
llation instructions
The maintenance staff must be informed about
the risks during dismantling and installing the
safety valves.
Contamination and damage to the safety valve
must be avoided. Suitable cartons, protective
covers for the flanges, transportation foil, trans-
portation palettes, ... are to be used. The pack-
agi ng must be compl etel y removed before
installation as otherwise the function of the safety
valve cannot be guaranteed.
The safety valves have to be handled with caution
as otherwise the vulnerable sealing surfaces can
be damaged or the safety valve might even be
rendered useless.
Safety valves must be stored in a dry place. The
optimum storage temperature is 2 C to 40 C. In
the case of o-ring discs temperatures below
freezing should if possible be avoided. The
temperature resistance, in particular of the o-ring
materials, has to be taken into account.
Upper limit for storage: 50 C
Lower limit for storage: -10 C
14 Supplementary loading system
Even if the external energy supply (compressed
air) fails, the direct-loaded safety valve is still fully
functional. In this case the function is equivalent
to the LESER standard safety valve without
supplementary loading system.
The compressed air filter must be serviced at
regular intervals. This is carried out as specified
in the maintenance specifications.
The installation should contain an air dryer. The
compressed air should have a dew-point of min.
+2 C.
The maximum pressure of the air supply is 10
bar, the minimum pressure is 3.5 bar. If the
pressure rises above or falls below that specified
interval, this may lead to temporary or permanent
faulty operating of the additional load. Result: the
safety valve does not function or it will work as a
standard valve without the supplementary loading
system.
The supplementary loading system should be
serviced and checked at least once a year by
specially trained staff. For this essential work
LESER offers a maintenance service which may
be incorporated in a service agreement. Training
and experience with handling the additional load
in combination with the safety valves are abso-
lutely necessary.
The supplementary loading system has to be
fi tted i n accordance to the regul ati ons and
specifications distributed by LESER. If correctly
serviced, failures due to contamination of the
pressure and control lines are impossible.
The control unit is to be protected from conta-
mination. It has to be ensured that it is always
closed. For special applications LESER offers an
encapsulated box enclosing the control unit.
The actuator on the safety valve itself must be
protected from contamination like the sliding
parts inside an open bonnet. Otherwise there is
the danger of jamming.
E
27
28
Temperatures:
The controls and drives are designed for appli-
cation between 2 C and 60 C.
- At temperatures above 60 C the compressed
air connections must be as long as possible
and equipped with a water seal.
- The control unit and the actuator have to be
positioned in such a location that their temper-
ature will not exceed 60 C.
- At a temperature below 2 C there may the
danger of icing up, therefore it may be nece-
ssary to heat the control unit the control lines
and tapping lines.
The supplementary loading system is connected
to the safety valve via a coupling. The coupling
must not be blocked by objects. It is neither
necessary nor permitted to apply a protective
coating to the drive.
The pressure tapping lines must not be blocked.
If there are locking devices they have to be
designed in such a way that they cannot be
closed, e. g. by means of locking bars or seals.
LESER control units are equipped with a locking
device for maintenance purposes. They are
secured against locking by means of a locking
bar. This locking bar must not be removed.
The pressure swi tches are wi re-l ocked and
sealed. This seal indicates that the setting has
not been changed. Al l mani pul ati ons of the
pressure swi tches are not permi tted (e. g.,
opening the seal and modifying the adjustment,
opening the switching contacts, ...)!
If a locking screw called test gag is used during
the pressure testing of the installation it must be
removed after the pressure test.
15 Combined Safety Valve and Bursting Disc
The type test approval of the combination of
bursting discs of a certain manufacturer with
LESER safety val ve ensures that both the
functional and performance requirements are
complied with. You may enquire at LESER which
combinations are tested.
If it has been certified that combinations of
LESER safety valves and bursting discs of other
manufacturers satisfy the safety requirements,
they are permissible. This shall be certified in
each individual case.
The following should especially be observed:
- Operating instructions for the bursting disc.
- Safety val ves may not be swi tched off by
placing the bursting disc upstream.
- The intermediate space between the rear side
of the bursting disc and safety valve inlet
should be monitored.
- The alignment of the bursting disc: It should be
designed in such a fashion that it is not possi-
ble for it to be improperly aligned.
- The bursting disc has to be free of fragments,
bursting disc components may not get into the
inlet connecting pieces of the safety valve thus
impairing functioning.
- Sets of rules with reference to bursting discs
(AD-A1, ASME, ...)
16 Unexpected conditions
Not all errors can be always prevented up to
100 %.
However, their consequences must be estimated
and reduced by:
- A risk analysis for the complete installation
- An estimate of the risk with the possible dam-
age that can be caused
- Instructions about the measures to be taken in
the case of a fault occurring
- Staff training at the manufacturers and at the
operators
- Protective measures for people and for the
environment.
17 Product overview
Refer to section Declaration of conformity
The manufacturer reserves the ri ght of
technical changes and improvements at any
time.
In detail the type-specific assembly instructions
have to be observed.
E
E
29
wrong!
Figure 4
correct!
Figure 3
add. drain pipe in case of
prepared drain hole
Das Sicherheitsventil/The Safety Valve
LESER GmbH & Co. KG
Hamburg, HRA 82 424 Hausanschrift/Home address Fon +49 (40) 251 65-100 Bank
PhG: Gebr. LESER Verwaltung GmbH, D-20537 Hamburg, Wendenstr. 133-135 Fax +49 (40) 251 65-500 Vereins- und Westbank AG, Hamburg
Hamburg, HRB 38 577 Postanschrift/Postal address e-mail: sales@leser.com USt-IdNr./VAT-No.: BLZ 200 300 00, Konto 3203171
GF/BoD: Martin Leser, Wolfgang Gorny D-20506 Hamburg, P.O. Box 26 16 51 www.leser.com DE 118840936 SWIFT: VUWB DE HH
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Declaration of Conformity/Konformittserklrung
in acc. to the pressure equipment directive 97/23/EC
nach Druckgerterichtlinie 97/23/EG
LESER GmbH & Co. KG
Wendenstrasse 133-135
D-20537 Hamburg/Germany
Name and address of the manufacturer/Name und Anschrift des Herstellers
Type*
Nominal size
Nennweite
EC-type examination no.
EG-Bauteilprfnummer
Type*
Nominal size
Nennweite
EC-type examination no.
EG-Bauteilprfnummer
411 20 - 150 / " - 6" 07 202 0111Z00080/02 462 15 - 20 / " - 1" 07 202 0111Z00080/14
421 25 - 100 / 1"- 4" 07 202 0111Z00080/03 532 + 534 20 - 50 / " - 6" 07 202 0111Z00080/15
424 25 - 200 07 202 0111Z00080/04 538 10 / " 07 202 0111Z00080/16
427 + 429 15 - 150 / " - 6" 07 202 0111Z00080/05 539 10 - 15 / " - " 07 202 0111Z00080/17
431 + 433 15 - 150 / " - 6" 07 202 0111Z00080/06 543 + 544 50 - 100 / 2" - 4" 07 202 0111Z00080/18
440 20 - 150 07 202 0111Z00080/07 546 25 - 100 / 1" - 4" 07 202 0111Z00080/19
441 + 442 20 - 400 / " - 16" 07 202 0111Z00080/08 483, 484, 485 25, 40 / 1" - 2" 07 202 0111Z00080/20
447 25 - 100 / 1" - 4" 07 202 0111Z00080/09 437, 438, 481 ", ", 07 202 0111Z00080/21
448 25 - 100 / 1" - 4" 07 202 0111Z00080/10 700 -- 07 202 0111Z00080/22
455 + 456 25 - 100 / 1" - 4" 07 202 0111Z00080/11 522 50-100/2" 4" 07 202 0111 Z00080/23
457 + 458 25 - 150 / 1" - 6" 07 202 0111Z00080/12 450/460 15-20/" 1" 07 202 0111 Z00080/24
459 10 - 20 / " - 1" 07 202 0111Z00080/13 488 25-100/1"- 4" 07 202 0111 Z00080/25
Description of the pressure equipment/Beschreibung des Druckgertes * See name plate/siehe Prfschild
Kategorie IV/Category IV
Applied category in acc. to article 3 and annex II/Angewandte Kategorie nach Artikel 3 und Anhang II
Module/Modul
Conformity assessment procedures/
Konformittsbewertungsverfahren
Certificate number/
Bescheinigungsnummer
B EC type-examination/EG-Baumusterprfung See table/siehe Tabelle
D/D1 Production quality assurance/Qualittssicherung Produktion 07 202 0111Z00080/01
Conformity assessment procedures in acc. to article 10/Angewandte Konformittsbewertungsverfahren nach Artikel 10
TV CERT - Zertifizierungsstelle fr Druckgerte der TV NORD GRUPPE
Identification number: 0045, Grosse Bahnstrasse 31, D-22525 Hamburg/Germany
Name and address of the notified body (monitoring a.m. conformity assessment procedures)
Name und Anschrift der benannten Stelle (Zertifizierung/berwachung nach o.g. Modulen)
The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this
pressure equipment meet the requirements of the pressure equipment directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prfung dieses
Druckgertes den Anforderungen der Druckgerterichtlinie entsprechen.
At the moment no harmonized standards available/zurzeit keine harmonisierten Normen verfgbar
Applied harmonized standards/Angewandte harmonisierte Normen
TRB 801. 45, AD-Merkblatt A2, TRB 403, TRD 421, TRD 721, DIN 3320, DIN 3840, VdTV 100
AD 2000-Merkblatt A2, AD 2000-Merkblatt A4
Other applied standards or technical rules/Andere angewandte Normen oder technische Spezifikationen
14.12.2001
Date Manufacturer stamp Authorized subscriber
3
8"
LESER GmbH & Co. KG
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LESER GmbH & Co. KG
Type*
Material/
Werkstoff
Nominal
size/
Nenn-
weite
Description of
pressure
equipment/
Benennung des
Druckgertes
Applied category in
acc. to article 3 and
annex II/
Angewandte
Kategorie nach Artikel
3 und Anhang II
Conformity assessment
procedures in acc. to
article 10/
Angewandte
Konformitts-
bewertungsverfahren
nach Artikel 10
CE-
marking/
CE-Kenn-
zeichnung
DN25
Art. 3 Par. 3
Art. 3 Abs. 3
Not necessary
Nicht erforderlich
No
Nein
310
1.0619
GS-C 25
GP 240 GH
1.4408
X5 CrNiMo19-11-2
DN40,
DN50
Change-over
Valve
Wechselventil
Cat. II
Kat. II D1
Yes
Ja
Module/Modul
Certificate number/
D1 Production quality assurance/Qualittssicherung Produktion 07 202 0111Z00080/01
Certificate number of module D1/Zertifikatsnummer Modul D1
The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this pressure
equipment meet the requirements of the pressure equipment directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prfung dieses Druckgertes
den Anforderungen der Druckgerterichtlinie entsprechen.
DIN EN 1503-1, DIN EN 10213-1, DIN EN 10213-2, DIN EN 10213-4
DIN 3840
14.12.2001
LESER GmbH & Co. KG
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LESER GmbH & Co. KG
Type*
Material/
Werkstoff
Nominal
size/
Nenn-
weite
Description of
pressure
equipment/
Benennung des
Druckgertes
Applied category in
acc. to article 3 and
annex II/
Angewandte Kategorie
nach Artikel 3 und
Anhang II
Conformity assessment
procedures in acc. to article
10/
Angewandte Konformitts-
bewertungsverfahren nach
Artikel 10
CE-
marking/
CE-Kenn-
zeichnung
DN15-
DN50
Art. 3 Par. 3
Art. 3 Abs. 3
Not necessary
Nicht erforderlich
No
Nein
0.6025
GG-25/
GJL-250
DN65-
DN100
Kat. I
Cat. I
A
Yes
Ja
DN15-
DN32
Art. 3 Par. 3
Art. 3 Abs. 3
Not necessary
Nicht erforderlich
No
Nein
612
1.0619
GS-C 25/
GP 240 GH
DN40-
DN100
Pressure Reducer
Druckminderer
Kat. I
Cat. I
A
Yes
Ja
Module/Modul
Certificate number/
D1 Production quality assurance/Qualittssicherung Produktion 07 202 0111Z00080/01
Certificate number of module D1/Zertifikatsnummer Modul D1
The signing manufacturer confirms by this declaration that the design, manufacturing and inspection of this
pressure equipment meet the requirements of the pressure equipment directive.
Der unterzeichnende Hersteller bescheinigt hiermit, dass Konstruktion, Herstellung und Prfung dieses
Druckgertes den Anforderungen der Druckgerterichtlinie entsprechen.
DIN EN 1503-1, DIN EN 1503-3, DIN EN 10213-1, DIN EN 10213-2
DIN 3840, DIN 1691, DIN EN 1561
14.12.2001
LESER GmbH & Co. KG, Hamburg
D-20537 Hamburg, Wendenstrasse 133-135 Fon +49 (40) 251 65-100
D-20506 Hamburg, Postfach/P.O.Box 26 16 51 Fax +49 (40) 251 65-500
www.leser.com e-mail: sales@leser.com
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Betriebsanl.A1 d(U1-17)+ U4 15.02.2002 9:24 Uhr Seite 18
Anschlsse
NPT Gewindeanschlsse
Gewindemuffen
Flanschanschlsse nach DIN/ANSI
Weitere Anschlsse auf Anfrage
Connections
NPT screwed connections
female screwed connections
flange connections acc. to DIN/ANSI
further connections on request
Eintrittskrperwerkstoff Temperatureinsatzgrenze
1)
Artikelnummer
Inlet body material Temperature range
1)
Article number
DIN EN ASME DIN EN ASME
d
o
[mm]
Werkstoffbezeichnung Werkstoff-Nr. von bis von bis
Material Designation Material No. from to from to
[C] [F] [C] [F] [C] [F] [C] [F]
X 14 CrMoS 17 1.4104 430F -10 +14 +220 +428 -29 -20 +220 +428 4373 .260* .261*
X 2 CrNiMo 17-12-2 1.4404
1) 2)
316L -270 -454 +280 +536 -268 -450 +280 +536 4374 .312* .314* .315*
Normal-Feder-Sicherheitsventil
Safety Relief Valve spring loaded
fr Dmpfe, Gase und Flssigkeiten
for steam, gases and liquids
Type 437
mit Anlftung H4, gasdicht,
Teller anlftbar
lifting device H4, gastight,
disc liftable
Long Version Standard Long Version
9
* Bitte hier gewnschte Ziffer fr Kappe oder Anlftung anfgen:
2 = Kappe H2 4 = Anlftung H4 (gasdicht)
1)
Zwischen -10 C und der niedrigsten, angegebenen Anwendungstemperatur
ist gem AD-Merkblatt W10 zu verfahren.
nderungen behalten wir uns vor.
* Please add number for the required cap or lifting device:
2 = Cap H2 4 = Lifting device H4 (gastight)
1)
Between -10 C and lowest temperature indicated AD-Merkblatt W10 shall be
taken into account.
Modifications reserved.
6 10
Leser 416.5/S. 9/10 neu 22.02.2002 9:28 Uhr Seite 1
4373 4374
Chromstahl/chrome steel korrosionsfest/corrosion resistant
kaltzh/cryogenic
Pos. Bauteile Parts Werkstoff Nr. ASME Werkstoff Nr. ASME
Item material no. material no.
1 Eintrittskrper Body (base) 1.4104 430F 1.4404
1)
316L
1)
2 Austrittsgehuse Outlet body 1.4104 430F 1.4404 316L
7 Teller Disc 1.4122 420RM 1.4404
1)
316L
1)
12 Spindel Spindle 1.4021 420 1.4404 316L
16 Federteller Spring plate 1.4104 430F 1.4404 316L
18 Druckschraube Adjusting screw 1.4104 430F 1.4404 316L
mit Buchse with bush PTFE + 15 % Glas PTFE + 15 % Glas
54 Feder Spring 1.4310 302 1.4310 302
40 Kappe H2 Cap H2 1.0718 steel 1.4404 316L
Anlftung H4 Lifting device H4 1.4104 430F 1.4404 316L
1)
d
o
6 gepanzert
1)
d
o
6 stellited
9
Werkstoffe /Materials
When the switch operates in systems according to DESINA standard, switching point SP2 has to be
programmed as monitoring function: Enter the value (error output) in programming step and
the value (normally closed function) in programming step .
In case of error idendification (see menu) a diagnosis signal is automatically actuated on the alarm
display on the front panel and on switching point SP2 (pin 2).
Electrical
connections
1. Product description
2. Starting operations
Intended Applications
- The dual pressure switch is a device to monitor system pressure and has up to two switching outputs
and one analog output.
- The dual temperature switch is a device to monitor media temperature into which the probe is immersed
and has up to two switching outputs and one analog output..
- According to DESINA
standard.
- The instruments must only be installed in systems where the maximum pressure Pmax or the maximum
temperature Tmax is not exceeded (according to the values on the type label).
- (only TempSwitch 2000) when the rotable display is adjusted the switch has to be fixed with the allen
screw at the front side with a 3 Nm torque (allen key 1,5 mm).
- Attention: This device is not designed to be used as the only safety relevant element in pressurized
systems according PED 97/23/RC.
Only assemble or disassemble the device when depressurized!
Connecting the switch
- Mount the pressure switch from bottom to the fitting with a wrench hex 36 (1/4) resp. 19 with 45 Nm
torque.
- Electrical connection depends on the type of pressure switch (see type label) according to the
chart below.
Art.-Nr.: 923-1092
Index D, 14. 02. 2004
Software version: V 2.1 and higher
Specifications are subject to
changes without notice.
Electrical connections (scheme)
1 4
The pressure switch should be installed and operated only by authorized persons. After being switched on
the UDS 7 runs through a self-test. The device is menu operated and configured with three keys on the
front. With the M key (= mode) you change between the dialog values and the adjusted / actual values.
With the keys = up and = down you change between the dialog values in the menu or change
the values / functions in the menues (see below: List of functions).
If the dialog is not continued within two minutes the device automatically returns to the measuring mode.
When the software lock is entered, LOCK appears in the display when an attempt is made to change
values.
Programming:
Operation:
DESINA conformity:
* SP2 = Diagnosis output (DESINA
-version)
Operating Instructions Dual Pressure Switch Switch 2000
and Dual Temperature Switch TempSwitch 2000
Dimensions
(in mm)
Switch 2000 TempSwitch 2000
Dimensions
(in mm)
Barksdale GmbH
Dorn-Assenheimer Strasse 27
D-61203 Reichelsheim / Germany
Tel.: +49 - 60 35 - 9 49-0
Fax: +49 - 60 35 - 9 49-111 and 9 49-113
e-mail: info@barksdale.de
www.barksdale.de
Pin 1
Pin 2
Pin 3
Pin 4
+Ub (12 ..32 V DC)
-
0 V
SP1 (0,5 A max.)
Plug
M 12 x 1,
4-pin
Model with 1
switching output
Model with 2
switching outputs
(DESINA
)
+Ub (12. ..32 V DC)
SP2 (0,5 A max.)
0 V
SP1 (0,5 A max.)
Model with 1
switching output
and 1 analog output
+Ub (12...32 V DC)
analog
0V
SP1 (0,5 A max.)
The setting menu is activated with the mode key. The dialog items are selected with the and keys.
If the mode key is pressed again the corresponding value for the dialog item is shown and can be altered
with the and keys. If the dialog with the unit is not continued within two minutes the device auto-
matically returns to the measuring mode without accepting the new values.
To terminate programming more quickly, you can switch back to the measuring mode (primary menu)
from any item in the menu by holding the M-key pressed for five seconds.
If the key lock has been activated, the values can be shown, but no changes made. ( appears in the
display when an attempt is made to change values). The key lock is activated by pressing the and
keys simultaneously for at least five seconds. Press again to deactivate the key lock again.
M12 x 1
c
a
.
1
2
1
1
8
1
2
G 1/4
hex 36
30
M12 x 1
1
2
1
1
0
1
2
G 1/4
1
7
6
SKT 19
*
(Temp)
Switch
2000
(Temp)
Switch
2000
Plug 4-pin,
M12 x 1
List of functions: Switch 2000
Dialog item Value Description
0...400 Display of the actually measured value
... Activation unit display
= unit display on (every 30 sec)
= no unit display
... = window technology
= standard evaluation
0...xxx Switch-on point for SP1; if the ON value is smaller than the OFF value
the switching point evaluation is falling
0...xxx Switch-off point for SP1
Switch-on / switch-off delay for SP1 in seconds
... Inversion of switching output SP1
= high-level-fail-save (normally open function)
= low-level-fail-save (normally closed function)
Only models with 2nd switching contact:
... = window technology
= standard evaluation
0...xxx Switch-on point for SP2; if the ON value is smaller than the OFF value
the switching point evaluation is falling
0...xxx Switch-off point for SP2
Switch-on / switch-off delay for SP2 in seconds
... Inversion of switching output SP2
= high-level-fail-save (normally open function)
= low-level-fail-save (normally closed function)
3
= error output
= error output
= no error
= exceeding pos. meas. range
= exceeding pos. meas. range
= sensor error
= error switching output 1
= error switching output 2
= data error (EEProm)
= program error
= calibration error
= error analog out
... Select the display unit Switch 2000 TempSwitch 2000
= Fahrenheit = mPa = bar
= psi x 10
= mbar
= hPa = Celsius
= psi
Only models with analog output:
0...xxx Scale the analog output - start value (e. g. 0 bar = 4 mA)
0...xxx Scale the analog output - end value (e. g. 400 bar = 20 mA)
(output signal start value always corresponds to the display initial value,
e. g. 0 bar = 4mA)
Maximum turn-down 4 : 1, i.e. at values below 25 % of the measuring
range the analog output is switched off
0...xxx Display of peak value Max (xxxx: = max. 125 % f. s.)
... Delete the maximum value memory
= no deletion
= delete value
List of functions: Switch 2000
Dialog item Value Description
Error display:

LV10

2/3 way valve
manual
operation

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

FV01.
LV07.
Butterfly valve

0040000082 4000 englisch
BR 012 - ZESA
BR 013 - GESA
1.0 General information on

operating instructions .............................................2
2.0 Notes on possible dangers .......................................2
2.1 Signicance of symbols ................................................ 2
2.2 Safety-related denitions .............................................. 2
2.3 Qualied personnel ....................................................... 2
3.0 Handling...................................................................3
3.1 Storage .......................................................................... 3
3.2 Transport ....................................................................... 3
3.3 Handling before installation.......................................... 3
4.0 Descriptions..............................................................3
4.1 Scope of applications .................................................... 3
4.2 Operating principles...................................................... 3
4.3 Diagram - assembly ...................................................... 4
4.4 Actuation arrangements ................................................ 4
4.5 Technical data - remarks ............................................... 5
4.6 Marking..........................................................................5
5.0 Installation................................................................6
5.1 General remarks on installation.....................................6
5.2 Installation of accessories ..............................................6
5.3 Conversion from lever with detent to clamping lever....7
5.4 Retrotting the THErmo-Appliance (THEA)................8
6.0 Notes on dangers during installation, operation
and maintenance......................................................8
7.0 Putting the valve into operation .............................9
8.0 Care and maintenance.............................................9
9.0 Troubleshooting .......................................................9
10.0 Troubleshooting table..........................................10
11.0 Dismantling the valve ..........................................11
12.0 Warranty ..............................................................11
13.0 EC declaration of conformity /
Manufacturers declaration.................................12
Operating and installation instructions
Buttery valves
Contents
page 2 00400000082 4000
Butterfly valves
1.0 General information on operating instructions
These operating instructions contain information necessary to install and operate the valve both safely
and effectively.
If problems arise which cannot be solved with the aid of these operating instructions, please contact the
supplier/manufacturer for further information. These operating instructions comply with applicable EN
safety standards as well as regulations and codes of practice applicable in the Federal Republic of
Germany. If the valve is used outside the Federal Republic of Germany, the operator or the person
responsible for the system design must ensure that valid national codes of practice are complied with.
The manufacturer reserves all rights to implement technical modications and improvements at any
time.
The use of these operating instructions assumes the user is qualied as described under Section 2.3
"Qualied Personnel".
The operating personnel must be instructed in accordance with the operating instructions.
2.0 Notes on possible dangers
2.1 Signicance of symbols
Warning of general danger
2.2 Safety-related denitions
The signal denitions DANGER, WARNING, CAUTION and NOTE are used in these operating
instructions as indications for particular hazards or for important information requiring special signs.
DANGER means that if the relevant information is disregarded, there is a danger of fatal injury and / or
considerable damage to property can occur.
WARNINGmeans that if the relevant information is disregarded, there is a danger of serious injury and
/ or damage to property can occur.
CAUTION means that if the relevant information is disregarded, there is a danger of injury and / or
damage to property can occur.
NOTE means that particular attention must be paid to certain technical aspects.
All other information not specically emphasised such as transport, installation, operating and
maintenance instructions as well as technical data (in the operating instructions, product documentation
and on the device itself) must also be complied with to the fullest extent in order to avoid faults which in
turn can cause serious injury to persons or damage to property.
2.3 Qualied personnel
The term "qualied personnel" relates to persons who are familiarised with installation, assembly, start-
up, operation and maintenance of the product and have the qualications corresponding to their
responsibilities such as:
Instruction and obligation to comply with all operational, regional and in-company regulations and
requirements;
Training or instruction in accordance with safety technology standards with regard to the upkeep and use
of appropriate safety and work protection equipment; First aid training, etc.
(see TRB 700).
00400000082 4000 page 3
Butterfly valves
3.0 Handling
3.1 Storage
- Storage temperature -20 to +65C dry, free of dirt
- The painting is only a primer, intending to guard against rust during stock or transportation. Dont
damage the paintwork.
- A desiccant or heating to prevent condensation is necessary in damp rooms.
3.2 Transport
- Transport temperature -20 to +65C.
- Protect against external force (impact, vibration etc.).
- Dont damage the paintwork.
3.3 Handling before installation
- If ange covers are tted, remove shortly before maintenance!
- Protect against atmospheric conditions e.g. wetness (applicate a desiccant).
- Correct handling protects against damage.
4.0 Descriptions
4.1 Scope of applications
Buttery valves are used to interrupt or restrict the ow of liquids and gases. It is the responsibility of
the plant designer to decide on their use in a specic application. The meanings of special markings on
the valve must be taken into account.
- Valves for inammable, aggressive or toxic media, must be off tensile material.
- With applications for media that demand special criteria, please consult.
- -marking for applications acc. to Pressure Equipment Directive.
4.2 Operating principles
The valve is closed by turning the disc shaft clockwise.
The shaft moves through 90.
page 4 00400000082 4000
Butterfly valves
4.3 Diagram - assembly
4.4 Actuation arrangements
- The detent pin of the lower lever must be fully disengaged to move the lever..
- The star knob screw must be slackened before and tightened again after moving the lever.
g. 1: ZESA
/ GESA
- Buttery valve
g. 2: ZESA
/ GESA
lever with detent

g. 3: ZESA
/ GESA
clamp lever
rotated view
Material designation:
EP = EPDM or
NBR or
FPM
00400000082 4000 page 5
Butterfly valves
- Gear type (actuation by hand wheel, clockwise for closing).
The CLOSE-position can be adjusted by 5 by a stop screw.
The stop screws are self-sealing and self-locking (see Fig. 7).
g. 4: Gear
- See separate operating and maintenance manual for drive (electric or pneumatic).
4.5 Technical data - remarks
- Main valve dimensions
See catalogue sheet.
- Pressures and temperatures
See catalogue sheet.
4.6 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notied body
Typ Type
Bj. Year of manufacture
Manufacturer
According to the Pressure Equipment Directive part 3, valves without safety function are only
allowed to bear the CE-marking DN32 onwards.
Lock nut
Stop screw
Position indicator
page 6 00400000082 4000
Butterfly valves
5.0 Installation
5.1 General remarks on installation
The following points should be taken into account besides the general principles governing installation
work:
- There must be no foreign bodies inside the valve or piping.
- The direction of ow need not be taken into account.
- The shaft can be in any position except for DN350, 400 and 500 (horizontal shaft).
- No gaskets required between anges, exible gaskets are not allowed.
- The buttery valve must be installed in open position, but the disc must not protrude beyond the
housing.
- Corresponding anges must be parallel and in line with the connecting holes.
- The valve must not serve as a xing point. It must be carried by the piping.
- Large actuators with horizontal application must be supported.
- Protect the valve from dirt, especially during construction work.
- Avoid damage to the rubber sheathing during handling, storage and installation.
- Install expansion joints to compensate for thermal expansion of the piping.
- Do not heat the valve (e.g. by welding, grinding, etc.) above its service temperature (see data sheets).
- Protect actuators from excessive ambient temperatures (see operating instructions for actuator).
5.2 Installation of accessories
Optional accessories (e.g. limit switches) supplies with valves must be tted as required for their
functions as shown in the plants of the plant.
00400000082 4000 page 7
Butterfly valves
5.3 Conversion from lever with detent to clamping lever
g. 5
The detent lever cap (8.1) can be used for the conversion.
- Set detent lever (20) to detent position 4.
- Slacken socket screw (20.1) (5 of 6 mm AF).
- Remove detent lever (20).
Note: The position of the valve disc is not positively located!
- Dismantle detend lever cap (8.1) and use a screwdriver to break out the window.
- Put the cap, with the nut (13) in it, in place and tighten it.
- Set the clamping lever (21) in position as shown in the diagram.
- Tighten the socket screw (item 21.1).
- Insert star knob screw (item 40) through the hole at the end of the clamping lever (21) and screw into
the hex. nut (item 13).
If the clamping lever must be on the same side as the original lever with detent, the detent lever cap must
be turned through 180.
For the angle limit stop , an additional nut can be placed in the cap for a locking screw.
Fenster
page 8 00400000082 4000
Butterfly valves
5.4 Retrotting the THErmo-Appliance (THEA)
g. 6
- Remove sticker from the hole in the lever (20).
- Insert the THEA temperature indicator (40) into the hole down to the stop.
6.0 Notes on dangers during installation, operation and maintenance
DANGER !
Operation can be completely safe only if the valve is properly installed, put into operation and
maintained by trained personnel (cf. point 2.3 Qualied personnel) paying full attention to the
warnings in these operating instructions. In addition, the general installation and safety rules for piping
and plant installation must be observed, and appropriate tools and safety equipment are to be used. Strict
attention must be paid to the operating instructions during all work on the valve and when handling it.
Injury or damage can be caused by ignoring them.
When used as an end-blockage, a safety precaution (e.g. plug-in disc, blind ange etc.) is demanded by
maintenance works.
If the buttery valve is in operation as a pipeend valve, regarde DIN EN 294 point 5.
00400000082 4000 page 9
Butterfly valves
7.0 Putting the valve into operation
- Before putting the valve into operation, check that the material, pressure, temperature and direction of
ow are as specied with the plans of the piping system.
- Regard the TRB 700.
- It is forbidden to use tools to increase the torque of the lever or hand wheel.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
DANGER !
Before putting a new plant into operation or restarting a plant after repairs or modication, always make
sure that:
- all installation and assembly work has been completed!
- only trained personnel (see point 2.3) are employed to start the plant!
- the valve is in the correct position for its function!
- existing guards have been attached and in good order.
8.0 Care and maintenance
Maintenance and maintenanceintervals have to be dened by the operator according to the service
conditions (see TRB 700).
It is advisable to actuate the valve at least once a month.
9.0 Troubleshooting
In the event of failures or malfunctions, check that the valve was assembled and installed as described in
these instructions.
Regard the TRB 700.
Compare the material, pressure, temperature and direction of ow with the information given in the
plans of the piping system. Check also that the service conditions correspond to the data given on the
data plate and the technical data.
DANGER !
It is essential that the safety regulations are observed when identifying faults!
If malfunctions cannot be eliminate with the help of the following troubleshooting table, the supplier
or manufacturer should be consulted.
page 10 00400000082 4000
Butterfly valves
10.0 Troubleshooting table
Caution: - Read point 11.0 prior to dismantling and repair work!
- Read point 7.0 before restarting the plant!
Fault Possible cause Corrective measures
No ow Valve closed. Open valve.
Little ow Valve not sufciently open. Open valve.
Strainer sieve clogged. Clean / replace sieve.
Relieve pressure rst!
Observe points 7.0 and 11.0!
Piping system clogged. Check piping system.
Valve is impossible or dif-
cult to open or close
Service conditions (e.g. medium, tempera-
ture) outside permissible limits.
Replace valve. Consult supplier or manu-
facturer.
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 (page 4, Fig. 1-2, item 2) or
valve disc (page 4, Fig. 1-2, item 3) dama-
ged by foreign bodies or medium
Replace valve. Consult supplier or manu-
facturer.
Valve with clamping arran-
gement cannot be opened
Clamping arrangement tightened. Slacken clamping arrangement.
00400000082 4000 page 11
Butterfly valves
11.0 Dismantling the valve
The following points must be observed beside the general principals rules and TRB 700 governing the
assembly work:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inammable, aggressive or toxic media.
- Have assembly work performed only by qualied personnel (see point 2.3).
12.0 Warranty
The extent and period of warranty cover are specied 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 conrmed
application.
No warranty claims can be made for any damage caused as the result of incorrect handling or disregard
of operating and installation instructions, accident prevention regulations, EN, DIN, VDE standards and
other applicable codes of practice.
This warranty also does not cover any damage which occurs during operation under conditions deviating
from those laid down by specications or other agreements.
Justied 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 modications or
natural wear.
Any damage incurred during transport should not be reported to us but rather to the competent cargo-
handling depot, the railway company or carrier company immediately or else claims for replacements
from these companies will be invalidated.
Technology for the Future.
GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schlo Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com
page 12 00400000082 4000
Butterfly valves
13.0 EC declaration of conformity / Manufacturers declaration
EC declaration of conformity
as dened by
the Pressure Equipment Directive 97/23/EC and
Manufacturers declaration
as dened by
the Machinery Directive 98/37/EC
Herewith we declare,
ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, 33756 Schlo Holte-Stukenbrock
that according to the above mentioned Pressure Equipment Directive (PED) and Machinery Directive
the belowlisted products comply and have been approved according to Category III , Module H through
Lloyds Register of Shipping (NB-No. 0525),
Mnckebergstr. 27, 20095 Hamburg
Certicate-No: 50003/1
Buttery valves
ZESA
/ GESA
Type 012, 013

Applied standards:
DIN EN 292
DIN EN 294
DIN EN 349
DIN EN 563
DIN 3230
DIN 3840
If the supplied model is intended to be incorporated into machinery or assembled with other machinery
to constitute machinery covered by this directive and must be put into service until the machinery into
which it is be incorporated has been declared in conformity with the provisions of the EC-Machinery
Directive as amended by 98/37/EC.
Schlo Holte Stukenbrock, 13.12.2001
(Brechmann, Managing director)
...................................................
2
Operating range depends on existing service conditions and technical regulations.
Intermediate values for max. permissible operational pressures can be determined
by linear interpolation of the given temperature / pressure chart from 120C upwards.
Technical data - ARI-ZESA
DN 25 - 65 DN 80 - 100
DN 125 - 150 DN 200
DN 250 - 300 DN 350 - 500
Pressure range: 16 bar
Max. differential 16 bar (DN 25-150)
pressure: 10 bar (DN 200-500)
Sealing leakage test: DIN 3230 T3 Leakage rate 1
Temperature range: EPDM - 10 C to + 130 C
NBR - 10 C to + 80 C
FPM - 10 C to + 150 C
(FPM not for hot water useable)
Body material: GGG-40 0.7040 DN 25/32 - DN 300
GGG-40.3 0.7043 DN 350 - DN 500
Selection of possible applications:
Cold -and cooling water installations Swimming pool-installations
Heating installations Powerstations
Drinking water and domestic water Gas installations
Waste water Shipbuilding
- Other applications on request -
Order text:
ARI-ZESA
- Butterfly valve with eyelets, maintenance free,

soft seal gasket/lining in ........
disc of material-no. .........., PN 6/16, DN .....,
type of actuator ...............
Pressure - temperature - classication
Material PN
Temperature
- 10C 120C 130C 150C
GGG-40 16 16 bar 16 bar 15,8 bar 15,5 bar
GGG-40.3 16 16 bar 16 bar 15,8 bar 15,5 bar
Figure 22.012
Materials Disc / Shaft Lining
DN 80 1.4581 / 1.4021
EPDM
NBR
FPM
DN 100-300 1.4401 / 1.4021
EPDM approval for DIN DVGW Reg. water NW6201AQ2024
NBR approval for DIN DVGW Reg. gas NG-4313AQ1489
water NW6201AQ2024
DN 80 1.4581 / 1.4571
EPDM
NBR
FPM
DN 100-300 1.4571 / 1.4571
DN 350 1.4581 / 1.4571
EPDM approval for DIN DVGW Reg. water NW6201AQ2024
NBR approval for DIN DVGW Reg. gas NG-4313AQ1489
water NW6201AQ2024
Edition 11/02 - Data subject to alteration
3
Figure 22.013
Materials Disc / Shaft Lining
DN 80 1.4581 / 1.4021
EPDM
NBR
FPM
DN 100-300 1.4401 / 1.4021
DN 80 1.4581 / 1.4571
EPDM
NBR
FPM
DN 100-300 1.4571 / 1.4571
DN 350 1.4581 / 1.4571 DN 25 - 65
DN 80 - 150 DN 200
DN 250 - 300 DN 350 - 500
Pressure range: 16 bar
Max. differential 16 bar (DN 25-150)
pressure: 10 bar (DN 200-300)
Sealing leakage test: DIN 3230 T3 Leakage rate 1
Temperature range: EPDM - 10 C to + 130 C
NBR - 10 C to + 80 C
FPM - 10 C to + 150 C
(FPM not for hot water useable)
Body material: GGG-40 0.7040 DN 25/32 - DN 300
GGG-40.3 0.7043 DN 350 - DN 500
Technical data - ARI-GESA
Selection of possible applications:

Cold -and cooling water installations Swimmingpool-installations
Heating installations Powerstations
Drinkingwater and domestic water Gas installations
Waste water Shipbuilding
- Other applications on request -
Order text:
ARI-GESA
- Butterfly valve with threaded eyelets, maintenance free,

soft seal gasket/lining in ........
disc of material-no. .........., PN 10/16, DN .....,
type of actuator ..............
Operating range depends on existing service conditions and technical regulations.
Intermediate values for max. permissible operational pressures can be determined
by linear interpolation of the given temperature / pressure chart from 120C upwards.
Pressure - temperature - classication
Material PN
Temperature
- 10C 120C 130C 150C
GGG-40 16 16 bar 16 bar 15,8 bar 15,5 bar
GGG-40.3 16 16 bar 16 bar 15,8 bar 15,5 bar
Edition 11/02 - Data subject to alteration

FV13/31

Orifice

damko Adjustable Throttle

damko Ventiltechnik GmbH & Co. KG
Langstdter Strae 31
64850 Schaafheim

Telefon (+0049) (0) 6073 72 26 0
Telefax (+0049) (0) 6073 72 26 19
http://www.damko.de
info@damko.de

Index: Adjustable Throttle
English
Page Name
1 Short Reference
2-3 damko-Adjustable Throttle SPB PN 16
4-5 Instructions for the Adjustable Throttle DN 25
1
SHORT INSTRUCTIONS
- SPB
- DAKS-MK/SPB
-LAPTOP with DAKS-Throttle Program
In Conjunction with the damko Adjustable Throttle, a Laptop-PC and the measuring
device DAKS MK/SPB it is possible to measure flow-rates under working conditions.
The power supply of the laptop can be connected directely to the accu of the measuring
device. With this stand alone unit it is possible to make measurements for 4 hours.
In order to measure flow rates with the throttle, the throttle has to be equipped with an
extension adapter.
You can connect the hose coupling of the pressure sensor under working conditions at
every time.
The adjustable throttle can be adjusted during the running process with an Allen key.
The differential pressure sensor is connected to the electronic ADU-card.
In addition you can connect an inlet pressure sensor and a temperature sensor to this
unit.
All measured values will be transfered via the CPU-card and the RS 485 interface to the
laptop PC.
All values can be displayed with the DAKS Throttle Program on the laptop.
All you have to do in addition is to type in the number of turns of the adjusting screw.
All values can be stored in a file.
2

damko-Adjustable Throttle SPB PN 16

damko-Adjustable Throttle helps you to gain
control of mass and voume flow.

With the aid of the diagram you can adjust the
throttle during the running process by means
of an Allen key.

You can use it to fix the outlet pressure of a
pump in accordance with the characteristic
curve of the pump.

You can use it to fix temperatures in a fluid
system.

You can use it as a stop valve in a special
design.

Size (D)
[mm]
Length (B)
[mm]
kvs
[m/h]
Weight [kg]
Steel
CuAl10Ni
DN 25 71 33 6,8 1,4 1,3
DN 32 82 33 15 1,8 1,7
DN 40 92 33 24 2,0 1,9
DN 50 107 43 38 2,1 2,0
DN 65 127 46 52 3,9 3,8
DN 80 142 64 87 5,8 5,7
DN 100 162 64 138 8,9 8,6
DN 125 194 70 275 12,5 12,1
DN 150 218 76 410 15,7 15,2
DN 200 273 89 600 29,2 28,2
DN 250 330 114 1000 57,8 56,0
DN 300 385 114 1440 70,4 68,2

Material of the different versions:

Part Steel Seawater Resistance
Body C45/GSC25N G-CuAl10Ni
Fixed Disk G-16Mn Cr5 G-CuAl10Ni
Control Disk G-16Mn Cr5 G-CuAl10Ni
Adjustable Throttle 1.4571 CuAl10Ni
Bolts 1.4112 CuAl10Ni
Sealing
Adjustable Screw
Perbunan PTFE

Flow Rate of the Adjustable Throttle
DN 50
for Water (20C)
0 1 2 3 4 5 6 7 8 9 10 11
Aperture Angle in Turns of the
Adjusting Screw
0
10
20
30
40
50
60
Water
[m/h]
p =
1 bar
0,1 bar
0,2 bar
0,3 bar
0,4 bar
0,5 bar
0,6 bar
0,8 bar
1,2 bar
1,4 bar
1,6 bar
1,8 bar
2 bar
Close:
Turn right
Open:
Turn left

3
damko-Adjustable Throttle SPB PN 16
D B
Size D
[mm]
B
[mm]
kvs
[m/h]
Weight [kg]
Steel CuAl10Ni
DN 25 71 33 6,8 1,4 1,3
DN 32 82 33 15 1,8 1,7
DN 40 92 33 24 2,0 1,9
DN 50 107 43 38 2,1 2,0
DN 65 127 46 52 3,9 3,8
DN 80 142 64 87 5,8 5,7
DN 100 162 64 138 8,9 8,6
DN 125 194 70 275 12,5 12,1
DN 150 218 76 410 15,7 15,2
DN 200 273 89 600 29,2 28.2
DN 250 330 114 1000 57,8 56,0
DN 300 385 114 1440 70,4 68.2
Materials
Steel Seawater-
Resistance
Body C45/GSC25N G-CuAl10Ni
Fixed Disk :G-16MnCr5 G-CuAl10Ni
Control Disk :G-16MnCr5 G-CuAl10Ni
Adjusting Screw :1.4571 CuAl10Ni
Bolts :1.4112 CuAl10Ni
Sealing
Adusting Screw
:Perbunan PTFE
18
Instructions for the Adjustable Throttle DN 125
1
2
4
5
10
11
18
19
20
21
26
27
28
24
23
3
9
12
The adjustable throttle can be adjusted during the running process. There is no need to remove the
throttle in order to change the flow rate. Before you can adjust the throttle, you have to remove the
screw plug (19) with an 8 mm Allen key.
With the same 8 mm Allen key you can adjust the throttle:
Turn right: The throttle will be closed.
Turn left: The throttle will be opened.
If you reach a stop while adjusting the throttle, please turn the key a little bit back again in order to
prevent canting between the disc and the adjust screw.
With the aid of the diagram you can adjust the throttle in every position. The following diagram
shows the flow rate of water with a temperature of 20C. The number of turns are counted from the
closed position on.
At the end you have to fix the screw plug (19) again.
The smaller screw plugs (18) can be used to mount a differential pressure sensor.
19
Flow Characteristics of the Adjustable Throttle
DN125
for Water (20C)
p =
Close:
Turn right
Open
Turn left
0,1 bar
0,2 bar
0,4 bar
0,6 bar
0,8 bar
1,0 bar
1,2 bar
1,4 bar
1,6 bar
1,8 bar
2,0 bar
0,3 bar
0,5 bar
0 1 2 3 4 5 6 7
Number of Turns
of the Adjusting Screw
0
100
200
300
400
Water
[m/h]
Example: At a Adjusting Screw position of 4,5 turns counted from the fully closed position
off, you can read a flow rate by the diagram of 120 m/h at a pressure difference of 1 bar
between the inlet and the outlet of this throttle. The maximum number of turns is 7.
Dont try to open or to close the throttle with violence - it could destroy the throttle.
Industde
gervlce
Rdesheimer Slrae 119
Pgs$ch 20 01 53
Telefon: 06151/ 600.34 1
/tfll
!t
7t
TUV Techni scl e Ubrwachung Hessen GmbH
64285 Darmstadt
64300 Darmsiadt
Telefax: 06151/ 600-366
Name rd Anschrift
des Hersiellers
Prfbericht
-
Nr.r
Geltungsbereichl
Fedigungssttte:
Bemerl<ungenl
Anlagen: Prfbedcht Nr. 41467506
deE TUV Hessen
Darmstadt, 2006-08-29
Ori, Dalum
,-rljU=..
\rdEEmz
ZERTIFIKAT
Konforinitt m:t der Bauart
(Modul
C1) nach Richtlinie 97lz3lEc
Zrtifikat
-
Nr.: lSDr2-06-0246
damko Ver*llte6hnlk GmbH & Co. KG
Langsldt* 9:ratle 31
D-64850
grhaafhaih
Der He.sleller ist berechtigt, fr die von ihm im Rhmn des Gelllngshe.eichs hergestellten
Druckge#te die CE
-
Kennzeichnung mit unserer Kennummerwi abgsbildatttr vrwendgn:
( ( 0091
41 467506 rur Fertlg!ngsstttenbesirhtigung
damko Segmentplattenvontile DN 32 bjs DN 200
D-64850 Schaafhoim
Die Anwendung dieses Ze.tiflkats zur Fertigung lnd
Abnalnre von Segmenlplattnventilen setzt elne glUge
Beschelr,gung be. ejne EG-Baumusterprrifung vorals.
Diass Zertifikat :st gltig bis Augst 2009
TV Technische bruachung Hssen GmbH
Benannte Stelle Nr.: 0091
6u
n*"*'
0091
,
S1glla
\slrJg $ t..lng. B, Kurth
ilmselge H nweise beachle.

LF01

Strainer

PROTECTION NOTE ACCORDING TO DIN 34 CONSIDER!
1
Location:
System:
+
1
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
maritime assembly systems GmbH
Zum Doc k 3, 23966 Wi smar , Ger many, +49( 0) 3841 3271 - 0
Prep.
Check
mas
mari ti me assembl y systems GmbH
mari ti me assembl y systems GmbH
Zum Dock 3
Germany
info@mas-wismar.com
www.mas-wismar.com
CLIENT: MANUFACTURER:
ORDER No.:
CABINET:
RESPONSIBLE: R.Heidtmann
mas GmbH
PROJECT:
VOLTAGE:
NOMINAL POWER:
CLASS:
DEGREE OF PROTECTION:
COLOR:
MAIN DIMENSION (HxWxD):
NEUTRAL:
SAFETY EARTH:
DARK BLUE H07V-K min. 1,5mm
GREEN/YELLOW H07V-K min. 1,5mm
PHASE: BLACK H07V-K min. 1,5mm
CONTROL VOLTAGE 230VAC:
CONTROL VOLTAGE 0VAC:
CONTROL VOLTAGE 24VDC:
CONTROL VOLTAGE 0VDC:
PLANT:
RED H07V-K min. 0,75mm
DARK BLUE H07V-K min. 0,75mm
WHITE H07V-K min. 0,75mm
LIGHT BLUE H07V-K min. 0,75mm
23966 Wismar
CABLE COLOURS & DIMENSION: (if not marked differently)
TABLE OF CONTENT: COVER SHEET
FRONT VIEW
CIRCUIT DIAGRAM
TERMINAL DIAGRAM
LIST OF APPARATUS
REVISION:
A
B
C
D
E
F
INDEX MODIFICATION DATE NAME
COVER SHEET
FAX: +49 ( 0) 3841 - 7125 - 23
PHONE: +49 ( 0) 3841 - 7125 - 0
MAIN CABINET
DIN40719
7221241
21.11.2007
E-1-7224561
RH
PS
none
RH
COMBINED WATER & LO MODULE
CATERPILLAR
POWER GENERATION SYSTEMS
"KABUL"
Ktr.: 265134, 265135, 265136
CATERPILLAR
=E1 "KABUL"
Ktr.: 265134, 265135, 265136
177kW
400V 50Hz
none
IP 23
RAL 7035
1600x600x400
=E1
MAIN CABINET
7224561_6, 7224541_6, 7224521_6
21.11.2007
1
Location:
System:
+
1
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
Prep.
Check
FRONT VIEW
=
MAIN CABINET
DIN40719
RH
PS
none
RH
CATERPILLAR
=E1
1
6
0
0
Mai n swi t ch
FRONT
SIDE
T1
A0 F2- F4
K1-K10
400 600
Fai l ur e
-
Power suppl y i nd.
- H1
H2
CW Pump pr eheat er
o f f - Au t o m.
CW Pump pr eheat er
I nd. Lamp
S1
H5
H3
H4
CW pr eheat er
St ep 1
CW pr eheat er
St e p 2
X
1
X
2
Q1
H1
S1
H2
H3 H5 H4
X
3
Q1
21.11.2007
7221241
21.11.2007
E-1-7224561
"KABUL"
Ktr.: 265134, 265135, 265136
"KABUL"
Ktr.: 265134, 265135, 265136
1 2 3 4 5 6 7 8 9
CABLE CONNECTED BY YARD
* SUPPLYED BY YARD
Location:
System:
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
CIRCUIT DIAGRAM
Prep.
Check
+INT
=E1
MAIN CABINET
DIN40719
RH
PS
none
RH
CATERPILLAR
1
3
N.1
L1.F5
70mm
1
-X1
2 3 PE
3x1x25mm
NSGAFu
SUPPLY
24VDC
BARKSDALE-TEMPSWITCH 2000
S
T
E
P
1
S
T
E
P
2
1 3 4 2
2 3 4
2A
1
2
-F5
16mm
4 5 6 PE
2A
1
2
-F4
3x1x10mm
H07VK
16mm
7 8 9 PE
2,5mm
10 11 12 PE
H07VK
3x1x4mm
H07VK
3x1x2,5mm
50A
-F1
25A
-F2
I > I > I >
2,5-4,0A
1 3 5
2 4 6
-Q2
33
34
43
44
/
2
.
3
2A
-F3
3x1x25mm
NSGAFu
3x1x10mm
H07VK H07VK
3x1x4mm
H07VK
3x1x2,5mm
63A
2
1
4
3
6
5
-Q1
1
2
3
4
5
6
-K4
/2.4
1
2
3
4
5
6
-K5
1
2
3
4
5
6
-K6
/2.5 /2.7
Cu 3x20x5
PHASE
BUS
=
~
2,5A OUT:
230VAC/24VDC
L
PE
N
L+
L-
-A1
PE
2,5mm
1
-X2
11
14
12
21
24
22
STEP1
A1
A2
-K1
/2.4
/2.4
STEP2
A1
A2
-K2
11
14
12
21
24
22
/2.5
/2.5
208-500/2x115V
100VA
1 4
31 32
-T1
1 3x25mm
-W1
2 3
=E1
+EXT
=E1
+MOD
COOLING WATER PREHEATER
M
3
CW PREHEATING PUMP
1,1kw/2,6A
U V W PE
=E1
+MOD
1 4x10mm
-W2
2 3 4 1 4x4mm
-W3
2 3 4 1 4x1,5mm
-W4
2 3 4 1 5x0,75mm
-W5
2 3 4
=E1
+MOD
TEMPERATURE CONTROLLER
230VAC
STEP 1
28kW / 39A
STEP 2
14kW / 19,5A
21.11.2007
7221241
21.11.2007
E-1-7224561
"KABUL"
Ktr.: 265134, 265135, 265136
POWER SUPPLY
PREFUSE: 63A
400V 50Hz
L1 L2 L3 -X?
/2.1
/2.1
1 2 3 4 5 6 7 8 9
* SUPPLYED BY YARD
Location:
System:
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
CIRCUIT DIAGRAM
Prep.
Check
+INT
=E1
MAIN CABINET
DIN40719
RH
PS
none
RH
CATERPILLAR
2
3
SOURCE
white
X1
X2
-H1
12 14
11
-K3
/2.3
L1.F5
N.1
2,5mm
5
-X2
6
FAILURE
red
X1
X2
-H2
22 24
21
-K3
/2.3
230VAC
FI 1x09
FAILURE
HEATER CABINET
=E1
+EXT
=E1
+MOD
=E1
+MOD
7 8
11
14
12
21
24
22
FAILURE
230AC
A1
A2
-K3
/2.2
/2.2
/2.2
/2.2
12 14
11
-K1
STEP1
A30
A1
A2
-K4
13 14
5 6
3 4
1 2
/1.7
/2.4
/1.2
/1.2
/1.2
STEP1
blue
X1
X2
-H3
13
14
-K4
/2.4
12 14
11
-K2
13 14
5 6
3 4
1 2
STEP2
A9
A1
A2
-K5
/1.8
/2.5
/1.3
/1.3
/1.3
STEP2
blue
X1
X2
-H4
13
14
-K5
/2.5
14
5 6
3 4
1 2
13
23
33
24
34
CW PUMP
A9
A1
A2
-K6
/1.4
/1.4
/1.4
/2.4
/2.7
CW PUMP
blue
X1
X2
-H5
33
34
-K6
/2.7
9 10
33
34
-Q2
/1.4
13
14
-K6
/2.7
0-Autom.
13
14
-S1
FH1
CW PREHEATER
THERMOSTAT
* CW PUMP ON/OFF
CLOSED WHEN
ENGINE STOPPED
1 1x2x0,75mm
-W6
2 1 2x1,5mm
-W7
2 1 2x1,5mm
-W8
2
21.11.2007
7221241
21.11.2007
E-1-7224561
"KABUL"
Ktr.: 265134, 265135, 265136
/1.9
/1.9
M
LO CONTROL VALVE 230V
LR01
1 14 11 PE
-Y4
M
HT CONTROL VALVE 230V
FR01
1 14 11 PE
-Y2
M
LT CONTROL VALVE 230V
FR02
1 14 11 PE
-Y3
1 2 3 4 5 6 7 8 9
* SUPPLYED BY YARD
Location:
System:
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
CIRCUIT DIAGRAM
Prep.
Check
+INT
=E1
MAIN CABINET
DIN40719
RH
PS
none
RH
CATERPILLAR
3
3
2 3 PE 5 6 PE
2,5mm
16 17 18 PE
2,5mm
19 20 21 PE
2,5mm
22 23 24 PE
2,5mm
25 26 PE
1 4x1,5mm
-W14
2 3 4 1 4x1,5mm
-W15
2 3 4 1 4x1,5mm
-W16
2 3 4 1 3x1,5mm
-W17
2 3
P
AUTOM.FILTER ALARM
LI04
11
12
-3B1
2,5mm
29 30 31 PE
P
T
1
0
0
LO TEMP.CONTROL SENSOR
LI13
4 3 1 2
1 2x2x0,75mm
-W19
2 3
2,5mm
27 28 PE
1 3x1,5mm
-W18
2 3
P
LI05
INDICATORFILTER ALARM
11
12
-3B2
16mm
7 8 9 PE
16mm
10 11 12 PE
16mm
13
-X3
14 15 PE
35mm
1
-X3
35mm
4
1 4x25mm
-W9
2 3 4
2 3 4 1 4x10mm
-W13
1 4x16mm
-W11
2 3 4
21.11.2007
7221241
21.11.2007
E-1-7224561
"KABUL"
Ktr.: 265134, 265135, 265136
M
3
HT-CW PUMP
FP01
400V 50Hz 37kW 67A
U1 V1 W1
PE
-3M1
M
3
LT-CW PUMP
FP03
400V 50Hz 30kW 55A
U1 V1 W1
PE
-3M3
1 4x25mm
-W10
2 3 4
M
3
HT-CW PUMP
400V 50Hz 37kW 67A
FP02
U1 V1 W1
PE
-3M2
1 4x16mm
-W12
2 3 4
M
3
LT-CW PUMP
400V 50Hz 30kW 55A
FP04
U1 V1 W1
PE
-3M4
M
3
PRE.LUB PUMP
LP01
400V 50Hz 22kW 40A
U1 V1 W1
PE
-3M4
Location:
System:
+
1
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
Zum Doc k 3, 23966 Wi s mar , Ger many, +49( 0) 3841 3271 - 0
Prep.
Check
INTERNAL
CONNECTION
INTERNAL
NAME
LINK
NUMBER
EXTERNAL
CONNECTION
EXTRNAL
NAME
P
A
G
E
E
X
T
E
R
N
A
L

K
A
B
E
L
S
T
R
I
P
:
SHEET / PATH
TERMINAL DIAGRAM
1
=
E
1
+
I
N
T
-
X
1
1
-
Q
1
1
=
E
1
+
E
X
T
-
X
?
L
1
1
.
1
-W1 3x25mm 1
2
-
Q
1
3
=
E
1
+
E
X
T
-
X
?
L
2
1
.
1
2
3
-
Q
1
5
=
E
1
+
E
X
T
-
X
?
L
3
1
.
1
3
P
E
1
.
2
4
-
K
4
2
=
E
1
+
M
O
D
-
R
1
1
.
2
-W2 4x10mm 1
5
-
K
4
4
=
E
1
+
M
O
D
-
R
1
1
.
2
2
6
-
K
4
6
=
E
1
+
M
O
D
-
R
2
1
.
3
3
P
E
1
.
3
4
7
-
K
5
2
=
E
1
+
M
O
D
-
R
4
1
.
3
-W3 4x4mm 1
8
-
K
5
4
=
E
1
+
M
O
D
-
R
4
1
.
4
2
9
-
K
5
6
=
E
1
+
M
O
D
-
R
5
1
.
4
3
P
E
1
.
4
4
1
0
-
K
6
2
=
E
1
+
M
O
D
-
M
1
U
1
.
4
-W4 4x1,5mm 1
1
1
-
K
6
4
=
E
1
+
M
O
D
-
M
1
V
1
.
5
2
1
2
-
K
6
6
=
E
1
+
M
O
D
-
M
1
W
1
.
5
3
P
E
=
E
1
+
M
O
D
-
M
1
P
E
1
.
5
4
MAIN CABINET
DIN40719
7221241
21.11.2007
E-1-7224561
RH
PS
none
RH
CATERPILLAR
"KABUL"
Ktr.: 265134, 265135, 265136
=E1 21.11.2007
3
Location:
System:
+
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
Prep.
Check
INTERNAL
CONNECTION
INTERNAL
NAME
LINK
NUMBER
EXTERNAL
CONNECTION
EXTRNAL
NAME
P
A
G
E
E
X
T
E
R
N
A
L

K
A
B
E
L
S
T
R
I
P
:
SHEET / PATH
TERMINAL DIAGRAM
2
=
E
1
+
I
N
T
-
X
2
1
-
A
1
L
+
=
E
1
+
M
O
D
-
B
1
1
.
7
-W5 5x0,75mm 1
2
-
A
1
L
-
=
E
1
+
M
O
D
-
B
3
1
.
7
2
3
-
K
1
A
1
=
E
1
+
M
O
D
-
B
4
1
.
8
3
4
-
K
2
A
1
=
E
1
+
M
O
D
-
B
2
1
.
8
4
5
-
K
3
1
1
2
.
2
-W6 1x2x0,75mm 1
6
-
K
3
1
4
2
.
2
2
7
-
F
5
2
=
E
1
+
M
O
D
-
B
1
2
.
3
-W7 2x1,5mm 1
8
-
Q
2
3
3
=
E
1
+
M
O
D
-
B
1
2
.
3
2
9
-
S
1
1
4
=
E
1
+
M
O
D
-
B
2
.
7
-W8 2x1,5mm 1
1
0
-
K
6
A
1
=
E
1
+
M
O
D
-
B
2
.
7
2
MAIN CABINET
DIN40719
7221241
21.11.2007
E-1-7224561
RH
PS
none
RH
CATERPILLAR
"KABUL"
Ktr.: 265134, 265135, 265136
=E1 21.11.2007
2
3
Location:
System:
+
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
Prep.
Check
INTERNAL
CONNECTION
INTERNAL
NAME
LINK
NUMBER
EXTERNAL
CONNECTION
EXTRNAL
NAME
P
A
G
E
E
X
T
E
R
N
A
L

K
A
B
E
L
S
T
R
I
P
:
SHEET / PATH
TERMINAL DIAGRAM
3
=
E
1
+
I
N
T
-
X
3
1
-
3
M
1
U
1
3
.
1
-W9 4x25mm 1
2
-
3
M
1
V
1
3
.
1
2
3
-
3
M
1
W
1
3
.
1
3
P
E
-
3
M
1
P
E
3
.
2
4
4
-
3
M
2
U
1
3
.
2
-W10 4x25mm 1
5
-
3
M
2
V
1
3
.
2
2
6
-
3
M
2
W
1
3
.
3
3
P
E
-
3
M
2
P
E
3
.
3
4
7
-
3
M
3
U
1
3
.
4
-W11 4x16mm 1
8
-
3
M
3
V
1
3
.
4
2
9
-
3
M
3
W
1
3
.
4
3
P
E
-
3
M
3
P
E
3
.
4
4
1
0
-
3
M
4
U
1
3
.
5
-W12 4x16mm 1
1
1
-
3
M
4
V
1
3
.
5
2
1
2
-
3
M
4
W
1
3
.
5
3
P
E
-
3
M
4
P
E
3
.
5
4
1
3
-
3
M
4
U
1
3
.
1
-W13 4x10mm 1
1
4
-
3
M
4
V
1
3
.
1
2
1
5
-
3
M
4
W
1
3
.
1
3
P
E
-
3
M
4
P
E
3
.
2
4
1
6
-
Y
2
1
3
.
2
-W14 4x1,5mm 1
1
7
-
Y
2
1
4
3
.
2
2
1
8
-
Y
2
1
1
3
.
3
3
P
E
-
Y
2
P
E
3
.
3
4
1
9
-
Y
3
1
3
.
4
-W15 4x1,5mm 1
2
0
-
Y
3
1
4
3
.
4
2
2
1
-
Y
3
1
1
3
.
4
3
P
E
-
Y
3
P
E
3
.
4
4
2
2
-
Y
4
1
3
.
5
-W16 4x1,5mm 1
2
3
-
Y
4
1
4
3
.
5
2
2
4
-
Y
4
1
1
3
.
5
3
P
E
-
Y
4
P
E
3
.
5
4
2
5
-
3
B
1
1
1
3
.
6
-W17 3x1,5mm 1
1
1
2
6
-
3
B
1
1
2
3
.
7
2
2
2
P
E
3
.
7
3
3
3
2
7
-
3
B
2
1
1
3
.
8
-W18 3x1,5mm
1
2
8
-
3
B
2
1
2
3
.
8
2
P
E
3
.
8
3
2
9
1
3
.
9
-W19 2x2x0,75mm
1
3
0
3
3
.
9
2
3
1
4
3
.
9
3
P
E
-
W
1
9
S
h
3
.
9
MAIN CABINET
DIN40719
7221241
21.11.2007
E-1-7224561
RH
PS
none
RH
CATERPILLAR
"KABUL"
Ktr.: 265134, 265135, 265136
=E1 21.11.2007
3
3
1
Location:
System:
+
1
of:
Sheet: Drawing No.
Part Client
Class
print
Norm
based on
Drawn
Date
mas
Prep.
Check
APPARATUS
P
a
g
e
N
a
m
e
M
a
n
u
f
a
c
t
u
r
e
r
N
o
.
Q
t
y
.
P
a
r
t

N
o
.
=
D
e
s
c
r
i
p
t
i
o
n
1
1
F
S
i
c
h
-
3
p
o
l
/
1
.
2
-
F
1
2
1
F
S
i
c
h
-
3
p
o
l
/
1
.
3
-
F
2
3
1
1
S
A
M
2
5
0
0
0
0
R
1
0
0
8
M
O
T
O
R

P
R
O
T
E
C
T
I
O
N

S
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2
MAIN CABINET
DIN40719
7221241
21.11.2007
E-1-7224561
RH
PS
none
RH
CATERPILLAR
"KABUL"
Ktr.: 265134, 265135, 265136
=E1 21.11.2007

26 Comb Gesamt Eng

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26 Comb Gesamt Eng

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Unit type: Comb. LO CW module

Q\QMH\DGR-KONF_ERKLRUNG mit Unterschrift.DOC / 008528

Ratings pursuant to article 9 of the PED

Non-return valve RK with spiral centering ring or self-centering body.

Flowserve Flow Control (UK) Ltd.

Flowserve Portuguesa, Lda.

GESTRA ESPAOLA S.A

Flowserve Flow Control S. A. S

1.0 General information on

lever with detent

Type 012, 013

- Butterfly valve with eyelets, maintenance free,

Selection of possible applications:

- Butterfly valve with threaded eyelets, maintenance free,

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